CEW May 2017

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

VOL.52 | ISSUE 5 | MAY 2017 | TOTAL PAGES 76 | US $ 10 | ` 150

CHEMICAL ENGINEERING WORLD MAY 2017 VOL.52 ISSUE 5 Mumbai ` 150 HYDERABAD - 2017

GUJARAT - 2018

13-15, December 2017 Venue: Hyderabad, India

23-25, January 2018 20-23, February 2019 Venue: Ahmedabad, Gujarat, India Venue: Mumbai, India

MUMBAI - 2019

Chemical Engineering World

amol_ Ad Template.indd 3

August 2013 • 3

8/23/2013 10:41:13 AM

CEW

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

EDITORIAL

Editor Editorial Advisory Board Contributing Editors

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

Sub Editor Feature Writer Design Team

Mittravinda Ranjan (mittra_ranjan@jasubhai.com) D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com) Mahesh Kallayil Arun Parab, Shankar Joshi

Subscription Team Marketing Co-ordinator Production Team

Dilip Parab Brenda Fernandes V Raj Misquitta (Head), Arun Madye

Place of Publication: Jasubhai Media Pvt Ltd

210, Taj Building, 3rd Floor, Dr. D. N. Road, Fort, Mumbai 400 001, Tel: +91-22-4037 3636, Fax: +91-22-4037 3635

SALES

General Manager, Sales

Amit Bhalerao (amit_bhalerao@jasubhai.com) Prashant Koshti (prashant_koshti@jasubhai.com)

MARKETING TEAM & OFFICES Mumbai

Ahmedabad

Godfrey Lobo / V Ramdas 210, Taj Building, 3rd Floor, Dr. D. N. Road, Fort, Mumbai 400 001 Tel: +91-22-4037 3636, +91-22-4213 6400 Fax: +91-22-4037 3635 E-mail: godfrey_lobo@jasubhai.com, v_ramdas@jasubhai.com 64/A, Phase 1, GIDC Indl Estate, Vatva, Ahmedabad 382 445 Tel: +91-79-49003636/627, Fax: +91-79-25831825 E-mail: sales@jasubhai.com

Vadodara

202 Concorde Bldg, Above Times of India Office, R C Dutt Road, Alkapuri, Vadodara 390 007 Tel: +91-79-49003636/627, Fax: +91-79-25831825 E-mail: sales@jasubhai.com

Bengaluru

Princebel M Mobile: +919444728035 E-mail: princebel_m@jasubhai.com

Chennai / Coimbatore

Delhi

Princebel M / Yonack Pradeep 1-A, Jhaver Plaza, 1 st floor, Nungambakkam High Road, Chennai 600 034 Tel: +91-44-43123936 Mobile: +919444728035, +919176963737 E-mail: princebel_m@jasubhai.com, yonack_pradeep@jasubhai.com Priyaranjan Singh / Suman Kumar 803, Chiranjeev Tower, No 43, Nehru Place, New Delhi – 110 019, Mobile: +919818148551 Tel: +91-11-46745555, Fax: +91-11-26427404 E-mail: pr_singh@jasubhai.com, suman_kumar@jasubhai.com

Hyderabad

Princebel M / Sunil Kulkarni Mobile: +919444728035, +919823410712 E-mail: princebel_m@jasubhai.com, sunil_kulkarni@jasubhai.com

Kolkata

E-mail: industrialmags@jasubhai.com

Pune

Sunil Kulkarni Suite 201, White House, 1482 Sadashiv Peth, Tilak Road, Pune 411 030 Tel: +91-20-24494572, Telefax: +91-20-24482059 Mobile: +919823410712 E-mail: sunil_kulkarni@jasubhai.com

Subscription Rate (per year with effect from 1st April 2013): Indian - ` 1620; Foreign - US$ 180 Student Concessional Rate: ` 800; Price of this copy: ` 150

VOL. 52 | ISSUE NO. 05 | MAY 2017 | MUMBAI | ` 150

NEWS Industry News

8

Technology News

22

Ensuring Efficacy in Automation through Digitization A Huge Relief for Sewage Treatment Coming Our Way Soon

28 30

NEWS FEATURES

FEATURE Leveraging Digitalization in Project Execution - Parag Mantri, Senior Manager- Instrumentation, Aker Solutions Safety & Security- What should we know in Control Safety Instrumented Systems?

- Vivek Gupta, General Manager & Head Instrument, DCM Shriram Limited Carbon Pricing Necessitates Asset Optimization, Smart Manufacturing Gets Smarter -Robert Golightly, Senior Product Marketing Manager, Sunil Patil, Director of Business Consulting, Asia Pacific, Aspen Tech Appraise Your Project Manager 360o – Vinod Ramnath, Management & Process Engineering Consultant Harnessing the Digital Potential across Chemical Industry

32

36

40 42 48

CASE STUDY Nitrogen Tri Chloride- the Explosive Contaminant - V.K.Kapur, Chloro-Alkali Consultant

MARKETING INITIATIVE

“Polyhose has grown by listening to the customer voice and implementing the best practices learned thro customer interaction” B&R Makes Investment Push Industrial IoT for Brownfields

PRODUCTS EVENTS PROJECT UPDATE BOOK SHELF AD INDEX INTERVIEW

45

51 52 53 54 68 69 71 72

Industrie 4.0: Doing It Differently

-Ashish M Gaikwad Managing Director, Honeywell Automation India Limited (HAIL) Country Leader, Honeywell Process Solutions (HPS) India

74

The Publishers and the Editors do not necessarily individually or collectively identify themselves with all the views expressed in this journal. All rights reserved. Reproduction in whole or in part is strictly prohibited without written permission from the Publishers.

Jasubhai Media Pvt. Ltd. Registered Office: 26, Maker Chambers VI, 2 Floor, Nariman Point, Mumbai 400 021, INDIA. Tel.: 022-4037 3737 Fax: 022-2287 0502 E-mail: sales@jasubhai.com nd

4 • May 2017

Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.”

Readers would do well to treat it as an advertisement.

Printed and published by Mr Hemant K. Shetty on behalf of Jasubhai Media Pvt. Ltd., 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at The Great Art Printers, 25, S A Brelvi Road, Fort, Mumbai 400 001 and published from 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001.

Editor: Ms. Mittravinda Ranjan, 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001.

Chemical Engineering World

Solutions for chemical applications To develop solutions that create the maximum beneďŹ ts for the customer: this is the aim of GEA GEA is one of the largest suppliers for process technology and components for sophisticated production processes for the chemical industry. We supply worldclass precision engineering the industry needs to develop new products, control costs and protect the environment. From single components to complete process units, GEA provides tailor-made solutions for process plants and fully integrated production lines, including mechanical and thermal separation, melt and solution crystallization, drying and particle processing and exhaust gas cleaning.

For more information, please contact: sales.india@gea.com

CEW Industry News Reliance Industries Attains Exclusive Rights to Produce RelWood for Resysta.

Reliance Industries Ltd. (RIL), India’s largest private sector company, enters into a license agreement with German company, Resysta International GMBH. The legal agreement gives RIL exclusive rights to produce and market RelWood, a Natural Fiber Polymer Composite (NFPC) in India. This compound will act as a raw material for production of various profiles which will be used as wood replacement and also for furniture making and home renovations.

The biggest advantage of the NFPC developed by Resysta is that it does not get affected by termites. It is highly water and weather resistant which gives you the real feel of wood. It promises to not splinter or rot over time. It is a fully recyclable material which is obtained from renewable resources.

Due to the crises of shrinking rainforests and inferior wooden quality, there was a high need to innovate a material that can fight all the odds which became one of the key factors in the innovation of NFPC material. NFPC material is based on a unique technology which allows the dispersion of natural fiber within the polymer matrix.

Bernd Duna CEO, Resysta International exclaimed that,” We are currently licensing out our technology across the world and have found in Reliance Industries our perfect partner for India which is at par with our global standards”.

Resysta is a German company found in 2011. It is a privately owned technology with global partners in its innumerable wood substitution applications.

Kirloskar Brothers Limited (KBL) felicitated

by ISRO for its Contribution to the Prestigious Hypersonic Wind Tunnel Project Pune, India: Recognising Kirloskar Brothers Limited’s capabilities to execute complex engineering projects amidst challenging environments, Indian Space Research Organisation (ISRO) recently felicitated the leading global fluid management company for successful completion of the project related to cooling piping system at its Vikram Sarabhai Space Centre (VSSC) at Trivandrum in Kerala. At a ceremony to recognise the prestigious vendors for their contribution to accomplish the task of national importance and pride, ISRO Chairman Shri A. S. Kiran Kumar felicitated Mr. Vishnu K, KBL engineer associated with the project, on behalf of KBL’s Marine & Defence (M&D) segment.

ISRO recently commissioned a Hypersonic Wind Tunnel at the VSSC at Trivandrum as part of its continuous and concerted efforts to minimise cost of access to space. Notably, the Hypersonic Wind Tunnel at the VSSC facility at Trivandrum is the third largest wind tunnel in terms of size and simulation capability in the world.

Kirloskar Brothers Limited (KBL) designed, supplied, erected and commissioned the cooling piping system for this facility through its engineering partner L&T. 8 • May 2017

According to ISRO Chairman Shri Kiran Kumar, commissioning of such facilities would help in future space transpor tation systems in the country and it will further strengthen our space venturing capabilities. The facility at VSSC, Trivandrum, has been indigenously designed, developed and ‘Made in India’ with the support of over 500 Indian companies.

On the company’s milestone achievement, Mr. Amit Dubey, General Manager, Marine & Defence Sector, Kirloskar Brothers Limited said, “It is a matter of great pride for KBL to have achieved recognition from ISRO for its capabilities. The task of commissioning of Cooling Piping System for the VSSC facility was challenging and the margin of error was nil. With our experience of dealing with similar projects in India and outside, we executed the project with our engineering partner L&T. This project is special to KBL as it is a testimony to the country’s indigenous engineering capabilities that only few countries in the world can boast of.”

Hypersonic Wind Tunnel can simulate flow speeds of Mach 6 to 12 with Reynolds Number up to 80 million per metre, while shock tunnel can simulate flight velocities up to 4.5 kilometres per second at a maximum stagnation pressure of 350 Bar. Hot Shut-off Valves (HSVs) are the most critical valve components in the Hypersonic Wind Tunnel, operating at high pressures and temperatures as high as 1550º K. Other important components of this system include nozzle, test section and diffuser. Contoured nozzles are used to generate Mach 6, 8, 10 and 12 flows.

The cooling system helps to keep the metal temperature within permissible limits (ambient temperature). The HSVs endure high temperature; hence, an elaborate cooling system is required independently for each valve element such as valve body, actuator stem and gate seat ring. The other system which requires cooling is the ‘nozzle system’. The system requires three different ranges from minimum to maximum conditions for three interchangeable nozzle equipment. Extensive discussions were held for the selection of pumps for the HSVs and to fulfill ISRO’s stringent requirements and for ease of operation. To achieve this, the number of pumps was minimised by clubbing supply and return lines for multiple valves.

The primary requirement involved meeting the specifications prescribed by ISRO, considering space constraints and operational ability of the system. Therefore, a Multi-Stage Multi-Outlet (MSMO) pump was supplied with appropriate pressure reduction before releasing the water back to sump. MSMO, with pressure reduction, is heart of the system and it was KBL’s USP for the entire project. KBL designed a system to transfer water from the pump to the HSVs and the nozzles to cool them.

KBL carried out design, supply, erection and commissioning of the entire cooling piping system despite labor issues and very challenging work environment. The necessary changes in the design and re-routing were carried out during the implementation as per the site condition. The project was completed in time without any trouble.

Chemical Engineering World

Customized Vacuum Technology Vacuum technology plays a vital role in many chemical and pharmaceutical processes. Robustness, reliability and energy consumption are now more important than ever.

With energy savings of up to 20% and reduced operating costs of up to 60%, Busch vacuum technology sets new standards.

Find out more about economical vacuum generation from Busch. Contact us.

Busch Vacuum India Pvt Ltd. +91 (0)124 421 2171 l sales@buschindia.com www.buschindia.com

CEW Industry News Coal India Gears Up for a Rs.10, 000 Crore Joint Venture for Chemicals Complex.

their new and existing products with this technology to compete in the IIoT/Industrie 4.0 landscape.

Coal India is all set for a Rs. 10,000 crore joint venture along with Rashtriya chemicals and fer tilizers, Gail India, and the FCIL (Fertilizers Corporation of India), to setup a chemicals complex made up of urea and ammonium nitrate which will run on gasified coal.

According to Arun Ananthampalayam, Honeywell Connected Plant senior product marketing manager, the new Matrikon FLEX SDK delivers a “one-stop-shop” client and server solution for industrial organizations with diverse connectivity needs.

There is a need to conduct a background study on the project for which Coal India has appointed Projects and Development of India (PDIC) to conduct a utility study. The plan will manufacture 3 lakh tonnes of urea annually for which 6 million tonnes of coal will be used from coalfields of Talcher in Odisha and 300-400 tonnes of ammonium nitrate will be produced per day.

The principal ingredient for making explosives that are used for blasting material at coal mines is Ammonium Nitrate which is facing a lot of supply crunch. Hence, the suppliers often increase the price which results in higher cost to company.

Honeywell Introduces Software Development Kit (Sdk) Simplifying Industrial Internet of Things (IIoT) Connectivity New Delhi, India – Honeywell (NYSE: HON) Process Solutions today announced the first robust, fully scalable software toolkit that simplifies the interconnection of industrial software systems, enabling them to communicate with each other regardless of platform, operating system or size. The Matrikon® FLEX OPC Unified Architecture (OPC UA) Software Development Kit (SDK) is ideal for applications where minimal memory and processing resources are common.

Honeywell made the announcement at Hannover Messe 2017 in Hannover, Germany. Intended for use by discrete and process industry manufacturers, commercial customers, and automation original equipment manufacturers (OEMs), Matrikon FLEX is the first high-performance developer toolkit that quickly and easily enables any application, regardless of size, with OPC UA. It is the only SDK that meets the entire scope of market requirements – from small, embedded chips to enterprise servers. It will be a key component of Honeywell’s Connected Plant.

“Matrikon FLEX incorporates embedded-first principles, which makes the toolkit smaller and more suitable for use in resource-constrained applications and then building a highly scalable architecture,” Ananthampalayam said. “This SDK has the industry’s lowest memory requirement, and as such, operates efficiently so there are sufficient CPU resources for correct device functionality.”

Tom Burke, president and executive director, OPC Foundation, commented, “In order to quickly and efficiently implement OPC UA, suppliers need a toolkit to minimize development time and effort, and deliver secure and reliable products. Honeywell’s new SDK is ideal for companies getting started with OPC UA to take advantage of the growth of the IIoT. It provides a way to launch OPC UA-enabled products faster and with fewer changes.”

With its “server/client-in-a-box” design, Matrikon FLEX provides a fast, seamless method of implementing optimized, highly reliable OPC UA products without requiring development personnel to be OPC UA experts. Unlike vendors requiring a separate OPC UA toolkit when implementing products on different platforms, Honeywell offers the only toolkit that developers need to use, maintain and update all of their products. It is an efficient and cost-effective answer to deploying IIoT connectivity across a product portfolio – and ultimately taking products to market sooner.

Matrikon FLEX also employs a robust and reliable design to maximize product uptime. This approach allows OPC UA to be implemented in products with minimal computing resources. The toolkit provides reliable, pool-based memory management and runs on virtually any system: from resourceconstrained embedded platforms to powerful, PC-based applications.

Fertial SpA Awards KBR License to Revamp 2 Ammonia Plants .

“Honeywell Connected Plant is our holistic approach to anticipating and meeting the needs of customers by leveraging the power of the IIoT,” said Shree Dandekar, vice president and general manager, Honeywell Connected Plant. “Within this environment, OPC UA plays a key role in enabling outcome-based business solutions. Our introduction of Matrikon FLEX underscores the importance of this technology.”

Considered a world leader in ammonia technology, the US based EPC company KBR Inc has been awarded a revamping contract

by Fertial SpA of their 2 ammonia plants, Annaba and Arzew in Algeria. The license is provided for giving basic engineering design services which can renovate the plants. According to the terms of the contract, KBR will provide Fertial their own ammonia technology, which will increase the production capacity of Annaba and Arzew plants significantly while also helping Fertial with reliability and energy effectiveness.

Growing adoption of the Industrial Internet of Things (IIoT) and Industrie 4.0 is driving requirements for open and secure connectivity between devices (e.g., machine-to-machine or M2M) and edge-to-cloud solutions. Since OPC UA serves as a key data connectivity standard, vendors are seeking to enable

“We are pleased to enter a contract with KBR which will help us complete the ambitious plan we have undertaken to revamp our ammonia plants in Algeria”, said Jorge Requena, Chief Executive Officer, Fertial SpA. Globally, KBR has been involved in licensing, design, construction, and engineering of more than 200 ammonia plants.

10 • May 2017

Chemical Engineering World

CEW Industry News WAC K E R E x p a n d s I t s I n t e g r a t e d K e t e n e Production in Burghausen L The WACKER Group is strengthening its integrated ketene production at its Burghausen site in Germany. The Munich-based chemical company is building a further reactor for the manufacture of isopropanol acetate (IPA) with an annual capacity of 2, Munich and Burghausen, April 25, 2017 – WACKER BIOSOLUTIONS, the life sciences and biotechnology 500 metric tons. IPA is an important starting material for acetyl acetone (AcAc), which is used in numerous applications, ranging from life sciences products through to construction and automotive applications.

Capital expenditures of almost € 2 million are budgeted for the capacity increase. Completion of the plant is scheduled for the second half of 2017. In addition, WACKER is taking over the sales and distribution of the fine chemical calcium acetylacetonate from Acetonate GmbH as of April. This derivative of AcAc will round out the existing integrated ketene production system in Burghausen.

“The new IPA reactor is an important step toward strengthening our integrated ketene production system in Burghausen,” says WACKER Board Member Auguste Willems. “The expansion is part of our strategy of raising the proportion of specialties in our business as a whole to boost growth and profitability. This measure, together with the sales and distribution partnership we have entered into with Acetonate GmbH, will strengthen our position as a leading manufacturer of fine chemicals across a wide variety of sectors – from pharmaceutical products through to industrial applications in the plastics sector.” The new plant is a key addition to the Burghausen site’s supply chain. In the integrated production system, acetic acid is converted first into ketene, then into isopropenyl acetate and finally to acetylacetone. Both IPA and AcAc serve as building blocks for syntheses in numerous branches of industry, from pharmaceutical active ingredients through to specialty automotive coatings. Additionally, AcAc is a starting material for further products in the WACKER portfolio.

To further strengthen the integrated production system and the degree of forward integration, WACKER is also, as of April, taking over distribution of calcium acetylacetonate (Ca-AcAc), a fine chemical made

by Acetonate GmbH in Greiz, eastern Germany. Acetonate GmbH will continue to produce Ca-AcAc on behalf of WACKER, but with WACKER taking charge of sales and distribution of the entire annual production volume of around 900 metric tons.

“This strategic cooperation will enable us to offer even greater security of supply, in addition to excellent product quality, for our customers, especially those in Europe, because we now cover the entire supply chain for calcium acetylacetonate,” says Gerhard Schmid, divisional president of WACKER BIOSOLUTIONS, describing the collaboration.

LANXESS increases capacities for iron oxide pigments.

Nuremberg, Germany: Specialty chemicals company LANXESS is expanding the capacity of its global production network to safeguard customer supply in the long term. In Krefeld-Uerdingen, site of the world’s largest synthetic iron oxide pigment plant, production capacities for red and black pigments will be gradually increased by around 23,000 metric tons, from the current 280,000 metric tons, by 2019. Furthermore, by means of modernization, LANXESS is also expanding capacities 12 • May 2017

for yellow pigments by another 2,000 metric tons per year at its site in Porto Feliz, Brazil. LANXESS already expanded its global production network recently by starting up operation of its site in Ningbo, China.

The synthesis production facility there, which commenced operation in the first quarter of 2016, is designed for an annual capacity of 25,000 metric tons of red pigment. By taking these measures, LANXESS will be increasing its global production capacities from 375,000 to 400,000 metric tons of iron oxide pigments by 2019.

Well positioned to meet rising demand

“The purpose of these investments is to support the growth of our customers,” says Jörg Hellwig, head of the Inorganic Pigments business unit (IPG). As the world market leader in iron oxide pigments and a leading supplier of chrome oxide pigments, LANXESS continuously evaluates the development of the global pigment market. The company expects global demand for iron oxide pigments to grow by an average of three percent per year beyond 2018. Demand for iron oxide pigments will rise significantly due to strong growth in countries like India and the continued recovery of the building industry in North America and parts of Europe. China will also contribute to this development with growth rates remaining at a high level.

Paints and coatings are the second-largest field of application for synthetic iron oxide pigments, making up one quarter of total global consumption – and the trend is on the rise. “By 2025, we expect global annual growth in the demand for iron oxide to reach an average of 4 percent. We believe in particular that the demand for high-quality pigments with uniform global standards will increase,” adds Hellwig.

Continued consolidation of the Chinese pigment industry

Although China is by far the largest producer of synthetic iron oxides, with over 50 percent of total global supply, the number of production locations for synthetic iron oxide pigments has been decreasing steadily for several years. This is a result of the consistent implementation of environmental regulations by both pigment manufacturers and the pigment processing industry. The number of production locations has dropped by half since 2008, resulting in a reduction in supply, particularly in the segment for red pigments. According to LANXESS, this consolidation process is likely to continue.

Uniform global production standards are an integral part of LANXESS’s image. Its production processes have always been designed to be safe, to conserve resources and to preserve the environment, and they are subject to ongoing improvement. The company’s consistent focus on sustainable production processes is paying off in China.

To ensure a reliable and sustainable supply of iron oxide red pigments to customers, LANXESS recently invested in the construction of a new production site in Ningbo, China. It uses the Ningbo Process, which is based on patented technology. The development and startup of this technology, which for the first time enables the eco-friendly production of yellow-cast red pigments and fulfills the very high Chinese environmental standards, went through a very intense development phase. “In light of our high quality expectations and in accordance with our own high demands on sustainable production, we have conducted extensive test runs since 2016. This trial phase has now largely been concluded,” says Hellwig Chemical Engineering World

CEW Industry News Sanner passes 60 million Euro mark Bensheim/Germany: With 63.7 million Euros in 2016, Sanner GmbH again achieved an increase in annual sales. The company strengthened its position as a provider of high-quality plastic packaging and components for pharmaceutical, medical and healthcare products with significant domestic and international investments, the expansion of the product portfolio, as well as efficient development services for customer-specific products such as the Atmo Guard System® and the newly introduced Sanner IDP-Process®.

“Once again, 2016 was a very successful year for us. Compared to the previous year, we were able to increase our total turnover by 6.9 percent, thus exceeding the 60 million Euro mark,” says Dirk Mähr, Managing Director of Sanner GmbH. “This continuous growth, as well as the numerous developments and investments show that we are well prepared for the future", says Ralf Tiemann, Managing Director Sanner Kunshan China.

Comprehensive investments and portfolio expansions Inestments included an exchange of most machines for Sanner products in Bensheim, Germany. “The increase in automation and the acquisition of new production machines contribute to an increase in capacity and efficiency,” says Mähr. In the coming years, Sanner will consistently expand its portfolio for capsules and desiccant packaging.

The company has also strengthened the range of services and developments of customer-specific products with the Sanner Atmo Guard System® and the IDP-Process®, which was recently introduced at Pharmapack Europe. The IDP-Process® meets the growing need for customized, holistic packaging concepts for pharmaceuticals and medical devices. Customers receive individual packaging 2 solutions with a design that not only meets the highest requirements, but which is also suited for large-scale serial production, while fulfilling all technical and regulatory demands.

Expansion of cleanroom capacities in China

The expansion of the cleanroom capacities in Kunshan, China, focused on efficiency and product safety. Since February 2017, 200 additional square meters of production space are available at the site. However, Sanner does not rest on its laurels: “The past years’ successful business results and our excellent future prospects in Asia will require continuous capacity expansions over the coming years,” says Ralf Tiemann. Upon completion of the second construction phase at the end of the first half-year, the company will be able to produce in 2,700 square meters of cleanroom space.

Well-positioned for further growth

A great deal has also happened at the production site in Hungary: on one hand, new employees could be recruited to strengthen the 16 • May 2017

team. On the other hand, the sites in Bensheim and Budapest are cooperating more closely to establish a broader platform for future growth projects in Europe. "With these numerous portfolio and capacity expansions, we are sustainably investing in the future of our production sites", Dirk Mähr summarizes.

Praj all set to unveil India’s First Integrated Biorefinery for Renewable Fuels & Chemicals Pune, India: Praj Industries announced a breakthrough in scale up of its 2nd generation ethanol technology with successful completion and start-up of smart bio-refinery. India’s first integrated bio-refinery is built on the company’s proprietary platform technology - “enfinity’’ for manufacturing ethanol from agri-waste.

Second generation demo plant can produce one MLPA of ethanol by processing a variety of agri-residue like rice and wheat straw, cotton stalk, bagasse, cane trash, corn cobs & stover, etc. into ethanol, with superior product yields. With continual research and development, further pipeline of other renewable fuels and chemicals is underway to be produced from this technology platform.

Talking about this landmark achievement, Mr Pramod Chaudhari, Executive Chairman of Praj Industries said: “Praj’s 2G demo plant is a testament of our technology leadership in the bio-energy space.

This innovative technology has substantial potential to enhance energy security and help India become energy self-reliant. It uses abundantly available cellulosic biomass while effectively addressing the challenge of agricultural waste management and mitigating pollution. Commercialization of 2nd generation ethanol technology will give an impetus to rural economy and create additional employment opportunities.”

Mr Chaudhari added further, “The menace caused by burning of farm residue can be addressed effectively by converting biomass into ethanol to be used as a transportation fuel. Such biofuels are of immense national importance as they can help partially meet India’s growing requirement for crude oil resulting in forex savings.

Progressively increased ethanol blending will help achieve GHG emission reduction targets agreed at COP 21 Paris summit.”

In India, an eco-system for 2nd generation ethanol is in the making to achieve the aspired 20% blend ratio. As a part of this drive, 10 to 12 Second generation ethanol projects are expected to be finalized, with average capex of around Rs 600 crore each. Each of these plants will have the capacity to produce 100,000 litres of ethanol per day.

Praj is at the forefront of this development and has already signed MoUs with IOCL and BPCL as their technology partner for certain project sites. Meanwhile experts from Oil Marketing Companies (OMCs) and their engineering consultants have already visited demo plant and endorsed the success of Praj’s technology.

Chemical Engineering World

CEW Industry News BASF India Limited announces FY 2016/2017 Audited Annual Result Mumbai, India : BASF India Limited (BSE code: 500042) registered sales of Rs. 55,257.9 million for the financial year ended March 31, 2017, representing an increase of 7% over the previous year. The Company reported Loss After Tax (after exceptional items) of Rs. 141.3 million as compared to Loss After Tax (after exceptional items) of Rs. 303.7 million in the previous year.

"BASF India Limited showed improved operating results, driven by growth in the Functional Materials and solutions as well as Performance Products divisions, optimization of cost and improved operational efficiency. Increased volumes at the Dahej plant also helped. We are confident that these measures will continue to help improve our performance,” said Dr. Raman Ramachandran, Chairman and Managing Director, BASF India Limited.

For the quarter ended March 31, 2017, the Company registered sales of Rs. 13,941.6 million as compared to Rs. 12,529.3 million in the corresponding quarter of the previous year. Net Profit After Tax (after exceptional items) stood at Rs. 425.5 million for the quarter ended 31 March, 2017 as compared to Net Profit After Tax (after exceptional items) of Rs. 787.6 million posted in the corresponding quarter of the previous year.

In view of the improvement in the operational and financial performance of the company, the Directors have recommended a dividend payment of Rs. 1/- per equity share of Rs.10/- each (i.e. 10%) for the financial year ended 31 March, 2017, subject to shareholders’ approval at the forthcoming Annual General Meeting.

KBL congratulates Government of India for historical step to build indigenously-developed 10 PHWRs While congratulating Gover nment of India for the significant announcement Mr. Sanjay Kirloskar, Chair man & Managing Director of Kir loskar Brother Limited said, “We welcome t h e U n i o n Po w e r & C o a l M i n i s t e r S h r i P i y u s h G o y a l ’s announcement to set up 10 Pressurised Heavy Water Reactors (PHWRs) for nuclear power generation. It is great to lear n that the capacity (7000MW) of these indigenously-built plants will be more than the existing overall nuclear power capacity in the countr y. For a power-deficient countr y like India, this is a great development and we are looking forward to the implementation of this project.

We at KBL congratulate the Government and the Power Ministry for the historic step. We are confident that the new indigenouslydeveloped nuclear power plants will go a long way in reducing the perennial energy deficit that the country has been living with. We feel this initiative will bring about a renewed vigor in 18 • May 2017

the country’s power generation sector, as it has the potential to create about 33,000 jobs and generate Rs 70,000 crores of revenues. “ KBL has been a strong advocate of nuclear energy.

Today, nuclear energy is the largest source of power that does not cause any air pollution—and the only one that can produce large amounts of electricity without any interruptions. Nuclear energy has a major role in altering India’s energy balance without causing any harm to the air around us. Notably, with rising concerns over the environment-damaging greenhouse gases, nuclear power plants are being set up in different parts of the world including in the US. KBL has been associated with BARC & NPCIL for decades, and has been participating in their various nuclear power project programs, in the past. With the rich experience acquired through the association with BARC and NPCIL, KBL is now all set to manufacture `state of the art’ technology pumping equipment at our Advance Technology Pump Division and support the ‘Make in India’ initiative of the Government of India.

S N C - L ava l i n w i n s e n g i n e e r i n g a n d p ro j e c t m a n ag e m e n t s e r v i c e s c o n t r a c t fo r g a s o i l separation plant in Saudi Arabia Abu Dhabi UAE: SNC-Lavalin (TSX: SNC) is pleased to announce that it was awarded a contract by Saudi Aramco for engineering and project management ser vices for the Berri Increment Program. New facilities are proposed at Saudi Aramco’s existing plants at Abu Ali and Khursaniyah to process a potential increased output of Arabian Light crude from the Berri Field on the east coast of Saudi Arabia.

SNC-Lavalin’s scope of work includes front end engineering design for a new 250 MBCD (thousand barrels of oil per calendar day) gas oil separation plant at the existing Abu Ali Gas Plant, as well as additional facilities at the Khursaniyah Gas Plant that will process 40 MBD (million barrels per day) of hydrocarbon condensate, all associated with the Berri Crude Increment. Under the contract, Saudi Aramco may also utilize SNC-Lavalin to provide technical support services for the construction phase.The front end engineering design project is due to begin this month and the pre-EPC construction stage services are expected to be completed by August 2018.

"To be selected by Saudi Aramco for this important project demonstrates our client's continued confidence in our ability to provide a highly qualified multi-disciplinary design team combined with world-class project management credentials and local constructability expertise,” said Martin Adler, President, Oil & Gas, SNC-Lavalin. “SNC-Lavalin has worked with Saudi Aramco for nearly 40 years and has maintained an impressive track record of safely and successfully delivering projects. This contract award shows the depth of our commitment to customer relations in Saudi Arabia and the region as a whole."

Chemical Engineering World

CMYK

For a life-saving operations Solutions for the Pharmaceutical industry

With our extensive knowledge and experience in the power transmission arena, we continuously innovate and launch new products, aimed at meeting the varied application needs of our customers. Our line of products for the Chemical & Pharmaceutical sector manufactured at our Chennai production facility in India, applying state-of-the-art technology, ensuring superior quality standards and matching the best cost/performance ratio.

While the AS Series is most dependable and performing solution for all inline drive applications featuring unsurpassed Quality to Price ratio, the light-weight F Series ensures rugged and effective operations. Compact, and yet extremely powerful, are the units of the 300 series planetary drives that make them the ideal choice for all the severe duty applications where shock loadings and impacts are more the rule than the exception.

Precision Planetary gearbox along with new range of AC Servomotors and servo drives along with Brushless DC Motors and drives is complete range of compact and flexible solution that are versatile and featuring control for high performance and unbeatable advantage in scalability.

Welcome to the world of Bonfiglioli!

Bonfiglioli Transmissions (Pvt) Ltd Survey No. 528, Perambakkam High Road, Mannur Village, Sriperumbudur Taluk • Chennai 602 105, Tamil Nadu www.bonfiglioli.com - salesindia.ins@bonfiglioli.com

CMYK

CEW Industry News ONGC in Talks with Middle Eastern Petrochem Companies to Sell Stakes in OPaL ONGC Petro Additions Ltd (OPaL) is in talks with local and overseas petrochemical companies to sell 25% in the Oil and Natural Gas Corp.

Ltd ( ONGC). The company is cooperatively owned by GAIC (India) Ltd, ONGC and GSPC (Gujarat State Petroleum Corp. Ltd. ONGC and GAIL hold 44% each in OPaL and GSPC holds the rest.

ONGC plans to have a public shareholding of 25% in OPaL along with other public sectors and strategic investors. ONGC officials said that they are in talks with some Middle Eastern petrochemical companies and Saudi Aramco is one amongst them.

OPaL at the moment is looking for a strategic investor who could add a lot of value to the project said an ONGC spokesperson. The mega petrochemical plant is located in Dahej, Gujarat.

ONGC which was previously in talks with several foreign firms for a stake were stuck due to several delays which include cost overruns.

The initial estimate of Rs. 12,440 crores has now increased to Rs.27, 011 crore so far.

Opal’s petrochemical complex will house India’s biggest Greenfields, single-location, and dual feed cracker. It can crack gaseous and liquid feed to produce 1100 kilo tonnes of ethylene per annum that can produce a wide spectrum of chemicals.

The petrochemicals business in India will set more competitive national and global market with OPaL commissioning its plant. OPaL will be competing with Reliance Industries Ltd, Indian Oil Corp, Haldia Petrochemicals and ONGC Manglore Petrochemicals Ltd (OMPL).

India is the leader in the rest of Asia with increasing demand for products containing petrochemicals and the flourishing manufacturing sector will enhance the regional market for petrochemical.

Reliance Commences Commercial Production Of Coal Bed Methane In Sohagpur Mumbai, India: Reliance Industries Limited (RIL) commenced commercial production from its Coal Bed Methane (CBM) block SP(West)–CBM–2001/1 from 24th March 2017 and is currently supplying CBM for commissioning the Shahdol Phulpur Pipeline (SHPPL). The production from RIL’s Sohagpur CBM fields will gradually ramp-up in the next 15-18 months making RIL among the largest unconventional natural gas producers in India.

CBM is an environmental friendly natural gas extracted from coal-bed and has become an important source of unconventional gas in many parts of the world. RIL was awarded the licence to explore two adjacent CBM blocks SP(West) and SP(East) with an area of 995 sq.km in the Round 1 of CBM block bidding by the Government of India in 2001.

RIL has drilled more than 200 wells connected to two Gas Gathering Stations in the first phase of development. RIL expects to drill 600800 wells further and develop associated infrastructure over the next phases of development.

20 • May 2017

Reliance Gas Pipelines Limited (RGPL) a wholly owned subsidiary of RIL, laid a 302 km Shahdol Phulpur Gas Pipeline that connects Sohagpur CBM fields from Shahdol to Hazira-Vijaipur-Jagdishpur (HBJ) pipeline Network of GAIL at Phulpur. With this new pipeline network these CBM Gas fields are now connected with the Indian Gas Grid.

GNFC wins the Golden Globe Tigers Award for Excellence & Leadership in CSR 2017 Kuala Lumpur: Gujarat Narmada Valley Fertilisers & Chemicals (GNFC) won the prestigious Golden Globe Tigers Award for Excellence & Leadership in CSR in the category of ‘E-Payment Leadership’ for implementation of digital transactions in its township.

The award recognizes "TIGERS" in marketing, branding CSR & social innovation, education & academic across leadership levels in individual and organisation that believes excellence is infinite, perfection has no limit and targets are milestones; not an end of the journey. A week ago, GNFC won the Golden Peacock Awards in the category of Innovative Product/Service for its cashless innovation.

GNFC won from among 214 applicants including SMEs, Public, Private, Government Enterprises and NGOs for the year 2017.

The Golden Globe Tigers CSR Award was given to GNFC at a gala ceremony of Golden Globe Tigers Night 2017 organized at the Pullman City Centre Hotel & Residences, Kuala Lumpur, Malaysia on 24th April 2017. The event was attended by global CSR leaders from over 43 countries.

The Golden Globe Tigers CSR Award was established by World CSR Institute. It follows a rigorous 3 level procedure of short listing and selection. The selection is done by independent assessors comprising experts in the field of Corporate Social Responsibility. This is followed by evaluation by academic council. A total of 30 applications were shortlisted, from which the executive council consisting of CMOs, HDRSs, COs, and VPs decided on the winners based on the impact, scale and replicability of the CSR initiatives. Among these, GNFC was selected as the winner for its outstanding leadership in the field of cashless payments.

GNFC emerged as the first fertilizer company in India to transition to cashless economy successfully. Company’s township in Bharuch, Gujarat became the first 100% cashless township of India. Township’s transition to cashless is a classic example of capturing value in a new way through steady transformation. It followed three precise and concise steps that began with trainings and digital literacy campaigns far and wide, followed by building and adapting infrastructure, and concluded with cross functional task force deployed for implementation, outreach and support. Knowledge sharing and cross silo functioning of GNFC Township and (n) Code, GNFC’s IT wing optimized results. It is an example to be emulated in corporate-led transformation by laying a strong foundation for digital economy.

Under the auspice of NITI Aayog, the apex planning body of India chaired by Hon’ble Prime Minister, GNFC’s cashless township model has been implemented in 81 integrated townships across 12 states. On 14th April, Hon’ble Prime Minister of India, Shri Narendra Modi launched these townships in a grand ceremony in Nagpur, and expressed hope that in the near future many more townships will become cashless.

Chemical Engineering World

The Official Organ CHEMTECH Foundation it is India’s premier technology magazine for chemical proces industry professional. This highly reputed monthly publication provides novel insights on the dynamics of Indian and global process industries.

Subscribe NOW !

Sr. Period of No. Subscription

Yearly Subscription (in `)

% Amount to be Amount You Discount paid (in `) Save (in `)

1

1 year

1800

10%

1620

180

2

2 year

3600

25%

2700

900

3

3 year

5400

40%

3240

2160

Please fill up the contact details First Name Last Name Company Name E-mail Mailing Address

City Pin Code State Contact Number

Please Tick the box

PAYMENT OPTIONS Cheque : Please send your cheque in favour of “JASUBHAI MEDIA PVT LTD”.

BANK TRANSFER Beneficiary: JASUBHAI MEDIA PVT.LTD Bank: HDFC Bank Ltd Branch: Marine Drive Address: 143, Ground Floor, Soona Mahal, Marine Drive, Mumbai-400021 Bank Account No.: 12122020002057 IFSC Code (NEFT/RTGS): HDFC0001207

All the above complete field along with cheque should reach us at: Jasubhai Media, 3rd Floor, Taj Building, 210 Dr D N Road, Fort, Mumbai-400001.

Tel: 022-4037 3636 / 4037 3620 (Direct) Email ID: prakash_powar@jasubhai.com Web: www.cewindia.com

CEW Technology News ISRO All Set to Get New Dinitrogen Tetroxide Plant by National Fertilizers.

New Siemens platform to support complete vision for global additive manufacturing market

National Fertilizers Ltd (NFL) is all set to invest Rs. 350 crores to set up a new production plant for dinitrogen tetroxide (N204) for ISRO. The plant will have capacity of around 1095 MT per annum (or 3 tonnes per day) which will be located at its Vijaipur (Guna, Madhya Pradesh) site.

Mumbai, India: As part of its comprehensive vision to provide the industry’s most complete set of seamless tools to support the global additive manufacturing industry, Siemens revealed plans today for a new online collaborative platform designed to bring on-demand product design and 3D printing production to the global manufacturing industry. The part manufacturing platform, being developed by Siemens’ product lifecycle management (PLM) software business and announced at Hannover Messe 2017, will provide an environment capable of connecting all members of the global manufacturing community in order to maximize resource utilization, access additive manufacturing expertise and expand business opportunity. For example, by linking part buyers to micro-factories, the platform would enable members to 3D print production parts on-demand where-needed across the world.

In addition, the platform will include collaborative capabilities to help streamline the co-innovation process and accelerate the adoption of 3D printing as a mainstream production method for industrial parts.

The company has already received Letter of Intent (LOI) for establishing the plant on own, operate, build, and supply model from Satish Dhawan Space Centre, Sriharikota (SDSC-SHAR).

The tenders for establishing the dinitrogen tetroxide was invited

by ISRO in August 2016.

ISRO will be utilizing Nitrogen tetroxide in specific stages of rocket launch. It will also be used for stages of launch vehicles and while ground testing of specific engines.

The sole producer and supplier of N204 for ISRO is Hindustan Organic Chemicals Ltd (HOCL) which was supplying the product irregularly. Hence, ISRO started looking to set up a new plant for an uninterrupted supply National Fertilizers plans to start construction of the plant in July 2017 with commissioning expected in the next 18 months.

NFL will supply N204 solely to SDSC-SHAR under long term agreement of 25 years period.

NBCC and Berger Paints to Work Jointly to Bring European Thermal Insulation Technology to India.

Europe’s popular external thermal insulation composite systems (ETICS) technology to be brought to India by NBCC Ltd and Berger Paints.

ETICS is a proven solution for improving energy performance of technology controlled buildings. Hence Bollix SA, the Poland based wholly owned subsidiary of Berger Paints India Ltd and NBCC signed a contract of business exploration at the capital for bringing it in India.

The technology is commonly used in Europe for new constructions as well as in retrofitting as it helps by contributing into greater thermal comfort and reduction of the thermal bridge due to the higher interior thermal inertia similar to traditional rendering.

ETICS is a very cost efficient technique and also provides excellent solutions to the building problem all around Europe. Germany and Poland where the ones who started using the technology initially.

Today the technology is used by 15 countries in Europe.

ETICS solutions will be brought to India will the sole objective to reduce energy requirements of cooling and heating significantly.

NBCC and Berger Paints together will develop, facilitate and promote ETICS solutions in the construction segment in India.

22 • May 2017

“Siemens is one of the only companies addressing the diverse needs of all additive manufacturing market participants – from designers and engineers, to manufacturers, 3D printing machine OEMs, material vendors and software providers – with a comprehensive set of seamless technology solutions for distributed industrial additive manufacturing and co-innovation,” said Tony Hemmelgarn, President and Chief Executive Officer, Siemens PLM Software.

Siemens is introducing the part manufacturing platform to address the growing need for on-demand, worldwide access to additive manufacturing expertise and the latest technology. The platform will create an online ecosystem made up of highly qualified members from a variety of areas such as product designers, job shops, part buyers, 3D printer OEMs, material suppliers, expert services providers, microfactories and much more. Members will be able to instantly connect with other members to initiate co-innovation of products using the latest software tools for additive manufacturing.

For example, a global network of experts all having access to the same gateway could participate in and contribute to the design and development of a reimagined product for additive manufacturing. Also, part buyers could use the platform to quickly find qualified services, enhance job scheduling and reduce the time to obtain production quantities of end-use parts at needed locations. At the same time, manufacturing service providers could create a pipeline of job orders for next generation designs, maximize machine utilization and expand their businesses. Finally, 3D printer OEMs could connect with the community regarding their latest systems, technology and expertise for repeatable production of industrial parts and quantities.

By exchanging information and practical knowledge, members will have the opportunity to enhance productivity, increase expertise, streamline co-innovation and accelerate the adoption of additive manufacturing technology to a new level of industrial use.

The new digital platform is expected to launch in mid-2018. Interested participants are invited to contact us about early access Chemical Engineering World

PROVEN PERFORMANCE

ROTOFORM GRANULATION FOR PETROCHEMICALS AND OLEOCHEMICALS High productivity solidification of products as different as resins, hot melts, waxes, fat chemicals and caprolactam has made Rotoform® the granulation system of choice for chemical processors the world over. Whatever your solidification requirements, choose Rotoform for reliable, proven performance and a premium quality end product.

Sandvik Process Systems Sandvik Asia Pvt. Ltd. Mumbai Pune Road Dapodi, Pune 411012 - India Tel: +91 20 2710 3346 · Fax: +91 20 27 10 31 32 · kumar.swamy@sandvik.com

SANDVIK_Chemical_ad_210x270_MASTER.indd 1

 High productivity – on-stream factor of 96%  Proven Rotoform technology – nearly 2000 systems installed in 30+ years  Complete process lines or retrofit of existing equipment  Global service / spare parts supply

www.processsystems.sandvik.com

18/11/2016 10:20

CEW Technology News PA N a l y t i c a l a n n o u n c e s E p s i l o n X f l o w fo r monitoring liquid-based processes Netherlands: At the 8th World Conference on Sampling and Blending (WCSB8), in Perth, Western Australia, PANalytical, world’s leading supplier of analytical X-ray instrumentation and software, announces the new Epsilon Xflow system. This new online solution is made for the continuous analysis of the elemental composition of any liquid, providing real-time feedback from a production process.

The Epsilon Xflow can be incorporated in many different process streams in a wide range of industries such as mining and metals or the production of petrochemicals, polymers or food.

Predefined conditions can be closely monitored, enabling an immediate reaction to any change, in this way avoiding waste and unnecessary expenses. Together with PANalytical specialists, customers will deter mine the positions in their processes, which can profit most from Epsilon Xflow. For example in the petrochemical industry the system can analyze sulfur in fuel even at concentrations lower than 10 mg/kg at many stages of the production process. At the same time low concentrations of vanadium and nickel, which may be harmful to the refinement process, can be determined. Industries will be able to closely check their waste water for hazardous compounds; a task becoming increasingly important with the obligation to comply with stringent environmental regulations.

The analytical core of Epsilon Xflow employs proven energy dispersive X-ray fluorescence (EDXRF) technology, which is robust and non destructive with low detection limits and highly accurate and reproducible analysis results. Elements from sodium up to americium at concentrations from a few ppm to 100% can be analyzed. Almost any liquid can pass through the flow cell across the detector which has a leakage protector in place. The system can be tailored to any customer’s needs with optional sample conditioning and common interfaces to manufacturing execution systems.

“Real-time monitoring of a production process is an essential tool for avoiding waste and achieving more cost-effectiveness.

With Epsilon Xflow we now offer this possibility for the on-line analysis of most liquid products,” says Mark Pals, PANalytical’s manager of the Priority Lane group. “Together with the customer we will analyze the production process and find the most profitable locations for on-line monitoring”.

ABB India expands footprint with a global service center for energy saving drives with remote digital services and new production line Bengaluru, India: ABB India launched India’s first digitalized remote service center for its energy saving drives solutions and added a new production line for digitalized low voltage drives 24 • May 2017

The ABB remote service center will provide 24x7 access to information and support on drives installed at customer facilities for predictive maintenance and condition monitoring for all industries including power, cement, oil and gas, metals, food & beverage and many other applications. The new center is the third of its kind in the ABB global footprint and is now fully activated in India. It will support customer installations in India and around the world.

In India, 31% of total electrical energy is consumed by industrial motors. Drives control the speed of these motors and hence are a key component of enabling energy efficiency and improving productivity. Benefits of such a remote center include faster identification of potential problems leading to increased uptime of customer assets and ultimately savings in operational costs.

“This is a reinforcement of our commitment to our nation and customers by establishing a world-class center using our expertise in digitally enabled technology,” said Sanjeev Sharma, CEO and Managing Director, ABB India. “We are also pleased to offer the benefits of our digital portfolio to our customers in India and partner them in the next level of their journey to develop a range of future services that will allow customer assets to become digital ready.” On the new digitally enabled drives, he added, “we are committed to innovating in country for country to make our global technology accessible by developing features that adapt to India's diversity for example in the device interface, this in turn allows us to tap into the geographically dispersed workforce.”

The new production line manufactures digitally enabled low voltage drives (ACS560 and ACS580 series). The drive information in the cloud can be accessed securely with daily devices like smar tphones. Drives are an environmentally friendly option to use energy efficiently while running motors based on their current load instead of running them on full speed continuously.

These drives provide multiple energy optimization features, are easily commissioned via smartphone, and include features for uninterrupted operations during power fluctuations.

“ACS560 has been developed in India for Indian customers, having user interface in Hindi and energy calculator in Indian Rupees. The new drive has application macros for industries like plastic, textile water and pharma, and unique icon based display for quick commissioning fulfilling the requests of Indian customers”,” said Morten Wierod, Managing Director of ABB’s global Drives business unit.

ABB recently launched ABB Ability globally with an industry leading por tfolio of 180 digital solutions and services. ABB Ability TM Condition Monitoring for Drives is one of the solutions.

According to various reports, due to various energy efficiency measures, India now has 10GW less load on the grid during peak hours in the last financial year. The two key measures for driving efficiency have been perform, achieve, trade scheme (PAT) to encourage usage of efficiency measures on shop-floors and the now globally acknowledged Ujala scheme of LED lighting.

Chemical Engineering World

Brilliant technology Italian quality Saurus939: The vacuum pump made to live longer. Unique in reliability, performance and consumption.

Fi t

an

or df

ge

Criox速 System: Patented rotary vacuum dryer/powderer with motor-driven lump breaker units

t!

Planex速 System: Multi-patented paddle vacuum dryer with ZeroFriction速 planetary movement eccentric agitator

CosmoDry速 System: Paddle vacuum dryer with concentric agitator, fitted with a shaft dismountable in sections.

Agent for vacuum pumps

Your vacuum drying specialist marketing@italvacuum.com | italvacuum.com

Vac Enterprises India LLP, Mr. Jayant Joshi B 102 Shubh Sarita, Appasheb Sidhaye Road Shree Krishna Nagar, Borivali (East) Mumbai 400 066 Tel. 02228975275 | Mobile 9820047858 info@electromechengineering.com

CEW News Features

Ensuring Efficacy in Automation through Digitization

D

igitization is an important fundamental of Automation. With the correct usage of technology, Automation can be enhanced and put into a more productive usage. During the Industry Automation and Control World Conference 2017, we had some of the most eminent speakers adorning the stage to speak in depth about Automation. The following are some valuable information shared by them.

“Digitization is here to stay. IIoT is the buzzword that is coming out loud. IIoT is the idea of connecting physical objects of the real world through sensors, where collected data is used for monitoring, for exchange, and analysis of data for instant action or solution without human intervention” says Ms. R. Priyamvada, GM (E&I) Engineers India Limited.

Digitization has a major impact on the socio-economic factors. It helps in economic development by reducing the time consumed in the fields of production and distribution. When digitization is used in the chemical industries, it helps in producing a more qualitative product than it used to be when done manually.

According to Mr. K. Nandakumar, CMD, Chemtrols Industries Ltd, “India’s biggest dream of digitization came true with the Make in India project by our PM Narendra Modi. Automation has helped pave way for industries to develop. According to Mr. Ananth kumar, Union Minister, Ministry of Chemicals and Fertilizers, Government of India,” Under the Make in India campaign, chemicals and petrochemicals have been listed as one the thrust areas with strong emphasis on deriving maximum value from crude through value addition along the downstream chemical value

28 • May 2017

(Left to Right) Mr. Ajay Sambrani, Ms. Priyamvada, Mr.Harendra Pandya, Mr.B Narayan, Mr.K Nandakumar, Capt.Kishore Sunderesan, and Mr. Ashish Garpure

chain”. The chemical and petrochemical industry has seen maximum amount of investment of the order USD 50 Billion (3.5 lakh crore) over the last few years.

The chemical industry would see the much needed boost in the coming years.

With the amount invested in the chemical industry, in the coming years, there is going to be a considerable growth in the petrochemical industry. The manufacturing will shoot up and increase the productivity.

According to Mr. B. Narayan, Group President (Procurement & Projects), Reliance Industries Limited, “To become a global manufacturing hub, continuous R&D in the manufacturing process has to be undertaken in order to improve quality & efficiency of the pumps. With joint efforts, we want our Indian suppliers to succeed. In the lieu of Digitization, Realtime Optimization is the need of today for our industry. The availability of Big Data has made room for improvements in the manufacturing process more durable and less cumbersome.”

According to Mr. Ashish Gharpure, Deputy Managing Director, Aker Solutions, “Digitization is going to bring interesting times for industry as we usher into digital-age. The process industry can look forward to global competition while leveraging Make In India with the support of digitization & IIoT.” India needs a paradigm shift to change its image from a consuming economy to producing economy.

Chemical Engineering World

Pioneer Spirit in Valve Automation Sizes From 15mm to 50mm

6812MXX6

6816/6819M

2 way / 3 way valves angle seated & straight type Pneumatic valves for On/Off Application

6812MXX1

6616/19E

6612E

6812MXX5

for Air, Water, Oil, Steam, Corrosive Fluids used in Textile, Chemical Processing, Pharma & Other Industry.

Our Other Most Popular Range of Products : Angle Seated & Straight Patterned Pneumatic Valves, Ball & Butterfly Valves with Pneumatic & Electric Actuators, Gas Regulation & Control Products & Gas Trains, Pneumatic & Electric Control Valves *Ask for the literature mentioning model number :

Plot No.65, Road No.13, MIDC Marol, Andheri (East), Mumbai-400 093. Email - avcon@avconcontrols.com Offices at : Contact No. : • Chennai : +91 044-24463041 • Coimbatore : +91 0422-2314527 • Hyderabad : +91 09391094865 • Kolkata : +91 033-22302471 • New Delhi : +91 011-26460811 • Pune +91 020-2712 0540

www.avconcontrols.com

Creative Concepts

Tel. No.+91 22 2834 9134, 9971/73, 28822 1505 Fax. +91 22 2821 6917/3298.

Angle Valve Ad3/2016

CEW News Features

A Huge Relief for Sewage Treatment Coming Our Way Soon…

T

axpayers in Mumbai have spent over Rs 13,000 crores towards cleanliness over the past decade. The Brihanmumbai Municipal Corporation (BMC) had allocated Rs. 8,839.5 crores for solid waste management in the last 5 years which also could not yield any satisfactory results.

The Navi Mumbai Municipal Corporation took up this challenge with the objective to convert sewage water into industrial grade water.

Ion Exchange (India) Limited joined hands with VITO NV, Belgium to set up a technologically advanced Sewage treatment and Recycle plant which was appreciated by Dr. Ramasami N, Municipal Commissioner, Navi Mumbai Municipal Corporation The plant has been set up at the sewage treatment facility of the Navi Mumbai Municipal Corporation.

The event was organised by Ion Exchange, where they welcomed Mr. Pieter De Crem, Secretary of State for Foreign Trade, Belgium and Dr. Ramaswami N, Municipal Commissioner, to witness the recently commissioned pilot plant. The plant has been set up to understand the treatment process involved in producing good quality water which will be used as an alternate source of water at the corporation’s premises.

“I hope this will lead to a cost effective system in India”, expressed Dr Ramaswami N, Municipal Commissioner, while addressing the media at the event. Mr. Ajay Popat, President, Ion Exchange further exclaimed that “This is a major responsibility for us as a company doing our bit for the nation. Our natural reserves of water are reducing day by day. We don’t have enough water today and that day is not far when we might face severe shortage of water. The pilot plant uses VITO’S proprietary IPC MBR Membrane technology. It has a capacity of 100 M^3/d and offers significant advantage as compared to conventional MBR Membranes in performance and lifecycle costs of recycle systems. The treated water is clear, as good as fresh water and can be used by industries as a substitute for municipal water thereby meeting dual objective of sewage treatment and generating an alternate source of water using sewage.

30 • May 2017

Mr. Ajay Popat (Ion Exchange), Dr. Ramaswami.N, Commissioner, NMMC, Mr. Pieter De Crem, Secretary of State for Foreign Trade, and Mr. Dirk Fransear (MD, VITO) examining the plant.

Hence, with the help of this plant, we can produce alternate source of water which can be used for domestic as well as industrial purposes. This plant is also much cost and space effective. While other plants provide water at Rs.40 per 1000 litres, this plant will provide water for Rs. 15 per 1000 litres. It is also very compact and saves a lot of space”.

The pilot plant uses VITO’S proprietary IPC MBR Membrane technology. It has a capacity of 100 M^3/d and offers significant advantage as compared to conventional MBR Membranes in performance and lifecycle costs of recycle systems. The treated water is clear, as good as fresh water and can be used by industries as a substitute for municipal water thereby meeting dual objective of sewage treatment and generating an alternate source of water using sewage. The pilot plant uses VITO’S proprietary IPC MBR Membrane technology. It has a capacity of 100 M^3/d and offers significant advantage as compared to conventional MBR Membranes in performance and lifecycle costs of recycle systems. The treated water is clear, as good as fresh water and can be used by industries as a substitute for municipal water thereby meeting dual objective of sewage treatment and generating an alternate source of water using sewage.

Adding to this, Mr. Ajay Popat said, “We understand the importance of waste treatment and have consistently worked towards providing solutions that are best in the

industry. The lower sludge production, very stable operations, fully automated plant and lower operating costs is what sets this sewage treatment plant apart from the rest. We were able to set up this pilot plant for Rs. 1 Crore.

We have very successfully managed to meet the requirements of the Municipal Corporation by treating sewage. Due to its modular design, the technology can be installed in housing complexes, hotels, institutions for similar purposes.

Mr. Mohan B. Dagaonkar, City Engineer, Navi Mumbai Municipal Corporation and his team have been involved in this project aimed at infusing state-of-the-art technology at an affordable cost to recycle treated sewage.

Mr Dirk Fransear, Managing Director, VITO NV expressed his gratitude to the commissioner for providing them an opportunity to demonstrate the technology developed by them. He further mentioned,” VITO NV and Ion Exchange (India) limited together with a European partner will soon be installing a demonstration project to convert organic kitchen waste generated by homes, hotels, etc along with sludge from sewage treatment into energy. Like the MBR system, this technology will be modular and will generate clean water, power and organic fertilizers.

With all essential technologies put into perspective, India will soon be able to produce best from waste Chemical Engineering World

Brilliant technology Italian quality Saurus939: The vacuum pump made to live longer. Unique in reliability, performance and consumption.

Fi t

a

f nd

org

Criox速 System: Patented rotary vacuum dryer/powderer with motor-driven lump breaker units

e t!

Planex速 System: Multi-patented paddle vacuum dryer with ZeroFriction速 planetary movement eccentric agitator

CosmoDry速 System: Paddle vacuum dryer with concentric agitator, fitted with a shaft dismountable in sections.

Agent for vacuum pumps

Your vacuum drying specialist marketing@italvacuum.com | italvacuum.com

Vac Enterprises India LLP, Mr. Jayant Joshi B 102 Shubh Sarita, Appasheb Sidhaye Road Shree Krishna Nagar, Borivali (East) Mumbai 400 066 Tel. 02228975275 | Mobile 9820047858 info@electromechengineering.com

ADVERTISE TO EXPAND

your reach through

INSIGHT INTO THE PHARMACEUTICAL AND BIOTECH INDUSTRIES

For Details Contact

Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com

CEW Features

Leveraging Digitalization in Project Execution Early Stages of a Project Lifecycle – Concept to Decommissioning Digitalization plays a significant role in the entire lifecycle of the project, from concept to decommissioning. The focus will be on the digitalization processes and its benefits, during the engineering phases of a project from concept to detailed engineering

I

nnovations in technology have created a digital revolution that is driving fundamental changes in almost all industries. Technological evolution has enabled the manufacturing of smart machineries and smart devices. This has resulted in an exponential increase in the amount of data available, with Industry 4.0, IOT and IIOT being the key drivers.

Channelizing this data using the right applications can be a significant success factor. Processes within engineering organizations also need to align with this industrial technological evolution.

Digitalization is the key window facilitating unique opportunities for accelerated industrial development.

Lifecycle of a Project The tremendous data made available from the smart machines and devices can be utilized for performing different analysis, health monitoring, predictive maintenance and forecasting. All of this is applicable in the operation phase of a plant life. Operation phase is only a part of the entire lifecycle of the plant, from concept to decommissioning. The plant lifecycle can be broadly classified into following phases:

Phase 1 : Feasibility Assessment Phase 2 : Concept Selection Phase 3 : Basic Engineering / FEED Phase 4 : Detailed Engineering Phase 5: Installation Erection and Commissioning Phase 6 : Plant Operation Phase 7 : Decommissioning Considering the targets of early Return of Investment (ROI), customers expect their 32 • May 2017

plant end products to reach the market ahead of schedule or with challenging targets. Delays in achieving these targets are a strict NO, irrespective whether the delay is attributed to logistics, engineering, procurement, construction or commissioning activities. In the chain of backward integration of plant lifecycle, it sets a high demand on the engineering organizations for shorter project cycles.

The cascade impact requires the engineering organizations to perform their engineering phases in swift manner, at the same time not compromising on the quality. The earlier days of sequential engineering during the basic engineering followed by detailed engineering, are fading away and there is need for concurrent engineering. The first time right concept becomes a key essence.

Customers are today relying on the vast data and experience available within the engineering organizations to provide technology enabled solutions at a speed and accuracy level that has not been delivered before. The challenging time frames available for completion of various phases in engineering are achievable with experience, tools, and resources and out of sequence execution but as stated earlier with first time right concept. Digitalization is the process which converts the individual personal specific data into an organizational database. The digitalization process simplifies the search and scalability of data and plays an important role in achieving the accelerated engineering schedule demands. All this needs to be performed honoring the confidentiality agreements with different customers.

Few factors that contribute towards swift engineering completion are: • Effective utilization of organization’s core experience • Digitalization in forms of tools that avoid repetitive task • Digitalization towards processing a centralized multi-discipline data and at the same time offering lateral data exchange between various disciplines • Planning tools facilitating the risk identifications towards engineering completions • Plant 3D digitalization • Automated calculation tools • Skilled work force • Trainings Digitalization Offerings for Engineering Phases Project’s engineering success is a result of synchronized multi-discipline efforts.

Digitalization in the field of engineering has enabled engineers to translate their engineering experience, code requirements and calculations into a package of digital data in the form of software suites, facilitating ease of engineering and ensuring consistency and quality.

In this article, we would focus on the main digitalized tools that engineering organizations utilize during the engineering phases: Process Engineering: Process Flow Diagrams: As we know post concept selection, basic engineering and detailed engineering are the two critical Chemical Engineering World

Features CEW phases for an engineering contractor.

Basic engineering is process discipline heavy and is also critical for disciplines associated with procurement of long lead items. The process flow diagram is amongst the most important process deliverable underpinning the process flow for the plant. The heat and mass balance defines the design premises for the lines, equipment’s and the process data. There are various commercial steady state process simulation softwares available in the market, which can perform the heat and mass balance, integrate these process parameters for generation of line list and equipment datasheets.

It also provides AutoCAD compatible facility, which can directly generate the process flow diagrams for a project.

This digitalized tool supports a quick turnaround for process deliverables.

Smart Piping and Instrumentation Diagram (P&IDs) are the current trend in the engineering world. The process data associated with the individual lines and equipment’s are superimposed on the 2D P&ID’s making it intelligent. Digitalization has helped in interfacing this smart P&ID data to multi-discipline deliverables. This has offered avoidance of duplications of data and maintaining the confidentiality commitments for all disciplines.

Mechanical Engineering: Internationally, validated software has now replaced the manual calculations performed by a mechanical engineer.

These commercially available softwares are nothing but the reflection of digitalization towards collation of multiple manufacturer’s data, code requirements, sizing etc. available to the users for performing the equipment sizing. General plant data once entered in the suite avoids repeated entries for individual equipment for a plant, during sizing or for different cases for equipment sizing. The software’s capability to offer correct solutions, highlight conflicting data, options for different code designs , generate 3D shape of the equipment for further engineering, reduced processing Chemical Engineering World

and checking time and easy iteration are some of the important elements that bring increased efficiency, better quality of analysis and safe design.

Process Control System Engineering: Instrumentation and Process control engineering rely heavily on input data from various disciplines for generating their own deliverables. As the quantum of deliverables delivered by Instrumentation discipline is large, efforts involved in developing these instrument deliverables is also remarkable. Till few decades, the input data was being delivered by the originating department to instrumentation as a standalone deliverables in form of P&ID’s, Instrument Process Datasheets (IPDS) and database. This approach of independent delivery by each discipline resulted into duplication of efforts and quality gaps during the reproduction of the original data. With the technological evolutions in digitalization, new tools and platforms are available which have a multidiscipline environment. This works on the principles of central data processing hence the data generated by the originating disciplines is being stored centrally. The data required by other disciplines is made available from this central data management system, resulting into efficiency and quality improvements. As a result the Instrument datasheets fetches the required data from IPDS and line list which resides within the suite. Integration of P&ID platform to these engineering tools offers data acquisition from smart P&ID directly.

Instrument sizing is an inherent feature for this tool, taking the advantage of all the required process data being available centrally. This eliminates the need for external instrument sizing softwares and backs up the fundamental of efficiency building with zero faults.

The most effort intensive deliverables for instrumentation are the wiring and loop diagrams. This is a combination of design performed by Instrumentation discipline by using automation system vendor data

and package supplier database. These digitalized tools also support the import of the package and automation system vendor database to offer a complete integrated database for the plant. This results into reduced engineering efforts as vendor data is directly used for generation of loop and wiring drawings.

These database suites also support integration of smart P&ID’s and 3D plant model. All this allows advantage of exchanging the P&ID related data to line list, procurement activities and also to the 3D plant model. Activities like cable routing tray filling and maintaining consistency check are the advantages yielded from this digitalization process.

In case the engineering deliverables are generated based on Microsoft suite, then digitalization is feasible using the embedded functionalities like pivot tables, writing macros and look-up tables.

Electrical Engineering The age of digitalization has transformed the discrete database concept into a common electrical consumer database.

This has facilitated generation of electrical discipline deliverables like single line diagram, load list, cable schedule, feeder list, drum schedules etc., without requiring repetitive data entry and also maintaining the consistency of data between different deliverables. The manual calculations for cable sizing, plant lighting and the lightning risk assessment have been faded by the digitalized sizing software suites. These suites offer the flexibility of built-in database of sizing parameters from various manufacturers and also the options on various codes and standards.

Having a centralized data also supports utilization of this data for cross discipline deliverables like termination drawings for MCC and automation systems 3D Plant Modeling In the earlier days, the construction of plants were performed based on the various construction deliverables generated by multi-disciplines in the form of drawings. Handling of this drawing at the construction site has always been a May 2017 • 33

CEW Features challenge. The visualization of actual 3D view of the plant pre-construction was feasible only if you could superimpose multiple multi-discipline deliverables and vendor documents together. But at the same time it would provide its own challenge and had an element of site engineering involvement. However in this digitalization era, a 3D plant model at the engineering stage can be developed.

With the 3D plant model, multi-discipline model reviews can be performed even before the construction is initiated and constructability study can be performed to derive the sequence of construction at site.

This has definitely supported considerably reducing the construction related queries received during the construction phase and the site engineering. Accessibility for maintenance can be firmed up using 3D model. The details on the bill of material ranging to nuts and bolts can be estimated with the help of 3D model.

Brownfield Engineering Nowadays a lot of brownfield engineering activities are required to be performed on the existing plants which could be a trigger due to various reasons like compliance to the current environmental regulations, debottlenecking due to capacity increase, flexibility to accept various grades of raw material based on the current market availability etc.

There is a challenge towards availability of as-built documentation, resulting into loss of engineering flexibility and cascading with longer project execution period and additional cost. In this digitalization phase, there are tools available which perform an onsite laser scanning of the asset. The scanned images using a software tool are then converted into a 3D plant environment.

This 3D plant model then can be utilized for further brownfield engineering. This laser scanning process not only reduces the time required for actual as-building at site but also replicates the existing plant with higher accuracy for further engineering.

34 • May 2017

Planning and Scheduling Planning and scheduling is the key forecasting tool for project management.

Various tools are available which help making the P990, P50, P10 project assessment based on the state of the project and identifies the risk involved in the project. Early risk identification and setting the plan for risk mitigations ensures timely delivery of the project execution schedule.

Digitalization will be a key element for seamless work flow integrations and to build its business value across engineering. With future progressing to 4D and 5D technology, the benefits expected in the engineering world are enormous. It is up to the users like us to decide how best we can utilize this digitalization revolution for organizational benefits, based on the evaluation of cost of investment and ROI’s.

Drawing Approvals Digitalization has offered concurrent e-review of drawings submitted by vendor for approval. The advantage of collating the multi-discipline comments simultaneously saves the time required for transferring the individual discipline comments on a master document and thus has brought in efficiency for engineering execution. Features like online checking and performing interdisciplinary checks, maintaining the revision trails come handy for the system audits. This also facilitates tracking of the life cycle of individual activity.

Technology evolutions and digitalization developments cannot yield benefits in isolation. Skilled work force plays a critical role. Continuous training and talent management is also an integral need and cannot be ignored.

Final Documentation Upon completion of a project, the final project documentation comprises of multiple volumes of data book submission to customers. These volumes of documentation require storage capacity within the customer’s data centers and at times offers handling challenges.

Digitalization in this field has reduced the documentation volumes to 1/10th and has also enabled quick access for remote operations.

This also assists in the global Green drive and prevents the environmental impact.

Depending upon the size of the project, digitalization processes have supported reduction in the overall engineering execution period by 20-30%.

Author’s Details Conclusion: Digitalization in engineering is a change that must be embraced by the industry, in order to deliver large and complex projects both on schedule and with quality.

Parag Mantri Senior Manager -Instrumentation Aker Solutions, Mumbai

Chemical Engineering World

CEW Features

Safety & Security – What should we know in Control Safety Instrumented Systems?

Basic Process Control System (BPCS) and Safety integrated System (SIS) networksare pivotal for efficient data communications, safety & productivity. Ideally this should be isolated from Internet from a security aspect but it will also affect the communication. This involves risk assessment. There are ANSI, ISA, NIST, IEC standards which offer guidelines to enhance and maintain security. Let us discuss the actions to maintain safety and security systems to ensure productivity high without sacrificing safety & security of the plant & environment.

I

n the past, we just wanted Automated Control & Instrumentation (C&I) systems.

With the evolution of technology and thanks to IT, requirement shifted to remote and then slowly now to Industry 4.0 which precisely calls for the Industrial Internet of Things (IIoT) with Internet of Services & People (IoS&P). To achieve this, control system local network has to work locally as well as globally i.e exposure to the external world and accessible from Internet & possibility of control and monitoring from remote through Internet.

Obtaining optimized leverage out of the Internet, calls for Connected Things.

Therefore the Security over process control and safety systems has become hot topic in the industry. Big data in Industry 4.0 has not only to be securely stored but to be used intelligently for taking decisions in the plant.

Plant operations have to be safe & secure all the time with an un-interrupted and optimized operations. Time calls for plant & project managers to have sufficient knowledge to improve control & safety systems.

Earlier there used to be only Basic process Control System (BPCS) and concept of Safety instrumented Systems (SIS) evolved later. With the result, many industries integrated Local Area Network (LAN) of both the systems with enterprise LAN and the Internet. Ideally total isolation of BPCS & SIS networks would be good from security aspect but will have problem of communication with rest of the world.

But to sustain in this competitive world, one has to remain connected and deliver the desired. Companies around the globe are currently exploring various ways of merging their Information Technology networks (IT) and Operational Technology (OT) infrastructures.

36 • May 2017

From Operational point of view, ensuring BPCS and SIS security involves Risk Assessment.

ANSI / ISA-99.00.01-2007, NIST 800-82 and IEC 62443 are among a number of International standards which gives the guidelines to enhance and maintain security. Any event that could affect security is a potential threat. Threat could originate from many sources including hackers, terrorists, operating problems etc. Software bugs, virus spread through internet, use of laptops by third party in the network having virus/ undesired files, videos/ photos having issues through USB drives , are the kind of threat which ultimately have access to the system files, resulting in damaging the system and hamper plant operations. The more you are exposed to external network, more vulnerable are systems and more safe operating procedures are to be made and followed.

Listed below are some of the adverse outcomes: Unauthorized Disclosure of information:

Disclosure of confidential, sensitive or embarrassing information can result in loss of credibility, reputation and competitive edge.

Disruption of computer services:

Be unable to access resources when they are needed can cause a loss of productivity. Disruption of services during critical processing time may be disastrous.

Codes can alter vital information. Safety Instrumented Function (SIF) is designed to open a valve in case of instrument air failure. The malicious code reverse the operation which can result in fir / explosion / damage to the property and even casualty.

Loss of productivity: Misuse of IT resources such as network bandwidth may cause slow response times, delaying legitimate computer activities that, in time-

critical applications such fire or an explosion.

BPCS/ SIS network priorities are availability, integrity and confidentiality.

• Place a backdoor that enables attackers to come back to the system at a later date, bypassing the usual security authentication and authorization steps.

Financial loss: The losses can be indirectly from the recovery of security incidents such as corruption of information or disruption of services like stoppage of the power etc In order to keep systems away from above calamities, there has to be controls in a defined manner.

Logical Access Controls Strong logical access control includes sound security policies, clearly defined security models, well-designed system architecture, proper implementation of security mechanisms such as passwords, encryption, access control lists, and firewalls. Only with the properly designed and implemented logical access control will companies be able to realize the benefits and potential of computer technology.

This will give their business the edge over their competitors to avoid being the next victim of security threats. Below are some of the methods and concepts which can be applied to remain unaffected and stay secure: • The first step is to conduct a cybersecurity audit of BPCS/ SIS to understand exactly how secure your system is today and where its vulnerabilities might lie. These audits typically will have a slightly different focus from the usual IT security audit, due to the different systems and goals of the process environment. It is also critical that it be conducted by people familiar with both security and plant floor.

• The next stage is to develop a security Chemical Engineering World

Features CEW safeguard but we should be ready.

Keep back up of atleast last two changes (date wise) on other drives like dedicated hard disk / CDs other than system to immediately install in case of any happening.

• Change Management practice should be followed strictly in case of any change required in BPCS/ SIS with proper Hazop study and approval of the Head of the Plant. This should be documented for records.

Risk assessment will help in a long way to achieve above. Like HAZOP / HAZID or SIL assessments are done, same way it should be done for the BPCS/ SIS network.

This team should essentially consist of Instrumentation & Control Engineers, Plant Engineers, OEM and IT support personnel. It will give clear picture of the untreated, treated, and residual risks. The results will give low risk, high risk etc. and necessary steps to be taken to mitigate / eliminate the risk.

•

•

•

policy for process control systems: a statement of the goals, responsibilities and accepted behaviours required to maintain a secure process environment.

The policy gives broad guidance and demonstrates senior management support for security-related facilities and actions across the organization.

Once the security goals are defined, an overall network architecture can be developed. This usually involves creating a multi-level network with firewalls between the layers. While the firewall is the lock on the door to the process network, it is not the burglar alarm. The tool to achieve this is known as an intrusion detection system (IDS) and can range from a simple scan detector, to a heuristic engine that profiles user behaviour, to a system that takes explicit action against the suspected intruder. In the process world, traffic patterns tend to be very consistent so even simple traffic matrices that show who is talking to who can be a big help. For example, if a PC in the accounting area suddenly starts chatting up a storm to a PLC, it might be time to take a closer look. IDS can also help configure firewall filters by showing what traffic patterns are normal and what patterns need to be blocked.

The final stage of the security strategy is to develop an incident response plan. Once hacked should know how to deal with it. Rather than waiting until they are in trouble, firms should have

Chemical Engineering World

•

•

•

•

•

•

•

established Security Response Team and a process to deal with incidents in advance. The team would monitor events and be prepared to act quickly in the event of a serious incident.

Periodic audits and updates: These need to be done periodically and monitored w.r.t. previous audit and documented.

Software patches are released from time to time. This should be installed under supervision / advice of the BPCS/ SIS vendor with original CDs etc.

Authorisation: System security features should be revisited so that passwords are given to only authorized people and be changed at regular intervals so as to avoid misuse. There has to be a policy as who will have the passwords of which level otherwise employees having bad intentions may damage the system.

Formalised

training

programme:

Training should be imparted at regular intervals as IT world is fast changing and regular updation will help systems keeping secure and safe.

Fail safe design: If a network fails, then it should take system to fail safe position. It is better to shut the plant is safe manner rather than unsafe trip.

Prepare plans to upgrade network systems and DCS/SIS in a phased manner way as older systems operating systems (OS) are not updated for possible threats Disaster recovery: This is not a

Some important steps which can be helpful are: • Have good internet & network security • Do not use commercially available hardware and software for networks, BPCS and SIS • Do not allow unauthorized access i.e use of infected flash drives, laptops not checked for virus, unsafe internet connections etc.

• Message popping in the event of network used by persons other than authorized personnel for early alarm Security and Safety of the system has to be an ongoing process and not a goal which is achieved and then stay there. It has to be there in the Culture of the Industry / Company. The attitude to system security throughout the workforce is on a par with safety. Best practices followed across the industry should be shared in the forum and adopted to keep the Industry Secure & Safe and in turn mankind.

Author’s Details Vivek Gupta General Manager & Head-Instrument DCM Shriram Limited Email: vivek_gupta@dcmshriram.com May 2017 • 39

CEW Features

Carbon Pricing Necessitates Asset Optimization.

Smart Manufacturing Gets Smarter “The best time to prepare for any carbon pricing legislation is now. Process manufacturers have access to an unprecedented wealth of innovation as part of asset optimization. In deploying the best innovation, smart manufacturers can accelerate ahead of the competition during tough times.”

I

n a complex and volatile marketplace, the industry needs to be prepared for new government legislation to reduce emissions. With carbon trading, it is where your factories are located that matters, according to experts like Alexander Rau from Climate Wedge.

Rapid globalization has resulted in many process manufacturers in the oil, gas and petrochemical verticals having multi-site operations. This includes companies owning plants outside their headquartered jurisdictions. Without the right strategy to mitigate changing market conditions, companies risk losing significant ground to the competition. Inefficient processes expose petrochemical plants and refineries to the double whammy of rising crude oil prices and the need to reduce emissions. Carbon trading is broadly recognized as an exchange of credits between nations to reduce carbon dioxide emissions. Companies can also trade polluting rights. Detractors of carbon trading advocate direct government regulation. Either way, companies need to address the downside with a systematic and sustainable approach to achieve holistic efficiency.

The world continues to change According to Alvin Toffler, the author of Future Shock, change is not merely necessary to life – it is life. As businesses and governments come to terms with what constitutes carbon pricing, China gears up for a national carbon trading schedule in the second half of 2017. Both industry players and observers have commented that the upcoming carbon trading initiative will have a greater impact on less efficient plants. This is a strong moot point for companies to adopt innovation to mitigate its impact while reaping benefits, such as 40 • May 2017

increased profitability. Singapore, a city state in Southeast Asia, has also hopped onto the carbon pricing bandwagon by announcing plans to impose a carbon tax from 2019 to reduce greenhouse gas emissions. The targeted gases include carbon dioxide, methane, nitrous oxide, hydrofluorocarbons, perfluorocarbons and sulphur hexafluoride.

In this furious race to tag a price on carbon emissions, companies are also taking initiative to preempt profitability and reduce pollution. ABC News has reported that oil major BP Australia is factoring a global carbon price in its future planning. According to Claire Fitzpatrick, the Australian-based managing director of exploration and production, BP actively prepares for a future with a potentially higher carbon price by using an internal carbon price for industrialized countries when it evaluates large, new projects.

In India, Mahindra & Mahindra is the first Indian company to announce an internal carbon price in October 2016.

The company is committed to reduce its greenhouse gas emissions by 25% before the end of 2019. Earlier this year, Indian multinational company Infosys has also announced its internal carbon price at an event organized by the Carbon Pricing Leadership Coalition (CPLC) in Zurich.

Asset optimization as the game plan As less efficient plants bear the brunt from any carbon pricing policies, there is still time for better prepared process manufacturers to accelerate their adoption of asset optimization. Better defined as a comprehensive, holistic philosophy that drives the highest possible financial return from an asset base over its long life, asset optimization is applied across the entire

asset lifecycle. As assets tend to be in service longer than the people working on them, it is a perpetual process. To unlock its full value, companies need to deploy five optimization initiatives – namely, capital expenditure (CapEx) excellence, operational excellence, supply chain excellence, organizational excellence, as well as the ability to sustain competitive leadership.

In subscribing to CapEx excellence, global refineries have reduced energy costs by millions of dollars per year using integrated design to achieve bestin-class energy intensity index (EII) ratings. Second, to achieve operational excellence, refineries and chemical companies have saved time and money by choosing innovative software, such as advanced process control (APC).

During APC controller revamps, industry averages for major units range from $2.5M to $6M savings per year. Third, in pursuit of supply chain excellence, chemical companies have achieved a 35% reduction in production workload. Increased efficiency helps companies better mitigate the impact of any carbon pricing initiative. Fourth, with organizational excellence, companies need to partner established technology partners and develop a center of excellence in process system engineering. Finally, to sustain competitive leadership, companies need to adopt a dynamic approach and address any operational challenges. They also need to make a concerted and continuous effort to adopt innovation.

Asset optimization benefits decision makers, who are empowered to make better and more informed decisions.

It is also made more powerful with the Chemical Engineering World

Features CEW latest technology, as the Industrial Internet of Things (IIoT) accelerates the optimization of business assets.

Supported by the capabilities of cloud computing, visualization and mobility, key stakeholders gain better insights into the use of data to address realtime operational needs. This propels process manufacturers into an era of unprecedented efficiency.

Smart manufacturing gets smarter As an added element of horsepower to the overarching concept of asset optimization, asset performance management (APM) 2.0 has incorporated advanced analytics to predict issues and prescribe operator actions. With advanced analytics, operators derive a holistic view of both the process and asset. Aspen APM software combines asset analytics, reliability modeling and machine learning to analyze, understand and guide. However, disruption seldom happens in isolation. This drives the need for dynamic assessment and a system of

success to address problems, according to the level of risk they represent. With Aspen APM, each new alarm triggers a recalculation of risk profiles to guarantee that the most current financial and risk probability assessment is used.

One of the world’s largest plastics, chemical and refining companies, LyondellBasell, agrees that APM can unlock significant value, in saying, “AspenTech’s new Asset Analytics contains a unique set of modeling and data science-based technologies.

Utilizing the additional process insight available from this promising new software solution brings with it the potential to operate closer to the true flooding limit on this tower. For a world scale olefins unit, this would be worth millions of dollars per year.”

More specifically, the proliferation of carbon pricing initiatives changes the way we view emissions as a company.

For instance, we now include managing

emissions, as part of our planning, scheduling, control, asset and financial solutions for customers. Thus, the best time to prepare for any carbon pricing legislation is now. Today, process manufacturers have access to an unprecedented wealth of innovation as part of asset optimization. In choosing to deploy the best innovation, smart manufacturers will achieve maximum efficiency and accelerate ahead of the competition during stringent times.

Author’s Details Robert Golightly Senior Product Marketing Manager AspenTech Author’s Details Sunil Patil Director of Business Consulting, Asia Pacific, AspenTech

ADVERTISE TO EXPAND

your reach through

INSIGHT INTO THE PHARMACEUTICAL AND BIOTECH INDUSTRIES

For Details Contact

Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com Chemical Engineering World

May 2017 • 41

CEW Features

Appraise Your Project Manager 360° Project Managers (PMs) work closely with the company’s senior management and are in-charge of a team to get the work done. The PM’s fame is capable of winning new contracts. Hence, a 360° appraisal of your company’s Project Manager is very essential to the company consolidating it’s position in the EPC workspace.

T

he Project Manager is a person in-charge of a specific project. In the Chemical Process Industry (CPI), PMs oversee a unit (chemical plant) or a group of units, either in EPCC (Engineering, Procurement Construction & Commissioning) or EPCM (Engineering, Procurement Construction Management) mode. They may be assisted by sub-unit PMs also.

This article refers to PMs who are at the helm of affairs of a project.

Projects executed by EPC companies are looked at from a business perspective. The organization’s focus is on the cost savings generated from the project’s execution strategy and its implementation. This can be achieved by micro-planning from engineering to procurement to construction. Emphasis on people and information technology will boost efficiencies in executing projects. For that winning edge, ground staff to managers, need to be alert, interactive and goal driven.

Project Team The PM leads a team of engineering discipline team leaders (Figure 1).

The multidisciplinary team consists of Process, Civil, Piping, Electrical, Rotary, Static & Instrumentation engineers.

Also reporting to him is the Project Engineering Manager who is responsible to straighten up the engineering issues with engineering disciplines and also ensure the work is done in the required engineering hours.

PROJECT MANAGER

PROJECT ENGINEERING MANAGER

DOCUMENT CONTROLLER

Supervisor / Group Leader PROCESS Supervisor / Group Leader CIVIL

LE PROCESS

Supervisor / Group Leader ROTARY

Supervisor / Group Leader PIPING

LE CIVIL

Supervisor / Group Leader ELECTRICAL

LE PIPING

Supervisor / Group Leader SUPPLY CHAIN MANAGEMENT

LE ELECT’

Supervisor / Group Leader STATIC

Supervisor / Group Leader INST’MENTATION

LE ROTARY

RESIDENT CONSTRUCTION MANAGER

LE INST’

PLANNING ENGINEER

LE STATIC

PROJECT ENGINEER

Fig-1

Figure 1 42 • May 2017

Chemical Engineering World

Features CEW and maintain records e.g. test & maintain piping welder’s Procedure Qualification Records (PQR). g) Records for equipment calibration to be maintained e.g. hydro test equipment gauges, crane load tests etc. h) Provide support and resources to the teams Performing work including purchase, if necessary. i) Conduct regular discipline interface meetings to identify lag and prepare catch up plans. j) Ensure compliance to all company policies. k) Resolve potential technical and budget issues that might a negative impact on the progress. l) Set objectives of the project inline with the organization or client needs. m) D e v e l o p i n g m i c r o l e v e l w e e k l y / monthly program management reports detailing program across schedule, budget and technical issues.

Supervisors / GL - Engineering Disciplines

PM

Other PMs

Sr. / Top Management

HODs Engineering

HOD – Supply Chain LEs Engineering Disciplines

Figure 2

Fig-2

Supply chain management Supervisor / Group leader is responsible for interaction with vendors, leading to award of equipment, material etc.

Document controller will transmit documents passed on by team members to his group to the client or owner, in line with the agreed transmittal list.

Planning engineer assists the PM in preparing the weekly / monthly performances to key metrics. He prepares the Gantt chart and plots the various parameters with time e.g. manhours consumed, piping inch dia fabricated, piles hammered in, etc. Usually Primavera or MS Project packages are used.

In a lean organization, project manager has the additional role of an engineering manager too.

Project Manager Responsibilities For a successful project, Project Managers should be clear in thought Chemical Engineering World

and action in delegating to the team.

Responsibilities are: a) Ensure deployment and mobilization of persons with required skill sets to contracted job. b) Control project budget. c) Single point contact for the project in communications with internal/ external stake-holders. d) Interfacing with the client e) Resolve site queries and minimize lost time. f) Training & certifying personnel SCALE

n) Managing and tracking the Design Change and the Site Information Processes. o) Keep management appraised on the lead / lag in the project. p) Study & present the impact of the project schedules and deadlines q) Revisit quality procedure at the end of the project and suggest changes, if necessary. r) Identify risks and develop the risk management plans. s) Select contract parties with

DESCRIPTION

5

Exceptional / Value added to the project / Face of the company in getting business

4

Competent / Knowledgeable / Good leader

3

Satisfactory / Meets job requirements / Requires more exposure for complex situations

2

Improvement required

1

Below Average

0

Totally Unacceptable / Requires Counselling

Figure 3 May 2017 • 43

CEW Features adequate procedures Project Manager Competence Several techniques maybe undertaken by a good Project Manager to complete the project in time.

Competency has varied interpretations, however for the purpose of this paper, it will be considered as the ability to successfully carry along the entire team within the specified time & cost boundaries of the project and earn a very satisfactory rating from the customer, with the focus on goal management.

Project Manager’s Appraisal In a 360 0 ° appraisal, the juniors, the peers and the PM’s line managers appraise the person involved. For the PM (Figure 2), the Group leader / LE’s, Other Project Managers / Quality audit team and the Senior Management rate, respectively.

Listed below are bullets, which are typically followed during the appraisal.

Each of these are assigned ratings in accordance with some pre-determined scale, in line with the organization’s practices.

A typical appraisal scale is shown in Figure 3 below.

A. By Senior Management 1. Successful completion of Project objectives.

2. Steering the entire project team out of rough waters and directing them ably.

3. Communication with the customer / owner, team members and other people that matter.

4. Overall Attitude.

5. Efficient in using organization resources.

6. Build and motivate the project team that has been effective to deliver.

7. Be proactive in planning all activities.

8. Use all available handles to exercise control enabling effective project execution.

44 • May 2017

9. Keeping customer satisfied.

10. Is a good brand image for the company.

B. By Peers / Quality Audit team 1. PM is familiar with the practices and methods for project management.

2. Are all grey areas in the tender document sorted out with client / PMC vide technical / commercial query records?

3. Is the approval system assigned for document approval in line with tender requirements?

4. Were the relevant sections of the contract shared with team members?

5. Quickly makes a “Plan-B” ready, incase “Plan-A” fails.

6. Keeps cool in demanding situations.

7. Ability to anticipate and analyze problems.

8. Sustained level of high customer satisfaction.

9. Ensure idle resources don’t contribute to cost.

10. Walks the last mile in accomplishment of the goal.

11. Are the extra hours spent properly recorded and justified and claimed?

12. Have the payments due, been properly pursued at appropriate times.

C. Project team (Group leaders / LEs) 1. Encourage and makes creative suggestions to team members.

2. Disseminates ideas.

3. Cheer up the guys who do good work.

4. Known for integrity.

5. Tests himself/herself and his/her abilities.

6. Pays attention to details.

7. Respects others and does not mock them.

8. Has an eye for detail.

9. Is methodical and systematic.

10. Is always seen as being in control of oneself.

11. Does his Professionalism come to the fore i.e. punctuality, promises,

12.

13.

14.

15.

16.

17.

18.

19.

20.

does not run away in demanding times, etc.?

Responds to calls made or emails that are marked to him.

Present options to choose and makes decisions in difficult times.

Ready to work with this Project Manager again on another project?

Is judgmental at times.

Is critical of project team members without specific examples and evidence.

Compares each team member to the other rather than on the individual’s performance.

Being fair and just to all team members.

Giving team members feedback throughout the project, consistently.

Discusses potentially sensitive issues with the concerned person privately.

While there is every possibility that a successful project will overlook the PM's short comings, the company management should correlate the appraisal result with various project control statistics and stages of the project as well as customer feedback. post this exercise, one can only look at all stakeholders coming out stronger.

Author’s Details Vinod Ramnath Management & Process Engineering Consultant, PUNE E-mail: vr.rv0029@yahoo.com Chemical Engineering World

Features CEW CASE STUDY

Nitrogen Tri Chloride –the Explosive Contaminant V K Kapur, a chloro-alkali industry veteran narrates his experience of tackling contamination of liquid chlorine after the organization received complaints from the customers. He takes the readers through an interesting trail of how the team finds the source of contamination,connects with the customers and takes immediate steps to prevent the disaster.

W

e were in Caustic -Chlorine business for over three decades and had rarely received serious complaint about the quality of liquid Chlorine supplied to the customers. All of a sudden, we had three unusual complaints from our consumers within a short period: Complaint no 1- A mild explosion was heard in a water treatment plant when the liquid chlorine ton container was nearing its end.

Complaint no 2- A small scale chemical factory reported Chlorine smell coming from their chlorine reactors vent Complaint no 3- A professionally managed company,M/S Arudhanti Chemicals; reported bursting of the rupture disc of chlorine evaporators and more than 15 discs have exploded in last one. Their consumption was more than 1000 tons per month of liquid chlorine from the ton containers First two complaints were investigated by sending area-in-charge but nothing unusual was reported by him, so no further action was initiated.

Our factory had two cell houses .The first cell house was for Membrane cells with its separate brine circuit to produce NaOH. The second cell house had mercury cells with the facility to produce both NaOH and KOH lye and had their separate brine streams. In total, we had three brine circuits. The chlorine gas produced in both the cell houses was cooled, dried separately and liquefied to go to a common storage tank for ton containers filling for the customers.

Part of cooled chlorine gas, before drying was diverted to produce Hydrochloric acid.

We were convinced that it had something to do with the NCL 3 contamination only and contacted Chlorine institute U.S.A, & Euro - Chlor, Brussels, asking them to send the available literature on NCL 3 urgently.

In the meantime we analyzed various streams for presence of nitrogen compound and checked NaCl brines (two streams),KCl brine, Sulfuric acid (used for wet chlorine drying) and water (for the chemical preparation).

The last complaints of rupture discs bursting from a company managed by professionals and the earlier complaint of the explosion sound in the water treatment plant, made us to think for a possible contamination in chlorine.

The NaCl brine solutions for the two cell houses (Mercury cell and Membrane cell), sulfuric acid and water; had traces of ammonia ruling out possibilities of NCl3 at such a low ammonia concentration.

However, Potassium chloride brine had more than 50 ppm of ammonia.

We were faintly aware that Nitrogen Tri Chloride (NCL 3) can be the possible contaminant which is known for its explosive property.

The chlorine produced in the Potassium hydroxide (KOH) cells was 10per cent of total chlorine produced by both the membrane and mercury cell plants.

Chemical Engineering World

As we didn’t have the facilities to analyze NCl3 in liquid chlorine, we advised our laboratory to analyze the chlorine gas of NaOH& KOH cell for NCl3 content and they asked for three days to set up the facility.

We studied the literature received from Chlorine institute U.S.A, & Euro - Chlor, Brussels carefully and found that: •

•

• •

•

13 per cent NCl3 in liquid chlorine appears to be limiting concentration to achieve detonation with change in the temperatures.

A mass of 1.5 grams of pure NCl 3 / cm2 on a metallic surface wetted with chlorine is capable of fracturing the metal of a typical chlorine ton container.

It has a vapor pressure much lower than the liquid chlorine.

Every 1 ppm of ammonia, present in the brine solution produces 50 ppm of NCl3 in chlorine gas.

For a safe plant operations, 5ppm ammonia in the brine solution is the limit as per the literature.

Our laboratory had reported 50 ppm ammonia in KCl brine stream ten times more than safe limits in a day. Based on the results, our team assumed the content of NCl3 at around 2500 ppm of NCl 3 in the chlorine gas coming out of the KOH cells when KCl brine ammonia content is 50 ppm.

After two days, the quality control laboratory submitted the report of gas analysis when the KCL brine had 35 ppm ammonia, KOH cell chlorine gas had 2150 ppm of NCl3 , the mercury cell house (where the KOH cells were operating) had 710 ppm and the mixed May 2017 • 45

CEW Features chlorine gas of both the cell houses going for liquefaction reported as 09 ppm.

Naturally, we started analysis of KCl salt bags in the warehouse to know the extent of ammonia contamination which was found in the range of 500 ppm to 50 ppm that was too high as compared to the limit of 5ppm set for our supplier.

We advised the following steps for reducing the NCl3 formation •

•

•

•

•

Discontinue use of KCl salt showing presence of ammonia and use old stock of salt lying with us from earlier supply Inject open steam and air in all the three KCl reaction tanks to increase the temperature and provide vigorous agitation (higher temperature is needed for the removal of ammonia from brine solution and hot air drives away ammonia) Increase the free chlorine content in return KCL brine by adjusting process condition (Free chlorine kills ammonia) Convert maximum possible KOH cells for NaOH production. We had the provision of converting few KOH cells to NaOH cells Divert the chlorine gas of mercury cell house for Hydrochloric acid production

After the implementation of steps A, B &C , the level of ammonia reduced to less than 3 ppm in KCl brine.

Post implementation of the above mentioned steps, we started daily analysis of NCl3 in KOH cell house &the mixed chlorine that was going for the liquefaction. Our team found the results to be very satisfactory.

With 3 ppm ammonia in KCL brine, we were sure that NCl3 would benegligible in liquid chlorine going to the storage tanks.

The Visit to M/S Arudhanti Chemicals We now visited M/S Arudhanti Chemicals armed with the literature received from Europe and U.S.A. During the meeting we accepted the presence of nitrogen tri chloride in our chlorine.

46 • May 2017

We explained the presence of ammonia in KCl salt causing the formation of NCl3. We had admitted that we were ignorant about the source of contamination and assured to inform once we located the source.

As a precautionary measure we advised them to reduce the withdrawal rate of liquid chlorine from the containers to half and increase the temperature in the evaporator to 70-75 degree Centigrade. (Boiling point of NCl3 is 71 degree Celsius). In this way the entire NCl3 dissolved in liquid chlorine will get vaporized and no NCl3will accumulate in the evaporator’s rupture disc.

We explained that using chlorine in liquid phase has very little chance of serious explosion compared to gaseous chlorine .When Chlorine gas is drawn from the top valve of the container,NCl3 doesn’t get evaporated (due to low vapor pressure compared to chlorine gas) and gets concentrated in container itself, with high risk of explosion. However, when liquid is drawn from lower valve of the container such situation can be avoided.

This container has two valves and when the container is positioned so as to bring the two valves in vertical position as shown in the picture below, the top valve gives the gas and lower gives the liquid chlorine.

We also advised M/S ArudhantiChemicals to use only 850 kg of liquid chlorine ,and return the tonners with 50 kg of chlorine.

We informed the steps taken for ensuring minimum NCl3 in future supplies. We had told them our inability to analyze NCl3 in liquid chlorine but gave gas analysis showing traces of NCl3 in mixed gas now.

A copy of Chlorine Institute U.S.A. literature was given to them.

Protection for Gas Users from NCl3 Contamination The next step was to protect the customers who were using chlorine gas only and we were scared about serious risk involved for them. We called for an urgent meeting of chlorine vendors and customers to inform them about some contamination problem

that was resulting in choking of containers outlet valves. This was also reported by some of the consumers.

We advised them not to use total 900 kg of Chlorine but draw only 850 kg and assured them to pay back for the 50 kg unused Chlorine. Further, we also offered to compensate the consumers who had to face the loss in production due to frequent choking of pipelines and outer valves.

At this point of time, we did not want to scare them with the information about contamination because of NCl3.

Locating the Source of Ammonia in KCl Salt?

KCl salt is imported and to make it free flowing, anti caking agent is added. We wrote to the Canadian supplier about the concentration of nitrogenous anti-caking agent used by them. But the supplier denied having used any ammonium compound in it which ruled out the possibility.

It is important to note that earlier KCl was being imported in H.D.P.E bags that were packed at supplier end. In order to reduce huge packing cost, we started procuring KCl salt in loose condition and bagging it at Indian port.

Now the only possibility that was left with us was that the consignment was contaminated at the Indian port. The consignment size of this shipment was 10,000 M.T that we had received six month back at Nhava Sheva port Bombay. We wanted to locate the source of ammonia contamination at Indian port now after a gap of almost 6 months which was like searching a needle in hay. Though we were not very hopeful of finding any clue, still we went there.

We found the jetty area to be very neat and clean where a 2 km long belt conveyor was used to unload loose materials from ship into any of the five warehouses used regularly for storage of food grains, fertilizer and other raw material.

Our team collected various deposits found on the steel structures along the length of Chemical Engineering World

Features CEW the belt conveyer from jetty to warehouses to examine the samples. The samples were muddy and a mix of wheat grains as well as several chemicals, but there was no odor of ammonia. We carried the samples to our lab for analysis. After collecting the samples, we went to the record keeping room at the port and found that the warehouse no 4 was exclusively used for chemicals where KCl that we procured from our suppliers, was unloaded and stored like all other chemicals.

The size of the warehouse was approximately 15 m in height and 200 X 50 m with capacity of around 50,000 MT to store loose chemical. We found many small heaps of dirty material lying around and collected samples from different heaps, many of which had strong smell of ammonia.

Though this seemed like a breakthrough for our team, the first question that crossed our minds was if ammonium salt was recently unloaded, we would still not be able to know how our consignment was contaminated. We further examined the eight months record of materials received in warehouse no 4 which confirmed that our consignment was unloaded just after the parcel of ammonium chloride after which no other chemical consignments were received in the same warehouse.

The port did not have proper system of cleaning the warehouse in place to prevent mixing of chemicals and even requesting the port authorities was of no help as they did not cooperate. Meanwhile, our

next consignment was due to arrive at the same port in next 30 days and we took more than a week to wash and clean the warehouse before unloading of parcel.

And as the consignment arrived, we got the same packed in our presence. After this experience, we received subsequent assignments at a port nearby NhavaSheva and ensured carrying out proper inspection during unloading & packing of salt.

Handling of Returned Containers in Factory Post our meeting with our customers, we had already started receiving containers with 50 kg chlorine rich with unknown quantity of NCl 3. We could not purge NCI from these containers chlorine destruction plant for the reasons already explained.

According to the literature from Chlorine Institute USA,safe limit for NCl 3 in ton containers is 20 ppm and 2 ppm in storage tanks; however 13 per cent in NCl 3 on steel surface of the container can result in an explosion. Since all the containers that were returned with 50 kg of chlorine rich with NCl 3 were still intact which indicated the quantity of contaminant to be less than 13 per cent.

Our team concluded that if we were to transfer the 50 kg of liquid chlorine parcels with less than 13 per cent NCl3 to storage tanks, with 50 MT of chlorine capacity, the increase would be much less than 2 ppm and very much within safety limits. Soon after detailed deliberations, we pushed chlorine into the storage tanks with the

help of uniform mixing of dry air which was bubbled through one of the outlet dip pipeline.

After transfer of chlorine to storage tank, all the containers were air purged, washed with water, steamed and dried. During the washing cycle, our team observed that the containers had more dirt, rust and lot of brackish material as compared to containers that were emptied regularly for reasons unknown to us.

Utilisation of Contaminated KCl Salt After all the exercise, we still had 500 MT of contaminated KCl purchased at the rate of around INR 12-13k per ton that was to be consumed… somehow!!

We dissolved 5 MT per day of contaminated KCl in the sludge pit in chlorinated water with vigorous air agitation and open steam heating. Once the level of ammonia reached 5 ppm, it was pumped back to the system. It took us almost three months to exhaust the contaminated stock of KCl. During this period, we received only one damaged container with its deformed welded portion of the end cover from a local consumer who did not report the accident at all.

It took us more than a year to overcome the NCL 3 contamination in liquid chlorine.

Had M/S Arudhanti Chemicals reported the bursting of their first rupture disc immediately, we would not have ignored the other complains and probably action would have been started much earlier.

Nitrogen tri –chloride (NCl3) is an explosive contaminant for chlorine.

It is formed during the electrolytic production of chlorine due to the side reactions between the chlorine and various nitrogen compounds in the brine (salt) solution.

It is a liquid with boiling point of 71 degree centigrade and is miscible in all proportions with liquid chlorine and compounds of chlorine such as carbon tetra chloride.

Pure liquid NCL3 has been calculated to be capable of generating a detonation pressure of 5.5 to 7,500 atmospheres, based on its concentration.

(Brief description of NCl3 found can be in library books) Chemical Engineering World

Author’s Details V K Kapur Chloro-Alkali Consultant, Mumbai May 2017 • 47

CEW Features

Harnessing the Digital Potential across Chemical Industry Chemical producers were among the first to use digital technologies extensively. However, in recent years, the chemicals sector has fallen behind other industries that have explored innovative ways to use digital technology to improve their businesses—not only in running their operations, but also in engaging customers and generating new value. Now, chemical companies are innovating again to catch up. Mr Sandeep Redkar, Manager – Process Solutions, Rockwell Automation, in an email interaction with Chemical Engineering World, examines how chemical industry adapted to new automation trends, major concerns and risk factors.

D

igitization of chemical industry started in early 80’s with the arrival of smart transmitters and over the last few decades, the industry itself has developed many analytical tools right from alarm management systems to optimization and enterprise-level planning and scheduling. Mr Sandeep Redkar, Manager – Process Solutions, Rockwell Automation explains how the industry is responding to the rapid pace at which digitization is driving the transformation.

“The chemicals industry has been quick to adapt the early digitization of process control as long as it was in the hands of automation engineers and comparatively impact of these adaptations was limited to automation field but did not impact overall operations effectiveness. However, the same industry is not as aggressive as let’s say the Life science industry, to adapt the higher levels of analytics, optimization and enterprise level effectiveness improvement tools. The primary reason could be apparent lack of top down approach to such implementations leading to lack of cohesiveness required among many functions within the user organization to contribute to company specific customization of the solution as well as the fear of such data and analytics could lead to disruption in established ways of operations which is based on philosophy of ignorance is bliss,” says Mr Redkar Elucidating the effective ways in which chemical manufacturers harness the digital potential across functions of products, manufacturing, business processes and managing human resources in integrated 48 • May 2017

manner, Mr Redkar told that in today’s environment, where frugal but effective operations are a necessity to extract the most out of company’s assets, paradigms of yesterday’s manufacturing need to change. New type of warfare needs new types of weapons.

“Operations automation technology (OT) has joined hands with Information Technology (IT) to create these new weapons which are available across the whole set of functions in any manufacturing organization. These are, by legacy, diverse operations such as plant and utilities operations, quality control and assurance operations, warehouse management, customer relationship management, financial controls etc.

The new solutions & services formed by confluence of OT and IT provide common set of tools to manage influence of one operation on other, in a way, where the system creates one version of truth across the whole organization and helps every role to use this one version of truth to effectively perform his role within the company,” Mr Redkar asserts.

New information technology trends, smart manufacturing initiatives, and a changing workforce are creating incredible opportunities for those manufacturers and industrial operators bold enough to capitalize – and risks for those who don’t do it well Enabling innovations like the Internet of Things, network convergence, cloud computing, big data and analytics, virtualization and mobility, along with global Smart Manufacturing initiatives, are resulting in a new inflection point

for how manufacturing and industrial organizations and their assets operate: isolated operations to • From integrated, responsive ecosystems • From automating labour to leveraging information • From pockets of expertise to global collaboration • From “open or secure” to “open AND secure” When asked about the flexibility digitization offers across all key functions of manufacturing, procurement, sales & marketing and logistics, Mr Redkar commented that the systems we employ today to manage various functions generate and store a whole lot of information on daily basis.” Rockwell Automation has created a set of solutions under the umbrella of ‘The Connected Enterprise’ to address this requirement of how to combine these different sources of data into a unified business model so that intelligent information can be extracted by any person I the organization irrespective of his role and knowledge of underlying technologies,” he says.

Through The Connected Enterprise, Rockwell Automation helps manufacturers and industrial operators capitalize on the promise of an ever more connected world – in the form of more agile response to changing conditions, faster time to market, lower total cost of ownership, improved asset utilization and enterprise risk management along with workforce efficiency.

A Connected Enterprise is a more competitive, innovative enterprise.

Chemical Engineering World

Features CEW Through enabling access to real time, contextualized information, it helps: • Operations manage and improve utilization and profitability, • Maintenance minimize downtime, • IT reduce network complexities, • Engineering improve technology and optimize the process, and • Business management optimize the enterprise.

Mr Redkar also warns on few major risk factors that the chemical manufacturers need to consider in the process of moving from conventional IT based models to fully integrated digitized models.

“While a Connected Enterprise is need of the hour and helps any manufacturer harness the value of today’s information technology innovations in manufacturing and industrial operations, implementation the same poses major disruptions in the organizational ways of working. Every manufacturer will enter and progress through the stages of The Connected Enterprise Execution Model that is most appropriate for it, at a pace determined by its own needs, infrastructure, readiness, and resources,” he suggests.

For operationalizing the Connected Enterprise, chemicals manufacturers need to draw a blueprint of the path forward which can be described as below: • Take a phased, holistic approach that leverages your existing automation assets and allows you to easily integrate promising new technologies • Partner with a solution provider who understands the unique needs of both IT and operational technology (OT), and have deep experience in helping users work toward common goals.

• The solution shall be based on contemporary, continuously evolving control and information technology hardware and software.

Investment involved in scaling and upgrading the conventional systems for cross-functional integration of processes by the chemical manufacturers.

Chemical Engineering World

According to Mr Redkar, Rockwell Automation have worked with organizations that are in relatively advanced positions (as identified by the assessment) in exploiting their installed systems and collaborating with suppliers; Rockwell also have worked with companies at the beginning of their OT/IT intelligence journeys. There are significant opportunities — and profits — for both. Investment will be based on the current situation as well as vision of the company and the speed at which they wish to reach the final goal.

To help manufacturers and industrial operators safely navigate the IoT along with other smart manufacturing initiatives and take advantage of real time information that drives profitability, Rockwell Automation offers a five-stage Connected Enterprise Execution Model that outlines how companies can safely and securely boost productivity: • Assessment: Evaluate current culture and all facets of an existing OT/IT infrastructure (information, controls and devices, networks, and security policies).

• Secure and upgraded network and controls: Securely upgrade the OT/IT network and controls to prepare for future configurations and advanced technologies (e.g., mobility, big data, and cloud computing).

• Defined and organized working data capital (WCD): Determine how to leverage available data and turn it into information for better business decisions and optimum gains.

• Analytics: Utilize the WDC yielded through the use of hardware, devices, software, and networks for continuous operational improvement.

• Optimize & Collaborate: Optimize operations and engage with internal business processes and teams, suppliers and customers; extend real-time information throughout the enterprise and supply chain, and leverage it to respond to internal and external events (e.g., supplier and customer activities, business trends, markets, political events, weather patterns).

The Indian government is quiet upbeat about increasing the share of manufacturing in GDP to 25 %, and the Make in India initiative to create globally competitive manufacturing sector. While major public and private players have the muscle to invest in revamping and upgrading the manufacturing facilities , it becomes a challenge for the small and medium scale players to get financing for the projects. Singapore Government has introduced Automation Support Package (ASP) to encourage the industry to improve productivity.

Mr Redkar thinks such concept can be emulated in India successfully.

“The government needs to actively promote Connected Enterprises enabled

by IT/OT convergence just like they do for other initiatives such as green initiatives. Just like green initiatives reduces impact of manufacturing on the environment, Connected Enterpise powered by IT/OT convergence will make manufacturing Smart , lean and agile leading to faster time to market, lower total cost of ownership, improved asset utilization and optimization and better management of enterprise risk thus improving the effectiveness and competitiveness,” adds Mr Redkar.

Last year Rockwell Automation had organised the customers’ meet in Mumbai. Most concerns voiced by the user community related to adapting to fast changing trends in automation revolved around following points: • Inefficiencies built into current assets and networks • Networks Evolved over Time (never designed) • Low Competency in Market (combined automation and IT expertise with one entity) • cHigh MTTR (issue identification/resolution) • High Capital Expense • Vulnerability of installed systems • Security is After Thought • Evolving Industrial Security Standards • Aging Industrial Control Systems May 2017 • 49

CEW Features •

•

•

Reactive Approach vs Proactive Approach Inflexibility of install base • Legacy Asset Islands • Too Much Data, Lack of Actionable Information • cProject Dependence upon IT Organization • d. of Scalable Lack Architectures Fear of Lock-In into a proprietary technology • Proprietary Network Protocols Control • Heterogeneous Environments • Selection of new Technologies (e.g. Big data, mobile, cloud) Rapidly Evolving

Mr Redkar opined that automation, internet of things have a great impact on employment in the chemical manufacturing industry and he shared his thoughts on how should the industry prepare the employees and itself for the future automation.

“We have experienced the transformation of workforce in user industry who have implemented Connected Enterprise as well as in Rockwell’s own manufacturing facility where it was implemented first.

The best practice we have seen in the user organization is to run a change management program driven by a crossfunctional team. Collaboration should be a goal at the onset of the design stage, not upon the completion of deployment. The more people you involve in the beginning, the better result you will get. Enterprisewide engagement is critical to establishing and understanding the type of connectivity needed, output goals and actionable information for each role,” he says.

In the weeks leading up to deployment, these team members should be onsite together to test the system and its communications. Training for workers can include focus groups and piloting the system in a simulated environment, where workers can become comfortable with the system in the functions that they’ll be using it for and familiarize themselves with new processes.

50 • May 2017

Even after deployment, collaboration is crucial to helping you get more out of your connected enterprise in the long run. In the Rockwell Automation journey, for example, the collaboration extended to the creation of an internal Challenge Team made up of multiple plants’ top engineers and plant managers who regularly collaborate to share best practices, lessons learned and new developments. Processes are in constant development, and ongoing collaboration allows engineers and plant managers to foster new ideas or learn how other plants are doing things, and possibly adopt those practices themselves.

Mr Redkar deduced that the automation companies like Rockwell Automation should develop synergistic partnerships with the IT companies to enable the chemical processing industries to leverage on digitization and IIoT. “Our unique enterprise-wide approach and partnerships help customers establish a secure environment that both protects the industrial control system and links end-point devices in manufacturing and industrial operations within the enterprise and supply and demand chain. Successful collaboration with strategic alliance partners like Cisco, Panduit and Microsoft results in unique expertise and insights that facilitate the design and management of a more secure and productive Connected Enterprise,” he states.

Rockwell’s strategic alliance partners are critical to its Connected Enterprise offering, to support company’s strategies Rockwell have partnered with: • Cisco to provide a common network and security environment on a single, unified network infrastructure.

Together we’re driving the adoption of the Common Industrial Protocol through the EtherNet/IP standard for safe and highly deterministic automation applications.

• Panduit to provide optimized physical network infrastructure

•

solutions and integrated solutions and services for customers.

Microsoft around application security, cloud computing and technology roadmaps to develop information solutions that enable customers to increase the value of ownership, and empower people by lowering the barriers of applying information technologies to optimize production.

Apart from the above, Rockwell enjoys a vast network of Alliance partners and Encompass partners which augment the offered solutions through their own innovative technologies.

Rockwell has deployed The Connected Enterprise in its own manufacturing facilities to optimize operations and supplier networks for increased visibility and better decision making. The results of this implementation were immediately seen which were: • Lower Total Cost of Ownership • Reduced inventory days nearly one-third • Captured 30 per cent capital avoidance • Faster Time-to-Market • Improved supply-chain delivery to 96 per cent • Improved Performance • Increased productivity 4 to 5 per cent per year • Enterprise Risk Management • Improved on-time delivery to 98 per cent “There is immense value in operationalizing Connected Enterprise in your organization.

There is a wealth of experience available in designing and implementing such systems which are future-proof and make significant impact on your business goals as can be seen from our own example.The early adapters are already enjoying the benefits that these new technologies are bringing to them and most who have not started on this path will find themselves at disadvantage in future,” concludes Mr Redkar.

Chemical Engineering World

CEW

Marketing Initiatives

"Polyhose has grown by listening to the customer voice and implementing the best practices learned thro customer interaction"

W

hat are the new products/services being offered by your company for the industry? What has your company always been striving for?

Polyhose has been striving to offer world class and high quality products to both International and Indian customers at a most competitive pricing by constantly innovating in Polymer Engineering and leveraging the scale of economy in our operations.

The most recent world class products has been XLPE Chemical Hose, Hoses for Food Grade application, SS Flexible Hose ranging from ¼ ID to 4”ID and ultra-High pressure Thermoplastic Spiral products which are launched recently.

How does your company differentiate themselves from their competitors?

Polyhose is a customer driven and customer focused organization and the top Management is hands on to customers, products and trend in technology which benefits the customer by way quick decisions. Polyhose has grown

only by Listening to the customer voice and implementing the best practices learned thro customer interaction in their business model.

What are the various certifications acquired and what has been the key achievement of your company over the past few years?

Company over the year has acquired following certification and will continue to focus on certification required critically to grow the business in Oil and gas Sector in the global Markets.

What is the percentage of funds allocated to carry out research work?

Infrastructural development, Make in India programme, and the large scale urbanisation which is fuelling demand. Polyhose is well positioned to service the growing demand in India.

What are your expectations with regards to development in the market?

Indian Market OEM Industry is now getting matured with quality dependable suppliers/ products and defining cost of poor quality etc. However the Industry is still price sensitive and make it very challenging for suppliers are unable to recover the true cost from the customer.

Management allocates Minimum of. 2% of group turnover for Research work.

Please share your views on the opportunities in the industry? In your opinion, what key growth drivers will fuel this demand?

Indian Market is expected to grow rapidly due to Gover nment of India focus on

Shabbir Y J Managing Director Polyhose India Pvt Ltd, Chennai

Contact Details: Polyhose (India) Pvt Ltd Polyhose Towers, 8Th Floor – Western Wing, No:86, Mount Road, Guindy, Chennai – 600 032, India. sales@polyhose.com Chemical Engineering World

May 2017 • 51

CEW

Marketing Initiatives

B&R Makes Investment Push Expanded production capacity and R&D infrastructure B&R is investing in R&D, infrastructure and workforce expansion. At the Hannover Messe trade fair, Managing Director Hans Wimmer and General Manager Peter Gucher announced B&R’s plans to up production capacity. The company will also be expanding its R&D offices in Salzburg. “These measures will bring our sales a big step closer to the billion mark.”

W

immer paints the acquisition of B&R by ABB as a unique oppor tunity for the company's employees and customers as well as its headquar ters in Eggelsberg. The transaction is expected to be finalized early this summer. "ABB is a fantastic p l a t fo r m fo r t h e n ex t c h a p t e r i n o u r long histor y of growth," said Wimmer.

"To-gether we'll be able to provide our customers with the full spectrum of solutions they need for the Industrial IoT." B&R will form its own business unit within the ABB Group and will continue to operate on the market as a legally

in d e pendent entity. "That means our management structures and points of contact with our customers will remain unchanged," emphasized Wimmer.

Expansion in Three Locations To handle the steadily increasing demand for B&R products, the company is currently boosting circuit board production capacity at its headquar ters in Eggelsberg by 2 0 p e r c e n t . A fe w k i l o m e t e r s a w ay, the company's Gilgenberg site will be expanded to accommodate production l i n e s fo r i t s m e c h a t r o n i c s o l u t i o n s .

At the Hannover Messe trade fair, Managing Director Hans Wimmer announced B&R's plans to expand production capacity and R&D infrastructure

52 • May 2017

Fur ther expansion and moder nization is planned for B&R's R&D offices in Salzburg, making room for 50 new highly skilled positions in the development of industrial communication, robotics and control technology.

"B&R's impressive track record of growth has been fueled by our innovative p r o d u c t s , " s a i d G u c h e r. O n e s u c h i n n o va t i o n p r e s e n t e d a t t h i s ye a r ' s Hannover Messe was the Orange Box, which makes it easy for plant operators to retrofit brownfield equipment with smar t manufactur ing connectivity by collecting data from existing machines and lines and passing it on to higherlevel systems or the cloud. "The Orange Box is extremely easy to install," said Gucher, "and software updates are as straightforward as with a smar tphone.

With the Orange Box, we can quickly get existing equipment up to speed for the Industrial Internet of Things."

Contact Details: B&R Industrial Automation Corporate Communications t +43 7748 6586-0 press@br-automation.com B&R-Strasse 1 5142 Eggelsberg Austria Website: www.br-automation.com Chemical Engineering World

CEW

Marketing Initiatives

Industrial IoT for Brownfields B&R’s Orange Box is the smart-factory upgrade for legacy equipment At the 2017 Hannover Messe, B&R presents its new Orange Box solution. The Orange Box enables machine operators to collect and analyze data from previously isolated machines and lines and get them fit for the smart factory with a minimal effort.

A

n Orange Box consists of a controller and B&R mapp Te c h n o l o g y ' s p r e c o n f i g u r e d software blocks - known as mapps. The controller collects operating data from any machine via its I/O channels or a fieldbus connection. From this data, the mapps generate and display OEE ratings and other KPIs, and can also share the infor mation with higher-level systems via OPC UA. Simple as a Smartphone I n s t a l l i n g t h e O r a n g e B ox r e q u i r e s n o c h a n g e s t o ex i s t i n g h a r d wa r e o r software. Equipment owners can achieve a substantial boost in productivity with a

remarkably small investment in time and cost. Thanks to the mapps, the Orange Box is as simple and intuitive to operate as a smar tphone.

Perfectly Fitted for Every Need T h e O r a n g e B ox i s e n t i r e l y f l ex i b l e and modular. To collect and analyze basic operating data, all you need is a 25-millimeter-wide compact PLC and the mapp OEE component. For more a d va n c e d fe a t u r e s - s u c h a s a l a r m management or energy monitoring - the solution can easily be scaled up with more powerful PLCs and additional s o f t w a r e c o m p o n e n t s . To g i v e t h e Orange Box a modern user interface in

B&R's Orange Box enables machine operators to collect and analyze data from previously isolated machines and lines and get them fit for the smart factory.

Chemical Engineering World

addition to PLC functionality, a Power Panel or a Panel PC can be used."

About B&R B&R is an innovative automation company with headquar ters in Austria and offices all around the world. As a global leader in industr ial automation, B&R combines state-of-the-ar t technology with advanced engineering to provide customers in vir tually ever y industr y with complete solutions for machine and factory automation, motion control, HMI and integrated safety technology.

With industrial fieldbus communication standards like POWERLINK and openSAFETY as well as the powerful Automation Studio software development envi-ronment, B&R is constantly redefining the future of automation engineering. The innovative spirit that keeps B&R at the forefront of industrial automation is driven by a commitment to simplifying processes and exceeding customer expectations.

For details Contact: B&R Industrial Automation Corporate Communications t +43 7748 6586-0 press@br-automation.com B&R-Strasse 1, 5142 Eggelsberg, Austria Website: www.br-automation.com May 2017 • 53

CEW Products VENTILUS V 5 with IHD 5 Hot Melt Device The VENTILUS V 5 machine dries, granulates and coats powders, crystals, granules, pellets and microtablets of any size from 10 µm to 2.0 mm in batches from 1,500 ml to 5,000 ml. Users in the pharma, food and chemical industries have trusted in the VENTILUS Series of laboratory scale systems for many years now.

Thanks to the homogeneous flow conditions in the container and the scalable spray rate, the technology is equally suited for both process development and scale-up tests. Furthermore, the new VENTILUS V 5 can be monitored wirelessly and remote controlled using mobile devices. This simplifies daily work in the laboratory because the lab technicians retain full control over the process even if they are no longer in the immediate vicinity of the machine.

The innovative Innojet IHD 5 hot melt device for pharma applications complies with all GMP requirements for coating and granulation with organic waxes and fats. The fact that there is no evaporation during the hot melt process is a crucial advantage. The processing times are up to 85 per cent shorter as a result. The IHD 5 features a design with all components – including the valve block, dosing unit and melting container in a compact, block-like housing. This makes it easy to connect the mobile device to the VENTILUS V 5 whenever this is called for by the formulation. All laboratory equipment in the VENTILUS V 5 Series can simply be fitted with the spray heater which is essential for hot melt applications. Heating the spraying air to 1200°C prevents the coating liquid from cooling down in the feeding channels and clogging the spray nozzle. The pulsation-free application of the pharma hot melt coating ensures outstanding precision and product quality.

For details contact: Romaco Group Am Heegwald 11 76227 Karlsruhe, Germany Tel: +49 (0)721 4804 0 Fax: +49 (0)721 4804 225 E-mail: susanne.silva@romaco.com or Circle Readers’ Service Card 1

Multi-Parameter M400 Transmitter Mettler Toledo Process Analytics offers a new version of its multi-parameter M400 transmitter series for process analytics applications. The new M400 features a combined touchscreen and tactile soft-key user interface. The high-contrast screen permits viewing in all light conditions and the soft keys allow operation even if protective gloves are being worn. Parameters covered by the M400 Series address the needs of the process industries from chemical applications to pharmaceutical production.

The new series is compatible with analog sensors and Mettler Toledo’s digital Intelligent Sensor Management (ISM) probes. ISM’s features include advanced sensor diagnostic tools that can be displayed on the M400 and accessed remotely via asset management software. The HART communication protocol provides integration of the diagnostics into process control systems. In addition, ISM sensors can be calibrated away from the process in any convenient location, then connected to the M400 which will set itself up appropriately.

A software tool supplied with the transmitter enables configuration of the M400 via PC and USB stick. The configuration can then be shared among other M400s. This simplifies setup and enhances batch configuration efficiency.

For details contact: Mettler Toledo India Pvt Ltd 36/37 Jolly Maker Chambers II Nariman Point, Mumbai 400 021 Tel: 022-22024046, 22850516 Fax: 91-022-22029278 E-mail: deplmum@vsnl.com or Circle Readers’ Service Card 23

54 • May 2017

Chemical Engineering World

Products CEW Gravity Metal Detector with Rejection Valve At certain sites, pre-weighing metal detection is required by the user. This type of metal detector is installed in line with a feed chute. An electromagnetic coil surrounding the non-metallic body of this equipment is used for detection of metal present in the material. At bottom of the equipment a diverter valve is fitted to divert the rejected part of the material into a small piece of rejection chute. When the material with presence of metal passes through this part of the feed chute, the metal is detected and the diverter valve is activated to divert this part of the material to the rejection chute. The diverter valve comes back to its normal position when the contaminated material is delivered to rejection chute. The equipment then starts feeding the material to the weighing machine normally. The rejected material is collected in a container below the rejection chute.

For details contact: Jasubhai Engg 64/a, GIDC Indl Estate Phase 1, Vatwa, Ahmedabad, Gujarat 382 445 Tel: 079-49003636, Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com

or Circle Readers’ Service Card 3

103) Falling Film Evaporator A falling film evaporator is used for concentration and evaporation of relatively low viscosity liquids. Steam, hot water or hot oil is used as the heating media and the process is carried out under atmospheric or vacuum condition.

The evaporator is used for volume reduction where dilute products are concentrated to a medium concentration. The process is continuous. The liquid to be concentrated is fed from the top and a distributor ensures proper feed distribution in each of the tubes.

The distributor also ensures that all tubes are wetted and that the liquid flows in a film. The liquid and vapour both travel vertically downward. Due to a relatively thin film, the heat transfer coefficient is better than that obtained in reactors and simple shell and tube evaporators.

If further concentation is required, the concentrated product can then be fed to the WFE. For details contact: Dalal Engg Kavesar, Thane-Ghodbunder Road Thane, Maharashtra 400 607 Tel: 022-25976201 Fax: 91-022-25976207 E-mail: sales@dalalengineering.com or Circle Readers’ Service Card 4

Chemical Engineering World

May 2017 • 55

CEW Products Modular Surge Protection Device Eaton’s new MTL SD Modular range provides comprehensive protection from transient surge events up to 20 kA, the highest level of protection currently available for a modular pluggable device. Eaton’s MTL SD Modular range offers complete cost-effective surge protection to valuable instruments and distributed control systems.

The design of the MTL SD modular device reduces maintenance cost and downtime, as modules can be quickly and easily replaced. The pluggable part is held in place with a simple retention tag and can be removed from its base without de-energising the protected device, saving the user valuable time and complexity. This is achieved using an innovative ‘make before break’ design to ensure uninterrupted loop operation during replacement.

A diagnostic LED option is available to provide a clear, visual indication of a failed module so that engineers can immediately see which module to replace. A portable surge test device is also available, allowing users to simply check the health of each module during routine maintenance. This new modular range inherits the proven reliability of the MTL SD range, increasing system availability in a wide range of industries including oil and gas, chemical, power and water/wastewater. With versions available for all process signal types, they are ideal for panel builders, system integrators and engineers looking to protect electrical and electronic assets. The range is fully ATEX/IECEx certified for use in intrinsically safe applications, is SIL suitable and is designed to meet global standards.

For details contact: Eaton Butterfield, Great Marlings, Luton Bedfordshire LU2 8DL, U.K. Tel: +44 (0)1582 723633 E-mail: mtlenquiry@eaton.com or Circle Readers’ Service Card 5

Pneumofore TPN Series pump provide the ultimate vacuum of 0.5 mbar with high capacity required for centralized vacuum system. TPN Series guarantees the highest performance compared to other small on board single stage oil lubricated vacuum pump and this TPN pumps are ready to use machines designed for easy installation and troublefree integration into industrial process. Design and efficiency of mechanical parts guarantee low power consumption and provide added value in terms of sustainability and reduced operation cost.

The closed-loop lubrication circuit ensures negligible coolant consumption prevents air and environment contamination with harmful substances and reduces maintenance requirement. Therefore, TPN Series vacuum pump offer best return of investment and low life cycle cost. Features air cooling system through an aluminum radiator and electric fan thermostat for operating without cooling water. No coolant consumption thanks to the closed-loop lubrication circuit and high efficiency separation element.

Coolant separator and recovery for clean air exhaust without treatment. Durability and efficiency guarantee by the special aluminium alloy vanes that ensure constant performances even after tens of thousands of hours of operation. They are ready-to-use machines that can be easily and directly connected to the vacuum plant and the power supply without foundations. Limited footprint thanks to the compact layout designed to minimize the space needs. It has direct coupling between motor and air end to avoid energy losses. It has a sound-proof cabin for reduced noise impact. Fully automatic operation: intake valve regulated by safety vacuum switch, coolant temperature control, thermostat and auxiliary control switches. Control panel complete with main power switch, easy to operate.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 6

56 • May 2017

Chemical Engineering World

Products CEW Compact Vacuum Packages/Roots Pumping Systems Toshniwal provides solution to your vacuum application. Toshniwal are counted among the prominent manufacturers, suppliers and exporters of a wide range of roots pumping systems.

Toshniwal replaces multistage water/liquid ring pumps, steam jet ejectors with compact vacuum packages. Available in a spectrum of specifications, these systems are used in distillation process, food processing, drying of powder and solids, and transformer evacuation.The volume flow is from 180 to 97,000 m3/hr. Energy savings resulting from low motor rating. Integral pipe work allows easier installation. Constant vacuum is in the range 0.1 to 400 mbar (absolute). Booster and rotary pump may be started at the same time. Built-in bypass value to protect from overloads.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 7

Ion Exchange & Specialty Adsorber Resins An efficient technology from LANXESS for treating water is the use of Lewatit ion exchange and specialty adsorber resins. Among other applications, ion exchange resins are used to remove pollutants, such as nickel, nitrate, perchlorate, borate and hydrocarbons from drinking water. During the ion exchange process, contaminated water flows through a container filled with ion exchange resin. It filters the contaminants, binding the ions of the pollutants and replacing them with harmless ions. A variety of resins are used, depending on the pollutant. In the treatment of wastewater, the ion exchange resins remove heavy metals, such as mercury or cadmium. In addition, precious metals, such as copper or platinum, can be filtered out and then used for other purposes.

Industrial applications include the treatment of water for industrial processes in power plants.

These costly facilities need large volumes of cooling and process water, which have to be demineralized to protect the systems against limescale, for example. The microchip and pharmaceutical industries require water in extremely pure form. Lewatit is used in these industries to produce ultra-pure water, which is a vital manufacturing resource.

For details contact: LANXESS India Pvt Ltd LANXESS House, Plot No: A 162-164 Road No: 27, MIDC, Wagle Estate Thane (W), Maharashtra 400 604 Tel: 022-25871000 E-mail: s.prakash@lanxess.com or Circle Readers’ Service Card 8

Chemical Engineering World

May 2017 • 57

CEW Products Monitoring Liquid-based Processes PANalytical offers the new Epsilon Xflow system. This new on-line solution is made for the continuous analysis of the elemental composition of any liquid, providing real-time feedback from a production process.

The Epsilon Xflow can be incorporated in many different process streams in a wide range of industries such as mining and metals or the production of petrochemicals, polymers or food. Predefined conditions can be closely monitored, enabling an immediate reaction to any change, in this way avoiding waste and unnecessary expenses. Together with PANalytical specialists, customers will determine the positions in their processes, which can profit most from Epsilon Xflow. For example in the petrochemical industry the system can analyze sulphur in fuel even at concentrations lower than 10 mg/kg at many stages of the production process. At the same time low concentrations of vanadium and nickel, which may be harmful to the refinement process, can be determined. Industries will be able to closely check their waste water for hazardous compounds; a task becoming increasingly important with the obligation to comply with stringent environmental regulations.

The analytical core of Epsilon Xflow employs proven energy dispersive X-ray fluorescence (EDXRF) technology, which is robust and non-destructive with low detection limits and highly accurate and reproducible analysis results. Elements from sodium up to americium at concentrations from a few ppm to 100 per cent can be analyzed. Almost any liquid can pass through the flow cell across the detector which has a leakage protector in place. The system can be tailored to any customer’s needs with optional sample conditioning and common interfaces to manufacturing execution systems.

For details contact: PANalytical BV Lelyweg 1, 7602 EA Almelo The Netherlands Tel: +31 546 534444 Fax: +31 546 534598 E-mail: info@panalytical.com or Circle Readers’ Service Card 9

Refrigerated Incubators The new Thermo Scientific refrigerated incubators utilize powerful compressor technology designed to provide optimal temperature conditions for applications that require thermal stability and uniformity above, around or below the usual ambient laboratory temperature. The systems are also suitable for standard 37 0°C incubation applications in warm laboratory environments.

Available in both a benchtop and a more spacious floor-standing unit, the new Thermo Scientific RI-150 and RI-250 models of refrigerated incubators have been equipped with key attributes to enable ease-ofuse, while facilitating temperature uniformity and precise temperature setting for optimal sample safety and reproducibility of results. The systems are suitable for use in a range of pharma, life science, water treatment, biological research and microbiology applications, including incubation of bacteria and yeast, water testing, hatching of insects and fish, sample storage at specific temperatures and biochemical oxygen demand (BOD) testing.

For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@theromofisher.com or Circle Readers’ Service Card 10

58 • May 2017

Chemical Engineering World

Products CEW Oil Lubricated Vacuum Pumps Toshniwal supplies oil lubricated vacuum pumps.

These oil lubricated vacuum pumps of the TMS Series are single stage, oil-lubricated rotary vane vacuum pumps with oil re-circulation system. The lubricant system is rated for continuous operation of high intake pressures so that the pump may be used in a versatile manner in most rough vacuum applications. The pumps are used for suction of air also in presence of water vapour and for continuous industrial use. TMS Series pumps are made from high quality materials, has economical features which matches together to achieve: high pumping speed over the range of absolute pressure 1000 mbar-0.5 mbar; high water vapour tolerance and low noise level; no pollution; air cooled: built-in anti-suck-back system. The pumping capacities available are: 17 m3/hr, 35 m3/hr, 65 m3/hr, 100 m3/hr and 150 m3/hr.

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 11

Field-mounted HART Temperature Transmitter Easy configuration and diagnostics from the front, the 7501 field-mounted HART temperature transmitter can be mounted in 3 ways: on the temperature sensor, on a pipe or on a bulkhead.

It finds application in linearized temperature measurement with TC and RTD sensors, eg, Pt100 and Ni100; HART communication and 4-20 mA analogue PV output for individual, difference or average temperature measurement of up to two RTD or TC input sensors; and conversion of linear resistance to a standard analogue current signal, eg, from valves or Ohmic level sensors.

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 12

Chemical Engineering World

or Circle Readers’ Service Card 11

May 2017 • 59

CEW Products Gloves Cole-Parmer offers ThinTouch line of gloves perfectly engineered for strength and dexterity.

Traditional disposable gloves provide protection for only short periods of time and typically have a thicker, sturdier design for long lasting protection. Cole-Parmer ThinTouch gloves not only offer high levels of protection for longer time but its unique Touch and Feel experience due to optimized tactile sensitivity makes it a perfect glove for varied applications. Its ergonomic design is manufactured using an advanced elastic thin-film formulation for supreme sensitivity, excellent comfort and max protection.

Cole-Parmer’s ThinTouch line of gloves include Nitrile and Latex Gloves. ThinTouch Nitrile Gloves and ThinTouchPROtect Nitrile Gloves Cole-Parmer are the first two launched products from the range.

ThinTouch Nitrile Gloves 9.5” are the Next-Gen Best-in-Class Nitrile Gloves for applications involving small parts or operations demanding speedy handling. These latex- and powder-free gloves have low-particulates to prevent glove-related work contamination. In addition, these gloves meet ASTM D 6319, ASTM D 6124, EN 455-1, EN 455-2, ISO 9001 / ISO EN 13485 performance standards.ThinTouchPROtect Nitrile Gloves are ideal for use in chemotherapy drug production area and provide proven barrier protection from bacteria, viruses and chemicals.

These 12” non-sterile gloves are tested against 29 chemotherapy drugs as per ASTM D6978-05 and offers a high level of protection against these drugs. These gloves have an advanced composition with higher breakthrough time of 127.5 minutes against Carmustine (3.3 mg/ml) and 240 minutes against ThioTepa (10.0 mg/ml) under standard test conditions - clearing it for use with Carmustine and ThioTepa. They have been tested as powder free gloves as per ASTM D6124 minimising occurrence of powder related complication such as irritant contact dermatitis. Not just protection, these gloves provide a conformable feel to the user-especially when worn over a long period.

For details contact: Cole-Parmer India Pvt Ltd 403, A-Wing, Delphi Hiranandani Business Park, Powai, Mumbai 400 076 Tel: 022-61394410, 61394444, Fax: 91-022-61394422 E-mail: vinita.singh@coleparmer.in or Circle Readers’ Service Card 13

Signal Convertors With their innovative, patented technologies, Toshniwal Hyvac Pvt Ltd make signal conditioning smarter and simpler. Their portfolio is composed of six product areas offering a wide range of analogue and digital modules covering over a thousand applications in industrial and factory automation.

Their multi-functional transmitters offer you a wide range of versatile devices for isolation, conversion, scaling, amplification, alarming, control and more. Having one variant that applies to a broad range of applications can reduce your installation time and training and greatly simplify spare-parts management at your facilities. Their devices are designed for long-term signal accuracy, low power consumption, immunity to electrical noise and simple programming.Through their detachable, intuitive, intelligent operator interfaces, their devices can be accessed and managed in seconds; making configuration, simulation and troubleshooting easy and simple. Toshniwal Hyvac enables smart engineers to perform asset management smarter and simpler.

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 14

60 • May 2017

Chemical Engineering World

Products CEW Fluid Bed Dryers/Coolers Fluid bed dryers/coolers are widely used in the industry for gentle drying/cooling of free-flowing solids.

In fluid bed sysrems, the material is fluidised with the help of air stream using specially designed perforated plate. In addition to this, the fluidiser can also be made vibratory to assist the fluidisation by imparting mechanical energy. Drying/cooling media (air/gas) area admitted in the plenum below the perforated plate. Fluidised state enables intensive interaction of the material and drying/cooling media (air/gas), hence high rates of heat transfer are achieved. Product residence time can be adjusted through adjustable discharge weir.

Product drying and cooling is possible in single unit. AVM offers customised fluid bed drying systems with variety of configurations.

For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3, Akurdi Indl Estate Opp: Ador Welding Ltd D-1 Block, MIDC, Chinchwad, Pune Maharashtra 411 019 Tel: 020-27459986, 27459987 Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net or Circle Readers’ Service Card 15

Furnace Monitoring System Furnace monitoring system manufactured by Tokyo Seiko, Japan, provides a real time temperature image inside a furnace. Up to 11 areas on a thermal image can be assigned for the temperature monitoring of specified positions inside a furnace. Combination of Si-CCD camera having the sensitivity in the near infrared region and a robust relay lens make it possible to monitor clear inside image with a wide viewing angle even if the furnace is hot and dusty. The graphic software works on the Windows OS. The temperature trend data and the live temperature pattern are displayed on a CRT and a monitor respectively.

For details contact: Toshniwal Sensors Pvt Ltd E 19/20 Indl Estate, Makhupura Ajmer, Rajasthan 305 002 Tel: 0145-2695536, 2695482 Fax: 91-0145-2695006 E-mail: info@tspl-india.com / sensor@sancharnet.in or Circle Readers’ Service Card 16

Chemical Engineering World

May 2017 • 61

CEW Products Bag Lifting Centrifuge

Disk Impellers

These are instant top discharge centrifuge in which filter bag is fitted in the basket having easy detachable top ring. The filter bag along with top ring is fitted by hydraulic device or hoist and moved to desired place for unloading by opening the centre of the filter bag.

For details contact: HydroTech Engineers Plot No: 8 (AWM), Indl Development Colony Nr CIPET, GNDU Road Amritsar, Punjab 143 104 Tel: 0183-2256262, 2256363 E-mail: sales@hydrotech-ngineersasr@gmail.com or Circle Readers’ Service Card 17

FEDA Inc offers disk impellers mostly used for gas dispersion application. Curve blade (concave, parabolic, etc) disc can handle 2 to 6 times more gas than flat blade disk turbine. Power drop between gassed and ungassed condition is very less than conventional flat blade disk impellers.

Hence, it is preferred choice for gas dispersion applications, viz, fermentation, hydrogenation, oxidation, carbonisation, ethylation, etc.

For details contact: FEDA Inc B-37 Maruti Indl Esate Plot No: 59/1/2/3, Phase 1, GIDC Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok.chaurasia@gmail.com or Circle Readers’ Service Card 18

Cutting Tool for Tubes Schwarze-Robitec has expanded its cutting tool and has combined the bending and the final cutting of short bent tube components for large dia of up to 76 mm (3”) and that in only one single working step. To do this, the cutting tool is integrated into the bending tool. This makes the whole process much more efficient and economical. The user’s benefits: a decrease in scrap material up to 90 per cent and clearly reduced production times.

Consequently, the system of the integrated cutting tool is perfectly suited for producing parts in high quantities due to the immense material and time savings. The tools can process these precise cuts in the shortest time possible. At the same time, the material savings prove to be very high: until now, up to 100 mm scrap accumulated for each part produced, depending on the bending system used. Machining of longer pipe units instead of cut-off pipe sections is also possible thanks to the integrated cutting process. This also reduces the time required for loading and unloading the machine.

With the new cutting technology all components receive a clean cutting edge and can be immediately processed further. Therefore, this technology is particularly suitable for series production. The controlled chip removal process keeps most of the chips produced during the cutting process away from the machine. A prerequisite for integrating the technology into all-electric machines of the high-performance series is the use of the CNC control NxG. The new controlling system enables the cutting at any bending angle between 0 and 90 degrees and is simply integrated into the bending program. The cutting tool processes all common materials including aluminized steels or hard-to-cut materials, such as chrome-nickel steels For details contact: Schwarze-Robitec GmbH Olpener Straße 460 – 474, 51109 Köln, Germany Tel: 0221-89008-0 Fax: 0221-89008-9920 E-mail: sales@schwarze-robitec.com or Circle Readers’ Service Card 19

62 • May 2017

Chemical Engineering World

Products CEW Industrial Gear Units with Extruder Flanges As an all-new supplement to the modular industrial gear range, NORD Drivesystems now provides extruder flanges optimized for heavy duty operation.

Several different extrusion flanges are available for each of the industrial gear units from size 5 to 11, with rated torques from 15 to 80 kNm. Almost all usual dimensions can thus be adapted. Extra-large thrust bearings ensure that all process forces are absorbed and provide enhanced durability for long lifespans.

This new option for the industrial gears enables primary and secondary plastics and rubber manufacturers and their suppliers to create safe and highly reliable drives in customizable configurations. The NORD industrial gear range offers a variety of input and output shafts and gaskets, flexible mounting directions and thermal monitoring solutions.

For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com or Circle Readers’ Service Card 20

Connector

a

Maplesoft and Phoenix Integration offers a new plugin that enables engineers to easily incorporate Maplesoft software products Maple and MapleSim into the ModelCenter workflow integration and automation platform from Phoenix Integration. The plugin allows engineers to take advantage of the reduced risk, improved designs, and shorter development times resulting from using Maplesoft’s engineering tools, along with the efficiencies that come from process integration platform.

MapleSim, an advanced system-level modeling and simulation tool, enables engineers to take advantage of modern techniques in modeling and simulation. Maple is a powerful math software tool for mathematical computations and explorations. ModelCenter is a vendor-neutral software framework for creating and automating multi-tool workflows, optimizing product designs, and sharing engineering data and knowledge. The new connector makes it easy to bring Maple and MapleSim into ModelCenter so they can be seamlessly incorporated into the ModelCenter-based engineering workflow.

A powerful application of this connector is functional verification of a system design by automatically testing MapleSim models against design requirements from Model-Based Systems Engineering (MBSE) software tools, such as IBM Rational Rhapsody or No Magic MagicDraw. Engineers can directly connect the parametric design constraints, which are derived by the MBSE tool, to multidisciplinary system simulations in MapleSim. When a change is made to the system parameters, ModelCenter calls MapleSim to run a simulation using the new parameter set. ModelCenter then checks the simulated results against the design constraints, and generates a report of the compliance test results. Any constraint failures are flagged, allowing the design team to make the necessary design changes very early in the process.Other applications include using MapleSim and Maple for design space explorations, optimization and development projects based on executable requirements, all inside ModelCenter. This connector can be freely downloaded from the Maplesoft website. Maplesoft products can also be integrated with other process integration platforms, such as Optimus from Noesis Solutions For details contact: Maplesoft 615 Kumpf Drive Waterloo, ON N2V 1K8, Canada or Circle Readers’ Service Card 21

Chemical Engineering World

May 2017 • 63

CEW Products Float-operated Level Transmitter Stem carrying series of reed switches and resistors forms a potentiometer circuit, which extends to the full indicating length of the transmitter. As the float travels through the indicating distance, the magnet located within it top off the reed switches, thereby varying the resistance fed to the electronics, which in turn converts the change in resistance to industry standard analogue output For details contact: Filpro Sensors Pvt Ltd No: 130, 10th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com

Flow Indicator and Integrator The FIQ-2000 flow indicator and integrator accept 4-20 mA/010 V input signal and displays the engineering unit and also cumulates the value. The process value is displayed on a 4-digit LED display, while the cumulative value is displayed on a 5-digit LED display. The FIQ-2000 employs SMD technology to optimise space and increase reliability. Housed in a sleek enclosure FIQ-2000 can be remotely accessed.

For details contact: SUN Indl Automation & Solutions Plot No: 95, Developed Electronic Indl Estate Perungudi, Chennai 600 096 Tel: 044-30788900 E-mail: sias@vsnl.com

or Circle Readers’ Service Card 22

or Circle Readers’ Service Card 23

Efficient Drive Solutions These drives meet the highest efficiency standards – IES2 system efficiency and IE4 or Super Premium Efficiency for the motor by itself – and reach excellent efficiencies even in the partial load range and at low speeds. The systems allow for simple daisy-chaining; short power lines can be connected from one drive to the next.

The user-friendly systems consist of a helical-bevel gearbox, an IE4 permanent magnet synchronous motor and a frequency inverter for installation near the motor. They are easy and quick to install thanks to all pluggable connectors. Maintenance switches, key switches and direction switches on the device allow for flexible direct access to individual drive axes for set-up or service. Built into a light alloy case, the compact drives are also easy to handle. Boasting a large overload capacity, the drives come in three preferred sizes that match the typical performance requirements in intralogistics and airport applications. Conveyor speeds and running directions are regulated by the LogiDrives’ frequency inverters. These VFDs are optionally available with an incremental encoder for highly dynamic applications. The STO and SS1 safety functions according to EN 61800-5-2 are included by default. Drive-related sensors can be connected via M12 plugs.

Sensor data collected by the inverters can be passed on to higher-level systems. LogiDrive installations can be deployed around the world thanks to comprehensive certifications. Interfaces for all common bus systems are readily available.

For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com / Muthusekkar@nord.com or Circle Readers’ Service Card 24

64 • May 2017

Chemical Engineering World

Products CEW Platinum Cured Silicone Hose Reinforced with Polyester Braiding Imafit is platinum cured silicone hose reinforced with polyester braiding. It has excellent flexibility for pressurized fluid transfer application in pharma and biotech industries.

These products are catered to all pharma and biotech companies in India as well as overseas markets. Imafit hose is manufactured under stringent quality parameters to have greater flexibility and minimum bend radius. Imafit conforms to US FDA 21 CFR 117.2600 Food Grade Standard, USP Class VI and ISO 10993-1. It is certified by ROHS and TSE/ BSE Certification (free of animal derived material). It is free of restricted heavy metals and Phthalate/Bisphenol/Volatile Plasticizer. Complete validation package available upon request. Imafit is manufactured from low volatile grade silicone resin. It is excellent in flexibility and has lot traceability features. It imparts no taste and odour. It is available with SS-316 L Tri-Clover end fittings in required length. It has also available in coloured outer layer and custom colour coding. It has flexibility at lower temperature up to -80 0°C and high heat resistance up to 180 0°C. It is sterilizable by Autoclave, Ethylene Oxide Gas & Gamma Radiation.

For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Road, Mira Road (E) Thane, Maharashtra 401104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 25

Hybrid & Iron Oxide Adsorbers Arsenic pollution is one of the most dangerous forms of drinking water contamination.

You can’t taste it, you can’t smell it, but the toxic substance accumulates in the body.

Some very high concentrations of arsenic occur in the groundwater in many regions. It is estimated that more than 100 million people worldwide drink water with an arsenic content higher than 50 micrograms per liter. Arsenic is a semi-metal that occurs in nature in the form of minerals. Under certain conditions, highly toxic arsenic compounds can be washed out of the stone and pass into groundwater. Numerous medical studies document the chronic illnesses suffered by people who drink water contaminated with arsenic for extended periods, including skin disorders and carcinomas. The hybrid adsorber Lewatit® FO 36 and the iron oxide adsorber Bayoxide® E 33 are specially designed to remove arsenic from drinking water and wastewater. The core of the Bayoxide® system is a solid bed of iron oxide beads. They have finely structured surfaces that adsorb pollutants when contaminated water flows over them. The beads are very stable in water and do not break down.

They consist of minute particles that can only be seen under a high-resolution electron microscope. Every gram of these particles has a surface area of around 150 square meters, ie, the floor area of an entire apartment on one gram of material, and it is on this surface that the arsenic is selectively adsorbed. Bayoxide E33 from LANXESS not only helps to treat drinking water. Other fields of application include wastewater treatment, eg, in mining, or the treatment of contaminated groundwater in the vicinity of abandoned industrial plants.

For details contact: LANXESS India Pvt Ltd LANXESS House, Plot No: A 162-164, Road No: 27, MIDC, Wagle Estate Thane (W), Maharashtra 400 604 Tel: 022-25871000 E-mail: s.prakash@lanxess.com or Circle Readers’ Service Card 26

Chemical Engineering World

May 2017 • 65

CEW Products Medium Voltage Drive

Radial Diaphragm Valves

CHH100 high voltage frequency inverter control system adopts the DSP + FPGA digital processing technologies so its control accuracy and response speed are improved significantly; its output side uses the phase-shifting multiple pulse width modulation (PWM) technology, it has an extremely low harmonic content while there is no output filter. The touch panel is friendly and convenient for operating. It has been extensively used in multiple industries like electric power, metallurgy, mines, cement and petrochemical industry, and well accepted by customers

Cipriani Harrison’s radial diaphragm valves are made from forged AISI 316L as per ASME BPE specifications.

Radial diaphragm valves are widely accepted due to their unique design features which minimise dead legs in critical pharma and biotech operations.

The aseptic design minimises hold-up volumes helping to avoid contamination. The diaphragms of these valves are compliant with FDA 177.2600 and USP Class-VI. The available sizes ranges from ½” to 2” both in manually and pneumatically actuated versions.

For details contact: Cipriani Harrison Valves Pvt Ltd 1901, GIDC, Phase IV, Vitthal Udyognagar Vallabh Vidyanagar, Gujarat 388 121 Tel: 02692-235082, 235182 Fax: 91-02692-236385 E-mail: info@harrisonengineers.com

For details contact: Shenzhen Invt Electric Co Ltd No: 4 Bldg, Gaofa Scientific Indl Park, Longjing, Nanshan District Shenzhen, China E-mail: overseas@invt.com.cn or Circle Readers’ Service Card 27

or Circle Readers’ Service Card 28

Petal Valve Gall Thomson offers an enhanced version of its Petal Valve MBC (Marine Breakaway Coupling) for the offshore hydrocarbon transfer market.

The robust design features CNC manufactured precision Petals and improved low pressure metal seals for reliability and reduced risk of leakage on activation. The Petal mechanism has no axles, shafts, hubs or bearings to seize and is totally failsafe. Petal17 fits standard flanges at any recommended location in the hose assembly.

A number of options are also available which include Locking Petals to further reduce the risk of post-activation leakage when low pressure coincides with a harsh environment; and Unit Status Indicators (USI) which allow the operator to conduct quantifiable visual integrity inspections of the MBC upon installation and during service without removing the device from the system. For easier handling during installation and post activation, lifting lugs can also be provided as an option. Gall Thomson MBCs provide an identified safe parting point in marine hose transfer systems and automatically shut-off product flow and prevent system damage in the event of an extreme pressure surge or undue significant tensile load on the hose system. Gall Thomson MBCs therefore minimise risk to assets and damaged reputation and reduces the risk of transfer downtime, injury to personnel, clean-up costs and environmental pollution.

For details contact: Gall Thomson Environmental Ltd Technology Centre, Suffling Road, Great Yarmouth Norfolk, NR30 3QP, U.K. Tel: +44 1493 857936 E-mail: sales@gall-thomson.co.uk or Circle Readers’ Service Card 29

66 • May 2017

Chemical Engineering World

Products CEW Drive Data in the Cloud All drive axes can be monitored from anywhere in the world via an Internet connection. AC vector drives and motor starters controlled via Profinet simultaneously transmit live status data in UDP packets, on the same bus line, without affecting regular control communication.

The cloud-enabled drives send data about their power consumption, speed, and voltage, as well as the status word. Tunneled through a Siemens PLC, all of this information is transmitted to an IoT gateway and on into the cloud. Status data can then be analyzed for energy profiling, asset management, and remote maintenance purposes. Of course, any overload and error states can be visualized. The drives can also transmit additional application data into the cloud at any time – for instance, data of connected sensors and actuators. Moreover, other parameters can be derived from available status data, notably current oil temperatures. NORD has successfully validated this in initial tests. Such data allows for conclusions about lubricant aging that can be used for predictive maintenance. NORD continues to work on and further refine IoT-related and Smart Factory concepts. Novel NORD drive solutions that have already been available for some time include economic condition monitoring implementations based on virtual sensors.

For details contact: NORD Drivesystems Pvt Ltd 282/2, 283/2, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC II Pune, Maharashtra 411 057 E-mail: marketing.in@nord.com / Muthusekkar@nord.com or Circle Readers’ Service Card 30

Connected Solutions for Higher Process and Product Safety Bosch Packaging Technology shows how Industry 4.0 solutions help to achieve higher process safety and product quality. Detailed information about each machine, line or process status is provided by the Condition Monitoring platform. It records data in real-time, enabling maintenance staff to react before cost-intensive process deviations or downtimes occur.

To ensure constant product quality, all process steps are subject to strict regulations. The Bosch Pharma Manufacturing Execution System (MES) enables pharma companies to take the step towards a transparent, paperless production. To this end, Bosch works with the software provider Parsec Automation Corp and configures the MES software TrakSYS according to the requirements of the pharma industry. Together with a complete audit trail, it includes all necessary functionalities to manage machines and processes, and to generate electronic batch records (EBR), thus facilitating the approval for batch releases by qualified persons. The Bosch Pharma MES can be integrated into any Bosch or thirdparty machines and lines, as well as into complete manufacturing facilities. When it comes to packaging, the unambiguous serialization of secondary packaging aims at protecting patients from counterfeit medicine ensures the traceability along the production chain. The Track & Trace solution fulfills both requirements. It consists of the CPI software and machine modules, which are connected within the serialization process. At the machine level, CPS modules print data matrix codes on to folding cartons, verify the codes and if required, equip the packaging with a tamper-evident seal. The CPI software integrates the CPS modules into the company IT. This ensures a reliable serialization from the allocation of the serial numbers through to the last aggregation step.

For details contact: Commha Consulting GmbH & Co KG Poststraße 48, D-69115 Heidelberg Germany Tel: +49 6221 18779-27 E-mail: bosch@commhaconsulting.com or Circle Readers’ Service Card 31

Chemical Engineering World

May 2017 • 67

Plastasia 2017 Dates: 08-11 July 2017 Venue: Pragati Maidan, New Delhi Details: This event has built a reputation as the ideal place to discover the latest innovations in plastics, live demonstration/s, share ideas and most importantly secure orders. Today, Plastics has become omnipresent and an integral part of day-to-day activities.

For details contact: Organiser: Triune Exhibitors Pvt Ltd Email: info@plastasia.in Website: http://www.plastasia.in/ Contact No.: 080 - 43307474 India Machine Tools Show Dates: 28-31 July 2017 Venue: Pragati Maidan, New Delhi Details: IMTOS a biennial event showcases path breaking ideas and innovation in machine tools, material handling and automotive technology.

The show witnesses participation from over 500 companies every year..

For details contact: Organiser: K & D Communications Ltd Email: kandd@engimach.com Website: http://www.kdclglobal.com/ Contact No.: 079-26460624 ENGIMACH Dates: 06-10 December 2017 Venue: Helipad Ground, Gandhinagar, Gujarat Event: The ENGIMACH showcase engineering products and services, heavy and light machines, machinery equipment and accessories, tools and parts, technological devices and products, engineering tools and allied products and services. It is the most trusted machines and tools show that exhibits latest products and services, latest innovations and technologies and is known to attract visitors around the world. It is an ideal event that witnesses the best buyer and seller partnership and is a dynamic platform.

For details contact: K & D Communications Ltd 3rd Floor, Kailash-A, Sumangalam Society Above HDFC Bank, Opp: Drive-In Cinema Bodakdev, Ahmedabad, Gujarat Waste Technology India Expo Dates: 18-20 January 2018 Venue: Bombay Convention & Exhibition Centre, Mumbai Event: Waste Technology India Expo is a 3 day event in Mumbai.

The waste management and recycling exhibition will have solutions for managing and recycling of different kinds of waste, both solid and liquid, generated in industries, cities, homes, etc, to ensure clean surroundings. This event showcases product from air and water management, environment and waste management industries.

For details contact: Virtual Info System Pvt Ltd 231 Mastermind-1, Royal Palms Mayur Nagar, Aarey Milk Colony Goregaon (E), Mumbai 68 • May 2017

China (Shanghai) International Chemical Technology & Equipment Fair Dates: 23-25 August 2017 Venue: Shanghai New International Expo Centre (SNIEC) Event: The event will showcase wide variety of chemical technology and equipment associated with this field. Thus event like this will organize wide variety of workshops, seminar presentation and open forum questionnaires with the help of it the exhibitors will showcase products and services like pumps, compressors, thermal process, instrumentation, control, automation techniques, chemical industry apparatus and also regarding plants associated with this field. In addition to this the event will cordially invite all the eminent and distinguished exper ts associated with this field.

For details contact: Organiser: Guangzhou Zhenwei International Exhibition Co Ltd Contact: Tel: + 86 (0)20 83953253

China Adhesive Dates: 23-25 August 2017 Venue: Shanghai World Expo Exhibition And Convention Center Event: China Adhesive is not only an event for adhesives industry but for all these related industry like package, construction materials, wood, windows, textile, aerospace, electricity, coating and decoration.

The exhibition is expected to attract more than 300 exhibitors to display the latest products and technologies. Over 15,000 professional visitors from more than 20 countries and regions will attend the exhibition.

For details contact: Organiser: CCPIT Sub-Council of Chemical Industry Contact: Tel: + 86-10-64288748

China International Chemical Industry Fair Dates: 30 August - 1 September 2017 Venue: Shanghai World Expo Exhibition and Convention Center, Shanghai, China Event: This fair is an international fair that has created enough space for the petrochemicals and processing, basic inorganic chemicals, basic organic chemicals, agrochemicals, fine and specialty chemicals, new chemical materials, chemical equipment and engineering products, chemical control apparatus and instruments and other chemical services. The fair allows the exhibitors to enter the Chinese market and discover new business traits and prospects. Through his fair, the exhibitors can penetrate through Chinese economy and develop new business ideas and solutions.

For details contact: CCPIT Sub-Council of Chemical Industry Building 16, Block 7, Hepingli Dongcheng District, Beijing, China Chemical Engineering World

Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.

CHEMICALS M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development.

5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.

Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure.

Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat.

The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.

Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra.

The current status of the project could not be ascer tained.

According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.

Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the manufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance.

Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village:

Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascer tained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, or tho anisidine/para anisidine from 100-TPM to 1,100-TPM, or tho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant.

Chemical Engineering World

May 2017 • 69

CEW Project Update district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator.

FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion.

Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years.

Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product.

Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018.

Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF 70 • May 2017

sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin.

The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-cu m/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator.

Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat.

The project is waiting for environmental clearance.

RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat.

Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date.

MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval.

Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7-million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal/kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha.

Chemical Engineering World

Book Shelf CEW Process Automation Handbook: A Guide to Theory and Practice Authors : Jonathan Love Price : USD 252.19 Pages : 1093 (Hardcover) Publisher : Springer About the Book : This book distils into a single coherent handbook all the essentials of process automation at a depth sufficient for most practical purposes. The handbook focuses on the knowledge needed to cope with the vast majority of process control and automation situations. In doing so, a number of sensible balances have been carefully struck between breadth and depth, theory and practice, classical and modern, technology and technique, information and understanding. A thorough grounding is provided for every topic. No other book covers the gap between the theory and practice of control systems so comprehensively and at a level suitable for practicing engineers.

Practical Laboratory Automation: Made Easy with AutoIt Author : Matheus C. Carvalho Price : USD 78.07 Pages : 248 (Paperback) Publisher : Wiley-VCH About the Book: By closing the gap between general programming books and those on laboratory automation, this timely book makes accessible to every laboratory technician or scientist what has traditionally been restricted to highly specialized professionals. Following the idea of “learning by doing”, the book provides an introduction to scripting using AutoIt, with many workable examples based on real-world scenarios. A large portion of the book tackles the traditionally hard problem of instrument synchronization, including remote, web-based synchronization. Automated result processing, database operation, and creation of graphical user interfaces are also examined.

Industrial Automation and Process Control Authors : Jon Stenerson Price : USD 93.77 Pages : 420(Hardcover) Publisher : Prentice Hall About the Book : Covers PLCs, process control, sensors, robotics, fluid power, CNC, Lockout/Tagout and safety, and more. Offers such a wide array of topics that readers can use this book as a reference for many different issues in industrial automation. Featuring the greatest breadth and depth of coverage available on the subject, this practical book explores the main topics in industrial automation; and provides a much-needed, understandable discussion of process control.

Chemical Engineering World

Automation Made Easy: Everything You Wanted to Know about Automation--and Need toAsk Author: Peter G Martin and Gregory Male Price: USD 89.00 Pages: 218 (Hardcover) Publisher: International Society of Automation About the Book : After a quick glance at the plant floor, it is very easy to see the industrial automation industry interoperates with other functions within the enterprise. Trying to keep up with changing technologies, however, is never easy and the industrial automation environment is no exception. Whether you are a student just starting out or are a top-level executive or manager wellversed in one domain, but have limited knowledge of the industrial automation industry, it’s easy to find yourself adrift in this evolving industry. That is where this easy-to-read book comes in; it provides a basic functional understanding in the field of industrial automation.

In an effort to understand this industry, the authors break down the barriers and confusion surrounding the technical details and terminology used in this converging field. They provide an introductory-level approach, covering most of the major industrial automation topics, such as distributed control systems (DCSs), programmable logic controllers (PLCs), manufacturing execution systems (MESs), and so on. You may even learn a recipe or two. This book is ideal for executives, business managers, information technologists, accountants, maintenance professionals, operators, production planners, just to name a few, and provides an in-depth but easy overview for people new to the field who want to quickly educate themselves.

May 2017 • 71

CEW Ad Index Sr. No.

Client’s Name

Page No

Sr. No.

Inside Cover I

11

Mist Ressonance Engg Pvt Ltd

11

Client’s Name

Page No

1

Atomic Vacuum Company (Exports)

2

Avcon Controls Pvt Ltd

29

12

Paharpur Cooling Tower

35

3

Bonfiglioli Transmission (Pvt) Ltd

19

13

Polmon Instruments Pvt Ltd

29

4

Busch Vacuum India Pvt Ltd

9

14

Sahajanand Valves Pvt Ltd

31

5

GEA Process Engineering (India) Pvt Ltd

5

15

Sandvik Asia Pvt Ltd

23

6

Hi-tech Applicator

3

16

Sulzer India Pvt Ltd

17

7

Horizon Polymer Engineering Pvt Ltd

6&7

17

Suraj Ltd

31

8

ImageGrafix Engineering Services Pvt Ltd

55, 57, 59, 61

18

Toshniwal Instruments (Madras) Pvt Ltd

27

9

Jay Water Management Pvt Ltd

15

19

Vac Enterprises India

27

10

Liberty Shoes Ltd

Inside Cover II

20

Chemtech World Expo 2017/2018

INSIGHT INTO THE PHARMACEUTICAL AND BIOTECH INDUSTRIES

ADVERTISE TO EXPAND your reach through

Back Cover

Jasubhai Media Pvt. Ltd.

For Details Contact

Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com

72 • May 2017

Chemical Engineering World

Are you making the most of our B2B platforms?

We bring out some of the best monthly and bi-monthly B2B titles for chemical, pharma, and oil & gas industry.

Print Website

All our publications are available online on their respective websites.

We send fortnightly and monthly newsletters to our subscribers which are thousands in number allowing you to connect with potential overseas customers as well.

eNewsletter Mobile App

Mobile applications of all our publications are now available

Don't lose your chance to meet your potential customers.

Contact our sales representative now and enjoy the benefits of our mediums and their reach.

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

VOL.52 | ISSUE 1 | JANUARY 2017 | TOTAL PAGES 118 | US $ 10 | ` 150

December 2016 Vol 15 | Issue 05 | Mumbai | Price ` 150 Total Pages 60

www.cpfindia.com Vol. 35 No. 5 December 2016-January 2017 Mumbai ` 100/-

PHARMA BIO WORLD

The Journal of Materials & Equipment for the Process Industries

www.pharmabioworld.com VOL.13 | ISSUE 6 | OCTOBER-NOVEMBER 2016 | US $ 10 | ` 150

VOL. 35 NO.5

INSIGHT INTO UPSTREAM & DOWNSTREAM HYDROCARBON INDUSTRY DECEMBER 2016

SPECIAL ISSUE

VOL 15 ISSUE 05

CHEMICAL PRODUCTS FINDER

SPECIAL ISSUE

MUMBAI

DECEMBER 2016-JANUARY 2017

AUTOMATION ACROSS HYDROCARBON INDUSTRY

` 150

MUMBAI ` 100

Mumbai 2017

14-17, February 2017 Mumbai, India

14-17, February 2017 Mumbai, India

Mumbai 2017 14-17, February 2017 Mumbai, India

International Exhibition & Conference February 2018 : Mumbai, India

www.oswindia.com

CEW INTERVIEW

Industrie 4.0: Doing It Differently The Industrial Internet of Things (IIoT) is a potential game-changer and the future of manufacturing in India. If India is to achieve its goals of increasing manufacturing output to 25 per cent of GDP and create up to 90 million domestic jobs by 2025, we have to go further and drive innovation in the field of industrial automation. To accelerate efficiency and productivity, manufacturers will need to invest in energy efficient technologies and automation solutions and processes.

A profound digital transformation is now under way in the world’s leading industrial companies.

Companies realize today that the role of digital technology is rapidly shifting – from being merely a driver of efficiency to an enabler of fundamental innovation. India is no exception.

exothermic reactions for which safety is a primary concern. Security of IIoT-based systems is also of paramount importance not just from a safety perspective, but also in cases of the production of essential and strategically important goods and services.

The country’s manufacturing sector is on a high growth trajectory. The Prime Minister’s Office launched the Make in India program to place India on the global map as a manufacturing hub. The sector has the potential to touch $ 1 trillion by 2025. If India is to achieve its goals of increasing manufacturing output to 25 per cent of GDP and create up to 90 million domestic jobs by 2025, we have to go further and drive innovation in the field of industrial automation. To accelerate efficiency and productivity, manufacturers will need to invest in energy efficient technologies and automation solutions and processes.

It is imperative for the sector therefore, to re-imagine the work place and the entire ecosystem – with computing inside.

Another fundamental difference between IIoT and human and consumer applications of IoT is that an industrial plant is a very long-lived, capital-intensive asset requiring long-term support in the face of rapid technological advances. In contrast, other applications of IoT involve short product lifecycles that are often driven by whims of fashion and budget.

INDUSTRIE 4.0 Industrial Internet of Things (IIoT) – sometimes used interchangeably with other terms such as Smart Manufacturing, Industry 4.0, Digitization and Connected Enterprise is the industrial revolution of the 21st century. IIoT focuses on the end-to-end digitization of all physical assets and their integration into digital ecosystems with value chain partners and exchange of information in real time. This revolution will transform the manufacturing processes in sync with the speed of change in customer needs – which implies, making the production process flexible without taking excess time.

IIoT differs from the more generic concept of the Internet of Things (IoT). A fundamental difference is that IIoT aims to enhance the operation and management of industrial production processes, many of which involve 74 • May 2017

The Promise of Greater Productivity, Efficiency and Security The cornerstone of IIoT is productivity. In the world of oil and gas, for instance, where plant owners have one eye on capital expenditure (CAPEX), and another on falling oil prices, the biggest driver of IIoT technology is the promise of greater output. Running applications on premise may offer information technology (IT) teams the illusion of control, but, in reality, the task of deploying and maintaining applications locally is becoming increasingly complex and costly. Cloud applications are quicker, cheaper and easier to deploy, but the greatest value comes from integrating data across a portfolio of plants. In a distributed organization, IIoT can help business leaders see unadulterated, clean data taken from across the entire business before they make big decisions.

Cloud-hosted applications eliminate the politics of local reporting, self-serving key performance indicators (KPIs) and incomplete data sets, producing a meaningful, global view of what is happening and allowing big decisions to be taken at a lower risk to the business.

The IIoT approach also provides a level of supply chain efficiency and decision support not possible with conventional methods. The

ability to collect more data from uncorrelated sources provides opportunities for applying data analytics, modeling and machine learning techniques to gain better insights into the current and future state of the enterprise.

That closed systems offer a greater chance of protection from cyber-attack is a view that has been proven false. Manufacturers are now waking up to the fact that many older products were designed largely without any cybersecurity measures at all. As hackers become more sophisticated, the safest systems are now connected ones.

What is in it for India?

Almost hand-in-hand with Make in India, the government also launched the Skill India campaign. IIoT will drive growth in productivity by presenting new opportunities for people to upgrade skills and new high skilled jobs will be created. The growing use of digital labor will transform the skills mix and focus of tomorrow’s workforce. This is even more important today, as the sector is seeing significant increases in labor costs, which mean that productivity, must be improved in order to maintain a competitive cost position.

In many ways, IIoT represents an “undiscovered country” – full of promise, but waiting to be explored and mapped out. The resulting vision is a new form of automation system architecture that balances the computational and lifecycle benefits of cloud computing with the requisite on premise, appliance-hosted capabilities necessary to provide safe, secure and longlasting automation for complex manufacturing systems and processes. Therein lies the future of industrial automation.

Author’s Details: Ashish M Gaikwad

Managing Director, Honeywell Automation India Limited (HAIL) Country Leader, Honeywell Process Solutions (HPS) India Chemical Engineering World