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

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NEWS Industry News

FEATURE VACUUM EJECTOR SYSTEM  A PROCESS ENGINEER’S PERSPECTIVE Sandeep Kadam, Assistant Manager, Process and SAE, Aker Solutions Dynyaneshwar Kinhalkar, Assistant Manager, Process and SAE, Aker Solutions Pankaj Motharkar, Assistant Manager, Process and SAE, Aker Solutions Mithu Saha, Manager, Process and SAE, Aker Solutions

SIZING OF THERMAL SAFETY VALVES TSVS IN CRYOGENIC SERVICE R Brannock, Managing Director (U.K. Branch), TGE Gas Engineering GmbH A Saxena, Process Engineer, TGE Gas Engineering Pvt Ltd

POLLUTION CONTROL TECHNIQUES IN REFINERY AND DOWNSTREAM PETROCHEMICAL PLANTS Ajay Popat, President – Technology, Corporate Marketing and, Corporate Diversification, Ion Exchange (India) Limited

COMBATING THE EFFECTS OF CORROSION IN REFINERIES WITH DUPLEX STAINLESS STEELS Mohan Gawande, Manager, Chemical Group, Sandvik Materials Technology

NEWS FEATURE Vinati Organics will Continue to Show Remarkable Growth

MARKETING INITIATIVES Energy-efficient Range of HRS FUNKE Plate Heat Exchanger

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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, 2nd Floor, Nariman Point, Mumbai 400 021, INDIA. Tel.: 022-4037 3737 Fax: 022-2287 0502 E-mail: sales@jasubhai.com

4 • October 2018

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.

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CEW Industry News Odisha Governor lays foundation stone for Second Generation (2G) Ethanol Bio-refinery in Bargarh

addition of Lightwork Design, Siemens PLM Software will provide customers with enhanced 3D data visualization, high-end rendering and VR capabilities via its comprehensive suite of 3D product lifecycle management (PLM) applications. In addition, the acquisition expands Siemens’ ‘open business’ strategy with a commitment to continue to provide software toolkits for 3D data pre-processing for visualization, rendering and virtual reality, helping continue Siemens’ market-leading position in technology licensing to independent software vendors. The offerings of Lightwork Design will be combined with Siemens‘ existing PLM Components business, which includes Parasolid software, D-Cubed software and Kineo software, where more than 240 companies integrate Siemens PLM Software technology into 350 commercial applications for the benefit of six million end-users.

The foundation stone for Second Generation (2G) Ethanol Bio-refinery of Bharat Petroleum Corporation Limited being set up at Baulasingha village, Bhatli Tehsil, Bargarh ditrict, Odisha was laid by Governor of Odisha Professor Ganeshi Lal today. Shri Dharmendra Pradhan, Minister of Petroleum and Natural Gas & Skill Development and Entrepreneurship, along with several dignitaries were present on the occasion. The Bio-refinery, the first of its kind to be set up, will have a capacity to produce three crore litres of fuel grade Ethanol annually using Rice straw as the feedstock. Ethanol produced from this plant will be blended with Petrol. The cost of the project is around ` 100 Crore. Biofuels have assumed importance recently due to the growing energy security needs and environmental concerns. Several countries have put forth different mechanism and incentives to encourage production and use of biofuels to suit their domestic requirements. Indi has surplus biomass availability of about 120-160 MMT annually which if converted, has the potential to yield 3000 crore litres of ethanol. The National Biofuel Policy of India 2018 targets 20% Ethanol blending to Petrol by year 2030. However, due to non-availability of Ethanol, the current Ethanol blending in Petrol is about 3 to 4%. Setting up of 2G Ethanol plants will help achieve the target of Ethanol blending in Petrol. The Bargarh Bio-Refinery will utilize about two lakh tonnes of Rice straw annually as feedstock which will be sourced from nearby locations like Bhati, Ambabhona, Sohela, Burla, Lakhanpur, etc. The Bio-Refineries will contribute to cleaner environment due to usage of waste Rice straw for Ethanol production thereby reducing waste straw burning in fields. Blending of Ethanol in Petrol will reduce Green House Gas emissions as compared to fossil fuels. The plant is based on Zero-liquid discharge plant technology where all water will be recycled back into the plant. In addition to cleaner environment, the project will also help improve the socio-economic conditions of the farmers due to additional income from sale of Rice straw to the bio-refinery. Also, this will generate employment for appx 1200 persons (both direct and indirect) during construction, operation of plant and supply chain management of biomass. This will boost the infrastructural development in the area and overall improvement in livelihood of people. Further, blending of ethanol enhances self-sufficiency of the Nation by reducing oil imports, thereby saving foreign exchange.

Siemens acquires Lightwork Design to deliver advanced 3D data visualization Siemens has entered into an agreement to acquire Sheffield, United Kingdom-based Lightwork Design, a computer software and technology licensing company specialising in 3D rendering software development and virtual reality (VR) experience generation. With the 6 • October 2018

“With this acquisition, we increase the accuracy of the digital twin by adding advanced visualization, rendering and virtual reality technology into all phases of the virtual product development process,” said Tony Hemmelgarn, CEO, Siemens PLM Software. “The visualization and virtual reality space is continually changing and growing, and Lightwork Design has the advanced 3D data visualization, rendering and virtual reality technology required to help keep us in the forefront of the marketplace.” This latest acquisition builds upon previous investments in software offerings for the digital enterprise, which connects virtual product development and production planning with the real production environment and lifecycle support. Lightwork Design capabilities are already embedded into NX™ software, Siemens' 3D design application, and will also be added to other offerings across the Siemens portfolio. This enhances the digital twin by adding critical visualization information to the virtual product: from the initial product design and sophisticated product engineering, to simulation and test and through design visualization. Using more realistic imagery, simulations and VR environments can help customers identify and address potential product problems early in the lifecycle, saving both time and cost. “The demand for high-end, interactive and consistent product visualization in design and manufacturing is growing quickly,” said David Forrester, CEO, Lightwork Design. “Combining our Iray®+ technology and virtual reality collaborative design review software with Siemens PLM Software’s business will enable us to provide world-class solutions to the design and manufacturing industry on an even larger scale. We look forward to the opportunities for further development and integration of our visualization technology with existing Siemens software to contribute to Siemens’ broader digitalization strategy.”

Japanese Prime minister Mr. Shinzo Abe offers support to Swachh Bharat Mission Prime Minister of Japan Mr. Shinzo Abe has offered his Government’s support to the Swachh Bharat Mission. In a written message, Mr Abe said that Japan will cooperate with India, which promotes the Clean India initiative under Prime Minister Modi’s leadership. He further underscored Japan’s commitment to realize healthy societies in Asia and congratulated India on the success of the Mahatma Gandhi International Sanitation Convention. “Securing clean water and improving sanitary conditions is a common challenge in the world. We hope for the further progress of each country’s efforts to address the challenge through active discussions at this convention (MGISC)”, Prime Minister Abe said in his message. Chemical Engineering World

CEW Industry News “SABIC in India, for the World”; Excited to Partner in Ongoing Journey of Growth, says Al-Benyan,VC&CEO, SABIC India’s chemical industry is an important enabler of the growth in India and is projected to reach USD $300 billion by 2025 at a compounded annual growth rate of 8-10 per cent, according to reports. “We at SABIC look forward to being a part of this growth journey,” said Mr. Yousef Abdullah Al-Benyan, Vice Chairman and CEO, SABIC. “India and Saudi Arabia are nations on the move. We both have economies with enormous potential. This potential is being unlocked by two new visions that represent the hopes and aspirations of the people in India and of Saudi Arabia – the Saudi Vision 2030 and Hon’ble Prime Minister Narendra Modi’s vision of ‘New India 2022”, he said. He added, “We at SABIC look earnestly forward to being a part of this growth journey,” he added. As part of this address, Mr. Al-Benyan also lauded the close trade and diplomatic relations between India and Saudi Arabia. “Given that SABIC has been present in India for more than 25 years, we are confident in terms of understanding the Indian market and being able to generate value for all stakeholders, the Government, our customers and business partners. We acknowledge the opportunities in India, and positively hope to continue strengthening our footprint and partnerships here,” he added. Mr. Al-Benyan further indicated that SABIC continues to contribute significantly towards Indian Government’s agenda of Make in India, through innovation and technology. “SABIC takes pride in the partnership with the Government and continues to leverage its global experience and world-class infrastructure towards building a strong Petrochemical ecosystem in India,” he added. SABIC in India covers all three of the company’s Strategic Business Units – Petrochemicals – including chemicals and polymers -- Agri-Nutrients, and Specialties. “We are very much aligned with the motto of ‘Make in India’.” Mr. Al-Benyan shared his suggestions on how future challenges could be addressed with sustainable growth that includes: Electric-powered vehicles; Planes, trains and automobiles made from lighter, yet stronger, materials; More energy efficient buildings; Packaging that keeps food fresher for longer – reducing spoilage and waste; Advanced fertilizers that can produce more food on the same amount of land. “Petrochemical are essential to the production of all of these products. It is only by preparing for this emerging marketplace that we can grow sustainably and create value for India and for the world.” SABIC in India is aligned with the Government in regards to the sustainability vision and is collectively making positive progress. With an investment of more than USD $100 million in the Technology & Innovation Center in Bengaluru - one of the largest investments in India by a Saudi company, the focus has been to build research competencies to support growing market needs in India and SABIC worldwide. The Bengaluru center comprises of more than 300+ research scientists and engineers driving innovation and highest sustainable standards in manufacturing for India and for the world. SABIC in India has also collaborated with country’s premier Government institutions like the Central Institute of Plastics Engineering and Technology and the Council of Scientific and Industrial Research to make positive progress together.

Global industrial gloves market set for rapid growth, to reach USD 10.02 billion by 2024 Zion Market Research has published a new report titled “Industrial Gloves Market By Product Type (Disposable Gloves And Reusable Gloves), By 8 • October 2018

Application (Food, Chemicals, Healthcare, Pharmaceuticals, Manufacturing, And Others), and By Material (Polyethylene, Nitrile, Rubber, Neoprene, Vinyl, And Others): Global Industry Perspective, Comprehensive Analysis And Forecast, 2017– 2024”. According to the report, the global industrial gloves market was valued at around USD 5.47 billion in 2017 and is expected to reach approximately USD 10.02 billion by 2024, growing at a CAGR of around 9.84% between 2018 and 2024. Gloves are important to maintain a contamination-free environment in the food & beverage, biotechnology, and pharmaceutical industries. It is also necessary for the safety of workers in the automobile, aerospace, manufacturing, electric, chemical industries, etc. as hands are the main body part used for performing any action at the workplace for any work. Industrial work may have the risk of extremeness such as cold, heat, electricity, sharpness, force, and chemical. Industrial gloves are made to provide protection. Governments of almost all the countries have applied a strict set of laws and policies for the safety of workers at the workplace. Gloves are made up of natural vinyl, rubber, nitril, neoprene, etc.

Global Brands and Key Governments to Tackle Plastic Waste from Source to Sea The Dow Chemical Company (Dow) is investing in a new partnership mobilized by the World Economic Forum to bring businesses, civil society, national and local governments, community groups and world-class experts together to collaborate on solving plastic pollution. The Global Plastic Action Partnership (GPAP) is funded and supported by the governments of Canada and the United Kingdom, as well as several companies, namely The Coca-Cola Company and PepsiCo Foundation. “Dow, across the whole manufacturing value chain, understands the important role materials innovation will play in solving this critical global challenge,” said Jim Fitterling, CEO of Dow. “Through innovation and collaboration, Dow is committed to improving the recyclability of plastics and will help facilitate the world’s transition to a circular economy, where waste is captured, valued and designed into new products and services.” The GPAP will translate ambitious commitments into local action and show how business, communities and government can redesign the global “take-make-dispose” economy as a circular one. “This is one of several collaborations Dow is leading alongside diverse stakeholders, all with the objective of eliminating plastics waste in our oceans,” said Mike Witt, Dow’s corporate director of plastics circular economy. “We can and must solve this problem, and Dow is using its materials innovation expertise as well as our passion for a clean environment to ensure that future generations will benefit from clean oceans and a circular approach to critical materials, including plastics.” GPAP’s first collaboration will be with the Government of Indonesia. The world’s largest archipelago is suffering a crisis of plastic waste and the government has a national plan to reduce it by 70 percent over the next seven years. The GPAP aims to have investable localized solutions in place by 2020, which can then be adapted and implemented in other countries. The partnership will announce collaborations in two other coastal nations (one in West Africa and a small island developing state) in the coming months. These three proof-of-concept projects will coincide with the UN’s next landmark ocean conference. GPAP aims to complement and build on the momentum of other partnerships, collaborations and efforts of businesses, entrepreneurs, governments, non-profit organizations and scientists who are doing critical – and often unheralded – work to eliminate plastic pollution in our land, rivers and seas. It also follows major commitments by world leaders. Chemical Engineering World

CEW Industry News KBL takes Another Step towards Environmental Sustainability

customer and product portfolio. We look forward to working with Charlie and the management team to support Specialty Chemicals as it embarks on a new phase as an independent company.” As agreed at the Extraordinary General Meeting of November 30, 2017, AkzoNobel will return the vast majority of net proceeds from the sale of Specialty Chemicals to its shareholders. Further details will be announced in due course.

Ashland celebrates 40 years of methylcellulose production at Doel, Belgium

Kirloskar Brothers Limited is an environmentally-conscious organisation that has always striven towards minimising the energy consumption and emissions arising from its manufacturing operations. In keeping with this belief and objective, KBL recently installed solar panels on the roof of its Sanand plant for facilitating the use of the biggest source of renewable energy- The Sun. This green initiative was basically undertaken to promote energy conservation and reduce energy costs. The panels consist of a 150 kW grid tied to the rooftop of the plant. This grid is estimated to generate almost around 18,500 kWh of energy per month. This will not only result in financial savings for the organisation but would also help lower the carbon footprints of its Sanand plant. Since 2014, the Sanand plant has been recurrently honoured with the prestigious GreenCo certification, a Confederation of Indian Industry (CII) initiative to assess and analyse the green footprints of the concerned company, which is a befitting testimony to KBL’s commitment to the environment. Thus, the installation of the solar panels at the Sanand plant is just an extension of KBL’s efforts and focus towards a greener and sustainable future.

AkzoNobel closes sale of Specialty Chemicals to The Carlyle Group and GIC Akzo Nobel N.V. (AKZA; AKZOY) has completed the sale of the Specialty Chemicals business to The Carlyle Group and GIC for an enterprise value of €10.1 billion. Thierry Vanlancker, CEO of AkzoNobel, commented: “Today is a key milestone in the history of AkzoNobel, creating a focused paints and coatings company, with market leading positions, strong global brands, and a clear strategy to create value for all our stakeholders. “This is also an important step for the Specialty Chemicals business and I would like to take this opportunity to say thank you to our colleagues and wish them a successful future with Carlyle and GIC.” Charles Shaver, CEO of Specialty Chemicals, said: “I am delighted to assume my new role at Specialty Chemicals and look forward to working with the management team, Carlyle and GIC to deliver long term success. Specialty Chemicals has a strong global presence and a talented and dedicated team and I believe there is significant opportunity to drive additional growth through innovation and customer focus to build on the company’s leading positions in its markets.” Martin Sumner and Zeina Bain, Managing Directors at The Carlyle Group, added: “We are excited to invest in Specialty Chemicals and we are committed to growing the business and continuing to enhance its competitive position. Specialty Chemicals has a great heritage, a high quality asset base and workforce, an excellent track record of innovation as well as a diversified 10 • October 2018

Ashland is celebrating 40 years of production at its Doel plant, the only Ashland facility exclusively devoted to the production of methylcellulose, a key ingredient in a wide array of products ranging from construction dry mixes (cement and gypsum based), emulsion paints, advanced ceramics to pharmaceuticals, cosmetics. You will even find it in many shampoos and shower gel products, as it boosts foaming properties, making for increased and stronger foam at bath time. Since initiating production in 1978, the facility has churned out an estimated 1 million metric tons of methylcellulose, a versatile ingredient found in thousands of industrial and consumer end market applications. Each year the majority of what is produced at Doel goes toward creating 10 million metric tons of dry mortar. That’s the equivalent of a convoy of trucks loaded with 25 metric tons each, queueing up bumper to bumper for 8,000 kilometers. “I’m very proud of all that our diverse family of employees and plant have achieved over the years,” said Erik Vanhove, site manager. “We are always working to deliver on Ashland’s brand promise of ‘always solving’ for our customers, and I’m excited to see what the future brings.” The plant recently completed building a steam network that takes steam generated from a nearby waste processing plant to the Ashland facility. Ashland will use the recycled steam to heat its five reactors to support production at the site. The steam network is expected to yield emission savings of 100,000 tons of carbon dioxide, equivalent to the energy savings of 50 wind turbines.

Usage of agricultural material for making chemicals can be a great game changer for the country Union Minister for Road Transport & Highways, Shipping, Water Resources, River Development & Ganga Rejuvenation, Nitin Gadkari has said it is time for the country to go for alternative fuel sources such as ethanol, methanol and bio-diesel. Stressing on the importance of alternative fuels, the Minister said that ethanol is the future and government has decided to increase its production. The Cabinet has given approval to finance ethanol factories. The Minister said that the country needs to reduce its imports and increase exports and new initiatives for import substitution are very important and need to be supported. He emphasized that India is the fastest growing large economy and those investing in India will have a huge advantage. He said, India is doing well in technology, entrepreneurship, innovation and R&D and that a lot of new research is happening through which India can work miracles in the world. Particularly in petrochemicals, India has huge potential but we need to be cost-effective and pollution-free. He talked about the importance of ecology and environment, and highlighted that bio-plastics can be made from ethanol. Organic plastics can give a new vision for the petrochemicals industry, he said. Speaking about the importance of diversification in agriculture towards the needs of the energy and power sector, Gadkari said that new crops have to be identified. The Minister exhorted the industry to explore the possibility of using agricultural material for making chemicals, which he said can be a great game changer for the country. Chemical Engineering World

CEW Industry News Cabot Corporation Announces Acquisition of NSCC Carbon (Jiangsu) Co., Ltd. Carbon Black Plant in China Cabot Corporation (NYSE: CBT) announced that it has acquired NSCC Carbon (Jiangsu) Co., Ltd. from Nippon Steel Carbon Co., Ltd., a subsidiary of Nippon Steel Chemical & Material Co., Ltd. The carbon black manufacturing facility in Pizhou, Jiangsu Province, China, was originally commissioned in 2015. Cabot has been actively exploring and implementing opportunities to increase capacity in its global carbon black network through plant expansions, operational improvements and debottlenecking projects. This bolt-on acquisition will further support Cabot’s growth objectives and broaden its capabilities to serve customers in China. The 50,000 metric ton plant will support Cabot’s specialty carbons product line within the Performance Chemicals segment. “This acquisition showcases the continued execution of our ‘Advancing the Core’ strategy,” said Cabot President and Chief Executive Officer Sean Keohane. “It will not only strengthen our global leadership position in carbon black, but also enable us to continue to serve the growing needs of our specialty carbons customers worldwide. With our plants operating at high utilization levels, this acquisition will enable us to continue to be the partner of choice for our customers in key growth markets.” President of Nippon Steel Carbon Co., Ltd., Shunichi Sakai, said, “We are pleased to transfer the business to Cabot that is the leader in the carbon black industry.” The plant is scheduled to be temporarily mothballed to conduct maintenance and technology upgrades. The upgrades to manufacturing and environmental equipment will enable the site to be more flexible to manufacture different carbon black products and meet ever-stricter environmental standards. The purchase price, which is payable upon satisfaction of certain conditions, and the equipment and technology upgrades are expected to result in spending of approximately $50 million over the next two years.

Innova® Lift responds to ethanol producers looking for greater stress tolerance and better yields. Novozymes launched its next yeast technology, Innova Lift, for the starchbased ethanol industry. The product follows the launch earlier this year of an ambitious yeast platform, Innova, and the first product, Drive. “We are continuing to deliver on our promise to quickly bring innovative yeast and enzymes to a market that is clearly looking for exactly that,” says Brian Brazeau, Novozymes’ Vice President for Biofuels Commercial. “Lift targets ethanol plants with long fermentation times – delivering greater tolerance to common stressors such as high temperature and organic acids.” An ethanol plant’s fermentation is a crucial part of securing better yields. However, the fermentation process is also tricky; even small spikes in temperature or organic acid levels can cause disruptions. Having the opportunity to use a robust yeast can help producers meet these two key challenges. Innova Lift expresses a glucoamylase that is two times more effective at converting difficult-to-reach starch. When paired with advanced enzyme solutions, Lift also has the potential to significantly increase ethanol yields, reduce fermentation risks and eliminate costly inputs, while improving performance reliability. Until now, yeast strains have remained largely unchanged. Novozymes’ new yeast platform, Innova, has been founded on new S. cerevisiae yeast – utilizing proprietary methods to enhance its ability to withstand the rigors of today’s ethanol production processes and goals. “The ethanol industry has clearly been longing for new and reliable innovation for a very long time, not just updates of old products,” Brazeau adds. 12 • October 2018

Numerous ethanol plants have begun using Novozymes’ yeast since the introduction of the Innova platform and are realizing the benefits in productivity. “By leveraging the synergies of our enzymes, yeast, and technical services, Novozymes has reset performance expectations for yeast and fermentation by delivering the most advanced and useful solutions, based on customer needs,” says Brian Brazeau.

Lanxess to build new production plant for highperformance plastics in Germany Specialty chemicals company Lanxess is continuing to invest in its global production network for high-performance plastics and is building another compounding facility at its Krefeld-Uerdingen site, Germany, for a mid double-digit million euro amount. Starting in the second half of 2019, the company will produce Durethan and Pocan engineering plastics, which are used primarily in the automotive as well as the electrical and electronics industry. In addition, a warehouse and a silo facility will be built. Construction will begin in the fourth quarter of 2018 and the investment will create around 20 new jobs at the Krefeld-Uerdingen site. "The highperformance plastics business is a central pillar of our growth strategy. By expanding capacity, we are further strengthening our position as a provider of innovative product solutions for modern mobility. At the same time, we are making even better use of the potential of our integrated value chain for these products," said Hubert Fink, Member of the Lanxess Board of Management. "The investment also shows that we are strongly committed to North Rhine-Westphalia as a business location." Lanxess already operates a polymerization and compounding plant for high-performance plastics in Krefeld-Uerdingen. It was only in March 2018 that the company put a new line for the production of specialty compounds into operation there. With the new investment, LANXESS is once again strengthening the importance of the site for the company. "Krefeld-Uerdingen is our central production platform for high-performance plastics, especially for the European markets. The expansion will enable us to better serve the continuing high demand from this market region in the future," said Michael Zobel, head of Lanxess’ High Performance Materials business unit. The new plant in Krefeld-Uerdingen will be designed so that Lanxess can expand its operations in the coming years, in line with demand. Lanxess high-performance plastics allow the construction of components that replace metal parts in motor vehicles and thus contribute to reducing weight, fuel consumption and emissions. The innovative materials are used, for example, in engine applications, door structures, pedals, front ends and cockpit cross members. Depending on the part, the lightweight construction can make a weight-saving of up to 50 percent. There are also many applications for Lanxess plastics in hybrid and electric vehicles, some of which are already successful in mass production. These include components for charging systems, carriers and cell holders for battery systems as well as sensors and housing parts for electric motors. The materials also have great potential in electro mobility infrastructure, such as in housing, switches and terminal clips for charging stations. Lanxess is highly backward integrated in the value chain of high-performance plastics. The company produces the precursors for its engineering plastics, like glass fibers for the PA and PBT compounds and the polyamide 6 monomer caprolactam, all in its own plants. In recent years, Lanxess has continuously expanded its compounding capacities so that the company can process most of the intermediates it produces into high-performance plastics itself in its global plant network. The specialty chemicals company is currently also building a new compounding plant in Changzhou, China, which is scheduled to come on stream in the second quarter of 2019. Chemical Engineering World

CEW Industry News BASF sets up new production facility in Taiwan for world’s first expanded thermoplastic PU BASF, inventor of the world’s first Expanded Thermoplastic Polyurethane (E-TPU) Infinergy®, has launched a new Infinergy production facility at its Changhua manufacturing site in Taiwan. The expanded capacity will meet growing demand for the revolutionary material solution across a variety of applications and industries. “The Changhua production site will play a key role in helping us to meet the rising demand for E-TPU,” said Jens Dierssen, Head of Global Business Management Infinergy, BASF. “With the new production facility, we are expanding our global footprint to better serve customers within the Asia Pacific region.” “This investment reflects our commitment to the market, providing efficient production, timely qualification process to meet the growing market demands and customer needs. We are now even closer to the market and our customers, ” added Kin Wah Chay, Managing Director of BASF Taiwan. The closed-cell, elastic particle foam has a unique blend of properties, such as high rebound, low density, durability over a wide temperature range, chemical resistance and low weight. This innovation is widely used in the transportation, furniture, construction and sports equipment, such as a bicycle saddle created by Ergon, a cycling innovation company based in Koblenz, Germany. Ergon’s bicycle saddles are comprised of two shells functioning in isolation from each other in a sandwich construction, held in a floating arrangement by the high-performance elastomer damper made of Infinergy. In a threewheeled concept vehicle, 05GEN from Yamaha Motor Co., Ltd., BASF’s Infinergy was used in the tires to enhance the overall riding experience, and its characteristic cellular structure contributed to its striking design. The material has also been adopted in construction, providing a safer and improved sporting experience on running track and playing fields, owing to the outstanding cushioning effect of the E-TPU particles. BASF’s Performance Materials division encompasses the entire materials knowhow of BASF regarding innovative, customized plastics under one roof. Globally active in four major industry sectors – transportation, construction, industrial applications and consumer goods – the division has a strong portfolio of products and services combined with a deep understanding of application-oriented system solutions. Key drivers of profitability and growth are our close collaboration with customers and a clear focus on solutions. Strong capabilities in R&D provide the basis to develop innovative products and applications. In 2017, the Performance Materials division achieved global sales of € 7.7 bn.

21 IORA Countries adopt the Delhi Declaration on Renewable Energy; To Collaborate with ISA Member Countries As many as 21 countries in the Indian Ocean Rim Association (IORA) adopted the Delhi Declaration on Renewable Energy in the Indian Ocean Region, post the 2nd IORA Renewable Energy Ministerial Meeting held at the 2nd Global Re-Invest India-ISA Partnership Renewable Energy Investor’s Meet & Expo in Greater Noida. The Delhi Declaration on Renewable Energy in the Indian Ocean Region calls for collaboration among IORA member states in meeting the growing demand for renewable energy in the Indian Ocean littorals, development of a common renewable energy agenda for the Indian Ocean region and promote regional capacity 16 • October 2018

building. The declaration also calls for promotion of technology development and transfer, strengthening of public private partnerships in renewable energy and collaboration among IORA member states and the member nations of the International Solar Alliance (ISA). IORA member countries also resolved to collaborate with the International Renewable Energy Agency (IRENA). Minister of State (IC) Power and New & Renewable Energy, Government of India Shri R.K. Singh, Secretary General, Indian Ocean Rim Association (IORA) Dr. Nomvuyo N Nokwe, Deputy Minister of Energy, Ministry of Energy, South Africa Ms.Thembisile Majola, State Minister for Foreign Affairs, Bangladesh Md. Shahriar Alam M.P. participated in the ministerial meeting. Ministerial representatives from Iran, Mauritius, Seychelles, Sri Lanka and Yemen also spoke at the meeting. As per the declaration adopted, IORA member nations will collaborate with the ISA member nations to exchange knowledge and share views and potential interests in the renewable energy sector; paved by the Memorandum of Understanding (MoU) signed between IORA and ISA on 3 October 2018, with a focus on joint capacity-building programs, research & development activities in solar energy and exchange of best practices. India, Australia, Iran IR, Indonesia Thailand, Malaysia, South Africa, Mozambique, Kenya, Sri Lanka, Tanzania, Bangladesh, Singapore, Mauritius, Madagascar, UAE, Yemen, Seychelles, Somalia, Comoros and Oman are members of IORA.

Green flag for LG Lifesciences & LG Chem merger The Competition Commission of India has granted the merger of LG Lifesciences into LG Chem. Both the companies belong to LG Corporation. LG Chem, a company incorporated in Korea, organizes its business in four divisions, viz., Basic materials and Chemicals Division; Energy Solutions Division; IT and Electronic Materials Division; and Advanced Materials Division. Basic materials and Chemicals Division is engaged in production of basic petrochemicals such as ethylene, propylene etc., polyolefin products, PVC/Plasticizers, Acrylates, engineering plastics used in electric/electronics, automotive and IT & electronic parts; Acrylonitrile butadiene styrene; and Rubber/Specialty Polymers. Energy Solutions Division is engaged in production of mobile batteries, automotive batteries and energy storage systems; IT and Electronic Materials Division is engaged in production of Optical materials, RO Filters, Glass substrates and High functional materials; and Advanced Materials Division is engaged in production of specialty chemical materials such as battery materials and display materials. LG LS, a company incorporated in Korea, is also a part of the LG Corporation. The primary business areas of LG LS are pharmaceutical products (including animal health business) and specialty chemicals. The specialty chemicals include two main business segments - active ingredients (actives) for agrochemicals and pharmaceutical intermediates. It is noted from the information given in the notice that there is no horizontal overlap between LG Chem and LG LS in India. As regards vertical relationships emanating from the Proposed Combination, the Commission noted that LG Chem supplies acetone to LG LS; the latter uses the same for contract manufacture of cephalosporin antibiotics which is then sold to a third party pharmaceutical company. The third party pharmaceutical company sells the products sourced from LG LS under its brand name across the world, including in India. In this regard, the Commission observed that the nature and extent of existing customer supplier relationship is insignificant to cause any competition concerns. Chemical Engineering World

CEW Industry News Catalent to invest USD 7.3 Million to upgrade facility Italy. Catalent Pharma Solutions, the leading global provider of advanced delivery technologies and development solutions for drugs, biologics and consumer health products, has announced that it had completed the first phase of a USD 7.3 million investment to upgrade and expand its packaging and softgel encapsulation capabilities at its facility in Aprilia, Italy. The first phase of investment, completed in August 2018, saw the expansion and upgrade of the facility’s integrated packaging capabilities, and the commissioning of the first of five new softgel encapsulation lines. The second phase of the investment, to add a further four encapsulation lines, will bring the total number of lines to 23 and significantly expand production, drying, and inspection capacity for nutritional supplements and beauty softgels at the site. It is expected that these four new lines will be fully operational by January 2019. “We have a long and proud history in softgel product development and commercial manufacturing,” commented Dr. Aris Gennadios, President of Catalent Softgel Technologies. He added, “This investment is driven by increasing demand for nutritional and beauty products globally, and will enable Catalent to better serve these markets.”

Covestro to invest EUR 1.5 billion in new world-scale MDI plant in Baytown, USA Covestro accelerates its investment activities to capitalize on the strong MDI market growth. Today, the Supervisory Board of Covestro has approved an investment of around EUR 1.5 billion to build a new world-scale MDI plant in Baytown, USA. This investment at the existing site in Baytown is the largest single investment in the history of the company. Total capacity of the new train will be 500 kilotons MDI per year, start of production is expected in 2024. At the same time an older, less efficient MDI unit of 90 kilotons production capacity will be closed. Thus, total MDI capacities of Covestro in the NAFTA region will reach around 740 kilotons per year making Covestro the industry capacity leader in the region by 2024. With that, Covestro will also strongly underline its global industry capacity leadership position. “Demand for innovative MDI materials will continue to grow for the foreseeable future and likewise promises attractive capacity utilization rates. We have already announced a significant increase in capital expenditures, now it’s time to put it into action”, said CEO Dr. Markus Steilemann. “With the new MDI train in Baytown, we will further strengthen our global leading position in Polyurethanes, even better serve our customers and create long-term shareholder value.” The global MDI market is expected to grow by about 5% per year in the long-term, outgrowing the world’s global domestic product (GDP) by about 2 percentage points. Key MDI market drivers include the substitution of less performing and less sustainable materials as well as global megatrends such as an increasing demand for energy efficient insulation solutions. MDI is a precursor for rigid foam, which is an excellent insulation material and is used, for example, in buildings and refrigerators. The expected global MDI demand growth translates into the need for approximately one additional world-scale plant per year. Although Covestro is already doubling its MDI production capacity in Brunsbuettel (Germany) from 200 to 400 kilotons per year in the second half of 2019, the strong growth in demand creates further significant market opportunities. Therefore, the investments – which are part of the already announced investment increase of up to EUR 1.2 billion per year for the next three years – will help Covestro to maintain and strengthen its leading position and support further profitable growth. Moreover, Covestro aims at further capitalizing on its technical and innovation capabilities as well as on its leading cost position. 20 • October 2018

Cost-effective CAPEX (capital expenditures) approach with superior return on investment CFO Dr. Thomas Toepfer explained: “Even with all capacity increase announcements considered, the projected industry supply is not sufficient to fully balance the expected demand growth. We are therefore confident that we will reach high utilization rates of our new capacities soon after the start-up, making the investment highly efficient. Building on existing infrastructure and processes, it will be a prime example of our value creating investment approach.” With its global MDI investment program Covestro follows a cost-effective CAPEX approach by leveraging existing infrastructure and supply networks to achieve lower specific investments and higher ROCE (Return on Capital Employed). The program also includes the continuation and expansion of Covestro’s Tarragona (Spain) and Caojing (China) sites as well as investments into the company’s production site in Antwerp (Belgium). The decision to build the new world-scale plant in Baytown was taken following a thorough analysis of different options. Besides the attractiveness of the domestic market, main advantages of Baytown are leading cash costs as well as significant benefits in terms of available infrastructure and logistics. The superior cost position is mainly driven by economies of scale and a high degree of vertical integration. Furthermore, low energy and shipping costs due to high domestic demand in North America add to the Baytown case. With the new plant, Covestro’s future MDI capacities in North America of 740 kilotons per year by 2024 will also catch up to the company’s future capacities in EMEA (820 kilotons per year by 2022) and APAC (670 kilotons per year by 2021).

Coal India to set up methanol plant 6.76 lakh tonne per annum capacity The world's largest coal miner CIL is aiming to produce 6.76 lakh tonne of methanol per annum to boost clean energy initiatives, its Chairman Anil Kumar Jha said. His statement comes at a time when the government is betting big on alternative fuel and pushing electric vehicles (EVs). Steps have been taken towards methanol production, with the Centre recently easing norms for Coal India (CIL) to extract natural gas, coal bed methane from coal seams, Jha said. Earlier, CIL had to apply for licence to oil and natural gas ministry to extract CBM (coal bed methane) from its coal seams but now the government has done away with any such requirement. "In 2017-18, the licensors for supply of coal gasification technology have been pre-qualified, and pre-feasibility study for producing 6.76 lakh metric tonne per annum of methanol has been completed," the chairman said in a report. He said CIL is planning to set up a coalbased methanol plant at Dankuni Coal Complex (DCC) of South Eastern Coalfields Ltd (SECL), a subsidiary of the company. "The methanol to be produced at DCC will likely find a definitive market in the eastern states once the government's policy of blending methanol with petrol comes into practice," he said. As part of its initiative to promote clean energy and environment, government think-tank Niti Aayog had earlier said it is preparing a road map for full-scale implementation of methanol economy in the near future. Methanol economy, if adopted by India, can be one of the best ways to mitigate the environmental hazards of a growing nation, it has said. In marine sector also, the government is planning to make methanol as a fuel of choice because of emission benefits. Pushing clean energy initiatives, Transport Minister Nitin Gadkari earlier this month said the government has decided to exempt EVs and all vehicles including autorickshaws, buses, taxis run on alternative fuel like ethanol, biodiesel, CNG, methanol and biofuel, from permit requirements. Source: PTI Chemical Engineering World

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CEW Industry News New Single Quadrupole Mass Spectrometry Technology for Chromatographers Chromatographers looking for bold confidence in their samples can now benefit from a single quadrupole mass spectrometer designed for ease-ofuse while offering application flexibility and reliable results for challenging mass confirmation analyses. Driven by industry demand for a robust, easy to implement system, Thermo Fisher Scientific designed the Thermo Scientific ISQ EM single quadrupole mass spectrometer for high performance and productivity standards in laboratories. With a mass range of 10–2000 m/z, the system offers the power to detect and quantify small and large molecules, and supports analytical needs across an extensive range of applications – from drug development to manufacturing support and quality control. The system’s high-performing heated electrospray ionization (HESI) and dual HESI/atmospheric pressure chemical ionization (APCI) probes facilitate the measurement of polar and non-polar analytes, enabling application flexibility. "Liquid chromatography users have been struggling with the inherent perceived complexities of mass spectrometry technology as they use LC-MS to routinely analyze samples," said Fabrizio Moltoni, vice president and general manager, High-Performance Liquid Chromatography (HPLC), Thermo Fisher Scientific. "With this top of mind, we designed the ISQ EM to enable novice and expert mass spectrometry users to take advantage of the technique’s excellent sensitivity and selectivity for the rapid and reliable analysis of complex sample matrices." The ISQ EM is integrated with HPLC systems and fully controlled by Thermo Scientific Chromeleon Chromatography Data System (CDS), which offers tools to guide users through LC-MS method development and select appropriate source conditions. Thermo Scientific Chromeleon XPS Open Access software also supports the ISQ EM with walk-up workflows for simple daily operation. Additionally, full integration with native control in Chromeleon CDS enables users to benefit from the entire productivity suite, from method creation through final reporting. A built-in reference standard also automates instrument calibration for a user-friendly experience.

Clariant signs agreement with PT Martina Berto, Tbk on distribution of natural ingredients Clariant, a world-leader in specialty chemicals, has signed an agreement today on a partnership with PT Martina Berto, Tbk (Martina Berto), a manufacturer of cosmetic products and herbal medicine based in Indonesia under the Martha Tilaar Group. With this partnership, Clariant will get access to unique South East Asia plants and algae, with potential to explore and invent new sustainable solutions globally. The cooperation between Martina Berto and Clariant began in 2015 and reaches the next level with the signing of the agreement today. Based on the cooperation, Martina Berto will gain global access for its innovative products by leveraging Clariant’s global distribution resources. Building on the expertise of Martina Berto, Clariant will enhance its capabilities as “nature expert” with access to biodiversity of Indonesia and build on/expand its ethical sourcing commitment. This represents another strategic step for the Personal Care business after its already successful collaborations with the Nature Experts: CRM (Mediterranean biome), Beraca (Brazilian biome) and BioSpectrum (Asia biome) which all increase the biome diversity of ingredients for customers. “We’re very excited about this very important agreement today with PT Martina Berto, Tbk. Our collaboration is based on our common enthusiasm for 100% natural ingredients and to make use of the great biodiversity of 22 • October 2018

Indonesia. We will further strengthen our position towards sustainable ingredients and boost our natural based innovations,” said Francois Bleger, Head of Clariant Business Unit Industrial & Consumer Specialty, Asia Pacific Region. A strong pillar of Martina Berto’s commitment is their “Green Movement Program” which focuses on the partnership with the local farmer community by providing guidance on how to explore the natural resources in a sustainable manner and to improve the local life quality. The Martha Tilaar Group that Martina Berto is formed under is fully committed to utilizing Indonesia’s natural richness to produce quality products leveraging the nation’s innovation. Since its establishment, Martina Berto has focused on producing innovative cosmetic products by combining wisdom of local culture and research carried on various Medicinal, Cosmetic and Aromatic (MAC) plants from nature. The research included fruits and flowers like Sariayu Putih Langsat and Mangosteen extract which are cultivated to develop new ingredients for innovative personal care products.

Bonfiglioli Sets Up a New Facility in Chennai The new 1,32,000-square-foot facility has been built adjacent to the existing plant at the SIDCO Industrial Area in Thirumudivakkam. It houses modern assembly lines, a global R&D center and test labs, all built to the highest quality and safety standards, consistent with Bonfiglioli locations worldwide. With a capacity of 75,000 units per year, the new facility will enable Bonfiglioli to serve existing and new markets and customers in off-highway, construction, mining, agriculture and material handling applications. On the development, Ms. Sonia Bonfiglioli, Chairman of Bonfiglioli Group, says, “We have believed in the potential of this country since 1999, when we laid the cornerstone in Chennai. We have grown over the years, investing in plants, research and development centers, and highly specialized staff. India is a key country for Bonfiglioli, and the good results up to now show we were right when we started the business here in Chennai. This expansion in India is part of the company’s global investment strategy in production and assembly facilities. Indeed, we are convinced that our factories are the first step in bringing value to our customers. With high-tech, real-time smart production and superior solutions, we will be able to cater to growing, evolving needs in India and in our overseas markets across the USA, Italy, China and Germany.” Mr. G. Balaji, CFO, Bonfiglioli India, Mr. Fausto Carboni, CEO, Bonfiglioli Group, Mr. Kennady V Kaippally, Country Manager, Bonfiglioli India and Mr. Ravi Pisharody, Independent Director, Bonfiglioli India were present during the press meet. This new investment is part of a wider expansion plan for India, which includes the existing facility in Chennai and a plant in Mannur, located close to Sriperumbudur, both focused on making gearboxes and gear motors for mobile machinery, wind turbines and industrial processes. Meanwhile, the recently opened assembly plant in Pune, western India, provides 90,000 units per year, serving customers in the food, packaging, cement, steel, pharmaceutical, textile, material handling, sugar, power generation, paper and water treatment sectors. Bonfiglioli’s 2017 revenue in India reached 7,332 million rupees, equal to 91.65 million euros, with a growth more than 80 percent over the past 5 years. With the new facility in Chennai, the company expects to continue growing in the next year. Chemical Engineering World

CEW Industry News Drones solving safety challenges within the tank storage industry A report published within the Journal of Loss Prevention in the Process Industries uncovered that 74 percent of accidents that occurred within industrial facilities took place in oil storage terminals and petroleum refineries. Human error was also identified as the biggest risk to terminal operators . As a result, the tank storage and terminal industry is increasingly turning to drones to improve safety. Growing at an annual rate of 20.9 percent, the unmanned aerial vehicles and drones’ market has grown beyond its initial defence application. The technology is revolutionising the industry by enabling businesses to cut costs and reduce staff exposure to risk. Four time s faster than traditional inspection methods, drones and unmanned aerial vehicles (UAVs) have enabled oil and gas businesses to report seven-figure savings. The technology also reduces or in some cases eliminates ‘Persons on Board’ (PoB) issues and downtime. Malcolm Connolly, Founder and Technical Director of Cyberhawk Innovations, comments: “We conducted the first UAV tank inspection in 2015 and have seen the industry embrace the technology wholeheartedly. “Traditional inspection methods require scaffolding and teams of surveyors and technicians to perform visual surveys and take measurements. There are multiple liabilities associated with this type of work, ranging from dropped objects when lowering equipment into the tank, to potential damage to the tank coating, and working at height within confined spaces. UAV inspection not only reduces this risks but also offers a quicker, cost-effective means of inspection” Drone inspection involves capturing, storing and analysing large quantities of data. When tapping into advancements such as ‘machine learning’, recording and processing data from the same site over time can help operators to better monitor tank structure. Advancements in drone technology are turning essential maintenance efforts into a safer and more streamlined data collection process for implementing maintenance management systems.

SPX FLOW Power Team Announces a New Cordless Hydraulic Battery Pump SPX FLOW Hydraulic Technologies, a worldwide leader in hydraulic pumps and tools, has broadened its hydraulic power pump range with the addition of the PB Series Cordless Battery Hydraulic Battery Pumps to its portfolio. The new PB Series Cordless Hydraulic Battery Pump was specifically engineered to meet the market demand with increased portability, longer run-time, larger valve selection and remote “plug-play” control options for a wide range of high-pressure tool applications. Powered by a Li-Ion 18VDC 9.0 Ah battery pack, the PB Series pump features a two stage, compact high-pressure hydraulic pump for quick tool advancement and setup in the first stage. A self-contained, rubber bladder reservoir enables pump usage in many positions with an impressive capacity of 1.1 litres usable oil. The quiet, smooth running, serviceable brushed 18VDC motor and other pump components are shelled with a high impact plastic, fiberglass reinforced shroud that protects your investment in some of the most demanding and harsh applications. The pump is extremely lightweight; only 11 kg, making it easier to handle those tight constraints and remote applications in order to get the job done quickly. To promote better handling and ergonomics, the pump is equipped with an integrated molded rubber handle and a shoulder strap to reduce 24 • October 2018

operator hand fatigue during use and transport. “Equipment operators will appreciate the portability and freedom of the PB Series cordless power for most maintenance, repair and operation (MRO) 700 bar hydraulic applications”, said Aaron Sztuk, Director of Product Management - SPX FLOW Hydraulic Technologies. “Whether it is a spreading, nut splitting, lifting, bending, cutting or crimping application, the Power Team PB Series Hydraulic Pumps delivers the performance to improve productivity while keeping safety in mind”.

thyssenkrupp Industrial Solutions (TKIS) implements caustic soda project for Tata Chemicals in India thyssenkrupp Industrial Solutions is implementing a membrane cell caustic soda upgradation project for Tata Chemicals Limited (TCL) at the company’s chemical facilities in Mithapur, Gujarat. The upgraded section of the plant will have a capacity of 60 tons per day, with the plant’s overall capacity being 100 tons per day of caustic soda (100 wt%). thyssenkrupp will provide basic and detail engineering services including project management and technical procurement assistance for upgrading the plant. The plant will deploy thyssenkrupp Uhde Chlorine Engineer’s leading single element BM electrolyser technology which is at work across a majority of Indian caustic soda installations. At the heart of the plant will be the group’s latest, energy and emissionfriendly membrane cell elements. The project envisages upgrading the membrane cell plant by deployment of the latest Uhde BM ‘zero-gap’ bipolar electrolyser generation. It will be completed within 14 months. P. D. Samudra, CEO & Managing Director at thyssenkrupp Industrial Solutions (India): “This contract vindicates the trust the industry places in our capabilities in the electrolysis field. Over 75% percent of the installed caustic soda-chlorine membrane cell capacities in the country are based on our proprietary bipolar design membrane cells. Our plants continue setting standards in energy savings and sustainability. We are proud to have been awarded this contract by Tata Chemicals.” Tata Chemicals is amongst the oldest companies in India for soda ash and caustic soda production, with a top three spot for the production of soda.

Jigish Doshi elected as President of Plastindia Foundation for 2018-21 In the elections held on 21st September 2018 for the new Managing Committee of Plastindia Foundation, Jigish Doshi was elected as the President, Ravish Kamath as Vice-President and Jayesh Rambhia as Treasurer of the Plastindia Foundation. All were selected unanimously. The new Managing Committee comprising of senior entrepreneurs of the Plastics industry assumed office with immediate effect. Jigish Doshi took over from K K Seksaria. Jigish Doshi commenting on his election as President , said, “I am grateful to the industry for the confidence reposed on me. Plastics Industry is one of the fastest growing industries in India which aims at serving the nation & its citizens by way of making their life easier & affordable as well as contributing to the national growth. Though there are various challenges before the industry, we are confident that with wider participation of all segments & stakeholders, we will be able to meet all challenges and to take plastics industry forward qualitatively and quantitatively. Our main agenda is to work for the Growth of Plastic Industries of India, also to make it more at Global Recognition and for betterment of Plastindia Foundation.” Chemical Engineering World

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CEW Features

Vacuum Ejector System - A Process Engineer’s Perspective Ejector systems are used in refineries to maintain the desired vacuum level in vacuum distillation columns. The desired vacuum level in a column permits the fractionation of reduced crude oil into its various products such as vacuum diesel, light vacuum gas oil and heavy vacuum gas oil. If the required vacuum level is not maintained, it affects the yield and also impacts the downstream unit operations in the refinery. Hence it is necessary to have a clear understanding of various factors that affect the performance of the ejector system. Although the design and manufacturing of the system is carried out by specialized ejector suppliers, it is the responsibility of the process engineer to correctly specify the vacuum system requirements. This article provides an overview of various components of the ejector system, factors affecting system performance and process design aspects of the system.

vacuum ejector system consists of ejectors, condensers and hotwell along with the associated interconnecting piping. The system continuously compresses column overhead vapors consisting of cracked gases, condensable hydrocarbon vapor, steam and inert gases to a pressure typically above the atmospheric pressure with the help of motive steam. Condensable and non-condensable gas mixtures go through inter- and after- condensers. The resulting condensed hydrocarbons, steam condensate and non-condensable gases are routed to the hotwell and then sent for further processing. Ejector systems can be single or multi-stage depending on the level of vacuum required. Figure 1 depicts the typical components of three stage vacuum ejector system.

The major components of ejector systems are described in the following sections.

on capacity needs, maintenance requirements and capital cost.

• Ejector Ejector is a static piece of equipment with no moving parts, consisting of a converging/ diverging motive steam nozzle, suction chamber and converging/diverging diffuser. Figure 2 illustrates basic ejector components

• Hotwell The hotwell vessel acts as a three phase separator for hydrocarbon liquid, steam condensate and non-condensable gases. A mixture of condensed hydrocarbon and steam condensates from condensers are collected in the hotwell through properly designed tailpipes. Since the operating pressure of condensers is sub-atmospheric, tailpipes are dipped into the hotwell for sufficient liquid sealing. Noncondensable gases from the last stage of the ejector are also typically routed to the hotwell.

• Condenser Condensers are shell and tube heat exchangers with special internal configurations. These condensers are manufactured as per Tubular Exchanger Manufacturers’ Association (TEMA) or API 660 guidelines, typically in three basic configurations: fixed tube sheet, u-tube or floating head bundle. The configuration selection is generally dependent

PIC

Free Draining

1st stage

2nd stage

3rd stage ST Steam Trap

1st stage Intercondenser

2nd stage Intercondenser

3rd stage Aftercondenser

Steam Supply

Free Draining

Tail pipe

45° min. Non-condensable Gases

VACUUM COLUMN

LIC

Interface FIC

FIC FT

Sour Water

Figure 1: Typical Three Stage Vacuum Ejector System

28 • October 2018

Hydrocarbon Condensate

Ejector Operating Principle Steam jet ejectors fall into two categories: • Non-critical: Discharge to suction pressure ratio < critical pressure ratio • Critical: Discharge to suction pressure ratio > critical pressure ratio Critical pressure ratio is defined as the ratio of discharge pressure to suction pressure at which fluid velocity in the diffuser throat is sonic. The critical pressure ratio generally ranges from 1.7 to 2, depending on the type of fluid being handled. In vacuum ejector systems, the ratio of discharge to suction pressure is in the range of 3-4 for each stage. Therefore refinery vacuum ejector systems fall under the critical category and this article focuses on these critical ejectors. It is an inherent property of compressible fluid that whenever the flow passes through a converging section, fluid velocity increases and pressure decreases if the flow is subsonic, whereas for a supersonic flow, velocity decreases and pressure increases. In the steam nozzle, motive steam pressure energy is converted into very high velocity, creating a low pressure region in the suction chamber which pulls in process gases. Chemical Engineering World

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Suction Chamber

Supersonic Diffusor

permit the design and testing of the ejectors using air at normal room temperatures or air and steam at any temperature convenient for the manufacturer. DAE is estimated using temperature and molecular weight entrainment ratio curves as provided in the HEI standard. Figure 3 shows a typical performance curve for a single stage ejector at designed suction pressure, designed discharge pressure and motive steam flow at fixed operating conditions.

Subsonic Diffusor

Throat

Steam Steam & Hydrocarbon Discharge Hydrocarbon

Velocity Mach = 1

Motive Steam Pressure Steam & Hydrocarbon Discharge

Pressure

Steam only

Hydrocarbon only

Steam and Hydrocarbon

Entering Hydrocarbon Pressure

Figure 2: Basic Ejector Components and Energy Conversion

These gases are combined with the motive steam and the mixture flows at supersonic conditions in the converging section of the diffuser. Furthermore, a sonic condition with shock wave is attained in the diffuser throat. In the diverging section of the diffuser, this mixture gets deaccelerated to subsonic conditions with considerable pressure recovery. Based on the principle above, motive steam compresses the column overhead gases to the required ejector discharge pressure. Figure 2 illustrates typical energy conversion in the ejector across its various components.

For any given ejector system, the manufacturer provides a performance curve wherein the suction/discharge pressure is plotted against the dry air equivalent (DAE) of suction load on a mass flow rate basis at a fixed motive steam condition and discharge pressure. The DAE load is used to define a process stream in terms of an equivalent amount of dry air load. It is not practical for a manufacturer of steam ejectors to maintain facilities for testing ejectors with all the numerous suction gas mixtures and temperatures for which ejectors are used.

The minimum motive steam pressure required for stable ejector operation is termed as pickup pressure. At a fixed suction and discharge pressure, if motive steam pressure reduces further, a point termed as break point will be reached where ejector capacity reduces rapidly and the system loses the vacuum. The ejector will not resume operations unless pick-up pressure is attained. This is primarily because the motive steam pressure is not sufficient enough to achieve the desired low pressure in the suction chamber.

Therefore, a method has been stated in the Heat Exchange Institute (HEI) standard to

30 â&#x20AC;˘ October 2018

The condensing of the steam and hydrocarbons takes place on the shell side of the condenser and the cooling water runs through the tube side. The inlet stream enters through the top of the condenser and spreads out along the shell. A major portion of the condensable vapor contained in the inlet stream will change phase from vapor to liquid as it passes over the tube

90 80

Pressure in mm HgA

Maximum discharge pressure is the highest discharge pressure that an ejector can achieve for a fixed motive steam condition and fixed suction pressure. If the pressure in the downstream system exceeds this maximum discharge value, the ejector will become unstable and cease operations.

Condenser Arrangements There are various arrangements of ejectors with pre-, inter- and after-condensers depending on the vacuum column design. Pre-condensers are used in the ejector system if hydrocarbons are able to condense at the given column pressure and available coolant temperature. Inter-condensers are used to condense the steam/condensable hydrocarbons from an ejector, reducing the inlet quantity of vapor mixture for the following stage. This helps to increase the steam economy. After-condensers normally operate at atmospheric pressure. They do not affect the steam economy or ejector performance, but they allow steam to be recovered. Any upset in the condenser performance will affect the downstream ejectors and thereby the vacuum level achieved. In multistage configurations, the first inter-condenser is the largest and most critical condenser.

70 60 50 40 30 20 10 0 2000

4000

6000

8000

10000

12000

14000

16000

DAE in Kgs/Hr SUCTION PRESSURE DISCHARGE PRESSURE

Figure 3: Typical Performance Curve of Single Stage Ejector

Figure 3: PERFORMANCE CURVE OF SINGLE STAGE EJECTOR (TYPICAL) Chemical Engineering World

CEW Features

Long Air Baffle

Horizontal Perforated Vapor Inlet Distributor (if required)

generic programs do not properly model the flow distributions. Hence, thermal performance and pressure drop estimations from these generic programs need to be revalidated based on engineering judgement.

Vapor Outlet I Horizontal Perforated Distributor (if required)

Cooling Water Outlet

Vapor Outlet II

Long Air Baffle

Performance Factors

Vapour Outlet

Side view of Tube Sheet

Tube support plates (typ.) (No. as per TEMA)

Cooling Water Inlet Condensate Outlet

Figure 4: Vapor Outlet at Shell Side

bundle. The liquid falls by gravity and exits via the tailpipe to the hotwell. The remaining noncondensables are then removed through the vapor outlet. Thermal performance of the condenser is dependent on the effectiveness of the heat transfer achieved based on the following parameters: • • • •

Proper inlet stream distribution Internal configuration to aid effective condensate separation and proper vapor removal without any entrainment Exchanger configuration to maintain allowable pressure drop Operating condition of cooling media

Normally, the type of shell configuration used is TEMA type E or X. The following section describes the various arrangements to remove the vapor from the condenser. Side Vapor Outlet Nozzle: In this configuration, a longitudinal baffle (long air baffle) is used and a vapor outlet is provided from the side of the shell. If required for proper distribution of vapor, a horizontal perforated plate distributor may be provided at the shell inlet. The proper shielding of the baffle through the length of the shell ensures no bypassing of vapor from the side outlet nozzle and the achievement of proper separation between liquid and vapors. The full support plates need to have proper cutouts at the bottom to aid condensate drainage and the side to avoid restriction to vapor flow. Figure 4 indicates a typical sketch of such an arrangement for a TEMA type X shell. 32 • October 2018

Top Vapor Outlet Nozzle In this configuration, the up and over baffle arrangement is used to maximize the vapor distribution in the bundle. This arrangement restricts vapor bypassing and improves vapor contact with tubes. These configurations are normally used for smaller units. Figure 5 indicates a typical sketch of such an arrangement for a TEMA type E shell. Vapor Outlet from the Condenser Boot In this configuration separation of the condensed liquid and the non-condensed vapor occurs at the boot provided at the bottom of the condenser. Figure 6 indicates a typical sketch of such an arrangement for a TEMA type X shell. All three configurations specified above involve complexity in design and are of critical importance. These designs are proprietary in nature and offered by ejector manufacturers. Due to unconventional internal configurations,

Vapor Inlet

Tube support plates (typ.) (No. as per TEMA)

Up & Over Baffles

• Process Conditions Condensable and non-condensable load from a vacuum column varies with the type of crude oil being processed. The designer also needs to specify the process conditions that define the capacity of the ejector. A suitable design margin is also considered based on capacity to address the variations in the suction load. Non-Condensable Loading: Noncondensable loading consists of light end hydrocarbons, cracked gases generated in the fired heater and air leakage into the system. An increase in the non-condensable loading from the column increases the load on the downstream ejector, making it operate above its design point. Since the downstream ejector is not designed to handle this increase in load, it creates higher backpressure on the upstream ejector. An increase in ejector discharge pressure beyond its maximum discharge pressure causes the ejector operation to break down, resulting in column overpressure. Condensable Hydrocarbons: Variations in the crude type or an upset in the fired heater/vacuum column operation may result in increased condensable load to the ejector system. Higher condensable hydrocarbon loading increases the oil film thickness on condenser tubes. This results in a reduced heat transfer coefficient, and ultimately raises the operating pressure of the condenser/ejector discharge pressure. An increase in ejector discharge pressure beyond its maximum discharge pressure causes the ejector Vapor Outlet

Cooling Water Outlet

Side view of Tube Sheet Condensate Cooling Water Inlet Outlet

Figure 5: Vapor Outlet at Shell Side

Chemical Engineering World E-SHELL UP AND OVER BAFFLE DESIGN

CEW Features Vapor Inlet

Horizontal Perforated Distributor (if required)

Cooling Water Outlet

Horizontal Perforated Distributor (if required)

Side view of Tube Sheet

Tube support plates (typ.) (No. as per TEMA)

Cooling Water Inlet Vapor Outlet Condensate Outlet

Figure 6: Vapor Outlet at Shell Side

operation to break down resulting in column overpressure. Liquid Entrainment with Suction Load: Liquid entrainment can lower the capacity of an ejector, which can then increase suction pressure resulting in reduced product yield. Hence, it is necessary to ensure provisions are made to arrest any entrainment from the column. • Utility Conditions Motive Steam Condition: The motive steam supply condition is one of the most critical variables affecting ejector performance. In refinery units, steam pressure and temperature conditions may fluctuate. Therefore, the ejector nozzle should always be designed considering the lowest available steam pressure. Also, a pressure control valve is normally provided on motive steam line to address the pressure fluctuations and maintain constant steam supply pressure. For economical ejector design, the motive steam should be saturated. To supply saturated steam, de-superheater can be provided on steam line at the inlet of ejector. It is also to be ensured that the steam is dry. If the steam is wet, the moisture droplets in high velocity steam erode the steam nozzle and might decrease the energy available for compression. Hence, a certain degree of superheat is generally maintained to avoid erosion. Generally, an adequate number of steam traps are provided on steam supply lines to arrest condensed water. In addition, the provision of a condensate separator with a trap can be considered to arrest any 34 • October 2018

excessive boiler feed water flow during control valve failure of the de-superheater. To avoid condensation in steam lines, proper insulation of these lines is required. If the operating steam pressure and temperature parameters differ from the values used for design of the ejector, it has an impact on steam consumption and ejector performance. Tables 1 and 2 provide details about the system performance if steam conditions differ from the design point. Cooling Water: Condenser heat duty is fixed by the amount of steam being used by the upstream ejector and the suction load available from the vacuum column. If cooling water supply temperature is above its design value, the available logarithmic mean temperature difference (LMTD) decreases and condenser performance deteriorates. This leads to the carry-over of more saturated vapors with noncondensables to downstream ejectors. As the downstream ejector load increases, system backpressure to the upstream ejector rises. Similarly, if cooling water flow rate falls below the design value, the condenser duty suffers resulting in similar consequences. Cooling water with a temperature lower than the design point performs favorably and helps to improve performance. Hence, vacuum column performance improves during the winter due to lower cooling water temperature. Design Aspects Specification of Ejector System: While preparing the process data sheet, it is important to specify the following key details:

• Vacuum level required and the discharge pressure expected at the package outlet • Specify suction load as per heat and material balance. For estimation of air leakage, the rate guidelines available in the HEI standard can be used. • Fluid composition, operating temperature, molecular weight and other details of the condensable and non-condensable load • Corrosive constituents in the process fluid such as hydrogen sulfide, ammonia and phenol • Available utility conditions • Material of construction details for each component of the system • The fouling factor and the allowable pressure drop for condenser design • Project specifications covering any specific design aspects to be considered by the vendor Piping Arrangement: The ejector may be installed either vertically or horizontally based on space availability. The suction line size shall be driven by estimating the total pressure drop from the vacuum column overhead to the ejector suction nozzle. If there are multistage ejectors and each stage has two or more elements, it needs to be ensured that the total cross-sectional area of each element supply line is equal to or higher than the crosssectional area of the main supply header. Each supply line shall have a provision for isolation with either a manual or motor-operated valve, depending on the sizes and the project specific requirement. Considering the low pressure system, utmost care should be taken while carrying out hydraulic calculations for the inter-connecting piping between different stages of ejectors. Available industry guidelines can be referred to for the criteria of the allowable pressure drop and velocity. Liquid from the condensers is drained to the hotwell through tailpipes. In the event of varying plant operation or an increase in motive steam flow, there is a possibility of an increased condensable load. To prevent condensate back-up in the condenser, a properly sized tailpipe is required. Tailpipes are sized for gravity flow considering the maximum possible liquid load with a suitable design margin. Consideration should be given to the relative elevation of the condenser and the hotwell to ensure that the static head in the tailpipe is greater than the pressure difference. Typical guidelines to estimate the height of the tail pipe is available in the HEI standard. It is preferred Chemical Engineering World

CEW Features Motive Steam

Compression Energy

Ejector Performance

Pressure lower than design point

Decreases

Unstable if pressure falls below pick-up pressure

Pressure higher than design point

Increases

Decrease in capacity and increases suction pressure

Temperature lower than design point

Increases

May decrease in capacity and increases suction pressure

Temperature higher than design point

Decreases

Poor ejector performance

Table 1: Effect of Motive Steam Condition on Ejector Performance

Motive Steam Condition

Steam Consumption

Minimum pressure at saturation temperature (design point for motive nozzle )

Design flow

Minimum pressure at maximum temperature

Less than design flow

Maximum pressure at maximum temperature

Vary depending on actual pressure and temperature values

Maximum pressure at saturation temperature Highest flow Table 2: Impact of Motive Steam Condition on Consumption

to have tailpipes vertically connected to the hotwell but 45º elbows can be considered if unavoidable. Horizontal runs with excessive elbows and fittings should be avoided as they are susceptible to gas pockets and other drainage problems. The ejector manufacturer needs to be consulted for any hardware provision that may be required during the field test run. Normally the ejector test run is done by isolating the vacuum system. Based on the manufacturer’s feedback, the necessary isolation facility and a test connection on suction piping need to be provided. During start-up, ejectors and condensers may experience higher operating temperatures (motive steam) due to the unavailability of suction load. Hence, the designer must take this scenario into account while deciding the mechanical design temperature of the system. Column Pressure Controls: Vacuum column performance and product quality depends on the column flash zone pressure. This makes pressure control necessary, which is achieved mainly with the controlled recycle of ejector discharge to the ejector suction. There are various recycling configurations possible based on the tap-off location of the recycle stream. The preferred method is recycling from the first stage of ejector discharge to the suction. The typical arrangement can be seen in Figure 1. When the recycle is taken from either the 36 • October 2018

second or third stage discharge, there is a possibility of an increase in non-condensable load at the first stage ejector. This would result in increases in the first stage ejector discharge pressure above its maximum value and have a negative impact on downstream ejectors. To maintain a steady column overhead pressure during turndown scenario, the recycle control valve is sized for the difference between DAE at design load and turndown load.

design and correct piping arrangement along with a suitable control scheme to address all operating scenarios. References 1. Ernest E. Ludwig, Applied Process Design for Chemical and Petrochemical Plants, Volume 2, Third Edition 2.

Heat Exchange Institute Standard for Steam Jet Vacuum Systems, Fourth Edition Author’s Details

Sandeep Kadam Assistant Manager Process and SAE Aker Solutions E-mail: Sandeep.Kadam@akersolutions.com

Dynyaneshwar Kinhalkar Assistant Manager Process and SAE Aker Solutions

There are other methods to control column pressure, either with injection of external gas stream (e.g. fuel gas, steam, nitrogen etc.) into the first stage or throttling of the ejector suction load depending on the capacity of the unit or column vacuum level.

E-mail: Dnyaneshwar.Kinhalkar@akersolutions.com

In case of parallel ejector trains, one or more trains can be isolated to achieve turndown requirement if adequate isolation facilities are available on the motive steam and process side lines.

Pankaj Motharkar Assistant Manager Process and SAE Aker Solutions E-mail: Pankaj.Motharkar@akersolutions.com

Conclusion Ejector systems support the vacuum column operation. There are various factors that impact the operation of the vacuum ejector system. Therefore it is necessary to have clarity on the significance of each parameter and its impact on the system performance. It is important to pay attention to design aspects like the selection of the motive steam condition, capturing all probable variations in suction load and utility conditions, proper condenser

Mithu Saha Manager Process and SAE Aker Solutions E-mail: mithu.saha@akersolutions.com Chemical Engineering World

Anzeige_180x240+3_RZ.indd 1

12.10.18 15:59

CEW Features

Sizing of Thermal Safety Valves (TSVs) in Cryogenic Service Thermal Safety Valves are a common safety feature of all plants handling cryogenic fluids (for example, LNG, ethane, propane, butane). TSVs are designed to prevent overpressure when a system is blocked in, and the fluid starts to expand due to ambient heat ingress. Historically, industry codes and standards gave guidance on the installation of TSVs for fluids at near ambient conditions mainly in the oil industry, but there has been no detailed methodology produced specifically for cryogenic systems.

he sizing of the TSVs for a cryogenic process plant can be a time-consuming process as each should be checked to ensure that the safety valve is adequately sized. An undersized TSV possesses a risk to plant safety while an oversized TSV will pose an unnecessary cost.

In the last two editions of API-521 (5 th and 6 th Edition), a rigorous design calculation is provided but not suitable for cryogenic fluids which undergo a phase change as the fluids heats up. The API-521 method can be considered as overly complicated, and a simpler method can be used. This article presents a calculation derivation and design methodology to efficiently and safely design TSVs to protect cryogenic systems. This articleâ&#x20AC;&#x2122;s straight-forward methodology also enables flow rates to be calculated and the TSV orifice to be sized or checked. Hydraulic Expansion Mechanism in Cryogenic Systems When a cryogenic fluid is blocked in within a system, the system can pass through several phases from the initial isolation to a final point. When blocked in at its normal operating pressure and temperature, the system will immediately start to gain energy from the ambient surroundings and fluid will try to expand as the density starts to decrease. Because of fixed system volume, the energy input will be eventually exhibited by the pressure increase. When the pressure reaches the TSV set point, the TSV will open and relieve the excess pressure thus preventing the continuous rise in the system pressure. 40 â&#x20AC;˘ October 2018

Initially only liquid would be relieved, but after a certain time the remaining liquid in the system start to flash and a vapour pocket is formed. Then the system will contain both vapour and liquid. For piping systems, it can be assumed that the vapour and liquid are in equilibrium and the fluid phase temperatures are equal. Therefore, from this point onwards the vaporisation of the remaining liquid will result in the pressure rise. Depending on the location of the TSV, this may lead to either vapour (high point location) or liquid (low point location) being discharged. The liquid within the fixed volume system will continue to vaporise until no liquid remains thus, a vapour filled system will be left at cryogenic conditions. The vapour will heat-up until it reaches an equilibrium with the ambient conditions, and this will lead to a gaseous relief. Hydraulic Expansion Derivation and Calculation The change in a volume for a blocked-in system is given as: đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; = â&#x2C6;&#x2020;đ?&#x2018;&#x2030;đ?&#x2018;&#x2030;/đ?&#x2018;Ąđ?&#x2018;Ą = (đ?&#x2018;&#x2030;đ?&#x2018;&#x2030;2 â&#x2C6;&#x2019; đ?&#x2018;&#x2030;đ?&#x2018;&#x2030;1 )â &#x201E;đ?&#x2018;Ąđ?&#x2018;Ą Equation 1

Considering đ?&#x2018;&#x2030;đ?&#x2018;&#x2030;2 = đ?&#x2018;&#x161;đ?&#x2018;&#x161;2 â &#x201E;đ?&#x153;&#x152;đ?&#x153;&#x152;2 and đ?&#x2018;&#x2030;đ?&#x2018;&#x2030;1 = đ?&#x2018;&#x161;đ?&#x2018;&#x161;1 â &#x201E;đ?&#x153;&#x152;đ?&#x153;&#x152;1 and for constant mass đ?&#x2018;&#x161;đ?&#x2018;&#x161;1 = đ?&#x2018;&#x161;đ?&#x2018;&#x161;2 = đ?&#x2018;&#x161;đ?&#x2018;&#x161; the above equation can be rearranged to: đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; = đ?&#x2018;&#x161;đ?&#x2018;&#x161;Ě&#x2021; (

đ?&#x153;&#x152;đ?&#x153;&#x152;1 â&#x2C6;&#x2019; đ?&#x153;&#x152;đ?&#x153;&#x152;2 ) đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1

Equation 2

From the First Law of Thermodynamics: đ?&#x2018;&#x201E;đ?&#x2018;&#x201E; = đ?&#x2018;&#x161;đ?&#x2018;&#x161;Ě&#x2021;đ??śđ??śđ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2020;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021; Equation 3

Substituting đ?&#x2018;&#x161;đ?&#x2018;&#x161;Ě&#x2021; from Equation 2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 â&#x2C6;&#x2019; đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x2018;&#x201E;đ?&#x2018;&#x201E; ) đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ??śđ??śđ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2020;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021;

đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; = (

Equation 4 & W1 = q x Ď 1

Liquid Relief Case

The area required for TSV in liquid service, designed in accordance with the ASME Code, is calculated by (Equation 29 of API-520). đ??´đ??´ =

đ??şđ??ş1 11.78đ?&#x2018;&#x17E;đ?&#x2018;&#x17E;â&#x20AC;˛ â&#x2C6;&#x161; đ??žđ??žđ?&#x2018;&#x2018;đ?&#x2018;&#x2018; đ??žđ??žđ?&#x2018;¤đ?&#x2018;¤ đ??žđ??žđ?&#x2018;?đ?&#x2018;? đ??žđ??žđ?&#x2018;Łđ?&#x2018;Ł đ?&#x2018;&#x192;đ?&#x2018;&#x192;1 â&#x2C6;&#x2019; đ?&#x2018;&#x192;đ?&#x2018;&#x192;2 Equation 5

For cryogenic fluids Kv = 1. Considering a 10% overpressure and system backpressure as 10%. Ps = (P1 - P2). Putting the values of Kd = 0.65, Kw = 1.0, Kc = 1.0, Kv = 1.0, PS, đ??şđ??ş1 = (đ?&#x153;&#x152;đ?&#x153;&#x152;1 â &#x201E;1000) and đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; â&#x20AC;˛ = (đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; đ?&#x2018;&#x17E; đ?&#x2018;&#x17E;đ?&#x2018;&#x17E;đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; đ?&#x2018;&#x17E; 60) in Equation 5, the TSV required area required is given as đ??´đ??´ =

11.78 â&#x2C6;&#x2014; đ?&#x2018;&#x17E;đ?&#x2018;&#x17E; â&#x2C6;&#x2014; 60000 (đ?&#x153;&#x152;đ?&#x153;&#x152;1 â &#x201E;1000) â&#x2C6;&#x161; đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018; đ?&#x2018; 0.65 Equation 6

Substituting q from Equation 4 đ?&#x153;&#x152;đ?&#x153;&#x152;1 â&#x2C6;&#x2019; đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ?&#x2018;&#x201E;đ?&#x2018;&#x201E; ) â&#x2C6;&#x2014;â&#x2C6;&#x161; đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018; đ?&#x2018; đ??śđ??śđ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2020;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021;

đ??´đ??´ = 34386.12 â&#x2C6;&#x2014; (

Equation 7

For insulated pipe, đ?&#x2018;&#x201E;đ?&#x2018;&#x201E; = đ??ťđ??ťđ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013; â&#x2C6;&#x2014; đ??żđ??żđ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? Equation 8

Equation 7 can be rewritten as đ??´đ??´ = 34386.12 â&#x2C6;&#x2014; (

đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ?&#x153;&#x152;đ?&#x153;&#x152;1 â&#x2C6;&#x2019; đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ??żđ??żđ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2014; đ??ťđ??ťđ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013; ) â&#x2C6;&#x2014;â&#x2C6;&#x161; đ??śđ??śđ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2020;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021; đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018; đ?&#x2018; đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 Equation 9

For simplicity, maximum đ??ťđ??ťđ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013; = 0.100 kW/m is considered at the fluid minimum temperature and the heat ingress at TS is given by Ht. Ht = (

|Ts â&#x2C6;&#x2019; Ta | ) â&#x2C6;&#x2014; 0.100â&#x20AC;&#x2C6;kW/m |Tmin â&#x2C6;&#x2019; Ta |

So Equation 9 can be written as

đ??żđ??żđ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? đ?&#x153;&#x152;đ?&#x153;&#x152;1 â&#x2C6;&#x2019; đ?&#x153;&#x152;đ?&#x153;&#x152;2 â&#x2C6;&#x161;đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ??´đ??´ đ??´ (34386.12 â&#x2C6;&#x2014; ( )â&#x2C6;&#x2014; â&#x2C6;&#x2014; đ??ťđ??ťđ?&#x2018;Ąđ?&#x2018;Ą )â&#x2C6;&#x2014; đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ??śđ??śđ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2020;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021; â&#x2C6;&#x161;đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018; đ?&#x2018; Or,

đ??´đ??´ = đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC; â&#x2C6;&#x2014;

Equation 10

đ??żđ??żđ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x161;đ?&#x2018;&#x192;đ?&#x2018;&#x192;đ?&#x2018; đ?&#x2018;

đ?&#x153;&#x152;đ?&#x153;&#x152;1 â&#x2C6;&#x2019; đ?&#x153;&#x152;đ?&#x153;&#x152;2 â&#x2C6;&#x161;đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ?&#x2018;¤đ?&#x2018;¤đ?&#x2018;¤đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;đ?&#x2018;&#x2019;đ?&#x2018;&#x2019; đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC; (34386.12 â&#x2C6;&#x2014; ( )â&#x2C6;&#x2014; ) â&#x2C6;&#x2014; đ??ťđ??ťđ?&#x2018;Ąđ?&#x2018;Ą đ?&#x153;&#x152;đ?&#x153;&#x152;2 đ?&#x153;&#x152;đ?&#x153;&#x152;1 đ??śđ??śđ?&#x2018;?đ?&#x2018;? â&#x2C6;&#x2020;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021; Equation 11

Chemical Engineering World

CEW Features area versus set pressure for liquid expansion and vapour generation cases for ethane, propane and n-Butane are compared below.

TSV Constant (k) for Ethane, Propane and n-Butane 0.40

0.35

0.30

0.25

0.20

0.15

0.10

-110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10

Ethane 5 barg Propane 5 barg nButane 5 barg

Ethane 10 barg Propane 10 barg nButane 10 barg

10 20 30 40

Temperature Â°C

Ethane 20 barg Propane 20 barg nButane 20 barg

Ethane 30 barg

0.40Propane 30 barg

nButane 30 barg

Figure 1: K Value Vs Temperature

It is observed that the vapour generation cases have a larger required orifice area than the liquid hydraulic expansion cases. Also, based on above results, it can be recommended that a standard API-lettered orifice â&#x20AC;&#x2DC;Dâ&#x20AC;&#x2122; diameter TSV is normally sufficient for liquid hydraulic expansion and vapour generation while considering ambient heat ingress as the heat input source and a normal back 50 60 70 80 90 100 110 TSV Constant (k) for Ethane, Propane and n-Butane pressure. Ethane 60 barg Propane 60 barg nButane 60 barg

Ethane 100 barg Propane 100 barg nButane 100 barg

However, it must be noted for flashing liquid relief flow caused by vapour generation an additional calculation would be required. This may occur if the TSV is not installed at the high point in the system.

0.35

Example Results - Hydraulic Expansion

đ??´đ??´ =

Area (mm2)

The specific heat ratio kâ&#x20AC;&#x2122; is based on the ideal 0.30 gas laws (API-520 section 5.6.3.1.1) The k values are calculated for ethane, TSV Areaintervals for Ethane, Propane n-Butane to haveand a conservative answer. propane and n-butane at temperature 1.20 of 10 oC for pressure values of 5, 10, 20, 30, 60 0.25 1.10 It is observed that for vapour generation and 100 barg are presented in Figure 1. The 1.00 scenario, the worst case, i e, the maximum Summary corresponding TSV orifice sizes are shown in 0.20 0.90 orifice area is at the lowest set pressure TSVs should be considered for all Figure 2 for a pipe length of 200 m. 0.80 (refer Table 1). potentially blocked-in sections of 0.15 It is evident from Figure 2, the required 0.70 cryogenic fluids, i e, there is no minimum orifice0.60 area calculated for liquid hydraulic Orifice Area Comparison volume criteria. For TSVs designed for 0.10 expansion cases decreases with an 0.50 The -110 comparison between the required -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0hydraulic 10 20 30expansion 40 50 60 due 70 80 to90 ambient 100 110 increase in temperature. The maximum 0.40 Temperature Â°C orifice area calculated for TSVs heatEthaneingress, theEthaneequations presented Ethane 5 barg Ethane 10 barg Ethane 20 barg 30 barg 60 barg Ethane 100 barg calculated required orifice area is at the 0.30 Propane 5 barg 10 barg Propane 20 barg Propane 30 barg Propane 60 barg Propane 100 barg considering liquidPropane hydraulic expansion nButane 5 barg nButane 10 barg nButane 20 barg barg nButane 60 barg nButaneIn 100 barg cannButane be 30used as standard method. all fluid coldest temperature. 0.20 cases and vapour generation cases is cases reviewed, the TSVs sized for the 0.10 shown in Table 1. Vapour Generation Due to Ambient vaporisation cases have larger area than 0.00 Heat Ingress -110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 The graphs between required TSV orifice the liquid expansion cases. Temperature Â°C The orifice area for the TSV considering Ethane 5 barg Ethane 10 barg Ethane 20 barg Ethane 30 barg Ethane 60 barg Ethane 100 barg TSV Ethane, Propane and n-Butane Propane 5 barg Propane 10 barg Propane 20 barg Propane 30 barg Propane 60 barg Area for Propane 100 barg vapour nButane generation cases is calculated 5 barg nButane 10 barg nButane 20 barg nButane 60 barg nButane 100 barg 1.20nButane 30 barg by (Equation 5 of API-520) Equation 12 1.10 at the bubble point temperature of fluid 1.00 corresponding to the relieving pressures 0.90 of 5.5, 11, 22, 33 barg (Set pressure plus 0.80 10% overpressure). 0.70 đ?&#x2018;&#x160;đ?&#x2018;&#x160;2 đ?&#x2018;&#x2021;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021;đ?&#x2018;&#x2021; â&#x2C6;&#x161; đ??śđ??śđ??žđ??žđ?&#x2018;&#x2018;đ?&#x2018;&#x2018; đ?&#x2018;&#x192;đ?&#x2018;&#x192;1 đ??žđ??žđ?&#x2018;?đ?&#x2018;? đ??žđ??žđ??śđ??ś đ?&#x2018;&#x20AC;đ?&#x2018;&#x20AC;

Equation 1

â&#x2C6;&#x161; â&#x20AC;˛( 2 ) đ??śđ??ś = 0.03948 đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC; đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC;â&#x20AC;˛ +1 Equation 2

W2 is calculated as (đ??ťđ??ťđ?&#x2018;Ąđ?&#x2018;Ą â&#x2C6;&#x2014; đ??żđ??żđ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;?đ?&#x2018;? ) â&#x2C6;&#x2014; 3600 đ?&#x153;&#x2020;đ?&#x153;&#x2020; Equation 3

42 â&#x20AC;˘ October 2018

0.50 0.40 0.30

(đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC;â&#x20AC;˛ +1) (đ?&#x2018;&#x2DC;đ?&#x2018;&#x2DC;â&#x20AC;˛ â&#x2C6;&#x2019;1)

đ?&#x2018;&#x160;đ?&#x2018;&#x160;2 =

0.60

0.20 0.10 0.00 -110 -100 Ethane 5 barg Propane 5 barg nButane 5 barg

-90

-80

-70

Ethane 10 barg Propane 10 barg nButane 10 barg

-60

-50

-40

-30

-20

Temperature Â°C

Ethane 20 barg Propane 20 barg nButane 20 barg

Ethane 30 barg Propane 30 barg nButane 30 barg

-10

Ethane 60 barg Propane 60 barg nButane 60 barg

Ethane 100 barg Propane 100 barg nButane 100 barg

Figure 2: TSV area Vs Temperature for hydraulic expansion.

Chemical Engineering World

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CEW Features The maximum relief rate caused by liquid hydraulic expansion is at the coldest temperature and decreases as the fluid temperature increases. For vapour relief generated by ambient heat ingress, only a single calculation is required. To avoid flashing liquid displacement, TSVs should always be installed at high points.

Ethane

-30

-10

n-Butane

0.594

T (Â°oC) T (Â°C)

P (barg)

PRR(barg)

Orifice Area

2 2) Orifice Area (mm (mm )

-45.32 -45.32

5.5 5.5

15.629 15.629

-26.01

7.051

-1.74

2.549

0.594

-26.01

0.341

Vapour Generation case

7.051

2030

0.197 0.341

15.05 -1.74

3322

1.051 2.549

0.518

10.86

5.5

7.090

34.36

0 20

Propane

0.968 0.968

Vapour Generation case

-1010 10

Propane

Glossary

1. API Standard 520, Sizing, Selection and Installation of Pressure-relieving devices - Part 1 - Sizing and Selection, 9 th Edition, July 2014 (Abbreviated to API-520). 2. API Standard 521, Pressure-relieving and Depressuring Systems, 6 th Edition, January 2014 (Abbreviated to API-521).

Liquid Hydraulic Expansion Case F l u i d Liquid Hydraulic Expansion Case Area NamFluid e Name T (Â°oC) PS (barg) Orifice Orifice Area 2 T (Â°C) PS (barg) (mm (mm2)) -50-50

Glossary

References

0.197

15.05

0.137

5 20

0.518 0.094

10.86 63.81

0.075

84.11

60.93

5.5

0.137

34.36

0.217

5.5 22 11

20 20

2010

0.094 0.152

63.81 88.01

20 20

3020

0.106 0.075

121.84 84.11

2233

0.217

60.93

5.5

0.085

145.08

1.051

1122 33

0.152

88.01

0.106

121.84

0.085

145.08

7.090 Orifice area not calculated as TR > TA (30 Â°C)

Orifice area not calculated as TR > TA (30 oC)

Table 1: TSV area Vs Set Pressure Temperature

25.0 Liquid Hydraulic Expansion Ethane

19.478

Area (mm2)

Cp G1 đ??ťđ??ťđ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013;đ?&#x2018;&#x2013; k kâ&#x20AC;&#x2122; Kd Kw Kc Kv Lpipe M đ?&#x2018;&#x161;đ?&#x2018;&#x161;Ě&#x2021; m P1 P2 Ps q qâ&#x20AC;&#x2122; Q t T TSV TA Tmin Ts TR V

Liquid Hydraulic Expansion Propane

Vapour generation case Propane

Density (kg/m3) Viscosity (cP) Mass Heat of Vaporisation (kJ/kg) Difference Required effective discharge area mm2 Function of ratio of the ideal gas specific heats of the vapour at inlet relieving temperature Specific heat capacity (kJ/kgK) Specific Gravity Heat ingress (kW) TSV Sizing Constant Specific heat ratio, kâ&#x20AC;&#x2122; = Cp/(Cp - R) for ideal gas Rated Coefficient of discharge Backpressure correction factor Combination correction factor Viscosity correction factor Pipeline length of blocked in liquid (m) Molecular weight Mass flow rate (kg/s) Mass (kg) Upstream relieving pressure (kPag) Total backpressure (kPag) Set pressure (kPag) Volumetric flow rate (m3/s) Volumetric flow rate (L/min) Total heat transfer rate (kW) Time (seconds) Temperature (oC) Thermal Safety Valve Ambient Temperature (oC) Fluid Minimum Temperature (oC) Specified Temperature (Â°oC) Relieving Temperature (oC) Volume (m3) Liquid hydraulic expansion case - Mass relief rate (kg/s) Vapour generation case - Mass relief rate (kg/h) Compressibility Factor

Authorâ&#x20AC;&#x2122;s Details

Liquid Hydraulic Expansion n- Butane

15.0

Vapour generation case Ethane

20.0

Ď Âľ Îť â&#x2C6;&#x2020; A

Vapour generation case n-Butane

10.0

R Brannock Managing Director (U.K. Branch) TGE Gas Engineering GmbH E-mail: Robert.brannock@tge-gas.com

5.0

0.0

Figure 3: TSV area Vs Set Pressure Temperature

44 â&#x20AC;˘ October 2018

15 20 Set Pressure, barg

A Saxena Process Engineer TGE Gas Engineering Pvt Ltd E-mail: Ajay.saxena@tge-gas.com Chemical Engineering World

CMY

CEW Features Technical Article

Pollution Control Techniques in Refinery and Downstream Petrochemical Plants Pollution is a universal problem that intensifies with each passing day due to growing population and pollution of surface & ground water sources. Indiscriminate industrial development and exploitation of limited water sources are compelling every industry to seriously address this problem. Besides this, availability of water has become a serious issue. Therefore, industries are considering various options to reduce their water usage and to recycle water to the extent possible along with adopting manufacturing technologies that require less water, produce minimum waste water as well as other solid & liquid waste. Increasing cost of water and stringent regulations have helped make water recycle a viable option. This article deliberates on the topics of recycle, zero liquid discharge and solid waste management and explores their various technologies.

revention is better than cure. This also applies to pollution. Prevention or minimisation of pollution at source is the best control method. Hence, before going into the methods of effluent treatment, we should look at the possibilities of preventing or minimising effluent generation. Pollution prevention is defined as the use of materials, processes or practices that reduce or eliminate the generation of pollutants or wastes at the source. Also known as reduction at source, pollution prevention includes practices that reduce the use of hazardous and non-hazardous materials, energy, water or other natural resources. Pollution prevention in the manufacturing industry can be achieved by changing production processes to reduce or eliminate the generation of waste at the source. As it applies to industry, the environmental management hierarchy stipulates that when possible:

• Pollution should be reduced at the source • Pollution products that cannot be reduced should be recycled in an environmentally safe manner • Disposal into the environment should

Raw Water

Water Treatment Plant

be used only as a last resort and should be conducted in an environmentally safe manner Recycle of Waste Water and Study of its Application in Various Industries Waste water recycle should take shape at the drawing board stage in contrast to the conventional treatment approach of designing the raw water and waste water treatment plants (end of pipe solutions) separately. This will enable planning for water recycle at the design stage itself. The benefits are many. Firstly, because water is recycled, raw water consumption reduces. The designer can therefore plan for a raw water treatment plant of lower capacity and cost. Secondly, the effluent treatment plant’s capacity is also reduced as we are treating the effluent which is not being recycled and hence the quantity of waste disposed is less, leading to further cost reduction. Investment is certainly required for product recovery, water recycle plants and advanced technologies to handle even higher concentrations of contaminants.

Treated Water

Process

Effluent

However, the life cycle and return on investment is quite attractive. Pollution is not just abated but prevented; pollutants are separated not destroyed; energy is saved and the total cost of water and waste water treatment is reduced. Hence, we can use this experience of on/ offsite recycle and integrated solutions for water and waste water treatment in large industries to achieve the goal of ‘Total Water Management’ at the design stage. We need to only apply these approaches in a complex industry in multiple ways. Guidelines for Selection of Recycle Scheme 1. Study the manufacturing process thoroughly and identify areas where reduction of water consumption is possible. 2. Identify the process where reduction of pollution load is possible by changing raw material or adopting cleaner manufacturing process. 3. Proper analysis of various streams especially targeting the contaminants which are process specific.

Effluent Treatment Plant

Discharge

Figure 1: Conventional Treatment

46 • October 2018

Chemical Engineering World

CEW Features Reduction at Source

Product Recovery Recovered Product

Raw Water

Water Treatment Plant Recycled Water

Water Reuse

Treated Water

Process

Effluent

Zero Liquid Discharge Plant

No Liquid Discharge

Product Recovery Plant Partially Recovered Effluent

Waste Minimisation

Figure 2: Modern Integrated Solution

4. Identify streams that can be segregated and treated economically. For example, in electroplating, the rinsed water can be segregated and treated for recovery of plating metal. This not only reduces the overall cost of recycle but also facilitates the recovery of valuable products from the waste water stream. 5. Identify effluents which are relatively clean and can be treated with simple processes so that they can be recycled internally without letting the water out into an effluent treatment plant. 6. Identify the quality of water required at various manufacturing stages. For instance, steam generation may require high quality water and washing or cooling water make up may not require high quality water. It is always economical to design a recycle system to produce water suitable for lower end usage. 7. Select a technology that is easy to implement, operate, maintain & service. 8. Look for the availability of spare parts that may be needed in the future. 9. Reliability of performance in the long run is extremely important. 10. Low in operating cost. 11. Good service network of the plant supplier. 48 â&#x20AC;˘ October 2018

Recycle Technologies Any waste water recycling plant requires four stages of treatment as follows: 1. Effluent treatment 2. Tertiary treatment 3. Advanced tertiary treatment 4. Zero liquid discharge Effluent Treatment For a good effluent recycle system, a good effluent treatment is a pre-requisite. Unless we remove the easily removable pollutants with cost-effective methods, it would be difficult to recycle the effluents economically. Usually effluent treatment plants (ETPs) are designed to meet statutory requirements for disposal. When recycling is considered, the ETP should also be designed considering overall requirements of treatment. For example, in India, disposal standards do not require complete removal of nutrients and dissolved salts. But, when we are installing a downstream reverse osmosis system, it is better to remove nutrients and dissolved salts in the biological system of the ETP. This will help reduce fouling of the reverse osmosis system. There are different technologies available for effluent treatment to remove different pollutants. Table 1 lists some generic technologies applied in effluent treatment.

Tertiary Treatment Treatment beyond disposal norms for reusing effluents for low end usages is called tertiary treatment. It acts as pretreatment to advanced treatment for complete recycle of effluents. Table 2 enlists some generic technologies applied in tertiary treatment. Advanced Tertiary Treatment Further treatment of secondary treated effluents is required for conforming to the requirements of high end usages (boiler feed, process, etc.) of treated water. Table 3 enlists some of the technologies available to remove various pollutants in advanced treatment: There are various other technologies which are contaminant and end use specific such as fluoride removal. Zero Liquid Discharge Treatment (Evaporation and recovery of waste water containing highly soluble salts) The highly concentrated reject from the process is further treated in multi effect evaporator (MEE) system generally after reducing dissolved salts by RO processes and the advanced tertiary treatment. Chemical Engineering World

CEW Features Table 1 Effluent Treatment Technologies (Primary and Secondary) Pollutant

Treatment Technology

Floating matter

Manual bar screens, mechanically cleaned screens, drum screens, etc.

Grit

Manual grit chambers, aerated grit chambers, deaerator, etc.

Oil & grease

Oil & grease traps, API oil separators, TPI oil separators, dissolved air floatation (DAF) systems, tubular ultra filtration, etc.

Acidity/alkalinity

Neutralisation using acid/alkali dosing

Suspended solids

Clarifiers, clariflocculators, high rate solid contact clarifiers (HRSCC), lamella clarifiers, tube settlers, DAF, ultra high rate clarifiers, pulsating clarifiers, etc.

BOD/COD/NH 4/TKN/TP/Phenol/CN/SCN

Biological systems such as activated sludge process, trickling filters, sequential batch reactors (SBRs), membrane bio-reactors (MBRs), etc.

Heavy metals

Precipitation using solid contact clarifiers, ion exchange processes, membrane systems for metal recovery, etc.

Toxic substances

Different treatment technologies are adopted based on the nature and concentration of toxic substances. For example, phenols can be removed with biological systems at low concentrations whereas chemical oxidation may be required for higher concentrations.

Recalcitrant compounds/COD

Photo-chemical oxidation is used to remove or break recalcitrant and complex organics such as phenols, benzene, pesticides, etc.

Table 2 Tertiary Treatment Technologies Pollutant

Treatment Technology

Turbidity

Gravity sand filters, pressure sand filters, dual media filters, multi media filters, continuous sand filters, auto valve-less filters, etc.

Bacteria

Chlorine dioxide, chlorination, ozonation, ultraviolet sterilisation, mixed oxidant systems, etc.

Colour

Oxidation, precipitation, adsorption, nanofiltration, etc.

Residual chlorine Activated carbon filtration, dosing of reducing agents, ultraviolet treatment, etc. Table 3 Advanced Tertiary Treatment Pollutant

Treatment Technology

Hardness

Chemical precipitation, ion exchange softeners, nanofiltration, etc.

Silica

Chemical precipitation, ion exchange processes, reverse osmosis, etc.

Turbidity, SDI

Sand or multimedia filtration, ultra filtration, microfiltration, etc.

Dissolved solids

Reverse osmosis systems, ion exchange processes, electrodialysis, etc.

The MEE process uses either mechanical or thermal vapour compression using forced circulation evaporators, falling film evaporators or in combination. Thus, evaporation is increasingly considered for the treatment of refinery and downstream petrochemical waste water to recover 52 â&#x20AC;˘ October 2018

more than 95% of water, or as a part of the zero liquid discharge (ZLD) process. Water Management in Refinery - Case Studies 1. Reliance Industries Limited Reliance Industries Limited (RIL) has

enhanced the capacity of the Jamnagar Refinery to 12,00,000 barrels per stream per day (1200 K BPSD) with the commissioning of the Jamnagar Export Refinery Project (JERP) in Gujarat. Waste water treatment is carried out in a dedicated state-of-the-art completely automated and PLC â&#x20AC;&#x201C; operated effluent treatment plant supplied by Ion Exchange. The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/fire water, with the objective of zero discharge from the new refinery complex. The treated water is recycled back as cooling tower make-up and partially used as process water after reverse osmosis treatment to the high total dissolved solids treatment train or guard tanks, as required. Effluents are segregated into four identical waste water streams designed for a treatment capacity of 500 m 3/h each and maximisation of reuse. The scope of treatment also includes three by-product streams generated during the treatment of refinery waste water (skimmed or slop oils, oily sludge and biological sludge). Skimmed oil Chemical Engineering World

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CEW Features

Effluent Treatment Plant at Reliance Industries Ltd., Jamnagar, Gujarat

is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing. Each of the above streams employs identical equipment for treating effluents, namely:

project, a new effluent treatment plant (ETP-III) treats effluents generated from the refinery project to meet the MINAS standard. With a view to conserving water, a new zero discharge plant (ZDP) was designed and constructed by Ion Exchange. This plant treats the treated water from ETP-III to enable use of the treated water as make - up to the demineralisation plant. The capacity of the ZDP is 200 m 3/h. The plant was commissioned in 2005 and is operated and maintained by Ion Exchange. 3. Indian Synthetic Rubber Limited Another such example of ZLD is for Indian Synthetic Rubber Limited (ISRL). Three streams containing 3000 m 3/d process effluent along with

requirements from buyers in case of exporters, etc. ZLD also gives enormous importance to sludge management (which is not discussed in this paper and which needs separate attention). Apart from these reasons, industries now identify recycle and ZLD as their social responsibility for environmental friendly manufacturing of goods. Many technologies are now available for managing industrial waste water and other waste. It is of utmost importance to involve environment management specialists right from the planning stage of the project so that the best optimum solutions can be developed. Priority should always be given to source reduction and product recovery rather than end of pipe waste water treatment

• Free oil removal facilities including pre-deoiler and API separators with continuous oil skimming and sludge removal facilities • Dissolved air Flotation (DAF) unit • Two stage biological treatment • Clarification • Dual media filtration • Activated carbon adsorption • Disinfection – with chlorine and chlorine dioxide The effluent treatment plant is treating 100 per cent effluent generated by the refinery since its commissioning in December 2008 and consistently produces treated effluent (pH 6 - 8.5, sulphide < 0.5 ppm, COD < 50 ppm, oil and grease < 5 ppm, phenol < 0.35 ppm) meeting guaranteed parameters for reuse for various applications mentioned earlier. 2. Chennai Petroleum Corporation Limited The ZLD plant for the expansion at Chennai Petroleum Corporation Limited (CPCL) uses advanced membrane processes to reuse water for its process requirement. CPCL, during its expansion, increased the crude refining capacity at Manali by 3 million metric tonnes per annum. As part of this 3 MMTA expansion 54 • October 2018

ISRL- Downsteam Petrochemical

360 m 3/d cooling tower blow down and 240 m 3/d DM plant effluent are being treated through primary, secondary, tertiary and advanced tertiary treatments. The final reject (from RO) is being treated in thermal MEE, thereby achieving the objective of > 95 per cent water recovery and ZLD.

and expensive methods of ZLD. Right technologies should be adopted for recovery and recycle of water from waste water. Final effluents which cannot be recycled should be treated and disposed of in an environmental friendly way.

Conclusion Waste water recycle and ZLD is mandatory for many industries because of water scarcity, legislation, rising water costs, unreliable water supplies, environmental

Ajay Popat President – Technology, Corporate Marketing and Corporate Diversification Ion Exchange (India) Limited

Author’s Details

Chemical Engineering World

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CEW Features Technical Article

Combating the Effects of Corrosion in Refineries with Duplex Stainless Steels As worldwide crude oil production levels intensify, duplex stainless steels are proving ever more crucial in withstanding corrosion challenges faced by oil refinery equipment, writes Mohan Gawande, Manager Chemical Group, India, Sandvik Materials Technology.

eat recovery processes are especially important to critical petroleum refining applications, supplying and reusing energy in order to help achieve more efficient, economic and productive processes. Nevertheless, corrosion aggravated equipment failures in heat exchanger tubes have always been a large and unavoidable issue in critical petroleum refining applications Traditional metallic tube components like carbon steels are failing to cope in the increasingly harsh corrosion environments, resulting in disruptive maintenance procedures or unplanned shutdowns. Such materials are extremely vulnerable to corrosion and austenitic stainless steels and, widely used in heat exchanger tubing, are susceptible to stress corrosion cracking (SCC) particularly in chloride bearing environments. According to statistics, such failures are thought to account for the losses of approximately 1-5 per cent of various countries’ gross domestic product (GDP) and around 6 per cent of the overall petrochemical industry’s GDP. The latter figure is twice as much as in other industries. Aside from the higher productivity demands, these problems are exacerbated by the decline in crude oil quality which is becoming sourer and more corrosive. For these reasons, it is ever more vital to select materials that can both withstand and eliminate failures throughout the plant. A wellconsidered material should possess superior anticorrosion and mechanical properties to help optimise equipment service lifecycles,

56 • October 2018

reduce the need for maintenance, prevent contamination of refinery products caused by corrosion and minimise heat losses caused by fouling of equipment. Corrosion factors in refineries The primary corrosion media in oil refineries include sulphides, chlorides, nitrides, hydrochloric acid, polythionic acid, oxygen and heavy metals. These elements tend to react under the dew point temperature, when vapour condenses into liquid water at the same rate at which it evaporates. Either in water or during catalysis, this condensation can cause serious corrosion in equipment. Dew point corrosion is generally initiated by the formation of hydrochloric acid, and chemical interactions between hydrochloric acid and hydrogen sulphide cause corrosion of the refinery equipment. Deposits in or on heat exchanger tubes emanate from the process side due to tenacious hydrocarbons, process slurries or even ammonium chloride (NH4Cl) deposits in crude overhead condensers. Non-hydrocarbon compounds and additives also build up during the refinery process resulting in further corrosion. These factors are detrimental to overall process efficiency and pose a threat to the refinery devices’ distillation, hydrotreating and catalytic reforming of crude oil. Corrosive elements in crude oil However, it should be noted that the main cause of corrosion in refinery applications from the process side is not the hydrocarbons themselves but the presence of contaminants in the crude oil as it is produced. Generally,

the heavier the oil the higher the boiling point. It is corrosion under high temperatures that causes carbon steel equipment to fail and leads to unplanned and costly maintenance, shutdowns or accidents. Most contaminants in crude oil end up in the refinery tankage along with contaminants picked up during the transportation. Crude oil contaminants that affect corrosion resistance in steels include carbon dioxide (CO2), hydrogen sulphide (H2S), nitrogen compounds, sulphur compounds and inorganic chlorides such as sodium chloride (NaCl), magnesium chloride (MgCl2) or calcium chloride (CaCl2). Crude oil is normally more than 90 per cent naphthenic acid, of which corrosion is most intense in environments with elevated temperatures and without water, and occurs at its greatest potential at temperatures of 270-2800 C (518-5360 F). The corrosion rate of naphthenic acid declines at temperatures above 2800 C (5360 F), rises rapidly again at 3500°C (6620 F) and stops corroding above 4000°C (7520 F). One of the most corrosive phenomena that affect stainless steels is the reaction of sulphur with oxygen to create sulphur dioxide (SO2). Sulphur is present in most processes where coal or oil is combusted at high temperature, and Figure 1 presents an overview of trends relating to global crude oil gravity and sulphur content including data by the American Petroleum Institute (API). Different fractions of sulphur levels are shown in Table 1. SO2 corrosion rates vary under different temperatures. Sulphide does not decompose Chemical Engineering World

D ough

SEALS OF INTERNATIONAL CLASS SEALS OF INTERNATIONAL CLASS STATE-OF-ART MANUFACTURING STATE-OF-ART MANUFACTURING SOLUTIONS... NOT MERELY PRODUCTS SOLUTIONS... NOT MERELY PRODUCTS

CEW Features Fractions

Gasoline

Kerosene

Diesel Fuel

Gas Oil

Residue

Sulphur levels (%)

<0.8

<5.2

6-15.5

13.5-44.5

43.6-76

applied to stainless steel which exposes test specimens to 6 per cent iron(II) chloride (FeCl) solution, also known as ferrous chloride, with and without crevices.

Source: Equipment corrosion status in refinery plant and solutions (part 1)* Table 1. Different fractions of sulphur levels.

under temperatures below 120 °C (248 °F), but corrodes and forms into a hydrogen sulfide (H2S-H2O type) under the dew point temperature or when it contains water. H2S is generated under temperatures between 2403400°C (464-6440°F) and is aggressive to carbon steel at these temperatures thereby corroding the equipment. 0

Corrosion worsens as the temperature increases, reaching its highest peak when the temperature falls within the range of 420-4300°C (788-8060°F). A superior replacement grade to carbon steels must therefore be capable of retaining superior anti-corrosion properties at high operating temperatures. Mitigating plant shutdowns Utilisation of corrosion resistant materials not only eliminates unscheduled plant shut downs, but also reduces the risk of costly lost production and expensive emergency maintenance and repair. Consideration should also be given to the formation of crevice corrosion beneath such deposits at temperatures below the critical pitting temperature (CPT) of the material. Carbon steel is extremely vulnerable to corrosion and austenitic stainless steels, widely used in heat exchanger tubing, become susceptible to SCC particularly in chloride bearing environments. Research Quality of crude oil and condensate, API degrees

Sulphur - containing amount

API (American Petroleum Institute) degree according to the weighted average yeild Sulphur - containing amount

Source: Cambridge Energy Research Associates Figure 1. The trends of global crude oil API degrees and sulphur content.

58 • October 2018

has shown that these materials are highly susceptible to corrosion at the elevated operating temperatures found in refineries. Gradually, the industry has recognized the advantages of duplex stainless steels that offer the optimum combination of corrosion resistance, mechanical properties and excellent fabrication capabilities which all lead to genuine cost advantages. Development of duplex stainless steels Since the development of duplex stainless steels began in the 1930s, they have emerged as a favoured alternative to traditional carbon steel tube in corrosive heat exchanger applications. The first generation grades contained chromium (Cr), molybdenum (Mo) and a high content of carbon (C) with low weldability. Further developments into the 1970s reduced the content of C, and alloy elements that improved the material’s corrosion resistance such as Mo, copper (Cu), silicon (Si) and especially nitrogen (N) were added. These innovations led to the formation of a new ‘second generation’ of N-containing duplex stainless steels that included the 18Cr-type, 22Cr-type and 25Cr-type, and a further three generations of duplex stainless steels which emerged later in the 1980s. These had low C content but high amounts of Mo and N with content of ferrite that is about 50 per cent or slightly lower. Some of these grades were called ‘superduplex’ and characterised by a Pitting Resistant Equivalent (PRE) number of at least 40. The PRE number (=%Cr + 3.3x%Mo + 16x%N) is a measurement for ranking the resistance of stainless steels to pitting and crevice corrosion. Exact testing procedures to determine the PRE number are specified in the ASTM G48 standard, one of the most severe pitting and crevice corrosion tests

In general, the higher the PRE value the more corrosion resistant the steel. The pitting resistance value of a stainless steel is of great importance when assessing its suitability for heat exchanger applications, and also fabrication practices like welding which are of vital importance for performance in service. As a comparison, typical grades like AISI 316L and AISI 317L have insufficient PRE values to withstand many corrosive heat exchanger environments – even when working at the upper limits of their standards. Improved corrosion resistance Figure 2 illustrates a comparison of several commonly used refinery materials’ resistance to SCC. They include duplex Sandvik SAF 2304TM (UNS S32304) and super-duplex Sandvik SAF 2507TM (UNS S32750). Both Sandvik grades are well suited to heat exchanger applications, and each possesses a combination of good corrosion resistance and high mechanical properties for advantages like reduced wall thicknesses and lower processing costs. The materials have proven especially useful in corrosive heat exchanger environments and are helping to solve many of the problems faced by today’s oil refining industry. Key attributes of Sandvik SAF 2304 include low Ni content, and a two-phase microstructure with approximately 50 per cent ferrite which imbues the grade with a more stable metallurgy than comparably instable high-nickel alloys. A high 23 per cent Cr content compensates for an absence of the vital yet costly anticorrosion element Mo, and N content further increases the material’s strength while improving weldability and resistance to pitting corrosion. The nominal chemical composition of Sandvik SAF 2304 is shown alongside the Chemical Engineering World

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CEW Features 6.0 per cent Mo steels: it is more readily available and therefore offers lower initial costs. Figure 3 compares the material’s critical pitting and crevice temperature alongside standard steel grades according to ASTM G48. The super-duplex stainless steel’s antisulphide and chloride SSC resistance and crevice corrosion resistance capabilities have been further enhanced compared to austenitic grades., see Figure 4.

Figure 2. A comparison of several commonly used materials’ resistance to stress corrosion cracking (SCC).

standard materials ASTM 304L and ASTM 316L in Table 2 with, for comparison, the minimum PRE numbers of each material. The duplex stainless steel has a PRE number of 24 which suits the material for used in the harshest corrosive environments at a temperature range of -50 to 3000°C (58 to 5720°F). As Table 2 shows, the PRE number for Sandvik SAF 2304 is considerably higher than the number for AISI 304L and comparable to the number for AISI 316L. In practical terms, the grade demonstrates better resistance to SCC compared to austenitic steels of AISI 304 and AISI 316 type, and is demonstrably better than AISI 316L in most acid environments, with resulting cost advantages, see Table 3.

The data shows that Sandvik SAF 2507 is a competitive alternative to high alloyed austenitics and nickel alloys in applications where standard austenitic steels corrode at a high rate; it is demonstrably the best choice material for use in high-temperature heat exchangers containing chlorinated or nonchlorinated water. Cost advantages On many projects cost is of primary importance. However, the ability of a material to fully meet the application requirements Alloy

% cr

Sandvik SAF 2304

AISI 316L

AISI 304L

18.4

% Mo

has to be a major consideration for plant efficiency. Strength of the material is a significant factor. For example, selecting a duplex grade such as Sandvik SAF 2304, despite a higher price per kilogram, can prove to be the most economical solution. This is because the wall thickness of the tubes as they are subjected to internal pressure or tensile loads is directly related to the material strength. As thinner wall tubes can be specified, the cost of the duplex material can be around 35 per cent lower. This should be compared to the cost of tubes of other material grades which would require a thicker wall in order to achieve the same strength, see Table 3. There are also associated savings to be achieved on transport, installation, welding etc when specifying the lighter thinner walled duplex grade tubes. Successful application in heat exchangers The Sandvik duplex stainless steel grade Sandvik SAF 2304 and the super-duplex material Sandvik SAF 2507 are among the manufacturer’s advanced materials that %N

PRE

0.1

2.2

24 18

Table 2: The minimum PRE numbers for Sandvik SAF 2304 and the austenitic standard stainless steels AISI 316L and AISI 304L.

For example, lean duplex stainless steels, such as Sandvik SAF 2304, offer high strength with a yield strength twice that of AISI 304L and AISI 316L austenitic stainless steels, low thermal expansion, very good weldability, physical properties that provide design advantages, as well as ease of fabrication and toughness. When looking at super-duplex grades, such as Sandvik SAF 2507, based on the established PRE values of AISI 316L and its variants like AISI 317L, the minimum standard PRE value of 42.5 for Sandvik SAF 2507 identifies the super-duplex grade as superior. The performance levels are comparable to 6.0 per cent Mo austenitic stainless steels like 254 SMOTM and AL-6XN. Yet Sandvik SAF 2507 has distinct advantages over these 60 • October 2018

Figure 3. Critical pitting and crevice temperatures in 6 per cent FeCl, 24h (similar to ASTM G48).

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CEW Features Material

Strength R p 0.2 MPa

Estimated relative cost

Density (g.cm3) Wall Thickness* relative mm

Sandvik SAF 2304

400

1.05

7.75

1.65

AISI 304L

190

1.0

7.90

2.77

AISI 316L

210

1.08

8.0

2.77

Table 3. Cost comparison of Sandvik SAF 2304™ and AISI 304L/316L for tubes subjected to internal pressure or tensile loads.

in refinery equipment including H 2S, dew point corrosion, chloride pitting, NH4Cl and under-deposit corrosion.

Figure 4. Stress corrosion cracking (SCC) resistance in oxygen bearing (~8 ppm) neutral chloride solutions. Test time 1,000 h. Load ≥ yield strength at testing temperature.

have become success stories in oil refineries around the world, and each has exhibited high performance cost advantages. In the USA, a plant was experiencing inadequate performances in the AISI 316 tube in its heat exchangers. The tube, used to process maleic anhydride which is an organic compound for applications in coatings and polymers, had failed due to SCC after only 2-3 years’ service. Sandvik SAF 2304 was chosen as the replacement grade, of which 7350 m of 19.05 x 1.65 mm tube was installed in the secondary cooler after the reactor and would be required to operate at temperatures of 204-2320°C (400-4500°F). The material exhibited superior mechanical and physical properties, along with excellent resistance to SCC and other forms of corrosion. In another installation, a refinery was experiencing corrosion problems in its overhead condensers. The system comprised four heat exchangers which each contained 951 steel tubes of length 19.05 x 1.65 x 6096 mm. Used to process crude oil, the tube was subjected to many of the main media sources that cause corrosion 62 • October 2018

The existing tubes, made of carbon steel, were again exhibiting a maximum service life of 2 to 3 years when subjected to condensation of hydrocarbons and H2O in small amounts (30-100 ppm Cl and 2001000 ppm H2S) generally at pH levels of 6-7, 45-550°C (113-131 °F) inlet temperatures, inlet pressures of 0.078 – 0.12 MPa (0.81.2 kg/cm2) and outlet temperatures of 60750°C (140-1670°F). An inspection carried out in April 2000 revealed that the tubes were still in good condition, and a visual inspection found a good connection of the pipe’s tube plate. The tube’s interior had not been subject to corrosion; and examination of the exterior found no under-deposit corrosion. In contrast, a phenomena of general corrosion on the old carbon steel tube plate was observed. Between the years 2000 and 2011, a total of four new heat exchangers were subsequently put into use at the refinery all using the duplex material. Similarly, a refinery in Italy required replacement tube in six overhead condenser system heat exchangers. Each heat exchanger comprised 1,298 tubes made from AISI A179 steel. After two years of use, multiple tubes in the bundle experienced an early onset of failure. Sandvik SAF 2507 was installed in the heat exchangers in 2003. An inspection in 2006 revealed the heat exchangers to be in good condition, despite serious decomposition seen in the tube plates and shell passes. It was not until 2008 that, with moderate concentrations of hydro-cleaning, some signs of corrosion were found.

Conclusions As heat recovery processes remain at the forefront of economical and environmentally compliant processes, refineries must implement the most reliable materials to fully-realise these objectives and also remain cost-effective. Duplex and super-duplex stainless steels by Sandvik can realise these goals, while addressing the ongoing decline in crude oil quality and the failure due to corrosion of a range of materials, such as copper based alloys as well as different types of austenitic stainless steels. In such environments, duplex stainless steels provide excellent resistance to corrosion attack as recorded in extensive laboratory testing, as well as in successful documented installations in process plants and refineries worldwide. Ease of fabrication and the durability of duplex stainless steels means significant advantages, not only for new equipment but also when retubing existing heat exchangers. Further to these advantages, duplex stainless steel Sandvik grades are today included in numerous refinery and equipment manufacturers’ preferred procurement lists.

Author Details Mohan Gawande Manager, Chemical Group Sandvik Materials Technology Chemical Engineering World

CEW News Features

Vinati Organics will Continue to Show Remarkable Growth Last decade has been a period of very strong growth for Vinati Organics Ltd and the company has shown phenomenal growth during the last one year. Vinati Saraf Mutreja, CEO, Vinati Organics Ltd shares insights into the strategies and growth plans of Indian specialty chemicals major in an exclusive interaction with Chemical Engineering World.

inati Organics Limited (VOL) is the world’s largest manufacturer of Isobutyl benzene (IBB). It began commercial production of IBB at its factory in Mahad, Maharashtra in 1992 and accounts for more than 60 per cent of the global market share in IBB. VOL is also the largest manufacturer of 2-Acrylamido 2-Methylpropane Sulfonic Acid (ATBS) in the world. It began commercial production of ATBS at its plant in Lote Parshuram, Maharashtra in 2002 and accounts for approx 65 per cent of the global market share in ATBS. The Isobutylene (IB) plant of VOL became operational from September 2010. It’s the largest IB plant in India and VOL accounts for more than 70 per cent of the local market of IB. Apart from these products, VOL is also the largest manufacturer of High Purity Methyl Tert Butyl Ether (HPMTBE) in India an also the only manufacturer in India of other specialty products like Tertiary Butyl Acrylamide (TBA), Tertiary Octyl Acrylamide (TOA), Tertiary Butyl Amine (TB Amine), Para Tert Butyl Benzoic Acid (PTBBA). VOL derives close to 70 per cent of its revenue from exports to USA, Europe, Asia, Middle East and China and has some of the largest chemical companies in the world such as BASF, Dow Chemicals, Nalco Company (USA), AkzoNobel, Clariant Chemicals, etc. as its clients.

She observes price and quality as the key challenges that need to be addressed by the specialty chemicals manufacturers. Mutreja says, “As in any business, the end-user is usually concerned about the price, quality and availability are the key concerns but in the specialty chemical industry there is something else apart from the above which is gaining more significance.” She adds that the significance of sustainable chemical process is gradually and definitively becoming the pivot on which this entire industry is getting looked upon with. Today the end-users are more concerned about whom they are sourcing their materials from rather just restricting themselves to source from the cheapest. In fact, some of the global chemical companies have started a joint initiative called “Together for Sustainability (TfS)” where their aim is to join forces in order to assess and improve sustainability sourcing practices with their global supply chains. The member companies of TfS have a worldwide program to audit and evaluate suppliers under pre-defined criteria regarding management, environment, health and safety, labour and human rights, and governance issues. Under this evaluation, VOL has been awarded a ‘Gold Rating’ and it was among the top 5 per cent performers based on defined parameters for corporate social responsibility.

A Decade of Good Performance

Collaborations Development

Talking about the remarkable achievements of the company and a very strong track record over the last decade, Mutreja shares, “AtVOL, we have always focused on having a sustainable growth based on working with innovative processes leading to higher operational efficiency and profitability. We strongly believe that to retain our global leadership and competitive edge, innovative products and processes would be a key differentiator and hence it forms a key part of our overall business strategy. This emphasis on innovation will allow us to keep growing by adding new products and geographies.” 64 • October 2018

for

Research

and

The company is leveraging in-house research, technology partnerships and associating with the academia for new product development. VOL has adopted a two-pronged strategy with respect to R&D and innovation. Our own inhouse R&D departments based in both of our manufacturing facilities undertake activities ranging from development of new products, enhancement of product efficiency and purity, development of new applications for existing products, etc. In addition to this, VOL has had a very robust, fruitful and symbiotic relationship with the academia in VOL’s pursuit for new

products. We have partnered with prestigious government and non-government research institutes/organizations, across India and the world, which has allowed us to introduce new products with innovative processes which are both cost efficient as well as clean and green. Way Forward VOL is preparing well for the future challenges and has already started using digital technologies to upgrade and getting ready for the future. Mutreja sees this as one of the key trends for the future growth in the chemical industry and says, “We are already employing digital technologies which are already making the operations efficient through usage of automation and analytics in the core operational functions like R&D, finance, production and supply chain management. But we are also aware that the industry is increasingly moving towards adopting advanced digital technologies like Artificial Intelligence, Big Data Analytics and adopting industry specific software and services. We are constantly evaluating and using these tools to boost our efficiency levels viz, reduced energy and waste, improved remote monitoring and surveillance etc.” VOL is expanding ATBS facility from 26000 TPA to 40000 TPA, entailing a CAPEX of approximately ` 100 crores. This expansion will be commissioned by the first quarter of 2020. In addition to this, the company had embarked on its Butylated Phenols project in FY18 and this project is expected to commence its operations during Q1FY20. It consists of 4 products: PTBP, OTBP, 2,4 DTBP and 2,6 DTBP. PTBP and OTBP are intermediated to be used in resins and perfumery industry whereas 2,4 & 2,6 DTBP go as raw materials for making an-tioxidants which are used as additives to widely used plastics like polyethylene, polypropylene, polystyrene etc. With a CAPEX of ` 240 crores, VOL estimating to clock in sales of ` 350 – 400 crores from this project. Chemical Engineering World

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RS Process Systems Ltd is the trusted heat transfer technology provider to a range of process sectors across India and has licence to manufacture, design, supply and service of Plate Heat Exchanger (PHE) in collaboration with FUNKE Warmeaustauscher GmbH. Funke is a leading company in quality heat exchangers, having a state-of-the-art facility in Germany focused on plate heat exchangers.

The construction of a PHE is the stack of embossed plates with suitable portholes fitted parallel to each other, resulting in equal fluid distribution on each side. Each plate is separated from the next with a gasket which separates the two and seals the flow gap from the atmosphere. The heat transfer plates separate two fluids and avoid mixing of process and utility fluids. There are a variety of corrugation patterns designed on heat transfer plates, which can be selected for specific applications to achieve higher heat transfer rate and optimum pressure drops. These plates allow different heat transfer area with acute and obtuse angled corrugation. Heat transfer plates are mostly produced

66 â&#x20AC;˘ October 2018

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gasket leaks. The installation of gaskets is depending upon the design and type of plate heat exchanger; it comes with two different types, ie, adhesive and clip-on gasket. Following are the various types of gaskets available for suitable processes, (see Table) HRS FUNKE PHE comes in following different models: â&#x20AC;˘ Gasketed Plate Heat Exchanger: It is the most widely used variant of PHE which consists of a set of embossed plates fitted adjoining to each other and each plate separated by a gasket. This is used for most oil, water, etc, applications. The gasket, which is mechanically secured or glued on to every plate, ensures that the flow gaps are securely sealed to the outside and from the second medium

Universal use for water or oil applications

(Ethylene-propylene Uses for chemical compound which do not contain mineral oil and grease and also for water and steam application

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involved in the heat exchange. Also, for different compositions and corrosive properties, the best fit material of construction of plates and gaskets are used. • Brazed Plate Heat Exchanger: Consists of embossed plates, fit into one another and vacuum brazed with copper, nickel or stainless steel to form a compact and pressure proof unit. It is designed for applications like cooling of lube oil, condensing in refrigeration plant. • Cladded Plate Heat Exchanger: This is a well-researched in-house design where the fixed plate and pressure plates are cladded with stainless steel or similar metals to make the outer surfaces compatible with process and utility fluids. This is effective in food, dairy, brewery and similar hygienic applications. Thermodynamically optimized designs make HRS FUNKE PHE efficient and cost-effective equipment for the heat transfer industry. Depending on the conditions of use, the plates and gaskets can be replaced, added, removed and reassembled several times. HRS FUNKE PHEs are low investment and lower in Chemical Engineering World

operation and maintenance cost as well. They have self-cleaning quality due to highly turbulent flow behaviour. It can also be used for smallest temperature difference </=1 oC. HRS FUNKE PHEs are effectively used in applications like heating, cooling, chilling, pasteurizing, sterilizing and the industries who perform such applications are food and beverages, chemical processing, polymers, pharmaceutical, pulp and paper, vegetable oil, textile, sugar processing, power, HVAC, marine. HRS PSL has extensive service support network all across India. PHE spares, ie, gasket, plates, etc, as required are easily made available to the customers. HRS PSL provides following service support solution to enhance productivity: • Servicing of PHE at site • Root cause detection for PHE malfunction • Deputation of HRS personnel at site • Expert telephonic and online support • Performance validation of PHE. HRS PSL is part of UK-based HRS Group of Companies, is at the forefront in innovative thermal process technology. HRS Group is equipped with a strong

network all across the globe in UK, Spain, USA, India, Australia, New Zealand and Malaysia. With a well-equipped ISO and ASME Certified design and manufacturing set-up in India, HRS PSL empowered to supply heat exchangers and systems to the domestic and international geographies. HRS FUNKE PHE is one of the most reliable thermal processing equipment for a wide spectrum of processes adding to the accountability on HRS PSL as an innovative and trusted brand in the heat exchangers market.

For details contact: HRS Process Systems Ltd 201/202 Karan Selene 851 Bhandarkar Institute Road Pune, Maharashtra 411 004 Tel: 020-25663581, 25663582, 66047894, 66047895 Fax: 91-020-25663583 E-mail: mktcom@hrsasia.co.in info@hrsasia.co.in October 2018 • 67

CEW Products Filter and Transfer Unit

Vacuum Systems

DEPUROIL is the ideal tool for decontaminating oil by removing suspended particles. It is fitted with a constantly operating volumetric pump which sends the fluid through a high-filtering capacity cartridge filter. Features a manometer for detecting clogged filter; wheeled support; noise level less than 70 dB; interchangeable cartridge filter with head; and two step filtration. It is supplied with series of spare cartridges. Filtering capacity 30/5 micron.

The condensor helps in reducing the process time of drying, distillation, etc, by effectively condensing the condensable vapours.The condensor has been standardised with 1.5 m2, 3 m2, and 6 m2, cooling surface area. The MoC can be given in Mild Steel/SS-304/SS-316 for Shell and Copper/Cu.Nickel/SS-304/SS-316 for the cooling coil.

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

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 01

Vacuum systems finds application in many fields, including pharma, chemical, plastic, food and pasta production, leather chemicals and centralized vacuum systems. Vacuum systems are variable and optimized by the selection for the application and working parameters. It is possible to decrease power, saving in the range 30-40 per cent.

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M Pumps Shanbhag and Associates is the sole, authorised, national distributor for M Pumps an Italian manufacturer of seal-less, magnetic driven pumps. M Pumps is a unit of the Mischiatti Group and has been manufacturing magnetic driven pumps for over 25 years. The seal-less, magnetic driven pumps are offered in centrifugal, peripheral, sliding vane, self-priming, centre-line mounted, inline and vertical pump versions. M Pumps manufactures these pumps in metallic, non-metallic and lined constructions. It finds application in oil and gas, chemical, pharmaceutical, industrial refrigeration, offshore platform, electronic and galvanising and nuclear plant areas amongst others. M Pumps is an ISO 9001 and ISO 14001 Certified company manufacturing to API 610 and 685 as well as non-API pump Standards. To safeguard the pumps Shanbhag also offer dry-running protection, temperature monitors on rear casing and ATEX Certification as options for many models as optional features. Contact Shanbhaag with fluid details and your pump requirements. Their national sales and service network will application engineer your pump requirements. With M Pumps Shanbhag can offer a good quality pump at a competitive price for your difficult applications. For details contact: Shanbhag & Associates B-50 Nandbhuvan Mahakali Caves Road Andheri (E), Mumbai 400 093 Tel: 022-40365700, 40365711 Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 03

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Chemical Engineering World

Products CEW Strainer & Filtration Solutions Including Airpel and Plenty brands, the vast array of products within the SPX FLOW filtration portfolio forms one of the biggest collection of filtration solutions available from a single supplier in the marketplace. Manufactured in Western Europe, the quality, durability and effectiveness of SPX FLOW filters and strainers have, for a long time, made them the solution of choice within industries such as oil and gas, water and wastewater, petrochemical, automotive and power generation. The diverse range of filtration solutions includes single, dual and multi-basket designs for pressures up to 50 bar; automatic and self-cleaning filters, back-flushing strainers, and models in a full range of sizes up to 36”. Standard, ‘commodity’ models are complemented by fully engineered, customized solutions, fabricated to meet customer needs in a range of materials including cast iron, cast steel, SS, duplex and super duplex. Large filtration areas reduce pressure drop and the amount of cleaning required, while quick release covers promote rapid and easy maintenance to reduce any process downtime. Duplex strainers provide two filtration chambers with an integral flow changeover valve, enabling cleaning and replacement of baskets to be carried out without any interruption to the flow and providing that one of the chambers is always in operation for continuous service. Models also have a compact design to offer a small footprint and easy installation. From cost-effective, standard models to custom-fabricated solutions; SPX FLOW has the experience and capability to deliver value, benefit and complete peace of mind to its customers. For details contact: SPX International Ltd Lodge Park House, Kettering Parkway Kettering Venture Park Kettering NN15 6XU, U.K. Tel: +44 (0)1604 889921 E-mail: Maryanne.Johnson@spxflow.com or Circle Readers’ Service Card 04

Drum Pumps Shanbhag & Associates is the authorised, national distributor for the entire range of Lutz products. Lutz Pumpen GmbH & Co KG, Germany is the premier manufacturer of electric and pneumatic drum/ container pumps in the world. The Lutz concept allows the complete pump (drive motor and pump tube) to be used in different containers and liquids as long as components in the pump tube are approved for use in the liquids. Lutz drum pumps can handle liquids which are aggressive, flammable, thin, viscous, hot or cold, hazardous to ground water and the environment, and vary with respect to their density. Liquids upto 100,000 cp can be unloaded from drums or IBCs. The wide variety of liquids and container types/dimensions necessitates an extensive range of drum pump models. They are available in a variety of materials, equipped with electric/air motors adapted to the output requirements, for different voltages (AC/DC), explosion-proof for hazardous applications, pneumatically-operated, with the required delivery rate and a suitable sealing system. Added to this are pump tubes in varying lengths and wide range of accessories permitting, eg, adaptation to problematic containers or operating conditions. Pump tubes are available with centrifugal impeller or with eccentric screw principle constructions. Tube materials are in PP/PVDF/Alu/SS-316 (Ti) / Hast-C. Tube drivers are available in electric (FLP/Non-FLP) and pneumatic options. Drum pumps can be offered in sanitary and non-sanitary constructions including 3A Certified construction. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E) Mumbai 400 093 Tel: 022-40365700, 40365711 Fax: 91-022-40365712 E-mail: info@shanbhags.com Circle Readers’ Service Card 24 or orCircle Readers’ Service Card 0500

Chemical Engineering World

October 2018 • 69

CEW Products Borewell Submersible Pumpset

Ultrafiltration Membranes Liqui-Flux ultrafiltration membranes are manufactured by Membrana, Wuppertal, Germany market leader in membrane technology. Liqui-Flux ultrafiltration membranes are microporous, hollow fibre, polyethersulfone membrane which are used to filter or separate micro-organisms down to macromolecules from water. The ultrafiltration membranes are typically engineered to provide large membrane separation area in a housing well designed to allow uniform flow of the feed liquid on one side of the membrane and the permeate/filtrate on the other side. The fluid flows from the inside of the hollow fibre membrane to the outside of the membrane. It finds application in RO pre-treatment, waste water reuse, drinking water, process water, swimming pool and beverage filtration. For details contact: Evergreen Technologies Pvt Ltd 3-D, Maker Bhavan-2 18 New Marine Lines Mumbai 400 020 Tel: 022-22012461, 22012706, 61566969 Fax: 91-022-22010024 E-mail: info@evergreenindia.com or Circle Readers’ Service Card 06

CRI 150 mm (6”) borewell submersible pumpsets are powered by water filled, rewindable submersible motor which is suitable for continuous duty. The stator is wound with special waterproof synthetic film insulated copper winding wires and made up of low wattloss silicon steel laminations assembled under pressure and rigidly locked in. CRI’s new double-depth BINDA 6D 150 mm (6”) borewell submersible pumps are specially designed for conditions where the ground water level is too deep. BINDA 6D is designed to work in more depths and is built with sturdy AISI grade SS material. This Series guarantees long life with energy-efficient performance. The built-in check valve prevents back flow and reduces the risk of water hammer. For details contact: CRI Pumps Pvt Ltd 7/46-1 Keeranatham Road Saravanampatty Coimbatore, Tamil Nadu 641 035 Tel: 0422-3027000 Fax: 91-0422-3027005 E-mail: corp@cripumps.com or Circle Readers’ Service Card 07

Vacuum Packaging Vacuum Packing is a technique of storing and preserving food. The foods are stored in an airtight pack or bottle to put off the growth of microorganisms. The vacuum environment provides the safe atmosphere without oxygen, protecting the food from spoiling by limiting the growth of fungi or aerobic bacteria. Vacuum packaging can extend the life up to 3-5 times. It increases the shelf life. After evacuating the air in the pack, still some amount of oxygen will remain. Air contains 21 per cent oxygen at atmospheric pressure 1013 mbar. The objective of packaging is to reduce the oxygen content by lowering the pressure, eg, if pressure is reduced to 10 mbar, the oxygen per cent will be 0.21. If it is non-food item, the vacuum packing protects it from oxidization, corrosion and moisture damage, eg, packing of matches, socks, medicines, etc. Moist foods will not dry out. Seal dehydrated foods and dried herbs will prolong storage. The pump has to evacuate air in presence of water vapour for food items like meat, fish, which are moist and also the pump should be able to withstand the cyclic load due to packing and also evacuation prior to flushing operation for Modified Atmospheric Packaging (MAP), like N2 filling. The vacuum oil used should be food grade oil and Toshniwal’s multivane semi-dry vacuum pump is the pump designed for packaging industry. It is reliable, suitable for continuous operation, quieter, better vacuum in short cycle time, and good water vapour handling capacity. 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 08

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Products CEW Hydro-transportation System

Vacuum Lifter

Hydro-transportation devices are considered by some to be the latest generation of sand removal devices. The operating principle is the introduction of wash water in a vortex manner. While effecting initial mobilisation of accumulated solid particles, an area of low pressure is produced at the centre of the induced vortex, which is utilised, by means of strategically placed piping, to transport the produced slurry out of the vessel. For details contact: Fenix Process Technologies Pvt Ltd K 6/1 Malini, Erandwane Co-op Hsg Scty Nr Mangeshkar Hospital, Opp: Sevasada School Erandwane, Pune, Maharashtra 411 004 Tel: 020-65008772, 60508770 E-mail: info@fenix.in or Circle Readers’ Service Card 09

Battery powered vacuum lifter with built-in battery charger designed for horizontal lifting and ideal for glass, laser cutter, thin metal sheets, panels, etc. Simply hooks on to your hoist. It is suitable for lifting sheets with a max weight of 160 kg and a size of 1.6 x 1.6 m. Features pressure switch to maintain minimum vacuum level visual alarm system to warn of low vacuum. Slider valve with On and Off position for the attachment of material to vacuum pads and release of material from vacuum pads. For details contact: Aardwolf Material Handling Solutions Harmara Road, RICO Indl Area Madanganj Kishangarh, Dist: Ajmer Rajasthan 305 801 E-mail: Gaurav.mathur@aardwolf.co.in or Circle Readers’ Service Card 10

I/O Terminals The EtherCAT Terminals in the ELX Series have been expanded by the addition of analog input terminals with TwinSAFE SC (Single Channel) technology. These highly compact I/O terminals can be used to support applications in hazardous areas that require both intrinsically safe signal transmission and functional safety capabilities. The highly compact ELX Series terminals, which are certified in compliance with the specifications of the ATEX and IECEx Standards, enable direct connection of intrinsically safe field devices through to Zone 0/20 based on an integrated safety barrier. The new terminal designs extended by TwinSAFE SC technology now also make it possible to achieve a safety level equivalent to PL d/Cat 3 according to EN ISO 13849-1 or SIL 2 according to EN 62061. In this way, it is possible to use all process data existing in a system for safety technology too, such as to monitor the speed of fans in areas sensitive to explosion hazards, for example. The new I/Os are available as 12 mm wide terminals with two or four analog input channels for 0/4…20 mA and for RTD resistance sensors, thermocouples/mV and strain gauges. Furthermore, a single-channel terminal is available for the direct connection of intrinsically safe incremental encoders, which evaluates a diagnostic-enabled NAMUR signal in accordance with IEC 60947-5-6. With the aid of TwinSAFE SC technology, it is possible to make use of standard signals for safety-related tasks in any network or fieldbus system. The data from a TwinSAFE SC terminal is fed to the TwinSAFE Logic, where it undergoes safety-related multi-channel processing. The data originating from different sources is analysed, checked for plausibility and submitted to a voting process. This is done by certified function blocks such as Scale, Compare/Voting (1oo2, 2oo3, 3oo5), Limit, etc. For safety reasons, however, at least one of the data sources must be a TwinSAFE SC component. For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers Don Bosco Marg, Yerwada Pune, Maharashtra 411 006 Tel: 020-40004802 Fax: 91-020-40004999 E-mail: a.phatak@beckhoff.com or Circle Readers’ Service Card 11

Chemical Engineering World

October 2018 • 71

CEW Products Visual Level Indicators

Laboratory Dry Vacuum Pump

Visual level indicators combine up to three functions in one instrument: level indicator, level switch and level transmitter. The display can be read even over large distances and works without energy and this automatically results in the physical law of liquids in communicating vessels. The visual level indicators are characterized by their compact design and have wide range of applications from a vacuum up to 500 bar. These applications are utilized for cryogenic liquid gases as well as in water hydraulics and steam boilers.

A laboratory vacuum pump is an adaptable tool that can aid a wide diversity of research scientists and engineers. Laboratory vacuum pumps are used routinely in labs to provide suction to drive the aspiration or filtration of liquid or suspended samples; to induce or control solvent evaporation by reducing vapour pressure, as in ovens, rotary evaporators, gel dryers, and concentrators; and to collect gas samples from test chambers or the atmosphere.

It finds application in the area of chemical, pharma industries, ship building and water management.

Vacuum filtration uses a pressure differential (atmosphere above filter paper and vacuum beneath) to drive a solution through filter paper. The vacuum pump should pump under corrosive atmosphere, conventional vacuum pump often fails. The dry chemical vacuum pump will be suitable, eg, the chemker can handle corrosive vapour basically a chemical resistant dry pump, for evaporation up to 100 Torr for corrosive media for laboratory oven for rotary flash evaporator.

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Graden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.com

For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshnwial.net

Visual level indicators offer the ideal solution for almost all operating conditions. Flexibility is through choice of suitable materials, energyfree automatic operation and accurate reading.

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AODD Pumps Shanbhag & Associates is the authorised national distributor for the entire range of Dellmeco Products with an all India sales and service network. The range of Dellmeco pumps includes solid block AODD pumps in PE, PTFE in conductive and nonconductive housings from 1/4” to 3”; SS, CI, PTFE, coated and aluminium housing AODD pumps from 3/4” to 3”; hygienic, zero hold-up SS-316L AODD pumps from 1/2” to 2.5”; jacketed and high-pressure AODD pumps for applications such as filter press; AODD pumps for powder transfer. The pumps internals are available in EPDM or with chemically bonded TFM diaphragms and ball valves. Dellmeco AODD pumps are absolutely lube-free; non-stalling in operation and corrosion-free. Air valve body is available in corrosion-free engineered plastics. There are fewer moving parts and commonly used spares across models and sizes. Dellmeco pumps find application in industries such as pharma, paint, chemical, clay and ceramics, electroplating/surface treatment, food, dairy and beverages, automotive, glass and fibreglass, oil and gas, marine/shipbuilding, metal and steel treatment, effluent-treatment, aircraft, etc. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E) Mumbai 400 093 Tel: 022-40365711 Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 14

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Products CEW Insertion Impeller Meter

Magnetic Level Switch Insertion impeller meter is suitable for pipe sizes from 1.5” to 100” (40 to 2,500 mm); accuracy from ±0.75% to ±1.5%; velocity ranges from 1 to 10 m/s; pressure ratings from 7 to 200 bar and temperature -40 to 121oC. Version suitable for hot tap installations and Quadrature pulse option for bi-directional flow measurement option are available.

It finds application in hot and cold water, fire systems, hydrant flow testing, water distribution (management and treatment). For details contact: MTS Engineers Pvt Ltd B-408, Wall Street-II, Opp: Orient Club, Nr Gujarat College Ellisbridge, Ahmedabad, Gujarat 380 006 Tel: 079-26400063, 30160063, Fax: 91-079-40047430 E-mail: impex@entes.com.in or Circle Readers’ Service Card 15

Magnetic level switch consists of non-abrasive float carrying permanent magnet and non-ferrous stem carrying one, two or multiple reed switches. The float glides along the stem and when the float nears the vicinity of reed switch, the magnetic field of permanent magnet forces the reed contact to close. The reed switch output is potentialfree contacts. It finds application in water, cooling towers, hydraulic oil, diesel, edible oil, chemicals and pharma. 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 or Circle Readers’ Service Card 16

Process Heating Control & Monitoring Thermon Group Holdings, Inc (Thermon) offers TraceNet Genesis Control & Monitoring System, a new solution for managing heat trace circuit performance on process lines, tanks and instrumentation. The TraceNet Genesis System gives instant access to comprehensive heat trace circuit information, including circuit performance history, fault analysis, and circuit drawings. Using this information, maintenance personnel can predict failures avoiding downtime or quickly restore operations minimizing downtime. The TraceNet Genesis System provides instant on-panel access to heat trace circuit performance trending and histories of up to 6 months, for up to 72 heat trace circuits. Until now, this capability was only available by networking back to a remote computer. A six-month history that reflects, eg, fluctuations or a steady decay in temperature could indicate that the system requires inspection to see whether the thermal insulation is being compromised or if an individual heater is not operating properly. By analyzing this data, maintenance engineers can assess the timing, process operating conditions, and any undesirable symptoms as an early indicator of a future problem. This type of data is critical to effective circuit and overall system maintenance. Another unique feature of the TraceNet Genesis System lies in its ability to allow circuit isometric drawings to be stored and viewed locally, at the heat trace panel. As a result, maintenance engineers can quickly determine the circuit’s precise location and quickly respond to alerts. For the first time, isometric drawings need not be viewed from a remote computer monitor, but are presented on the local TraceNet Genesis touchscreen at the panel. The TraceNet Genesis System includes an easy-to-navigate touchscreen user interface. With a single touch, the user can easily navigate into circuit details in order to modify set points, manage alarms, see trending or view a drawing. For details contact: Thermon San Marcos, Texas, U.S.A. Tel: +1 512-396-5801, Ext: 2239 E-mail: lance.bielke@thermon.com / contact sales@thermon.com or Circle Readers’ Service Card 17

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Electronica 2018

Powder & Bulk Solids Montreal

Dates: 13-16 November 2018 Venue: Messe Muenchen, Munich, Germany Event: Whether it comes to PCBs, semiconductors, sensors, connectors or displays: Electronica is the best place to find out which components, systems and applications are made possible by the latest developments. You can see the entire world of electronics here - on Planet e. For the first time, SEMICON Europa will take place in parallel with Electronica in 2018, for example. It is the largest microelectronics trade show and conference in Europe.

Dates: 14-15 November 2018 Venue: Palais des Congres de Montreal, Montreal, Canada Event: The event will showcase wide variety of automation related services 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 accessories, components, automation, instrumentation, controls, conveyers, feeders, dryers, dust collection, scrubbers and material handling equipment associated with this field. Beside this the event will cordially invite all the eminent and distinguished experts associated with this field.

For details contact: Messe Muenchen India Pvt Ltd “INIZIO” 507 & 508, 5th Floor Cardinal Gracias Road, Opp: P&G Bldg Chakala, Andheri (E), Mumbai 400 099 Tel: 022-42554705 Website: www.mm-india.in

TURKCHEM International Chemical Industry Exhibitions 2018 Dates: 8-10 November 2018 Venue: Istanbul Expo Center Events: TURKCHEM International Chemical Industry Exhibitions 2018 will entail 3 distinct exhibitions under one roof as ‘ChemShow Eurasia: 8th International Fine and Specialty Chemicals, Commodity Chemicals, Petrochemicals and Chemical Intermediates Exhibition’, ‘ChemLab Eurasia: 8th International Laboratory, Test-Measurement Equipment, Auxiliary Materials and Lab Consumables Exhibition’ and ChemTech Eurasia: 8th International Chemical Process and Automation Industry, Packaging, Recycling, Logistics, Labour Safety and Environmental Technologies Exhibition’ For details contact: Artkim Fuarcılık Tic AŞ Sultan Selim Mah Akyol Sitesi Çıkmazı Sk No: 6 Artkim Center 34415 4.Levent / İstanbul, Turkey Tel: +90 (0212) 324 00 00, Fax: +90 (0212) 324 37 57 E-mail: sales@artkim.com.tr Website: www.artkim.com.tr 3rd International Conference on Chloro Alkanes Date: 29 November, 2018 Venue: India Habitat Centre, New Delhi Organisers: Jasubhai Media Pvt Ltd & Eurochlor. Event: Chlorinated alkanes have been under the scanner due to the developments in the regulatory frameworks. Manufacturers have realized the need to enhance the efforts in the field of technology & research to improve product quality and develop innovative processes. One day conference will highlight global trends in CA business, regulatory status, substance evaluations, risk assessments, product benefits and global cooperation. For details contact: Jasubhai Media Pvt Ltd Taj Bldg, 3rd Floor, 210 Dr D N Road, Fort Mumbai 400 001, India Tel: 022-40373636 (Board), Fax: 91-022-40373635 E-mail: sales@jasubhai.com 74 • October 2018

For details contact: UBM UBM plc, Ludgate House 245 Blackfriars Road London, U.K. Tel: +44-0-20-7921-5000

Chemtech World Expo 2019 Date : February 20th - 23rd, 2019 Venue : Bombay Convention & Exhibition Centre, Goregaon (East), Mumbai, India Event : CHEMTECH World Expo 2019 will create a common platform to bring the entire ecosystem of the chemicals manufacturing and the allied services providing sectors for 27th time in India. The event is for equipment, services or developing processes for the Chemical and Process industries. The evolution and the growth of Indian chemical and related industries has been both reflected and catalyzed by CHEMTECH. The interactive Exhibition and Trade Fair pioneered by Chemtech has become the event that the chemical industry comes together. Concurrent events include EPC World Expo, Industry Automation & Control World Expo, Bio Pharma, Pumps Valves & Fittings World Expo; and international conferences on Refining & Petrochemicals and Specialty Chemicals. For details contact: Vaishali Pednekar Senior Executive – Conference Tel: +91-22-4037 3619 Email: vaishali_pednekar@jasubhai.com 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 Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.

valuation of the prospective deal is not known. JSW Energy refused a comment on the status of its takeover plans of Monnet Power and JITPL. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW.

MINING KIOCL will revive mining in Karnataka, after the State granted the company a lease of over 474 hectares at Devadaru hills in Ballari. KIOCL had suspended mining in the eco-sensitive Western Ghats following a Supreme Court directive in 2006. Once approvals are given, it would invest ` 1,500-crore in a pellet plant and also a unit to enrich iron ore from the mines. After suspension of mining, KIOCL had shifted to operating 3.5-million tonne per annum pellet plant in Mangaluru. Last year, it produced 1.46-million tonnes, utilising half its capacity, as against almost nil production in the previous year. International agencies have already implemented pilot projects by bringing high grade iron ore from South America, Iran and other parts of the world and utilising KIOCL's facility, have taken away pellets facilitating better utilisation of its plant capacity and profitability utilising its manpower. The company's blast furnace unit having a capacity of 216,000-tonnes of pig iron which was put under suspension since 2009 has been taken for repair and the unit is ready for operation for producing foundry grade pig iron adding towards its profitability in the coming financial year. The firm earned a profit of ` 47.93 crore in FY17 as against a loss of ` 80.15-crore the previous year. Revenues grew 353 per cent to ` 929.36-crore from ` 205.57-crore in the previous fiscal.

Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose.

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

Singareni Collieries Co Ltd (SCCL) the State-owned coal mining giant, has initiated preparations to start Koyagudem Opencast Project-III (KOC-III) in Lingala Koyagudem coal belt of Godavari valley coalfield in Tekulapally mandal soon. The extractable reserves in the KOC-III are estimated to be around 111.98-million tonnes as against the estimated geological reserves of 146.81-MT.The KOC-III project is expected to produce around 3.6-million tonnes per annum, SCCL sources said. In pursuit of its aggressive growth strategy, the SCCL has drawn up ambitious plans to open 31 coal mines including 20 OCPs and 11 underground mines in the next five years. It presently has 30 underground mines and 16 OCPs spread across the vast Godavari valley coalfield spanning Bhadradri-Kothagudem, Khammam, Karimnagar, Adilabad and a few other districts in the State. The company has set a coal production target of 66.06-million tonnes for the current fiscal.The company is aiming to set new benchmarks in coal production, dispatches and overburden removal besides enhancing the coal production capacity to around 900-lakh tonnes by 2020-2021, SCCL sources said. The SCCL has reportedly obtained the mandatory forest clearance from the Central government agencies concerned for the KOC-III. The project envisages use of 1,158-hectares of forest land and 448-hectares of non-forest land. October 2018 • 75

CEW Project Update The upcoming KOC-III, which is surrounded by the Koyagudem OCP-II, is expected to augment coal production in Yellandu area of the SCCL. Preparations are on to commence the works on removal of 17 lakh cubic meters of overburden at the KOC-III to commence coal production in the project SCCL. The KOC-III has already obtained all the mandatory approvals from the Central government agencies concerned. The project is likely to be opened soon.

limestone reserves, making them attractive destinations for cement companies. Among the other major investment proposals, Hyderabadbased Rain Group, which also has cement manufacturing operations, has expressed interest in establishing a calcined petroleum coke plant, cement grinding unit, an R&D facility and a waste heat recovery power plant at Achutapuram SEZ in Visakhapatnam district, the government said. The company proposes to invest ` 1,096-crore in these projects.

OIL & GAS Kochi-Mangaluru Natural Gas Pipeline Project would be completed by this October-November, according to Dharmendra Pradhan, Union Minister for Petroleum, Natural Gas, Skill Development and Entrepreneurship. He said that Mangaluru is very much there in the new bidding round for city gas distribution (CGD). There would be a new executor for the CGD in the city in the next three months. The single initiative will create new techno economic eco system in Mangaluru, the Minister said and added that the fertilizer plant, refinery, petrochemicals and other industries in the city are eagerly waiting for LNG supply.The LNG terminal in Kochi was completed six years ago. However, the desired pipeline was not there. Works are on the fast track to lay the pipeline, and the local governments in Kerala and Karnataka are cooperating in the matter, he said.

FERTILIZER Hindustan Urvarak and Rasayan Ltd (HURL) will award projects for the first of its three gas-based fertilizer plants before the year-end. HURL is the joint venture between NTPC Ltd, Coal India Ltd, Indian Oil Corpn, Fertiliser Corpn of India Ltd and Hindustan Fertiliser Corpn Ltd.The JV was assigned the responsibility of reviving three fertiliser plants at Gorakhpur, Sindri of FCI, and Barauni of HFCL in June 2016. Indian Oil Chairman who is also the Chief of the Joint Venture, said, Our target is to commission all the three plants in 2020. We have got the environmental clearance for all the three plants that are located in the same areas. Area clearing and pre-project activities are going on. We have got the tenders, we have lined up the consultant. We have got the tenders for EPC contractors and the technology selection will also be in their scope. We have shortlisted technologies. We have opened the tenders and evaluation is going on. The task for setting up of these three fertilizer plants have been entrusted to three Maharashtra Public Sector Companies on equal cost-sharing basis. An official statement had said that it was proposed to install an ammonia plant of 2,200-tonne per day and urea plant of 3,850-tonne per day at each of these units at Gorakhpur, Sindri and Barauni at an estimated cost of ` 6,000-crore for each unit. The total project cost was estimated at `18,000-crore for the three plants, the statement added. But, crude oil refiner IOCL, power generator NTPC, and coal miner CIL are not known for setting up fertilizer plants.

The National Agricultural Cooperative Marketing Federation of India (Nafed) will set up a bio-CNG plant in Delhi’s Azad Mandi, said Minister for Petroleum and Natural Gas Dharmendra Pradhan. Speaking at the Delhi Energy Dialogue-2018 organised by Ashden India Collective. He said, The Nafed plant will use agricultural and vegetable waste of the mandi produce CNG. Indraprastha Gas will buy the bio-CNG produced. He said public sector oil marketing companies, particularly Indian Oil, are procuring bio-fuel across the country at a competitive market price. I can visualise ` 1 lakh crore of new business across the country in bio-fuel and bio-CNG industry, he added. Pradhan said he had met the Chief Economist of BP earlier this week who told him that India is currently the third largest primary consumer of energy after the US and China. In comparison to any developed economy and as a very upcoming economy, our per capita energy consumption is very low. Global experts are predicting that the CAGR growth of energy consumption in India over the next 25 years will be at 4 per cent, he said. The nearest competitor will be China with a 1.5 per cent growth. By 2030, we will be surpassing China’s consumption. Our incremental energy requirement will be equal to the entire Europe’s energy consumption, he added. CEMENT Chettinad Cement Corporation Pvt Ltd and KCP Ltd of Tamil Nadu are planning to invest ` 1,350-crore and ` 531-crore respectively to establish their new units in the State of Andhra Pradesh. The State investment promotion board headed by Andhra Pradesh Chief Minister N Chandrababu Naidu has cleared six investment proposals, including these two, involving a total investment commitment of ` 3,303-crore. According to the government, Chettinad will set up a cement grinding unit on 75-acres and a manufacturing plant on 1,000-acres of land in Vizag and Guntur districts respectively. The mega project will start production in March 2019.KCP Ltd will be setting up a unit on 100-acres of land in Krishna district with the first phase scheduled to start operations in a year's time. The cement industry in South India in general, and in Telangana and Andhra Pradesh in particular, is facing a huge capacity overhang with an installed base of around 150-million tonnes against a total demand of around 60-million tonnes. An additional 20-million tonnes goes to the neighbouring markets in the eastern and western parts of the country from here, according to the industry representatives. The two Teluguspeaking States together possess more than 30 per cent of the country's 76 • October 2018

ENERGY India Yamaha Motor has installed 1,100-kW rooftop solar power plant at its manufacturing facility near Chennai at a cost of ` 5-crore. With this, the Chennai plant’s total solar capacity has increased to 1,450-kW. The company has plans to increase the total rooftop solar capacity to 3,500-kW by the year-end. The new rooftop installation will reduce CO2 emission to the extent of 1,600-tonnes/year. Yamaha has partnered with Mahindra Susten for installing the rooftop solar panels. Yamaha has partnered with Amplus Solar for installation, operation and maintenance of solar power system at its Surajpur plant. This is one of the largest rooftop solar power plants with total capacity of 6,200-kW. This project was commissioned in two phases. Phase I was inaugurated in January 2016 with generation capacity of 4.000-kWp and Phase II was commissioned in October 2017 with generation capacity of 2,200-kWp. Recently under Phase II, 105-kW capacity solar power plant was installed in the car parking area inside the plant premises and 47 cars can be parked under the solar power plant which is also capable of meeting the future requirement of charging battery-operated cars. This particular area has a power generation capacity of 500 units per day. The Indian Wind Turbine Manufacturers Association (IWTMA) announced that the wind industry is poised to meet the Government’s target of 60-GW ahead of the 2022 deadline. The domestic wind market is on a growth path in the competitive bidding regime and there is an increased demand for clean energy, which has now become a reliable, affordable and mainstream source of energy. The industry has regained momentum and there is a clear business visibility of 10-12 GW even before the start of this financial year with announcement and plan of bids by the Ministry of New and Renewable Energy (MNRE). Chemical Engineering World

Book Shelf CEW Corrosion Problems and Solutions in Oil Refining and Petrochemical Industry Author: Alec Groysman Price: $179.99 No of pages: 356 pages (Hardcover) Publisher: Springer (1st Edition) About the book: This book addresses corrosion problems and their solutions at facilities in the oil refining and petrochemical industry, including cooling water and boiler feed water units. Further, it describes and analyzes corrosion control actions, corrosion monitoring and corrosion management. Corrosion problems are a perennial issue in the oil refining and petrochemical industry, as they lead to a deterioration of the functional properties of metallic equipment and harm the environment – both of which need to be protected for the sake of current and future generations. Accordingly, this book examines and analyzes typical and atypical corrosion failure cases and their prevention at refineries and petrochemical facilities, including problems with pipelines, tanks, furnaces, distillation columns, absorbers, heat exchangers and pumps. In addition, it describes naphthenic acid corrosion, stress corrosion cracking, hydrogen damages, sulfidic corrosion, microbiologically induced corrosion, erosion-corrosion and corrosion fatigue occurring at refinery units. At last, fouling, corrosion and cleaning are discussed in this book.

Fundamentals of Petroleum Refining Authors: Mohamed A Fahim, Taher A Al-Sahhaf and Amal Elkilani Price: $210.44 No of pages: 516 pages (Hardcover) Publisher: Elsevier Science (1st Edition) About the book: This book presents the fundamentals of thermodynamics and kinetics, and it explains the scientific background essential for understanding refinery operations. The text also provides a detailed introduction to refinery engineering topics, ranging from the basic principles and unit operations to overall refinery economics. The book covers important topics, such as clean fuels, gasification, biofuels and environmental impact of refining, which are not commonly discussed in most refinery textbooks. Throughout the source, problem sets and examples are given to help the reader practice and apply the fundamental principles of refining.

Guidelines for Seismic Evaluation and Design of Petrochemical Facilities Author/Editor: J Greg Soules Price: $104.85 No of pages: 372 pages (Paperback) Publisher: American Society of Civil Engineers; (2nd Edition) About the book: These guidelines offer practical recommendations on several aspects affecting the design and safety of new and existing petrochemical facilities both during and following an earthquake. In the area of new design, this book emphasizes interpretations of the intent of building codes as applied to petrochemical facilities, and gives practical guidance on design details and considerations that are not included in building codes. For existing facilities, the authors present evaluation methodologies that rely heavily on experience from past earthquakes, coupled with focused analyses. Guidelines for Seismic Evaluation and Design of Petrochemical Facilities is an updated edition in a collection of state-of-the-practice reports produced by the ASCE Petrochemical Committee. It will be valuable to structural design engineers, operating company personnel responsible for establishing seismic design and construction standards, and local building authorities. Chemical Engineering World

Petroleum Refining Author: A Kayode Coker Price: $202.96 No of pages: 654 pages (Hardcover) Publisher: Wiley-Scrivener (1st Edition) About the book: There is a renaissance that is occurring in chemical and process engineering, and it is crucial for today’s scientists, engineers, technicians and operators to stay current. With so many changes over the last few decades in equipment and processes, petroleum refining is almost a living document, constantly needing updating. With no new refineries being built, companies are spending their capital re-tooling and adding on to existing plants. Refineries are like small cities, today, as they grow bigger and bigger and more and more complex. A huge percentage of a refinery can be changed, literally, from year to year, to account for the type of crude being refined or to integrate new equipment or processes. This book is the most up-to-date and comprehensive coverage of the most significant and recent changes to petroleum refining, presenting the state-of-the-art to the engineer, scientist or student. Useful as a textbook, this is also an excellent, handy go-to reference for the veteran engineer, a volume no chemical or process engineering library should be without. Written by one of the world’s foremost authorities, this book sets the standard for the industry and is an integral part of the petroleum refining renaissance. It is truly a must-have for any practicing engineer or student in this area.

October 2018 • 77

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