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Contents CHEMICAL ENGINEERING WORLD RNI Registration No. 11403/66 Chairman Publisher & Printer Chief Executive Officer
Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty
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08 24
40 42 44 48 54 56
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Lokesh Kumar Singh, BEng CEng MIChemE, Lead Process Engineer, China Petroleum Abu Dhabi Challenges in Engineering and Fabrication of Combination Units with Double Side Metal Lined Intermediate Dished Heads.
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Somnath Bhattacharya, Mechanical Engineering,, Fluor Daniel India Pvt Ltd Industry Reacts to Change in Corporate Tax
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Chemical Engineering World
CEW Industry Roundup Refining Roundup
India’s Refining Capacity and Refinery Crude Throughput Trend
Ramp-up of Refineries Made China’s Crude Oil Throughput Record High in Sep’19 China’s crude oil throughput scored a record-high of 9.4 percent owing to the increases from new refineries and the rejuvenation of some independent plants after returning from maintenance. As the official data of National Bureau of Statistics (NBS) showed, refinery runs hit 56.49 million tonnes, or about 13.75 million barrels per day (bpd). As data suggested, the September rate was as high as 8 percent compared to its previous month’s bpd value, which is 12.72 million. It even has beaten the recent high recorded in the month of June which is 13.07 million bpd. The throughput in first 9 months gained 6.2 percent y-o-y to 480.38 million tonnes or 12.85 million bpd. However, it is expected that the thin margins will curtail the increases in oil product output in fourth quarter. This is due to soaring freight cost faced by refineries and elevated premiums for the imported crude in the wake of September’s oil attack in Saudi Arabia.
Source: petroleum.nic.in
India has emerged as a refinery hub. It’s the second largest refiner in Asia after China. Country’s refining capacity exceeds the demand. India’s total refining capacity increased from 233.97 million metric tonnes (MMTPA), as on 1-Apr-2017, to 247.57 MMTPA at present with the capacity additions in BPCL Kochi, HMEL Bhatinda, and RIL (SEZ) Jamnagar refineries. Capacity of BPCL – Kochi has increased from 9.5 MMTPA to 15.5 MMTPA. Further, there has been an addition of 2.3 MMTPA and 8.2 MMTPA capacities in HMEL – Bhatinda and RIL (SEZ) Jamnagar refineries respectively during the year.
In the meantime, a 2.9 percent y-o-y rise in China’s crude oil production to 15.64 million tonnes or 3.81 million bpd has been observed. Jan – Sep output was up by 1.2 percent y-o-y at 143.13 million tonnes or 3.83 million bpd. The production of natural gas was up by 10.6 percent y-o-y to 13.5 billion cubic metres (bcm), but was still at the lowest level since October 2018 according to the bureau’s records. Gas output for Jan – Sep was hiked by 9.5 percent y-o-y corresponds to 127.7 billion cubic metres (bcm). Information source: hydrocarbonprocessing.com
GTM ONE Chosen Topsoe SynCOR Technology for World-scale Methanol Plant in Volgograd “All technology customers are looking for well-proven and advanced technologies, high performance and low environmental impacts, high energy efficiency, and low CAPEX. In most cases, customers face a difficult choice of how to reach a compromise between these interests. We have selected Topsoe as the Topsoe SynCOR Methanol™ process is the ultimate uncompromising choice. We have found everything we need,” says Osipov Alexander, Technical Director, GTM ONE. “We are very pleased to offer a solution that not only helps our customers comply with environmental regulations, but also stands out as the most cost-effective in large-scale methanol production. We see increasing demand for this technology both in Russia and in other markets. We are also very content to continue our well-established cooperation with Mitsubishi Heavy Industries Engineering in Russia,” says Peter Vang Christensen, Managing Director of Haldor Topsoe's Moscow office. Haldor Topsoe, Mitsubishi Heavy Industries Engineering, and GTM ONE have signed a license agreement for the design, construction, and operation of a 3,000 tons-perday methanol plant based on Topsoe’s SynCOR Methanol technology. The plant will be erected at the Khimprom site in Volgograd, Russia. Topsoe will provide license, basic engineering, catalysts, and proprietary hardware for methanol production. In the first stage, Topsoe will provide basic engineering for the process unit, and MHI Engineering will develop the Front End Engineering Design (FEED) package for the site. At a later stage, the parties expect to sign an EPC contract. Construction is slated to begin in the second half of 2020. It is to mention that SynCOR solutions are industrially proven to deliver exceptional cost-efficiency, high availability, and low environmental impact in large scale single train methanol production.
Information source: topsoe.com
8 • October 2019
Chemical Engineering World
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CEW Industry Roundup RIL’s Refining and Petrochemical Business in Q2 FY 2019-20 Reliance Industry’s second quarter result clearly indicates the revival of its Gross Refining Margin (GRM). Despite the slowdown in the domestic market, the Indian Giant secured a 4.8 percent increase in its consolidated revenue. For the quarter ended 30-Sep-2019, RIL achieved a consolidated revenue of Rs 163,854 crores (USD 23.1 billion) as compared to Rs 156,291 crore in the corresponding period of the previous year. Exports (including deemed exports) from RIL’s India operations were lower by 12.1 percent at Rs. 53,161 crore (USD 7.5 billion) as against Rs. 60,460 crore in the corresponding period of the previous year. This is primarily due to lower price realization for refining and petrochemical products, and emphasis in domestic placement. (In ` Crore) (In `` Crore)Revenue Segment Segment EBIT Segment Refinery Revenue throughputEBIT Segment (MMT)* Refinery
2Q FY2 0 2Q 97,229 FY2 0 4,957
1Q FY20 1Q 101,721 FY20
2Q FY1 9 2Q 98,760 FY1 9 5,322
% chg. w.r.t 1Q FY20 % chg. w.r.t (4.4%) 1Q FY20 10.0% (4.4%)
% chg. w.r.t. 2Q FY19 % chg. w.r.t. (1.6%) 2Q FY19 (6.9%) (1.6%)
10.0%
(6.9%)
1H FY2 0 1H 198,950 FY2 0 9,465
1H FY1 9 1H 194,406 FY1 9 10,637
198,950 34.2 9,465
194,406 34.3 10,637
97,229 16.7 4,957
4,508 101,721 17.5 4,508
98,760 17.7 5,322
16.7 9.4
17.5 8.1
17.7 9.5
34.2 8.8
34.3 9.9
($ / bbl) (*GRM* Standalone RIL)
5.1% 9.4
4.4% 8.1
5.4% 9.5
4.8% 8.8
5.5% 9.9
EBIT Margin (%)
5.1%
4.4%
5.4%
4.8%
5.5%
GRM* ($ / bbl) throughput (MMT)* EBIT Margin (%)
% chg. w.r.t. 1H FY19
% chg. w.r.t. 1H2.3% FY19 (11.0%) 2.3% (11.0%)
% chg. w.r.t 1Q FY20 % chg. w.r.t 1Q FY20
% chg. w.r.t. 2Q FY19 % chg. w.r.t. 2Q FY19
2.5%
43,745 8,120
7,508 20.0%
8,120 18.6%
19.7% 9.9
20.0% 8.7
18.6% 9.4
9.9
8.7
9.4
Segment Revenue
1Q FY2 0 1Q FY2 0 37,611
2Q FY1 9 2Q FY1 9 43,745
Segment Revenue Segment EBIT
38,538 7,602
37,611 7,508
Segment EBIT EBIT Margin (%)
7,602 19.7%
EBIT Margin (%) Production (MMT) Production (MMT)
(In `` Crore) (In ` Crore)
Table Caption: RIL Petrochemicals BUSINESS RIL Petrochemicals BUSINESS
quarter. This excellent result reflects benefit of our Oil to Chemical (O2C) value chain. During this quarter, our O2C businesses gained from favourable fuel margins environment, feedstock higher petrochemicals
Data courtesy: ril.com
2Q FY2 0 2Q FY2 0 38,538
record net profit for the
sourcing flexibility, and
(* Standalone RIL)
RIL REFINING & MARKETING BUSINESS
“The Company has reported
% chg. w.r.t. 1H FY19
volumes. Our O2C business, with new partnerships,
1H FY1 9 1H FY1 9 84,032
% chg. w.r.t. 1H FY19
(11.9%)
1H FY2 0 1H FY2 0 76,149
(9.4%)
creation”, said Mukesh
2.5% 1.3%
(11.9%) (6.4%)
76,149 15,110
84,032 15,977
(9.4%) (5.4%)
D Ambani, Chairman &
1.3%
(6.4%)
15,110 19.8%
15,977 19.0%
(5.4%)
19.8% 18.6
19.0% 18.6
18.6
Data courtesy: ril.com
is best placed to pursue growth and substantial value
Managing Director, Reliance Industries Limited
18.6
Data courtesy: ril.com
Table Caption: RIL Petrochemicals Q2 FY20 revenue fromBUSINESS the Petrochemicals
courtesy: ril.com segment Data decreased by 11.9 percent Y-o-Y to Rs 38,538 crore (USD 5.4 billion) reflecting fall in prices of petrochemical products. Segment EBIT decreased by 6.4 percent Y-o-Y to Rs 7,602 crore (USD 1.1 billion) mainly due to weaker petrochemical product margins offset by record petrochemical production and cost optimization through light-feed cracking. There was a significant decline in margins for major products – MEG (-53 percent), PX (-37 percent), PE (-25 percent), and PP (-21 percent) as a result of new capacity, inventory overhang, and global demand slowdown.
Saudi Aramco and RIL signed a non-binding Letter of Intent (“LOI”) regarding a proposed investment in the Oil to Chemicals (O2C) division comprising the Refining, Petrochemicals, and fuels marketing businesses of RIL. Saudi Aramco’s potential 20 percent stake is based upon an Enterprise Value of USD 75 billion for the O2C division. This would be one of the largest foreign investments ever made in India. Information courtesy: ril.com 10 • October 2019
Chemical Engineering World
CEW Industry Roundup Grading Innovation Helps to Deal with Changing Market Requirements
EDS mapping of spent catalyst. The intensities in the maps shows the elemental concentrations. Picture Courtesy: topsoe.com
Topsoe grading innovation keeps ahead of the market so that their clients can keep ahead in their operations, and deal with their specific challenges. The playing field is changing all the time. It’s an ongoing process of continuous groundbreaking research and engineering innovation, not least because market requirements and expectations are in constant flux – worldwide. Circumstances continuously changing: The feedstocks that refineries need to process are increasingly unpredictable, with fluctuating specifications (including a growing percentage of renewables) and a broad spectrum of impurities and contaminants that can be difficult to deal with. At the same time, legislation requirements and emission restriction place new demands on many aspects of hydro-processing operations. We strive to make sure that our clients are in a good position to tackle all these effectively, and keep ahead of the curve wherever possible. Research, monitoring, and analysis: Nothing beats analysis, experience, and expertise when tackling complicated operating challenges. Topsoe has built up an unparalleled 40 years’ of industrial experience about grading chemistry as well as vast experience with tackling complex reactor fouling challenges. It’s difficult to realistically simulate the processing cycle in the lab or in pilot units when it comes to grading. Therefore, Topsoe continuously
sample the grading materials when the catalyst is being unloaded from industrial units, to secure valuable data about how specific contaminants lodge in and migrate through the different grading layers, as well as conduct comprehensive analysis of spent grading products. Their new grading products are always tested industrially prior to launch. This is usually done by installing test canisters in particular locations within a specific hydroprocessing reactor. Such canisters are loaded with multiple grading catalysts in different compartments, to measure how each reacts to a known set of contaminants in the course of the entire cycle. They remove the canister for comprehensive analysis once the cycle is complete. They install more than 100 such test canisters in different refinery setups every year, enabling their experts to compare grading performance across a vast range of different feedstock and conditions. Topsoe proclaims, as a result, the provided grading solution draws on a vast body of data accumulated from hydro-processing operations all over the world. Clients get the best of the best, continually updated and refined to benefit from the latest scientific research and worldleader chemical engineering capabilities. Every two years(-ish): As a market leader in advanced grading products and services for refineries’– and in the groundbreaking atomic-level research that makes this possible – Topsoe is able to release a steady stream of new products. They are increasing their focus on providing their refinery customers with exceptional reactor grading capabilities. This means they’re launching new products at fairly regular intervals – currently in every two years approximately. The most recent ones are: the TopTrap series, the SiliconTrap series, and the 300 series for renewables. Most recent Topsoe grading innovations are: • Inert topping material: TK-18 TopTrap, TK-22 TopTrap, TK-24 TopTrap • For trapping of arsenic in VGO and gasoil where it can also trap V, Ni, and Si: TK-41 • For removal of Si and P: TK-455 MultiTrap • When maximum arsenic pick-up is needed: TK-49 • Specially designed for renewable feedstocks: TK-335 and TK-337 Information source: topsoe.com
Thyssenkrupp Entered into a Contract with Nayara Energy for Their Petrochemical Units @ Vadinar in Gujarat, India Thyssenkrupp Industrial Solutions (India) – a leading partner for engineering, construction, and service of industrial plants and systems in India and abroad – has inked a contract with Nayara Energy, an integrated downstream company, through a global tendering process. In terms of the contract, Thyssenkrupp will provide project management consultancy services for Nayara Energy’s upcoming petrochemical units in Vadinar, Gujarat, India. Nayara Energy currently operates the second-largest private sector refinery in India with a capacity of 20 MMTPA at Vadinar, Gujarat. The company endeavours to diversify its energy basket with a foray into petrochemicals, and a vision for making Devbhumi Dwarka district in Gujarat which is a petrochemical hub in India. The project will mark Nayara’s foray into the Petrochemical sector by building a world-scale capacity Polypropylene Unit and Methyl Tertiary-Butyl Ether (MTBE) Unit. It also involves revamp of the existing FCC unit and building of a Propylene Recovery Unit and associated off-sites & utility facilities. Thyssenkrupp is currently engaged in implementing projects for a number of refining and petrochemical complexes in India and abroad, on PMC and EPCM basis. In addition to the petrochemical business, the company has a global presence in other chemical process and allied industries.
“We are delighted to collaborate with Nayara Energy for the second time, after 2000. We are honoured to be entrusted with implementing their upcoming Petrochemical units. The project validates our expertise in the refining and downstream sector. With this partnership, thyssenkrupp will support Nayara Energy with project management consultancy services and help them in achieving their project plans”, said P D Samudra, CEO & MD of Thyssenkrupp Indusrial Solutions (India) Pvt Ltd, while commenting on the partnership.
“Nayara Energy’s endeavours in the petrochemical sector are aligned towards our larger aspiration to play a vital role in India’s development story. Through this association, Thyssenkrupp will help us steer this expansion project keeping in mind two aspects extremely close to us - excellence and agility”, said B Anand, CEO of Nayara Energy, on this development. 12 • October 2019
Chemical Engineering World
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CEW Industry Roundup Mr S M VaidyaTook Over as Director (Refineries) of Indian Oil Mr. Shrikant Madhav Vaidya has taken over as the Director (Refineries) of IndianOil - India's highest ranked Public Sector Enterprise in 'Fortune 500' global listing. He is also a Director on the board of Chennai Petroleum Corporation Ltd. (CPCL) & the 60 MMTPA West Coast Refinery and Petrochemicals Project, the world's largest grass root refinery project, coming up in Maharashtra.
Indian Oil Launched New Marine Fuel Grades & Lubricant Range at International Bunker Meet
Mr. Vaidya now spearheads the business & operations of nine refineries & petrochemical plants of IndianOil. With a robust Refineries Division, IndianOil (including its group companies) remains the nation's top refiner with a group refining capacity of 80.7 million tonnes per annum/161.4 million barrels per day. A Chemical Engineer from the National Institute of Technology, Rourkela, Mr. SM Vaidya has 33 years of extensive experience in refining & petrochemicals operations. Mr. Vaidya has had a decade-long association with India's largest Cracker Plant-the Panipat Naphtha Cracker Complex-right from its commissioning stage, which is one of the major drivers of IOC's petrochemicals business. He is among the select technocrats in the Indian oil & gas industry, who is proficient in all the facets of refinery-petrochemicals integration, desirable for the sustainability of the oil & gas industry in the long-term. Prior to his elevation, Mr. Vaidya was heading the Operations Dept. of the Refineries Division, ensuring healthy gross refining margins, smooth supply of products and eco-friendly business operations. During his tenure, the Refineries Division registered a record performance on all major physical parameters. He also steered the timely roll-out of BS-VI grade auto fuels in NCR, and has expanded green energy options with bio-fuel & ethanolblended fuel related projects in refineries. Mr. S M Vaidya has also led IndianOil's 8 MMTPA Mathura Refinery, and his dynamic tenure saw the introduction of innovative initiatives for greater sustainability and profitability. With a strong technological prowess, business acumen and people-centric leadership style, Mr. Vaidya nurtures a strong vision of leveraging technology, innovative & sustainable solutions for the company's transformation into an integrated energy major.
Indian Oil has launched two new marine fuel grades and a lubricant range at the Bunker ConFab 2019, an international bunker meet recently held at Mumbai. The new range of fuel grades are in line with IMO 2020, the new International Maritime Regulation (IMO) regulation limiting the sulphur content from the current 3.5 percent to 0.5 percent. The new range lubricants have been specially formulated with lower reserve alkalinity, to suit low sulphur IMO 2020 fuels. The new marine fuels shall be available at Indian ports from mid - October 2019. The international bunker meet was attended by ship owners and bunker trading companies from India, as well as world's top two major bunkering hubs Singapore & Fujairah. Indian Oil's decision to launch IMO 2020 compliant marine fuels & lubricants was well applauded by the global shipping and oil industry representatives conveying that such decision has put India on the global map of ship bunkering as a trusted bunkering destination. Information source: iocl.com
Information source: iocl.com
HPCL has Recently Commissioned its VVSPL Capacity Expansion Project HPCL’s Visakh-Vijayawada-Secunderabad-Pipeline (VVSPL) Capacity Expansion Project has been commissioned ahead of schedule and put into operation smoothly.The Project has enhanced VVSPL capacity from 5.38 MMTPA to full design capacity of 7.7 MMTPA. As part of the project, 13 new pumps have been installed: 3 each at the 2 new Intermediate Pump Stations (IPS) viz. M B Patnam IPS and J K Gudem IPS, 2 at the new Bogaram IPS, 1 each at the existing Pump Stations of Visakhapatnam, Rajahmundry, Vijayawada and 2 at Suryapet. In addition to above, OSTT-SS Jetty Sub-Sea Pipeline has also been mechanically completed. It is pertinent to mention here that all project sites have reported impeccable safety record with NIL incidents and ZERO man-hour loss. Information source: https://www.hindustanpetroleum.com
20 • October 2019
Chemical Engineering World
CEW Industry Roundup HPCL Bagged ‘Best Navratna’ under Manufacturing Category at Dun & Bradstreet PSU Awards 2019
BPCL privatisation, however, will need Parliament's approval. The Supreme Court had in September 2003 ruled that BPCL, as well as Hindustan Petroleum Corporation Ltd (HPCL), can be privatized only after Parliament amends a law it had previously passed to nationalize the two firms. The ruling had followed a plan of the then BJP-led NDA government headed by Prime Minister Atal Bihari Vajpayee to privatize the two firms. The apex court ruling had stalled the plan to sell 34.1 per cent out of government's 51.1 per cent stake in HPCL to a strategic partner along with management control. Reliance Industries Ltd, BP plc of UK, Kuwait Petroleum, Petronas of Malaysia, the Shell-Saudi Aramco combine and Essar Oil had expressed their interest in acquiring that stake before the Supreme Court stalled the process.
HPCL has recently bagged ‘Best Navratna’ award in ‘Manufacturing Category’ at Dun & Bradstreet PSU Awards 2019 consecutively for second year in a row. The award ceremony was held on 22nd August, 2019 at New Delhi. The award winners were felicitated by Shri Arvind Ganpat Sawant, Hon’ble Minister of Heavy Industries & Public Enterprise; in the august presence of Shri Subhash Chandra Garg, Secretary, Ministry of Power, and Shri Manish Sinha, Managing Director-India, Dun & Bradstreet. CGM - Co-ordination, Shri Alok Kumar Gupta and CGM- PRCC, Shri Rajeev Goel received the award on behalf of HPCL. Dun & Bradstreet PSU Awards have been instituted to recognize and felicitate the top performing PSUs in India for business excellence and acknowledge their contribution in socio-economic development of the country. The awards are given across various categories based on multiple performance parameters. Award winners were selected based on a proprietary financial model developed by M/s Dun & Bradstreet India. The model takes into consideration of size, growth and profitability indicators to arrive at the award winners. This prestigious award is the testimony of HPCL’s excellence across all facets of business. Information source: https://www.hindustanpetroleum.com
Government Plan to Privatize BPCL Needs Parliament's Nod The government is considering a proposal to sell India's second-largest state refiner and fuel retailer BPCL to foreign and private firms but the privatisation plan will need a prior nod of Parliament, officials said. Keen to get multi-nationals in domestic fuel retailing to boost competition, the government is mulling the selling most of its 53.3 per cent stake in Bharat Petroleum Corporation Ltd (BPCL) to a strategic partner, as said by the officials aware of the development. Privatization of BPCL will not just shake up fuel retailing sector long dominated by state-owned firms but also will help meet at least a third of the government's Rs 1.05 lakh crore disinvestment target. BPCL at the close of market on September 27 had a market capitalisation of about Rs 1.02 lakh crore and even a 26 per cent stake sale at this valuation would fetch the government Rs 26,500 crore plus a control-and-fuel-market-entry premium ranging anywhere between Rs 5,000 crore to Rs 10,000 crore, officials said. 22 • October 2019
Officials said BPCL in present times will be an attractive buy for companies ranging from Saudi Aramco of Saudi Arabia to French energy giant Total SA which are vying to enter the world's fastestgrowing fuel retail market. BPCL was previously Burmah Shell, which in 1976 was nationalized by an Act of Parliament. Burmah Shell, set up in the 1920s, was an alliance between Royal Dutch Shell and Burmah Oil Co and Asiatic Petroleum (India). HPCL was incorporated in 1974 after the takeover and merger of erstwhile Esso Standard and Lube India Ltd through the ESSO (Acquisition of Undertaking in India) Act passed by Parliament. The company was in January last year taken over by state-owned Oil and Natural Gas Corp (ONGC) for Rs 36,915 crore. At that time, Oil Minister Dharmendra Pradhan had cited the four-decadeold Nationalization Act to justify exempting ONGC from making an open offer after acquiring the Government's 51.11 per cent stake in HPCL. "We are bound by the Nationalization Act and character of HPCL could not have changed so no open offer was mandated," he had said. The Supreme Court had in September 2003 cited the ESSO (Acquisition of Undertaking in India) Act and the Burmah Shell (Acquisition of Undertaking in India) Act, 1976 and Caltex (Acquisition of Shares of Caltex Oil Refining India Ltd and all the Undertakings in India for Caltex India Ltd) Act, 1977 to rule that the government cannot privatize HPCL and BPCL without approaching Parliament for changing the Nationalisation Act. "There is no challenge before this Court (Supreme Court) as to the policy of disinvestment. The only question raised before us whether the method adopted by the Government in exercising its executive powers to disinvest HPCL and BPCL without repealing or amending the law is permissible or not. We find that on the language of the Act such a course is not permissible at all," Justice S Rajendra Babu and G P Mathur wrote in the September 16, 2003 order "restraining the Central Government from proceeding with disinvestment resulting in HPCL and BPCL ceasing to be Government companies without appropriately amending the statutes concerned suitably." BPCL operates four refineries at Mumbai, Kochi in Kerala, Bina in Madhya Pradesh, and Numaligarh in Assam with a combined capacity to convert 38.3 million tonnes of crude oil into fuel. It has 15,078 petrol pumps and 6,004 LPG distributors. India has a total refining capacity of 249.4 million tonnes of refining capacity and 65,554 petrol pumps and 24,026 LPG distributors. Information source: ptinews.com
Chemical Engineering World
CEW News Indian Chemical Council Flagged Concern Regarding Need to Safeguard Indian Chemical Industry Mumbai, India: Built as world’s biggest trade agreement, the Regional Comprehensive Economic Partnership (RCEP) comprising of 10 ASEAN countries with its 6 Free Trade Agreement (FTA) partners including India, China, Australia, New Zealand, Japan, and South Korea are likely to completely transform the global trade dynamics. However, with the final round of RCEP negotiations due in November 2019, concerns have been flagged by the Indian Chemical Council (ICC) to prevent misuse of ‘Rules of Origin’ since it places the members of RCEP into a quasi-bloc with higher dominance of China. For India, the biggest issue is to protect the economy from the flooding of cheap imports of Chinese chemicals, creating an enormous disadvantage for the Indian Chemical industry. The Indian Chemical industry is an industryof-industries with a combined turnover of USD 150 billion. Welcoming the Government’s move on proactively seeking feedback from the domestic industry on the ongoing RCEP negotiations and making sincere efforts to safeguard the interests of the Indian manufacturers, the ICC felt the Indian Government has been moving cautiously and felt it was unclear if their demand for applying product-specific ‘Rules of Origin’ under RCEP to avoid unscrupulous exporting of negative list goods to India would be implemented. Rules of Origin under RCEP have a criterion which can potentially prove to be damaging for products with multiple stage production process. Termed as ‘Produc ed Entirely’ It suggests that in a multi stage production process if all the inputs in the final production stage are from RCEP countries, its origin will be conferred. Elaborating on the issue, Mr. H.S. Karangle, Director General of Indian Chemical Council says, “The liberal origin rules adopted under the RCEP coupled with the ‘regional cumulation’ rule would permit the latter country to be treated as the country of origin and accordingly, the goods imported into India from this country would get preferential treatment, as the product figures in the positive list for tariff liberalization for that country. In this way, MFN duties otherwise applicable on the goods impor ted from China can easily be circumvented.” Under RCEP, the tariff liberalization is not uniform for all the participating countries. In case of China, India’s offer list reportedly covers around 74-80% of the tariff lines and this implies that around 20-25 percent of the tariff lines should be excluded from the tariff cuts. Whereas, In the case of other RCEP countries, the offer list reportedly covers around 90% of the tariff lines. In the case of these countries, tariffs would be phased out over a period of time ranging from 10 years to 25 years. The industry has already proposed that product-specific rules of origin should be formulated at least for those products which are not subject to tar iff cuts under the RCEP or where the tariff differential has been prescribed. From the industry’s point of view, the better origin rule should be such that the originating status goods would be conferred by applying the twin criteria of 40% value addition plus change in tariff sub-heading/heading, as adopted under ASEAN-India FTA and SAFTA. Another option worth exploring would be to confer origin based on 40% value addition criterion only, as adopted under ASEAN-China FTA. This would be much better than the existing agreed upon rule, under which origin shall be conferred by applying one of the two criteria, via 40 percent value addition or change in CTH.
At international trade show IFAT, which has taken place from October 16 to 18, 2019, in Mumbai, Specialty Chemicals Company LANXESS is presenting its comprehensive range of products and services relating to process water and wastewater. A custom selection of products and technologies is often vital here. In many cases, optimum results can be achieved only with the smart combination of several technologies. Lanxess has many years of combined expertise for this in the areas of ion exchange, adsorbers, reverse osmosis, and ultrafiltration. Current trends such as electro-mobility provide LPT’s operations with additional impetus: “Recently implemented improvements to processing technology and process efficiency in the production of ion exchange resins in Leverkusen are already bearing fruit. Thanks to the resulting capacity enhancement, we can successfully satisfy the recent rise in demand from the battery industry, for example”, explains Prakash Shanmugam. Numerous ion exchange resins from the Lewatit product range are also being produced at the plant in Leverkusen for use in the food industry. The range of Lewabrane high performance (HP) RO membrane elements for energy-efficient brackish water treatment, which was recently launched in the market, is already well established. On the basis of an optimized membrane structure, they offer improvedrejection with a higher flux rate compared with standard elements. The company’s involvement in the Multi-ReUse research project shows just how important reverse osmosis is to Lanxess, especially for wastewater treatment. One aim in this context is to take suitable action to minimize fouling and thereby ensure stable operation in the long term. On the basis of a sales partnership with French company Polymem SA, which was agreed in 2018, Lanxess has added Gigamem ultrafiltration elements to its portfolio for water treatment. The first projects to result from this cooperation have been successfully launched in the Mediterranean region. The combination of reverse osmosis and ion exchange opens up new areas of application for water treatment, for which a single technology would be no match. For Example: Textile effluent recycling using ion exchange resins for hardness removal as well as color and organics removal as a pretreatment to reverse osmosis to enhance the recovery and operating life of membranes. This process is already being used successfully in many textile effluent zero liquid discharge (ZLD) plants. The current version of the LewaPlus software developed by LANXESS that is used for designing combined systems of this kind now also features a cost module for ion exchange, so that – in combination with the integrated cost calculation for reverse osmosis – it is easy to estimate the total investment costs and operating costs.Arsenic pollution is one of the most dangerous forms of drinking water contamination. Some very high concentrations of arsenic occur in the groundwater in many regions of the United States, South America, and Asia. Elevated arsenic levels are also found in Bangladesh and North East of India for example. Using Bayoxide iron oxide adsorbers, LANXESS is providing an efficient technology for the removal of arsenic from drinking water and wastewater. The core of the Bayoxide system is a solid bed of iron oxide beads. The beads have finely structured surfaces that adsorb pollutants when contaminated water flows over them.
Contribution of Lanxess to Innovative Water Treatment
The LPT business unit is part of the LANXESS Performance Chemicals segment, which generated sales of EUR 1.35 billion in fiscal year 2018.
Amsterdam, Netherlands: “Innovative solutions for water and waste water treatment are gaining in importance in an attempt to use this resource responsibly. Lanxess can make valuable contributions to this in all application areas,” emphasizes Prakash Shanmugam, Head of the Liquid Purification Technologies (LPT) business unit at LANXESS India.
LPT offers a comprehensive range of tailor-made ion exchange resins and reverse osmosis and ultrafiltration membrane elements for various applications in the field of water treatment. You can find more detailed information about products from the business unit on the website at http:// lpt.lanxess.com.
24 • October 2019
Chemical Engineering World
CEW News Indian Chemical Industry Expects to Double its Size at USD 300 billion by 2025
(L – R) Ravi Goenka, Vice President, ICC; Vijay Sankar, President, ICC; Bima Goculdas, Addl. Vice President, ICC
Mumbai, India: Indian Chemical Council (ICC), the apex national body dedicated for the growth and development of Chemical Industry in its conference titled ‘Making India’s Chemical Sector Future Ready’ highlighted the future prospects of Indian Chemical Industry. Being a prominent industry of industries, Chemical Industry in India covers more than 80,000 commercial products and it is expected to double its size at USD 300 billion by 2025. The focus of the conference was to shed light on the bright future of this sunrise industry by decoding the potential that lies with the chemical industry and how it needs to take the next leap towards development and sustainability. Being one of the oldest industries in India, the Chemical Sector is steadily moving up the ranks as a global economic power and is proving to be India’s business magnet with higher investments and expansion. Speaking at the conference, Mr. Vijay Sankar, President, Indian Chemical Council, said “The Indian chemical industry has witnessed robust growth in the past decade and the potential for future growth is significant. In coming years, India is expected to rise as both, a manufacturing capital for valued goods as well as a consumer-driven economy from a broader perspective. Growth in consumer base, changes in lifestyle, increase in disposable income and focus on healthcare and hygiene etc. has spurred a higher demand for the sector. Also, factors like boost in specialty chemicals and pharmaceuticals segment, low per capita consumption including agrochemicals, likely growth in demand from paints, textiles and diversified manufacturing base are set to scale up the potential of Indian Chemical Industry”. “At ICC, we always believe in promoting and supporting all branches of the sector through a variety of events, awards, policy advice, and other activities. With ICC Awards 2018, we provide a platform for leading chemical companies to come together to showcase their achievements on various fronts including technology development, environment, and safety”, added Mr. Sankar.
ADNOC, Adani, BASF and Borealis Signed Memorandum of Understanding to Further Evaluate Collaboration for a Chemical Production Complex in Mundra, India Mundra, India: Abu Dhabi National Oil Company (“ADNOC”), Adani Group (“Adani”), BASF SE (“BASF”) and Borealis AG (“Borealis”) have signed a Memorandum of Understanding (MoU) to engage in a joint feasibility study to further evaluate a collaboration for the establishment of a chemical 28 • October 2019
complex in Mundra, Gujarat, India. This is the next step of BASF’s and Adani’s investment plans as announced in January 2019. With the inclusion of ADNOC and Borealis as potential partners, the parties are examining various structuring options for the chemical complex that will leverage the technical, financial, and operational strengths of each company. The total investment is estimated to be up to USD 4 billion. The collaboration includes evaluating a joint world-scale propane dehydrogenation (PDH) plant to produce propylene based on propane feedstock to be supplied by ADNOC. Propylene will be partially used as feedstock for a polypropylene (PP) complex, owned by ADNOC and Borealis, based on proprietary state-of-the-art Borealis Borstar technology. The PP complex will be the first overseas production joint investment by ADNOC and Borealis as part of a strategic framework with their current joint venture Borouge. Furthermore, propylene will be the key raw material for the previously announced acrylics value chain complex comprising glacial acrylic acid (GAA), Oxo-C4 (butanols and 2-ethylhexanol), butyl acrylate (BA), and potentially other downstream products as part of a joint venture of BASF and Adani in which BASF holds a majority. The designated site is planned at Mundra port in Gujarat, India, and the products are predominantly for the Indian market, serving a wide range of local industries, including construction, automotive and coatings. The chemical complex in Mundra is intended to be entirely supplied from renewable energy resources. The partners are evaluating co-investment in a wind and solar park; plans are at an advanced stage of development. If realized, this would be the world’s first world-scale CO2-neutral petrochemical site to be fully powered by renewable energy, fully in line with the partners’ commitment to sustainability and energy efficiency. Commenting on the MoU signing, Dr. Sultan Al Jaber, UAE Minister of State and ADNOC Group CEO, said: “This strategic collaboration further underscores how ADNOC is fostering smart and mutually beneficial partnerships, whilst also leveraging its strong hydrocarbon position. Creating the first-of-its-kind polypropylene plant in India, allows ADNOC and its partners to capture the promising growth in the Indian polyolefins market and also demonstrates our continued commitment to India.” Gautam Adani, Chairman of the Adani Group, stated: “We are very pleased to collaborate with our international partners to establish a Chemical Manufacturing Complex at Mundra Port. We stand committed to the ‘Make in India’ initiative and serve the larger purpose of aligning growth opportunities with creation of goodness for the nation.” “BASF remains committed to investing in India’s growth. We will play a key role in driving this joint collaboration which is also pioneering in terms of sustainability. We look forward to working together with our partners in establishing a chemical cluster in Mundra and to supplying the Indian market with high-quality downstream products,” said Dr. Martin Brudermueller, Chairman of the Board of Executive Directors of BASF SE. Alfred Stern, CEO of Borealis, added: “This partnership is a unique opportunity to strengthen our PP presence in India with proprietary Borealis Borstar PP technology and to create value and tangible benefits through innovation for customers across multiple industries.” The partners aim to finalize the joint feasibility study by the end of Q1 2020. Production is intended to commence in 2024. Chemical Engineering World
CEW News Covestro’s Circular Economy Initiative with Plastic Waste as a Resource Mumbai, India: With a long-term program, Covestro has planned to place a strong focus on the circular economy and to be a creative force for the entire plastics industry. In particular, the company aims to use raw materials from sustainable sources such as waste, plants and CO2 as much as possible in production. The aim is to achieve the greatest possible departure from fossil resources such as crude oil. Above all, used plastics must be recycled systematically and to the greatest possible extent. Covestro intends to develop new technologies exactly for this purpose. Overall, the company wants to shape the transition from a disposable economy to a circular economy with as many partners as possible and expects this to open up entirely new business opportunities.
“The great challenges of our time, such as climate change and the increasing consumption of resources by the growing world population, make truly sustainable ways of living and economies an indispensable necessity. The linear patterns in consumption and production based on one-time use have become obsolete – we must rather strengthen the idea of recycling and consistently align our actions accordingly, ” stresses Covestro CEO Dr. Markus Steilemann. According to Steilemann, the plastics industry in particular can and must drive the change to achieve a circular economy. “Our company wants to be a pioneer in this process – for the benefit of the environment and society, but of course also for the benefit of our customers, who want to join us on our path to the circular economy.” In order to promote the circular economy, Covestro has taken a first step in establishing a global strategic program to establish circularity throughout all areas of the company. It will then be backed by concrete and measurable objectives. The materials manufacturer has already taken several steps in this direction. For instance, it has recently been using alternative raw materials instead of crude oil to move the important element carbon virtually in a circle. Especially when it comes to using CO2 as a new raw material, Covestro sees itself as a pioneer and, with its innovative technology, is now in the grand finale of the prestigious German President’s Award. However, the greatest potential for closing cycles is likely to lie in the recycling of plastic waste. In order to be able to make greater use of it than before, waste disposal systems must be considerably improved and redesigned. Covestro wants to contribute to this above all by developing new recycling technologies. The aim must be to use the most energy-efficient methods possible to convert used plastics back into their molecules. In a joint project, for example, the company is conducting concrete research into the reuse of soft polyurethane foam, which is used to make mattresses. On top of this, Covestro intends to increasingly design plastics from the outset so that they can be effectively recycled. At the same time, plastic products must last as long as possible and be used to avoid waste. "Society, but also industry, must produce less waste. Above all, waste has to be disposed of systematically and must no longer end up uncontrolled in the environment," says CEO Steilemann. "Plastic waste in our oceans is essentially the result of inadequate waste management. Plastic in itself is not the problem and should not be prohibited. On the contrary, high-quality plastics are a problem solver and are urgently needed – for renewable energies, new forms of mobility and sustainable construction, for instance." In order to stop the flow of plastic waste into the bodies of water, Covestro is also involved in the Alliance to End Plastic Waste, a worldwide company network that has been active since early 2019. In the new Circular Plastics 30 • October 2019
Alliance, the company is also working with numerous other businesses and organizations to promote the recycling of plastics in Europe. Overall, Covestro wants to cooperate with as many players as possible in all areas of the value chain in order to find the best solutions for the circular economy. The company assumes that a recycling-oriented economy will also lead to new business opportunities. New value creation paths and new business relationships beyond the existing B2B business are potential opportunities. At the world's largest plastics trade fair, K 2019 in Düsseldorf, Covestro will be presenting many prime examples of products and technologies that can help close material cycles in various sectors. Together with its partners, Covestro has for example developed a concept for manufacturing new electronic components from used polycarbonate. Covestro will also be hosting a special theme day at its booth on October 23 dedicated to the topic of the circular economy.
Lanxess Inaugurated High-tech Plastics Plant in China
Cologne, Germany; Changzhou, China: Specialty chemicals company Lanxess officially inaugurated its new plant in Changzhou, China, on September 25, 2019. The compounding facility produces Durethan- and Pocan-branded high-tech plastics, especially for the automotive sector and the electrical & electronics industry. “This facility was built to address several strategically vital markets,” said Hubert Fink, Member of the LANXESS Board of Management, in his speech at the opening ceremony. “In the automotive industry, lightweight materials become ever more important in new mobility. At the same time, the electrical & electronics sector sees an increasing need for best-in-class flame retardant, easy flow, and easily processable grades”. “With the new plant, we are responding to the trend towards the increased use of lightweight materials. We are committed to this longterm development”, said Michael Zobel, Head of the High Performance Materials business unit. Intelligent production is a substantial highlight of the new plant. From batching, hot melting, mixing, cooling, granulating, pellet cooling to palletizing, the entire system is designed to be intelligent. For example, the batching system adopts multiple continuous loss-in-weight feeders to realize continuous production. The pellet processing system can conduct feeding and convey in a fully automated manner. The high-temperature plastic strands from the extruder can automatically enter a cooling bath for full cooling, before being sent to the automatic conveyor, and then to the pelletizer for granulation. Lanxess equips all its new production sites with state-of-the-art technology, also with regard to environmental standards. To this end, the new plant incorporates various innovative measures in environmental protection such as state-of-the-art mixers with high performance and low energy consumption and efficient wastewater, waste gas and dust treatment systems to achieve a clean production process with low energy consumption, low material consumption, and less pollutants. The business unit High Performance Materials operates a global production network at the following locations: Dormagen (Research & Development); Krefeld-Uerdingen (PA 6 Polymerization, Compounding); Hamm-Uentrop (PBT Polymerization, Compounding); Brilon (Tepex Production and Development); Antwerp, Belgium (PA 6 Polymerization); Wuxi, China (Compounding); Changzhou, China (Compounding); Jhagadia, India (Compounding); Gastonia, USA (Compounding); and Porto Feliz, Brazil (Compounding) Chemical Engineering World
CEW News 11TH PLASTINDIA Exhibition will Actively Focus on Responsible Innovation to Conserve Environment
industry requires the highest ever safe, secure & hygienic packaging and its perfect solution is provided by Flexible Packaging including Plastic woven sacks. The plastics industry continues to break into newer spheres, thereby enabling India to manufacture world class products. I am optimistic that the PLATINDIA 2021 will be a reflection of this and I wish the team great success.” PlastIndia is also taking active steps to support the decision of the Central Government for single use plastics. It is working towards fully backing the circular economy with focus on Recycle and Multiple use of Plastic Products in line with the vision of the Hon’ble Prime Minister of India Shri Narendra Modi ji.
Shri Kashi Nath Jha - Joint Secretary, Department of Chemicals & Petrochemicals, Ministry of Chemicals & Fertilizers, Government of India (09th from right); Shri Rajesh Agrawal, IAS - Executive Director, India Trade Promotion Organization (08th from right); Mr. Erhard Wienkamp - Executive Director, Foreign Trade Fairs Division, Messe Duesseldorf GmbH (06th from right); Mr. Ajay Shah – Chairman, National Executive Council Plastindia (1st from right) at Launch of 11th Edition of PLASTINDIA – 2021
Mumbai, India: Plastindia Foundation recently held an event in Mumbai to announce the launch of the 11th Edition of PLASTINDIA to be held in the year 2021 in New Delhi. PLASTINDIA is the third largest exhibition of its kind in the world and the largest in India. It is held once every three years and this edition will be organized from February 4 to 8, 2021 at ITPO, Pragati Maidan, New Delhi. The launch event in Mumbai was graced by Shri Kashi Nath Jha – Joint Secretary, Department of Chemicals & Petrochemicals, Ministry of Chemicals & Fertilizers, Government of India along with Shri Rajesh Agrawal, IAS, Executive Director, India Trade Promotion Organization, Mr. Jigish Doshi – President, Plastindia Foundation, Mr Ashok Goel Chairman National Advisory Board, Plastindia Foundation and Mr. Ajay Shah – Chairman, National Executive Council Plastindia 2021. The PLASTINDIA 2021 International Plastic Exhibition & Conference will be supported by Department of Chemicals & Petrochemicals - Ministry of Chemicals & Fertilizers, Government of India. This edition of the expo will be held at the new world class venue at ITPO, Pragati Maidan, New Delhi and will showcase India as a global hub for sourcing processed items related to plastics, raw material, machinery and various other products for use in different segments. PLASTINDIA 2021 is known to provide a superlative platform to showcase world-class innovations and products from the plastic industry that are likely to benefit a host of sectors. Over the years, the Expo has successfully facilitated support from the government where the latter has constituted several groups to address important issues like quality and specifications, recycling and waste management etc. of plastic. While PLASTINDIA and Plastindia Foundation are proactively engaged in enabling the sustainable growth of the Indian Plastic Industry, there has also been an ample amount of focus on quality, human health, and most importantly environment. Speaking on the occasion, Shri Jha said, “The plastics industry in India is contributing significantly in the economic development and growth of various key sectors in the country. Right from automotive, agriculture, horticulture, construction, medical equipment, health care, irrigation, sanitation, drinking water, sports, plastic composites and packaging – all sectors are impacted by the use of plastic. In fact, the food security 32 • October 2019
Plastindia Foundation will meet all stakeholders and submit concrete proposals to the Department with special focus on Plastics and Environment in the near future. Mr. Jigish Doshi said, “We are devoted to promoting excellence in the field of plastics and making India a preferred sourcing base in plastic products for the world. But we will also be focusing very specifically on environmental concerns. We completely support the vision of our Hon’ble Prime Minister of India Shri Narendra Modi ji and will be focusing on the idea of Recycle and Multiple use of Plastic Products. This edition of PLASTINDIA - 2021 is all set to surpass the landmarks created by its previous editions. It will see the presence of more than 2,000+ exhibitors from India, participants from 45+ countries and over 2 lakh business visitors-- both national and global. With every edition we are growing and building more number of exhibitors, visitors and participants.” Mr. Ajay Shah said, “Our mission is to enhance the image and growth of the Indian plastics industry by holding world-class exhibitions in India, at regular intervals. Plastindia Foundation has been taking this initiative over the years to bring together the best in this field globally, which has provided a platform for our domestic industrialists to share their experiences with their global counterparts”. Mr. Doshi further added, “The focus should be on developing new technologies and innovations in order to facilitate growth of the plastic industry. India's plastics industry offers immense potential in terms of capacity, infrastructure and skilled manpower. In this age of globalisation and constant need to improve the standard of living, the demand for plastic is bound to increase exponentially and turn India into the world's next plastic destination. But having said this we must use plastic responsibly to minimise its impact on environment. There is a need to create awareness about recycle, re-use of plastic and adopt a better waste management facility for sustainable growth of the industry.” Some of the dignitaries present at the Launch Function of PLASTINDIA – 2021 include Mr. Erhard Wienkamp, Executive Director, Foreign Trade Fairs Division,Messe Duesseldorf GmbH, and Shri Dr S K Nayak, DG, CIPET The previous edition of PLASTINDIA 2018, which was held in Gujarat, had been inaugurated by the Hon’ble Chief Minister of Gujarat Shri Vijay Rupani. The expo had proved to be an extremely successful global event, attracting a large number of participants and visitors from across the world. Chemical Engineering World
CEW News Lanxess Won Responsible Care Competition 2019 of German Chemical Industry Association (VCI)
Cologne, Germany: Specialty chemicals company Lanxess bagged the first prize in the nationwide Responsible Care competition from the German Chemical Industry Association (VCI) held on September 26, 2019. The company submitted the project - resource-efficient manufacturing of leather chemicals (ReeL). Responsible Care is the chemical industry's global initiative to continuously improve its performance in environmental protection, health, and safety. This year's competition was held under the motto “Sustainability in the supply chain”. “Sustainability is also crucial for the leather industry and this award confirms to us that we are on the right track. In particular, the recycling of residual materials and the development of material cycles are essential topics,” said Luis López-Remón, Head of the Lanxess Leather business unit, “Our ReeL project is not only good for the environment, but also brings economic benefits for the tanners.” In this research project, LANXESS has developed a completely new technology for tanneries. Thanks to a modular system, it is possible to recycle all the residues from leather production directly on site. The main raw materials are biomass, collagen-containing shavings and waste cuts, which have so far generally been disposed of. Tanners can now produce X-Biomer retanning agents from these byproducts themselves and use them for the production of leather. A medium-sized tannery produces about one to two tons of shavings per day. The waste materials used in the plant can be fully recycled – no residues remain and no emissions are generated. The pilot plant for the project was developed in cooperation with the Leverkusen research institute INVITE. The process has since been tried and tested at the third cooperation partner HELLER-LEDER GmbH & Co. KG and proved its feasibility. Eight times larger production plants are currently being planned in cooperation with leading large-scale tanneries in Europe. In April 2019, LANXESS won the Responsible Care state competition in North Rhine-Westphalia with “ReeL”. As the state winner, the Group also took part in the national competition. A jury of independent experts decided on the winners. The project has already won several awards, including the Climate and Environment Innovation Award in February 2018, which is presented by the Federation of German Industries (BDI) and the German Federal Ministry for the Environment, Nature Conservation, Construction and Nuclear Safety. 34 • October 2019
Pocan XHR: Lanxess Unveiled New Generation of Hydrolysis-stabilized PBT Compounds
Cologne, Germany: Compounds based on polybutylene terephthalate (PBT) need greater resistance to hydrolysis and aging in hot and humid environments when used in automobiles. For instance, the high electrical power densities of high-voltage systems in electric vehicles lead to greater temperature loads. Furthermore, additional thermal loads arise when charging the battery. In combustion engines, there is a trend towards turbocharged engines, which results in increased temperatures in the engine compartment. With this in mind, the specialty chemicals company LANXESS has developed the new PBT product range Pocan XHR (Xtreme Hydrolysis Resistance). At K 2019, the international trade show for plastics and rubber taking place in Düsseldorf from October 16 to 23, the High Performance Materials business unit will be showcasing these innovative compounds. They have achieved outstanding results in the SAE/USCAR-2 Rev. 6 longterm tests of the American Society of Automotive Engineers (SAE). “In the automotive industry, these tests on the finished part are the absolute benchmark in terms of hydrolysis resistance,” explains Dr. Claudia Dähling, PBT material expert at LANXESS. “In our very strict internal specimen tests, based on the USCAR specification procedure, the new compounds achieve Class 4 or even Class 5, the two highest gradings. This makes them the material of choice for PBT components, which have to work reliably under the influence of humidity and temperature throughout their service life.” In the SAE/USCAR long-term tests, a finished part is exposed to temperatures from -40 °C to +175 °C (Class 5) at relative air humidities of up to 100 percent in 40 eight-hour cycles. The finished parts then undergo various function tests. The test process is extremely demanding, as heat and humidity affect aging more intensely when the two factors are combined. At present, there are four products in the Pocan XHR range. Pocan B3216XHR and B3233XHR have glass fiber contents of 15 and 30 percent respectively, and attain Class 5 classification. Pocan TP155-002 is specially tailored for laser transmission welding. The laser-transparent compound with a glass fiber content of 30 percent is suitable, for instance, for resource-efficient production of sophisticated housings for electrical/ electronic components, and achieves results between Class 4 and 5 in the USCAR test. “Particularly interesting is the unreinforced Pocan B1205XHR, which achieves the second-highest grading in the SAE/USCAR test with Class 4. It can be processed with next to no distortion, thus enabling highly intricate geometries,” says Dähling. LANXESS is currently working on adding further product types to the Pocan XHR range. As well as its outstanding hydrolysis resistance, Pocan XHR has other benefits. “For example, its elongation properties and high resistance to alternating temperatures make it suitable for overmolding of metal parts that are exposed to temperature fluctuations,” Dähling relates. Further strengths are its improved chemical resistance to substances such as caustic soda, and a much greater long-term temperature stability than standard PBT types, even in dry environments. In other respects, with its properties, Pocan XHR is similar to the hydrolysisstabilized PBT compounds in the Pocan HR series that have become established in many series production applications. In particular, the balanced processing characteristics so valued by the market have been transferred to the new XHR generation. Dähling: “For instance, the melt viscosity at injection-molding temperatures customary for PBT remains constant for longer, ensuring a reliable production process with a wide processing window.” Furthermore, flowability is up to 35 percent higher compared with PBT standard products. Chemical Engineering World
A world leader in chemical solidification and handling solutions Granulation, solidification and handling systems for different kinds of chemicals like resins, waxes, hot melts, antioxidants and residuals. • High productivity – on-stream factor of 96% • Proven Rotoform technology – nearly 2000 systems installed in 30+ years • Complete process lines or retrofit of existing equipment • Global service / spare parts supply
ipco.com/applications
IPCO_Chemicals_ad_210x270.indd 1
18/04/2019 11:23
CEW News Clariant Inaugurated a New Waste Water Treatment Plant in Bonthapally, India
management efficiency. The Honeywell Forge Cybersecurity Platform is part of the Honeywell Forge for Cybersecurity portfolio of products and services that increases cybersecurity across industrial environments. The new platform safely moves data from one site to another and uses operations data to strengthen endpoint and network security, and improves cybersecurity compliance. The platform also delivers a scalable software solution to better address cybersecurity pain points in OT and IIoT environments.
The Waste Water Treatment Plant at the Bonthapally Site, Telangana, India. (Photo Credit: Clariant)
Hyderabad, India: Clariant, a focused and innovative specialty chemical company, today inaugurated a new state-of-the-art Waste Water Treatment Plant (WWTP) at the Industrial & Consumer Specialties (ICS) site in Bonthapally, India. The new waste water treatment plant at the zero liquid discharge site has the capacity to treat 300 kiloliters of waste water per day. The WWTP has a host of highly efficient processes to enable purification and removal of contamination at various stages. Effluents are introduced to the WWTP, where it is subjected to biological treatment, ultra-filtration, reverse osmosis, multiple evaporation techniques and agitated thin film drying. With the inauguration of the new Waste Water Treatment Plant at Bonthapally, Clariant can continue to drive its growth strategy for its Industrial and Consumer Specialties business, while ensuring it continues to focus on sustainability and environment protection. “Clariant’s philosophy prepares for a better tomorrow for all its stakeholders and the communities it operates in. This investment in the WWTP marks another milestone in Clariant’s commitment towards sustainable business in India, one of its strategic growth markets. We are pursuing a dedicated strategy aimed at increasing and sharpening the focus on BU Industrial & Consumer Specialties in India,” said Adnan Ahmad, Region Head, Clariant in India. “The new WWTP is in line with our focus to uphold a greener economy. Through the treatment plant, we have reiterated the values we stand for. I am happy to see this being executed successfully and excited about its benefits going forward,” said Atul Sharma, Head of Operations, BU ICS, Bonthapally, at the inaugural ceremony. The Bonthapally site has been awarded a three star rating in recognition of Environment, Health and Safety (EHS) practices in the CII-SR EHS Excellence Awards for the year 2018. It also has the cGMP certification that helps meet customer expectations and ensures the deliverance of the highest quality products and production standards in line with European Union (EU) guidelines.
Honeywell Unveiled New Software Platform To Simplify, Strengthen And Scale Industrial Cybersecurity New Delhi, India: Honeywell, a global leader in industrial cybersecurity, has recently announced the release of new software that simplifies, strengthens and scales cybersecurity for asset-intensive businesses and critical infrastructure facing cyberthreats. The Honeywell Forge Cybersecurity Platform improves cybersecurity performance at a single site or across an enterprise by increasing visibility of vulnerabilities and threats, mitigating risks, and improving cybersecurity
36 • October 2019
“Honeywell Forge for Cybersecurity is a big step forward in the company’s overall cybersecurity strategy. The unified suite of applications, services and products can address a range of end-user cybersecurity requirements from asset discovery and monitoring and Secure Remote Access to fully managed services,” said Larry O’Brien, vice president of research at ARC Advisory Group. “Honeywell Forge Cybersecurity Platform represents a common approach to OT-level cybersecurity that recognizes the impact of IoT on manufacturing, including the monitoring of virtual machines, firewalls, and other assets in industrial environments.” Based on technology installed in thousands of sites globally, the Honeywell Forge Cybersecurity Platform improves cybersecurity performance by giving customers the tools they need to strengthen their cybersecurity operations and asset management, all through a single dashboard. In addition, multi-site, multi-vendor capabilities support an enterprisewide solution with greater efficiencies and lower total cost of ownership regardless of the control system used. “Customers now have a better choice to strengthen industrial cybersecurity across their enterprise to enable IT-OT convergence and digital transformation, improving enterprise performance while reducing the cost of cybersecurity,” said Jeff Zindel, vice president and general manager, Honeywell Connected Enterprise, Cybersecurity. “The Honeywell Forge Cybersecurity Platform provides multiple industry-proven capabilities in a single dashboard to simplify cybersecurity management and better protect people, processes and assets from evolving cyberthreats.” The Honeywell Forge Cybersecurity Platform is available in three versions, allowing customers to scale when needed to match cyber-requirements and budget. For customers with more secure multi-site connectivity needs, Enterprise Core delivers the core cybersecurity operations management enablers including secure remote access with advanced granular controls engineered for industrial environments, and secure content transfer with built-in, file-based threat detection. In addition to capabilities found in Enterprise Core, Enterprise Premium also delivers cybersecurity asset management which includes asset discovery and inventory, continuous monitoring and alerting, software patching and antivirus management, risk and compliance management for corrective action and mitigation. For customers exploring select platform capabilities at a single site level, the site offering includes asset discovery and inventory, continuous monitoring and alerting, and risk and compliance monitoring. Customers that may not have the cybersecurity expertise or resources to support the Honeywell Forge Cybersecurity Platform, but want to get the most out of their cybersecurity investment, can benefit from Honeywell’s Managed Security Services to host and run the software. With experts in industrial cybersecurity around the world, Honeywell provides Cybersecurity Consulting Services to complement the Honeywell Forge Cybersecurity Platform to help further strengthen cyber defenses. The Honeywell Forge Cybersecurity Platform is part of Honeywell Forge, a new category of software solutions that deliver Enterprise Performance Management for Operations Technology to aerospace, building, industrial and worker segments. Honeywell Forge was launched earlier this year to improve the way a variety of companies collect, analyze and act on data from their operations. Chemical Engineering World
TECHNICALLY ADVANCED SOLUTIONS - for Polyol & Isocyanate
FOAM MATTRESSES, INNER LININGS IN CARS, CHAIRS, SOFAS ETC. Isocyanate is one of the components in broadly all foam products such as foam mattresses, inner linings in cars, cushioning in car seats, chairs and sofas. The hard qualities are used for insulation of houses, machines, tubes, etc. There are various types of isocyanate, but common to all of them is that they react to the humidity of the air by forming very hard crystals, which wear out the pumps and mechanical seals, if any.
ROTAN® ED Up to 90 m3/h
For MDI (Isocyanate) it is recommended to use positive displacement pumps and the leading MDI producers are recommending the DESMI ROTAN® series (magdrive pumps). They have been successfully used for a long period of time at many different applications.
MARINE & OFFSHORE
INDUSTRY
PROVEN TECHNOLOGY Chemical Engineering World_Rotan CD and ED Pumps.indd 1
OIL SPILL RESPONSE
DEFENCE & FUEL
UTILITY
DESMI India LLP IP Nadergul, SY No.519, Nadergul Village Saroor Nagar Mandal, Ranga Reddy Dist Telangana State 501510 Phone : +91 8790122223 Email: srai@desmi.com
18-10-2019 11:24:06
CEW Gujarat Special
EPP Composites Pvt. Ltd. About the Company EPP Composites is one of the leading global players in the Composite Industry in India. EPP was established in 1986 with the intention to develop its place in the Composite Market with focus on Quality and Customer Service. It is a global multi-product, multi-divisional group that is engaged in manufacturing of Composite Products in India, spread over 500 thousand square feet manufacturing EPP has got multiple manufacturing plants manufacturing extensive range of products like - GRP/GRE Pipes, Fittings & Liners, FRP Cooling Towers/Scrubbers/Blowers/ Hoods/Ducts & Chimneys, FRP Storage Tanks, various FRP Pultruded Products, FRP Cable Trays, SMC Electrical Boxes, Electrical Poles. EPP is the first Indian Company manufacturing, large diameter GRP Dual Helical Filament Wound cross country pipelines with an indigenous technology. Along with this, the company uses latest composite technology which includes Pultrusion Technology, Resin Transfer Moulding Technology, Spray Up Technology, Vacuum Infusion Technology, Compression Moulding Facility, Hand Layup Process and Advancing Mandrel Process for making large diameter Pipes.FRP Doors & Roofing Sheets. EPP is the first Indian Co to have API Spec 15LR license. EPP owns ultra modern testing laboratories as per international norms where raw material testing, in process testing to final product testing are done as per international standards. EPPs growth has been phenomenal during last decade. EPP’s customer centric approach, comprehensive solutions and after sales support has made it possible to achieve a compounded growth rate of 120%.in last 5 years.
ing, Cold Rolling Mills in Chemical Equipment and Pultrusion Verticals, • Irrigation, Drainage, Desalination Plants, SEZ & Green field projects, Ship Building, Fire Hydrant industry needs for GRP Pipes and Fittings and Rehabilitation of old pipelines by liner pipes in Pipe Verticals. • Electrical Distribution lines, Electrical OEM’s and Retail markets in SMC Verticals. • Railways & Mass Transport ,MES ,Telecom Industries, Smart Cities ,Underground Petroleum Storage Tanks in General Moulding Verticals , As per ICERP, overall Indian Composites Industry has experienced a comparatively healthy growth during past 5-6 years. The market is driven by growth in Mass Transportation, Electrical and Electronics, Infrastructure, Building and Construction. The percapita composites consumption reached 0.3 kg in 2018 from 0.25 kg in 2012 in comparison to 1.2kg in Brazil, 2.1 in China and 8.2 in the US. The Indian Composites industry is projected to grow rapidly to reach 4.9 lakh metric tons by 2022 at a substantial CAGR of 8.2%,as per the ICERP report.
Growth Strategy for next Five years: Corrosion – Chemical Process: Tanks & Vessels, Pipes • Growth envisaged in Power Plant Utility Market especially FGD Market. Large diameter Ducts, Stacks, Chimney liners, Storage Tanks, Abrasion Piping and FGD Internals. 25% Growth in revenue expected out of this Segment.
About the Business & Services
Building & Constructruction- Pultrusion
EPP’s involvement from design to commissioning in detailed project and engineering jobs has made it possible to develop its own designing capacity and ability to offer consolidated and concrete proposals as per the requirement of customers with good hold and reputation with specialist designer and consultants.
• Large infrastructure activity in Energy segment, by way of growth of Structural Composites Like Pultruded Profiles /Sections / Handrails / Cable Trays/Molded Gratings . The areas of application include Cooling Tower, Platforms for Oil & Gas and Chemical Plants, 15-20 % growth in revenue expected out of this Segment.
EPP proposes through its various product verticals, product and application solutions to all sectors of industries in general and following segments in particular: • Chemical,Petrochemicals,Refineries,Pharmaceutical,WaterTreatment,Metal Smelt40 • October 2019
Water & Waste Water: Desalination - GRP Piping • GRP Piping is the Key infrastructure growth envisaged as a potential segment which can go year on year steady growth with our Additional Lines, Large Diameter Piping Capa-
Mr. Siddharth Shah Chairman
Mr. Jayraj Shah Managing Director
bilities, and Introduction of Dual Laminates Production. Major Drivers in this segment include New Desalination Projects, Cross Country Piping and Power Plant Utility Sea water Intake Piping. Railways & Metro Rail: • With the Developments happening in the Large Network of Railways by way of New Metro Rail Projects, Composites applications are poised for a large growth strategy by way of Products for Electrical applications, Railway Internal Panels and Fire retardant composites. Growth Strategies in this Segment EPP is setting up New Fabrication / Manufacturing Techniques, Testing facilities and Newer Technologies from Global Companies. Geographical Expansion & Exports • EPP Setting up Additional Manufacturing capabilities in GRP Piping / Pultrusion and Chemical Process Equipments, with the Additional Capacities besides domestic demand and Market needs, balance of capacities are being built and utilized for export markets to USA /Middle East. Setting up Manufacturing Capabilities in the Middle East and South Africa on the cards. • EPP Is looking for M&A opportunities in the European and SEA region Market Dynamics in the Current Global Economy: Automotive Segment: Sheet Molded Components / Compression Molded Components – Fiberglass Markets takes a nose dive and Fortunately EPP focuses less on this Segment especially Automotive Parts. Wind Energy Segment: The Alternate Renewable Market is getting Attention like Solar, Making Wind Energy Investments regulated, and during the Slow down wind energy Growth gets a dip, EPP Focus is not in this segment. Chemical Engineering World
CEW Gujarat Special
G M Flowlines Pvt Ltd
G
M Flowlines Pvt Ltd was founded in the year as a group company of G M Engineering Pvt Ltd, which is in the business of manufacturing Ball, Gate, Globe, Check, Butterfly, Forged Steel Valves since 1996. The company has emphasized on a customer-driven organizational philosophy, and investment in the best technology & human resources as enablers to constantly meet high standards set by their customers. G M Flowlines is accredited with ISO 9001:2015 certification by TUV.
excel. The products have been maintaining a sustainable presence in the national market since 1996. The core strength of manufacturing, adequate in-house manufacturing facility, timely investment in technology up-gradation and process innovation, shorter product development cycles, a rigorous & disciplined process based approach to continual improvement in all aspects of business have been helping to meet the exacting standards set by the customers.
Strength of the company lies on providing quality products at affordable prices, prompt delivery, and unflinching commitment to
Some reputed names the company caters to, are: Indian Oil, Hindustan Petroleum, Adani Group, GNFC, SAIL, ONGC, TATA Chemicals Limited, IFFCO, Nirma, Organosys, Essar, EIL, Divis Laboratories Limited, Aarti Industries Limited, Thermax Limited, Laxmi Organic Industries Limited, Hindustan Fluorocarbons Limited, Lupin, Hindustan Zinc Limited, Wipro, Lanxess, Mylan, Dr Reddy’s, etc.
Offerings: The company offers a complete
Sleeved Plug Valve
Sleeved Jacketed Plug Valve
Lined Plug Valve
42 • October 2019
range of plug valves and PFA / FEP lined valves & fittings to meet International Standards like ASME, ANSI, ASTM, API. As a part of Company’s primary objective, they have developed full range of polymer lined
Lined Jacketed Plug Valve
Soft Seat Butterfly Valve
valves and fittings in PTFE / FEP / PFA for the complete range of products. The products are widely used in chemical, refinery, petrochemical, fertilizer, pharmaceutical, oil exploration, thermal & nuclear power, mining, food & beverage, effluent treatment & sewerage, water treatment, cooling water & water supply, and process industries. Some notable products are: sleeved plug valve, sleeved jacketed plug valve, lined plug valve, lined jacketed plug valve, soft seat butterfly valve, lined butterfly valve, lined ball valve, lined diaphragm valve, lined ball check valve, lined swing check valve, P P ball valve, lined fittings, etc.
Company’s Focus on Quality: G M Flowlines embarks upon their quality. The company is well equipped with specialized production facilities & special purpose machines to manufacture world class quality products. It strictly follows stringent quality checks at each & every stage of production, right from procurement of raw materials to the finished product as per respective international standards to ensure consistent quality in the product. In addition to this, to put cross check on the actual practice, G M Flowlines follows a systematic documentation & management practice as per ISO 9001:2015 standards which has a complete backbone of comprehensive ERP. The quality system is further backed by superior quality control facilities like HVDC spark test, hydraulic bench test, pneumatic bench test, lining thickness measurement meter & colour thickness measurement gauge. All products are tested individually which gives complete peace of mind to their valued customers. All quality control facilities are being calibrated regularly as per ISO requirements against National Standards to ensure accuracy. They also provide third party inspection certification on request. For details contact: G M Flowlines Pvt Ltd Manufacturer of Sleeved Plug Valves, PFA / FEP Lined Valves & Fittings Plot No. 2836 / 2837, Road No. J / Almighty Gate, GIDC: Lodhika, Village: Mettoda-360021, Dist. Rajkot, India Phone: 02827-297303, 090990 85057 Email: info@gmflowlines.com sales@gmflowlines.com Web: www.gmflowlines.com Chemical Engineering World
CEW Gujarat Special
Xylem Water Solutions India Pvt. Ltd. Background As India rises with a growth rate of 6-7% over the last two decades, the country is facing severe water crisis due to rising population & middle class, increasing freshwater demand, industrialization and commercialization etc. As a result, wastewater treatment has become a necessity for a sustainable living; it’s no longer an option. The development of India’s agriculture and industrial sectors rest on the strong chemical and petrochemical industrial growth, which is supported by various chemical, petrochemical, fertilizers and pharmaceutical plants across the country. The challenges of water sector for chemical and petrochemical industries are significant. Xylem, a global leader in Water & Waste Water treatment, is equipped with the innovative, smart & proven technologies which can address the critical challenges across the entire Water cycle. Our solution for Chemical and Petrochemical Industries: Xylem offers green technology for drinking, process-, waste-, and cooling water treatment. The treatment methodology rests on the efficient, effective, reliable, non-toxic chemical, clean and environmental friendly process.
Green Technology – Ozone and Advanced Oxidation Process (AOP) Technology Ozone is a powerful oxidant with a redox potential of 2.07. AOP (Advanced Oxidation Process) technologies are a combination of several processes such as Ozone (O3), Hydrogen Peroxide (H2O2), UV radiation, Titanium Oxide (TiO2-photocatalyst), Fenton process, as well as several other processes that can produce hydroxyl radicals. OH radical is an active species that reacts with other compounds around it, has the highest relative oxidation potential of about 2.8 V. Ozone possesses several significant advantages over other chemical alternates: • Most powerful oxidant with high oxidation potential. • It leaves no traces as it is generated online and decomposes back to oxygen. • The reaction with ozone doesn’t produce toxic halogenated compounds. 44 • October 2019
• It is a powerful disinfectant that reacts rapidly with the wide range of pathogens and viruses.
of cooling tower are - Corrosion of pipe and heat exchanger unit; Scaling of pipelines and Microbiological growth.
1.Green technology for wastewater treatment
Green technology treatment of cooling water by Ozonation offers a reliable alternative against the use of various biocides. Scaling due to the deposition of calcium and magnesium ions form an isolation layer in heat exchanger negatively affects its heat transfer efficiency. Biofilm due to the microorganism such as algae also results into increase of the scaling by attaching the microcrystals deposition on the surface. The treatment technology acts as a disinfectant and decomposes biofilm which in turn decreases the problem of biofilm deposition and thus prevents fouling and scaling. Corrosion which is also enhanced due to the microbial activity is targeted through this treatment. A corrosion preventing film is formed over the surface of metal from its own oxides. This treatment is efficient disinfection that prevents microbial growth in the water system. It helps in deactivation of Legionella bacteria. The treatment along with operation rigor typically results in enhanced operational efficiencies and decrease in makeup water consumption.
Wastewater from chemical and petrochemical industries has complex organic and inorganic chemicals that require the advanced treatment along with conventional treatment methods. Xylem’s ozone and advanced oxidation process (AOP) is a very powerful and viable technique that is suitable for tough-to-treat waste water and addresses the issues of wastewater treatment in an efficient, robust and sustainable way. This treatment process can be Pre or Partial Oxidation and Post or complete oxidation process. A. Pre or Partial Oxidation of raw water/ wastewater helps in the following: • It directly attacks the hard COD, increasing its biodegradability and improvement of BOD/COD ratio. • The oxidation of ions like iron, manganese present in the wastewater results in the improved flocculation and filtration in a wastewater treatment process. • The treatment process makes use of the strong oxidant which attacks color, toxic compounds like phenols and odour. B. Post or Complete oxidation of wastewater helps in the following: • Reduction of further COD • Disinfection of wastewater for reuse at indirect contact applications
2. Green technology for cooling water treatment Cooling water treatment is vast and complex as it typically involves usage of biocides, corrosion inhibitors and scale inhibiting chemicals. Three most important factors that must be controlled for a successful operation
There are many references across the globe that has successfully implemented the Ozone and AOP in combination with other conventional technologies for treatment of tough wastewater. Some of these reference are as follows: i. Wastewater of the chemical and industrial park Zeitz, Germany contains persistent COD that is mainly discharged from an oil refinery complex situated at the site. The existing biological treatment in combination with activated carbon was not able to eliminate the pollutants effectively to meet legislative requirements. The Ozone system having designed capacity of 35 kg/h from LOX was installed that assures the operators to meet safely the discharge limits while simultaneously the manpower to operate and maintain the system and the specific treatment costs are significantly reduced. Chemical Engineering World
Waste water aeration with increased efficiency Cost cutting in aeration tanks and SBR plants with Körting ejectors • high oxygen efficiency • no deposits • 100 % availability at any time • maintenance-free
www.koerting.de +49 511 2129-447 · st@koerting.de
www.koerting.in +91 44 284757-61/-62 · info@koerting.in
CEW Gujarat Special Operating data of Yangzi Petro-chemical WWTP 70 60 COD (mg/l)
50 40 Inlet COD (mg/l)
30
Outlet COD (mg/l)
20 10 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Day
ii. Dow Chemicals, chemical production sites in Böhlen, Leuna, Schkopau and Teutschenthal. The chemical waste water discharged by the production site is a multi-component mixture containing a significant fraction of hardly biodegradable components and even components that inhibit biological processes. The implementation of the ozone system in between the two existing biological treatment stages assures ideal operation of the biological processes and Ozone oxidation. Additionally any toxic components (i.e. nitrophenols, etc) are eliminated during the Ozonation process, thus improving also the stability of the biological post treatment process.
About Xylem
iii. Yangzi Petro-chemical wastewater treatment in Nanjing used advanced treatment process Ozone and biological aerated filter to treat effluent of flow 2000 m3/hr. The influent COD > 85 mg/l and effluent COD : <65 mg/l. The total ozone production capacity was of 30 kg/ hr. Two unit of SMO 900 ozone generator was installed and running successfully since startup in 2010. 46 • October 2019
Xylem (XYL) is a leading global water technology company committed to developing innovative technology solutions to the world’s water challenges. The Company’s products and services move, treat, analyze, monitor and return water to the environment in public utility, industrial, residential and commercial building services settings. Xylem also provides a leading portfolio of smart metering, network technologies and advanced infrastructure analytics solutions for water, electric and gas utilities. Xylem Water Solutions India Private Limited was established in 2011 from the spin-off water related business of ITT Corporation India Pvt. Ltd. At present, Xylem India has its Technology Centre campuses in Vadodara and Bengaluru, state-of-the-art assembly and testing facility in Vadodara
and sales offices in Bengaluru, Noida, Thane, and Pune. Xylem brings advanced management system and superior work culture to India with Integrated Management System Certifications for ISO 14001:2004 and OHSAS 18001:2007. Xylem Water Solutions India facility located in Vadodara, is IGBC-LEED Gold rated and caters to India and neighbouring countries by offering solutions for Water and Wastewater transport, treatment and testing to Power, Irrigation, Commercial Building Services and Municipal sectors.
For more information:
Web: www.xylem.com/india E-mail: Indiasales@xyleminc.com Chemical Engineering World
CEW Gujarat Special
Meghmani Organics Limited
M
eghmani
Organics
Limited
(MOL) is a leading diversified chemical company poised for
growth across its business verticals viz Pigment, Agro Chemicals and Chlor-
Company Snapshot Presence in 75+ countries across three business segments
400+ Global Customers
1 Distribution Subsidiary each in US and Dubai
7 dedicated Manufacturing facilities in India
Exports clocked 53% of Revenues (FY19)
Segment Highlights
Segment Highlights
Alkali & Derivatives. The company is amongst one of the top three global pigment players along with a vertically
Pigments
integrated Agro Chemical business.
• •
Chlor-Alkali & Derivatives vertical is
• • • •
under Meghmani Finechem Ltd (MFL), a subsidiary (MOL holding 57 percent)
Agrochemicals
Started in 1986 Amongst top 3 global Phthalocyanine based pigment players 14% global market share FY19 Revenues: Rs 6,048 Mn EBITDA Margin: 13.5% 29% of Overall Company Revenues
• • • • • •
and is India’s leading cost-effective
Basic Chemicals
Started in 1995 One of the largest producers of pesticides in India Products across entire value chain FY18 Revenues: Rs 7,905 Mn EBITDA Margin: 22.7% 37% of Overall Company Revenues
• •
Started in 2009 One of the lowest cost producers of caustic soda in India FY18 Revenues: Rs 7,104 Mn EBITDA Margin: 43.9% 34% of Overall Company Revenues
• • •
Caustic-Chlorine manufacturer. Consolidated Financial Highlights: FY19 Revenues – Rs. 20,880 Mn (12.7% CAGR*)
EBITDA – Rs. 5,445 Mn (28.0% CAGR*)
PAT – Rs. 2,954 Mn (58.8% CAGR*)
EBITDA Margin – 26.1% PAT Margin – 14.1%
Debt/Equity – 0.62x
ROCE – 29.2% ROE – 26.3%
Based on FY19 Financials, * FY15-FY19 CAGR
Decoding Key Financial Metrics
Decoding Key Financial Metrics
Robust Return Ratios • • •
Consistent Revenue Growth • •
Revenues have grown at CAGR 12.7% over FY15-19, with higher contribution from Basic chemicals Improving capacity utilization and completion of on-going Rs 6.4 Bn capex in Basic Chemical and Rs 1.27 Bn capex in Agrochemical will further provide significant scope for growth over coming years
•
4
1
2
Consistent Improvement in EBITDA margins • •
48 • October 2019
EBITDA margin has improved from 15.7% to 26.1% over FY15-19 Operationalization (by Q3FY20) of the on-going Rs 6.4 Bn capex in high margin Basic Chemicals segment will further drive the overall EBITDA margin for the company
•
Improving profitability Leaner balance sheet Significant improvement in return ratios ROCE – 9.7% in FY15 to 29.2% in FY19 ROE – 7.4% in FY15 to 26.3% in FY19
3
Strong FCF Generation leading to Significant Debt Repayment •
D/E reduced from 1.00x in FY15 to 0.62x in FY19
Chemical Engineering World
ADV_TCM Pvt_Chemical Engineering magazine_101021.pdf
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EXCELLENCE IN OIL & GAS, PETROCHEMICALS, FERTILIZERS AND POWER
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CM
MY
CY
CMY
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ENGINEERING, PROCUREMENT & CONSTRUCTION We are an EPC contractor with extensive experience worldwide in management of large integrated complex projects. Tecnimont Private Limited Tecnimont House Chincholi Bunder 50, Link Road Malad (W), Mumbai 400064 - India info@tecnimont.it www.tecnimont.it
CEW Gujarat Special
The Roadmap for Achieving Rs. 10bn from Each Business Segment
Business & Industry Dynamics Pigment Business • •
• •
Agro Chemical Business
Basic Chemical Business
Total Capacity: 32,940 MTPA • Total Capacity: 28,260 MTPA • Total Capacity* Largest manufacturers of Phthalo- • Leading manufacturer of pesticides – Caustic-Chlorine: 271600 MTPA, cyanine-based pigments with 14% products across entire value chain Caustic Potash: 21,000 MTPA global market share & amongst top • Presence across 17 states, with ~2,800 stockists, agents, distributors and CMS: 50,000 MTPA 3 (capacity wise) global pigments players dealers’ network • Hydrozen Peroxide:60000 MTPA The Roadmap for Achieving Rs. 10bn from Each Business • Segment Strong global presence in 70 • Key Brands: Megastar, Megacyper, One of the lowest cost Caustic-Chlorine producer countries Megaban, Synergy, Courage, etc. in India Strong client relationships (90% busi• Strategically located with proximity to the port ness from repeat clients) (importing coal) and customers (Caustic Soda & Chlorine supplied via pipeline), leading to lower • Meghmani is one of the largest producers logistics costs
Industry Overview:
Industry Overview:
•
of phthalocyanine pigments
Industry• Overview: Diversify into new pigment products •
Continue to focus on increasing domestic
• The Indian Caustic a well-established presence andindustry captureismarket share mature industry with a capacity of 3.8 Mn MTPA (Caustic Soda) and an annual turnover of Rs. 70 Bn • The global Chlor-Alkali industry is expected to grow • at 5.3-5.9% CAGR (2017-2023), to reach USD 125 backward integrated facilities • Bn by •2023Meghmani’s driven by diverse demand from industrial puts it in an advantageous position, given • uses - glass, alumina, vinyl, water treatment, polyvicurrent risingsoaps, raw material prices from nyl Chloridethe (PVC) plastics, detergents, pulp China etc. and paper, textiles, • Phase 1 Capex: Doubling 2,4-D Capacity presence and capture market share by addition of 10,800 MTPA with capex of • Rs 127 crores (Operational by June The Roadmap for Achieving Rs. 10bn from Each Business Segment 2020). Meghmani’s margin segment • •Expand brandedhigh products portfolio • Meghmani’s backward integrated facilities • Meghmani is one of the largest producers The Rs 6.4 Bn on-going capex plan and puts it in an advantageous position, given • of phthalocyanine pigments new capex of Rs 2.75 Bn for the current rising raw material prices from • Diversify into new pigment products Epichlorohydrin (ECH) by H1FY22 China • Continue to focus on increasing domestic provides a solid revenue growth visibility • Phase 1 Capex: Doubling 2,4-D Capacity presence and capture market share over coming years by addition of 10,800 MTPA with capex of • Continue to leverage the market Rs 127 crores (Operational by June leadership position and capitalise on 2020). domestic market demand • Expand branded products portfolio
•
India is the leader in Phthalocyanine • blue and green pigments Global pigment market pegged at $29bn in 2017 and is expected to grow at 4.5% CAGR surpassing • $43bn by 2026 owing to rise in • demand for packaging inks, paints & coatings and plastics industry • •
• Meghmani is one of the largest producers of phthalocyanine pigments • Diversify into new pigment products • Continue to focus on increasing domestic presence and capture market share 52 • October 2019
India is the 4th largest global producer • of Pesticides with an estimated market size of USD 4.9 Bn in FY17 after United • States, Japan and China The global crop protection market is set toMeghmani grow steadily to reach 58.7producers Bn is one of theUSD largest byof2020 owing to growing population, phthalocyanine pigments declining land pigment & rising pest Diversifyarable into new products concerns Continue to focus on increasing domestic
• Meghmani’s backward integrated facilities puts it in an advantageous position, given the current rising raw material prices from China • Phase 1 Capex: Doubling 2,4-D Capacity by addition of 10,800 MTPA with capex of Rs 127 crores (Operational by June 2020). • Expand branded products portfolio
• Meghmani’s high margin segment • The Rs 6.4 Bn on-going capex plan and new capex of Rs 2.75 Bn for Epichlorohydrin (ECH) by H1FY22 provides a solid revenue growth visibility over coming years • Continue to leverage the market leadership position and capitalise on domestic market demand Chemical Engineering World
Meghmani’s b puts it in an ad the current ris China Phase 1 Cape by addition of Rs 127 crores 2020). Expand brand
Meghman The Rs 6. new cape Epichloroh provides a over comi Continue leadership domestic
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BPMARRK®: Real-time Crude Oil Assay for Monitoring & Optimization of Crude Distillation Units BPMARRK® is a patented technology for predicting detailed refining characteristics of oil within an hour. Refining characteristics of crude oil consist of key information such as distillate yields and their quality, residuepotential, crude oil/blends selection, and hydrogen consumption in Hydroprocessing etc. These characteristics are usually deduced from detailed analysis such as true boiling point distillation, ASTM distillation or detailed molecular and spectroscopic analysis. Although established and widely practiced worldwide, these methods often require significant time, large sample quantity and effort for analysis. BPMARRK® requires only four physical parameters as input to generate about 500 data information of any unknown crude oil or mix. BPMARRK® is differentiated among any static crude oil database by profiling of unknown crude oils or mix in short time. The methodology has been validated with a large number of crude oils sourced from different origins at laboratory for accuracy. ASTM has recommended this innovation for developing a new standards in ASTM D02.04 K section. BPMARRK® application for real-time monitoring and optimization of crude distillation units has been validated in five different Indian refineries for real-time monitoring & optimization of plant performance on daily basis. The accuracy of predicted vis-à-vis actual plant distillation yields of the products observed to be within ±1.5 wt%. This has been used by Process Engineers to assist in Refinery Operations (currently implemented in BPCL refineries) for advance planning and regular monitoring, controlling and taking operational decision related to crude oils.
C
rude oil is a complex hydrocarbon mixture which is obtained from geological formations beneath the earth. Therefore, quality of crude oils vary considerably from each other and knowing the potential of unknown crude oil/blends in advance can help in making wise business decisions for effective operation of a refinery [1, 2]. The classical evaluation method to identify the potential of crude oils is done through laboratory experiments and analyses, which are lengthy and time consuming processes. Typically, it requires 30-40 liters sample quantity for detailed evaluation and, usually, it takes three to four weeks to complete, and analysis costs over USD 30,000 [9-12]. However, the detailed information is typically unavailable during the selection of crude oils. Even during actual refining operations where multiple feeds and blends are processed, the process and operation decisions are sub-optimal [13]. BPMARRK® Crude Oil Assay In contrast, to get realistic assay for any unknown crude oil parcel or blend of two or three crude oils testing of only four physical parameters is required in laboratory which is then fed into BPMARRK®. This requires small quantity (25 ml) of sample and 45 minutes to analyze the parameters. BPMARRK® is a novel concept for predicting detailed refining characteristics of any unknown crude oil within one hour including device processing time (2-5 minutes) as depicted in Fig 1. This generates detailed cut-wise data consists of distillation yields including gas composition and characterization of 6-Naphtha
60 • October 2019
cuts (IBP-60, 60-70, 70-90, 90-110, 110-130-140), 4-Kero cuts (140-150, 150-180, 180-200, 200-240), 5-Gas Oil cuts (240-250, 250-290, 290-310, 310-350, 350-360), 6-VGO cuts (360-370, 370-450, 450-500, 500-525, 525-550, 550-565), LR (360+) and VR (565+) as depicted in Table 1. BPMARRK® predictions have been validated and accepted by third party for accuracy (Indian and global companies). Real-Time Monitoring & Optimization of Crude Distillation Units Real-time monitoring and unit-level optimization of crude distillation units using BPMARRK® has been established. During crude mix change and switch over, the transient value loss can be minimized as data for each tank is available in advance before processing through BPMARRK®. A simple methodology is depicted in Fig 2. The predictions of plant yields by BPMARRK® has been compared with Actual and conventional database for two months and found closely matching with Actual Plant as shown Fig 3. Along with Chemical Engineering World
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CEW Features
Figure 1: BPMARRK® Crude Assay
distillation yields, other critical properties of the distillate streams especially feed to secondary processing units can also be monitored with the detailed data output generated by BPMARRK®. The present approach enables to maximize non-bituminous crude oil processing during bitumen production Commercial Implementation In general, unit-level optimization of crude distillation units wait for laboratory data or crude oil database approximation of crude mix feeding to the columns used during crude switchover. Crude tanks typically changes every 1-3 days depending upon capacity. During each crude switchover, it requires about 6-8 hours for stablization of the plant for optimization based on laboratory data. BPMARRK® provides data in advance even much before feeding to the colulm therefore, the stablization of the plants achieved very fast. This is much helpful when crude mix is drastically changing from low API (high Sulphur) to high API (low sulphur) when distillaiton profiles are signficantly different. The comparison of distillation profile
of BPMARRK® and Actual (PLANT) data of one of the BPCL Refineries (crude distillation unit, CDU III) has been depicted in Fig 4. Recently, commerical trial runs conducted in different refineries other than BPCL, the comparison of distillation data of BPMARRK®, Actual Plant, DATABASE & SimDist for two different crude distillation units (AVU- I & II) have been depicted in Fig 5. Commercial trial runs concluded that BPMARRK® plant distillation predictions is superior among all currently used methods like database and SimDist. Implementation of BPMARRK® on daily basis is expected to result in savings up to USD 0.1-2.0/bbl depending upon the current operating practices along with quick stablization of the plant. Ranking of Crude Oils Oil price variations impact the selection process for refinery crude slates. When considering crude and product prices, product demand, refinery configurations and other constraints, the evaluation process can be exhaustive. Software tools are comprehensive and time-consuming to screen and rank crude oils on regular basis [20-23]. To simplify the process, a quick method has been developed and integrated for assessing & ranking of crude oils for making business decisions [4, 14, 15]. The differential in crude oils price (D1) and processing costs (D2) are the most influencing factors that determine crude oil selection. The differential in crude oil prices (also called discount) is influenced by Brent price and crude oil qualities (API, Sulphur). The differential in processing cost is mainly due to cost associated with hydroprocessing and residue evacuation at lower price. Using these basis, net differential (D1-D2) has been estimated. Further, this has been correlated with crude oil properties to estimate the coefficients to develop the model using aforementioned method.
Table 1. BPMARRK® Crude Assay
62 • October 2019
Chemical Engineering World
Hydrogen Sulphide (H₂S) & Ammonia (NH₄)
UNIQUE Method : UV Spectroscopy a�er gas stripping
Real Time Water Quality Monitoring
1: strippping pot 2: temperature probe 3: flow cell 4: air pump 5: xenon lamp 6: spectrograph
A UNIQUE method: The Hydrogen Sulphide (Ammonia) measurement method is based on the UV light absorp on of H₂S (NH₃) in the gas phase a�er reaching the liquid-gas equilibrium that follows the Henry law. S- (NH₄⁺) present in the water is converted in to gas phase by addi on of HCL (NaOH for ammonia measurement).
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CEW Features Table 2 depicted the illustration of estimation of hydrogen consumption in HCU for VGO derived from Arab Mix crude oil. Similar approach has been opted for estimation of hydrogen consumption in DHDS. The total hydrogen consumption has been considered for both HCU and DHDS configurations. Further, the coefficients have Table 2. Illustration of hydrogen consumption in HCU for VGO of Arab Mix Hydrogen Consumption
Basis (AM VGO): Capacity 5200 TPD in HCU
T/D
% of Feed
For saturation
Difference of hydrogen content in feed and product
115
2.21
23
0.44
0.5
0.009
139
2.67
Figure 2: Methodology for real-time monitoring & optimization of Crude distillation units
Fig 6 depicts the ranking of crude oils vis-à-vis Brent crude price variations for given crude oils e.g., Arab Mix (source: Saudi Arabia), Brega (source: Libya), BH crude (source: India), Saharan Blend (source: Algeria) and Kuwait (source: Kuwait). The crude price variations are due to variation in net differential discounts (due to crude oil qualities and refinery processing cost) for various Brent crude price scenarios. As shown in the Fig 6, the cross over in net margin (ranking of crude oils) is evident due to variation in Brent crude oil price. Thus, measurement of physical properties of oil sample can be used for the ranking of crude oils for net margins at refineries with varying Brent crude pricing. The ranking of crude oils can be then used for selection of appropriate blend of crude oil. With this approach, refiners, crude-oil traders, supply-chain optimizers and crude schedulers can make quick and accurate business decisions. Hydrogen Consumption in Hydroprocessing Typically hydroprocessing involves removal of sulphur (S), nitrogen (N) and saturation of aromatics. Characteristics of distillate streams like kerosene, diesel, and VGO obtained from particular crude oil have been considered to estimate the hydrogen consumption. The affecting variables are C/H ratio, aromatics, sulphur, nitrogen and metals etc of that particular distillate streams. Further, to estimate the hydrogen consumption, Carbon (C), Hydrogen (H) and Impurities (I) balance has been considered across the Diesel Hydro-Desulphurization (DHDS) and Hydrocracker Unit (HCU) configuration while upgrading the straight run distillate streams to superior quality distillates[10, 17-19].
For ‘S’ removal
For ‘N’ removal Total
C9H8S + 3H2 C9H12+ H2S (Methyl-Benzothiophene) (1-ethyl-2-methylbenzene ) 2N + 3H2
2 NH3
been generated by regression between crude oil properties and total hydrogen consumption (including DHDS and HCU) for development of model using aforementioned method. Further, this has been used to estimate the total hydrogen consumption of Arab Mix-AM (source: Saudia), Kuwait-KW (source: Kuwait) and Kimanis blend (source: Malaysia) crude oils and reported Fig 7. The estimated total hydrogen consumption for AM crude is in agreement with plant data. Summary BPMARRK® is a rapid tool for generating Crude Oil Assay within an hour to facilitate decisions on real-time basis which has larger impact on overall economics of refining business. This enables fast business and operational decisions related to crude oils and enables Oil Suppliers, International Trades and Supply Chain Optimization
Figure 3: Comparison of distillation yields of BPMARRK, Actual Plant & Database
64 • October 2019
Chemical Engineering World
Features CEW
Figure 4: Comparison of distillation data of BPMARRK® and Actual Plant for one of the BPCL Refineries (CDU III)
Figure 5: . Comparison of distillation data of BPMARRK®, Actual Plant, DATABASE & SimDist for one of the Indian Refineries (AVU-I & II)
for advanced planning, selection of crude oil and Process Engineers for real-time monitoring and unit-level optimization of refinery operations. Indeed BPMARRK® is significantly contributing to reduce human efforts for detailed crude oil characterization at laboratory by saving time. The accuracy of BPMARRK® output is acceptable to the Industry.
Figure 6 : Ranking of crude oils
Chemical Engineering World
Awards/Accolades BPMARRK® received several recognition at National/International forums viz. (i) Special Commendation Award for “Innovator of the Year – Team”, by Petroleum Federation of India (now FIPI) in the year 2014, (ii) Innovation Award 2015/16 - Best Innovation in R&D instituted by Ministry of Petroleum & Natural Gas (MOP&G) and (iii) Jury’s Special Mention Award October 2019 • 65
CEW Features 15. Scherzer, J, and A. J. Gruia, “Hydrocracking Science and Technology”, Marcel Dekker New York, 1996. 16. Kumar, R., P. Parihar and R. K. Voolapalli; “New crude oil basket for hydrogen savings”, Petroleum Technology Quarterly, spring 2012. 17. US Bureau of Standards, Miscellaneous Publication No. 97 (9.11.1929).
Figure 7: Prediction of hydrogen consumption in hydroprocessing
in ‘Digital Modeling’ categor y in Frost & Sullivan’s Project Evaluation and Recognition Program 2018. Acknowledgement The authors express their sincere thanks to BPCL management for constant suppor t in validation of the model at refineries and interest in commercialization. And many thanks to Refinery colleagues (Syed Imran Ahmed R & Mr. Rajan VR) for implementation of the work.
Sanjay Bhargava Executive Director (R&D) Corporate R&D Centre, Bharat Petroleum Corporation Limited
Ravi Kumar Voolapalli General Manager Corporate R&D Centre, Bharat Petroleum Corp Ltd
References
1. US patent application US 7904251 (2011) 2. US patent application US 7803627 (2010) 3. Hand Book on Crude Oil Evaluations, Vols. 1 and 2, Corporate R&D Centre, Bharat Petroleum Corp. Ltd., 2007.
Rajeev Kumar Chief Manager (R&D) Corporate R&D Centre, Bharat Petroleum Corp Ltd
4. Lambert, D., “Determination of crude properties”, Petroleum Technology Quarterly, spring 2007. 5. Hartmann J. C. M., “Crude valuation for crude selection”, Petroleum Technology Quarterly, winter 2002. 6. Swafford, P. and M. McCarthy, “Improving crude oil selection”, Petroleum Technology Quarterly, autumn 2008. 7. Parihar P., Kumar R., Ravi Kumar V., and Agrawal S., “Optimization of hydrogen management for distillate production”, Hydrocarbon Processing, March 2012. 8. Bacon, R. and S. Tordo, “Crude oil price differentials and differences in oil Qualities: a statistical analysis”, Energy sector management assistance programme technical paper 081, 2005. 9. Fattouh, B., “The dynamics of crude oil price differentials”, Centre for Financial and Management Studies”, SOAS and Oxford Institute for Energy Studies, January 2008. 10. Blume, A. M. and T. Y. Yeung, “Analyzing economic viability of opportunity crudes”, Petroleum Technology Quarterly, autumn 2008. 11. Kumar, R., Tushar S. T., Chithra V., Vivek R., Peddy Rao V.C., and Choudary N.V., “Processing opportunity crude oils—A catalytic process for high-acid crudes”, Hydrocarbon World, Vol. 4, No. 2, pp. 64–68, 2009. 12. Kumar R., Parihar P., and Ravi Kumar V., “Improve feedstock selection for your refinery”, Hydrocarbon Processing, June 2012. 13. US patent application US Pat. number: 9846147
Mohammad Muzaffar Ahsan Senior Manager (R&D) Corporate R&D Centre, Bharat Petroleum Corp Ltd
Prashant Parihar Senior Manager (R&D) Product & Application Development Centre, Bharat Petroleum Corp Ltd
Mathew John Senior Manager (R&D) Corporate R&D Centre, Bharat Petroleum Corp Ltd
Srinivasareddy Palle Senior Research Engineer (R&D) Corporate R&D Centre, Bharat Petroleum Corp Ltd
14. European patent application EP 2699900 (2014)
66 • October 2019
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Features CEW
How to Determine the Fire Case PSV Relieving Temperature This is one of the most confusing and contradicting concept of how to determine the accurate relieving temperature and how to develop HYSYS simulation model to predict it accurate. There are many ways for process engineers to use this concept in the hydrocarbon design industry. But very few methods could predict the accurate relieving temperature. To develop the HYSYS simulation model for determining the most accurate relieving temperature, we need to build HYSYS model in such a way that it represents the exact same situation which happens during fire, specially across an equipment on which PSV is mounted. During fire case, equipment is isolated by automatically closing inlet and outlet valves across a vessel. Now there is a trapped inventory in the vessel closed loop, which consists of some piping volume and the vessel volume. There may be two scenarios for calculating the inventory volume trapped in the equipment loop – normal liquid level operating case and maximum liquid level operating case. The inlet flow rate is not dependent on building a HYSYS simulation model whether plant is running on design flow rate or turndown flow; instead, it is impacted by the liquid level in the vessel, operating pressure, and operating temperature of the vessel at the moment fire happens. As because the liquid level contributes to the wetted area calculation and P&T play a critical role to know the time length when the relief valve will open, how much heat energy will be generated, and how long it will consume before the vessel get pressurized to the PSV set pressure. In this article, the author has explained the fundamental concept to calculate the PSV relieving temperature for fire case, and also enumerated the step by step guide to build the HYSYS steady state model.
R
eaders might be interested to know why this topic has been selected, and what is so special & important in calculation of PSV relieving temperature for fire case? In PSV sizing calculation for fire case, as a Process Engineer, we use process simulator like AspenHYSYS to do the modeling and obtain the results for further design work. Many methods are being used by the process design engineers with different approach for simulation modeling to calculate the PSV relieving temperature for fire case. Author here has explained why the proposed method of simulation modeling is more realistic and accurate in comparison to other methods being used by the process engineers in design consultancies. First of all, readers should know that both Pressure Safety Valve (PSV) or Pressure Relief Valve (PRV) are almost the same; the only difference is in opening mechanism, and the time of opening when the PSV or PRV set pressure hit due to some emergency or unexpected disturbance in the plant operation. PSV and PRV both act as the ultimate protection mechanical device for any equipment. PSV is designed to protect the equipment for burn-out conditions where all the primary protection by means of instrumentation or electrically controlled
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devices is burnt out during the fire case. Therefore, PSV is the very important device to protect the vessel in case of fire, where all other devices already stopped working due to the burn out of electrical and instruments facilities. As PSV plays such an important role in safeguarding the equipment on which it is mounted, therefore it should be designed with utmost care. The major parameters for designing a PSV is its orifice area calculation based on the maximum allowable peak mass flow from the PSV discharge to flare network during fire; and the second parameter is calculation of PSV relieving temperature for verifying the PSV outlet line material temperature design limits. This article also explains about the PSV relieving temperature calculation for fire case by using process simulator AspenHYSYS. It is assumed that process engineers working in the design industry might be doing HYSYS simulation and might be capable enough for calculating the PSV orifice area for the maximum allowable peak mass flow or PSV peak load.
especially across the equipment on which PSV is mounted. During fire case, equipment is isolated by automatically closing inlet and outlet valves across a vessel. Now there is a trapped inventory in the vessel closed loop, which consists of some piping volume and the vessel volume. There may be two scenarios for calculating the inventory volume trapped in the equipment loop – normal liquid level operating case and the maximum liquid level operating case. The inlet flow rate does not get impacted by building a HYSYS simulation model no matter whether plant is running on design flow rate or on turndown flow. What matters is – liquid level in the vessel, operating pressure, and the operating temperature of the vessel at the very moment it catches fire. This is as because the liquid level contributes to the wetted area calculation, and P&T plays a very critical role to know the time length required for relief valve to open, the amount of heat energy to be generated, and also the time to be consumed before vessel get pressurize to the PSV set pressure.
Simulation & Modeling Executive Summary To develop the HYSYS simulation model for determining the most accurate relieving temperature, we need to build HYSYS model in such a way that it represents the exact same situation which happens during fire,
Basis and Assumptions 1. There is a vessel on which PSV is mounted and the normal operating liquid level in the vessel is 40 percent. In real scenario, it can be any value depending on the process and its operation. October 2019 • 67
CEW Features 2. Volume of the vessel and that of the associated piping have already been calculated. The combined volume of vessel and associated piping is known as total volume of the vessel. 3. Although it is assumed that vessel’s normal operating liquid level is 20m 3 and the total vessel volume as per vessel dimension is 100 m 3, in real case it will be different. Therefore it is to be kept accordingly. 4. It is assumed that readers are aware of the basics of AspenHYSYS viz. steady state simulation and modeling, defining the material stream, simulating it to get the fluid properties, and the model building components. Simulation Methodology This simulation is to be performed in steady state by using multiple adjusters. 1. First, it is to define the vessel inlet fluid streams in HYSYS at normal operating pressure and temperature, and to simulate it. 2. In HYSYS model, a two-phased separating vessel is to put to connect the inlet material stream to this vessel. 3. The liquid volume denotes the total liquid volume in the vessel, in addition to the one trapped in the associated piping. If the vessel inlet stream is of two-phased and the fluid trapped in the piping has both liquid phase as well as vapor phase, then the associated piping volume is to add accordingly based on the liquid volume fraction. Let’s say, in the vessel inlet, the stream is two-phased; it has 20 percent vapor fraction and 80 percent liquid fraction; and the associated calculated piping volume is 10 m 3. Therefore the total liquid volume in the vessel is 10+20=30m 3. 4. Next step is to define the vessel volume in m3; and it is also to manually adjust the liquid level percentage in the vessel to define the liquid volume 30 m3. 5. In the fifth step, the two outlet-streams are to be defined from this two-phased separating vessel. Top stream 1 is of the vapor outlet and the bottom stream 2 is of the liquid outlet. 6. Now, at this step, stream splitter is to be used to split stream one to 2, 3, & 4; similarly stream 2 to be split to 5 & 6. 7. Further step is to adjust the mass flow rate of stream 4 to actual volume flow with the user defined level of 70m3. To run the adjuster, one needs to define some initial value of mass flow in the stream 3. 8. Now the mass flow rate of stream 5 is to adjust to its actual volume flow with an user defined level of 30m3. To run the adjuster, one needs to define some initial mass flow value in the stream 6. 9. A stream adder is to be used to add adjusted streams 4 and 5, and to define the adder outlet stream as 7. 10.Stream 7 here represents the actual liquid and gas volume condition in fire case when the vessel is isolated by closing the vessel inlet and outlet boundary valves. 11.During fire, this vessel gets heated up, however PSV will not pop up until and unless the pressure inside the vessel reaches to the PSV relieving pressure. It means, during the heating procedure because of fire, the mass inside the vessel will be constant till the vessel reach to the PSV relieving pressure; because the fluid mass will come out only when the PSV will open up at the relieving pressure, and thus will release the mass. 68 • October 2019
12.Now stream 8 is to be defined which has the same composition as stream number 7, pressure is to be defined as PSV relieving pressure, and the temperature as operating temperature. 13.Next is to adjust the temperature of stream 8 in such a way that mass density (mass/volume) of it remains the same as that of stream number 7. 14.Adjusted temperature of stream number 8 will be PSV relieving temperature for fire case. 3
1
4 A
A
Inlet Stream
7 8 A
M 5
2
6
Legend
=
^
Adjuster Splitter
Adder Material Streams j=
Mass Balance
Confirmation towards the Efficiency of the Model: This type of process simulation modeling for PSV relieving temperature calculation for the fire case is being used in many top design companies and well accepted by the operating companies like Shell,Petronace and Exxon mobile. Therefore, this is the first qualification of using this method; and the second qualification is the technical background which proves the practicality of this model to the fire case scenarios as compared to any other methods. In this model, by mass flow rates of gas and liquid streams coming out from the two phase separator is to be adjusted to the actual volume flow rate based on the actual vessel volume occupied by gas and liquid. It means if the adjusted gas and liquid streams are added to make the stream 7 in the model, then the actual volume flow of stream 7 will represent the actual condition of the vessel at steady state on which PSV is mounted. Stream 8 represents the actual situation when the vessel is isolated by closing the vessel boundary inlet and outlet valves. That’s why stream 8 is heated by adjusting the temperature keeping the mass density of the stream 8 same as the mass density of stream 7. As the volume of vessel is constant and the mass is also constant inside the vessel, till the inside pressure of the vessel increases to the PSV relieving pressure due to heating by fire, hence the mass density remains constant. Author Details Lokesh Kumar Singh BEng CEng MIChemE, Lead Process Engineer China Petroleum Abu Dhabi Chemical Engineering World
Features CEW
Challenges in Engineering and Fabrication of Combination Units with Double Side Metal Lined Intermediate Dished Heads. Combination units are quite common in refinery, chemical, and other industrial applications. A combination unit is a pressure vessel that consists of more than one pressure chamber, operating at the same or different pressures and temperatures. The parts separating each pressure chamber are the common elements, generally an intermediate dished head. The Intermediate dished heads may be designed either for differential pressure and mean metal temperature, or to operate independently. If the operating fluids are corrosive in nature then the vessel is required to have a high alloy metal lining, hence the intermediate dished head require a high strength base material with metal lining on both sides, either by cladding or by weld overlay. Metal lining on both sides of the dished head possess many challenges in fabrication. In this paper, the author has specifically talked about one of the possible configuration and fabrication sequence for double side metal lined intermediate head to metal lined shell joint. It also presents the common element design for combination units and weld joint design for shear based on pressure inside the chambers.
C
ombination units are used where the pressure chambers are required to be isolated from one another due to process reasons and one chamber is to be maintained at an elevation above other chamber. Refer figure (a). The Combination units are the pressure vessels that are having two or more pressure chambers separated by a common element. Each pressure chamber operates at same or different pressure and temperatures. These pressure chambers can be independent or dependent to each other. In the independent pressure chambers, each chamber can operate without pressure in adjacent chamber. However, in case of dependent units, both the chambers need to pressurize simultaneously so that the common element is subjected to the differential pressure. The design and fabrication of common element have many complexities. If the vessel is in sour service or the operating fluid is corrosive in nature then the vessel inside as well as both sides of intermediate dished head require high alloy metal lining. In such case the design of weld joint for intermediate dished head to shell require additional sequence of operation; these will be discussed in detail in the subsequent section of this paper. The availability of both side cladded plates is also very limited and only few steel mills offer this type of plates. The dished head can also be made with single side clad plate with weld overlay on
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the other side or both side overlay, if proper care is taken to control the distortion.
the design temperatures of its adjacent chambers or a combination of both.
The thickness of common element of a combination unit, which operates as an independent chamber, is generally very high as this need to be designed with pressure and temperature on convex side of dished head equal to the pressure inside one of the chamber. Due to high thickness it becomes difficult to form the dished head.
Joint configuration of the type shown in Figure (c) is generally used for all types of vessels. However, the outside diameter of the head straight flange shall be a close fit inside the overlapping ends of the adjacent length of cylinder.
On the other hand, as one chamber is directly placed above the other, omits the requirement of additional structure for top chamber, and in turn reduces the cost of material. As an alternative to combination unit, two chambers with independent dish-end and an intermediate skirt support can also be used. Refer figure (b). Design Pressure chambers of combination units can be designed to operate independently and in this case each element, including the common elements, shall be designed for at least the most severe condition of coincident pressure and temperature expected in normal operation. It is also permitted to design each common element for a differential pressure less than the maximum of the design pressures of its adjacent chambers or a mean metal temperature less than the maximum of
The shell circumferential joint shall be considered as backing strip joint with efficiency as per the extent of radiography considered. For the strength calculation of this joint the butt weld and fillet weld shall be able to take shear based on 1.5 times the maximum differential pressure that can exist. The allowable stress value for the butt weld shall be 70 percent of the stress value for the vessel material and that of the fillet it shall be taken as 55 percent. The area of the butt weld in shear is the width at the root multiplied by the length of weld. The area of the fillet weld is the minimum leg dimension multiplied by the length of weld. The fillet weld may be omitted based on the process conditions. Fabrication In the combination units the most difficult joint is the combination of shell and intermediate dished head. The shape and size of dished head shall be such that it shall form a close fit with the adjacent shells. There will be a small air gap on top October 2019 â&#x20AC;˘ 69
CEW Features 8) Carbon steel or Low alloy steel buttering of stripped area on outside of dished head, leaving a small gap from cladding. Refer figure (d) step 8. 9) Gap on step 8 shall be filled with nickel alloy or higher alloy than cladding chemistry. Refer figure (d) step 9. 10) Assemble top shell, bottom shell, and dished head ensuring proper fitment. Refer figure (d) step 10. 11) Carryout the circumferential weld with carbon steel or low alloy steel consumables based on chemistry of base material. Carryout the fillet welding from inside. Refer figure (d) step 11. 12) Clad restoration from inside with high alloy lining. Refer figure (d) step 12. In step 2, 5, 8 and 11 the selection of carbon steel or low alloy steel will depend on the base material used for construction of vessel. Also, proper clad stripping on each step shall be ensured with CuSO4 or HNO3 tests. On completion of fabrication and testing of equipment, the vent hole shall be filled with hard grease to avoid any ingress of water or moisture during transportation or operation. Where, th : Head thickness ts1, ts2 : Adjacent shell thickness I.D : Inside diameter
Figure (c) side of the butt joint, refer figure (c), proper arrangement shall be made for venting of this air due to heating during welding or operation. Below sequence of fabrication provides one of the solutions to the issues discussed above. 1) Clad stripping of bottom side of top shell adjacent to the joint to the suitable length. Refer figure (d) step 1. 2) Carbon steel or low alloy steel buttering of stripped area, leaving a small gap from cladded portion, Refer figure (d) step 2. 70 â&#x20AC;˘ October 2019
3) Drill vent holes up to shell buttering. Refer figure (d) step 3. 4) Clad stripping of top side of bottom shell adjacent to the joint to the suitable length. Refer figure (d) step 4. 5) Carbon steel or low alloy steel buttering of stripped area, leaving a small gap from cladded portion, refer figure (d) step 5. 6) Gap on bottom shell shall be filled with nickel alloy or higher alloy than cladding chemistry. Refer figure (d) step 6. 7) Clad stripping on both the sides of intermediate dished head to suitable length. Refer figure (d) step 7.
The lining on dished head straight flange outside surface is required to strip back, without which it will not be possible to make the shell butt joint with carbon steel or low alloy steel consumables as this will result in brittle welds. Other possible weld configurations can be either the use of nickel based consumables for the shell butt joint keeping the lining on outside of dished head, or the solid stainless steel head instead of double side metal lined intermediate dished head. With stainless steel dished head the butt joint between top and bottom shell is to be made with stainless steel consumables. In both these arrangements at higher temperatures there are thermal expansion differences between carbon steel or low alloy on the one hand, and nickel based or stainless steel alloy on the other, which generates additional stresses on this joint and is not a very good solution. Testing Once the fabrication is complete and all the nondestructive tests are done, the vessel shall be subjected to hydro-test as per rules of applicable construction code. If the pressure chambers of combination units are designed to operate independently Chemical Engineering World
Features CEW in diameter and shape to ensure proper fitment and in many cases it may require to machine all the mating surfaces. A crevice is formed on the bottom side of this joint between outside of dished head and bottom shell, refer figure (c), where any vapor formed at the bottom chamber can accumulate and chances of crevice corrosion are there, which is unavoidable with this configuration. The straight flange of intermediate dished head works as permanent backing strip for the adjacent shells, hence difficult to ensure proper nondestructive examination and repair of flaws in welding during fabrication, if any. Conclusion The use of common element, in case of lined vessels, shall be evaluated from process perspective, economy and ease of fabrication against the option of using an intermediate skirt. If a common element is used, the thickness of intermediate dished head increases; on the other hand , if an intermediate skirt is used, then one additional head and skirt will be required and this will reduce the complexities of fabrication to a large extent. Use of stainless steel common elements is also not a feasible solution due to the differential thermal expansion of material at higher operating temperatures. If a lined vessel with common element is the selected option then a well-planned fabrication sequence can be useful while manufacturing. This paper presents one of the possible sequences, which can be adopted by manufacturer.
References.
then each chamber shall be hydrostatically tested as separate vessels, that is, each chamber shall be tested without pressure in the adjacent chamber. When pressure chambers of combination units have their common elements designed for the maximum differential pressure the common elements shall be subjected to a hydrostatic test pressure based on the differential pressure to be marked on the unit. Care shall be taken that the common element is subjected to allowable differential pressure only. Chemical Engineering World
Challenges of both sides metal lined common element The thickness of common element of independent chamber combination units is generally very high; hence, the forming of dished head becomes very difficult. If the forming is done from a double side clad plate, then it adds further difficulties in forming as the lining may get damaged during forming. Outside of straight flange of intermediate dished head and the inside of adjacent shells shall be formed in very close tolerance both
ASME Boiler and Pressure Vessel Code, Section VIII Div 1 and Div 2.
Author Details
Somnath Bhattacharya Mechanical Engineering, Fluor Daniel India Pvt Ltd October 2019 â&#x20AC;˘ 71
CEW Paints & Coatings
New Multifunctional Additive for Water Based Coating – UCAR The paint industry is constantly searching for alternatives in water-borne formulations to reduce odor and to improve its application properties. An essential component to ensure good paint stability, as well as efficient performance of dispersants and rheology modifiers, is the pH adjuster (also called alkalizing or neutralizing). Even being used in small quantities, it can affect in some properties of a water based paint application, such as water resistance, and also being able to bring some other benefits such as low odor. Based on these needs, Dow has developed a new neutralizer for architectural coatings: UCAR MF-90, a multifunctional, low odor additive with neutralizing efficiency compared to other products of the same function. In addition, it provides an improvement in the blister resistance and alkaline efflorescence. The article talks about the study on UCAR MF-90 for evaluating the performance of a new pH neutralizer UCAR MF 90 in typical water-borne architectural coatings formulations. It also provides effective comparison of new neutralizer composition, traditional organic amines, and ammonia.
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he most commonly used inorganic neutralizers include ammonia and strong inorganic bases, such as potassium hydroxide (KOH) or sodium hydroxide (NaOH). While ammonia is an efficient neutralizer, it also has a strong odor, making it unsuitable for use in low-odor paint. Strong inorganic bases like KOH and NaOH are odorless, but result in coatings with poor scrub resistance and water resistance. The use of siliconates, which are less commonly used inorganic neutralizers, often result in loss of gloss and cause stability issues of the paint. pH control in water-borne formulation is an important matter due to the necessity of alkali character during rheology adjustment. Most rheology modifiers, both non-associative and associative, have pH dependency, being soluble only in alkali environment. Figures 1 and 2 show thickeners’ behavior in low and intermediary pH:
Organic amines are widely accepted by the coatings industry for their multifunctional benefits beyond pH neutralization, such as pigment co-dispersancy, and In-can corrosion protection. As a result, there is continuing interest from industry for an organic additive that could provide the multifunctional benefits of an organic amine without negatively affecting the application or dry-film properties of the coating. Based on these needs, Dow has developed a new neutralizer for architectural coatings: UCAR™ MF-90, a multifunctional, low odor additive and with neutralizing efficiency compared to other products of the same function. In addition, it provides an improvement in the blister resistance and alkaline efflorescence. The objective of this study was to evaluate the performance of a new pH neutralizer UCAR MF 90 in typical water-borne architectural coatings formulations. The study provides effective comparison of new neutralizer composition, traditional organic amines, and ammonia.
RAW MATERIAL AND GUIDELINE RECIPE Figure 1 – Alkali soluble emulsion – Volume exclusion thickening (eg. PRIMAL ASE)
Figure 2 - Hydrophobically modified Alkali Soluble Emulsions (eg ACRYSOL RM-5)
72 • October 2019
BINDER Table 1: Details of various binders evaluated Description
Pure Acrylic
Styrene-Acrylic
Vinyl Acrylic
MFFT, °C
16-20
14-18
15-19
Solids content %
48-50
48-52
54-56
Viscosity, @25 °C
>1000
<300
< 1000
pH
8.0-9.0
9.0-10.0
4.0-6.0
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Paints & Coatings CEW NEUTRALIZER Table 2: Details of various neutralizer evaluated Description
Ammonia
Amine 1
Amine 2
UCAR™ MF 90
Boiling Point
100
100 - 165 °C
190 - 210 °C
100 - 243°C
pKa Value
9.40
9.75
9.70
NA
∞
∞
Miscible
∞
Water Solubility GUIDELINE FORMULATION
Table 3: Guideline Formulation recipe for product evaluation Formulation 1 – Standard
Formulation 2 – Premium
Formulation 3 – Standard
(Vinyl-Acrylic)
(Acrylic)
(Styrene Acrylic)
Grind
% Weight
Grind
% Weight
Grind
Formulation 4 – Premium (Styrene Acrylic)
% Weight
% Weight
Grind
Water
24.72
Water
13.86
Water
49.40
Water
28.00
Dispersant
1.41
Dispersant
0.81
Dispersant
0.18
Dispersant
1.20
Surfactant
0.20
Surfactant
0.20
Surfactant
0.15
Surfactant
0.30
Ethylene Glycol
0.74
Propylene Glycol
0.69
Titanium Oxide
6.89
Titanium Oxide
10.00
Titanium Oxide
11.26
Titanium Oxide
20.31
Other pigments
23.35
Other pigments
32.00
Other pigments
25.59
Other pigments
20.62
Defoamer
0.18
Defoamer
0.10
Thickener
0.45
Thickener
0.18
Salts
0.15
Neutralizer
0.10
Defoamer
0.15
Defoamer
0.03
LetDown
LetDown
LetDown
LetDown
Resin
12.92
Resin
20.00
Resin
16.80
Resin
31.56
Preservatives
0.39
Preservatives
0.70
Opaque Polymer
4.97
Preservatives
0.38
Water
2.75
Water
4.95
Water
12.72
Water
8.33
UCAR Filmer IBT
0.50
UCAR Filmer IBT
0.80
UCAR Filmer IBT
0.32
UCAR Filmer IBT
1.90
Opaque Polymer
1.68
Hydrocarbon solvent
0.60
Defoamer
0.04
Defoamer
0.10
Defoamer
0.18
Defoamer
0.20
Neutralizer
0.10
Neutralizer
0.03
Neutralizer
0.13
Neutralizer
0.15
Rheology modifier
0.52
Rheology modifier
1.02
Rheology modifier
1.15
Rheology modifier
0.90
EXPERIMENTAL PROCEDURES Optical properties The measurements were performed using a color guide (L*a*b system) before and after the exposition, with which we can numerically measure the yellowing caused by exposure. L*a*b*: L* represents lightness – scale measures from black (0) to white (100). a* = represents Red/Green – scale measures from green (-) to red (+). b* = represents Yellow/Blue – scale measures from blue (-) to yellow (+).
Δ E* is a parameter that allows to understand the color difference between a control sample and experimental sample. In this case, the control sample was the initial paint applied in the leneta and the experimental was: 1 The one after heat age (one week at 60oC)
2
The one after 500 hours in QUV exposure
The equation of ΔE* is expressed below:
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CEW Paints & Coatings Whiteness was measured according to ASTM E 313 – using a colorimeter with readings B and G. It is a measure of how close a surface matches the properties of a perfect reflecting diffuser, for example an ideal reflecting surface that neither absorbs nor transmits light, but reflects it at equal intensities in all directions. Gloss measurement was done submitting the leneta into a the gloss meter equipment according to ASTM D523-14 Standard Test Method for Specular Gloss, under angles of light incidence of 60°, 20°, and 85°. Opacity was measured with an xrite -spectrophotometer CI 4200, in a paint applied in a leneta 12H with 3 mils of thickness. Scrub resistance The scrub resistance is the ability of a paint film to withstand mechanical wear caused by brushing with abrasive paste. It’s the number of scrub cycles required to remove the coating to a specified end point. In a typical scrub test, the coating is applied in a PVC panel at a specified film thickness, allowed to dry during 7 days under temperature and humidity controlled environment (25°C and 50 percent RH), then subjected to scrubbing with a straightline scrub tester. A 10 mil shim is inserted under the panel to accelerate failure and thereby reduce testing time. The results must be expressed in the number of cycles required to obtain an uniform wear in the form of a continuous line parallel to the direction of brushing (on the width of the shim) on the shim in the paint film.
A continuous line parallel to the direction of brushing identify the end of the test.
The test consists on painting a substrate, dried in temperature and humidity controlled environment (25°C and 50 percent RH) for 24 hours and immersing it on a box containing DI water. The substrate is normally a glass panel when a decorative coating is tested. The blister box forces water vapor through the uncoated side, simulating for example the process of humidity permeating the walls of building. The blister resistance is a good parameter to understand adhesion of the coating. Efflorescence resistance This test consists in evaluating the efflorescence resistance of a paint when applied in an alkaline substrate. Efflorescence is defined as an encrustation on the surface of a coating, usually caused by salts or free alkalis leaching from mortar or adjacent concrete as moisture moves through it. Efflorescence defect is better observed in tinted coatings and can affect gloss and whitening. The procedure consists in applying the coat in ceramic panel with the same amount of paint by weight and let it dry for 7 days at 50 percent RU and 25oC. Then, the panels are placed in a condensation box with NaOH 2 percent solution until the first panels show superficial damage. The panels are evaluated after 1 week drying in ambient temperature. The results are compared visually. Stain Removal Resistance Stain Removal is defined as the paint property which describes its ability to resist soiling from common household stains. This procedure consists in applying the coat in a leneta chart P-121-10N with a 7 mils applicator and let it dry for 7 days at CTR (25oC and 50 percent RU). The stains are then applied in the leneta and they are let soak for ½ hour. The stains used are divided in hydrophobic and hydrophilic: Hydrophilic: tea, mustard, grape juice, coffee, ketchup, spaghetti sauce, red wine, etc.
Figure 3 – Pictorial example for scrub testing panel
It is important to mention that in usual formulations the procedure was done according to ASTM D2486. Blister resistance Blister resistance is the ability of a coating to resist the formation of liquid or gas-filled blisters between the dried film and the substrate. 74 • October 2019
Hydrophobic: 2B pencil, pen, crayon, red sharpie marker, lipstick, etc. Then, the leneta are put on a scrub resistance equipment and they are scrubbed for 200 cycles with a prepared non-abrasive solution (soap solution). The stain removal is then evaluated visually. Stability test Stability test was done based in viscosity (high and med-shear) and pH. They were measured during the formulation (in pH and Chemical Engineering World
Paints & Coatings CEW viscosity adjustment), after the formulation, 24 hours later and 10 days after heat exposure (50oC in an oven).
Required Stormer viscosity: 95 KU – 100 KU (Krebs units) Table 4 – Amount of buffer added to reach required pH and viscosity
Stormer Viscosity Measurement (ASTM D562-10) Stormer viscosity is a measure of mid-shear viscosity conditions, which are created during paint stirring and pouring. Stormer viscosity is reported in Krebs Units (KU). The KU viscosity was measured using a KU-2+ viscometer from BYK-Gardner. A paddle type spindle was driven at 200 rpm by a constant speed motor. The reaction torque of the spindle rotating at 200 rpm is converted into Krebs Units by the instrument. The KU viscosity of the sample was measured by lowering the spindle into the center of the ¼ pint container holding the sample, allowing it to equilibrate for 5 to 10 seconds, then recording the displayed value on the unit. The spindle was cleaned, dried, and put back in place for the next sample. The process was repeated for all samples. pH measurement of a paint The procedure consists in the following steps: 1. Immerse the electrode into the neutral pH buffer (typically in a 1 oz. vial) to be used for calibration, release the standby button, and depress the pH button. Measure the temperature of the buffer solution, and set the temperature control to this value. Turn slope knob to 100.
Table 5 - Optical properties for finished paint formulations
Amount of UCAR MF 90 required to reach desired pH (8.5 – 9.0) was similar to ammonia and other common amines used in this application. So, in terms of pH adjustment, UCAR MF 90 can replace 1:1 the other neutralizers. Figure 4: Scrub Cycle performance of various formulations
2. Adjust the calibration control, until the readout displays the pH value of the standard buffer solution (pH = 7). 3. Remove the electrode from the buffer solution. Rinse the electrode with water to prevent carryover of the buffer. 4. To attain the second calibration point, immerse the electrode into the second standard buffer solution of known pH value and temperature. Adjust the slope knob, until the readout displays the pH value of the second buffer standard. Raise the electrode and rinse. 5. The calibration of the pH meter is now complete. To determine the pH of unknown samples, lower the electrode into the unknown and release the standby button. The display now indicates the pH of the unknown. Allow the meter to equilibrate (~ 15 seconds) before recording pH. 6. After each measurement, raise and rinse the electrode thoroughly with water.
Blister resistance It is possible to see that UCAR MF 90 can provide a better water resistance according to blister resistance tests. In Formulation 1 the vinyl-acrylic binder was designed to provide good water resistance, so changing the buffer did not impact the results. In the case of formulation 3, the standard formulation did not resist to water with any buffer, which means all films have unbidden from the substrate. Figure 5: Blister resistance performance of products
Results and Observation Before analyzing properties of the paint after applied in a substrate, it is important to understand the power to increase alkalinity in the paint. It means the amount of buffer added to reach required pH. In the case of the paints evaluated in this study the required pH was between 8.5 and 9.0. The required viscosities to the formulations evaluated in this study were: Chemical Engineering World
October 2019 • 75
CEW Paints & Coatings Efflorescence resistance It is possible to see that UCAR MF 90 improved the efflorescence resistance in all four evaluated formulations. It is more notable in formulations 1 and 2, but it also happens in formulations 3 and 4 even with lower difference between painted panels. It is important to note that even when compared to ammonium the new Dow´s buffer showed better performance.
Figure 9: Stability Performance of product evaluated
Figure 6: Efflorescence resistance performance of product evaluated
CONCLUSION UCAR MF 90 can be potential alternate to various other available neutralizers at 1:1 keeping the same performance in the following properties: optical properties, scrub resistance, surfactant leaching, stain removal and stability. Improvements in blister and efflorescence resistance were discovered considering the four evaluated formulations in this study. Summary of performance of the new neutralizer versus benchmark products evaluated in this study: FigureTable 9: Stability Performance of product evaluated 6 – Summary of comparative in performance of XUS 40894.00 vs Benchmark products UCAR™ MF 90
Stain removal resistance Regarding stain removal resistance, it is possible to note similar performance between the samples analyzed. Figures 7 & 8: Stain Resistance performance of products evaluated
Optical properties
Scrub Resistance
Pure Acrylic Formulation
=
=
Styrene Acrylic formulation
=
=
Vinyl Acrylic Formulation
=
=
Blister Resistance
Efflorescence Resistance
++
++
+
+
+
++
Stain Removal Resistance =
Stability
=
=
=
=
=
Legends: ++ Considerably better performance than benchmark, + better performance than benchmark, = similar performance to benchmark, - lower performance to benchmark REFERENCES Coatings R&D notebook – The importance of pH in Waterborne: https://www.pcimag.com/articles/93973-coatings-r-d-notebook-8 Graziani, M.; Juriyama,Natalense, J.C.;. Tintas Ciência e Tecnologia; 4th edition, Fazenda J.M.R/ Blucher: São Paulo, 2009; American Society for Testing and Materials. ASTM G154-16 - Standard Practice for Operating Fluorescent Ultraviolet (UV) Lamp Apparatus for Exposure of Nonmetallic Materials American Society for Testing and Materials. ASTM E313 - Standard Practice for Calculating Yellowness and Whiteness Indices from Instrumentally Measured Color Coordinates American Society for Testing and Materials. ASTM D523-14 - Standard Test Method for Specular Gloss American Society for Testing and Materials. ASTM D2486 - Standard Test Methods for Scrub Resistance of Wall Paints American Society for Testing and Materials. ASTM D562-10 - Standard Test Method for Consistency of Paints Measuring Krebs Unit (KU) Viscosity Using a Stormer-Type Viscometer
Stability test It is possible to note that the largest variation in viscosity was with ammonia but all the others did not have differential > 10 KU´s in formulations evaluated. It means that for the rheology modifiers evaluated none of the tested neutralizer impacted significantly in viscosity. 76 • October 2019
Contributors:
Abhisar Jain – TS&D Specialist, Industrial Solutions, Dow Chemical International Pvt Ltd Siddhartha Ghosal – Sr. TS&D Manager, Industrial Solutions, Dow Chemical International Pvt Ltd Rodolfo Di Nápoli Nogueira – TS&D Specialist, Industrial Solutions, Dow Chemical International Pvt Ltd Heidi Verónica Salinas Sánchez – TS&D specialist, Industrial Solutions, Dow Chemical International Pvt Ltd
Chemical Engineering World
CEW
Marketing Initiatives
Oil-in-water Analyser Measurement Technique: UV Fluorescence Real Time Water Quality Monitoring
T
ethys
manufacture
oil-in-
water analyzer based on UV
Silent Features of Tethys Oil-in-water analyzer: • High sensitivity (detection limit < 10 ppb phenol)
Fluorescence
• Very low turbidity effect (proprietary method)
technique
in
manufacturing
the facility
measurement state-of-the-art at
• No solvent
Meylan,
• Simple hydraulic circuit, means high reliability
France. Turbidity and organic matter
• Fast measuring time (< 5 sec)
compensated by the reference detector
• Low maintenance (lamp lifetime > 10 years)
using a polynomial curve which is
• Automatic cleaning facility
proprietary method develop by Tethys.
• Automatic Zero on each cleaning cycle ensure drift free measurement
The patented flow cell allows very
• The color touch screen and intuitive User-friendly interface
high level of suspended solid without clogging. The UV source is a xenon
• A USB port allows to transfer the recorded measurement that may be imported to Excel for treatments or graphs.
flash lamp specified for 10 9 flashes that
• Multiplexing facility allows measurement upto 6 various sample stream
corresponds to more than 10 years of life time with one measurement every minute. Automatic Cleaning System – A Key for Successful Oil-in-water measurement: Cleaning of sample flow cell by air or ultrasonic is not effective as sample with oil is sticky in nature and strongly deposit on optical path, results in inaccurate measurement. To avoid deposits on the optical windows and tubing, Tethys oil-in-water analyzer has a built-in automatic cleaning system that injects a 5% sulphuric solution normally once day. An auto-zero is
a number of screens that are used to set
Ammonia NH4 (UV Spectroscopy after
and check all of the operating conditions
gas stripping), Phosphate (Colorimetric),
of the instrument. A protective film limits
Turbidity (Nephelometric), pH, DO, TSS
the risk to damage the surface of the
(External Sensor attachment).
touch screen, especially against solvent and corrosive liquid. Unique modular concept The unique modular concept allows to
monitor
simultaneously
different
parameters together with oil-in-water. Thanks to the Tethys R&D team who invented innovative modular concept for online water analysers which allows
performed at the same time to avoid any
measurement of various parameters -
drift of the measurement.
even if it follows different measurement
User-Friendly Interface Tethys oil-in-water analyzer has colour touch screen display interface which allows the user to easily navigate through
Chemical Engineering World
For details contact: TETHYS Instruments 57, Chemin du Vieux Chene, 38240 Meylan-FranceTel : +33 4 76 41 86 39 Fax : +33 4 76 41 92 27 Mail : sales@tethys-instruments.com Web : www.tethys-instruments.com
technology – in one analyser. For example, Tethys can offer in one analyser – measurements like Oil-inwater (UV Fluorescence), COD/BOD/ TOC/TSS
(UV
Spectroscopy),
H 2 S/ October 2019 • 77
CEW
Marketing Initiatives
A Place for Positive Displacement PD flowmeters quietly excel in low flow rate, high viscosity, and liquid and gas metering applications
P
ositive displacement (PD) flowmeters are the workhorses of today's flowmeter world. They perform many important flow measurements most people take for granted. For example, they are widely used for metering both water and gas in residential, commercial, and industrial applications. Chances are good the flowmeter that measures how much water you use at your house is a PD meter. PD flowmeters separate the fluid to be measured into distinct compartments of known volume. As the liquid or gas passes through the flowmeter, the compartments are repeatedly filled and emptied. Flow rate is calculated from the number of times these compartments are filled and emptied. PD meters differ according to the shape and size of the compartments involved, and accordingly they are designed for liquid or gas.
sales that exceed $500 million, PD meters will be around for many years to come. Applications for PD Meters The use of PD meters can best be understood by dividing them into water utility, gas utility, oil and industrial liquid applications: * Water utility applications mainly are for billing purposes. Water utility companies buy these meters and put them in industrial plants, commercial buildings and homes to measure how much water is used at those facilities. Just as private homes need flowmeters
to measure the amount of water used, so do hotels, apartment complexes, and other commercial buildings. These buildings are likely to use PD, although they may use turbine meters instead for higher volume flows. Many smaller commercial buildings use PD flowmeters to measure water use within the building. Most PD meters for line sizes of 1-1/2 or 2 inches are for commercial applications. * Gas utility applications are for billing purposes to measure the amount of gas used at homes, commercial buildings and industrial plants. The meters used for billing purposes in industrial plants
Positive displacement flowmeters excel where many other flowmeters have difficulties: low flow rates and high viscosity liquids. In addition, they provide a cost-effective solution for utility applications requiring low-cost meters that last for many years; they still occupy a niche where they are the best solution. And with annual worldwide
78 â&#x20AC;˘ October 2019
Chemical Engineering World
CEW
Marketing Initiatives such as chemical, food processing and pharma plants are different from the meters used to measure gas as part of the manufacturing process. Many of the PD meters used for gas utility measurements are diaphragm meters. However, these are being replaced by rotary meters for some applications, since rotary meters are smaller and lighter. Rotary meters are also used for non-utility gas flow measurements in industrial environments.
can measure heavy crude oil accurately and they are not affected by variations in velocity or viscosity of the measured product.
* Oil, refined fuels and hydrocarbon products have a large PD flowmeter market segment. Some PD meters are used for loading and unloading trucks, tankers, aeroplanes and ships. Most of this measurement is for the purpose of custody transfer. This measurement occurs both upstream and downstream of refineries. Oil trucks that deliver oil to people's homes use a flowmeter to measure the amount of oil dispensed. Often this is a PD meter. Some PD meters rely on the lubricating property of oil or hydrocarbon liquid when the liquid is in contact with the measuring chamber. These meters can measure gasoline, diesel fuel, heavy fuel oil and many other hydrocarbon based liquids. Unlike turbine meters, PD flowmeters can easily handle highviscosity liquids. For this reason, they are often used to measure petroleum at terminals, in production, and downstream for delivery. PD meters
Change is Evolutionary Change in the positive displacement flowmeter market is more evolutionary than revolutionary. Some PD meter companies are not even currently investing in new product research. However, there are some new developments in PD meters. Some of these developments focus on improved methods to increase component manufacturing precision. For example, improved coordinate measuring machines make it possible to create more perfectly round pistons and other components. The only difference between positive displacement flowmeters and new-technology meters (Coriolis, magnetic, ultrasonic, vortex, and multi-variable differential pressure) is in the display; PD meters typically compute flow by counting pulses. The pulsed output of PD meters is typically not a flow rate but a pulse value. To compute flow rate, these need to be related to time. This computation is
* Process liquid applications include industrial chemicals, pharma chemicals, paints and varnishes, printing ink, dairy products, cosmetics and many other liquid products. In many cases, PD meters provide a highly accurate measurement for a lower price than meters such as magnetic or Coriolis.
often done not in the flowmeter but in a separate totalizing device that may be panel-mounted. One potential growth path for positive displacement meters is integrating this computational capability in the flowmeter instead of having it done in a separate totalizing device and some vendors are already doing this. One aspect of transmitter technology that has not yet had a major impact on positive displacement meters is communication protocols. While some magnetic flowmeter and pressure transmitter suppliers have made HART a default capability for their products, only Brooks Instrument and Bopp & Reuther have so far introduced HART versions of PD meters. It is likely that more smart PD meters will be produced in the future as new technology meets old. PD Prospects Positive displacement flowmeters are a traditional technology flowmeter that will be around for many years to come. Even though they face stiff competition from new technology meters in some segments, they still remain the best solution for certain applications. This market is so large that, like differential pressure flowmeters, they will still be around for years from now. Positive displacement meters are very effective at making low-cost mechanical measurements for utility purposes. These include residential, commercial, and industrial utility applications.
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net Website: www.toshniwal.net Chemical Engineering World
October 2019 â&#x20AC;˘ 79
CEW Features
Industry Reacts to Change in Corporate Tax India’s Finance Minister has recently announced a slash in Corporate Tax, which gave the Business Houses in India a sigh of relief. They are considering this decision of Indian Government will fire up the economy. Here we have covered a few industry leaders’ point-of-view.
Covestro India
Ajay Durrani MD Covestro India
tax in India “The recent change in corporate p taken by is a ver y positive and bold ste Cor por ate the gov ern me nt. Red uct ion in economic Tax to 25 percent will spur the wa y and gro wth of the cou ntr y in a big est ic and wil l als o pro vid e reli ef to dom er extent. manufacturing companies to a larg ian tax level With this positive step, the Ind level and is now at par with the global tax pan ies to wil l ope n doo rs for Ind ian com compete internationally”.
80 • October 2019
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Features CEW
Aarti Industries Limited Rajendra V Gogri Chairman & Managing Director Aarti Industries Limited
str uct ure : â&#x20AC;&#x153;Th e cha nge in cor por ate tax tax ref orm is the sin gle big ges t dir ect is no sm all in the las t two dec ade s and tax rat e of acc om plis hm ent . The rev ise d est in the 15 percen t is am ong st the low cat aly st to wo rld and wo uld be a gre at attr act ing the Ma ke- in- Ind ia pro gra m for o pro vid e for eig n inv est me nt. It wil l als acturers to better opportunities for manuf g trade war play a neutral role in the existin acture rs in between US and Chi na. Manuf able tariff India can now export at a reason ing global taking the opportunity in ser vic petitiveness markets to demonstrate its com e to other and attractiveness relativ wil l lea d to nei ghb our ing cou ntr ies . Thi s ort uni ties an inc rea se in em plo ym ent opp surrounding and support ancillary business , resulting the large-scale industrial growth ent. in an overall economic developm por ate tax In add itio n to the cut in cor lab ou r rat e, cos t dif fer ent iat ion , low s, ski lled cos t, cap ex and ope x sav ing tio n, and wo rkf orc e, str ong er IP pro tec l also help better regulator y framework wil ntr y to do position India as a favourable cou companies, business with. We expect Indian ver nm ent tra de ass oci atio ns, and the Go cap ital izin g to act mo re agg res siv ely in for wa rd to on the opp ort uni ty and loo k pan ies to col lab ora tin g wit h glo bal com
Chemical Engineering World
set up their base in India. This move will indirectly look to position India as a global sour cing hub for spec ialty chem icals . Cons ideri ng the dead line of Marc h 2023 , thes e refor ms will act as an acce lerat or for new inve stme nts to boos t grow th in spec ialty chem icals and phar mac eutic als businesses in India. At Aarti Industries, we have been trusted by global specialty chemicals conglomerate for multi-year contracts to produce various spec ialty chem icals . We have deve lope d a dive rsifi ed and de-r iske d port folio comprising of about 200 products that are mark eted to mor e than 1100 cust ome rs acro ss the glob e. Aarti Indu strie s is also bene fittin g from its deep relat ion with dom estic cust ome rs, who are setti ng up for expa ndin g capa city and dow nstre am prod ucts , as a struc tural shift of glob al dem and cont inue s to favo ur cons isten t Indian suppliers. Aarti Industries has been com mitt ed to its grow th initia tives with thru sts to cont inuo usly impr ove on the sust aina bilit y initi ative s as well . Thes e tax refo rms help us prov ide addi tion al ince ntive s and ratio nale to our glob al customers to look at India as a strategic sourcing destination and thereby help us contribute to the larger Indian cause.
October 2019 â&#x20AC;˘ 81
CEW Features
Praj Industries Limited Sachin Raole CFO & Director Finance & Commercial Praj Industries Limited
ic numbers “On the backdrop of weak econom ister, Ms. and sentiments, Hon. Finance Min ced ma jor Nir ma la Sit har am an ann oun the board. corporate tax reduction across happened The reduction in corporate tax has shows the after 14 years and that clearly tax es fro m imp ort anc e of the cor por ate get . The the Go ver nm ent ’s rev enu e bud Ord ina nce , Tax atio n Law s (am end me nt) porate tax 2019, reduced the effective cor from 34.94 rate for all domestic companies 10 percent percent (including surcharge of percent. For and cess of 4 percent) to 25.17 orporated the manufacturing companies inc me nci ng afte r 1st Oct obe r 201 9 and com before 31st commercial production on or is further March 2023, the effective tax rate at does this slashed to 17.16 percent. Wh economy? mean for corporate India and the ion in the For cor por ate Ind ia, the red uct with their tax rate clearly brings it at par es the m a AS EA N cou nte rpa rts and giv economy. level playing field in the global the low er Co rpo rat es, bef ore cho osi ng ut certain tax regime need to be aware abo lower tax conditions. While choosing the wil l not be rat es, the dom est ic com pan y cen tive s allo we d to cla im ded uct ion s/in SE Z uni ts, like ded uct ion ava ilab le to end itur e on acc ele rat ed dep rec iati on, exp ded uct ion s in- hou se sci ent ific res earch, , 80- IE etc , und er Sec tion 80- IA, 80- IAB
82 • October 2019
loss es brou ght forw ard attri buta ble to the abov e men tione d dedu ction s. Mos t importantly, MAT credit will not be available for setting off against the payment of lower tax. Corporate India really needs to assess the situa tion befo re optin g for lowe r tax rate beca use once the optio n is take n, a corp orate cann ot go back to the old tax regime. This also indicates that in the near future we will usher in the era of Direct Tax Code. For the Indian economy, it can be a major boost in a form of providing impetus to the Mak e-in- India initia tive and attra ct more forei gn inve stme nt in the man ufac turin g spac e. It can also fuel the cons ump tion cycl e as corp orat es are pass ing on the bene fits of the redu ced tax rate to the consumers. All in all, reduction in corporate tax rate has the pote ntial to brin g the economy back on to a growth path”.
Chemical Engineering World
Features CEW
Ava Chemicals Pvt Ltd Viejay Bhatia Director Ava Chemicals Pvt Ltd
har am an’s “Fi nan ce Min iste r Nir ma la Sit ate tax rate decision to slash basic corpor corporates to 22% from 30% for existing for new and reduction from 25% to 15% undeniably, manufacturing companies - is porate tax one of the most significant cor goo ds and ref orm ann oun ced aft er the ser vices tax (GST). the cos t The new rat e wil l be red uci ng me nts by of cap ital and cat aly ze inv est the mo st rep osi tio nin g Ind ia as one of tax outflows competitive economies. Lower s and can wil l lea ve mo re cas h wit h firm Aside from help to boost the investment. ps for wa rd tax rat e red uct ion , it als o ste g the direct in streamlining and simplifyin itive rate of tax structure. Also, the compet estment. taxation will increase India’s inv
Due to the prevailing slow growth scenario, automobile companies and other corporates in the FMCG sector have already slashed prod uct price s and/ or start ing offer ing discounts. It needs to be seen how much actual tax benefit gets passed to the end consumers”.
n that the Many economists are of the opinio pushing the corporate tax cut will help in t of gross fiscal deficit closer to 4 per cen domestic product. to become With the new tax system, India reg ion wit h an agg res siv e ma rke t in the ling in the the rates similar to those prevai ASEAN countries. l brin g the Red uct ion of cor por ate tax wil ustry will overall positive growth. The ind st prudent utilize this endowment in the mo economy. way, and will help to improve the
Chemical Engineering World
October 2019 • 83
CEW Products Precision Ovens
Oil-lubricated Vacuum Pumps Toshniwal offers oil-lubricated vacuum pumps. The TMS Series are single stage, oil-lubricated rotary vane vacuum pumps with oil re-circulation system. The lubricant system is rated for continuous operation of high intake pressures so that the pump may be used in a versatile manner in most rough vacuum applications. The pumps are used for suction of air also in presence of water vapour and for continuous industrial use. TMS Series pumps are made from high quality materials, has economical features, which matches together to achieve: high pumping speed over the range of absolute pressure 1,000 mbar-0.5 mbar; high water vapour tolerance and low noise level; no pollution; air-cooled: built-in anti-suck back system. The pumping capacities available are: 17 m3/hr, 35 m3/hr, 65 m3/hr, 100 m3/hr and 150 m3/hr.
Toshniwal ovens are all fan circulated models for accuracy and minimum temperature deviation. Features max temperature of 300oC; rapid heating up to 200oC C-5o/min up to 300oC; temperature variation less than ±1, 2oC at 105oC empty; temperature fluctuation less than ±0, 2oC. Toshniwal’s controller is the best for ergonomy and precision. Available in six volumes: 30, 60, 115, 230, 340 and 490 litres with heating mantles, heating tapes, electric bunsen, and ceramic heating pads. Toshniwal’s universal ovens are suitable for all applications for drying, heating, heat preservation, sterilization with hot air (Poupinel), component aging, curing or thermal tests in laboratories and in all branch of the industry. For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net
For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448983, 26448558 Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 01
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Butterfly Valves Garlock butterfly valves are renowned throughout the chemical, petrochemical, process and other industrial sectors for their quality, performance and reliability in arduous conditions. Garlock valves set the standard in TA-Luft compliance plus the valves are certified with SIL 3 according to EN 61508. Garlock butterfly valve product lines are: GAR-SEAL valves used extensively where corrosive, abrasive and toxic media need to be reliably controlled. They are typically used for accurate control, throttling and shut-off duties in the chemical, petrochemical, chlorine, paper, electro-plating and other industries. GAR-SEAL butterfly valves offer reduced maintenance requirements and increased operational reliability. MOBILE-SEAL valves are used on road tanker vehicles, railway wagons, silos, and other transportation and storage containers where high chemical resistance, reliability and special safety requirements are essential. MOBILESEAL is EN 14432 approved. SAFETY-SEAL valves are used in applications where corrosive, abrasive and toxic media need to be handled and electrostatic charges must be avoided at the same time. STERILE SEAL valves are used in applications where sterile processes need to be maintained in the pharma and food industries without unnecessary and costly overhauls and replacement. The special characteristic of this valve is its external sterilization capability. Offering a full range of valve accessories, Garlock can supply standard handles, special locking handles, gear operators, air actuators, limit switches and electro pneumatic positioners. For details contact: Garlock India Pvt Ltd Plot No: 21, “S” Block, MIDC Bhosari, Pune, Maharashtra 411 026 Tel: 020-30616608 Fax: 91-020-30616699 E-mail: sales.india@garlock.com or Circle Readers’ Service Card 03
84 • October 2019
Chemical Engineering World
Products CEW Filtration Unit (Double Filter, Triple Control) This filtering unit provides double filtering for oil and diesel fuel, and absorbs water and impurities. The unit features a supply and suction pipe with integrated bottom valve. Features sturdy wheeled structure with large-dia wheels; flow rate 56 l/min; and filtering capacity: first stage 30 µ with water absorption, second stage 5 µ for impurities; two step filtration; continuous AC operation 230 V; and duty cycle 30 min DC version. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net
Impellers Anchors/Gate Type impellers are closeclearance impellers that fit the contour of the vessel. These impellers provide adequate mixing under the laminar flow conditions encountered in high viscosity applications for heat transfer. There are many applications that other types of impellers are integrated with the anchor. These impellers sweep the whole wall surface of the vessel and agitate most of the fluid bath through physical contact. Anchor impellers are used for liquid viscosities between 5,000 amd 60,000 cP. When reaction/ mixing homogeneity is required, other types of impellers are recommended. For details contact: FEDA Inc B-37 Maruti Indl Estate Plot No: 59/1/2/3, Phase 1, GIDC, Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok@fedainc.com / reena@fedainc.com
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Additive for Thermoplastic Elastomers WACKER offers a new silicone additive for thermoplastic polyurethanes (TPU). GENIOPLAST Pellet 345, the additive lowers the hardness of TPUs, while boosting their elasticity and enhancing their properties. The surfaces of moulded parts modified with the additive are pleasantly soft to the touch and more resistant to scratches, abrasion and contamination. The new additive is readily incorporated into thermoplastic polyurethanes and has fewer undesirable secondary effects than conventional silicone products. GENIOPLAST Pellet 345 complements WACKER’s portfolio of silicone-based additives for the compounding of thermoplastic polymers. The product has been specifically developed with thermoplastic polyurethanes (TPUs) in mind, but can be used for modifying other thermoplastic elastomers as well, eg, the product, which is supplied in pellet form, can markedly boost the properties of thermoplastic polyamide and copolyester elastomers. Organic polymer segments contained within GENIOPLAST Pellet 345 make it so compatible with thermoplastic polyurethanes that, unlike conventional silicones, it disperses very finely and homogeneously throughout the polyurethane matrix. The copolymer becomes physically bound to the matrix and is therefore unable to migrate. In Europe, GENIOPLAST Pellet 345 is authorized for food-contact applications. Adding GENIOPLAST Pellet 345 boosts the surface smoothness of thermoplastic polyurethanes, thereby enhancing their scratch and abrasion resistance. Moreover, surfaces become more resistant to contamination by foodstuffs and cosmetics. These effects are achieved at additions of just 3 to 5 per cent. Adding more than 10 per cent to a thermoplastic polyurethane elastomer affects its hardness and mechanical properties, rendering it softer and more elastic. For every 10 per cent rise in amount added, the hardness drops by roughly 5 points on the Shore A scale. As the polymer softens, it necessarily loses some of its mechanical strength. However, this undesirable secondary effect is less pronounced with GENIOPLAST Pellet 345 than with other silicone-based technologies routinely used to soften TPU polymers. By virtue of this property set, GENIOPLAST Pellet 345 has extended the range of applications for thermoplastic polyurethanes. There is considerable demand in the entertainments, microelectronics and sports equipment sectors for moulded TPU parts that have a pleasant feel and retain their looks upon protracted use. For details contact: Wacker Chemie AG Hanns-Seidel-Platz 4 81737 München, Germany Tel. +49 89 6279 1588 E-mail: agnes.froeschl@wacker.com
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CEW Products Motor-operated Burette MICROLIT E-Burette offers 3 pre-set speeds for dispensing. The instrument comes with 3 individually calibrated pre-set speeds, including dropwise dispensing (high speed dispensing 1.517 ml/sec, low speed dispensing 0.491 ml/sec and dropwise dispensing at 0.010 ml/sec). MICROLIT E-Burette offers motor controlled piston movement. In conventional digital burettes, dispensing is done manually with the help of a rotating wheel, whose speed of rotation is not fixed and varies from user to user. Any abrupt changes in the speed may result in inaccurate and imprecise results. The motor controller piston movement of MICROLIT E-Burette, at 3 pre-set speeds, rules out the effort invested in manual wheel operation and hence, any inconsistences arising due to the variations in its speed. Built by their in-house team of product design engineers, it offers a host of features like motor controlled piston movement, a touch screen-enabled control panel with an intuitive graphical user interface and 3 calibrated pre-set speeds to perform highly accurate titrations. Designed with ergonomics and intuitive handling in mind, MICROLIT E-Burette is widely used in industries like pharma, environmental monitoring and food and beverages. It exhibits excellent chemical compatibility and helps in performing precise titrations with reliability in practical laboratory environments. For details contact: MICROLIT 627 Pakramau, Kursi Road, Lucknow Uttar Pradesh 226 026 E-mil: info@microlit.com or Circle Readers’ Service Card 07
Distributed Servo Drive system Complete wind farms can be optimised with PC-based control technology. For this purpose, the complete, universal component kit from Beckhoff is available, ranging from the TwinCAT Wind Framework software to the ultrafast EtherCAT communication and from powerful condition monitoring functions to the AMP8000 as an advanced drive solution for azimuth control. Hydraulic brake systems are typically used for the horizontal orientation and locking of the wind turbine nacelle apart from electric drives. During wind direction tracking, these brake systems provide a counteract torque to that of the electric drive. The permanent use of the brake unit for active wind tracking, however, not only causes unwanted noise, but also constant abrasion and wears in the azimuth system, resulting in high maintenance and service requirements. The use of electric drive systems, which already exist in any case, to develop the required counter-torques and to clamp the yaw mechanism reduces wear and improves efficiency. With the AMP8000, the required braking performance or rigidity with optimum torque distribution can be implemented directly in the electric drive system. As today’s wind turbines offer less and less space for control cabinets, any additional weight and volume must be avoided, in the nacelle in particular. The AMP8000 significantly reduces the space requirements for the drive in the control cabinet. In fact, the space requirements for the drive in the control cabinet can be eliminated entirely through the use of the new AMP8620 IP65 supply module, because the AMP8620 module is directly connected to the mains supply and contains all circuitry components required for this, such as mains filter, rectifier and charging circuits for the integrated DC link capacitors. Depending on the power requirements, the supply module can control up to five distributed AMP8000 Servo Drives via EtherCAT P, ie, via a single cable for EtherCAT and power. Preassembled connecting cables simplify logistics considerably and minimise wiring errors. The motor cabling and installation requirements are also reduced effectively. For details contact: BECKHOFF Automation Pvt Ltd Suyog Platinum Tower, 9th Floor Naylor Road, Off Mangaldas Rd Pune, Maharashtra 411 001 E-mail: a.phatak@beckhoff.com or Circle Readers’ Service Card 08 00
86 • October 2019
Chemical Engineering World
Products CEW Mass Flow Controllers
Distillation Plant with Heating and Cooling Oil Bath
The mass flow meters and controllers consist of a metal body with a straight through flow path. Two sensors are encased with SS and protrude inside this bore; one is designed as a heater and the other one is designed as a temperature probe. The working principle is based on King’s Law of The Ratio between the mass flow and the heater energy. That means, the higher the flow the more energy is required to maintain the chosen. Features direct inline measurement principle; useable for virtually every kind of gas or gas-mix; mass flow measurement and control for a wide scope of applications; compact and robust design; IP65 for full product range; no inlet pipe required; measurement without moving parts; customised adjustable multi-functional display: actual fow, totaliser with memory and reset, alarm, set-up and much more. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558, 26448983 Fax: 91-044-26441820 E-mail: sales@toshniwal.net
Ablaze also offers reactors with oil bath. It is a traditional, yet effective design for distillation wherein the reactor is put in a metallic bath with coils for heating or cooling. Such units can sustain higher utility pressure and are available in standard and customised designs. Feature reactor up to 500 litre capacity, zero hold-up with temperature sensing valve and quick closer for addition of solid. Process can be visually monitored thereby improving production safety and reliability. It has dual functional heating and cooling oil/water bath. It can be designed for batch as well as continuous operations. All wetted parts are made from borosilicate glass, and PTFE, providing universal corrosion resistance. It has low CAPEX and is easy to maintain. It is suitable for installation in fume hoods. Zero hold-up in reflux. They are available in wide range of operation -90 to +250oC on request. For details contact: Ablaze Export Inc E-52/4 Sardar Estate Ajwa Road, Vadodara Gujarat 390 019 Tel: 0265-2570105 E-mail: info@ablazeexport.com
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Ultra-compact Industrial PC Equipped with Intel Core i processors of the 6th and 7th generation – up to the Core i7 with four 3.6 GHz cores – the C6032 is ideal to support extensive axis controls, complex HMI applications, extremely short cycle times or handling of large data volumes. Both the compact motherboard and the die-cast zinc and aluminium housing have been newly developed in accordance with the familiar high Beckhoff standards such as industrial compatibility. Other features are the exceptionally compact design and the flexible installation with vertical or horizontal mounting options on the rear panel – and a free orientation of the connection area. By means of two PCIe compact module slots, the freely accessible connection area on the front of the device can be flexibly expanded. The first PCIe modules to be available are the following: 2 x Gbit Ethernet, 2 x USB 3.0, 2 x RS232, and 1 x CP-Link 4. The use of an extremely durable, speed-monitored and controlled fan makes the C6032 suitable for a temperature range of up to 55oC. Available options are Windows 7 or Windows 10 operating systems as well as a second M.2 SSD in RAID configuration. The C6032 offers storage capacity of 40 GB M.2 SSD, 3D flash even in the basic configuration. The Microsoft Azure-certified devices of the ultra-compact IPC Series are ideal to meet current requirements in machine building, eg, increasing modularisation, reduced space requirements in control cabinets, increased computing power and growing price pressure. The new device generation is suitable for use in a broad range of application scenarios such as distributed architectures and current IoT or Industrie 4.0 concepts. The computing power is flexibly scalable to suit individual requirements: C6015 and C6017 for medium performance requirements with Intel Atom CPUs (up to four cores), and C6030 and C6032 as high-end devices with Core i processors with up to 3.9 GHz per core (for dual core processors). For details contact: BECKHOFF Automation Pvt Ltd Suyog Platinum Tower, 9th Floor Naylor Road, Off Mangaldas Rd Pune, Maharashtra 411 001 E-mail: a.phatak@beckhoff.com or Circle Readers’ Service Card 11
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CEW Products Distillery Spent Wash Evaporators Molasses-based distillery effluent known as spent wash/vinasse/dunder/thin slops is one of the most difficult applications for evaporators. These effluents are characterised by a high chemical oxygen demand (COD) and high volumes, creating a heavy pollution load on the environment. SS Techno has developed various innovative evaporation technologies to achieve total zero liquid discharge solutions for the distillery industry. SS Techno integrated evaporators are designed using a mixture of alcohol and water vapour as the heat source in place of steam. SS Techno has installed these units for both multi-pressure distillation columns and atmospheric RS/ENA distillation columns to reduce the spent wash effluent quantity by more than 50 per cent. Successful references are available for raw spent wash and bio-methanated (post-biogas) spent wash applications. The total solid percentage in the spent wash feed is enhanced almost by a factor of 2.4 in the product concentrate. These evaporators produce crystal clear condensate, which can be completely recycled by secondary treatment in a condensate polishing unit (CPU). For details contact: SS Techno Ltd 502 Mayfair Towers I, Wakdewadi Shivajinagar, Pune Maharashtra 411 005 Tel: 020-66524431 Fax: 91-020-66524434 E-mail: marketing@sstechno.com
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Full Bore Cement Head Cement jobs in unconventional land operations with extended lateral sections often face significant challenges toward properly placing cement barriers with minimal channeling. The Commander Full Bore cement head enables rotation and reciprocation, long considered the gold standard to deliver effective barriers, to help improve cement coverage while reducing communication between frac stages and maximizing asset value. The Commander full bore cement head incorporates a number of operational efficiency features to help reduce non-productive time (NPT) and deliver effective barriers at a faster pace. Quick Rig-Up can be accomplished in as few as 30 minutes on average, while on-site plug loading provides rig site verification. Fast rig-to-rig transitions are capable with minimized downtime, as the Commander full bore cement head can complete up to five runs before redress is required. Advanced safety features can help reduce risk to on-site personnel. Wireless capability helps prevent personnel from being hoisted, loading plugs, and hand-torquing on active rigs. Embedded wireless logic prohibits plugs from being launched out of sequence, and external tattletale indicators offer easy visual verification when plugs have successfully launched. On-site plug loading offers operators real-time assurance without relying on alternative offsite verification, and if needed, plugs can be launched manually as a contingency. The Commander full bore cement head is specifically designed to improve cement head reliability, increase efficiency and help deliver the best possible cement barrier. Multiple industry studies have shown that rotation during cementing can greatly improve barrier coverage and can help reduce channeling. With rotation and reciprocation capabilities delivering enhanced cement bonds, the Commander full bore cement head can help maximize barrier coverage in challenging unconventional land operations. For details contact: Halliburton Company A-18, MIDC Estate Cross Road B, Andheri (E) Mumbai 400 093 Tel: 022-67809500 E-mail: info@solutions.halliburton.com / pr@halliburton.com or Circle Readersâ&#x20AC;&#x2122; Service Card 00 13
88 â&#x20AC;˘ October 2019
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CEW
NATIONAL
INTERNATIONAL Plastivision India
Dates: 16-20 January 2020 Venue: Bombay Exhibition Centre, Goregaon, Mumbai Event: This event provides the perfect platform for plastic industry players
Corrosion Protection
Dates: 10-11 December 2019 Venue: ACHAT Plaza Karlsruhe, Germany Event: Corrosion Protection benefits for this
like manufacturers, dealers, buyers and end-users. It is well-appreciated for helping participants stay updated with the latest technological trends. Visitors can participate in numerous live product launches, seminars, conferences and consultation sessions. They also get a chance to network with overseas delegates and industry influencers. The event has a glorious history that dates back to 1992. It is only a trading fair exhibition from the plastic industry approved by UFI (the leading Paris-based exhibition authority). For details contact: The All India Plastics Manufacturers’ Assn AIPMA House, A-52, Street No: 1, MIDC Marol Andheri (E), Mumbai 400 093
seminar is they know the mechanical and chemical influences that lead to corrosion and are familiar with the specific properties of various materials. In addition, you will learn about the risks of corrosion and various countermeasures and, in exchange with other solutions, develop practical case studies. For details contact: German Machinery and Plant Manufacturers’ Assn c/o VDMA e.V. Lyoner Street 1860528 Frankfurt/Main Germany
Renewable Energy Expo
Corrosion Conference & Expo
Dates: 13-15 February 2020 Venue: Chennai Trade Centre, Nandambakkam, Chennai Event: The 2 nd Edition of this event will be held in Chennai. The scope of this exhibition is to stimulate the growth of renewable in the region through collaboration of technology and product sharing. This event will be bringing together businesses, sustainable energy industry trade associations, government agencies, and energy policy research organizations to showcase the status and potential of the cross-section of renewable energy (biofuels/ biomass, geothermal, solar, wind) and energy efficiency technologies. The expo is proclaimed at the right time when there is a paradigm shift in the global trend towards massive deployment of solar power and other renewables along with investments worth billions of dollars in technology and green energy. For details contact: Water Today Pvt Ltd 3D Bhaghreetha Residency, 125 Marshalls Road Egmore, Chennai 600 008
Chemspec India
Dates: 16-17 April 2020 Venue: Bombay Exhibition Centre, Goregaon, Mumbai Event: The Fine and Specialty Chemicals Exhibition features exhibits of organic and fine chemicals, active pharma ingredients, drug intermediates, dyes and pigments, agrochemicals, contract and toll manufacturing, coatings, cosmetic chemicals or ingredients, pigments and solvents, surfactants, laboratory chemicals and a host of specialty chemicals. For details contact: Chemical Weekly 602, 6th Floor, B-Wing, Godrej Coliseum B/h Everard Nagar, Off Eastern Express Highway K J Somaiya Hospital Road, Sion (E), Mumbai 400 022 Tel: 022-24044477, Fax: 91-022-24044450 E-mail: corporate@chemicalweekly.com Chemical Engineering World
Dates: 15-19 March 2020 Venue: George R Brown Convention Center, Houston, U.S.A. Event: Corrosion Conference & Expo showcase your newest products in front of customers, prospects, partners, and influencers; generate leads efficiently and effectively; build relationships with key players and decision-makers; bolster the global influence and reach of your company’s product or service; and expand your reach and tap into new markets meeting new potential buyers and suppliers. For details contact: Nace International - The Corrosion Society Houston, U.S.A. Tel: +1 281-228-6411 E-mail: tiffany.krevics@nace.org
International Converting Exhibition Europe
Dates: 09-11 March 2021 Venue: Exhibition Munich, Munich, Germany Event: This event will showcase product like chemicals and dyes, office and commercial supplies, packaging materials, plant, machinery and equipment, plastic and plastic products, business services, paper and paper products and much more. For details contact: Mack Brooks Group Romeland House, Romeland Hill St Albans, Herts AL3 4ET, U.K. Tel: +44 (0)1727 814400 Fax: +44 (0)1727 814401 E-mail: info@mackbrooks.co.uk October 2019 • 89
CEW
Project Update New Contracts/Expansions/Revamps
The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS NOCIL Ltd has commissioned the Phase 1 of expansion of capacities of rubber chemicals and their intermediates at Navi Mumbai, The aforementioned CAPEX programme had been approved by the Board of Directors at its Meeting held on 16th March 2017. Tata Chemicals has completed the acquisition of the silica business of Allied Silica for `123-crore. The company entered into a business transfer agreement to acquire Allied Silica’s precipitated silica business on a slump sale basis. The deal was part of the ` 295-crore investment approved by the Board in February 2017, towards this specialty business. The acquisition includes a manufacturing facility in Tamil Nadu, which will produce highly dispersible silica. The specialty chemical product represents a downstream value addition to Tata Chemicals soda ash business, where it ranks among the top manufacturers globally. R Mukundan, Managing Director, Tata Chemicals, said the next focus would be to enhance the operational readiness of the plant to maximise throughput of product portfolio, while meeting the requisite safety and quality specifications. Precipitated silica is a versatile product with applications in many industries including rubber, oral care, coatings and agrochemicals. The acquisition also offers the possibility to make value added silica for applications that demand high performance. Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about `100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of ` 1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country. Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly production capacity of 2,180-kilolitres. Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry. Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals 90 • October 2019
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.
MINING Coal India Ltd (CIL) had supplied in 2018-19, 491.54-million tonnes (MT) coal to power plants which was 8.2 per cent more than the coal supplied in 2017-18. Singareni Collieries Co Ltd (SCCL) supplied 55.3-MT coal to power plants in 2018-19 which was a growth of 3.6 per cent over the same period of previous year. This has led to creation of a coal stock of 30.95-MT at the power plants as on 31st March 2019 which was sufficient for 18 days requirement. In 2018-19, the power plants of Tangedco have supplied 23.26-MT coal from CIL with a growth of 3.5 per cent over the supply of 22.49-MT in 2017-18. As on 16th June 2019, Tamil Nadu power plants have coal stock of 9.67-lakh tonne which is sufficient for 12 days requirement. At present, no power plant in Tamil Nadu is in critical/super critical category. Hindustan Copper Ltd (HCL), on 2nd February, 2019, held a ground-breaking ceremony at Ghatsila Unit of HCL for construction of concentrator plant at Rakha, initiating Chapri-Sidheswar mine, a new mine development and Rakha mine re-opening projects. CMD informed that considering the opportunity to further increase the resource base of copper mineral in the State has finalized plan to undertake depth exploration up to 1,000-meter from surface in its existing lease area in next two years. HCL, in its Unit located at Ghatsila planned to implement total five mine expansion projects to increase the mine capacity from current 4.0 to 72.0-lakh tonne. Successful implementation of the project will also reduce country's dependence on imported copper concentrate. Singareni Collieries Co Ltd (SCCL) has received a boost for its plans of increasing the coal production to 70-million tonnes in 2019-20 by getting the green nod for Kistaram open cast mine recently after suffering some setbacks in getting environmental clearance for its proposed new mines and expansion of existing ones earlier this year. The coal company has achieved a production of 64.4-million tonnes in 2018-19 and getting the environmental clearance for Kistaram open cast mine, with a capacity of 2-million tonnes per annum (MTPA), in Sathupalli mandal of Khammam district is expected to go a long way in its plans to jack up the production by nearly 6-million tonnes. The green nod to the proposal has come three years after public hearing conducted on it. According to SCCL officials, a committee of experts in the Ministry of Environment and Forests (MoEF) that has gone through the proposal has recommended clearance to
Chemical Engineering World
Project Update the mine earlier and stipulating several conditions to keep impact of the mining activity under check on air, water and local people. Environmental conditions in and around Sathupalli town were also appraised separately by the panel before giving its nod. The committee also asked the coal company to take specific measure to minimise the mining impact on air, water, noise, vibrations, stability of structures, health of people in nearby villages and their socio-economic conditions and relief and rehabilitation operations. MOIL recently said production at its Parsoda manganese mine is expected to begin soon. The mine will be operated by open cast mining method. MOIL has been granted mining lease of Parsoda manganese mine near village Parsoda, 46-km from Nagpur in the year 2016. The lease extends for 50 year period, ie, from April 22, 2016 to April 21, 2066 and the project cost is estimated to be ` 19.54-crore. MOIL, under the Ministry of Steel, operates around 10 mines, including six in Maharashtra and four in Madhya Pradesh. Balaghat mine is its largest, which produces top quality manganese ore. NTPC Ltd hopes its captive coal production will reach 100-million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer. Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000-tonnes a day by March 2019, having resolved land-acquisition related problems. Coal from the Rajmahal mine helps NTPC run close to 4,200-MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce coal bed methane (CBM). Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop SAIL’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. 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. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW Chemical Engineering World
coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corpn. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. 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 EoI from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. 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.
OIL & GAS Haldia Petrochemicals (HPL), plans to deploy an innovative technology for its project that seeks to convert crude oil into chemicals and petrochemicals directly. As opposed to the customary production of refined petroleum products, HPL’s plant will concentrate on higher output of petrochemicals. HPL, is setting up an integrated refinery with aromatic complex for production of paraxylene and purified terephthalic acid (PTA) units in the first phase. The production capacity of paraxylene unit will be 1.6-million tonne per annum (MTPA) and PTA will have 2.5-MTPA capacity. The first phase of the HPL project approved is expected to be operationalised within five years of allotment of land. HPL has committed an investment of ` 28,700-crore ($4.05-billion) in the first phase on its Odisha project. Recently, the High Level Clearance Authority (HLCA) in Odisha headed by Chief Minister Naveen Patnaik gave its nod to the proposal, which HPL submitted on March 1. Official sources have touted HPL’s proposal as the country’s single-largest domestic investment in the last 12 months. Vedanta Ltd’s has received environment clearance for the expansion of its oil and gas operation in Rajasthan that would entail an investment of ` 12,000-crore. The proposal is to expand onshore oil and gas
October 2019 • 91
CEW
CEW
Project Update production from the existing 3,00,000-BOPD (barrels oil per day) to 4,00,000-BOPD and 165-MMSCFD (million standard cubic feet per day) to 750-MMSCFD from the 'RJ-ON-90/1' block located in Barmer and Jalore districts, Rajasthan. The environment clearance (EC) is, however, subject to compliance to certain conditions. The estimated project cost is `12,000-crore. The company aims to implement the project in a phased manner during seven years. The project involves oil augmentation to produce up to 4,00,000-BOPD and 250-MMSCFD of associated gas from the oil field and natural gas augmentation to produce up to 500-MMSCFD. Total area of the oil and gas block is 3,111-sq km. Out of it; the project presently covers an area of 1,501.7-hectare in Barmer and Jalore districts. Additional 150 hectare of land in Barmer district will be used for the proposed expansion. The 'RJ-ON-90/1 block' comprises of Vedanta Ltd and state-run ONGC for hydrocarbon exploration, development and production activities in the block, while Cairn Oil and Gas division (part of Vedanta Group) is the operator of the block. BPCL-Kochi Refinery is going ahead with its second petrochemical project to produce polyols at an investment of ` 11,300-crore. An import substitute, polyols are used in the production of polyurethanes used in diverse products such as automotive seats, mattresses and shoe soles. The project is expected to go on stream by 2022. BPCL is in talks with various global firms to finalise the technology for six different products. There is a huge demand for polyols and it is growing at 10 per cent per annum providing good scope for MSMEs to set up units in the complex. The first petrochemical project of BPCL-KR constructed at a cost of ` 5,500-crore is all set to commence operations by the middle of the year. It will produce acrylic acid, acrylates and oxo-alcohol that are used in the manufacture of paints, super absorbent polymers, detergents, adhesives, sealants and solvents. The technology has been sourced from Mitsubishi, Air Liquide Global and Johnson Mathey Davy. The two projects will facilitate ` 13,000-crore forex savings per annum for the country. With the completion of the second petrochemical project, BPCL-KR is expecting around 16 per cent increase in its turnover in three years. BPCL-KR is slated to complete its fuel upgradation project to comply with BS-VI norms by February next year. The project cost is around ` 3,300-crore. Vedanta Ltd announced an oil discovery in its Krishna Godavari basin block in the Bay of Bengal. The block previously had a gas discovery in the very first well drilled. Vedanta holds 100 per cent participating interest in the block. "Multiple reservoir zones were encountered in the well H2 within the Mesozoic sequence between the depths of 3,310 to 4,026-metres with hydrocarbon indications during drilling and downhole logging," it said. The zone from 3,403 to 3,431-metres was tested through conventional well testing (Drill Stem Test) and flowed oil to the surface. Further appraisal will be required to establish the size and commerciality of the oil discovery. The first exploration well A3-2 drilled in the block was a gas discovery. Cairn India, the company Vedanta bought and merged with itself, had in June 2010 won the KG-OSN-2009/3 block in the 8th round of New Exploration Licensing Policy (NELP). It had committed to drill six exploratory wells on the block. These were expandable to 10. The KG basin is a proven basin where there have been many hydrocarbon
92 â&#x20AC;˘ October 2019
discoveries. The company acquired around 1,000-sq km of 3D seismic data based on which it drilled two wells. KG-OSN-2009/3 offshore block in the Bay of Bengal was originally spread over in an area of about 1,988-sq km which was later reduced to 1,298-sq km due to exclusion of area within firing range. It is located in the shallow waters of the Indian Ocean along the East coast of India, approximately 1.5 km from the Indian coastline. Chennai Petroleum Corpn Ltd (CPCL) the Indian Oil Corpn's (IOC's) group company is planning to set up a greenfield refinery at Nagapattinam in Tamil Nadu, at a cost of ` 27,460-crore. The products, including motor spirit (MS) and high speed diesel (HSD), which will be produced from the refinery will help meet the latest BS-VI specification in the southern States. The new refinery will be part of the Government of India's plan to set up a petroleum, chemicals and petrochemicals investment region (PCPIR) in this region. The boards of CPCL and IOC have accorded in-principle approval for the 9-million metric tonne per annum (MMTPA) refinery at CBR at an estimated investment of ` 27,460-crore, plus or minus 30 per cent. The investment includes ` 2,800-crore for setting up a polypropylene unit of around 500 thousand metric tonne (TMT) per annum capacity. Detailed feasibility report (DFR) preparation is underway. The refinery is expected to be operational by 2023-24. It will produce valuable products, including liquefied petroleum gas, petrol, diesel, aviation turbine fuel, polypropylene, etc, besides petrochemical feed stocks. The petrochemical complex will also feed stocks to downstream industries, including pharma, paint and lacquer, printing inks, adhesives, coatings, chemicals, automobile lubricants, and PVC, among others. CPCL operates two refineries with a total capacity of 11.5-MMTPA (10.5-MMTPA at Chennai and 1-MMTPA near Nagapattinam) in Tamil Nadu. The company's crude throughput increased to 10,789-TMT in 2017-18, from 10,256-TMT in 2016-17. Its profit after tax stood at ` 913 crore in 2017-18, as compared to ` 1,030-crore in 2016-17. Reliance Industries Ltd has secured backing of the key expert appraisal committee (EAC) in the Ministry of Environment, Forest and Climate change to expand the capacity of its export-oriented refinery in the special economic zone (SEZ) at Jamnagar by 5.8-million tonnes (MT). The planned expansion will raise the installed capacity of the SEZ refinery to 41-MT from 35.2-MT and lift the overall capacity of the Jamnagar refinery complex to 74-MT. The additional terms include prior transfer of environment clearance issued on March 30, 2010 to Reliance Jamnagar Infrastructure Ltd to Reliance Industries Ltd (the entity that applied for the environment clearance).The Jamnagar refinery processed 69.8-MT of crude in FY18, exceeding its installed capacity of 68.2-MT. Between April and December 2018, Reliance refined 52.3-MT of crude. Reliance Petroleum Ltd, a unit of Reliance Industries, built its first refinery at Jamnagar with an installed capacity of 18-MT which was later expanded to 27-MT. The capacity of the Jamnagar refinery and petrochemical complex was further expanded by Reliance Industries to 59.7-MT during which the production was split between Reliance Petroleum (26.7-MT) as an only for exports refinery unit and Reliance Industries (33-MT) that sold most of its products in the local market. The capacity of the SEZ refinery was further expanded by Reliance Jamnagar Infrastructure Ltd to 35.2-MT from 26.7-MT.
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Corrosion Problems and Solutions in Oil Refining and Petrochemical Industry
The Chemistry and Technology of Petroleum
Author: Alec Groysman
Price: $279.06
Price: $179.99
No of pages: 980 pages (Hardcover)
No of pages: 356 pages (Hardcover) Publisher: Springer (1 Edition) About the book: Corrosion Problems and Solutions in Oil Refining and Petrochemical Industry 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 analyses 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 â&#x20AC;&#x201C; both of which need to be protected for the sake of current and future generations. Accordingly, this book examines and analyses 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. st
Handbook of Refinery Desulfurization Authors: Nour Shafik El-Gendy and James G Speight Price: $121.13 No of pages: 492 pages (Hardcover) Publisher: CRC Press (1 st Edition) About the book: Handbook of Refinery Desulfurization describes the operation of the various desulfurization process units in a petroleum refinery. It also explains the processes that produce raw materials for the petrochemical industry. It illustrates all the possible processes to lower the sulphur contents in petroleum and its fractions to decrease emissions of sulphur oxides. This book introduces you to desulfurization concepts, including bio-desulfurization, as well as technology, giving guidance on how to accomplish desulfurization in various refining processes. It contains background chapters on the composition and evaluation of feedstocks and includes diagrams and tables of feedstocks and their respective produce. It also outlines how to decide which method should be employed to remove sulphur from different feedstocks. A practical and thorough discussion of the field, Handbook of Refinery Desulfurization gives you a strong grasp of the various processes involved with industrial desulfurization while giving you pointers on which procedures to use under certain conditions. Chemical Engineering World
Author: James G Speight
Publisher: CRC Press (4 th Edition) About the book: Refineries must not only adapt to evolving environmental regulations for cleaner product specifications and processing, but also find ways to meet the increasing demand for p e t r o l e u m products, particularly for liquid fuels and petrochemical feedstocks. The Chemistry and Technology of Petroleum, 4 th Edition offers a 21 st Century perspective on the development of petroleum refining technologies. Like its bestselling predecessors, this volume traces the science of petroleum from its subterranean formation to the physicochemical properties and the production of numerous products and petrochemical intermediates. Presenting nearly 50 per cent new material, this Edition emphasizes novel refining approaches that optimize efficiency and throughput. It includes new chapters on heavy oil and tar sand bitumen recovery, deasphalting and dewaxing processes, and environmental aspects of refining, including refinery wastes, regulations and analysis. The text also features revised and expanded coverage of instability and incompatibility, refinery distillation, thermal cracking, hydrotreating and desulfurization, hydrocracking and hydrogen production. A unique, well-documented and forwardthinking work, this book continues to present the most complete coverage of petroleum science, technology and refining available. The Chemistry and Technology of Petroleum, 4th Edition provides an ideal platform for scientists, engineers and other professionals to achieve cleaner and more efficient petroleum processing methods. October 2019 â&#x20AC;˘ 93
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Manufacturer of:
Lined piping systems, Columns, Vessel and Tanks for corrosive media applications
Lining Material: PTFE/PFA/FEP/PVDF/PP/HDPE
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Techno-commercial solutions provider with pre-engineering and case study of corrosion issues RESISTOTECH INDUSTRIES PRIVATE LIMITED
C-11, MIDC, SINNAR, DIST.: NASHIK, MAHARASHTRA, INDIA, PIN - 421 301. M: 0091 9820429054 | T: 0091 2551 230540 | E: sales@resistotech.com | W: www.resistotech.com