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VOL. 50 | ISSUE NO. 10 | OCTOBER 2015 | MUMBAI | ` 150 NEWS ► Industry News/ 6 Technology News / 20
NEWS FEATURES ► Bharat Petroleum to Commence Operation on Kochi Refinery Expansion / 26
FEATURES ► Combating the Effects of Corrosion in Refineries with Duplex Stainless Steels / 28 – Mohan Gawande, Manager, Chemical Group, Sandvik Materials Technology Chemical Characterisation in the Safe Handling of Acids and Caustics / 36 – Richard W Prugh, Jitendra Kumar, Chilworth Technology Inspection for Non-Piggable Pipelines
Renewable Chemicals worth 84.3 bn by 2020; Catalyst Market Size to Reach 6.18 bn by 2022 / 53
MARKETING INITIATIVE ► Munsch Non-Metallic Pumps and their Applications / 54 The Evolution Of The Species / 56 Taking Account Of The Trend Towards Individual Vacuum Solutions / 58 Capex, Opex can be saved using multi-tubular catalytic reactor in place of conventional fixed bed catalytic reactor / 59
PRODUCTS ► / 61 EVENTS ► / 67
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Chemical Engineering World
CEW Industry News Fertiliser Industry to Experience Cautious Growth in FY15-16
Pidilite’ Construction Chemicals Sets a Target of ` 900 Crore
Mumbai, India: In the current financial year, the volume growth of the fertiliser industry is cautious because of having a weak monsoon but the reduction in the domestic gas prices for urea is a positive step for the industry. The fertiliser industry report by ICRA stated that the sowing level was good as a result of the early monsoon but the rainfall in the latter part of the monsoon season was not encouraging. Due to the low monsoon rainfall, at the end of August 2015, system inventory levels of non-urea fertilisers had reached a five-year high. As a result of all this, there will be moderation in the fertiliser volumes. The overall urea demand may show a minor growth of 1-2 per cent at 31-31.5 MMT during the financial year 2015-16 and the P&K segment is likely to show a moderate growth in volume at 2-5 per cent. The report stated that the outlook for fertilisers is cautious on two fronts the agro-climatic pressure and its effect on the Rabi volumes and profitability as far as P&K segment is concerned.
Chennai, India: Pidilite’s Construction Chemicals Division is set to reach revenue close to ` 900 crore in the present financial year. While speaking at the formal inauguration first Dr Fixit Experience Centre, Sanjay Bahadur, Global CEO, Construction Chemicals, Pidilite Industries stated that the company would see revenues of about ` 900 crore this financial year. He added that the division would witness a CAGR of 25 per cent. When asked about the outlook for exports, he said that exports accounted for about 10 per cent of the division’s revenue and the division is faring well in Singapore and Thailand. The company is looking to tap the emerging Asian and African markets.
Adani May Take Over Sindri Fertiliser Plant Ranchi, India: The Adani Group may take over Sindri fertiliser plant through bidding; earlier this year it had announced that the group would want to set up a urea plant in Jharkhand. A meeting took place between the representatives of the Jharkhand industry department and a delegation from Adani conglomerate where this issue was raised. The group was also formulating an infrastructure overhaul plan for the defunct facility. D P Vidyarthi, Deputy Industry Secretary, stated that the group has expressed its willingness to take over the Sindri plant and have a plan to develop the facility if they are allowed to run it. This would need the group to go through a bidding process that is organised by the Union ministry of chemicals and fertilisers. In June 2015, an MoU was signed between Adani Group and the state government for building a urea plant with a net investment of ` 20,000 crore and the group also signed deals for investment of ` 30,000 crore for acquiring coal-based substitute natural gas. The group would need land in excess of 3000 acres and it is still identifying the location.
ABCL Completes Acquisition of Jayashree’s Chlor-alkali DIvision New Delhi, India: Aditya Birla Chemicals Ltd (ABCL) has completed the acquisition of Jayashree Chemicals Ltd’s chlor-alkali division. This division includes a caustic soda manufacturing unit in Ganjam, Odisha and a salt manufacturing facility in Pundi, Andhra Pradesh. A regulatory filing stated that the unit at Ganjam would be renamed as ABCL. Jayashree’s chlor-alkali division has 57,000 tonnes per annum capacity at Ganjam. The company has salt works in Andhra Pradesh of 1,600 acres. Last year in September ABCL had stated that it would acquire Jayashree Chemicals Ltd’s chlor-alkali division for ` 212 crore cash consideration. 6 • October 2015
Ramagundam Urea Plant Receives Environmental Clearance Hyderabad, India: The ` 5,465 crore fertiliser plant proposed at Ramagundam, Telangana has received environmental clearance from a committee under the Ministry of Environment and Forests (MoEF). A joint venture has been formed between Engineers India Ltd (EIL), Fertiliser Corporation of India (FCIL) and National Fertilizer Limited (NFL) where an agreement was signed earlier to set up two new plants; Ammonia and Urea at the existing site of the plant in Ramagundam. The company formed through JV is called Ramagundam Fertilizers and Chemicals Ltd. The Expert Appraisal Committee’s minutes of meeting stated, “After detailed deliberations, the committee recommended the project for environmental clearance and recommended the following specific conditions along with other environmental conditions while considering for accord of environmental clearance.” Having a production capacity of 1.1 million tonnes per annum, this gasbased plant is likely to be commissioned in 2018-19. Previously, the plant was a coal-based one and had become dysfunctional; it could not maintain production as there was a shortage of raw materials like phosphate.
KRIBHCO to Invest ` 1,000 Crore New Delhi, India: Krishank Bharati Co-operative Ltd, (KRIBHCO) will be setting up a phosphoric and potassic fertiliser plant, an investment of ` 1,000 crore, in Andhra Pradesh at Krishnapatnam. This is the first time KRIBHCO would be setting up a P&K fertiliser plant which would produce only urea. Chandra Pal Singh, Chairman, KRIBHCO stated that Andhra Pradesh offers a host of benefits to KRIBHCO amounting to ` 500 crore. The plant’s annual capacity would be 6 lakh tonnes and this project would be operational in about 4-5 years. Singh also added that the second phase of the project would see capacity being increased top 1.2 million tonnes. Chemical Engineering World
CEW Industry News Grundfos Launches Knowledge Hub for Pumping Solutions
Orgneftekhim Standardises AVEVA Engineering & Design Software
Chennai, India: Grundfos Pumps India Pvt Ltd (Grundfos India), recently launched the Grundfos for Engineers website. This site provides knowledge, training and guidance for all pumping solutions with a specific focus on Buildings, Water Utilities and Industries. It is a complete guide that addresses the daily challenges of consulting engineers and system designers. Grundfos for Engineers is an ideal platform to find pump systems knowledge quickly, and provides an opportunity for engineers to optimise specification tasks promptly. This website also provides source materials, references and successful case studies. For example, a simple sizing tool available in the website allows engineers to enter duty points and then search for matches by application, pump design or family of pumps. The decision making also becomes easy through a huge range of downloadable product and application guide and video insights from experts. To know more about the website and its offerings, please visit http://in.grundfos. com/grundfos-for-engineers.html
Moscow, Russia: AVEVA announced that Orgneftekhim Holding, the parent company for a number of Russian engineering institutes and construction and procurement companies, has standardised on AVEVA Everything3D (AVEVA E3D) for all engineering and design projects. Orgneftekhim selected AVEVA E3D based on its requirement for a 3D multi-discipline plant design solution with common administration, integrated report generation and data management capabilities. Orgneftekhim already has an excellent reputation in its market for delivering high quality projects and the AVEVA software allows group of companies to work in a more collaborative way on complex projects and continue to raise project standards. Orgneftekhim Holding is the key contractor for the Afipsky Oil Refinery, a large capital project on the south of Russia. ‘Having one common platform for all 3D design work and procedures across all our companies is a strategic step in our development. AVEVA E3D is easy to implement, maintain and use. We have experienced a hassle-free deployment across the group and some of the groups companies have already successfully accomplished projects with the new AVEVA software. Our very positive experience with AVEVA resulted in our decision to standardise all our engineering and design activities on the AVEVA software platform,’ said Alexander Babynin, Managing Director, Orgneftekhim.
To continuously enrich their knowledge and to keep up with the global trends, engineers can take course modules at their own pace from this website through an innovative and free online training platform, ‘Grundfos Ecademy’ where completion of every course module will count towards their professional accreditation.
Polypropylene Market to Reach USD133.3 Billion by 2023 New York, USA: A new Transparency Market Research report states that the global polypropylene market was valued at USD 81.6 billion in 2014 and is predicted to reach USD 133.3 billion by 2023. It is expected to expand at a 5.7 per cent CAGR in the forecast period between 2015 and 2023. The title of the report is ‘Polypropylene Market - Global Industry Analysis, Size, Share, Growth, Trends and Forecast 2015 – 2023’. The rising demand for polypropylene within the food and beverages packaging industry, along with the rising demand for lightweight vehicles, is predicted to fuel the market for polypropylene in the coming years. On the other hand, the rising concern regarding the hazardous effects of plastics on the environment and the unpredictable prices of raw materials may inhibit the growth of the market for polypropylene in the coming years. To overcome this obstacle, manufacturers of polypropylene are focusing on biobased polypropylene, which will bring in new opportunities by the end of 2023. On the basis of end user, the polypropylene market is segmented into automotive, packaging, electrical and electronics, consumer products, construction, and others including agriculture, medical, furniture, etc. Amongst these, in 2014, packaging dominated the market, representing a share of over 45 per cent and is also the most swiftly developing enduse segment in the polypropylene market. This is due to the fact that polypropylene has significant uses in both rigid and flexible packaging because of its resistance to high temperatures and strong chemicals. 8 • October 2015
Stahl Appoints New Directors Sustainability & Polymers Waalwijk, Netherlands: Stahl announced the retirement of Mike Tomkin, who has been Stahl’s Director of Sustainability for the last three years. His successor, Michael Costello, comes from within our own ranks as he currently holds the position of Group Director Stahl Polymers. In turn, Costello will be succeeded by Raymond Bakker. Raymond currently holds the position of Business Manager North and West Europe for Performance Coatings and will assume the position of Global Business Director Stahl Polymers. All new positions will be in effect as per October 1st, 2015. Until Mike Tomkin retires on January 1, 2016, he will provide support to Michael Costello. Under the guidance of Mike Tomkin, Stahl started numerous sustainability projects and took a leading role in making the chemical and leather industry more sustainable. “I am looking forward to continuing Tomkins’ good work and to further strengthen Stahl’s position as a sustainable chemical company,” says Michael Costello. He has a chemical background and a solid understanding of the Stahl business. Costello will bring sustainability to the next level required by both the world and by the company itself. Raymond Bakker will be Costello’s successor and become Global Business Director Stahl Polymers. “Stahl has over 50 years of experience in polymer technology,” he says. “I feel privileged to have been given the chance to work with high-quality products used in a wide variety of coatings and ink systems that have less impact on the environment. Altogether, I look forward to bringing Stahl Polymers and our customers to the next level of durable technologies.” Chemical Engineering World
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CEW Industry News AkzoNobel Opens New Coil Coatings Production Line
Evonik Plans Additional World-Scale Methionine
Amsterdam, Netherlands: AkzoNobel has opened a new production line for coil coatings at its facility in Garcia, Mexico. As well as doubling current capacity, the new line will also serve local coated steel manufacturers, including Ternium, Zincacero and Galvasid. Coil coating products that are manufactured at the site support the construction and domestic appliance s e c t o r s. I n a d d i t i o n , t h e n ew l i n e w i l l p r o d u c e s p e c i a l t y products, including metallic and ‘wrinkled’ finishes. Volumes currently imported from the US will now be manufactured locally in Mexico. “The Garcia facility will allow us to participate in new regional markets. We will also improve our response time and customer service, as well as giving a big sign of our commitment to the Mexican market and to our customers,” explained Miguel Rocha, Regional Sales Manager Mexico and Central America for AkzoNobel’s Metal Coatings business.
Essen, Germany: Evonik Industries has started the planning stage for the construction of an additional world-scale plant complex in Singapore. The facility, which will produce the amino acid DLmethionine for animal nutrition, will have an annual production capacity of 150,000 metric tons and is expected to start operations in 2019. It still requires authorisation from the Evonik committees. With this decision Evonik follows the global megatrends of health and nutrition, which are driving the growth of the DL-methionine business. With the timely and demand driven expansion of capacities over the past few years Evonik has continuously accompanied this strong market growth.
Another related event was when AkzoNobel announced plans to invest in its Performance Coatings business in Vietnam. As well as doubling capacity at its powder coatings facility in Dong Nai, the company also intends to open a new office for Performance Coatings in Ho Chi Minh City. The new production line in Dong Nai will be ready in November and will be supported by a 20 per cent increase in workforce. In addition to serving the local market, the expanded plant will also supply customers across Southeast Asia, India, Australia and New Zealand. “Vietnam has proven to be strategic market for AkzoNobel in Southeast Asia and we are strongly committed to expanding our position,” said Alan Alex, Business Manager for AkzoNobel’s Powder Coatings business in Southern Asia. “With focused investment, we aim to sustain our high double-digit growth in the domestic market in Vietnam, as well as Southern Asia overall.”
SUEZ Group Launches Aqualead Dedicated To Industrial Water Treatment Paris, France: SUEZ Group has launched a water conditioning services offering specifically for industrial customers: aqualead. aqualead is a complete water conditioning offer focussed on the industrial water cycle. The offer ranges from the provision of water conditioning products for the treatment of all aspects of industrial water management through to dedicated wastewater, cooling and boiler water conditioning services. This new water conditioning activity, supplementing the historic business areas of construction, operation and provision of specialised solutions, gives the group unique positioning in the industrial market. The offer coincides with the launch of a ‘green’ product range, with the new aqualead nexgen collection. Elise Maury, CEO, Water Conditioning Services France, explains, “With aqualead, we are offering all industrial customers a global solution and increasing the visibility of our expertise at international level.” Formulated and developed in their Services Technical Centre at La Courneuve in France, using expertise from across the group, these products reduce the amount of phosphorus discharged, by more than 50 per cent when compared with conventional treatments. 10 • October 2015
Evonik’s most recent methionine plant took up its operations in Singapore in the fourth quarter of 2014 after a two-year construction period— precisely as planned—and operations are utilised according to plan. In its new, backward-integrated production complex, Evonik will also produce all associated strategically relevant precursors. The construction of the plant complex is planned next to the existing Evonik methionine plant on Jurong Island in Singapore. The location in Singapore allows Evonik to serve especially Asian growth markets well. The specialty chemicals company produces DL-methionine at world-scale plants in Antwerp (Belgium), Wesseling/Cologne (Germany), Mobile (Alabama, USA), and Singapore.
Wacker Launches Self-Emulsifying High-RefractiveIndex Silicone Fluid Munich, Germany: Wacker launched a new phenyl silicone fluid for water-based formulations at in-cosmetics Brazil. BELSIL PF 200 is an innovative product which offers a wide range of benefits. Its high refractive index enables the formulation of shampoos, conditioners and hair sprays that enhance shine and gloss and produce a soft feel. It also has excellent processing properties, being self-emulsifying in water and readily miscible with cosmetic oils and esters, thus facilitating transparent formulations. BELSIL PF 200 is a phenyl-modified polydimethylsiloxane whose chemical structure has a large number of beneficial properties, such as a high refractive index, which imparts high shine and gloss, and good surface characteristics which ensure that hair stays pleasantly soft and supple even after being washed or styled. The product also offers significant processing advantages: unlike conventional phenyl silicone fluids, which are not readily miscible with water, BELSIL PF 200 is selfemulsifying in water due to its polarity. Wacker’s focus at in-cosmetics Brazil beyond BELSIL PF 200 will include BELSIL ADM 8301 E, a silicone emulsion specifically developed for hair treatments. In addition to lending hair a natural, silky softness, and making it easy to comb, the new emulsion also helps prevent hair from losing colour and protects it from heat damage caused by blow dryers. BELSIL ADM 8301 E is available as a microemulsion. The active silicone ingredients contained in this emulsion form a protective film on the surface of the hair. This product is suitable for rinse-off and leave-on hair-care formulations and for hair-styling products. BELSIL ADM 8301 E is translucent, making it possible to formulate transparent products. Chemical Engineering World
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CEW Industry News BASF Opens Construction Chemicals Production Facility in Lagos Lagos, Nigeria: BASF has inaugurated its new production plant for concrete admixtures in Lagos, Nigeria. The production site is BASF’s answer to the increasing demand for construction chemicals in western Africa. BASF produces standard and custom-made performance concrete additives, so-called admixtures, from the company’s comprehensive Master Builders Solutions portfolio. “We are now able to rapidly supply our customers with admixtures for all cement and aggregate types, whether their construction projects are located in the urban areas of western Africa or in more remote sites,” said Nair Narayanan, Country Manager for BASF Construction Chemicals, West Africa. “We as experts in construction chemistry are where our customers need us with the foremost aim to fulfil the many needs and requirements of the industry in Nigeria, and then to further expand the business to export to neighbouring west African countries such as Ghana, Liberia, Benin, Togo, Burkina Faso and the Ivory Coast”, added Narayanan.
EuroChem Ships First Phosphate Rock from Kazakhstan Mine Zurich, Switzerland: Swiss agrochemical company EuroChem has completed its first intra-group delivery of ground phosphate rock from its mining operations in Kazakhstan. EuroChem-Belorechenskie Minudobrenia (BMU), a unit of EuroChem, took delivery of around 11,000t of phosphate rock, which contains an average of 30.5 per cent phosphorus oxide content. In southern Russia, EuroChem-BMU produces phosphate and compound fertilisers. EuroChem expects to ship more than 50,000t of ground phosphate rock from its Kazakh mining facility to its phosphate plants in Russia and Belgium by the end of this year.
Jordan, India Open USD 860m Phosphoric Acid Plant Amman, Jordan:India and Jordan have jointly inaugurated a USD 860m sulphuric acid plant at Eshidiya, located 325km from Jordan’s capital Amman. Considered to be the largest sulphuric acid plant in the world, the facility has been built in a joint-venture between Indian Farmers Fertiliser Cooperative Limited (IFFCO), and Jordanian Phosphate Mines Company (JPMC). The partnership was struck in 2007, and is expected to fulfill India’s phosphate requirements in the agr icultural sector. Jordan’s Aqaba por t, located close to the plant, will expor t phosphoric acid produced at the plant to the Kandla port in Gujarat. “In the case of this particular project, we and our Indian partners are working on converting around two million tonnes of rock phosphates extracted from Eshidiya Mine into phosphoric acid, a major component of several types of fertilisers, which will then be purchased by IFFCO to manufacture its complementary products in India, JPMC chairman Amer al-Majali stated to Jordan news agency Petra. 14 • October 2015
Praxair Starts up New Air Separation Plant Conn, USA: Praxair, Inc has announced the start-up of its new air separation plant at the Liaoning Oxiranchem, Inc. (Oxiran) facility in Yangzhou Chemical Industrial Park, Jiangsu Province, China. Praxair is the exclusive industrial gas supplier in the growing chemical park in east China, which has port access to the Yangtze River. Through a long-term contract, the 600-ton-per-day plant will supply on-site, high-purity oxygen and nitrogen to Oxiran, a leading industrial company focused on the development and sale of ethylene oxide derivative (EOD) chemicals in China. EOD chemicals are used in a variety of applications including the manufacturing of bottles and production of polyester fibres. “Praxair China is proud to expand upon the strong relationship we have enjoyed with Oxiran for many years,” said John Panikar, president of Praxair Asia. “As the exclusive industrial gas supplier in the park, we look forward to supporting Oxiran’s growth and leadership position in China’s EOD market while also meeting the needs of a diverse set of customers throughout the region.”
MHPS Receives Order for 2 Sets of H-25 Gas Turbine and Generator Yokohama, Japan: Mitsubishi Hitachi Power Systems, Ltd (MHPS) has received an order for two sets of its natural gasfired H-25 gas turbine and generator to be installed at a fertiliser production plant, which Turkmenhimiya, a state-owned chemical company in Turkmenistan, is building in the city of Garabogaz. The power generation system is scheduled to go on-stream in June 2018. The order marks the first H-25 gas turbine to be supplied to Turkmenistan. The fertiliser plant is currently being constructed in the northwest region of Turkmenistan, on the coast of the Caspian Sea, by Mitsubishi Heavy Industries, Ltd (MHI), jointly with GAP Insaat Yatirim ve Dis Tiscaret A S, a Turkish construction company, and Mitsubishi Corporation. The plant will be one of the largest urea fertiliser production plants in the country. The two sets of gas turbine and generator on order, with a combined power output of 50 megawatts (MW), will serve as the core equipment of an in-house co-generation (combined heat and power supply) system to operate in the plant. In recent years Turkmenistan has undergone steady economic growth sustained by its abundant reserves of natural gas, ranked 4th in volume worldwide. Today the Turkmenistan government is aggressively promoting development of high-value-added natural gas products as well as diversification of the country’s gas exports and sales channels, and construction of the new fer tiliser plant in Garabogaz is an integral component of these initiatives. Chemical Engineering World
CEW Industry News Brenntag to Acquire Strong Industrial Chemicals Distribution Base across Asia Pacific
NCBR, Synthos SA Together For Benefit of Innovation in Polish Chemical Sector
Mülheim an der Ruhr, Germany: Brenntag, the global market leader in chemical distribution, has signed an agreement to acquire TAT Group, a Singapore based distributor for industrial chemicals. The company’s facilities in Singapore cover supply chain requirements and value added services including modern blending, packaging, storage and logistics facilities. Via its subsidiaries in Singapore, South Korea, Vietnam, Hong Kong and Indonesia, TAT offers its local and overseas customers a broad product range of solvents and related products. “TAT has a strong market position and reputation as well as high coverage in South East Asia, Hong Kong and South Korea. The acquisition is a significant complement and important investment into Brenntag’s geographic and strategic position in Asia Pacific. TAT’s distribution network serves a broad customer base in the coatings, pharmaceutical, plastics, electronics and other industries and will contribute to further enhance Brenntag’s relationships with its Global Key Accounts as well as major suppliers,” said Steven Holland, CEO Brenntag Group.
Warsaw, Poland: On 21 July the National Centre for Research and Development (NCBR) and Synthos SA signed an agreement under which they will launch an open innovation-based project dedicated to the chemical industry. The partners will jointly allocate PLN 200 million to support R&D. The aim of the implementation of this joint venture by the NCBR and Synthos SA is to develop and implement a new generation of chemical products that will contribute to the innovativeness of the Polish chemical industry. Thanks to this co-operation, the best R&D projects will receive support for which the partners decided to allocate PLN 100 million each. “Polish chemical companies have great potential. The best strategy to make use of this is to develop on the basis of new technologies. Investment in innovation allows obtaining a lasting competitive advantage. It is pleasing to me that one of the leaders of the Polish chemical market has decided to develop new technologies in co-operation with Polish scientists. Together with our partner we undertake the project, which will fund top level R&D that can increase the competitiveness of the Polish economy and thus affect everyone’s standard of living”, said Prof Krzysztof Jan Kurzydłowski, Director of the NCBR
Pepperl+Fuchs Acquired MACTek Corporation Ohio, USA: Pepperl+Fuchs, a world leader in process automation and applications, has acquired MACTek Corporation, a leading provider of HART protocol devices. The move is part of Pepperl+Fuch’s strategy to further extend its integrated solutions offerings and strengthen its position in the WirelessHART market. “We are pleased to add the MACTek WirelessHART product line to our existing portfolio. This acquisition complements our current product lines well, and allows us to provide an even greater breadth of services to our customers,” said Jim Bolin, Executive Vice President – the Americas, Pepperl+Fuchs. Founded in 1993, MACTek specialises in HART modems, including VIATOR HART Interface modems. One of the company’s most recent innovations, the BULLET WirelessHART adapter, can be mounted on any device rated for hazardous areas. The HART modem family includes wireless access to HART field devices designed for hazardous areas and Bluetoothenabled technologies.
Inovyn to Open Potassium Hydroxide Plant in Antwerp, Belgium Inovyn is planning to open a potassium hydroxide (KOH) production facility, with an annual production capacity of 160,000t, at its Lillo site in Antwerp, Belgium. The construction of the new plant will be completed by the end by 2017. Inovyn has already started working on the project, which includes key additional site infrastructure and procurement of major plant items. Jean-Michel Mesland, Operations Director, Inovyn, said, “This is a very exciting project for INOVYN and we are delighted with progress made so far. Through this project Inovyn is leading the way in providing continuity of supply to customers at a time when mercury based production plants need to be closed or converted, Mesland added. Inovyn’s Antwerp site directly offers chlorine, which is co-produced with KOH through pipeline to its customers. 16 • October 2015
Linde Develops a New Production Process for Synthesis Gas Munich, Germany: The Linde Group officially opened the new Linde Pilot Reformer research facility at Pullach near Munich – Linde’s largest location worldwide. The event was attended by customers, par tners and employees. Linde has invested approximately Euro 5 million in total to expand Pullach’s research and development capacity. The Linde Pilot Reformer will be used to refine steam reforming technology for the production of synthesis gas – a mixture consisting of hydrogen (H 2) and carbon monoxide (CO). The carbon feedstock for synthesis gas can be in the form of natural gas, liquid petroleum gas (LPG), naphtha or even carbon dioxide (CO2). “Inventiveness and innovation are ingrained in Linde’s DNA. The official opening of the pilot reformer provides further proof of our customer-centric approach to development and sends a strong signal confirming Germany’s role as an innovation hub,” commented Dr Wolfgang Büchele, Chief Executive Officer, Linde AG.
Blast at Shandong Chemical Factory Kills Nine Beijing, China: Shandong Tianbao Chemical Industry factory’s blast has killed nine people. The accident occurred at a Shandong Tianbao Chemical in Pingyi County, Linyi City in the morning and damaged 401 workshops. This was the latest industrial accident to hit the country, which also injured two other people working in a neighbouring workshop, one of whose condition is critical. Chemical Engineering World
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CEW Industry News Perstorp Polyols Signs Agreement with Nexeo Solutions
Lukoil Commissions Second Catalytic Cracking Complex of Vacuum Gas Oil
Stockholm, Sweden: Following the overall review of the Group’s use of sales channels, specialty chemicals company Perstorp announced the signing of a distributorship agreement between Perstorp Polyols Inc. (Toledo, Ohio) and Nexeo Solutions, LLC (formerly Archway Sales, St. Louis).
Moscow, Russia: The second Catalytic Cracking Complex of vacuum gas oil (CCC-2) has been commissioned at the LUKOILNizhegorodnefteorgsintez refinery (a fully owned subsidiary of PJSC LUKOIL) in Kstovo (Nizhny Novgorod Region) today. Dmitry Medvedev, Prime Minister of the Russian Federation, Mikhail Babich, Presidential Plenipotentiary Envoy to the Volga Federal District, Valery Shantsev, Governor of Nizhny Novgorod Region, and Vagit Alekperov, President of PJSC LUKOIL, took part in the ceremonial launch. Construction of CCC-2 began in 2010 following the launch of the first Catalytic Cracking Complex that allowed LUKOIL-Nizhegorodnefteorgsintez to switch to production of Euro-5 class fuels. The launch of CCC-2 will increase the production of Euro-5 class fuels by 1.1 million tons (the annual production of the refinery is currently 3 million tons). Production of propylene, raw material for petrochemistry, will increase nearly twofold, up to 300 thousand tons per year. The investments in the project came to USD 1 billion. Therefore LUKOIL completed the obligations under the quadruple agreement between the oil companies, the Federal Antimonopoly Service of the Russian Federation, Rostechnadzor and the Federal Agency on Technical Regulating and Metrology.
As of September 2015, Nexeo Solutions will be responsible for distributing a wide range of Perstorp’s specialty products, including Capa caprolactones, Charmor carbon sources for intumescent systems and Alkoxylated polyol product lines. The distributorship agreement covers the Southeast, Ohio Valley and Central United States regions, excluding the West Coast and Northeastern regions. “We see a natural synergy between the performance offered by Perstorp’s specialty product lines and the ability of Nexeo Solutions to bring that value to new and existing customers. Nexeo Solutions will optimise the “solutions” component of our customer offering,” Rob Magro, Perstorp’s Sales Director of Specialties and Solutions for the Americas Region, said.
Celanese, Mitsui Sign Agreement for Methanol Unit in Texas Texas, USA: Celanese Corporation and Mitsui & Co Ltd of Tokyo, Japan, entered into an exclusive arrangement to explore a joint venture for methanol production at Celanese’s integrated chemical plant in Bishop, Texas. The potential methanol unit at Bishop is expected to have an annual capacity of 1.3 million tons and would leverage the design benefits of the Clear Lake, Texas methanol unit that is currently under construction. Celanese has filed for air permits with the Texas Commission on Environmental Quality for a potential methanol unit in Bishop, Texas and a final decision to build the unit will consider several factors, including prevailing methanol market conditions as well as construction costs. The companies also entered into an amended five year arrangement for Celanese to purchase methanol from Mitsui, upon completion of the methanol unit at their joint venture in Clear Lake, Texas. Start-up of the unit is expected in October 2015. “We are pleased to expand our partnership with Mitsui. Together with Mitsui, we will explore the benefits of an additional methanol unit at our Bishop, Texas facility to ensure our long-term and competitive supply of methanol,” said Mark Rohr, Chairman and Chief Executive Officer, Celanese Corporation. “The supply agreement, along with our own methanol production at Clear Lake, Texas, will ensure that we are balanced in our methanol needs in the US, but it will not completely offset our methanol-related earnings headwinds.” 18 • October 2015
Dow to Sell Stake in Kuwait JV to Greater EQUATE Michigan, USA: The Dow Chemical Company intends to restructure its participation in its group of Kuwaiti Joint Ventures with the objective of optimising its investment and expanding its relationship with Greater EQUATE on the US Gulf Coast. This announcement aligns with Dow’s prior stated commitments to optimise its investments in certain joint ventures. The optimisation is expected to occur in two phases. Under the first phase, EQUATE would acquire MEGlobal for a total equity consideration of USD 3.2 billion. The transaction will result in Dow receiving USD 1.5 billion in pre-tax proceeds. Following completion of this acquisition, which is expected to close by year-end 2015, Dow will retain a 42.5 per cent ownership stake in MEGlobal through its ownership of Greater EQUATE. This acquisition is also expected to drive efficiencies and cost savings due to existing synergies between MEGlobal and EQUATE.
Total awards FEED Contract to CB&I for USD 2bn Ethylene Cracker Project Paris, France: French energy group Total has started front-end engineering and design (FEED) for the construction of a USD 2 billion steam cracker project at its Port Arthur facility in Texas, US. The plant will have the capacity to produce one million tonnes of ethylene a year. For the new project, Total has awarded a contract to Woodlands-based CB&I to provide its ethylene technology and front-end engineering and design (FEED) services for the proposed new ethane cracker. Under the deal, CB&I will also provide seven SRT cracking heaters for the second integrated steam cracker to be built at its Port Arthur complex. A final decision on the project is yet to be made. Chemical Engineering World
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CEW Technology News
Scientists Paint Quantum Electronics with Beams of Light Chicago, USA: A team of scientists from the University of Chicago and Penn State University has accidentally discovered a new way of using light to draw and erase quantum-mechanical circuits in a unique class of materials called topological insulators. In contrast to using advanced nanofabrication facilities based on chemical processing of materials, this flexible technique allows for rewritable ‘optical fabrication’ of devices. This finding is likely to spawn new developments in emerging technologies such as low-power electronics based on the spin of electrons or ultrafast quantum computers. “This observation came as a complete surprise. It is one of those rare moments in experimental science where a seemingly random event—turning on the room lights—generated unexpected effects with potentially important impacts in science and technology,” said David D Awschalom, the Liew Family Professor and deputy director in the Institute of Molecular Engineering at UChicago, who was one of two lead researchers on the project. “To be honest, we were trying to study something completely different. There was a slow drift in our measurements that we traced to a particular type of fluorescent lights in our lab. At first we were glad to be rid of it, and then it struck us—our room lights were doing something that people work very hard to do in these materials,” said Andrew Yeats, a graduate student in Awschalom’s laboratory and the paper’s lead author. Read more about the research on news.uchicago.edu
Single Atom Alloy Platinum-Copper Catalysts Boost Green Technology Massachusetts, USA: A new generation of platinum-copper catalysts that require very low concentrations of platinum in the form of individual atoms to cleanly and cheaply perform important chemical reactions is reported by Tufts University researchers in the journal Nature Communications. The Tufts researchers discovered that dispersing individual, isolated platinum atoms in much less costly. Copper surfaces can create a highly effective and cost-efficient catalyst for the selective hydrogenation of 1,3 butadiene, a chemical produced by steam cracking of naphtha or by catalytic cracking of gas oil. Butadiene is an impurity in propene streams that must be removed from the stream through hydrogenation in order to facilitate downstream polymer production. The current industrial catalyst for butadiene hydrogenation uses palladium and silver. Copper, while a relatively cheap metal, is not nearly as catalytically powerful as platinum, noted Professor of Chemistry Charles Sykes, PhD, one of the senior authors on the paper. The researchers first conducted surface science experiments to study precisely how platinum and copper metals mix. “We were excited to find that the platinum metal dissolved in copper, just like sugar in hot coffee, all the way down to single atoms. We call such materials single atom alloys,” said Sykes. The Tufts chemists used a specialised low temperature scanning tunneling microscope to visualise the single platinum atoms and their interaction with hydrogen. “We found that even at temperatures as low as minus 300 degrees F these platinum atoms were capable of splitting hydrogen molecules into atoms, indicating that the platinum atoms would be very good at activating hydrogen for a chemical reaction,” Sykes said. Know more on now.tufts.edu/news-releases/ 20 • October 2015
Low-cost wafers for solar cells Freiburg im Breisgau, Germany: Silicon wafers are the heart of solar cells. However, manufacturing them is not cheap. Over 50 per cent of the pure silicon used is machined into dust. A new manufacturing technique developed by Fraunhofer researchers puts an end to these material losses, with raw material savings of 50 per cent along with an 80 per cent reduction in energy costs. A key component of solar cells are thin silicon wafers. The manufacture of these wafers is very time and energy consuming, and correspondingly expensive. What is more, around half of the silicon is lost during production of the wafers. This is not the case with the new process developed by researchers at the Fraunhofer Institute for Solar Energy Systems ISE in Freiburg. “With our method, we can avoid almost all of the losses that occur during the conventional production process. This means we are reducing material losses by 50 per cent while using 80 per cent less energy,” says researcher Dr Stefan Janz at the ISE. In short, the wafer grows exactly how the researchers want it to, with no need for cumbersome sawing – a process step that wastes almost half of the high-purity input material. Another advantage of the new process is that it allows the wafers to be made as thin as desired. With the conventional process, the silicon wafers must be at least 150 to 200 micrometres thick, as otherwise the cutting losses would be too high. But solar cells can make do with far thinner wafers. And the thinner the wafer, the cheaper the solar cell. So the new process saves material in two ways: by avoiding a wasteful wafer manufacturing process and by permitting reduced wafer thicknesses. Read more on www.fraunhofer.de/en/press/research-news
Toward Clearer, Cheaper Imaging of Ultrafast Phenomena Washington, USA: Many mysteries of nature are locked up in the world of the very small and the very fast. Chemical reactions and material phase transitions, for example, happen on the scale of atoms — which are about one tenth of one billionth of a metre across — and attoseconds — which are one quintillionth (10^-18) of a second long. A research team from Massachusetts Institute of Technology (MIT), Massachusetts, in collaboration with the Singapore Institute of Manufacturing Technology (SIMTech), Singapore, have proposed a new technique that may help record better images of such ultrafast phenomena. Ultrafast electron pulses are one tool scientists use to probe the atomic world. When the pulses hit the atoms in a material, the electrons scatter like a wave. By setting up a detector and analysing the wave interference pattern, scientists can determine information like the distance between atoms. Conventional electron pulse technology uses a static magnetic field to compress the electrons transversely. However, the static field can interfere with the electron source and the sample and lead to temporal distortion of the electron pulses — both of which can lead to lower quality images. Read more on the research at www.osa.org/en-us/ Chemical Engineering World
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CEW Technology News Africa’s urban waste, a valuable source of electricity
Faster Design, Better Catalysts
Brussels, Belgium: Estimated electricity production from the total waste generated in Africa could reach 122.2 TWh in 2025, or more than 20 per cent of the electricity consumed in 2010 at continental level (661.5TWh), according to a JRC co-authored study which analysed the potential of urban solid waste for Africa’s electricity needs. This is an equivalent to the energy needed for 40 million households in 2025 in Africa. However waste management is poor – the potential electricity of waste actually collected was estimated at 83.8 TWh in 2025. Still, this represents energy needed for 27 million families in 2025, considering the average electricity consumption in 2010 in Africa. Many Africans do not have access to energy. Besides providing an interesting share of gross energy consumption and electricity as a renewable resource, energy recovered from waste could also help minimise the impact of municipal solid waste on the environment. The study Evaluation of energy potential of Municipal Solid Waste from African urban areas provides an estimate of the total potential of energy from waste incineration and from landfill gas (LFG) 2025 for each African country. In 2010, there were more than 600 waste-to-energy facilities in the world, most of them in Europe (472), Japan (100) and the US (86). In Africa, a very limited share of waste is recovered and reused, and only major or capital cities have waste management systems. In a number of countries, the use of waste to generate electricity could have a significant impact. Waste can have a very high contribution to providing electricity to citizens and alleviate energy poverty especially in countries with low access to electricity and reduced electricity consumption per capita, such as the Central African Republic, Burundi, Guinea-Bissau, Mali, Sierra Leone, Rwanda and Somalia.
Garching, Germany: While the cleaning of car exhausts is among the best known applications of catalytic processes, it is only the tip of the iceberg. Practically the entire chemical industry relies on catalytic reactions. Catalyst design plays a key role in improving these processes. An international team of scientists has now developed a concept that elegantly correlates geometric and adsorption properties. They validated their approach by designing a new platinum-based catalyst for fuel cell applications. Hydrogen would be an ideal energy carrier: Surplus wind power could split water into its elements. The hydrogen could power fuel cell-driven electric cars with great efficiency. While the only exhaust would be water, the range could be as usual. But fuel cell vehicles are still a rare exception. The required platinum (Pt) is extremely expensive and the world’s annual output would not suffice for all cars. A team of scientists from Technical University of Munich and Ruhr University Bochum (Germany), the Ecole normale superieure (ENS) de Lyon, Centre national de la recherche scientifique (CNRS), Universite Claude Bernard Lyon 1 (France) and Leiden University (Netherlands) have set out to determine what constitutes an active centre
New Molecular Modelling Techniques for Catalysis in Unmixed Systems Ames, USA: Scientists at the US Department of Energy’s Ames Laboratory have developed molecular modelling simulations and new theoretical formulations to help understand and optimise catalytic reactions that take place in chemical environments where the reactant ‘ingredients’ for catalysis are not well mixed. In catalysis a chemical reaction is accelerated by adding another component, the catalyst, which remains unchanged during the reaction. In many cases, such as when the catalytic reaction takes place in a solution, the reactants are able to mix together easily (and are sometimes stirred to ensure mixing). This mixing is assumed in standard theories of chemical kinetics that describe how quickly and efficiently catalytic reactions occur. But not all catalytic reactions occur where ingredients are able to mix. For instance, catalytic reactions to create fuels in mesoporous particles and to remove pollutants in high-pressure surface reactions happen in unmixed systems. And for those cases, the standard analysis of chemical kinetics needed to be refined. In papers that appeared recently in Chemical Reviews and the Journal of Chemical Physics, Ames Laboratory chemists Jim Evans, Dajiang Liu and their research team focused on modelling reactions in three classes of catalytic environments where chemical components do not easily mix. Read more about the research on www.ameslab.gov/news/ 22 • October 2015
In order to validate the accuracy of their new methodology, the researchers computationally designed a new type of platinum catalyst for fuel cell applications. The model catalysts were prepared experimentally using three different synthesis methods. In all three cases, the catalysts showed up to three and a half times greater catalytic activity. To know more log on to www.tum.de/en/about-tum/news
New Type of Bed Material Turbo Charges Combined Heat and Power Plants Göteborg, Sweden: Researchers at Chalmers University of Technology have discovered that a certain bed material improves the combustion efficiency of waste and biomass while decreasing operating and maintenance costs significantly. In collaboration with the energy supplier Eon, the researchers have proven the concept in today’s commercial boilers. The findings make combined heat and power (CHP) technology highly interesting both from a profit and a climate perspective, and open up for smarter next generation designs. The discovery of how metal oxides’ oxygen-carrying properties can be used in circulating fluidised bed (CFB) boilers has been verified and scaled up from the lab to commercial reality within record time. During last winter, from November 2014 to May 2015, researchers at Chalmers University of Technology and Eon personnel have conducted long-term testing with a new bed material in a state-of-the-art combined heat and power (CHP) plant, Händelöverket in Norrköping. “This brings forth an array of positive effects, which testing completed in Norrköping confirms. The combustion becomes more uniform and efficient. The boiler’s total efficiency increases. The emission of carbon monoxide is lowered radically, as are problem related to ash fouling,” says Fredrik Lind, PhD at the Department of Energy and Environment and project coordinator at Chalmers University of Technology. Read more on www.mynewsdesk.com/uk/chalmers Chemical Engineering World
CEW News Features
Bharat Petroleum to Commence Work on Kochi Refinery Expansion
B
h a r a t Pe t r o l e u m C o r p o r a t i o n (BPCL), India’s second-biggest gover nment-owned refiner and fuel marketer is all set to star t work on ` 5,000-crore project at its Kochi Refinery. According to S Varadarajan, Chairman and Managing Director, BPCL, the company has all the permissions in place from the Environmental Ministry and other regulatory authorities for the ` 5,000-crore petrochemicals complex in Kochi. The company is hopeful to resume work and complete it as per schedule in 2018. The Kochi petrochemical project is par t of the ` 1 lakh crore planned CAPEX for the next five years. BPCL has decided to spend ` 40,000 crore for refinery expansion. The expansion of Kochi petrochemical project is likely to end India’s dependence o n i m p o r t s o f s p e c i a l i t y p r o py l e n e derivatives-based products such as acr ylic acids and acr ylates used in plastics, paints, coatings, adhesives, inks and textiles, the company claimed. BPCL had earlier signed a MoU (memorandum of understanding) with LG Chemicals for this project and had even agreed to offer 51 per cent stake in the JV (joint venture). However, LG Chem did not confirm its participation in the project. Benzene, toluene and propylene are some of the products which are being produced at the refiner y. After the expansion, it will be able to process Euro-V petrol and diesel. The refinery is likely to produce 250 million tonnes of speciality propylene derivative products, which are fully imported now. BPCL has declared to invest about ` 100,000 crore in the next five
26 • October 2015
years. The company has embar ked on a new five-year plan called project S a n k a l p u n d e r w h i c h t h e c o m p a ny will be doubling its investments. The 1 lakh crore investments in next five years by BPCL will include refining capacity expansion from 30 mtpa to 50 mtpa, upstream investment of about ` 25,000 crore for Mozambique and Brazil projects and expansion of downstream operations in Nepal, Bangladesh, Ghana, and Tanzania. Indian petrochemical industry may touch USD 100 Billion by 2020 Petrochemicals currently contr ibute about 30 per cent to India’s USD 120 Billion worth chemical industry, which is likely to grow at a CAGR of 11 per cent over next few years and touch USD 250 Billion by 2020, reports ‘Indian Petrochemical Industry: An overview’ a study by the Associated Chambers of Commerce and Industr y of India (ASSOCHAM).
petrochemical industry is growing at a superb pace, with the middle class household boosting the consumption and also annually contr ibutes over ` 8,000 crores by way of taxes and duties to the national exchequer” said Rawat. “India stands a good chance of providing a lucrative market to the world as the general trend in the global petrochemicals market has shifted to the Middle-East and Asia from the West. Encouragement for investment has been another significant growth factor for the petrochemical industry as the capacity of different products is in production, segmentation, and consumption trend of each of the products and so the economies of scale play a very important role in the profit making mechanism of this industry, thereby determining scope of each of the competitors in the industry,” he added further.
T h e r e p o r t w h i c h wa s r e l e a s e d i n the month of April 2015, states that petrochemicals sector is one of the fastest growing segments with a growth rate of 13 per cent which is more than twice of growth of India’s gross domestic product (GDP) and also the global growth rate in petrochemical space which is stagnant at 6 per cent. The study has been prepared by the Energy Division of ASSOCHAM. “Huge investments made in the petrochemical space bode well for the growth of this segment, besides there is a steadfast growth in the production activity of the main petrochemicals,” said D S Rawat, Secretar y General, ASSOCHAM while releasing the findings of the chamber’s study. “Polymers, which is the dominant par t of Indian Chemical Engineering World
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CEW Features Technical Article
Combating the Effects of Corrosion in Refineries with Duplex Stainless Steels As worldwide crude oil production levels intensify, duplex stainless steels are proving ever more crucial in withstanding corrosion challenges faced by oil refinery equipment, writes Mohan Gawande, Manager Chemical Group, India, Sandvik Materials Technology.
H
eat recovery processes are especially important to critical petroleum refining applications, supplying and reusing energy in order to help achieve more efficient, economic and productive processes. Nevertheless, corrosion aggravated equipment failures in heat exchanger tubes have always been a large and unavoidable issue in critical petroleum refining applications Traditional metallic tube components like carbon steels are failing to cope in the increasingly harsh corrosion environments, resulting in disruptive maintenance procedures or unplanned shutdowns. Such materials are extremely vulnerable to corrosion and austenitic stainless steels and, widely used in heat exchanger tubing, are susceptible to stress corrosion cracking (SCC) particularly in chloride bearing environments. According to statistics, such failures are thought to account for the losses of approximately 1-5 per cent of various countries’ gross domestic product (GDP) and around 6 per cent of the overall petrochemical industry’s GDP. The latter figure is twice as much as in other industries. Aside from the higher productivity demands, these problems are exacerbated by the decline in crude oil quality which is becoming sourer and more corrosive. For these reasons, it is ever more vital to select materials that can both withstand and eliminate failures throughout the plant. A wellconsidered material should possess superior anticorrosion and mechanical properties to help optimise equipment service lifecycles,
28 • October 2015
reduce the need for maintenance, prevent contamination of refinery products caused by corrosion and minimise heat losses caused by fouling of equipment. Corrosion factors in refineries The primary corrosion media in oil refineries include sulphides, chlorides, nitrides, hydrochloric acid, polythionic acid, oxygen and heavy metals. These elements tend to react under the dew point temperature, when vapour condenses into liquid water at the same rate at which it evaporates. Either in water or during catalysis, this condensation can cause serious corrosion in equipment. Dew point corrosion is generally initiated by the formation of hydrochloric acid, and chemical interactions between hydrochloric acid and hydrogen sulphide cause corrosion of the refinery equipment. Deposits in or on heat exchanger tubes emanate from the process side due to tenacious hydrocarbons, process slurries or even ammonium chloride (NH4Cl) deposits in crude overhead condensers. Non-hydrocarbon compounds and additives also build up during the refinery process resulting in further corrosion. These factors are detrimental to overall process efficiency and pose a threat to the refinery devices’ distillation, hydrotreating and catalytic reforming of crude oil. Corrosive elements in crude oil However, it should be noted that the main cause of corrosion in refinery applications from the process side is not the hydrocarbons themselves but the presence of contaminants in the crude oil as it is produced. Generally,
the heavier the oil the higher the boiling point. It is corrosion under high temperatures that causes carbon steel equipment to fail and leads to unplanned and costly maintenance, shutdowns or accidents. Most contaminants in crude oil end up in the refinery tankage along with contaminants picked up during the transportation. Crude oil contaminants that affect corrosion resistance in steels include carbon dioxide (CO2), hydrogen sulphide (H2S), nitrogen compounds, sulphur compounds and inorganic chlorides such as sodium chloride (NaCl), magnesium chloride (MgCl2) or calcium chloride (CaCl2). Crude oil is normally more than 90 per cent naphthenic acid, of which corrosion is most intense in environments with elevated temperatures and without water, and occurs at its greatest potential at temperatures of 270-2800 C (518-5360 F). The corrosion rate of naphthenic acid declines at temperatures above 2800 C (5360 F), rises rapidly again at 3500°C (6620 F) and stops corroding above 4000°C (7520 F). One of the most corrosive phenomena that affect stainless steels is the reaction of sulphur with oxygen to create sulphur dioxide (SO2). Sulphur is present in most processes where coal or oil is combusted at high temperature, and Figure 1 presents an overview of trends relating to global crude oil gravity and sulphur content including data by the American Petroleum Institute (API). Different fractions of sulphur levels are shown in Table 1. SO2 corrosion rates vary under different temperatures. Sulphide does not decompose Chemical Engineering World
CEW Features Fractions
Gasoline
Kerosene
Diesel Fuel
Gas Oil
Residue
Sulphur levels (%)
<0.8
<5.2
6-15.5
13.5-44.5
43.6-76
applied to stainless steel which exposes test specimens to 6 per cent iron(II) chloride (FeCl) solution, also known as ferrous chloride, with and without crevices.
Source: Equipment corrosion status in refinery plant and solutions (part 1)* Table 1. Different fractions of sulphur levels.
under temperatures below 1200°C (2480°F), but corrodes and forms into a hydrogen sulfide (H2S-H2O type) under the dew point temperature or when it contains water. H2S is generated under temperatures between 2403400°C (464-6440°F) and is aggressive to carbon steel at these temperatures thereby corroding the equipment. Corrosion worsens as the temperature increases, reaching its highest peak when the temperature falls within the range of 420-4300°C (788-8060°F). A superior replacement grade to carbon steels must therefore be capable of retaining superior anti-corrosion properties at high operating temperatures. Mitigating plant shutdowns Utilisation of corrosion resistant materials not only eliminates unscheduled plant shut downs, but also reduces the risk of costly lost production and expensive emergency maintenance and repair. Consideration should also be given to the formation of crevice corrosion beneath such deposits at temperatures below the critical pitting temperature (CPT) of the material. Carbon steel is extremely vulnerable to corrosion and austenitic stainless steels, widely used in heat exchanger tubing, become susceptible to SCC particularly in chloride bearing environments. Research Quality of crude oil and condensate, API degrees
Sulphur - containing amount
API (American Petroleum Institute) degree according to the weighted average yeild Sulphur - containing amount
Source: Cambridge Energy Research Associates Figure 1. The trends of global crude oil API degrees and sulphur content.
30 • October 2015
has shown that these materials are highly susceptible to corrosion at the elevated operating temperatures found in refineries. Gradually, the industry has recognized the advantages of duplex stainless steels that offer the optimum combination of corrosion resistance, mechanical properties and excellent fabrication capabilities which all lead to genuine cost advantages. Development of duplex stainless steels Since the development of duplex stainless steels began in the 1930s, they have emerged as a favoured alternative to traditional carbon steel tube in corrosive heat exchanger applications. The first generation grades contained chromium (Cr), molybdenum (Mo) and a high content of carbon (C) with low weldability. Further developments into the 1970s reduced the content of C, and alloy elements that improved the material’s corrosion resistance such as Mo, copper (Cu), silicon (Si) and especially nitrogen (N) were added. These innovations led to the formation of a new ‘second generation’ of N-containing duplex stainless steels that included the 18Cr-type, 22Cr-type and 25Cr-type, and a further three generations of duplex stainless steels which emerged later in the 1980s. These had low C content but high amounts of Mo and N with content of ferrite that is about 50 per cent or slightly lower. Some of these grades were called ‘superduplex’ and characterised by a Pitting Resistant Equivalent (PRE) number of at least 40. The PRE number (=%Cr + 3.3x%Mo + 16x%N) is a measurement for ranking the resistance of stainless steels to pitting and crevice corrosion. Exact testing procedures to determine the PRE number are specified in the ASTM G48 standard, one of the most severe pitting and crevice corrosion tests
In general, the higher the PRE value the more corrosion resistant the steel. The pitting resistance value of a stainless steel is of great importance when assessing its suitability for heat exchanger applications, and also fabrication practices like welding which are of vital importance for performance in service. As a comparison, typical grades like AISI 316L and AISI 317L have insufficient PRE values to withstand many corrosive heat exchanger environments – even when working at the upper limits of their standards. Improved corrosion resistance Figure 2 illustrates a comparison of several commonly used refinery materials’ resistance to SCC. They include duplex Sandvik SAF 2304TM (UNS S32304) and super-duplex Sandvik SAF 2507TM (UNS S32750). Both Sandvik grades are well suited to heat exchanger applications, and each possesses a combination of good corrosion resistance and high mechanical properties for advantages like reduced wall thicknesses and lower processing costs. The materials have proven especially useful in corrosive heat exchanger environments and are helping to solve many of the problems faced by today’s oil refining industry. Key attributes of Sandvik SAF 2304 include low Ni content, and a two-phase microstructure with approximately 50 per cent ferrite which imbues the grade with a more stable metallurgy than comparably instable high-nickel alloys. A high 23 per cent Cr content compensates for an absence of the vital yet costly anticorrosion element Mo, and N content further increases the material’s strength while improving weldability and resistance to pitting corrosion. The nominal chemical composition of Sandvik SAF 2304 is shown alongside the Chemical Engineering World
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CEW Features 6.0 per cent Mo steels: it is more readily available and therefore offers lower initial costs. Figure 3 compares the material’s critical pitting and crevice temperature alongside standard steel grades according to ASTM G48. The super-duplex stainless steel’s antisulphide and chloride SSC resistance and crevice corrosion resistance capabilities have been further enhanced compared to austenitic grades., see Figure 4.
Figure 2. A comparison of several commonly used materials’ resistance to stress corrosion cracking (SCC).
standard materials ASTM 304L and ASTM 316L in Table 2 with, for comparison, the minimum PRE numbers of each material. The duplex stainless steel has a PRE number of 24 which suits the material for used in the harshest corrosive environments at a temperature range of -50 to 3000°C (58 to 5720°F). As Table 2 shows, the PRE number for Sandvik SAF 2304 is considerably higher than the number for AISI 304L and comparable to the number for AISI 316L. In practical terms, the grade demonstrates better resistance to SCC compared to austenitic steels of AISI 304 and AISI 316 type, and is demonstrably better than AISI 316L in most acid environments, with resulting cost advantages, see Table 3.
The data shows that Sandvik SAF 2507 is a competitive alternative to high alloyed austenitics and nickel alloys in applications where standard austenitic steels corrode at a high rate; it is demonstrably the best choice material for use in high-temperature heat exchangers containing chlorinated or nonchlorinated water. Cost advantages On many projects cost is of primary importance. However, the ability of a material to fully meet the application requirements Alloy
% cr
Sandvik SAF 2304
23
AISI 316L
17
AISI 304L
18.4
% Mo
has to be a major consideration for plant efficiency. Strength of the material is a significant factor. For example, selecting a duplex grade such as Sandvik SAF 2304, despite a higher price per kilogram, can prove to be the most economical solution. This is because the wall thickness of the tubes as they are subjected to internal pressure or tensile loads is directly related to the material strength. As thinner wall tubes can be specified, the cost of the duplex material can be around 35 per cent lower. This should be compared to the cost of tubes of other material grades which would require a thicker wall in order to achieve the same strength, see Table 3. There are also associated savings to be achieved on transport, installation, welding etc when specifying the lighter thinner walled duplex grade tubes. Successful application in heat exchangers The Sandvik duplex stainless steel grade Sandvik SAF 2304 and the super-duplex material Sandvik SAF 2507 are among the manufacturer’s advanced materials that %N
PRE
0.1
24
2.2
24 18
Table 2: The minimum PRE numbers for Sandvik SAF 2304 and the austenitic standard stainless steels AISI 316L and AISI 304L.
For example, lean duplex stainless steels, such as Sandvik SAF 2304, offer high strength with a yield strength twice that of AISI 304L and AISI 316L austenitic stainless steels, low thermal expansion, very good weldability, physical properties that provide design advantages, as well as ease of fabrication and toughness. When looking at super-duplex grades, such as Sandvik SAF 2507, based on the established PRE values of AISI 316L and its variants like AISI 317L, the minimum standard PRE value of 42.5 for Sandvik SAF 2507 identifies the super-duplex grade as superior. The performance levels are comparable to 6.0 per cent Mo austenitic stainless steels like 254 SMOTM and AL-6XN. Yet Sandvik SAF 2507 has distinct advantages over these 32 • October 2015
Figure 3. Critical pitting and crevice temperatures in 6 per cent FeCl, 24h (similar to ASTM G48).
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CEW Features Material
Strength R p 0.2 MPa
Estimated relative cost
Density (g.cm3) Wall Thickness* relative mm
Sandvik SAF 2304
400
1.05
7.75
1.65
AISI 304L
190
1.0
7.90
2.77
AISI 316L
210
1.08
8.0
2.77
Table 3. Cost comparison of Sandvik SAF 2304™ and AISI 304L/316L for tubes subjected to internal pressure or tensile loads.
in refinery equipment including H 2S, dew point corrosion, chloride pitting, NH4Cl and under-deposit corrosion.
Figure 4. Stress corrosion cracking (SCC) resistance in oxygen bearing (~8 ppm) neutral chloride solutions. Test time 1,000 h. Load ≥ yield strength at testing temperature.
have become success stories in oil refineries around the world, and each has exhibited high performance cost advantages. In the USA, a plant was experiencing inadequate performances in the AISI 316 tube in its heat exchangers. The tube, used to process maleic anhydride which is an organic compound for applications in coatings and polymers, had failed due to SCC after only 2-3 years’ service. Sandvik SAF 2304 was chosen as the replacement grade, of which 7350 m of 19.05 x 1.65 mm tube was installed in the secondary cooler after the reactor and would be required to operate at temperatures of 204-2320°C (400-4500°F). The material exhibited superior mechanical and physical properties, along with excellent resistance to SCC and other forms of corrosion. In another installation, a refinery was experiencing corrosion problems in its overhead condensers. The system comprised four heat exchangers which each contained 951 steel tubes of length 19.05 x 1.65 x 6096 mm. Used to process crude oil, the tube was subjected to many of the main media sources that cause corrosion 34 • October 2015
The existing tubes, made of carbon steel, were again exhibiting a maximum service life of 2 to 3 years when subjected to condensation of hydrocarbons and H2O in small amounts (30-100 ppm Cl and 2001000 ppm H2S) generally at pH levels of 6-7, 45-550°C (113-131 °F) inlet temperatures, inlet pressures of 0.078 – 0.12 MPa (0.81.2 kg/cm2) and outlet temperatures of 60750°C (140-1670°F). An inspection carried out in April 2000 revealed that the tubes were still in good condition, and a visual inspection found a good connection of the pipe’s tube plate. The tube’s interior had not been subject to corrosion; and examination of the exterior found no under-deposit corrosion. In contrast, a phenomena of general corrosion on the old carbon steel tube plate was observed. Between the years 2000 and 2011, a total of four new heat exchangers were subsequently put into use at the refinery all using the duplex material. Similarly, a refinery in Italy required replacement tube in six overhead condenser system heat exchangers. Each heat exchanger comprised 1,298 tubes made from AISI A179 steel. After two years of use, multiple tubes in the bundle experienced an early onset of failure. Sandvik SAF 2507 was installed in the heat exchangers in 2003. An inspection in 2006 revealed the heat exchangers to be in good condition, despite serious decomposition seen in the tube plates and shell passes. It was not until 2008 that, with moderate concentrations of hydro-cleaning, some signs of corrosion were found.
Conclusions As heat recovery processes remain at the forefront of economical and environmentally compliant processes, refineries must implement the most reliable materials to fully-realise these objectives and also remain cost-effective. Duplex and super-duplex stainless steels by Sandvik can realise these goals, while addressing the ongoing decline in crude oil quality and the failure due to corrosion of a range of materials, such as copper based alloys as well as different types of austenitic stainless steels. In such environments, duplex stainless steels provide excellent resistance to corrosion attack as recorded in extensive laboratory testing, as well as in successful documented installations in process plants and refineries worldwide. Ease of fabrication and the durability of duplex stainless steels means significant advantages, not only for new equipment but also when retubing existing heat exchangers. Further to these advantages, duplex stainless steel Sandvik grades are today included in numerous refinery and equipment manufacturers’ preferred procurement lists.
Author’s Details Mohan Gawande Manager, Chemical Group Sandvik Materials Technology Chemical Engineering World
CEW Features Technical Article
Chemical Characterisation in the Safe Handling of Acids and Caustics Employers must be aware of workplace hazards facing their employees and take appropriate action to minimise or eliminate exposure to these hazards. This paper discusses the hazards and the precautions that can prevent serious health risks to workers due to exposure to corrosives. Corrosive chemicals are essential to many work processes; however, they can enter the body through ingestion, inhalation, or contact with the skin and eyes.
E
mployee exposure to corrosives must be evaluated to determine the need for engineering and administrative controls as well as the need for personal protective equipment. The results from injuries can be severe and even fatal. Mists produced by liquids can result in lung damage if inhaled, serious burns or irritation can be the result of accidental contact to the skin or eyes, and lung and skin cancer have been linked to chromic acid. Additional threats to employees are posed by the ease with which many corrosive chemicals ignite, explode or react with incompatible substances. Acids and caustics have two common key properties; they are all corrosive and are extremely common in industry. Taking the time to ensure that acids and caustics are managed appropriately is critical to process safety. They can damage human tissue, and attack many other materials as well. They can react with metals, producing hydrogen gas which is highly flammable. Many acids and some caustics may have toxic properties, and they may release corrosive vapours at room temperature when in a concentrated form, such as nitric acid and hydrochloric acid. Some chemicals turn corrosive when they come into contact with water or humidity; for example, 1, 2-dichloroethane attacks iron and some other metals in the presence of moisture at high temperatures. Corrosive substances widely used in industry can be grouped into general classes, such as those that are listed below, in order to facilitate training and organising process safety information:
36 • October 2015
• • • •
Acids and acidic anhydrides Alkalis (bases/caustics) Halogens and halogen salts Organic halides, organic acid halides, esters, and salts • Miscellaneous corrosive substances (substances that are widely used but do not fall into the above-mentioned classes)
Due to potentially hazardous properties, it is extremely important to fully characterise all process stream raw materials, intermediates, by-products, products, and residuals/wastes that are corrosive or have the potential to generate corrosives. The characterisation should be used to develop prevention and control strategies in the programs such as mechanical integrity, management of change, process safety, hazard communication, personal protective equipment, industrial hygiene, engineering controls, uncontrolled emissions, permitting, and emergency response planning. Characterisation, Use, and Handing of Acids & Caustics The common term `corrosive substances’ originated in the United Nations Committee of Experts on the Transport of Dangerous Goods. In 1956, these were defined as: `These are substances which, by chemical action, will cause severe damage when in contact with living tissue or, in case of leakage, will materially damage or even destroy other goods or the means of transport; they may also cause other hazards’. Corrosive material may be in the form of: Gas (chlorine, nitrogen oxides, and ammonia); Liquid (sulphuric acid, and hypochlorite
solutions); or Solid (sodium hydroxide, and aluminium chloride). Groups of substances with corrosive properties include: • Acids and Anhydrides such as Acetic Acid and Acetic Anhydride; Phosphoric Acid and Phosphorous Trioxide; Sulphuric Acid and Sulphur Trioxide. • Alkalis (bases/caustics such as Sodium Hydroxide; Aqua Ammonia; Organic Amines such as Ethanolamine • Halogens and Acid Halides such as Chlorine gas; Iron (Ferric) Chloride; Chlorite solutions; Acetyl Iodide • Other Compounds such as Mercury; Ammonium Polysulfide; Hydrazine; Peroxides The US Department of Transportation (DOT) regulations consider a corrosive material to be a liquid or solid that causes visible destruction or irreversible alterations in human skin tissue at the site of contact or in the case of leakage from its packaging, a liquid that has a severe corrosion rate on steel. The DOT further develops this definition by offering the following: A liquid is considered to have a severe corrosion rate if its corrosion rate exceeds 1/4 inch per year on SAE 1020 low-carbon steel at a test temperature of 130 0°F. The pH scale is used to compare the level of acidity or alkalinity of various acids and bases and their diluted solutions. The pH value is related to the amount of hydrogen ions present in the solution. The pH of a neutral solution or substance is 7. Acids have a pH of that is less than 7, and Chemical Engineering World
CEW Features Substance
Concentration in Water
Effect on Concrete
Acetic Acid
Up to 10%
Negligible
Acetic Acid
10% and Above
Corrosive; Rate depends on Concentration
Acetic Anhydride
Concentrated
Slow decomposition
Ammonium Hydroxide
All Concentrations
None
Arsenic Acid
All Concentrations
None
Barium Hydroxide
All Concentrations
None
Boric Acid
All Concentrations
Negligible
Calcium Hydroxide
All Concentrations
None
Carbon Disulfide
Up to 99.8%
None
Formic acid
Up to 10%
Negligible
Formic acid
10% and Above
Slow decomposition
Hydrogen chloride
Up to 37% [Saturation]
Corrosive; Rate depends on Concentration
Hydrogen fluoride
All Concentrations
Corrosive; Rate depends on Concentration
Nitric acid
All Concentrations
Corrosive; Rate depends on Concentration
Oxalic acid
Up to 9% [Saturation]
Negligible
Perchloric acid
All Concentrations
Corrosive; Rate depends on Concentration
Potassium hydroxide
Up to 5%
Negligible
Potassium hydroxide
5% to 53% [Saturation]
Corrosive
Sodium hydroxide
Up to 1%
Negligible
Sodium hydroxide
1% to 52% [Saturation]
Corrosive
Sulphuric acid
All Concentrations
Corrosive; Rate depends on Concentration
Tartaric Acid
Up to 17% [Saturation]
None
Table 1: Effects of Some Corrosive Liquids on Concrete
bases have a pH that is greater than 7. The pH scale is logarithmic, and for every whole number increase or decrease, the pH changes 10-fold. For example, the alkalinity of wet cement is 30 million times higher than the pH of skin; a pH of 13, as compared to 5.5 for human skin. Strong acids may have a pH that is less than 1.0, and strong alkaline solutions can have pH values above 14. The health effects of acids and caustics resemble those caused by heat. Effects of direct contact vary from irritation causing inflammation, to a corrosive effect causing ulceration, and, in severe cases, chemical burns. Occupational hazards due to contact with corrosives mostly affect skin, eyes and the respiratory tract. The tissues most susceptible to rapid, severe, and often irreversible damage are those of the eyes. The effect depends on the properties of the substance, on its concentration, and the time of contact with acid or caustic. Even a dilute solution may cause irritation 38 • October 2015
Controlling the Hazards of Acids and Caustics Engineering and administrative controls can be used to reduce employee exposure to corrosive liquids, and mists or dusts in the air and – in particular – to lessen the hazard of direct contact of corrosive materials with the eyes, lungs, and skin.
Administrative controls include: Operating procedures and training to reduce unplanned or uncontrolled releases associated with the handling, transporting, processing, and storing of corrosive liquids; Safety procedures – including lock-out and confined-space entry – to reduce employees’ exposure duration to liquids, mists, and vapours; and Hazard Analysis to identify unrecognised sources of exposure to corrosive liquids. .
Engineering controls include: Eliminating the use of a corrosive liquid, or replacing it with a liquid that is less corrosive; Containment of acids and caustics, in equipment that is constructed from materials that can resist corrosion, or where a corrosion allowance is provided for a known corrosion rate; Limitation of process temperatures to minimise corrosion rates; and Local exhaust ventilation (hoods, or process enclosures) to limit personnel exposures to corrosive vapours.
The characteristics of corrosive materials are both general and specific. Effective process safety management includes both the toxic and physical hazards associated with process chemicals. Information on the properties of a given substance should be obtained before handling. The use of testing and screening tools such as corrosivity and compatibility tables (Tables 1 to 4), safety data sheets, and/or chemical safety cards can be helpful in evaluating chemicals prior to purchase and process changes. Proper hazard assessment is key
with prolonged or repeated contact, for example with skin.
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CEW Features Plastics
Max. Temp. (oC)
Typical Uses
PVDF (polyvinylidene fluoride)
Storage tanks and pipes for sulphuric acid, nitric acid, hydrogen chloride, hydrogen fluoride Vaporisers Drying tower for chlorine Scrubbers and pipes for sulphuric acid, phosphoric acid, hydrogen chloride, hydrogen fluoride 100 Dilution tank for sulphuric acid
FEP (fluorinated ethylene propylene; tetrafluoro ethylene)
95 120 90 90 100
LPE (linear high density polyethylene)
90 85 70 70
Electrolytic bath Pipes Equipment for sulphuric acid regeneration Tanks containing chlorine Pipes for chlorine
Room Laboratory bottles temperature
PP (polypropylene)
80 80 70 70 70 60
Pipes for sulphuric acid, hydrogen chloride, hydrogen fluoride Entrainment separator for sulphuric acid, phosphoric acid, hydrogen fluoride Storage tanks for sulphuric acid, hydrogen chloride Gas pipes for sulphuric acid, sulphur dioxide, sulphur trioxide Scrubbers of sulphuric acid, phosphoric acid Blowers, fans
PVC (polyvinyl chloride, rigid)
50 50 50 30 40
Surface treatment baths and pipes Entrainment separator for sulphuric acid, chromic acid Pipes for sodium chlorate Storage tanks for hydrogen chloride Blowers, fans
Table 2: Uses of Plastics for Corrosive Liquids
to process safety, which includes support â&#x20AC;&#x201C; upstream and downstream â&#x20AC;&#x201C; processes, materials, and activities. It is important to ensure that receiving, warehousing, and logistics employees are able to stage and properly store chemicals upon arrival. In addition, a hazard evaluation checklist can be used in the change-control process to identify potential hazards within operations where these chemicals may be processed and/or generated. The Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules require specific preventive actions that the employers need to implement. The occupier is responsible to ensure safe operation and adequate engineering and administrative control to provide safe operating facility to its employees and neighbouring population. The Process Safety Management (PSM) provides good guidance for gauging process safety awareness. Chilworth offers PSM gap analysis, training, process 40 â&#x20AC;˘ October 2015
hazard reviews and audits to assist clients in proactively managing process hazards on a global basis, including India. Storage of Corrosive Raw Materials and Corrosive Wastes Taking the time to ensure that acids and caustics are managed appropriately is critical to process safety. Also, it is important to characterise process-stream raw materials, intermediates, products, byproducts, and wastes or residuals that are corrosive or can react with moisture or air to generate corrosives. All containers need to be properly labelled so that the contents can be readily identified. Pay close attention to expiration dates, making sure that unstable acids and caustics are disposed of on or before the expiration date. Additional factors that should be taken into consideration when storing acids and
caustics include: First and foremost is to make sure that acid and caustics are not stored together. If there were to be a spill, chemical reactions could occur if they are stored in the same storage area. Second, make sure you check the MSDS of the acid or caustic to determine concentrations and any other storage conditions which must be maintained such as temperature or low moisture, etc. Anticipating acidic and caustic constituents in residual waste streams is also very important. Aerosols of solid or liquid corrosive substances are air pollutants, and so are corrosive gases, and they may require control measures subject to permitting. Changes in the level of acidity and alkalinity affect the flora and fauna in soil and water. For example, acidity of pH 4 can be lethal to crickets and frogs. Some alkalis such as ammonia also have an acute toxic effect on fish. Soil may be classified as contaminated due to acidity when at a Chemical Engineering World
CEW Features Substance
Incompatible With:
Acetic Acid
Chromic acid, nitric acid, hydroxyl compounds, ethylene glycol, perchloric acid, peroxides, permanganates
Ammonia (Anhydrous)
Mercury, chlorine, bromine, iodine, calcium hypochlorite, hydrofluoric acid (anhydrous)
Bromine; Chlorine
Ammonia, acetylene, butadiene, butane, methane, petroleum gases, hydrogen, sodium carbide, benzene, finely divided metals, turpentine
Chromic Acid
Acetic acid, naphthalene, camphor, glycerol, alcohols, flammables
Fluorine
A wide range of substances and construction materials
Nitric Acid
Acetic acid, aniline, chromic acid, cyanides, sulfides, flammable solids, liquids or gases, copper, brass, heavy metals
Sodium Hydroxide; Potassium Hydroxide
Aluminum, zinc, or galvanised metals: produce flammable gases: hydrogen and dichloroacetylene.
Sodium Nitrite
Ammonium nitrate and other ammonium salts
Sulphuric Acid
Potassium chlorate, potassium perchlorate, potassium permanganate and similar compounds of sodium, magnesium and lithium
Table 3: Uses of Plastics for Corrosive Liquids
pH value of 4 to 5 and heavily contaminated when the pH is 2 to 4. When soil has a pH value of 9 to10, it is contaminated due to alkalinity and, at a pH value10 to 12, it may be classified as heavily contaminated. Neutralisation does not always remove the hazards to the environment, as the salts produced in this reaction may also be harmful. Checklist for the Handling of Corrosive Materials The following aspects can be incorporated into a preliminary hazard review or checklist and should be considered when planning or organising the use, storage and handling of corrosives at your facility: 1. The physical and chemical properties of materials, from ingredients to wastes. 2. The level of acidity or alkalinity of acids and bases and their diluted solutions, as expressed by the pH value. 3. The occupational exposure limits required to control and prevent adverse effects of acids and bases on health. 4. Incompatible materials and conditions such as illustrated in the Example Tables in Figures 1 to 4. 5. Materials of construction for storage tanks, to resist internal and external corrosion. 6. The potential mixing points, such as process vessels, mixers, pumps, and other equipment. 7. The need for isolation of piping that contains incompatible materials. 42 • October 2015
8. The need for procedures such as lockout, vessel entry, and line-breaking. 9. Consideration of alternative materials of construction, piping configurations, equipment design, and accessibility for maintenance, inspection, and testing. 10.Minimising the hazard to workers and to the surroundings, using distance or barricades. 11.Gas and vapour sensors or monitors, with alarms. 12.Dikes, trenches, sumps, or reservoirs to collect spillage of hazardous liquids. 13.Ventilation to limit the extent of gas and vapour releases. 14.Emergency planning, training, and drills. 15.Spill-response teams and equipment, including sampling and monitoring, and personnel control. 16.Personal protective equipment, particularly for members of the spillresponse teams. 17.Hazard markings for all tanks and containers, including appropriate dating. 18.Compliance with national, international, and local regulations, codes and standards. 19.Internal and external inspections and/ or tests, with permanent record of findings. 20.A file for each process vessel that contains – or could contain – corrosive material, to include equipment drawings, materials of construction,
welder’s certificates, heat treatment, vessel supports and/or foundations, maintenance procedures, inspection and test schedules, and changes made since fabrication and installation. References 1. National Institute for Occupational Safety and Health, “Pocket Guide to Chemical Hazards”. 2. Jernkontoret [Stockholm], “Corrosion Tables” (1979). 3. Dillon, C. P., “Materials Selection for the Chemical Process Industries”, McGrawHill, Inc., (1992). 4. North Carolina Department of Labor Education, Training and Technical Assistance Bureau, “Industry Guide #30” (September, 2011)
Author’s Details Richard W. Prugh Principal Process Safety Specialist Chilworth Technology E: safety-usa@chilworthglobal.com Jitendra Kumar Senior Process Safety Specialist Chilworth Technology E: jitendra.kumar@dekra.com Chemical Engineering World
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CEW Features Technical Article
Inspection for Non-Piggable Pipelines The responsibility for managing an asset safely, efficiently and to optimise productivity lies solely with the pipeline operators. To achieve these objectives, operators are implementing comprehensive pipeline integrity management programmes. This articles talks about In Line Inspection (ILI) which has been proven to be extremely successful techniques for non-piggable pipelines.
A
critical aspect of an operator’s Integrity Management Plan (IMP) is to evaluate the history, limitations and the key threats for each pipeline and accordingly select the most appropriate integrity tool. The guidelines for assessing piggable lines, where an internal inspection tool can easily pass through a pipeline - have been well documented but until recently there was not much awareness for assessment of nonpiggable pipelines. Major concerns commonly found with these non-piggable pipelines remains: • Never been previously inspected • Minimal history and record keeping for historical data • Traversing through High Consequence Areas (HCA’s) For years, the corrosion engineers were left with only two pipeline integrity validation options - Hydrostatic Pressure Testing or In Line Inspection (ILI) - also known as Intelligent Pigging. In many cases the non-availability of traps for pigs or operational and design constraints in a pipeline restricted the passage for an internal inspection tool classifying such lines as non-piggable. These lines would get classified as non-piggable pipelines and common reasons for this classification could be presence of miter bends, 1 D bends, un-
barred tee’s, low flow conditions, obstructions in line, telescopic lines, lack of pipeline history or any other reason that does not give the operator the confidence to put an intelligent pig through the pipeline as displayed in figure 1. More than half of the world’s oil and gas pipelines are classified as non-piggable1. In the present context, health assessment of non-piggable lines has become a great challenge. From a pigging point of view especially for the Indian environment, all the pipelines regardless of being onshore or offshore can be split into the following five categories: 1. Piggable lines in which cleaning pigging is carried out 2. Piggable lines in which cleaning pigging has not been performed 3. Piggable lines which are difficult to pig such as prior stuck pig instances etc 4. Non-piggable pipelines such as well flow lines/ jetty lines/ spur lines etc 5. SPM / sub-sea lines having no loop To inspect these non-piggable lines that fall under the category of item 2 to 5 as per above, an option remains of running specialised ILI tools designed specifically for inspection of
Figure1: Conditions making a pipeline non-piggable (Source: Quest Integrity)
44 • October 2015
non-piggable. The ILI itself is a great tool for finding the existing anomalies in the pipeline; a successful ILI run can provide a complete ‘snap shot’ on the current condition of the pipeline. For applying these ILI techniques to a nonpiggable pipeline, an operator may be faced with several challenges for making the line ‘temporarily’ piggable. This could mean retrofitting the line such that an opening for the tool to enter and exit the pipeline as per the tool dimensions is possible, providing the appropriate medium/product for tool to function and ensuring correct tool velocity is maintained during inspection. This may result in taking a line temporarily out of service, which the operator may feel is difficult especially if the pipeline is supplying product to a community fed by a single pipeline. The question the operators needs to ask themselves here is that, is the pipeline critical enough and is safety a priority enough, that a well-planned ‘scheduled’ interruption of the pipeline may be taken for a short duration to allow accurate inspection? Rather than taking the risk of an unplanned unfortunate incident which may occur due to the unknown condition of the pipeline. Depending on the subject pipeline history and future demand of the asset, an operator may find it to be economically feasible for going ahead with such specialised ILI for non-piggable pipelines. This of course is much specialised inspection and comes at an added cost. Today, there are intelligent pigs available specifically designed for the ‘non-piggable’ pipelines, which may also be classified as ‘difficult to inspect’ as shown in figure 2. This would definitely provide Chemical Engineering World
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CEW Features taken the predictive methodology of DA to another dimension. Some of the tools and techniques available as a sub-part of the DA process have been historically used by the industry as a standalone technique but never as a comprehensive process to assess the full integrity of the pipelines. Figure 2: Specialised Ultrasonic (UT) based Intelligent Pig for ‘non-piggable’ pipelines (Source: Quest Integrity)
the operator with the most comprehensive inspection for their non-piggable pipelines. On the other hand, hydrostatic pressure testing may not be feasible due to several reasons. This could include non-availability of treated water to be used for test or lack of water disposing facility or the criticality of the line that may not allow an operator to interrupt service for longer duration. If these challenges for performing hydrostatic test are overcome, a major limitation remains in the test results, as it does not identify or report other existing anomaly in the pipeline except the near critical axial flaws that must fail during testing. Post a hydrostatic run, an operator does not get the confidence on the existing pipeline anomalies and the remaining life of the pipeline. Though, hydrostatic pressure testing is considered a great ‘final’ screening tool for assessing the safety of keeping the line in service. Hydrostatic pressure testing may also be part of a mitigation strategy if other integrity assessment tools have been applied to assess the integrity of the pipeline. Introduction of Direct Assessment (DA) The corrosion engineers required a practical yet reliable alternative to assess the integrity of the pipeline asset, especially the nonpiggable pipelines. This led to integrity teams from various oil and gas companies collaborating and devising the Direct Assessment (DA) process in 2002 resulting in the inaugural release of External Corrosion Direct Assessment (ECDA) standard. Since the release of the ECDA Standard Practice, an additional five other NACE International Standard Practices related to DA have been published as shown in table 1 and at least four more are under varying degrees of development. The accuracies and applications of the ICDA standards have 46 • October 2015
The DA process can be applied for both piggable and non-piggable pipelines as stated under section 1.1.6 in NACE ECDA standard. By design, Direct Assessment is meant to be another integrity assessment technique similar to ILI or hydrostatic pressure testing and is considered just as protective of public safety and the environment as the other two inspection techniques. Each integrity assessment method complements the others. They do not have identical performance, but each has advantages over the others. 2 Direct Assessment in India In India, the governing body for development of self-regulatory standards for the Indian oil and gas industry that is Oil Industry Safety Directorate (OISD) recognised a need for development of guidelines specifically for integrity assessment of nonpiggable pipelines. These guidelines were
formalised and accepted by the Indian Ministry of Petroleum in September 2013 as OISD-GDN-233. OISD-GDN-233 standard has been well accepted based on assessing the time dependent threats of External Corrosion (EC), Internal Corrosion (IC) and Stress Corrosion Cracking (SCC) through applying the nonintrusive techniques of ‘Direct Assessment’. Direct Assessment (DA) is a structured, iterative improvement process through which an operator can assess the integrity of a pipeline. This non-intrusive process integrates an attained knowledge of the physical characteristics and operating history of a pipeline with the results of diagnostic and direct measurements performed on the pipeline. The four-step (ECDA, ICDA and SCCDA), continuously iterative DA process requires the integration of data from available line histories, multiple indirect above ground field surveys for external defects and internal corrosion predictive modelling (ICPM) for internal, direct examination on the pipe surface and the subsequent post assessment of the documented results. Typically, the DA process combines both existing and newer
Threats
DA Process
NACE International Standards
External Corrosion (EC)
External Corrosion Direct ECDA SP-0502-2010 Assessment (ECDA)& Confirmatory ECDA (EC- EC-CDA-SP0210-2010 CDA)
Stress Corrosion Cracking Stress Corrosion Cracking (SCC) Direct Assessment (SCCDA)
SCCDA-SP0204-2008
Internal Corrosion (IC)
Dry Gas - DG-ICDA SP0206-2006
Internal Corrosion Direct Assessment (ICDA)
Wet Gas - WG-ICDA SP0110-2010 Liquid Petroleum (crude) LP-ICDA SP0208-2008 Multiphase - MP-ICDA TG-426 Being released as a NACE standard soon) Table 1
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quality
CEW Features Diameter L e n g t h Year of Service Product (kms) Commissioning
Unique Features
10”
11
1996
Crude
Offshore
30”
1
2000
Dry Gas
Main feeder line to a 5,000 kms gas network
10”
2.5
2010
Heavy Crude
Insulated and heated above 65 degree C
16”
6.5
1998
Refined Products
High Consequence Area- within city, 50% of line under busy roads, Re-routed and modified
48”
15
2005
Several varieties Offshore to Onshore, of crude SPM line
40”/38”
7
1959
Export Crude
Old line with no inspection history, High Consequence Area
14”
3.3
1979
Wet Gas
Miter bends and 1D bends
And many more similar pipelines………………the list goes on. Table 2
techniques for understanding the integrity of a pipeline. The key major advantages of DA over the other available integrity assessment techniques are: • Can locate and predict susceptible areas where defects could form in the future rather than areas where defects have already formed (proactive) • No product interruption is required (nonintrusive) • Mandatory for DA programmes to perform the ‘root cause analysis’ for determining the corrosion mechanism. Answers the paramount question asked by operators ‘Why does the corrosion anomaly exist?’ • A need to deliver a go forward plan for the operator (mitigation plan) These advantages highlight the major technical differences between ILI or/and pressure testing and DA and reflects how these techniques complement each other rather than compete with each other. ILI management results focus upon complete corrosion detection with no requirement by the ILI operator to determine why, how or what is driving their pipeline corrosion matters. The owner or operator is left to their own devices to sort these important matters out. On the 48 • October 2015
contrary, DA requires these elements to be addressed when the NACE DA protocols are adopted. Conclusions The industry’s need for understanding DA and knowing how it fits in the overall integrity management plan has been given paramount importance. Now the industry has ILI (along with specialised ILI for non-piggable pipelines), hydrostatic pressure testing and DA available as the inspection techniques to optimise their pipeline integrity management programs for non-piggable pipelines. NACE International has already introduced their 5-day ‘DA course’ to India, which was previously being taught in Houston for the past few years. This course expands into how DA can be utilised for inspection of piggable and non-piggable pipelines. The primary author (A Khera) of this paper has been one of the key members of the team that developed and instructs the NACE DA course. All of these are ‘non-piggable’ lines, which had no previous inspection being performed and recently (within the last 5 years) their owners opted for integrity assessment of these challenging pipelines. As shown in table, these lines are of different heritages, products, offshore/onshore and several other
unique features. By performing integrity assessment of these pipelines, the pipeline owners were able to determine not only the safest operating pressure of EACH pipeline but also the remaining life for each of the pipelines along with their respective reinspection intervals and the way forward. If you have non-piggable pipelines that face similar challenges, then these can be inspected too. Acknowledgments 1. Beugen P.V. “Bidirectional MFL Inspection Of Non-Scrapable Pipelines” ‘Pipeline & Gas Journal’ March 2008 2. NACE International Standard SP01132013 “Pipeline Integrity Method Selection” item 1.1.8 References 1. Khera, Ashish, Marr, James E., AlMithin Abdul W., Safri, Shabbir T. and Al-Sulaiman, Saleh “KOC’s Integrity Management Program for Non-Scrapable Pipelines - A Case Study” presented to the 8th International Pipeline Conference (IPC 2010) at Calgary, Canada in 2010 2. Teevens, Patrick J., Khera, Ashish “Pipeline Integrity Management Successfully Applied for Oil and Gas Pipelines by utilizing Internal Corrosion Direct Assessment (ICDA)” presented at Best Practices in Pipeline Operations & Integrity Management at Bahrain 3. ASME B31.8S “Managing System Integrity of Gas Pipelines”, 2010. 4. NACE Direct Assessment Course (2012)
Authors’ Details
Ashish Khera Director, Allied Engineers akhera@alliedengineer.com Rajesh Uprety Additional Director Oil Industry Safety Directorate (OISD), E: upretyr.oisd@nic.in Bidyut B Baniah Project Manager Allied Engineers, E: bbaniah@alliedengineer.com Chemical Engineering World
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CEW Features Technical Article
Surface Pre-Treatment for Application of Corrosion Control Paints In today’s world with the pollution levels high in most cities, standard coatings cannot provide corrosion control for steel structures. New technology coatings are being designed and formulated by most coating manufacturers for better life of steels. To achieve the best results, one of the important factors is the need for good surface pre-treatment.
S
urface treatment is a time consuming job and comes at a cost and eventually helps provide a good adhesion between the coating and the substract and increase the barrier effect and the life of the substract that needs to be protected. Coating manufacturers will guarantee their coatings system if the surface preparation is carried out well and the coating is applied as per the manufacturers’ recommendations. We need to remind ourselves that a coating does not stop corrosion but reduces the rate of corrosion. All new steel has a scale which is caused by oxidation during the manufacturing process; steel is widely used in the industry. Mill scale is the oxidation layer on steel. Electrochemically, mill scale is cathodic compared to steel. Any kind of breakage in the scale could lead to accelerated corrosion in the steel at the point of breakage. Surface preparation is important. It helps remove the catalyst which accelerates the corrosion process. This is done by various methods after understanding the type of coating and the environment in which the steel is to be used. One must take note that surface preparation needs to be carried out on all types of steel ie, Carbon Steel, Galvanised Steel, Stainless Steel, Aluminium When coating carbon steel: • Blue-black deposits formed on new steel, by a reaction between the hot steel and oxygen
50 • October 2015
• Cathodic relative to bare steel • Should be removed prior to coating When coating galvanised steel: • Freshly galvanised steel should be painted within 24 hours, or allowed to sufficiently oxidise, and prepared per specification • May be prepared by water washing, sandblasting or acid etching • Oil-based coatings perform poorly on galvanising due to saponification • Review SSPC-SP 16: Brush of Blast Cleaning of Coated and Uncoated Galvanised Steel When coating aluminium: • Protective oxide film should be removed • If abrasive blasting, high profile should be avoided • Special aluminium treatment (eg, etch primer) may be required • Being a soft metal, abrasive blasting may develop a higher profile than expected When coating stainless steel: • Protective film, which forms when exposed to atmosphere, must be removed.
Figure 1: Mill scale on new steel
• Any rust-spotting must be removed. • Steel grit shot induces galvanic corrosion* • Generally glass bead is used for SS blasting Almost all modern steel mills are capable of supplying products with the mill scale eradicated and the steel painted with primers that are suitable for welding. Today’s high performance coatings need this mill scale to be removed to have proper adhesion with the subtract. Surface preparation is achieved by various methods; viz, Hand tool cleaning, Power tool cleaning, Solvent cleaning and Abrasive blast cleaning (Manual and Automatic, Air Blasting and Airless Blasting) All tools have its advantages and limitations and the suggested surface preparation process needs to be specified in a specification or is recommended by the coating manufacturer. Hand tool and solvent cleaning are inexpensive but they cannot create a
Figure 2: Mill Scale removed by Blasting
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Features CEW profile for coatings to have good bonding with the surface. Some coatings do not need more than a hand tool cleaning or solvent cleaning. Solvent cleaning surface preparations help remove all contaminants from the surface. Solvent cleaning could be a water wash to remove chlorides or chemicals to remove oil grease contaminations that could be present on a steel surface during manufacturing/ machining. Power tool cleaning do clean the surface fast and effectively and provide a profile for good adhesion of the coating to steel. Care needs to be taken with power tool cleaning. Power tools can create a smooth surface which will cause the coating not to adhere to the steel surface. Abrasive blasting has its challenges; it is expensive, needs capital equipment and is a time consuming process. Abrasive air blasting equipment is conventional air operated which uses compressed air at high velocity to throw the abrasive on substrate. Airless blasting uses centrifugal force to throw the abrasive on the surface to help achieve the cleanliness. Airless blasting is generally large machinery and used for continuous operations and with very high production rates. Depending on the type of abrasive being used, the surface cleanliness can be Unblasted
Class SA-1
achieved. Visual standards by NACE / SSPC provide the industry some reference to follow. The higher the surface cleanliness, the time consumed for surface preparation is more. Coating manufacturers recommend an SA2 ½ standard for best results. Abrasives used are expandable abrasives (Oxides) of aluminium and copper. Garnet is a widely used abrasive. Glass beads are generally used for stainless steel blasting. Steel grit and shot in a combination is used for surface preparations in closed environments and airless blasting equipment as they can be recycled 100 times. Steel shot can only be used for steel/ concrete cleaning, if used on stainless steel/ aluminium it could embed in them and cause corrosion. Care should be taken to choose the correct abrasive (sieve size) to achieve the correct profile. Profile is recommended by coating manufacturer and is a range and not specific as it is tough to achieve an exact profile because of various applications factors. Too small a profile can cause poor adhesion and too large a profile can cause poor wetting of the substrate and increase in the paint consumption and the coatings not covering the profile well which will lead to premature corrosion failures. Class SA-2
Class SA-2 1/2
When air blasting, it is very important that the compressed air is clean and free of oil which can contaminate the surface before coatings, recycling of abrasives is also important and care should be taken when recycling abrasives. Dust dirt and old paint when removed from the subtracts should be separated from the abrasives by using recycling systems. If it is not separated the same will get deposited on the surface and provide poor adhesion of the coating on the surface. Surface preparation in controlled environments like in a blast room help achieve best results where temperature and humidity can be controlled. Alternative surface preparation method used is high pressure water blasting. This technology can only be used to clean the surface but cannot create a profile. Wet blasting or slurry blasting is used when the abrasive blasting is a concern on open subtracts and use of water helps in reducing the dust and contamination of the environments. Wet blasting causes flash rust and coatings need to be chosen which can accommodate this wet blasting and applied immediately or on flash rust. Most conditions require a surface to be coated with the first coat within few hours of being surface prepared, unless in a controlled environment where the time can be extended because of the controlled conditions.
Class SA-3
Rust Grade A
Rust Grade B Figure 4: Blasting in controlled environments
Rust Grade C
Rust Grade D
Figure 3: Abrasives Blasted steel Substrates
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Figure 5: Automatic Plate blasting unit
October 2015 â&#x20AC;˘ 51
CEW Features
VOL. 49 NO. 3 March 2014 US $ 10
`
Figure 6: Application of a strip coat before coating
` 150
Figure 7: Airless painting application
Prior to surface preparation visual inspection of the subtract should be carried out. Fabrication defects, weld splatter, rough welds need to be removed as abrasive blasting cannot remove these defects and coatings cannot cover these defects. It is advised to stripe coat corners and weld joints before applying a coating on the entire surface.
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Coatings applications should also be applied in controlled environments. It is not recommend to apply a primer coating on a surface blasted with a roller as it does not help in proper wetting of the surface and can cause pinholes. Coatings applied with the improper application equipment can cause problems . It is required to follow the coating material supplier’s recommendations. Adding solvents in a coating beyond the recommendations of the material supplier or incompatible solvents can cause coating failures. Our industry is in need of some type of skill development and knowledge certifications for application for surface preparation and coatings. We only have certifications for inspectors but in this industry which protects country’s assets, the only knowledge gained is through experience which is passed down the line. An industry that consumes 1600Chrs of protective coatings needs to see some type of certifications to help improve the quality of the surface preparations.
Author’s Details Denzil Dcosta Sales Manager, Graco Hong Kong Ltd (India Representative Office) E: Denzil_Dcosta@graco.com 52 • October 2015
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Market Insights CEW
Renewable Chemicals worth 84.3 bn by 2020; Catalyst Market Size to Reach 6.18 bn by 2022
A
ccording to a recent report by MarketsandMarkets, the Renewable Chemicals Market size in terms of value will grow from an estimated USD 49.0 billion in 2015 to USD 84.3 billion by 2020, with a CAGR of 11.47 per cent between 2015 and 2020. The drivers for renewable chemical market include abundant and low-cost feedstock, technological innovations, consumer acceptance for eco-friendly products, and government support for eco-friendly sources and processes. The factors hindering the growth of the renewable chemicals market are high price when compared to the conventional polymers and associated performance issues. However, with the increasing research and innovation, improvement is expected in the near future. The growth opportunities for the renewable chemicals market are increasing the scope in end-user segments, new raw materials, under penetration in the Asian countries, and potential for cost reduction through economy of scale. Ethanol is the most commercialised segment among all the major renewable chemicals. The US and Brazil together account for more than 80 per cent of the global ethanol production. There is ample scope of growth in Canada, Europe, and developing nations such as China and India in the Asian region. In the bio-polymers segment, bio-PET and bio-PE together account for more than 50 per cent share, in terms of volume. Bio-PET is projected to register the highest CAGR of over 20 per cent (by volume), followed by PLA during the forecast period. The renewable chemicals market is relatively niche with less number of players globally. In future, with the increase in demand for these chemicals, the trend is estimated to move toward full scale commercialisation from pilot scale projects. New players will have to make significant investments in R&D and facility development for entry into the market. However, favourable government policies toward green and biodegradable products and EU’s wide policy support will allow more companies to enter into the market with increased capacities. Currently, this market has a limited number of companies and a lot of potential. The players in the market require high capital investments and technology knowledge. Therefore, players entering into this market are required to have high R&D capabilities and financial assistance. Another report by Grand View Research, Inc has reported that the global refinery catalyst market is expected to reach USD 6.18 billion by 2022. Growing need for environmental friendly/
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high performance fuels is expected to remain a key driving factor for global refinery catalyst market. Stringent EPA and REACH environmental regulations to curb sulfur and NOx emissions caused due to growing refinery is also expected to have a positive impact on the market growth. Increasing refinery complexity along with growing requirement to optimise tight oil and sour crude processing has led to the usage of specialty catalysts with improved efficiency. The report states that Zeolites were the most preferred catalyst material with demand share exceeding 30 per cent of total market volume in 2014. Zeolites are expected to witness significant growth on account of high requirement in various refinery processes including catalytic reforming, hydrotreating, and FCC. High porosity and adjustable acidity are key properties on account of which zeolites are used as catalysts in refining and petrochemical production. Chemical compounds are anticipated to witness the highest growth of 3.5 per cent from 2015 to 2022. Low price of chemical compounds as compared to zeolites, metals, and enzymes are expected to have a positive impact on market growth. According to the report: • Global refinery catalyst market demand was 1,300.8 kilo tons in 2014 and is expected to grow at a CAGR of 3.3per cent from 2015 to 2022. • Fluid catalytic cracking (FCC) refinery catalyst demand stood at 617.9 kilo tons in 2014. Growing demand for highperformance transportation fuels including gasoline and diesel are anticipated to drive this segment over the forecast period. • Hydrotreating is anticipated to witness highest the growth of 4.7 per cent in terms of market value over the forecast period. High requirement to upgrade the middle distillates to high-grade finished kerosene, heating fuel oils and diesel along with pretreatment of mixed distillates obtained from various process streams prior to catalytic cracking is attributed to high growth. • Asia Pacific was the leading regional market and accounted for over 30 per cent of global demand in 2014. Increasing refining capacity particularly in China, India, Indonesia, Vietnam and Malaysia are expected to drive the regional growth. China and India were reported as the second and fifth largest countries in global capacity refining market in 2013. Asia Pacific is also expected to witness the highest growth over the forecast period. • European Commission’s inclination towards reducing GHG emissions coupled with regulatory bills intended for promoting biofuel industry is expected to increase demand for enzyme catalyst in Europe. • Key industry participants include W R Grace & Co-Conn, Zeolyst International Inc, UOP LLC, Evonik Industries, DuPont, INEOS Group Limited, and Johnson Matthey PLC. October 2015 • 53
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The magnetically coupled pumps also lend themselves excellently to draining makeup acid tanks and are therefore used in many tank farms in the steel industry. Main construction materials used in the manufacture of Munsch non-metallic pumps are polypropylene (PP), polyethylene (PE), polyvinylidene fluoride (PVDF) and perfluorolkoxy polymers (PFA). This range of high-performance engineered plastics allows a very broad spectrum of service conditions to be covered. Targeted material selection matched to the specific service environment ensures on optimum. The Munsch REA mechanical seal features a simple design, ease of access and is amply dimensioned for maximum operating reliability while being at the same time easy to assemble and repair. The choice of non-metallic pumps for a specific application is ultimately determined by the pump efficiency and the hydraulic 54 • October 2015
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The Evolution Of The Species
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osmoDry System: horizontal paddle vacuum dryer with concentric agitator, fitted with a shaft dismountable in sections, for maximum ease of cleaning and inspection. Maximum ease of cleaning, maintenance and internal inspection; a mix of qualities that make CosmoDry System the ideal solution even for multi-product applications. C o s m o D r y S y s t e m i s t h e i n n ova t i ve horizontal paddle vacuum dryer created by Italvacuum as the result of a deep analysis, conducted in cooperation with the most demanding customers, regarding the most urgent requirements of their production. Power, loading flexibility, drying speed, ease of unloading, maximum product q u a l i t y. T h e s e a r e a l l f u n d a m e n t a l values. But Italvacuum went further, in order to facilitate cleaning and internal i n s p e c t i o n . A q u a l i t y t h a t a l l ow s t o m a i n t a i n o v e r t i m e t h e m a c h i n e â&#x20AC;&#x2122;s perfect efficiency and to optimise the production processes. CosmoDry System is based on an operating philosophy conceived for the drying of wet powders coming from filtration or centrifugation stages and it is suitable for the production of Active Pharmaceutical Ingredients (API), Fine Chemical and Intermediates.
designed to limit mechanical and thermal stresses, thus allowing the treatment of thermo-sensitive products. But that is not all. Its special features allow to reduce product deposition at a minimum, providing an easy and efficient unloading operation, for which a dedicated operative cycle has been introduced. Finally a value that has always been a m i l e s t o n e fo r I t a l v a c u u m , s a fe t y. CosmoDry System is safe for the product and the operators, because it is designed and manufactured in compliance with the increasingly strict safety standards and according to cGMP and ATEX regulations. Constructive details For the parts that are in contact with the product CosmoDry System is built in AISI 316L stainless steel, but other weldable materials are also available if requested by customer, for instance ALLOY C-22 and AISI 904L. The walls of the dr ying chamber, the port lid and the agitator shaft are heated through diather mic liquid circulation. Inter nal surfaces are mirror polished or electropolished in order to optimise resistance to corrosion, reduce friction on the product and simplify cleaning operations.
CosmoDry System consists of a horizontal cylindr ical chamber, equipped with a concentric agitator, fitted with a heated shaft dismountable in sections: this is the great added value of the CosmoDry System, setting it apart from conventional paddle vacuum dryers.
The agitator shaft is equipped with a double mechanical seal system, conceived to guarantee perfect vacuum tightness and absolute purity of the dried batch, avoiding any risk of product contamination. The mechanical seal can be pressurised through liquid or inert gas.
The peculiar configuration of the agitator enables continuous stirring of the product and facilitates its ther mal exchange, reducing drying time. Moreover, it was
Maximum ease of cleaning and inspection Easy internal cleaning is guaranteed by an efficient CIP system, that allows the
56 â&#x20AC;˘ October 2015
washing of all the parts in contact with the product. The frontal port lid and the easy disassembling of the agitator in different p a r t s p r ov i d e gr e a t a c c e s s i b i l i t y fo r inspection and SWAB testing: no bulky equipment is required, thus preventing long machine stops. A feature that makes CosmoDry System unique compared to vacuum dryers. The exterior of CosmoDry System is easy to clean as well. The watertight external cladding of the entire machine (cGMP 'particle free' configuration) covers the insulation, the electric wiring and the hy d r a u l i c a n d p n e u m a t i c p i p i n g . I n addition no support frame occupies the sterile room, only the dr ying chamber flanged to the wall. This makes external c l e a n i n g ex t r e m e l y e a s y, p r eve n t i n g product accumulation. These features, together with the par titioning solution, Chemical Engineering World
Marketing Initiative allow clean room installation, guaranteeing pressurisation and separation of sterile room from technical room. Turn-key systems Italvacuum is the only manufacturer in the world that, in addition to the dryer itself, can design and build internally all the auxiliary units that complete the plant, properly sizing them to meet every process requirement, vacuum system included: • High vacuum group SAURUS 939 • Va c u u m c o n d e n s a t i o n g r o u p f o r reduction of drying time and recovery of extracted solvents
• External safety filtering unit for powders containment • Heating and cooling group for system thermoregulation • Control panels with PLC for complete p l a n t m a n a g e m e n t , p r ov i d e d w i t h software that is certifiable according to CFR 21 – Part 11 regulations, and that guarantees reproducibility of the dried batches and communication with centralised supervision systems. Dimensions CosmoDr y System presents a great loading flexibility. It is manufactured in volumes ranging from 150 to 4.400 liters. The loading capacity can vary from 30 to 80 per cent of the chamber’s volume, a c cord ing to the pr oces sed pro duc t , meeting in this way the multiple needs of chemical and pharmaceutical industries.
• Specific unloading programme • Very easy external clearing thanks to: oWater tight cladding of the entire machine oAbsence of support frames in the clean room oPossibility of installation in clean room with separation between clean room and technical room (Particle Free Configuration) • Total system automation capable of guaranteeing process reproducibility for all batches. For further info visit: www.cosmodry.it
Strengths • Eas ines s of inter nal c leaning and washing, thanks to: • Agitator dismountable in different parts • Total absence of sharp corners in the drying chamber • CIP systems that enable reaching the required residual ppm value with few washing cycles • Agitator profile designed to limit mechanical and thermal stress on the product and reduce to a minimum the formation of agglomerates. • Very easy internal accessibility to the chamber for inspection and 'swab' test thanks to the front por t lid and the possibility of dismantling the agitator in different parts. • Very high final vacuum values • Further reduced drying times • Homogeneity and uniformity of dried batch thanks to the complete stirring of the product. • Very easy product unloading thanks to: • Total absence of friction points on the product • Reduced gap between the agitator paddles and the wall of the drying chamber Chemical Engineering World
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Marketing Initiative
Taking Account Of The Trend Towards Individual Vacuum Solutions
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he trend towards individual vacuum solutions for single processes or entire production plant continues to increase. The driving force behind this development is the desire to make p r o c e s s e s a s r e l i a bl e , e f f i c i e n t a n d reproducible as possible. Busch is helping to realise this objective by conducting a massive worldwide expansion of its vacuum systems operations. Busch has been manufacturing vacuum pumps in Germany for more than 40 years, specialising exclusively in the planning, design and constr uction of individual vacuum systems. The most impor tant market sector for Busch products is the chemical processing industry, in which Busch vacuum pumps are used in practically all applications r e q u i r i n g va c u u m . B u s c h s p e c i a l i s t s can call on the experience gained from thousands of vacuum system installations throughout the world. In recent years Busch system construction departments in various countries have been expanded and upgraded, and competence centres have been opened specifically for the chemical and pharmaceutical processing industries. These competence centres respond directly to the main Busch subsidiar y of their country. One of the centres in Germany is located in Maulburg, where – as in other countries – customers are assigned experienced process engineers and chemists as contacts to assist with consultation, vacuum system planning, and design. The detailed planning of the project is carried out by a system construction team. All vacuum systems are completely assembled and tested in-house before delivery, installation and commissioning at the customer’s site. The customer has 58 • October 2015
Busch vacuum system for chemical processes with COBRA screw vacuum pumps
the advantage of a single contact for enquiries, who will assist throughout the project – even after the commissioning phase. Busch offers service agreements providing a full guarantee for the vacuum system, all maintenance tasks, and an immediate response if a fault should occur. Busch process engineers and vacuum specialists can draw on a wide range of Busch vacuum pumps when designing va c u u m s y s t e m s. T h e C O B R A s c r ew vacuum pump series alone has twelve models, with pumping speeds of up to 2500 m 3/h. These dry vacuum pumps are available in a number of variants. Liquid ring vacuum pumps of various Dolphin series are also frequently used as standard modules in Busch vacuum systems. The Busch standard product range offers Dolphin vacuum pumps as single-stage or two-stage versions with pumping speeds of up to 4400 m 3/h. They may be operated with process-compatible
fluids. The extensive choice of construction materials, seals, and sealing materials allows systems to be perfectly matched to process parameters. A suitable booster pump model may be chosen from several ser ies of rotar y lobe vacuum pumps. All Busch vacuum c o m p o n e n t s a r e a v a i l a b l e i n AT E X cer tified versions. The wide range of individual components allows vacuum systems to be custom made to meet customer requirements: the most suitable, economical and reliable solution for the individual customer is selected.
Uli Merkle Busch Dienste GmbH Busch Vacuum Pumps and Systems Chemical Engineering World
Marketing Initiative
Capex, Opex can be saved using multi-tubular catalytic reactor in place of conventional fixed bed catalytic reactor
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n case of exothermic and endothermic reaction carried out in multiple catalytic fixed beds reactors figure 1 or fixed beds in series reactors shown in figure 2, we need to provide heat exchanger between the reactors or catalyst beds as shown in figure 1 and 2 to add or remove heat to maintain temperature of reaction. In place of using above arrangement, we can think of using multi-tubular reactor shown in figure 3. If we need length of tube much more than height of bed for m u l t i - t u b u l a r r e a c t o r, w e c a n h a v e arrangement shown in figure 4 for better heat transfer. Here is a case study. For production of Ethylbenzene, in place of using conventional reactor like figure 1 and 2 , we have used multi-tubular reactor as shown in figure 3. We do not need to use heat exchangers as shown in figure 1 and 2 as heat exchange is sufficient in reactor itself. Results and Discussion We have calculated capital cost and operating cost for all three heat ex c h a n g e r s fo r p r o d u c t i o n o f 8 . 3 7 4 t o n e s / h r E t hy l b e n ze n e. D e t a i l s o f a l l the three heat exchangers (kettle type) PRODUCT PRODUCT
REACTANTS
Bed of catalyst Reactor- 1
Reactor-2
Reactor- 3
PRODUCT Heat exchanger - 1
Heat exchanger-2
Heat exchanger-3
Figure 2: Multiple catalytic bed reactors with external heat exchangers
Figure-2 Multiple catalytic bed reactors with external heat exchangers
including results obtained by HTRI software is given in Table 1
0 .034 m. Thickness of tubes is 2mm. Cost of shell is `2,99,281.
Capital Cost Capital cost of heat exchanger 1 obtained by calculations is:
Cost of Head 1 (Torispherical): MS can be used as MOC. Blank dia required 1.116m, Thickness of plate required is 0.0151m. Cost of head 1 is `9,486.
Cost of Shell: Carbon steel SA Gr 70 can be used as MOC for shell. Required length of shell 4.81m, Outside dia. of shell is 1.83 m , Inside dia. of shell is 1.825 m. Thickness of shell 5 mm. Cost of shell is `44,184. Cost of Tubes: Required MOC for tubes is SS-316. No. of tubes required are 92. Required length of tubes 4.8 m. Outside dia. of tubes is 0.0381 m. Inside dia. of tubes is
BED 4 4OF BED OFCATALYST CATALYST HEAT EXCHANGER HEAT EXCHANGER 3 3 BEDBED 3 OF 3 OFCATALYST CATALYST HEAT EXCHANGER HEAT EXCHANGER 2 2 BEDBED 2 OF 2 OFCATALYST CATALYST HEAT EXCHANGER HEAT EXCHANGER 1 1
Cost of Head 2 (Torispherical): MOC required for head 2 is SS-316. Blank dia required 1.132m, Thickness of plate required is 0.01225m. Cost of head 2 is `43,477. Cost of Tube Sheet: 01 tube sheet is required here. MOC required is incoloy alloy 1800. Thickness required 72mm. Dia. of sheet required 1.027 m. Cost of sheet is `2,86,646. Total cost of heat exchanger 1 is approximately `3,96,428. Similarly, Capital cost of heat exchanger 2 is `2,45,721 and heat exchanger 3 is `1,94,496.
BED BED 1 OF CATALYST 1 OF CATALYST
REACTANT REACTANTS
Figure- 1 FIXED BEDS CATALYST IN SERIES REACTOR
Figure1: Fixed beds catalyst in series reactor
Chemical Engineering World
Figure 3: multitubular reactor
Capital cost saved for all the three heat exchangers is `8,36,646 (Here, cost of designing, fabrication and small parts is not included. Only cost of material for major parts are calculated here.) October 2015 â&#x20AC;˘ 59
Marketing Initiative Final summary Hot fluid – gas mixture Cold fluid – water Flow rate of gas mix. Kg/s Water flow rate, kg/s Inlet temp of gas mix Outlet temp of gas mix Total inlet press and pressure drop shellside Inlet temp of water Outlet temp of steam MOC for tube Overall U Delta P for shell Delta P for tube Total HE area, m2 No. of tubes Tube inside dia., mm Tube side passes
HE-1 Tube side Shell side 3
HE-2 Tube side Shell side 3
HE-3 Tube side Shell side 3
1.8301 948 350
0.8487 649 350
0.40 499 350
1000 and 7.7 kPa
1000 and 6.35 kPa
1000 and 3.1 kPa
25 180 SS 316 270 W/m2K 7.3 7.1 52.9 92 34 2
25 180 SS316 313.5 W/m2K 6.3 34 19.53 34 34 2
25 180 SS316 426.7 W/m2K 3.1 52 12 24 34 2
Table 1: Final summary
5
3 Y
1. 2.
1
X
2
3. Y 4.
5. 6.
4 X
Bed ofof Catalyst in tubes Bed Catalyst in tubes Mesh for support of Catalyst which is Mesh for support of sandwiched between the flange joints 3. Catalyst Tube sheet which is 4. sandwiched Empty tubes between 5. Reactants inlet the flange joints 6. Product mixture outlet X Tube Nozzle forsheet D.M. water Empty tubes Y Nozzle for saturated steam outlet Reactants inlet Product mixture outlet X Nozzle for D.M. water Y Nozzle for saturated steam outlet 1. 2.
Y X
Y
Figure-4 Multitubular reactor
Figure 4: Multitubular reactor
Operating Cost Operating cost for all three heat exchangers in this case is negligible (`1301 per yer) because here steam of very high pressure (10 bar) is generated. If there is no phase change high operating cost can be saved every year. Conclusion If multi tubular reactor is used in place of multiple fixed bed in series reactor or fixed beds in series reactor considerable capital and operating cost can be saved for other processes also. In case of replacing with multiple catalytic fixed bed reactors as shown in figure 1. cost of vessels can also be saved.
Shilpa Patel Lecturer, Government Polytechnic, Gandhinagar Prof S B Thakore, L D.College of Engineering, Ahmedabad Email: shilpapatelchemical@yahoo.com 60 • October 2015
Chemical Engineering World
Products CEW Next Generation PURON MBR Koch Membrane Systems (KMS) PULSION MBR is energy efficient, requires a smaller system footprint and reduces long-term operational costs. It pulses a large bubble through a chambered fiber bundle creating a highly efficient pumping action resulting in lower air and aeration energy requirements than traditional air scour methods. Improved recirculation of mixed liquor within the membrane module, not only results in lowered air requirements, but also boosts achievable fluxes. Coupling greater productivity with an increase in packing density allows the overall system footprint to be significantly reduced. Operating with a continuous supply of air eliminates the need for air cycle valves. A reduced airflow rate applied to the membranes on a continuous basis instead of high air flows applied cyclically reduces the size of the air delivery equipment by 50 per cent. For details contact: Koch Membrane Systems, Inc 850 Main Street, Wilmington, Massachusetts 01887-3388, U.S.A. Tel: +1-978-694-7000 | Fax: +1-978-657-5208 E-mail: Anthony.Lauletta@kochmembrane.com or Circle Readers’ Service Card 1
Pocket pH Tester HI 98100 Checker Plus Hanna Instruments offers the new pocket pH tester HI 98100 checker plus. It is the next generation of the original Hanna Checker pH tester. The checker has been helping people with their pH measurement as a meter that is simple to use and operate. This meter is easy to operate; it has features like single button operation, replicable pH electrode, etc. The HI98100 Checker Plus pH tester has been designed with many advanced features while maintaining the look and feel of the original Checker. The Checker Plus now offers automatic calibration to one or two points, automatic buffer recognition, calibrated buffer tags, stability indicator, low battery indicator and selectable automatic shut-off. The Checker plus still maintains the iconic pentagon design with a probe that measures 103mm in length and tapered to a 8-mm dia making it ideal for test tubes and vials. It has a large LCD that displays reading, stability indicator, low battery indicator and calibration tags. The HI1271 supplied gel filled pH electrode is 103 mm long and tapers to an 8 mm dia at the sensing end. This narrow electrode easily fits into test tubes, vials and other containers with small opening. For details contact: Hanna Equipments (India) Pvt Ltd 3/4/5/6 Aum Sai Bldg, Plot No: 23-C, Sector 7 Kharghar, Navi Mumbai 410 210 Tel: 022-27746554 | Fax. 91-022-27746557 E-mail: kondiba.metkari@hanna-india.com or Circle Readers’ Service Card 2
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CEW Products Silicone Rubber Sheet Silicone rubber is a perfect choice for medical, pharma and food processing industries. Silicone has comparatively low mechanical properties, tensile strength, elongation and tear strength; however, they keep constant even at high temperatures but should not be used for high temperature steam. Its resistance to oil and hydrocarbon is fairly limited and similar to that of chloroprene rubbers. Reasonable resistance to a whole range of general chemicals but acids, alkalis, esters and kerosene should be avoided. Silicone has excellent resistance to heat up to 220oC intermittent. It remains flexible at low temperature of (-50oC) and it is also resistant to UV light, ozone and weathering. Exhibits low inflamability and low smoke toxicity. It has good electrical insulation properties. For details contact: Kiran Rubber Industries 135 Shiv-Krupa Indl Estate, LBS Road, Opp: Raj Legacy Vikhroli (W), Mumbai 400 083 Tel: 022-42637400 | Fax: 91-022-42637499 E-mail: info@kiranrubber.com or Circle Readers’ Service Card 3
Online Measurement of Sulphuric Acid Concentration Due to the physical properties of sulphuric acid, the most suitable measuring method for determining the acid strength is sonic velocity measurement. The LiquiSonic analyzers of SensoTech are successfully used to determine the sulphuric acid strength in plants worldwide. The modern and high-end sensor technology provides stable measuring results updated every second with an accuracy of up to 0.03 wt%. Corrosion-resistant materials and the robust construction ensure a maintenance-free sensor operation with long-term stability. The sensors are installed directly into pipes or vessels and measure inline. The data is sent online and in real time to process control systems via 4-20 mA signal, digital outputs, fieldbus or Ethernet. For details contact: SensoTech GmbH Steinfeldstr 1, D-39179 Magdeburg-Barleben, Germany E-mail: info@sensotech.com or Circle Readers’ Service Card 4
Canned Motor Pump Kirloskar Brothers Ltd (KBL) offers small Series of canned motor pumps (i-CM Series), which offer many advantages to the process industries. To address the increasing demand for environmental safety at a reasonable cost, a unique challenge of the process industries is to develop and utilize equipment that handle toxic, explosive, expensive, hazardous, carcinogenic and corrosive fluids without any possibility of emissions into the environment and while operating it should be eco-friendly, leak-proof with efficient and reliable performance. Canned motor pumps, designed and manufactured by KBL, meet and exceed these challenges. Refrigerant transfer is one of the important and critical applications in the process industries, where canned motor pump is used to handle liquid refrigerant (mainly ammonia). Ammonia is natural, most efficient and cost-effective industrial refrigerant as it does not destroy atmospheric ozone and does not contribute to the greenhouse effect linked to global warming. Circulating refrigerant enters the compressor and is compressed to a higher pressure resulting in a higher temperature as well. The hot compressed vapour is then routed through a condenser where it is cooled and condensed into a liquid. This liquid refrigerant then passes through an expansion valve where it undergoes an abrupt reduction in pressure. That pressure reduction results in auto-refrigeration effect of the adiabatic flash evaporation lowers the temperature of the liquid and then it is routed through the coil or tubes in the evaporator. A fan circulates the warm air in the endosed space across the coil or tubes, which evaporates the liquid part of the cold refrigerant mixture. At the same time, the circulating air is cooled and thus lowers the temperature of the endosed space to the desired temperature. Major application areas of canned pump in refrigeration include meat processing, agriculture produce, fishery industries, ice making plant, etc. For details contact: Kirloskar Brothers Ltd Global Headquarters Yamuna, Survey No: 98/(3-7), Baner, Pune, Maharashtra 411 045 Tel: 020-27214444 or Circle Readers’ Service Card 5
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Chemical Engineering World
Products CEW High-performance Doors High-speed doors designed and manufactured by Gandhi Automations are sturdy, dependable and are the ideal solution for medium and large entrances. The doors are manufactured with European collaboration and technology with innovative and creative engineering. Fast moving functional and reliable doors are needed in industrial and commercial contexts. Gandhi’s high-speed doors are versatile and solid ensuring long-lasting reliability. The modular structure of the curtains, assembled and joined by anodized aluminium extrusions, provides for a wide range of polyester sections available in a variety of colours. Wide, full-width window panels ensure a safer traffic and allow more light in. Their fast and easy replacement, in case of accidental tearing, saves money and time. The alternating metal tubular structure inserted ensures high wind-resistance. Prime highspeed doors are the ideal solution for internal and external entrances for medium and large entrances and effectively operate in any situation, even when strong winds are blowing, in rooms with high volume traffic. For details contact: Gandhi Automations Pvt Ltd Chawda Commercial Centre, 2nd Floor Link Road, Malad (W), Mumbai 400 064 Tel: 022-66720200, 66720300 | Fax: 91-022-66720201 Email: sales@geapl.co.in or Circle Readers’ Service Card 6
Rugged HMIs The innovative ET-208 HMI comes with a number of serial interfaces including USB and connectors for different bus systems as well as Industrial Ethernet. Simatic S7-300, -400 and -1200 connector modules allow data transfer using PROFINET, PROFIBUS or MPI protocols. Barcode scanners and RFID readers can be connected via a reader box. It withstands ambient temp ranging from -40°C to +65°C and is highly vibration-resistant, which makes it suitable for applications in harsh environments, such as on drilling rigs or in close proximity to compressors, mixers or centrifuges. The device boasts a seawater-resistant, IP66-rated metal enclosure. The easy-to-use widescreen operator interface features a resolution of 800 x 480 pixels and with its powerful Cortex A8 processor is as user-friendly as a smartphone. If required, the unit is also available with an additional matrix of up to 4 x 8 keys. The default HMI comes with preinstalled Windows Embedded Compact 7; upon request, an open-source operating system can be installed to integrate customer-specific software. The ET-208 can be configured with the SPSPlusWIN project engineering software, a very popular tool in machine engineering that allows comfortable configuration of parameters such as display, process control or notification settings. Reverse compatibility with the monochrome FALCON Series product line ensures an easy changeover to this new line of HMIs offered by R STAHL HMI Systems. For details contact: R STAHL Pvt Ltd Plot No: 5, Malrosapuram Main Road Sengundram Indl Area, Singaperumal Koil, Kanchipuram District, Tamil Nadu 603 204 Tel: 044-30600600 | Fax: 91-044-30600700 E-mail: Sales@rstahl.net or Circle Readers’ Service Card 7
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October 2015 • 63
CEW Products Multistage Vertical In-Line High-pressure Pumps KSB has further enhanced range of materials for its existing range of pump Series – Movitec B. Multistage, vertical in-line high pressure pumps, Movitec B; are now available in complete SS materials in addition to the existing version of Cast Iron (VCF). These versions will be known as VF and VSF having SS 304 and SS-316 grades respectively. Movitec pumps are capable of handling variety of applications like RO plants, irrigation systems, pressure boosting, washing plants, chemical applications, HVAC system, etc. Pumps are available in 2, 4, 6, 10, 15 sizes. Higher sizes can also be made available on request. These pumps can generate a flow up to 22 cu metres per hr with the head up to 250 metres. And can handle liquid having temperature between -20 and +140 degree Celsius with a pressure of 25 bar. For details contact: KSB Pumps Ltd Mumbai-Pune Road, Pune, Maharashtra 411 018 Tel: 020-27101000, 2710 1233 | Fax: 91-020-27426000 E-mail: bipin.kode@ksb.com or Circle Readers’ Service Card 8
Liquid CO2 Storage Tanks ‘Mellcon’ offers skid-mounted preengineered tankage for liquid CO 2 storage tanks with storage capacity ranging from 3,000 kg to 50,000 kg of liquid CO 2 duly approved by Chief Controller of Explosives as per SMPV Rules. These are designed as per the recommendations in ASME SecVlll DlV-1 codes and the MoC are SA-516/SS-304 or as per the specific requirement of the customer meeting all requirements. The vessel can be horizontally and vertically mounted with 175 mm thick insulation and aluminum cladding. Mellcon also offers these tanks under any third party inspection according to customers’ specific requirement. These storage tanks are equipped with all standard instruments and controls. For details contact: Mellcon Engineers Pvt Ltd B-297 Okhla Indl Area, Phase 1 New Delhi 110 020 Tel: 011-26811727, 26816103 | Fax: 91-011-26816573 E-mail: mellcon@Mellcon.Com or Circle Readers’ Service Card 9
RPS Endurance Inverters RPS Endurance inverters with new parallel operation feature now available for the Indian market. Bonfiglioli’s RPS Endurance inverters are now ready to tango: With the introduction of the new tandem feature, up to 4 units operate seamlessly in parallel on a single medium-voltage transformer winding. This makes the performance and ease of handling of RPS Endurance inverters now fully available for megawatt-scale PV stations. Thanks to the further extended power range of single RPS Endurance units of up to 563 kWac at 50°C ambient temperature, the new features allows the effortless realization of 2 MW+ tandem configurations with a common ac connection, paired with the best-in-class 15% permanent overload capacity (up to 648 kWac) at reduced ambient temperatures. The innovative two-zone ambient protection system distinguishes the RPS Endurance from other solutions and makes it a preferred choice for harsh plant environment of India Projects. The intelligent encapsulation design maximizes uptime through a certified full IP54 ambient protection degree of active components. Thanks to advanced air cooling technology, the inverter design ensures outstanding reliability and serviceability. With numerous self-protection functions and grid management options, the RPS Endurance is built to satisfy even the most demanding power control requirements in the fast developing global PV market. Bonfiglioli´s high-level competence is proven by an installed power of over 2.5 Gigawatts in the segment of medium-size and large Grid Connected PV-plants. As a supplier of a couple of the world´s largest PV-plants, Bonfiglioli is trusted by many companies every single day. RPS Endurance is a robust, compact powerhouse with a rated power of up to 563 kWac for each inverter unit with capability of operating up to 4 inverters in parallel connected to single LT side winding of MV Transformer For details contact: Bonfiglioli Vectron GmbH Europark Fichtenhain B6, 47807 Krefeld Tel: +49(0)2151/8396-0 | Fax: +49(0)2151/8396-999 E-mail: info@vectron.com or Circle Readers’ Service Card 10
64 • October 2015
Chemical Engineering World
Products CEW Welded Pipes & Tubes Welded tubes making operation are carried out on the tube mill. Cold/hot stainless steel strips are slitted to the required width as per the diameter of tube to be formed. The strips are then fed to the uncoilar from where it passes through series of rollers and continuously formed into a tubular shape and welded by tungsten inert gas (TIG) welding. It is highly precision complete automated process where the edge of script are treated and fused together under protect in atmosphere of argon gas through a non-consumable electrode without using any filler metal. The tubes also pass through a series of sizes rolls to ensure quality, tolerance and then are cut to length. It is then annealed, straightened, hydro-tested, pickled and passivated. The tubes then undergo a 100 per cent visual and dimensional inspection. Then the tubes are marked and suitably packed before dispatch. For details contact: MBM Tubes Pvt Ltd Maruti Mandir Marg 5th Kumbharwada Lane Mumbai 400 004 Tel: 022-66381354, 66381355 Fax: 91-022-66595047 E-mail: mbmtubes@gmail.com or Circle Readersâ&#x20AC;&#x2122; Service Card 11
Water-cooled Refrigerated Air Dryers Ingersoll Rand offers water-cooled refrigerated air dryers in 1,000-2,500 cfm range These dryers will cater to industries like automotive, cement, manufacturing, oil and gas, pharma and glass. This new offering of refrigerated dryers offer multiple design features to ensure a constant dew point at all load levels and will deliver a continuous dry air that satisfies ISO 8573.1 Class-4 air quality standards. These units have phenomenal lower pressure drop and the new innovative heat exchanger design has allowed setting new benchmark in terms of power consumption. Zero air loss level controlled condensate drain prevents energy loss and pressure regulated water valve helps to manage load fluctuations more effectively. The control panel comes with advanced features for safety and connectivity, and refrigeration scroll provides better protection at extreme conditions for enhanced reliability. Fpr details contact: Ingersoll-Rand (India) Ltd Plot No: 35, KIADB Indl Area, Bidadi Bengaluru Karnataka 562 109 E-mail: Contact-India@irco.com or Circle Readersâ&#x20AC;&#x2122; Service Card 12
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CEW Products LUTZ AODD Pumps Shanbhag & Associates is the sole distributor for the entire range of Lutz products with an all-India sales/ service network. The Lutz air-operated double diaphragm (AODD) pumps are a natural complement to the Lutz pump range. The pump size ranges from 1/4” to 3”. Pump housings are available in PP, PVDF, nylon, aluminium and SS, and internals in Teflon, EPDM, nitrile rubber or Viton. The pumps run on dry, non-lubricated clean air. In addition, the company also offer solid-block AODD pumps in complete PTFE as well as in PE housings – both housing options in conductive or non-conductive construction. Lutz double diaphragm pumps are in bolted construction and are designed for a variety of industrial applications. They are self-priming and can carry solid particles/slurries without any damage. Lutz AODD pumps are absolutely lube-free; non-stalling in operation; weight reduction, air valve body available in corrosion-free engineered plastics; and similarity of spares across models and sizes. It finds application in pharma, glass and fiberglass, oil and gas, marine/shipbuilding, metal and steel, effluent treatment, paint, aircraft, electroplating/surface treatment, food and beverage, automotive, chemical, clay and ceramics, etc. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E), Mumbai 400 093 Tel: 022-28346604, 28340071, 28218008 | Fax: 91-022-28388334 E-mail: info@shanbhags.com or Circle Readers’ Service Card 13
DESMI Industrial Gear Pumps Shanbhag & Associates are the authorised distributor for DESMI internal gear pumps. The ROTAN internal gear pump provides favorable flow conditions, as the direction of the liquid flow is only changed slightly through the pump. This means that superior self-priming capability and gentle liquid handling are achieved, and also that highly viscous liquids can be pumped. ROTAN pump offers the following additional advantages: pumping in either direction; easy maintenance and inspection based on modular design; sturdy and uncomplicated construction with only two rotating parts and one shaft seal; comprehensive choice of configurations available as standard; genuine back pull-out design; and end-clearance axial adjustment. All ROTAN pumps are hydrostatically and performances tested and get their own certificate before leaving the factory. ROTAN pumps can be supplied in accordance with the ATEX directive for use in potentially explosive environments. DESMI, ROTAN offers pumps in cast iron, SS, cast steel and ductile iron MoC along with different sizes, bearing materials and sealing options. ROTAN pumps are offered with pressure relief valve and heating jackets on front and rear cover. For hazardous, toxic or corrosive liquids DESMI magnetic drive gear pumps are also available in CI, WCB and SS-316. Over the past decades, DESMI has proved as one of the world’s leading pumps within internal gear pumps by providing best pumping solutions for chocolate, specialty chemicals, asphalt and bitumen, sugar and molasses, isocyanate and polyol, soap and detergents, paint and ink, pulp and paper, and oil blending industries. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road Andheri (E), Mumbai 400 093 Tel: 022-28346604, 28340071, 28218008 | Fax: 91-022-28388334 E-mail: info@shanbhags.com or Circle Readers’ Service Card 14
66 • October 2015
Chemical Engineering World
ChemTECH Chennai 2015 Dates: 10-12 December, 2015 Venue: TNTPO, Exhibition Ground, Chennai Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
ChemTECH Gujarat 2016 Dates: 10-12 February, 2016 Venue: Ahmedabad, India Details: World meet of chemicals, petrochemicals, pharma and process industry in India encompassing exhibition and conferences. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
2015 SNO Conference Dates: 8 - 10 November, 2015 Venue: Portland, USA Details: This year’s SNO conference sessions will be organised around selected ‘systems’ eg, air-water systems Organiser: Sustainable Nanotechnology Organization Email: info@susnano.org Website: http://susnano.org/
2015 Chem Show Dates: 17-19 November 2015 Venue: Javits Center, New York Details: Executives from companies across the Chemical Process Industries (CPI) come to see the latest technology for their process operations Contact: 001 203 221 9232 Email:info@chemshow.com Website: www.chemshow.com
It is time to Migrate to an advanced Structural Analysis Software
Easy User Interface Chemspec 2016
ORPEC 2017
Dates: 7-8 April, 2016 Venue: Bombay Exhibition Centre, Mumbai Details: Meeting and networking with existing and potential partners and business facilitators Organiser: Quartz Businesss Media Ltd, Contact: +91 22 240 44472 Email: rohit@chemicalweekly.com Website: www.chemspecevents.com
Dates: 13-15 May 2017 Venue: Muscat, Oman Details: Designed to deliver key buyers to Oman’s growing refining and petrochemical industries creating a forum aligned with the government’s growth plans Organiser: OMANEXPO LLC Contact: Mr Ebrahim Taher Email: info@omanexpo.com Website: www.omanexpo.com
Conformancee to nuclear industry QA/QC - NRC Integration with smartPlant 3D / Tekla / STAAD.Pro Validation & veri�cation for more than 5000+test problems Base plate modeling & analysis Linear and Non linear Static-Dynamic analysis Steel Frame & reinforced concreate design CIS/2 analysis data interface Comprehensive & detailed user documentation Offshore structure analysis & deisgn
Automation 2016 Dates: 22 - 25 August 2016 Venue: Bombay Exhibition Center, Mumbai Details: Automation 2016, a four day automation event is set to introduce new and upcoming technology this year Organiser: IED Communications Ltd Contact: 91 22 22079567 Email: jyothi@iedcommunications.com Website: www.iedcommunications.com Chemical Engineering World
Plastics Recycling Show 2015 Dates: 25-26 November, 2015 Venue: Belgium Details: European exhibition & conference for plastics recycling Organiser: Engineering Conferences International Contact: +32 2 742 96 82 Email: info@plasticsrecyclers.eu Website: www.plasticsrecyclers.eu
Email: sales@iges.in
www.iges.in TOLL FREE : 1800 102 4437
October 2015 • 67
CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. • CHEMICALS Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312 sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigment and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500 sq m of existing land. The project will entail expansion of single super phosphate capacity from 400-TPD to 600-TPD, granulated super phosphate from 200-TPD to 300TPD and addition of new products namely 150-TPD triple super phosphate, 550 - TPD synthetic gypsum, 30 - TPD di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM itopide HCl, 1.20-TPM loxapine succinate, 0.30-TPM amoxapine, 6-TPM venlafaxine, 6-TPM progunil HCl, 6-TPM CB2-L-Valine, 0.60-TPM nateglinide, 0.60-TPM quetiapine, 24-TPM carbomazepin and 12-TPM oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m3/day) will be treated 68 • October 2015
in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Astrica Laboratories is implementing a 240-TPA synthetic organic chemicals manufacturing project at a cost of ` 78.8-million in village: Ananthsagar, district: Medak, Telangana. Team Labs & Consultants are the environmental consultants. The project will come up on 6.97-acre of land. According to MoEF sources, it is proposed to treat all HTDS effluent in stripper followed by MEE and ATFD. All LTDS effluent including domestic effluent shall be treated in biological treatment followed by RO system. RO rejects sent to MEE and permeate is used for cooling towers as make up. Solid wastes are generated from the process, solvent distillation, collection/neutralization tank, waste oil from DG sets, used batteries from DG sets. The ash from boiler is sold to brick manufacturers. The solid wastes; evaporation salts, wastes from the process in inorganic form, ie, process salts and filtration aids shall be disposed to the TSDF, while the hazardous wastes of organic nature, i.e, distillation residues shall be disposed to authorized cement units and other wastes like used oil and used batteries shall be sent to authorized recyclers. The sludge from treatment plant shall be sent to TSDF. The basic technology involved in the manufacturing of bulk drugs is the process kettles, heat exchangers, centrifuges and storage tanks. To suppor t the process, equipment boilers, chilling plants, cooling towers, etc, are required. All the above equipment can be sourced indigenously. 80 per cent of civil work has been completed and remaining 20 per cent is in progress. The project is scheduled for completion in December 2015. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. Superhouse is planning an expansion of its chemical mix-manufacturing project from 200-kg/day to 500-kg/ day in UPSIDC Industrial Area, district: Unnao, Uttar Chemical Engineering World
Project Update CEW Pradesh. The product will be used in leather tanneries. The project will involve installation of containers. The project is in planning stage. Stellar Chemical Laboratories is planning an expansion of its organic chemical manufacturing project from 7.1-TPM to 84.1-TPM in village: Derol, district: Panchmahals, Gujarat. Machinery is yet to be ordered. Work on the project is expected to commence after receipt of environmental clearances and the completion date is yet to be finalized. • MINING Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal. DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence in December 2015. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LOI) for mining contract has been granted for a period of 9 years. Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals & Raj West Power, a subsidiary of JSW Energy is planning an expansion of the Kapurdi Open Cast Lignite Mining project from 3.75-MTPA to 7-MTPA in Kapurdi, district: Barmer, Rajasthan at an estimated cost of ` 18,000-million inclusive of a Chemical Engineering World
new lignite mining project at Jalipa mines. The project is waiting for environmental clearance. • NON-CONVENTIONAL ENERGY Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on the roof-tops of 31 of HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million. Karnataka Renewable Energy Development is planning a 10MW solar power project at an estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Tumkur, Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of the project. Maharashtra State Power Generation Company is planning a 50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company is scouting for land. Other details are yet to be finalized. Azure Power India is implementing a 10-MW solar photovoltaic power project in taluka: Hiriyur, district: Chitradurga, Karnataka. PPA has been signed with Bangalore Electricity Supply Company (BESCOM). Civil work and panel installation work is in progress. Government of Odisha is planning a 20-MW solar power plant in Manmunda, district: Boudh, Odisha. Green Energy Development Corporation of Odisha is the nodal agency. According to reports, the nodal agency has identified about 120-acre of land at Manmunda for establishment of the project. The land has been allotted to the agency from the industrial park area earmarked by Odisha Industrial Infrastructure Development Corporation (IDCO).The EPC tender is for development of the power plant and maintenance for a period of 10 years. Apart from the Boudh project, the agency is in the lookout for additional land in Koraput, Kantamal and Bolangir areas for installing about 200-MW solar energy capacity.
ACME Solar Energy is planning a 30-MW solar photovoltaic independent power project at a cost of ` 2.4-billion in Chhattisgarh. The company is a JV between ACME Cleantech Solutions, EDF Energies Nouvelles (EDF EN) and EREN, Luxembourg. PPA is yet to be signed with Chhattisgarh State Power Distribution Company (CSPDCL). The project is in planning stage. The project is planned for completion in 1-year from zero date.
• NON-CONVENTIONAL POWER BMS Starch, a part of the BMS Group, is implementing a 6-MW biomassbased co-gen power plant in village: Kurandi, district: Bastar, Chhattisgarh. The project is coming up along with a starch manufacturing unit on 26-acre of acquired land at a total estimated cost of ` 1,350 million. Equipment supplier is yet to be appointed. Civil work is in progress. The project is expected to be completed by 2016. October 2015 • 69
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
49
15
Integral Process Controls India (P) Ltd
Inside Cover I
16
Kirloskar Brothers Ltd
Avians Innovations Technology Pvt Ltd
33
17
KSB Pumps Ltd
15
4
Busch Vacuum India Pvt Ltd
31
18
Lubrizol Advanced Materials India Pvt Ltd
29
5
C R I Pumps Pvt Ltd
41
19
Rasaii Flow Lines Pvt Ltd
35
6
De Dietrich Process System India
11
20
Sandvik Materials Technology
7
Desmi Pumping Technology A/S
21
21
Shanbhag & Associates
19
8
Economy Refrigeration Pvt Ltd
9
22
SPX Flow Technology (India) Pvt Ltd
27
9
Emjay Engineers
45
23
Suraj ltd
47
10
Fluorotech Engineering Works
45
24
SYP Engineering Company Pvt Ltd
39
11
Hi-tech Applicator
3
25
Toshniwal Instruments (Madras) Pvt Ltd
47
12
HRS Process Systems Ltd
5
26
Uni Klinger Ltd
37
13
ImageGrafix Engineering Services Pvt Ltd
61, 63, 65, 67
27
Chemtech Events
14
Impart International Pvt Ltd
1
Arvind Anticor Ltd
2
Atomic Vacuum Company (Exports)
3
70 • October 2015
23
Inside Cover II
7
Back Cover
17 Chemical Engineering World
Book Shelf CEW Intelligent Coatings for Corrosion Control Author Price Pages Publisher
: Atul Tiwari, Lloyd Hihara, James Rawlins : USD 162.43 : 746 (Hardcover) : Butterworth-Heinemann
About the Book: Intelligent Coatings for Corrosion Control covers the most current and comprehensive information on the emerging field of intelligent coatings. The book begins with a fundamental discussion of corrosion and corrosion protection through coatings, setting the stage for deeper discussion of the various types of smart coatings currently in use and in development, outlining their methods of synthesis and characterisation, and their applications in a variety of corrosion settings. Further chapters provide insight into the ongoing research, current trends, and technical challenges in this rapidly progressing field. • Reviews fundamentals of corrosion and coatings for corrosion control before delving into a discussion of intelligent coatings - useful for researchers and grad students new to the subject • Covers the most current developments in intelligent coatings for corrosion control as presented by top researchers in the field • Includes many examples of current and potential applications of smart coatings to a variety of corrosion problems
Corrosion Prevention by Protective Coatings, 2nd Edition Author Price Pages Publisher
: C. G. Munger : USD 115 : 520 (Paperback) : Natl Assn of Corrosion
About the Book: The comprehensive text covers all aspects of the use of high-performance coatings. Two new chapters, on elasto-meric linings and computer-assisted coatings project management programs, treat new technology developed since the first edition was published. The book is a comprehensive reference tool for engineers, paint superintendents, and maintenance personnel.
Corrosion Failures: Theory, Case Studies, and Solutions, 1st Edition Author Price Pages Publisher
: K Elayaperumal, V S Raja : USD 65.12 : 256 (Hardcover) : Wiley
About the Book: Provides corrosion basics in a lucid manner to students and working professionals and over 80 corrosionfailure analysis case studies; Correlates Failure Analysis with Corrosion Science; Exclusively provides corrosion-related failure analysis case histories in one place in a convenient format; One-stop shop for both science and real time occurrence of the phenomenon of corrosion; Full coverage of all MOC, Materials of Construction, used for process equipments; Simple but Lucid presentation of Failure Analysis procedure. Chemical Engineering World
Internal Corrosion 1st Edition Author Price Pages Publisher
of
Pipelines
: Anil Bhardwaj, Baldev Raj : USD 98.95 : 374 (Hardcover) : Alpha Science International Ltd
About the Book: Internal Corrosion Of Pipelines dwells upon various factors responsible for internal corrosion of pipelines, which include corroding gases like O2, CO2, H2S; different types of bacteria; environmental factors such as temperature and pressure; aqueous chemistry including salinity, buffer ion concentration, ionic composition and pH; flow regimes in case of multiphase flow etc. Mechanisms, causes and effects have been explained in user-friendly language with apt case studies and examples. Internal corrosion of pipes in seawater environment is a very specific issue relevant to coastal, offshore and shipping industry. The options of corrosion resistant materials and corrosion control have been elaborated which can vary depending upon requirement of industry, temperature and flow conditions. Two types of pipeline systems are common to most chemical process industries, viz. cooling water and firewater. They are essential for efficient and safe operation of a chemical process plant. The environmental and flow conditions are different for these lines and unique corrosion control measures, including specific materials of construction, for these two categories of lines have been dealt in this book in separate chapters. Finally, there is a chapter on holistic approach to handle corrosion through corrosion management tools. October 2015 • 71
CEW Interview
Interview CEW
Plastic... A Cost Competitive Packaging Material By 2019, the global flexible packaging market is expected to grow at a CAGR of 4.1 per cent to reach a value of USD 99.1 billion. Girija Dalvi seeks views of Sunil Kumar, Business Director Industrial Adhesives, Henkel India on various issues in the domestic market such as how the Indian market will pan out in the years to come, the challenges companies will face and how will they remain cost competitive with the growing competition from China and sectors that Henkel is focused on which will drive its growth.
72 â&#x20AC;˘ October 2015 Chemical Engineering World
October 2015 â&#x20AC;˘ 72
Interview CEW What are the market conditions you foresee in the India market? Anywhere in the world, evolution is the most essential parameter for an industry’s growth, and it is strongly applicable to the Indian market as well. One evolution that has recently hit the Indian shores is the use of flexible pack pouches for beverage, food and personal care products. Last year, the flexible pack pouch was introduced in the country’s largest alcoholic beverage market, Bangalore, in Karnataka, and the sales soared up with the introduction of this novel packaging for the drink. Alcohol industry is on the verge of experiencing a significant change in the dynamics of liquor packing in India. Ironically, for many, the flexible pack pouches are still largely associated with fruit juices and milk. India, with its more than 300 million cases (of 9 litre each) branded spirits market, possibly has the biggest market potential for this new age packing style. What are the challenges companies face in the Indian market and how can they be resolved? For any company operating in the flexible packaging space, the major challenge is to offer durability, safety and ease of storing and transporting, in their entire gamut of offerings. To counter these challenges companies have introduced pack pouches, which have a number of benefits starting from durability to safety and easy storage. Other forms of packaging are more prone to duplication and adulteration, which is a major area of concern for industries, especially the packaged food business. A flexible pack pouch, once broken is difficult to reuse. Hence, this assures that the end consumer is delivered a quality product and at the same time it is a boon for the packaging industry to curb adulteration issues. National Green Tribunal supports imposing curbs on plastic packaging and has urged companies to adopt bio-degradable materials only. If the regulations are changed, how can companies remain cost competitive? Chemical Engineering World
Plastic is a very cost competitive packaging material. It is also light weight, break resistant, leak proof and convenient to use. It is our duty to secure the environment and it is very important for everyone who is a part of the packaging industry to come together and look for a grassroots solution to manage plastic packaging waste. In 1990, a study conducted by the Boston-based Tellus institute for the US Environment Protection revealed that although glass appears to be an excellent packaging material, it actually has a higher environmental impact per use than paper and plastic. In addition, the study also established that flexible packaging would cost as low as 20 per cent of the traditional glass bottle packaging. Moreover, it pointed out that there are better biodegradable packing materials available in the market that are made from starch-based plastics. These materials use plant starches to make a thermoplastic; additives are used to increase the heat resistance of the material. Plant starch-based materials also absorb humidity, which is a bonus in packaging. The government wants to come up with plastic parks in the North East, Tamil Nadu, Orissa and Gujarat. Would the market have enough demand to absorb these capacity additions? What are your thoughts on the same? The government has approved the scheme for setting up of need-based Plastic Parks, with necessary modern infrastructure and enabling common facilities that will assist the sector to move up the value chain and effectively contribute to the economy. Such a scheme will help increase competitiveness and investments, while achieving environmentally sustainable growth. It will foster the adoption of the cluster development approach; thereby, consolidating the capacities in the plastic sector. The projects have been shortlisted
depending on either their proximity to market or PCPIR zone where raw material availability is an issue. PCPIR, the acronym for Petroleum, Chemicals and Petrochemical Investment Region, is a flagship scheme of the Department of Chemicals and Petrochemicals for developing projects that will ensure the availability of raw materials required by the industry. Currently, the petrochemical and plastic industry is highly fragmented and disorganised. Moreover, there is no large hub from where one can source plastic capacities. On the other hand, there are many sectors of the industry which are regularly facing a problem of timely availability of raw material both in basic or processed form. Therefore, such a park will act as a hub for manufacturers to source raw materials. How much has the flexible packaging industry been impacted by China’s dumping into the country? How can this be countered? There is no known dumping of Flexible packaging in India from China – what comes through from china are films such as BOPP (Biaxially Oriented Polypropylene), Polyester and metals such as Aluminium foil, which are used in making flexible packaging products. At the end of the day, it is a global market, and customers will source products from the cheapest source, China being one of the cheapest producers of commodity products such as BOPP and PET– a lot of these get imported. Which are the key industries that your company would be focused on viz, food, beverage, personal care products, etc.? Food processing industry is a big focus in India, and we are clearly seeing a lot of action in this space. Ready-toeat foods, retorted food products, fruit juices, etc, are the areas where we are
A flexible pack pouch, once broken is difficult to reuse. Hence, this assures that the end consumer is delivered a quality product and at the same time it is a boon for the packaging industry to curb adulteration issues. October 2015 • 73
CEW Interview Food processing industry is a big focus in India, and we are clearly seeing a lot of action in this space... We are also seeing products such as liquid cleaners, detergents, shampoos, hair oils, edible oils, etc, being increasingly packed in flexible packaging formats
focusing our efforts. We are also seeing products such as liquid cleaners, detergents, shampoos, hair oils, edible oils, etc., being increasingly packed in flexible packaging formats; however, our focus is on high end applications. A number of MNCs in the chemical industry offer flexible packaging solutions in the Indian market. What is the USP of the products you have to offer? The trend in the market is to convert packaging applications from rigid packaging such as HDPE bottles, Glass bottles, Pet bottles, etc. used in the past to Flexible packaging. Flexible packaging continues to grow in importance. In order to produce high quality flexible packaging materials, the adhesive used is a key factor. The film composition, the printing ink as well as the adhesive need to be aligned to deliver the required properties of modern flexible packaging. Henkel was one of the early anticipators of the need for highperformance laminating adhesives, which led to the development of the Loctite product range for flexible packaging. In doing so, major importance was given to application convenience and product safety. Whatever the substrate, we offer a broad range of products from standard applications sophisticated laminates for the most demanding performance. At Henkel, we believe in putting our customers at the centre of what we do and work closely with them to develop solutions to challenges faced by them. One of our key tasks is to support and be a solutions provider to our customers not only in supplying the tight grade of adhesives but also solving any problem by helping them with industry knowledge to improve their process. We believe in being a partner in the growth of our customers. As the market leader in the flexible packaging space in India, we set up the Henkel Flexible Packaging Academy at Thane to address the felt need of providing a platform to educate professionals from the industry on the right application techniques. This academy will keep us ahead as industry innovators.
2014 E
27.8
2011 E
17.3
2009
13.3
2004 0.0
CAGR:14.9 %
6.9 5.0
10.0
15.0 20.0 25.0
30.0
Market Statistics - Global flexible packaging market will reach an estimated value of USD 99.10 billion by 2019 - Based on volume, the demand for flexible packaging stood at 18,666.0 kilotons in 2012 and is expected to reach 24,728.7 kilo tons by the end of 2019, developing at a 4.1% CAGR during the forecast period. - The Indian packaging industry was valued at USD 13 billion and estimated to reach USD 28 billion in 2014 at a 10-year compound annual growth rate of 15 per cent. - Greater demand because of economic growth and increasing share of organised retail will be the key growth drivers. - At 49 per cent, plastics are the largest single material used for packaging in India - *Sources – Transparency Market Research, IBEF
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Chemical Engineering World
R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MCS/095/2015-17 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 29th & 30th of every month. Total Pages No.:76