CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966
CHEMICAL ENGINEERING WORLD OCTOBER 2016 VOL. 51 ISSUE 10
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VOL. 51 | ISSUE NO. 10 | OCTOBER 2016 | MUMBAI | ` 150 NEWS Industry News 6 Technology News 36
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4 • October 2016
Rotary Pressure Filter - Present Solid- Liquid Separation Trends in PTA Industries 50 - Amol Patil- Aker Solutions, India
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INTERVIEW
76 “Kurkumbh Manufacturing Facility Will Strengthen Henkel’s Growth Strategy for Emerging Markets” - Shilip Kumar, President, Henkel India
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CEW Press Release Honeywell UOP announces Ionic Liquids Alkylation Technology
facilities undergoing capital expansion. It can produce alkylate from a wider range of feedstocks using a lower volume of catalyst. This liquid catalyst has a negligible vapor pressure and can be regenerated on-site, giving it a lower environmental footprint than other technologies. Alkylation technologies are commonly used in the refining industry to produce high-octane gasoline blending components to make clean-burning fuels. Currently, the majority of alkylation processes use hydrofluoric or sulfuric acid processes that were developed by or in concer t with UOP, and introduced between 1938 and 1942. Today, more than half of the world’s approximately 700 refineries currently have alkylation units that use hydrofluoric or sulfuric acid.
Des Plaines, USA: Honeywell UOP has announced that it has introduced to the refining industry a new alkylation technology developed by Chevron U.S.A. Inc., that employs ionic liquids as a catalyst to produce high-octane motor fuels. Chevron licensed the technology to Honeywell UOP, which will offer the technology under the ISOALKY™ brand name as alternative to traditional technologies that use hydrofluoric or sulfuric acids as a liquid alkylation catalyst. “Ionic liquids alkylation offers a compelling economic solution compared to conventional liquid acid technologies while delivering the same yields and high levels of octane,” said Mike Millard, vice president and general manager of Honeywell UOP’s Process Technology and Equipment business. “This is a revolutionary new technology for refiners to produce alkylate and improve the quality of their gasoline pool.” The ISOALKY technology is the first successful liquid alkylation technology to be introduced in 75 years. Chevron proved the technology in a small demonstration unit at its Salt Lake City refinery, where it has operated successfully for five years. Earlier this week, Chevron committed to convert its hydrofluoric acid (HF) alkylation unit in Salt Lake City to ISOALKY technology. Construction is expected to commence in 2017, pending permit approvals, with the ISOALKY technology becoming fully operational As part of this project, the refinery’s HF-specific equipment and its inventory of hydrofluoric acid will be permanently removed. This new technology uses a non-aqueous liquid salt, or ionic liquid, at temperatures below 100ºC to convert a typical stream from a fluid catalytic cracker into a valuable high-octane blending component that lowers the environmental impact of motor gasoline. Among the other benefits of this technology, the ionic liquids process can be used in new refineries, as well as existing 6 • October 2016
Ionic liquids have strong acid properties, enabling them to perform acid catalysis, but without the volatility of conventional acids. They represent the first new class of liquid alkylation technology since World War II. They are technically a salt in liquid state, comprised largely of ions that convert C4 paraffins and other olefins into an excellent gasoline-range blending product. Due to its low vapor pressure, ionic liquid requires simpler handling procedures than either sulfuric or hydrofluoric acids. ISOALKY is a cost-effective solution for many refining companies that have expressed growing interest in the technology as an alternative to conventional liquid acid systems or recent solid catalyst systems to produce high-quality alkylate for cleanburning fuels.
Wacker Honors Researchers for New 3D Printing Process to Manufacture Silicone Parts Munich, Germany: Wacker Chemie AG has announced that it has conferred its “Alexander Wacker Innovation Award” on Dr. Frank Achenbach, Dr. Bernd Pachaly, Dr. Maximilian Peter and Dr. Ernst Selbertinger for their development of a new 3D printing process to produce silicone rubber par ts. Previously, there was no mature industrial 3D printing technology available for silicones. That is why the process developed by the four WACKER researchers is considered a milestone in additive manufacturing. This year’s €10,000 innovation award, now in its eleventh year at WACKER, focused on process innovation. The ACEO® technology developed by the researchers uses a dropon- demand method. The printer head deposits tiny silicone droplets on a substrate. In this way, the workpiece is built up layer by layer. The silicone is formulated so that the droplets flow together before the curing process begins, activated by UV light. The silicone droplets and layers thus produce a homogeneous workpiece, which does not differ much from injection-molded par ts. With the aid of water-soluble suppor t materials, it is also possible to make parts with complex geometries, such as overhang materials and internal lattice structures. Chemical Engineering World
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CEW Press Release IFAT India 2016 lays the roadmap for environmental technologies
beneficial efforts for environmental initiatives and growth in the environmental sector. Apart from various conferences and supporting programmes, this year IFAT India added a unique platform, which benefited both visitors and exhibitors. Messe München India along with their cooperation Par tner DWA, the German Association for Water, Wastewater and Waste, presented “The Active Learning Center” (ALC). The Active Learning Centre consisted of The University Challenge India, Water Skills India and a special live demonstration called Products in Practice, which together offered the trade-fair visitors an interesting insight into the special abilities and knowhow needed in the environmental sector.
Mumbai, India: IFAT India kicked off with its fourth edition on September 28th 2016 at the Bombay Exhibition Centre, Mumbai. This year, the trade fair focuses on environmental technologies for India like Water Scarcity, Water Management & Solutions etc. This exhibition infused the most updated technologies with an amalgamation of superior quality services across sectors of the environment industry. IFAT India 2016 was inaugurated by Mr. Vijay Shivtare, Honourable Minister of State for Water Resource along with industrial dignitaries and Government officials. The trade fair opened its doors to exhibitors and visitors of future-oriented technologies, science experts, government officials and education institutes from the environmental technology sector. One of the key highlights of the exhibition is the Innovation Exchange Forum, which would deliberate, exchange ideas and highlight solutions over the three days, for sustainable Water, Waste& Resource Management in India. Besides key notes by the Minister and government officials, there were panel discussions and presentations with contributions from notable local and international partners, such as German Association for Water, Wastewater and Waste; German Water Partnership, GIZ –Deutsche Gesellschaft für Internationale Zusammenarbeit, German and Indian Biogas Association, Indus Media, International Solid Waste Association, University of Applied Sciences Hof and from various companies as well. I n o r d e r t o fa c i l i t a t e b i l a t e r a l c o o p e r a t i o n a n d e n h a n c e communications between Chinese and Indian Industries, the Foreign Economic Cooperation Office, Ministry of Environmental Protection (MEP/FECO) and Messe München India organised the Sino-Indian Environmental Protection Technology and Industry Dialogue within the framework of IFAT India in Mumbai on Day 1. The expected outcome of this event is matchmaking between India and Chinese companies to promote mutually 8 • October 2016
IFAT India witnessed key Speakers such as Mr. K Ashok Natarajan, Chief Executive Officer, Tamil Nadu Water Investment Company Ltd., Mr. Sajid Hussain, Chief Operating Officer, Tamil Nadu Water Investment Company Ltd., Mr. Umesh Krishna Shenoy, Vice – President - Works, Jk Tyres Vikrant Plant Mysore, Dr. Prasad Modak, IL&FS Academy of Applied Development (IAAD), Mumbai, India , Dr. Uttam Kumar Sinha, Fellow at the Institute for Defence Studies and Analyses, Prof. Dr. Dr. h.c. Jürgen Lehmann, President of the University for Applied Sciences Hof, Mr. Michael Kuhn, Head of Country Section India of German Water Partnership and Mr. Michael Dörr, Head of training center Sewage treatment plant Nuremberg, Germany. Key dignitaries like Christine von Lonski, General Manager, German Water Partnership, Dipl. Geol. Roland Knitschky, DWA German Association for Water, Dr. Jürgen Morhard, German Consul General, Stefan Rummel, Managing Director, Messe München GmbH, Dr. Suresh Kulkarni, Secretary, Maharashtra Water Resources Regulatory Authority (MWRRA), Dr. Vivek Agrawal, International Solid Waste Association were present for the current edition of IFAT India. Dr. Suresh Kulkarni, Secretary, Maharashtra Water Resources Regulatory Authority (MWRRA) said, “Trade fairs like IFAT India help in creating awareness about the issues of waste water management, and Messe Muenchen India is taking a great initiative by organizing such trade fairs which address these challenges. We are looking forward to wider participation and in the coming years we are looking at including a larger segment of the business eco-system which includes people, companies and policy makers.” Mr. Igor Palka, COO of Messe München India said, “One of our main objectives at IFAT India is to inspire practitioners and decision makers to share knowledge and experiences on reliable, approved and innovative environmental technologies. Our supporting program will perfectly complement IFAT India which will showcase proven and innovative solutions for metropolitan, industrial and rural regions likewise.” Chemical Engineering World
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CEW Press Release LANXESS Announces Plan to Acquire Chemtura Cologne, Germany: LANXESS has announced its plans to acquire US-based Chemtura Corporation, one of the major global providers of high-quality flame retardant and lubricant additives. With the largest acquisition in its history, LANXESS is building on its own additives portfolio and will become one of the world’s major actors in this growing market. The companies have signed a definitive acquisition agreement. Under the terms of the agreement, Chemtura shareholders will receive $ 33.50 per share in cash for each outstanding share of common stock held, which represents an 18.9 per cent premium to the stock’s closing share price of $ 28.18. The transaction with an enterprise value of approximately $ 2.64 billion will be financed by LANXESS mainly through senior and hybrid bonds, as well as from existing liquidity. The transaction, which is expected to close around mid-2017, is subject to approval by Chemtura shareholders, required regulatory approvals and certain other customary closing conditions. Headquartered in Philadelphia, Pennsylvania, Chemtura has 20 sites in 11 countries and approximately 2,500 employees wor ldwide. The company repor ted sales of around $ 1.65 billion in the last four quarters with EBITDA pre-exceptional of approximately $ 269.36 million (EBITDA margin of approx. 16 per cent). Approximately 45 per cent of Chemtura’s revenue is generated in North America. In addition to additives, Chemtura’s portfolio includes urethanes and organometallics. “With this acquisition, we are forming a champion in the field of additives and are strengthening our already profitable portfolio,” said Matthias Zachert, Chairman of the Board of Management of LANXESS AG. “Through the acquisition, we are fur ther implementing our strategy to become a more resilient and profitable chemical company. We are significantly building on our competitive positioning in medium-sized markets and increasing our presence in North America. LANXESS is taking a next and major step forward on its growth path.” “The transaction provides premium value to our shareholders and benefits our customers and employees by making Chemtura part of a much larger, stronger global enterprise with the resources to fully support a more diverse suite of specialty chemicals products and services,” said Craig A. Rogerson, President, Chief Executive Officer and Chairman of the Board of Chemtura. For LANXESS, the acquisition of Chemtura will be accretive to earnings per share (EPS) in the first fiscal year, with annual synergies of approximately $ 109.94 million expected by 2020. LANXESS is paying an EV/EBITDA multiple of approximately 7x including synergies for this transaction, meeting its target of 7-9x for acquisitions including synergies. Chemtura’s two additive segments form the main pillars of the company’s business. Both will, together with LANXESS’ Rhein Chemie 10 • October 2016
Additives business unit (ADD), form the new Performance Additives segment after the closing of the transaction. ADD already offers a wide range of specialty additives and service products for the plastics, rubber, lubricants and colorants production, and employs around 1,600 employees worldwide at more than 20 locations. “Additives is a very attractive business field in specialty chemicals. In addition to their relatively low capital intensity, they require strong expertise and enable customized solutions. In this area, both Chemtura and LANXESS have long-standing expertise, “said Anno Borkowsky, head of the LANXESS business unit Rhein Chemie Additives. The first pillar of Chemtura’s additives business includes lubricant additives and synthetic lubricants for industrial applications, such as in power generation and aviation. “Chemtura holds a competitive position in industrial lubricant additives. Moreover, Chemtura manufactures the necessary precursors and intermediates. Combined with our own additives portfolio, we will be a major supplier for industrial lubricants and will further strengthen our competitiveness through our integrated value chain,” explained Borkowsky. LANXESS expects the industrial lubricant additives market to grow at an annual rate of three to four percent in the medium term, primarily driven by steadily increasing requirements with respect to the performance and environmental sustainability of lubricants. The second pillar is mainly comprised of the brominated flame retardant additives, elemental bromine and further bromine derivatives businesses. Brominated flame retardant additives are used because of their high effectiveness, especially in the construction industry for insulation and in the electronics industry. Chemtura is a major supplier of bromine and brominated products and is well positioned due to its backward integration. “Flame retardant requirements continue to rise mainly due to the trend for energy-efficient construction,” said Borkowsky, adding: “With this acquisition, we will become a major global supplier of high performance flame retardant additives. In the future, we can offer our customers brominated and phosphorousbased products from one source.” Rhein Chemie Additives already has a competitive position in the phosphorous-based flame retardants business and features a backward integrated value chain. LANXESS also expects medium-term growth rates of three to four percent per year in the field of flame-retardant additives. Chemtura’s urethane business is a major provider for hot-cast prepolymers and for special, aqueous urethane dispersions and polyester polyols. These are components for special polyurethanes, which are used mainly in the construction, mining, oil/gas, sports and electronics industries. For example, rollers for conveyor belts and roller skates are manufactured from these polyurethanes. The urethanes business will be integrated into LANXESS’ High Performance Materials segment, in which the high-tech plastics business is anchored. Chemtura is counted among the major companies worldwide in organometallics. Organometallics are chemical compounds that are used, among other things, as catalysts in polymer production and for synthesis of fine chemicals and pharmaceuticals. This business will in the future be par t of LANXESS’ Advanced Industrial Intermediates business unit. Chemical Engineering World
CEW Press Release Covestro doubles production capacities for hightech plastic at Shanghai site
Airbus Safran Launchers selects Siemens to fully transform Its Product Lifecycle Process
Shanghai, China: To satisfy growing demand for polycarbonates in Asia, Covestro has announced that it is doubling production capacities for the high-tech plastic from 200,000 to 400,000 metric tons per year at its site in Shanghai, China. Two new world-scale production lines for polycarbonate resins were inaugurated there on Wednesday, with state-of-the-art technologies and energy saving processes. This thrusts Covestro into becoming the world’s largest producer of such resins.
Munich, Germany: After a comprehensive competitive evaluation, Airbus Safran Launchers has announced that it has selected Siemens over other suppliers to help transform its entire product lifecycle process in order to maximize quality and efficiency and minimize costs associated with the development and realization of all its launcher programs. Airbus Safran Launchers is a joint venture equally owned by Airbus Defence and Space and Safran, created by the desire of the two groups to take the European space industry to the highest possible level. It develops and supplies innovative and competitive solutions for civil and military space launchers. With estimated sales of 2.5 billion euros, it employs more than 8,000 highly qualified staff in France and Germany. This new space industry leader will standardize on Siemens’ integrated aerospace solution –which leverages its product lifecycle management (PLM) and manufacturing operations management (MOM) software portfolios– to establish a common digital product development and realization platform. Airbus Safran Launchers cited the “end to end solution” of Siemens’ aerospace industry software and expertise as critical selection criteria.
During the inauguration celebration, Michelle Jou, Head of the Polycarbonates segment at Covestro, said: “In Asia and especially China, the demand for polycarbonates and solutions based on it is growing in important industries like electronics, healthcare and automotive. By expanding our polycarbonates production capacity in the region, we can adapt and react even better to the changing needs of our customers. And we optimize our service, guaranteeing sustainable supply and relentless innovation.” Satisfying customer needs Especially lightweight, highly transparent, unbreakable and easy to shape, polycarbonates are used in many areas of modern life – from medical devices to automotive parts to smartphones and LED lighting. Polycarbonate resins can also be combined with other substances to produce blends with an optimally balanced set of properties. With the two new production lines, compounding capacities at the Shanghai site have also nearly doubled, further enhancing Covestro’s ability to meet the increasing customer requirements for diversified and individual solutions. The new production lines are the last cornerstone of a multi-year investment program for the Shanghai site with a volume of more than EUR 3 billion. Earlier this year, another new world-scale plant had been opened there producing up to 50,000 metric tons of HDI per year – a crucial raw material used in coatings and adhesives. Commitment to China Dr. Klaus Schäfer, Covestro Management Board member responsible for production and technology, said: “The addition of the new production lines makes Shanghai the largest production center for polycarbonate resins in the world. The successful completion of this project strengthens our global production network and demonstrates Covestro’s continuous commitment to the Chinese market.” At the same time, Covestro underscores its leading position in highly efficient and environmentally compatible technology by recycling process water. It is used to produce chlorine and sodium hydroxide – two chemicals that in turn are needed as raw materials for polycarbonates. Contributing to innovative, sustainable technologies, products and application solutions, is among Covestro’s top priorities – according to the company’s purpose “to make the world a brighter place”. 12 • October 2016
“As we are implementing a new way of producing launchers, Siemens has challenged our working methods the most and enabled us to define the end to end solution of our PLM and manufacturing needs,” said David Quancard, Chief Operating Officer at Airbus Safran Launchers. “We appreciated the benefits from Siemens’ working methodology from the start, including the bidding and implementation phases. They were able to offer us both software tools and project management capabilities compatible with our requirements. With the introduction of this innovative PLM system, Siemens has become a key partner to help us successfully achieve our goals of integrating our teams and working methods to enhance our competitiveness and efficiency.” Airbus Safran Launchers offers in a single entity all the capabilities, experience, resources and capacity for the innovation necessary to meet the challenges of space access today and into the future. Airbus Safran Launchers aim is to reduce its product development cycle and time-to-market, as well as maintenance costs. The new system should ensure full traceability of products and improve team collaboration. “We are honored and proud to be associated with an aerospace industry leader like Airbus Safran Launchers,” said David Riemer, VP Aerospace & Defense at Siemens PLM Software. “The complexity of space launchers requires a systems-based product development approach, which combines systems engineering and an integrated product definition and realization. We are confident that our integrated aerospace industry solutions and expertise, combined with the impressive Airbus Safran Launchers leadership team will create great value for the organization and the industry.” Chemical Engineering World
CEW Press Release KEPL awarded by Quality Circle Forum of India Pune, India: Kirloskar Ebara Pumps Ltd (KEPL) has announced that it has won gold and silver trophies at the “31st Chapter Convention CCQC-2016”, organised by Quality Circle Forum of India (QCFI), on September 24th 2016 in Pune, India.
are excellent platform for sharing and learning. Our plant people developed a culture of adopting best ideas and implement similar concepts to solve their day to day problems. We are honoured to receive such awards for our quality and Kaizen improvement practices. We look forward to receiving more such recognitions in the coming year which will further encourage our Kaizen culture”.
Kirloskar Brothers Limited participated at the India Cold Chain Show (ICCS) – 2016
Established in 1982, QCFI was recognized as the institution representing “The Quality Concept” movement in India. It has successfully implemented quality concepts under the TQM umbrella across several industry verticals which have experienced phenomenal enhancement of their work processes and productivity after implementation of quality concept tools. Three teams from KEPL (Team Anand, Team MSD and Team Utkarsh) participated and presented their Kaizen case studies. The case studies were highly appreciated and awarded with the “gold and silver trophies”. The theme for this convention was “quality circle and its allied concepts”. Teams have passed through the entry gate for National Convention Quality Control (NCQC) which will be held at Raipur, Chhattisgarh during December 16 – 19, 2016. This was a forum for interaction and, sharing of knowledge and ideas on quality circle and other allied concepts such as TPM, 5-S, Six Sigma, Kaizen, Poka-yoke, SMED, JIT, Kanban etc. The programme was categorized in a QC and allied case study, model exhibition, poster, presentation and visual display. KEPL team “Anand” presented their Kaizen case study titled “cost reduction through VA/VE project” and were awarded with silver trophy, team MSD presented their case study on “improve the utilization of cutting tool (broach) by enhancing keyway sizing machine capacity” and were awarded with gold trophy. Team Utkarsh presented a case study on “throughput improvement by reducing NVA’s in steam turbine assembly” and were recognized with gold trophy. The presentation flow started with the introduction of Kirloskar Group and its uniqueness, introduction to the case study, followed by systematic problem solving steps like problem identification, root cause analysis, permanent solution amongst available alternatives, Kaizen theme and Kaizen idea, implementation and benefits, horizontal deployment of Kaizen theme etc. The effective use of problem solving tools and techniques was demonstrated through this case study. The presentation was concluded with an interactive session of questions and answers. S S Katare, Plant Head, KEPL said, “since 2012, KEPL is participating in various competition organised by Confederation of Indian Industries (CII), Poona Divisional Productivity Council (PDPC) and Quality Circle Forum of India (QCFI). These forums 16 • October 2016
Pune, India: Kirloskar Brothers Limited (KBL) has announced that it had showcased its Canned Motor (i-CM) Pump series for Ammonia Refrigeration at the recently concluded India Cold Chain Show (ICCS) – 2016. ICCS is the leading exhibition and conference for cold chain, cold logistics, temperature controlling, refrigeration, storage, distribution and cold supply chain sectors. The 6th annual edition of ICCS was held in Mumbai during October 17 - 19, 2016 at Bombay Exhibition Centre (BEC). The event focused on cold storage infrastructure, temperature controlling and IT solutions for cold storages/warehouses, and material handling solutions for cold storages, cold chain and cold supply chain. Since 2011, ICCS is organised jointly with Reed Manch every year, with active national and international participation. i-CM pump, categorised under i - CAN series pumps, caters to industries such as refrigeration (cold storage), ice plants, chemical and process and windmill. i-CM pumps are mainly used for pumping hazardous fluids such as radioactive coolants, corrosive and noxious liquids (free of suspended solids and par ticles), liquefied gases, etc. It comes with innovative features, such as optimised stator & rotor design, apar t from its compact size, 80% lighter body than conventional canned motor pump, and includes seamless stator band, off the shelf terminal box, three in one adapter plate, optimized bearings & sleeves, improved aesthetics and application base bearing wear monitoring system. Besides, it is known to reduce assembly time by 50 per cent. Chemical Engineering World
CEW Press Release Bonfiglioli to Expand Operations in India & Bologna
Chennai, India: Bonfiglioli Transmissions Pvt Ltd has announced an expansion of operations in India and also in the company headquarters in Bologna, Italy. Expansion plans in India include improvements to existing facilities in Chennai and construction of a new facility in Pune (Chakan area), for a total investment of $ 12 million. The current plants in Chennai; located at the SIDCO Industrial Area, Thirumudivakkam covers an area of 180,000 sq.ft and the Mannur plant located close to Sriperumbudur covers an area of 100,000 sq. ft. These plants are highly integrated facilities that manufacture gearboxes and gear motors for mobile machinery, wind turbines and industrial processes. The facilities also house an R&D Centre, which develops products tailor-made for the Indian market. • A new facility of 140,000 sq.ft will be built, adjacent to the current plant at Thirumudivakkam. It will house moder n assembly lines, R&D Centre and test labs, all built with the highest standards of quality and safety, consistent with Bonfiglioli locations worldwide. The expected capacity is 75,000 units per year and will enable Bonfiglioli to serve existing and new markets and customers in off-highway, construction, mining, agriculture and material handling applications. • A completely new facility will be built in Pune (Chakan area, western India) and is expected to be ready in March 2017. This new facility will be approximately 45,000 sq. ft., including 3,000 sq. ft. of office space and will contain 11 assembly centers and 2,000 warehouse locations, all built to the highest standards of quality and safety, consistent with Bonfiglioli locations worldwide. The expected capacity is 150,000 units per year to ser ve customers in food, packaging, cement, steel, pharmaceutical, textile, material h a n d l i n g , s u g a r, p o w e r g e n e r a t i o n , p a p e r a n d w a t e r treatment sectors. 20 • October 2016
In Bologna, Italy, the company will break ground on a new SMART factory based on Industry 4.0 technologies and innovations. The new production plant, an investment of $ 67 million, will cover an area of 1.6 million sq.ft and produce 800,000 units per year in an ecofriendly and people-friendly environment. With over 32,000 sq. ft. of rooftop gardens, nearly 500 trees, and a photovoltaic installation of 3MWp the building will be nearly zero-energy while using the same energy requirements as today. The building will also have noise, emissions and soil impact control to lessen the environmental impact. Construction is expected to begin in early 2017. Sonia Bonfiglioli, Chairman of Bonfiglioli Group, stated “Bonfiglioli is celebrating its 60th anniversary this year, but we are not looking at the past. We are looking toward the future and how Bonfiglioli can become a model for industrial development, and how we can better serve our customers in high growth countries like India. The new plant in Bologna will be an industry benchmark, with smart and efficient systems required for Industry 4.0 operations, while the expansions in India will enable Bonfiglioli to increase the production capacity in India to drastically reduce lead times to customers in India and nearby countries – all with the goal to help sustain Bonfiglioli through the next 60 years and beyond.” In addition to the expansions, Bonfiglioli has also announced plans to build a second home for abandoned and disadvantaged children in Chennai, India. The first home, CheerFutureLand Home for Boys, was built in 2009 near the Chennai plant of Bonfiglioli to give disadvantaged boys the chance to have a better life and a future to look forward to. Since it opened, dozens of boys have lived at CheerFutureLand where they received a loving home environment and a solid education. One young man has grown up in the home and now works at the Bonfiglioli Chennai plant as a technician. Now, the company wants to give the same opportunities to young girls and a second home will be built near the current boys’ home. The new home in Govindavadi Village (Kancheepuram District) will include accommodations, dining facilities, gardens, a playground and areas for recreation and extra-curricular activities like drawing, dancing, sports, music, gardening and more. Vocational training in disciplines such as tailoring and computer skills, in addition to education in a core subjects (mathematics, science, English language, etc.) will be part of the daily routine as well. For safety and security, CCTV cameras will be installed, along with the presence of security personnel and women wardens. The puja for the girls’ home will be on Wednesday, 19 October. “My father had a passion for helping children, especially in educating them and giving them a chance for a better future,” said Ms. Bonfiglioli. We built the boys home in Chennai because, while the Bonfiglioli plant in Chennai was having great success, we could not ignore the children in that area who needed help. We hope to continue this trend in order to give back to the communities where our plants are located around the world.” All media are invited to attend the puja. Chemical Engineering World
CEW Industry News Bayer inaugurates Global Formulation Technology Lab at Vapi
“ T h i s i s a s p e c i a l a c h i eve m e n t a s t h i s i s t h e f i r s t C r o p Science formulation development facility in this region and demonstrates the importance of the region for our future business”, added Grimmig. K R Sekhar, Managing Director, Bayer Vapi Private Ltd. added, “The Laboratory is the culmination of fantastic team work across different functions within Bayer. It is a collaborative effort to provide customers with the best possible, world-class solutions in agrochemicals. It is also an opportunity to demonstrate the technical and scientific skills of our employees at the Vapi site.”
Vapi, Gujarat: Bayer has announced that it has inaugurated a new Global Formulation Technology Laboratory at its site in Vapi, Gujarat. The Plant in Vapi is a production site for active ingredients for the Crop Science Division of Bayer globally, with expertise in Analytics and Formulation Development. In India the demand for high quality food is growing rapidly with its fast growing population and rising incomes. “With our innovative crop protection products, we are contributing to finding solutions to some of the major challenges of our time including feeding a fast growing world”, said Dr. Bernhard Grimmig, Global Head of Global Formulation Technology at Crop Science, a division of Bayer. Bayer is aiming at providing high yielding seeds, efficacious and safe crop protection solutions and services for farmers worldwide to secure their harvests and incomes. “Bayer has a long presence in India with the development and production of crop protection chemicals as well as the provision of seeds for vegetables and arable crops. The transformation and importance of Indian Agriculture in the last decades has been a critical factor in determining Bayer’s long term investments in the country in order to meet the growing demand for improved seeds, professional pest management products and integrated crop management solutions for major agricultural crops. In the last few years, Bayer has been making strategic investments in various research & development, production and infrastructure projects in India”, said Richard van der Merwe, Senior Bayer Representative, South Asia. Bayer has invested more than $ 2 million for this laboratory. With this new facility, the company aims to increase resource flexibility in its global formulation activities, helping to increase its capacities for innovations around formulation and delivery technologies. The new formulation lab unit will focus on developing seed treatments, herbicides, fungicides, and insecticides for the local demand of small-holder farmers, and also for regional and global demand. 22 • October 2016
Bayer Vapi is a core manufacturing site for Bayer globally. It employs close to 1300 people. The site has invested heavily in upgrading its safety and environment aspects in order to make it comparable with world standards. It aims at high powered research and development, along with the manufacture of eco-friendly, innovative and internationally competitive agrochemicals. The site is engaged in the manufacturing of active ingredients for use in a wide array of products for modern sustainable agriculture, professional pest management and animal health.
US-based PolyOne to build Specialty Engineered Materials Plant in Pune Pune, India: PolyOne Corporation has announced that it will set up a production unit for specialty engineered materials at its present Pune site to support the mounting demand for engineering plastics in the country. The company anticipates the new unit to begin production of specialty engineered materials in January, 2017. “PolyOne endures to build upon our strong reputation in India for collaborating and innovating with our local and multi-national customers. We are motivated and proud to have expanded our commitment to customers in India, through local production of our prominent specialty engineered materials and reinforced by sales and technical support personnel,” stated Craig Nikrant, President, Specialty Engineered Materials, PolyOne. The new capability will facilitate the company to more broadly support customers and surge their speed to market through its expansive portfolio of high-performance solutions and services. Initial production at the new unit will include specialty engineered polymer materials used in high performance applications that have the need for flame retardant properties, high strength and durability, stiffness, chemical resistance. Vikas Vij, Managing Director, PolyOne, India added, “India remains a region of growth for manufacturers and consumers, and by enhancing speed to market, it gives our customers a competitive advantage. We are proud to be their materials and service provider as we innovate and grow mutually for the future.” Chemical Engineering World
CEW Industry News Rosneft and Trafigura’s consortium buys Essar Oil for $ 10.9 billion
Manali Petrochemical acquires Notedome to tap polyurethane market in UK
Mumbai, India: Russia’s Rosneft and investment conglomerate led by Trafigura has announced that it has signed agreements to acquire 98 per cent stake in Essar Oil Ltd (EOL) at an enterprise valuation $ 10.9 billion. Essar Group will also receive an additional $ 2 billion for the acquisition of Vadinar Port, which has storage and import-export facilities. While Petrol Complex Pte Ltd (a subsidiary of PJSC Rosneft Oil Company) will hold 49 per cent stake in EOL, Kesani Enterprises Company Limited (owned by a consortium led by Trafigura) will own 49 per cent.
Chennai, India: Manali Petrochemicals Ltd has announced that it has acquired Notedome Limited, the UK-based system house, for $ 16.57 million to further magnify its overseas business of polyurethane (PU) products. MPL acquired Notedome Limited through its Singapore based subsidiary Amchem Speciality Chemicals Private Limited, which it had established to procure system house overseas.
The all-cash deal comprises EOL’s 20 million tonne refinery in Gujarat, India, and its pan-India retail outlets. The closing of the transaction is provisional upon receiving mandatory regulatory approvals and other customary conditions. “We have once again reinforced our unique expertise in project incubation, execution, value creation and monetisation. We have established world-class assets that have attracted the attention of leading global companies and investors. The deals we have done have led to an FDI infusion of more than $ 30 billion into India,” said Prashant Ruia, director, Essar. Investing in Essar Oil, which operates one of the world’s most complex refineries and runs the country’s largest private sector retail network, gives the new stakeholders a strong foothold in the Indian market that will witness robust demand growth for petroleum products in the long term. The growth for refined petroleum products in the Indian market for the next five years is expected to be in the 5-7 per cent range. “This is a substantial milestone for the company. Rosneft is entering one of the most promising and fast-growing world markets. At the same time, this project offers unique prospects for synergies with the prevailing assets of the company and is steady with Rosneft’s enriched presence in the fast growing markets of other APR countries, such as Indonesia, Vietnam and The Philippines,” commented Igor Sechin, CEO, Rosneft. EOL’s value has also been reinforced by the integrated nature of its business and the strategic positioning of its assets. Its 20 million tonne oil refinery in Vadinar, which accounts for 9 per cent of India’s total refining output, is supported by a 1,010 MW captive power plant, and complemented by a network of around 2,700 operating retail outlets. The additional $ 199.42 million that the new stakeholders have approved to pay is for the 58 million tonne deep draft port in Vadinar that helps in importing crude and exporting finished products. “This is a significant and exciting investment. Essar Oil occupies a strategic position in the global oil market and owns world-class refining and infrastructure assets that will generate multiple synergies with our trading business.” asserts Jeremy Weir, CEO, Trafigura. 24 • October 2016
While polyurethane is made using chemicals such as polyols and isocyanides (methyl di-p-phenylene isocyanate or MDI and toluene di-isocyanate or TDI), system houses are blending units that tailor the PU formulation according to customer’s needs.
Harshad Naik appointed as MD-India Subcontinent of Huntsman Corporation
Harshad Naik, MD-India Subcontinent Huntsman Corporation
Mumbai, India: Huntsman Corporation has announced that it has appointed Harshad Naik as managing director (India Subcontinent) to succeed Rohit Aggarwal who was appointed president of textile effects division in July this year. The new responsibility is in addition to his current role as director, polyurethanes business, India Subcontinent.
Rohit Aggarwal stated, “We are delighted to welcome Harshad as the new managing director. The company is well positioned to tap on the growth prospects in India and the experience that Harshad brings will add substantial value to the overall performance of the company. We are poised that his strong business acumen and deep industr y knowledge will lead Huntsman to its next growth phase.” In his new role, Naik will lead the cross divisional collaboration essential to deliver growth, build external par tnerships and asset investments. He will represent Huntsman in engaging with government organisations and other key stakeholders in the region. “India is presently the fastest growing large economy due to encouraging demographics. We will leverage on the current growth trends and market potential. We will integrate and implement strategic plans for differentiated growth. Customer’s centricity is the core to all activities and will continue to be the foremost priority for every contributor in the organization. We will reinforce our market position and drive efficiency for overall excellence across verticals. I am confident that through our commitment and effor ts we will achieve higher growth and contribute considerably to Huntsman’s global performance” added Harshad. Chemical Engineering World
CMYK
For a life-saving operations Solutions for the Pharmaceutical industry
With our extensive knowledge and experience in the power transmission arena, we continuously innovate and launch new products, aimed at meeting the varied application needs of our customers. Our line of products for the Chemical & Pharmaceutical sector manufactured at our Chennai production facility in India, applying state-of-the-art technology, ensuring superior quality standards and matching the best cost/performance ratio. While the AS Series is most dependable and performing solution for all inline drive applications featuring unsurpassed Quality to Price ratio, the light-weight F Series ensures rugged and effective operations. Compact, and yet extremely powerful, are the units of the 300 series planetary drives that make them the ideal choice for all the severe duty applications where shock loadings and impacts are more the rule than the exception. Precision Planetary gearbox along with new range of AC Servomotors and servo drives along with Brushless DC Motors and drives is complete range of compact and flexible solution that are versatile and featuring control for high performance and unbeatable advantage in scalability. Welcome to the world of Bonfiglioli! Bonfiglioli Transmissions (Pvt) Ltd Survey No. 528, Perambakkam High Road, Mannur Village, Sriperumbudur Taluk • Chennai 602 105, Tamil Nadu www.bonfiglioli.com - salesindia.ins@bonfiglioli.com
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CEW Industry News Deepak Nitrite’s Hyderabad Unit Receives Closure Orders from TSPCB Hyderabad, India: Deepak Nitrite Ltd has announced that it has received an order from the Telangana State Pollution Control Board (TSPCB) for closure of one of its three manufacturing units located at Hyderabad. Deepak Nitrite manufactures DASDA (diamino stilbene disulfonic acid); a chemical used in the manufacturing of optical brightening agents (OBA), at its Hyderabad facility and the unit, for which order has been received, is a processing unit. The company’s DASDA production will be affected due to the TSPCB’s directive. The company said that it is undertaking all the essential effective steps to correct the irregularities pointed out by the TSPCB authorities in the manufacturing system in the supposed unit at Hyderabad facility. “Appropriate pre-eminent efforts are being put to get the closure notice annulled within a week or so. There will not be any major impact on service to DASDA customers. The week long interval in production will not have any major influence on the optical brightening agents’ production also, as suitable inventories are available,” it further stated.
Petrofed signs MoU with TERI to Undertake a Study on Climate Change Risks New Delhi, India: PetroFed, an apex society of entities in the Hydrocarbon sector has announced that it has signed a Memorandum of Understanding (MoU) with TERI to undertake study on “Climate Change Risks: Preparedness for Oil and Gas Sector”. The MoU was signed in New Delhi in the presence of Mr. Dharmendra Pradhan, Minister of State (I/C), Petroleum & Natural Gas and Mr. K.D. Tripathi, Secretary, M/o Petroleum & Natural Gas and representatives from oil and gas industry. Praising the initiative, Mr. Pradhan said that it will provide a missing link between the policy and the practice in the Hydrocarbon sector. He said COP 21 will come into effect soon and it is important for the country to know the effects of greenhouse gases and ways to control them. The Minister said that India is a low per capita energy consumer but as the country is moving towards double-digit growth rate; its energy consumption is bound to increase. The Government is focusing on gas, renewable energy and bio-energy to meet its requirements. It is important to understand the implications of various energy sources and to develop an Indian model for the nation’s energy sector. Mr. Pradhan emphasised on scientific research, appropriate business models and creation of awareness among the people. He said that this study will provide important inputs for future strategy on oil and gas infrastructure development. He stated that the study will also 28 • October 2016
provide a comprehensive analysis of threats posed by Climate change to Oil & Gas sector and shall provide a way forward to tackle the challenges posed by climate change. The study will suggest suitable measures for the Oil & Gas sector to achieve India’s INDC target of reducing emission intensity of GDP by 33 – 35 per cent below the levels in 2005 by 2030. The study would further highlight how the global market and technological options are likely to change as a result of global climate policy measures; and how the 1.5 degree and 2 degree scenarios of global warming are likely to affect the infrastructure and operations in different climatic zones of India. The Minister said the share of gas in the Indian energy basket is 6.5 to 7 per cent while the world average is 24 per cent. India aspires to take the share of gas to 15 per cent in the next 3 to 5 years so as to have a new gas based economy. He said 80 lakh connections have been provided under the Prime Minister Ujjwala Yojana to BPL women and target of 1.5 crore will be achieved this year. The Minister said the country will zoom from BS IV to BS VI by 2020 so as to have clean fuel.
Clariant Eyes to tap Indian Personal Care Market with Novel Ingredients Mumbai, India: Swiss specialty chemicals major Clariant has announced that it is eyeing major gains in the flourishing Indian personal care sector by offering a fresh variety of ingredients to generate pioneering formulation. These solutions, combined with its new trend guide BeautyForward, will benefit brand owners and formulators develop futuristic personal care products. Called Metamorphosis by Plantasens, this solution highlights the synergistic effect between nature and technology, through two-inone texture transformations within the same product. “Consumer demand in India for sustainable and innovative products in personal care has augmented considerably, and thus brand owners are comprehensively looking at solutions that can offer a competitive distinguishing advantage,” said R Kumaresan, Head - Industrial & Consumer Specialties, Clariant in India. Clariant is dynamically supporting companies in the consumer care space achieve claim substantiation with such innovative solutions. “To develop BeautyForward, we used a distinctive discovery process to decode social and cultural trends into four personal care stimulating trends that will influence all regions over the coming years. Now it’s up to our customers to embrace this knowledge, open their minds and enjoy exploring ways with us to generate exciting new products for tomorrow’s beauty” added Nicolas Lasbistes, Global Technical Marketing Manager-Personal Care, Clariant. Chemical Engineering World
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CEW Industry News Australia’s Nufarm Sells Stake in Excel Crop Care to Sumitomo Chemical
Henkel inaugurates Acoustic Lab in Pune for Automotive Industry
Mumbai, India: Australian agrochemicals company Nufarm has announced that it has sold its 14.69 per cent stake in Excel Crop Care to Sumitomo Chemical for $ 153.41 million.
Pune, India: Henkel Adhesives Te c h n o l o g i e s I n d i a P v t h a s announced that it has opened an acoustic lab at its Pune innovation centre for automotive and general industry. The lab will facilitate the company to offer cutting-edge solutions to meet the progressing and perplexing requirements of customers in the area of noise, vibration and harshness (NVH).
In June this year, Sumitomo Chemical acquired 45 per cent stake in Excel Crop Care Ltd from the Shroff family and other financial investors for about $ 9.36 million . While the Shroff family offloaded its 25 per cent stake, Sumitomo Chemical bought the remaining 20 per cent stake in Excel Crop Care from Ratnabali Group. The acquisition will help Sumitomo Chemical to expand and develop its agrochemicals business in India.
Tata Chemicals Europe obtains Government Fund for Soda Ash Facility in UK Winnington, UK: Tata Chemicals Europe has announced that it has opened a $ 6.74 million turbine which will efficiently provide energy for its soda ash business in Cheshire, UK. The turbine - the beneficiary of $ 3.06 million European Regional Growth Fund grant from the UK government - is housed at Tata Chemicals’ Winnington CHP plant, which as a result performs at more than 80 per cent efficiency. Alan Runciman, General Manager- Soda Ash Business Unit, Tata Chemicals Europe, remarked, “Anyone involved in synthetic soda ash manufacturing will know that it’s an energy-intensive industry, where the cost of energy makes up the largest part of the overall cost base. This turbine allows us to provide power for our manufacturing process and produce soda ash much more efficiently.” Craig Thornhill, Head Of Sales-Soda Ash Business Unit, Tata Chemicals Europe, added, “As the UK’s sole manufacturer of soda ash, it is vital that we remain a reliable and long term partner to the UK glass, detergent and chemical industries, all of which rely heavily on our product and service. Significant investments in our business such as this should therefore be seen as investments in the future of our customers and UK manufacturing.” In 2013, Tata Chemicals acquired Winnington CHP so that it could take full control of its energy costs. Since then, the company’s energy team have been very busy maximising this state-of-theart CHP plant’s efficiency and thereby radically reduce its carbon footprint. The plant itself is now capable of powering 200,000 homes - an area the size of Liverpool. Martin Ashcroft, Managing Director, Tata Chemicals Europe, said, “The opening of the steam turbine signifies a key moment for the soda ash business. The new steam turbine is seamlessly sized for our operation and as a result, the overall plant is much more efficient. The investment guarantees that soda ash has affordable energy for the long-term and underpins the long term future of the business.” 30 • October 2016
The acoustic lab will enable vehicle and component level testing for different applications as per international standards. It will also help meet high level product validation tests based on customer requirements. Henkel’s trained team of engineers analyse acoustic material properties of structures and panels to regulate their effectiveness in automotive, off-road equipment and appliance applications. With the latest equipment and software, to perform measurements and analysis, Henkel is able to offer full capabilities comprising computer aided engineering (CAE), finite element analysis (FEA) and lab testing. “Both noise and vibration plays a critical role in a vehicle’s quality. Automotive OEMs have started developing vehicles with competitive NVH performance in shorter design cycles, and at lower development and vehicle costs. At Henkel, we put our customers at the centre of what we do and work closely with them to develop solutions to challenges encountered by them. At this acoustic lab, we will co-operate with our customers by solving NVH problems,” said Shilip Kumar, Country President, Henkel India and Business Director, Transportation & Metal SBU, Henkel IMEA.
Sumitomo Chemical increases Polypropylene Compounds Capability in India Chennai, India: Japanese firm Sumitomo Chemical Company has announced that it has reinforce its polypropylene (PP) compounds capabilities in India with a production facility in Chennai (Tamil Nadu) to assist the growing demand for plastics from automotive industry. Sumika Polymer Compounds India, the company’s local arm has started production facility with a capacity of 5,000 tonnes per annum (TPA). Polypropylene compounds are high-performance materials made by kneading synthetic rubber, glass fibres, and inorganic fillers into PP to improve or vary such parameters as impact resistance and functionalities according to target applications, for example, automobile bumpers, interiors and household electrical appliances. Sumitomo Chemical is engaged in polypropylene compounds operations at various locations around the world, fully leveraging the company’s distinct strength of wide feedstock availability via a network of PP manufacturing strongholds in Japan, Singapore and Saudi Arabia, which amount to the production capacity of approximately 1.7 million TPA in total. Chemical Engineering World
CEW Industry News Sanmar Group picks Nuberg to set up Calcium Chloride Plant in Egypt Chennai, India: Sanmar Group has announced that it has conferred a contract of $ 20 million to Nuberg Engineering to build a calcium chloride plant in Egypt on EPC (engineering, procurement, & construction) and LSTK (lump sum turnkey) basis. TCI Sanmar is in process of setting up a mega chemical complex, with an investment of $ 1.5 billion, in Port Said (Egypt) for future business growth. The plant, which will have production capacity of 135,000 tonnes per annum (TPA), is slated for commissioning by the end of 2017. Nuberg’s scope of work includes plant design, detailed engineering and procurement of complex chemical equipment for TCI Sanmar for the anhydrous calcium chloride pellets/granules production at its site in Port Said.
par tner as TCI Sanmar and Nuberg will allow us to provide efficient application of our experience and knowledge in high quality anhydrous calcium chloride pellets production for different purposes of worldwide calcium chloride market which, from our point of view, feels shortage of high quality product.”
Indian Oil Corp to Invest $ 147 Million for Expansion of Its Two Refineries
Russia’s Zirax will be responsible for the transfer of technology for production of liquid & anhydrous product and for providing basic engineering & technical regulation documents. The calcium chloride plant is a part of Sanmar’s already existing chemical complex, incor porating caustic soda plant, EDC (ethylene dichloride), VCM (vinyl chloride monomer) and PVC (polyvinyl chloride) plants. This chemical complex produces hydrochloric acid (HCl) which will be used to manufacture calcium chloride. TCI Sanmar chemicals has established world class plants for manufacturing 200,000 TPA of PVC and 275,000 TPA of caustic soda at Port Said (Egypt). These are the largest capacities in the MENA (Middle East & North Africa) region. The company has already invested $ 1.2 billion in its facilities at Port Said and in phase 2 of the project the company will invest another $ 300 million taking the total investment to $ 1.5 billion. After the completion of phase 2 the PVC plant capacity will double to 400,000 TPA and a new calcium chloride granule plant with a capacity of 135,000 TPA will come up. “The start-up of new calcium chloride granules production plant, which we will build up together with Nuberg and Zirax, will significantly raise TCI Sanmar’s revenues and also permit us to expand our product portfolio,” mentioned K Satyanarayana Rao, Managing Director, TCI Sanmar Chemicals SAE. “We are quite happy of our cooperation with Zirax for TCI Sanmar’s calcium chloride plant and we suppose that our this experience in Port Said will consolidate our relationship for joint performance as in current project and in other future possible projects with a high professional involvement to meet the requirements of new customers,” supposed A K Tyagi, Chairman, Nuberg Engineering. M i k h a i l Pe t r u s h i n , G e n e ra l D i r e c t o r, Z i ra x , a d d e d , “ T h e cooperation with such respectful and professional client and 32 • October 2016
Mumbai, India: Indian Oil Corporation Ltd has announced its plans to spend $ 147.13 million for expansion of its two refineries at Barauni (UP) and Panipat (Haryana). While IOCL will invest $ 124.23 million to surge the capacity of Barauni refinery from 6 million metric tonne per annum (MMTPA) capacity to 9 MMTPA, it will spend $ 22.89 million for the expansion of its Panipat refinery. “The board of directors of Indian Oil Cor poration Ltd has sanctioned expansion of Barauni refinery from 6 MMTPA capacity to 9 MMTPA along with downstream polypropylene unit at an projected cost of $ 124.23 million, and implementation of olefin recovery project along with expansion of existing naphtha cracker unit, MEG (monoethylene glycol) revamp and benzene expansion unit modifications at Panipat at an estimated cost of $ 22.89 million” the company stated. Over the years, Barauni refinery, which obtains crude oil by pipeline from Paradip on the east coast via Haldia, has, through several facelifts and expansion projects, added the capability to process high-sulphur crude - high-sulphur crude oil (sour crude) is inexpensive than low-sulphur crudes - thereby increasing not only the capacity but also the profitability of the refinery. IOCL’s Panipat refinery complex has capacity of 15 MMTPA and also operates a world-scale naphtha cracker, with four downstream units for production of polymer (plastics) intermediates. Its integrated PXPTA (paraxylene-purified terephthalic acid) plant is the single largest unit in India, with a capacity of 5,53,000 MTPA producing polyester intermediates. IOCL produces ethylene and propylene, which are further used to produce polymers like polypropylene, low & highdensity polyethylene and monoethylene glycol (MEG). Chemical Engineering World
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CEW Industry News Cabinet approves acquisition of 11 per cent stake in JSC Vankorneft by ONGC Videsh Limited New Delhi: The Cabinet Committee on Economic Affairs, chaired by the Prime Minister Mr. Narendra Modi, has given its approval to an acquisition by ONGC Videsh Limited (OVL) for 11 per cent stake in JSC Vankorneft from M/s Rosneft Oil Company (Rosneft), the National Oil Company (NOC) of Russian Federation (Russia). Rosneft operates Vankor fields, with Vankorneft, its wholly owned subsidiary. OVL will be paying an amount of $ 930 million for acquiring 11 per cent stake in Vankorneft. The procurement of stake in Vankorneft will provide 3.2 Million Metric Ton of Oil Equivalent (MMTOE) to OVL by 2017. It will also provide a prospect to Indian public sector Oil and Gas companies to obtain new technologies from Rosneft. The acquisition is in line the ONGC’s stated objective of adding high quality international assets to India’s Exploration and Production (E&P) portfolio and thereby enhancing India’s energy security. Of late, an Indian Consortium comprising of Oil India Limited (OIL), Indian Oil Corporation Limited (IOCL) and Bharat PetroResources Limited (BPRL) acquired 23.9 per cent stake in Vankorneft at a cost of $ 2020.35 million which will give them 6.56 MMTOE. Earlier, in May 2016, ONGC Videsh Ltd (OVL) concluded the formalities on acquisition of 15 per cent stake in Vankorneft at a cost of $ 1.284 billion which gave OVL 4.11 MMTOE.
Arkema to Invest $ 15 million in Resins Capacity in India Mumbai, India: French specialty chemicals major Arkema has announced that it plans to invest $ 15 million for setting up a new polyester powder resin manufacturing facility, the first of its kind in India, on its prevailing resin platform in Navi Mumbai, Maharashtra. The project, targeted for completion in 2018, comprises a new manufacturing unit and a devoted new laboratory to provide both application development and technical support. The new facility will support customers in the fast growing powder coating market. “Offering increasingly environmental-friendly solutions with lowVOC (volatile organic compound) content, resins for powder coatings is an important and growing part of our product portfolio. This new facility will complement our existing manufacturing sites in Europe and North America, and underpins our commitment to meet our customers’ needs wherever they operate around the world,” said Richard Jenkins, Global Group President, Coating Resins Business Unit, Arkema. The new facility will produce polyester powder resins promoted under the Reafree trade name. The principal use for polyester powder coatings includes a wide range of industrial coatings along with automotive and architectural applications. 34 • October 2016
This investment supports Arkema’s ambition to escalating its geographical coverage of its environmentally friendly, low-VOC coating resins portfolio, including powder resins, waterborne resins, UV photocure and high solid solutions, as well as high performance coating additives. Arkema’s manufacturing site in Navi Mumbai also produces alkyd, acrylic solutions and oil-free polyester resins, as well as reactive polyamide resins. The investment in upgrading the capabilities of its Indian production facility is part of the continuing commitment of the group to stay a leading and global supplier to the coating industry while at the same time providing customers with all of the benefits of cutting edge technology, locally manufactured with strong technical support.
India & Russia signs three MoU’s In the Hydrocarbon Sector New Delhi, India: Minister of State (I/C) for Petroleum & Natural Gas Mr. Dharmendra Pradhan underlined the ongoing cooperation between India and Russia in the Hydrocarbon Sector, including the acquisition of 23.9 per cent stake in Vankorneft and 29.9 per cent in Taas-Yuryakh by an Indian Consortium of IOCL, OIL and BPRL and acquisition of 15 per cent and 11 per cent stake by OVL in Vankorneft from Rosneft Oil Company of Russia. While the Indian Consortium has completed all formalities related to acquisition of its stakes, Cabinet level approvals on both sides have been obtained for acquisition of 11 per cent stake by OVL and the deal is expected to complete by end October 2016. In the presence of Prime Minister of India and President of Russia, following three Agreements/MoUs were signed between India and Russia in the Hydrocarbon sector: 1. MoU between Engineers India Ltd and Gazprom on the Joint Study of a gas pipeline to India and other possible areas of cooperation; 2. Cooperation Agreement in the area of Education and Training between ONGC Videsh Ltd and Rosneft Oil Company; and 3. Programme of Cooperation (PoC) in the Field of Oil and Gas for the period 2017-18. The PoC was signed by Mr. Pradhan on the Indian side and Mr Alexander Novak, Minister of Energy from the Russian side. Both India and Russia agreed to further work towards enhancing their bilateral engagement in the hydrocarbon sector to make it a two way trade. Following the delegation level talks, Prime Minister Modi stated, “In the last four months alone, in a clear expression of our strong and deep engagement in the Hydrocarbon sector, Indian companies have invested close to $ 5.5 billion in Russia’s Oil and Gas sector And, with President Putin’s support, we are ready and willing to expand the scope of our engagement further. Chemical Engineering World
CEW Technology News Morgan Advanced Materials Develops New Alumina Sensor to Resist Extreme Temperatures
Windsor, UK: Morgan Advanced Materials has announced that it has produced a new type of alumina sensor specially designed for high pressure and high temperature water and sub-metering.
The sensor has been specifically developed to withstand extreme temperatures, making it ideally suited to both heat metering and high temperature fluid metering. Manufactured using Morgan’s specially-formulated proprietary alumina, the sensor solves many of the problems associated with high temperature environments, with a focus on reducing thermal drift and zero flow offset over a large temperature range. Morgan’s new sensor significantly minimises the flow offset because the material has been manufactured to control the thermal properties of both the internal and external structure. This enables the minimum flow rate range to be kept as small as possible, enhancing the overall accuracy of the reading. Morgan’s sensor design has been tested up to 100 bar pressure and 150oC which surpasses the current market requirements for heat metering. This is a direct benefit of using alumina in the sensor design, a material which has minimal expansion properties, and is renowned for its strength and durability. Due to its thermal stability, the sensor is also excellent for metering of potable water or other fluids. The inert nature of alumina makes a component that is suitable in food and pharmaceutical environments, as well as providing a long operational lifetime. Morgan also has its own ceramic pressing and injection moulding capabilities, enabling complete vertical integration from start to finish of the housing and Lead Zirconate Titanate (PZT) elements of the sensor. These in house capabilities allow Morgan to provide a full design and development package. Charlie Dowling of Morgan Advanced Materials commented: “Our new range of high temperature sensors has undergone extensive research and development to ensure that it is our strongest and most effective sensor for use in extreme temperature environments. Available as part of a standard range, or bespoke to order, it promises to reduce environmental factors during metering.” 36 • October 2016
Mettler Toledo Introduces Sensors that LearnTM
Urdorf, Switzerland – A significant issue in the operation of in-line process analytical measurement systems is not knowing when pH sensors will require maintenance or if a sensor is going to fail unexpectedly. METTLER TOLEDO has announced a solution to this in the form of its Intelligent Sensor Management (ISM®) technology and Sensors That Learn™.
ISM is a digital platform for analytical sensors that increases process reliability, simplifies senor handling, and reduces maintenance. At its core, ISM features a series of advanced algorithms that continuously monitor a sensor's "health" and provide diagnostic tools that predict when maintenance will be required and when a sensor will reach the end of its reliable lifetime. New ISM algorithms launched in 2015 allow pH sensors to actually learn from the conditions in a process. Sensors That LearnTM delivers more accurate sensor health diagnostics, quicker than previous versions, and enhances the consistency of sensor lifetime information. iSense software is a support and maintenance tool for ISM sensors. When an ISM sensor is connected to a PC running the software, all relevant data is displayed on the software's iMonitor screen using simple color coding, allowing at-a-glance evaluation of the probe. Should the diagnostics recommend that the sensor needs ser vicing (e.g. calibration), iSense guides operators step-by-step using simple animations to a successful end result. A newly released version of iSense offers features such as transferring learned data on applications between sensors to provide the highest assurance of sensor performance from first installation. For the pharmaceutical industry, a version of iSense is available that is compliant with 21 CFR Part 11, which enhances the security of eDocumentation. Chemical Engineering World
CEW News Features
‘GST will Stimulate GDP Growth’ Tubacex entered into Indian market through acquisition of stainless steel seamless division of Prakash Steelage Limited. “We are focussed on conveying our quality and systems at par with our European & American equivalents and offer same value proposition to Indian market”, says Ajay Sambrani, Managing Director - Asia Pacific, Tubacex India Pvt Ltd.
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ubacex has established its first manufacturing footprint in Asia by acquisition of seamless division of Prakash Steelage Ltd at Umargaon Gujarat. Tubacex is world’s largest producer of seamless stainless steel tubes & pipes having leadership position in various segments of Oil & Gas and Power-gen. Tubacex’s rich experience in the segment will give competitive edge to acquired unit and increase market share in Asia” Says Sambrani. It’s admirable that Honourable Pr ime Minister Narendra Modi has given its initial gift of GST. This would make business much simpler not just for our customers but also for our suppliers. This would give that impetus to stressed GDP growth that we are all looking forward to. Energy market in India is our focus and we are hoping to see EPC and Equipment Fabricators doing fine soon, he adds.
Asia. The company shall continue to train and skill employees in achieving our long term objectives, under flagship program of the Indian Government “Make in India” & “Skill India”. To further leverage distribution market, the company will invest in establishing state of art distribution centre in India, for its products Tubes, Pipes, Fittings, Round Bars & Billets centre for Asia. To suppor t our growth plans, Tubacex will invest in their own sales channels
We have by this time invested nearly € 40 million and plan to build state of art facilities to produce value added stainless seamless tubes & pipes for the growing need of energy segment in Asia. Indian Business Segment & Competition from Chinese Companies The unit will focus on all applications of oil & gas and power-gen segment in Asia. Soon, Tubacex India would assume the leadership position in this region. Future Plans in India Tu b a c e x w i l l c o n t i n u e t o i n v e s t i n Technology and producing value added seamless stainless tubes & pipes to increase our footprints and market share in
with offices in Mumbai and Delhi and at the same time appointing distributors across geographic region in the country. The company will also have technical m a r ke t i n g , s p e c i a l i s t t o s u p p o r t o u r customers in selection of newer material gra des, development of new grades, optimization of design with cost. Tubacex also has plans to open up special application service like Ceramic Coating and other value added ser vices over period of time.
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Note: The above content has been revised and republished due to printing error in terms of information in September-2016 issue. 38 • October 2016
Chemical Engineering World
CEW Features Technical Article
Minimal Liquid Discharge: Adopting A ‘Less Is More’ Mindset Minimal Liquid Discharge (MLD) is a cost effective water management approach that helps increase recovery and also mitigates discharge. If zero liquid discharge (ZLD) is too costly and the associated infrastructure is a latent deterrent, water reuse and sustainability can still be prioritized and realized through MLD. It can assist municipal and industrial plants to make substantial gains in minimizing liquid discharge and help plants considerably abate their capital and operating costs, since achieving the final 3-5 per cent of liquid elimination to accomplish ZLD can prove contemptibly expensive. The article deliberates in-depth on benefits of adopting MLD approach over ZLD approach. It also explains its role in reducing CAPEX, OPEX and other environmental impacts.
Industry challenge Due to urbanisation and industrialisation, India faces major challenges in the water sector with the per capita availability going down and demand going up. Inefficiency of water use in agriculture, over-exploitation of underground water and contamination are other issues associated with water management in India. Since the amount of water available is more or less constant, rising demands due to increasing population and economic growth are straining the demand-supply balance. Also with environmental norms becoming increasingly stringent and water becoming a “scarce commodity”, treating water to make it reusable has become an imperative for water intensive industries across the globe. As we are heading towards developing a circular economy, where raw materials are recycled and reused, many industries realise that the wastewater they generate could well be their cheapest & most reliable source of water and MLD technology can lead the way in that direction. Why MLD? Maximizing the efficient use of water by industry is critical for both the environment and the bottom line. Depending on individual regulatory and environmental needs and requirements, as well as the capital and operating budget, MLD can be a good fit for many industrial and municipal sites. By conducting a water audit to match waste streams and appropriate water requirements, companies can better 40 • October 2016
identify how much wastewater requires processing and the approach that will most economically and sustainably match their plant’s needs. MLD can help municipal and industrial plants make substantial gains in minimizing liquid discharge and help plants significantly minimize their capital and operating costs, since achieving the final 3 to 5 per cent of liquid elimination to achieve ZLD can prove outrageously costly. (See graphic below.) Benefits of MLD over ZLD While zero liquid discharge (ZLD) — a water treatment process in which all wastewater produced is purified and recycled, leaving zero liquid discharge at the end of the treatment cycle — is a viable solution for some companies;
it’s not the most realistic solution for all. Due to the additional material, energy and disposal resources they typically require, it is technically daunting, highly expensive and not necessarily environmentally friendly. Hence when facing significant discharge mitigation costs, businesses often wonder, “What are my other options besides ZLD?” One solution is minimal liquid discharge (MLD), a more cost-effective and sustainable way for companies to improve their water footprint, enabling up to 95 percent liquid discharge recovery at a fraction of ZLD’s costs. Coined by Dow, the processes on which it is based rely on proven water filtration technologies such as ultrafiltration, reverse osmosis (RO), and nanofiltration.
Cost Comparison Of Minimal Liquid Discharge (MLD) VS Zero Liquid Discharge (ZLD)
Chemical Engineering World
CEW Features New MLD-related technologies are enhancing these efforts. For e.g., for municipal desalination plants, it’s possible to get to 93 per cent recovery using a traditional dual-membrane treatment system, chemical adjustments and precipitation. It’s typically a combination of brackish water reverse osmosis, nanofiltration and seawater reverse osmosis. To dispose the remaining concentrate, for many desalination plants, the preferred method of concentrate disposal is discharge into the ocean and if that is not an option, alternatives vary by geography.
Minimal Liquid Discharge
An excellent example of an MLD mind-set in action can be found at the General Motors (GM) vehicle assembly plant in San Luis Potosi, Mexico. The plant, which employs up to 1,800 and has an annual capacity of 160,000 cars, is located in an arid, remote area with no receiving stream or municipal sewer available to discharge wastewater. Yet by using a combination of RO technology, a proprietary high-rate chemical softening process, the plant can convert up to 90 per cent of its tertiary wastewater into reusable water, leaving less than 10 percent of liquid waste for discharge into adjacent solar ponds for evaporation. MLD provides users with a spectrum of options to achieve the results most optimal for a particular plant, based on a variety of factors. For some, it could be 90 percent, for others, it could be 80 or even 70 per cent. Diversity of Dischargers – MLD Solutions The diversity of types of discharge 42 • October 2016
streams across industries, markets and municipalities calls for MLD solutions tailored to individual needs. Potential discharge sources and opportunities for MLD-driven improvement include
In the United States, which primarily has small-scale desalination plants, the primary locales for concentrate disposal are evaporation ponds and injection wells. But in much of Asia, given its population densities and environmental factors, surface- or injection-based concentrate disposal are not viable options. In such instances, a reverse osmosis system is typically used to pre-concentrate the brine. Newer technology enhancements for this process include disk tube reverse osmosis, in which an open-channel structure RO system is fed by a turbulent feed water flow system. Through this process, the system can avoid settling of suspended solids carried in the feed water inside the membrane module.
Cooling tower blowdown – in heavy industry and power plants Ion exchange regenerative streams – particularly in food and beverage processing Flue gas desulfurization – wet wastewater stream Municipal potable water systems – wastewater streams Process water reuse – from agricultural, industrial and municipal streams
Another newer technology variant is the use of forward osmosis, which uses a water permeable, salt-rejecting membrane to separate water from dissolved solutes. The driving force for this separation is an osmotic pressure gradient, so that a “draw” solution of high concentration (relative to that of the process feed solution) is used to induce a net flow of water through the membrane and into the draw solution. This process helps eliminate the need and use of high-pressure pumps and can thus potentially operate using a lower energy footprint than evaporative technologies.
In general, all of these discharge sources can be broken into two main themes: volume streams and complexity streams. A tailored approach for MLD will depend on whether it’s tackling a volume stream, a complex stream, or some kind of combination, as well as the geography.
Reduced CAPEX, OPEX and Environmental Impact The cost of membrane-based pretreatment and filtration technologies applied in MLD is relatively minimal compared with the exponentially greater capital and operating costs of ZLD-related Chemical Engineering World
CEW Features
Evaluating MLD Needs So what is the best way to determine if your plant is a candidate for MLD? Often, the first step is to conduct a water audit to identify the sources and types of wastewater generated in a facility, especially in terms of flow and total dissolved solids content. By matching waste streams and appropriate water requirements, you can better identify how much wastewater (if any) requires processing and the approach that will most economically and sustainably match your plant’s needs. For e.g., some
wastewater sources, such as condensate and storm water require minimal cleaning while those with high concentrations of organic compounds, salts, metals and suspended solids, will likely require more rigorous treatment. Similarly, cooling water and process water do not need to be treated to the same standards as potable water. The most important factor is that an MLD approach enables your plant to address the substantial ‘limbo’ that exists between minimizing discharge, and go-for-broke ZLD.
environmental impact while reducing operating costs, the mill owners partnered with Dow Water & Process Solutions (DW&PS). As a result of this engagement, the research team in DW&PS developed a new product line called FORTILIFE™, which is designed to handle the most challenging water applications such as waste water reuse and MLD and give these applications the reliability and efficiency they badly need. With success of the existing pilots, the FORTILIFE™ products are now well on their way to be rapidly adopted by the industry.
Real-Life MLD Approach Benefits: India Due to considerable effluent discharge by the textile mills of Tiruppur, Tamil Nadu, the Madras High Court, in February 2011, decreed that all dyeing units in Tiruppur would have to shut down for violating pollution norms and would only be reopened when they implemented zerodischarge protocols in order to protect the surrounding farmlands and rivers. In their effort to comply with regulation, minimize
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evaporators and crystallizers. That’s why the advent of new technologies, such as disc-tube reverse osmosis and forward osmosis, is so important to users. They not only extend recovery but can also minimize or even eliminate the size or need for evaporators and crystallizers. Waste heat can be used from some of these operations to provide additional benefit to an MLD approach.
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CEW Features Case Study
Revamp Of Pre-cooling Unit of an Air Separation Unit One of the steel plants of India wanted to revamp the pre-cooling unit of their Air Separation Unit (ASU) to optimise Direct Contact Air Cooler (also known as Water Wash Tower) & Water Chiller (also known as Nitrogen Chiller or Vaporization Cooler) in order to handle increased temperature of Inlet Air. The case study looks at successful installation of 3rd generation Metal Random Packing ‘Medal-Pak’ along with high performance Polypropylene Random Packing ‘Omni-Pak’ for the beds of Direct Contact Air Cooler & Water Chiller.
P
rocess Overview: The purpose of the ASU is to separate atmospheric air into its primary components, typically nitrogen, oxygen and sometimes other rare inert gases like argon. These primary components can be separated from air by first cooling it until it liquefies then selectively distilling the components at their boiling temperatures. The process can produce high purity gases but it requires lots of energy to do so. Though this process was pioneered in the early 20th century by Dr. Carl von Linde but it is still used today to produce high purity gases.
The Direct Contact Air Cooler uses chilled water from Water Chiller & cooling water from Cooling Tower to cool the air. At the same time Water Chiller uses waste nitrogen from the Separation unit to chill the cooling water of Cooling Tower. Hence a water circuit is formed between the Direct Contact Air Cooler, Water Chiller & Cooling Tower.
Packed Towers are appropriate choice for this operation. In Packed Towers, heat is transferred by means of intimate contact between the fluids. The absence of fouling & scaling in the Packed Columns results in achieving higher heat transfer rate and in turn higher heat transfer coefficients. This leads to closer temperature approaches
An ASU consists of following units:• Pre-cooling unit • Purification unit • Separation unit Pre-Cooling Unit: Pre-cooling unit is also called as the Air Refrigeration System. Atmospheric air passes through the filter placed on the suction side of the compressors where the solid particles and dust are removed. The filtered air is pressurized in the air compressor so water vapor present in the air changes to liquid phase and the same is removed by the separators. The purpose of pre-cooling unit is to cool air by using cold & bone dry waste nitrogen coming from the Separation unit (cold box). The Pre-cooling unit consists of the following equipment. • Direct Contact Air Cooler • Water Chiller 46 • October 2016
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CEW Features cooling 115 0C Air & revised requirement was to cool 130 0C air to 150C while keeping the bed heights same as existing. They also required lesser pressure drop across the column. In case of Water Chiller they required to achieve close temperature approach at cold end.
Results Achieved: Post revamp, the Direct Contact Air Cooler cooled the inlet Air temperature from 1300C to about 150C & pressure drop was also within desired limits. In case of Water Chiller the circuit water flow rate was cooled to sub 13oC. These results were achieved with high performance packing which led to no alteration in the existing bed heights and hence no hot work. Both the columns have achieved the revamped objective and are performing satisfactory.
Separation Unit: In the Separation unit, purified compressed air is liquefied & then separated by two stage distillation into primary components.
Study & Solution: KEVIN visited the Steel Plant and did detailed study of existing Cooler & Chiller. Heat transfer calculations were carried out to simulate & confirm the output flow rate conditions along with temperatures. Hydraulic rating of towers was done to confirm minimal pressure drop. Adequacy check of the existing Internals like, Distributors, Misteliminators, Support plates, etc were done for the revamp conditions.
Customer Requirements: Customer required to optimise the Direct Contact Air Cooler so that it can cool the higher temperature incoming air. Initially Direct Contact Air Cooler was designed for
KEVIN selected 3rd generation Metal Random Packing ‘Medal-Pak’ along with high performance Polypropylene Random Packing ‘Omni-Pak’ for the beds of Direct Contact Air Cooler & Water Chiller.
between the two fluids thereby considerably reducing the initial equipment costs. In addition to the above, lower pressure drops can be achieved using Packed Columns so we end up having comparatively lesser operational cost as well. Purification Unit: The Purification unit removes moisture, carbon dioxide and hydrocarbons from pre-cooled compressed air by adsorbents present in the ducts. During this process air may carry some adsorbent particles & same are removed by passing air through filters before it enters the main exchanger.
Author’s Details Sameer Mehta Manager – Process Design Kevin Chemical Process Products Email Id- sameerm@kevincpp.com
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Chemical Engineering World
CEW Features Technical Article
Rotary Pressure Filter - Present Solid- Liquid Separation Trends in PTA Industries In the earlier Purified Terephthalic Acid (PTA) plants, centrifuges (pressure and atmospheric) were used for separating the PTA cake from the PTA slurries. This is an age old separation method, having distinct disadvantages due to the very high speed of the machine. In today’s competitive market, there is a necessity to reduce the downtime of the machine, its maintenance requisite and to enhance the operating cost by reducing the wash ratio and power consumption etc. With the advancement in technology, the filtration specialists have developed Rotary Pressure Filter (RPF) machine to encounter these requirements. The article deliberates the basics of the RPF separation technology. It’s principles of operation and filtration cycle. It is also elucidates the benefits received from RPF technology over the traditional centrifuge technique.
R
otary Pressure Filter: The rotary pressure filter is a continuously operating unit for pressure filtration, cake washing, and drying of slurries up to 50 per cent solids. The main components of the machine are filter casing, filter drum, filter cloth mounted on external surface of the drum, control head, agitator, screw conveyor for material transfer (may not be required for some suppliers), rotary valve etc. The surface of the drum is divided in several longitudinal filter cells. Further, the filter is divided into various process zones as shown in figure 3 and 4. The cells on the filter drum run through the filter zones by rotating the drum. These filter zones (for e.g. cake filtration, intermediate drying, washing, cake discharge, bubbling) are connected through a piped connection to the control head. The function of control head is used to separate filtrates coming from different zones and to apply different pressure levels to each process zone. (Cake formation, cake wash, cake dewatering, cake discharge and cloth cleaning) The filter drum is placed in the trough (feeding zone) and the trough is connected to the slurry feed line, overflow etc. The trough, has an agitator preventing the sedimentation of the solids in the slurry. 50 • October 2016
Rotary Pressure Filter Courtesy: Andritz KMPT, Germany
The discharge device which is usually a scraper blade is also installed in the trough. A screw conveyer is placed under the discharge device.
The complete filter is installed in a pressure casing. The pressure can be maintained by process gas or steam. The cake thickness can be varied by varying Chemical Engineering World
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CEW Features
Figure 1: PTA Filtration Process with Centrifuge Technology (Courtesy: INVISTA UK)
Figure 2: PTA Filtration Process with RPF Technology (Courtesy: INVISTA UK)
the pressure difference between RPF and filtrate vessels. The overall cycle time for filtration, cake washing, and drying is typically less than 2 minutes. Operating Principle: Description of the various process steps in RPF machine. Cake formation: The slurry is fed continuously under pressure to the RPF machine. A certain percentage of the drum surface is submerged inside the slurry that is constantly fed to the trough and kept in suspension by means of an agitator. The trough level can be controlled by a level control device or the filter operates under overflow. 52 • October 2016
Figure 3: Process zones (Courtesy: BHS Filtration)
Chemical Engineering World
Features CEW This wash filtrate is drained through the pipe system to the control head, where it can be collected in unmixed form that is separate from mother filtrate. Cake dewatering (drying) After the cake wash, the cake is dewatered with the help of process gas and steam. The filtrate is collected separately from the former filtrates and can be used for a first stage counter current wash. Cake discharge At the end, the cake discharge is either done by back-blowing or by scraping. The cake falls down in the screw conveyor (may not be required for some suppliers) and is transported out of the pressure vessel to rotary valve. Filtrate outlets from various process zones are connected internally to a control head where each stream can be directed to different filtrate separator tanks based on end user requirement. This allows for better process control as well as reuse of wash water.
Figure 4: Process zones (Courtesy – Andritz KMPT)
After automatic cake discharge, the filter cloth is washed, the clean filter cloth then re-enters the feeding and filtration zone thereby continuing the process.
Figure 5: Typical filter cells arrangement (Courtesy: Andritz KMPT)
By means of an adjustable pressure difference between pressure vessel and filtrate separators a filter cake gets built up on the filter cloth and the mother filtrate is drained off by the filtrate drainage system. By changing the speed, throughput can be changed, increase in filter speed will increase the throughput and vice versa. Chemical Engineering World
Cake washing The filter cake is washed immediately with a certain number of dedicated wash pipes. Depending on the specific requirements, washing can take place in one or more stages. Each pipe is equipped with adjustable wash nozzles and its position and angle can easily be adapted to process requirements.
Case study: PTA Retrofit Project, Indonesia A PTA plant in Indonesia has a PTA separation section consisting of 2 pressure centrifuges and 2 atmospheric centrifuges, to meet the production capacity of 58 TPH. Refer to figure 1 above for PTA filtration process with centrifuge technology. The plant is currently executing Retrofit Project to improve the production and process efficiency, by adopting the RPF technology over the existing installed centrifuge technology. Refer to figure 2 : PTA filtration process with RPF technology. October 2016 • 53
CEW Features Below is a case study showing the benefits of RPF separation technology over the centrifuge technology in the Retrofit Project. Sr. No
Parameter of evaluation
Centrifuge Technology
RPF Technology
Remark
1
Residual Moisture content in cake (per cent wt/wt wet)
Residual moisture: Design- 10 wt per cent Actual: 14-15 wt per cent
Residual moisture: Design- < 7.5 wt per cent Expected- 8-10 wt per cent
Improved dryness will reduce the steam consumption in the downstream PTA dryer.
2
Capacity (TPH)
~ 35 to 40 TPH per centrifuge
65 TPH (max can go up to 88 TPH) per machine.
Currently the plant operates with 2 pressure centrifuges and 2 atmospheric centrifuges, to meet the production of ~ 58 TPH. This will be replaced by a single RPF.
3
Operating Speed
Centrifuges: 900 RPM Very high speed machine
RPF: 0.6 to 6 RPM Very low speed machine
4
Down time
Higher downtime being a very high speed machine.
Very high availability and reliability due to very low speed machine. Downtime is typically expected for only RPF cloth replacement and cloth repair and exchange of wear parts.
Saving in maintenance requirement and cost in RPF technology.
5
Power Consumption (kW)
For 58 TPH capacity:
For 65 TPH capacity:
Total: 720 kW
Total: 8 kW
Huge saving in power consumption and operating cost.
Motor rating (kW)
Pressure Centrifuge: 300 kW x 2 nos = 600 kW Atm Centrifuge: 300 kW x 2 nos = 600 kW
Drum: 5.5 kW Screw: 15 kW Agitator: 2.2 kW Rotary Valve: 5.5 kW
Total: 1200 kW (total connected load)
Total: 28.2 kW
6
HT motors are replaced by LT motors.
7
Water requirement (kg water per kg dry solids)
Re-slurry water ratio is usually 0.550.6 Kg/Kg of slurry. However, this water is usually reused as recycle solvent (unless a too high RSW ratio is used) and therefore there is no loss of water. However, all the water is to be heated-up to 148 deg C, resulting in excess steam consumption.
Cake wash water ratio: 0.35 kg water per kg dry solids Total used wash water incl. cloth wash: 0.4 kg water per kg dry solids Only this much water has to be heated to 148 deg C. The rest (recycle solvent) need to be heated to 98 deg C only.
Saving in steam consumption for heating in RPF technology.
8
Weight (Metric Tonne)
Pressure Centrifuge (1W+1SB): 26.5 + 26.5 Atm Centrifuge (1W+1SB): 23.5 + 23.5
RPF: 23.6 Rotary valve: 3
Centrifuge machines also require slightly heavy foundation due to high centrifugal forces resulting from high speed.
Total: 26.6 MT
Total: 100 MT 9
Space required (LxWxH) m
54 â&#x20AC;˘ October 2016
More footprint due to 2 pressure and 2 atm. Centrifuge configuration
Less footprint due to single RPF machine Chemical Engineering World
Features CEW With RPF replacement case study it can be concluded that below objectives are met: a) Reduced residual moisture in cake thus reducing the load on downstream PTA dryer. b) Reliable operation with lower maintenance cost due to low speed machine. c) Improved wash water ratio and less steam consumption. d) Low operating cost due to significantly lower power consumption as single RPF machine with LT drives replaces 2 atmospheric and 2 pressure centrifuges with HT drives. e) Reduction in space and foundation requirement of RPF machine will also reduce the capital investment in case of the green field project. However there are few disadvantages of the RPF technology over Centrifuge technology namely: a) The technology is relatively new and few challenges were faced while implementing this technology change by some customers. However this is inevitable for any new technology and now the system is getting stabilised and in operation after gaining commissioning and operating experience.
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b) There is huge quantity of nozzles mounted on single machine. For some suppliers all the nozzles and piping is located on one side of the casing. Considering this and other requirements such as meeting slopes for filtrate and slurry lines etc. the layout becomes complex. References: - Catalogue literature of Andritz KMPT, Bokela & BHS
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Author’s Details Amol Patil Deputy Chief Engineer- Mechanical, Aker Solutions, India E: Amol.Patil@akersolutions.com Chemical Engineering World
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October 2016 • 55
CEW Features Technical Article
Configuration Study of Sour Water Stripper Units at Refinery Refineries worldwide are increasing their capacity accordance with the increase demand of refined oil products and to process high Sulphur crude. To facilitate this change the revamp of auxiliary process units such as Sour water Stripper (SWS) units and Amine treating Units (ATU) is a vital need for the refinery. The article discusses about various possible configurations for the design and revamp of SWS units at Refinery.
A
s the demand of the refined oil product increases, the refiners are increasing the capacity of their crude processing facility to accommodate higher throughput. In addition, considerable shift is noticed in the countries where indigenous crude production is going down necessitating the need to process imported high sulfur crude. To facilitate this change the revamp of auxiliary process units such as Sour water Stripper (SWS) units and Amine treating Units (ATU) is a vital need for the refinery. As these units are not the profit earning units in a refinery, clients do not want to spend much on these units and look for very cost effective means by carrying out revamp of these auxiliary units rather than going for a new unit. Advantage of revamping rather than constructing a new unit is less turnaround time. Space availability in existing refineries is also a big constraint in constructing a new unit. This paper discusses about various possible configurations for the design and revamp of SWS units. The objective is maximum utilisation of existing SWS units for the revised feed configuration with necessary modifications. If existing SWS units are not adequate to handle the increased capacity, a new SWS unit may be recommended. The bottom line is achieving the desired goals with minimum capital cost expenditure. Background The revamp of refineries is required due to the following reasons: 56 โ ข October 2016
1) Increasing margins of the existing refinery unit 2) Increasing the flexibility of the existing refinery to process high sulfur crude. 3) Meet future product specification requirements. 4) Meet the fuel (energy) security of the country. Refinery revamp typically include revamp of primary processing units like Crude Distillation Unit (CDU), Vacuum Distillation Unit (VDU) and secondary processing units like hydrocracker (HCU), Fluid Catalytic Cracking (FCC), Diesel Hydrotreater (DHT), Naphtha Hydrotreater (NHT) etc. New secondary processing units may also be required to meet the gasoline and diesel product specifications. Typically feed to the SWS unit is from CDU, VDU, FCC, DHT, Kerosene Hydrotreater (KHT), Sat Gas Plant (SGP), Naphtha Hydrotreater (NHT), Selectfining unit, Sulfur recovery unit (SRU) etc. Introduction The SWS unit in a refinery consists of a sour water storage tank to collect the sour water, a sour water surge drum to separate entrained vapors from the sour water and a sour water stripper column with reboiler and overhead condenser to strip H 2S and NH 3 from the sour water. Feed is pumped from feed surge drum to the column via a feed-stripper bottom exchanger to preheat feed to the column feed temperature. Sometimes two different stripper columns are used for the removal of H 2S and NH 3 separately due to the severity of feed.
Another configuration is to use packed bed column instead of trays. The column can be steam stripped or reboiled. The column has a pump around type overhead condenser which reduces plugging and corrosion problem in the column. The operating pressure in a sour water stripper is normally in the range of 0.8 kg/cm 2g to 1.1 kg/cm 2g. Normally the stripper pressure is set at the minimum level required to deliver the sour gas to the disposal destination. There are several advantages of operating stripper at minimum possible pressure. As the operating pressure increases, the required area in the reboiler increases because of the higher bottom temperature and resulting in smaller temperature difference between heating medium and stripper bottoms. Higher operating pressure may also require the use of more expensive steam to provide an adequate reboiler temperature differential. NH 3 removal efficiency is also improved by operating at the lowest possible pressure. The stripper feed temperature is determined by an economic balance between the cost of feed / bottoms exchanger surface v/s the cost of heating steam required to heat the feed. A feed temperature in the range of 95ยบC to 105ยบC in the column is a good practice. If the temperature is set too high an excessive amount of water vapor would be carried over with the sour gas. This excess water can cause combustion problem in the sulfur plant or incinerators. The reflux temperature is also one of the most critical design parameter of the stripper system. If this temperature is set Chemical Engineering World
Features CEW too low, the resulting high concentration of H 2S and NH 3 will cause corrosion in the overhead system and also plugging may occur in the overhead condenser due to the deposition of solid ammonium hydro sulfide. For these reason feed temperature is set above 85ºC. H 2 S composition in the severe feed may be as high as 18000 wppm whereas NH 3 concentrations may go up to 24000 wppm. A typical product target specifications for the stripped water is 10 wppm H 2 S and 25 wppm ammonia. Block flow diagram of a typical SWS unit is shown in Figure 1.
limit the project spending and meet the target specifications. A typical refinery may have a large number of sour water stripper units based on the sour water generated by the process units in the refinery. Routing of sour water streams to the existing SWS unit during refinery revamp should be done in such a way that the modifications would be cost effective yet most efficient. The review includes: • Identifying the various sour streams from refinery process and re-routing of existing sour streams to different SWS units. • Check of the existing SWS
water units water units
SWS units are evaluated. This can be done with the help of heat of material balance document and refinery LP model. The location of different process units with respect to the existing SWS unit in the plot plan is an important consideration that needs to be taken care during configuration study. This will be followed by adequacy check of existing SWS units for revised feed conditions and finalise the design considering the options described in the following paragraphs. Typical configuration of a sour water stripper unit is given in the below
Figure 1: Block Flow Diagram, typical sour water stripper unit.
In case of a revamp, the revised sour water flow rates and compositions from various process units and equipment design data of existing SWS units will form the design basis for the sour water stripper revamp project. The first step is the configuration review to evaluate different options for routing the sour water streams into the existing SWS units and the second step is to check the adequacy of existing SWS unit as per the outcome of first step. These are explained below. Configuration Review The configuration review is a brainstorming process so as to assist the client to Chemical Engineering World
to evaluate the design margins available by analysing the operating data and discussion with the client operations engineers. • Adequacy checks of the existing equipment and identify the constraints. • Carry out the process simulations keeping the constraints of the existing unit in mind and finalise the optimum design. This will require simulation of various combinations of feed streams. New additional sour water stripper units may also be set up if required. In the first step different options for routing the sour water streams into the existing
schematic (Figure 2) as an example. In this example, sour water streams from CDU, VDU, DHT, KHT and RCD are routed to this existing SWS unit whereas sour water from Sat Gas Concentration, Selectfining, NHT and LPG are routed from this existing SWS unit to different SWS units in the refinery as an outcome of configuration review. Depending on the nature of sour water and concentration of contaminants like H 2 S and NH 3 in the sour water feed, there are various possible configurations to design a SWS unit to facilitate refinery revamp. October 2016 • 57
CEW Features
Figure 2: Schematic of configuration review of a sour water stripper unit.
The nature of the sour water in the refinery is either phenolic or non phenolic. The phenolic sour water is generated mostly from the FCC unit whereas the non phenolic sour water is generated from process units other than FCC unit. The stripped water generated from phenolic sour water cannot be recycled back to refinery process units for re-use as wash water as it is harmful to the catalyst; however there is no such issue with non phenolic stripped water. Dedicated SWS units are designed for processing sour water from FCC process units. Sour water generated by FCC unit is phenolic in nature, in addition to H 2S and NH 3 it contains phenols, cyanides and other undesirable pollutants generated in catalytic cracking and coking operations. It is not possible to recycle this stripped water as wash water for the refinery because these pollutants cannot be removed during stripping and these are corrosive and harmful to the catalyst. Therefore stripped water is sent to effluent treatment plant. The sour water from the other refinery process units eg. HCU, DHT, KHT, SGP, CDU, VDU, Selectfining etc. contains essentially only H 2S and NH 3; hence the stripped water is recycled to process units for use as injection wash water. 58 â&#x20AC;˘ October 2016
In some cases, separate columns are used in series for removal of H 2S and NH 3 from sour water. This is due to very high concentration of NH 3 and H 2S in the sour water. Since H 2S is much less soluble in water than NH 3 and is therefore more readily stripped out in the H 2S stripper which is the first column. The feed from the sour water feed surge drum is first heated to the H 2S stripper feed temperature by exchange heat with NH 3 stripper bottoms and H 2S stripper bottoms. The off-gases from the H 2S stripper are routed to SRU. Incase SRU is down, off-gases are routed to Flare. On the other hand due to the higher solubility of NH 3 in water, it is the controlling design component. The H2S stripper bottom is sent to the NH 3 stripper column for removal of NH 3 from sour water. The acid gases from the NH 3 stripper are routed to incinerator. Use of a single column in such case may also lead to larger column diameter thereby causing operational problem. Refer Figure 3 for SWS unit with separate columns in series for stripping H 2S and NH 3. Packed columns are used in sour water strippers where high turn down is required that may not be possible to meet by using trayed columns. A trayed column cannot be used when the flow rate is very less due to its size limitation and turndown
issue at lower flowrates. A packed column does not have such problems at lower flow rates and there is no issue with a packed column when high turn down is desired. A typical packed column sour water stripper is depicted in Figure 4. Another configuration of sour water stripper design is pump around column or non pump around column with no reflux. In a pump around stripper column, most of the steam at the top section of the column is condensed and returned back to the stripper. This pump around material is rich in H 2 S and NH 3 and therefore, increases the load on the stripper. Hence more stripping and heating steam is required and a larger diameter of stripper is necessary. There is some corrosion issue in the pump around section of the stripper column and can be taken care by selecting proper metallurgy. However the overhead gas contains less water compared to a non pump around stripper column. In case of a non pump around stripper column the overhead material contains larger amount of water compared to the pump around stripper. Removal of this water vapor is essential before sending overhead material to Sulfur Recovery Unit (SRU). Refer Figure 1 for a pump around type SWS Chemical Engineering World
Features CEW
Figure 3: SWS unit with separate column in series for H2S and NH3 Stripping.
unit. The main advantage of using the pump around stripper column is that the overhead acid gas contains minimum amount of water which is required for the downstream SRU unit. The stripping medium may be steam or reboiled. Regardless of the medium used, if NH 3 removal is desired, a temperature of 110ÂşC or more is required (near
atmospheric pressure) to have reasonable stripping. Generally, a reboiler may be more economical than direct steam injection considering the value of recovered condensate. On the other hand the amount of stripped water will increase by use of direct steam. This will increase the initial investment cost of downstream waste water plant. The disadvantages of a reboiler are the increased capital
cost and increased maintenance due to corrosion, fouling and sludge build up. For steam stripped columns the overhead vapor contains considerable amount of water to send it as a feed to the sulfur plant. The entrained water need to be removed before sending overhead vapor to Sulfur plant (SRU). Refer Figure 4 for a steam stripped SWS unit.
Figure 4: Steam stripped SWS with Packed Column.
Chemical Engineering World
October 2016 â&#x20AC;˘ 59
CEW Features Caustic is added in sour water to remove ammonia. Sour water contains not only H2S and NH3 but also various acid forming compounds such as carbon di oxide (CO 2 ) and cyanides (CN). These compounds fix the NH3 in solution which hinders the formation of free NH 3 by hydrolysis. When the situation exists, there is always a residual NH 3 concentration in the tower bottoms even with the high stripping steam rates or a large number of stages. To remove the residual NH 3 a strong base such as NaOH is added to the sour water. The sodium Ion replaces the NH 4 + ion resulting in the formation of ammonium hydroxide (NH 4 OH) which makes NH 3 strippable. However the disadvantage of adding caustic is that the NaOH will react with H 2 S to form excessive amount of Na 2 S in the stripper bottoms. To prevent this, the caustic solution is added at an intermediate point in the stripper, where due to its low solubility, most of the H 2 S has already been removed. Other Design Considerations • Sour gases from the SWS column overhead should be routed to sulfur recovery unit (SRU). In case SRU is down sour gas can be routed to Flare. • Column overhead pressure should be set in such a way that sufficient pressure gradient is available for the sour gas to send it to SRU. Hence, review the location of SRU in plot plan and set column overhead pressure accordingly. • Separate storage tanks are designed for sour water from FCC units and sour water from other refinery units due to the presence of phenolic components in FCC sour water, which cannot be routed to process units after stripping. • Stripped water from the FCC unit is routed to effluent treatment instead of recycling back to process units due to the presence of phenolic components. For sour water from non FCC units, the H 2 S and NH 3 free stripped water is recycle back 60 • October 2016
to process units like CDU, VDU, DHT, NHT, RCD, SRU etc. as per requirement of process units. • Provision of a blower/ compressor for sending off gases to SRU/ incinerator.
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• The stripping medium may be steam, fuel gas or fuel oil. The use of fuel gas introduces CO 2 in the system and fuel gas becomes contaminated with H 2S and water. Because of the economic considerations and strictly environmental standards, steam is recommended as a stripping medium. • Mineral acids such as H 2SO 4 or HCL can be added to the sour water prior to stripping to facilitate the removal of H 2S. These acids fix the NH3 in solution as ammonium sulphate or ammonium chloride. A disadvantage of this process is that stripped water is contaminated with ammonium salts. Conclusion As there are various combinations possible in the refinery to process sour water generated from different refinery units, a configuration review in consultation with client is essential where sour water streams from different process units are re-routed to the existing SWS units in such a way that the modifications are cost effective. The configuration review will also envisage the design of new units, if required. Based on the selected configuration, modification of existing SWS units and / design of new SWS units are carried out considering various possible options, as discussed above to achieve an efficient yet cost effective design. Author’s Details Subrata Das Process Specialist Fluor Daniel India Pvt Ltd Email: subrata.das1@fluor.com
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Naresh Kumar Singh Sr. Process Specialist Fluor Daniel India Pvt Ltd Email: naresh.k.singh@fluor.com Chemical Engineering World
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October 2016 • 61
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For details contact: Toshniwal Instruments (Madras) Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-26448983, 26448558 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 3
or Circle Readers’ Service Card 4
Speciality AODD Pumps Shanbhag & Associates is the authorised national distributor for the entire range of Dellmeco Products with an all India sales and service network. The range of Dellmeco Pumps includes solid block AODD pumps in PE, PTFE in conductive and non-conductive housings from 1/4” to 2”; SS, CI, PTFE-coated and Aluminium housing AODD pumps from 3/4” to 3”; Hygienic SS-316L AODD pumps from 1/2” to 2.5”; jacketed and high-pressure AODD pumps for applications such as filter press; unique design of motorised double diaphragm pumps which are energy-efficient and ideal for long running; and AODD pumps for powder transfer. The pumps internals are available in EPDM or PTFE. Dellmeco pumps find applications in industries such as pharma, paint, chemical, clay and ceramics, electroplating/surface treatment, food, dairy and beverages, automotive, glass and fibreglass, oil and gas, marine/shipbuilding, metal and steel treatment, effluent-treatment, aircraft, etc. Dellmeco AODD pumps are absolutely lube-free; non-stalling in operation and corrosion-free. Air valve body is available in corrosion-free engineered plastics. There are fewer moving parts and commonly used spares across models and sizes. For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate Mahakali Caves Road, Andheri (E), Mumbai 400 093 Tel: 022-40365700, 40365711 | Fax: 91-022-40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 5
62 • October 2016
Chemical Engineering World
Products CEW Electromagnetic Meter
Ceramic-lined Rubber Hose
The instrument works on the principle of Faraday’s Law of Electromagnetic Induction. A magnetic field is generated by the instrument in the flow tube. The fluid flowing through this magnetic field generates a voltage that is proportional to the flow velocity. This voltage is measured by the electronics and a corresponding output provided.
Industrial Ceramics Division offers CUMI FLEXTUFF a ceramic-lined rubber hose with an excellent wear/abrasion resistance, catering to an additional advantage with good flexibility. In industries which deal with bulk material handling/ slurry conveying, steel pipes and rubber hoses are being used for transferring abrasion materials from one end to another. CUMI FLEXTUFF wear-resistant ceramic-lined flexible rubber hose is ideal for connecting conveying systems requiring movement and flexibility, subjected to vibrations, impact and thermal expansions. They can be easily connected to existing pipe systems by means of flanges as end connection offering a good flexibility support. Based on application it is possible to have different grades/geometrics of ceramic-lining such as sleeves and tiles.
It accepts any voltage from 90 to 265 V AC. Measures the flow in both forward and reverse directions. It provides a separate totalized volume value for flow in each direction. Easy monitoring of the process even in hard to reach places. Designed to meet global requirements and available with international approvals. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558, 26448983 | Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 6
For details contact: Carborundum Universal Ltd Indl Ceramics Divn Plot No: 47 & 48 (Part) Sipcot Indl Complex, Hosur, Karnataka 635 126 Tel: 04344-304748 | Fax: 91-04344-304809 E-mail: enquiryic@cumi.murugappa.com. or Circle Readers’ Service Card 7
Ceramic-coating Solution Industrial Ceramics Division offers CUMI PROFIX, a ceramic coating solution for erosion and corrosion resistance to static and dynamic applications. In industrial application subjected to bulk handling process pre-engineered wearresistant tiles are used to fit pre-fabricated lined equipment. There are some complex designs and structures where these tiles cannot be applied on to surfaces subjected to wear with a minimum level of thickness. To overcome these demerits, decisions were taken to develop a ceramic product in the form of viscous paste/brushable and sprayable liquid compound. CUMI PROFIX is ideal for application to complex structures where hard ceramic tiles are difficult to install. It has an excellent hardness, resistance to the mechanical loads and at the same time, possesses a good abrasion-resistance. It can be coated for a thickness of 0.40 mm to a max of 5 mm, thus offering wear and corrosion protection for surfaces of minimum thickness. Based on application it is possible to have different grades of ceramic coating at various temperatures up to 2500C. For details contact: Carborundum Universal Ltd Indl Ceramics Divn Plot No: 47 & 48 (Part) Sipcot Indl Complex, Hosur 635 126 Tel: 04344-304748 | Fax: 91-04344-304809 E-mail: enquiryic@cumi.murugappa.com. or Circle Readers’ Service Card 8
Chemical Engineering World
October 2016 • 63
CEW Products Orb Pilot for Reaction Scale-up Syrris offers the Orb Pilot jacketed reactor. This unique system offers flexible and cost-effective pilot scale batch chemistry. The Orb Pilot is a user-friendly, floor standing scale-up jacketed reactor providing an exceptional combination of performance, versatility and value for money. It offers a choice of vessel sizes from 10 to 50 liters on a single system, and is precision engineered to withstand temperatures from -40 to +235 oC. Available with a selection of single and vacuum jacketed vessels, plus a wide range of accessories and stirring options, the Orb Pilot can be easily configured to match your exact requirements. It features a unique clamp, easy motor lift and rapid oil drain mechanism – offering fast vessel changes – while a spring-loaded base avoids the need for frame adjustments to accommodate different vessels or thermal expansion. Combined with an incredibly robust and durable design, this will ensure the Orb Pilot provides years of continuous, cost-effective service for virtually any batch chemistry application. For details contact: Syrris Scientific Equipment Pvt Ltd 420/421 Corporate Avenue Sonawale Road Goregaon (E), Mumbai 400 063 Tel: 022-26864410 E-mail: info@syrris.com or Circle Readers’ Service Card 9
Resources on Heat Transfer, Scale-up and Mixing Mettler Toledo offers new web-based resources focused on heat transfer and scale-up and mass transfer to control the reaction rate. Addressing common challenges for chemists and engineers working in process development in the pharma and fine chemical industries, the new online resources provide useful information to scale-up new products faster with decreased costs and high quality. A precise heat transfer coefficient is required to successfully scale-up a chemical process from lab to plant. Measuring the reactor and jacket temperature enables scientists to calculate the thermal resistance. Thermal resistance is utilized to model the heat transfer and determine the necessary predictions for reactors at large scale. Reaction calorimetry is required to define parameters that influence heat transfer and the heat transfer coefficients to develop models to maximize manufacturing productivity. Mixing is the removal or decrease of inhomogeneity between phases that are either miscible or immiscible. Process scale-up and optimization necessitates quantifying the impact of mixing on the reaction rate. Precise experiments can be run automatically in a lab reactor system to investigate the mass transfer correlation, and deliver the opportunity to quickly adjust the gas/liquid mass transfer and reaction rate. This accomplishes the required conditions for process scale-up or scale-down. For details contact: Mettler Toledo India Pvt Ltd Process Analytics Solutions Amar Hill, Saki Vihar Road Powai, Mumbai 400 072 or Circle Readers’ Service Card 10
64 • October 2016
Chemical Engineering World
Products CEW Control Valve
Biochemical Oxygen Demand Analyser
Luthra Pneumsys offers range of Y Type control valve. It is a cost-effective solution to control fluid media, which cannot be controlled by diaphragm valves or poppet valves. These valves can handle fluids at high temperature up to 180 oC and does not react to most corrosive fluids. The 2/2 way pneumatic On-Off Y Type control valve is manufactured using SS-316 (ASTM-A351 CF8M) SS-304 (ASTM-A351 GR CF8) and CS (ASTM-A-216 GR WBC) with a range of ½” (15-mm) to 2” (50-mm). For details contact: Luthra Pneumsys Unit No: 24, Samhita Indl Estate No: 8 B/h MTNL Telephone Exchange Safed Pool Andheri (E), Mumbai 400 072 Tel: 022-42290856 E-mail: pooja.pneumsys@gmail.com
BOD is a measure of the DO consumed by microorganisms during the oxidation of bio-degradable substances in waste waters. A high BOD would therefore imply a higher depletion in the DO content. Water with high BOD if discharged into common streams and rivers, will starve the rest of the aquatic life. Wastewater is therefore treated to bring down the BOD value to levels below those prescribed by pollution regulatory bodies. The Forbes Marshall BioSens uses a revolutionary BOD measuring technique. This technique helps to determine the BOD value within 40 minutes in contrast to the 3 or 5 days required by the BOD3 and BOD5 methods. For details contact: Forbes Marshall Steam Systems Pvt Ltd (Formerly Spirax Marshal Pvt Ltd) Opp: 106th Milestone, Bombay Pune Road, Kasarwadi Pune, Maharashtra 411 034 Tel: 020-27145595, 39858555 | Fax: 91-020-271474143 E-mail: pasales@forbesmarshall.com
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AODD Pumps in Aluminium Wilden offers aluminum versions of its 420/430 Advanced FIT AODD pumps. Wilden 420/430 Advanced FIT pumps have been specifically designed to be direct replacements for existing 38 mm (1-1/2”) pump installations. The release of the aluminum 420/430 Advanced FIT pumps now completes the Advanced FIT pump line, which is available in 38 mm through 76 mm sizes with either aluminum or SS wetted path options. Providing increased performance with no repiping necessary, Advanced FIT pumps precisely FIT boltto-bolt and pipe-to-pipe in existing fluid-handling piping systems that utilize competitor pumps or Wilden Original and Advanced pump models. Wilden Advanced FIT pumps feature superior flow rates and easier installation compared to other brands. They have been engineered to be an easy, cost-effective way to enhance and upgrade existing pump performance with superior bolted product containment. Wilden Advanced FIT pumps are available with the patent-pending Pro-Flo SHIFT Air Distribution System (ADS) for outstanding energy efficiency and max Mean Time Between Repair (MTBR) or the Pro-Flo X ADS offering high operational flexibility. A wide range of Wilden diaphragms are available for a greater diversity in fluid compatibility including exceptional performance for abrasive applications. The 420 Advanced FIT pumps are supplied with NPT or BSPT threaded connections, and the 430 Advanced FIT pumps are available with ANSI or DIN flanged pipe connections. For details contact: Dover India Pvt Ltd 40 Poonamallee By-pass Senneerkuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 13
Chemical Engineering World
October 2016 • 65
CEW Products Multi-parameter Photometer with pH Electrode Input Hanna Instruments offers HI83300 family of multi-parameter photometers which saves valuable laboratory benchtop space, and doubles as a professional pH meter with its digital pH/temperature electrode input. Now one meter can be used for both photometric and pH measurements. It features nine models to cover a wide variety of applications. These meters are compact and versatile making them ideal for both lab or field operations. From aluminum to zinc, these photometer is essential for important water and waste water analysis using 60 different methods. This photometer features an innovative optical system that uses LEDs, narrow band interference filters, focusing lens and both a silicon photodetector for absorbance measurement and a reference detector to maintain a consistent light source ensures accurate and repeatable photometric readings every time. The meter is one of the most advanced photometers available with an innovative optical design that utilizes a reference detector and focusing lens to eliminate errors from changes in the light source and from imperfections in the glass cuvette. Two USB ports are provided for transferring data to a flash drive or computer and to use as a power source for the meter. For added convenience and portability the meter can also operate on an internal 3.7 V DC Lithium-polymer rechargeable battery. For details contact: Hanna Equipments (India) Pvt Ltd Office No: 3/4/5/6, 1 st Floor, Aum Sai Bldg Plot No: 23 C, Sector 7, Kharghar, Navi Mumbai 410 210 Tel: 022-27746554, 27746555, 27746556 | Fax: 91-022-27746557 E-mail: marketing@hanna-india.com or Circle Readers’ Service Card 14
Graphite Laminated Gaskets Flexible graphite, PTFE, Mica Type and traditional gasket materials are all supplied as interlayed materials. Both disc-mounted and body-mounted styles are supplied in sizes from 2” (50 mm) to 60” (1,500 mm) with specials available up to sizes 118” (2,950 mm). The critical technical requirements of the sealing face are fully understood and achieved through precision clamping and machining of the laminate. Solid seals, disc/body seats and clamp rings are supplied fully machined to customer drawings. Norton Gaskets Pvt Ltd has the capability to machine both interior and exterior surfaces. For details contact: Norton Gaskets Pvt Ltd 66-B Nehru Nagar Indl Estate, 2nd Link Road, Kottivakkam Chennai 600 041 Tel: 044-24540095 E-mail: nortongaskets@gmail.com
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66 • October 2016
Electronic Turbine Meter Toshniwal Hyvac Pvt Ltd offers turbine flow meter T24 built in nominal size of 4 to 200 mm with an accuracy of 1% after calibration within 10 90 (liters/min) 2,65 23,8 (gallons/min) range. The turbine meter is used for flow and volume measurement of liquid media such as crude and mineral oils, acids, alkaline solutions, solvents, water, etc. For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net
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Chemical Engineering World
Products CEW Single Point Insertion Flow Meter
Digital Clampmeter
The SPI Mag Insertion Flow Meter provides a highly cost-effective solution for the accurate measurement of liquid flow in closed conduit, pressurized pipe applications. Unlike conventional magnetic meters, the SPI Mag’s cost is independent of pipe size. The SPI Mag reliably measures flow in water and wastewater as well as any type of industrial flow processes involving conductive fluids such as potable water, slurries, sludge, cooling water and pulp stock. Its proven electromagnetic technology is based on Faraday’s Law. Debris shedding, self-cleaning sensor eliminates costly maintenance. Cost is independent of line size. It has an easy hot tap installation - no interruption of flow process. It finds application in wastewater - effluent, waste activated sludge (WAS), return activated sludge (RAS) and reclaimed/recycled.
KM 1001 digital clampmeter is completely portable meter. This clampmeter is designed for use in the laboratory, field, servicing at home, under any circumstance where high current measurement is required. This meter is built with a design of finger guard, which ensures safety operating, and electronic overload protection for all function and range. In addition, a carrying case is available for easy portability of the meter and avoiding damage. It comes with a rugged fire retardant and shock resistant casing.
For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road, Chennai 600 010 Tel: 044-2644 8558, 26448983 | Fax: 91-044-26441820 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 17
Features 3-1/2 digit 2,000 counts LCD with automatic polarity indication, over range indication, overload protection, protected by PTC in the resistance range (protection up to 500 V AC RMS). For details contact: Kusam Meco G-17 Bharat Indl Estate, T J Road Sewree (W), Mumbai 400 015 Tel: 022-24181649, 24124540 | Fax: 91-022-24149659 E-mail: kusam_meco@vsnl.net or Circle Readers’ Service Card 18
Humanoid Robotic Hand The German Aerospace Centre (DRL) has developed a new robotic hand in conjunction with the Harbin Institute of Technology (HIT). The new DLR-HIT Hand II has five fingers, each with four joints and three degrees of freedom and is smaller and lighr. Four fingers are required for clasping conical parts, and a thumb is used as an outer support. The mechanical range of movement must be properly controlled and monitored to enable the hand to be used fully. The motors are fitted directly into the fingers. This means that particular attention has to be paid to the control processor’s information with positioning and operating data. Every finger joint is therefore fitted with a self-developed non-contacting angle sensor and a torque sensor. Due to the application, both sensors must resolve very highly. A high-speed bus transmits the data flow. Rapid feedback for comparing target and actual value is crucial for the function of the controller, particularly in precise and elicit applications. Therefore, aside from the data volume, speed of transfer is also vital. Each finger needs several drives that can all be controlled separately. Maxon motor’s EC 20 flat drives meet several key requirements. The motors, including Hall sensors, create a unit that is only 10.4 mm long with an outer dia of 21.2 mm. Each motor weighs 15 g. They are mounted with harmonic drive gears from the HDUC 05 range, which have the same dia. The 3 W motors are available in a 12 or 24 V version and provide max torque of 8.04 mNm. Good dynamic behaviour and preloaded ball bearings ensure precise response behaviour of control commands, including changing the direction of rotation. The motors idle at 9,300 rpm. For details contact: Maxon Precision Motor India Pvt Ltd No: 4 Subhodayam, 3rd Floor, New BEL Road, RMV II Stage Bengaluru, Karnataka 560 094 Tel: 080-41734132 E-mail: info.in@maxonmotor.com or Circle Readers’ Service Card 19
Chemical Engineering World
October 2016 • 67
Chemtech World Expo 2017
International Water Conference 2016
Dates: 14 – 17 February 2017 Venue: BC&EC Mumbai, India Details: Platform to showcase services, technologies, innovations and current & future trends of entire value chain of process industry. Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
Dates: 06 – 10 November, 2016 Venue: San Antonio, Texas Details: WC brings together end users, researchers, practicing engineers, managers, educators, suppliers and contractors. It is dedicated to advancing new developments in the treatment, use and reuse of water for industrial and other engineering purposes. Attendees come to learn unbiased details about the latest applications available in the industry get educated on current technology and hold wide ranging discussions with their peers active in water treatment. Organiser: Engineer’s Society of Western Pennsylvania Contact: +412-261-0710 Email: eswp@eswp.com Website: https://eswp.com/water/overview/
Copexpo 2016 Dates: 25-27 November, 2016 Venue: Chennai, India Details: The event showcases products like India for the promotion of painting and coating industry. The show will enhance the desirable growth in the respective industry with advanced technology and useful expert views. Organiser: Smart Expos & Fairs (India) Pvt. Ltd Contact: +91 44 2250 1986 Email: info@smartexpos.in Website: http://www.copexpo.in/index.html
Chemspec South East Asia - 2016 Dates: 30 Nov to 01 Dec, 2016 Venue: Queen Sirikit National Convention Center, Bangkok, Thailand Details: Exhibitions for the fine and speciality chemical industry Organiser: Mack Brooks Exhibitions Asia Ltd Contact: +66 (0) 2684 6894 Email: wendy@mackbrooks.com Website: www.chemspec-southeastasia.com
7th Plast Show India 2016 SOMChE - 2016
Dates: 26-29 November, 2016 Venue: Ahmedabad, India Details: The show dedicates itself in offering a comprehensive range of plastic products and processing equipment’s. This exhibition strives to offer complete information about the recent inventions made in the plastic manufacturing sector. Organiser: Radeecal Communications Contact: +91 9925 010 553 Email: plastshow@plastshowindia.com Website: http://www.plastshowindia.com/
Dates: 1 – 3 December 2016 Venue: Miri Marriott Resort & Spa, Malaysia Details: an established platform for chemical engineers from academia and industries to disseminate their latest research and to highlight new technologies. Organiser: Curtin University, Sarawak Malaysia Contact: +60 85 44 3939 Email: somche2016@curtin.edu.my Website: www.curtin.edu.my
Petrotech – 2016
5th World Congress on Petrochemistry and Chemical Engineering
Dates: 05 – 07 December, 2016 Venue: New Delhi, India Details: The event aims to explore areas of growth in petroleum technology, exploration, drilling, production and processing, refining, pipeline transportation, petrochemicals, natural gas, LNG, petroleum trade, economics, legal and human resource development, marketing, research & development, information technology, safety, health and environment management in the oil & gas sector. Organiser: Indian Oil Contact: +91 9873020408 Email: shankar@indianoil.in Website: http://petrotech.in/index.aspx
68 • October 2016
Dates: 05 – 07 December, 2016 Venue: Phoenix, Arizona, USA Details: The conference directs towards addressing main issues as well as future strategies of global energy industry. This is going to be the largest and most promising international conference where oil and gas industry professionals as well as decision makers will come to discuss and debate on various aspects of the challenges, risks and investment opportunities throughout the complete integrated energy and utilities supply chain. Petrochemistry International Conference will also provide the proper business opportunities and provide an in opportunity to make new decisions by meeting decision makes in the energy sector Organiser: Conference series LLC Contact: +1-650-268-9744 Email: petrochemistry@chemseries.com Website: http://petrochemistry.omicsgroup.com/ Chemical Engineering World
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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 M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development. 5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation. Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat. The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam. Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the amanufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance. Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village: 70 • October 2016
Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure. Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascertained. According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board. Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascertained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, ortho anisidine/para anisidine from 100-TPM to 1,100-TPM, ortho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant. Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, Chemical Engineering World
Project Update CEW district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator. FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years. Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products â&#x20AC;&#x201C; red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product. Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018. Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF Chemical Engineering World
sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-cu m/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator. Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat. The project is waiting for environmental clearance. RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date. MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval. Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7-million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal/kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha. October 2016 â&#x20AC;˘ 71
CEW Project Update NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal. DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence soon. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast 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. NON-CONVENTIONAL ENERGY Viaton Energy, promoted by the 3F Group and Creative Group, is planning a 10-MW power project in Punjab. Discussion is in progress with the Government for allocation of site. The company is already operating a 10-MW biomass-based IPP at village: Khokhar Khurd, district: Mansa, Punjab from July 2013. The generated power is being sold to the Government of Punjab. Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on roof-tops of 31 HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million. NON-CONVENTIONAL POWER BMS Starch, a part of the BMS Group, is implementing a 6-MW biomass-based co-gen power plant in village: Kurandi, district: Bastar, Chhattisgarh. The project is coming up along with a starch manufacturing unit on 26-acre of acquired land at a total estimated cost of ` 1,350-million. Equipment supplier is yet to be appointed. Civil work is in progress. The project is expected to be completed in this year. THERMAL POWER Surguja Power, a 100 per cent subsidiary of Adani Mining, proposes a 540/600-MW coal washery rejects based thermal power project spread over 47.5-hectare of land in villages: Parsa, Kete, district: Surguja, Chhattisgarh. The estimated cost of the 72 â&#x20AC;˘ October 2016
project is ` 35-billion. According to MoEF sources, Greencindia Consulting is the environmental consultant. The project will comprise of a 4 x 135/150-MW power plant based on the coal washery rejects within the Parsa East and Kete Basan coal block at Udaypur Tehsil, district: Surguja. The Group has been assigned work by Rajasthan Rajya Vidyut Utpadan Nigam (RRVUNL) for mining, development and operation of Parsa East coal block and supply of beneficiated coal. Sizeable amount of rejected coal will be generated, which shall be utilized for power generation by setting up the power project within the coal block. The plant is proposed to have circulating fluidized bed combustion-based (CFBC) coal fired boilers. Rain Cements is planning a 7-MW waste heat recovery-based power plant in village: Boincheruvupalli, Peapully Mandal, district: Kurnool, Andhra Pradesh. The estimated cost of the project is ` 700-million. The project will come up in the existing cement plant premises. The project will generate up to 7-MW of gross electrical energy from the waste heat and the flue gases evolved during the cement manufacturing process. The project that will be financed by a combination of internal accruals and bank loans is expected to be completed in about 14 months. The Board of Directors of the company had approved of the project at its meeting held on 27 th February, 2015. Seven Star Steels is planning an expansion of its thermal (coalbased) captive power project from initial 8-MW to 12-MW at a cost of ` 600-million in village: Kalendamal, district: Jharsuguda, Odisha. The project will come up along with an expansion of its sponge iron plant from 60,000-TPA to 180,000-TPA and ingot plant from 39,200-TPA to 80,000-TPA. Machinery will be partially procured locally and partially imported; orders are yet to be placed. The project is waiting for industrial clearance. Work on the project will commence soon. FERTILISER Fertilizer Corporation of India is planning to set up a 1.27-MTPA natural gas-based urea plant in district: Gorakhpur, Uttar Pradesh. Deloitte Touche Tohmatsu India is the Financial Advisor. Request for Qualification (RFQ) invited for selection of investor for setting up the project at the Gorakhpur unit of FCIL in August 2015. The Ministry of Chemicals and Fertilizers, has authorized FCIL for revival of the Gorakhpur Unit by selecting a suitable investor to setup, design, finance, construct, establish, operate and maintain the project for a term of 33 years, which may further be renewed. The total land area of 993.81 acres is available with FCIL. The estimated investment size is ` 60-billion. The Government has earmarked 2.4-MMSCMD of domestic natural gas for the project from Daman Field of Oil and Natural Gas Corporation, which is expected to commence production from September 2016. The natural gas is proposed to be transported through the upcoming Jagdishpur-Phulpur-Haldia pipeline to be constructed by GAIL (India). The construction period is 3 years. Chemical Engineering World
Project Update CEW Agrocel Industries is implementing a potassium schonite manufacturing unit in village: Dhordo, district: Kutch, Gujarat. Civil work is in progress. PETROLEUM Indian Oil Corporation is planning a common user facility (CUF) for storage of petroleum products in Berhampur, district: Ganjam, Odisha. Single window clearance has been received. Land acquisition and land allotment is under progress. The project is planned for completion in 3 years from zero date. Bharat Petroleum Corporation is planning a 2.6-MTPA diesel hydro treatment (DHT) unit and associated facilities in Chembur, Mumbai, Maharashtra. According to MoEF sources, BPCL intends to set up a diesel hydro treater (DHT) unit to produce diesel conforming to BS-IV/V norms. DHT would hydro treat diesel, kerosene and naphtha streams (with diesel product from new DHT unit conforming to 8 ppmw sulphur). Along with DHT unit, the following associated facilities will be installed: 1) revamp of existing hydrogen generation unit-II (HGU-II) to meet the additional hydrogen requirement for DHT; 2) new amine regeneration unit (ARU); 3) sour water stripper (SWS) unit to treat additional sour water generated from DHT; 4) revamp of all four SRU trains to meet the additional acid gas processing; and 5) new gas turbine (GT) with heat recovery and steam generator (HRSG) for additional power and steam requirements. Implementation of this project will enable Mumbai refinery to increase BS-IV HSD production from 3.5-MTPA to 5.9-MTPA. Proposed DHT unit will be installed in existing tank farm area comprising of tanks 501, 502, 503, 504 and 508. The above tanks will be removed after reallocation of existing tanks on these services (Plot Area of 52 x 203 meters approx). Power and steam requirement will be met from proposed new gas turbine (GT) combined with heat recovery and steam generator (HRSG) system. A debt to equity ratio of 1.5:1 is considered. Removal space clearance work is in progress. The project is waiting for environmental clearance. Work on the project commenced in July 2015 and is planned for completion in 2017. Indian Oil Corporation is planning an ethylene derivative plant at Paradip refinery complex, district: Jagatsinghpur, Odisha. The estimated cost of the project is ` 40-billion. The plant will provide products that will facilitate manufacturing of polyester chips, fibers, PET bottles, PET chips, polyester yarn, etc. The corporation is evaluating the feasibility for setting up the plant. CEMENT Wonder Cement proposes a 2Ă&#x2014;1.5-MTPA clinker grinding unit in village: Takarkhede, taluka: Amalner, district: Jalgaon, Maharashtra under 2 phases. The current status of the project could not be ascertained. According to MoEF sources, 1.5MTPA will be set up under each phase. The total plant area Chemical Engineering World
is 35.4-hectare. About 33 per cent of the land area will be covered under green belt. The estimated cost of Phase-I is ` 4,120-million and Phase-II is ` 2,620-million. Power requirement will be 15-MW for Phase-I and 15-MW for Phase-II, which will be sourced from state grid. A 6.5-MW DG set is proposed under Phase-I. The plant will adopt dry process to manufacture PPC and OPC. A small township with guest house, officer, hostel club building will be constructed. The project will be completed in 18 months after receipt of regulatory approvals. The Ramco Cements proposes capacity upgradation of Line-1 cement plant and setting up a new captive power plant in village: Jayanthipuram, district: Krishna, Andhra Pradesh. The current status of the project could not be ascertained. According to BSE reports, Petron Engineering Construction has received Letter of Intent (LoI) from the company for civil and mechanical works for the project. The contract value is ` 225-million. Shreeji Infraspace is planning a ready mix c e me n t manufacturing unit in district: Bulandshahr, Uttar Pradesh. An in-house team will render civil contractual services. The project is in planning stage. The company is preparing the approval documents to be submitted to the Government of Uttar Pradesh. Work on the project will commence after the receipt of the approval. Jaiprakash Associates is planning an integrated cement project at a cost of ` 12,000-million in Dalla, district: Sonbhadra, Uttar Pradesh. The project will be spread over 67-acre of existing land and will comprise of a 2.20-MTPA clinker plant and a 1.50-MTPA cement plant. This is an expansion of the cement plant by setting up of an additional clinker and cement plant. The existing plant has a production capacity of 2.0-MTPA clinker, 0.5-MTPA cement, 27-MW power along with 6 captive limestone mines. Limestone will be received from the mine in the same plant. The project is waiting for environmental clearance. Work on the project will commence after receipt of environmental clearance. METALLURGY JSW Steel has re-commissioned two of its blast furnaces at Vijayanagar, district: Ballari, Karnataka and at Salem, Tamil Nadu. The furnaces were shut down in August and November 2015 respectively for relining and modification. The furnaces have been re-commissioned in February 2016. The re-commissioning work of the blast furnace at Dolvi Works, district: Raigad, Maharashtra, is in an advanced stage and is expected to be operational shortly. APL Apollo Tubes is planning an expansion of its tubes manufacturing project at Murbad, district: Thane, Maharashtra from 22,000-TPM to 30,000-TPM. Consultant is yet to be appointed. The project is in planning stage. October 2016 â&#x20AC;˘ 73
CEW Book Shelf Filters and Filtration Handbook Author/s: Price: Page: Publisher:
Kenneth S Sutherland, George Chase ` 16,112 520 (Hardcover) Elsevier Science
About the Book: Filters are used in most industries, especially the water, sewage, oil, gas, food and beverage, and pharmaceutical industries. The new edition of this established title is an all-encompassing practical account of standard filtration equipment and its applications. Completely revised and rewritten, it is an essential book for the engineer working in a plant situation-who requires guidance and information on what’s available and whether it’s suitable for the job. Co-published with the Institution of Chemical Engineers.
Liquid Filtration Author/s: Nicholas P Cheremisinoff Consulting Engineer Price: ` 3,805.31 Page: 320 (Paperback) Publisher: Butterworth-Heinemann About the Book: This book is a state-of-the-art review of liquid filtration in the chemical process and allied industries. Interpretations of the phenomenological observations of the hydrodynamics of filtration are given in the hopes of establishing more theoretical and generalized bases of design methodology. Specific design and selection criteria are reviewed, and typical industrial problems and their solutions are presented. Liquid Filtration is a fundamental unit operation extensively practiced throughout the chemical process, petroleum, and allied industries. It involves the separation, removal, and collection of a discrete phase of matter existing in a dispersed or colloidal state in suspension. This separation is most often performed in the presence of a complex media structure in which physical, physiochemical and/or electrokinetic forces interact.
Membrane Filtration Author/s: Greg Foley Price: ` 8,750.00 Page: 346 (Hardcover) Publisher: Cambridge University Press About the Book: This book focusses on the application of membranes in an engineering context, from microfiltration to reverse osmosis; this hands-on computational guide makes previously challenging problems routine. Its modern approach formulates problems as systems of non-linear algebraic or ordinary differential equations solved with MATLAB. Encourages active learning through worked examples and end-of-chapter problems.
Principles of Filtration Author/s: Chi Tien Price: ` 6,580.00 Page: 360 (Hardcover) Publisher: Elsevier About the Book: This book covers filtration in various modes of operation for both solid/gas and solid/liquid suspensions. It provides the necessary knowledge and background information to prepare and equip persons who are interested in serious filtration work. It is a useful reference/text for students and practicing engineers. It can also be adopted as an advanced text book for various engineering courses in chemical, environmental, mechanical and metallurgical engineering. The book presents analysis and treatment of filtration processes employing different filter media operating in various modes for both gas/solid and liquid/solid systems. 74 • October 2016
Progress in Filtration and Separation Author/s: Price: Page: Publisher:
E. Steven Tarleton ` 9,459.00 698 (Hardcover) Academic Press
About the Book: This book contains reference content on fundamentals, core principles, technologies, processes, and applications. It gives detailed coverage of the latest technologies and research, models, applications and standards, practical implementations, case studies, best practice, and process selection. Extensive worked examples are included that cover basic calculations through to process design, including the effects of key variables. Techniques and topics covered include pervaporation, electrodialysis, ion exchange, magnetic (LIMS, HIMS, HGMS), ultrasonic, and more. • Solves the needs of university based researchers and R&D engineers in industry for high-level overviews of subtopics within the solid-liquid separation field • Provides insight and understanding of new technologies and methods • Combines the expertise of several separations experts Chemical Engineering World
Ad Index CEW Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
Inside Cover I
17
Prima Equipment
37
Bonfiglioli Transmission Pvt Ltd
27
18
Shanbhag & Associates
33
3
Busch Vacuum India Pvt Ltd
21
19
Sharplex Filters (India) Pvt Ltd
29
4
C R I Pumps Pvt Ltd
35
20
Sintex Industries Ltd
15
5
De Dietrich Process System India Pvt Ltd
11
21
Suraj Ltd
49
6
Dow Chemicals
Back Cover
22
Toshniwal Instruments Madras Pvt Ltd
49
7
Ferolite Jointing Ltd
51
23
Uni Klinger Ltd
31
8
Fluorotech Engineering Works
47
24
UNP Polyvalves (India) Pvt Ltd
9
Gea Process Engineering (I) Ltd
5
25
Vac Enterprises
47
10
Hi-tech Applicator
3
26
Chemtech World Expo 2017
41
11
Ingersoll Rand India Ltd
9
12
Jay Water Management Pvt Ltd
13
Kirlsokar Brothers Ltd
14
KSB Pumps
15
Mettler-Toledo India Pvt Ltd
16
Paharpur Cooling Tower
1
Atomic Vacuum Company (Exports)
2
Chemical Engineering World
18 & 19
39
Inside Cover II
17
7
23 October 2016 • 75
CEW Interview
“Kurkumbh Manufacturing Facility Will Strengthen Henkel’s Growth Strategy for Emerging Markets” Backed by the success of nearly 140 years, Henkel Adhesive Technologies India Private Limited (Henkel India), a subsidiary of Henkel AG & Co. KGaA, Germany is the market leader in adhesive technologies, sealants and functional coatings. Shilip Kumar, President, Henkel India, discusses his new role of leading the organization and the investments in India to provide adhesive technologies domestically as well as in the international markets in a candid conversation with Mittravinda Ranjan Let us start with the portfolio of Henkel in India and your plan to drive the growth of the organization. Globally, we are organized into three business units of adhesive technologies, beauty care and laundry & home care, out of which, the first two are our key focus areas in India. In my new role, I will be responsible to drive the growth of Henkel in India, which also includes the vertical of transportation & metal adhesives business that I was leading earlier. India has always been a key market for our global growth strategy and we have major plans to grow our footprint in the Indian market as well as serving some international markets through our Indian operations. We are a specialty material company, and innovation has been the key driver for our growth globally and we have tried to emulate the same in India. Chemical Engineering World 76 • June October 2016 2016
Availability of a large talent pool in the Indian market offers us competitive advantage. We intend to tap these skills by working extensively in the areas of developing new applications for the Indian and international markets. Typically, we follow a four year strategic cycle and during the next cycle, starting 2017, we intend to further strengthen our efforts in this area. Henkel has already set up an innovation centre at Pune with an aim to develop products for various adhesive technologies across multiple industrial applications. Here, our teams work closely with the customers to understand their requirements and develop the products accordingly. I am delighted to share that we have been able to develop cost – effective solutions for many of our customers. At present, we have a core team of 50 engineers and scientists who are working at the innovation centre.
We have recently inaugurated the acoustic lab which has an anechoic and reverberation chamber. This will facilitate vehicle and component level testing for different applications as per international standards. It will also help meet high level product validation tests based on customer requirements. Currently, we are also in the process of setting up manufacturing unit to produce adhesives in Kurkumbh, near Pune, which will be one of the largest adhesive facilities to cater to various end user segments such as general industry, metal and automotive industries. With this new manufacturing unit, we intend to further localise our product portfolio and offer cutting edge solutions to the Indian market. Considering the proximity of the plant to our customers in India, it will also help us to work diligently with them to develop customised solutions for various applications. We are taking these Chemical Engineering World
Interview CEW initiatives with the aim to win a greater market share in India, which is one of the biggest emerging markets. What is the rationale behind setting up the Flexible Packaging Academy in India? If you look at the statistics, the packaging industry in India is expected to reach $ 73 billion by 2020. Though, per capita polymer consumption in India is much less as compared to the global average, the market is expected to double in size within next five years which will be driven by the changing consumer behaviour and modern lifestyle. Globally, Henkel offers cutting edge solutions in adhesive technologies and has set up the academy in the year 2015 in collaboration with Indian Institute of Packaging (IIP) with the idea of working closely with the customers to understand their requirements and develop laminating adhesives for sectors such as food, beauty care etc. We follow the principle of ‘Learning by Doing’ where we offer hands on practical training on different aspects of flexible packaging to entrepreneurs, production managers, supervisors, operators, quality controllers and other professionals. The modules are designed to cover key aspects such as printing, lamination, web handling, finished product testing, substrates, their properties and material handling etc., just to name a few. What is the kind of investment Henkel India is making in the manufacturing facility that is coming up in Kurkumbh, Pune? Henkel will be investing $ 36 million to set up the first phase of the largest adhesives sealants and speciality coatings plant in Kurkumbh, Pune to cater to end user segments of automotive, metal and packaging sectors. The production facility will go on stream by mid-2017. In its initial phase, the new manufacturing plant Chemical Engineering World
will have an operational area of about 20,000 square meters and the annual capacity is expected to be about 80,000 metric tonnes of adhesives and surface treatments. This investment has been made with the intent to further support Henkel’s global strategy to increase footprint in emerging markets. Please talk about other business areas of Henkel in India. Besides adhesives, sealants and functional coatings, the other key business areas for us in India, where we are present in B2B side, is beauty care. In the beauty care business, we are focused on salons and our Schwarzkopf Professional brand caters to all the new-age hair care needs with a range of cutting edge products. The Indian beauty care market is showing very strong growth and we see strong business potential for us. Can you throw light on your functional coating business? Coming to the segment of functional coatings, we produce anti-corrosive coatings for pre-treatment of metals and functional coatings for the automotive sector. These are high end applications and there is a niche clientele for these applications. How big is the market for adhesive & sealants in India? If we look at the present market for our products, we would be very disillusioned. To me, the market means existing conventional market as well as the untapped market which can be tapped into with the new innovative sealing solutions that replace the existing technologies. The challenge
here is to translate potential markets into actual markets by creating new markets for the innovative products that would replace the conventional ones. Replacing the mechanical fastenings with liquid sealants, is just one such example. We see India as a high potential market for us, and as market leaders we intend to take on the challenge of converting the latent potential into actual market. As a company, we are determined to grow double digit every year creating opportunities in the markets by providing new innovative solutions that cut across different industry verticals. There is a global vision for the company, a strategy to accomplish that vision and each region, or each country or each business unit works towards execution of the company strategy. Henkel is recognised for sealing solutions for industrial equipment, what kind of opportunities do you see here in India? We are primarily a bonding and sealing company and we offer chemical sealing solutions for various industrial equipment viz. pumps, engines, gensets and chemical processing equipment to name a few. Typically, mechanical fastenings such as nuts and bolts are used by the industrial equipment manufacturers, which we feel can be replaced with adhesives that are highly effective and can perform very well under extreme conditions. This is one of the examples of disruptive innovations that are going to set new market trends and open a lot of avenues in the future.
Besides adhesives, sealants and functional coatings, the other key business areas for us in India, where we are present in B2B side, is beauty care. In the beauty care business, we are focused on salons and our Schwarzkopf Professional brand caters to all the new-age hair care needs with a range of cutting edge products. The Indian beauty care market is showing very strong growth and we see strong business potential for us. October 2016 • 77
CEW Interview My biggest focus area is strengthening Henkel’s manufacturing & innovation footprint as well enhancing product development resources. These areas essentially go across our business units. What are the organisation’s future plans for India operations? India holds a strategic position for Henkel as a part of the company’s long term growth strategy both as a domestic market and base to serve the other international markets. We have already made an investment of $ 36 million to set up the manufacturing unit; and have invested in setting up flexible packaging academy and innovation centre which is a testimony of our commitment to the Indian market. We observe strategic cycles of four years, where we set try achieving our goals by the end of this cycle. Just to give you an example- Our global vision for the last four years was 20-
10-10 that translates into generating $ 20 billion revenue of which $ 10 billion was to be generated from the emerging markets with 10 per cent CAGR, by 2016, globally. Now, that we are heading towards the new cycle starting next year, the group will announce the next four years strategy shortly.
next year. My biggest focus area is strengthening Henkel’s manufacturing & innovation footprint as well enhancing product development resources. These areas essentially go across our business units.
Well, in India, our focus at present is increasing company’s footprint as well as delivering innovative technologies and solutions that help create value for our customers. We have started with the construction of the first phase of the new manufacturing facility and we are focussed on doing it right. Phase II is already under discussion and we will possibly announce it
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For Details Contact Jasubhai Media Pvt. Ltd. Taj Building, 3rd Floor, 210 Dr D N Road Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com 78 • October 2016
Chemical Engineering World
PRIMAL™ offers excellent alkali and efflorescence resistance, good adhesion on concrete, scrub and early chalking resistance. In addition early application of primer and subsequent top coats reduces labour costs.
DM_16AL_045_AD_DirtshieldPrimal_210x148_160817_FA2.indd 2
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
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For further information visit our website www.dowcoatingmaterials.com or contact us via phone: +91 22 6674 1500 or e-mail: infoindia@dow.com
New water-borne binder on fresh concrete
PRIMAL™ PR-1016
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.:80