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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
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VOL. 53 | ISSUE NO. 09 | SEPTEMBER 2018 | MUMBAI | ` 150
NEWS Industry News
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FEATURE ENERGY CONSERVATION THROUGH PROPER CONDENSATE RECOVERY Siddharth Jain, Product Manager – Steam Systems, Forbes Marshall POLLUTION CONTROL TECHNIQUES IN REFINERY AND DOWNSTREAM PETROCHEMICAL PLANTS Ajay Popat, President – Technology Corporate Marketing and Corporate Diversification, Ion Exchange (India) Limited
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CHALLENGES IN SETTING UP ETP FOR REFINERIES Satya Narayana Y V V, SFC Environmental Technologies Pvt Ltd
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MINIMAL LIQUID DISCHARGE: ADOPTING A ‘LESS IS MORE’ MINDSET Fei Wu, Regional Marketing Manager- RO/NF, Dow Water & Process Solutions
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NEWS FEATURE Stricter monitoring requirements for combustion emissions
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Can India replicate Middle East’s Desalination Success Story
48
MARKET INSIGHTS Energy Efficient Compressors for Cost Reduction
50
MARKETING INITIATIVES Bio-trickling Technology for Highly-polluted Odorous Emissions
52
ECOFLUX* Corrugated Tube Heat Exchanger
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PRODUCTS
55
EVENTS
68
PROJECT UPDATE
69
BOOK SHELF
71
INTERVIEW
72
Bringing Colours to Life: Soujanya Group Priya Bhumkar, Managing Director, Soujanya Group
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AD INDEX
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The Publishers and the Editors do not necessarily individually or collectively identify themselves with all the views expressed in this journal. All rights reserved. Reproduction in whole or in part is strictly prohibited without written permission from the Publishers. Jasubhai Media Pvt. Ltd. Registered Office: 26, Maker Chambers VI, 2nd Floor, Nariman Point, Mumbai 400 021, INDIA. Tel.: 022-4037 3737 Fax: 022-2287 0502 E-mail: sales@jasubhai.com
4 • September 2018
Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement. Printed and published by Mr Hemant K. Shetty on behalf of Jasubhai Media Pvt. Ltd., 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at The Great Art Printers, 25, S A Brelvi Road, Fort, Mumbai 400 001 and published from 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms. Mittravinda Ranjan, 3rd Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001.
Chemical Engineering World
CEW Industry News Charging Stations for e-Vehicles Inaugurated in Dwarka
Anant G Geete inaugurating e-charging infrastructure in New Delhi
Union Minister of Heavy Industries & Public Enterprises,Anant G. Geeteinaugurated Charging Infrastructurein the premises ofDwarka metro station in New Delhi Charging Infrastructure has been developed by Rajasthan Electronics & Instruments Ltd. (REIL) having 18 charging stations. Speaking on the occasion the Minister said 400 e-rickshaws may be charged from these stations free of cost. The Minister said that if sponsors are ready then charging will remain free of cost. REIL has already set up 45 charging stations till datein different cities. Department of Heavy Industry funds charging station installed by REIL. Earlier the Minister had launched 8 charging stations in the premises of Udyog Bhawan in New Delhi for facilitating charging of e-vehicles. For reduction in pollution levels and making cities cleaner and environment friendly, the Government is working on FAME-II Scheme having focus on mass & shared public transportation based on electric powertrain. The necessity for development of charging infrastructure for smooth roll out of electric mobility in the country is being addressed in the Phase-II of FAME Scheme. The Department has notified FAME India Scheme in the year 2015 under National Electric Mobility Mission Plan of the Government. The Phase-1 of this scheme is being implemented through four focus areas namely Demand Creation, Pilot Projects, Charging Infrastructure and Technology Platform and R&D. Under Demand Creation component of the scheme, incentive is available to buyers of electric and hybrid vehicles (xEVs) in the form of an upfront reduced purchase price to enable wider adoption. Managing Director, Delhi Metro Rail Corporation was also present on this occasion.
About 10,000 CNG stations to be in place; Bio-ATF and Bio-CNG policies to be formulated The Union Minister of Petroleum and Natural Gas & Skill Development and Entrepreneurship Dharmendra Pradhan has emphasized on a clean, efficient and affordable mobility system. In his opening remarks at the Global Mobility Summit 2018, he said that despite changing global trends, consumption of petrol and diesel in India is growing in excess of 5% per annum. Whatever be the scenario of the growth of Electric vehicles, India would still need higher refining capacities. To achieve cleaner emissions, the Minister added, India will leapfrog from BS-IV to BS-VI standards, and the NCT of Delhi has already switched to the better fuel since April this year. Pradhan said the Government has already implemented fuel efficiency norms for commercial heavy vehicles. Talking about the gas based transportation solutions, the Minister said that the use of CNG, LNG and Bio-CNG is being promoted in the sector, and there are plans in place to have about 10,000 CNG stations within a decade, covering over half of the country. On the issue of promoting LNG as a fuel for long distance transportation by heavy commercial vehicles, Pradhan informed about the efforts being made by Public sector oil companies and some private enterprises in setting up LNG distribution infrastructure. He 6 • September 2018
said that 12 bio-refineries are being set up and steps are being taken to achieve 10% ethanol blending. Soon, Bio-ATF and Bio-CNG policies will be formulated. Indian Oil has tied up with the Delhi Government to introduce 50 Hydrogen enriched CNG buses next year. On the issue of Electric Vehicles, Pradhan said that there are challenges concerning setting up of infrastructure and economy of converting to EVs, and Interministerial teams are working to put in place a comprehensive policy on the matter. In the session, Graham Stuart, Parliamentary Under Secretary of State, UK, Dr Lam Pin Min, Senior Minister for Health and Transport, Singapore and Mrs Sindisiwe Chikunga, Deputy Minister of Transport, South Africa also participated. All of them outlined the trends and developments in the mobility sector in their respective countries. Stuart appreciated the Indian Government’s efforts to provide LPG and Electricity to a large number of citizens.
Cabinet approves on Fixation/Revision of ethanol price The Cabinet Committee on Economic Affairs, chaired by the Prime Minister Narendra Modi has given its approval to revise / fix the price of ethanol derived from B heavy molasses / partial sugarcane juice and fix a higher price for 100% sugarcane juice based ethanol for the forthcoming sugar season 2018-19 during ethanol supply year from 1st December 2018 to 30th November 2019. The decision will serve multiple purposes of reducing excess sugar in the country, increasing liquidity with the sugar mills for settling cane farmer's dues and making higher ethanol available for Ethanol Blended Petrol (EBP) Programme. All distilleries will be able to take benefit of the scheme and large number of them are expected to supply ethanol for the EBP programme. Remunerative price to ethanol suppliers will help in reduction of cane farmer's arrears, in the process contributing to minimizing difficulty of sugarcane farmers. Ethanol availability for EBP Programme is expected to increase significantly due to higher price being offered for procurement of ethanol from B heavy molasses / partial sugarcane juice and 100% sugarcane juice the for first time.Increased ethanol blending in petrol has many benefits including reduction in import dependency, support to agricultural sector, more environmental friendly fuel, lesser pollution and additional income to farmers. Ethanol Blended Petrol Programme was launched by the Government in 2003 on pilot basis which has been subsequently extended to the Notified 21 States and 4 Union-Territories to promote the use of alternative and environment friendly fuels. This intervention also seeks to reduce import dependence for energy requirements and give boost to agriculture sector. Government has notified administered price of, ethanol since 2014. This decision has significantly improved the supply of ethanol during the past four years. The ethanol procured by Public Sector OMCs has increased from 38 crore litre in ethanol supply year 2013-14 to estimated 140 crore litre in 2017-18. Consistent surplus of sugar production is depressing sugar price. Consequently, sugarcane farmer's dues have increased due to lower capability of sugar industry to pay the farmers. Government has taken many decisions for reduction of cane farmer's dues. With a view to limit sugar production in the Country, Government has taken multiple steps including, allowing diversion of B heavy molasses / sugarcane juice for production of ethanol. As the ex-mill price of sugar has increased from the earlier estimated price, there is a need to revise price of B heavy molasses / partial sugarcane juice and 100% sugarcane juice for production of ethanol. It is worth noting that as compared to ethanol derived from C heavy molasses route, diversion of B heavy molasses reduces the sugar by about 20% and increases ethanol availability by about 100%. On the other hand, diversion of sugarcane juice reduces sugar by 100% and increases ethanol availability by about 600%. Chemical Engineering World
CEW Industry News HURL executes Agreements for revival of units of FCIL & Barauni Hindustan Urvarak & Rasayan Limited (HURL), a Joint Venture company of NTPC, IOCL, CIL and FCIL/ HFCL incorporated to implement the fertilizer revival projects at Gorakhpur, Sindri, and Barauni, has executed land lease agreements and concession agreements with Fertilizer Corporation of India Limited (FCIL) and Hindustan Fertilizer Corporation Limited (HFCL). In order to facilitate HURL to set up the fertilizer projects at the three locations, the Union Cabinet had accorded its approval in respect of the land lease on 9th August, 2018, as per which the agreements were signed and the land would be leased to HURL for a period of 55 years by FCIL/HFCL. The revival of Gorakhpur and Sindri units of FCIL and Barauni unit of HFCL will ensure substantial investment in the fertilizer sector.This will create job opportunities and also boost the economy of the eastern region/state of the country. The revival of fertilizer units will also augment indigenous production of urea there by enhancing self-reliance in urea. All the three new plants are currently under implementation and are expected to be commissioned in early 2021. The signing of the documents was completed in the presence of Secretary (Fertilizers), Smt. Bharathi Siva Swami Sihag and other senior officers of the department and HURL, FCIL, HFCL and PDIL.
Dr Harsh Vardhan inaugurates 13th Sustainability Forum Emphasising that circular economy and resource efficiency can provide solutions to the challenges posed in the process of reconciling economic growth with environmental sustainability, Union Minister for Environment, Forest and Climate Change, Dr. Harsh Vardhan has pointed to the need for corporate participation in building resource efficiency and a circular economy. Addressing the 13th Sustainability Summit with the theme – “Everyone’s future” here today, Dr. Vardhan underlined the growth of Indian economy, along with successful management and development of forests, wildlife habitats and ecosystems. He stated that India has registered 1 per cent growth in its forest and tree cover, according to the latest report of Forest Survey of India. The Minister stressed that while talking about sustainable development, economy and ecology must go together. “The present Government has given equal thrust to both these components and we are marching towards the path of Sustainable Development”, he said. Dr. Vardhan referred to the recent implementation of ‘PARIVESH’- a single window clearance system in the spheres of Environment, Forest, Wildlife and Coastal Regulation Zone. He pointed out that the automated system will help applicants track the application status, as well as help in improving environmental compliance. The Minister highlighted India’s affirmative action in embracing a sustainable lifestyle by aligning the 5 Ps – People, Planet, Prosperity, Peace and Partnership. Acknowledging that the quality of air is an environmental issue that impacts the health of the country’s citizens, Dr. Harsh Vardhan said that the National Clean Air Action Plan and air quality monitoring infrastructure are the Government’s key areas of focus. The Minister averred that environmental challenges necessitate coordinated action from all sections of the society. He said that human beings have put immense pressure on the systems of nature, which has resulted in the emergence of global challenges such as climate change, melting of glaciers, loss of biodiversity, poverty and growing inequity. Dr. Vardhan alluded to the development of strategies for proper segregation of municipal solid waste and utilisation of plastic waste for recycling and recovery. “We have engaged with various municipal authorities and state pollution control boards to facilitate better understanding of regulatory frameworks to ensure an efficient waste collection and disposal system”, Dr. Vardhan said. 8 • September 2018
The Minister also invited the industry representatives to join hands with the Government on various initiatives such as air pollution control, waste management river conservation, or biodiversity conservation. Speaking on the occasion, Minister of State (Independent Charge) of Housing and Urban Development, Mr. Hardeep Singh Puri said, “India’s development trajectory will be ‘green’ and in consonance with the ethos of the 2030 development agenda”. He stated that India stands united in its efforts against rising global temperatures and elaborated that a quick glance at India’s Intended Nationally Determined Contributions reaffirm this point and referred to the target of 175 GW renewable energy capacities by 2022 as unprecedented. He averred that the adoption of the Sustainable Development Goals in 2015 recognized the intrinsic linkages between climate change and urbanization. “Goal 11, titled “Make cities and human settlements inclusive, safe, resilient and sustainable” has embedded in it, critical elements of climate action. Solid waste management, air pollution, slum housing, and water related disasters, are just some of the climaterelated aspects covered in Goal 11”, he outlined. Pointing to the objective of the Swacch Bharat Mission (SBM) to make India ODF and have 100% scientific solid waste management by October 2, 2019, the Minister suggested that SBM is not only about infrastructure, but also bringing about behavioural and cultural changes among citizens. He added that to ensure India’s city driven development is sustainable, the government has embarked on the world’s largest planned urbanization programme. The key to the process is “integration”, meaning all policies, projects, and proposals are considered in relation to one another, he added. Puri stated that the use of new and alternate construction technologies in the construction of houses, locally available eco-friendly materials suited to local climatic conditions are being encouraged, reducing not only the cost of construction but also the resultant carbon footprint. He also emphasised on affordable, eco-friendly and modern urban transportation services and said that Delhi Metro is today comparable to the best in the world. Director General, Confederation of Indian Industry (CII), Mr. Chandrajit Banerjee, European Commissioner, Mr. Karmenu Vella and representatives from industry and civil society were among those present on the occasion.
Cabinet approves equity infusion of RCF in Talcher Fertilizers Ltd The Cabinet Committee on Economic Affairs, chaired by the Prime Minister Narendra Modi has approved the proposal of the Department of Fertilizers for equity investment of ` 1033.54 crore (+) @ 29.67% of the total project cost for setting up a Coal Gasification based fertilizer project in Talcher Fertilizer Ltd. (TFL) by Rashtriya Chemicals & Fertilizers Limited (RCF). The revival of the Talcher project will ensure huge investment in the fertilizer sector from the Government through PSUs. This will create job opportunities and also boost the economy of the State and the eastern region. The revival of the fertilizer unit will also ensure increase in indigenous production of urea leading to greater self-reliance in urea. TFL, a Joint Venture company of GAIL, RCF, CIL and FCIL was incorporated in November, 2015 with shareholding of 29.67% of GAIL, RCF and CIL each and 10.99% of FCIL to revive the Talcher Fertilizer Plant. TFL has been formed to set up a coal gasification based fertilizer project at Talcher, District Angul, Odisha. The share of GAIL, CIL and RCF in the equity of TFL shall be ` 1033.54 crore (+ 15%) based on the Capex of ` 11,611.48 crore (+ 15%) for the Coal gasification based fertilizer plant. GAIL and CIL are both Maharatna Public Sector Enterprises and their Board is competent to approve their equity investment in the Joint Venture company TFL. RCF is a Miniratna company and its equity investment in the project is beyond the delegated financial powers of its Board. Chemical Engineering World
CEW Industry News Haldor Topsoe invests in Indian fertilizer plant Topsoe, IFU, and DAF have signed a shareholder agreement with promoter companies National Fertilizers Limited (NFL), Engineers India Limited (EIL), Fertilizer Corporation of India Limited (FCIL), the natural gas processing and distribution company GAIL, and the State of Telangana. The partners have agreed on a shared investment in the Ramagundam fertilizer plant, which is scheduled to begin operation in the second quarter of 2019 as the first of the revival projects. “We see Topsoe and IFU’s investment as a very important aspect of the financial closure and as a sign of their confidence in the project management team and fundamental parameters of the venture. It brings about a tangible support from Topsoe in terms of future operational efficiencies, optimal energy efficiency, and back-end support from the world’s leading ammonia technology supplier. In addition, we expect that the international experts from Topsoe and IFU on the Board of Directors of RFCL will pave the path for good corporate governance as well as technical vision for our future direction,” says V. K. Malhotra, CEO, Ramagundam Fertilizer. Topsoe’s uninterrupted dedication to the Indian fertilizer industry for more than five decades has made the company the largest supplier of process and catalyst solutions in the Indian market. “Topsoe has a long-standing presence in India where our world-leading ammonia technologies have been instrumental in building a domestic Fertilizer industry. Today, we are proud to expand our engagement in the revival process by becoming an active investor in the Ramagundam plant together with our extremely competent Indian and Danish partners. This is yet another important step in the Indian government’s efforts towards self-sufficiency in urea production and as a consequence: food security,” says Amy Hebert, Executive Vice President and Deputy CEO, Topsoe. The Indian fertilizer sector consists mainly of publicly owned companies, and foreign direct investment in the sector is not customary. However, Topsoe is now a member of the group of owners of the Ramagundam plant because of the important role of Topsoe’s ammonia technologies and catalysts in the plant. Topsoe and its Danish partners will have a seat in the Board of Directors of the Ramagundam plant and will take an active role to secure long-term success.
INEOS Styrolution announces agreement to acquire two polystyrene production sites from Total S.A. INEOS Styrolution, the global leader in styrenics, has signed an acquisition agreement with Total S.A. for two polystyrene (PS) production sites in China. The deal includes the purchase of the wholly owned Chinese PS business including two production sites in Ningbo and Foshan and two related offices in Guangzhou and Shanghai. The transaction signals INEOS Styrolution’s first production move into China and underlines the company’s commitment to the Asian growth market, as derived from the company’s “Triple Shift” growth strategy. “A little more than one year after our first acquisition, INEOS Styrolution continues to grow its footprint in the Asian market,” says Kevin McQuade, CEO INEOS Styrolution. “Not only does this move allow us to significantly increase our presence in a region with growing demand for polystyrene, it also enables us to provide customers in our core industries with locally produced best-in-class materials.” The Foshan site is located in the Guangdong Province in South China. The Ningbo site is located in the Zhejiang Province south of Shanghai in Eastern China. The annual nameplate capacity of each site is 200kt per year. “This is an important milestone for both INEOS Styrolution and the INEOS Group as it represents our first manufacturing assets in China,” comments Steve Harrington, President Asia Pacific & Global Styrene Monomer 10 • September 2018
Bentley Institute organizes the first edition of Product Training Partner Summit 2018 in Bengaluru
Bentley Institute recently organized its first ever Product Training Partner Summit 2018 in Bengaluru. The objective of the Summit was to establish a knowledge-sharing platform to apprise the authorized Product Training Partners about Bentley Institute’s vision, upcoming plans, current industry trends and opportunities to enable Bentley Institute and its stakeholders align their growth paths. Bentley Institute’s Product Training Partners from India, Middle East and South East Asia attended the Summit. Vinayak Trivedi, Vice President, Global Head, Bentley Institute delivered the key note speech about ‘Going Digital’ with Bentley’s technology, introduced the audience to various facets of Bentley Institute and the variety of programs offered by the Institute to help existing and future industry professionals advance in their infrastructure careers. He also stressed on the effects and solutions of the existing skill gap in the infrastructure industry and potential solutions and avenues available for up-skilling of talent. Vinayak Trivedi expressed, “In the current scenario, the focus of the infrastructure industry professionals is to execute projects within limited time in a cost-effective manner, without losing focus on digitalization. For existing industry professionals and future professionals to be employable, it is important for them to upskill their knowledge with practical experience of using cutting-edge technologies and tools. Our Product Training Partner Program offered by Bentley Institute enables them to achieve it”. Bentley Institute advances project delivery and asset performance best practices through Advancement Academies, partnering with leading industry organizations, project delivery firms, and owner operators.
Beckhoff launches communicator faster data exchange The TwinCAT IoT Communicator makes it easy for PLCs to communicate with mobile devices by connecting the TwinCAT controller directly and securely to a messaging service through TLS encryption. For smartphone and tablet users, the associated IoT Communicator App ensures that process data can be represented on all mobile devices in a clear overview. Alarms are sent to the device as push messages. The TwinCAT 3 IoT Communicator exchanges data using a publish/subscribe mechanism. Since no special firewall settings are needed, integration into an existing IT network is easy. Information is exchanged via a message broker that uses the standardised MQTT protocol and acts as a central messaging service in a cloud or local network. A high level of communication security is guaranteed by proven TLS encryption (up to version 1.2). Transmitted process data can be displayed on mobile devices using the IoT Communicator App, which is available for both Android and iOS operating systems. The IoT Communicator App also incorporates an integrated QR code scanner to facilitate entry of access data for communication between the broker and individual users. Chemical Engineering World
CEW Industry News Linde-Praxair merger receives conditional clearance The Competition Commission of India (CCI) has approved the combination of Linde Aktiengesellschaft and Praxair Inc. The approval is, however, subject to the condition that the parties divest their current shareholdings in companies in India that may impact competition. German company Linde and US-based Praxair manufacture and supply industrial, medical and specialty gases. In addition, Linde operates in the related engineering and services sectors. In India, it has a joint venture with Inox Air Products Ltd. Praxair has an Indian unit. “The proposed combination is likely to have an appreciable adverse effect on competition in some markets in India but the same could be addressed by way of modifications to the proposed combination,” said CCI in a statement.
U.S. Chemical Industry Investment Linked To Shale Gas Reaches USD 200 Billion The American Chemistry Council (ACC) has announced that U.S. chemical and plastics industry investment linked to plentiful and affordable domestic supplies of natural gas and natural gas liquids (NGLs) from shale formations has surpassed USD 200 billion. Since 2010, 333 chemical industry projects cumulatively valued at USD 202.4 billion have been announced, with 53 percent of the investment completed or under construction and 41 percent in the planning phase. Fully 68 percent of the total is foreign direct investment or includes a foreign partner. Project types include new facilities and capacity expansions. "This is an exciting milestone for American chemistry and further evidence that shale gas is a powerful engine of manufacturing growth," said ACC President and CEO Cal Dooley. "The U.S. remains the most attractive place in the world to invest in chemical manufacturing. We look forward to continuing to transform energy into a stronger economy and new jobs." ACC analysis shows that USD 202.4 billion in capital spending could lead to USD292 billion per year in new chemical and plastics industry output and support 786,000 jobs across the economy by 2025. These include 79,000 chemical industry jobs, 352,000 jobs in supplier industries, and 355,000 jobs in communities where workers spend their wages. Additional, temporary jobs are created during the capital investment phase. Robust supplies of NGLs, especially ethane, are key to the U.S. chemical industry's competitiveness. NGLs are the main feedstock for basic petrochemicals and plastics in the United States, while companies overseas mostly use naphtha, which is oil-based. Since feedstock comprises about 75 percent of the cost of ethylene production, lower prices favour U.S. chemical makers in global markets. A note of caution is in order. U.S. manufacturers often rely on inputs that are not available or made in the U.S. to create products that cost less, yet perform at the high level our downstream customers have come to expect from us. Protectionist trade policies such as tariffs and quotas unnecessarily raise the costs of those inputs, deter innovation and economic growth, and could ultimately weaken our country's competitive advantage. Today's announcement provides another update to ACC's first report, "Shale Gas, Competitiveness, and New U.S. Chemical Industry Investment – An Analysis of Announced Projects." Released in May 2013, the report analyzed 97 chemical and plastics industry projects totaling USD72 billion in potential investment that had been announced as of March 2013. As new projects are announced, we update our tally of announced projects and cumulative investment. 12 • September 2018
ACC analysis employs the IMPLAN input-output methodology, an economic model that quantifies interdependencies among industries or economic sectors. IMPLAN is used by government agencies including the Army Corp of Engineers, U.S. Department of Defense, U.S. Environmental Protection Agency, and over 20 others, and by over 250 colleges and universities, local governments, non-profits, consulting companies, and other private sector companies.
ExxonMobil Signs Framework Agreement for Proposed Chemical Complex in China Exxon Mobil has signed a cooperation framework agreement with the Guangdong Provincial People’s Government to advance discussions concerning the proposed construction of a chemical complex in the Huizhou Dayawan Petrochemical Industrial Park. The new facility would help meet expected demand growth for chemical products in China. The multibillion-dollar project, which remains subject to a final investment decision, would include a 1.2 million-tons-per-year ethylene flexible feed steam cracker, two performance polyethylene lines and two differentiated performance polypropylene lines. ExxonMobil’s decision to proceed with the project will be based on a number of factors, including receipt of permits and project competitiveness. Startup is planned for 2023. “Our agreement with the Guangdong Provincial Government demonstrates ExxonMobil’s interest in advancing this project from concept to completion,” said John Verity, president of the ExxonMobil Chemical Company. “We value the government’s support and its experience in moving such a large-scale project forward.” The new complex would rely on advanced proprietary technologies in direct crude steam cracking and performance polymers manufacturing. It would support progress toward China’s national petrochemical development priorities, which include self-sufficiency, diversified feedstock sources, rebalancing fuels versus chemicals and advancing new competitive technology. The framework agreement also confirms Guangdong Province’s support in progressing the Huizhou LNG receiving terminal, in which ExxonMobil intends to participate, including supply of LNG. The company is also evaluating other chemicals manufacturing projects in Asia to help meet expected demand growth in the region. ExxonMobil expects to grow chemicals manufacturing capacity in Asia Pacific and North America by about 40 percent. That growth will be achieved in part by adding 13 new facilities, including two world-class steam crackers in the United States that are part of the company’s Growing the Gulf initiative. These investments would enable the company to meet increasing demand in Asia and other growing markets. The company recently commenced operations at its new 1.5 million tonper-year ethane cracker at the company’s integrated Baytown chemical and refining complex in Texas. ExxonMobil and SABIC have also created a new joint venture to advance development of the Gulf Coast Growth Ventures project, a 1.8 million tonne ethane cracker currently planned for construction in San Patricio County, Texas. The facility will also include a monoethylene glycol unit and two polyethylene units. ExxonMobil’s downstream and chemical businesses both have a presence in China, and the company operates primarily through its Shanghai-based ExxonMobil (China) Investment Co. Ltd. affiliate. The company is also a joint venture partner with Sinopec, Fujian Province and Saudi Aramco in China’s first integrated refining and petrochemical facility to include international participation. ExxonMobil is committed to social investment where it operates and supports programs that focus on the environment, health and education. Chemical Engineering World
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CEW Industry News Lanxess Increases production line for corrosion inhibiting additives
Specialty Chemicals Company LANXESS has commissioned a new production line at its Mannheim site for the synthesis of dimercaptothiadiazole (DMTD) derivatives. These chemicals are added to lubricants as multifunctional additives. The production line, which started in May 2018, doubles the annual production capacity of these specialty additives. The investment volume is in the single-digit-million-euro range. “With this investment, we have responded to the increased customer demand for these specialties. The new plant will enable us to meet their requirements for high-quality lubricant additives, but also helps us acquire new customers, and further develop our own package solutions for a rapidly growing market,” says Dr. Martin Säwe, Head of the Lubricant Additives business line in LANXESS’s Additives (ADD) business unit. DMTD derivatives are multifunctional additives, and are initially used as corrosion protection for lubricants in contact with steel alloys containing so-called nonferrous metals such as copper, nickel or cobalt. They prevent the leaching of nonferrous metal ions from the alloy, protect the metal surface from aggressive chemicals, and thus guarantee the integrity and longevity of steel alloys. Thanks to their metal-surface bond, they also act as lubricants, even when under extreme conditions and high pressures metal surfaces start contacting each other. Therefore, and in addition to their function – that is, to provide protection against corrosion, they are also referred to as extreme pressure additives. Last but not least, these additives interact with and absorb aggressive chemical breakdown products in the lubricant, which could otherwise cause material damage in the long term. The main areas of application for these versatile products are industrial oils, greases, and metalworking fluids. Under the Additin brand name, ADD supplies customers worldwide with DMTD derivatives, which are also used in additive packages at LANXESS. Due to a special manufacturing process used to reach the optimal composition, their performance is both excellent and consistent. Compared to competitor products, the additives stand out due to their stable quality and performance, a mild odor, and their bright, clear appearance. The products are manufactured exclusively at the site in Mannheim.
Clariant makes a step change into higher value specialties Clariant, a world leader in specialty chemicals, today announced an updated strategy and financial outlook as well as the signing of a Memorandum of Understanding with SABIC on a significant collaboration opportunity between the two companies in the area of high performance 16 • September 2018
materials. The Group intends to expand more strongly by focusing on customer-specific products and solution offerings with attractive growth prospects and above average value potential. Clariant, a world leader in specialty chemicals, today announced an updated strategy and financial outlook as well as the signing of a Memorandum of Understanding with SABIC on a significant collaboration opportunity between the two companies in the area of high performance materials. The Group intends to expand more strongly by focusing on customer-specific products and solution offerings with attractive growth prospects and above average value potential. By 2021, following the creation of High Performance Materials and the divestment of the remaining Plastics & Coatings Business Area, Clariant expects to deliver significantly higher sales of around CHF 9 billion and an EBITDA margin of approximately 20 % with an operating cash flow of more than CHF 1.2 billion. “The portfolio upgrade together with the continuation of Clariant’s strategy enables the Group to realize a significant step change into higher value specialties, which will allow the Group to considerably augment value creation for all our stakeholders”, said Hariolf Kottmann, CEO of Clariant. The intended combination of Clariant’s Additives and high value Masterbatches (color, high temperature resins and health care) and parts of SABIC’s Specialties business will create a uniquely positioned provider of highly customer-specific high performance materials and solutions under the name High Performance Materials. This new Business Area will offer a customer-specific, application know-how driven and competitively advantaged product range of highperformance thermoplastics for demanding thermo-electro-optical and mechanical environments, specialty additives and masterbatches in tandem with an outstanding global compounding platform. Major applications include smart electronics, health care, aerospace, automotive, robotics, additive manufacturing, renewable energy, and e-mobility. These applications demand the fulfillment of stringent customer specifications which require exclusive technology and formulation know-how. The combination of Clariant’s and SABIC’s offerings within Clariant is expected to result in significant synergies with an anticipated annual run-rate of CHF 100 million, realized over three years from closing. Implementation costs are estimated at CHF 80 million over the same time. The combination will be significantly EPS accretive in the first year. Clariant will have the majority stake in the intended business combination. Depending on the definitive valuation which is to be determined by both parties in the coming months, an equalization consideration will be made by Clariant to SABIC. In addition, Clariant announced that by 2020 it intends to divest the Pigments, standard Masterbatches and Medical Specialties businesses which will not be included in the newly formed Business Area High Performance Materials. This divestment decision underlines Clariant’s commitment to move the portfolio into higher specialty areas and to ensure best ownership for each of its businesses. Despite being well positioned and having significantly increased their profitability over the past years, the businesses to be divested do not match the Group’s criteria to differentiate through innovation in higher growth and higher profitability areas. By 2021, following the creation of High Performance Materials and the divestment of the remaining Plastics & Coatings Business Area, Clariant expects to deliver significantly higher sales of around CHF 9 billion and an EBITDA margin of approximately 20 % with an operating cash flow of more than CHF 1.2 billion. Chemical Engineering World
CEW Industry News Markus Regner takes over at the Karlsruhe facility The Romaco Group has just appointed Markus Regner (51) as new Managing Director of Romaco Pharmatechnik GmbH, the facility where Romaco’s Noack and Siebler brands are manufactured in Karlsruhe (Germany). Amongst other things, Mr. Regner will be responsible for sales, customer service, operations and engineering. He will work alongside Carsten Strenger, who will remain CFO/COO of Romaco Holding GmbH as well as joint Managing Director of Romaco Pharmatechnik GmbH. “Markus Regner is a true all-rounder with an inside knowledge of the industry”, emphasised Jörg Pieper, CEO Romaco Group. “We’re delighted that he has agreed to join the Romaco management. He has an impressive biography and is thoroughly familiar with the complex executive functions of a mid-market company – a leader who is very much in touch with the grass roots.” A graduate in Aerospace Engineering, Markus Regner began his career in the solar technology sector in the mid-nineties. He switched to the pharmaceutical packaging industry, which has remained his professional home to this day, at the turn of the millennium. He has held various executive positions with pharmaceutical technology groups over the past 20 years, most recently as Technical Manager at a supplier of customised machines for filling liquids. When asked about his reasons for moving to Romaco Pharmatechnik GmbH, Markus Regner replied as follows: “I believe Romaco has everything it takes to be very successful. Noack and Siebler have a particularly strong brand essence with a lot of potential still waiting to be tapped. My aim is to systematically strengthen this innovation capability and drive those technologies forward. It’s an exciting challenge and I’m looking forward to it immensely.”
TÜV SÜD inaugurates Non-destructive and Destructive testing laboratory in Noida TÜV SÜD, the German training, inspection, consultancy, testing and certification giant, today, announced the inauguration of the Non-destructive testing (NDT) and Destructive testing (DT) laboratory in Noida. The fully equipped state-of-the-art laboratory can help businesses prevent incidents that are hazardous to human life and environment and mitigate financial as well as reputational losses, through standard as well as customised NDT and DT services. TÜV SÜD’s specialists ensure products, material, manufacturing assets, components, equipment and systems continue to operate effectively and efficiently for a long time. The laboratory is fortified with world-class facilities to deliver reliable and accurate results that enable businesses to safeguard their operations and products. TÜV SÜD will cater to conventional and advance NDT needs with state-of-theart equipment and technical specialists conducting tests to ensure the sudden downtime and shutdown of the manufacturing plants and projects is reduced. TÜV SÜD provides testing in accordance with international standards such as UIC 960 (DIN 27201-7), EN ISO 9712 (superseding EN473), ISO 9712, PCN, SNT-TC- 1A, EN4179/NAS410 and API. NDT methods are implemented non-invasively and do not require the plant or process to shut down, thus being cost and time effective. Some of the testing services offered are: eddy current testing, advance ultrasound testing, long range ultrasound testing and corrosion testing to name a few. During inspection, the experts can also conduct a gap assessment and identify an organisation’s NDT training and certifications needs. TÜV 20 • September 2018
SÜD can offer trainings such as Level I & II training for conventional NDT techniques like RT, UT, MT, PT, VT & ET and Level I & II training for advance NDT techniques like PA/TOFD, LRUT, MFL, RMS and Tube inspection. Destructive Testing (DT), includes a host of invasive mechanical tests, metallurgical tests, corrosion tests and chemical tests that give deep insight and help determine the product integrity. The tests involve breaking down a product to its failure point and monitoring the performance closely through high-end equipment and software. The real-time assessment of strength, hardness, load bearing capacity, elemental and alloy composition state of the product can enable businesses to manufacture fail-proof products that are durable and comply with the existing quality standards like ASME, API, ASTM, ISO, NACE & BIS. The laboratory has the capability to carry out different types of hardness tests, tensile tests, weld tests, compression tests, impact tests, fracture toughness tests, fatigue tests, creep tests and many more. TÜV SÜD’s country wide network of offices and pan India presence assures a prompt collection of samples and quick transfer to the laboratory. Commenting on the inauguration, Niranjan Nadkarni, CEO, South Asia, South East Asia, Middle East & Africa Region, TÜV SÜD said: “Technological advancements and digitalisation have transformed the way consumers perceive and expect quality. Product integrity cannot be compromised, and businesses need to bolster their manufacturing processes through comprehensive testing to ensure that the end product embodies superior quality and safety standards. Our new Non-destructive testing (NDT) and Destructive testing (DT) laboratory will support businesses uphold organisational goodwill, brand credibility and inspire confidence among consumers. With an established international repute, we maintain a consistent level of premium TÜV SÜD quality in all our services to ensure the businesses that partner with us offer the same premium quality products to their consumers.” Sectors such as Chemical, Oil & Gas, PWS and Energy, Construction, Real Estate, Heavy Engineering, Rail, Infrastructure, Automotive, Marine, and Leisure & Entertainment can benefit from Non-Destructive testing services Destructive testing services cater to sectors such as Aerospace, Food, Health & Beauty, Telecommunications and Information Technology, Automotive & Transportation, Chemical, Oil and Gas, Manufacturing & Industrial Machinery, Infrastructure, Healthcare & Medical Devices, Heavy Engineering, Marine and Construction, Textiles & Real Estate
WACKER Starts Cystine Production in Spain WACKER BIOSOLUTIONS, the life sciences division of the WACKER Group, has begun producing fermentation-generated cystine at its new site in León, Spain. Over the past eighteen months, the division has extensively modernized part of the 800 m³ fermentation capacity acquired there at the end of 2016. In addition, it has built a production line for cystine. Capital spending for the site totals some € 30 million. In the next few months, the plants are to be gradually qualified and ramped up to full capacity. The new site enables WACKER to meet its customers’ rising global demand. Cystine and cysteine produced from cystine are used in the food and pharmaceutical industries. WACKER currently employs more than 40 people in León. “With our investment in the León site, we are well equipped to further strengthen our position as the global market and technology leader for fermentation-generated cystine,” said Dr. Gerhard Schmid, head of WACKER BIOSOLUTIONS, explaining the expansion measures. “The modernized fermentation plants and the new cystine production plant enable us to reliably meet our customers’ growing demand for cysteine and cystine, and to commercialize new fermentation-generated products. Chemical Engineering World
CEW Features
Energy Conservation through Proper Condensate Recovery Increasing fuel cost have led to increase in steam cost, which is an area of concern for the process industry. Most chemical plants have adopted energy savings measures to optimise their fuel consumption in boilers. Article offers recommendations to reduce energy bills through effective condensate evacuation and maximising Condensate Recovery Factor (CRF).
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team has been used as a working fluid or utility media throughout industry not only for mechanical power production (ie, driving steam turbines to produce electrical power) but also for many space heating and process applications. The advantage of using steam as the working fluid is due to the ease of distribution and control. Fuel prices across the world are on the rise which has resulted in an increase in steam cost and hence an area of concern for the process industry.
Most chemical plants have adopted energy savings measures to optimise their fuel consumption in boilers. This ensures the best steam cost in day to day operation of their steam boilers. In a typical process plant, the boiler generates steam to meet the steam demand of the process. Any optimisation in the steam utilisation leads to reduction in the steam generated. Thus, optimum steam utilisation for the process direct impacts the annual fuel bill. The chart below indicates the spiralling cost of solid fuel price used for steam generation in the span of 10 years - ` 2.8/kg to ` 6.2/kg (CAGR of 8.27 per cent, ahead of inflation in most years) For optimising the annual fuel bill it is recommended to focus on the following two broad categories: 1. Effective condensate evacuation by selecting the correct type of steam trap along with the essential accessories 22 • September 2018
6.2
2018
2.8
When steam transfers its heat to any process, it is the enthalpy of evaporation, which is transferred first, and the steam thus condenses back into water at the same temperature. Steam utilisation and condensate management, in a proper engineered way, plays a crucial role in bringing down operational costs. This directly impacts the revenue savings for the industry and thus become the need of the hour.
2008
• Rugged construction for least maintenance costs • Robust internals for delivering high up-time In the industry, very often the procurement of steam traps is based on the lowest cost and not on the overall cost of ownership. The total cost of the steam trap should include tangible incidental costs, such as piping cost, steam loss through the failed trap or the steam loss due to the bypass valve kept cracked open, reduced production output, loss of production due to frequent downtime. Taking such factors into consideration such as, reduction in the overall cost of installation, operation and maintenance is critical. 2. Benefits of Condensate Recovery
2. Maximising Condensate Recovery Factor (CRF), ratio of condensate recovered to the total steam generated 1. Proper Selection of Process Steam Trap – Effective Condensate Evacuation A fundamental step for ensuring optimum steam consumption for any process application is to ensure selection of right type of steam trap. Proper selection of steam trap must consider many factors; a few of them are listed below: • Quick plant start up with continuous venting of air and incondensable gases • No tolerance for loss of steam under all operating conditions • Efficient temperature control / steam consumption through effective condensate discharge • Self-draining to prevent damage from freezing during plant shutdown • No disruption of operation if the trap fails • “All-in-one design,” with a strainer, check valve and air vent
When steam heats the process liquid, around 75 per cent of its energy is transferred to process and steam condenses. Balance 25 per cent energy is held by the condensed water. The condensate is pure water, having almost zero TDS, which is ideal to be used as boiler feed water. Since it is at a higher temperature, less fuel will be required to produce steam. Every 6 Degree Celsius rise in feed water temperature saves 1 per cent on the fuel bill. In a nutshell, the advantages of condensate recovery would be 1. Elevated boiler feed water temperatures 2. DM quality water 3. Minimises the amount of chemicals required to treat boiler feed water 4. Minimises water usage that is critical in most geographical locations 5. Effective return can lower load on cooling tower, overall costs thus positively influencing profitability 6. Addresses environmental concerns, norms (Zero Liquid Discharge) In the chemical industry, one of the major concerns for condensate recovery is the fear of contamination. Chemical Engineering World
CEW Features
1. Multiple Effect Evaporator section (comprising of stripper, MEE and ATFD section) 2. Solvent Recovery Unit ( SRU) 3. Multi Utility Reactors ( MURs) The optimisation of above processes is mainly achieved with 1. Correct process temperature control – PID based instead of On-Off control valves 2. Optimised steam condensate evacuation systems (evacuation of condensate even under stall conditions) 3. Segregation and recovery of pure steam condensate from Multi Utility Reactors These solutions have been implemented at a major chemical plant in Vishakhapatnam, and results are close to ideal. Section-wise challenges and solutions MEE Challenge • Steam condensate evacuation issues from Agitated Thin Film Dryer (ATFD) due to group-trapping • Stripper condensate evacuation issue thereby requiring the bypass valves to be always kept cracked open (due to stalling) • Huge wastage of flash steam from this section Solution • To save the cost of additional steam traps and related installation and maintenance issues, a single steam trap is used to drain condensate from the multiple sections of the ATFD. This practice is commonly termed as “group trapping”. On the face of it, this sounds perfect as due to common pressure, chances of water logging are eliminated. In reality, no two coils or heat exchangers are identical. Even though the pressure at which steam is received by both heat exchangers is same, the heating loads will vary differently. As a result, the 24 • September 2018
Solvent Recovery Unit (SRU) Challenges • Solvent Recovery Unit condensate evacuation issue from the columns thereby requiring the bypass valves to be always kept cracked open (due to stalling) • Manual operation of steam inlet to the process always led to fluctuations of +/- 5oC in the column bottom and top temperatures also disturbing the reflux and recovery rate
• Recovery of pure condensate from MUR due to fear of contamination with cooling water. Solution • Recovering of pure condensate from reactors using heat optimisation segregation units and recovery of condensate through steam operated condensate recovery systems at elevated temperatures The chart below indicates the impact of the above recommendations on the overall condensate recovery factor for the plant. Average %
Best % 80
Case Study: Proper monitoring and control of process parameters in the following major areas of steam consumption in a chemical plant facilitates energy savings:
pressure difference will come in the picture and the section at low pressure will be unable to discharge. Along with this, the pressuredrop taking place across each of the heat exchangers will be different. Pressure drop taking place in a heat exchanger depends of a large number of parameters like: fouling factor, process temperature profile, ambient temperature ,etc. It is quite clear that all these parameters are beyond manual control and if group trapping is done, it will result in issues like water logging and damage to the equipment. Installation of correct size and type of individual process trap for draining condensate from each section of ATFD instead of group trapping. • “Stall” is the reduction or the cessation of condensate flow from the steam space, and occurs when the pressure in the steam space is equal to, or less than, the total backpressure acting on the steam trap. Stripper condensate evacuation was optimised by installing a process trap that can evacuate condensate even under negative differential pressure thus optimising removal of condensate. • Closed loop condensate management system such that the flash steam from ATFD is recovered in the Stripper and the condensate is then recovered at elevated temperature ( >100o Celsius).
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Modern day solutions help in recovering the effective heat from contaminated condensate, thus enabling optimised condensate recovery factor.
CONDENSATE RECOVERY FACTORS ( CRF)
Addressing the issues mentioned above led to a 18 per cent increase in condensate recovery and direct saving of 7 per cent in the annual fuel bill. The benefits of modern day energy conservation methods are now being realised, and slowly but surely replacing traditional methods in the chemical industry. This not only will help the plants attain their energy conservation goals and reduce their carbon footprint, but also contribute to a healthy bottom line that is crucial to stay ahead in a competitive market place.
Solution • Installation of adequately sized PIDbased temperature control valves with proper position indicator indicating the percentage of opening under varying load conditions. • Stripper condensate evacuation optimised by installing a process trap that can evacuate condensate even under negative differential pressure thus optimising removal of condensate. Multi Utility Reactors (MURs) Challenge
Author Details
Siddharth Jain Product Manager – Steam Systems Forbes Marshall E-mail: syjain@forbesmarshall.com Chemical Engineering World
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CEW Features Technical Article
Pollution Control Techniques in Refinery and Downstream Petrochemical Plants Pollution is a universal problem that intensifies with each passing day due to growing population and pollution of surface & ground water sources. Indiscriminate industrial development and exploitation of limited water sources are compelling every industry to seriously address this problem. Besides this, availability of water has become a serious issue. Therefore, industries are considering various options to reduce their water usage and to recycle water to the extent possible along with adopting manufacturing technologies that require less water, produce minimum waste water as well as other solid & liquid waste. Increasing cost of water and stringent regulations have helped make water recycle a viable option. This article deliberates on the topics of recycle, zero liquid discharge and solid waste management and explores their various technologies.
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revention is better than cure. This also applies to pollution. Prevention or minimisation of pollution at source is the best control method. Hence, before going into the methods of effluent treatment, we should look at the possibilities of preventing or minimising effluent generation. Pollution prevention is defined as the use of materials, processes or practices that reduce or eliminate the generation of pollutants or wastes at the source. Also known as reduction at source, pollution prevention includes practices that reduce the use of hazardous and non-hazardous materials, energy, water or other natural resources. Pollution prevention in the manufacturing industry can be achieved by changing production processes to reduce or eliminate the generation of waste at the source. As it applies to industry, the environmental management hierarchy stipulates that when possible:
• Pollution should be reduced at the source • Pollution products that cannot be reduced should be recycled in an environmentally safe manner • Disposal into the environment should
Raw Water
Water Treatment Plant
be used only as a last resort and should be conducted in an environmentally safe manner Recycle of Waste Water and Study of its Application in Various Industries Waste water recycle should take shape at the drawing board stage in contrast to the conventional treatment approach of designing the raw water and waste water treatment plants (end of pipe solutions) separately. This will enable planning for water recycle at the design stage itself. The benefits are many. Firstly, because water is recycled, raw water consumption reduces. The designer can therefore plan for a raw water treatment plant of lower capacity and cost. Secondly, the effluent treatment plant’s capacity is also reduced as we are treating the effluent which is not being recycled and hence the quantity of waste disposed is less, leading to further cost reduction. Investment is certainly required for product recovery, water recycle plants and advanced technologies to handle even higher concentrations of contaminants.
Treated Water
Process
Effluent
However, the life cycle and return on investment is quite attractive. Pollution is not just abated but prevented; pollutants are separated not destroyed; energy is saved and the total cost of water and waste water treatment is reduced. Hence, we can use this experience of on/ offsite recycle and integrated solutions for water and waste water treatment in large industries to achieve the goal of ‘Total Water Management’ at the design stage. We need to only apply these approaches in a complex industry in multiple ways. Guidelines for Selection of Recycle Scheme 1. Study the manufacturing process thoroughly and identify areas where reduction of water consumption is possible. 2. Identify the process where reduction of pollution load is possible by changing raw material or adopting cleaner manufacturing process. 3. Proper analysis of various streams especially targeting the contaminants which are process specific.
Effluent Treatment Plant
Discharge
Figure 1: Conventional Treatment
32 • September 2018
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CEW Features Reduction at Source
Product Recovery Recovered Product
Raw Water
Water Treatment Plant Recycled Water
Water Reuse
Treated Water
Process
Effluent
Zero Liquid Discharge Plant
No Liquid Discharge
Product Recovery Plant Partially Recovered Effluent
Waste Minimisation
Figure 2: Modern Integrated Solution
4. Identify streams that can be segregated and treated economically. For example, in electroplating, the rinsed water can be segregated and treated for recovery of plating metal. This not only reduces the overall cost of recycle but also facilitates the recovery of valuable products from the waste water stream. 5. Identify effluents which are relatively clean and can be treated with simple processes so that they can be recycled internally without letting the water out into an effluent treatment plant. 6. Identify the quality of water required at various manufacturing stages. For instance, steam generation may require high quality water and washing or cooling water make up may not require high quality water. It is always economical to design a recycle system to produce water suitable for lower end usage. 7. Select a technology that is easy to implement, operate, maintain & service. 8. Look for the availability of spare parts that may be needed in the future. 9. Reliability of performance in the long run is extremely important. 10. Low in operating cost. 11. Good service network of the plant supplier. 34 • September 2018
Recycle Technologies Any waste water recycling plant requires four stages of treatment as follows: 1. Effluent treatment 2. Tertiary treatment 3. Advanced tertiary treatment 4. Zero liquid discharge Effluent Treatment For a good effluent recycle system, a good effluent treatment is a pre-requisite. Unless we remove the easily removable pollutants with cost-effective methods, it would be difficult to recycle the effluents economically. Usually effluent treatment plants (ETPs) are designed to meet statutory requirements for disposal. When recycling is considered, the ETP should also be designed considering overall requirements of treatment. For example, in India, disposal standards do not require complete removal of nutrients and dissolved salts. But, when we are installing a downstream reverse osmosis system, it is better to remove nutrients and dissolved salts in the biological system of the ETP. This will help reduce fouling of the reverse osmosis system. There are different technologies available for effluent treatment to remove different pollutants. Table 1 lists some generic technologies applied in effluent treatment.
Tertiary Treatment Treatment beyond disposal norms for reusing effluents for low end usages is called tertiary treatment. It acts as pretreatment to advanced treatment for complete recycle of effluents. Table 2 enlists some generic technologies applied in tertiary treatment. Advanced Tertiary Treatment Further treatment of secondary treated effluents is required for conforming to the requirements of high end usages (boiler feed, process, etc.) of treated water. Table 3 enlists some of the technologies available to remove various pollutants in advanced treatment: There are various other technologies which are contaminant and end use specific such as fluoride removal. Zero Liquid Discharge Treatment (Evaporation and recovery of waste water containing highly soluble salts) The highly concentrated reject from the process is further treated in multi effect evaporator (MEE) system generally after reducing dissolved salts by RO processes and the advanced tertiary treatment. Chemical Engineering World
CEW Features Table 1 Effluent Treatment Technologies (Primary and Secondary) Pollutant
Treatment Technology
Floating matter
Manual bar screens, mechanically cleaned screens, drum screens, etc.
Grit
Manual grit chambers, aerated grit chambers, deaerator, etc.
Oil & grease
Oil & grease traps, API oil separators, TPI oil separators, dissolved air floatation (DAF) systems, tubular ultra filtration, etc.
Acidity/alkalinity
Neutralisation using acid/alkali dosing
Suspended solids
Clarifiers, clariflocculators, high rate solid contact clarifiers (HRSCC), lamella clarifiers, tube settlers, DAF, ultra high rate clarifiers, pulsating clarifiers, etc.
BOD/COD/NH 4/TKN/TP/Phenol/CN/SCN
Biological systems such as activated sludge process, trickling filters, sequential batch reactors (SBRs), membrane bio-reactors (MBRs), etc.
Heavy metals
Precipitation using solid contact clarifiers, ion exchange processes, membrane systems for metal recovery, etc.
Toxic substances
Different treatment technologies are adopted based on the nature and concentration of toxic substances. For example, phenols can be removed with biological systems at low concentrations whereas chemical oxidation may be required for higher concentrations.
Recalcitrant compounds/COD
Photo-chemical oxidation is used to remove or break recalcitrant and complex organics such as phenols, benzene, pesticides, etc.
Table 2 Tertiary Treatment Technologies Pollutant
Treatment Technology
Turbidity
Gravity sand filters, pressure sand filters, dual media filters, multi media filters, continuous sand filters, auto valve-less filters, etc.
Bacteria
Chlorine dioxide, chlorination, ozonation, ultraviolet sterilisation, mixed oxidant systems, etc.
Colour
Oxidation, precipitation, adsorption, nanofiltration, etc.
Residual chlorine Activated carbon filtration, dosing of reducing agents, ultraviolet treatment, etc. Table 3 Advanced Tertiary Treatment Pollutant
Treatment Technology
Hardness
Chemical precipitation, ion exchange softeners, nanofiltration, etc.
Silica
Chemical precipitation, ion exchange processes, reverse osmosis, etc.
Turbidity, SDI
Sand or multimedia filtration, ultra filtration, microfiltration, etc.
Dissolved solids
Reverse osmosis systems, ion exchange processes, electrodialysis, etc.
The MEE process uses either mechanical or thermal vapour compression using forced circulation evaporators, falling film evaporators or in combination. Thus, evaporation is increasingly considered for the treatment of refinery and downstream petrochemical waste water to recover 36 • September 2018
more than 95% of water, or as a part of the zero liquid discharge (ZLD) process. Water Management in Refinery - Case Studies 1. Reliance Industries Limited Reliance Industries Limited (RIL) has
enhanced the capacity of the Jamnagar Refinery to 12,00,000 barrels per stream per day (1200 K BPSD) with the commissioning of the Jamnagar Export Refinery Project (JERP) in Gujarat. Waste water treatment is carried out in a dedicated state-of-the-art completely automated and PLC – operated effluent treatment plant supplied by Ion Exchange. The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/fire water, with the objective of zero discharge from the new refinery complex. The treated water is recycled back as cooling tower make-up and partially used as process water after reverse osmosis treatment to the high total dissolved solids treatment train or guard tanks, as required. Effluents are segregated into four identical waste water streams designed for a treatment capacity of 500 m 3/h each and maximisation of reuse. The scope of treatment also includes three by-product streams generated during the treatment of refinery waste water (skimmed or slop oils, oily sludge and biological sludge). Skimmed oil Chemical Engineering World
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CEW Features
Effluent Treatment Plant at Reliance Industries Ltd., Jamnagar, Gujarat
is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing. Each of the above streams employs identical equipment for treating effluents, namely:
project, a new effluent treatment plant (ETP-III) treats effluents generated from the refinery project to meet the MINAS standard. With a view to conserving water, a new zero discharge plant (ZDP) was designed and constructed by Ion Exchange. This plant treats the treated water from ETP-III to enable use of the treated water as make - up to the demineralisation plant. The capacity of the ZDP is 200 m 3/h. The plant was commissioned in 2005 and is operated and maintained by Ion Exchange. 3. Indian Synthetic Rubber Limited Another such example of ZLD is for Indian Synthetic Rubber Limited (ISRL). Three streams containing 3000 m 3/d process effluent along with
requirements from buyers in case of exporters, etc. ZLD also gives enormous importance to sludge management (which is not discussed in this paper and which needs separate attention). Apart from these reasons, industries now identify recycle and ZLD as their social responsibility for environmental friendly manufacturing of goods. Many technologies are now available for managing industrial waste water and other waste. It is of utmost importance to involve environment management specialists right from the planning stage of the project so that the best optimum solutions can be developed. Priority should always be given to source reduction and product recovery rather than end of pipe waste water treatment
• Free oil removal facilities including pre-deoiler and API separators with continuous oil skimming and sludge removal facilities • Dissolved air Flotation (DAF) unit • Two stage biological treatment • Clarification • Dual media filtration • Activated carbon adsorption • Disinfection – with chlorine and chlorine dioxide The effluent treatment plant is treating 100 per cent effluent generated by the refinery since its commissioning in December 2008 and consistently produces treated effluent (pH 6 - 8.5, sulphide < 0.5 ppm, COD < 50 ppm, oil and grease < 5 ppm, phenol < 0.35 ppm) meeting guaranteed parameters for reuse for various applications mentioned earlier. 2. Chennai Petroleum Corporation Limited The ZLD plant for the expansion at Chennai Petroleum Corporation Limited (CPCL) uses advanced membrane processes to reuse water for its process requirement. CPCL, during its expansion, increased the crude refining capacity at Manali by 3 million metric tonnes per annum. As part of this 3 MMTA expansion 38 • September 2018
ISRL- Downsteam Petrochemical
360 m 3/d cooling tower blow down and 240 m 3/d DM plant effluent are being treated through primary, secondary, tertiary and advanced tertiary treatments. The final reject (from RO) is being treated in thermal MEE, thereby achieving the objective of > 95 per cent water recovery and ZLD.
and expensive methods of ZLD. Right technologies should be adopted for recovery and recycle of water from waste water. Final effluents which cannot be recycled should be treated and disposed of in an environmental friendly way.
Conclusion Waste water recycle and ZLD is mandatory for many industries because of water scarcity, legislation, rising water costs, unreliable water supplies, environmental
Ajay Popat President – Technology, Corporate Marketing and Corporate Diversification Ion Exchange (India) Limited
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CEW Features Technical Article
Challenges in Setting Up ETP For Refineries Petroleum refining is a complex operation and unit operations within refineries vary depending on the type of crude and the type of end products. Refining is a water intensive operation which generates large quantity of waste water that needs to be treated so as to avoid environmental degradation. A proper understanding of the unit operations as well as pollutant loads is necessary in order to set up a suitable Effluent Treatment Plant (ETP). This article discusses about various challenges that we have faced in the designing and operating of several Refinery ETPs in India.
C
haracterisation Of Waste Water In order to design an ETP for an upcoming refinery, design parameters like the flow rate, Biological Oxygen Demand (BOD), Chemical Oxygen Demand (COD), Suspended Solids (SS), Oil & Grease (O&G), Sulfides, Phenols, Ammonia etc., have to be assumed. The selection of the scheme and the estimation of unit sizes depend on the inlet characteristics and hence it is imperative that the assumed design parameters be as close to the actual parameters that will be encountered once the plant is commissioned. It is quite normal to assume higher values while designing the plants. However, one should keep in mind that some processes do not perform efficiently when they are over designed.
separator followed by a Dissolved Air Flotation (DAF) or Induced Air Flotation (IAF) unit. • Flow Equalisation: Flow of wastewater generated from refinery from various manufacturing process units is not uniform. The flow variation is equalised by providing an equalisation tank of sufficient capacity and constant flow is maintained in all downstream treatment units. This makes the process control much easier. • Removal of Suspended Solids: This is achieved using a clarifier or it can be combined with O&G removal in a DAF unit
Typical Treatment Scheme The treatment philosophy adopted to treat refinery waste waters consists of a series of steps to sequentially remove the pollutants so that the treated wastewater meets the required regulatory norms. The typical treatment steps are:
• Removal of Sulphides: Lower sulphide concentration can be handled in biological treatment system. However, high concentrations of sulphides need to be taken care before wastewater enters into biological treatment system. Oxidation of sulphides using Hydrogen Peroxide is most popular method of oxidising them.
• Removal of O&G: This is necessary as downstream operations are sensitive to the presence of high levels of O&G. In a refinery wastewater treatment system, two steps of oil removal are typically required to achieve the necessary removal of free oil from the collected wastewater prior to feeding it to a biological system. This oil removal is achieved by using an American Petroleum Institute (API) or Tilted Plate Interceptor (TPI) or equivalent oil water
Various • Biological Treatment: biological systems have been adopted including Activated Sludge Process, Bio-tower, Sequential Batch Reactor, Anaerobic reactors, Membrane Bioreactors etc. Every process has its own inherent advantages and disadvantages and a suitable system has to be selected by the designer based on factors such as organic load, treatment efficiency required, land area available etc.
40 • September 2018
• Polishing of Treated Waste Water This step includes units like Pressure Sand Filters (PSF), Dual Media Filters (DMF), Activated Carbon Filter (ACF) to remove the residual suspended solids as well organic pollutants that have passed through the earlier treatment steps. • Reuse and Recycle : As the refinery consumes a large quantities of water, it is imperative one must try and reuse the treated waste waters back in the process. Additional treatment units like Microfiltration, Ultrafiltration or Reverse Osmosis may be adopted in order to meet the reuse water quality that is required Challenges and Solutions in Biological Treatment of Refinery Wastewater The key treatment step in the refinery ETP is the biological treatment as the bulk of the pollutants are removed in a cost effective manner in this step. Hence it is important to design this system in a robust manner so that it can operate efficiently. It is important to note that in the biological treatment step, the pollutants are degraded by microorganisms and it is imperative that a conducive environment is maintained such that the microorganisms can operate up to their maximum potential. A list of various factors that influence the design and operation of the biological system are given below: • Fluctuation of Wastewater Characteristics: One of the main challenges in refinery wastewater treatment is its variation in characteristics. As mentioned earlier, when assuming the Chemical Engineering World
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CEW Features in a biological system of a refinery is shown here (Figure 1).
Figure1: Foam in refinery
Figure2: Typical Refinery ETP
pollutant load for design of the ETP, it is normal to assume higher values so that the designs are ‘safe’. This causes problems during the operation of the ETP when the actual pollutant load is much lower. Also, based on variations in quality of crude and refining process, wastewater quality also varies. The biological system should be selected to take care of these variations. The biological system should be able to vary process parameters such as air supply, Mixed Liquor Suspended Solids (MLSS), Food to Microorganism (F/M) ratio, etc., to suit variations in feed. Modular design of biological process also helps in handling variations of wastewater quality. If provided with multiple process tanks, plant can be operated based on the actual pollution load by using all process tanks or part of them. • Oil & Grease: The performance of the O&G removal equipment is sometimes upset due to a surge in the inlet O&G quantity due to dumping of oil within the refinery. This causes O&G to slip into the biological system affecting the microorganisms. This also causes foaming in the aeration tanks that affects the quality of the treated water. A figure showing the foaming 42 • September 2018
• Sulphides: Refinery wastewaters contain high levels of Sulphides that are toxic to microbes and hence have to be removed prior to the biological treatment. In case sulphides slip into the biological system, it exerts demand on the aeration system since it consumes the oxygen that is meant for the respiration of the microorganisms. Hence it is normal to consider a safety margin in the design of the air blowers so that it can meet any contingency due to sudden air demand because of sulphides. Care should be taken that sulphide concentration in biological system are below toxic limits. • Complex Organic Compounds and Heavy Metals: Complex organic compounds such as phenols, benzene products, etc. are also part of refinery wastewater. Their concentrations depend on the source and quality of crude oil. These compounds are not easily biodegradable and may be toxic to biological system at higher concentrations. Hence, the ETP should be designed to handle these complex organics in case they are present in wastewater. Heavy metals also pose problem to biological treatment. Both complex organics and heavy metals should be taken care in pretreatment if present in higher concentrations. • Nutrients: The growth and performance of the microorganisms depend on the availability of critical nutrients like nitrogen and phosphorous in the waste water. Ideally, a BOD:N:P ratio of 100:5:1 is required for best performance. Normally abundant nitrogen is present in the refinery wastewater. However, it is important to constantly analyse the wastewater and add nitrogen (typically as Urea) and phosphorous (as Phosphoric acid or Di Ammonium Phosphate) to make up for any deficit. Many a times, total nitrogen levels in the wastewater are much more than required which necessitates treatment to reduce them. Hence, the biological system selected should be able to remove excess nitrogen along with organic pollutants.
• Energy efficiency: The oxygen required for the microorganisms are delivered through fine bubble diffusers that release small bubbles of air from the bottom of the aeration basins. Air blowers are installed to supply air into biological process. Air blowers constitute major portion of power consumption in the ETP. Any steps taken to optimise energy consumption shall result in energy efficiency of the plant. Biological process should be provided with oxygen control system to supply air as per the organic pollution load coming into it. Dissolved Oxygen (DO) or Oxygen Uptake Rate (OUR) based blower control optimizes both energy consumption and process performance. Energy efficient blowers further improve the energy efficiency of the ETP. • Process Automation: Due to variations in wastewater characteristics, it is advisable to install process automation to control vital process parameters such as DO, OUR, MLSS, Sludge recirculation, Sludge wasting, etc. This helps in automatically keeping the process parameters at their optimum levels and generates consistent quality of treated wastewater. Conclusion Refinery wastewater characterisation is very complex exercise that requires an understanding about the refining processes involved. The designing of the ETP is a challenging job as treatment units have to be robust enough to handle continuous variations in the concentration of pollutants. The operation of the biological system governs the performance of the ETP, as it removes the bulk of the pollutants. Ideal operating conditions have to be provided for the microorganisms in order to ensure effective treatment. The biological system should be selected to handle any variations in flow and characteristics of refinery wastewater.
Author’s Details Satya Narayana Y V V SFC Environmental Technologies Pvt Ltd satya@ctechsbr.com Chemical Engineering World
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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 44 • September 2018
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
Features CEW 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 Chemical Engineering World
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 September 2018 • 45
CEW Features 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. 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. 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
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.
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Fei Wu Regional Marketing Manager- RO/NF Dow Water & Process Solutions
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Stricter monitoring requirements for combustion emissions
T
he new monitoring requirements being imposed on Medium Combustion Plants (MCPs) and Large Combustion Plants (LCPs) in Europe is symptomatic of environmental initiatives affecting a wide variety of industries. In the following article, Dr Andrew Dixon from Gasmet Technologies UK (formerly Quantitech) explains how instrumentation manufacturers are responding to these new challenges. The combustion of fuel and waste produces a wide variety of pollutants and greenhouse gases, so regulators around the world are increasingly imposing stricter emissions limits and monitoring requirements as part of initiatives to improve air quality and fight climate change. Generally, emission limit values are being lowered, the number of parameters being monitored is increasing, and the requirement for continuous monitoring is growing. The growing number of parameters that have to be monitored means that operators have to employ multi-parameter technologies such as FTIR, or purchase a number of analysers to meet the requirements. For this reason, Gasmet UK has developed an integrated systems capability, so that it is now able to design and build complete MCERTS approved monitoring systems, designed to meet plants’ individual requirements. However, one of the pollutants of major concern, mercury, necessitates a specific monitoring technology, and since the emissions limits are so low, it is necessary for this technology to have performance certification at these levels. In Europe, member states have the opportunity to set specific limits and monitoring requirements that fit within the framework established by the Industrial Emissions Directive (IED). So, individual states may set stricter limits, or individual plants may implement more rigorous monitoring and abatement technology in order to demonstrate good environmental performance. In most cases, this is undertaken: as part of a corporate responsibility strategy; in response to demands from stakeholders, or in anticipation of tighter future regulatory requirements.
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Mercury is considered by the World Health Organisation to be one of the top ten chemicals of major public health concern, so there are global initiatives to lower the emissions of this toxic element in its various compounds – particularly from power plants, waste combustion and cement plants. In November 2015 the European Parliament signed a new directive that imposes emission limits on MCPs. Under the directive, an MCP is any equipment that burns fuel, with very few exceptions, and where the rated thermal input is between 1 and 50 MW. Diesel or gas engine generators rated above 400 kVA are also applicable, in addition to any appliance that uses fuel to generate heat or electricity. Boilers, generators and other mobile plants rated above 1 MW thermal input are also included. By regulating emissions to air of SO2, NOx and dust, the MCP directive aims to reduce air pollution and lower risks to human health and the environment. It has been estimated that the MCP directive will apply to over 30,000 plants in England and Wales. The controls will apply to GasmetCMM Continuous Mercury Monitor new plants from December 2018, and to a combustion plant. This includes the existing plants from 2024 or 2029. gasification of coal and other fuels, and the waste co-incineration plants for nonNew environmental standards for LCPs hazardous waste (>3 tonnes/hour) or for strengthen the requirements of the IED for hazardous waste (10 tonnes/day). both reduction and monitoring requirements. The new specifications stem from a review Continuous monitoring is required: for of the Best Available Techniques (BAT) ammonia where NOx reduction by ammonia Reference Document for LCPs, the so- is employed; for mercury on plants ≥ 300 called LCP BREF. This includes new BAT- MWth, when coal and/or lignite is used, associated emission levels (BAT-AELs) including waste co-incineration; and for and sets new monitoring requirements for hydrogen chloride when solid biomass sulphur dioxide, nitrogen oxides, mercury, and/or peat is used in LCPs or waste coand particulate matter. The BAT conclusion incineration plants. was published in August 2017, and will come The BAT-AELs for mercury emissions to air into effect with a four year transition period. from coal and lignite burning power plants The LCP BREF applies to combustion plants are extremely low. For example, a new th with a total rated thermal input exceeding coal-fired power plant with ≥ 300 MW has 3 50 MW. However, it also applies to smaller a BAT-AEL of <1-2 μg/Nm mercury (yearly units where they are directly related to average), and an existing lignite-fired power September 2018 • 47
CEW News Features station with a thermal input under 300 MW has a BAT-AEL of <1-10 μg/Nm3 mercury. It is interesting to note that the draft waste incineration BREF (WI BREF) also requires continuous mercury monitoring and currently stipulates a daily average of 5-20 μg/Nm3 mercury emissions to air for new plants and 5-25 μg/Nm3 for existing plants. In the BREF guidance for cement kilns (CLM BREF), mercury has a BAT-associated emission level of 50 µg/ Nm3 for the half-hour average. However, in countries such as Germany, stricter emission limits have been adopted. In some circumstances continuous mercury monitoring will be specified in the regulations, but in others, non-continuous methods may be allowed. This latter option may have a lower purchase cost, but it merely provides an average of a plant’s emissions over a certain time and therefore may not be considered the most effective way to protect the environment, because continuous monitoring provides a complete
picture of a plant’s emissions. This helps to identify the source of pollution peaks, and to inform mitigation and abatement strategy. In addition, as emissions monitoring and control regulations become more stringent, continuous monitoring may become obligatory at a later date, for some types of plant. Monitoring equipment must be MCERTS certified to perform within the requirements of a permit, which is why the possibility of continuous monitoring should be considered, and both current and future requirements for certified monitoring ranges and levels of uncertainty should be addressed. For these reasons, the recent certification of Gasmet’s Continuous Mercury Monitor (CMM) is of particular significance. The Gasmet CMM has successfully completed EN15267-3 testing using CVAF (Cold Vapour Atomic Fluorescence). Importantly, this instrument now provides the world’s lowest EN15267 certified range for measurements of Mercury. The CMM is certified for operation across a
number of different ranges up to 1000 µg/ m3, but considering the latest regulatory requirements, the CMM’s certified range of 0 to 5 µg/m3 will be of particular relevance to the operators of combustion processes. In summary, when defining a monitoring strategy it is vitally important to take future requirements into account (from both regulators and stakeholders) when choosing appropriately certified technology. In addition, for new plants, monitoring requirements should be assimilated into the plant design at an early stage. Expert advice should be sought to ensure that the right equipment is specified in order to optimise the installation, ensure compliance and future-proof monitoring activities.
Can India replicate Middle East’s Desalination Success Story
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ater is an essential ingredient in across industries, not just in the products but also in the preparation for cleaning the products, processing and other uses. While 71% of the earth’s surface is covered with water, only a tiny amount (0.6%) is fit for consumption. The supply of clean and fresh water is fast decreasing. In contrast, the demand for consumption of water is fast increasing due to a growing global population, agricultural activities and economic development. Pressures from both, the supply and demand sides means that clean water is increasingly becoming hard to source. While the future outlook for India’s capability to meet the growing demand seems to be grim, India can perhaps turn to their neighbours in the middle east to replicate their desalination model. In the last two decades, desalination plants have evolved rapidly to extract fresh water from the sea. At present, nearly 150 countries 48 • September 2018
rely on desalination plants to meet their fresh water requirements. The Middle East and North Africa (MENA) region accounts for nearly half the world’s desalination capacity, according to World Bank calculations, making it the largest desalination market in the world. According to Global Water Intelligence, the world’s desalination market is projected to reach $7 billion by 2022, with the Middle East and North Africa region to account for $4.3 billion. Middle East’s desalination success story Typically, in the desalination process, the source water (either sea or polluted water) is distilled using either thermal or electrical energy. This process removes salts (fluorides, chlorides, sulphates, etc.) which are found dissolved in water, thereby rendering the source water fit for consumption (called distillate). However, this process has one major drawback — it consumes a large amount of energy, which is traditionally derived from
fossil fuels. Considering the fact that India is steering itself towards fossil-free energy generation, it would be practical to combine the shift towards renewable energy with desalination technique. Set up over a decade ago by the Arabian Construction Company, the Shuweihat S1 Independent Power and Desalination Plant in Abu Dhabi, UAE, is currently one of the world’s largest combined power and water plant complexes, delivering 1500 MW of power to the emirate of Abu Dhabi. The plant is linked to a seawater desalination facility which is supplied with steam from the turbines. Similarly, in Oman, the desalination market in the country has been expanding by a little over 5 percent per year thanks to rapid urbanization and population growth. South Korea’s Doosan Heavy Industries & Construction Co. will take part in a $203.9 million desalination project in Oman, the latest in its series as the world’s biggest Chemical Engineering World
News Features CEW desalination plant builder. The new desalination plant will be built in Sharqiyah region, 220 kilometers South East of Oman’s capital, Muscat. The plant will be designed to use reverse osmosis method and will be able to supply 80,000 tonns of fresh water, enough to meet the water demand of 200,000 people a day. Why desalination is relevant in India Potable water is scarce in India and has become one of the major challenges for the country today. According to a recent report by the National Institution for Transforming India, a policy think tank, about 200,000 Indians die each year due to inadequate access to potable water, with 600 million facing what is termed ‘extreme water stress.’ Furthermore, studies suggests that by 2030, the water demand in India will double. This would result in severe water shortages for millions of people. India holds just 4 percent of the global freshwater, despite having nearly 16 percent of the world’s total population. The ability to use seawater that most coastal states have access to is perhaps the most prudent solution. Combining renewable energy based technologies to power desalination plants will ensure that the production of pure water is non-polluting. The benefit of this scheme would be two-fold. Firstly, clean drinking water would be produced to alleviate water stress. Secondly, the use of renewable energy based plants will help abate the effects of climate change. Current industry overview and steps taken by the Government of India The most popular desalination technologies include Multi Effect Distillation (MED), Multi Stage Flash (MSF) and Reverse Osmosis. MED and MSF techniques are heat based while reverse osmosis is a pressure based technology using a membrane, similar to a filter paper, to separate salts from the raw water. Over 70% of the thermal desalination plants have already shifted over to reverse osmosis technology globally. While looking forward, Adsorption Desalination (AD) is being researched and developed as one of the most energy efficient processes. These can be powered by multiple renewable energy based power systems. The final combination of desalination technologies and their renewable energy Chemical Engineering World
based power systems depends on factors such as source water availability, environmental constraints, location, distillation capacity and cost of desalination. However, cost and capacity are usually the key considerations. The government is already working on implementing a desalination policy. At present, India has three operating desalination plants on the Lakshadweep islands. The country’s topmost think-tank NITI Aayog has been planning similar plants across the country. Proposals for desalination plants at Tuticorin, Paradip and Kandla are also already under consideration. However, not everyone is in favour of desalination. Effluent waste management from desalination plants including brine concentrate and other effluents pose huge concerns globally. Despite advancements made towards ‘zero liquid discharge’ technologies, where the brine concentrate is converted into solids fit to be disposed at landfills, the costs at present remain steep and must be taken into consideration to avoid any serious ecological complications which have occurred in the past due to poor planning. Call to action Ensuring access to safe water for the masses is the need of the hour. This essential resource is both limited and steps for course correction are still at a nascent stage. Freshwater sources are drying up quicker than the rate at which they are being replenished. Getting the desalination policy right would definitely be a shot in the arm for India’s long-term strategy to mitigate water stress and solve the country’s water problems. AVA Chemicals offers a wide range of chemicals for the water treatment industry. The broad range of water treatment chemicals includes HEDP 60%, ATMP, DETPMP, PBTC, BKC, etc. Most of these products are used in manufacturing of formulation / ready to use products for the water treatment industry. Our products find application in specifically formulated products for treatment of boilers, cooling towers and cooling water systems, wastewater and industrial effluents, etc. AVA Chemicals has been catering to many large companies in this sector. It also provides its facilities for 3rd party contract manufacturing.
AVA Chemicals is open to JVs and partnerships in the segment. REFERENCES https://edition.cnn.com/2018/07/11/middleeast/ middle-east-water/index.html https://www.utilities-me.com/power/11628doosan-heavy-to-take-part-inoman%E2%80%99s-200mn-desalination-project https://www.accsal.com/projects/shuweihat-s1independent-power-and-desalination-plant/ https://www.utilities-me.com/power/11628doosan-heavy-to-take-part-inoman%E2%80%99s-200mn-desalinationproject https://www.hindustantimes.com/health/indiaset-to-launch-national-mission-on-desalination/ story-G5pOUgNwEY8RlwjvlOfmLL.html https://www.dw.com/en/indias-waterman-keeping-liquids-flowing-despitecrisis/a-45073472 https://sputniknews.com/ asia/201711151059127465-india-drinking-water/ https://timesofindia.indiatimes.com/india/ gadkari-says-no-water-shortage-in-indiabut-calls-for-better-resource-management/ articleshow/64590628.cms https://yourstory.com/2017/06/potable-sea-water/ http://www.avachemicals.net/water-treatmentchemicals.html
Compiled by AVA Chemicals E-mail: relations@avachemicals.com September 2018 • 49
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Market Insight
Energy Efficient Compressors for Cost Reduction Conrad Latham, General Manager, Compressor Technique, Atlas Copco (India) Ltd shares insights into the company’s growth strategy in India and innovations for improving overall efficiencies and cost reductions for customers.
T
he growth strategy for Atlas Copco compressors in India is to provide our customers with the most suitable solution depending on their needs. Customers are foremost focused on a compressed air system that is reliable. In order to produce their products they need compressed air. Atlas Copco compressors provide this reliability as standard and over the years manufacturing has demanded more in terms of energy efficiency. This is the driving business strategy for Atlas Copco and it is what shapes the decisions for product and service developments. “In today’s India market the key to success is understanding the needs of the customer and then being able to adapt your offering to meet this need. For this close interaction with the customer is required and this remains our focus as we develop our sales and service channels,” says Latham. Talking about the growth growth strategy f o r A t l a s C o p c o ’s A i r C o m p r e s s o r business, Latham expresses that the company is replicating the global model for the customers in the Indian market. Competitiveness of customers is often driven by the ability to reduce costs and increase productivity. He observes that specifically the energy cost for compressed air forms a large portion of the energy bills for their customers. Knowing that, the constant push to reduce energy costs through developing innovative solutions drives the global products and solutions. Even a small percentage if reduction in energy costs can result in significant reduction in energy costs for the customers. Market size data is difficult to assess both globally and for India as there is no single, independent reporting process. However,
50 • September 2018
the best estimates that Atlas Copco has for the global size of screw air compressors is somewhere between 200,000 – 250,000. For India, Latham says that it is estimated at approximately 10 per cent of global market. The competition in the Indian market can be clearly divided between the organized and the unorganized compressor suppliers. The organized competitors are those companies that have a diverse product portfolio and a structured sales channel of direct sales and indirect sales (dealers). They are constantly developing their products and some are even having multiple service solutions like Atlas Copco. The organized players are well dispersed with sales and service people across India. The unorganized players are companies that are either importing compression elements and then mounting locally a drive system and selling in a local area. Often such companies struggle to develop the product and to provide service beyond the local region. “For us, India is an extremely exciting market due to the present and expected growth in manufacturing. The focus to make manufacturing a larger portion of the GDP and the Make In India initiative is beginning to see companies investing,” states Latham. He shares that compressor technology under goes regular innovation and the drive to reduce the energy bills of our customers is the main force behind a lot of the innovation. Some of the big changes are the move from fixed speed compressors to variable speed compressors, that use only as much energy as required from the varying demand of the customers application. Recent changes have seen new designs in the compression process of the oil-free screw
compressors. Atlas Copco has invested a lot of money in Computational Fluid Dynamics calculations to truly understand the detailed flow patterns of air as it moves through a compressor and has used it years of experience, test data and production statistics to highly refine the air and cooling medium channels in a compressor to drastically reduce pressure drops thereby improving the energy efficiency of the compressors it develops. A lot of innovation is taking place with Industry 4.0 and Atlas Copco has developed its Smartlink system, where it connects the compressors and dryers to a centralized data warehouse. From here it can provide a huge amount of running data to improve uptime reliability for its customers as well as energy optimization solutions. The latest central compressed air room controller, Optimizer 4.0, is a great development in innovation, again driven by the desire to reduce customers energy usage. This unique controller can centrally optimize multiple compressors and dryers of different technologies as well as different compressor manufacturers. It is not only in compressors and software t h a t d eve l o p m e n t s a r e t a k i n g p l a c e. Compressed air dryers are also a great area of energy saving and recently Atlas Copco launched the world’s first rotary drum dryer that guarantees -40 o Celsius pressure dewpoint. This is a compressed air dryer that uses almost no electricity to provide compressed air at a very high quality. Normally such systems would cost customers more than ` 11lakhs in electricity per year, and now we can provide a solution that is almost free to operate, which is real innovation. Chemical Engineering World
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CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966
VOL.52 ISSUE 12
One of the major challenges remains similar to many traditional engineering industries is to right level of graduating students. A lot of investment in promotional activities to attract the right level of engineers is required and then a lot of training is required to develop them to the expected level. Atlas Copco has a strong brand reputation and we continuously invest in training and still see the need to work closer with many institutes to find the right talent and that which is able to deliver the expected work class solutions that our customers demand. Worldwide, Atlas Copco is using ‘CHEMWATCH’ -The Group chemical handling management system where safety data sheets for all the chemicals used and sold can be found. Safety data sheets in the local languages are available to employees for all chemical products, such as oils, greases and lubricants.
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In the last year Atlas Copco has seen a very positive trend in the growth of products sold to the Chemical Industry in India. There are a couple of reason for this growth. First is investment is coming to update existing production facilities to be more productive. We have seen investment in not only the compressor and blower equipment but also in the updating of the compressed air pipe network to reduce leakages and pressure drops which saves a lot of in running costs. The second is in the development of new plants. Here companies are expanding to cater for the growing demand and are choosing energy efficient solutions.
Recently Atlas Copco launched a series of new products from its Oil-free Air Division. These included it’s next generation of screw blowers which are able to deliver energy savings up to 35 per cent for applications like fermentation and waste water treatment. Also, the new oil-injected screw compressor which as well as bringing market leading energy efficiency also reduces the service time by 50 per cent. This provides customers with a higher uptime. The latest extension of the oil-free turbo ZH range was also launched and now the standard centrifugal compressor is available up to 3.1 MW. This is a great product for the chemical industry where more and more standardization is being seen globally. Drive for efficiency and lower delivery times are the main focus for customers. A new heat of compression rotary drum dryer that can guarantee a pressure dewpoint of -40 o C elsiushas been launched as well. This is a unique product in the market and no other company has the capability to do this. It means that the normally high energy costs of twin tower desiccant dryers can be almost eradicated. To top the new products, we have also launched an extremely innovative oil-free screw compressor which will cut energy costs by 10 per cent. The new ZR90160+ VSD range is using all the years of proven experience we have in oil-free screw technology and combining it with cutting edge technology to further improve reliability and energy efficiency.
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Indian market is highly price sensitive as compared to other global markets, which all the international players are very much aware of. They understand that to be competitive in India, they need to provide products that represent their brand promise of quality and reliability at prices acceptable in the market. There are companies that are willing to pay for the value of options that are normally associated with improved energy efficiency like variable speed drive compressors, permanent magnetic motors, cost-effective adsorption dryers or even higher IE rated motors.
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23-25, January 2018 20-23, February 2019 Venue: Ahmedabad, Gujarat, India Venue: Mumbai, India
Dear Readers, Chemical Engineering World (CEW), the Official Organ of ChemTECH Foundation, is India’s premier technology magazine for the chemical process industry professionals. This highly reputed monthly publication provides novel insights on the dynamics of Indian and global process industries. CEW, a niche publication with proven track record, has been disseminating authentic information on process industry innovations for more than five decades. You can contribute in the magazine with technical articles, case studies and product write-ups. The length of the article should not exceed 1,500 words with maximum three illustrations, images, graphs, charts, etc. All the images should be of high-resolution (300 DPI) and attached separately in JPEG or JPG format. Have a look at our editorial calendar on the Website – www.cewindia.com. To know more about ChemTECH Foundation, Jasubhai Media and other publication and events, please visit our Website – www.chemtech-online.com Thank you, Regards, Mittravinda Ranjan Editor Jasubhai Media Pvt Ltd T : +91-22-40373636 D : +91-22-40373615) E-mail: mittra_ranjan@jasubhai.com
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Marketing Initiatives
Bio-trickling Technology for Highly-polluted Odorous Emissions
T
he clean air is not a luxury, it is one of the most important natural resources and we see it as a precondition for a peaceful coexistence of humankind.
The introduction of the harmful substances to the atmosphere causes harm to all the living organisms creating worse scenarios and it has become a major environmental issue worldwide with increasing public demand for better control of highly polluted odorous emissions. BTF - Process Our SLURED bio-trickling filters combine the advantages of the bio-filter and the bio-scrubbing process, eliminating both odours and volatile organic compounds (VOC) from wastewater in treatment plants and similar industrial processes.
to its low CAPEX and almost ZERO OPEX combined with very high removal efficiencyâ&#x20AC;?
â&#x20AC;&#x153;This technology has recently become very attractive with all customer segments due
The process combines the chemical principles of absorption and adsorption.
In the system, micro-organisms settle on the surface of an organic carrier material. Their metabolic processes are used to convert the polluted emissions into carbon dioxide and water. To that end, the polluted gas is blown through the bio-media from the bottom of the system. In the roof of the system, automatically controlled nozzles are installed, spraying water with nutrients and minerals into the trickling layers, on which micro-organisms are located. The nutrient liquid ensures the optimal metabolic conditions for the micro-organisms used. And the automatic recirculation of the nutrient liquid ensures a very high-efficiency by removing polluted air with very low operating expenditure.
52 â&#x20AC;˘ September 2018
Chemical Engineering World
CEW
Marketing Initiatives Comparison between bio-trickling and chemical scrubber. Bio-trickling Filter
Chemical Scrubber
Reactions
The odorous gases are converted through the reaction mediated by microorganisms
The odorous gases are reacted with chemicals which are dosed in the chemical scrubber unit
Capital cost
For equipment size, the capital costs are the same or lower than the chemical scrubbing units
The chemical scrubbers are slightly expensive
Contact time
Longer contact time of 10-15 sec
Shorter contact time, thus smaller footprints required
Media and chemicals
Does not require any chemicals, it uses the activated sludge which is characterized by nutrient feed and trickling liquid
From an operational standpoint, the performance of the scrubbers depends on the chemicals added
Gas volume
Higher volumes of odorous gases treated on the time-weight basis
Higher volumes of odorous gases treated on the timeweight basis
Chemical requirement
No chemicals required except the nutrients dosing Excessive chemicals required with an external dosing for growth of micro-organisms system.
Water consumption
Very less water for re-circulation trickling line
Consumes more water for operation (dilution of chemicals, etc)
Operating cost
Almost “ZERO” operating costs (no chemicals, less water and minimum energy costs)
High operating costs (power, chemicals, water, etc)
Risk
No risk and accidents due to non-usage of chemicals
Potential risks due to the chemical usage and retreatment
VOC and Efficiency: Hydrogen Sulphide (H2S): Hydrocarbons Ammonia Methyl Mercaptans Carbon Disulphide (CS2) Indole and Skatole
>95% : > 95% : > 95% : > 95% : > 95% : > 95%
Conclusions Our SLURED bio-trickling filters are a very cost-effective and environmental-
friendly technology to treat polluted and odorous emissions without the usage of any chemical reactants. Therefore, our bio-trickling filter technology is very economical and intrinsically safe for all domestic and industrial wastewater treatment processes. Decisive are significant savings on the avoidance of chemicals as well as easy operations and maintenance. We therefore see that bio-trickling filter technology will
“ Never doubt that a small group of thoughtful committed citizens can change the world; indeed, it is the only thing that ever has. ” – Margart Mead Chemical Engineering World
replace conventional chemical scrubbing technology on a large scale in the near future. So far our SLURED BTF technology was installed and successfully running over thousand projects worldwide.
For details contact: Liku-Tech Environmental Solutions (India) Pvt Ltd
B G Vihar, Plot No: 1213, 12th Street, “Z” Block Annanagar West, Tel: 044-48590425 Fax: 91-044-48590426 E-mail: saran@likutech.com Website: www.likutech.com / www.likusta.de September 2018 • 53
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Marketing Initiatives
ECOFLUX* Corrugated Tube Heat Exchanger
H
RS Process Systems Ltd, India, is part of UK-based HRS group of companies, a leading heat transfer technology provider. HRS is equipped with a strong network all across domestic and international market like UK, Spain, USA, India, Australia, New Zealand and Malaysia to fulfil technology needs of process industries.
The high demand for heat transfer equipments in industries like chemical, pharmaceutical, agrochemical, petrochemical, oil and fats, fertilizer, food and beverages, engineering and others is driving the advancement in heat transfer technology. Heating, cooling, chilling, condensing, re-boiling, pasteurizing, sterilizing, evaporating are the key processes in these industries. To carry out such processes effectively, heat exchanger becomes heart of the process plant. During heat transfer process, over a period of time, deposition of substance occurs. Formation of this boundary layer
is referred to as FOULING, a factor which poses resistance to product flow. Fouling is typically high in shell and tube (smooth tube) heat exchangers and significantly impacts the heat transfer process. HRS offers ECOFLUX corrugated tube heat exchanger (CTHE), which is a shell and tube heat exchanger where “corrugated tubes” are used instead of plain tubes. This is a definitive option to tackle fouling seen in regular shell and tube heat exchangers. The tubes in ECOFLUX CTHE are corrugated to induce turbulence in both the flows
(product and service) even at lower velocity. Corrugated tube thus, boosts heat transfer multi-fold even at low Reynold’s number with minimum increase in pressure loss. This enables efficient heat transfer even in liquids with high viscosity, large fibers or particulates. ECOFLUX corrugated tube heat exchangers are compact in yet give significantly enhanced performance over smooth tube heat exchanger. It can be customized according to the process needs with wide choice of MOC like SS-304L, SS-316L, 904L, 321, Titanium, Duplex, Hastellloy, Alloy 20 and Copper depending upon compatibility of process fluids. ECOFLUX CTHE is offered in a range of models as per ISO, TEMA and latest design standards to suit different process applications. It enables continuous process running for longer duration, requires low maintenance and also gives high response to CIP. This proves to be a versatile, economical and energy-efficient equipment for multiple process industries. For details contact:
HRS Process Systems Ltd 201-202 Karan Selene 851 Bhandarkar Institute Road Pune, Maharashtra 411 004 Tel: 020-25663581, 25663582, 66047894 E-mail: info@hrsasia.co.in
Website: www.hrsasia.co.in 54 • September 2018
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Products CEW Ultra-compact Industrial PC
Slideway Low Friction Material
The newest generation of universal, flexible and ultra-compact IPCs from Beckhoff is ideal for all tasks in the fields of automation, visualisation and communication. The Series has been expanded with the addition of the C6017, with an increased variety of interfaces and an integrated UPS. The C6017 is practically identical in design to the popular C6015, currently the smallest ultra-compact IPC from Beckhoff. The existing C6015 configuration with DisplayPort connection, an onboard dual Ethernet adapter with two 100/1000Base-T connections as well as a USB 3.0 and USB 2.0 port, is being extended on the C6017 with an additional two RJ45 and two USB 2.0 interfaces. Moreover, an optional capacitive 1-second UPS is integrated, which ensures storage of persistent data in the event of a power supply failure. Equipped with an Intel Atom CPU with up to four processor cores, the passively cooled IPC also features a robust aluminium and zinc die-cast housing so it is equally ideal for automation, visualisation and communication tasks up to the midperformance range. For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers Don Bosco Marg, Yerwada Pune, Maharashtra 411 006 Tel: 020-40004802, Fax: 91-020-40004999 E-mail: info@beckhoff.co.in or Circle Readers’ Service Card 1
Slideway is an engineered thermoplastic developed for use in linear sliding elements to avoid metal-to-metal sliding contacts. It is a self-lubricating, wearresistant material manufactured under technical know-how from BUSAK + SHAMBAN, USA. Rollon Slideway provides low friction, stick slip-free operation, better positioning accuracy, repeatability, vibration damping and long life with minimum wear. It is dimensionally stable, maintenance-free and can be operated with or without lubrication for short duration; the allowable bearing pressure is 115 kg/cm² and is suitable for high speed applications (conditions apply). Rollon Slideway is used extensively on the guideways of new and reconditioning of guideways in SPMs, CNCs and conventional machine tools. It is available in thickness ranging from 0.8 to 4.0 mm and standard width of 12”, length as per customers’ requirements. For details contact: Rollon Bearings Pvt Ltd Shah Sultan Complex Cuinningham Road Bengaluru, Karnataka 560 052 Tel: 080-22266928, 22250287 Fax: 91-080-22250319 E-mail: rollon@rollonbearings.com or Circle Readers’ Service Card 2
Indexing Plungers Corrosion resistance, hygiene and material quality are properties which are highly appreciated in the pharma and food industry, in hospital engineering, fresh water supply and waste-water engineering, the aerospace industry, conveyor engineering and in machine and plant construction. For these industries ELESA+GANTER’s standard machine elements has added to its product range of index plunger models GN 613 / GN 617 and GN 617.1 the design variant with stainless steel knob - the first all stainless steel index plunger. The GN 613 indexing plungers have no collar and boast extremely small dimensions, designed to absorb axial forces in their end position. The GN 617 and GN 617.1 indexing plungers are each fitted with a collar, with the GN 617.1 indexing plunger featuring an additional indexing lock. These are used if the index pin is temporarily not allowed to protrude. To engage, the knob is turned by 90° after pulling out. An index notch prevents the disengaged knob inadvertently turning back under the impact of vibrations. All stainless steel indexing plungers are made in consistently high quality and feature a long service life. Options - Ganter offer include the holding fixtures GN 612.1 and GN 412.1 as mounting aids for indexing plungers, cam action-indexing plungers and positioning bushings (GN 412.2). For details contact: Elesa and Ganter India Pvt Ltd A-54, Sector-83 Noida, Uttar Pradesh 201 305 Tel: 0120-4726666 Fax: 91-0120-4726600 or Circle Readers’ Service Card 3
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CEW Products Tight Head Drums
Axial/Basket Extruders for Powder
Liquids present particular challenges when they are transported, stored and handled, especially if they are high purity or problematic substances. They pose no problem, however, for Muller’s highly practical and ruggedly constructed tight head drums. These drums can also be used with the cleverly designed Muller emptying systems.
Extruder is used to convert wetted powder/dough material into uniform size extrudes/granules with addition of binders. Applications are mainly pharma, chemicals, agrochemicals, foods, confectionery industries, etc.
They are available from 23 to 240 litre capacity containerisable, stackable and completely drainable. Internal and external surface coatings galvanised, UN Certified and FDA/BGA/BAG-compliant versions on request.
They are available from 1 to 5,000 kg capacity. Forming pharma extrudates prior to spheronisation for controlled release applications; production of water dispersible and water soluble granules of agriculture chemicals; densification of organic chemicals; formation of free-flowing vulcanisation compounds; different models in extruders such as single screw axial, double screw axial, radial extruder and basket extruder; change of extrusion diameter/pellet size by changing die and sieve; etc, are some of the features.
For details contact: Vinisa E I Pvt Ltd 6 Himalaya House Palton Road Mumbai 400 001 Tel: 022-22614088, 22622391 E-mail: vinisa@vsnl.net
For details contact: Prism Pharma Machinery Plot No: 3713, Phase IV, GIDC Vatva, Ahmedabad, Gujarat 382 445 Tel: 079-29095204 Fax: 91-079-25841623 E-mail: mkt@prismpharmamachinery.com or Circle Readers’ Service Card 04
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Automation of Centrifuges The API production and schedule M drugs limitations require time-based production with necessary process steps. The dependence of production on human-beings may spoil the quality of production. ACE has thoroughly studied all the process steps of bottom discharge centrifuge. The total control of the machine is done electronically. Use of variable frequency drive (VFD) coupled with PLC has opened the gateway of automation. Their FLP control system has been incorporated with HMI/MMI. The user can easily get the following time-based benefits with their flameproof control panel: batchwise recordings of individual steps with respect to date/time/batch numbers are stored in the system and the printout is available as and when required. The total cyclic operation can be different for different products. The control of the equipment can be managed from a particular desktop computer. The use of VFD in centrifuges is a great advancement. The VFD of a standard make is used preferably one that has an in-built braking chopper and resistor. The centrifuge runs with high starting and braking torque. Although ACE clutch pulleys and hand brakes are sturdy enough to do the job, the VFD does it electronically. The wear and tear of brake and clutch liners is negligible. It is worthwhile to invest in a VFD. The variable speed is welcome to save power. The VFD gives smooth centrifuging operation. Also, the work of feeding and washing can be done at lower basket speeds and the centrifuge drying can be done at higher speeds, if the basket charge is properly balanced. For details contact: ACE Industries (India) Pvt Ltd 113 Alpine Indl Estate, Marol Military Road Andheri (E), Mumbai 400 069 Tel: 022-42258000, 29201763 Fax: 91-022-29204939 E-mail: ace_centrifuges@yahoo.co.in or Circle Readers’ Service Card 06
56 • September 2018
Chemical Engineering World
Products CEW Inflatable Dock Shelters
Multi-collector ICP-MS
Inflatable dock shelters are elastomeric tubes designed to round out with the introduction of a medium (usually air) to form a tight barrier between a mounting and striking surface. Inflatable shelters provide the most versatile seal available to service the widest variety of truck and trailer configurations. Contrary to other types of dock shelters, the vehicle does not push towards the shelter. Instead the shelter is inflated around the docked vehicle providing complete seaming. The cushions retract rapidly to their rest position when the fan is switched off to let the vehicle go.
Meet the ever-expanding application demands of earth sciences, nuclear sciences and other fields requiring high precision isotope ratio measurements with the Thermo Scientific Neptune Plus high resolution multi-collector ICP-MS system. The Neptune Plus system combines field-proven technology with the latest innovations. This powerful double-focusing mass spectrometer, with high mass resolution, variable multi-collectors, and multi-ion counting capability, offers ground breaking sensitivity, high dynamic ranges, unsurpassed linearity and robust stability.
For details contact: Gandhi Automations Pvt Ltd Chawda Comml Centre Link Road, Malad (W) Mumbai 400 064 Tel: 022-66720200, 66720300 Fax: 91-022-66720201 E-mail: sales@gapl.co.in
For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 07
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Pump Impeller The KSB Group offers a special impeller for its Movitec multi-stage high-pressure pumps. This new impeller significantly improves these pumps’ suction characteristics (NPSH value). It proves its worth particularly in applications with critical inlet conditions (eg, boiler-feed applications) as well as applications in which the pump is required to take in water from low-lying tanks or at higher temperatures. Under these conditions, a pressure drop in the intake area may cause cavitation to occur in the first pump stage. This can result in excessive wear of pump parts or motor bearings as well as a reduced service life of the pump due to damaged parts and an unbalanced hydraulic system. The new impeller features a modified inlet dia, vanes allowing a slightly diagonal throughflow and a newly designed stage casing, all of which serve to substantially improve the pump’s NPSH curve. The multi-stage centrifugal pumps from the Movitec range are designed for handling fluids such as water, coolants, condensate and mineral oils. They are ideal for a wide variety of applications ranging from industrial boiler feed installations in steam circuits, recirculation and fire-fighting systems, cooling water circuits and washing plants to pressure boosting in general process applications. For details contact: KSB Pumps Ltd Mumbai-Pune Road Pune, Maharashtra 411 018 Tel: 020-27101231 Fax: 91-020-27426000 E-mail: Yagnesh.Buch@ksb.com or Circle Readers’ Service Card 09 24
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CEW Products Air Cleaner Catering to large indoor premises of up to 10,000 sq ft per unit, CC 6000 air cleaner is one stop solution for dusty environments and large indoor premises such as pharma facilities, food factories, heavy industry, warehouses, offices, supermarkets, etc. With flexible installation options for both mobile and stationary needs, the unit can also be ceiling mounted. Designed and engineered in Sweden, the air cleaner is equipped with E11 filter upgradable to H13 HEPAcapable of removing the smallest and most dangerous particles from the air eliminating tobacco smoke, weld smoke, construction dust, asbestos and particles of all sizes down to ultrafine. CC6000 comes equipped with advanced molecular filtration capabilities that include activated and impregnated carbon filters for odour and gas phase contaminant removal. This helps in removing bad odours, smoke, and corrosive gases. Molecular filtration using adsorption techniques is the industry accepted method to remove the corrosive agents from the air. The air cleaner is even efficient in reducing the average temperature in high ceiling rooms, with carbon upgrade available to remove unwanted odours. With an air flow capacity of up to 6000 m3³/h, CC6000 adapts to specific needs and purification requirements with user-friendly control panels, premium efficient fans with adjustable airflow and Modbus connection, silencers for sound reduction, and easy change of front and back filters, significantly resulting in the reduction of dust particles from the air. For details contact: Camfil Air Filtration India Pvt Ltd 62 IDC, Mehrauli Road Gurgaon, Haryana 122 001 Tel: 0124-4874101 Fax: 91-0124-4082405 E-mail: pksv.sagar@camfil.com or Circle Readers’ Service Card 10
Low Monomer Urethane Prepolymers for Adhesives & Sealants Specialty Chemicals Company LANXESS offers new low monomer products for adhesives and sealants. With its Adiprene LF products the Urethane Systems business unit brings unparalleled performance and industrial hygiene to cast elastomers, coatings, adhesives and sealants applications. The Adiprene LF product range has been extended to include grades with less than 0.1 per cent free MDI (methylene diphenyl diisocyanate) for adhesives and sealant applications. Adiprene LF urethane prepolymers minimize potential exposure to free isocyanate, a subject of increasing regulatory focus. LANXESS is the only manufacturer offering LF urethane prepolymers with levels of free isocyanate below 0.1 per cent across a wide range of chemistries, including MDI, IPDI, HDI, TDI and pPDI. Adiprene LF prepolymers are chemically structured to provide superior performance, including viscosity for wetting and coverage, tensile and tear strength for improved adhesion, and resistance to heat, moisture, and chemicals for harsher environments. The unique synthesis of these prepolymers also results in more consistent performance batch to batch. For details contact: LANXESS India Pvt Ltd LANXESS House, Plot No: A 162-164 Road No: 27, MIDC Wagle Indl Estate, Thane (W) Mumbai 400 604 Tel: 022-25871000 E-mail: s.prakash@lanxess.com or Circle Readers’ Service Card 11
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Products CEW Noble Gas MS
Digital Refractometer
Take the next step in noble gas mass spectrometry. The new Series of Thermo Scientific noble gas mass spectrometer gives you unsurpassed precision, sensitivity, dynamic range, linearity and stability. Improve age precision in Ar-Ar dating by an order of magnitude. Get all five argon isotopes simultaneously with the Thermo Scienific Argus VI static vacuum noble gas mass spectrometer. Redetermine the isotope ratios of neon, argon, crypton and xenon by unsurpassed high resolution and precision of the Thermo Scientific Helix MC Plus Multicollector noble gas mass spectrometer.
Anton Paar’s range of Abbematrefractometers embody over years of technical expertise. They measure the refractive index and concentration of liquids, gels and solids. These truly universal refractometers cover all applications in all industries. Abbematrefractometers are built with care and precision using the highest quality materials.
Enter new fields of research with unique subpermil precision by using the new Thermo Scientific Helix SFT split flight tube noble gas mass spectrometer. For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494, Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 12
It is designed for routine analysis and quality control ranging from checks on incoming raw materials to intermediate and final product. Selectable from industry specific sets of scale. Built-in LCD screen and membrane keys are resistant to spillage and dirt. For details contact: Shreedhar Instruments 16 Shreeji Krupa Society Opp: MGVCL Circle Office Next to GNERS Medical College Gotri Road, Vadodara Gujarat 390 023 Telefax: 91-0265-2323041 E-mail: sales@shreedhargroup.com or Circle Readers’ Service Card 13
Condition Monitoring & Predictive Maintenance NORD DRIVESYSTEMS uses condition monitoring and predictive maintenance to achieve max plant availability and high cost-efficiency. While condition monitoring only enables the state of wear to be detected, predictive maintenance can ideally enable a maintenance date to be planned well in advance. This requires intelligent frequency inverters with integrated PLCs, which can take autonomous decisions and evaluate motor and gear unit status data from virtual and physical sensors. With the aid of virtual sensors based on mathematical algorithms and the PLC which is integrated into the NORD frequency inverter, in combination with the known physical characteristics of the gear oil, the lifespan of the oil can be determined with sufficient accuracy from the calculated drive output which is determined from the measured electrical data. This allows an assessment of the degree of use of the gear oil and the predicted date for the oil change. For industrial gear units, physical temperature and vibration sensors are both economical and advisable. Especially vibration sensors offer a range of advantages. Detailed manufacturers’ databases exist for all of the bearings which are installed in industrial gear units. These databases contain the characteristic vibration frequencies for all components of each bearing type. The individual frequencies can therefore be clearly identified and attributed to particular components. The frequency spectrum can be analysed on the basis of the time signal or an FFT analysis (Fast FourierTransform). This not only enables the ideal or necessary maintenance time to be calculated, it also indicates the location of the fault and which replacement parts are required. The autonomous drive communicates its status data to a secure cloud. There, this data is available for analysis with filter and analysis tools, so that monitoring of the drive units can be carried out from anywhere in the world. The data are transparently presented in a browser-based web interface and the plant can be viewed at a glance in a clear 3D illustration. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1, 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0, Fax: +49 45 32 / 2 89 -22 53 E-mail: Joerg.Niermann@nord.com or Circle Readers’ Service Card 14
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CEW Products Helical Worm Gear Unit The new SK 02040.1, made from high strength aluminium, replaces the previous cast iron product. The one-piece die cast UNICASE housing guarantees max strength and rigidity with low weight. In addition, aluminium is considerably more corrosion-resistant than steel and can be further protected with the aid of additional measures such as the highly effective nsd tupH surface treatment. The SK 02040.1 has a wide power range from 0.12 to 1.1 kW and an output torque of up to 100 Nm. The wide range of speed ratios (from 5.37:1 up to 330:1) enables optimum adaptation to the customer’s requirements. The new NORD gear unit is available in a universal foot flange version and offers ultimate versatility through many equipment versions and includes mounting options such as flanges and torque arms. All versions are available with solid or hollow shafts. The motor can be mounted directly without a coupling of adapter (IEC or NEMA). Powerful, light and versatile – with the SK 02040.1 NORD DRIVESYSTEMS has a reliable and compact helical worm gear unit in its range of products, which can be quickly and simply configured for a wide range of different applications. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89-0 Fax: +49 45 32 / 2 89-22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 15
Ultra-Compact IPC for Edge Computing The ultra-compact C6015 Industrial PC (IPC) is the ideal space-saving, high-performance IoT edge device to fully utilise the advantages for new and legacy systems in the process industries. By integrating comprehensive IoT and analytics functionality, PC-based control technology opens up a wealth of options to optimise production. System consistency in the control platform ensures simple implementation and high transparency: a universal portfolio of components for explosion protection, including the ELX Series EtherCAT Terminals, enables end-to-end automation of even large and complex processing plants; the TwinCAT software platform offers specific interfaces and libraries for process technology, and enables convenient cloud integration via TwinCAT IoT and data analysis via TwinCAT Analytics in perfect synchronisation with control cycles; and a high-performance IoT edge device is available in the form of the C6015 ultra-compact IPC, a universally suitable machine control platform. Equipped with an Intel Atom processor offering up to four CPU cores, the C6015 provides sufficient processing power for simple collection, processing and provision of process data and for the more complex tasks required of a modern IoT gateway. The Microsoft Azure Certification of the C6015 underscores that the device is ideal for state-of-the-art Industrie 4.0 applications. The C6015 is predestined for such communication tasks especially when retrofitting and connecting legacy systems. Existing process technology systems can be easily equipped with additional IoT capabilities using this IoT edge device or they can be readied to meet future communication requirements. In addition, system availability and productivity can be increased and cloud-based services used, eg, to implement predictive maintenance. For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers Don Bosco Marg, Yerwada Pune, Maharashtra 411 006 Tel: 020-40004802 Fax: 91-020-40004999 E-mail: a.phatak@beckhoff.com or Circle Readers’ Service Card 16 24
60 • September 2018
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Products CEW External Gear Pump DARTec
High Shear Rotor-Stator Mixer
The DARTec gear pump (DosingAutomation-Robot-Technology) was specifically designed for applications that depend on the highest level of repetition and dispensing precision. The 700 gram lightweight pump basically comprises a front plate, a center plate, two bear plates and a rear plate, the pairs of gear, a pump shaft and a drive shaft which are guided in high-precision bearings. To achieve the greatest precision, reproducibility and best possible total efficiency, the clearances inside the pump are adapted depending on the medium to be delivered, the differential pressure and the viscosity. Thus, high reproducible volumetric efficiencies can be achieved. Due to the corrosive wear, the use of coatings and special materials suitable to the application are used, leading to a technically ideal and cost-effective as well as optimum life time. It finds application in handling equipment and robots, process engineering and technology, mobile communication technology, automotive industry, mechanical engineering and plant construction, electronic industry, and plastics and wood processing.
The Batch Model high shear rotorstator mixer design consists of a single stage rotor that turns at high speed within a stationary stator. As the rotating blades pass the stator, they mechanically shear the contents. The Batch Model can be either permanently mounted to a vessel or suspended over a vessel on a portable lift. The mobile configuration offers the flexibility to use a single mixer in multiple vessels. It also allows the user to vary the position of the stator to process a variety of materials. The rotor-stator of the Batch Model is generally positioned 2-3 head dia off the bottom of the vessel and slightly off centre. To ensure adequate suspension of heavier solids, the rotor-stator generator may be positioned in the centre of the vessel. Interchangeable rotor-stator combinations provide unlimited flexibility to adopt to a variety of product formulations. The Inline Models are supplied in many sizes and MoC from 1/2 through 100 HP. For details contact: Ross Process Equipment Pvt Ltd Plot No: D-233/3, Chakan Indl Area Phase II, Village: Bhamboli, Tal: Khed Dist: Pune, Maharashtra 410 501 Tel: 02135-628400, 628401, 628402, 628403 E-mail: mail@rossmixers
For details contact: Bedaflow Systems Pvt Ltd W-7, Sector-11 Noida, Uttar Pradesh 201 301 Tel: 0120-43299 - 90 Fax: 91-0120-43299 - 20 E-mail: info@bedaflow.com or Circle Readers’ Service Card 17
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Advanced Retention and Drainage Solutions MicroSolSM is a revolutionary technology package from Solenis that combines the company’s new patented PerForm SP7242 structured polymer with its uniquely structured PerForm MP9031 colloidal silica to give printing and writing paper producers a no-compromise solution for maximizing retention and drainage without sacrificing formation in the manufacturing process. As a result, papermakers enjoy a wider operating window that increases flexibility, improves machine efficiency and reduces operating costs. PerForm SP molecules are highly anionic, three-dimensional structures that interact readily with cationic sites on fibers, fines and fillers in the forming paper. This structure allows the molecules to grab hold of ash and distribute it evenly to increase paper strength, retention and formation. The PerForm MP colloidal silica offers a similar microstructure developed with attention to its size, surface area, structure, surface modification and solids content to ensure optimal performance in today’s paper machine processes. Solenis designed MicroSol as a flexible component in a papermaker’s retention and drainage program, which could also include cationic or anionic polyacrylamide. The end result is a controllable program with a linear dosage response that offers papermakers an improved operating window with more versatility. For details contact: Solenis 3 Beaver Valley Road, Suite 500 Wilmington, Delaware 19803 U.S.A. Tel: +1 866 337 1533 E-mail: cmabernathy@solnis.com or Circle Readers’ Service Card 19
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CEW Products
Ultra-compact Industrial PC The ultra-compact C6015 Industrial PC (IPC) is high-performance IoT edge device to fully utilise these advantages for new and legacy systems in the process industries. By integrating comprehensive IoT and analytics functionality, PC-based control technology opens up a wealth of options to optimise production. System consistency in the control platform ensures simple implementation and high transparency: a universal portfolio of components for explosion protection, including the ELX Series EtherCAT Terminals, enables end-to-end automation of even large and complex processing plants; the TwinCAT software platform offers specific interfaces and libraries for process technology, and enables convenient cloud integration via TwinCAT IoT and data analysis via TwinCAT Analytics in perfect synchronisation with control cycles; and a high-performance IoT edge device is available in the form of the C6015 ultra-compact IPC, a universally suitable machine control platform. Equipped with an Intel Atom processor offering up to four CPU cores, the C6015 provides sufficient processing power for simple collection, processing and provision of process data and for the more complex tasks required of a modern IoT gateway. The Microsoft Azure certification of the C6015 underscores that the device is ideal for state-of-the-art Industrie 4.0 applications. The C6015 is predestined for such communication tasks especially when retrofitting and connecting legacy systems. Existing process technology systems can be easily equipped with additional IoT capabilities using this IoT edge device or they can be readied to meet future communication requirements. For details contact: BECKHOFF Automation Pvt Ltd Suite 4, Level 6, Muttha Towers Don Bosco Marg, Yerwada Pune, Maharashtra 411 006 Tel: 020-40004802, Fax: 91-020-40004999 E-mail: a.phatak@beckhoff.com / info@beckhoff.co.in or Circle Readers’ Service Card 20
Intelligent Drive Solu�ons NORD offers networked, autonomous and scalable drives. The decentralised drive systems form master-slave groups, which intelligently communicate with each other so that they can autonomously monitor and control particular sections of plant. If this is not possible, the blockage is reported to the central control unit and a networked replacement drive is started. Through integration of the PLC into the frequency inverter, NORD drive units can record the drive and application data and evaluate all of the available sensor and actuator data as the basis for condition monitoring. NORD can also develop predictive maintenance solutions for predictable and therefore plannable maintenance of the drive units. In particular, IE4 synchronous motors meet the most stringent efficiency regulations – including in the partial load and low speed ranges, thanks to PMSM technology. NORD frequency inverters also ensure energy-efficient operation. They are equipped with energy-saving functions and can automatically adapt motor powers to the actual requirements in case of fluctuating loads. The new NORDBLOC.1 single-stage helical gear units feature ultimate efficiency, high torsional rigidity, low running noise and long service life. In addition, they also meet even the most stringent hygiene requirements thanks to their wash-down design. They are drive solution for pumps, mixers and fans, as well as for material handling applications. NORD has extended its MAXXDRIVETM industrial gear unit series: Two additional sizes (rated torques from 15 and 20 kNm) as well as extruder flanges supplement the modular series and provide new solutions for heavy duty applications. NORD plans complete drive systems for heavy duty operation with motors and drive electronics, for tasks including conveyor technology, pumps and agitators. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 00 21
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Products CEW Compact Torsion Swivel
EPLAN Database OPW Engineered Systems, part of OPW’s Fluid segment within Dover Corpn offers compact torsion swivel (CTS) hose loader the solution that is ideal to replace loading arms in situations where tight clearances are required.
The CTS hose loader features a fully integrated internal torsion spring for a streamlined profile and has been engineered to replace existing FMC TL Loaders or any application where space is a premium. The CTS is another addition to OPW Engineered Systems’ complete line of terminal equipment including loading arms, swivel joints, couplers, electronics and accessories. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass, Sanneerkuppam, Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 22
EPLAN Electric P8 is one of the most important software solutions for CAD projects. EPLAN P8 provides almost unlimited possibilities for project planning, documentation and management of automation projects. EPLAN P8 product macros are available for motor starters and frequency inverters from the NORD Series SK135E, SK180E, SK200E and SK500E, as well as for all NORD electronic drive technology accessories. Under the heading Documentation/Software on the NORD website, all currently available product macros for EPLAN P8 are also available as free downloads. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0, Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com . Joerg.Niermann@nord.com or Circle Readers’ Service Card 23
Prime Freezer Doors Gandhi Automations Pvt Ltd offers high-speed freezer doors. Prime Freezer Doors are the ideal solution where temperature control is critical and safety concerns are at a premium. The doors are manufactured with European collaboration and technology with innovative and creative engineering. The high operating speed combined with an excellent seal optimizes the internal traffic flow and provide energy savings. Heavy duty motor: 400 V three-phase, opening speed up to 2.5 m/s with inverter system. It can be equipped with transparent PVC vision windows. It is suitable for both positive and negative temperature, operating temperature range +5 to -35oC. Prime freezer door has special double curtain construction with space in-between. High speed freezer doors are the ideal solution for internal heating system provided within the guide prevents ice formatting even during intensive cooling and effectively operate in any situation. Innovative insulated curtain with high thermal efficiency is available optionally, for additional saving on energy costs. High speed freezer doors have revolutionary soft bottom edge and sensor combine to ensure operator safety at all times. For details contact: Gandhi Automations Pvt Ltd Chawda Commercial Centre Link Road, Malad (W) Mumbai 400 064 Tel: 022-66720200, 66720300 Fax: 91-022-66720201 E-mail: sales@geapl.co.in or Circle Readers’ Service Card 24
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CEW Products 8-Axis FaroArm FARO offers 8-Axis FaroArm system. This comprehensive, solution combines either the portable Quantum FaroArm, Quantum ScanArm or Design ScanArm portfolio products with a functionally integrated, yet physically separate, 8th axis. The 8th axis is a complete rotational axis identical to and a natural extension of all FaroArm products. It plugs directly into the FaroArm and results in a seamlessly integrated, high accuracy additional axis that requires no additional setup time or effort. Moreover, unlike a turntable, the 8th axis is completely transparent to the measurement software, so no software updates or upgrades are needed. This innovative functionality enables the part to be rotated in real time relative to the Arm versus requiring the Arm to be moved around the part. As a result, it is not only easier to scan and measure typically harder to reach areas, but also both measurement time and human measurement error are dramatically reduced since the part itself rests on a stable, consistent platform. The 8-Axis system is ideal for addressing a range of non-contact measurement and design challenges, including point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modelling of free-form surfaces. For details contact: FARO Business Technologies India Pvt Ltd E-12, B-1 Extension, Mohan Co-op Indl Estate Mathura Road, New Delhi 110 044 Tel: 011-46465664, 46465656, 46465644 E-mail: amrita.gokhale@faro.com / india@faro.com or Circle Readers’ Service Card 25
Drive Solutions To optimise the total cost of ownership (TCO) NORD DRIVESYSTEMS offers individual TCO calculations, integrated concepts for costs and efficiency optimisation as well as powerful and efficient drive technology. The total costs which a product generates over the course of its life cycle can be calculated with the aid of a TCO calculation. To optimise the TCO, NORD supplies efficient drive solutions which considerably reduce operating costs. Here, the focus is on an integrated approach. This includes reduction of the number of versions with the aid of the NORD modular system, reduction of energy consumption through the use of efficient IE4 synchronous motors; long service life and low maintenance NORD drive units. Drive systems count as the main consumers of energy in industry. Energy saving IE4 synchronous motors from NORD are highly efficient, thanks to PMSM technology, also in the partial load and speed ranges. The second largest factor for reducing costs is the deliberate reduction of the number of versions. This minimises administrative expenses, and enables leaner manufacturing, logistics, storage and service processes. The necessary basic versions which are required in order to reduce the total number of versions can be selected from the extensive NORD modular system. In addition, NORD systems facilitate reduction of the number of versions and spare parts management. For Intralogistics and airport applications, NORD supplies the LogiDrive standardised geared motor system consisting of an IE4 synchronous motor, a two-stage bevel gear unit and a NORDAC LINK field distributor is a perfectly matched drive system. For pallet conveying technology NORD offers an economical combination of an asynchronous motor and the NORDAC BASE frequency inverter. Also, with the aid of NORD frequency inverters, maintenance and repair costs can be significantly reduced and plant availability increased. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0, Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 26
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Products CEW Drive Solutions
Cushion Dock Shelters
NORD DRIVESYSTEMS offers application-specific equipment options characterised by high performance and efficiency, specially designed for pumps, agitators, and mixers whose processes result in high radial and axial bearing loads. An agitator version (VL2 bearing) with increased bearing spacing and reinforced bearings as well as a Drywell version (VL3 bearing) with additional oil drip plate and leakage or oil sensor are also available. The bearing spacing of the VL2 and VL3 versions is increased with attachments while the gear unit size remains unchanged. NORD also offers bearings that were intentionally oversized to meet the requirements of applications such as pumps or agitators. Chemical, pharmaceutical, food or water treatment sector – the robust drive solutions by NORD DRIVESYSTEMS offer top reliability and ensure unobstructed operation. Reinforced and larger output shaft bearings allow the gear unit to absorb the high axial and radial forces and thus prolong the service life.
Thanks to its high insulation factor, the cushion dock shelter is the ideal solution for controlled temperatures. The three cushions are made of elastic polyurethane foam, covered with PVC coated polyester fabric, supporting vehicle pressures and perfectly sealing the three sides including the space between opened rear doors and sides of the vehicles. The two vertical cushions have continuous overlapped anti-friction limpets allowing for the up and down heavy friction of the vehicle on its suspensions, during the loading.
For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1, 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0, Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 27
Bold guidance markings at the front of the seal side cushions are useful point of orientation when reversing on to the dock seal. For details contact: Gandhi Automations Pvt Ltd Chawda Comml Centre, Link Road Malad (W), Mumbai 400 064 Tel: 022-66720200 Fax: 91-022-66720201 E-mail: sales@geapl.co.in or Circle Readers’ Service Card 28
ATEX Compliant Drive Systems NORD DRIVESYSTEMS supplies individually configured drive systems in accordance with EU Directive 2014/34/EU and IEC Ex for application in potentially explosive atmospheres. The explosion-protected drive systems can be operated in category 2D or 3D dust atmospheres (Zones 21 and 22) as well as in category 2G or 3G gas atmospheres (Zones 1 and 2). A combined dust/gas explosion protection is also available. NORD supplies application-specific drive solutions with individual configurations and equipment from its SAP-supported modular system with validated configuration processes according to ISO 9001. On the basis of customer specifications, NORD calculates individually by testing the ATEX conformity and also delivers the appropriately modified type plate. If required, the maintenance intervals which are determined for the specific application can be stamped on the type plates.The company offers flexible drive concepts with motors which are optionally designed for use with inverters as well as the option of IEC or NEMA motor mounting. In many cases, it can be mounted directly on the gear unit for an especially compact solution. Depending on the explosion protection zone, various options can be integrated. The explosion protection range by NORD includes systems for ambient temperatures up to +60oC. NORD works closely with the Physikalisch-Technische Bundesanstalt (PTB) and the DEKRA EXAM GmbH. All Category 2 motors have type test certification. Explosion-protected drives by NORD are used in almost all industry sectors in a wide variety of applications, eg, to drive pumps, agitators or lifting gear. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0, Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 29
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CEW Products Separation for Wet/Dry Applications The high performance Russell Eco Separator is engineered to handle screening problems experienced by customers throughout the processing industries. It accurately separates products into five fractions in one operation; increases productivity with higher capacities and provides complete material control to optimise separation quality. They are available in sizes 600, 750, 1,000, 1,200, 1,500 and 1,800 mm. For details contact: Russell Finex Pvt Ltd A-1201 Rustomjee Adarsh Regal Adarsh Vihar Complex, Off Marve Road, Malad (W) Mumbai 400 064 E-mail: sales.rfsf@russellfinex.com
Vacuum Lifter Like other air compressed driven devices, no electric power and lubrication are required for the 160 kg-180o rotation vacuum lifter. A builtin gas spring allows the self-adjustment of counter balance of lifter upon the load weight for safely and securely lifting and rotating the slab. A slide valve for control of the inflow and outflow of compressed air through the air cylinder is equipped in such an assured way that suction pads keep the load safely and securely as the rotation and lifting of slab. Furthermore, for the safety of operator, an alarm system and vacuum gauge are equipped to make an audio visual warning in event of leakage or low vacuum level. For details contact: Aardwolf Material Handling Solutions Harmara Road, RIICO Indl Area Madanganj-Kishangarh Dist: Ajmer, Rajasthan 305 801 E-mail: gaurav,mathur@aardwolf.co.in
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Drive Solutions NORD Electronic DRIVESYSTEMS GmbH is a member of the NORD DRIVESYSTEMS Group. Drive solutions from NORD DRIVESYSTEMS also feature a great depth of production. Whether for series production devices, individually configurable products or one-offs, enables orders of any size to be produced. A batch size of 1 is also achievable without further set-up. The demand for individual adaptations is increasing and the present high proportion of customised devices is continually growing. In 2017, a further increase resulted from the successful introduction of the NORDAC LINK field distributor. The drive controller for flexible, decentralised installation is freely configurable according to the particular requirements and application and provides considerably more options for customisation than the previous products. NORD not only uses the latest technologies for its products. The objective: max speed and efficiency, a lean logistics chain and largely paperless production. The entire production process is controlled via a central order. On receipt, each package is given a 2D code and can therefore be continuously traced until it is used. The automated small parts warehouse (AKL) with 2,000 six-fold segmented containers is centrally integrated into the production process and is used not only to store components, but also for semi-finished products. After the SMD department, the assembled modules are returned to the AKL, from where they are removed for further THT (Through Hole Technology) processing. This implements an automatic FIFO (First In – First Out) procedure within the production process. As almost all products are produced directly according to customers’ orders, only a short production lead time and storage buffer are required. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 32 24
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Chemical Engineering World
Products CEW Gas Isotope Ratio MS
Automatic Inspection-Cum-Polishing Machine
Combine all isotope ratio mass spectrometry applications in a single analyser. The Thermo Scientific Delta V IRMS systems combine outstanding sensitivity with excellent linearity and stability to address applications as diverse as the detection of honey adulteration by EAIRMS to δ13C analysis of PAHs in soil with GCIRMS. Get the highest sensitivity and precision for the determination of isotope ratios with the Thermo Scientific MAT 253 stable isotope ratio mass spectrometer. It provides a flexible and open platform for the connection of inlet systems and preparation devices for the smallest amounts of sample in IRMS. For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 33
Another useful product is automatic capsule inspection with polishing (in two stages). It has two polishing chambers with 6 inch of inspection belt. Features output up to 50,000 to 60,000 capsules per hour; feeding section is compatible with stainless steel hopper and vibrator with powder collector; inspection section is compatible with conveyor belt with different speed drive; defect capsule sort out manually by pluckers or by hand; polishing section is compatible with two stainless steel chambers, installed with filter cloth and nylon brush. For details contact: Pharma Chem Machineries 311/2484, Motilal Nagar No: 2 M G Road, Goregaon (W), Mumbai 400 090 Telefax: 91-022-28735321 E-mail: pharmach@gmail.com / pharmachem79@gamil.com or Circle Readers’ Service Card 34
PROFIsafe Module With the SK TU4-PNS PROFIsafe interface module, NORD DRIVESYSTEMS provides even greater safety. The optional module meets the most stringent safety requirements, enables flexible integration of various safety components and ensures secure communication in PROFINET environments. PROFIsafe is generally used technology for safety applications for production and process automation. With SIL3 and PLe (Performance Level e) Category 4, the fail-safe communication protocol fulfils the most stringent safety requirements. In combination with a safety PLC, the drive electronics reliably communicate via PROFIsafe in PROFINET. Safe inputs and outputs, for example for emergency stop switches and light barriers, can be connected to the application with plug connectors. A rotary encoder can be connected to supervise the safe drive function. The module is equipped with two redundantly operating microprocessors and is self-monitoring. Various safe movement functions can be easily integrated and therefore extend the safety stop functions of the drive units: SLS (Safety Limited Speed), SSR (Safe Speed Range), SDI (Safe Direction), SOS (Safe Operation Stop) and SSM (Safe Speed Monitor). With this, the PROFIsafe module provides comprehensive safety for the reliable operation of plant and machinery. The module is suitable both for control cabinet installation as well as decentralised installation and is available for the NORDAC LINK, NORDAC FLEX and NORDAC PRO inverter Series. For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg Germany Tel: +49 45 32 / 2 89 -0 Fax: +49 45 32 / 2 89 -22 53 E-mail: pl.muthusekkar@nord.com / Joerg.Niermann@nord.com or Circle Readers’ Service Card 35
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IFAT India
India Chem 2018
Dates: 15-17 October 2018 Venue: Bombay Exhibition Centre, Mumbai Event: India’s leading trade fair for water, sewage, solid waste and recycling will again open its doors for everyone in Mumbai. IFAT India is an ideal platform to network with industry leaders and business partners in the environmental technology sector from across the globe. For details contact: Messe Muenchen India Pvt Ltd INIZIO 507 & 508, 5th Floor Cardinal Gracias Road, Opp: P&G building Chakala, Andheri (E) Mumbai 400 099 Tel: 022-42554744 E-mail: enquiry@ifat-india.com
Date: 4 – 6 October 2018 Venue: Bombay Exhibition Center, Mumbai Event: The largest event of Chemicals and Petrochemical Industry in India, in its 10th edition i.e. India Chem 2018 would be organized from 4-6 October 2018 jointly by the Department of Chemical and Petrochemicals, Government of India and FICCI. The Indian chemical industry is at the threshold of rapid growth with the Government of India providing an atmosphere of support and encouragement. India’s vibrant chemical and petrochemical industry plays a significant role in the economic development of our country. In terms of volume, the Indian chemical industry is the 6th largest in the world and the 3rd largest in Asia with the size worth USD 108.4 Billion.
TURKCHEM International Chemical Industry Exhibitions 2018
Chemtech World Expo 2019
Dates: 8-10 November 2018 Venue: Istanbul Expo Center Events: TURKCHEM International Chemical Industry Exhibitions 2018 will entail 3 distinct exhibitions under one roof as ‘ChemShow Eurasia: 8th International Fine and Specialty Chemicals, Commodity Chemicals, Petrochemicals and Chemical Intermediates Exhibition’, ‘ChemLab Eurasia: 8th International Laboratory, Test-Measurement Equipment, Auxiliary Materials and Lab Consumables Exhibition’ and ChemTech Eurasia: 8th International Chemical Process and Automation Industry, Packaging, Recycling, Logistics, Labour Safety and Environmental Technologies Exhibition’ For details contact: Artkim Fuarcılık Tic AŞ Sultan Selim Mah Akyol Sitesi Çıkmazı Sk No: 6 Artkim Center 34415 4.Levent / İstanbul, Turkey Tel: +90 (0212) 324 00 00, Fax: +90 (0212) 324 37 57 E-mail: sales@artkim.com.tr Website: www.artkim.com.tr 3rd International Conference on Chloro Alkanes Date: 29 November, 2018 Venue: India Habitat Centre, New Delhi Organisers: Jasubhai Media Pvt Ltd & Eurochlor. Event: Chlorinated alkanes have been under the scanner due to the developments in the regulatory frameworks. Manufacturers have realized the need to enhance the efforts in the field of technology & research to improve product quality and develop innovative processes. One day conference will highlight global trends in CA business, regulatory status, substance evaluations, risk assessments, product benefits and global cooperation. For details contact: Jasubhai Media Pvt Ltd Taj Bldg, 3rd Floor, 210 Dr D N Road, Fort Mumbai 400 001, India Tel: 022-40373636 (Board), Fax: 91-022-40373635 E-mail: sales@jasubhai.com 68 • September 2018
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For details contact: Girish Ahuja Senior Assistant Director, FICCI Tel: 91 11 2335 9734 Email: Girish.ahuja@ficci.com
Date : February 20th - 23rd, 2019 Venue : Bombay Convention & Exhibition Centre, Goregaon (East), Mumbai, India Event : CHEMTECH World Expo 2019 will create a common platform to bring the entire ecosystem of the chemicals manufacturing and the allied services providing sectors for 27th time in India. The event is for equipment, services or developing processes for the Chemical and Process industries. The evolution and the growth of Indian chemical and related industries has been both reflected and catalyzed by CHEMTECH. The interactive Exhibition and Trade Fair pioneered by Chemtech has become the event that the chemical industry comes together. Concurrent events include EPC World Expo, Industry Automation & Control World Expo, Bio Pharma, Pumps Valves & Fittings World Expo; and international conferences on Refining & Petrochemicals and Specialty Chemicals. For details contact: Vaishali Pednekar Senior Executive – Conference Tel: +91-22-4037 3619 Email: vaishali_pednekar@jasubhai.com Chemical Engineering World
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.
valuation of the prospective deal is not known. JSW Energy refused a comment on the status of its takeover plans of Monnet Power and JITPL. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets, is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an Expression of Interest (EoI) from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW.
MINING KIOCL will revive mining in Karnataka, after the State granted the company a lease of over 474 hectares at Devadaru hills in Ballari. KIOCL had suspended mining in the eco-sensitive Western Ghats following a Supreme Court directive in 2006. Once approvals are given, it would invest ` 1,500-crore in a pellet plant and also a unit to enrich iron ore from the mines. After suspension of mining, KIOCL had shifted to operating 3.5-million tonne per annum pellet plant in Mangaluru. Last year, it produced 1.46-million tonnes, utilising half its capacity, as against almost nil production in the previous year. International agencies have already implemented pilot projects by bringing high grade iron ore from South America, Iran and other parts of the world and utilising KIOCL's facility, have taken away pellets facilitating better utilisation of its plant capacity and profitability utilising its manpower. The company's blast furnace unit having a capacity of 216,000-tonnes of pig iron which was put under suspension since 2009 has been taken for repair and the unit is ready for operation for producing foundry grade pig iron adding towards its profitability in the coming financial year. The firm earned a profit of ` 47.93 crore in FY17 as against a loss of ` 80.15-crore the previous year. Revenues grew 353 per cent to ` 929.36-crore from ` 205.57-crore in the previous fiscal.
Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open-cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. Total cost is estimated to be ` 263-crore. Among the conditions specified, the company has been asked to get 'Consent to Operate' certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the 'Consent to Establish' for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity. With regard to transportation of coal, the company has been asked to carry out by covered trucks and take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation plan covering an area of 376.04-hectare at the end of mining. Of the total quarry area of 231.73-hectare (on floor) and 291.21-hectare (on surface), the backfilled quarry area of 115.39-hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose.
JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Monnet Power had accumulated debt in excess of ` 5,000-crore. Though lenders had earlier denied a haircut in JSW Energy’s prospective deal to acquire majority equity in Monnet Power, the Sajjan Jindal-owned firm is still believed to be in the hunt for the asset. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. But, coal paucity and absence of firm linkages had caused disruptions in the operations of the power plant. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corporation. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The Chemical Engineering World
Singareni Collieries Co Ltd (SCCL) the State-owned coal mining giant, has initiated preparations to start Koyagudem Opencast Project-III (KOC-III) in Lingala Koyagudem coal belt of Godavari valley coalfield in Tekulapally mandal soon. The extractable reserves in the KOC-III are estimated to be around 111.98-million tonnes as against the estimated geological reserves of 146.81-MT.The KOC-III project is expected to produce around 3.6-million tonnes per annum, SCCL sources said. In pursuit of its aggressive growth strategy, the SCCL has drawn up ambitious plans to open 31 coal mines including 20 OCPs and 11 underground mines in the next five years. It presently has 30 underground mines and 16 OCPs spread across the vast Godavari valley coalfield spanning Bhadradri-Kothagudem, Khammam, Karimnagar, Adilabad and a few other districts in the State. The company has set a coal production target of 66.06-million tonnes for the current fiscal.The company is aiming to set new benchmarks in coal production, dispatches and overburden removal besides enhancing the coal production capacity to around 900-lakh tonnes by 2020-2021, SCCL sources said. The SCCL has reportedly obtained the mandatory forest clearance from the Central government agencies concerned for the KOC-III. The project envisages use of 1,158-hectares of forest land and 448-hectares of non-forest land. September 2018 • 69
CEW Project Update The upcoming KOC-III, which is surrounded by the Koyagudem OCP-II, is expected to augment coal production in Yellandu area of the SCCL. Preparations are on to commence the works on removal of 17 lakh cubic meters of overburden at the KOC-III to commence coal production in the project SCCL. The KOC-III has already obtained all the mandatory approvals from the Central government agencies concerned. The project is likely to be opened soon.
limestone reserves, making them attractive destinations for cement companies. Among the other major investment proposals, Hyderabadbased Rain Group, which also has cement manufacturing operations, has expressed interest in establishing a calcined petroleum coke plant, cement grinding unit, an R&D facility and a waste heat recovery power plant at Achutapuram SEZ in Visakhapatnam district, the government said. The company proposes to invest ` 1,096-crore in these projects.
OIL & GAS Kochi-Mangaluru Natural Gas Pipeline Project would be completed by this October-November, according to Dharmendra Pradhan, Union Minister for Petroleum, Natural Gas, Skill Development and Entrepreneurship. He said that Mangaluru is very much there in the new bidding round for city gas distribution (CGD). There would be a new executor for the CGD in the city in the next three months. The single initiative will create new techno economic eco system in Mangaluru, the Minister said and added that the fertilizer plant, refinery, petrochemicals and other industries in the city are eagerly waiting for LNG supply.The LNG terminal in Kochi was completed six years ago. However, the desired pipeline was not there. Works are on the fast track to lay the pipeline, and the local governments in Kerala and Karnataka are cooperating in the matter, he said.
FERTILIZER Hindustan Urvarak and Rasayan Ltd (HURL) will award projects for the first of its three gas-based fertilizer plants before the year-end. HURL is the joint venture between NTPC Ltd, Coal India Ltd, Indian Oil Corpn, Fertiliser Corpn of India Ltd and Hindustan Fertiliser Corpn Ltd.The JV was assigned the responsibility of reviving three fertiliser plants at Gorakhpur, Sindri of FCI, and Barauni of HFCL in June 2016. Indian Oil Chairman who is also the Chief of the Joint Venture, said, Our target is to commission all the three plants in 2020. We have got the environmental clearance for all the three plants that are located in the same areas. Area clearing and pre-project activities are going on. We have got the tenders, we have lined up the consultant. We have got the tenders for EPC contractors and the technology selection will also be in their scope. We have shortlisted technologies. We have opened the tenders and evaluation is going on. The task for setting up of these three fertilizer plants have been entrusted to three Maharashtra Public Sector Companies on equal cost-sharing basis. An official statement had said that it was proposed to install an ammonia plant of 2,200-tonne per day and urea plant of 3,850-tonne per day at each of these units at Gorakhpur, Sindri and Barauni at an estimated cost of ` 6,000-crore for each unit. The total project cost was estimated at `18,000-crore for the three plants, the statement added. But, crude oil refiner IOCL, power generator NTPC, and coal miner CIL are not known for setting up fertilizer plants.
The National Agricultural Cooperative Marketing Federation of India (Nafed) will set up a bio-CNG plant in Delhi’s Azad Mandi, said Minister for Petroleum and Natural Gas Dharmendra Pradhan. Speaking at the Delhi Energy Dialogue-2018 organised by Ashden India Collective. He said, The Nafed plant will use agricultural and vegetable waste of the mandi produce CNG. Indraprastha Gas will buy the bio-CNG produced. He said public sector oil marketing companies, particularly Indian Oil, are procuring bio-fuel across the country at a competitive market price. I can visualise ` 1 lakh crore of new business across the country in bio-fuel and bio-CNG industry, he added. Pradhan said he had met the Chief Economist of BP earlier this week who told him that India is currently the third largest primary consumer of energy after the US and China. In comparison to any developed economy and as a very upcoming economy, our per capita energy consumption is very low. Global experts are predicting that the CAGR growth of energy consumption in India over the next 25 years will be at 4 per cent, he said. The nearest competitor will be China with a 1.5 per cent growth. By 2030, we will be surpassing China’s consumption. Our incremental energy requirement will be equal to the entire Europe’s energy consumption, he added. CEMENT Chettinad Cement Corporation Pvt Ltd and KCP Ltd of Tamil Nadu are planning to invest ` 1,350-crore and ` 531-crore respectively to establish their new units in the State of Andhra Pradesh. The State investment promotion board headed by Andhra Pradesh Chief Minister N Chandrababu Naidu has cleared six investment proposals, including these two, involving a total investment commitment of ` 3,303-crore. According to the government, Chettinad will set up a cement grinding unit on 75-acres and a manufacturing plant on 1,000-acres of land in Vizag and Guntur districts respectively. The mega project will start production in March 2019.KCP Ltd will be setting up a unit on 100-acres of land in Krishna district with the first phase scheduled to start operations in a year's time. The cement industry in South India in general, and in Telangana and Andhra Pradesh in particular, is facing a huge capacity overhang with an installed base of around 150-million tonnes against a total demand of around 60-million tonnes. An additional 20-million tonnes goes to the neighbouring markets in the eastern and western parts of the country from here, according to the industry representatives. The two Teluguspeaking States together possess more than 30 per cent of the country's 70 • September 2018
ENERGY India Yamaha Motor has installed 1,100-kW rooftop solar power plant at its manufacturing facility near Chennai at a cost of ` 5-crore. With this, the Chennai plant’s total solar capacity has increased to 1,450-kW. The company has plans to increase the total rooftop solar capacity to 3,500-kW by the year-end. The new rooftop installation will reduce CO2 emission to the extent of 1,600-tonnes/year. Yamaha has partnered with Mahindra Susten for installing the rooftop solar panels. Yamaha has partnered with Amplus Solar for installation, operation and maintenance of solar power system at its Surajpur plant. This is one of the largest rooftop solar power plants with total capacity of 6,200-kW. This project was commissioned in two phases. Phase I was inaugurated in January 2016 with generation capacity of 4.000-kWp and Phase II was commissioned in October 2017 with generation capacity of 2,200-kWp. Recently under Phase II, 105-kW capacity solar power plant was installed in the car parking area inside the plant premises and 47 cars can be parked under the solar power plant which is also capable of meeting the future requirement of charging battery-operated cars. This particular area has a power generation capacity of 500 units per day. The Indian Wind Turbine Manufacturers Association (IWTMA) announced that the wind industry is poised to meet the Government’s target of 60-GW ahead of the 2022 deadline. The domestic wind market is on a growth path in the competitive bidding regime and there is an increased demand for clean energy, which has now become a reliable, affordable and mainstream source of energy. The industry has regained momentum and there is a clear business visibility of 10-12 GW even before the start of this financial year with announcement and plan of bids by the Ministry of New and Renewable Energy (MNRE). Chemical Engineering World
Book Shelf CEW Water and Wastewater Conveyance Author: Frank R Spellman Price: $172.15 No of pages: 445 pages (Hardcover) Publisher: CRC Press (1st Edition) About the book: Water and Wastewater Conveyance: Pumping, Hydraulics, Piping, and Valves provides fundamental, basic information on the conveyance of water and wastewater. Written in straight-forward and easy-to-understand language for professionals and non-professionals alike, it provides the techniques to assist water and wastewater operators to better understand basic pump operations and applications, maintenance regimens, and troubleshooting procedures. Addressing a multitude of water quality issues, it provides an introduction to water hydraulics, piping systems, tubes, hoses, and ancillaries as well as valves, and the maintenance requirements of each. It also discusses common operational problems and their appropriate corrective actions. Definitions of key terms and self-examination questions are provided at the end of each chapter.
The Wastewater Operator’s Guide to Preparing for the Certification Examination Authors: Water Environment Federation, Association of Boards of Certification and C2EP Price: $89.00 No of pages: 154 pages (Paperback) Publisher: Water Environment Federation About the book: The Wastewater Operator’s Guide to Preparing for the Certification Examination was prepared jointly by the Water Environment Federation, the Association of Boards of Certification (ABC), and the Certification Commission for Environmental Professionals (C2EP). It outlines what you can expect from the exam, provides key formulas, and let you test your skills with sample questions. Updated job tasks and types of knowledge are addressed in four levels of competency. The approximately 200 questions included in this guide have been chosen to sample as many different aspects of a wastewater operator’s job responsibilities as possible. Questions in the study guide are intended to provide an example of style and possible topics for certification exam questions. This guide includes C2EP’s education and experience requirements, tips for taking a certification examination, and sample formulas and conversions. Detailed answers to mathematical problems and references are provided.
Basic Principles of Wastewater Treatment Author: Marcos Von Sperling Price: $73.94 No of pages: 212 pages (Paperback) Publisher: IWA Publishing About the book: Basic Principles of Wastewater Treatment is the second volume in the Biological Wastewater Treatment series, and focus on the unit operations and processes associated with biological wastewater treatment. The major topics covered are: microbiology and ecology of wastewater treatment; reaction kinetics and reactor hydraulics; conversion of organic and inorganic matter; sedimentation; and aeration. The theory presented in this volume forms the basis upon which the other books in the series are built. The Biological Wastewater Treatment series is based on the book Biological Wastewater Treatment in Warm Climate Regions and on a highly acclaimed set of bestselling textbooks. This international version is comprised by six textbooks giving a state-of-the-art presentation of the science and technology of biological wastewater treatment. Other books in the Biological Wastewater Treatment series: Volume 1: Wastewater characteristics, treatment and disposal Volume 3: Waste stabilisation ponds Volume 4: Anaerobic reactors Volume 5: Activated sludge and aerobic biofilm reactors Volume 6: Sludge treatment and disposal Chemical Engineering World
Wastewater Engineering Authors: Inc Metcalf & Eddy, George Tchobanoglous, H David Stensel Prof of Civil and Environmental Engg, Ryujiro Tsuchihashi and Franklin L Burton Price: $135.00 No of pages: 2,048 pages (Hardcover) Publisher: McGraw-Hill Education (5th Edition) About the book: Wastewater Engineering: Treatment and Resource Recovery is a thorough update of McGraw-Hill’s authoritative book on wastewater treatment. No environmental engineering professional or civil or environmental engineering major should be without a copy of this book - describing the rapidly evolving field of wastewater engineering technological and regulatory changes that have occurred over the last ten years in this discipline, including: a new view of a wastewater as a source of energy, nutrients and potable water; more stringent discharge requirements related to nitrogen and phosphorus; enhanced understanding of the fundamental microbiology and physiology of the microorganisms responsible for the removal of nitrogen and phosphorus and other constituents; an appreciation of the importance of the separate treatment of return flows with respect to meeting more stringent standards for nitrogen removal and opportunities for nutrient recovery; increased emphasis on the treatment of sludge and the management of bio solids; increased awareness of carbon footprints impacts and greenhouse gas emissions, and an emphasis on the development of energy neutral or energy positive wastewater plants through more efficient use of chemical and heat energy in wastewater. This revision contains a strong focus on advanced wastewater treatment technologies and stresses the reuse aspects of wastewater and bio solids. September 2018 • 71
INTERVIEW CEW Interview
Bringing Colours to Life: Soujanya Group
Soujanya group is amongst the top three colour dispersion manufacturers globally, and the largest in Asia. In a candid conversation, Priya Bhumkar, Managing Director, Soujanya Group talks about the legacy the group has created in last 3 decades. The company has 500,000 litres by far the largest in Asia to manufacture colour dispersions and is scouting for 10 to 12 acres of land parcel for capacity addition. “Adding life to colour,” a tagline that aptly describes the unique brand value Soujanya Group as a dominant colour dispersion manufacturer demonstrates for more than three decades holding the mantle of family-owned business strong and reigning a supreme competitive edge in the industry. The group is now evolving further to emerge as a tech player in the colour space. The group was founded by paint technologist, C G Bhumkar in 1982 as Soujanya Enterprises, a proprietorship 72 • September 2018
unit in Navi Mumbai. The first batch of aqueous paste was produced and released only in 1983. Since then, the company has been growing from strength to strength with an optimistic outlook for the future. “During the last decade, we have grown significantly in terms of size, scale, markets and number of customers. Today, we are amongst the top three colour dispersion manufacturers globally, and
the largest in Asia. Our products are not just sold in India but also globally across 30 countries. We hone repute amongst our customers as a ‘reliable partner for colour’,” says Bhumkar. Technical Excellence Soujanya Group is a 200-people organisation and grown at a rate of 20 to 30 per cent, year-on-year over the last seven years. Bhumkar strongly believes technology as the most important driver Chemical Engineering World
Interview CEW for business and has about 20 qualified professionals in her R&D team. “R&D is always integrated into marketing, so they go hand-in-hand at Soujanya. The marketing team works very closely with the technology department to develop customised solutions and, together they form a team to do business acquisition. Our technology department is a marketfacing department which is directly exposed to the markets.” The unified team at Soujanya Group works towards understanding customers and how they can help them do business better. “We adhere and abide by the international best practices and standards – be it in product manufacturing, communication, team and people, quality, technology, approach to customers, markets or marketing strategy. 30 per cent of the company’s sales is from export markets. We do not see ourselves as a product seller but as a solution provider,” Bhumkar asserts. For over thirty years, Soujanya has been at the forefront of innovation in colourant manufacturing and research. The company has state-of-the-art manufacturing facility in Mumbai built on 3-acres of land. It is a fully-automated high-tech facility with the entire plant being engineered in Switzerland. “Our engineering partner is a Swiss company responsible for designing our current manufacturing plant, the equipment and machinery is from Germany and Switzerland. Inauguration of our firstof-its-kind facility in 2010 created a splash in the industry and set new benchmarks in colour manufacturing,” Bhumkar shares. The current facility operating at full-capacity is the largest in Asia manufacturing 500,000 litres of colour dispersion. Also, having started satellite manufacturing units in the area, the company is currently on keen lookout for 10 to 12 acres of land parcel to set up another facility within Maharashtra limits, relatively closer to Mumbai. “We have one of the best technologies in colour dispersion on a global scale and can claim ourselves to be the tech leader in the space. We operate on home-grown technology and have no tie-ups with any external parties as technology partners.” Chemical Engineering World
Business Challenges Raw material costs are one major challenge faced by the industry at large. Dealing with the pressure and situation at hand, she thinks, “We are in an industry dependent on organic chemicals, which is further dependent on the price of crude. I think the world is right now in a state of chaos and in this rapidly changing world, it is important to try to do the best you can under given circumstances. We are trying to be an agile, flexible and adaptable organisation. Considering the trend of inflation and increase in prices, we have to wait and watch to see the change in industry trends. As a company we are extremely committed to markets, growth and to becoming a global corporation of top-notch order.” Industry Expectations from GoI Bhumkar highlights two clear expectations from the Government of India (GoI), one is the need for clear and simplified policies from the government and further crystal-clear communication of these policies to the industry at large. The industry should be extremely clear on what is expected of them in terms of performance and delivery. Second better infrastructure provision is expected from the government. Looking at infrastructure such as roads, power, water, hygiene and sanitation facilities, the gaps need to be addressed effectively with right solutions. If government works towards meeting these expectations and bridging gaps, you will witness rapid accelerated growth of a nation. The company aims to be a strong and dominant player in the colour dispersion space.
norms and it is a zero-discharge facility. “We have worked with a French-design firm to get the architecture of the manufacturing plant designed right. The plant is beautifully designed with ventilation, air, and lighting to operate under ambient conditions without the need for extra lights, thus minimising overall power consumption. We work at par with international standards and make no compromises on the same. The policies designed for products and manufacturing practices is formulated bearing on mind sustainability goals of the organisation.” Sounjanya Group incorporates peoplefriendly workplace policies and reinforces consistent belief in equality at every level of operations – right from an individual on the shop floor to the directors, helming the group’s overall operational workings. Bhumkar believes, “Every job is important, and when each person delivers their best is when the company grows. So, there is equality, and everyone is treated equally. In terms of CSR activities, today we are falling under the purview of the CSR norms as per the Indian Companies Act. We have a rule of making allocations, which is divided into few of the areas wherein we feel the need to make contributions towards the society. From this year onwards, we will not only be donating sums but will also be participating in social causes.”
CSR (Corporate Social Responsibility) in Focus Sounjanya is a silver-rated CSR-certified company by EcoVadis, a globally reputed major that certifies corporations for their CSR contributions. Honing a mindset of sustainability at its core over the years, the manufacturing processes at Sounjanya are leaning towards greener chemistries. Some of the new products slated to launch soon in the market are all green. The manufacturing facility is also built as per the green-building design September 2018 • 73
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
Inside Cover I
12
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33
13
Saka Engineering Systems (P) Ltd
15
Inside Cover II
14
Sulzer India Pvt Ltd
21
35
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Suraj Ltd
37
3
16
TMVT Industries Pvt Ltd
35
18 & 19
17
UNP Polyvlaves (India) Pvt Ltd
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Ion Exchange (india) Ltd
17
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Jay Water Management Pvt Ltd
31
20
Venus Trading Company
10
Lubi Industries LLP
21
CHEMTECH WORLD EXPO 2019
11
Mist Ressonance Engg Pvt Ltd
1
Atomic Vacuum Company (Exports)
2
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3
Grundfos
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Horizon Polymer Engineering Pvt Ltd
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7
9 33
37 Back Cover
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R.N.I. No. 11403/1966 Date of Publication: 29th of every month. Postal Registration No: MCS/095/2018-20 Posted at Patrika Channel Sorting Office, Mumbai 400001, on 30th of every month. Total Pages No.:76