Chemical Engineering World September 2019 by Chemical Engineering World

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

VOL.54 | ISSUE 09 | september 2019 | TOTAL PAGES 68 | US $ 10 | ` 150

CHEMICAL ENGINEERING WORLD september 2019 Vol.54 Issue 09 Mumbai ` 150

Pumps, Valves & Fittings ChemTECH SOUTH WORLD EXPO 2019

4-6 December 2019 Venue: HITEX Exhibition Center, Trade Fair Office Building Izzat Nagar, Kondapur PO, Hyderabad, India

24-27 February 2021 Bombay Exhibition Center Goregaon (East), Mumbai, India

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

Maulik Jasubhai Shah Hemant K. Shetty Hemant K. Shetty

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D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com)

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4 • September 2019

news Industry News Technology News

08 12

Fearures Digital Transformation of Chemical Manufacturing Plants

Amit Paithankar, Vice President Sales, Final Control Asia Pacific, Emerson

210, Taj Building, 3rd Floor, Dr. D. N. Road, Fort, Mumbai 400 001, Tel: +91-22-4037 3636, Fax: +91-22-4037 3635

SALES

Vol. 54 | ISSUE No. 09 | september 2019 | Mumbai | ` 150

Vacuum Pump Reinforces Reliability, Performance, and Consumption Efficiency

Shruti Tawte, Vacuum Drying Technology India LLP Digitalization – The Future of Valves and Valve Manufacture

Mohandas Sugumar, Deputy General Manager for New Product Developments and R&D, L&T Valves, India Yaser Ahmed Palikonda Latheef, Digital Initiatives coordinator – Coimbatore Plant, L&T Valves, India Four Reasons to Choose AODD Pumps for Chemical Processe

Erik Solfelt, Wilden, USA Dover India Pvt Ltd – PSG Business Exhibits on Energy Loss in Cooling Water Pumping Applications Anil Kulkarni and Saurabh Thorawade, AB – Chemtech

PRODUCTS 48

events 61 PROJECT UPDATE

book shelf 65

Ad Index 66 Cover Page Photo Courttesy: Emerson

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

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CEW Industry News Covestro (India) in Collaboration with ARCH Foundation launched 6 new Brighter World Labs in Cuddalore

Cuddalore, India: Covestro (India), a leading producer of advanced and high-performance polymers in India and around the world, has recently announced the launch of 6 new Brighter World Labs for students in Cuddalore. In collaboration with ARCH Foundation, Project Brighter World Lab aims at promoting scientific reasoning among children and creating a new generation of analytical thinkers. In India, only 29 percent of children attend private schools, while the remaining join government or state-funded educational institutes that have zero or exceptionally low fees and ride on a host of problems. With Brighter World Lab, a holistic and pioneering intervention, Covestro (India) tries to ensure that each child is brought closer to science and to add meaningful and long-lasting experiences aiming to create a life-changing impact on the less privileged section of society. Speaking at the inauguration, Mr. Ajay Durrani, Managing Director, Covestro (India) said, “At Covestro, we truly believe that education is a fundamental right and it should be available to all. Our vision for Brighter World Lab is to ignite scientific interest in children so that they can learn through discovery and connect scientific knowledge of the textbook to the real world. We realized that setting up good infrastructure is not guaranteed enough that it will have a direct academic benefit on students in government schools and thus the whole idea of project Brighter World Lab has derived because we feel that there is a vast difference between reading from a textbook and experiencing it first-hand.” “We at Arch Development Foundation, believe that each child deserves opportunities and exposure in order to showcase their talent and that’s where the whole idea of Brighter World Lab came into existence. With Brighter World Labs, we tend to create projects which can enrich the world in a brighter way. With Covestro (India), the whole idea of Brighter World Lab got conceptualised and executed in a very great way and we look forward for many such initiatives in future”, said Sonkee Shah, CEO, ARCH Development Foundation. Initiated in 2017, project Brighter World Lab was launched with installations of 10 Maths and Science laboratories in four cities – Greater Noida, Ankleshwar, Mumbai, and Cuddalore. In 2018, the project became more formidable after collaborating with the ARCH Foundation and with the addition of 20 Brighter World Labs. In 2019, the expansion and growth plan for project Brighter World Lab has become more comprehensive and 20 more Brighter Labs have been added in Greater Noida, Ankleshwar, Mumbai and Cuddalore. 8 • September 2019

Lanxess Addressed the Topics of New Mobility, Urbanization and Digitalization at “K 2019”

Cologne, Germany: Lanxess will be presenting a broad portfolio at the international trade fair for plastics and rubber K 2019. On its 700 square meter stand, the specialty chemicals company will focus primarily on the topics of new mobility, urbanization and digitalization. “Innovative mobility solutions and modern urban concepts are currently being developed worldwide. These are important growth areas for us and our customers. We are constantly developing sustainable material solutions and technologies for this purpose and are also focusing on new possibilities for digitalization”, explained Hubert Fink, member of the Lanxess Board of Management. All in all, six of Lanxess’s eleven business units – High Performance Materials, Urethane Systems, Polymer Additives, Rhein Chemie, Inorganic Pigments, and Advanced Industrial Intermediates – will be showcasing their products at K 2019. The High Performance Materials (HPM) business unit will be presenting a wide range of new products relating to electric mobility. “Our objective with our materials is to help the various types of drive system involved in electric mobility to break through the market. We are focusing on a series of different technologies, from mild hybrid and plug-in hybrid to electric-only vehicles. Our developments are also aimed at additional mobility trends such as autonomous driving and digital connectivity”, said Michael Zobel, Head of HPM. New HPM materials include orange, heat-stabilized compounds for high-voltage applications; materials that prevent electrical corrosion upon contact with live metal parts; and halogen-free, flame-retardant materials for components such as battery cell holders and cover plates. In terms of lightweight design, Lanxess is working primarily on hollow-profile hybrid technology and thermoplastic composites under the Tepex brand. As Zobel explained, “Our composite material is becoming more and more established in structural lightweight construction in mass production. At K, we will be presenting an extremely durable seat shell and a highly integrated front-end carrier made from Tepex, both of which exhibit an excellent crash resistance.” To be on show at K, new compounds for cost-effective blow-molding components for air management in turbocharged combustion engines and of liners for vehicles are powered by hydrogen and natural gas. “At our technical center in Dormagen, we have commissioned a state-of-the-art blow-molding system and set up a global team tasked with developing materials for special applications”, said Zobel. Chemical Engineering World

DP400TS

CEW Industry News Grundfos India Appointed Saravanan Panneer Selvam as General Manager

Chennai, India: Grundfos, a global leader in advanced pump solutions and water technology, has recently announced the appointment of Saravanan Panneer Selvam as the General Manager of Grundfos India, with effect from September 1st, 2019. Saravanan will report to Ranganath N K, Area Managing Director, INDO Region, Grundfos; and will be responsible for the company’s business and operations in India, Bangladesh, Bhutan, Maldives, and Nepal.

Saravanan has more than 20 years of experience in the pump industry. He joined Grundfos India in April 1998 and has held various positions in the company through the years. In late 2012, Saravanan took on a role oversees as Segment Manager - Industry segment in Grundfos South Africa, before taking up the role of Deputy General Manager for Grundfos Ghana in May 2013 with the responsibility for the West Africa area. After establishing Grundfos Ghana, Saravanan returned to Grundfos India in July 2015, to strengthen the organization as Sales Director with the full responsibility of the whole sales organization in the company. Commenting on Saravanan’s appointment, Ranganath N K said, “Saravanan has been an integral part of Grundfos’ journey in the county over the last two decades. Given his experience and sales acumen, we are happy to have him taken on the role of General Manger to ensure Grundfos India’s future growth in this region.” Before joining Grundfos India, Saravanan worked with steam boiler companies like IAEC Industries in Chennai and Al-Saghyir Steam Boilers in the Kingdom of Saudi Arabia. He has an engineering degree in Mechanical and Production from the Annamalai University in Chidambaram, India (1991).

Lanxess Commissioned Two Additional Production Lines for Composite Material Tepex

Cologne, Germany: At its site in Brilon Germany, Bond-Laminates GmbH – a wholly owned subsidiary of specialty chemicals company Lanxess – has commissioned two new production lines for Tepex continuousfiber-reinforced thermoplastic composites. “We have increased our capacity for manufacturing Tepex by around 50 percent and, in doing so, are responding to the strong demand in the mass production of highly stressable components for lightweight vehicles and consumer electronics”, says Dr. Christian Obermann, Managing Director of Bond-Laminates. To accommodate the expansion from six to eight production lines, a new hall covering around 1,500 square meters was constructed. The total investment ran to the mid single-digit millions and also comprised three cutting machines, including a new four-head waterjet cutting machine for prefabricating component cuts. Tepex is becoming increasingly popular in the automotive industry for the large-scale production of lightweight structural components such as frontend and bumper brackets, brake pedals, and underbody paneling components. One recent example involved two electrically adjustable single rear seats for a variant of the Audi A8, whose seat shells are manufactured in a hybrid molding process using the polyamide-6-based Tepex dynalite. The seat shells are around 45 percent lighter than a comparable metal version. 10 • September 2019

Lanxess also sees potential for Tepex to be used to produce backrests and armrests as well as seat shells for new, highly complex seating concepts in autonomous cars or for comfort seats for shuttle, VIP, and family buses. Electric vehicles offer further attractive potential for Tepex. “The spectrum of applications ranges from brackets for frontends, doors and bumpers, luggage compartment recesses, battery housings and brackets for electrical and electronics modules through to structural components in the greenhouse section and structural trims in the underbody area to protect the battery,” says Henrik Plaggenborg, head of Tepex Automotive at Lanxess. Typical applications of Tepex in consumer electronics include the thinwalled yet exceptionally strong and rigid structural components for cellphones, tablets, laptops and TVs – components that also have to meet strict aesthetic requirements regarding design and haptics. In the sports sector, Tepex is used for example in the manufacture of shoe soles, bicycle components, ski boots, body protectors, and helmets.

Volker Brück was Appointed as New Sales Director at Romaco Pharmatechnik GmbH

Karlsruhe, Germany: Volker Brück has been appointed new Sales Director of Karlsruhe (Germany) based Romaco Pharmatechnik GmbH. He will in future be responsible for marketing the Romaco Noack and Romaco Siebler product lines. Volker Brück (aged 51) took over as new Sales Director of Karlsruhe (Germany) based Romaco Pharmatechnik GmbH in July 2019. He is responsible in his new role for international marketing of the single-source supplier’s Romaco Noack and Romaco Siebler product lines, including blister, strip, and rigid tube filling solutions which are designed, assembled, and commercially supported at the Romaco facility in Karlsruhe. Volker Brück was born and bred in Dusseldorf. After graduating in economics and business administration from the Universities of Bonn and Duisburg, he embarked on a professional career in sales at a food manufacturer operating worldwide. He gained significant managerial experience there as VP Sales & Marketing and spent eight years as a Member of the Board before founding Encotecc GmbH in 2010. From then on, as a self-employed entrepreneur and sales representative, Volker Brück advised European and North American producers of packaging materials and technology. Prior to joining Romaco, he coordinated the development and market launch of a new filter paper for tea bags on behalf of a US paper group, amongst other things setting up a global network of agents. “We particularly value Mr. Brück’s practical experience and cosmopolitan outlook”, emphasised Markus Regner, Managing Director Romaco Pharmatechnik GmbH. “He has worked in the industry for many years now and is very open to new ideas. His drive and enthusiasm inspire those around him and his knowledge of the market is immense. As a former professional handball player, he has tremendous willpower and team spirit – exactly what Romaco needs to be a strong contender in the international league table.” “Romaco has grown at a rapid pace over the last few years and come a long way from where the company began. It’s a process that is still ongoing and leaves me plenty of margin for play”, commented Volker Brück, Sales Director Romaco Pharmatechnik GmbH. “I’m very much looking forward to becoming proactively involved in Romaco’s realignment in my new position. On the sales side, my prime goal will be to put our hidden champion qualities into the spotlight, in other words harness our forces effectively and expand the Romaco brand’s global reach.” Chemical Engineering World

CEW Technology News Cole-Parmer Introduced Jenway’s New Split-beam Spectrophotometer with CPLive Connectivity Mumbai, India: It’s time to experience an easier way to perform spectrophotometry with IoT in the lab. ColeParmer, a leading manufacturer and supplier of laboratory and industrial products, instrumentation, and supplies, has recently introduced the new Jenway 76 Series Visible and UV/Visible Scanning Spectrophotometer featuring split-beam optics and CPLive connectivity. Split-beam technology offers improved accuracy and repeatability when determining samples. CPLive connectivity gives users the ability to safely and securely upload and archive data to the cloud, manage multiple devices at one time with the CPLive App, share data with colleagues, and access complimentary unlimited data storage. The spectrophotometer provides fast and reliable results ideal for a variety of applications from teaching, to R&D, to routine sample analysis in quality control environments. Available as Jenway model 7615, it has a 1.5 nm spectral bandwidth, and the split-beam optics offset any signal fluctuations for increased stability over prolonged use, making it ideal for time course and kinetic measurement. The high-definition, color touchscreen, and intuitive user interface makes the spectrophotometer easy to use. The touchscreen interface is fast and responsive even when wearing gloves. This spectrophotometer is compatible with both Android and iOS devices; has 10GB of onboard storage for methods and results; is designed with multiple USB ports for data storage and printer connectivity; features multi-language options; and is versatile with a range of optional accessories. The Jenway 76 Series joins the existing Jenway family of products that include the Jenway 74 Series equipped with CPLive connectivity. This family of ‘live’ spectrophotometers complement one another, and provide accurate and reliable results. They are also pre-programmed with measurement modes that are relevant to their applications.

of bulky stirrers sitting around in their laboratory. These stir plates come with many features including the ability to attach up to 10 stir plates based on need, simple touch and slide operation, LCD display with real time parameters, corrosion-resistant glass stir top, and waterproof USB attachments. Multiple stirring options allow a choice between one direction or reversing every 45 seconds for thorough mixing. The built-in timer can be set for up to 9 hours or continuous operation. The modular magnetic stirrers are adaptable to any application required to mix up to 1L at 1500 RPM, and is IP44. When something small, cost effective, and reliable is needed, the ColeParmer elements ultra-thin magnetic stirrer is appropriate This stirrer is sleek with a top plate diameter of 10 cm, a length of 18 cm, and a height of 1.2 cm. This makes the device easy to store, and easy to operate in the tightest spot on the lab bench. It can also handle a robust workload with a maximum stirring volume of 1 L and a maximum RPM of 1500. Combined with its small footprint it also boosts a simple touch and slide operation, LCD display with real time parameters, and is IP65.

Lanxess Launched High Performance Wheel Solution Cologne, Germany: Specialty chemicals company Lanxess recently launched the new system Adiprene LFM C525 cured with Vibracure 2101 developed for the most challenging wheel applications. This MDI polycaprolactone based prepolymer offers excellent performance and great dynamics such as high tear strength, outstanding fatigue, and abrasion resistance. To demonstrate the performance and reliability of this differentiated system to the market, Lanxess undertook testing comparing the material with the highest industry standard utilized in polyurethane wheels. Adiprene Low Free (LF) MDI C525 is a polycaprolactone based prepolymer with a level of free MDI less than 1 percent. When cured with Vibracure 2101, the system delivers a 96 Shore A material. Lower hardness elastomers are also possible with variants of Vibracure 2101. Tests were carried out at different loads, speeds, and wheel geometries; and followed ISO industry standards. In conclusion, the system has proven to perform as good as the highest performance industry standard, delivering great dynamics but also a lower rolling resistance allowing energy savings. In addition to the excellent performance Adiprene LFM C525 prepolymer is easy to process, requiring on average 16-24 hours at 115-120°C post cure time, and it is stable at room temperature for ca. 36 month.

Cole-Parmer Introduced Ultra-thin Magnetic Stirrer to Optimize Stirring Needs

This PU system is a unique Lanxess solution, whereby the LF isocyanate technology facilitates the use of this differentiated curative. The LF technology avoids the “starring” effect which creates “star” shaped crystals within the elastomer due to curative precipitation. Along with easier handling and excellent performance, the LF technology also brings unsurpassed health and safety conditions to the processor.

Mumbai, India: Cole-Parmer, a leading manufacturer and supplier of laboratory & industrial products instrumentation and supplies, has come up with two different offerings from the Cole-Parmer elements line to stirring needs. With the Cole-Parmer elements Modular Magnetic Stirrer, up to ten stirrers can be connected to one controller in almost an infinite amount of combinations. By either connecting a module directly to another module, or tethering the modules with a USB connector, any lab layout can be accommodated. This stirrer is ideal for anyone who needs more stirring equipment but has minimal work space or doesn’t want a bunch

A complete solution for the wheel industry: Understanding the complexity of different wheel applications, Lanxess has developed other LF MDI polycaprolactone systems based on different curative combination allowing reaching hardness from 88 to 96 Shore A. Through many years of technical experience related to PU formulations specific to wheel applications, Lanxess has developed a predictive wheel model tool that will predict with good accuracy the wheel performance within the final application. Therefore Lanxess can support its customers in evaluating Adiprene LFM C525 in different wheel designs and/or different load/speed conditions.

12 • September 2019

Chemical Engineering World

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CEW Technology News Nahodka Mineral Fertilizer Plant Selected Topsoe as Licensor for World-scale Methanol Plant

Copenhagen, Denmark: Haldor Topsoe, Mitsubishi Heavy Industries Engineering, and GTM ONE have signed a license agreement for the design, construction, and operation of a 3,000 tons-per-day methanol plant based on Topsoe’s SynCOR Methanol technology. The plant will be erected at the Khimprom site in Volgograd, Russia. Topsoe will provide license, basic engineering, catalysts and proprietary hardware for methanol production. In the first stage, Topsoe will provide basic engineering for the process unit, and MHI Engineering will develop the Front End Engineering Design (FEED) package for the site. At a later stage, the parties expect to sign an EPC contract. Construction is slated to begin in the second half of 2020. “All technology customers are looking for well-proven and advanced technologies, high performance and low environmental impacts, high energy efficiency, and low CAPEX. In most cases, customers face a difficult choice of how to reach a compromise between these interests. We have selected Topsoe as the Topsoe SynCOR Methanol process is the ultimate uncompromised choice. We have found everything we need,” says Osipov Alexander, Technical Director, GTM ONE. “We are very pleased to offer a solution that not only helps our customers comply with environmental regulations, but also stands out as the most costeffective in large-scale methanol production. We see increasing demand for this technology both in Russia and in other markets. We are also very content to continue our well-established cooperation with Mitsubishi Heavy Industries Engineering in Russia,” says Peter Vang Christensen, Managing Director of Haldor Topsoe's Moscow office. Syncor solutions are industrially proven to deliver exceptional costefficiency, high availability, and low environmental impact in large scale single train methanol production. 16 • September 2019

` 150

GTM ONE Chose Topsoe SynCOR Technology for World-scale Methanol Plant in Volgograd

Mumbai

The world scale methanol plant will be located near the major Russian seaport Nakhodka in the Primorsky region with an intent to export its products to the Asia-Pacific Region.

VOL.54 | ISSUE 09 | SEptEmbEr 2019 | tOtAL pAGES 68 | US $ 10 | ` 150

VOL.54 IssuE 09

“We are pleased that Nakhodka Mineral Fertilizer Plant has selected Topsoe technology for their flagship project. This signals both confidence in our technology and our dedication to the Russian methanol industry. We look forward to deliver a world scale methanol plant in partnership with China Chengda Engineering Co,” says Amy Hebert, Deputy CEO of Haldor Topsoe.

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

sEptEMbER 2019

“We have chosen Topsoe for this very important project because they came to the table with proven and reliable technology, very competitive pricing, and a long-standing presence in Russia. We look forward to realizing Russia’s most modern and effective methanol plant together with Topsoe”, says Mr Taras Ganaga, CEO Nakhodka Mineral Fertilizer Plant.

Contribute to CEW CHEMICAL ENGINEERING WORLD

Copenhagen, Denmark: Nakhodka Mineral Fertilizer Plant has chosen Haldor Topsoe technology for a 5,400 tons-per-day methanol plant near Vladivostok in the Eastern part of Russia. China Chengda Engineering Co Ltd has been chosen for engineering, procurement, and construction (EPC). Topsoe will provide license, basic engineering, catalysts, and proprietary hardware for the methanol plant which will be based on Topsoe’s two-step reforming technology.

Pumps, Valves & Fittings ChemTECH

4-6 December 2019 Venue: HITEX Exhibition Center, Trade Fair Office Building Izzat Nagar, Kondapur PO, Hyderabad, India

24-27 February 2021 Bombay Exhibition Center Goregaon (East), Mumbai, India

SOUTH WORLD EXPO 2019

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 insight 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 highresolution (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 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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01.08.19 13:59

CEW Features

Digital Transformation of Chemical Manufacturing Plants

Author has brought out an insight here on digitalization as a mandatory way forward for chemical processing industry to win over various challenges. Towards this endeavor, light has been thrown on to various facades viz data collection and analysis, digital operational infrastructure, predictive analysis, pervasive networking, pervasive sensing, and associated others.

he chemical manufacturing industry faces many challenges affecting plant performance and reliability, safety and compliance, and production.

Keeping

Plants may struggle with unscheduled downtime due to unexpected equipment failures or excessive scheduled downtime for turnarounds, thus losing several days of production every year. In addition, it may be difficult for personnel to keep up with a preventive maintenance schedule, and many plants have escalating maintenance costs.

compliance. Again, manpower cannot be

Some process equipment may see a premature end of life, due to a reactive maintenance culture. Loss of containment due to aging of piping and vessels is another challenge. Moreover, plants are expected to improve performance without increasing headcount. 18 â&#x20AC;˘ September 2019

pace

with

inspection

and

verification requirements in new health and safety directives also can be difficult, leading

potential

fines

for

non-

added to perform these tasks. Finally,

manual

operation

causes

production bottlenecks. Operating costs may be escalating, and as staff retires the remaining personnel are left with more to do.

Improving data collection and analysis: To achieve operational excellence, chemical manufacturers can now digitally transform how the plant is run and maintained. For example, plants are switching to new automatic, digital, software-based and data-driven working methods that enable personnel to carry out their daily duties more effectively. Routine manual collection of maintenance, reliability, and integrity data from equipment like pumps and valves with

Plants may struggle with unscheduled downtime due to unexpected equipment failures or excessive scheduled downtime for turnarounds, thus losing several days of production every year due to a reactive maintenance culture. In addition to this, many plants have escalating maintenance costs. Even some process equipment may see a premature end of life for this. Chemical Engineering World

SANWA STAINLESS STEEL

MAGNET DRIVE PUMP Completely leak-free MAGNET DRIVE PUMPS MAGPAC Series As we enter the 21st Century, environmental concerns, new technology, and renovated manufacturing techniques make changes in pumping equipment mandatory... yet, very feasible. Stainless steel, sealless magnet drive pumps with leak free construction, safety, reliability and long life can now fulfill the requirement and demands of today’s pumping requirements. For about 80 years, with the technological advancement we’ve mastered, high quality is assured in the field of basic design, material selection as well as test run of final product. Furthermore, we are constantly working on developing more and more reliable customer relationship from the initial consulting to after service stage.

Signiﬁcantly increased dry running capability!

Manufacturer SANWA HYDROTECH CORPORATION OSAKA, JAPAN | www.sanwapump.com Distributor S Y P ENGINEERING CO. PVT. LTD. 29, Patel Ind. Estate, S.V. Road, Dahisar (E), Mumbai-68. Ph.: +91-22-28489969 / 28488586, Fax: +91-22-28488781 Email: syppumps@gmail.com | Website: www.sypco.co.in

CEW Features Procedures, drawings, and manuals can be accessed on a tablet in the plant, eliminating the need to carry papers or return to the office to pick up additional documents. Ad-hoc visits to the plant to check if a manual valve was closed, dipping to see if the tank is nearly full, or inspection for leaks and spills can be replaced by automatic detection, digital transmission, and indication in control room software as well as use in interlocks.

Figure 1: Remotely located expert seeing the problem in real time via field technician with wearable technology

portable testers, and time-consuming interpretation, are no longer required. Instead, vibration, acoustic, corrosion, and other data is collected automatically to detect early signs of potential problems, transmitted digitally, and analyzed by software to predict and distinguish between various equipment failure modes. Notifications of developing issues can be sent to an operator’s smartphone or tablet at any location.

Any remaining manual inspection rounds make use of a tablet, software, and secure connectivity to supply information to a central pool of domain experts who analyze the data and provide actionable information in support of plant personnel. This support includes two-way digital video and audio between a field technician via a wearable camera on-site, and a remotely located expert seeing the problem in real time via a software application (see Figure 1).

What’s more, the geo-location of every person is sensed digitally in real-time and automatically tallied in software. An alarm is issued if personnel breaches permitted work areas or enter high-risk areas. Automatic detection, digital transmission, and alarms on safety shower activation or “man-down, not moving” situations all increase safety. Digital operational infrastructure There is no need to replace or significantly overhaul the existing control system, as the operational infrastructure is compatible with existing automation. In addition, the existing historian can be used as an analytical platform.

Figure 2: Plantweb™ Insight Dashboard

20 • September 2019

Chemical Engineering World

CEW Features In a digitally transformed plant, work done by everyone from the plant manager down is data-driven. A key success factor is that the information must be easily accessible in a timely manner, and it must directly be delivered to the person responsible. For instance, predictive instrument alarms and data should be delivered to the laptop and smartphone of the instrument technician. Dashboards and alarms are generated by mobility software using information from underlying analytics applications that perform functions such as equipment condition monitoring. Dashboards (see Figure 2) contain KPIs specific to the person’s responsibilities, displayed on tablets or smartphones, making information immediately available at any location. Predictive analytics Many digital transformation solutions involve simple monitoring of key elements such as corrosion, temperature, and pressure, needing no analytics. However, predictive equipment analytics applications which leverage embedded subject matter expertise are used for performance and condition monitoring of complex process equipment. They use multiple measurements to anticipate problems, allowing failures to be averted. Such equipment includes – for instance – pumps, compressors, and valves. Through

these applications, raw data from sensors is distilled into actionable information. When a problem arises, the technician already knows the most effective course of action and what tools to bring before going to the field. The fault models uncover early signs of trouble and distinguish between many types of equipment-specific failures. Analytics software can be installed on servers, on-premise, or on virtual machines in the cloud. A layered, open architecture has real-time analytics at the sensor level, and edge analytics are conducted in higherlevel devices and servers, feeding up to big data analytics. Web-based analytics applications are not dependent on any particular control system or historian. The plant’s existing historian remains in place, with no need to add another middleware platform, thus protecting the plant’s investment and keeping the administration cost low. The analytics use data aggregated from multiple sources: new wireless sensors, existing sensors, package unit PLCs, control systems, safety system, machinery protection systems, intelligent device management (IDM) software, and any historian or future platform. Real-time equipment monitoring makes it easy to maintain; and is also reliable

for professionals to use with features like overview dashboards, an alarm summary with simple health index, priority, plain text problem description, the ability to zoom into detail, and history-trend to see accelerated degradation as well as to estimate remaining life (see Figure 3). The analytics uses verifiable first-principle models and statistical algorithms to detect signs of developing equipment issues, predicting failure, and providing an early warning on these leading indicators so that breakdown can be prevented. These applications are pre-engineered based on years of experience, so no long algorithm learning periods are required, just baseline to capture. No custom programming or code maintenance is required. Pervasive networking Data-driven practices require sensors to collect the critical data. It would be impractical to hardwire hundreds or thousands of sensors using 4-20 mA and on-off signals point-to-point. Plants built with Foundation Fieldbus networking can simply add instrumentation to existing field junction boxes with minimal wiring to the sensors. Plants deploy a plant-wide wireless sensor network and, optionally, a wireless LAN infrastructure, depending on which tasks will be digitally transformed. The infrastructure consists of wireless gateways for the sensor networks, and wireless access points for the Wi-Fi network as the central nervous system of a digital plant. The gateways can be embedded inside the access points when WirelessHART and Wi-Fi are deployed together. Since these networks are used for operational functions, both wireless networks integrate with the control system, historian, machinery protection system, safety system, and other operations systems.

Figure 3: Easy-to-use analytics apps

22 • September 2019

Pervasive sensing Equipments such as pumps, compressors, valves, and steam traps have process sensors but usually no sensor for condition monitoring. This equipment is instrumented with additional sensors to cover these missing measurements. Chemical Engineering World

CEW Features remote, continuous assessment of critical equipment and processes and delivering the actionable insights that maintenance departments need to improve performance. With Microsoft Azure cloud services, as well as with a scalable and secure application environment, automation technology suppliers can offer support via subscription-based health monitoring services. This eliminates the need for companies to focus on developing in-house domain experts and instead can leverage services that can immediately deliver improvement as well as cost reductions across many operational areas. For example, diagnostic data is helping to identify potential control valve failures before they cause significant interruptions to operations. By analyzing a wide variety of diagnostic data collected from digital valve controllers, remotely-located experts are identifying failure conditions.

Figure 4 – Connected services installation

Automatic data collection is much faster, providing early detection of developing problems, thereby making the asset management more predictive and far more productive. Wireless sensors often take the place of mechanical instruments, portable testers, and clipboards. Control valves, steam traps, and pressure relief valves – not already digitally integrated – are fitted with wireless adapters. Many of these sensors are non-intrusive or reuse existing process connections, meaning they can be installed while the plant

is running, without shutting down the process. Condition monitoring and reporting Often there are not enough experts at a site. To address this, some plants opt for a digital solution with experts in a central location, monitoring equipment across multiple sites globally. Companies have the option of either performing this analysis inhouse or using external experts. Developing dedicated in-house experts can be costly and hard to retain. Automation technology suppliers are helping by offering

Conclusion: Embracing digital transformation is not about a single software installation. Instead, it requires a focused commitment from company leadership to alter the technological foundation of the company and critical business processes for the good of the business. Companies that embrace this outlook and the innovations that enable to realize improved performance along with reliability with better safety and less compliance issues within their manufacturing operations and position themselves to add more value to customer interactions. This will, in turn, lead to sustained success and long-term profitability. Author’s Details

Figure 5 – Experts monitor critical equipment

24 • September 2019

Amit Paithankar, Vice President Sales, Final Control Asia Pacific, Emerson Email ID: amit.paithankar@emerson.com Chemical Engineering World

CEW Features

Vacuum Pump Reinforces Reliability, Performance, and Consumption Efficiency Vacuum pumps play a very crucial role in Chemical Processing industry. Italvacuum is one of the leading manufacturers of vacuum pumps with worldwide reference point. The article enumerates how Italvacuum’s Saurus939 solution empowered with LubriZero system makes a marked difference in the league. to the innovative LubriZero system that guarantees perfect operation and optimum results with total respect for the environment, oil consumption has been virtually eliminated. Saurus939 remains unaffected by aggressive and corrosive solvents, powders and condensates, as well as distillation by-products. It is designed and manufactured to work 24 hours a day with a sustained excellent performance and minimum operating costs, thanks to its low-energy motor, negligible oil consumption, and easy immediate maintenance. The solution guarantees optimum safety through the whole process and complete purity of the final product. In other words, it ensures an uncontaminated vacuum.

Vacuum pump

hemical reactions are widely used in synthesizing compounds, where vacuum is required to avoid high temperatures, and to remove oxygen & secondary products. Reactions normally take place at temperatures around 10/20 mbara. Vacuum reactors generally have a volume between 1 m 3 and 10 m 3. For these applications, it is recomended to use a vacuum pump with a nominal output between 80 to 380 m 3/h. Due to its resistance to corrosive solvents and reliability in the most demanding work 28 • September 2019

Source: Italvacuum

environments, we recommend Saurus939 as a solution. Being the core business of Italvacuum and one of the leading manufacturers of vacuum pumps, Saurus939 guarantees unrivalled performance in all the main chemical and pharmaceutical processes, thus ensuring total recovery of extracted solvents, even in severe operating conditions. It is a simply designed machine that combines traditional robustness and reliability with the most evolved technology. Thanks

Applications: The Saurus939 vacuum pump has a wide range of usage, as it can be used in the following sectors in drying, reaction, distillation, crystallization, filtration, evaporation, and polymerization processes: • • • • • • •

Chemicals Pharmaceuticals Cosmetics Oil & gas Plastic & rubber Bio-science Waste management.

Features: It is designed for roundthe-clock usage. The design is simple and traditional. On top of all, the greatest value addition is Italvacuum’s consolidated experience that has perfected, innovated, and improved the Saurus939 vacuum pump, thus guaranteeing optimum operation in all Chemical Engineering World

CEW Features Strengths of Saurus939

■ Complete robustness in any work environment ■ Lower operating technology ■ High resistance against corrosion • LubriZero ■ High resistance against powder, condensates ■ Continuous recovery of the extracted solvents ■ Unlimited use over the entire vacuum range ■ Uncontaminated vacuum and complete purity of final product

■ Low noise (<70db) and low operating speed (250 ■ Low average working temperatures. ■ ATEX certification up to zone 0. chemical and pharmaceutical processes such as drying, distillation, reaction, and crystallization. Saurus939 can intake both the vapours of common solvents (viz methyl alcohol, ethylic alcohol, chloroform, acetone, ethyl acetate, methyl chloride, benzene, toluene, isopropyl alcohol, ethyl ether, heptane) as well as those of more aggressive solvents (viz hydrochloric acid, acetic acid, chlorobenzene, dimethylformamide, acrylonitrile, dichloroethane, cyclohexane, pyridine, dimethyl sulfoxide, dichloromethane).

system

with

negligible

oil

consumption

and distillation by-products

rpm)

costs than any other vacuum

•

Extremely limited environmental costs

•

Low-energy motors

•

Easy and economical maintenance

■ Absence of warm-up cycles and waiting times ■ Physical separation between process and mechanical parts

■ Unrivalled performance in the constant recovery of extracted solvents

LubriZero system – an injection of value, with negligible consumption: Saurus939 is equipped with the exclusive LubriZero system that ensures best possible performance with truly negligible oil consumption, completely compatible with the environment. The LubriZero system combines the metered injection of oil with a kit of new materials in PTFE with special charges that are not only resistant to corrosion, but require virtually no lubrication. This

also allows for the use of synthetic FDA approved oils. The metered flow of a few drops of fresh oil (about 10 g/h) guarantees an effective barrier from even the most aggressive solvents, considerably increasing the duration of the perfect cylinder-piston coupling and hence the working life of the vacuum pump. Uncontaminated vacuum Saurus939 guarantees the purity for the final product. It is powerful, resistant, efficient, and completely safe. It ensures

A new level of robustness in construction: Cylinder, pistons, piston rings, and head are made of special anti-acid cast iron. The other components are made of cast iron, special steel, and PTFE with special charges. The pump is completely sealed: a characteristic that makes it extremely reliable and efficient for a long time, even in damp and dusty environments. The discharge valves have automatic openings and are available in different materials, including hastelloy. Saurus939 has two completely separate, independent lubrication circuits: • one circuit for the process part, with metered injection of fresh oil, thanks to the LubriZero system • one circuit for the mechanical part with re-circulated oil. 30 • September 2019

Chemical Engineering World

CEW Features

32 â&#x20AC;¢ September 2019

Chemical Engineering World

CEW Features maximum safety throughout the whole process to impart purity to the final product. In other words, it guarantees uncontaminated vacuum. In fact, during the entire work cycle, not even one molecule of oil reaches to the processed product. This is certified by the Department of Material Science and Chemical Engineering at the Politecnico of Torino, as part of specific research carried out on a complete process of vacuum drying. The result has revealed that the final product is absolutely pure with no risk of oil contamination in the process. Best results Ensuring and maintaining better quality is never an expense; instead it’s an investment. And that investment is always rewarded with good results. Over time, the Saurus939 vacuum pump has achieved more. It lasts longer and has lower running costs with respect to other main technologies for vacuum systems. The use of oil not only avoids any contamination in the process, but also improves performance and increases pump life, thus reducing the maintenance costs, even in the presence of very aggressive solvents. The choice of materials, technology employed, and the appropriate solutions taken by Italvacuum in every design detail make Saurus939 the best in the sector with reliability and results beyond comparison. Range Saurus939 range includes single stage and double stage models. Its double stage models are also available with one or two compressor roots in order to increase the

pump rotation speed and to reach lower final pressures at high vacuum levels. Accessories A winning choice for complete installations The high quality of Saurus939, not only in the unquestionable reliability of the vacuum pump, but also the wide range of accessories, allows for turn-key installation of the entire vacuum group: 1. Atmospheric post-condenser for the recovery of solvents from the pump outlet 2. Condensate recovery tank from the postcondenser outlet 3. Pump suction filter with particle centrifuge separation and metal filtering cartridge 4. Control panel board, also available in compliance with ATEX DIRECTIVE 94/9/EC

Certifications Excellence is a recognized value Saurus939 complies with the requirements of the most demanding European Directives: • Machinery directive 2006/42/EC • Electromagnetic compatibility directive 2004/108/EC • Atex directive 94/9/EC The standard version, CE εx II 2G T4/T3, is suitable for installation in an area classified as ZONE 1-GAS and temperature class T4 (135 oC). The Saurus939 special version can be supplied with ATEX certification up to ZONE 0-GAS (internal pump), ZONE 1-GAS (external pump) with three different classes of temperature T4 / T150 oC / T3.

5. Support base for easy, fast installation.

For More Details: Shruti Tawte Vacuum Drying Technology India LLP B- 102, Shubh Sarita, Appasaheb Sidhaye Marg, Shrikrishana Nagar, Borivali (East), Mumbai : 400 066. India. Contact : +91-7738160367 Email: accounts@electromechengineering.com 34 • September 2019

Chemical Engineering World

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182

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Pharma & Biopharma Bulk Drugs APIs Biotechnology Chemical Processing Chemicals & Petrochemicals Agrochemicals Fine & Specialty Chemicals Oil, Fats & Oleo Chemicals Food & Beverages Advanced Materials Material Testing & Inspection Contract Research & Manufacturing Research Laboratories Clinical Research Labs Government Agencies Municipalities & ETPs Pollution Control Boards Water & Waste Management

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CEW Features

Digitalization – The Future of Valves and Valve Manufacture The Future is digital. L&T Valves has pioneered the digitalization drive in the valve industry, launching IoTready products and processes empowered by IIoT (Industrial internet of Things). From the first customer contact to aftermarket support and beyond, the digital solutions maximise operational efficiency and customer satisfaction. The authors, in this article, has given a comprehensive account of the mentioned subject. LAMP (L&T Valves Asset Management Programme) – Smart Valve At the core of LAMP, it is a time-tested SIL3-capable valve, upgraded to a ‘Smart Valve’ by the addition of sensors and communication modules, to provide complete valve health and diagnostic information. The parameters monitored include flow rate, upstream and downstream temperatures and pressures, gland pressure, cavity pressure, torque, vibration, valve position (open or close), number of times the valve has been operated, and the number of hours it has been running. The location of the valve can be detected through GPS for easier tracking during emergencies.

to detect issues before valve performance goes down. The next phase of the smart valve would be to develop prescriptive maintenance where the product has the knowledge base not only to identify the issue but also to guide the technician on what to do for repairing the issue. Also, the data generated would help design a valve that is future-ready.

smART.view empowered with Augmented Reality L&T Valves has launched a digital collaboration platform that leverages augmented reality (AR) technologies to virtually teleport customers to the manufacturing facilities, thus minimizing the limitation of distance and time. smARt.view facilitates interaction and collaboration with the subject matter experts (SMEs) in the plant and site personnel anywhere in the world through voice, chat, and annotation in the AR space.

The smart valve is a patented product that communicates with an Asset Management Platform (AMP). The AMP sends data to stakeholders in two forms. The first one comprises alerts and notifications sent in raw form, especially in case of emergencies. In the second form, the data is analyzed through a data analytics platform and then presented to the stakeholders in a visual, graphic, and easy to understand format. LAMP data can be viewed by logging in to a cloud computing platform, and in the case of non-cloud solution, a wireless gateway sends the data to the AMP using a Modbus TCP. The smart valve has revolutionized valve maintenance in user industries - from reactive (repair after failure), preventive (scheduled maintenance regardless of failure), and condition monitoring (alert based on trend for a single variable) to predictive maintenance (PdM) where equipment specific algorithm/machine learning (ML) combines multiple variables 36 • September 2019

Valv.Trac

Source L&T Valves

Chemical Engineering World

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CEW Features The tag makes it easier for the installation engineer to know about the valve details and install the correct valve at the correct location in the system. RFID tags can offer a link to data such as customer purchase order number, valve serial number, L&T Valves sale order and line item number, material description, tag number, customer name, inspection release note, shipment release note, component name, heat no, MPI and X-ray no of castings, DPI no, etc. The tag also provides a link to online server where documents such as general assembly drawing (GAD), valve and material test reports (VTR, MTR), installation manuals, etc are stored.

LAMP

Source L&T Valves

The technology offers customers the option to carry out remote inspection of valves before dispatch, thereby realizing significant savings in cost on account of travel by multiple agencies. The technology also enables virtual plant tours and audits for potential customers. Further, training of customers at site, especially on missioncritical flow-control solutions is a definite advantage that ‘Smart.view’ offers. ValvTrac Digital Traceability ValvTrac literally offers information at your fingertips. The revolutionary traceability solution uses RFID (Radiofrequency Identification) technology to provide the customers all documents related to the valve digitally. The passive RFID tag operates in the XF frequency band, and designed to perform in harsh environments.

This RFID tag will be especially helpful for technicians at site to quickly identify valve and troubleshoot in case of failures. Also, re-ordering of valves during expansion, or ordering of spare valve or spare parts becomes easier for buyers as all the data and references become available on the tag. ValvTrac was successfully implemented at one of the largest refineries in the world.

Experience the Future Customers’ response to digital products and solutions have been encouraging, and we are excited about the rapid progress being made in the domain. We welcome all to join us and experience the future of valves.

SPEED Digital Manufacturing Platform SPEED is a proprietary manufacturing and project management platform that leverages digital man-machine interfaces to ensure end-to-end visibility and errorfree on-time manufacture. SPEED enables collaboration across functions, facilitates concurrent decision making, and enhances transparency trust & speed. SPEED is a platform that consolidates all the digital features on the shop-floor, planning, and supply chain. It achieves ontime delivery through backward scheduling. SPEED also guarantees weekly and daily plans that is digitally displayed on the shop-floor. The displays also show actual production status against the plan. During manufacturing, RFID technologies provide 100 percent visibility to major

The smart valve has revolutionized valve maintenance in user industries – from reactive (repair after failure), preventive (scheduled maintenance regardless of failure), and condition monitoring (alert based on trend for a single variable) to predictive maintenance (PdM). 38 • September 2019

components, and ensure on-time errorfree manufacturing. In addition to RFID, barcodes are used internally at the plants to track the progress of major components. A traveler card (TRC) attached to valve components also enhance visibility as they advance through various stages of machining, assembly, and testing. Confirmation done at every stage allows us to follow the progress of the valve manufacturing digitally. Moreover, the TRC has a barcode which can be scanned at the assembly station to not only retrieve assembly and testing procedures that guide the assembly and testing technicians in doing their work, but also to notify them about any special requirements specific to that customer.

Author Details

Mohandas Sugumar Deputy General Manager for New Product Developments and R&D L&T Valves, India

Yaser Ahmed Palikonda Latheef Digital Initiatives coordinator – Coimbatore Plant L&T Valves, India Chemical Engineering World

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CEW Features

Four Reasons to Choose AODD Pumps for Chemical Processes Chemical processing requires completion of some of the most intricate and complex industrial operations in the world. One of the most crucial operations is the transfer of liquids along the production chain. Due to the importance of many fluid transfer operations along the breadth of the chemical manufacturing chain, facility operators need to identify the best pumping technology for the job. The author, in this article, narrated what makes AODD pumps advantageous over its contemporary leagues.

ince its invention in 1955 as a mining pump, the air operated double diaphragm (AODD) pump has established a well-earned reputation as a technology that is ideally suited for utilitarian, auxiliary, or basic liquidhandling and transfer applications. AODD pumps excel in these types of applications because they have design characteristics that allow them to offer simple, seamless

operation and enable them to self-prime, run dry, achieve suction lift up to 30 feet (9 meters or 14.7 pounds per square inch absolute [psia]), resist deadhead pumping conditions, operate while submerged, and pass solids up to 3 inches (76 millimeters [mm]) in diameter. It did not take long for companies to see why these operational characteristics would be highly desirable in many process applications and why AODD pumps are true â&#x20AC;&#x153;processâ&#x20AC;? pumps capable of performing efficiently, reliably, and safely in a wide range of critical fluid handling applications. AODD pumps also hit the operational sweet spot in many of the fluid handling tasks that are prevalent in the chemical processing industry. There are four key areas in which AODD pumps often outperform other technologies in terms of efficient, reliable, and costeffective operation. Chemical processors who are looking to optimize their operations would be wise to consider the advantages that AODD pumps can provide in these areas.

Figure 1: While plastic pumps are typically a go-to pumping technology in chemical processing, there can be instances where metal pumps are a better choice for the operator. (Image courtesy: Wilden)

40 â&#x20AC;˘ September 2019

1. The Importance of Air: As the name states, the operation of AODD pumps relies on

compressed air, which can be found in most chemical-processing plants around the world. Leveraging this readily available air can make the AODD pump a plug-and-play device that requires no infrastructure upgrades to incorporate. Additionally, the use of air to power the pump is the key source of one of its most sought-after capabilities: the ability to deadhead without damaging the pump, system, or fluid. This makes AODD pumps easy and flexible to operate. Keeping air usage low is critical to maintain a healthy environment and a healthy processing plant, and recent technological advances have taken significant steps toward realizing these goals. The advances have been focused around one shortcoming in AODD pump operation. At the end of every pump stroke, a small amount of air is consumed that does not contribute to the movement of the fluid. Imagine hitting the gas pedal in a vehicle that is on ice; the wheels spin, but the car does not move. One redesigned air distribution system addresses this problem with an air control spool that reduces the amount of air allowed into the pump at the end of the stroke, which reduces the amount of wasted energy that had traditionally been lost to the atmosphere. Chemical Engineering World

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CEW Features construction and function over the years has been meaningful. Chief among them is that long-lived diaphragms that have been engineered for use in chemical-processing activities require less-maintenance, which lowers repair costs for the operator. One-piston diaphragm pump has an outer piston that is completely encapsulated within the diaphragm’s thermoplastic elastomer (TPE) material, which provides several benefits. Figure 2: A newly developed air control spool eliminates costly air loss at the end of the pump stroke, resulting in up to 60 percent savings in air consumption when compared to competitive models.

This allows the AODD pump to realize up to 60 percent savings in air consumption, improves the pump’s suction-lift capabilities, and enables the pump to better handle high inlet pressures, all while delivering more yield per standard cubic feet per minute (scfm) of air consumed than AODDs that feature traditional air distribution technology. Low Maintenance Costs through 2. Proper Diaphragm Selection: Diaphragm pumps have a unique benefit when compared to many rotating-pump technologies in that they do not require any seals. Elimination of the need for packing or mechanical seals means that maintenance costs tend to be inexpensive and infrequent. Combined with the ease of operation, AODDs are a “set-and-forget” type of pump, provided the right diaphragms are selected for the application. Diaphragm material choice, shape and pump design all play a role. Along with the advances of air distribution design and operation, the improvements made in diaphragm

First, the design removes the phenomenon known as outer piston abrasion, which is when the outer piston rubs against the diaphragm as it cycles and over time, like sandpaper, wears away the material. Removing the outer piston eliminates this failure mode, dramatically increasing diaphragm life. Secondly, it also removes a known leak point in traditional diaphragm designs around the outer piston, improving overall safety when handling dangerous chemicals. Finally, the design eliminates an area along the outer piston where pumped fluid can be trapped. In the end, the downtime and maintenance that unplanned failures can incur are typically more expensive for the facility operator than the spare parts required to keep the AODD pump operating. The use of these newer designs allows the pump to run longer before requiring diaphragm maintenance and will translate directly to a healthier bottom line. 3. Versatility and Compatibility: By definition, chemical processing requires the completion of some of the most intricate and complex industrial operations in the world. One of the

AODD pumps are true “process” pumps capable of performing efficiently, reliably, and safely in a wide range of critical fluid handling applications. It hits the operational sweet spot in many of the fluid handling tasks that are prevalent in the chemical processing industry. 42 • September 2019

Quality pump construction is the key when handling dangerous chemicals, and using a pump designed with the right materials is important to the safety of a plant. most crucial operations is the transfer of liquids along the production chain. Due to the importance of many fluid transfer operations along the breadth of the chemical manufacturing chain, facility operators need to identify the best pumping technology for the job. The technology must possess the versatility to perform reliably and efficiently at any number of points in the production hierarchy. AODD pumps can offer a number of operational advantages: • They are appropriate for use with high-viscosity fluids and can handle fluids that range from water-like to medium and very-viscous liquids. • They can run dry and strip discharge lines without getting damaged. If the pressure becomes too much, the pump will just stop running, but it will not break. • They are simple devices and their control replies solely on solenoid operators, pump cycle counters, and surge-dampener assemblies. • Their operating costs can be lower when all of the maintenance, accessories, and controllers are included and in many cases their total cost of ownership is lower over their entire operational lifespan when compared to competitive pump styles. Additionally, some of the AODD pump styles have been designed to be direct bolt-to-bolt and pipe-to-pipe dropin replacements in existing pumping systems. This makes the AODD pump styles a cost-effective way to upgrade fluid-transfer performance while Chemical Engineering World

CEW Features

Figure 3: One diaphragm is designed with a piston that is integrated into the diaphragm itself. The result is that unlike conventional diaphragms, this diaphragm has no outer piston abrasion, which is a key failure mode for conventional diaphragms and eliminates a potential leak point around the outer piston. This means improved diaphragm life and peace of mind when handling hazardous liquids.

simultaneously realizing the benefits inherent in the operation of an AODD pump that features an advanced air distribution system. These benefits include reduction in air consumption and expense, optimized product handling and containment, and scaledback maintenance and replacement costs. Finally, the design and operation of AODD pumps allow them to transfer a wide range of liquids with varying handling characteristics. One of the most prominent is viscosity, or the thickness of the liquid that is being transferred. The operation of AODD pumps virtually eliminates product slip, regardless of the fluid’s viscosity, since the pump’s ball check valves control fluid transfer. Conversely, gear, screw, and lobe pump technologies use fixed tolerances to control slip, which means they are less likely to adequately adjust to viscosity changes. 4. Pump Construction: Quality pump construction is the key when handling dangerous chemicals, and using a pump designed with the right materials is important to the safety of a plant. To satisfy these demands, AODD pumps are available in a wide range of materials

of construction in order to meet a variety of chemical handling needs. Common chemical pump materials include polypropylene, kynar, stainless steel, ductile iron, and hastelloy, with some companies possessing the capability to offer special materials like super duplex when really unique materials are required to ensure uninterrupted production processes and the safety of plant personnel. If metal pumps are required, one overlooked material in the chemical processing world is ductile iron, which works well in both acidic and basic pH application ranges of 4 to 10. Provided that the chemical compatibility is correct, operators who use ductile-iron pumps can realize all the benefits of stainless steel, but at a lower purchase cost. A bolted design does not, as mentioned earlier, rely on packing and expensive mechanical seals to prevent leaks. In this case, the most important benefit of bolted pumps is their ability to offer one of the highest levels of product containment. This is critical for two main reasons: many raw or finished chemicals are high-value products and any loss through leakage can be detrimental to the operation’s bottom line; and second, most chemicals

The design and operation of A O D D p u m p s a l l o w t h e m t o transfer a wide range of liquids with varying handling characteristics. 44 • September 2019

can be harmful to humans and the environment. Go-To Technology: Thanks to its simple yet innovative design, the AODD pump has proven to be able to consistently meet the demands of chemical processors while building a reputation as a go-to pumping technology where basic fluid transfer capabilities are required. The AODD pump, which possesses a stable of notable operational characteristics, has become a first-choice technology for chemical manufacturers who are searching for a pump that meshes costconscious air consumption with reliable production rates.

Author Details Erik Solfelt, Wilden, USA Contact: Dover India Pvt Ltd – PSG # 33, NH4, Pazhanchur, Mevalurkuppam, Chennai – 600 123. India. Ph: +91 44 6719 3000 www.psgdover.com Chemical Engineering World

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CEW Features Business Case Study

Business Exhibits on Energy Loss in Cooling Water Pumping Applications Cooling water pumps handle large flow rates and are continuous in operation. They also consume lot of power. The manufacturers of pumps offer wide and detailed selection criteria encompassing model number, flow-rate, and discharge pressure with operating curves highlighting the efficiency, etc. However, the system designers are expected to take utmost care on various factorials viz. to evaluate the pressure drop in the system, heat load, flow-rate calculations, etc. Many a times in actual practice the pumps are operating at far different parameters which can result in major power wastages draining the financial resources. Here the experts have furnished a few business case exhibits to unveil the problem situation with the proposed solution.

e elaborate some Industry specific cases, which exhibit significant energy loss, and which can also create some other operational problems.

3. The pressure drop in piping has also increased due to higher flowrate of water.

2. CASE – II:

CASE – I:

Challenge: Design flow condition is much higher than required.

Challenge: Design pump head data given is much higher than the actual head.

Requirement: Calculation of accurate heat load is necessary.

Elaboration: Required Pumps: 360 m3/hr x 21 meter head x 2 pumps. Available pumps with 82.5 percent efficiency & power consumption of 24.8 kw per pump. Total power consumed 24.8 x 2 = 49.6 kw Pumps in use : 360 m3/hr x 70 meter head x 2 pumps. Pump operates at efficiency lower than 60 percent Delivers more than 560 m3/hr flowrate at 21 Meter head. Power consumed 53.40 kw per pump. Total power consumed 53.4 x 2 = 106.8 kw

Elaboration: In one of the cases, the flowrate has been decided as 1100 m3/hr and pump head of 35 meters. The heat load is 1870 KCals/hr giving a delta T of 1.7o C. For chilling plants delta T of around 4.0o C is acceptable. Whereas for process plants delta T could be 8o C. For the above heat load of 1870 KCals/hr with delta T of 8.0o C flow-rate would work out to 234 m3/hr. Power required for pumping 1100 m3/hr at 35 meter head with 82.5 percent efficiency would be 127.1 kw Power required for pumping 234 m3/hr at 35 meter head with same efficiency would be 27.1 kw Inference: This would show a power saving of 100 kw meaning a saving of ` 55,44,000/- per year.

Total power loss = 106.8 – 49.6 kw = 57.2 kw

3. CASE – III:

Impact: Considering power cost at ` 7.00 per kwh and 330 working days in a year, the energy loss would be ` 31,71,168 /- per year.

Challenge: Plants operating at Part Load.

Inference: From the above it is clear that not providing the appropriate data to manufacturer of pump can have following result: 1. Power wastage to the tune of ` 31.7 Lakhs per year

For large plants, instead of having 1 working + 1 standby pump of full capacity, it may be advisable to have 2 working + 1 standby pump of half the flow-rate. This will save power at reduced plant capacity.

2. The actual flow would be more than 560 m3/hr x 2, whereby flooding in Cooling Tower can take place & Cooling Tower performance thus affected.

4. CASE – IV:

46 • September 2019

Proposed Solution: The system designers have to consider cooling water for part load applications.

Focus: To use available pump in stores. This is one more area which needs attention.

Major Challenges: Large Cooling Towers are slightly away from the plant, hence there is a tendency to give higher design pressure values to the pump manufacturer. Along with, in absence of precise heat load calculations, the flow-rates are also given on higher side. Way-out: These days it is possible to calculate the exact pressure drop with 3-D drawings and with heat load calculations deciding the flow-rate, so that the manufacturer is given the right data. The power loss can incur a major operating cost, which can be eliminated. Proposed Solution: In a typical case a 100 m3/hr pump is needed at 12 meter head. The available pump in stores was 100 m3/hr at 40 meter head. On a similar analysis as in Case-I, power lost would be worth ` 2,27,500/per year. Conclusion: The system designers have to play a major role in deciding the flowrate, pressure drop, heat load, part load plant operation, etc. This would give more flexibility in plant operation, save power as pumps otherwise consume lot of power, and avoid other operational problems like Cooling Tower flooding etc. Cooling tower flooding can sharply reduce the Cooling Tower performance also. Note: The energy cost of Rs.7/- per KWH can vary with type of industry & location Author’s Details Anil Kulkarni and Saurabh Thorawade, AB – Chemtech Chemical Engineering World

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CEW Products Silicone Diaphragms

Pitched Blade Turbines

Medical-grade, platinumcured silicone is widely accepted in pharma and biotech applications and is often used throughout the plant. Like all of their diaphragm materials, silicone diaphragms meet USP Class VI and FDA 21 CFR 177.2600 Standards. It is suitable for biomedical/pharma application. All diaphragms meet the standards for quality, purity, lack of toxicity, strength and consistency.

These are axial mixing impellers with considerable amount of radial flow. It produces suction when placed near the liquid surface. Hence used for blending of immiscible liquids, solid incorporation, etc. It is also a preferred choice for applications where the viscosity change during the process is large. These are mostly available in four blades at 45 degree. But different number of blades with various angles is also used depending on the application.

For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com

For details contact: FEDA Inc B-37 Maruti Indl Estate Plot No: 59/1/2/3, Phase 1, GIDC Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok@fedainc.com / reena@fedainc.com or Circle Readers’ Service Card 01

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Stirrers For many, a standard stirrer does the trick. However, certain benchtop constraints and price point can often create a barrier of entry and require a unique solution. Cole-Parmer, a leading manufacturer and supplier of laboratory and industrial products, instrumentation, and supplies, has alleviated these issues with two different offerings from the Cole-Parmer elements line. Both offer a solution to cost and a crowded working area. With the Cole-Parmer elements Modular Magnetic Stirrer, up to ten stirrers can be connected to one controller in almost an infinite amount of combinations. By either connecting a module directly to another module, or tethering the modules with a USB connector, any lab layout can be accommodated. This stirrer is ideal for anyone who needs more stirring equipment but has minimal work space or does not want a bunch of bulky stirrers sitting around in their laboratory. These stir plates come with many features including the ability to attach up to 10 stir plates based on need, simple touch and slide operation, LCD display with real time parameters, corrosion-resistant glass stir top, and waterproof USB attachments. Multiple stirring options allow a choice between one direction or reversing every 45 seconds for thorough mixing. The built-in timer can be set for up to 9 hours or continuous operation. The modular magnetic stirrers are adaptable to any application required to mix up to 1-L at 1,500 RPM, and is IP44. When something small, cost-effective and reliable is needed, the Cole-Parmer elements ultra-thin magnetic stirrer is appropriate This stirrer is sleek with a top plate diameter of 10 cm, a length of 18 cm, and a height of 1.2 cm. This makes the device easy to store, and easy to operate in the tightest spot on the lab bench. It can also handle a robust workload with a max stirring volume of 1-L and a max RPM of 1,500. Combined with its small footprint it also boosts a simple touch and slide operation, LCD display with real time parameters, and is IP65. For details contact: Cole-Parmer India 403, A-Wing, Delphi Hiranandani Business Park, Powai Mumbai 400 076 Tel: 022-61394444 Fax: 91-022-61394422 E-mail: response@coleparmer.in or Circle Readers’ Service Card 03

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Chemical Engineering World

Products CEW Bottle Top Dispensers Traditional bottle top dispensers contain two valves with glass balls: Inlet valve is vertical. It operates under gravity and does not require a spring to hold the glass ball in its position, in order to keep the valve closed. The outlet valve is horizontal. It requires a spring to keep the glass ball in its position, in order to keep the valve closed while aspirating reagents in the barrel. It opens only when a reagent is being dispensed. The spring, housed in the outlet valve, poses a lot of problems: The user has to procure different kinds of bottle top dispensers for different applications owing to spring metal reactivity. This proves to be an expensive proposition. Apart from this, the spring also offers a surface for deposition of chemicals. This results in a piston jam, thereby compelling the user to repeatedly clean the valve or replace it altogether. Their product design engineers have expertly addressed these problems by designing a system where both inlet and outlet valves are vertical and hence do not require any spring. This Springlass Valve technology makes MICROLIT BEATUS a universal bottle top dispenser that can be conveniently used with both organic and inorganic reagents. It not only offers smooth, jam-free piston movement but also ensures service-free operation. Recirculation valve prevents the loss of reagents during purging by re-directing them into the mounted bottle and facilitates bubble-free dispensing. MICROLIT BEATUS is available in six unique volume ranges. For details contact: MICROLIT 629 Pakramau, Kursi Road Lucknow, Uttar Pradesh 226 026 E-mail: customercare@microlit.com or Circle Readers’ Service Card 04

Spectrophotometer Experience an easier way to perform spectrophotometry with IoT in the lab. Cole-Parmer offers the new Jenway 76 Series Visible and UV/Visible Scanning Spectrophotometer featuring split-beam optics and CPLive connectivity. Split-beam technology offers improved accuracy and repeatability when determining samples. CPLive connectivity gives users the ability to safely and securely upload and archive data to the cloud, manage multiple devices at one time with the CPLive App, share data with colleagues and access complimentary unlimited data storage. The spectrophotometer provides fast and reliable results ideal for a variety of applications from teaching, to R&D, to routine sample analysis in quality control environments. Available as Jenway model 7615, it has a 1.5 nm spectral bandwidth, and the split-beam optics offset any signal fluctuations for increased stability over prolonged use, making it ideal for time course and kinetic measurement. The high-definition, colour touchscreen and intuitive user interface makes the spectrophotometer easy to use. The touchscreen interface is fast and responsive even when wearing gloves. This spectrophotometer is compatible with both Android and iOS devices, has 10 GB of onboard storage for methods and results, is designed with multiple USB ports for data storage and printer connectivity, features multi-language options and is versatile with a range of optional accessories. The Jenway 76 Series joins the existing Jenway family of products that include the Jenway 74 Series also equipped with CPLive connectivity. This family of ‘live’ spectrophotometers complement one another and provide accurate and reliable results. They are also pre-programmed with measurement modes that are relevant to their applications. For details contact: Cole-Parmer India 403, A-Wing, Delphi Hiranandani Business Park, Powai Mumbai 400 076 Tel: 022-61394444 Fax: 91-022-61394422 E-mail: response@coleparmer.in or Circle Readers’ Service Card 05

Chemical Engineering World

September 2019 • 49

CEW Products Hydrofoil Impellers

Counter-flow Impellers

These are most efficient axial flow impellers. It is recommended for blending, solid suspension, heat transfer, etc. It provides max flow at minimum power. It is mostly available in three blade version. But different number and width of blade are also common in special applications. This is also called fabricated propeller.

Flow generated by impellers tip is opposite to the bulk flow produced by the central part. In many cases the slurry fluidity reduces due to high solid concentration. Tip of the impeller provides momentum to the fluid near vessel wall. These are mainly used for slurry with high solid concentration. It efficiently operates at much higher impeller to tank dia ratio and have higher flow capacity than conventional impellers.

For details contact: FEDA Inc B-37 Maruti Indl Estate Plot No: 59/1/2/3, Phase 1, GIDC Vatva Ahmedabad, Gujarat 382 445 E-mail: ashok@fedainc.com / reena@fedainc.com

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PROFIsafe-Module Functional Safety is becoming increasingly important as a fundamental component of modern machine and plant design and it is an indispensable aspect of the drive systems from NORD. At present, NORD DRIVESYSTEMS supplies frequency inverters with integrated STO and SS1. The drive specialist provides fail-safe communication and safe movement functions according to IEC 61800-5 with the SK TU4-PNS PROFIsafe module. Functions such as SLS (Safety Limited Speed), SSR (Safe Speed Range), SDI (Safe Direction), SOS (Safe Operation Stop) and SSM (Safe Speed Monitor) can be integrated and expand the drive units’ safe stop functions. With this, the PROFIsafe interface module provides comprehensive safety for the reliable operation of plant and machinery. With SIL3 and PLe (Performance Level e) Category 4, the fail-safe communication protocol fulfils the most stringent safety requirements. The PROFIsafe fail-safe protocol extension for PROFINET enables standard and fail-safe information to be transmitted with integrated functional safety between the higher level machine or the plant control system and the NORD drives in a single network cable. Elimination of conventional hard-wired safety technology reduces the amount of wiring and therefore reduces costs. Furthermore, networking via PROFIsafe makes extensive safety-relevant machine data accessible and globally available. The PROFIsafe bus interface SK TU4-PNS monitors safe compliance with the limit values and provides safe inputs and outputs. If a limit value is exceeded or undershot, the bus interface switches to a safe state. The voltage is disconnected from all outputs, input information is reset and transmitted to the higher level fail-safe controller. This is essential for the use of the PROFIsafe module. Integration of safety functions into the drive unit offers many advantages in comparison with a drive solution with discrete safety technology. Less installation space is required, the number of external safety components is fewer and the system is modularly scalable. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 08

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Chemical Engineering World

Products CEW AODD Pumps Almatec, part of PSG, a Dover company, has extended its line of solid plastic C-Series air-operated double-diaphragm (AODD) pumps to include new C 40 (1-1/2”) and C 50 (2”) Models. Engineered to be a more cost-effective alternative to similar plastic pumps, Almatec C-Series pumps feature an industry-leading design that increases bolt torque to improve pump safety when compared to competitive pumps. What further separates the C-Series is the incorporation of Almatec’s exclusive Perswing P air control system, which offers superior efficiency to optimize production rates and lower energy costs. Ideally suited for the most difficult pumping applications, C-Series pumps ensure the suction and discharge ports are available as separate housing parts with different footprints. This feature allows the C-Series to be quickly and easily matched to existing installations. C-Series pumps do not have any mechanical seals, drives or rotating parts that cause wear over time, which improves reliability and extends product life. C-Series pumps feature self-priming and dry run capabilities, critical considerations for most pumping applications. The C-Series pump line now consists of five pump sizes – C 10 (3/8”), C 15 (1/2”), C 25 (1”), C 40 (1-1/2”) and C 50 (2”). The wetted housing parts are made of either abrasion-resistant polyethylene or chemically resistant PTFE. For applications in explosive atmospheres, C-Series pumps are available in versions that conform to ATEX requirements according to the 2014/34/EU directive. 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 09

Qdos Metering Pump Building on its highly successful Qdos Series of chemical metering pumps, WatsonMarlow Fluid Technology Group (WMFTG) offers a version for mobile and remote applications that can be powered by a 12-24 V DC power supply. The latest Qdos pump will aid any user requiring a precise, closely-controlled metering pump where mains power is not readily available or practical to use. Qdos pumps boost productivity and cut chemical wastage via more accurate, linear and repeatable metering than conventional solenoid or stepper-driven diaphragm metering pumps. As a result, Qdos users can reduce chemical costs even when metering difficult fluids or when pressure, viscosity and solids content vary. This capability combines with peristaltic technology to ensure precise, continuous, smooth flow for optimal fluid mixing. Suitable for both remote static and mobile battery-powered applications, typical uses of the new 12-24 V DC version include agricultural seed coating and crop irrigation, remote water treatment/sampling, potable water refining and on-truck pumping operations, to list just a few. For very remote applications, the pump is able to run from batteries that can be recharged via solar cells, other renewable energy sources or split charge relays. The product is reliable, self-contained and does not require any additional components. Ultimately, with the addition of this new variant into the existing WMFTG range, Qdos is now the first choice when it comes to accurate chemical metering in applications and locations where there is no practical access to grid electricity. For details contact: Watson-Marlow India Pvt Ltd S No: 81/7, Opp: JSPM Institutes Pune-Mumbai Bypass Road Tathawade, Pune, Maharashtra 411 033 E-mail: info@wmftg.in or Circle Readers’ Service Card 10

Chemical Engineering World

September 2019 • 51

CEW Products Rotary Vacuum Dryer

Mixing Device without Rotation

Rotary vacuum dryer offers clean, simple and effective method of drying filtered/centrifuged wet cakes, wet powders and slurries. Operating under vacuum, the dryer effectively dries heat sensitive materials to very low LOD levels. Solvents are condensed and recovered. Operation is batch and drying time depends on material being dried, amount of solvent or water to be removed, desired LOD level, permissible jacket temperature, etc. Rotary vacuum dryer is a horizontal cylindrical jacketed shell with hollow agitator, rotating in close clearance. A batch operation, drying is done under vacuum, heating is through jacket. The dryer offers a simple but effective method of drying wet cakes and sometimes slurries. Due to vacuum and agitation, it is possible to dry heat sensitive materials. For details contact: Tech-Mech Engineers A-227, 16th A Road, Wagle Indl Estate Thane, Maharashtra 400 604 Tel: 022-25828749 Telefax: 91-022-25827883 E-mail: info@techmecheng.com / techmecheng@gmail.com or Circle Readers’ Service Card 11

The FUNDAMIX is a universal device for mixing liquids in open or closed vessels under vacuum or pressure, even in sterile conditions. FUNDAMIX can be operated continuously without overheating or amplitude variations. The electro-magnetic drive operates at 50 to 60 cycles and transmits the vibration via the mixing device or mixer plate attached to a special clamp coupling into the medium. The amplitude resp mixing effect is controlled by a thyristor controller and adjusted by approximately 0 to 3 mm. The flow direction can be adapted to suit the medium and the required mixing effect. Standard mixers are SS-316, but can be manufactured from a wide range of materials including Hastelloy, Titanium and various plastics. For details contact: DrM Filter Technology Pvt Ltd Plot 46, 1 & 2, Village Pungam Ankleshwar, Dist: Bharuch Gujarat 393 020 Tel: 02646-652774 E-mail: info-in@drm.ch or Circle Readers’ Service Card 12

Bottle Top Dispensers MICROLIT SCITUS with springless valve technology is fully autoclavable at 121oC and 15 psi for duration of 10-15 minutes. The Springless valve technology operates jam-free and works without hassle with springless valve technology. Traditional bottle top dispensers contain two valves with glass balls: Inlet valve is vertical. It operates under gravity and does not require a spring to hold the glass ball in its position, in order to keep the valve closed. The outlet valve is horizontal. It requires a spring to keep the glass ball in its position, in order to keep the valve closed while aspirating reagents in the barrel. It opens only when a reagent is being dispensed. The spring, housed in the outlet valve, poses a lot of problems: The user has to procure different kinds of bottle top dispensers for different applications owing to spring metal reactivity. This proves to be an expensive proposition. Apart from this, the spring also offers a surface for deposition of chemicals. This results in a piston jam, thereby compelling the user to repeatedly clean the valve or replace it altogether. Their product design engineers have expertly addressed these problems by designing a system where both inlet and outlet valves are vertical and hence do not require any spring. This Springlass Valve technology makes MICROLIT BEATUS a universal bottle top dispenser that can be conveniently used with both organic and inorganic reagents. It not only offers smooth, jam-free piston movement but also ensures service-free operation. MICROLIT SCITUS is available in six unique volume ranges. For details contact: MICROLIT 629 Pakramau, Kursi Road Lucknow, Uttar Pradesh 226 026 E-mail: customercare@microlit.com or Circle Readers’ Service Card 13

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Chemical Engineering World

Products CEW Platinum-cured Silicone Hose Reinforced with Polyester Braiding and SS-316 Helical Wire Imavacfit is platinum-cured silicone hose reinforced with SS-316L helical wire and polyester braiding having better flexibility with high pressure resistance. Imavacfit is having high burst pressure rating along with high vacuum resistance compared to Imavac. The product is suitable in pressurized fluid transfer application. Imavacfit conforms to US FDA 21 CFR 117.2600 Food Grade Standard, USP Class VI and ISO 10993-1. It is certified by ROHS and Animal Origin Certification (free of animal derived material), free of restricted heavy metals. It is free of Phthalate/Bisphenol/Volatile Plasticizer. It has USFDA DMF accreditation #26201. Complete validation package available upon request. Imavacfit has high burst pressure resistance compared to Imafit and Imavac. It is designed for high vacuum rating applications. It has anti-static properties to dissipate static electrical charge makes it suitable for highly volatile flammable fluid transfer. It imparts no taste and odour. It is lot traceable. Its temp range is -80 oC to 180 oC and is available with SS-316 L Tri-clover end. It is sterilizable by autoclave, ethylene oxide gas and gamma radiation. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 14

O-rings/FEP Encapsulated O-Rings (Silicone/Viton/EPDM/Neoprene/Nitrile) APPL offers its wide range of O-rings from 1.0-mm ID to 600-mm ID from its 5,000 single piece moulds. APPL’s O-rings are manufactured on a hydraulic press with tightly controlled temperature, pressure and time which ensures accurate dimensions, glossy finish and invisible flash line, properly post-cured and absolutely defect-free articles. These O-rings are also manufactured as per the dimensional tolerance specified by the customers and available from Nitrile, Neoprene, Silicone, EPDM, Hapalon, NBR, Viton and Butyl rubber or in any other rubber as per customer’s specification. It is also available in Viton O-rings from 1-mm ID – 3,000-mm ID or in any sizes through step moulding process which gives joint less O-rings of dimensionally accurate, excellent workmanship and finish. APPL’s Silicone, Viton and EPDM Encapsulated O-rings with FEP encapsulation are designed to address the growing problem of sealing in the most hostile chemical and temperature environments. It combines the best qualities of FEP material on the outside with its chemical inertness and an elastomer on the inside for resilience. This unique combination forms a highly effective, long lasting seal for the most demanding applications. These O-rings are comprised of FEP over Silicone, Viton or EPDM and can be used in temperatures from -75oF to +400oF (-60oC to +205oC) depending upon the choice of elastomer core. There are certain applications which prohibit the use of conventional rubber O-ring seals. The use of hostile chemicals or extreme temperature (both high and low) during various processes can make effective sealing very difficult. The main advantage encapsulated O-rings have over solid PTFE is that it has the chemical inertness whilst with its energising core, the O-ring returns to its original form. For details contact: Ami Polymer Pvt Ltd 319 Mahesh Indl Estate, Opp: Silver Park Mira-Bhayander Rd, Mira Road (E) Thane, Maharashtra 401 104 Tel: 022-28555107, 28555631, 28555914 E-mail: mktg@amipolymer.com or Circle Readers’ Service Card 15

Chemical Engineering World

September 2019 • 53

CEW Products Distillation Plant with Glass Reactor

Distillation Plant with GL Reactor and Glass Cover

Ablaze offers customised distillation systems with jacketed glass reactor. It includes vapour column, condensers, reflux provision, phase separator, addition and receiver vessels, along with valves at suitable places and supporting metal structure. The units are supplemented with TCU (thermal control unit) for circulation in jacket of reactor.

Ablaze offers standard distillation systems with glass-lined reactors, with rest of the assembly same as Type AGR. This helps in scale-up to production design offers excellent heat transfer and replicates process conditions of production very closely. It is suitable for high value, low volume production from 25 to 630 litres.

For details contact: Ablaze Export Inc E-52/4, Sardar Estate Ajwa Road, Vadodara Gujarat 390 019 Tel: 0265-2570105 E-mail: info@ablazeexport.com

For details contact: Ablaze Export Inc E-52/4, Sardar Estate Ajwa Road, Vadodara Gujarat 390 019 Tel: 0265-2570105 E-mail: info@ablazeexport.com or Circle Readers’ Service Card 16

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Fully-automatic Plate Shifter Filter Press In applications where the filter cake may not discharge immediately when shifting the plates due to adhesion to the filter cloth, a hydraulic bump mechanism is available as an attachment to the automatic plate shifter. When the bump option is included, the lift mechanism attached to the shifter carriage on one side of the filter press lifts the filter plate handle on that side of the press and drops it. The force of the filter plate handle impacting the side bar knocks the filter cake loose from the cloth. An automatic plate shifter eliminates the need for operator intervention during filter cake discharge. It is used in PLC controls, to provide the highest level of filter press automation available. An automatic plate shifter is desirable when there are multiple filter presses installed in one location, where operator contact with the filter cake is undesirable or where a dedicated operator is not available to shift each filter plate every time the filter press is opened. The automatic plate shifter features continuously adaptive shifting speed to optimise filter cake discharge times. Shifter speed is varied throughout each plate shift to provide quick and smooth operation. Automatic plate shifters can also be built with an automated filter cloth washer. Their design is the most compact and efficient on the market. It takes up a minimal amount of space above and around the filter press. It is designed with a variable speed drive so the cloth washer can run fast for a heavy rinse or more slowly for very soiled cloths. The automatic plate shifter self-corrects crooked filter plates by pushing the plate stack back prior to shifting. If your filter cake is particularly sticky, the shifter speed can be increased to strengthen the pull of the shift. For details contact: Thorat Filtration Pvt Ltd A-12, A-Building, 3rd Floor Garni Indl Park Plot No: C-39/A, TTC Indl Area Pawane MIDC, Navi Mumbai 400 709 E-mail: info@thoratfiltration.com / sales@thoratfiltation.com or Circle Readers’ Service Card 18

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Products CEW Effluent Treatment Plants

Single-stage Bare Shaft End-suction Pumps

WTE Infra Projects Pvt Ltd are having promising technologies to treat wastewater generated from various industries containing highly organic, inorganic load, oil and grease, heavy metals and suspended solids. Based on the effluent parameters as per nature and compositions, the company designs steady state model to overcome environmental issues related to industry. The processing involved for the treatment of various effluents are anaerobic (UASBR, anaerobic filter, bio-digestor). It finds application in sugar, dairies, food processing, electroplating, paper and pulp, automobile, pharma, paint and chemical. For details contact: WTE Infra Projects Pvt Ltd 26/6 Apte Colony, B/h Ayappa Temple Pune-Nashik Road, Bhosari Pune, Maharashtra 411 039 E-mail: enq@watertreatmentindia.net or Circle Readers’ Service Card 19

Lubi Industries LLP offers single stage bare shaft endsuction pumps in flow range up to 1,060 m 3/ hr and head range up to 158 metres. It finds application in water supply, pressure boosting for high rise buildings, hotels, industrial washing and cleaning systems, cooling and air conditioning systems, boiler feed and condensate transfer system, irrigation systems for fields including sprinkler and drip irrigation systems. For details contact: Lubi Industries LLP Nr Kalyan Mills, Naroda Road Ahmedabad, Gujarat 380 025 Tel: 079-30610100 Fax: 91-079-30610300 E-mail: indsales@lubipumps.com or Circle Readers’ Service Card 20

Industrial Gear Unit The latest generation supplements the long-standing series with an applicationoptimised two-stage angled gear unit, which is especially suitable for conveyor belt systems and can be individually tailored to the particular application. The power and speed range was specially designed for the industry, in which low speed ranges are required in combination with high powers. Output torques of the MAXXDRIVE XT Series range between 15 and 75 kNm with speed ratios of 6.3 to 22.4. MAXXDRIVE XT industrial gear units are available in seven sizes for powers from 50 to 1,500 kW. In contrast to the previous designs, as standard the Series is equipped with a heavily ripped UNICASE housing with an integrated axial fan. Due to the increased surface and the air guide covers, the cooling air flow is optimised and a very high thermal limiting power is achieved. In many cases, addition cooling is not required. Large roller bearings and centre distances increase the load capacity and service life of the components. NORD also offers innovative predictive maintenance concepts especially for heavy industrial gear units. Via the frequency inverter, networked NORD drive units communicate their status data via the control system or communicate directly into a secure Cloud. With optional vibration monitoring, condition changes can be detected at an early stage and predictive maintenance can be scheduled in good time. Recording of the performance data also ensures optimal dimensioning of the system as well as continuous condition monitoring of the drives. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com

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CEW Products Fire Sleeve Fire sleeve (for 1,050oC to 1,650oC) is the perfect sleeve and jacket choice for protecting industrial hydraulic hoses and lines, pneumatic lines, fuel and oil lines, brake lines, wires and cables from exposure to high temperature, heat, flame, fire and pyro exposure. The extra thick special formulation of silicone rubber on our fire sleeve sheds molten metals, slag, welding splatter, electrical or grinding sparks and contamination. Fire sleeve also provides protection from ozone, UV and abrasion. The standard colour of fire sleeve is red-oxide, but custom colours such as blue, grey, black, yellow and green are available; great for identifying hose and cable use when the sleeve is installed. Fire sleeve is standard high-temperature and molten splash pyro protection jacket and sleeve for hose and cable. Fire sleeve is normally supplied in 10 to 25 meters, but custom lengths are also available. The industrial grade of fire sleeve is fabricated from a knitted fiberglass yarn substrate, while the aviation grade fire sleeve is fabricated from a thicker and denser braided fiberglass yarn. Industrial fire sleeve is available in sizes from inner dia 10 to 130 mm. For details contact: Dali Electronics 8a, Haroon Building 190 Shamaldas Gandhi Marg Princess Street Mumbai 400 002 E-mail: sleeves@domadia.com / sales@domadia.com or Circle Readersâ&#x20AC;&#x2122; Service Card 22

Innovative Drive Solutions All NORD drives are Industry 4.0 READY and can be directly integrated as active components in Industry 4.0 environments throughout the world. The prerequisites for this are the internal PLC as decentralised intelligence and the extensive range of communication options. The drive units are compatible with all common field buses and Ethernet-based protocols and provide analogue and digital interfaces for sensors and actuators. Thanks to the integrated PLC in the drive electronics they can provide autonomous control of sequences and movements and reduce the load on the central control system. As well as this, the drive systems are scalable, so that they can be individually adapted to the automation application with regard to complexity, quantity and size. NORD drives are prepared for integration into a cloud and can be connected to various external cloud systems. Fast, efficient and comprehensive evaluation of analogue and digital data by the intelligent PLC in the drive electronics forms the basis for modern maintenance and servicing concepts such as condition monitoring and predictive maintenance. Due to continuous monitoring of the field level, linking of communication, sensors, process data and vital parameters of the drive, deviations from the normal state can be quickly detected. Drive operators therefore have the possibility of responding in good time before damage or breakdowns occur. Condition-oriented maintenance replaces time-based maintenance. At present NORD is investigating sensorless monitoring of oil ageing and the condition of geared motors with virtual sensors. The aim is a predictive maintenance concept which determines the optimum oil change and maintenance intervals for each individual geared motor, oriented to the actual condition of the geared motor and the gear oil. For this, intelligent algorithms evaluate the operating data of the frequency inverter and determine the oil temperature from this information. Without the hardware costs for external sensors, oil ageing and the optimum time for replacing the gear unit lubricant can be determined with great reliability. Tests have shown that the oil temperature as measured in tests can be reliably calculated. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readersâ&#x20AC;&#x2122; Service Card 23

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Products CEW Submerged Centrifugal Pumps

Online Turbidimeter for Turbidity Testing

Lubi Industries offers submerged centrifugal pumps in flow range up to 48 m3/hr and head range up to 120 metres. It finds application in industrial cooling water application, industrial washing and cleaning systems, firefighting application, domestic water supply systems, water supply in commercial buildings, complexes, hotels, hospitals, schools, bungalows, sprinkler systems, gardens, farms and fountains, and dewatering applications. For details contact: Lubi Industries LLP Nr Kalyan Mills, Naroda Road Ahmedabad, Gujarat 380 025 Tel: 079-30610100 Fax: 91-079-30610300 E-mail: indsales@lubipumps.com

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The HF Scientific MicroTOL online turbidimeter has been specifically designed to meet regulations of the EPA and ISO 7027. Features include fast and easy calibration, verification in seconds, low maintenance; fail safe design which ensures your instrument is always reading accurately, bubble rejection system and a data acquisition software system that allows logging and data storage for multiple turbidimeters. For details contact: Orbit Technologies Pvt Ltd B-50 Indl Estate, Sanath Nagar Hyderabad, Telengana 500 018 Tel: 040-67216354 Fax: 91-040-23801579 E-mail: orbit@orbitindia.com or Circle Readers’ Service Card 25

Amine Contactor Temperature Measurement Temperature control is essential in amine contactors in order to minimise foaming and carry over. Quality temperature information also helps operators optimise contactor/stripper performance by locating where most of the heat of absorption profile is taking place. If temperature is too high, dirty process could be carried out of the contactor. If it is too low, stripper column energy is wasted. The Gayesco multipoint thermocouple array for amine contactors can be retrofit into existing contactors often through an unused nozzle or old thermowell location. The multipoint thermocouple array is threaded through the contactor trays and sized so that there is a measuring junction at specific tray heights. Typically 18 trays are instrumented for temperature, allowing the operator a picture of how the contactor is performing and providing the necessary tools to optimise performance. The cooler the lean amine temperature, the better H2S absorption. However, temperature below the gas inlet temperature can cause hydrocarbons to condense and possibly foam. The lean amine solution temperature needs to be higher than the feed gas to the amine contactor and good temperature indications are essential for smooth operation. The dirty process enters the column at relatively low temperature and is exposed to the lean amine. Adsorption is exothermic and the process fluid will experience a rise in temperature. Optimally, the bulk adsorption is done low in the contactor with the remaining height removing the remaining acid gas to low exit level conditions. By knowing where that heat of adsorption rise is taking place, the operator now knows where the bulk of the acid gas removal is going on and can make adjustments to the flow rate and energy consumption of the unit to maximise efficiency. The Gayesco multipoint thermocouple array for amine contactors utilises a linear multipoint design with multiple junctions inside a single sheath. This allows for a large number of thermocouples in a small cross-sectional area and minimum interference with the process flow in the contactor. The thermocouples are ungrounded and available in a variety of types and sheath metallurgies. The sheath passes through contactor trays and is supported by specialised hardware that is easily assembled in the field and does not require any welding or hot work during installation. For details contact: Gayesco International 2859 Westside Drive Pasadena, Texas 77502, U.S.A. Tel: 713 941 8540 Fax: 713 944 3715 or Circle Readers’ Service Card 26

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CEW Products Digital Transformation in Process Industries Companies can speed transition from document-based to digital workflows, improving both productivity and quality of outcomes across the lifecycle. Aspen Technology, Inc, the asset optimization software company and Hexagon PPM, the global provider of engineering software for the design, construction and operation of plants, ships and offshore facilities, offers a new level of collaboration founded on a MoU that will more closely align AspenTech’s conceptual, basic engineering and cost estimation solutions with the detailed engineering suite from Hexagon PPM, to enable a fully data-centric workflow across the asset lifecycle. As the first to market with a fully digital design and engineering process with integrated economic evaluation, AspenTech and Hexagon PPM suites align to help customers better manage the financial risks of complex projects, which is a major challenge today. The combined capabilities can accelerate digital transformation and enable deployment of best-in-class integrated solutions from two leading software providers. Working together, AspenTech and Hexagon PPM can provide a more complete digital twin, inclusive of both the plant infrastructure and the chemical processes occurring within that physical infrastructure, to allow operators to make better decisions that maximize throughput, quality and uptime. AspenTech’s planning, scheduling and reliability software, coupled with the Hexagon PPM expertise for the detailed engineering phase of facility and plant design, will help operators more easily leverage engineering models during operations, obtain the most from their investments and allow them to respond better to changing market conditions. For details contact: Hexagon PPM 305 Intergraph Way Madison, AL 35758, U.S.A. or Circle Readers’ Service Card 27

Short Route to Optimum Drive Solutions Customers are guided through the order process stepby-step. A wide range of search and sorting functions (eg, motor power, output speed, output torque) facilitate selection of the optimal drive technology. Thanks to the plausibility check, the product configurator in the myNORD customer portal only shows options which match the requirements that have already been entered. Explanations of the configuration features can be displayed with information symbols. Online configuration and conformity checking of ATEX geared motors is also possible. There is also the option of configuring decentralised drive technology or control cabinet inverters. All configuration steps are carried out on a single screen. All of the specifications which have been entered as well as the features which are still to be selected are clearly displayed in a box at the right hand side of the screen and are always in view. In addition, 3D models, outline drawings and dimensioned drawings can be generated for the configured drive solutions. Furthermore, customers can simply download the CAD data which has been created and integrate it directly into their CAD program. Even during configuration, all purchase prices are visible and on completion an offer can be called up and the order process triggered. In the document centre the product documentation for the specific order can be downloaded in a wide variety of languages. Documents include operating and maintenance manuals or spare parts lists. The documents can be downloaded or conveniently forwarded as a link. The team function enables joint access by all colleagues involved with drive technology within the company - not only to the configurations, but also to all other available data. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 28

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Products CEW Electromagnetic Flow Meter

Dual Shaft Mixer

Process Control Devices offers a Series of digital flow meters. Designed to measure the flow rate of liquids flowing through the closed pipe. The electromagnetic flow meter is volumetric flow meter having no obstruction as there are no moving parts. Hence, pressure drop is negligible. The performance is independent of density, viscosity, temperature and pressure of the flowing liquid. The magnetic flow meter is calibrated using water and can measure the flow of other conductive fluids, with no further correction. This is a special feature that other type of flow meters does not have. Electromagnetic flow meters work on the principle of Faraday’s Law of electromagnetic induction. According to the law, when a conductive liquid cut the magnetic field, voltage induces. Further, that voltage signal is sensed by the electrode which is mounted on the wall of the flow tube. That induced voltage signal is processed by the electronic transmitter to determine the flow. The generation of voltage is directly proportional to the velocity of the fluid. For details contact: Process Control Devices Plot No: 22, Rautara Indl Estate B/s Hanuman Hotel, Shil-Mahape Road Shilphata, Thane, Maharashtra 400 612 E-mail: sales@pcd-flowmeter.com / sales.pcdpl@gmail.com or Circle Readers’ Service Card 29

The dual shaft mixer includes an anchor agitator and a high speed disperser. The anchor feeds product into the high speed disperser blade and ensures that the mixture is constantly in motion. The anchor can be provided with scrapers to remove materials from the interior vessel walls to enhance the heat transfer capabilities of the mixer. Both agitators are available for variable speed operation. A second high speed dispersion mixer can also be added for increased shear. Multiple blades on each of the disperser shafts can also provide added mixing. 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 or Circle Readers’ Service Card 30

Centrifugal Pump NeoMag is a high-performance, magnetically coupled standard centrifugal pump made from SS with a borosilicate canister, the patented BOROHARDCAN. The single-stage, non-self-priming NeoMag pump has been developed based on the latest findings in fluid and hydraulic technology. The installation and replacement are simple thanks to modular design. With the NeoMag pump energy savings of up to 30 per cent are possible, since the BOROHARDCAN consists of an electrically non-conductive material, whereby it does not generate any eddy currents. Hence, the pump as well as the motor and the coupling can be dimensioned smaller than before. This reduces not only the investment costs, but also the subsequent costs during operation. The NeoMag pump technology is hermetically sealed via the magnetic coupling and the canister, and therefore functions absolutely leakagefree and almost wear-free. The NeoMag pump is equipped with a soft start feature, which prevents an unnecessary stress on the aggregate. During the development of the NeoMag, it was possible to increase the hydraulic efficiency by various geometric optimisations, eg, of the impeller, to just over 70 per cent. Such an optimisation offers further energy and cost saving potentials. It finds application in water management, industrial and chemical applications, petro chemistry/mineral oil, process engineering and technology, pharma industry, biotechnology and food industry. For details contact: Bedaflow Systems Pvt Ltd W-7, Sector-11 Noida, Uttar Pradesh 201 301 E-mail: info@bedaflow.com or Circle Readers’ Service Card 31

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CEW Products Point Level Measurement Probes AMETEK Drexelbrook has expanded its point level measurement with the new 700-3201 Series of fully 3A Certified Capacitance/RF Admittance probes, specifically designed for mid-level to premium point level measurement products within sanitary applications that require 3A approval. This 700-3201 Series is optimized to meet the requirements of the food industry and in hygienic applications that require clean-in-place and steam-in-place services. Featuring FDA-Certified materials and fittings, the new probes’ gapless designs ensure safe trouble-free use. Drexelbrook’s Cote Shield Technology eliminates the effect of product build-up on the probes, further eliminating service disruptions. The new probes are designed for use with liquids, slurries and bulk solids such as grains and powders. As part of Drexelbrook’s Capacitive/RF Admittance 3 terminal probe sensors, the 700-3201 Series includes broad system capabilities as they are compatible in most existing Point Level System product lines, including the Z-Tron IV, Point and IntelliPoint Series. The 700-3201 Series comes in standard 3A approved tri-clamp fitting sizes, including 1-1/2”, 2”, 2-1/2”, 3” and 4”. For details contact: AMETEK Drexelbrook 205 Keith Valley Road Horsham, PA 19044, U.S.A. Tel: 215-674-1234 Fax: 215-674-2731 or Circle Readers’ Service Card 32

Decentralised Drive Technology Decentralised frequency inverters offer many advantages. With its extensive range of modular products for decentralised drive electronics NORD DRIVESYSTEMS covers practically all requirements and applications. The drive components have a power range up to 22 kW and an integrated PLC as standard to enable a high level of plug-in capability. They can be freely configured, to adapt them to any application. NORD decentralised drive technology can be integrated into all automation architectures and significantly reduces plant design costs. The inverters’ integrated PLC is able to reduce the load on the higher level control system and take on independent control tasks. This allows a plant design with autonomous production groups and production islands. The freely programmable PLC processes the data from sensors and actuators and can initiate control sequences, as well as communicating drive and application data to a control centre, networked components or to cloud storage. This enables continuous condition monitoring and therefore forms the basis for predictive maintenance concepts as well as optimum plant dimensioning. This drive control for flexible decentralised installation is available as frequency inverter (up to 7.5 kW) or motor starter (up to 3 kW) and provides what it takes to enable fast commissioning, simple operation and maintenance. With NORDAC LINK all connections are made with simple plug connectors. In addition to the high plug-in capability, integrated maintenance switches and switches for manual operation ensure a high level of user-friendliness. With its power range of up to 22 kW, the NORDAC FLEX is the most flexible NORD inverter. With simple parameter transfer via EEPROM memory, installation and servicing are quick and reliable. NORD inverters can be easily extended and offer an impressive variety of scenarios for use in Industry 4.0 automation networks. Their fields of use range from conveyor technology and intralogistics, to drive tasks in the packaging and food industries as well as pump applications and general mechanical engineering. For details contact: NORD DRIVESYSTEMS Pvt Ltd 282/2 & 283/2, Plot No: 15, Village Mann Tal: Mulshi, Adj Hinjewadi MIDC Phase II Pune, Maharashtra 411 057 Tel: 020-39801217 Fax: 91-020-39801416 E-mail: monika.mishra@nord.com / pl.muthusekkar@nord.com or Circle Readers’ Service Card 33

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CEW

NATIONAL

INTERNATIONAL IFAT India

Dates: 16-18 October, 2019 Venue: Bombay Exhibition Centre, Goregaon, Mumbai Event: Exhibiting at IFAT India is an extremely effective way to place your products and technologies in front of your current and potential customers in a highly influential environment and to establish and enhance your foothold in this competitive environment. Gain access to one of the highly buoyant markets of Asia and find channel partners and distributors. Meet the decision makers. Their widespread promotional campaign specifically targets visitors with decision making power. Profit from the competence of the organizers of IFAT in Munich. Environmental Solutions Provider platform for products and technologies by experts under one roof. For details contact: Messe Muenchen India Pvt Ltd Solitaire Corporate Park Bldg No: 7, 167, Unit No: 762/862 Guru Hargovindji Marg Andheri-Ghatkopar Link Rd Andheri (E), Mumbai 400 093 Plastivision India

Dates: 16-20 January 2020 Venue: Bombay Exhibition Centre, Goregaon, Mumbai Event: This event provides the perfect platform for plastic industry players

Chemistry In Power Plants Conference

Dates: 23-24 October 2019 Venue: Maritim Hotel Magdeburg, Germany Event: The Chemistry in Power Plants is a forum for operators of energy utilities and industrial power plants. It will be discussed and technical developments will be represented in the field of power plant chemistry. For details contact: VGB PowerTech e.V. Deilbachtal 173 45257 Essen, Germany Tel: +49 201 8128 0

Chem Show

Dates: 22-24 October 2019 Venue: Jacob K Javits Convention Center, New

like manufacturers, dealers, buyers and end-users. It is well-appreciated for helping participants stay updated with the latest technological trends. Visitors can participate in numerous live product launches, seminars, conferences and consultation sessions. They also get a chance to network with overseas delegates and industry influencers. The event has a glorious history that dates back to 1992. It is only a trading fair exhibition from the plastic industry approved by UFI (the leading Paris-based exhibition authority). For details contact: The All India Plastics Manufacturers’ Assn AIPMA House, A-52, Street No: 1, MIDC Marol Andheri (E), Mumbai 400 093

York, U.S.A. Event: The Chem Show is a well-acclaimed event that has been alarming visitors with the massive presence of heating and cooling systems, filters and dryers, dry materials, gaseous materials and other related products and substances. It aims to bridge the gap between the buyers and sellers and provide them an interactive platform where they can foster business deals, by means of networking and direct interaction. For details contact: International Exposition Co 15, Franklin, Westport, U.S.A.

Renewable Energy Expo

Corrosion Conference & Expo

Dates: 13-15 February 2020 Venue: Chennai Trade Centre, Nandambakkam, Chennai Event: The 2 nd Edition of this event will be held in Chennai. The scope of this exhibition is to stimulate the growth of renewable in the region through collaboration of technology and product sharing. This event will be bringing together businesses, sustainable energy industry trade associations, government agencies, and energy policy research organizations to showcase the status and potential of the cross-section of renewable energy (biofuels/ biomass, geothermal, solar, wind) and energy efficiency technologies. The expo is proclaimed at the right time when there is a paradigm shift in the global trend towards massive deployment of solar power and other renewables along with investments worth billions of dollars in technology and green energy. For details contact: Water Today Pvt Ltd 3D Bhaghreetha Residency 125 Marshalls Road Egmore, Chennai 600 008 Chemical Engineering World

Dates: 15-19 March 2020 Venue: George R Brown Convention Center, Houston, U.S.A. Event: Corrosion Conference & Expo showcase your newest products in front of customers, prospects, partners, and influencers; generate leads efficiently and effectively; build relationships with key players and decision-makers; bolster the global influence and reach of your company’s product or service; and expand your reach and tap into new markets meeting new potential buyers and suppliers. For details contact: Nace International - The Corrosion Society Houston, U.S.A. Tel: +1 281-228-6411 E-mail: tiffany.krevics@nace.org September 2019 • 61

CEW

Project Update New Contracts/Expansions/Revamps

The following list is a brief insight into the latest new projects by various companies in India.

CHEMICALS NOCIL Ltd has commissioned the Phase 1 of expansion of capacities of rubber chemicals and their intermediates at Navi Mumbai, The aforementioned CAPEX programme had been approved by the Board of Directors at its Meeting held on 16th March 2017. Tata Chemicals has completed the acquisition of the silica business of Allied Silica for ` 123-crore. The company entered into a business transfer agreement to acquire Allied Silica’s precipitated silica business on a slump sale basis. The deal was part of the ` 295-crore investment approved by the Board in February 2017, towards this specialty business. The acquisition includes a manufacturing facility in Tamil Nadu, which will produce highly dispersible silica. The specialty chemical product represents a downstream value addition to Tata Chemicals soda ash business, where it ranks among the top manufacturers globally. R Mukundan, Managing Director, Tata Chemicals, said the next focus would be to enhance the operational readiness of the plant to maximise throughput of product portfolio, while meeting the requisite safety and quality specifications. Precipitated silica is a versatile product with applications in many industries including rubber, oral care, coatings and agrochemicals. The acquisition also offers the possibility to make value added silica for applications that demand high performance. Insecticides (India) Ltd has announced a ` 200-crore expansion plan to increase its capacity in the next three years. In the first two years, it would spend about ` 100-crore, followed by an investment of ` 100-crore in 2020. The firm is planning to set up an Export Oriented Unit in Gujarat with an eye on increasing export component of the business. Exports contributed about ` 35-crore in the total turnover of ` 1,109-crore in 2017-18. The firm has a share of about 5 per cent in the ` 18,000-crore crop protection market in the country. Shalimar Paints lays down the foundation of its Nashik manufacturing plant with a planned monthly production capacity of 2,180-kilolitres. Shalimar's state-of-the-art Nashik facility will increase the brand's overall production capacity by 65 per cent. The newest Shalimar plant hints at the brand's aggressive push to capitalise on the growing market demand for its high-quality, high-performance paint and coating products, as well as to further consolidate its position as one of the fastest growing paints companies in the country. Shalimar has also pledged further investment into its Nashik plant and aims to establish it as a key component within its regional distribution network, as well as its pan-India supply chain. The paint industry has been growing at a rapid rate in India and measures between 1.5 to 2 times GDP growths. Rapid urbanization, better transparency and consumer evolvement has been leading the growth of the industry. Songwon Industrial Co Ltd a specialty chemicals company of South Korea has launched its new pilot plant in Panoli (Gujarat), thereby strengthening the organisation’s overall specialty chemicals 62 • September 2019

development capability. Built on Songwon’s Indian site with all the necessary main unit operations, the new plant is equipped with the most up-to-date technologies and materials for producing a wide range of chemicals for a broad spectrum of applications - from one kilo up to several hundred kilo samples. To reinforce the organisation’s position in existing areas of business and enhance its ability to enter new areas, the new pilot plant will be supported by the Songwon’s strong local R&D team in Panoli, as well as its central technology innovation center located in Maeam, Korea.

MINING Coal India Ltd (CIL) had supplied in 2018-19, 491.54-million tonnes (MT) coal to power plants which was 8.2 per cent more than the coal supplied in 2017-18. Singareni Collieries Co Ltd (SCCL) supplied 55.3-MT coal to power plants in 2018-19 which was a growth of 3.6 per cent over the same period of previous year. This has led to creation of a coal stock of 30.95-MT at the power plants as on 31st March 2019 which was sufficient for 18 days requirement. In 2018-19, the power plants of Tangedco have supplied 23.26-MT coal from CIL with a growth of 3.5 per cent over the supply of 22.49-MT in 2017-18. As on 16th June 2019, Tamil Nadu power plants have coal stock of 9.67-lakh tonne which is sufficient for 12 days requirement. At present, no power plant in Tamil Nadu is in critical/super critical category. Hindustan Copper Ltd (HCL), on 2nd February, 2019, held a ground-breaking ceremony at Ghatsila Unit of HCL for construction of concentrator plant at Rakha, initiating Chapri-Sidheswar mine, a new mine development and Rakha mine re-opening projects. CMD informed that considering the opportunity to further increase the resource base of copper mineral in the State has finalized plan to undertake depth exploration up to 1,000-meter from surface in its existing lease area in next two years. HCL, in its Unit located at Ghatsila planned to implement total five mine expansion projects to increase the mine capacity from current 4.0 to 72.0-lakh tonne. Successful implementation of the project will also reduce country's dependence on imported copper concentrate. Singareni Collieries Co Ltd (SCCL) has received a boost for its plans of increasing the coal production to 70-million tonnes in 2019-20 by getting the green nod for Kistaram open cast mine recently after suffering some setbacks in getting environmental clearance for its proposed new mines and expansion of existing ones earlier this year. The coal company has achieved a production of 64.4-million tonnes in 2018-19 and getting the environmental clearance for Kistaram open cast mine, with a capacity of 2-million tonnes per annum (MTPA), in Sathupalli mandal of Khammam district is expected to go a long way in its plans to jack up the production by nearly 6-million tonnes. The green nod to the proposal has come three years after public hearing conducted on it. According to SCCL officials, a committee of experts in the Ministry of Environment and Forests (MoEF) that has gone through the proposal has recommended clearance to

Chemical Engineering World

Project Update the mine earlier and stipulating several conditions to keep impact of the mining activity under check on air, water and local people. Environmental conditions in and around Sathupalli town were also appraised separately by the panel before giving its nod. The committee also asked the coal company to take specific measure to minimise the mining impact on air, water, noise, vibrations, stability of structures, health of people in nearby villages and their socio-economic conditions and relief and rehabilitation operations. MOIL recently said production at its Parsoda manganese mine is expected to begin soon. The mine will be operated by open cast mining method. MOIL has been granted mining lease of Parsoda manganese mine near village Parsoda, 46-km from Nagpur in the year 2016. The lease extends for 50 year period, ie, from April 22, 2016 to April 21, 2066 and the project cost is estimated to be ` 19.54-crore. MOIL, under the Ministry of Steel, operates around 10 mines, including six in Maharashtra and four in Madhya Pradesh. Balaghat mine is its largest, which produces top quality manganese ore. NTPC Ltd hopes its captive coal production will reach 100-million tonne as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India's largest power producer. Coal India aims to raise output from its troubled Rajmahal mine in Jharkhand to 60,000-tonnes a day by March 2019, having resolved land-acquisition related problems. Coal from the Rajmahal mine helps NTPC run close to 4,200-MW of power generation plants in eastern India, which supply power to Bihar, Jharkhand and West Bengal, and also to northern India including Delhi and Uttar Pradesh. NTPC’s generation capacities were faced with depleting coal stocks and lower power generation as supplies from Rajmahal dwindled. It led to drastic fall in supplies and stocks at the coalfield, as well as at two critical power plants in the region - at Farakka and Kahalgaon. CIL, ONGC to produce coal-bed methane from 10 new mines: support SAIL in one more. The Coal Ministry has identified 11 mines to produce coal bed methane (CBM). Initially, ONGC will harness the gas and then CIL will extract coal from them. In addition to the mines with CIL, the two (ONGC and CIL) will also help develop SAIL’s Parbatpur coal block (Jharkhand). Here too, ONGC will first harness the CBM. SAIL had surrendered the Sitanala and Parbatpur coal mines. SAIL had engaged MECON to prepare a techno commercial viability report, which declared the project unviable. JSW Energy, part of the Sajjan Jindal-led JSW Group, is believed to be in the race for buying out the thermal power assets of Monnet Power and Jindal India Thermal Power Ltd (JITPL) in Odisha. Monnet Power’s 1,050-MW coal-based power plant near Angul was in advanced stage of commissioning. Monnet Power’s parent company, Monnet Ispat & Energy had won the Mandakini coal block in Odisha in competitive bidding, it surrendered the block later on grounds of economic unviability. Besides Monnet Power, JSW Energy is also eyeing takeover of BC Jindal controlled JITPL’s 1,200-MW Chemical Engineering World

coal-based plant at Derang near Angul. The first unit (600-MW) of the 1,200-MW plant had begun commercial operations and started power supplies to the Odisha grid. This project has been completed at a cost of ` 7,537-crore which includes a debt component of ` 5,900-crore. JITPL has power purchase agreements (PPAs) with Odisha’s Gridco Ltd, Kerala State Electricity Board and Tata Power Trading Corpn. Apart from JSW Energy, JITPL also had competing offers from Adani Power and Singapore’s SembCorp. The valuation of the prospective deal is not known. NLC India (formerly Neyveli Lignite Corporation) which is in the hunt for buying out power assets is understood to have shown interest in the 700-MW Odisha plant of Hyderabad-based Ind-Barath Power Infra Ltd (IBPIL). The power plant located at Sahajbahal, near Jharsuguda, has commenced commercial operations. Though the exact size of the potential deal is not known, the valuation could be anywhere in the range of ` 5,000-5,500-crore. In August last year, NLC India had floated an EoI from companies owning coal and lignite-based power projects, for a possible acquisition. NLC India’s installed thermal power capacity is 3,240-MW. It runs a 10-MW solar power unit and wind power assets with a capacity totalling 37.5-MW. Western Coalfields has received the environment clearance for its ` 263-crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open cast mine to 1.875-million tonnes per annum (MTPA) from the existing 1-MTPA. The mine, located in 767.17-hectare, has a mineable reserve of 14.50-million tonnes. The clearance to the project is subject to certain conditions. The company has been asked to get Consent to Operate certificate from the State Pollution Control Board for the existing production capacity of 1-MTPA and also the Consent to Establish for the proposed capacity of 1.875-MTPA prior to enhancing the production capacity.

OIL & GAS Haldia Petrochemicals (HPL), plans to deploy an innovative technology for its project that seeks to convert crude oil into chemicals and petrochemicals directly. As opposed to the customary production of refined petroleum products, HPL’s plant will concentrate on higher output of petrochemicals. HPL, is setting up an integrated refinery with aromatic complex for production of paraxylene and purified terephthalic acid (PTA) units in the first phase. The production capacity of paraxylene unit will be 1.6-million tonne per annum (MTPA) and PTA will have 2.5-MTPA capacity. The first phase of the HPL project approved is expected to be operationalised within five years of allotment of land. HPL has committed an investment of ` 28,700-crore ($4.05-billion) in the first phase on its Odisha project. Recently, the High Level Clearance Authority (HLCA) in Odisha headed by Chief Minister Naveen Patnaik gave its nod to the proposal, which HPL submitted on March 1. Official sources have touted HPL’s proposal as the country’s single-largest domestic investment in the last 12 months. Vedanta Ltd’s has received environment clearance for the expansion of its oil and gas operation in Rajasthan that would entail an investment of ` 12,000-crore. The proposal is to expand onshore oil and gas

September 2019 • 63

CEW

Project Update production from the existing 3,00,000-BOPD (barrels oil per day) to 4,00,000-BOPD and 165-MMSCFD (million standard cubic feet per day) to 750-MMSCFD from the 'RJ-ON-90/1' block located in Barmer and Jalore districts, Rajasthan. The environment clearance (EC) is, however, subject to compliance to certain conditions. The estimated project cost is ` 12,000-crore. The company aims to implement the project in a phased manner during seven years. The project involves oil augmentation to produce up to 4,00,000-BOPD and 250-MMSCFD of associated gas from the oil field and natural gas augmentation to produce up to 500-MMSCFD. Total area of the oil and gas block is 3,111-sq km. Out of it; the project presently covers an area of 1,501.7-hectare in Barmer and Jalore districts. Additional 150 hectare of land in Barmer district will be used for the proposed expansion. The 'RJ-ON-90/1 block' comprises of Vedanta Ltd and state-run ONGC for hydrocarbon exploration, development and production activities in the block, while Cairn Oil and Gas division (part of Vedanta Group) is the operator of the block. BPCL-Kochi Refinery is going ahead with its second petrochemical project to produce polyols at an investment of ` 11,300-crore. An import substitute, polyols are used in the production of polyurethanes used in diverse products such as automotive seats, mattresses and shoe soles. The project is expected to go on stream by 2022. BPCL is in talks with various global firms to finalise the technology for six different products. There is a huge demand for polyols and it is growing at 10 per cent per annum providing good scope for MSMEs to set up units in the complex. The first petrochemical project of BPCL-KR constructed at a cost of ` 5,500-crore is all set to commence operations by the middle of the year. It will produce acrylic acid, acrylates and oxo-alcohol that are used in the manufacture of paints, super absorbent polymers, detergents, adhesives, sealants and solvents. The technology has been sourced from Mitsubishi, Air Liquide Global and Johnson Mathey Davy. The two projects will facilitate ` 13,000-crore forex savings per annum for the country. With the completion of the second petrochemical project, BPCL-KR is expecting around 16 per cent increase in its turnover in three years. BPCL-KR is slated to complete its fuel upgradation project to comply with BS-VI norms by February next year. The project cost is around ` 3,300-crore. Vedanta Ltd announced an oil discovery in its Krishna Godavari basin block in the Bay of Bengal. The block previously had a gas discovery in the very first well drilled. Vedanta holds 100 per cent participating interest in the block. "Multiple reservoir zones were encountered in the well H2 within the Mesozoic sequence between the depths of 3,310 to 4,026-metres with hydrocarbon indications during drilling and downhole logging," it said. The zone from 3,403 to 3,431-metres was tested through conventional well testing (Drill Stem Test) and flowed oil to the surface. Further appraisal will be required to establish the size and commerciality of the oil discovery. The first exploration well A3-2 drilled in the block was a gas discovery. Cairn India, the company Vedanta bought and merged with itself, had in June 2010 won the KG-OSN-2009/3 block in the 8th round of New Exploration Licensing Policy (NELP). It had committed to drill six exploratory wells on the block. These were expandable to 10. The KG basin is a proven basin where there have been many hydrocarbon

64 â&#x20AC;˘ September 2019

discoveries. The company acquired around 1,000-sq km of 3D seismic data based on which it drilled two wells. KG-OSN-2009/3 offshore block in the Bay of Bengal was originally spread over in an area of about 1,988-sq km which was later reduced to 1,298-sq km due to exclusion of area within firing range. It is located in the shallow waters of the Indian Ocean along the East coast of India, approximately 1.5 km from the Indian coastline. Chennai Petroleum Corpn Ltd (CPCL) the Indian Oil Corpn's (IOC's) group company is planning to set up a greenfield refinery at Nagapattinam in Tamil Nadu, at a cost of ` 27,460-crore. The products, including motor spirit (MS) and high speed diesel (HSD), which will be produced from the refinery will help meet the latest BS-VI specification in the southern States. The new refinery will be part of the Government of India's plan to set up a petroleum, chemicals and petrochemicals investment region (PCPIR) in this region. The boards of CPCL and IOC have accorded in-principle approval for the 9-million metric tonne per annum (MMTPA) refinery at CBR at an estimated investment of ` 27,460-crore, plus or minus 30 per cent. The investment includes ` 2,800-crore for setting up a polypropylene unit of around 500 thousand metric tonne (TMT) per annum capacity. Detailed feasibility report (DFR) preparation is underway. The refinery is expected to be operational by 2023-24. It will produce valuable products, including liquefied petroleum gas, petrol, diesel, aviation turbine fuel, polypropylene, etc, besides petrochemical feed stocks. The petrochemical complex will also feed stocks to downstream industries, including pharma, paint and lacquer, printing inks, adhesives, coatings, chemicals, automobile lubricants, and PVC, among others. CPCL operates two refineries with a total capacity of 11.5-MMTPA (10.5-MMTPA at Chennai and 1-MMTPA near Nagapattinam) in Tamil Nadu. The company's crude throughput increased to 10,789-TMT in 2017-18, from 10,256-TMT in 2016-17. Its profit after tax stood at ` 913 crore in 2017-18, as compared to ` 1,030-crore in 2016-17. Reliance Industries Ltd has secured backing of the key expert appraisal committee (EAC) in the Ministry of Environment, Forest and Climate change to expand the capacity of its export-oriented refinery in the special economic zone (SEZ) at Jamnagar by 5.8-million tonnes (MT). The planned expansion will raise the installed capacity of the SEZ refinery to 41-MT from 35.2-MT and lift the overall capacity of the Jamnagar refinery complex to 74-MT. The additional terms include prior transfer of environment clearance issued on March 30, 2010 to Reliance Jamnagar Infrastructure Ltd to Reliance Industries Ltd (the entity that applied for the environment clearance).The Jamnagar refinery processed 69.8-MT of crude in FY18, exceeding its installed capacity of 68.2-MT. Between April and December 2018, Reliance refined 52.3-MT of crude. Reliance Petroleum Ltd, a unit of Reliance Industries, built its first refinery at Jamnagar with an installed capacity of 18-MT which was later expanded to 27-MT. The capacity of the Jamnagar refinery and petrochemical complex was further expanded by Reliance Industries to 59.7-MT during which the production was split between Reliance Petroleum (26.7-MT) as an only for exports refinery unit and Reliance Industries (33-MT) that sold most of its products in the local market. The capacity of the SEZ refinery was further expanded by Reliance Jamnagar Infrastructure Ltd to 35.2-MT from 26.7-MT.

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