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83 “We Target Becoming Rs. 5000 Crore Company by End of This Decade Serving Our Global Customers” - Dr. Deepak Parikh, Vice Chairman & Managing Director, Clariant Chemicals India Ltd

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CEW Press Release LANXESS closes acquisition of Chemours’ Clean and Disinfect Business

Samir Surlaker, MD, MC-Bauchemie announces his retirement

Cologne, Germany: Specialty chemicals company LANXESS has announced that it has closed the acquisition of the Clean and Disinfect business of U.S.-based chemicals company Chemours on August 31, 2016. All relevant antitrust authorities have approved the transaction.

Mumbai, India: Mr. Samir Surlaker, one of the frontiersman and advocates of the construction chemical industry has announced his retirement from day to day management as Managing Director of MC-Bauchemie (India) Pvt. Ltd. His retirement comes in after an association of 38 years with MCBauchemie Germany.

LANXESS has paid around EUR 210 million for the Clean and Disinfect business, which comprises various active ingredients and specialty chemicals especially for disinfection and hygiene solutions.

The company has financed this first post-realignment acquisition from existing liquidity. “The acquisition is the first milestone on our path of growth and a further step toward strengthening our business in North America,” said Matthias Zachert, Chairman of the Board of Management of LANXESS AG. “The successful integration of the new business now has absolute priority so we can quickly benefit from this expansion of our specialty chemicals portfolio.”

Samir Surlaker, Managing Director, MC-Bauchemie (India) Pvt. Ltd

Mr. Sur laker founded MC India in collaboration with MCBauchemie, Germany in 1985 and has been instrumental in promoting the brand to one representing Trust and Reliability.

MC- Bauchemie set a benchmark India in maintaining high technical standards under his leadership.

The acquisition will be accretive to the company’s earnings per share (EPS) in the first fiscal year. The acquired business is expected to deliver an annual EBITDA contribution of around EUR 20 million, which will be gradually increased by synergy effects to about EUR 30 million by 2020. The new business is to be integrated into LANXESS’ Material Protection Products business unit, not only expanding its active ingredients portfolio but also extending the value chain in the veterinary disinfection segment through to the end market. The acquired business has three production sites in Memphis and North Kingstown in the United States and Sudbury in the United Kingdom. It achieved 2015 sales of around EUR 100 million, with about half accounted for by the United States. The business comprises three product lines: disinfectants, potassium monopersulfate and chlorine dioxide.

MC is one of the companies in India to have a state-of-the-art production facilities, dedicated training Centre and Concrete Technology Lab for their own staff and training of Applicators and clients.

The disinfectants are marketed for biosecurity applications in the veterinary segment. The core product brand is Virkon S, the world’s leading powder disinfectant with proven performance against a broad range of viruses, bacteria and fungi. It is used, for example, to combat Foot-and-Mouth disease and Avian Influenza. The second segment focuses on the production and marketing active ingredient potassium monopersulfate with its core brand Oxone. It is used in pool and spa applications, personal hygiene products and electronics applications and as active ingredient in the formulation of disinfection products, especially in Virkon branded products.

He has received several national and international Awards. He has been a Recipient of Outstanding Contribution to Concrete Technology Award, 2005 by ICI, Recipient of Outstanding Concrete Engineer Award by ICI-Ultratech, Goa. Under his leadership MC-Bauchemie was awarded the Best Construction C h e m i c a l s M a nu fa c t u r i n g C o m p a ny i n 2 0 1 5 by B u i l d e r ’s Association of India.

Thirdly, chlorine dioxide is a proven package solution provider for industrial water treatment applications. Material protection solutions from LANXESS. The LANXESS Material Protection Products business unit currently has a workforce of around 350, with production sites in KrefeldUerdingen and Dormagen (Germany), Pittsburgh (United States), Jhagadia (India), Changzhou (China) and Singapore. It is part of the Performance Chemicals segment, which posted 2015 sales of around EUR 2.1 billion.

6 • September 2016

Mr. Surlaker, a Civil and Structural Engineer, has over 40 years of National and International experience and exposure in Concrete Technology and Construction Chemicals in Germany, Europe, Middle East, Far East and India. He has delivered over 800 lectures nationally and internationally and training programs all over India and overseas. His over 100 technical papers and Ar ticles are published in several national and international Engineering Journals in the field of Construction Chemicals.

He is co-author of Handbook of Advanced Concrete Technology.

He is also contributing actively to the cause of Advancement of Construction Chemicals and Concrete Technology as Vice President (W) of Indian Concrete Institute, Director of India Chapter of American Concrete Institute, Governing Council Member of Association of Consulting Civil Engineers India and as the President of Construction Chemicals Manufacturers Association. He is member of the Bureau of Indian Standards (BIS) in CED 2, CED 5 and CED 41 and several handbooks by ICI. He has immensely and relentlessly contributed to the cause of the Construction Chemical Industry and the Civil Engineering fraternity. It is heartening to know he will continue to be a part of the industry even after his retirement.

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CEW Press Release Shilip Kumar succeeds Jeremy Hunter as President - Henkel India Mumbai, India: Henkel has announced that it has appointed Shilip Kumar as the President of its India business, effective June 1, 2016. Besides, steer ing the Adhesives and Beauty care businesses of Henkel Adhesives Te ch n o lo g ie s I n d ia Pr ivate Limited Shilip Kumar, (Henkel India), he will continue in his President, existing role of Business Director for Henkel India Transportation & Metal Adhesives SBU in the India, Middle East, Africa (IMEA) region.

Shilip succeeds Jeremy Hunter, who led the India business for over five years, and has now moved to Shanghai as President – Henkel China. Based out of Henkel India‘s head office at Navi Mumbai, Shilip will be responsible for leading Henkel’s businesses in India through its next growth phase.

Shilip star ted his journey with Henkel in 2011 as Business Director of the Transportation and Metal SBU in India. He was at that point in time responsible for integrating the SBU’s operations across 3 legal entities, including 2 Joint Ventures, to leverage the scale of its business in the country. He also spearheaded the India Innovation Center – Pune project for Henkel.

The Center was commissioned in October 2013 and has since contr ibuted significantly to the success of Henkel’s Adhesives business in India. He was promoted as Business Director of Transpor tation and Metal SBU in the then newly created region of India, Middle East and Africa (IMEA) in April 2013 and has since successfully led the profitable growth of that business. He relocated to the IMEA regional HQ in Dubai in January 2015 Commenting on his new role Shilip said, “I am pleased to take up the additional responsibility as President of Henkel India. India offers considerable growth potential for Henkel and it will be our endeavor to ensure that we utilize effectively the resources and investments made by our parent company to capitalize on this potential.

Our focus remains on delivering innovative technologies and solutions that help create value for our customers in the country.”

Shilip star ted his career in 1989 with the Management Consultancy Division of A.F. Fergusson & Co., followed by stints with Asian Paints and Rohm & Haas. His most recent assignment prior to joining Henkel was with Dow Chemicals as the Business Director for Dow Coating Materials in South Asia.

8 • September 2016

He was part of the “startup” team at Rohm & Haas in India, which developed the business from scratch to a multi-million dollar business including setting up of local green field manufacturing in the country.

He holds a Bachelor’s degree in Mechanical Engineering and a MBA from Universities in India. Born and brought up in Mumbai, he resides in the city with his wife Anjali a psychologist who works with children with special needs and his daughter Sneha a graduate student in Literary & Cultural Studies.

Great Lakes Solutions Invests In New, Global Flame Retardant R&D and Applications Laboratories Philadelphia, PA: Great Lakes Solutions has announced the completion of its new, global center of excellence for flame retardant research and development and applications development at the Nudenberg-Wheeler Technology Research Campus in Naugatuck, Connecticut, USA. Having opened on August 1, 2016, these laboratories house state of the art equipment for organic synthesis, flame retardant testing, physical property testing, chemical analysis, and process development. These new facilities reinforce Great Lakes Solutions’ commitment to fire safety, the development of innovative, new products, and customer collaboration and support.

The custom built facility has been designed not only for efficiency, with close alignment of interaction between synthesis and applications scientists, but also for synergy between the Great Lakes Solutions chemists and engineers and those of Chemtura’s Petroleum Additives and Urethanes businesses, who are colocated on the Naugatuck R&D campus.

The applications areas include not only small scale bench top extrusion, injection molding and combustion testing equipment for the rapid formulation of new, exploratory flame retardants, but also large scale extruders and molding equipment for formulation improvement and new applications of existing products. The testing area ser vices all of the necessar y mechanical and burn performance tests for new and existing products, and the unsurpassed analytical instrumentation provides required data regarding polymer structure, small molecule composition and interactions thereof.

“Naugatuck is the primary global R&D location for Chemtura” explains Dr. Dave Sikora, Global Director, Chemical Technology.

“Locating the new flame retardant laboratories at this research campus will accelerate innovation for our customers through the collective wealth of technical expertise, knowledge and experience of all our scientists. We look forward to partnering with our key flame retardant customers and leveraging our multiple, diverse chemical disciplines to solve their most pressing problems.”

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CEW Press Release Birla Carbon awarded Gold rating by EcoVadis for Sustainability

New Heraeus recycling facility for spent reforming catalysts offer Indian petrochemical industry

Mumbai, India: Birla Carbon has announced that it has been awarded a Gold Recognition Level in sustainability perfor mance pursuant to the sur vey conducted by EcoVadis. The sur vey further goes on to place Birla Carbon among the top 2% of all performers in the survey.

India: Heraeus has announced that it has opened a new facility in India to recover precious metals from spent petroleum catalysts. The new site in Udaipur/Rajasthan will be operated by the German-Indian joint venture “Ravindra Heraeus” and will André Christl, offer India’s petrochemical industr y President, more capacity and state-of-the-ar t Heraeus Metal Management technology to recycle Platinum and Palladium in the country.

Dr. Santrupt Misra, Chief Executive Officer, Birla Carbon

EcoVadis based its findings on the Company’s four th sustainability report titled ‘Maximizing our Potential Through Sustainable Operational Excellence’ for its analysis.

The report focusses on Birla Carbon’s Sustainable Operational Excellence (SOE) strategy driving sustainable business growth.

EcoVadis recognized Birla Carbon as being part of the top 3% in its industry sector (manufacture of other non-metallic mineral products) and have also acknowledged it in the top 4% in the same category for its fair and effective labour practices.

Commenting on this achievement, Dr. Santrupt Misra, Chief Executive Officer, Birla Carbon said, “At Birla Carbon, we look at sustainability as a means of maximizing potential more than minimizing risks. It is a proud moment for us to be recognized by EcoVadis for the results that we have achieved.

This recognition is a further validation for the direction that we are taking as a Company and the collective commitment of all our employees towards sustainability.”

He further added, “This Gold Rating from EcoVadis will further strengthen the conviction of our partners and customers about our long term sustainability and commitment.”

Joe Gaynor, Chief Sustainability Officer, Birla Carbon said, “This is yet another outstanding international recognition of our continued commitment to sustainability.

Birla Carbon continues to monitor and assess its environmental impact and adapt to the planetary and social megatrends coming our way so as to ensure that we maximize any resources that we apply and minimize any negative impact to the environment, our employees, and the communities in which we operate.

Indian companies will therefore benefit from larger national recycling facilities, which will provide less transpor t costs and easier file processing, faster recycling times and better transparency in the market and overall improved costing for catalyst recycling.

The new technology will furthermore offer latest environmental and social standards. After the recycling process, “Ravindra Heraeus” offer its customers to either receive new precious metals products, precursors or the pure recycled precious metals.

“The new recycling facility of Ravindra Heraeus in India will allow our customers from the petrochemical sector to receive outstanding catalyst recycling standards in India. We will be the only globally active precious metal company with local recycling capabilities in this very important sector.

Together with our trusted and long-term partner Ravindra we will be able to offer fast, local and first class recycling services to our customers.” said André Christl, President of Heraeus Metal Management, the companies precious metal recycling and trading unit.

Ravindra Heraeus is one of India’s most renowned companies for precious metal products. Established in 1994, the Joint Venture is equally owned by the Ravindra Choksi family and Heraeus. The JV Managing Director, Shailesh Choksi stated: “Our Company is specialized in the manufacturing of high-tech precious and specialty metal products and solutions.

Ravindra Heraeus’ comprehensive refining services cover various types of precious metal containing material and make us the leading partner for the customer’s business.”

This is all consistent with our vision to be the most respected, dynamic and sustainable global carbon black business.”

10 • September 2016

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CEW Industry News Indian Chemical Industry Stalwarts Pledge Support Towards Building a Sustainable Supply Chain with TfS

Indian chemical industry to grow at 9 per cent p.a. to become a USD 226 billion sector: Ananth Kumar

Mumbai, India: Industry stalwarts from 19 companies of the Indian chemical industry came together for the Together for Sustainability (TfS) summit in Mumbai. Organized at the Grand Hyatt, the summit built awareness around the importance of creating a sustainable supply chain in the chemical Industry, and saw participation from over 500 representatives from suppliers and TfS member companies as well as local and international associations, international audit companies and experts. The attendees pledged their commitment towards creating sustainable supply chains in the chemical industry.

Mumbai, India: Union Minister for Chemicals & Fertilizers, Ananth Kumar affirmed that the Indian chemical industry is estimated to grow at 9 per cent p.a. to become a USD 226 billion sector, compelled by growth in end-use industries and government initiatives. The existing size of the industry is USD 147 billion.Speaking at the inaugural session of the 9th edition of biennial IndiaChem International Exhibition and Conference in Mumbai, the minister observed that the current PCPIR (Petroleum, Chemicals & Petrochemicals Investment Regions) Policy needs modifications to make it more rational and practical. He invited the industry leaders and experts gathered at IndiaChem to offer suggestions over the next one month to make the policy more vibrant.

The event featured presentations from key executives of participating companies as well as industry bodies like Confederation of Indian Industry (CII), Indian Chemical Council (ICC). Senior leaders also came together for a media panel discussion around the theme of “Charting a sustainable ecosystem in the Indian chemical industry”.

The attending panellists’ agreed on the critical need of developing and implementing the global audit program to assess and improve sustainability practices within the chemical industry in India.

Stalwarts from Indian Chemical Industry

TfS’ formal launch in India comes at a time when the Indian Chemical industry is rated 6th in the World and 3rd in Asia in value added terms at constant prices. India is at the cusp of becoming the manufacturing hub for the world with government support and initiatives like Make in India. Business activities of all organizations are thus becoming more global and supply chains more complex.

Considering the important role played by chemical industry across sectors including automobile, pharmaceuticals, textiles and even manufacturing, aligning with sustainability will help the sector to drive innovation as well as their growth engine. It is here that the TfS initiative leads by example in corporate responsibility through creating benchmarks for sustainable supply chains.

Since its initiation, the sustainability performance of 4,600 suppliers has been rated within the TfS initiative based on EcoVadis assessments and 446 TfS audits have been conducted globally. The initiative plans to establish benchmarks in the supply chain that can cover all the pillars of sustainability and grant relevant long-term gains both - to the companies and to their suppliers. In 2015, a total of 2,580 sustainability assessments have been shared among TfS Members and 179 new TfS audit reports were received by the TfS initiative. In India, 300 suppliers have been assessed through EcoVadis and audits at 28 sites have been concluded already.

12 • September 2016

Mr. Kumar said that India’s long coastline, large refining capacity and a satisfactory R&D capacity are the strengths for the growth of the chemical industry, but observed that ease of doing business still needs to improve further. He said that imports from China and South East Asia continue to dominate, as raw material cost and availability pose challenges for domestic businesses. Ananth Kumar emphasized that ‘Make In India’ campaign is the key driver for the chemical industry as there exist prospect for import substitution in many petrochemical derivatives. He further said that execution of GST would bring manufacturing costs down, thus making Indian products competitive.

The minister also observed that the Indian chemical industry, which employs nearly 2 million people, needs 8.5 lakh skilled technicians. He howled that current infrastructure to impart skill training is insufficient; as a result most of the training is taking place on site. He said that in a bid statement the issue of skill development, the government is planning to set up Central Institutes of Chemical Engineering & Technology at different locations where the chemical industry has substantial manifestation. The minister announced that the first such institute will come up in Mumbai. Minister of State for Chemicals & Petrochemicals, Mansukhbhai Mandaviya, Secretary, Chemicals & Petrochemicals Anuj Kumar Bishnoi, Bangladesh Minister for Industries, Amir Hossain Amu, leaders of chemical industry were present on the occasion.

Reliance Sibur Elastomers obtains term loan of USD 330 million Gujarat, India: Reliance Sibur Elastomers Pvt Ltd (RSEPL) has announced that it has signed agreement for availing a term loan facility of USD 330 million (about ` 2193 crore) through external commercial borrowing (ECB). ECB, with door to door tenor of 10 years, will be consumed to part finance the capital expenditure to set up India’s first butyl rubber manufacturing facility at Jamnagar, Gujarat.

The supposed ECB will be secured by way of charge on the transferable fixed assets of RSEPL relating to the project. This ECB is one of the longest tenor USD loan till date in Asia other that Japan, since RIL’s 10 year corporate loan for USD 2 billion in 2007.

Reliance Industries Limited owns a majority stake of 74.9 per cent in RSEPL, while the balance in held by Sibur.

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CEW Industry News Aarti Industries Commences Commercial Production at Ethylation Unit

Gail increases polyethylene capacity by 400,000 TPA at UP petrochemical plant

Gujarat, India: Aarti Industries Ltd has announced that it has initiated the commercial production at its multipurpose ethylation unit in Dahej SEZ, Gujarat, and the second phase of PDA expansion.

These units will assist the company to further reinforce its global presence in the end-user applications of agrochemicals and polymers.

Uttar Pradesh, India: Gail India Ltd has announced that it has commissioned a new processing line for polyethylene at its Pata petrochemical facility in Uttar Pradesh (UP) amassing its PE capacity by 400,000 tonnes per annum (TPA).

The Greenfield ethylation unit, which will obtain input material from its nitro-toluene plant, has the capacity to manufacture about 8,000-10,000 tonne per annum (TPA) of ethylene derivatives. While the primary product manufactured at this unit finds application in herbicides, the company strategies to add other products in due course with applications essentially into agrochemicals catering to global companies. Aarti Industries anticipates the first-of-its-kind ethylation unit in India, to reach near complete utilisation within a span of 3-4 years.

In the meantime, the company has also commenced commercial production of its second phase of PDA expansion from 450 tonnes per month (TPM) to 1,000 TPM. Earlier in FY16, Aarti Industries had scaled-up the capacity of PDA, which is used in engineering polymer, from 250 TPM to 450 TPM. With this, the company has enriched its presence in high-end polymers and additives, making it the only Indian source for MNCs that are currently importing this product in the country. Aarti Industries expects to reach near full utilisation of these capacities within a span of 3-4 years.

Dhunseri Petrochem enters Into JV with Thailand’s Indorama Ventures Kolkata, India: Dhunseri Petrochem Ltd has announced the conclusion of equal joint venture partnership with Thailand’s Indorama Ventures Public Company Limited (IVL) for polyethylene terephthalate (PET) resins. As per the agreement, announced in February this year, Dhunseri assimilated 50 per cent stake in IVL’s PET company in India, Micro Polypet Private Limited (MicroPet), and IVL subscribed 50 per cent stake in Dhunseri’s PET company, Dhunseri Petglobal Ltd (DPGL). By merging the two companies as equal partners, the subsequent total capacity of 700,000 tonnes per annum will make the new joint venture the second largest in India.

C K Dhanuka, Chairman, Dhunseri Petrochem stated that, “Dhunseri considers that upcoming years will convey prospects for expansion in the petrochemical sector and this JV will bring scale benefits to all stakeholders. The Indian JV will advantage from IVL’s global presence and technological leadership,” “The JV is a significant step in driving IVL’s strategic priorities forward while conveying together two leading companies with complementary strengths, brands and experiences. India is a very large country with a well-educated and booming middle class that will embrace the modern, hygienic lifestyle offered by PET packaging.” asserted Aloke Lohia, Group CEO, Indorama Ventures.

16 • September 2016

“In a step towards realising the Make in India initiative of the Government of India, Gail India Ltd has efficaciously started its first Unipol PE process line with the capacity of produce 400,000 tonnes per annum (TPA) of polyethylene (PE). The total production capacity of Gail’s petrochemical plant at Pata is now 810,000 TPA,” said the company.

Gail’s flexible swing plant, which produces both high density polyethylene (HDPE) and linear low-density polyethylene (LLDPE), delivers access to a full range of resin applications, which will allow Gail and its customers to capture fresh market prospects as demand for PE rises.

The fresh process line, based on Univation technology, provides Gail the platform to magnify its PE competencies, providing Indian PE converters with quality, domestically-produced resin products needed for both large-volume markets as well as advanced performance applications.

“Introduction of Unipol PE resin products in the Indian market has started getting positive feedback from customers. Gail team at the project site cherished the US-based Univation Technologies for providing good support to the commissioning of the project right from the hook up and the start-up of the new plant,” said the company.

Gujarat Alkalies Appoints Chematur Engineering for Hydrogen Peroxide Project Dahej, India: Gujarat Alkalies and Chemicals Ltd (GACL) has announced that it has appointed Chematur Engineering AB, Sweden, to deliver technology and engineering services for its forthcoming hydrogen peroxide plant in Dahej (Gujarat).

Swedish firm will offer technology, know-how & basic engineering services for the formation of hydrogen peroxide plant, while IBI Chematur Engineering & Consultancy Ltd, Chematur Engineering’s JV in India, will deliver comprehensive engineering and project management services for the project.

In July this year, Gujarat Alkalies and Chemicals had announced the endorsement of establishment of 14000 metr ic tonne per annum (MTPA) hydrogen peroxide plant at Dahej with an investment of Rs 143 crores. The plant is projected to be operational by Q1 of 2018-19.

Chemical Engineering World

CEW Industry News Indian Oil Appoints Praj for setting up 2G BioEthanol Plants Mumbai, India: Indian Oil Corporation Limited (IOCL) has announced that it has designated Praj Industries as its technology partner for setting up multiple second generation (2G) bio-ethanol plants based on indigenously developed technology. Indian Oil will be setting up three such 2G bio-ethanol plants.

IOCL is mixing biofuels in transportation fuels at the depot to bring down dependency on crude oil imports and to advantage of the resultant economic and environmental benefits. In order to enrich ethanol availability in the country for blending with petrol, Indian Oil is developing 2G ethanol production infrastructure using ligno-cellulosic biomasses as feedstock.

Pramod Chaudhari, Executive Chairman, Praj Industries Ltd, said, “It is a great honour for us to be chosen by Indian Oil to become their technology partner in multiple 2G bio-ethanol projects in India.

We have prepared ourselves to accomplish 2G ethanol projects over ` 3,000 crore in two-three years. Praj is offering end-to-end 2G ‘Smart Bio-refinery’ solutions globally. Our ‘Smart Biorefinery’ is capable of producing bio-ethanol and other co-products such as bio-CNG, power and a variety of bio chemicals.” Praj is also providing support to Indian Oil for realizing several milestones towards holistic development of these projects at numerous apposite locations across the country, he asserted.

IOCL to Consult Engineers India for BS-VI Upgradation Project at Six Refineries Mumbai, India: Engineers India Ltd (EIL) has announced that it has bagged a contract from Indian Oil Corporation Ltd (IOCL) for providing engineering, procurement and construction management (EPCM) services for executing BS VI quality upgradation program at its six refineries located in Panipat, Mathura, Gujarat, Haldia, Bongaigaon and Digboi.

The quality upgradation projects are being undertaken in view of the Government of India’s objective to implement BS-VI norms across the country b April 1, 2020. As per guidelines of Government of India, these quality upgradation projects need to be concluded across all the refineries of IOCL on time in order to safeguard that BS-VI norm fuel (MS and HSD) can be made available from April 2020.

EIL has lately steered the configuration study for the facilities required at these refineries to make them BS VI compliant.

Engineers India will render EPCM services and will provide project management, process design and detailed engineering, procurement & expediting services, quality assurance, construction management & supervision and assistance in start-up, commissioning services to IOCL. For Gujarat, Haldia and Bongaigaon, the technology for the diesel upgradation unit is authorized indigenously.

18 • September 2016

PCPIR Policy requires Calibration: Ananth Kumar New Delhi, India: Petroleum, Chemicals & Petrochemical Investment Regions (PCPIRs) policy launched in 2007 to promote investment in petroleum and petrochemical sector, needs fine tuning to make it more practical and hands-on, according to Ananth Kumar, Minister for Chemicals & Fertilizers.

Industr y, specifically the downstream sectors that require petrochemicals as raw materials for production, has been raising the issue of shortage of feedstock in the country. Pushed as gamechanger for Indian chemical and petrochemicals industry, the PCPIR policy was launch with an objective to entice investments worth around USD 100 billion in these regions. PCPIRs were to be designed precisely to appeal investments for instituting production facilities for petroleum, chemicals and petrochemicals. However, the policy has failed to deliver anticipated results.

Clariant to Procure Kel-Tech and X-Chem USA: Swiss firm Clariant has announced that it has signed deals to acquire two US-based companies, including X-Chem, and Kel-Tech The procurement of the two oilfield production chemicals business will reinforce Clariant’s Nor th American oilfield production chemicals business. It is also projected to add nearly USD 200 million of sales, as well as personnel, technology and expertise to its prevailing activities in North America.

Hariolf Kottmann, CEO, Clariant stated that, “It is part of our global strategy to seize business prospects in key markets with exceptional future projections through innovations and bolt-on acquisitions.” Both of these procurements allow us to toughen our position in one of the world’s largest specialty chemicals markets, to advantage from the strong, innovation-driven growth outlook of the oil services industry in North America and are accretive to our earnings from year one on, he asserted.

The company expects that the new acquisitions to fast-track the growth of its business unit Oil & Mining Services (OMS) as a prominent provider of oilfield production chemicals in the region.

The effective closing date of both acquisitions is 1st October, and they are financed in cash. “The procurements are a noteworthy step towards strengthening our footprint in North America”, said John Dunne, Global Head-BU, Oil & Mining Services, Clariant.

With this we will offer customers a stouter and more extensive product offering with customised products and solutions.

“Both Kel-Tech and X-Chem are well-run businesses with complementary operational efficiencies, which we can immediately incorporate into our existing business and combine with our stateof-the-art technology and R&D.” The purchase of Kel-Tech from Arsenal Capital Partners has been agreed and received regulatory clearance, while the acquisition of X-Chem from NCH has also received regulatory clearance.

Chemical Engineering World

Marketing Initiatives

PILOT Gaskets- Striving to make India AsbestosFREE by 2020

P

ILOT Gaskets is India’s prominent solution provider for 100% A s b e s t o s F R E E G a s ke t s, G l a n d Packings, Insulation, Millboard, Welding Blanket, and Brake Liners. They represent Manufacturers from Europe, USA & India that specialize in environmental safe products and focus primarily on fugitive emissions, contamination free sealing solutions, and 100% AsbestosFREE. Established in 1983 as the export arm of Supreme Mill Stores, under the leadership of Mr. Amul Jagjivandas Parekh, Pilot Gaskets have extended their customer base from Chile, Hongkong, Middle East, Sri Lanka and Nigeria. Domestically we cater to nearly all major Industrial Segments across Maritime, Iron & Steel, Defense, Nuclear, Energy, Chemicals and Oil & Gas within India.

Fr o m 2 0 1 0 , t h ey h ave p i vo t e d t h e i r business to focus on solutions that align with India’s growth story. Its vision is to make India AsbestosFREE by 2020 and they continue to identify and partner with compatible International organizations that follow their severe levels of quality, cer tification and 100% AsbestosFREE S o l u t i o n s. I t s g o a l i s t o r e p l a c e t h e carcinogenic Asbestos products being employed in Industries with economical, p ra c t i c a l , c e r t i f i e d a n d p e r fo r m a n c e oriented sealing solutions that are on par with International compliance.

Their Gaskets and Seals have European Cer tification such as EN, DIN, WRAS, TA-LUFT, NSAF, ANSI. They precisely manufacture and offer API 607 Certified Gaskets, API 622, API 624 for Valve Packing, IS 16752 for pump packing, and ISO 11612 for Fire Safety.

20 • September 2016

Pilot Gaskets are also diversifying into a nanotechnogy based hydrophobic coatings that are a Universal Corrosion Prevention and can be used across all surfaces including steel, iron, wood, cement and ceramic. Trials runs are being conducted by the Ministry of Defence.

Its technical advisors and relationship managers coordinate with client’s factory maintenance team with a persistent goal to reduce production downtime, leakages, fugitive emissions, carbon footprint and offering cer tified 100% AsbestosFREE Solutions ensuring there is a stringent compliance and quality control by client’s

maintenance team. They pride themselves in their technical advice and half a century experience in sealing and gaskets.

Help them in making India 100% AsbestosFREE! Contact Details: Pilot Gaskets And Engineers 36 Bhajipala Lane, Next to Bombay Mercantile Bank, Nagdevi, Mumbai 400003 Phone No: +91 8080890022 Email: pilotgaskets@gmail.com Website: http://www.pilotgaskets.com Chemical Engineering World

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CEW Technology News Simulation Technology Center Coming to UC College of Engineering and Applied Science

These co-op working students will be placed on impor tant software development programs and related projects in Siemens PLM Software’s Milford, Ohio office. This strategic co-op program includes additional training in the business and skill development programs to prepare these students for their careers upon graduation.

"UC, including our College of Engineer ing and Applied Science, is known for having one of the best co-op and experiential lear ning programs in the world,” said Beverly J. Davenpor t, UC Interim President. “The new Siemens PLM Simulation Technology Center takes CEAS to new heights by giving our students the latest tools to enhance their hands-on experiences.”

Boston, USA: Siemens and the University of Cincinnati has announced a partnership to establish an innovative simulation and modeling center enabled with Siemens product lifecycle management (PLM) software.

Housed on UC’s main campus in its College of Engineering and Applied Science (CEAS), the Siemens PLM Simulation Technology Center will be a hub for developing and applying new methodologies and technologies in engineering education and research in all aspects of PLM. Through a significant pledge from Siemens of up to $1 million, as well as Siemens’ staff support and additional PLM software, this partnership will enhance experiential learning opportunities for students in UC’s CEAS. “As manufacturing companies’ worldwide move closer to Industr y 4.0, it is more impor tant than ever for academic institutions and educators to move beyond only CAD software and embed digitalization into their curriculum,” said Chuck Grindstaff, president and CEO, Siemens PLM Software. “The Siemens PLM Simulation Technology Center will help establish the connection between academia and industry to develop future employees for the digital enterprise.”

CEAS faculty led by Dr. Jay Kim, Department Head of Mechanical and Materials Engineering, and Dr. Sam Anand, a professor of Mechanical Engineering who will also serve as the operational director of the Center, will work with Siemens PLM Software staff to educate and train up to 500 students over five years at the center. Through this close collaboration, a transformational change in undergraduate engineering and applied science curricula is expected, which will incorporate CAD, Digital Design & Manufacturing and Computer Aided Engineering (CAE) from early year courses to multi-year projects with global multidisciplinary teams in upper-level courses.

In addition, Siemens PLM Software has entered into a long term talent development partnership with UC to employ co-ops on a strategic and programmatic basis.

22 • September 2016

“It’s like co-op 2.0,” said CEAS Dean Teik Lim. “At the new center, students will have the oppor tunity to actively solve problems using Siemens’ PLM software and gain valuable hands-on lear ning exper ience. We are committed to producing outstanding engineers and scientists; this center provides a vital tool in our workforce readiness effor ts by training students on software used in the field by 140,000 companies globally.

We are grateful to Siemens PLM Software for its par tnership, which will enable us to produce even better engineers. In fact, par t of the Siemens PLM Software business came from its acquisition of SDRC, a company that grew out from UC engineering about 50 years ago, making this par tnership even more meaningful.”

At the new Siemens PLM Simulation Technology Center students will have access to Siemens’ full suite of PLM offerings including its recently announced Simcenter™ por tfolio, a robust suite of simulation software and test solutions based on predictive engineering analytics to more accurately predict product performance.

Using these solutions, students will have the oppor tunity to perfor m state-of-the-ar t design, engineering analysis, p r o d u c t d ev e l o p m e n t a n d m a n u fa c t u r i n g s i m u l a t i o n s , and lear n from industr y exper ts. In addition, upper level u n d e r gra d u a t e s t u d e n t s a n d gra d u a t e s t u d e n t s w i l l b e exposed to solving real life multi-physics, multi-domain engineering problems through simulations in the for m of ver tical industr y specific template apps.

“With Simcenter, Siemens has one of the wor ld’s most comprehensive and robust simulation software por tfolios,” said Dr. Jan Leuridan, Senior Vice President, Simulation and Test Solutions, Siemens PLM Software. “We believe that simulation exper tise will be a real differentiator for UC, and we are proud that together we are empowering the next generation of digital talent.”

Chemical Engineering World

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CEW Technology News Noncontact Temperature Monitoring In Hazardous Areas

industry; petrochemical applications such as sulfur recovery and monitoring boilers, reactors, pipes, and flare control; manufacture and storage of various chemical and agricultural products such as vinyl, fertilizer, starch, alcohols, and flour; fire detection; monitoring mining equipment and conveyors; hazardous waste disposal; and sewage treatment.

Monitoring Sulfuric Acid Concentration OnlineWith Sonic Velocity to the Peak

Berlin, Germany: All models from Fluke Process Instruments’ versatile MI3 infrared sensor series are now also available as intrinsically safe versions for use in hazardous environments.

The intelligent miniature sensors are fully ATEX and IECEx certified for use in Zones 1 and 2 (gas) and Zones 21 and 22 (dust). The manufacturer supplies a complete intrinsically safe package including the sensor, a communication box, and an Ex power supply. All three components are IP65-rated, and each can be easily exchanged in the field without Re-calibration of the entire system. One or two intrinsically safe MI3 sensing heads can be powered by one power supply. The sensor cables can be up to 30 m long in total, providing high flexibility for setting up safe monitoring scenarios.

Featuring stainless steel housing with integrated electronics, the rugged MI3 pyrometer is the smallest stand-alone digital infrared temperature sensor for fixed installation on the market today. The MI3 ser ies compr ises pyrometers for var ious spectral ranges and applications, including the 1M and 2M short wavelength models with an excellent 100:1 resolution and 10 ms response time, which are suitable for monitoring temperatures up to +1,800 °C. Each intrinsically safe MI3 sensing head is labelled with the Ex I certification. In the case of the MI3100, this also covers the laser sighting function for easy positioning and aiming.

MI3 sensors have excellent EMC characteristics and can be used in ambient temperatures up to +180 °C. Communication boxes are available with RS485, Modbus, Profibus, Ethernet, and Profinet IO interfaces and with four galvanically isolated a n a l o g o u t p u t s . Au t o m a t i c h e a d d e t e c t i o n a n d d i g i t a l communication between sensor and box enable plug and play.

The ATEX and IECEx certifications open up many additional areas for the MI3 series, for example steel industry processes using hydrogen atmospheres such as galvanizing, annealing, p l a t i n g , a n d c o a t i n g ; hy d r o g e n r e d u c t i o n i n t h e s o l a r 24 • September 2016

Magdeburg-Barleben, Germany: In various industries, monitoring the sulfuric acid concentration is vital for a preventive quality management, sustainable resource efficiency and increased safety. Precise and reliable monitoring places high demands on the analysis. For the concentration determination, sonic velocity meters have proven to be ideal, as sonic velocity forms a strong and unambiguous function to the concentration of sulfuric acid and oleum in the production-relevant concentration ranges.

With the LiquiSonic® analyzer by SensoTech, the concentration of sulfuric acid and oleum is continuously monitored in real time using just one single sonic velocity sensor that is installed directly in the pipe. The robust construction and Hastelloy C-2000 as sensor mater ial make the sensor completely maintenance-free. Due to the chemical and physical properties of sulfuric acid and oleum the LiquiSonic® technology provides highly accurate and clear results.

The measurement accuracy is up to ± 0.03 m% and the results are updated every second. The LiquiSonic® controller displays and stores the real-time information. Via 4-20 mA signal, digital outputs, serial interfaces, fieldbus or Ethernet, the controller can be integrated into the network and control system.

The analyzer monitors the acid concentration, for example, in processes of sulfuric acid production, including the double contact double absorption (DCDA) process and the wet sulfuric acid (WSA) process. Moreover, LiquiSonic® analyzers are used in synthesis gas drying, fertilizer production, decomposing ore mining or in etching and pickling baths of the chemical and steel industry.

Chemical Engineering World

CEW News Features

‘Dahej is a major stride forward as we double capacity, with leveraging novel technology’ Shernaz Vakil, CMD, Dai-ichi Karkaria Limited shares details of successful partnership of five decades with Japanese Technology Company Dai-ichi Kogyo, Seiyaku Co Ltd, maintaining strong position in Indian and global markets and the new state of the art alkoxylation facility based on Swiss technology in Dahej which will be commissioned next year.

“B

ack in 1960, when India was decades away from economic liberalisation and having stringent restrictions on imports and foreign investments, a visionary and forerunner set his expedition into the field of speciality chemicals. Mr Dhunjishaw Neterwala, one of the pioneers in Indian specialty chemical industr y, entered into the business of producing surfactants with the technology partnership with Japanese company Daiichi Kogyo, Seiyaku Co Ltd. and took up the challenge of setting up an Ethoxylation unit in Pimpri Pune. Today, Dai-ichi Karkaria of Neterwala group is a distinguished name in the field of specialty chemicals.

the market based on quality, reliability and on innovation, so it was very easy for us to recapture our market position”, she adds.

India was a closed market back then; but my father saw a great opportunity in it. He thought it would be a good opportunity to tie up with Dai-ichi Kogyo and set up the plant since there were not many ethoxylaters in the market at that time. On one hand the closed market had its own restrictions, but on the other hand, you have the luxury of having a large market,” shares Shernaz Vakil, daughter of Mr. Dhunjishaw Neterwala, CMD Dai-ichi Karkaria.

“Innovation is one of the significant areas that have cemented Dai-ichi Karkaria’s strong market presence, as well as driving company’s quality, along with premier standards of integrity and social responsibility”, she adds.

“Economic liberalisation opened up the country to the global economy and paved the way for competition in the market.

After the economy opened up, we had to reorganise and reengineer significantly, since in the beginning there were a lot of imports coming in, products that were similar to ours. In the course, we lost some market share; but you have to recuperate, look at your strengths, focus on your USP & claim back the market. For us, fortuitously we had built on a strong good reputation in 28 • September 2016

Company’s Response to Changing Dynamics of Specialty Chemicals Users “Dai-ichi Karkaria Limited has always been open to changing dynamics, and to customers that are conscious of quality and the environment. We have often developed products which have been ahead of the times. These products have found resistance in the past because of price. However, c h a n g i n g p e r c e p t i o n s a n d i m p r ove d environmental consciousness have proved to be advantageous to us.” says Vakil.

Challenges of Human Resources Aspect in Indian Chemical Industry “Dai-ichi Karkaria Limited has been fortunate to have very good old guard who have been there with company right from the time of Mr. Neterwala. Dai-ichi Karkaria has experienced the privilege of employee retention since its inception. The old guard train fresh manpower and mentor them. “There is a great sense of commitment in the old guard that is a rarity in today’s ever-evolving working culture and the knowledge base is very strong. They have supported us in the past and even after their retirement, many of them have continued functioning with us as consultants and have been training the fresh generation of research scientists. So that’s the path we charted,” she asserts. Our old guard have been in the R&D department

Shernaz Vakil CMD, Dai-ichi Karkaria Limited

and have stayed with us during the journey”, Vakil articulates.

“We manufacture performance chemicals.

Each product that we make is specific to certain performance need, which means that the R&D person has to go to the market in order to recognize the customer’s need and develop the product to meet the requirement, accordingly. We need more people who are good in research, also worthy technical resources who can assist in developing business by visibly understanding the market necessities and transform into products,” adds Vakil.

Market Demand in India and Globally “Nalco Champion Dai-ichi India Pvt Ltd is a Joint Venture Company, formed between the world leader in supply of Production Chemicals & Integrated Services to Oil and Gas Industry & Dai-ichi Karkaria Ltd. The company is in the core business of Chemical Solutions to Upstream Oil & Gas E&P companies. The company delivers world class Chemical Solutions and Services to Indian customers. The company is well positioned to serve the more challenging sector of Deep Water Oil & Gas sectors and Flow Assurance for difficult Oils.

Chemical Engineering World

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CEW News Features Our partnership with Nalco Champion has not only been successful for the Indian market but we have also been able to export to them some of their requirements for the Far East markets. Though we are largely committed to the upstream area of supplying products for oil production we do supply few downstream products for refinery applications” says Vakil.

Impact of Declining Crude Oil Prices on the Market “Declining Crude Oil prices have resulted in a slowing down of projects and expansions w o r l d w i d e . C o m p a n i e s h ave e i t h e r decreased production or are holding on to production levels. Our expectations of 25% to 50% growth over next three to five years has not transpired because of the substantial reduction in prices” says Vakil.

Key Industries for Business “Dai-ichi Karkaria Limited manufactures Po ur Point D epre ssant s fo r Cr u de & Lubricating Oils, Emulsifiers for emulsion Pa i n t s & A d h e s i ve s, A d d i t i ve s fo r Construction industries. They also have APEO free equivalent replacements for several emulsifiers. Dai-ichi has started m a n u fa c t u r i n g A l k y l Po l y G l u c o s i d e surfactants which are non-ionic surfactants obtained from renewable natural raw material such as vegetable oils and starch.

It has also developed reactive surfactants w h i c h a r e u s e d i n m a n u fa c t u r i n g o f external coatings due to its excellent water resistance properties.

Textiles is also one of the key areas, that the company has supplied to in the past.

Today the company supplies only highly specialized products.

We h ave a c c e s s t o t e c h n o l o g y f r o m Matsumoto Japan for Spin Finish. With our integrated R & D facility, we are able to manufacture products with complex reaction for spin finishes for POY/DTY and polyester sizing business” adds Vakil.

Dahej’s State-of-the-Art Facility & Sustainable Solutions Offered “After much deliberation, we zeroed in 32 • September 2016

Manufacturing Facilities • Pune plant: Multipurpose plant designed to allow high degree of flexibility essential to meet varied and stringent customer requirements.

• Kurkumbh plant: Equipped with specially designed photo polymerization belt reactor to manufacture non- ionic, anionic, cationic, and amphoteric polyelectrolytes for use as flocculants and dewatering applications.

• NALCO Dai-ichi JV facility in Jejuri near Kolhapur to manufacture products for petroleum industry.

• Dahej facility – a Greenfield site with total plant capacity of approximately 30,000 MT per annum to manufacture alkoxylates its derivatives and other oilfield chemicals. The targeted date for commissioning of project is end of 2017.

on the idea of moving to a Greenfield site. It is more of a brownfield expansion using similar technology and products. We are setting up a total of 30,000 MTPA to manufacture alkoxylates & derivatives and other oilfield chemicals. The targeted date for commissioning of the project is end of 2017” says Vakil.

Technological Innovation & Evolving R&D “Our model is such that we received the base technology from Dai-ichi Kogyo, but having said that – we have developed almost more than 300 products for various industrial applications through our own R&D efforts. We have Customised chemistries and Formulated various products as per the customer demand,” adds Vakil Future Plans in India “Expansion at Dahej is an ambitious plan as we are doubling the EO capacity, while absorbing new technology; doubling the capacity of pour point depressants technology, and also looking at expanding

our product basket by producing new produc ts for Pers o n a l Ca r e a n d Agricultural Applications.

We have initiated hiring process for new technical staff and Business Managers.

Though, their requirement comes into action towards end of 2017, but we have already started training them, getting the pulse of the market and making in-roads into the market” states Vakil.

Goods & Services Tax Bill & its Impact on Indian Chemical Industry “In the way it is present today, there are some glitches that need to be ironed out. It is supposed to be an indirect tax reform and should play out like that. There are clauses like taxation on perceived income etc., which have been taken from Excise, Custom duties etc., that need to be ironed out and unless all this is cleaned out, it won’t be as groundbreaking as it is expected to be. If it has to be reformative, it must be able to bring about reformative modifications,” shares Vakil Key Essentials for Specialty Chemicals to Stay Competitive Globally “Our reputation in the market has been one of the principal cornerstones. Dai-ichi Karkaria Limited cherish a strong brand image that it has developed over the last five decades based on reliability in high quality standards, timely deliveries and faith of the customers. Customers feel at ease while dealing with value based ethical companies” says Vakil.

Indo-Japan Partnership & Opportunities for Chemical Industry “Japanese technologies are very expensive in terms of products – which are very high end in quality. Couple of technologies that we tried to bring in the late 80s, were not able to translate very comfortable – since those were too high end and much ahead of their time at that point for the Indian market. Though those products did not work at that point but still at present those products have been top of class. Since you have to compete in the market, and the raw material requirement were often very high priced. It becomes challenging to translate the technology into the Indian setting”, states Vakil Chemical Engineering World

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CEW News Features

Siemens Launches Latest release of Solid Edge software: Solid Edge ST9 John Fox, Vice President of Marketing, Mainstream Engineering, Siemens PLM Software, recently visited India to launch Solid Edge ST9 which combines the cloud and data management capabilities you need, with unprecedented flexibility and excellence in 3D CAD. In a press conference, he shared insights into its pioneering capabilities for fast and flexible design.

J

ohn Fox along with the India team was on the last leg of India tour in Pune after visiting 11 cities and meeting customers across the country to introduce the new version of Solid Edge software.

Siemens’ latest release of its Solid Edge® computer-aided design (CAD) software (Solid Edge ST9) provides flexible and easy access to the full capabilities of Solid Edge with cloud-based licensing, user preferences, and collaboration tools. In addition, the new built-in data management capabilities, with zero IT support requirements, enable users to easily index their CAD data, while the new migration tools enable rapid conversion of legacy design data from virtually any CAD system. For more comprehensive data management capabilities, Solid Edge ST9 also offers a significantly enhanced integration with Siemens’ Teamcenter®,; the world’s most widely used digital lifecycle management software, which ensures fast and consistent completion of critical data management tasks.

Fox stated, “Implementing Solid Edge has never been faster or easier. Solid Edge ST9 provides the industry’s most flexible licensing options. This combined with new cloudenabled options helps us to further fulfill our commitment to deliver easy to deploy software that gives customers the power to choose how they buy, deploy and collaborate.”

John Fox Vice President of Marketing, Mainstream Engineering, Siemens PLM Software

34 • September 2016

H e a d d e d t h a t t h e n ew bu i l t - i n d a t a management capabilities enable users to take control of ever increasing volumes of CAD data, with instant searches for files and properties, as well as impact analysis. As part of the new capabilities the new design manager utility provides for fast and simple revision and release management. There is no database software to install or database tables to maintain and the new capabilities will result in significantly improved data organization and consistency, and faster completion of everyday data management tasks for Solid Edge users.

New cloud capabilities provide faster and more flexible deployment options, improved user access and collaboration across remote designs teams. Licenses and user preferences can be stored on the cloud enabling users to access their personal environment anytime and anywhere. Solid Edge ST9 also adds data storage options via cloud-enabled vaulting so users can store and share design data in a controlled manner with external suppliers and customers, using popular online storage service like Dropbox, OneDrive® software, Google Drive™ online storage service and Box. While this allows users to efficiently work online, the option to work locally, i.e. offline, is always available.

The enhanced Teamcenter integration includes a new ribbon in the Solid Edge

“Implementing Solid Edge has never been faster or easier. Solid Edge ST9 provides the industry’s most flexible licensing options. This combined with new cloud-enabled options helps us to further fulfill our commitment to deliver easy to deploy software that gives customers the power to choose how they buy, deploy and collaborate.”

user interface for easy access to data management tasks, and a new embedded window for Active Workspace. The ribbon helps designers quickly perform whereused searches and initiate Teamcenter workflows; easily view and edit properties infor mation; and see how this data is synchronized. This helps speed the learning curve for new users and helps existing users complete data management tasks faster and more consistently. Active Workspace, an intuitive, highly visual, and personalized environment for instantly accessing infor mation, gives designers the ability to perform simple text based “filter” type searches to find the data they need, and then drag parts into Solid Edge for editing, or placing them into an assembly.

New migration tools build on the existing toolset for importing CAD data. For example, the associativity between SolidWorks® software models and drawings can now be migrated to Solid Edge. Additionally, a robust Solid Edge 2D to AutoCAD® software export tool ensures seamless mapping of Solid Edge drafting elements to AutoCAD. Solid Edge ST9 also provides easy access to the 2D designs created in Siemens’ newly announced Catchbook™ software, to rapidly create 3D models and professional engineering drawings from sketches.

Fox s h a r e d t h a t S i e m e n s h a s b e e n receiving strong positive response from the users, since cloud based access offers much needed flexibility, allowing users to work from anywhere, whether it’s from a work station in the office or working remotely on a tablet, Solid Edge users can quickly complete their design tasks.

Solid Edge ST9 is available today for the Indian market.

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CEW Features Technical Article

Membrane Technology: Unique Solution for Waste Water Treatment & Reuse for Industrial Water Hyflux Ltd has recognized vital drivers to present its membrane based technology for waste water treatment and reuse in the Indian market, oscillating from treating sewage up to industrial grade water, to the model of integrated membrane solutions for Zero Liquid Discharge (ZLD). The article discusses about treatment schemes, case studies along with latent applications, innovative membrane technologies for cooling tower blow down and ZLD in power plants.

A

ZLD system encompasses treatment to the waste generated from the water treatment process & produces the good quality of water to recycle it back to the main process. Discharge from the ZLD plant is only in solids form which can be disposed easily. There are wide ranges of advanced wastewater treatment technologies to recycle, recovery and reuse of the ‘treated’ wastewater and thereby ensure there is no discharge of wastewater to the environment.

In power plants, fresh water consumption is very high in terms of steam generation, cooling tower make up. Over a period of time cooling water gets saturated with minerals & needs to be bleed off/ blow down from the cooling tower. This waste cooling tower blow down water we can recycle back to the Cooling Tower by giving membrane based treatment & waste generated from the CTBD treatment can be reused in the different processes of Power plant.

system for the Ultra Filtration & reverse osmosis (RO) process at a Cooling Tower Make Up plant. The plant recycles Cooling Tower Blow Down into high-grade industrial water for cooling Tower makeup & high grade of boiler feed water.

Treatment Process Cooling water used in the power plant primarily for condensation of steam and auxiliary heat transfer needs & it is recycled back to the cooling tower. Over a period of time high mineral concentration at cooling water will be bleed off / blow down. Simultaneously it will get replaced with cooling tower make up water. This cooling tower blow down (CTBD) water needs to be treated & recycled back to cooling tower as cooling tower make up and for production of boiler feed water.

CTBD treatment plant has a membrane system (UF/RO) system installed to produce high quality of water which can be reused as a cooling tower make up & also as boiler feed water. A conventional high rate clarification followed by multigrade filtration pre-treatment system is used before the UF & RO process to remove suspended solids, organics & microorganisms, and salts. Clarified water from pre-treatment is fed to the UF system to achieve SDI less than 3, to make it suitable for RO process. UF system is operating at 95% recovery.

UF permeate water is feeding to RO system to reduce TDS from 2080 ppm to cooling water make up quality (TDS – less than 100 ppm). RO system is operating at 85% recovery. High concentrated RO

The article deliberates about the prevailing Hyflux installations on subsequent applications of industrial waste water: 1. Cooling tower blow down water - Power Plant 2. Secondary treated waste water to Boiler feed water - Chemical & fertilizer Plant 3. Waste water treatment through membrane system for ZLD plant Textile effluent Case Study 1: National Thermal Power Corporation (NTPC) Jhajjar ZLD NTPC used a conventional Clarification, multi-grade filtration pre-treatment 38 • September 2016

Hyflux Ultrafiltration Installation on Cooling Tower Blow Down Recycle

Chemical Engineering World

Over 25 years of service to Chemical Process Industry

008

CEW Features which can be reused in process as boiler feed water (TDS less than 100 ppm). In this way we are reducing the wastage of water upto 80% by treating and reusing domestic sewage in Industrial applications.

Case Study 3: Jay Jay Mills, Tiruppur, Tamil Nadu Textile Company Jay Jay Mills was established in 1971 in Tirupur in the South Indian state of Tamil Nadu as a manufacturer of Cotton Knitwear. Jay Jay mills were keen to improve the quality of the waste water discharge from one of its factories while lowering water consumption.

Treatment Scheme

Treatment Process To reclaim the waste water, a combined UF and RO waste water treatment was required. The entire treatment process involved a number of steps to remove lint, chemicals and large suspended solids before the waste water was feed into the UF-RO system.

Cooling Tower Make Up Analysis

reject (13500 ppm) is recycled back to Coal Handling plant for Ash suppression.

As a result there is no waste disposed to environment in a liquid from.

Case Study 2: Rashtriya Chemicals and Fertilizers (RCF), Mumbai RCF, a government-owned company and one of the leading fertiliser producers in India, uses ultra-filtration membrane technology followed by the reverse osmosis (RO) process at a sewage recycling plant. The plant recycles municipal sewage into high-grade industrial water for chemical and fertiliser production processes.

Treatment Process Municipal sewage is collected from the city and treated into high-grade

industrial water for chemical and fertiliser production processes. Pretreatment scheme correct the pH and homogenize to remove floating particles and scheme of aeration. Biological treatment to reduce the BOD and COD value and pass into the scheme of clarifier. Adding chemicals for flocculation and coagulation and settled the sludge TSS particle in the secondary clarifier and high rate clarifier.

Waste water from the textile industry is generated from chemical processing and dyeing process of textiles.

Rapid gravity filter, Pressure sand filter and cartridge filter has been replaced by the Ultrafiltration system. Ultra filtration removes the suspended and turbidity particle and RO remove all dissolved particles and colors.

In the pretreatment, correct the pH and homogenization is done to remove floating particles. Textile effluent is treated biologically further to reduce the BOD and COD in the water followed by electro chlorination. Chemicals like coagulant & flocculants are dosed in pretreatment for coagulation and flocculation. Flocculated particles are settled in the clarifier.

Clarified water is fed to Pressure sand filter to reduce the suspended particle and to ACF to remove the chlorine, turbid particle and colour if any.

By treating domestic/municipal sewage we are producing good quality water

Treated water recycles back to textile process and final reject is evaporated

Treatment Scheme

40 • September 2016

Chemical Engineering World

Features CEW

Water Quality at Different Stages

in 4 stage Multiple effect evaporator.

Final reject from the RO plant having 45000 ppm concentration which is concentrating upto 350000 ppm.

Condensate from the evaporation plant is having 100 ppm TDS which we is blended with the RO permeate water. Slurry from evaporator of 35% concentration is fed to the centrifuge for further recovery of water. Output of the centrifuge is sodium chloride salts & filtrate is recycled back to the feed water tank.

Conclusion Membrane based treatment process is the utmost dire & significant process to accomplish Zero Liquid Discharge

through a ZLD process plant. ZLD plants are advantageous in realizing various advantages to the industries and environment when compared to other conservative methods.

• Reclaim a scarce water resource.

• ZLD technology is beneficial for the plant’s water management; encouraging close monitoring of water usage, avoiding wastage and promotes recycling • Possibility of use of sewage for recovery of water, for Industrial and municipal use, using ZLD technologies.

• Reduce wastewater discharge by as much as 70-80%.

• A more sustainable growth of the

industry while meeting most stringent regulatory norms.

• Reuse of consistent, high-quality water source for lower cost than the cost of purchased water.

• Increase operating profit by reusing an existing resource.

• Reduction in water demand from the Industry frees up water for Agriculture and Domestic demands.

Author’s Details

Treatment Scheme

Chemical Engineering World

Ashutosh Gopal Sales Director Hyflux Engineering (India) Pvt. Ltd, India E: ashutosh_gopal@hyflux.com September 2016 • 41

CEW Features Case Study

Addressing Water Scarcity in Tamil Nadu- Novel Perspective Tamil Nadu is facing a water insufficiency of more than 11 per cent at present and it is expected to upsurge in the coming years. As a matter of fact, due to lack of flowing rivers, Tamil Nadu is reliant on on its adjacent states. To improve the water stress, Tamil Nadu has taken steps to implement water reuse and sea water desalination system.

T

hoothukudi District: Thoothukudi District is an administrative district of Tamil Nadu state and it is situated in the south eastern part of TamilNadu which is in arid and water scarce region. The city of Thoothukudi is the district headquarters.

Thoothukudi district spreads over an area of 4621 km². The District comprises of 1 Municipal Corporation, 2 Municipalities, 19 Town Panchayats and 1718 habitations in 12 blocks having 4,62,010 households and a population of 17,50,176 (Census,2011).

Ramanathapuram District: Ramanathapuram District is an administrative district of Tamil Nadu state and it is situated in the south eastern part of the TamilNadu which is in arid and water scarce region. The city of Ramanathapuram is the district headquarters.

Ramanathapuram District has an area of 4123 sq.km. It is bounded on the north

by Sivaganga District, on the northeast by Pudukkottai District, on the east by the Palk Strait, on the south by the Gulf of Mannar, on the west by Thoothukudi District, and on the northwest by Virudhunagar District.

The District Comprises of 4 Municipalities, 7 Town Panchayats and 2520 rural habitations in 11 blocks.

Need for Desalination Plant: Considering the existing scenario of nonsustainable and drinking water quality of ground water in these Districts, the Hon’ble Chief Minister of Tamil Nadu has announced in the Floor of Assembly on 10.04.2013, under Rule 110 of Legislative Assembly, that Desalination Plants of 100 MLD Capacity each will be installed in Ramanathapuram and Tuticorin Districts, as a permanent measure to provide drinking water to the public for all seasons.

In the above context, Tamilnadu Water Supply and Drainage Board (TWADB), Chennai entrusted the assignment to M/s Tamilnadu Water Investment Company Limited, Chennai for conducting planning study and preparation of pre-feasibility report including financial viability, for setting up of either one number of 100 MLD or more than one plant of various capacities, totaling 100 MLD sea water

42 • September 2016

Chemical Engineering World

Features CEW

Population and Water Requirements Thoothukudi District: Details of Population & Water Demand S.No

Description

1

Year

2

Units

Reverse Osmosis Desalination plants in these districts.

Details

Yr.

2016

2031

2046

Urban Population

Nos.

2,40,900

2,73,500

3,12,600

3

Rural Population

Nos.

8,85,050

9,27,300

9,71,550

4

Total Population

Nos.

11,25,950

12,00,800

12,84,150

5

Rate of Supply for Urban

LPCD

135

135

135

6

Rate of Supply for Rural

LPCD

55

55

55

7

Demand at Delivery Point

MLD

81.20

87.92

95.64

8

Existing supply from Various CWSS

MLD

20.99

22.37

24.00

9

Net Demand

MLD

60.21

65.55

71.64

10

Transmission Losses at 10%

MLD

6.02

6.56

7.16

11

Demand inclusive of Water Loss

MLD

66.23

72.11

78.80

12

Industrial Demand and rounding off

MLD

8.77

17.89

26.20

13

Total Demand

MLD

75.00

90.00

105.00

Chemical Engineering World

Field Study and Survey Work: Field study and survey work was done to evaluate each site for: • Access to good quality sea water; Brine disposal and dispersion • Physical suitability for construction of desalination plant, eg soils and flooding • Acceptability from an environmental point of view and Access to electrical power And the following activity was performed.

• Obtained Present population and Existing Water Supply Scheme & Infrastructure details.

Identified candidate site by carrying out reconnaissance survey.

• Obtained data/records of Government lands, for fixing up the site in and around to the probable locations.

• Obtained details from TNEB on the source and availability of electrical power to the site and preliminary assessment were made on the power requirement for each site.

September 2016 • 43

CEW Features Ramanathapuram District: S.No

Description

Units

Details

1

Year

Yr.

2016

2031

2046

2

Urban Population

Nos.

377920

468810

582950

3

Rural Population

Nos.

1044590

1150520

1256460

4

Total Population

Nos.

1422510

1619330

1839410

5

Rate of Supply for Urban

LPCD

135

135

135

6

Rate of Supply for Rural

LPCD

55

55

55

7

Demand at Delivery Point

MLD

108.47

126.57

147.80

8

Existing supply from Various CWSS

MLD

46.45

54.12

63.33

9

Net Demand

MLD

62.02

72.45

84.47

10

Transmission Losses at 10%

MLD

6.20

7.24

8.45

11

Demand inclusive of Water Loss

MLD

68.22

79.69

92.92

12

Industrial Demand and rounding off

MLD

6.78

10.31

12.08

13

Total Demand

MLD

75.00

90.00

105.00

• Collected Sea Water Samples for analysis of Water Quality Parameters.

• Carryout Oceanographic survey covering, Bathymetry, Sea Bed Geology, Wind, Current, Tides, Waves & Marine Ecology and Biology

Site Selection & Sizing of Plant Capacity Thoothukudi District: Initial Site Identification Potential sites for a desalination plant were identified as a result of meetings with the TWAD board officials and

knowledge of local conditions. Sites were selected to leverage existing distribution infrastructure. The site selection process initially identified 10 sites that represent a wide range of potential locations. These sites are Manapadu, Tharuvaikulam, Veppalodai, Sippikulam and Vaippar/Vembar.

Initial Site Screening and Selection Out of 10 sites initially identified, five sites were eliminated due to nonsuitability of engineering parameter like sea water depth, intake and outfall, land availability, potential environmental and social concerns or the potential lack of community acceptance. The site identified for further studies are Alanthalai, Kayalpattinam South, Kayalpattinam North, Tharuvaikulam, and Vaippar Evaluation of Site and Selection Criteria After initial screening further study was done for the selected site to assess the suitability for setting up the SWRO Plant based on the following criteria as present in the below table Ramanathapuram District: Initial Site Identification Potential sites for a desalination plant were identified as a result of meetings with the TWAD Board officials and knowledge of local conditions. Sites

Selection of Technology Almost all the new stand-alone desalination plants, which have come up worldwide in the recent past, are based on reverse osmosis as this has a distinct edge over other desalination technologies in such applications. Chennai Metro Water have also selected seawater reverse osmosis technology for the Minjur & Nemmeli plant and the Pre-feasibility Report was prepared by TWIC

44 • September 2016

Chemical Engineering World

Features CEW Criteria

Alanthalai

Kayalpattinam South

Kayalpattinam North

Tharuvaikulam

Vaippar

Availability of land close to Sea

Y

Y

Y

Y

Y

Extend of land available for minimum 20 MLD Capacity

Y

Y

Y

Y

Y

Alanthalai

Kayalpattinam South

Kayalpattinam North

Tharuvaikulam

Vaippar

Proper access to Land / Site identified

Y

Y

N

Y

Y

Water quality - Requires extensive Pre treatment

Y

Y

Y

Y

Y

seabed sediment - Affect the intake Water Quality

N

N

N

Y

N

Suitability for intake & Brine Discharge ( Proper Dispersion)

Y

Y

Y

N

Y

Suitable Depth availability Bathymetry

Y

N

Y

N

Y

Nature of geology of Seabed Suitable for execution

Y

Y

Y

Y

Y

Suitability for Plant Construction Soil & Flooding

Y

Y

Y

Y

Y

Access to Electrical Power Supply

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Acceptability from Social point of view No disturbance to human settlement & Fishing

Y

Y

N

N

Y

Compliance with CRZ regulations

Y

Y

Y

Y

Y

Criteria

Acceptability from an environmental Ecologically non- sensitivity region Marine Fauna & fisheries

Easier for Statutory clearances Note: Y – Yes, N – No were selected to leverage existing distribution infrastructure. The site selection process initially identified 10 sites that represent a wide range of potential locations. These sites are Kannirajapuram, Narippayur, Kuthiraimozhi, Valinokkam, Chinna Ervadi, Kilakarai, Uchipuli / Mandapam, Keelanagachi / Mandapam, Chithrakottai / Devipattinam, Karankadu/ Near Thondi Evaluation of Site and Selection Criteria After initial screening, further study was done for the selected site to assess the suitability for setting up the SWRO Plant based on the following criteria as present in the below table Chemical Engineering World

September 2016 • 45

CEW Features Narippaiyur

Kuthiraimozhi

ChinnaErvadi

KeelaNagachi

Karankadu

Availability of land close to Sea

Criteria

Y

Y

Y

Y

Y

Extend of land available for minimum 20 MLD Capacity

N

Y

N

Y

N

Proper access to Land / Site identified

Y

Y

Y

Y

Y

Water quality- Requires extensive Pre treatment

Y

Y

Y

Y

Y

seabed sediment - Affect the intake Water Quality

N

N

Y

N

Y

Suitability for intake & Brine Discharge (Proper Dispersion)

Y

Y

N

Y

N

Suitable Depth availability Bathymetry

Y

Y

N

Y

N

Nature of geology of Seabed Suitable for execution

Y

Y

Y

Y

Y

Suitability for Plant Construction - Soil & Flooding

Y

Y

Y

Y

Y

Criteria

Narippaiyur

Kuthiraimozhi

ChinnaErvadi

KeelaNagachi

Karankadu

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Acceptability from Social point of view No disturbance to human settlement & Fishing

Y

Y

N

Y

N

Compliance with CRZ regulations

Y

Y

Y

Y

Y

Access to Electrical Power Supply Acceptability from an environmental Ecologically non- sensitivity region Marine Fauna & fisheries

Note: Y – Yes, N- No Techno Economic Feasibility option Thoothukudi District: Based on the above, two options were shortlisted as detailed below: S.NO 1 2 3

Option 1- Multipe Location 2- Single Location

Supply Center

Based on the above the grouping of beneficiaries, capacity of plant for multiple location and single location are estimated as detailed below Intermediate Demand (MLD)

Ultimate Demand (MLD)

Alanthalai

50

60

Vaippar

40

45

Vaippar (Combined Capacity)

90

105

Option -1 (Multiple Location): Grouping the beneficiaries considering the proximity for conveying product water from two supply centers, one at Alanthalai another at Vaippar

S.NO

Option -2 (Single Location): Total beneficiaries conveyed product water from one supply center i.e. at Vaippar considered the best ranking.

2

46 • September 2016

Option

1

3

1- Multipe Location 2- Single Location

Supply Center

Ramanathapuram District: Based on the above para, two options were shortlisted as detailed below: Option -1 (Multiple Location): Grouping the beneficiaries considering the proximity for conveying product water from two supply centers, one at Kuthiraimozhi another at Keelanagachi Option -2 (Single Location): Total beneficiaries conveyed product water from one supply center i.e. at Keelanagachi considered the best ranking.

Intermediate Demand (MLD)

Ultimate Demand (MLD)

Kuthiraimozhi

20.0

25.0

Keelanagachi

70.0

80.5

Keelanagachi

90.0

105.0

Chemical Engineering World

Features CEW Based on the above the grouping of beneficiaries, capacity of plant for multiple location and single location are estimated as detailed below Financial Analysis Overview • Evaluation period: 3½ Years Development / Construction and 30 Years of Operation Construction Start date: 2016; Likely COD: 2018 Evaluation under three Financing Options • 100% Grant • 50% Grant and 50% Loan • Under PPP (with 70% Loan & 30% Equity) Levelized Cost: • Based on the above the levelized cost was worked out for various funding pattern.

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Break Even Tariff: • Based on the above assumption the Break Even Tariff was worked Conclusions The TN Govt sanctioned the Prefeasibility and financial model and sanctioned 2 nos 60 MLD in phase one at Kuthiraimozhi and Alanthalai. It was decided to go for DBOT model with 25 years O&M. This was the initial model adopted by TN Govt based on prefeasibility study alike to the one followed by the states in Australian Coast. This distinctive experiment by TN Govt. would help to address the issue of water security in the two districts as well bring about major savings in cost and time.

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Author’s Details Mr. K. Ashok Natarajan Chief Executive Officer Tamil Nadu Water Investment Company Limited E-mail Id: ashokn@twic.co.in Chemical Engineering World

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CEW Features Case Study

MWH Global Water Recycling Plant Design Eases Water Consumption by 60 Per Cent Severe water restrictions and the construction of expensive desalination plants in recent years have not adequately comforted the New South Wales region from the effects of a 10-year long drought. In a process to tackle the issue, GTPL amalgamated a water recycling plant into the Googong Greenfield Development project. Googong retained MWH Global to assist the plant design based on its expertise working on some of the world’s largest and most significant water and natural resource projects. The case study discusses in-depth about how the software facilitated MWH to work meticulously with constructors, providing valuable information comprising material takeoffs, tabulated 3D coordinates, and spool piece equipment lists to diminish construction costs. It also explores how Bentley software helped safeguard water efficiency by recycling up to 62 per cent of the township’s wastewater for non-potable use.

Creating a Water-efficient Culture Googong is a pristine site located in New South Wales, less than 20 kilometers southeast of Canberra, Australia’s national capital. Googong Township Proprietary Limited (GTPL), a newly formed partnership, is developing the area into a self-contained community comprising schools, parks, shops, businesses, and 6,200 homes for 18,000 residents. Given that severe water restrictions and the construction of expensive desalination plants in recent

48 • September 2016

years have not sufficiently relieved the New South Wales region from the effects of a 10year drought, GTPL incorporated a water recycling plant into the Googong Greenfield Development project. Googong retained MWH Global to facilitate the plant design based on its expertise working on some of the world’s largest and most significant water and natural resource projects.

GTPL wanted a design that used membrane bioreactor technology (MBR)

as the foundation for an integrated water cycle with a dedicated water recycling plant that would meet water demand and ensure sustainability by only using the equivalent water needed for 6,500 people. To begin the cycle MWH had to tap into the main supply line to Canberra for fresh potable water, and feed that water into assigned potable water storage tanks in Googong. That water then would be gravity fed from the tanks to Googong residences for drinking and

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Googong’s water recycling plant will meet the water demand of 18,000 residents and ensure sustainability by only using the equivalent water needed for 6,500 people.

showering. Wastewater, runoff water from the properties, and rainwater was also needed to be collected and pumped into the water recycling plant to be filtered and disinfected. This water was then sent to the water recycling storage tanks to be gravity fed back to the residences for irrigation, toilet flushing, and household washing. Facing complex challenges from difficult terrain and tight deadlines, the project team required precision engineering to deliver the project on time and on budget. To overcome these challenges, MWH utilized global resources and implemented an integrated and collaborative design approach using Bentley software.

Optimizing Information Mobility Harnessing resources from Sydney, Melbourne, Brisbane, and Pune, India, MWH required collaborative software to seamlessly integrate workflows among the multi-site design teams. “Being a multi-national company, we don’t always have the skills we need in our home office. Therefore, we do a lot of drafting in our Pune, India, office. We used ProjectWise® to control the models and drawings,” explained MWH head CAD designer Terry Sowden. Implementing an integrated design approach using Bentley Navigator allowed MWH to simultaneously deliver drawings and models with managed version control, and capitalize on the time difference between Australia and India to keep the project moving along the tight schedule.

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MWH used 3D modeling from concept through detailed design, including earthwork, roads, structures, piping, and mechanical equipment. Information mobility kept design and construction on schedule. The team used automatic signoff to issue drawings and models, and i-models kept data integrity to the client on site. MWH used 3D models, via Navigator and i-models, in review meetings and twoday workshops involving all stakeholders early in the design process. This provided MWH with valuable insight on where to locate valves and pumps and how they would operate as part of the plant under various scenarios.

With this information, the design team could identify and address operational, maintenance, construction, and clash and dimensional issues at the 3D model review stage before beginning construction. This saved significant time that might otherwise be spent making costly changes later in the process.

Accurate Modeling Establishes Freshwater Connection With Googong’s fresh potable water being fed from a single water line to Canberra, MWH had just a six-day tie-in window to tap into the city’s water supply before the supply to Canberra was threatened.

Precise modeling was crucial to establishing the DN1800 pipe connection within this time constraint. The spool pieces for the pipe that were designed based on the plant model and they had

to be absolutely millimeter perfect, and had to fit within the inconsistent incline of the pipe. With four circumferential welds required to attach the spools, each taking six hours to complete, there was no room for error. MWH relied on Bentley software to create intelligent collaborative models enabling the team to streamline design and analysis and ensure accuracy to fit the spools and keep the project on schedule.

Within the six-day tie-in period, each day was predicated on the success of the prior day’s work, with the fifth day being the most crucial as the final spool was to be fitted. “There were a lot of nervous people monitoring the progress on site and through photos. On day five, the final spool slotted in perfectly, and there were a lot of relieved and happy faces,” stated Sowden.

Overcoming Terrain and Site Restrictions Another challenge facing MWH was managing the site constraints of the Googong area. Located on a sixmeter sloping terrain overlaying rock formations, the AUD 7 million water treatment project required optimum cutand-fill ratios to minimize costly rock excavation for the underground piping and services. MWH used PlantWise® to lay out the yard piping separated in three strata with services on top, process piping in the middle, and drainage on the bottom. Working with many gravityfed pipes that required a 300 millimeter September 2016 • 49

CEW Features

Project Summary

Fast Facts

Organization MHW Global

• MWH designed Australia’s first integrated water cycle to provide potable, recycled, and wastewater services to a new Greenfield community development.

• Bentley 3D modeling applications facilitated collaborative design and decision making enabling MWH to meet the developer’s tight delivery schedule and overcome challenging terrain.

• ProjectWise, PlantWise, and Navigator provided MWH with an integrated modeling solution by optimizing information mobility among a multi-site design team, allowing all stakeholders’ input during the model review stage.

Location New South Wales, Australia Project Objective • Deliver a water treatment plant using MBR technology with an integrated water cycle.

• Reduce potable water consumption for the new Greenfield community.

• Minimize wastewater discharge to the environment by substituting recycled water for household use and urban irrigation.

• Ensure timely delivery and operation to coincide with township development.

Products Used ProjectWise, AECOsim Building Designer, InRoads, Bentley Navigator, PlantWise, and LumenRT separation between each pipe and numerous pipe crossings, MWH needed to accurately define the location of the directional changes within the model and accommodate changes in real time from construction crews already onsite.

With the Export Coordinates function in Bentley PlantWise, MWH was able to input thousands of coordinates for each separate pipe and automatically export that information to an Excel spreadsheet.

Using this function accelerated information sharing allowing design and construction to occur simultaneously.

“While we were still designing, the construction people were on site actually constructing this. We were able to make the changes in the model and then have the Excel spreadsheet quickly updated,” explained Sowden.

In addition to sub-terrain piping, the above-ground facilities had a limited footprint imposed by the developers to allow more space to accommodate homes as well as to minimize noise to the residences. The above-ground pumps 50 • September 2016

ROI • The water plant design will reduce the community’s potable water consumption by 62 per cent.

• Identifying operational, maintenance, construction, and design issues using 3D modeling enabled MWH to meet an aggressive deadline and minimize risk.

water-efficient design during township consultations. The 3D visualizations helped instill Googong’s residents with a richer understanding of project intent, and revealed where the plant would situate in the Greenfield development.

Bentley’s collaborative software enabled MWH to work closely with constructors, providing valuable information including material takeoffs, tabulated 3D coordinates, and spool piece equipment lists to minimize construction costs.

Engaging operations, construction, maintenance, and design staff during the model reviews helped identify clashes, diminishes changes during construction, and reduce operational costs. The real payoff, however, is that wastewater from Googong homes is now treatable and the new integrated water cycle will reduce potable water consumption by 62 per cent.

needed to be shielded by the bioreactor wall from the homes for noise prevention and had to maintain an equivalent gap on all sides for maintenance purposes.

3D collaborative modeling was essential to meeting these requirements, and enhanced communication among the designers and constructors to ensure plant integrity.

Advancing Water Management With an integrated design approach using ProjectWise (collaboration and model control), Bentley plant design applications (piping design), AECOsim Building Designer (BIM), InRoads® (civil design), and Navigator (3D model reviews), MWH delivered its drawings on time and met the project deadline. The project delivery team brought life to the 3D plant models using LumenRT, Bentley’s immersive visualization software, integrating flythrough animations and presenting the

Author’s Details Aidan Mercer Industry Marketing Director, Utilities and Government, Bentley Systems Chemical Engineering World

Features CEW Case Study

Water, Effluent Treatment & Recycling and Zero Liquid Discharge Solutions India is recognized as having major issues with water pollution, predominately due to untreated Industrial Wastewater and failure to achieve Zero liquid Discharge- i.e. no effluent discharged into surface waters from industry. Environmental concerns are steadily increasing and regulatory authorities constantly tightening the eco standards and insisting the industries to adopt advanced wastewater treatment technologies including Zero Liquid Discharge Solutions. The case study explores Praj Industries Zero Liquid Discharge Solutions successful installation & commissioning of multiple effect evaporation plant at one of its client’s site. The client was able to recover salt from ETP & all the parameters for discharge to sea were met. It also talks about the challenge of selecting appropriate technology/ technologies on the basis of wastewater characteristics and volumes.

I

ndia is a large and diverse country.

Industrial production has increased in India, owing to an increasingly open economy and greater emphasis on industrial development & international trade. Water consumption for various sectors like Chemical & Fertilizers, Textile & Dyeing, Power, Food & Beverages, Oil & Gas, and Pharmaceuticals etc has consequently risen & will continue to rise unless we adopt green process & recycle the wastewater. Poor air quality, water pollution and garbage pollution – all affect the food and environment quality necessary for ecosystems. India is recognized as having major issues with water pollution, predominately due to untreated Industrial Wastewater and failure to achieve Zero liquid Discharge- i.e. no effluent discharged into surface waters from industry.

As per Wikipedia, wastewater treatment is the process of converting wastewater into water that is no longer suitable for domestic use or for any industrial application and which can’t be discharged into environment.

Broadly there are two types of wastewater: 1) Domestic wastewater 2) Industrial Wastewater Treatment of both the type of wastewater is important so as to remove organic & Chemical Engineering World

inorganic matter, bacteria which would otherwise cause pollution in order to protect environment & aquatic and human life. Environmental concerns are steadily increasing and regulatory authorities constantly tightening the eco standards and insisting the industries to adopt advanced wastewater treatment technologies including Zero Liquid Discharge Solutions.

Impurities in wastewater: Water analysis plays an important role not only for designing water treatment & wastewater treatment plant but also for operating and maintaining the plant. It helps knowing the impurities present in water which helps in properly choosing a treatment method for the desired end use. There are various impurities present in wastewater. Hardness, pH, BOD (Bio chemical oxygen demand), COD (Chemical oxygen demand, alkalinity, TDS (Total Dissolved Solids), TSS (Total Suspended Solids) etc indicate the relative health of the water. Praj being leading technology provider has end to end solutions for Water, Effluent treatment & recycling and Zero Liquid Discharge solutions.

Effluent treatment & recycling solutions offered by Praj: Praj has been dealing with complex wastewater treatment in Distilleries &

process industries from last 30 years; hence have developed strong knowledge & data base for treatment of wastewater of various industries. Today’s major concerns for the industry are to have suitable Zero Liquid Discharge solutions addressing some of the following challenges: 1. Innovative and Customized Solution offerings 2. Highly Corrosive Effluent - Selection of Metallurgy 3. Recovery of pure process condensate for reuse and recycle 4. Operating temperature and pressures – Scaling and fouling tendency 5. Continuous operation of the system – Minimization of Cleaning In Place (CIP) effluents 6. Selection of appropriate type of evaporator effects in Multi effect evaporation system 7. Optimization of CAPEX and OPEX for Zero Liquid Discharge Solutions Zero Liquid Discharge Solutions: (Evaporator & Dryer) “Any Process or combination of Processes, by virtue of which there is no liquid effluent, or discharge from a process Plant “. It implies that wastewaters generated are treated and effectively recycled/reused such that there is no effluent discharge.

The objective of zero liquid discharge is September 2016 • 51

CEW Features usually accomplished by concentrating the effluent using various techniques like membrane based and /or Multi Effect Evaporation based systems Challenges of Zero Liquid Discharge • High Recovery system – More than 95 %.

• Effluent Composition • Effluent Characteristics – Corrosion / Temperature issues • Material Compatibility • Operating Cost for the treatment The challenge is to select appropriate technology/ technologies on the basis of wastewater characteristics and volumes.

Techno-economic considerations are important in devising the zero discharge strategy for effectively recovering water and producing no effluent discharge.

Praj provides state of the art Evaporation technology. Praj offers following types of evaporators & dryers: • Falling Film Evaporators • Forced Circulation Evaporators • Forced Falling Film Evaporators

52 • September 2016

• Pusher Centrifuge • Agitated Thin Film Dryer

 Effluent Plant capacity 749 m3/day  Evaporation plant Capacity 249m3/day

Case study for Chemical Process Industry in India: Praj recently executed turnkey project including Design, Engineering, manufacturing, Construction & commissioning for one of the leading chemical manufacturing company in India.

Client was facing problems for the treatment of effluent as it was very high in TDS, COD & BOD. Client was looking for reliable technology supplier having knowledge of Zero Liquid Discharge solutions.

Lab Scale trials (R&D Centre)

After successful installation & commissioning of multiple effect evaporation plant client was able to recover salt from ETP & all the parameters for discharge to sea were met.

Project requirement:  Clients requirement included effective wastewater management & Zero Liquid discharge solution to handle complex wastewater

at

Praj

Matrix

This was a complete green field project hence client was also not very sure about the effluent specifications. Effluent from similar chemical unit was brought to Praj R&D centre at Pune. Praj along with client conducted various trials at R&D which included physico chemical treatment, clarification, lab scale evaporation & drying of the salt.

Pilot study results showed that effluent is having very high TDS i.e 22% w/w and high COD & BOD. Due to high TDS value it was not possible to go for biological treatment. Praj developed special High TDS sustaining bacteria for this application & same was carried to site for further development. Praj offered schematic based on piloting result which was commissioned successfully.

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Water analysis plays an important role not only for designing water treatment & wastewater treatment plant but also for operating and maintaining the plant. It helps knowing the impurities present in water which helps in properly choosing a treatment method for the desired end use. There are various impurities present in wastewater.

Hardness, pH, BOD (Bio chemical oxygen demand), COD (Chemical oxygen demand, alkalinity, TDS (Total Dissolved Solids), TSS (Total Suspended Solids) etc indicate the relative health of the water

Typical schematics of effluent treatment & evaporation plant High TDS effluent stream which is reach in Sodium Chloride (NaCl) is directly treated in 3 stages Multiple Effect Evaporator followed by pusher centrifuge where it is concentrated up to 90% & salts are taken out with 10% moisture. Since inlet TDS was high material compatibility & selection was crucial here Final product NaCl is of saleable quality results in reduction of OPEX due to saving in disposal cost of the salt. Here client is generating 55 Tons of NaCl daily which is sold in the market.

SN

Parameters Final treated effluent

Unit

1

Flow rate

m3/day

2

pH

7.5-8.0

Plant Schematics: Evaporation plant

3

COD

<250

mg/L

4

BOD

<50

mg/L

5

TSS

<40

mg/L

Typical effluent treatment characteristics at Inlet & outlet

Typical outlet effluent parameters

749

Typical inlet effluent parameters SN

Parameters Bleed from Evaporation section

Composite stream

Unit

1

Flow

24

725

m3/day

2

pH

6.5-8.0

6.5-8.0

3

COD

36608

5744

mg/L

4

BOD

9300

2192

mg/L

5

TSS

1000

400

mg/L

6

TDS

280000

16000

mg/L

Chemical Engineering World

Advantages:  Turnkey solution under one roofDesign, engineering, manufacturing, supply, installation & commissioning for effluent treatment, biological treatment & evaporation systems.  Customized design, solution backed by piloting at R&D which ensures minimization of performance risk  Lower cleaning frequency cycles for Evaporation system Result of commissioning of the plant:  For this project, Praj has successfully designed, manufactured & installed & commissioned integrated biological effluent treatment & evaporation plant.

Author’s Details Ravi Chandran Selvaraj Executive Vice President, Praj Industries Email Id: RSelvaraj@praj.net September 2016 • 53

CEW Features

Zero Liquid Discharge Solutions By Praj

Effluent treatment plant

Salt at the outlet of Pusher Centrifuge

Multiple Effect Evaporation plant

54 â&#x20AC;¢ September 2016

Chemical Engineering World

Features CEW Technical Article

VECL’s Smart Conveyance of Treated Industrial Wastewater and Real Time Online Monitoring Vadodara city is one of the vital industrial hubs of Central Gujarat since 1977. Industrial complex of Central & State Governments like IOCL, GSFC, GACL, IPCL (now RIL), GIPCL units along with the Small & Medium scale industries in the Nandesari, Padra as well as in and around GIDC Areas, contributed huge revenue to the Country as well as to the State.

Up to 1983, major State and Central Government Complex, Nandesari Industrial Estate of GIDC and small & medium scale industries of Petro-Chemical Complex (PCC) were facing problems of the disposal of treated wastewater.

D

uring 1970, the project for the safe disposal of treated water was conceived by the Gujarat State Government. Later, it was developed and constructed by G.I.D.C on behalf of the participating industries.

Thus during 1983, the Effluent Channel Project was commissioned. The channel has designed capacity to convey about 1,45,000 M3/day (145 MLD) of treated wastewater over a distance of 55 km in the Gulf of Cambay. It is in the constant service of the Industries for over 32 years.

During 1999-2000, the Effluent Channel Project was converted in to the Company with a major stake of all four Major units like IOCL, IPCL (now RIL), GSFC & GACL, and about 14 % stake of G.I.D.C and named the Company as an Effluent Channel Project Limited (ECPL).

The channel is a brick masonry conduit constructed in “U” shape laid with gradient in 1 in 3000.It is provided with 139 cross drainage works ensuring that there is no hindrance to traffic of 29 villages that are located along with the alignment of the channel.

Entire channel is covered with RCC Slab and it has fully asphalted Inspection Road from take-off point at Dhanora up to the disposal points in the Gulf of Cambay.

From November 23rd 2011, the name of the Company has been changed from Effluent Channel Project Limited to VADODARA ENVIRO CHANNEL LIMITED Chemical Engineering World

Google Image of the Conveying System of VECL

(VECL), with the same Liability and Responsibility considering the future plan for the new business like Recycling of the Treated wastewater, Analysis of Treated wastewater, Waste Exchange data bank, Renewable energy to reduce the cost of the overall pumping of treated wastewater, Training for the overall Environmental Management etc.

Keeping in view of the usage of the channel for around last three decades, the Board of Directors of the Company at its 51st Board Meeting had sealed the conveying capacity to 130 MLD out of 145 MLD designed capacity.

As on August 1st 2016, VECL have about 37 Members. (Apart from the Four Major Unit members like GSFC, GACL, IOCL & RIL). Two Common Effluent Treatment Plant namely Nandesari CETP and EICL

– CETP of Umraya also the members of the VECL. Nandesari CETP has about 200 Members whereas EICL –CETP have about 75 Members.

Thus VECL safely conveying the generated treated wastewater from more than 300 Industrial Units in and around Vadodara District of Gujarat through the 55 km long Channel and safely disposed in to the Bay of Cambay.

For the smooth Operation & Maintenance entire Conveyance System and to maintain the quality of the discharge wastewater to meet the SPCB Standards, VECL Management regularly carries out the following activities: • Dedicated Security force for the complete surveillance of the Conveying System.

• Regular sample taken from the discharge September 2016 • 55

CEW Features point of the Member industries into the conveying system. About 300 Samples have been collected in a month.

About 200 samples analysed in inhouse Laboratory and partly outsourced at the Approved Laboratory Company have a systematic Disciplinary Action Plan. As per that those member violating the Inlet norms have been penalized as well as termination of the Membership also.

Surprise check by the most senior staff of the company.

Regular cleaning of the Channel during the Annual S/D.

Along with the Installation of the Electromagnetic Flow meter VECL also installed MECOM Software for the compilation of the flow meter data as well as generating the Invoice for each Member Industries considering their actual treated wastewater discharge. Installation of this system has streamlined the revenue of the Company.

Before 2010, Company invoices its members a fixed price for channel usage.

This charge had been fixed basis an agreed quantity of treated wastewater release. There are also agreed guidelines pertaining to the wastewater quality.

As per the Analysis Report, if there is any deviation in the treated wastewater discharge parameters observed, VECL act as per the Disciplinary Action Plan of the Company.

•

•

• •

During 2011, Company has observed and notified several instances of breach of agreed quantities. Many units discharge more wastewater quantities than agreed and hence create an imbalance in the channel volume.

Considering the same, it has been decided to install a dedicated flow meter at the each member industries’ treated wastewater outlet.

Thus during 2011, itself a dedicated electromagnetic flow meter has installed at the each member industries’ treated wastewater discharge pipeline.

There have been many instances where the quality of the toxicity levels in the wastewater was found to have been way above permissible limits. Such violations could attract punitive action on company from statutory authorities.

After success in the quantity part, and revenue management, VECL installed Real Time Online Monitoring system at the outlet point of the wastewater discharge to measure mainly six Parameters like: • pH • NH3-N • SS • COD • BOD • Colour.

It had improved an overall performance of the Conveying System.

VECL also installed a cloud based Real Time Monitoring system for all these data, which provide the real scenario of the system.

Installation of Electromagnetic Flow meter

VECL also installed dedicated Cameras at most of its campuses as well as at the Critical part of the Conveying System, which provide the real picture of the Conveying system regularly.

Thus VECL successfully implemented a Digital Concept to operate and maintain the entire Conveying System of the Company.

The benefits have been derived post implementation: There are lots of benefits achieved from the implementation of the above. The brief about the same as under: • The revenue of the Company has increased due to correct measurement for the quantity of the Treated wastewater discharge.

• The New Avatar of the Company has changed its overall Image of the Company.

• Due to strict implementation of the Disciplinary Action Plan, the performance of the wastewater discharge at the sea has drastically improved and complies most of the statutory parameters.

• Industries now realized the importance of the water and tried to recycle as maximum as possible.

• Due to strict monitoring the CETP – (Common Effluent Treatment Plant) has implemented the newer technology to treat the wastewater.

Author’s Details Mr Satish Panchal Managing Director, Vadodara Enviro Channel Limited.

Email id: md@envirochannel.in 56 • September 2016

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Features CEW

Indian Water Chemicals Market: An Overview The Indian market for water chemicals is just 1.5 per cent of the global market. Though, the market has grown from USD 0.2 billion in 2009 to its existing size of USD 0.4 billion at a CAGR of 12 per cent over 2009-14 and in the next five years this growth rate is projected to further accelerate to ~15 per cent per year, leading to a market size of USD 0.8 billion by 2019. This makes India one of the fastest developing markets and presents a remarkable prospect for both global and Indian companies. The Asia-Pacific market is growing at a CAGR of ~8 per cent compelled by escalating standards of industrial water quality, adoption of complex manufacturing processes and strong economic growth resulting in greater municipal and industrial spending in water treatment efforts. Growth is also driven by rise in environmental concerns and superior efforts to modernise municipal water treatment facilities. The article explores Global Water Chemicals Market Scenario, Parameters responsible for growth of the Indian market and competitive landscape for the global players.

W

ater treatment chemicals are used to add some specific properties to water or alter the physical or chemical properties of water for domestic, commercial and industrial applications. The industrial applications of water treatment chemicals largely entail waste water management, and enhancing efficiency of industrial equipment by minimizing corrosive and other adverse impacts of water.

Based on their action, water chemicals are further classified into coagulants, flocculants, biocides, disinfectants, algaecides, defoamers, neutralizing agents, oxidants, oxygen scavengers, pH adjusters, boiler water chemicals, resin cleaners and scale inhibitors.

Global Water Chemicals Market â&#x20AC;&#x201C; An Overview The global market for water chemicals in 2014 is estimated at USD 25.1 billion. In the past five years the market has grown from USD 19.1 billion at a CAGR of 5.6 per cent. From 2014 to 2019, the market is estimated to grow at 5.8 per cent p.a to reach USD 33.3 billion by 2019.

There are large global players operating in this space such as Nalco-Ecolab (USA), Kemira (Finland), Solenis (USA), Kurita (Japan), BASF (Germany), Air Products and Chemicals Inc. (USA), AkzoNobel (Netherlands), Dow Chemical Chemical Engineering World

Company (USA), BWA Water Additives (UK), GE Water & Process Technologies (USA) and Lonza Group (Switzerland).

Many of these are present in India.

The Asia-Pacific market is growing at a CAGR of ~8 per cent driven by rising standards of industrial water quality, adoption of complex manufacturing processes and strong economic growth resulting in greater municipal and industrial spending in water treatment efforts. Growth is also driven by increase in environmental concerns and greater efforts to modernise municipal water treatment facilities.

Indian Water Chemicals Market â&#x20AC;&#x201C; A Fast Growing Space The Indian market for water chemicals is just 1.5 per cent of the global market.

However, the market has grown from USD 0.2 billion in 2009 to its present size of USD 0.4 billion at a CAGR of 12

Source: Industry Interviews and analysis Water chemicals market structure

per cent over 2009-14 and in the next five years this growth rate is expected to further accelerate to ~15 per cent per year, leading to a market size of USD 0.8 billion by 2019. This makes India one of the fastest growing markets and presents an interesting opportunity for both global and Indian companies.

The short term growth in demand for water chemicals would be largely fueled by the stricter industrial effluent discharge norms being enforced by the Central Pollution Control Board. Power and energy sectors are the largest industrial consumers of water chemicals (constituting ~88 per cent of the total industrial water consumption in India).

Power plants require cooling and boiler chemicals for controlling corrosion and boiler treatment, respectively. India has a huge power deficit, and the Government has been planning several power projects since past few years which are expected

Source: Literature review Sector wise water consumption in India

September 2016 â&#x20AC;˘ 57

CEW Features to be commissioned soon, further boosting demand for the water chemicals industry. Other major industrial uses are engineering, pulp and paper, textiles, steel, sugar and fertilizers.

The long term growth for water chemicals will also be driven by municipal water consumption. The growing urban population is adding to the demand for water purification and waste water management across India. As per the 2011 census, more than 30 per cent of the Indian population lived in urban areas and this is expected to grow to nearly 40 per cent over the next decade.

In the long run there may be a huge demand from implementation of the government’s vision of 100 new ‘smart’ cities and ‘Swachh Bharat’ mission.

and flocculants are used for waste water management and are replacing traditional products such as alum.

Driven by high growth industrial and municipal water treatment, coagulants and flocculants are expected to grow at ~17 per cent.

Biocide and disinfectant market in India is expected to grow at 15 per cent driven by demand from oil and gas (eg. application in drilling fluids, where the drilling efficiency increases greatly by eliminating microbial growth), hygiene and industrial preservative industries.

The other segments including defoamers and pH adjusters are small, but growing segments. Defoamers find application in the pulp and paper, and oil & gas industries and are expected to grow at

Source: FICCI; Literature review Indian water chemicals market segmentation, 2013

Irrigation has traditionally been the largest consumer of water (76 per cent of the total water consumption in India). The segments employing water treatment chemicals, municipal and industrial segments, together constitute ~18 per cent of the water consumption in India.

Most industrial water treatment companies produce a variety of products used commonly across these end industries.

In terms of application, coagulants and flocculants constitute the largest segment, ~38 per cent of the total market, followed by biocides and disinfectants, constituting ~19 per cent of the market. Other large segments are defoamers (7 per cent share) and pH adjusters (5 per cent share).

The growth of these segments is driven by their end-use applications. Coagulants 58 • September 2016

9 per cent. pH adjusters are expected to grow at 12 per cent, driven by their application in the rapidly growing soil treatment market in India.

The major global players include NalcoEcolab (USA), Kemira (Finland), Solenis (USA), Kurita (Japan), BASF (Germany), Air Products and Chemicals Inc. (USA), AkzoNobel (Netherlands), DowChemical Company (USA), BWA Water Additives (UK), GE Water & Process Technologies (USA) and Lonza Group (Switzerland).

Many of these are present in India.

In the water chemicals market, most players are integrated end to end water solutions providers or are in process of expanding in the value chain. Players such as Thermax, Ion Exchange and Nalco (Ecolab) are end-to-end water solution providers and are present across the value chain. They have their own water chemical manufacturing capability, provide complete water projects on a turnkey basis (including EPC) and provide onsite service support as well. Water treatment companies such as VA Tech Wabag and Siemens do not operate in chemical manufacturing segment, but focus on construction and maintenance of water treatment plants.

There are a few mid–scale players such as Vasu Chemicals and Chembond which are pure–play chemical manufacturers operating in this segment.

It is estimated that 80 per cent of market share for water chemicals in India belongs to the organised sector.

However, there are small players from the unorganized sector who are in some or the other way a part of supply chain in this segment either manufacturing

Competitive Landscape of the Indian Water Chemicals Market

Value Chain of the Water Treatment Industry

Chemical Engineering World

Features CEW

Conclusion With the revival of the economy, several strong government initiatives and pickup in industrial activity, a recovery of private investment is expected to further strengthen growth.

The recent government initiatives targeted towards cleanliness are expected to have a pivotal impact on the water treatment market. The ‘Swachh Bharat’ Mission, Clean Ganga initiative, and National Rural Drinking Water Program, are all aimed towards improving hygiene including better water and waste water treatment.

~` 500 billion has been approved for the Atal Mission for Rejuvenation and Urban Transformation and of the ` 510 billion planned for the Ganga Rejuvenation Plan; ` 200 billion has been approved.

increase in demand for effective water treatment plants and chemicals, making it an attractive and fast growing market over the next 3-5 years.

States such as Andhra Pradesh and Telangana have also taken steps to cater to industrial areas in order to accelerate growth. As per the Industrial policy framework of Telangana, every industrial park will be provided with a common effluent treatment plant whereas the government of Andhra Pradesh announced the Industrial Water Allotment Policy and plans to prepare a plan for the recycling of sewage water for industrial purposes.

Author’s Details

The recovery in industrial activity in the Indian economy combined with the implementation of stricter effluent norms such as zero liquid discharge plants, waste water treatment, and polluted water discharge is expected to lead to an

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themselves but have limited or no presence in international markets due to various constraints. It is becoming increasingly important for the SMEs operating in this segment to comply with the global standards to be competitive as India is gearing up to be a part of the global supply chain.

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Chemical Engineering World

September 2016 • 59

CEW Features Technical Article

Pollution Control Techniques in Refinery and Downstream Petrochemical Plants Pollution is a universal problem that intensifies with each passing day due to growing population and pollution of surface & ground water sources. Indiscriminate industrial development and exploitation of limited water sources are compelling every industry to seriously address this problem. Besides this, availability of water has become a serious issue. Therefore, industries are considering various options to reduce their water usage and to recycle water to the extent possible along with adopting manufacturing technologies that require less water, produce minimum waste water as well as other solid & liquid waste. Increasing cost of water and stringent regulations have helped make water recycle a viable option. This article deliberates on the topics of recycle, zero liquid discharge and solid waste management and explores their various technologies.

P

revention is better than cure. This also applies to pollution. Prevention or minimisation of pollution at source is the best control method.

Hence, before going into the methods of effluent treatment, we should look at the possibilities of preventing or minimising effluent generation. Pollution prevention is defined as the use of materials, processes or practices that reduce or eliminate the generation of pollutants or wastes at the source. Also known as reduction at source, pollution prevention includes practices that reduce the use of hazardous and non-hazardous materials, energy, water or other natural resources. Pollution prevention in the manufacturing industry can be achieved by changing production processes to reduce or eliminate the generation of waste at the source. As it applies to industry, the environmental management hierarchy stipulates that when possible: • Pollution should be reduced at the source • Pollution products that cannot be reduced should be recycled in an environmentally safe manner • Disposal into the environment should

Raw Water

Water Treatment Plant

be used only as a last resort and should be conducted in an environmentally safe manner Recycle of Waste Water and Study of its Application in Various Industries Waste water recycle should take shape at the drawing board stage in contrast to the conventional treatment approach of designing the raw water and waste water treatment plants (end of pipe solutions) separately. This will enable planning for water recycle at the design stage itself.

The benefits are many.

Firstly, because water is recycled, raw water consumption reduces. The designer can therefore plan for a raw water treatment plant of lower capacity and cost.

Secondly, the effluent treatment plant’s capacity is also reduced as we are treating the effluent which is not being recycled and hence the quantity of waste disposed is less, leading to further cost reduction.

Investment is certainly required for product recovery, water recycle plants and advanced technologies to handle even higher concentrations of contaminants.

Treated Water

Process

Effluent

However, the life cycle and return on investment is quite attractive.

Pollution is not just abated but prevented; pollutants are separated not destroyed; energy is saved and the total cost of water and waste water treatment is reduced.

Hence, we can use this experience of on/ offsite recycle and integrated solutions for water and waste water treatment in large industries to achieve the goal of ‘Total Water Management’ at the design stage.

We need to only apply these approaches in a complex industry in multiple ways.

Guidelines for Selection of Recycle Scheme 1. Study the manufacturing process thoroughly and identify areas where reduction of water consumption is possible.

2. Identify the process where reduction of pollution load is possible by changing raw material or adopting cleaner manufacturing process.

3. Proper analysis of various streams especially targeting the contaminants which are process specific.

Effluent Treatment Plant

Discharge

Figure 1: Conventional Treatment

60 • September 2016

Chemical Engineering World

Features CEW Reduction at Source

Product Recovery Recovered Product

Raw Water

Water Treatment Plant Recycled Water

Water Reuse

Treated Water

Process

Effluent

Zero Liquid Discharge Plant

No Liquid Discharge

Product Recovery Plant Partially Recovered Effluent

Waste Minimisation

Figure 2: Modern Integrated Solution

4.

Identify streams that can be segregated and treated economically.

For example, in electroplating, the rinsed water can be segregated and treated for recovery of plating metal.

This not only reduces the overall cost of recycle but also facilitates the recovery of valuable products from the waste water stream.

5. Identify effluents which are relatively clean and can be treated with simple processes so that they can be recycled internally without letting the water out into an effluent treatment plant.

6. Identify the quality of water required at various manufacturing stages.

For instance, steam generation may require high quality water and washing or cooling water make up may not require high quality water.

It is always economical to design a recycle system to produce water suitable for lower end usage.

7. Select a technology that is easy to implement, operate, maintain & service.

8. Look for the availability of spare parts that may be needed in the future.

9. Reliability of performance in the long run is extremely important.

10. Low in operating cost.

11. Good service network of the plant supplier.

Chemical Engineering World

Recycle Technologies Any waste water recycling plant requires four stages of treatment as follows: 1. Effluent treatment 2. Tertiary treatment 3. Advanced tertiary treatment 4. Zero liquid discharge Effluent Treatment For a good effluent recycle system, a good effluent treatment is a pre-requisite. Unless we remove the easily removable pollutants with cost-effective methods, it would be difficult to recycle the effluents economically.

Usually effluent treatment plants (ETPs) are designed to meet statutory requirements for disposal. When recycling is considered, the ETP should also be designed considering overall requirements of treatment. For example, in India, disposal standards do not require complete removal of nutrients and dissolved salts. But, when we are installing a downstream reverse osmosis system, it is better to remove nutrients and dissolved salts in the biological system of the ETP. This will help reduce fouling of the reverse osmosis system.

There are different technologies available for effluent treatment to remove different pollutants. Table 1 lists some generic technologies applied in effluent treatment.

Tertiary Treatment Treatment beyond disposal norms for reusing effluents for low end usages is called tertiary treatment. It acts as pretreatment to advanced treatment for complete recycle of effluents. Table 2 enlists some generic technologies applied in tertiary treatment.

Advanced Tertiary Treatment Further treatment of secondary treated effluents is required for conforming to the requirements of high end usages (boiler feed, process, etc.) of treated water.

Table 3 enlists some of the technologies available to remove various pollutants in advanced treatment: There are various other technologies which are contaminant and end use specific such as fluoride removal.

Zero Liquid Discharge Treatment (Evaporation and recovery of waste water containing highly soluble salts) The highly concentrated reject from the process is further treated in multi effect evaporator (MEE) system generally after reducing dissolved salts by RO processes and the advanced tertiary treatment.

September 2016 â&#x20AC;˘ 61

CEW Features Table 1 Effluent Treatment Technologies (Primary and Secondary) Pollutant

Treatment Technology

Floating matter

Manual bar screens, mechanically cleaned screens, drum screens, etc.

Grit

Manual grit chambers, aerated grit chambers, deaerator, etc.

Oil & grease

Oil & grease traps, API oil separators, TPI oil separators, dissolved air floatation (DAF) systems, tubular ultra filtration, etc.

Acidity/alkalinity

Neutralisation using acid/alkali dosing

Suspended solids

Clarifiers, clariflocculators, high rate solid contact clarifiers (HRSCC), lamella clarifiers, tube settlers, DAF, ultra high rate clarifiers, pulsating clarifiers, etc.

BOD/COD/NH 4/TKN/TP/Phenol/CN/SCN

Biological systems such as activated sludge process, trickling filters, sequential batch reactors (SBRs), membrane bio-reactors (MBRs), etc.

Heavy metals

Precipitation using solid contact clarifiers, ion exchange processes, membrane systems for metal recovery, etc.

Toxic substances

Different treatment technologies are adopted based on the nature and concentration of toxic substances. For example, phenols can be removed with biological systems at low concentrations whereas chemical oxidation may be required for higher concentrations.

Recalcitrant compounds/COD

Photo-chemical oxidation is used to remove or break recalcitrant and complex organics such as phenols, benzene, pesticides, etc.

Table 2 Tertiary Treatment Technologies Pollutant

Treatment Technology

Turbidity

Gravity sand filters, pressure sand filters, dual media filters, multi media filters, continuous sand filters, auto valve-less filters, etc.

Bacteria

Chlorine dioxide, chlorination, ozonation, ultraviolet sterilisation, mixed oxidant systems, etc.

Colour

Oxidation, precipitation, adsorption, nanofiltration, etc.

Residual chlorine Activated carbon filtration, dosing of reducing agents, ultraviolet treatment, etc.

Table 3 Advanced Tertiary Treatment Pollutant

Treatment Technology

Hardness

Chemical precipitation, ion exchange softeners, nanofiltration, etc.

Silica

Chemical precipitation, ion exchange processes, reverse osmosis, etc.

Turbidity, SDI

Sand or multimedia filtration, ultra filtration, microfiltration, etc.

Dissolved solids

Reverse osmosis systems, ion exchange processes, electrodialysis, etc.

The MEE process uses either mechanical or thermal vapour compression using forced circulation evaporators, falling film evaporators or in combination. Thus, evaporation is increasingly considered for the treatment of refinery and downstream petrochemical waste water to recover 62 â&#x20AC;˘ September 2016

more than 95% of water, or as a part of the zero liquid discharge (ZLD) process.

Water Management in Refinery - Case Studies 1. Reliance Industries Limited Reliance Industries Limited (RIL) has

enhanced the capacity of the Jamnagar Refinery to 12,00,000 barrels per stream per day (1200 K BPSD) with the commissioning of the Jamnagar Export Refinery Project (JERP) in Gujarat.

Waste water treatment is carried out in a dedicated state-of-the-art completely automated and PLC â&#x20AC;&#x201C; operated effluent treatment plant supplied by Ion Exchange. The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/fire water, with the objective of zero discharge from the new refinery complex. The treated water is recycled back as cooling tower make-up and partially used as process water after reverse osmosis treatment to the high total dissolved solids treatment train or guard tanks, as required.

Effluents are segregated into four identical waste water streams designed for a treatment capacity of 500 m 3/h each and maximisation of reuse.

The scope of treatment also includes three by-product streams generated during the treatment of refinery waste water (skimmed or slop oils, oily sludge and biological sludge). Skimmed oil Chemical Engineering World

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Effluent Treatment Plant at Reliance Industries Ltd., Jamnagar, Gujarat

is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing.

Each of the above streams employs identical equipment for treating effluents, namely:

project, a new effluent treatment plant (ETP-III) treats effluents generated from the refinery project to meet the MINAS standard. With a view to conserving water, a new zero discharge plant (ZDP) was designed and constructed

by Ion Exchange. This plant treats the treated water from ETP-III to enable use of the treated water as make - up to the demineralisation plant. The capacity of the ZDP is 200 m 3/h. The plant was commissioned in 2005 and is operated and maintained

by Ion Exchange.

3. Indian Synthetic Rubber Limited Another such example of ZLD is for Indian Synthetic Rubber Limited (ISRL). Three streams containing 3000 m 3/d process effluent along with

requirements from buyers in case of exporters, etc. ZLD also gives enormous importance to sludge management (which is not discussed in this paper and which needs separate attention). Apart from these reasons, industries now identify recycle and ZLD as their social responsibility for environmental friendly manufacturing of goods.

Many technologies are now available for managing industrial waste water and other waste. It is of utmost importance to involve environment management specialists right from the planning stage of the project so that the best optimum solutions can be developed. Priority should always be given to source reduction and product recovery rather than end of pipe waste water treatment

• Free oil removal facilities including pre-deoiler and API separators with continuous oil skimming and sludge removal facilities • Dissolved air Flotation (DAF) unit • Two stage biological treatment • Clarification • Dual media filtration • Activated carbon adsorption • Disinfection – with chlorine and chlorine dioxide The effluent treatment plant is treating 100 per cent effluent generated by the refinery since its commissioning in December 2008 and consistently produces treated effluent (pH 6 - 8.5, sulphide < 0.5 ppm, COD < 50 ppm, oil and grease < 5 ppm, phenol < 0.35 ppm) meeting guaranteed parameters for reuse for various applications mentioned earlier.

2. Chennai Petroleum Corporation Limited The ZLD plant for the expansion at Chennai Petroleum Corporation Limited (CPCL) uses advanced membrane processes to reuse water for its process requirement.

CPCL, during its expansion, increased the crude refining capacity at Manali by 3 million metric tonnes per annum.

As part of this 3 MMTA expansion Chemical Engineering World

ISRL- Downsteam Petrochemical

360 m 3/d cooling tower blow down and 240 m 3/d DM plant effluent are being treated through primary, secondary, tertiary and advanced tertiary treatments. The final reject (from RO) is being treated in thermal MEE, thereby achieving the objective of > 95 per cent water recovery and ZLD.

and expensive methods of ZLD. Right technologies should be adopted for recovery and recycle of water from waste water. Final effluents which cannot be recycled should be treated and disposed of in an environmental friendly way.

Conclusion Waste water recycle and ZLD is mandatory for many industries because of water scarcity, legislation, rising water costs, unreliable water supplies, environmental

Ajay Popat President – Technology, Corporate Marketing and Corporate Diversification Ion Exchange (India) Limited

Author’s Details

September 2016 • 63

CEW Features

Gasket: Strengthening Your Weakest Link Water is one of the valuable resources in India and the Ministry of Water Resources’ focus on efficiency and conservation is one of the hallmarks of the revolution being brought into the country as it prepares itself for future growth. The change required is alternating and needs a wider interpretation by implementing strict obedience with zero tolerance by understanding all the moving parts in the network from water extraction to water utilization.

Water has to pass through several stages, systems, factories, pipelines and mechanical devices before it reaches our drinking glass. These can range from pumps, meters, valves, pipe joints all of which necessitate Gaskets and Seals that are in direct contact with the water and can be exceptionally prone to leakages and contamination. In fact, Gaskets are generally the weakest link and the network is only as strong as your weakest link.

W

ater is one of the precious resources in India and the Ministry of Water Resources’ focus on efficiency and conservation is one of the hallmarks of the change being brought into the country as it readies itself for future growth. Unfortunately, the change required is intermittent and needs a broader view by enforcing strict compliance with zero tolerance by understanding all the moving parts in the Network from Water extraction to Water utilization.

In a study conducted by The Delhi ASSCHAM (2010) approx. 40% of water is wasted through leaks and incorrect fittings. While, The Observer Research Foundation (ORF, 2012) reports that due to leaking pipes, Mumbai alone loses 650 million litres of Water every single day.

Water has to pass through multiple stages, systems, factories, pipelines and mechanical devices before it reaches our drinking glass. These can range from pumps, meters, valves, pipe joints all of which require Gaskets and Seals that are in direct contact with the water and can be extremely prone to leakages and contamination. In fact, Gaskets are usually the weakest link and your network is only as strong as your weakest link.

The Indian Standard for Pipe Fittings (IS SP 57 (QASM)) formulated during the Rajiv Gandhi National Drinking Water Mission offers some recommendation on Pipe Fittings and Mechanical Devices; but it is extremely vague on Gaskets and

64 • September 2016

Seals Specifications. The only Material recommended is either Compressed Fiber Board (it doesn’t specify the widely used Compressed Asbestos Fiber) or using Synthetic / Natural Rubber (as per IS 638).

Certification Unlike India, the importance of the Gasket is taken extremely seriously on an International scale due to Seals being in direct contact with the water and increasing chances of contamination. The major specifications international followed are the NSF/ANSI 61 Certification (for Drinking Water), the FDA Guidelines (Food and Drug Safety, USA), the WRAS (UK) and ISO 4633 (Only for Cold Water) along with DIN (Germany) and EN (Europe) standard.

FDA Gaskets deemed to comply with Food and Drug Administration (FDA) regulation is a broad and complex area and frequently extends beyond food processing plants to those involved in the making of pharmaceutical products. Hence while it may be acceptable it doesn’t necessary adhere to the strict guidelines of the NSF / ANSI 61 & WRAS regulations.

A gasket is considered FDA compliant through three methods: • GRAS—Materials that are generally regarded as safe (GRAS). Many materials have been used without problems in FDA applications and are listed as GRAS. The use of a food substance gasket may be GRAS either through scientific procedures or, for a substance used in food before 1958, through experience based on common use in food.

• Existing FDA Regulations—some materials are already covered by existing regulations. For example, perfluorocarbon resins and PTFE are found in 21 CFR 177.1550.

• FDA FCN—New materials not covered by either of the above can be submitted to the FDA under a food control notification (FCN).

FDA Regulations also have separate specifications required for the Adhesive used (if there is) and there is additional CFR Guidelines on the contents of the Marking Ink used on the Gasket Sheet.

NSF/ANSI 61 The NSF / ANSI 61 Specification and its similar equivalent across the Atlantic WRAS

The Indian Standard for Pipe Fittings (IS SP 57 (QASM)) formulated during the Rajiv Gandhi National Drinking Water Mission offers some recommendation on Pipe Fittings and Mechanical Devices; but it is extremely vague on Gaskets and Seals Specifications. The only Material recommended is either Compressed Fiber Board (it doesn’t specify the widely used Compressed Asbestos Fiber) or using Synthetic / Natural Rubber (as per IS 638).

Chemical Engineering World

Features CEW

Drinking Water Pipelines

Asbestos Cement Water Leak

inspected and reviewed on an annual basis. Any deviation from any of the specifications at any stage results in non-compliance and resubmission of the Gasket again for certification.

Material used in India: Rubber Elastomers and Rubber compounds account for majority of the preferred Gaskets and Seals because of their resilient properties. Compounds of Natural, Styrene Butadiene, Acrylonitrile and Neoprene are preferred for pipe seals, gate valves, flange gaskets and O-rings.

Old Rusty Pipes

(UK); verifies the entire Gasket manufacturing process to ensure stringent quality control throughout. Each aspect of the Gasket is taken under strict formulation to ensure it is contamination free and safe to be in contact with drinking water. The certification process is extremely rigid and throughout and takes into account the following factors: • Application: The raw material of the Gasket used is specified and each chemical component is independently tested. This requires the Manufacturer to disclose not only the chemical nomenclature, chemical abstract service (CAS) number, but also their percentage of the composition, formulation and toxicology.

• NSF formulation review: NSF toxicologists further conduct their own formulation review of each Gasket raw Chemical Engineering World

•

•

•

•

material to determine if there are any ingredients, contaminants, or reaction by-products that could potentially leach from the material into drinking water.

Plant audit and sample collection: NSF then inspects the production facility to verify the formulation and production process and to ensure that adequate quality control procedures are in place to prevent the use of unauthorized materials.

Laboratory testing: The Gasket is then evaluated for three weeks according to the exposure and analysis methods of the standard.

Toxicology evaluation: Contaminant concentrations are then evaluated by a toxicologist to pass/fail criteria as per standard.

Follow-up program: Once products are certified and listed by NSF, they are

The recommended Indian Standard (IS 638) for Rubber Gaskets is unfortunately extremely insufficient as it neither specifies the Rubber or Elastomer compound or performance or taste or odour or microbiogical growth support.

The actual recommended and certified Elastomer for Drinking Water should ideally be Ethylene Propylene Diene (EPDM) Rubber with its superior hydrolytic stability and resistance to chloramines compared to the other homogenous elastomers. Fluoroelastomers are also increasingly being used in gaskets for CPVC piping, where leaching of plasticizers from other elastomers can compromise the piping.

Rubber Gaskets and Seals generally suffer from the same drawbacks based on the selected Elastomer but as a rule, majority of Rubber Elastomers are extremely poor in any equipment where September 2016 • 65

CEW Features there is still no Indian Standard or a Quality standard to use as a benchmark.

For nonAsbestos Gaskets used in Drinking Water systems, recommend using certified Seals with NSF/ANSI 61 Certification (USA) or WRAS Certification (UK, Europe) to ensure material is safe and free from all contamination.

PTFE/Teflon Polytetrafluoroethylene and Teflon (Dupont) are again material that is chemically inert and offers excellent application where high level of purity is required. The problem with using PTFE in its Virgin form is the inherent Creep and Cold Flow properties that shorten the life expectancy of the actual seal. The recommended material is usage of FilledPTFE or Expanded PTFE which offers a more suitable sealing solution, high level of purity and with the life expectancy similar to Elastomers.

Assorted Rubber Gaskets

Gasket Fitted into Pipe Hose

the Operating Temperature is above 100 Deg C and Operating Pressure is more than 2 bar.

Asbestos The Usage of Carcinogenic Asbestos Fiber (CAF) in Gaskets is still extremely relevant across India especially in cases where there is a higher operating Pressure and Elastomers is not an option. India continues to be the largest importer and consumer of Asbestos in the world imperious to the future health hazard at its doorstep. While, ingesting Asbestos Fiber is not as dangerous as inhalation, new studies have shown a link 66 â&#x20AC;˘ September 2016

between Asbestos and Gastrointestinal Tract problems. The obvious solution is nonAsbestos Gaskets. These Rubberbound fiber sheets find application in a variety of flange gaskets where, because limitations on size or gasket stress or pressure homogenous elastomers cannot be used.

100% AsbestosFREE Gaskets are a combination of Elastomers, Fibers and Binders in different proportions and for different Operating Temperature and Pressure ranges. While there is an increase in using Asbestos Free Gaskets,

Conclusion Gaskets are generally dismissed as the most inconsequential part of the Pipeline chain and rarely get the importance it deserves. It is extremely important to not only understand the compliance requirements, but to also ensure that they are being regularly met. As evidenced by issues with other products that come into human contact either directly or indirectly, use of sealing materials that are either unsafe or not recognized as being safe can have significant adverse consequences. While the price economics of the Gasket is negligible the risk of using non-certified Gaskets in the overall specification can cost a lot more than initially anticipated. Strengthening the Weakest Link in the pipeline will go in a long way into ensuring the overall integrity of the Network.

Authorâ&#x20AC;&#x2122;s Details Darshan A. Parekh Managing Director Pilot Gaskets And Engineers Email Id: darshan.parekh@pilotgaskets.com Chemical Engineering World

Features CEW Technical Article

How Electronic Pressure Control Works As the trend toward automation continues, electronic control of pressure is a logical progression. Such electronic control of pressure has in fact become commonplace — both to allow automatic control of pressure for production machinery and for controlling pressure from a central location, even if the regulator is placed in an inaccessible or hard-to- reach location.

I

nstead of requiring operators to set pressure manually, a regulator may contain an electric motor that turns an adjusting stem until the desired outlet pressure is reached.

With the I/P, E/P or U/P the command signal and acting accordingly to either decrease or increase outlet pressure, which in turn, increases or decreases the regulator outlet (process) pressure.

Another design — sometimes referred to as an I/P, E/P or U/P transducer — accepts an electronic input signal (either I for current, E or U for voltage input), and produces an output pressure that is proportional to that signal.

However, process pressure is affected by changes in flow, temperature and other process disturbances, so to sense these changes and adjust the pilot pressure accordingly; the “loop” is often closed in a PLC or central control room.

If the command signals 4-20 mA (or 1-5 V DC) or 0-10 VDC calls for greater pressure, a valve in the regulator shifts to expose the outlet connection to the higher incoming pressure.

A third type of electronic controller “closes the loop” with an on-board microprocessor that takes an electronic signal from a pressure transmitter located on the outlet of the regulator, compares that signal to the command signal and designs, the device controls regulator pilot pressure, comparing this pressure to Electropnuematic PID controller with

If lower pressure is called for, a valve shifts to open and bleed the outlet to atmospheric pressure.

mechanical regulator produces output pressure equal to a command signal high (±0.1%) accuracy when combined with an accurate pressure transmitter.

(Photo courtesy of Emerson Process Management) automatically adjusts the pilot pressure to obtain the desired process pressure to compensate for any process disturbance.

The pneumatic controlled regulator will be selected to meet the needs of the application like inlet and outlet pressure range, flow capability, media compatibility, porting configuration while the electronic control head is common.

By this combination a great variety of applications can be served.

If needed, the regulator can also supply an electronic signal representative of the process pressure for monitoring, data acquisition, etc. Versions that interface with digital controls are also available. The accuracy of such a closed loop control is down to 0.1% if using an electronic regulator TESCOM ER5000 as a standalone component. If it is working together with a pneumatic controlled pressure regulator, the accuracy of the entire system depends on many factors like hysteresis of the regulator, sticking effects of O-rings, the application environment and therefore is difficult to determine. Typically, pressure control accuracies of 0.25% can be achieved.

Author’s Details (Compiled by)

Electropnuematic PID controller with mechanical regulator produces output pressure equal to command signal high (±0.1%) accuracy when combined with an accurate pressure transmitter. (Photo courtesy of Emerson Process Management)

Chemical Engineering World

Rushil Shah Managing Director, Shavo Technologies Pvt. Ltd Email Id: rushil@shavogroup.com September 2016 • 67

Marketing Initiatives

Toshniwal’s V -Cone System for Municipal & Industrial Water Flow Meter

T

h e V M V- C o n e S y s t e m h a s a n a d va n c e d d i f fe r e n t i a l p r e s s u r e flow sensing design. The flow meter features built-in flow conditioning for superior accuracy. The VM V-Cone is the idyllic new or retrofit flow meter for multiple clean water and wastewater treatment applications.

The McCrometer VM V-Cone SystemMeasurement Simplified With its built-in flow conditioning technology, the V-Cone also can be placed in comparatively close vicinity to elbows, valves, pumps, pipe U's, etc., where other flow measurement technologies would be impractical or erroneous.

VM V-Cone System's pre-packaged, builtin 3-way valve separates the transmitter f r o m t h e p r o c e s s f l u i d f l ow fo r e a s y maintenance. No need to shut down the pipeline. The flow meter arr ives wetflow calibrated direct from the factory.

The ready-to-install VM V-Cone System diminishes many difficulties of adding a flow meter to most flow installations.

Features & Benefits: The VM V-Cone System guarantees longterm performance because there are no moving parts to repair or replace. Once installed, the primary element hardly, if ever, needs to be removed from service, apart from the flow transmitter with the occasional recalibration over its lifetime.

The V-Cone family of flow meters has demonstrated long life with installations surpassing 20 years devoid of the need to be removed or re-calibrated.

• System accuracy of ±0.5% of rate • Flow range: 10:1 • Installation: Typically 0-3 diameters upstream and 0-1 diameter downstream 68 • September 2016

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Marketing Initiatives

• No parts to wear so little maintenance required • HART® and Digital Protocols • Totalizer pulse and linear 4-20mA outputs • 3 - w a y m a n i f o l d f o r i s o l a t i n g t h e transmitter • Displays both rate of flow and total flow.

• Rate and total functions are independent of each other allowing for many different combinations of flow units.

Technical Specifications: The VM V-Cone Water and Waste Water Flow Meter System consist of a flanged Flow Tube, Flow Transmitter and Flow Indicator. The Flow Transmitter identifies f l ow a n d t r a n s m i t s a 4 - 2 0 m A s i g n a l propor tional to the flow rate. The Flow Indicator translates the signal into a flow Rate and Total, displayed on an LED display. The flow indicator is either integrated to the flow transmitter or remote mounted from the meter body. The Flow Indicator outputs an auxiliary 4-20 mA Chemical Engineering World

signal and an open collector transistor alar m pulse transferrable to Rate or Total. A 3-way-valve isolation manifold is standard. The VM V-Cone System is ISO 9001:2008 Certified.

Performance • A c c u r a c y : ± 0 . 5 % o f r e a d i n g o ve r standard flow range • Head Loss: </- 2psi at Full Scale • M a x i m u m Te m p e r a t u r e : ( S t a n d a r d Construction) 180ºF constant • Pressure Rating: 150 psi, 300 psi • Power: 24VDC, Remote Display 110 VAC • Outputs: Analog 4-20mA

• • • • • • • •

Well Water Production Raw Water Influent Filter and Pipe Galleries Finished Water Effluent Collection and Distribution Systems Facilities Distribution Cooling Water Reclaimed Water

Contact DetailsToshniwal Hyvac Pvt Ltd 267, Kilpuak Garden Road Chennai - 600010 Contact: +91 44 26445626/ 8983 Email: sales@toshniwal.net Web: www.toshniwal.net

Applications: The VM V-Cone System acts as its own flow conditioner, fully conditioning and mixing the flow prior to measurement.

R e a d i n g s a r e a l w ay s a c c u r a t e a n d r e l i a b l e , ev e n u n d e r c h a n g i n g f l o w situations in the following Municipal and Industrial water applications: September 2016 • 69

Marketing Initiatives

Weld Eezy offers Spectrum of Piping & Welding Solutions

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eld Eezy is a pioneer since its commencement in 2005 in the critical area of Industrial Pipes and fittings. They are associated with various Desalination Plant manufacturers, Effluent Treatment Plants manufacturers, Chemicals, Pharmaceuticals, Bio-Mass Power plants manufacturers where piping is a critical input.

They possess wide knowledge bank of risks involved like leaks, clogging etc. in conveying water, Effluents, acids, chemicals etc., and how defective piping can disrupt and foul up the process, resulting in avoidable break down and loses.

W i t h t h e o b j e c t i ve o f s e r v i n g t h e s e businesses with Quality products in HDPE and PP, Weld Eezy offers a wide spectrum to the customers on Supply includes Supply of HDPE Fittings, Butt Welding machine, HDPE Tailor Made HDPE Tanks, Reaction Vessels, Scrubbers of size upto 3000mm Dia and any other special type HDPE Products in HDPE/PP. They also offer

70 â&#x20AC;˘ September 2016

Chemical Engineering World

Marketing Initiatives

at their R& D lab facility. The research team has developed certain unique application/ solution oriented welding machines.

services include welding & laying of pipes & fittings, etc. We can carry out welding of HDPE/PP pipes upto 1600mm OD Their manufacturing unit is proficient to manufacturer all HDPE Fittings of sizes upto 1600mm OD. Fittings such as Stubends, Flanges, Bends, Tees, Reducers, Puddle Flanges, Fabricated Bends/ Tee / Unequal Tees etc at their factory at Madurathangam, Near Chennai, Tamilnadu.

Besides being armed with the right tools, Weld Eezy has dedicated people, who provides them with competitive edge to undertake and complete challenging piping jobs, cost effectively and on schedule. There is a continuous research process in action Chemical Engineering World

Weld Eezy’s talented research resources had led to their promoters being awarded

by Ministry of Chemicals & Fertilisers for developing special Butt-fusion Machine in the Year 2012 and for developing special Marine fishing HDPE product in the year 2015. It holds the rank of being the first company in India to fabricate unequal tee of size 1600x450x1600 mm by Sidewall Fusion Welding Technique for ILFS Power Project Ltd, Cuddalore thru M/s. Coastal marine & Engineering Company, Mumbai for Marine applications.

They also have been awarded with Best Service contractor award for executing HDPE piping work for India’s biggest desalination plant near Chennai for sizes from 110mm to 1200mm by M/s. Vatech Wabag Ltd.

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Tee of Sizes 32-1600mm as per ISI, ISO, Manufacturers standards Manufacturers of UF & RO Headers in HDPE of any sizes by Sidewall Technique.

DIFFUSER Fabrication in HDPE for OUTFALL /INTAKE installations.

Manufacturers of Reaction Vessels, Scrubbers, Storage Tanks as per tailormade requirements.

Executors of Turnkey HDPE Pipeline Installations from Sizes 32 -1600mm

Contact Details Weldeezy G2, Vijay Flats No. 3 Railway Border Road Kodambakkam Chennai – 600024 Phone No: 044 4501 8888 Email: dinesh@hdpefittings.in, dineshhdpe@gmail.com Website: www.hdpefittings.in

Features: • Manufacturers of HDPE Stubends of sizes : 32-1600mm as per ISI , ISO, Manufacturers standards • Manufacturers of HDPE Reducers of all Types like Concentric / Eccentric of sizes : 32-1600mm as per ISI , ISO, Manufacturers standards • Manufacturers of HDPE all types of Fabricated fittings like Elbow, Tee, Y type September 2016 • 71

CEW Products New Intuitive GC Solution

Hand-held Infrared Thermometer

The Agilent Intuvo 9000 GC solution offers users new innovative technology that will help laboratories meet operational, scientific and financial goals and makes complex technology easy to use.

Click-and-run connections eliminate ferrules, guard-chip technology extends column life, and the trim-free column eliminates retention time shifts due to column trimming maintenance. With Intuvo Flow Technology chips and Smart ID Keys, the Intuvo 9000 system selfidentifies installed components and self-configures methods. Operations like midcolumn backflush are made routine by eliminating complex setup and extra calculators.

The touchscreen user interface provides quick access to system status and real-time data, and it guides the user through routine maintenance operations. Connection via smartphone or tablet notifies laboratory managers remotely of system status. The new system, especially when coupled with mass spectrometry, is ideal for high-throughput contract laboratories, and for labs dealing with challenging sample matrices in fields such as food, environmental, chemical, pharma and forensics testing.

Toshniwal Hyvac Pvt Ltd offers hand-held infrared thermometer in the temperature range of -320C to 5350C (0C/0F switchable) with built-in laser pointer to improve the aim.

It has a 12:1 field of view, and auto-hold and power-off facility (backlit display with data hold).

For details contact: Agilent Technologies Inc 5301 Stevens Creak Blvd Santa Clara, CA 95051. U.S.A. Tel: +1 877 424 4536, +1 408 345 8886 E-mail: us@agilent.com, victoria.wadsworth-hansen@agilent.com or Circle Readers’ Service Card 1

Response time is 500 ms and adjustable emissivity (ST 642).

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558 26448983 E-mail: sales@toshniwal.net or Circle Readers’ Service Card 2

Monitoring Sulphuric Acid Concentration Online For the concentration determination, sonic velocity meters have proven to be ideal, as sonic velocity forms a strong and unambiguous function to the concentration of sulphuric acid and oleum in the production-relevant concentration ranges.

With the LiquiSonic analyzer by SensoTech, the concentration of sulphuric acid and oleum is continuously monitored in real time using just one single sonic velocity sensor that is installed directly in the pipe. The robust construction and Hastelloy C-2000 as sensor material make the sensor completely maintenance-free. The measurement accuracy is up to ±0.03 m% and the results are updated every second. The LiquiSonic controller displays and stores the real-time information. Via 4-20 mA signal, digital outputs, serial interfaces, fieldbus or Ethernet, the controller can be integrated into the network and control system.

The analyzer monitors the acid concentration, eg, in processes of sulphuric acid production, including the double contact double absorption (DCDA) process and the wet sulphuric acid (WSA) process. Moreover, LiquiSonic analyzers are used in synthesis gas drying, fertilizer production, decomposing ore mining or in etching and pickling baths of the chemical and steel industry.

For details contact: SensoTech GmbH Steinfeldstr 1 D-39179 Magdeburg-Barleben Germany Tel: +49 (0) 39203 514 100 Fax: +49 (0) 39203 514 109 E-mail: info@sensotech.com or Circle Readers’ Service Card 3

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Products CEW Mass Flow Controller The MCRH can accommodate flow rates of up to 5000 slpm, without compromising speed or precision of gas control. The highly stable controller manages industrial processes with more chaotic upstream fluctuations.

The MCRH 5000 slpm precisely and rapidly controls mass flow rate, volumetric flow rate or back pressure of gases in high flow processes. To overcome the poor turndown ratio and slow response of existing methods (such as interlinking a meter with an external valve) Alicat designed a new flow geometry. This new design accommodates the higher flow rates, with a low pressure drop of 14.1 psig at full scale.

The instrument’s Gas Select firmware includes a library of up to 130 preloaded gases, user selectable in the field. The MCRH 5000 slpm can be programmed with the instrument’s pushbutton menus and onboard display or via remote connection. Digital communications options include RS-232 or RS-485 Serial, Modbus, or PROFIBUS, as well as analog 0-5 V DC, 1-5 V DC and 0-10 V DC or 4-20 mA. For details contact: Halma India Prestige Shantiniketan Gate No: 1, Tower C, 7th Floor ITPL Main Road, Whitefield Mahadevapura Bengaluru, Karnataka 560 048 Tel: 080-67475300 E-mail: sunil.balan@halma.com or Circle Readers’ Service Card 4

17 mm DC Miniature Motor With high torque carrying capabilities reaching up to 6.14 mNm, the 17DCT provides outstanding performance with efficiency reaching up to 85 per cent while providing a long lifetime. Due to the inherent design of the 17DCT motor, it can deliver higher torque per ampere resulting in better battery life. This makes it ideal for demanding applications such as medical and industrial pumps, drug delivery systems, miniature industrial power tools and more. Other applications, including lab automation and humanoid robots, can benefit from the features of the 17DCT Athlonix motor.

Athlonix 17DCT miniature DC motors are available in 2 variations, precious metal commutation and graphite commutation with a neodymium magnet inside. The unique constant force spring design for carbon brush provides consistent performance. An REE (restriction of electro erosion) coil is an available option, which prolongs the life of the motor and provides an environment of intrinsic safety especially at high speed conditions.

Athlonix motors are available with encoders and gearheads of various sizes and ratios. They are manufactured in an ISO certified facility and are RoHS compliant.

For details contact: Portescap Unit No: 2, SDF-1 SEEPZ-SEZ Andheri (E), Mumbai 400 096 Tel: 022-42006200 Fax: 91-022-42004036 E-mail: sales.asia@portescap.com or Circle Readers’ Service Card 5

Chemical Engineering World

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CEW Products Pyro Epsilon

Fully Automated Synthesis

Toshniwal Hyvac Pvt Ltd offers 2-wire 4-20 mA output Pyro Epsilon housed in a rugged IP65 stainless steel in temperature range of -20 0C to 500 0C. Adjustable emissivity is via 4-20 mA input; optional Pyro Tune emissivity adjuster with 2:1, 15:1, 30:1 or close focus optics.

For details contact: Toshniwal Hyvac Pvt Ltd 267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26448558, 26448983 E-mail: sales@toshniwal.net

or Circle Readers’ Service Card 6

Syrris offers the Atlas HD automated jacketed reactor system.

The Atlas HD is designed to offer supreme flexibility and ease of use, combining intuitive touch screen control with a wide range of options to suit virtually any reaction set-up. It is available with a choice of easily interchangeable reaction vessels – from 50 ml to 5 l – and a selection of sensors to allow fully automated monitoring of temperature, turbidity and pH. Reaction parameters can be easily programmed and monitored in the system’s firmware, as well as adjusted in real time, helping to achieve unrivalled reproducibility and performance.

For complete process automation, the Atlas HD’s PC software offers straightforward third party device integration, providing a truly modular solution for a variety of laboratory workflows.

For details contact: Syrris Scientific Equipment Pvt Ltd 420/421 Corporate Avenue, Sonawala Road Goregaon (E), Mumbai 400 063 Tel: 022-26864410 E-mail: info@syrris.com. or Circle Readers’ Service Card 7

Polyamide 6 for Engine Oil Pan The engine oil pan for one of the latest car consists of an upper and a lower part made from 30 per cent glass fiber-reinforced Durethan BKV 30 H2.0 from LANXESS. The upper part is screw-connected to a pipeline carrier that is also made from polyamide 6. Using plastic instead of aluminium means that numerous functions can be shaped directly during injection moulding, thereby integrating them into the component.

This has helped to reduce the number of separate parts that need to be manufactured and mounted for the oil pan, and key work. Steps needed in the final assembly of the engine has also been cut. Furthermore, the oil return lines of the turbocharger, the oil separator and the air-oil separator are combined in the pipeline carrier.

Polyamide 6 has helped to reduce the weight of the upper and lower sections of the oil pan. Overall, the oil pan is more lighter than its aluminum predecessor, due to the lower density of the plastic and the optimized wall thicknesses.

A key argument in favour of the oil pan using injection moulding was the huge potential that the process offers for integrating functions and thereby cutting costs. The lower energy costs are another benefit in favour of manufacturing injection-moulded parts.

For details contact: LANXESS LANXESS House, Plot No: A 162-164 Road No: 27, MIDC Wagle Estate Thane (W), Maharashtra 400 604 Tel: 022-25871000 Fax: 91-022-25871287 or Circle Readers’ Service Card 8

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Products CEW Monitoring the Oil Concentration in Cooling Processes For the lubrication of compressors in air-conditioning systems, refrigerant oils circulate in the refrigeration cycle, however, they reduce the cooling effectiveness. Therefore, continuous monitoring of the oil content is especially important in the development of air-conditioning systems in order to determine the optimum oil circulation ratio.

With the LiquiSonic OCR analyzer by SensoTech, specifically designed for refrigerant applications, the oil circulation ratio in the refrigerant can be monitored online and directly in the process using sonic velocity measurement. The LiquiSonic sensor is installed in the pipeline and combined with a pressure transducer. Additionally, two Pt1000 temperature probes are integrated in the sensor, so that the temperature- and pressure-compensated oil concentration can be calculated in real time. The LiquiSonic controller displays and stores the measurement results. Via 4-20 mA signal, digital outputs, serial interfaces, fieldbus or Ethernet, the controller can be integrated into the network and control system.

For details contact: SensoTech GmbH Steinfeldstr 1 D-39179 Magdeburg–Barleben Germany Tel: +49 39203 514100 Fax: +49 39203 514109 E-mail: info@sensotech.com or Circle Readers’ Service Card 9

Asia Automated Reagent Injector Syrris offers its Asia Automated Reagent Injector designed for use with Asia flow chemistry systems, enabling fully automated experiments with multiple reagents.

Driven by the Asia Syringe Pump module, the compact Asia Automated Reagent Injector offers high performance, fully automated sample injection via two independent channels, allowing complex matrixed libraries to be synthesized.

Gas blanketing provides the inert sampling conditions required for safe handling of air and moisture sensitive reagents and with sample pre-pressurization up to 20 bar, dispersion and pressure drops during reactions can be avoided, enabling even small volumes to be injected. For max flexibility, sample loops from 0.1 to 10 ml are available, as well as a selection of removable racks for 2, 8 and 40 ml vials.

Complete process automation is provided by connection to the Asia Manager PC Software, enabling sophisticated multiple sample injections and experiments to be performed, including key applications such as synthetic library generation, reagent screening, reaction optimization, kinetic and degradation studies, and LogD screening.

For details contact: Syrris Scientific Equipment Pvt Ltd 420/421 Corporate Avaenue Sonawale Road Goregaon (E), Mumbai 400 063 Tel: 022-26864410 E-mail: info@syrris.com or Circle Readers’ Service Card 10

Chemical Engineering World

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CEW Products Compressed Air Rental Services

Membrane Compensators

Ingersoll Rand responds to this market need with the launch of compressed air rental services. This new offering provides a wide range of compressed air solutions for rent. Customers can now depend on reliable temporary compressed air solutions that will allow them to minimize their downtime and maximize their production, maintaining critical processes in a sustainable manner.

Compressed air rental services continues to add new equipment to its range of oil-free Class 0 and oil-flooded compressors, for short and long term rental solutions. For industries such as food and beverage, pharma, electronics, glass, textile and chemical it is critical to maintain productivity and quality in a sustainable manner.

Ingersoll Rand compressed air rental services is the solution for seasonal peak demand: unexpected equipment failure, planned outages and maintenance, and tight capital budgets.

For details contact: Ingersoll Rand India Plot No: 35, KIADB Indl Area Bidadi, Bengaluru, Karnataka 562 109 E-mail: Contact-India@irco.com or Circle Readers’ Service Card 1

Bhastrik Mechanical Labs offer membrane compensators, which are used for absorption of changes in volume due to temperature difference (insulation oil in high-voltage).

SS diaphragms are pressed with a special profile. They are welded together on their exterior diameter with ‘0’ wrinkles and distortion.

For details contact: Bhastrik Mechanical Labs Pvt Ltd Plot No: 95 & 96 1 st Main Road Nehru Nagar Indl Estate Kottivakkam Chennai 600 041 Tel: 044-43593702, 4359703 Fax: 91-044-24540353 E-mail: admin@bhastrikbellows.com / sales@bhastrikbellows.com or Circle Readers’ Service Card 2

Liquid Concentration Analyzers Based on the modern principle of sonic velocity measurement, the LiquiSonic V10 provides an inline analytical solution used to determine the concentration of process liquids in industry and research. The V10 fuses this principle into a remarkably user-friendly system with a high level of accuracy.

The sensor design includes a new electronics enclosure, which is characterized by increased compactness and maximum robustness. The use of the latest technology allows even more precise and faster measurement and improved repeatability.

The V10 sensors use less energy and meet the increased requirements on energy efficiency and environmental protection. For use in hazardous areas like petrochemistry, the V10 sensors are ATEX-, IECEx- and FM-certified, while other V10 sensor types are 3-A-certified for use in the food and pharmaceutical industry. The internal data storage with 2 GB SSD gives a clear lead in the market.

By simultaneous visualization of multiple process parameters and optimized charts, the trend view is more informative with clear structure. An absolutely unique feature of the touch screen and the virtual keyboard is the integration of not only Latin but also Cyrillic and Asian characters, which allows a worldwide comfortable use of LiquiSonic systems and sets benchmarks for controllers in process analytics. Under highest safety standards, it is possible to access the controller via the network interface or through a web browser connection.

For details contact: SensoTech GmbH Steinfeldstr 1 D-39179 Magdeburg–Barleben, Germany Tel: +49-39203 514100 Fax: +49-39203 514109 E-mail: info@sensotech.com or Circle Readers’ Service Card 3

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Chemtech World Expo 2017 Dates: 14 – 17 February 2017 Venue: BC&EC Mumbai, India Details: Platform to showcase services, technologies, innovations and current & future trends of entire value chain of process industry.

Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com

Tube India 2016 Dates: 05-07 October, 2016 Venue: Mumbai, India Details: The event aims to attract engineers, specifiers and purchasing managers from India and south Asia to this international presentation of tube and pipe materials and components, manufacturing and processing machinery and equipment.

Organiser: Messe Düsseldorf India Pvt. Ltd. Contact: +91 11 26901600 Email: messeduesseldorf@md-india.com Website: http://www.md-india.com/ Powder & Bulk Solids India 2016 Dates: 13 – 15 October 2016 Venue: BCEC, Mumbai, India Details: Event for mechanical Processing Technologies and Bulk Solids Handling Technologies Organiser: NuernbergMesse India Pvt. Ltd. Contact: +91 11 47168830 Email: priya.sharma@nm-india.com Website: www.powderbulksolidsindia.com Petrotech – 2016 Dates: 05-07 December, 2016 Venue: New Delhi, India Details: The event aims to explore areas of growth in petroleum technology, exploration, drilling, production and processing, refining, pipeline transportation, petrochemicals, natural gas, LNG, petroleum trade, economics, legal and human resource development, marketing, research & development, information technology, safety, health and environment management in the oil & gas sector.

Organiser: Indian Oil Contact: +91 9873020408 Email: shankar@indianoil.in Website: http://petrotech.in/index.aspx

Chemical Engineering World

Chemspec South East Asia - 2016 Dates: 30 Nov to 01 Dec, 2016 Venue: Queen Sirikit National Convention Center, Bangkok, Thailand Details: Exhibitions for the fine and speciality chemical industry Organiser: Mack Brooks Exhibitions Asia Ltd Contact: +66 (0) 2684 6894 Email: wendy@mackbrooks.com Website: www.chemspec-southeastasia.com Nawc Water Summit 2016 Dates: 02-04 October, 2016 Venue: San Diego, California Details: Each year the NAWC Water Summit provides a dynamic forum for leaders in the water industry, public officials and other key stakeholders to exchange ideas, learn from one another and share solutions that sustain businesses and communities.

Organiser: NAWC Contact: +202-349-7300 Email: carlos@nawc.com Website: http://www.cvent.com/events/2016-nawc-water-summit/ event-summary-4e26c567b91e4f06a40875f5ab2089c5.aspx International Water Conference 2016 Dates: 06-10 November, 2016 Venue: San Antonio, Texas Details: WC brings together end users, researchers, practicing engineers, managers, educators, suppliers and contractors. It is dedicated to advancing new developments in the treatment, use and reuse of water for industrial and other engineering purposes. Attendees come to learn unbiased details about the latest applications available in the industry get educated on current technology and hold wide ranging discussions with their peers active in water treatment.

Organiser: Engineer’s Society of Western Pennsylvania Contact: +412-261-0710 Email: eswp@eswp.com Website: https://eswp.com/water/overview/ SOMChE - 2016 Dates: 1 – 3 December 2016 Venue: Miri Marriott Resort & Spa, Malaysia Details: an established platform for chemical engineers from academia and industries to disseminate their latest research and to highlight new technologies.

Organiser: Curtin University, Sarawak Malaysia Contact: +60 85 44 3939 Email: somche2016@curtin.edu.my Website: www.curtin.edu.my

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CEW Project Update

New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India.

CHEMICALS M Chemicals proposes an expansion from 10-TPM to 35-TPM of its synthetic organic chemicals manufacturing unit in GIDC Sachin, district: Surat, Gujarat. The estimated cost of the expansion is ` 12-million. The current status of the project could not be ascertained. According to MoEF sources, EIA report has been prepared by Aqua-Air Environmental Engineers. The existing plant manufactures 10-TPM 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid. The expansion entails addition of new products namely, 25-TPM G-Salt, R-Salt, Amido G-Acid, Aniline 2,4 DSA, Aniline 2,5 DSA, Para Nitro Chloro Benzoyl Sulphonic Acid, Sulfo Tobias Acid, Para Cresidine Ortho Sulphonic Acid, Schaffer’s Acid, Broenner’s Acid. Total plot area is approximately 1,650-sq m, out of which, 300-m 2 has been used for green belt development.

5-KLD effluent will be treated in-house ETP and 10-KLD effluent will be sent to common MEE of MEPL for evaporation.

Mamta Texdyes (Samba) proposes a synthetic organic chemicals manufacturing unit in GIDC Sarigam, district: Valsad, Gujarat.

The project is spread over 2,250-sq m. The estimated cost of the project is ` 32-million. The current status of the project could not be ascertained. According to SEIAA sources, Eco Chem Sales Services is the environmental consultant. The proposed products are 200-TPM sulphur black grains, 300-TPM sulphur black liquid and the by-products are 250.1-TPM sodium thio sulphate crystal and 47.12-TPM sodium chloride salt. 700-sq m area has been proposed for green belt development. Industrial waste water will be treated in primary and tertiary treatment plant and treated waste water will be discharged into CETP Sarigam.

Resipol Adhesives proposes an expansion of synthetic organic chemicals manufacturing unit in village: Rajpur, district: Mehsana, Gujarat. The estimated cost of the expansion is ` 40-million. The current status of the project could not be ascertained. According to SEAC sources, the amanufacturing of existing products, 2.0TPM benzyl alcohol, 1.1-TPM benzyl benzoate, 3.0-TPM benzoic acetate, 1.4-TPM sodium benzoate, 1.8-TPM sodium acetate will be discontinued and 300-TPM polyester resins (different grades) and alkyd resins (different grades), 90-TPM melamine formaldehyde resin and 85-TPM urea formaldehyde resin will be manufactured as new products. The plot area is approximately 6,033.00-sq m. Unit has proposed 2,000-sq m area for green belt development. Industrial effluent of 0.42-KLD after primary treatment will be evaporated in kettle type evaporator. Two DG sets each of 65-KVA will be provided. It was decided to recommend the project to SEIAA, Gujarat for grant of environmental clearance.

Royal Wood proposes a 90-TPM phenol formaldehyde resin, urea formaldehyde resin, melamine urea formaldehyde resin and melamine formaldehyde resin manufacturing unit in village: 78 • September 2016

Modvadar, district: Kutch, Gujarat. The current status of the project could not be ascertained. According to MoEF sources, existing products are 3-million sq m per month plywood, flush door, block board and veneer. The manufactured resin will be used for in-house consumption at the wood products plant. The project will come up on 11,603.62-sq m of existing land. The greenbelt area is 600-sq m. A base platform will be constructed for the resin plant; remaining will be MS structure.

Eternis Fine Chemicals proposes an expansion of synthetic organic chemicals manufacturing unit from 42,200-TPA to 60,000-TPA in MIDC Kurkumbh, district: Pune, Maharashtra. The current status of the project could not be ascertained. According to MoEF sources, total land area is 100,400-sq m and built-up area is 42,710-sq m. 33 per cent will be developed as green belt area. The project will entail: 1) capacity expansion of existing products and by-products; 2) addition of similar products and by-products; 3) introduction of new eco-friendly biomass boiler as replacement to furnace oil. Project involves manufacturing of fragrance from organic raw materials by chemical process like hydrogenation, esterification, Diels-Alder reaction, cyclisation, dehydrogenation, aldol condensation, etc, followed by distillation to match precise quality standards. By-products capacity will be augmented from 11,400-TPA to 20,000-TPA. The estimated cost of the project is ` 1,050-million. The power requirement 12,000KVA will be available through Government Electricity Board.

Panoli Intermediates (India) proposes an expansion of its specialty chemicals manufacturing unit and a new 10-MW coal-based captive power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat. The estimated cost of the project is ` 100-million. The current status of the project could not be ascertained. According to MoEF sources, the total plot area is 15,480-sq m. The capacity of isomers and DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented from 200-TPM to 2,200-TPM, ortho anisidine/para anisidine from 100-TPM to 1,100-TPM, ortho nitro aniline/para nitro aniline from 300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a new product namely, 1,500-TPM derivatives of nitro phenol and a new 10-MW coal-based captive power project. 10-MW power requirement is to be met from MGVCL and 10-MW from the captive power project. The effluent will be treated in proposed effluent treatment plant.

Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, Chemical Engineering World

Project Update CEW district: Valsad, Gujarat. The existing land area is 1.5 acres. The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months. The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator.

FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance. According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion.

Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years.

Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute phosphoric acid. Environment clearance has been obtained for the products â&#x20AC;&#x201C; red pigments and yellow pigments. Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product.

Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from China. Civil work is in progress. The project is scheduled for completion in 2018.

Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF Chemical Engineering World

sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin.

The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-cu m/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator.

Adi Finechem is planning a 40-TPA specialty products manufacturing project on a 2-acre land at an estimated cost of ` 400-million in village: Chekhala, district: Ahmedabad, Gujarat.

The project is waiting for environmental clearance.

RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat.

Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date.

MINING Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting Government approval.

Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7-million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal/kg useable as fuel in FBC boilers. The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha.

September 2016 â&#x20AC;˘ 79

CEW Project Update NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal Block at Odisha by the Ministry of Coal.

DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance.

Mining work is expected to commence soon. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LoI) for mining contract has been granted for a period of 9 years.

NON-CONVENTIONAL ENERGY Viaton Energy, promoted by the 3F Group and Creative Group, is planning a 10-MW power project in Punjab. Discussion is in progress with the Government for allocation of site. The company is already operating a 10-MW biomass-based IPP at village: Khokhar Khurd, district: Mansa, Punjab from July 2013. The generated power is being sold to the Government of Punjab.

Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, installation, testing and commissioning of solar RTPV grid connected power plants on roof-tops of 31 HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including operation and maintenance for a period of five years. The approximate amount put to tender is ` 18.62-million.

NON-CONVENTIONAL POWER BMS Starch, a part of the BMS Group, is implementing a 6-MW biomass-based co-gen power plant in village: Kurandi, district: Bastar, Chhattisgarh. The project is coming up along with a starch manufacturing unit on 26-acre of acquired land at a total estimated cost of ` 1,350-million. Equipment supplier is yet to be appointed. Civil work is in progress. The project is expected to be completed in this year.

THERMAL POWER Surguja Power, a 100 per cent subsidiary of Adani Mining, proposes a 540/600-MW coal washery rejects based thermal power project spread over 47.5-hectare of land in villages: Parsa, Kete, district: Surguja, Chhattisgarh. The estimated cost of the 80 â&#x20AC;˘ September 2016

project is ` 35-billion. According to MoEF sources, Greencindia Consulting is the environmental consultant. The project will comprise of a 4 x 135/150-MW power plant based on the coal washery rejects within the Parsa East and Kete Basan coal block at Udaypur Tehsil, district: Surguja. The Group has been assigned work by Rajasthan Rajya Vidyut Utpadan Nigam (RRVUNL) for mining, development and operation of Parsa East coal block and supply of beneficiated coal. Sizeable amount of rejected coal will be generated, which shall be utilized for power generation by setting up the power project within the coal block. The plant is proposed to have circulating fluidized bed combustion-based (CFBC) coal fired boilers.

Rain Cements is planning a 7-MW waste heat recovery-based power plant in village: Boincheruvupalli, Peapully Mandal, district: Kurnool, Andhra Pradesh. The estimated cost of the project is ` 700-million. The project will come up in the existing cement plant premises. The project will generate up to 7-MW of gross electrical energy from the waste heat and the flue gases evolved during the cement manufacturing process. The project that will be financed by a combination of internal accruals and bank loans is expected to be completed in about 14 months. The Board of Directors of the company had approved of the project at its meeting held on 27 th February, 2015.

Seven Star Steels is planning an expansion of its thermal (coalbased) captive power project from initial 8-MW to 12-MW at a cost of ` 600-million in village: Kalendamal, district: Jharsuguda, Odisha. The project will come up along with an expansion of its sponge iron plant from 60,000-TPA to 180,000-TPA and ingot plant from 39,200-TPA to 80,000-TPA. Machinery will be partially procured locally and partially imported; orders are yet to be placed. The project is waiting for industrial clearance. Work on the project will commence soon.

FERTILISER Fertilizer Corporation of India is planning to set up a 1.27-MTPA natural gas-based urea plant in district: Gorakhpur, Uttar Pradesh.

Deloitte Touche Tohmatsu India is the Financial Advisor. Request for Qualification (RFQ) invited for selection of investor for setting up the project at the Gorakhpur unit of FCIL in August 2015. The Ministry of Chemicals and Fertilizers, has authorized FCIL for revival of the Gorakhpur Unit by selecting a suitable investor to setup, design, finance, construct, establish, operate and maintain the project for a term of 33 years, which may further be renewed.

The total land area of 993.81 acres is available with FCIL. The estimated investment size is ` 60-billion. The Government has earmarked 2.4-MMSCMD of domestic natural gas for the project from Daman Field of Oil and Natural Gas Corporation, which is expected to commence production from September 2016. The natural gas is proposed to be transported through the upcoming Jagdishpur-Phulpur-Haldia pipeline to be constructed by GAIL (India). The construction period is 3 years.

Chemical Engineering World

Book Shelf CEW Water and Wastewater Technology Author/s: Price: Page: Publisher:

Mark J. Hammer Sr. ` 6,230 536 (Hardcover) Prentice Hall

About the Book: This book provides comprehensive coverage of the fundamental principles and current practices in water processing, water distribution, wastewater collection, wastewater treatment, and sludge processing. The objective is to transfer knowledge of these subjects to persons interested in continuing their study in sanitary technology and engineering, and to persons interested in operation and maintenance of water and wastewater facilities.

This fourth edition updates the subject matter, illustrations, and problems to incorporate new concepts and issues related to the water environment. The most extensive revisions in this edition are the addition of new problems, hydraulics, disinfection of drinking water, wastewater processing, and editing of the previous text.

Water and Air Effluents Treatment Handbook

Principles of Membrane Bioreactors for Wastewater Treatment

Author/s:

Author/s: Price: Pages: Publisher:

Price: Pages: Publisher:

Hee-Deung Park, In-Soung Chang, Kwang-Jin Lee ` 4,884.00 445 (Hardcover) Asia Pacific Business Press Inc.

About the Book: This book covers the basic principles of membrane bioreactor (MBR) technology, including biological treatment, membrane filtration, and MBR applications. The book discusses concrete principles, appropriate design, and operational aspects.

It covers a wide variety of MBR topics, including filtration theory, membrane materials and geometry, fouling phenomena and properties, and strategies for minimizing fouling. Also covered are the practical aspects such as operation and maintenance.

Case studies and examples in the book help readers understand the basic concepts and principles clearly, while problems presented help advance relevant theories more deeply. Readers will find this book a helpful resource to understand the state of the art in MBR technology..

Handbook of Solid Waste Management Author/s: Price: Pages: Publisher:

George Tchobanoglous, Frank Kreith ` 9,527.57 950 (Hardcover) McGraw-Hill Education

About the Book: This handbook offers an integrated approach to the planning, design, and management of economical and environmentally responsible solid waste disposal system.

Let twenty industry and government experts provide you with the tools to design a solid waste management system capable of disposing of waste in a cost-efficient and environmentally responsible manner. Focusing on the six primary functions of an integrated system-source reduction, toxicity reduction, recycling and reuse, composting, waste- to-energy combustion, and landfilling--they explore each technology and examine its problems, costs, and legal and social ramifications.

Chemical Engineering World

NPCS Board of Consultants & Engineers ` 1,148 325 (Paperback) Asia Pacific Business Press Inc.

About the Book: Water treatment describes those processes used to make water more acceptable for a desired end use. These can include use as drinking water, industrial processes, medical and many other uses. The goal of all water treatment process is to remove existing contaminants in the water, or reduce the concentration of such contaminants so the water becomes fit for its desired end use.

Effluent can be treated in different ways, it is classified as; preliminary treatment, primary treatment, secondary treatment and complete final treatment.

The atmosphere contains hundreds of air pollutants from natural or from anthropogenic sources. The book presents a concise but through an overview of state of technology for water and air effluent treatment. The water and air effluent treatments are organized into chapters by broad problem area, treatment of industrial effluent, industrial waste management, etc. This will be helpful to technocrats, consultants, educators, architects, industry executive, students and others concerned with saving environment problem.

September 2016 â&#x20AC;˘ 81

CEW Ad Index Sr. No.

Client’s Name

Page No

Sr. No.

Client’s Name

Page No

Inside Cover I

17

Vac Enterprises

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Avcon Controls Pvt Ltd

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18

Vega India Level Pressure Measurement Pvt Ltd

33

3

Busch Vacuum India Pvt Ltd

19

19

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Dow Chemicals

5

5

Hi-tech Applicator

3

6

Ingersoll Rand India Ltd

9

7

Ion Exchange (India) Ltd

27

8

Koerting Engineering Pvt Ltd

33

9

Mazda Ltd

39

10

Mist Ressonance Engineering Pvt Ltd

11

11

Pilot Gaskets & Engineers

21

12

Schenker India Pvt Ltd

15

13

Sintex Industries Ltd

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Suraj Ltd

37

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Uni Klinger Ltd

30

16

UNP Polyvalves (India) Pvt Ltd

17

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Atomic Vacuum Company (Exports)

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82 • September 2016

Inside Cover II & BC

7

Chemical Engineering World

Interview CEW

“We Target Becoming ` 5000 Crore Company by End of This Decade Serving Our Global Customers” “Indian legal system is good and is expected to provide confidence to foreign investors. These along with good labour laws, low R&D cost and also low cost of capital, could push India as a more preferred destination for setting up manufacturing units,” envisages Dr. Deepak Parikh, Vice Chairman & Managing Director, Clariant Chemicals India Ltd. He shares his views on Indian Specialty Chemical Market, growth prospects, product portfolio expansions, global partnering and relevance of GST in chemical industry and much more in a candid conversation with Mittravinda Ranjan.

Chemical Engineering World

September 2016 • 83

CEW Interview During the last financial year ending March 2016, Clariant India has posted 12 per cent growth over the period of 15 months and increase in quarterly growth by 21 per cent. What have been the growth drivers for the company and how do you see the business in the near foreseeable future?

The Indian market is witnessing strong positive trends in consumer behaviour, which is a strong driver for product demand in, among others, home and personal care, consumer goods and infrastructure. These are growing at rate higher than the GDP and have been strong external drivers for our business.

The real help came from the stability in pricing of raw materials and crude oil and the subsequent derivative and transportation costs. The slide in crude prices does not have an impact of as high as 70- 80 per cent as in case of manufacturing of commodity chemicals but there is an impact of 35-40 per cent which is quite significant when it comes to managing the operational costs and maintaining a healthy bottom line.

Internally, our team has been working aggressively on our marketing strategy for products and services and developed effective channels for distribution to ensure strong pan India market presence.

Our entire product portfolio has seen a strong positive trend in the past quarter and there was no weakness that I could point out, and I am pretty pleased with our performance.

Looking at the orders, customer sentiment, assuming the stability of crude prices and pent up demand- it is going to be a solid year for us and the outlook is positive for the next few quarters.

Please share insights into your presence in Indian market.

In India, Clariant has a balanced portfolio comprising of eleven manufacturing locations present across the states of Madhya Pradesh, Gujarat, 84 • September 2016

Maharashtra, Tamil Nadu, and Kerala, out of which two are globally strategic sites. We are very well positioned as far as manufacturing, and latest technology availability is concerned; and will continue to serve our customers in Indian as well as global markets.

Clariant launched a Greenfield project for healthcare packaging in Cuddalore earlier this year? How does this fit into company’s growth strategy?

We all know that India is one of the undisputed market leaders in APIs for drug manufacturing and with a population size of over 1.2 billion (and growing); it is a strong market for the pharma industry. The medical packaging industry is now witnessing a boom which is driven by the growth of the pharma sector. Clariant is present in the space of desiccants and produces packaging for generic drugs for over a billion units for supplying globally.

The state-of-the-art production facility in Cuddalore complies with FDA norms and is built in accordance with the best manufacturing practices so as to produce products with the highest standards of global compliance. It is about ` 70 crores of investment and the project is well on schedule. We expect the production to go operational sometime by early half of next year and when that happens, we will be ready to supply to the whole Indian market.

I would like to point out that we are not looking into the commodities in this space of the healthcare industry.

Instead, we definitely are concentrating on specialties which play the critical role in enhancing the value of products that go into healthcare; and that’s what we are going to focus on. As I see, in the

next 5 years, the healthcare sector will play a major role in our growth strategy.

What is the significance of Clariant venturing in the innovation portfolio of the group and how do you go about identifying the partners for the company?

As a group we have a very strong focus on innovation which is carried out in-house and our teams are always scouting for innovative technologies that can be a strategic fit for our business or technology portfolio. The intent of Clariant Venturing is to identify innovative technologies which are at nascent stage of development and to get them patented and invest into the technologies that are in early stages of expansion and align ourselves with them.

Our teams are constantly engaged with the chemical research institutes and Universities across the globe, which play a very vital role in carrying out basic research work; and also with various private parties outside our company.

We continuously get a lot of enquiries but the biggest challenge here is to fit the new entities into the portfolio of the company and geographies.

Recently, Mr Ananth Kumar has stated that the GST will reduce the tax burden by 12-15 per cent for the chemical industry. How do you see the impact of GST on specialty chemical manufacturers after it is implemented on specialty chemicals industry?

Even today, India has a complex processes for setting up any kind of business – irrespective of the nature of the project - whether it is a Greenfield project, Brownfield expansion, joint venture or acquisition. Once the GST is in place and things get streamlined,

The Indian market is witnessing strong positive trends in consumer behaviour, which is a strong driver for product demand in, among others, home and personal care, consumer goods and infrastructure.

These are growing at rate higher than the GDP and have been strong external drivers for our business.

Chemical Engineering World

Interview CEW India has a skilled labour force and our cost of manufacturing in India is very competitive; at times substantially lesser for the same technologies if you compare with the rest of the world, which makes India preferable manufacturing hub for the world. Also the Make in India campaign will make things positive and bilateral trade will be a bonanza. this will definitely help the specialty chemicals industry to grow aggressively.

The trickle-down and cascading effects of the GST in other sectors such as logistics, manufacturing, automotive and consumer products will have a positive impact on the chemical industry too.

We, as a company, do expect very positive things from the GST. However it is not going to affect us this calendar year because of the financial cycle we follow. But we are definitely looking at this as a big plus during the next financial year.

Do you feel that there is a need for other reforms like relooking at antidumping to provide a level playing field for chemical manufacturing industry in India?

There cannot be a blanket rule of imposing the anti-dumping duties as chemical manufacturers continue to depend on imports of certain chemicals in significant quantities for processes.

But from case to case, when there is blatant dumping of products, the governments have to impose antidumping duty to protect the interest of domestic manufacturers.

There are few cases where measures have been taken by the government to protect the interest of local manufacturing.

How do you plan to leverage on Make in India campaign?

India has a skilled labour force and our cost of manufacturing in India is very competitive; at times substantially lesser for the same technologies if you Chemical Engineering World

compare with the rest of the world, which makes India preferable manufacturing hub for the world. Also the Make in India campaign will make things positive and bilateral trade will be a bonanza.

manufacturing which cannot be manufactured like general chemicals and are produced by handful of manufacturers globally which cannot be produced in SEZs.

At Clariant, we have been manufacturing in India for the world without compromising on the quality. Now, in the recent past, with energy price under control because of low crude prices, we have a win-win situation because of a combination of factors such as domestic demand, favourable energy price and high domestic consumption. In fact I believe that Make in India initiative is getting more momentum in our space and for us as a company, we are already exporting 45 per cent of manufactured products to various international markets which itself is a testimony of our stance.

Overall, SEZs is a good concept and I am very pleased to see what Iran is doing and Bangladesh could evolve in the near future.

For our space I see South East Asia, Middle East and Africa to be the real corridor for us along with China and we plan to leverage on this opportunity in a robust manner.

What are your thoughts on Reverse SEZs that India is setting up in Iran and announced having the same arrangement with Bangladesh recently?

Reverse SEZs are always going to be about commodities and high volumes and will enable the development of downstream chemicals and petrochemicals industry.

However, specialty chemicals are a very niche industry with many highly specialised sub segments within the chemical industry.

There are many key ingredients that are required for specialty chemical

Within the world of Clariant which geographies are performing the best and what is your vision for 2020?

In the last few quarters, the India operations are delivering solid performance with dynamic growth rates.

We have observed positive growth momentum in most of the regions we are present in.

To answer your question about our vision 2020 â&#x20AC;&#x201C; we target becoming ` 5000 Crore company by end of this decade serving our customers across the globe Availability of human resources has been identified as one of the key challenges for the chemical industry where the industry needs to develop the skillset first and then later face the challenge of retaining the talent in the organization. How do you address this for your organisation?

We operate in a large number of countries around the world. As an international Company the effective deployment of employees on a global basis is important for the continued development and success of Clariant.

We continue to invest in our people by implementing learning & capability development programs, providing September 2016 â&#x20AC;˘ 85

CEW Interview tailored continuing education and career pathing opportunities ranging from individual global training programs to leadership seminars to enhancing refresher training for our employees at the shopfloor.

Clariant in India aims to continue enhancing its exemplary sustainable standards, not only through products, services and performance, but also through integrity and behaviour. We also constantly engage with our employees to educate them on the importance of ensuring compliance across our standards.

For example: • Internet-based training modules on the topic of Preventing Bribery and Corruption to provide employees with a good understanding of the demands of anti-bribery and corruption laws.

• A performance driven remuneration policy structured to motivate employees, recognize their merits & achievements and promote excellence in their performance.

• The Whistle Blower Policy for employees to report to the management about any incidents of unethical behaviour, fraud or violation of Company’s code of conduct After tax, it is the feedstock & the high cost of power that every chemical manufacturer is concerned about in the country. In your view to what extent do these two parameters are deciding factor for the specialty chemical manufacturers to be globally competitive?

Chemical companies are increasingly working towards reducing energy intensity of their operations and diversifying their raw material base to include bio-feedstock. For chemical companies, availability of feedstock is one of the most critical criteria for setting up a production base. It is here that a lot of companies in India face a challenge.

86 • September 2016

Either the feedstock is unavailable or limited in the country. This is certainly hindering growth of the chemical sector.

However, feedstock is not necessarily a challenge for a specialty chemicals manufacturer, as the focus is more on R&D and innovative products for enduser applications.

Which are the key areas that still need to be addressed by the government, by the industry - holistically and by the organizations – within to take the industry to greater heights …and how?

Increasing global demand is most likely to result in increased production by low cost manufacturing locations of Asia Pacific. At present, India exports to most of the Asia-pacific countries and other developed countries of Europe and America. Going ahead, India’s exports is likely to increase further as many of the nearby countries don’t have competitive capacities and developed countries are likely to prefer India as a sourcing destination. India has a balanced IPR regime with good talent pool. Indian legal system is good and is expected to provide confidence to foreign investors.

It can act as REACH like legislation for safe use of chemicals for protection of human health & environment.

Establishment of PCPIRs is of immense importance for chemical industry as the policy is expected to attract major investments, both domestic and foreign for chemicals. Policies have been initiated to set up integrated petroleum, chemicals and petrochemicals investment regions (PCPIRs).

However there is a need for faster implementation of PCPIRs projects.

Additionally, there should be larger emphasis by the government on publicprivate partnerships for R&D.

These along with good labour laws, low R&D cost and also low cost of capital, could push India as a more preferred destination for setting up manufacturing units.

The government’s readiness to provide incentives for bio-based raw materials to reduce dependence on crude oil, encourage companies to seek “Responsible Care Certification” and facilitate priority loans to those who meet environment norms, has been a positive step towards enhancing the industry. The government is planning to expedite the consolidation of multiple legislations governing the chemical industry into one Integrated Chemical Legislation. This legislation should cover the entire life cycle of chemicals.

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