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Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
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VOL. 52 | ISSUE NO. 09 | SEPTEMBER 2017 | MUMBAI | ` 150
NEWS FEATURE
Industry News Technology News
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Renaissance of Petrochemical sector in NE India through RPI - Refinery Petrochemical Integration - by Pranjal Changmai , Deputy General Manager, Subodh Kumar, Deputy Manager, Tamagna Ghosh, Deputy Manager ,Roseleen Ahmed, Deputy Manager, Brahmaputra Cracker and Polymer Limited (BCPL)
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Smart Refineries – A Move into the Future, - by Mahesh Kendurkar, Engineering Manager – Instrumentation, Aker Solutions
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Experience of Carbon Steel in Petroleum Refinery- Asset Integrity Approach - by Chidambaram Subramanian, Officer Grade A (Metallurgy & Inspection), Inspection Department 30 Excel® Rejuvenation: DHT Unit Case Study with Asian Refiner - by Michael Martinez, Global HPC Technical Manager, Porocel Industries, LLC , Guillaume Vincent, HPC Business Segment Manager, Catalyst Recovery Europe S.A.
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Machine Learning – a holy grail in the next generation industrial automation revolution - by Michael Brooks, Senior Director, APM Business Consulting, Sunil Patil, Director of Business Consulting, Asia Pacific, AspenTech,
40
Challenges in Design and Engineering of Electric Heaters, - by Ritabrata Pramanik, Mechanical Engineering, Srinath NR Mechanical Engineering, Fluor Daniel India Pvt. Ltd.
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MARKETING INITIATIVE When others stop, Saurus939 carries on The vacuum pump unique in reliability, performance and consumption.
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A Place for Positive Displacement
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PRODUCTS EVENTS PROJECT UPDATE BOOK SHELF AD INDEX INTERVIEW
62 71 72 75 76
“Willingness of Industry to adapt to New Advancements in the field of CorrosionControl would ensure Safety and Long Life” Dr Vivkeananda Kain, Outstanding Scientist and Head, Materials Processing & Corrosion Engineering Division, BARC
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The Publishers and the Editors do not necessarily individually or collectively identify themselves with all the views expressed in this journal. All rights reserved. Reproduction in whole or in part is strictly prohibited without written permission from the Publishers. Jasubhai Media Pvt. Ltd. Registered Office: 26, Maker Chambers VI, 2 Floor, Nariman Point, Mumbai 400 021, INDIA. Tel.: 022-4037 3737 Fax: 022-2287 0502 E-mail: sales@jasubhai.com nd
4 • September 2017
Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
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Chemical Engineering World
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CEW Industry News DowDuPont Merger Successfully Completed Wilmington, USA: DowDuPont has announced the successful completion of the merger of equals between The Dow Chemical Company (“Dow”) and E.I. du Pont de Nemours & Company (“DuPont”), effective Aug. 31, 2017. The combined entity is operating as a holding company under the name “DowDuPont™” with three divisions – Agriculture, Materials Science and Specialty Products. Shares of DuPont and Dow ceased trading at the close of the New York Stock Exchange (NYSE) on Aug. 31, 2017. Beginning today, DowDuPont will start trading on the New York Stock Exchange under the stock ticker symbol “DWDP.” Pursuant to the merger agreement, Dow shareholders received a fixed exchange ratio of 1.00 share of DowDuPont for each Dow share, and DuPont shareholders received a fixed exchange ratio of 1.282 shares of DowDuPont for each DuPont share. “Today marks a significant milestone in the storied histories of our two companies,” said Andrew Liveris, executive chairman of DowDuPont. “We are extremely excited to complete this transformational merger and move forward to create three intended industry-leading, independent, publicly traded companies. While our collective heritage and strength are impressive, the true value of this merger lies in the intended creation of three industry powerhouses that will define their markets and drive growth for the benefit of all stakeholders. Our teams have been working for more than a year on integration planning, and -- as of today -- we will hit the ground running on executing those plans with an intention to complete the separations as quickly as possible.” “For shareholders, customers and employees, closing this transaction is a definitive step toward unlocking higher value and greater opportunities through a future built on sustainable growth and innovation,” said Ed Breen, chief executive officer of DowDuPont. “DowDuPont is a launching pad for three intended strong companies that will be better positioned to reinvest in science and innovation, solve our customers’ ever-evolving challenges, and generate longterm returns for our shareholders. With the merger now complete, our focus is on finalizing the organizational structures that will be the foundations of these three intended strong companies and capturing the synergies to unlock value. With clear focus, market visibility and more productive R&D, each intended company will be equipped to compete successfully as an industry leader.”
Evonik Opens New Plant for Specialty Silicones in Shanghai
Evonik’s growth strategy. We’re focusing on businesses with a clear orientation toward specialty chemicals and on powerful innovations to significantly increase the value of the company.” Organically modified specialty silicones form part of specialty additives. This is one of four growth engines in which the Essen-based industrial group sees above-average potential for growth and margins. Kullmann says: “Demand for specialty silicones has grown strongly over the past few years. China and its neighbouring countries are key markets for many applications. Thanks to the new plant, we will now be able to support our customers in the Asia region with even more speed and flexibility. At the same time we’ll be consolidating our position as the global market and technology leader for organically modified specialty silicones.” Evonik has been successfully operating in China for more than decades. With the takeover of the specialty additives business of Air Products at the beginning of 2017 and the opening of new plants in Nanjing, Evonik has once again significantly extended its activities in Asia.
Air Liquide Engineering & Construction and Mitsubishi Chemical Announced a New Partnership Frankfurt, Germany: Air Liquide Engineering & Construction has signed a cooperation agreement with Mitsubishi Chemical Corporation to license MCC’s Butene-to-crude-Butadiene technology used in the petrochemical ndustry .Mitsubishi Chemical Corporation (MCC) has developed this state-of-the art oxidative dehydrogenationtechnology of n-butene to produce crude Butadiene and verified the viability in a demonstration plant at MCC Mizushima, Japan. Butadiene is an important industrial chemical used in many day-today products, mainly as synthetic rubber for the automotive industry. Butadiene can also be used as a raw material for the production of products such as polymers, plastics and paper chemicals. Air Liquide Engineering & Construction can now offer its customers a unique integrated solution for both, butane dehydrogenation and butadiene extraction. This allows to extend the production of Butadiene from the conventional extraction from a Naphtha Cracker product to on-purpose production based on a wider range of feedstocks. Air Liquide Engineering and Construction is a worldwide recognised butadiene licensor with 37 references and it’s capabilities in custommade design and engineering of butadiene units have been recognized as a benchmark in the industry, providing production reliability, low energy consumption and product quality.
Shanghai, China: Evonik has started up a new plant in Shanghai, China, for production of a wide range of organically modified specialty silicones. The products, which are manufactured in batch processes, are used in, for example, polyurethane, paints, and coatings applications as well as in a variety of industrial applications.
Domenico D’Elia , Vice President and Chairman of Air Liquide Engineering & Construction, said , “Partnership with Mitsubishi Chemical Corporation is yet another important step to enhance our integrated offer in butadiene technology licensing. The combination of high-quality solutions in addition to our existing technology portfolio will create sustainable alternative production routes to our customers and create value over the long-term’’.
Christian Kullmann, Chairman of the Executive Board of Evonik, formally inaugurated the plant on September 5, in the presence of about 300 guests from the worlds of politics and business. On this occasion he said: “The plant is yet another important cornerstone in
Mitsubishi Chemical Corporation takes its position as one of the world’s top chemical companies and has a long history not only as a high quality petrochemical products manufacturer, but also as a licensor for reliable petrochemical technologies and a broad range of high performing catalysts.
8 • September 2017
Chemical Engineering World
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CEW Industry News New Ro Membrane Elements Impress in Practice Cologne, Germany: New reverse osmosis (RO) membrane elements from LANXESS with ASD feed spacers have undergone a trial in Germany’s largest industrial water treatment plant. More than 50,000 cubic meters of water are needed every day for pulp manufacturing at Zellstoff Stendal GmbH, Arneburg, and this is treated using reverse osmosis and ion exchange resins. The new grades impressed with their performance and consistently high level of rejection.Optimized for applications in brackish water, these Lewabrane-branded elements are characterized by very low energy consumption (LE = low energy) and high fouling resistance (FR = fouling-resistant). “The outstanding results of our ASD products in benchmark tests with other manufacturers at one of the largest pulp manufacturers in Europe once again underline the extraordinary quality of our products,” says Alexander Scheffler, responsible for LANXESS’s global membrane business. One year ago, Zellstoff Stendal launched a project to test LANXESS’s newly developed Lewabrane ASD range of membrane elements. This involved installing conventional reverse osmosis (RO) elements with a standard feed spacer and FR elements with LANXESS’s new ASD spacer in parallel in a single pressure vessel. Feed spacers are essential components for spirally wound membrane elements. They are made of polymer material and are optimized to ensure constantly good performance for a wide range of raw water compositions and various process parameters. The LANXESS spacers have a special “netting” that reduces biological growth and particle fouling by minimizing dead zones. The netting has an alternating strand design (ASD) of thin and thick filaments, which is what gives the spacer its name. Frank Gorges, plant technician for water treatment at Zellstoff Stendal GmbH in Arneburg, was excited about the result: “We were very impressed by the performance of the ASD membrane elements from LANXESS. We test a lot of products in our plant and hardly any of them have been able to provide such consistently high results throughout an entire year.”
Praj Recognised by IIMM for its Supply Chain Management Practices Pune, India: Praj Industries, a global process solutions company, has been recognised for its supply chain management (SCM) practices by Indian Institute of Materials Management (IIMM). Praj has been awarded the “Best Supply Chain Management Practices” in the large manufacturing sector category at the 4th Annual Awards held at Sheraton Grand Pune. IIMM is a national apex body representing a wide spectrum of professionals engaged in various facets of Material Management such as planning, sourcing, logistics & supply chain management. It has a network of 51 branches and 19 chapters and IIMM Pune is the oldest branch established way back in 1966. IIMM Pune started First Logistics and Supply Chain Management Awards in 2014 and these awards have gained widespread acceptability in India Inc. The 4th Annual Award recognizes an organisation that has demonstrated superior commitment, innovative strategic leadership and significant 10 • September 2017
supply chain management/logistics contributions within the industry. It had esteemed jury comprising industry stalwarts and they unanimously selected Praj for implementing effective supply chain management using powerful SCM solutions. Speaking on this development, Mr Pramod Chaudhari, Executive Chairman of Praj Industries said, “Innovation is the backbone of Praj’s operation, be it 2nd Generation Ethanol technology or processes including supply chain management. It is in the DNA of Praj to challenge ourselves and come up with newer ways of conducting business, and achieving better efficiencies in a competitive environment. Praj is happy to be recognised by the National Apex Body of Material Management for our practices in supply chain management. In the scheme of manufacturing, and especially in the case of Praj, supply chain management plays a pivotal role. In fact, it would only be fair to say that it plays a ‘strategic business’ role and that’s why SCM is being discussed in board meetings too”.
Ingersoll Rand launches Next Generation R-Series Rotary Screw Air Compressors in India New Delhi, India: Ingersoll Rand, a global leader in compression technologies and services, today introduced new models to its line of Next Generation R-Series oil-flooded rotary screw air compressors, which provide a more energy-efficient solution for customers with high capacity air requirements. The RS200 to RS250 models rotary screw air compressor will reduce energy cost by approximately 10% for large manufacturing facilities. The RS200 to RS250 models are available with the new, state-of-theart single-stage airend, or the two-stage airend that increases airflow by up to 16 percent. The new fixed-speed models are 10 percent more efficient compared to legacy products, while the variable speed option is up to 35 percent more efficient compared to the industry average. Commenting on the launch, Amar Kaul, Chairman and Managing Director, Ingersoll Rand India Limited said, “Around the world, businesses turn to Ingersoll Rand to redefine reliability and efficiency. The next generation R-series will help our customers do just that by delivering world class efficiency, increase uptime and deliver the right solution for operational excellence. The new series will enable our customers in India to be more competitive in the global environment by boosting their productivity with a state of the art airend that delivers as much as 15% improved efficiency and 16% greater airflow capacity. The IE3 premium efficiency motor will help deliver significant energy savings and the optional variable speed drive (VSD) will further decrease energy demands. With the launch of next generation R-Series, we continue to push the edge of innovation to help our customers achieve real business results, including cost reductions and lower total cost of ownership.” “The ability for these compressors to deliver outstanding efficiency without compromising reliability meets the increasing demands of industries to increase productivity while reducing energy use,” said Kevin Kosobud, Portfolio Leader, Oil Flooded Compressors for Compression Technologies and Services at Ingersoll Rand. “Our Next-Generation R-Series RS200 to RS250 models help customers increase overall Chemical Engineering World
CEW Technology News New Scrap Metal Detector Delivers High Sensitivity to Industrial Manufacturing Sites Minnesota, USA: Belt conveyor operators at mining, mineral, steel, cement and other industrial manufacturing sites can now install a new, highly-sensitive scrap metal detector designed to optimize production time, protect process equipment and reduce false alarm rates. The Thermo Scientific Ramsey Oretronic IV tramp metal detector builds upon the existing line of tramp metal detectors by increasing sensitivity for improved detection capabilities. Thermo Fisher designed the new detector to work with belt conveyors that move minerals, iron pellets, coal, aggregates and other bulk materials, to better detect all types of metallic scrap, including bucket teeth, manganese steel mantles, bore crowns, bar scrap, chains and tools. The increased sensitivity in the Oretronic IV detector allows it to identify tramp metal buried in wet conductive materials quickly and accurately. “Protecting expensive conveyors, crushers and other process equipment from damage is vital for owners of processing and manufacturing plants to avoid costly operation downtime,” said Paula Frisk, product manager, bulk weighing and monitoring solutions, Thermo Fisher Scientific. “With increased sensitivity in this newest tramp metal detector, manufacturers can feel even more confident that damaging scrap metal will be found before it causes equipment failure and profit loss.” The Oretronic IV tramp metal detector, which is available in two versions with two levels of sensitivity, includes a microprocessor based control unit, a receiver coil, a transmitter coil and a support frame. Additional features of the Oretronic IV tramp metal detector include: • Variable frequency, designed to allow the operator to adjust the frequency to eliminate interference and false alarms from motors, radios and other external devices; • A fiberglass support structure for coils that is resistant to moisture; • Advanced electronics with an LCD display, touch button keypad and new menu for easy setup, calibration and system use; and • Simple installation and easy upgrade from existing instruments in the Oretronic tramp metal detector line.
Inpro/Seal Raises Record Donation for Local Charity Rock Island, USA: The 30th annual Inpro/Seal® VIP Charity Golf Tournament raised a record $23,066 for Aspire, a non-profit recognized throughout the Midwest as a leader in providing bold, pioneering and uncompromising services to children and adults with developmental disabilities. This year’s donation is $3,000 more than last year’s record donation. One hundred twenty-eight Inpro/Seal customers, vendors and employees attended the Inpro/Seal VIP Charity Golf Tournament, held Monday, August 14 at Oakwood Country Club in Coal Valley, Ill., to raise money for this deserving local cause. The $23,066 donation was supported in part through a matching grant initiative by the philanthropic arm of Inpro/Seal’s parent company, Dover Corporation. The Dover Foundation helps to support not-for-profit organizations, causes and/ or projects that benefit the local communities in which its operating 12 • September 2017
companies are located. The Inpro/Seal family contributed to the cause through charitable giving, sponsorships and on-site events. “This year’s record-setting VIP Charity Golf Tournament saw the most attendees and largest donation in its 30 year history,” said Jim Coryell, Inpro/Seal Director of Sales – Americas. “It’s exciting to watch this event grow through the years and make a large impact in helping those with developmental disabilities.” Inpro/Seal has partnered with Aspire for the last six VIP Charity Golf Tournaments, raising more than $93,000 to support the non-profit’s enterprises, including Aspire Kids, Aspire Careers and Aspire Living. “We are so humbled and grateful to have the support of incredible partners like Inpro/Seal and Dover Corporation,” said Jim Kales, CEO of Aspire. “This record-breaking check will help hundreds of kids and adults with developmental disabilities to get the therapy, job training, and life skills they need and deserve.”
B e C a r e f r e e t h i s M o n s o o n w i t h G r u n d fo s Dewatering Pumps Chennai, India: Over the last few years, the monsoons are getting more intense and unpredictable. Due to the rains in the different parts of our country, many cities, towns and rural areas are experiencing extreme water logging, flooding and power cuts. In addition to the heavy rains, lack of efficient water and wastewater management systems is another key reason for this water logging issue. It is therefore important to be equipped with the right pumping solutions to help during such situations. Grundfos India, the leading manufacturer of intelligent & efficient pumping technologies, has the ideal solutions for the monsoons. Grundfos’ reliable dewatering pumps, DPK and DWK, aim at easing the way of life while restricting the economic losses. These compact submersible pumps can dewater effectively. DPK & DWK can be used not only in homes, offices, gatedcommunities but also at construction sites, excavations, tunnels, underground parking, industrial drainage pits, and more, hence making it a perfect solution for all the water logging and drainage related issues during the monsoons. The DPK and DWK range of dewatering pumps are conceptualized and engineered after going through many levels of stringent tests. They come with intelligent features such as Built-in bi-metal sensor that protects against overheating of the motor Pump performance is unhindered by sand or other abrasives is required, or if the available power supply is limited Combining installation flexibility with reliability and ease of service Speaking about Grundfos’ dewatering pumps, Shankar Rajaram, Vice President – Business Development, Grundfos India said, “Indian monsoons are becoming more unpredictable every passing year. It is therefore essential to be proactive in addressing issues such as water logging by being equipped with the right pumping solutions. Grundfos range of dewatering submersible pumps are designed to work optimally in such environments. These pumps are easy to install and service and therefore are a perfect solution for both commercial and domestic customers”. Chemical Engineering World
CEW Features
Renaissance of Petrochemical sector in NE India through RP Petrochemicals and refineries continues to grow in close co-operation and focus is on maximizing the synergies between the two technologies. In view of spiraling availability of the crude oil, associated-gas and Refineries, it has become almost inevitable to look for value-added opportunities to be integrated with the already existing upstream facilities through Petrochemical integration. With the advent of high-edge competitive market, price volatility of feedstock and products, and more stringent environmental regulations impacting the operating costs, it is necessary to identify and capture opportunities for more profitability through RPI which will moderate the risks related to raw materials while reducing the carbon footprint substantially. This article evaluates the level of integration achieved through BCPL, a key-driver in the petrochemical sector and the future potential of integration of refinery and petrochemical businesses bringing renaissance in NE India.
W
ith outbreak of economic crisis in 2008-09 due to drastic change in crude oil prices, the refineries which are operating their plants at modest capacity and low operating margins have incurred losses in their profit margins. The idea of integration emerged for a desire of higher profitability in the competitive market and Experts and Researchers put their innovative ways to squeeze out costs and capture new opportunities to take advantage of close proximity to low-price feedstock source to make cost effectiveness in the result of Refinery and Petrochemical Integration. Taking into account the risks associated with setting up a petrochemical in integration with refinery in North East India, it is imperative that the viability of the project be sufficiently ensured. This requires (i) reducing the level of investment (ii) confirmed feedstock availability at moderate price (iii) competitive finished product pricing considering remote location of the plant. The petrochemical business being cyclical in nature, the project financials must be sound enough to absorb the polymer price fluctuations. The per capita consumption of plastic in the North-Eastern region is ~2.8 kilogram against a national average per capita consumption of ~9.7 kilogram, and global consumption of ~28 kilogram. Until
16 • September 2017
recently, the entire NE region accounted for a share of around 9 percent of the polymer consumption whereas it has a share of 23 percent of the Indian population. Settingup of BCPL has provided the NE region the necessary fillip in feedstock sourcing in the polymer processing sector along with increased growth in End-user industries which would propel the growth of plastics in North-East India further. BCPL-A result of RPI in NE India Considering the geographical remoteness and logistics constraints in NE region- a collection of 7 sister states connected with mainland of India through a “Chicken-Neck”, the dream of BCPL came into reality with the help of integration with the major players in Hydrocarbon sector in NE India. Natural gas from OIL & ONGC, Naphtha from NRL, if provided with moderate prices will give a strong economic advantage to BCPL in turning Natural gas and naphtha into intermediate chemicals and an array of finished polymer products. Integrative optimization of BCPL OIL, the main supplier for Natural Gas to BCPL, had taken steps to augment its natural gas production potential in Assam. The terminal gas production potential has been already increased and with the commissioning of the BaghjanMadhuban gas pipeline, and substantial amount of associated natural gas is
being monetized. Potential is also being explored for using of condensate byproduct of the LPG Recovery Plant as a cracker feed in BCPL. Further, possibility of utilizing the vented CO2 from BCPL Gas Sweetening Unit is being explored for the oil well blanketing which will help to lower down the global warming. The C2 and C3 components present in natural are recovered in the Gas processing unit, in BCPL, with C2+ Recovering technology, and the “lean natural gas”, containing almost 99% methane is sent for use in downstream fertilizers. This lean gas can be used as a fuel replacing naphtha and fuel gas in both petrochemicals and refineries. Also, the additional saved naphtha can be used as a feed stock in Cracker unit for petrochemical complex. What remains to be seen is that how the next decade will be different for the petrochemical and plastic industry from other previous decades as it relates to the prominence of these raw materials? Propylene Integration Existing Refineries are planning to recover Propylene by proposed Propylene Recovery Unit along with the upcoming INDMAX FCC Units for increasing LPG Production. The process has been optimized to enhance propylene yield from reduced crude oil lighter Chemical Engineering World
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CEW Features Py-Gas followed by benzene saturation of C6 streams to convert benzene to cyclohexane. This resultant HPG is expected to meet a benzene specification of 1 Vol % (max) and Sulphur less than 10 ppm by weight, with a RON and MON value of ~95 and ~82 respectively, so as to blend it with Motor spirit. A Butene-1 plant is proposed to be set up in BCPL for catering the needs of the Polymer Unit (PE Plant) with a typical ethylene dimerization process. The byproduct of this plant will be a C6 rich stream, which may be used for blending with MS in the nearby refineries.
Figure 1: Proposed/ Existing integration at BPCL Complex Integration
fraction, with approximately 12-27% of the feed getting converted to Propylene. The heavy petroleum oils and low-value residues will be converted into high yields of propylene, ethylene and butylenes etc. In existing facility LPG produced in FCCU is mainly used for domestic purpose as a fuel. This future modification will enhance propylene indirectly contributing to mitigate the higher demand of polymers.
directly used as MS blend component due to high Benzene content. Also the inherent characteristics of HPG being carcinogenic and prone to adulteration in MS, a long term solution for safe and convenient evacuation of HPG is required. Looking into this, a Second stage hydrogenation plant of Pyrolysis-Gasoline is proposed, which will hydrogenate the
New RPI based development concepts which are continuously growing-up need to be assessed, analysed and evaluated properly based on its potential and through CBA-cost benefit analysis. Anyhow, what is stated in this article clearly shows that there is potential for achievement of positive synergies between NE Oil &Gas players through RPI. Conclusions: The main driving force for RPI is to enhance profit knowing that this integration is no longer a theoretical postulate and has already materialized
Refinery Off-gas integration Refinery off-gas generally contain heavy hydrocarbon which is almost greater than 30 mole% C2. Refinery off-gases from different units of refinery may be used to extract petrochemical compounds like ethane, ethylene, propylene, butanes and propane etc. But it may not be cost effective for some time as the processing of such gas involves higher operating cost in comparison to the price of associated / non associated natural gas. Future Butene-1 and HPG integration Hydrogenated Pyrolysis Gasoline, a byproduct at BCPL, is unsuitable to be 18 • September 2017
Figure 2: Recovery of Propylene from ICCU LPG Integration Chemical Engineering World
CEW Features
Figure 3 : Proposed Butene-1st & 2nd stage PG hydrogenation integration
in the Industrial practice in India resulted in enlarged profits bringing down the doubts, but it is still unexplored that to which degree of new integrations this RPI will be economically viable. In a country like India this viability has been calculated as a mixture of socio-economic interests keeping in mind that Technoeconomic feasibility and price forecasting for valorizing of exchange streams to the highest possible degree is important for increasing the overall revenues for the refinery-petrochemical integrated complex. BCPL is the latest addition to RPI in the NE region of India, will prove to be a potential game-changer in shifting the focus of plastic industry to eastern states of India and become the hub for future growth. BCPL being the only mega Petrochemical Industry in the entire NE region, it is expected to bring a renaissance in the polymer sector in NE India. With raw material readily available, numerous downstream polymer industries will be set up in the region, and polymer consumption will also rise. A plastic park in the nearby region is also coming up, for facilitating 20 • September 2017
entrepreneurs for setting up new polymer industries. It is expected to house around 256 downstream plastic industries, and to market the products in South-East Asia including Myanmar, Bangladesh and Bhutan. Indian petrochemical industry has unrealized potential and latest studies indicates that with adequate support from government and growth in end use demand, the market for plastic processing industry in India is expected to grow at a CAGR of 10.5% from FY15 to reach 22 MMTPA by FY20. Polymer import dependency remained high at 32% in 2015-16 and is expected to come down in next two years to ~30%. India’s petrochemical industry, like the overall economy, faces near-term challenges, but the long-term growth outlook for the industry remains positive through refinery-petrochemical Integration.
Authors’ Details PRANJAL CHANGMAI Deputy General Manager, BCPL E-mail: pchangmai@bcplindia.co.in
SUBODH KUMAR Deputy General Manager, BCPL E-mail: subodh@bcplindia.co.in
TAMAGNA GHOSH Deputy Manager, BCPL E-mail: tghosh@bcplindia.co.in
ROSELEEN AHMED Deputy Manager, BCPL E-mail: rahmed@bcplindia.co.in
Chemical Engineering World
CEW Features
Smart Refineries – A Move into the Future Smart automation systems in refineries provide immense advantages over conventional automation, which is used only for operational control and safety of the processing units. The article will focus primarily on the need for smarter systems in today’s refinery industry. It will give an insight into some valuable smart features and their benefits, including enhanced production and efficiency. With continuous technological advances and increased emphasis on digitalization and the Industrial Internet of Things (IIoT), the nature of automation systems is changing very fast. The article will also address future trends in smart automation that could prove beneficial to the refining industry.
E
ngineering organizations play a vital role in the concept finalization, selection and engineering of such systems in refineries. It is critical that they remain updated on the latest developments in order to suggest the best and most future-ready options to their clients. The Need of the Hour The evolution of smart instrumentation changed the concept of automation in the process industry decades ago. With continuously increasing market competition, refineries find it extremely necessary to make refinery automation smarter and take it to the next level of technical superiority. Smarter refineries are no longer a vision of the future but the need of the hour. What is ‘Smart’? Conventional automation systems in refineries consist of basic process control systems (BPCS) and safety instrumented systems (SIS). They handle the control, monitoring and safety of refinery processes. The BPCS acts as the first layer of protection and takes care of all monitoring and control of process parameters. If the BPCS is not able to control process behavior, SIS shifts the process to safe mode by initiating and executing shutdown actions. Nowadays the expectations from smarter automation systems are not limited to 22 • September 2017
control, monitoring and safety of the plant. A combination of smart engineering, smart operations and smart maintenance make the operation of new refineries significantly safer and more efficient.
Minimizing Downtime Smart instrumentation and automation systems play a very important role in reducing unscheduled production downtime.
Advantages of Being ‘Smart’ Employing a state of the art smart instrumentation and automation system is critical in making the refining industry safe, reliable, profitable, predictable and environmentally friendly. Smart instrumentation and automation systems add features like increased diagnostic data, increased predictive maintenance capabilities, operational ease and flexibility to control the process, reduced commissioning time, ease in troubleshooting and many more. They also offer immense operational advantages like maximizing refinery production, minimizing downtime, enhancing efficiency and improving energy management. Maximizing Refinery Production Maximizing throughput is always the ultimate goal of all refinery operations. Needless to say, smarter automation helps in bringing down wastes in the processes, predicting production profiles and stabilizing production. Smart systems help operators in performing many advanced calculations easily, enabling the fine tuning and early stabilization of processes.
The failure of rotating equipment like pumps, motors, and compressors can severely affect plant production. To prevent this, there has been a paradigm shift away from reactive maintenance and towards predictive maintenance. Advanced smart sensors and instrumentation and health monitoring systems for large machines are considered as key factors in deciding predictive maintenance requirement, thereby reducing the probability of an unexpected shutdown. Enhancing Efficiency Efficiency in refinery processes is nothing but maximizing the gain in the process while continuing with the same input conditions. Many smart applications in automation systems help operators in enhancing efficiency. The most critical is the use of advanced process control (APC), which is deployed over basic process control to improve efficiency. APCs help operators to operate the process or equipment close to its controllable limit, thereby increasing Chemical Engineering World
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CEW Features throughput. They enable the efficient handling of process disturbances, increased understanding of process dynamics, and prediction of process behavior. There are many complex process units like reformers, crackers and cokers, where optimizing control manually based on the operator’s knowledge and experience becomes challenging. In such complex situations, adopting APCs can significantly improve efficiency. The most commonly used APC technique is multi-variable control, which uses predictive control based on process dynamic models to improve output. Efficiency enhancement using such APCs has now become an inherent feature of most of smart automation systems. Energy Management Enhancing energy efficiency is another important advantage offered by smart automation systems which has a direct impact on profitability. Energy is one of the biggest expenses in a refinery, often constituting up to 40 percent of the running cost. Smart process designs compounded with smart automation systems help in conserving energy, reusing energy or utilizing waste to generate energy. Some examples of such methods include utilizing flue gases, utilizing the enormous heat generated by exothermic reactions for steam generation and power generation. Smart Applications in Automation Systems Continuous research and development in automation has resulted in developing many smart applications and tools. This has enabled the refinery industry to convert the benefits mentioned above to reality. While there are a number of applications that can make systems smarter, a few important ones are explained below. 24 • September 2017
Alarm Management Systems Alarm management forms an important layer of protection between the BPCS layer and the emergency shutdown system (ESD) layer wherein process upsets are managed by refinery operators to prevent the process being safely shut down by the ESD systems. Better alarm management puts less stress on the ESD system. It is often said that it is very easy to add alarms during process or safety reviews, but extremely difficult to manage them in control rooms. This is because alarm flooding, where more alarms go off than a human operator can effectively respond to, can happen in no time. In this situation, operators find it almost impossible to decide priorities and subsequent actions to control the behavior of processes in the refinery. It is in situations like this that alarm rationalization and alarm priorities become critical. Alarm management is actually an application of human factor engineering in automation systems. It enables operators to handle abnormalities in an effective way so that plant shutdowns and equipment damage are reduced. Advance Process Control (APC) In the past, APCs in refinery units used to be a costly affair, complicated and difficult to maintain. As a result, many such systems were turned off within a few years of commissioning. With technological advances, APC tools are now available at a competitive price and are operator friendly with no additional hardware and software. APC applications enable many features like multi-variable predictive control, optimized tuning of proportional–integral–derivative (PID) controllers and dynamic feed forward control which help in enhancing efficiency. Increased production due to efficiency improvement and enhanced operational excellence are the main benefits of using smart applications like APCs in a refinery.
OPC (Object Linking and Embedding for Process Control) Open platform communication has become one of the most important smart features in refinery automation systems. It entails the real-time communication of plant data between systems of different manufacturers. Although refinery processing units have one common automation system, there are several large mechanical packages which require independent systems. Operators can monitor all the plant data better through a centralized automation control system. This integration of discrete automation systems with the main system is often done through OPC technology. This smart feature enables the integration of alarms and events from the control systems of different packages into the main refinery automation system without significant engineering effort. Inventory Management Effective inventory management cannot happen without a smart automation system. Most of the leading automation system manufacturers, therefore, have developed specialized tools and smart applications for tank farm management systems and terminal automation systems. Refinery managers are dependent on reliable, accurate, real-time inventory information. Smart inventory management systems can accurately detect the deviation between actual production and exported material, which can have a significant economic impact. Intelligent inventory management systems also offer other advantages like tank inventory calculations and the status of loading / unloading pumps and valves. The huge inventory of hazardous and flammable products in refineries can also pose a threat in terms of human safety, asset loss and environmental damage. Hence smart, reliable and accurate inventory management becomes a necessity in refinery operations. Chemical Engineering World
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CEW Features Future Trends in Smarter Refineries Smart Wireless Instrumentation Smart wireless instrumentation is not a new technique in the refinery industry. However the use of wireless instrumentation is currently limited to the monitoring of non-critical parameters. With the fast changes in technological developments, we can expect to see rapid growth in the use of smart wireless instrumentation even for control applications. Going forward, wireless instrumentation will constitute a large section of refinery systems. IIoT in Refineries In many industries, the investment in Industrial Internet of Things (IIoT) is growing exponentially, and refinery automation is no exception. An enormous volume of data is generated by smart instruments and smart automation systems in refineries. This is collated, visualized and analyzed for overall operational benefits. Since the late 90s, the number of hardwired input/outputs (I/Os) in a refinery has approximately doubled, which gives an idea of the growth in the quantum of instrumentation as well. The growth in I/Os is predicted to be close to another 100% in the next decade. This shows the immense importance of techniques of data handling and analysis tools in refineries. With the decreasing cost of networking, connectivity and data storage, IIoT will play an important role in future refinery operations. The advantages of IIoT in a refinery are countless, and include increased profitability, agile process control and a reduction in operating cost and reduced downtime. Increased usage of IIoT may facilitate the use of smart phones and tablets by refinery operators in future. Cloud technology can be used which requires only a browser and internet access 28 • September 2017
to connect from offsite or to share information. However, it is critical to note that cyber security may pose a hurdle in setting up such innovative smarter refineries. There are hardly any known standards for cyber security in refineries, but with an increased use of IIoT, it will become an inevitable part of successful refinery operation. Role of Engineering Companies in Implementing Smart Refineries Engineering companies play an important role in implementing a smart refinery during the basic and detailed engineering phases, which form the foundation of a refinery’s lifecycle. In consultation with all stakeholders, engineering companies are responsible for defining the concepts of smart instrumentation and smart automation systems for the refinery under development. The company outlines the project definition, design basis and smart features of the automation system in the first phase. This is in alignment with the client’s expectation and taking into consideration recent industry trends to maximize the benefits of the latest technological developments. These concepts are further developed and implemented in the engineering phase. In the engineering phase, engineering companies conventionally manage the complete procurement lifecycle of smart automation systems, including requisitioning, technical bid evaluations and vendor drawing review. They generate all engineering deliverables which form the basis for implementation of Smart Automation systems throughout the project. Conducting studies and workshops for alarm rationalization and defining alarm priorities for implementation in the automation system also falls under the scope of the engineering company. Aker Solutions has recently executed complex refinery units such as a crude
distillation unit, sulfur recovery unit and vapor recovery unit, as well as polymers and olefins projects, which use smart instrumentation and smart automation systems. Various smart features like APC, alarm management, inventory control, energy efficiency and OPC were specified and implemented in the engineering phase. For a few projects, wireless instrumentation was selected for pump seals, vibration monitoring and for monitoring process parameters like pressure, temperature, flow on all lines at the battery limits of process units. This significantly increased diagnostic capability while reducing the cost. Machine monitoring systems (MMS) were implemented on many projects to determine the health of big rotating machinery. Another smart feature used on the projects is the use of two out of three (2oo3) initiators for safety systems like ESD. This system, which requires input from two out of three sensors, was implemented as a philosophy on many projects. This ensures increased reliability of the safety system and helps avoid spurious trips which can cause production loss. Such engineering efforts are the backbone of smart refining operations for later phases of a refinery lifecycle. It must be acknowledged that smarter instrumentation and automation systems are the need of the hour and will be increasingly integral to refinery operations. With significant advances in technology on an almost daily basis, smarter and more sophisticated systems will be developed to make refineries safer, more profitable, more predictable and more environmentally friendly. Authors’ Details Mahesh Kendurkar Engineering Manager Instrumentation Aker Solutions Chemical Engineering World
Beda_AP_15 Dec 14.indd 1
12/10/2014 1:41:53 PM
CEW Features
Experience of Carbon Steel in Petroleum RefineryAsset Integrity Approach Large number of static equipments fabricated by variety of carbon steel class of grades for chemical, petroleum, petrochemical, power and utility industries. Although third generation High Entropy Nano Composite Steels (HEC Steel) and composite materials were developed recently, still carbon steel is candidate material for pressure vessel, boiler, concrete structures and pipes etc. The author claims his own experience with carbon steel material selection, fabrication, corrosion, testing, characterization and evaluation. Few case studies with carbon steel were presented in brief for validating material suitability in petroleum and power industry. The weldability and welding process were also discussed in brief with respect to repair procedures of static equipments made of carbon steel
Static Equipments Material Requirement As far as petroleum industry is concerned the material behavior with respect to chemical resistance in various service conditions like atmospheric, salt water, sour water, boiler steam, acid handling, petroleum processing and petroleum products is considered important for material selection. The weldability of chosen material is another important factor with respect to fabrication of all static equipments by various welding techniques. Material selection plays a vital role for static equipments which undergoes repair and replacements during turn around. Fundamentally material selection and design is specified in various codes and standards which clearly define specifications for large number of petroleum industry applications. American Society of Mechanical Engineers (ASME)-Boiler and Pressure Vessel codes (BPV), National Association of Corrosion Engineers (NACE), Indian Boiler Regulations (IBR), Oil Industry Safety Directorate (OISD), American National Standard Institute (ANSI) and American Petroleum Institute (API) were different codes specifies procedures for construction of equipments, procedures for in service inspection and procedures for inspectionduring shut down after several years of refinery processing. The length of any hydrocarbon or steam fluid services in static equipment without degradation and deterioration depends on material selection and fabrication. The factor of safety is considered important factor for design which prevents static equipments from unpredictable causes. Prior history and its empirical data, experience and judgment based on industry data are major factor 30 • September 2017
contributing to factor of safety. Equipments design against static loads in refinery may subject to dynamic loads due to various engineering reasons like induced & applied stressors, damping and vibrations. All codes and standards design against dynamic conditions with superimposing dynamic loads on static loads for specified conditions. Carbon Steel Candidature Among various classes of steels, carbon steel is most used material for construction of petroleum refinery static equipments like pressure vessel, columns, boilers, heat exchangers, condensers and pipelines. The carbon steel is candidate material of concrete structures for withstanding heavy loaded Liquefied Petroleum Gas (LPG) mounded bullets supports, crude & refinery products storage tanks bottom supports and column & pressure vessel fire proof supported structures. Almost 98% of refinery equipments constructed from different grades of carbon steel. The various advantage of using carbon steel in refinery equipments is low cost, intermediate corrosion resistance, availability, easy to recycle, excellent weldability, erosion resistance, oxidation resistance at intermediate temperatures etc. Elements
% Atomic weight
Iron
99.18 – 99.53
Carbon
0.08 – 0.13
Manganese
0.30 – 0.60
Phosphorous
0.040 max
Sulfur
0.050 max
Table 1 shows chemical composition of carbon steel 1010 grade
Also carbon steel shall be used up to 450 deg C high temperature service conditions and -29 deg C low temperature service conditions. Various classes of carbon steel grades available and with ranges of alloying compounds like manganese, silicon, phosphorus and sulfur specified. One such carbon steel chemical composition 1010 is shown in table 1. The steels supplied in various forms like plate, pipe, structural bars, wire rod, sheet metal, galvanized steels, pre-stressed rods & bars for refinery static equipment construction and repairs. Brief Examples in Refinery The corrosion is multifaceted phenomena generally depends on steel composition, service fluid, velocity, flow rate, temperature, environment conditions, metallurgical structure, stress applications etc. As shown in figure 1 large amount of energy spends on iron oxide to producing single ton of steel which revert back to original configuration i.e. formation of iron oxide on carbon steel plate, pipe, tube, vessel of refinery static equipments after certain time frame. Every codes and standards ensures safe life design philosophy for all specific cases of refinery processing. The carbon steel undergoes various forms of corrosion specific to refinery processing units. Although carbon steel is sufficient material used for general utility piping certain conditions like non draining structures and dead ends in pipelines will severely affected by corrosion before design life due to stagnant conditions irrespective of service and environments. In specific cases like boilers although design life is higher, IBR specify mandatory material evaluation Chemical Engineering World
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CEW Features
Figure 1: Figure1 shows Uniform corrosion, Pitting corrosion, Cavitation damage, Stress Corrosion, Hydrogen Cracking of Static Equipments made of Carbon steel. Top Centre shows Life Cycle of Carbon steel
and assessment for every 8800 hours of operation approximately every year. After several hours of boiler operation if any flaw detected shall be evaluated under scope of fitness for service. The detected flaw were recorded and inspected every year generates specific data of flaw characteristics in extended time frame. The generated data’s and detailed inspection further increases confidence for full proof structural integrity of boilers. Other examples like LPG mounded bullets and storage tanks were one among static equipments subjected to full proof structural integrity. Another classic example of corrosion in refinery is distillation column overhead pipeline made of carbon steel and corrosion resistance is ensured by altering the service environment (corrosion inhibitor). Figure1 shows Uniform corrosion, Pitting corrosion, Cavitation damage, Stress Corrosion, Hydrogen Cracking of Static Equipments made of Carbon steel. Top Centre shows Life Cycle of Carbon steel The Cavitation damage in steam drum and steam pipes of boiler grade steel were designed with superimposing dynamic stress on static load. Biological stability of material is another important requirement for material selection in refinery, because of hydrocarbon processing contains sulphur and dissolved oxygen gases which produce bacteria on material while in operating or in stagnant conditions. Although carbon steel is less resistant to biological degradation, carbon steel pipe or plate with internal coating is highly resistant. Prevention of equipments from general atmospheric corrosion lasts 32 • September 2017
for many years by painting and coating with few micron layers on exposed industrial atmosphere. Therefore with proper selection and design based on qualitative and quantitative assessments the various grades of carbon steel is candidate material for refinery static equipments. Repairs and Replacements NACE specifies various forms of corrosion tests of material subjected to corrosive service like sour gas, amine and high total acidic number crudes. If in case flaw were developed beyond the code and standards accepted criteria permanent repair procedures were employed. Repair procedures of carbon steel constructed static equipments are less complex than other grades of high alloyed steels. Repair and replacements in static equipments made of carbon steel is comparatively easier than any other material grades. Repair arises due to various causes like low wall thickness, pitting corrosion, erosion, and oxidation damage from crude refining processing conditions. In major cases, static equipments was carbon steel cladded with higher grade materials like stainless steel for corrosion resistance rather than constructing whole equipment from higher grade which is economically cheap and viable for refiners. NACE specifications for corrosion coupon which monitors corrosion rate in refinery equipments are also made of carbon steel available in round and flat shaped specimens. The corrosion coupon installation is major corrosion monitoring technique for service
water, steam, sour water and distillation column overhead services which provides a result corrosion rate less than 1.5mpy (miles per year) after appropriate process design conditions. Several Non destructive testing like ultrasonic thickness gauging, profile radiography are useful for evaluating remaining wall thickness, corrosion coupons provide a process related remaining wall thickness. Gas tungsten arc welding and shielded metal arc welding were mostly employed welding techniques for repairs and replacements made of carbon steel. Heavy wall thick pipe may employed by submerged arc welding process technique. The welding of carbon steel is complex phenomena and structural integrity of equipments directly depends on quality of weldments. The electrode and filler wire for welding carbon steel is equivalent material. The structural integrity directly depends on welding quality and workmanship. The welding of carbon steel is complex in nature due to difficulties in achieving homogeneity of welded sections adjacent to original base metal. Therefore design considerations were taken into account to avoid any kind material failure due to non-homogeneity. The carbon steel suspected hydrogen induced failure which shall be controlled by pre heating before welding. The homogeneity shall be achieved by post weld heat treatment near to base metal. Cumulatively, welding process includes pre heating and post weld heat treatment for ensuring quality assurance. Some Non destructive tests (NDT) like radiography, magnetic particle inspection and ultrasonic flaw detector were quantitatively measure flaws in weld joints of carbon steel. The hardness is only mechanical property of material measured for carbon steel structures, vessels, pipes for field joints of static equipments. The hardness shall vary from 120 BHN to 200 BHN (Brinell hardness number) irrespective of any grade of carbon steel fabrication.
Authors’ Details Chidambaram Subramanian Officer Grade A (Metallurgy & Inspection) Inspection Department Chemical Engineering World
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CEW Features
Excel® Rejuvenation: DHT Unit Case Study with Asian Refiner Recent developments in rejuvenation technology enable activity recovery near fresh levels. By combining high activity rejuvenated catalyst with comprehensive top bed grading packages refineries are meeting stringent low sulfur diesel targets and achieving substantial cost savings. Through careful analysis of the feed and operating conditions, high activity rejuvenated catalysts can be installed with no impact on performance in a wide range of hydroprocessing applications. This article focuses on the commercial application of Excel® rejuvenated Type 2 CoMo catalyst in an Asian refiner that has observed equal performance to fresh catalyst while benefitting from reduced fill cost.
C
onventional regeneration is a wellaccepted industrial process used to restore catalyst activity to 60 - 85% of fresh. The temperatures applied during the regeneration process effectively convert the active sites back to metal-oxides while removing carbon and sulfur. However, the exposure to high temperatures can cause sintering of the active metal sites and formation of agglomerates in the crystal structure such as CoMoO4 and NiMoO4, which inhibit full sulfiding of the metal oxides. Traditional rejuvenation is a proven method to redisperse the active metal sites and increase the HDS and HDN activity beyond conventional regeneration. However, the rejuvenation technologies available to date have limited their application to select catalyst grades. Excel® rejuvenation technology expands the range of hydrotreating catalysts across all major manufacturers and consistently restores relative volumetric activity (RVA) to about 95% for Type 2 and about 100% for Type 1 catalysts of their initial activity. This patented process gives refiners an excellent alternative to fresh catalyst in a wide range of hydrotreating applications from naphtha through heavy gas oil. Excel® rejuvenation can be performed on the refiner’s catalyst as a post-regeneration process. First, Porocel evaluates the spent catalyst to ensure only high quality uncontaminated catalysts are selected for rejuvenation. Catalyst chemical and physical properties are evaluated after regeneration and again after rejuvenation to confirm adequate activity. The two-step process consists of an initial thermal regeneration to remove carbon and sulfur followed by a proprietary chemical 34 • September 2017
Porocel® has developed its own HPC kinetic model based on extensive in-house pilot tests in order to simulate hydrotreating unit’s performance. Extensive technical support from startup through the end of cycle is included with all catalysts sold to ensure refiners achieve maximum performance including:
treatment, which re-disperses metals and restores/stabilizes active sites for maximum activity. The process is applicable to Porocel regenerated catalysts or other brands, and can be performed at all of Porocel’s facilities in North America, Europe and Asia. Up to date, Excel® rejuvenated catalysts have been loaded in many hydrotreating applications, worldwide, as Full Reactor Load (FRL) or as stacked beds, namely: • • • • •
• Complete design of reactor catalyst loading • ─Catalyst performance projections based on refinery process conditions • Review of start-up procedures with the refiner • On-site technical support during loading and activation • Troubleshooting • Unit monitoring during the cycle • Performance warranty
─ Diesel Hydrotreating Units (DHT) ─ Naphtha Hydrotreating Units (NHT) ─ Ultra-Low Sulfur Diesel (ULSD) ─ Cat Feed Hydrotreating (CFH) ─ Re-refining for lube oil production
Commercial Experience
Durocel-M1 CatGuard® PMT-20 Excel® Type 2 Catalyst 18 MT Durocel-222 Quench Zone
Excel® Type 2 Catalyst
D-86 D-886
Rx
Feed: 70% SRGO/30% g/cc °F °F
psi
0.85 664 718
290
50 MT
Durocel-222
. profile and process conditions of DHT Unit loaded with Excel® Type 2 CoMo catalyst in Asia. Figure 1: Loading
.
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CEW Features Table 1: Asian refiner DHT performance with Excel® Type 2 CoMo catalyst.
SOR Performance SOC WABT °F (°C) 653 (345) Exotherm °F (°C) 14 (8) Cetane Uplift 2.0 Product Sulfur ppmw 400 – 450 Product Nitrogen ppmw 50 – 60 Guaranteed Parameters Product Sulfur ppmw ≤ 450 Cycle Length Months ≥ 26 Table 1: Asian refiner DHT performance with Excel® Type 2 CoMo catalyst
Full Reactor Loads (FRL) of high activity regenerated and/or Excel® rejuvenated catalysts drawn from Porocel’s inventory combined with CatGuard® grading materials and ceramic bed supports (Durocel-222) are well suited for use in most units to meet your expected cycle length and product specifications. Up to date, Porocel® can supply the following top bed grading to maximize the cycle length of the hydrotreating unit: • Durocel-M1: Inert ceramic medallion offering better flow distribution • CatGuard® PMT-20: NiMo catalyst offering mild HDS/HDN activity to control hydrogenation of reactive components and mitigate pressure drop issues • CatGuard® PMT-21: NiMo catalyst specially designed to trap silicon while offering mild hydrogenation • CatGuard® PMT-30: NiMo catalyst specially designed to trap Nickel/ Vanadium from heavier feedstocks • CatGuard® PMT-40: NiMo catalyst specially designed to trap Arsenic Porocel’s FRL approach allows refiners to realize significant catalyst cost saving and decrease the quantity of hazardous waste generated, versus installing 100% fresh catalyst. Porocel’s Excel® rejuvenation technology has been installed commercially and demonstrated high activity and robust stability. A full load 36 • September 2017
of Type 2 CoMo catalyst was rejuvenated with Porocel’s Excel® technology and combined with CatGuard® top bed grading catalysts in a Diesel Hydrotreating (DHT) unit in Asia (Fig. 1). The unit processes a blend of 30% light vacuum gas oil (LVGO) with straight run diesel (SRGO) in a challenging service with high throughput (LHSV =1.5 hr-1) and low inlet pressure 20 barg (290 psig). The primary objective of the hydrotreater is to produce low sulfur diesel, targeting a product sulfur of 450 ppmw. Porocel worked closely with the refiner to design a catalyst load incorporating high activity Excel® rejuvenated catalyst to meet all unit objectives. The Excel® rejuvenated catalyst is outperforming the fresh Type 2 CoMo catalyst loaded in the previous cycle and the actual performance of the DHT unit loaded with Excel® rejuvenated Type 2 CoMo is summarized in Table 1. After 6 months on stream, the Excel® rejuvenated catalyst is exhibiting excellent stability despite the low unit pressure and heavy feed blend. A plot of normalized WABT vs Days on stream is presented in Excel® rejuvenated catalyst is giving the refiner the expected performance, while enabling substantial cost savings versus loading fresh catalyst. The Asian refiner by using Porocel’s FRL has saved approximately 450,000 USD (or
400,000 EUR) for its DHT unit compared to an entire fresh load while achieving the same performance. Conclusion With the continuous refining-industry focus on value, Porocel’s latest development, Excel® rejuvenation technology, provides the highest hydroprocessing catalyst activity at an unmatched economic value. Refiners seeking high activity hydroprocessing catalyst while keeping a close eye on catalysts costs are very well served by this method of rejuvenation, which can be applied to catalyst from the refiner’s own units (as a service) or to regenerated catalyst from Porocel’s own extensive catalyst inventory. By combining Excel® rejuvenated main bed catalysts with other HPC products, such as Durocel-222 (ceramic bed support) and CatGuard® metal traps, for a Full Reactor Load (FRL), Porocel’s HPC solutions enable refiners to achieve all unit objectives while saving 30 – 70% versus the cost of fresh catalyst loads. In addition, catalyst reuse helps refiners to significantly reduce the cost and the environmental impact of catalyst disposal. Porocel maintains a global inventory of rejuvenated catalyst available for use in combination with fresh catalyst or on its own. All Porocel rejuvenated catalysts are analyzed to ensure they meet stringent physical and chemical standards and come with a complete certificate of analysis to ensure high performance..
Authors’ Details Michael Martinez Global HPC Technical Manager Porocel Industries, LLC mmartinez@porocel.com Guillaume Vincent HPC Business Segment Manager Catalyst Recovery Europe S.A. gvincent@porocel.com Chemical Engineering World
CEW Features
Machine Learning – a holy grail in the next generation industrial automation revolution. Today’s imperative means extracting additional value. Going for ward, only data-driven solutions incorporating comprehensive information from operations, maintenance, financial, and human resources system will detect conditions that limit asset effectiveness and expose profit opportunities. The key element is the proper application of Machine Learning technology. Indeed, the time for companies to implement Machine Learning is now.
I
n 2017, McKinsey & Company conducted a study on productivity gains driven by technology transformations. McKinsey points out three transformational phases – the steam engine, early robotic technology and advances in information technology. McKinsey also suggests that manufacturing is at the brink of the next generational industrial automation revolution. Advances in robotics, artificial intelligence and Machine Learning will match or outperform humans in a range of work activities involving fast, precise, repetitive action, including those requiring cognitive capabilities. Consequently, McKinsey sees unprecedented annual productivity growth between 0.8 – 1.4% in the decades ahead. The man versus machine debate provokes both positive and negative opinions but the reality is that to remain competitive, complex industries need to deploy industrial automation more than ever. Improving reliability and maintenance outcomes ARC Advisory Group calculates that the global process industry loses $20 billion annually from unplanned downtime. Companies spend millions of dollars on traditional maintenance approaches searching for specific wear and age-based failures using techniques to optimize inspection routines. However, the ability to detect the “apparently” random failures causing more than 80% unplanned downtime eludes them. Lead time is the critical issue. A significant need exists 40 • September 2017
to detect all types of degradation early and enable decisions to change the outcomes. Failure prevention must evolve from opinion-driven estimates to datadriven truths. Machine Learning is powering that change. Not only, can it detect patterns of impending degradation far earlier than contemporary approaches but applied within context, it can cast a “wider net” around machines to capture process induced degradation that causes most failures. While it is generally impossible to separate the behavior of both the machine and process, only a unique technology approach can do so. Thus, the answer is not a maintenance only approach but one that arrives at the confluence of maintenance and operations department activities that is critical for asset intensive industries, such as manufacturing and transportation. With a data-driven technology in place, organizations can decipher patterns of looming degradation and secure sufficient warning to prevent failures and change outcomes.
Autonomous in nature and requiring minimal human resources, this advanced technology constantly learns and adapts to new signal patterns when operating conditions change. Failure signatures learned on one machine inoculates that specific machine, so the same condition does not recur. Learned signatures readily transfer to similar machines, preventing the same degradation conditions from affecting them.
Predicting downtime with Machine Learning software
For example, a North American energy company was losing up to a million dollars in repairs and lost revenue from repeated breakdowns of electric submersible pumps. The advanced Machine Learning software application learned the operational behavior of 18 pumps from archived historical values and maintenance events. In doing so, it detected the pattern leading to casing leak that caused an environmental incident on one pump. In applying this failure signature to all 18 pumps, it provided an early warning on another pump, which was about to suffer the same failure. Early action to pull and repair the pump avoided a repeat incident and major losses.
Advanced Machine Learning software has demonstrated incredible successes in the early identification of equipment failure. State-of-the-art software is almost autonomous and learns behavioral patterns from streams of digital data produced by sensors – which reside on and around machines and processes.
In another instance, a leading railway freight firm operating across 23 states in the US used Machine Learning software to address perennial locomotive engine failures, costing millions in repairs, fines and lost revenue. The Machine Learning software application was deployed on a very large fleet of locomotives to examine Chemical Engineering World
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42 • September 2017
CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966
MAY 2017
In addition to Machine Learning, current market conditions are ideal for process manufacturers in capital intensive industries to accelerate performance with emerging technologies. Tablets, smartphones, and wearables enable engineers, technicians, and plant operators to make decisions on the go. Like minded professionals collaborate and solve problems using social networking. Cloud containers streamline the deployment experience, reduce cost of ownership, and increase application scope. The Industrial Internet of Things (IIoT) connects plants with model based sensors on all equipment, to enable machine-to-machine communication, across control systems and reliability management systems. Advanced algorithms used in search and pattern recognition automatically detect databased patterns to predict future outcomes and guide optimal responses. As such, emerging technologies increasingly help users to navigate complexity and address the biggest areas of opportunity. Analytics, models, and big data open the exploration of data potential inside the plant fence, and across a corporation. High performance computing also provides the necessary computational horsepower to address larger issues around asset optimization; and stimulate further advances in metadata sharing
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Today’s imperative means extracting additional value. Companies can no longer rely solely on traditional maintenance practices. A large asset, such as a manufacturing process, comprises building blocks based on many processes and equipment types. Risk occurs at many levels from specific equipment failure, the way a process is operated, and perhaps due to the design and overall plant configuration. They need a robust, multi-faceted solution to avoid and mitigate issues that affect profitability, safety, and the environment. Going forward, only data-driven solutions incorporating comprehensive information from operations, maintenance, financial, and human resources system will detect conditions that limit asset effectiveness and expose profit opportunities. The key element is the proper application of Machine Learning technology. Indeed, the time for companies to implement Machine Learning is now.
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lube oil data looking for extremely early indicators of engine failure. Such early detection has made it possible to avoid dozens of catastrophic engine failures. In one case, the application detected the degradation signature for engine leaks, even while the engine passed a lowpressure leak test. Such early warnings, well before failure, provide leeway to make decisions. In doing so, locomotives can complete a journey before proceeding for service in a convenient manner, avoiding a breakdown and saving the company millions of dollars in costly downtime and fines.
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Challenges in Design and Engineering of Electric Heaters This article discusses the basic design and engineering issues of Electric heaters which, if addressed properly in early stages can minimize the changes during detailed engineering stage.
E
lectric heaters are used in the Process Industries as an alternative to fired heaters or process exchangers for some specific applications. When specified and used properly, electric heaters will last for many years without problems. However, unlike shell and tube heat exchangers, the design and engineering of Electric Heaters are carried out by the suppliers. This fact and the lack of international standards and specifications pose challenges to detailed engineering contractors in selection and detailed design of these heaters. More over Electric heater is just not a piece of heat transfer equipment with pressure components; they are equipment with electric terminal box, electrical control panel and transformer in some cases. Hence other than supplier and Process engineers interface with Electrical and Instrument engineers are also required to design and engineer these heaters. Abbreviations: 1. ASME: American Society of Mechanical Engineers 2. DEC: Detailed Engineering Contractor 3. NEMA: National Electrical Manufacturers Association 4. IEC: International Electrotechnical Commission 5. MAP: Maximum Allowable Pressure 6. MAWP: Maximum Allowable Working Pressure 7. FEA: Finite Element Analysis
• The heat required to maintain the process at a particular operating temperature. In both these cases, the heater bundle is inserted inside a shell, more like a shell and tube exchanger with the fluid being heated placed in the shell side and heating element acting like tubes.. In former case the fluid will flow through the shell with certain velocity to attain the required process temperature, whereas in latter case the fluid is just stored in the shell to maintain the process operating temperature. The mechanical design aspect of the heater in the former case is more critical and will be discussed in detail in this article. Electric Heater Construction: For the given duty the number of heater bundles is selected based on allowable watt density of element, which in turn is dependent on the properties of the fluid being heated. The heater element material is selected based on factors like maximum fluid temperature, fluid properties etc. Both the material of heating element and Cooling Space
44 • September 2017
Components of Electric Heaters: Heater bundle: This is a non pressure part and comprises of seamless tubular electric heating elements, rod baffles, heat shield baffles, cooling baffle and electric terminal box. • Heating element: The material of construction for heating element varies from steel to nickel based alloys. In hydrocarbon industries, generally with high temperature application, heating
Unheated Length
Baffles (Heat Shields)
Terminal Box
Element Bundle Hot Bundle
Basic Heater Configuration: Electric heaters are used in applications where the process duties are low but fluids are heated to high temperature. Configuration is generally specified by Process Licensors mainly based on one of the following two factors: • The heat required to bring the process up to the desired temperature and
the allowable watt density are generally specified by the Process licensor. In Hydrocarbon Industries watt density varies between 4650 W/m2 to 34000 W/ m2 where various forms of hydrocarbons and hydrogen are the most commonly heated fluids. The heaters are oriented either in horizontal (Fig.1) or in vertical (Fig.2) position. Vertical orientation is preferred in services with very high operating process temperature where the heaters are required to be supported on spring supports to avoid transfer of high loads on heater supports and connected piping system due to higher heater shell expansion.
OUTLET
Weld Sheath To Flange
Welding Tee
Process Connection Flange
INLET
Cold Bundle
Shell Flange
Cooling Baffle
Heater Shell
Heater Flange
Figure 1: XElectric heater oriented horizontally Chemical Engineering World
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CEW Features Hot Bundle Terminal Box
Cooling Space
Cooling Baffle
Weld Sheath To Flange
Heater Flange
Unheated Length
Baffles (Heat Shields)
VERTICAL
Welding Tee
Element Bundle Heater Shell
OUTLET
46 • September 2017
Shell Flange
Power Control Panel: This is required to provide control power supply to the heater. Tripping of heater during any
INLET
Heater tube sheet and Shell: These are the pressure components of Electric heaters. All the heating elements are welded to the heater tube sheet. Heater bundle along with the tube sheet is inserted into the heater shell. Heater shell has a body flange on one end where the tube sheet of the heater bundle is bolted and another end is connected to piping system. The process fluid flows longitudinally over the heater elements inside the shell from cold end to the hot end of the shell. Tee connections are required for interconnecting the heater vessels in case of multiple bundles.
Cold Bundle
elements are made of 80 Ni - 20 Cr alloy heating wire packed with magnesium oxide insulation enclosed in a tubular element sheath. Some portion of the heating element will be ineffective, known as unheated element length, which will be occupying the space from the heater flange face to the nearest tangent line of the welding tee opening, as shown in Fig.1 and Fig.2. • Rod baffle: Unlike a conventional shell and tube exchangers, where the flow of fluid inside the shell is a combination of co-current/ counter current and cross flow, the flow inside the electric heater shell is longitudinal. Hence the tubular elements inside the heater shell are supported on rod baffles. • Heat shield baffle: A minimum two full solid heat shield baffles (as shown in Fig 1 & 2) will be provided in unheated section to reduce the heat loss through the heater flange. • Cooling baffle: A cooling baffle outside the heater flange is provided to avoid heat transfer to heater terminal box, thereby preventing the terminal box from getting heated. • Electric terminal box: An electric terminal box is provided on one end of heater bundle and inbuilt duplex type thermocouples will be welded on element sheath to measure and control the temperature of heater bundle.
Figure 2: Electric heater oriented vertically
abnormal condition such as ground fault, over temperature, etc is controlled by power control panel. Transformer: Step down transformer is required for the high duty, low voltage heaters. In case of high duty heaters the required current ampere will be higher. Hence medium voltage supply will be provided to avoid bigger cable size and loss of current. However, since there are very few Suppliers who supply medium voltage heaters, in many cases we may have to go for low voltage heaters with the step down transformer. Challenges in design and engineering of heater components: The basic configuration and orientation is generally specified by Process Licensor much before the start of detailed engineering and is finalized by the heater
supplier when the detailed engineering is at its peak. In order to avoid changes in heater configuration at late stage of engineering, it is advisable to have a detailed review of the following aspects of design and downstream engineering by the detailed engineering contractor prior to design freeze. Selection of watt density: Since the selection of heater configuration is largely dependent on watt density, this needs to be reviewed when specified in process datasheet. If not specified, the DEC should ask the Process Licensor to specify the same. Orientation of heater orientation: The heater orientation should be finalized after discussion with Process Licensor and Piping before issuing enquiry to bidders to avoid unnecessary changes at a later stage with adverse impact on cost and schedule. Chemical Engineering World
CEW Features Optimum voltage level of the heating element: The higher is the voltage level, lower is the size of the electric heater. However, not all electric heater suppliers have capability to manufacture heater with high voltage level. Hence DEC needs to carry out a detailed study to check the commercial viability of heater with high voltage, with limit suppliers, vis-à-vis low voltage heater with additional step down transformer but with more number of suppliers. Proper specification of Power Control Panel: Generally heater power control panels are located away from the hazardous area, either indoor or outdoor. However sometimes the control panel needs to be located outside, under a hazardous area, due to lack of space inside Electrical & Instruments room. Since the price of power control panel, suitable for hazardous area, will be much higher due to requirement of additional safety protection when compared to panel suitable for non hazardous area, a prior study in consultation with Electrical group regarding the pros and cons before specifying the requirement in the enquiry document to avoid changes during later stage. For example, if the hazardous area classification is class 1, zone 2, then the panel shall be pressurized by air purging and panel enclosure require closed loop cooling system or outside heat sink to put out the heat produced inside the panel, making the panel bigger and costlier. The enquiry document shall also specify the following in order to avoid unnecessary changes at a later stage with adverse impact on cost and schedule • The minimum and maximum design temperatures of the panel. In many cases the minimum temperature will become critical design due to issue in digital display at temperature below 0°C. • Control panel enclosure type in accordance with NEMA or IEC standards, suitable for the installation location. • The width and swing angle of enclosure access doors based on available layout. 48 • September 2017
• Required spare quantities and • spare component mounting space inside the panel. Selection of Design Code: Since the purpose of the Electric Heater is to heat up the process fluid and not merely to transport the process fluid, Pressure Vessel design code is a more appropriate code for mechanical design of the heater. In addition, ASME Code Section VIII Div.1 contains mandatory appendix 41 that is specific for the design of Electric Heaters tube sheet. DEC needs to check whether any mechanical design code has been specified by the Process Licensor and resolve the design code issue with the Process Licensor in case piping design code is specified instead as per Pressure Vessel design code. Calculation of MAP and MAWP: Electric Heater suppliers tend to consider design pressure as the MAP and MAWP in order to avoid engineering effort to calculate MAP & MAWP as per design code. DEC shall clearly specify the requirement to calculate MAP & MAWP as per applicable design code, in case the Project Design Basis calls for it. Tube sheet design: Electric heater tube sheet is generally designed as per Appendix 41 of ASME Sec VIII Div.1.[a] DEC shall specify the complete applicable design conditions for tube sheet design, including that of full vacuum, if any. Generally heater supplier will adopt tube sheet thickness based on standard blind flange and perform strength calculation per appendix 41 for internal pressure at design temperature to check the adequacy of adopted thickness. Hence in scenario where full vacuum design condition is applicable then same shall be specifically included for tube sheet design also to avoid changes during later stage. Shell design: Equipment Vendors generally design electric heater shells as per ASME Sec VIII Div.1. Structural strength of shell shall be adequate for system pressure, for supporting heater(s) and for applicable piping loads. The shell strength check for heater support reaction loads and piping
loads are performed by FEA method. Stress analysis of shell shall be carried out for following types of piping loads, 1. Sustained load- Operating: Weight (operating) + thermal load (operating) 2. Sustained load- Design: Weight (operating) + thermal load (design) 3. Occasional load: Thermal (operating) + weight (operating) + wind loads. With the above load combinations, in the calculated stresses may exceed the allowable stress of the heater shell with standard wall thickness. Hence to ensure an optimum design, only the following combinations sustained and occasional load cases of may be adopted: • Sustained load-Operating: Weight (operating) + thermal load (operating), since the nozzles will “see” only the operating temperatures. • Occasional load: Thermal (operating) + weight (operating) + wind loads. Electrical and thermocouple terminal box: In hydrocarbon processing industries heaters area are classified as hazardous area. Hence these terminal boxes shall be designed for hazardous area. Example terminal box are rated for NEMA 4X and IP6 as per NEMA and IEC standards respectively are suitable for class 1, zone 2 area. Since there will be a minimum of two duplex thermocouples for each bundle, and in general each thermocouple requires separate junction box, the purchase order shall specify the minimum required junction box properly. Step down transformer: As explained earlier this is required only in application where the high voltage supply is provided to low voltage heater. Since transformers are located nearer or within the heater skid, the hazardous area classification will be applicable. Generally NEMA 3R rated transformers are suitable for hazardous area - class1, zone 2. An additional weather proof kit may be necessary for Dry type transformers for protection against blowing snow in cold countries. Chemical Engineering World
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CEW Features Heater Hydro test: If designed as per ASME Sec VIII Div 1, hydro test pressure for heater will be as per UG-99 of ASME Sec VIII Div.1, which requires hydro test pressure to be 1.3 x MAWP with temperature correction.[a] However, in specific application, where the heater is connected to piping system by butt welded joints (Fig.2), and no “golden joint” is allowed as per local code, the applicable site hydro test pressure need to be as per ASME B31.3, which requires the hydro test pressure for the butt joints to be 1.5 x Design Pressure with temperature correction.[b] In this case, the heater pressure parts needs to withstand this hydro test pressure without exceeding 90% of yield strength.[b] This needs to be specified in the requisition document to avoid unnecessary changes at a later stage with adverse impact on cost and schedule. It is good practice to hydro test piping system to 1.5 x Flange rating pressure (after ensuring that heater and connected piping can take
the stress) to account for possible re rating of piping system in the future.
2.
Process Piping – ASME Code for Pressure Piping (ASME B31.3)
Conclusion: These days since the end users are expecting more cost competitive and schedule driven projects, detailed engineering contractors are expected to correctly and completely specify all the technical requirements in the requisition document to avoid changes at a later stage which may affect the project cost and schedule. A close coordination among various engineering disciplines, Process Licensor, Client and Suppliers can help the DEC for early finalization of the selection and design of the electric heater and minimize changes during the detailed engineering stage. .
Ritabrata Pramanik Mechanical Engineering Fluor Daniel India Pv.Ltd.
Srinath NR Mechanical Engineering Fluor Daniel India Pvt. Ltd.
References: 1.
Authors’ Details
ASME Boiler and Pressure Vessel Code (Section VIII, Division 1)
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aurus939 has all the Italvacuum experience, a vacuum pump that guarantees unrivalled performance in all the main chemical and pharmaceutical processes, ensuring total recovery of extracted solvents, even in severe operating conditions. A simply designed machine, that combines traditional robustness and reliability with the most evolved technology. Saurus939 has always been the core business of Italvacuum, one of the leading manufacturers of vacuum pumps as well as a worldwide reference point in the design and manufacture of vacuum dryers. Resistance, strength and consumption of oil virtually eliminated thanks to the innovative LubriZero system that guarantees perfect operation and optimum results with total respect for the environment. Saurus939 has no fear of aggressive and corrosive solvents, powders and condensates, nor distillation by-products. But above all it does not fear confrontation because it is designed and manufactured to work 24 hours a day with a constant excellent performance and minimum operating costs, thanks to a low-energy motor, negligible oil consumption and easy, immediate maintenance. Powerful, efficient, but absolutely safe: Saurus939 guarantees optimum safety through the whole process and complete purity of the final product. In other words, ensures an uncontaminated vacuum.
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54 • September 2017
Figure 1: Saurus939_vacuum pump (front view)
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Figure 2: Saurus939_yearly operation costs_eng
one or two compressor roots in order to increase the pump rotation speed and reach lower final pressures (high vacuum levels). Accessories The high quality of Saurus939, not only in the unquestionable reliability of the vacuum pump, but also the wide range of accessories, allows for turn-key installation of the entire vacuum group: 1) Atmospheric post-condenser for the recovery of solvents from the pump outlet 2) Condensate recovery tank from the post-condenser outlet 3) Pump suction filter with par ticle centrifuge separation and metal filtering cartridge 4) Control panel board, also available in compliance with ATEX Directive 94/9/EC 5) Support base for easy, fast installation. Certifications
Saurus939 complies with the requirements of the most demanding European Directives: • Machinery Directive 2006/42/EC Directive • ElectromagneticCompatibility 2004/108/EC • ATEX Directive 94/9/EC. The standard version, CE εx II 2G T4/T3, is suitable for installation in an area classified as ZONE 1-GAS and temperature class T4 (135°C). The Saurus939 special version can be supplied with ATEX certification up to ZONE 0-GAS (internal pump), ZONE 1-GAS (external pump) with three different classes of temperature T4 / T150°C / T3. Strengths • Complete robustness in any work environment • High resistance against corrosion • High resistance against powder, condensates and distillation by-products • Continuous recovery of the extracted solvents • Unlimited use over the entire vacuum range • Uncontaminated vacuum and complete purity of final product • Lower operating costs than any other vacuum technology • LubriZero system with negligible oil consumption • Extremely limited environmental costs • Low-energy motors • Easy and economical maintenance • Absence of warm-up cycles and waiting times • Physical separation between process and mechanical parts • Unrivalled performance in the constant recovery of extracted solvents • Low noise (<70 db) and low operating speed (250 rpm) • Low average working temperatures. • ATEX certification up to ZONE 0.
Contact Details:
Website: www.italvacuum.com Figure 3: Saurus939_break-even_eng 56 • September 2017
Chemical Engineering World
Brilliant technology Italian quality Saurus939: The vacuum pump made to live longer. Unique in reliability, performance and consumption.
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Vac Enterprises India LLP, Mr. Jayant Joshi B 102 Shubh Sarita, Appasheb Sidhaye Road Shree Krishna Nagar, Borivali (East) Mumbai 400 066 Tel. 02228975275 | Mobile 9820047858 info@electromechengineering.com
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A Place for Positive Displacement PD flowmeters quietly excel in low-flow rate, high viscosity, in liquid and gas metering applications
P
ositive displacement (PD) flowmeters a r e t h e w o r k h o r s e s o f t o d ay ' s f l o w m e t e r w o r l d . T h ey p e r fo r m many important flow measurements most people take for granted. For example, they are widely used for metering both water and gas in residential, commercial, and industrial applications. Chances are good the flowmeter that measures how much water you use at your house is a PD meter. PD flowmeters separate the fluid to be measured into distinct compartments of known volume. As the liquid or gas passes through the flowmeter, the compartments are repeatedly filled and emptied. Flow rate is calculated from the number of times these compartments are filled and emptied. PD meters differ according to the shape and size of the compartments involved, and according to whether they are designed for liquid or gas. Positive displacement flowmeters excel where many other flowmeters have difficulties: low flow rates and high-viscosity liquids. In addition, they provide a very cost-effective solution for utility applications requiring lowcost meters that last for many years; they still occupy a niche where they are the best solution. And with annual worldwide sales that exceed $500 million, PD meters will be around for many years to come. Applications for PD Meters The use of PD meters can best be understood by dividing them into water utility, gas utility, oil and industrial liquid applications: Water utility applications mainly are for billing purposes. Water utility companies buy these meters and put them in industrial plants, commercial buildings, and homes to measure how much water is used at those facilities. Just as private homes need flowmeters to measure the amount of water used, so do hotels, apartment complexes and other commercial buildings. These buildings are likely to use PD, although they may use
58 â&#x20AC;˘ September 2017
turbine meters instead for higher volume flows. Many smaller commercial buildings use PD flowmeters to measure water use within the building. Most PD meters for line sizes of 1-1/2 or 2 in are for commercial applications. Gas applications include billing meters to measure the amount of gas used at houses, commercial buildings and industrial plants. The meters used for billing purposes in industrial plants such as chemical, food processing and pharmaceutical plants are different from the meters used to measure gas as part of the manufacturing process. Many of the PD meters used for gas utility measurements are diaphragm meters. However, these are being replaced by rotary meters for some applications, since rotary meters are smaller and lighter. Rotary meters are also used for non-utility gas flow measurements in industrial environments. Oil, refined fuels and hydrocarbon products are a very large PD flowmeter market segment. Some PD meters are used for loading and unloading trucks, tankers, airplanes and ships. Most of this measurement is for the purpose of custody transfer. This measurement occurs both upstream and downstream of refineries. Oil trucks that deliver oil to people's homes use a flowmeter to measure the amount of oil dispensed. Often this is a PD meter. Some PD meters rely on the lubricating property of oil or hydrocarbon liquid when the liquid is in contact with the measuring chamber. These meters can measure gasoline, diesel fuel, heavy fuel oil and many other hydrocarbon-based liquids. Unlike turbine meters, PD flowmeters can easily handle high-viscosity liquids. For this reason, they are often used to measure petroleum at terminals, in production and downstream for delivery. PD meters can measure heavy crude oil accurately and they are not affected by variations in velocity or viscosity of the measured product.
Process liquid applications include industrial chemicals, pharmaceutical chemicals, paints and varnishes, printing ink, dairy products, cosmetics and many other liquid products. In many cases, PD meters provide a highly accurate measurement for a lower price than meters such as magnetic or Coriolis. Change is Evolutionary Change in the positive displacement flowmeter market is more evolutionary than revolutionary. Some PD meter companies are not even currently investing in new product research. However, there are some new developments in PD meters. Some of these developments focus on improved methods to increase component manufacturing precision. For example, improved coordinate measuring machines make it possible to create more perfectly round pistons and other components. And one difference between positive displacement flowmeters and new technology meters (Coriolis, magnetic, ultrasonic, vortex, and multivariable differential pressure) is in the displays. PD meters typically compute flow by counting pulses. The pulsed output of PD meters is typically not a flow rate but a pulse value. To compute flow rate, these need to be related to time. This computation is often done not in the flowmeter but in a separate totalizing device that may be panel-mounted. One potential growth path for positive displacement meters is integrating this computational capability in the flowmeter instead of having it done in a separate totalizing device, and some vendors are already doing this. One aspect of transmitter technology that has not yet had a major impact on positive displacement meters is communication protocols. While some magnetic flowmeter and pressure transmitter suppliers have made HART a default capability for their products, only Brooks Instrument and Bopp & Reuther have so far introduced HART versions of PD meters. It is likely that more smart PD Chemical Engineering World
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Marketing Initiatives meters will be produced in the future as new technology meets old. PD Prospects Positive displacement flowmeters are a traditional technology flowmeter that will be around for many years to come. Even though they face stiff competition from new-technology meters in some segments, they still remain the best solution for certain applications. This market is so large that, like differential pressure flowmeters, they will still be around years from now. Positive displacement meters are very effective at making low-cost mechanical measurements for utility purposes. These include residential, commercial and industrial utility applications. Contact Details: Toshniwal Hyvac Pvt Ltd
267 Kilpauk Garden Road Chennai 600 010 Tel: 044-26445626, 26448983 E-mail: sales@toshniwal.net Website: www.toshniwal.net
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CEW Products Multi-gas Continuous Emission Analyser The SERVOPRO 4900 is specifically designed for the continuous emission monitoring, where legislation requires the measurement of several gas components in flue gas. The 4900 offers multi-gas capability for pollutants, greenhouse gases and reference O2, including O2, CO, CO2, NO, SO2, CH4 and N2. For details contact: Spectris Technologies Pvt Ltd Plot No: A-168 MIDC Thane Belapur Road, Khairane Navi Mumbai 400 710 Tel: 022-39342700 E-mail: MEI_Sales@servomex.com
Medium Pressure Push-in Fittings MP is a push-in fitting conceived for medium pressure grease applications up to max 80 bar. MP completes, with its technical features the existing products offer for central lubrication applications and highlights further the distinguishing markets of the whole C MATIC production: quick connections, performance and reliance guarantee For details contact: Luthra Pneumsys 38 Madhu Vrinda Dhuri Indl Estate Waliv Pata, Vasai (E) Dist: Thane, Maharashtra 401 208 E-mail: Pooja.pneumsys@gmail.com
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Die-cut Strip Packaging Siebler unites heat-sealing technology with die-cut packaging formats. Formats for both standard and individual-shaped strips can be produced using Romaco Siebler heatsealing technology. The Siebler HM 1 machines can be configured to manufacture diecut strips at the customer’s request. Individual-shaped strips can be designed entirely according to each Romaco customer’s requirements. There are no limits to the possible geometries. With integral grooves as opening aids, the heat-sealing technology unites design with functionality. Bespoke strip perforation patterns are also no problem. The unique primary packaging helps strengthen the product’s brand personality. To enable individual-shaped strips to be manufactured, a heat-sealing machine belonging to the Romaco Siebler HM 1-350 series is equipped with a continuous cutting station. Two servo-driven punches cut strips out of the foil layer with a drawing cut. Nothing more is needed to create air, light and moisture-tight unit dose packaging with an individual design. Several specimen sealing pattern options are likewise available. Any machine configured for die-cutting individual-shaped strips can also be used to make standard strip formats. All in all, the Romaco Siebler HM 1-350 is capable of delivering up to 900 individual-shaped strips per minute.Choosing the right heat-sealing foil is crucial in order to produce strip packaging efficiently and reliably. The machinability of a foil in relation to the speed at which it is to be processed is always the decisive factor. This calls for a detailed analysis of the sealing parameters, so that the processes and features of the heat-sealing machine can be adapted accordingly. The aim is to achieve packaging which remains absolutely tight in any circumstances. All packaging must pass various stability tests before it is approved by the pharma regulatory authorities for a particular product. For details contact: The Romaco Group Am Heegwald 11 76227 Karlsruhe, GermanyTel: +49 (0)721 4804 0 Fax: +49 (0)721 4804 225 E-mail: susanne.silva@romaco.com CircleReaders’ Readers’Service ServiceCard Card0323 oror Circle
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Products CEW Electro Magnetic Meter The instrument works on the principle of Faraday’s law of Electromagnetic Induction. A magnetic field is generated by the instrument in the flow tube. The fluid flowing through this magnetic field generates a voltage that is proportional to the flow velocity. This voltage is measured by the electronics and a corresponding output provided. Universal power supply accepts any voltage from 90 to 265 V AC. Bi-directional flow measurement measures the flow in both forward and reverse directions. Built-in totaliser provides a separate totalized volume value for flow in each direction. Remote monitoring is monitoring of the process even in hard to reach places. Conforms to International Standards - designed to meet global requirements and available with international approvals. It can be used to measure flow rate of all conductive liquids and perfect for use in effluent treatment plants; PTFE lining option for corrosive liquid applications; and effective flow measurement of slurries owing to zero obstruction to flow. 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 04
Rotary Steam Tube Dryers In this dryer, tubes are fixed to the outer shell housing and rotate along with the shell.Single/multiple rows of tubes are circumferentially arranged on the internal periphery of the rotary shell. Rotary shell is supported on tyres/rollers and driven through suitable drive arrangement. Wet feed material is fed through centre of one end of the dryer by feed screw. Steam is admitted in the circumferential tubes from a rotating manifold installed towards material discharge end of the shell through rotary joint. Condensate is also collected through the same rotary joint. Material gets dried by conduction heat transfer and discharged from the openings provided on the shell at the other end. The openings also serve for fresh air intake. Vapours are removed from the feed end. Spiral flight lifters shower the feed material on tube. AVM offers customized configurations of conduction dryers with feed preconditioning, product back-mixing systems; feed and product handling, pneumatic conveying systems. For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3, Akurdi Indl Estate Opp: Ador Welding Ltd, D-1 Block, MIDC, Chinchwad Pune, Maharashtra 411 019 Tel: 020-27459986, 27459987 Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net or Circle Readers’ Service Card 05
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CEW Products Double Cone Blender
Octagon Blender
Leveraging on their years of experience and in-depth knowledge of this domain, Shefa Industries are offering a broad spectrum of quality assured double cone blender. These double cone blenders are widely used for mixing granules and dry powder homogeneously. Offered array of double cone blender is manufactured by using premium quality SS, which is procured from the reliable vendors of the market. These blenders are commonly used in the pharma, chemical, food and cosmetic industries.
The octagon blender ensures good rolling and cross-mixing. A-shaped frames provide stability of structure. Main drive provided with variable frequency drive to control blender RPM. There is a start-stop arrangement to ensure that the blender always stops in an upright position. Internal baffles ensure good blending and break lumps. Guard rails are provided with limit switch for safety. PLC/HMI-based control panel models available.
For details contact: Shefa Industries Gala No: 1, U K Quari Compound Gandhi Nagar, Vikhroli (W) Mumbai 400 083 Tel: 022-25942473 E-mail: shefaindustries@yahoo.co.in
For details contact: Kunal Machines 104 Kothari Indl Estate, Next to Asian Paints LBS Marg, Bhandup (W), Mumbai 400 078 Tel; 022-61271111, 67251949 E-mail: kunalmachines@gmail.com or Circle Readers’ Service Card 06
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Scrap Metal Detector Belt conveyor operators at mining, mineral, steel, cement and other industrial manufacturing sites can now install a new, highly-sensitive scrap metal detector designed to optimize production time, protect process equipment and reduce false alarm rates. The Thermo Scientific Ramsey Oretronic IV tramp metal detector builds upon the existing line of tramp metal detectors by increasing sensitivity for improved detection capabilities. Thermo Fisher designed the new detector to work with belt conveyors that move minerals, iron pellets, coal, aggregates and other bulk materials, to better detect all types of metallic scrap, including bucket teeth, manganese steel mantles, bore crowns, bar scrap, chains and tools. The increased sensitivity in the Oretronic IV detector allows it to identify tramp metal buried in wet conductive materials quickly and accurately. The Oretronic IV tramp metal detector, which is available in two versions with two levels of sensitivity, includes a microprocessor-based control unit, a receiver coil, a transmitter coil and a support frame. Additional features of the Oretronic IV tramp metal detector include: variable frequency, designed to allow the operator to adjust the frequency to eliminate interference and false alarms from motors, radios and other external devices; a fiberglass support structure for coils that is resistant to moisture; advanced electronics with an LCD display, touch button keypad and new menu for easy setup, calibration and system use; and simple installation and easy upgrade from existing instruments in the Oretronic tramp metal detector line. For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi C-Wing Hiranandani Business Park, Powai Mumbai 400 076 Tel: 022-67429494, Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 08
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Products CEW Under Driven Cone Mill Under driven technology meets all your requirements of over driven cone mill with additional advantages including easier inline integration, compact design, unhindered inline product flow for quicker discharge. Easily interchangeable parts can cover same unit into rotary sifter applying centrifugal principal for sifting. Advanced compact design with higher throughput allows milling with table top models for R&D labs.Under driven design can be readily installed in through the wall concept. For details contact: Tapasya Engg Works Pvt Ltd Plot A/212, Road No: 30 Wagle Indl Estate Thane, Maharashtra 400 604 Tel: 022-61579400 Fax: 91-022-25825243 E-mail: sales@tapasyaindia.net or Circle Readers’ Service Card 09
Vacuum Dryers Vacuum dryers are widely used in the industry for drying in variety of products.Vacuum dryers are batch dryers ideal for drying of heat sensitive products, drying of products in solvents (for subsequent solvent recovery), drying requirements necessitating achievement of very low moisture or low oxygen drying environments to minimise oxidation or for explosion-prone products. AVM offers customised vacuum drying systems with variety of configuration: In agitated cylindrical vacuum dryer, heat is supplied to jacket of stationary cylindrical housing. The material to be dried is kept in agitation by means of specially designed rotor. In double cone vacuum dryer, heat is supplied to double conical shaped rotating jacket. The material to be dried is kept in continuous tumbling within the rotating housing. Conical shape facilitates easy drain-out of material at the end of the batch. For details contact: New AVM Systech Pvt Ltd AVM House, 3B+3 Part, 1/3, Akurdi Indl Estate Opp: Ador-Welding Ltd, D-1 Block, MIDC, Chinchwad Pune, Maharashtra 411 019 Tel: 020-27459986, 27459987, Fax: 91-020-27459988 E-mail: avmtechnologies@vsnl.net or Circle Readers’ Service Card 10
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CEW Products Adjustable Level Switch
Oval Wheel Meter
Adjustable level switch consists of separate level switch assembly for each level like low, high, middle or multi-level. These individual level switch assy, are suspended through SS rope and are freely adjustable along the SS rope. The level switch assy, are provided with adjustable disc which can slide through the SS rope and are secured to SS rope with stopper or cable tie at required levels. The cables are terminated inside a weatherproof enclosure. The adjustable level switch is provided with mounting flange of standard size.It finds application in water tanks and cooling towers. For details contact: Filpro Sensors Pvt Ltd 130, 10 th Cross, Petechennappa Indl Estate Kamakshipalya, Magadi Main Road Bengaluru, Karnataka 560 079 Tel: 080-23286463 E-mail: sales@filprosensors.com or Circle Readers’ Service Card 11
Oval wheels (Type OV) is an ideal choice for all liquid measurements. the Oval Wheel displace precisely known volume of liquid through the meter from inlet to outlet. The number of revolutions, therefore, is directly proportional to the measured volume.For the protection of oval wheel meters and turbine meters against foreign matter and solids contained in the liquids, measured with these meters. These strainers may also be used for protection of piping systems for contamination, Strainers, Type N... without heating jacket size 15-100-mm (1/2” to 4”) It features 2-wire technique and has only 2 moving parts (oval wheels); high accuracy; measurement at high viscosities and direct measurement of volumetric flowrate. 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 12
Level Indicators Visual level indicators combine up to three functions in one instrument: level indicator, level switch and level transmitter. The display that can be read even over large distances works without energy and automatically as a result of the physical law of liquids in communicating vessels. The WEKA visual level indicators are characterized by their compact design and the wide range of applications. Operating pressures can range from a vacuum up to 500 bar as well as calculation pressures for the float standpipe up to the nominal pressure PN 630. Liquid densities >0.27 g/ cm3 as well as a temperature range from 77 K to 673 K (-196 oC to 400 oC) allow use in applications for cryogenic liquid gases as well as in water hydraulics and steam boilers. Hermetically sealed floats for condensing media are available up to a max operating pressure of 320 bar. Flexibility through choice of suitable materials - standard materials: 316/316L 1.4435/1.4404, Group A4 stainless austenitic steel. Other possible stainless austenitic steels: 304/304L 1.4301/1.4306, 1.4571, 321, 1.4541. The WEKA visual level indicator is ideal for the commissioning of systems. The display works without energy and automatically as a result of the physical law of liquids in communicating vessels. Independent of a controller - and thus also independent in the event of a power supply failure - visual level indication on site is ensured. The wide, red- and silver-colored flag indicator system is easily and clearly readable, even from over large distances. The fully transparent flag indicator system made of polycarbonate (PC) also ensures readability from the side. The liquids, which are not always unproblematic and sometimes also hazardous, are safely enclosed in the dense and pressure-tight float standpipe and separated from the indicator. WEKA visual level indicators offer the ideal solution Many designs can, eg, also be used in hazardous areas according to ATEX or IECEx (ATEX is a widely used synonym for the ATEX guidelines of the European Union). Toshniwal’s instruments can thus also be used in potentially explosive atmospheres. 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 13
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Products CEW Manifold Valves Excel Metal & Engg Industries offers wide range of instrumentation fitting and valves for use in diverse range of industries and are capable to provide their customers with best possible solutions to meet their various requirements. The production process followed is of higher standards with its modern production and quality assurance facilities where due attention is paid at every level with maximum resource utilization.Excel Metal & Engg Industries offers manifold valves in SS, brass, CS, alloys ,etc; pressure rating up to 6,000 psi (413 bar) at 100 oF (38 oC); temperature rating: -65 oF to 973 oF (-54 oC to 523 oC) with Grafoil packing; 2 V, 3 V and 5 V as standard; remote or direct mounting; non-rotating globe stem tip. For details contact: Excel Metal & Engg Industries 177/181 J T Bldg, 3rd Kumbharwada Lane Mumbai 400 004 Tel: 022-23892476, 66394004 Fax: 91-022-23884109 E-mail: info@excelmetal.net / excelmetal@mtnl.net.in or Circle Readers’ Service Card 14
Multi-mill Multi-mill available in standard cGMP and customised models with SS-304/316/316L contact parts.It is ideal equipment for the granulation of pharma material. Precision designed to grind/compress/impact and shear in an effective manner. Most suitable for granulating, pulverizing, mixing, shredding and kneading of a range of wet and dry material. Features low energy consumption and high degree operation; facilitates automation capability and dust-free product transfer; helps to reduce containment and cross-contamination; and provided with butterfly valve for discharge. It is available in batch capaciites ranging from 50 to 500 kg as per particle size. For details contact: IPEC Engg Pvt Ltd Plot No: 5175, GIDC, Ankleshwar, Gujarat 393 002 Tel: 02646-221175 Telefax: 91-02646-225175 E-mail: md@ipecengg.com / marketing@ipecengg.com or Circle Readers’ Service Card 15
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CEW Products Conta Bin Blender
Gantry Palletizer
Customers can avail of their superior quality conta bin blender. These bin blenders are appreciated by large number of clients due to high quality and durability. These products are available in the market at most economical rates. Conta bin blenders are used for mixing, lubricating and blending in pharma, food, chemical, ceramics, plastics and other allied industries of dry powder.
It is a low cost palletizer. The same can be offered for low palletizing speed of 4 bags/min. It works on 3 axis and controlled by stepper motors, photo-electric sensors and pneumatics. The pick and place operations are configured by the PLC logic number of bags per layer and total number of layers is limited to 6 layers in a standard version.
For details contact: Shefa Industries Gala No: 1, U K Quari Compound Gandhi Nagar, Vikhroli (W) Mumbai 400 083 Tel: 022-25942473 E-mail: shefaindustries@yahoo.co.in or Circle Readers’ Service Card 16
For details contact: Jasubhai Engg 64/a GIDC Indl Estate Phase 1, Vatwa Ahmedabad Gujarat 382 445 Tel: 079-49003636 Fax: 91-079-25831825 E-mail: mhd-sales@jasubhai.com or Circle Readers’ Service Card 17
Generator Control Station The generator control station is a complete digital console for generators to monitor and control the key parameters thereby ensuring the safety of the generator. GCS-909 is suitable for local and remote start/stop applications. The controller can be used to electronic and non-electronic engines for providing monitoring and protection. The same controller can also be used in industrial engine only applications. The controller is equipped with graphics LCD display for showing the parameters and running faults in graphical and character formats. The controller monitors key engine parameters such as oil pressure, water temperature, fuel level, battery voltage, charging current, RPM (monitored through main alternator voltage/ MPU/charging alternator) and frequency. It also monitors safety switches such as high water temperature, low lube oil pressure, low fuel level, radiator water level and canopy temperature.The controller supports basic level configuration using keys and display; allowing field level staff to modify parameters which require customisation at the time of installation. All advanced level parameters are configurable only from a PC-based application through USB port. The controller offers electronic start/stop facility without need for manual keys. The controller offers many features such as setting delay values, set-points, switch configurations, etc. For details contact: SUN Industrial Automation & Solutions Plot No: 95, Developed Electronic Indl Estate Perungudi, Chennai 600 096 Tel: 044-30788900 E-mail: sias@vsnl.com or Circle Readers’ Service Card 18
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Products CEW Triplex Series Pumps Mouvex offers the integration of Finder Triplex Series pumps into its growing portfolio of transfer solutions for the energy and industrial markets. Triplex Series pumps are highly reliable reciprocating plunger pumps specifically designed for a wide variety of critical applications found in oil and gas (onshore and offshore), nuclear and general industrial industries. These pumps are also compliant with API 674 to provide the best in reliability and safety. Triplex Series pumps are available in seven models – TD18, NF50, NH77, NJ116, NL171, TN 260 and TP420 – with power rating ranging from 13 to 310 kW (18 to 420 HP). Typical applications include water jetting, methanol injection, glycol recirculation, descaling, boiler feeding, and others. For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass Sanneerkuppam, Chennai 600 056 Tel: 044-26271020, 26271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 19
Evisceration System Principle of the system is to recover any substance from the main product for further process. The system is built in fabricated structure incorporated with vacuum pump motor, automatic valves, pipings, switches and control panel. The capacity of the vessel for collection of the substances is approximately 200 litres. The vessel is manufactured in food grade SS-316. The liquid ring vacuum pump develops vacuum in the vessel. The suction nozzles are bypassed through the storage vessel to its connecting point. The suction nozzle functions with vacuum sensor which is connected to foot-operated switch on both sides of the unit for dual operation.Indovac provides hydro/pneumatic circuit for automatic disposal of the substance to other subsequent processes as may be feasible and as per the customers’ needs. This system is used mainly in sea food process, pharma industries, chemical applications, distillation and recovery processes in any industry. For details contact: Indovac Pumps & Engg Co 21 Anand Raj Indl Estate, Sonapur Lane B/h Asian Paints, Off LBS Marg Bhandup (W), Mumbai 400 078 Tel: 022-25664917, 65062751, Telefax: 91-022-25664917 E-mail: indovac@yahoo.co.in or Circle Readers’ Service Card 20
Chemical Engineering World
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CEW Products Automatic Adapter Test System
Triple Quadrupole Mass Spectrometer
Automatic adapter test system is a fast and easy testing of DC adapters, most ideal for mobile chargers, battery chargers, etc. It is computer controlled with user-friendly software.
For labs looking for the next step up in triple quadrupole GC-MS/MS productivity, the Thermo Scientific TSQ 8000 Evo triple quadrupole mass spectrometer provides more capacity, more information, more compounds and more results per unit of time for higher levels of productivity and efficiency in analytical workflows. Unlike other GC triple quadrupole mass spectrometers that require extensive, time consuming method setup, the TSQ 8000 Evo GC-MS/MS has purpose-built software, AutoSRM, for automated SRM method creation, optimisation and management from full scan to the complete analytical method setup. It is fast, simple and reliable.
Scans at one stroke all the parameters of each and every output as per pre-defined program of the test procedure. One can test all the outputs with programmable DC load (up to 2A) at any four fixed steps of input AC voltage to adapter. For details contact: Vasavi Electronics No: 95, Road No: 6A Jyothi Colony Secunderabad Andhra Pradesh 500 015 Tel: 040-27744445 E-mail: vasavi@vasavi.com
For details contact: Thermo Fisher Scientific India Pvt Ltd 102, 104, Delphi ‘C’ Wing Hiranandani Business Park Powai, Mumbai 400 076 Tel: 022-67429494 Fax: 91-022-67429495 E-mail: sagar.chavan@thermofisher.com or Circle Readers’ Service Card 21
or Circle Readers’ Service Card 22
Zero Hold-up Filter Press In reverse flow zero hold up type, the direction of flow of liquid is exactly opposite to the flow in standard filter, ie, the impure liquid to be filtered enters the filter from the bottom into the center channel and goes to the top of each plate. The clear filterate flows out from openings on side of plates to the shell and then to the outlet. This flow ensures almost 100 per cent filtration of the liquid. Complete filtration of the batch without any hold up due to reverse flow of liquid hence large saving in time and cost. Backwash facility can be provided for continuous operations. No scavenger arrangement required.The cake, filteraid and solids remain totally enclosed allowing filtration of toxic, hazardous and explosive liquids.The top dome structure ensures fast and easy removal of cartridge assembly and cleaning of cake For details contact: Brilliant Process Machinery Pvt Ltd Unit No: 1, 2,14 Mordan Indl Estate Opp: Ipol, Waliv Phata Vasai (E), Dist: Thane Maharashtra 401 208 Tel: 0250-3293636 E-mail: brilliantprocess@rediffmail.com or Circle Readers’ Service Card 23
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Chemical Engineering World
19 th International Conference INDIAN Petrochem – 2017 Date : 11-12 October 2017 Venue : Hotel The Lalit, Mumbai Event : This premier exclusive petrochemicals forum will have focused coverage of the entire petrochemical sector with a primary focus on Indian markets and overview of Asian and Global markets. The conference will broadly focus on the petrochemicals markets, feedstocks, downstream sectors and technology. For details contact: Tel: 91 22 23851430 Email: info@eliteconferences.com
The Waste Management and Recycling Africa Summit 2017 Dates : 2–3 October 2017 Venue : Radisson Blue, Nairobi, Kenya Event : The Waste Management and Recycling Africa Summit 2017 will be the first major event of this year in Nairobi focusing on the waste management and technology used to make this earth better place. We expect several hundred people from emerging markets to participate, including ministers, entrepreneurs, scientists, and other innovators. Additionally, the event will feature leading companies, officials and experts on waste treatment, environment and recycling from leading academic institutions, NGOs, and start-ups from Africa, Asia, Latin America, and Europe
4 th International Conference & Exhibition on “Pipeline Integrit y Management” Date : 10-11 November 2017
For details contact: BIZENIUS conference@bizenius.com
Venue : Holiday Inn Hotel, Mumbai Event : The integrity of pipelines is a basic concern for pipeline operators, and therefore, the ability to detect anomalies due to corrosion, erosion, milling and mechanical damage shall be of significant interest to the operators. Pipeline Integrity Management Program not only can extend the life of the existing pipelines, also helps to prevent any future damage if follows during design and construction of the new pipelines, maintain adequate safeguards for assets, human life and the environment. This event- 4th ICEPIM will provide an ideal platform for experts and technocrats to share ideas to improve safety & control measures to effectively minimize corrosion and other damages. For details contact: Somdatt Chamber Bhikaji Cama Place New Delhi-110066 Tel: 011-4654 5757 Email: consultmatcorr@gmail.com matcorr@pipelineintegritymanagement.in Waste Technology India Expo Dates : 18-20 January 2018 Venue : Bombay Convention & Exhibition Centre, Mumbai Event : Waste Technology India Expo is a 3 day event in Mumbai. The waste management and recycling exhibition will have solutions for managing and recycling of different kinds of waste, both solid and liquid, generated in industries, cities, homes, etc, to ensure clean surroundings. This event showcases product from air and water management, environment and waste management industries. For details contact: Virtual Info System Pvt Ltd 231 Mastermind-1, Royal Palms Mayur Nagar, Aarey Milk Colony Goregaon (E), Mumbai Chemical Engineering World
AgroChemEx 2017 Date : 15-17 October,2017 Venue : Shanghai World Expo Exhibition and Convention Center (SWEECC) Event : One of the largest international event for agrochemicals, whether to meet with governmental authorities, high-level decision makers or visit to see the exhibition gathering most of qualified manufactures, formulators in China, AgroChemEx provides you excellent one-stop service. For details contact: Overseas Visitor Contact:Linda HSU Tel: +86-10-84885108 Email:ccpiaxyq@126.com Overseas Exhibitor Contact:Jack ZHAO Tel: +86-10-84885931 Email:ccpiazyj@126.com Yapex Building Exhibition 2017 Date : 15 November 2017 - 18 November 2017 Venue : Antalya Expo Center, Antalya, Turkey Event : Yapex Building Exhibition 2017 is an International Trade Fair for Building Materials, Construction Technology and Building Renovation. Yapex Building Exhibition 2017 to be held on 15-18 Nov 2017 at Antalya Expo Center, Antalya, Turkey. It is an excellent occasion to meet the expanding building market of Turkey, to present the latest products to international professional visitors and to establish new contacts with industrialists and businessmen. For details contact: Mr. Faith Onkar Tel: 90-242-3164600 September 2017 • 71
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 Coal India is planning a ` 10,000-crore joint venture along with GAIL India, Rashtriya Chemicals & Fertilizers (RCF) and The Fertilizer Corporation of India (FCIL) to set up a urea and ammonium nitrate chemicals complex that will run on gasified coal. Coal India has appointed Projects and Development India (PDIL) to conduct a feasibility study on the project. The plan is to use around 6 million tonnes of coal from coalfields at Talcher in Odisha and manufacture about 3 lakh tonnes of urea annually and around 300-400 tonnes of ammonium nitrate per day. AkzoNobel, a Dutch specialty chemicals company and Atul Ltd have agreed to jointly set up a manufacturing plant for monochloroacetic acid (MCA) at Atul’s facility in Gujarat. Each partner will hold a 50 per cent stake in the venture. The partnership will build on Atul’s status as a leading global supplier of the herbicide 2,4-D (which uses MCA as a key raw material) and AkzoNobel’s leading global position in MCA market, with plants in the Netherlands, China, Japan and the US. The investment is subject to regulatory approvals and signing of final agreements. The partnership will use chlorine and hydrogen manufactured by Atul to produce the monochloroacetic acid, taking advantage of both Atul’s existing infrastructure and the leading ecofriendly hydrogenation technology supplied by AkzoNobel. From an initial annual capacity of 32 kilo-tonnes (KT) at start-up, the plant has been designed for future expansion to 60 KT. The plant will produce enough MCA to meet the captive requirement of Atul; AkzoNobel will market the rest of it, primarily in India. Monochloroacetic acid is an essential building block in the chemical industry and is used in a wide variety of chemicals. Camlin Fine Sciences Ltd, which offers shelf-life solutions (antioxidants and intermediates), performance chemicals and aroma chemicals, has received environmental clearance from the State Level Environment Impact Assessment Authority of Gujarat for setting up a manufacturing facility for hydroquinone (HQ) and catechol and their down-stream products at Dahej SEZ. The Dahej plant will expand capacities and provide CFS with a base to manufacture hydroquinone and catechol in India. The plant will also help Camlin Fine Sciences to add capacity for manufacturing of vanillin, for which catechol is a key raw material. The company expects to commission the Dahej plant in FY18. The plant will have capacity to produce 9,000 metric tonne per annum (MTPA) and 6,000 MTPA of HQ and catechol, respectively. Bodal Chemicals, the Ahmedabad-based Bodal Chemicals has received environmental clearance (EC) from the Ministry of Environment, Forests & Climate Change for the expansion of dyes and dyes intermediates manufacturing facility located at Vadodara, Gujarat. The company is expanding its dyes and intermediates manufacturing capacity from 2,200 metric tonne per month (MTPM) to 6,000 MTPM, and set up a co-generation power plant (5-MW) in Gujarat. Perstorp, a Swedish specialty chemicals firm is planning to set up a manufacturing facility for pentaerythritol (penta) in Maharashtra. To evaluate the opportunity to invest in a new world scale production plant 72 • September 2017
for penta in India, the company has signed an MoU with Maharashtra Industrial Development Corporation (MIDC). Pentaerythritol, a white crystalline polyhydric alcohol containing four primary hydroxyl groups, is used as building blocks in alkyd resins for coatings, radiation curing monomers, polyurethanes, rosin esters, synthetic lubricants and explosives. IOL Chemicals & Pharmaceuticals Ltd (IOLCP), a producer of active pharmaceutical ingredients (APIs), has increased the production capacity of ibuprofen to 6,200 tonnes per annum (TPA) at Barnala plant in Punjab. Expansion follows a de-bottlenecking project undertaken by the company at an estimated cost of ` 24 crores. MINING NTPC Ltd, the state-owned power generator hopes its captive coal production will reach 100 million tonnes (MT) as soon as its five coal blocks commence operations, aided by faster regulatory clearances and the part-privatization model of Mine Development and Operator (MDO). The success of the plan would determine fuel security of the operations of India’s largest power producer. KIOCL will revive mining, after the State granted the company a lease of over 474 hectares at Devadaru hills in Ballari. KIOCL had suspended mining in the eco-sensitive Western Ghats following a Supreme Court directive in 2006. Once approvals are given, it would invest ` 1,500 crore in a pellet plant and also a unit to enrich iron ore from the mines. After suspension of mining, KIOCL had shifted to operating 3.5 million tonne per annum pellet plant in Mangaluru. Last year, it produced 1.46 million tonnes, utilising half its capacity, as against almost nil production in the previous year. The company’s blast furnace Unit having a capacity of 216,000 tonnes of pig iron which was put under suspension since 2009 has been taken for repair and the Unit is ready for operation for producing foundry grade pig iron adding towards its profitability in the coming financial year. The firm earned a profit of ` 47.93 crore in FY17 as against a loss of ` 80.15 crore the previous year. Revenues grew 353 per cent to ` 929.36 crore from ` 205.57 crore in the previous fiscal. Coal India arm Western Coalfields has received the environment clearance for its ` 263 crore expansion project in Nagpur district, Maharashtra. The proposal is to enhance the production capacity of the Gokul open cast mine to 1.875 million tonnes per annum (MTPA) from the existing 1 MTPA. The mine, located in 767.17 hectare, has a mineable reserve of 14.50 million tonnes. Among the conditions specified, the company has been asked to get ‘Consent to Operate’ certificate from the State Pollution Control Board for the existing production capacity of 1 MTPA and also the ‘Consent to Establish’ for the proposed capacity of 1.875 MTPA prior to enhancing the production capacity. With regard to transportation of coal, the company has been asked to take mitigative measures to control dust and other fugitive emissions all along the roads by providing sufficient numbers of water sprinklers. The company has been informed to adopt controlled blasting techniques to control ground vibration and flying rocks. It has also been told to implement a progressive afforestation Chemical Engineering World
Project Update CEW plan covering an area of 376.04 hectare at the end of mining. Of the total quarry area of 231.73 hectare (on floor) and 291.21 hectare (on surface), the backfilled quarry area of 115.39 hectare should be reclaimed with plantation and there will be no void left at the end of the mining operations. The land after mining should be restored for agriculture purpose. GVMC has initiated a process to take up bio-mining of the accumulated waste proposed at Kapuluppada dump. To begin with bio-mining is proposed to be taken up in five acres of the dumpyard. GVMC has sought the involvement of private companies under corporate social responsibility or by investing money to salvage the dump yard to which garbage is being transported for nearly two decades and piled up there. About 60 of the 100 acres in the dump yard has been filled up, according to officials. The cost of bio-mining is roughly put at ` 400 a tonne going by the experience of other civic bodies. With the city generating about 1,000 tonnes of garbage the cost comes to a whopping ` 4 lakh a day. GVMC has recently come out with plans to set up organic waste converters at six rythu bazars and Poorna Market and asked bulk generators like hotels to go in for OWCs. Also separation of waste in 72 colonies of as many wards has also been taken up. ENERGY Infrastructure Leasing and Financial Services Limited (IL&FS) is set to invest about ` 35,000 crore for setting up 6,000 megawatt (MW) of power generation capacities in Kutch, Gujarat. IL&FS Group has already laid out plans for a multi-product Special Economic Zone at Kutch and two power generation facilities combining 6,000 MW capacities in the SEZ. The group is proposing to set up 4,000 MW of coal-based power project with a cost of ` 28,004.65 crore and 2,000 MW of gas-based power project at the cost of ` 7,187 crore. The funding will be met through an appropriate mix of debt and equity funds. The company has already signed the agreements with the Gujarat Maritime Board, Government of Gujarat for the development of the Shipyard, Captive Jetties and LNG Terminal at Nana Layja and also for the development of SEZ and Free Trade and Warehousing Zone (FTWZ). IL&FS Group company, IL&FS Maritime Infrastructure Company Ltd. (IMICL) is undertaking the day-to-day project development activities for an Integrated Maritime Complex comprising a Shipyard and a multi-product SEZ at Nana Layja where IL&FS is the co-developer, company’s web site says. The Project site is located at the mouth of Gulf of Kutch and is 95 km from Kandla Port and 65 km from Bhuj. Gujarat Energy Transmission Corporation’s (GETCO’s) ` 12,500-crore expansion plan will see the utility leveraging 70 per cent of the required funds. The expansion plan entails adding 10,000 circuit km (ckm) of the transmission line and construction of 400 new substations by 2022, through the extension of 2,000 ckm transmission line as well as 80 new substations annually for the next five years. As on date, GETCO has a network of 1,770 substations and over 58,500 circuit km of the transmission line, varying in voltage class levels of 66 kilovolts (kV) to 400 kV. With the addition of 500 substations and 13,500 circuit km of the transmission line, the load handling capacity of GETCO’s network is expected to grow to over 30,000-32,000 MW, from the current 25,000 MW. Chemical Engineering World
CleanMax Solar, the Mumbai-based solar energy firm, which reported to have a 23 per cent market share in rooftop solar space, is planning to double its rooftop installation to 100 MW with an investment of around ` 500 crore. The company is in talks with various investors including private equity firms to raise funds. The investment would be approximately ` 5 crore per megawatt as project cost and it would require roughly ` 500 crore for the rooftop projects this year. Around 70 per cent would be debt and the rest would be equity. The company is in discussion to raise private equity fund, which is not concluded yet. The company has bagged a contract from the Chennai Metro Rail Ltd to install rooftop and ground mounted solar PV plants at 12 metro stations and the Koyambedu maintenance depot in Chennai, providing low-cost and renewable solar energy for CMRL’s operations. Once fully operational, the total capacity of rooftops and ground mounted power systems CMRL’s facilities will be 6 MW, which will make it one of the largest onsite solar projects in India. This is expected to help Chennai Metro reduce carbon dioxide emission by 7,438 tonne per annum and help save ` 150 lakh per annum. Cleanmax Solar has installed more than 200 projects, with a combined on-site capacity of more than 80 MW, with a market share of 23 per cent, as per Bridge to India 2016 report. CleanMax Solar was also the first to supply open access solar power to corporate clients in States like Karnataka. Currently have 30 MW Solar Farms in Karnataka and Tamil Nadu respectively. FERTILISERS Nagarjuna Fertilizers and Chemicals Ltd, is planning to invest ` 5,000 crore in expanding its fertilizer facility in Kakinada by setting up a 1.3 million tonne per annum brownfield urea project. The new expansion facility is slated to come up within the existing complex. It will take two years to complete. The company hopes to raise funds for the expansion through a combination of debt, equity and internal accruals Greenstar Fertilizers Ltd is kicking off `135-crore expansion of its phosphoric acid unit to meet the raw material demand for Diammonium Phosphate (DAP) production. The company has started the environmental clearance plans for the project with a public hearing to be held on December 30. The project is coming up on its existing facility at Tuticorin in south Tamil Nadu. Greenstar Fertilizers, promoted by Ashwin Muthiah, son of AC Muthiah, the promoter of SPIC, acquired the phosphatic businesses of SPIC, through a business transfer agreement in October 2011. Under this agreement, the DAP, aluminium fluoride, SSP units, sulphuric acid and phosphoric acid units came under Greenstar Fertilizers’ fold. Urea production was retained with SPIC. In the proposed project, the raw materials handling will more than double with rock phosphate handling increasing to 62,100 tonnes a month and sulphuric acid capacity to 54,900 tonnes. Phosphoric acid output will double to 1.5 lakh tonnes. The raw material for the proposed project will be brought in from Gujarat, Rajasthan or imported. The final products DAP, SSP and aluminium fluoride will be sold in the domestic market. This will bring down the import dependence of DAP Indian Farmers Fertilizer Cooperative (IFFCO) has awarded a `300-crore contract to Essar Projects, an engineering procurement and construction (EPC) company, for construction of a new phospho gypsum stack at IFFCO’s Paradip unit in Odisha, which is India’s largest phosphatic fertiliser complex. This is Essar Projects’ fourth major contract from the Indian fertiliser industry giant. The project September 2017 • 73
CEW Project Update will be completed in two phases. Phase I, valued at about `190 crore, involves completion of approximately 60 per cent of the total construction and must be completed in 20 months. The second phase involves construction of the remaining 40 per cent and will have to be completed in 10 months. Essar Projects’ previous contracts for IFFCO includes construction and commissioning of two 2,500 MT DAP / NAP silo, revamping of an existing sulphur silo, and EPC and commissioning of the eighth evaporator system of the phosphoric acid plant (PAP) at the IFFCO Paradip complex. Ramagundam Fertilizers and Chemicals Limited’s Urea plant gets green nod from the Ministry of Environment and Forests (MoEF) Committee for the proposed ` 5,465-crore fertiliser plant in Ramagundam, Telangana. National Fertilizers Limited ( NFL), Engineers India Limited (EIL) and Fertilizer Corporation of India (FCIL) had earlier signed an agreement to form a joint venture company ( JVC) for setting up two new -- Ammonia and Urea -- plants at the existing site of Ramagundam Fertilizer plant. The JV formed a new company called Ramagundam Fertilizers and Chemicals Limited. The gas-based plant which will have the capacity to produce 1.1 million tonnes of urea per annum is expected to be commissioned in 2018-19. The Rashtriya Chemicals and Fertilisers (RCF) is likely to get clearance from the Public Investment Board (PIB) for establishing a new urea plant at its current manufacturing facility at Thal in Maharashtra with an estimated investment of ` 5,500 crore. As per the proposal, an ammonia-urea plant will be set up at Thal in Maharashtra with a capacity of 1.27 million tonnes per annum at the company’s current manufacturing location. Tender for the plant’s engineering and construction has been awarded to a consortium of Technip and L&T. The Mumbai-based PSU’s annual urea capacity is more than 2 million tonnes and it also produces various grades of complex fertilisers at its two manufacturing units in Thal and Trombay in Maharashtra. RCF, along with Coal India, GAIL and Fertiliser Corporation of India (FCIL), has also formed a consortium to revive the sick unit of FCIL at Talcher at a cost of ` 8,000 crore to manufacture urea and ammonium nitrate via coal gasification. PETROLEUM, OIL & GAS AG&P (Atlantic, Gulf and Pacific Company), and Hindustan LNG (HLNG), a Hyderabad-based LNG import terminal development company, have signed a memorandum of understanding (MoU) to supply tolled gas to power stations in the East Godavari region of Andhra Pradesh. AG&P is a leading global integrator of LNG infrastructure solutions, including LNG terminals and related supply chains. Under the agreement, AG&P will provide an integrated solution to deliver regasified LNG through a new LNG import terminal that it will design and build at a port in Andhra Pradesh. The MoU would pave way for a fully integrated solution for tolled gas in India, including design, construction, financing, operations and maintenance of the new terminal, which will ensure a reliable and low-cost supply to power producers, fertiliser plants, cold storage and other industries in Andhra Pradesh and other markets along the east coast. AG&P will be responsible for designing and building all the required facilities for the import terminal, including a floating storage and mooring system, regasification terminal, related utilities and the provision of tolled gas to power plants and other users. It will also carry out any necessary conversion works and, upon commissioning, ongoing operations and maintenance activities. 74 • September 2017
Bharat Petroleum Corporation Ltd (BPCL), India’s second biggest state-run refiner, plans to spend about ` 13,000 crore on expanding its Numaligarh refinery in Assam by 2017-18. The company plans to expand the Numaligarh refinery to 9 million tonnes from the current 3 million tonnes. IOC, BPCL and HPCL, State-owned oil firms recently signed an agreement to jointly set up India’s biggest refinery at Ratnagiri district of Maharashtra at a cost of $30 billion or ` 2 lakh crore.Indian Oil Corp (IOC) will be the lead partner with 50 per cent stake while Hindustan Petroleum Corp Ltd (HPCL) and Bharat Petroleum Corp Ltd (BPCL) will take 25 per cent stake each. The three oil refining and marketing companies signed the joint venture agreement. The pact was signed by IOC Chairman, HPCL Chairman and Managing Director and BPCL Chairman and Managing Director. Officials said the 60 million tonnes capacity refinery at Babulwadi, Taluka Rajapur in Ratnagiri district is being set up keeping in mind the future fuel demand and the export potential of the country. The refinery and the accompanying mega petrochemical complex will be set up in two phases. Phase-1 will be 40 million tonnes together with an aromatic complex, naphtha cracker and polymer complex. Phase-1 will cost ` 1.2-1.5 lakh crore and will come up in 5-6 years from the date of land acquisition, they said. The entire refinery will include three crude units of 20 million tonnes each -- first of these will be part of Phase-1. The second phase will cost ` 50,000-60,000 crore, they said.IOC has been looking at West coast for a refinery as catering to customers in West and South was difficult with its refineries mostly in the North. HPCL and BPCL have also been looking at a bigger refinery because of constraints they face at their Mumbai units. The refinery will produce petrol, diesel, LPG, ATF and feedstock for making petrochemicals that are basic building blocks in plastic, chemical and textile industries. Fifteen million tonnes a year is the biggest refinery any public sector unit has set up in one stage. IOC recently started its 15 million tonnes unit at Paradip in Odisha.Being on the West coast will provide the unit a natural advantage of easily sourcing crude oil from the Middle-East, Africa and South America, officials said, adding East coast was not being considered as shipping crude oil there will add at least USD 1 per barrel to cost. Also, moving products to consumption heartland from west will not be difficult. India has a refining capacity of 232.066 million tonnes, which exceeded the demand of 194.2 million tonnes in 2016-17 fiscal. According to International Energy Agency (EA), this demand is expected to reach 458 million tonnes by 2040. IOC has 11 refineries with a total capacity of 81.2 million tonnes while BPCL has 4 refineries with a total capacity of 33.4 million tonnes. HPCL has 3 refineries with a total capacity of 24.8 million tonnes. PACKAGING Emami Paper Mills is investing ` 1,000 crore to double the capacity of its paperboard unit at Balgopalpur in the next three years. -- the current capacity is 132,000 tonnes per annum. The bulk is supplied by smaller, unorganised entities. Emami’s paperboard unit would entirely use imported pulp, sourced from North America, Europe, New Zealand and Scandinavia. Emami also has a newsprint unit here, with a capacity of 145,000 tonnes a year. The high-end paperboard market in the country is estimated to be growing at 15 per cent yearly, fuelled by increased consumer spending and growth in the organised retail sector. Separately, another Emami Group company, Emami Cement, hopes to put on stream a grinding unit at Tangi near Cuttack in the next 12 months. Chemical Engineering World
Book Shelf CEW Petroleum Refining in Nontechnical Language Author/s : William L. Leffler Price : USD. 67.942 Pages : 270 (Hardcover) Publisher : PennWell Books About the Book: William Leffler’s “Petroleum Refining in Nontechnical Language, Fourth Edition” is designed to give the reader an overview of key refining topics by using relevant analogies, easy-to-understand graphs, formulas, and illustrations. New to this edition is important information on the nature of crude oil and raw materials and a comprehensive discussion on what sets crude oil and oil products price differentials. Also new is a chapter on lubricants as well as the latest technologies employed by refiners. Each chapter was carefully written in nontechnical language to give the reader a basic understanding of the refining industry. The book can be used for self-study, as a classroom textbook, or as a quick reference.
Planning and Integration of Refinery and Petrochemical Operations Author/s : Khalid Y. Al-Qahtani, Ali Elkamel Price : USD 79.41 Pages : 206 (Hardcover) Publisher : Wiley, 2011 About the Book: Clearly divided into three main sections, this practical book familiarizes readers with the area of planning in petroleum refining and petrochemical industry, while introducing several planning and modeling strategies encompassing single site refinery plants, multiple refinery networks, petrochemical networks, and refinery and petrochemical planning systems. It equally provides an insight into possible research directions and recommendations for the area of refinery and petrochemical planning. Furthermore, several appendices are included to explain the general background necessary, including stochastic programming, chance constraint programming, and robust optimization. For engineers and managers working in the petroleum industry as well as academic researchers in production, logistics, and supply chain management.
Petroleum Refining Technology Author/s : Mall I.D. Price : USD 6.220 Pages : 576 (Hardcover) Publisher : CBS Publishing About the Book: It is one of the important courses in chemical, petroleum engineering and petrochemical courses at Btech and Mtech programs. The book contains 26 chapters dealing with introduction to petroleum refining, status of global and Indian petroleum industry, various aspects of crude oil production and processing, and recent trends in petroleum refinery processes, natural gas processing and integration of petroleum and petrochemical, biofuel and separation processes in petroleum refining. In addition, the book also presents energy management, environmental protection, corrosion control and selection of construction material in petroleum refining industry. Oil movement, storage, crude and product blending and handling have been also discussed. The appendix contains glossary of terms; list of abbreviations; properties of important hydrocarbons, petroleum, natural gas and petroleum products: standards and specifications; list of major petroleum and petrochemical complexes; and list of major consultancy and research organizations dealing with exploration, petroleum and natural gas processing. Chemical Engineering World
Handbook of Petrochemicals Production Processes (Mechanical Engineering) Author/s : Robert A. Meyers Price : USD 169.551 Pages : 744 (Hardcover) Publisher :McGraw-Hill Education About the Book: Although described as a handbook, this work is more an encyclopedic description of 53 industrial process technologies for producing 18 different petrochemicals. Each process is described in a separate chapter by a different author or authors from one of 18 different companies from North America, Europe, or Japan. The descriptions are mostly brief (averaging 13 pages) and include the following information: general process description, process chemistry, process perspective, process description, product specifications, wastes and emissions, and process economics. The amount of detail varies, but the most common elements are the chemistry and flow diagram of each process, with other details being mostly of a qualitative or descriptive nature. The reader should be aware that there are many other large companies that have patented processes for a number of the chemicals included (notably absent is ICI, one of the largest, so the compilation should be considered representative rather than extensive. This excellent introduction and summary of typical plant operations is recommended as a valuable reference for any technical library that includes industrial chemistry and/or chemical engineering.
September 2017 • 75
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Inside Cover I
16
Lubrizol Advanced Materials India Pvt Ltd
Client’s Name
Page No
11
Atomic Vacuum Company (Exports)
9
2
Avcon Controls Pvt Ltd
59
17
Mist Ressonance Engg Pvt Ltd
3
Bedaflow Systems Pvt Ltd
29
18
Munters India Humidity Control Pvt Ltd
4
Bonfiglioli Transmission (Pvt) Ltd
33
19
Rasaii Flow Lines Pvt Ltd
43
5
Busch Vacuum India Pvt Ltd
27
20
Sandvik Asia Pvt Ltd
23
6
Chemlin Pumps & Valves Pvt Ltd
61
21
Sulzer India Pvt Ltd
41
7
Cole-Parmer India
55
22
Suraj Ltd
57
8
GET Water Solutions Pvt Ltd
45
23
Tecnimont Pvt Ltd
19
9
Hi-tech Applicator
3
24
Three Ten Initiative Technologies LLP
61
10
Horizon Polymer Engineering Pvt Ltd
6&7
25
Toshniwal Instruments (Madras) Pvt Ltd
57
11
ImageGrafix Engineering Services Pvt Ltd
63,65,67,69
26
Uni Klinger Ltd
39
12
Jay Water Management Pvt Ltd
17
27
UNP Polyvalves (India) Pvt Ltd
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13
Kirloskar Brothers Ltd
11
28
Vac Enterprises India
55
14
Koerting Engineering Pvt Ltd
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76 • September 2017
Chemical Engineering World
CEW
INTERVIEW
Interview CEW
“Willingness of Industry to adapt to New Advancements in the field of Corrosion Control would ensure Safety and Long Life” Corrosion is the deterioration or destruction of metals and alloys in the presence of an environment by chemical or electrochemical means. In simple terminology, corrosion processes involve reaction of metals with environmental species. It can be viewed as a universal phenomenon, omnipresent and omnipotent. Dr Vivkeananda Kain, Outstanding Scientist and Head, Materials Processing & Corrosion Engineering Division, BARC How prepared is the industry to realise the vision of Honourable Prime Minister envisions Zero Defect, Zero Effect as far as corrosion is concerned, which is a critical factor to be successful in the global markets? Zero Defect, Zero Effect is a much broader concept that would certainly ensure efficiency, safety, plant availability and productivity in industry. As far as corrosion is concerned, industry has to start from the design of components and materials. Measures against corrosion as well as to ensure trouble free design life have to be incorporated from design stage as well as by proper material selection. Subsequently quality of materials being used, fabrication Chemical Engineering World
route and quality during fabrication, care during storage & transportation and installation (and conditioning, if required) are equally important steps. Industry knows that any error in design, material selection and fabrication steps would have a bearing on performance of the components in service. Similarly, during operation of plants/components, proper corrosion control measures need to be implemented. Indian products would certainly compete in global markets with Indian industry giving due importance to this concept of Zero Defect, Zero Effect. This would involve Indian industry imbibing knowledge on corrosion and how defects at various stages of manufacturing and operation affect corrosion degradation
and affect safety and productivity. Major industries are already giving emphasis on corrosion being given its due weightage in all stages of manufacturing and operation. As per the estimates, India is losing close to USD 100 billion (these numbers vary from Rs. 2 lakh crore to Rs. 6 lakh crore from various sources and have increased ) each year to corrosion; and this is a major part of our GDP. To what extent this can be reduced or taken care of for the future these losses can be curbed and how? A recent corrosion survey projects corrosion costs to be 4.2% of our GDP (2013) and the figure may be actually September 2017 • 77
CEW Interview be higher as all the sectors were not covered in that survey. Certainly in India also, we have the realization of the cost due to corrosion and the fact that about a third of this cost can be saved if we implement corrosion control measures. To achieve this objective, the first step is to spread awareness about corrosion costs to all segments of industry. Once the management is convinced of the corrosion costs or the savings when corrosion control measures are implemented, we would see implementation of corrosion control measures and corrosion costs coming down gradually. Professional bodies in the field of metallurgy and corrosion would play a key role in spreading awareness about corrosion and corrosion control measures. How has the approach to attend to corrosion related issues changed across the industry as well as the policy makers since the beginning of your career? I started my career in 1986 and I remember at that time there was not much awareness about corrosion costs in industry or academia. I started to see signs of corrosion awareness in industry from late 90s and it has now spread to the segments of industry that get directly affected by corrosion. What I would like to see is the spread of corrosion awareness right from design stage to fabrication stage in industry. We need to convince management that any expenditure on account of corrosion results finally in substantial savings in terms if plant availability, safety and profitability. Similarly, manufacturers should realize that incorporating measures against corrosion right from design stage to manufacturing stages would result in products that would be globally competitive. Please share insights into the research in the field of new materials and what kind of acceptance are new materials getting across multiple user industries. New materials keep entering the market and find specific applications in industry. 78 • September 2017
At the same time industry too demands materials for more and more aggressive environments. It is not that every new application requires a new material. Most of the currently available materials would be able to meet the demands of a new application. One has to critically assess and test the materials for use in a given application. Certainly, newer materials are being brought in the market as they offer certain advantages. In many applications non-metallic materials are being favoured. Indian economy is showing burgeoning growth and in the years to come will see significant investments across the manufacturing verticals of chemicals and petrochemicals; infrastructure; and energy etc. In your view, what are the critical factors that should be taken into consideration to ensure safety and longevity of the assets? New plants in any of these industries should be set up with corrosion control measures incorporated right from design and manufacturing stages. Chemical and petrochemical and energy industries have to take continuous precautions during operation to avoid corrosion damage. Corrosion monitoring techniques and corrosion control techniques have made tremendous advancements and have a lot of potential to be applied in these industries. Willingness of the industry to adapt these new advancements in the field of corrosion control would ensure safety and long life. How critical is it for India to have its own National Corrosion Standards for various industries? In your view, is there any international model that could possibly be emulated to set the corrosion standards in India?
corrosion resistant materials (for a specific industry), acceptance values in specific tests and its correlation to corrosion damage during long term plant operation etc. Such specific standards, not covered by BIS, should be brought out as National Corrosion Standards. It is important to have these national standards keeping in mind local rules and regulations. How do you compare corrosion audits and inspections in India vis-à-vis other countries? There is a need for a National Corrosion Audit Board. This would ensure uniform and standard practices for corrosion audit. There is also a need for specifying corrosion audit practices for a specific industry. As a thumb rule, what are the key steps that should be taken in your view by the industry as well as the regulators to curb the impact of corrosion in the long run? The following steps may be used by industry: •
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Incorporate corrosion control measures in design, manufacturing, installation and operation stages. Regularly have corrosion awareness and corrosion control programs Apply corrosion monitoring techniques to be alerted about onset of corrosion damage Have regular corrosion audit done Keep abreast of and use the latest corrosion control techniques and materials
Bureau of Indian Standards (BIS) is the apex body dealing with standards in all fields including corrosion. However, there is a need to have standards in those areas that are not dealt by BIS e.g. recommended operating practices to avoid/minimize corrosion, choice of Chemical Engineering World