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CHEMICAL ENGINEERING WORLD SEPTEMBER 2014 VOL. 49 ISSUE 9 Mumbai ` 150 Cover June 2014.indd 1
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CEW Contents CHEMICAL ENGINEERING WORLD RNI REGISTRATION NO. 11403/66 Chairman Publisher & Printer Chief Executive Officer
EDITORIAL
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Jasu Shah Maulik Jasubhai Shah Hemant Shetty Mittravinda Ranjan (mittra_ranjan@jasubhai.com) D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com) Harshal Y Desai (harshal_desai@jasubhai.com) Arun Parab, Umesh Chougule Abhijeet Mirashi Dilip Parab Brenda Fernandes V Raj Misquitta (Head), Arun Madye
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4 • September 2014
NEWS ►
Industry News / 6 Technology News / 18
NEWS FEATURES ►
Innovating for the VUCA World / 22
FEATURES ► The Market with Manifold Opportunities / 24 – Dr Raman Ramachandran, Head, South Asia and Chairman, BASF India
Place of Publication: Jasubhai Media Pvt Ltd
SALES
VOL. 49 | NO.9 | SEPTEMBER 2014 | MUMBAI | ` 150
Growth at Center-Stage / 26 – Rajiv Rao, Sales Director, Basic & Performance Chemicals, Dow India A New Dawn in Waiting for Water Treatment Chemicals / 28 – Tushar Jhaveri, CEO, Vasu Chemicals Soda Ash Industries: A Victim of Policy Paralysis? / 30 – N N Radia, Chief Operating Officer, Soda Ash, GHCL Ltd Think Global & Act Local / 34 – Vinod Saraf, Managing Director, Vinati Organics Ltd NG – Fuelling Integration of Refining & Petrochemicals / 38 – Tanmay Taraphdar, M K E Prasad, Praveen Yadav, Technip KT India Can Responsible Care Thrive in India? / 50 – Debra M Phillips, MD, Responsible Care & Value Chain Outreach, ACC Doing If Differently / 54 – Steve Gimre, MD, UOP India Pvt Ltd Protecting Integrity of Fired Heaters / 62 – Richard D Roberts, Quest Integrity Group, Ashish Khera, Allied Engineers “It’s time We Realised the Significance of Optimal Conservation & Efficient Use of Water Resources” / 66 – S Masood Husain, DG, NWDA
MARKET INSIGHTS ►
Common Facility Centre to Boost R&D in Chemicals in Gujarat / 70
MARKETING INITIATIVE ► Making the Grade / 74
PRODUCTS ► / 76 EVENTS ► / 89 PROJECT UPDATE ► /90 INTERGRAPH: SPECIAL COVERAGE ► /94 BACK OF BOOK ► Ad Index / 100
Book Shelf / 92 Interview/ 101 “Deliver Better Overall Economics than Existing Process Technologies” – Dr Christophe Schilling, CEO, Genomatica Cover image courtesy: UOP (China’s Wison Facility) Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
Printed and published by Mr Maulik Jasubhai Shah on behalf of Jasubhai Media Private Limited, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021 and printed at Anitha Art Printers, 29-30, Oasis Ind. Estate, Next to Vakola Market, Santacruz (E), Mumbai-400055 and rd published from 3 Floor, Taj Building, 210, Dr. D N Road, Fort, Mumbai 400 001. Editor: Ms Mittravinda Ranjan, 26, Maker Chamber VI, Nariman Point, Mumbai 400 021.
Chemical Engineering World
CEW Industry News P D Samudra is New MD of Uhde India Mumbai, India: P D Samudra is the new Managing Director of Uhde India Private Limited, the engineering consulting company based in Mumbai and Pune, and the Deputy CEO of the Regional Cluster for India of the parent company ThyssenKrupp Industrial Solutions. He succeeds Dr Benno Lueke who stayed in India from 2009 P. D. Samudra to 2014, and who has now relocated to Germany Managing Director Uhde India Pvt Ltd due to his appointment as CEO Chemicals and Oil & Gas Operating Unit of the Business Unit Process Technologies of ThyssenKrupp Industrial Solutions. Though effective July 1, 2014, the official handover was formalised at an exclusive business meet of the groupÊs customers, business associates and press at the Trident in Mumbai on August 13, 2014. For Samudra, a Chemical engineer from IIT Mumbai, who headed the Sales function at Uhde India for over 2 decades, the appointment is a remarkable achievement, as he is the first Indian to head the company since its incorporation in 1977.
GCPL Considering Setting Up New Plant in Seemandhra New Delhi, India: To suffice the growing demand for its products, Godrej Consumer Products Ltd (GCPL) is mulling over setting up a new plant in Seemandra besides the present on-going expansion of capacity at the North East and Jammu plants. Although plans have not been finalised, this new plant is most likely to manufacture insecticides and soaps. The company is waiting for details on the benefits the new state could offer for putting up a plant there. Currently, GPCL has manufacturing facilities at Baddi in Himachal Pradesh, Malanpur in Madhya Pradesh, Guwahati in Assam as well as Jammu, Goa and Puducherry. The company is looking for acquisitions outside India as well. The company plans to focus majorly on India, Indonesia and Sub Saharan Africa. In 2011, GCPL acquired a controlling stake in Darling Group Holdings. The company bought out the Issue Group from Latin America which is the market leader for hair-colour in Peru, Argentina, Paraguay and Uruguay.
Revival of Talcher Urea Plant through Two JVs New Delhi, India: Two joint ventures would be formed between Coal India Ltd, GAIL India and RCF and FCIL for reviving the urea plant in Talcher, Odisha and would cost about ` 8,200 crore. GAIL would be having a majority stake in the first joint venture which would be for setting up an upstream coal gasification unit and Rashtriya Chemicals Fertiliser (RCF) will have a majority stake in the second JV through which a urea-cum-ammonia nitrate complex would be set up. This plant will have a production capacity of 1.2 million tonnes per annum. These JVs would be called GAIL Coal Gas Ltd and Talcher Fertlizer and Chemicals Ltd respectively. This plant will be the first greenfield plant set up in the fertiliser sector in almost a decade as well as the first to use the coal gasification technology. 6 • September 2014
FAI Asks Government to Retain Subsidy for Naphtha-based Unit Mumbai, India: Until pipeline gas connectivity is ensured, Fertilizer Association of India (FAI) has asked the government to retain the naphtha-based unitsÊ subsidy. The Modified New Pricing Scheme notified this April 2 by the government states that naphtha based units will continue to produce fertilisers till gas is made available or June 2014, either being the earliest. Even as the urea units have made the investments for conversion, FAI said that the government has failed to ensure gas supply connectivity. In the last week of August, the Government promised subsidy to Southern Petrochemical Industries Corporation, Mangalore Chemicals and Fertilizers and Madras Fertilizers until September. Cumulatively, 14 lakh tonnes of urea has been produced by these companies. The import demand from India would have increased if the urea production units would have shut down. This would in turn boost the urea prices in the international market. It is a paradoxical situation where the government has set its focus on reviving sick units while the survival of efficient urea units is made difficult.
Infosys Awarded 5-year IT Services Deal by BP Bengaluru, India: Infosys has been selected by BP to provide IT services, in particular Application Support and Development to BP. Infosys was chosen to support BP in running, enhancing and developing business applications and improving business IT processes across all key BP IT operations. The agreement, which is effective September 1, 2014, will provide IT ser vices (in par ticular Application Suppor t and Development) across BPÊs operations, including cor porate functions, upstream and downstream segments, energy trading and marketing. The agreementÊs geographical scope includes BPÊs main facilities in Houston, Texas, and in the UK, as well as support in locations as diverse as Azerbaijan, Angola, Brazil and Singapore. Central to these services, Infosys will also continue to invest in the Infosys Information Systems and Technology University. This academy provides training to Infosys engineers in industry knowledge, technology systems, BP processes and key applications. Rajesh K Murthy, Executive Vice President and Global Head, Energy, Communications and Services, Infosys, said, „Winning this contract demonstrates how we have evolved as a supplier and continue to work collaboratively with BP across their range of activities.‰
IndiaÊs chemical industry can grow to USD 290 billion by 2017 at CAGR of 15
per cent.
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CEW Industry News GNFC & EcoPhos Manufacturing JV for Di-Calcium Phosphate
Indian Agrochemical Industry Poised to Touch $7.5 Billion by FYÊ19
Bharuch, India: GNFC and EcoPhos have signed a Memorandum of Understanding for setting up a 150,000 MT per Annum Animal Feed grade Di-Calcium Phosphate (DCP) plant at GNFC TDI Dahej site, Gujarat, India in a Joint Venture. The memorandum was signed by Mr V S Sirohi, Executive Director, GNFC and Mr Mohamed Takhim, Chief Executive Officer, EcoPhos sa Belgium in the presence of Dr Rajiv Kumar Gupta, IAS, Managing Director, GNFC and Mr L Chuaungo, IAS, Principal Secretary - Energy and Petrochemical Department, Government of Gujarat on August 30, 2014 at Gandhinagar, India.
Mumbai, India: In FYÊ14, the Indian agrochemical industry is estimated at USD 4.25 billion. Furthermore, by FYÊ19, it can grow at a compound annual growth rate of 12-13 per cent and reach USD 7.5 billion states a report released at the 4th National Agrochemicals Conference 2014 which was held last month. The report by FICCI and Tata Strategic Management Group details that about 50 per cent of the Indian Crop protection industry is accounted for by exports. The report states that insecticides have the largest share of the industry at 60 per cent while fungicides and herbicides come in at 18 per cent and 16 per cent respectively. The report highlights the important pointers for all the stakeholders, viz, agrochemical companies, government and regulatory bodies.
The co-operation is to incorporate a Joint Venture (JV) Company for manufacturing DCP. EcoPhos will have majority stake in the proposed JV Company. The DCP JV plant will be set up based on eco-friendly, energy efficient and renowned world class technology provided by EcoPhos, utilising Hydrochloric Acid (HCl) and Low grade Rock Phosphate as feed stock. GNFC will provide HCl, utilities and other required services and EcoPhos will provide License, Engineering services and proprietary equipments to the proposed JV Company. EcoPhos will market the output of the JV´s production site at Dahej. According to EcoPhos´ CEO and Founder Mohamed Takhim, this is a substantial step in the realisation of EcoPhosÊ target to become the global market and cost leader in animal feed phosphates through its Animal Feed division.
Solvay to Buy ChevronÊs Ryton PPS Business New Delhi, India: Solvay has signed an agreement to buy the Ryton PPS (polyphenylene sulphide) business from US based petrochemical company Chevron Phillips Chemical Company for USD 220 million, expanding its offering of high-performance polymers and entering a solid growth market. Solvay Specialty Polymers will gain access to new business segments and customers and broaden its offer in many innovative and demanding applications. Ryton PPS has a strong share in the automotive sector, replacing metal parts to make cars lighter and more energy efficient. Other worldwide leading positions are in electronics where it enhances fire resistance of components and in filter bags to extend their lifetime in reducing pollution at coal-fired power stations. The group will buy from Chevron Phillips Chemical two Ryton PPS resin manufacturing units in Borger, Texas, its pilot plant along with R&D laboratories in Bartlesville, Oklahoma and a compounding plant in Kallo-Beveren, Belgium. Chevron Phillips ChemicalÊs compounding unit in La Porte, Texas, will provide temporary tolling services to Solvay. Chevron Phillips Chemical recently developed a highly innovative PPS production technology, which has not yet achieved its full potential. Solvay will invest and use its engineering know-how and operational excellence process to raise this new technology capacity over the next three years, leveraging the talent and quality of the 200 Ryton PPS employees who will join the group. This acquisition is part of SolvayÊs strategic development into a more specialised solutions provider, delivering higher growth, and greater returns while reducing cyclicality. 10 • September 2014
India and Ghana Renew Plans for Urea Plant JV Set Up New Delhi, India: India and Ghana have renewed plans of entering into a joint venture (JV) for setting up a urea plant in Ghana. The African nation has an abundant gas supply which would be the feedstock for urea production. Fertilizer Minister, Ananth Kumar, said that Ghana has found new sources of gas so it has approached India for a urea plant JV set up. Samuel Panyin Yalley, High Commissioner, the Republic of Ghana met Kumar to engage in discussions of setting up the plant. This would be the second time the two countries are exploring setting up a JV urea plant. Kumar added that a JV similar to OMIFFCO is also being explored with Oman. He also said that the government is focusing on increasing the countryÊs urea production in a cost effective manner.
Mike McMullen is now CEO of Agilent New Delhi, India: Agilent Technologies Inc, announced that Mike McMullen, Senior Vice President, Agilent, and President of the companyÊs Chemical Analysis Group (CAG), will succeed William (Bill) Sullivan as CEO. As a first step in the transition, AgilentÊs board of directors has appointed McMullen President and Chief Operating Officer, effective immediately. „This transition is the culmination of our succession planning, and comes at a time of strength as Agilent begins to deliver the shareholder benefits of the recent spinoff of its electronic measurement business,‰ said James Cullen, Chairman of Board of Directors, Agilent. As President and COO, McMullen will be responsible for the companyÊs businesses, CAG and Life Sciences and Diagnostics Group, Order Fulfillment and the newly formed Agilent CrossLab Group, as well as the global organisation that houses IT, workplace services, global sourcing and logistics. Chemical Engineering World
CEW Industry News ExxonMobilÊs Equipment Builder Group Celebrates 100th Anniversary New Delhi, India: ExxonMobil Lubricants Private Limited showcased its outstanding mining equipment lubrication products and lubrication solutions. ExxonMobil comprehensively elaborated on its safety, environmental care and productivity concept of sustainable development and practical experiences, attracting wide attention from participating companies and representatives at the 10 th edition of Minerals, Metals, Metallurgy & Materials international exhibition and conference (MMMM) held in New Delhi from September 4ă7, 2014. With industry-leading technology and engineering resources, Mobil Industrial Lubricants offers innovative products and services that help deliver tangible performance and ÂAdvancing ProductivityÊ related benefits. While consistently leading the lubricants market and industry requirements through its suite of next-generation technology lubricants, ExxonMobil is also celebrating the 100 th anniversary of its Equipment Builder Group, a diverse team of engineers and lubrication experts focused on helping manufacturers optimise the performance and efficiency of their equipment. Established in 1914, the Equipment Builder Group has a legacy for facilitating the designing and monitoring of innovative equipment testing programs with builders and ExxonMobil Research, evaluating lubrication approaches and carefully accessing equipment and lubricant performance. The insights gained from these processes have long played a key role in helping manufacturers to enhance equipment performance, increase energy efficiency, as well as identify and rectify potential equipment performance issues before they occur.
NRL Signs MoU with Chempolis Assam, India: Numaligarh Refinery Limited (NRL) signed a Memorandum of Understanding (MoU) with a Finland based Company, Chempolis Oy, for carrying out a feasibility study for production of ethanol from bamboo biomass. The MoU was signed between Mr S R Medhi, Director-Technical, NRL and Mr Pasi Rousu, President, Asia-Pacific & Americas, Chempolis. As per the MoU, NRL & Chempolis shall jointly undertake an assessment study for ascertaining the availability of the required feedstock in North Eastern India. NRL & Chempolis shall also co-ordinate with various Government/ Private Agencies to identify the main feedstock supply areas in North Eastern India and explore tie ups with the prospective suppliers for supplying the feed stock for the proposed plant. Chempolis shall also carryout experimental testing of various specimens of bamboo and other potential biomass feedstock materials available in North Eastern India and provide the entire pre project technical consultancy required for completion of the Detailed Feasibility Study for the project. Both NRL & Chempolis have agreed to cooperate with each other in carrying out the feasibility study and implement the project, if found feasible and on mutually acceptable terms and conditions through a JV/SPV, subject to environmental clearance from Ministry of Environment & Forest (MoEF), Government of India and other statutory clearances. 12 • September 2014
KBL Signs MoU with PeruÊs National Water Authority Pune, India: Starting a new leaf to India-LatAm relationship Kirloskar Brothers Limited (KBL) signed a Memorandum of Understanding (MoU) with the National Water Authority of Peru (ANA). Under the terms of the MoU, the Indian company will help the Peruvian water authority in the management of water resources in Peru. The MoU was signed at the LatAm Mine Water Conference, held at Lima on August 27 and 28. As per the MoU, KBL and ANA will share information and experience in relation to the management, efficient use and implementation of best practices in the management of water resources in order to contribute to the overall development of these issues in Peru. The two involved parties have expressed willingness to develop capability enhancement programs for the ANA staff on management, efficient use and implementation of the best practices in the area of water management.
Fertiliser Dept Asked to Draw-up Plans for Urea Plants Revival New Delhi, India: The Department of Fertilizers (DoF) has been asked to come up with plans for reviving at least two or more urea plants in the eastern region by the Prime MinisterÊs Office (PMO). This move is with the aim of reducing the urea imports of the nation. A high level meeting between the Secretary Fertilizer, Secretary Petroleum and senior officials of PSUs like CMDs took place at the PMO where discussion were conducted on increasing the domestic urea output through revival of closed plants as well as having the Jagdishpur-Haldia pipeline set up. Other related issues discussed were methods to ensure domestic production of urea is feasible in comparison with the import prices, requirement of guaranteed buyback as well as setting up the JagdishpurHaldia gas pipeline for other industries besides fertilisers. The thought is to increase the domestic urea production and reducing the dependency on imports so that the sudden rise in prices in the international market can be stopped. At the moment, 8 urea units owned by PSUs are closed; these include five and three units of Fertiliser Corporation of India and Hindustan Fertilizer Corporation respectively.
Odisha to Get ` 1 Lakh Crore Investment New Delhi, India: Dharmendra Pradhan, Minister of State (MoS) for Petroleum and Natural Gas (P&NG) met Naveen Patnaik, Odhisha CM to brief him about a number projects in P&NG sector at different stages of implementation in Odisha. Pradhan said that Odisha would receive investment of ` 1 lakh crore during the next 5 years for Petrochemicals, Oil & gas pipelines, LNG & LPG terminals, Strategic oil reserve, etc, including the investment of ` 34,000 crore made in the Paradip Refinery. Odisha will be among the few states to have gas from three sources viz, domestic natural gas, imported LNG and Coal Bed Methane (CBM). For eastern India, these investments would turn Odisha into an ÂEnergy Gateway.Ê Chemical Engineering World
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CEW Industry News Pembina to Set Up New West Coast Propane Export Terminal
New Biological Wastewater Treatment System Launched by UOP
Calgary, Canada: Pembina Pipeline Corporation (Pembina) has selected the site for the companyÊs planned West Coast propane export terminal project. Pembina entered into an agreement with the Port of Portland, Oregon that sets forth the terminal site, which includes an existing marine berth.
Des Plaines, USA: UOP LLC announced its commercial launch of an integrated bioreactor system to efficiently remove organic and inorganic contaminants from a wide range of industrial wastewater streams. HoneywellÊs UOP XCeed bioreactor system, based on HoneywellÊs immobilised cell bioreactor technology, helps industrial, manufacturing, and groundwater remediation facilities meet contaminant removal specifications for wastewater discharge or reuse. UOPÊs commercial launch of this technology builds on the experience associated with more than 50 successful installations.
The Terminal Agreement now enables Pembina to begin the process of engaging and consulting with the neighbours of the project and other stakeholders within the city of Portland, municipal, state and federal governments, and all applicable environmental and regulatory authorities. Pembina intends to initially develop a 37,000 barrel per day propane export facility for an expected capital investment of approximately USD 500 million and with an anticipated in-service date of early 2018.
Lanxess Business Unit Leather Under New Leadership Cologne, Germany: Luis López-Remón (57) is heading the business unit Leather (LEA) of specialty chemicals company, Lanxess. He succeeds Markus Eckert, who is now fully concentrating on his role as head of the group function Corporate Development (DEV), which he took over already in March 2014. López-Remón began his professional career in 1984 at Pall Filtrationstechnik in Frankfurt, Germany. Between 1986 and 2003, he worked for Air Products and Chemicals, Inc. (APCI), where he held top positions in sales and marketing. López-Remón then became the General Sales and Business Manager at Air Products Polymers, a joint venture between Air Products and Wacker Chemie that he was instrumental in establishing and integrating. López-Remón joined Bayer Chemicals as Head of Regional Coordination in 2003, and was in charge of two Board initiatives. From January 2004 until the end of 2006, he headed up LanxessÊ Textile Processing Chemicals business unit and since 2007 was the Head of the Rubber Chemicals business unit.
CHS to Set Up a $3 Billion Fertiliser Plant St Paul, USA: CHS Inc, will proceed with construction of a fertiliser manufacturing plant at Spiritwood, ND. The CHS Board of Directors approved final plans for the approximately USD 3 billion project at its September meeting. Groundbreaking will take place following completion of additional details, with the plant intended to be fully operational in the first half of calendar 2018. The fertiliser plant at Spiritwood will be the single largest investment in CHS history, as well as the single largest private investment project ever undertaken in North Dakota and the company would be the plantÊs sole investor. The plant will produce more than 2,400 tons of ammonia daily which will be further converted to urea, UAN and Diesel Exhaust Fuel (DEF). When fully operational, it is expected to use an estimated 88,000 MM British thermal units/day of natural gas, 40 megawatts/ day of electricity and 2,400-2,700 gallons/minute of water. 14 • September 2014
UOPÊs XCeed bioreactor system has been proven reliable and cost-effective in food and beverage, chemical and textile manufacturing, groundwater remediation, and refiner y and petrochemical applications worldwide. The integrated treatment process can be delivered as a modular system and incorporates mixed-media support for immobilised bio-catalysts, or microbes. The system has a relatively simple mechanical design that minimises energy consumption and required operator attention.
Wacker Named Bosch GroupÊs Preferred Silicon Supplier Munich, Germany: Wacker has been named BoschÊs ÂPreferred SupplierÊ in the Âelastomers and thermosetting plasticsÊ materials group. Stuttgar t-based Bosch awarded the status recently. In BoschÊs annual assessment, Wacker scored top marks in the categories of quality, logistics, innovation and strategic collaboration. As a preferred supplier, Wacker can now play an even stronger par t in the development of new products and technologies. Once a year, Bosch assigns its Preferred Supplier status to the best of its 4,000 suppliers in its subassemblies and materials groups. „WackerÊs outstanding achievements in the fields of quality, delivery reliability, innovation and strategic collaboration made it an obvious choice for this award,‰ said Dr Norber t Neumann, Senior Vice President, Purchasing and Logistics, Automotive Business Subassemblies and Materials, Bosch. Wacker and Bosch have been collaborating closely in automotive electronics and household appliances for over 30 years. The chemical company currently supplies over 100 different silicone products to Bosch, including adhesives, sealants, silicone rubber grades, and specialty silicone gels for potting electronic components.
Global Industrial Automation Market in Chemical and Petrochemical industry to grow at 7.22 per cent between 2013-2018. Chemical Engineering World
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CEW Industry News ABB will Divest Full Service Business to Nordic Capital Zurich, Switzerland: ABB has signed an agreement to divest the ABB Full Service business for an undisclosed amount. The sale is expected to close in the fourth quarter of 2014, subject to regulatory approval.The ABB Full Service business provides fully outsourced industrial maintenance services. ABB Full Service was developed as an adjacent business to ABBÊs life-cycle service business and has become a successful stand-alone business unit. ABB is divesting this business because of limited synergies with ABBÊs core portfolio. ABB will continue to supply its standard life-cycle services for the companyÊs installed base.
Mettler Toledo Launches Moisture Guide for Plastics Columbus, USA: To assist those who work with plastics, both in the laboratory and along the production line, Mettler Toledo has launched a new guide on moisture and water content determination in plastics. The ÂMoisture Guide for PlasticsÊ presents the different methods of moisture and water content determination; loss of weight, chemical reaction, thermogravimetric, spectroscopic and other types of analysis. The guide reviews the advantages and disadvantages of the respective methods, offers tips and tricks to enhance the reliability and performance of measurements and shows solutions to common challenges. Moisture content of resins, such as polyamides or polycarbonates, is an important factor in plastic processing, appearance and properties of the final plastic product. Injection moulding of too moist of plastic pellets results in processing problems and loss in quality of the final product. Typical symptoms of too much moisture are. splaying, formation of flash and impaired mechanical properties such as reduced impact and tensile strength. The control of moisture content is crucial for the manufacturing of high quality products. Two well-known principles are widely used in laboratories and production floors ă loss of weight methods and Karl Fischer titration. The guide presents best practices for both methods.
Non-intrusive Flow Measurement in Harsh, Corrosive Environments Singapore: The FLUXUS F705 and G705 ultrasonic liquid and gas clampon flow meters allow for an inherently precise bi-directional, highly dynamic flow measurement of volume and mass flow rates of virtually any gaseous and liquid FLUXUS F/G705 ultrasonic media ă even at wet gas applications (up to a Liquid Volume Fraction of 5 per cent) clamp-on gas and liquid flow meter or liquid media carrying high contents of solids. With the transmitter being ATEX, IECEx Zone 2 and FM Class I, Div 2 certified ă transducers for ATEX, IECEX Zone 1 and FM Class I, Div 1 are available; it is also the ideal flow meter for hazardous areas. Moreover, with its stainless steel enclosure (316L / 1.4404), it is highly corrosion resistant and especially suited for applications Offshore. 16 • September 2014
Air Products Awards News Gas Complex Contract to Technip Paris, France: Technip was awarded a contract by Air Products to provide project management and engineering, procurement and construction management (EPCM) services for a new industrial gas complex for Bharat Petroleum Corporation Limited ă Kochi Refinery (BPCL-KR). Being built on a ÂBuild-Own-OperateÊ basis (BOO), the industrial gas complex of Air Products is designed to cater to the requirement of industrial gases (Hydrogen, Nitrogen and Oxygen) of BPCL-KR for its Integrated Refinery Expansion Project (IREP), which will increase BPCL-KRÊs crude refining capacity from 9.5 million metric tons per annum to 15.5 million metric tons per annum and produce clean transportation fuels to meet Euro IV/V specifications. The project includes the following main units; Two trains of hydrogen production unit (based on steam methane reforming), of 8.2 metric tons per hour capacity (approximately 91,000 Nm3/hr), An air separation unit to produce nitrogen and oxygen, Steam generation and export to BPCLÊs manufacturing process, A gas turbine to produce power for the Air Products facility, Other utilities required for the BOO facility. The plant will feature the latest technology advancements to maximise energy efficiency and minimise emissions.
Blackmer Debuts New Oil-Free Reciprocating Gas Compressor in India Michigan, USA: Blackmer announced the availability of its new LB081 Model Oil-Free Reciprocating Gas Compressor within the Indian market. With transfer rates ranging from 16 to 47 gpm (61 to 178 L/min), the LB081 compressor is well-suited for use in small plants or on vessels that handle propane, butane and anhydrous ammonia in applications ranging LB081 Model Oil-Free from tank unloading, line-stripping, vapour Reciprocating Gas recovery and on portable evacuation skids. Compressor Manufactured in Pump Solutions GroupÊs (PSG) Chennai, India, facility, the LB081 compressors are designed to provide maximum performance and reliability under the most severe service conditions, and offer the combined characteristics of sustained high-level performance, lower energy consumption, trouble-free operation and low maintenance costs.
David Gibble Promoted to Product Manager Hamilton, USA: David Gibble has been promoted to Product Manager for OPW Engineered Systems within its Chemical & Industrial (C&I) business unit. Prior to this appointment, Gibble was part of the Inside Sales Team for OPW Engineered Systems. GibbleÊs new role will require managing the complete range of Quick & Dry Disconnect products. With an intense focus on growing revenues for new and existing markets, both geographically and industrially, David will also have the responsibility of facilitating the growth of new products including product ideation, design, strategy, launch, features, enhancements and performance. Chemical Engineering World
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Technology News Fracking Not a Risk to Groundwater Pennsylvania, USA: Hydraulic fracturing - fracking or hydrofracturing - raises many concerns about potential environmental impacts, especially water contamination. Currently, data show that the majority of water injected into wells stays underground, triggering fears that it might find its way into groundwater. New research by a team of scientists should help allay those fears. In a paper published in the current issue of the Journal of Unconventional OIL and Gas Resources, Terry Engelder, Professor, Geosciences, Penn State; Lawrence Cathles, Professor, Earth and Atmospheric Sciences, Cornell University; and Taras Bryndzia, geologist, Shell International Exploration and Production Inc, report that injected water that remains underground is sequestered in the rock formation and therefore does not pose a serious risk to water supplies. Log on to http://news.psu.edu/ to read more about the research.
Advanced Membranes could Catch GHG Kyoto, Japan: Researchers in Japan have engineered a membrane with advanced features capable of removing harmful greenhouse gases from the atmosphere. Their findings, published in the British journal Nature Communications, may one day contribute to lower greenhouse gas emissions and cleaner skies. Greenhouse gases, originating from industrial processes and the burning of fossil fuels, blanket the earth and are the culprits behind current global warming woes. The most abundant among them is carbon dioxide, which made up 84 per cent of the United StatesÊ greenhouse gases in 2012, and can linger in EarthÊs atmosphere for up to thousands of years. Countries all over the world are looking to reduce their carbon dioxide footprint. However, carbon dioxide is essentially a waste product with little immediate commercial value and large treatment costs. Therefore, new low-cost technologies are sorely needed to incentivise greenhouse gas capture by industry. To know more log onto http://www.icems.kyoto-u.ac.jp
Scientist of Indian Origin Wins Illustrious Award in Chemistry Washington DC, USA: Dr Thomas John Colacot has been given ACSÊs award in Industrial Chemistry by the American Chemical Society. The India-born scientist is currently working as the Global R&D Manager in the homogenous catalysis area at Johnson Matthey. Colacot studied at St BerchmanÊs College in Kerala and IIT Madras. This is one of the highest honours in industrial Chemistry and he is the first Indian to receive it. He has an MBA degree and was also an elected Fellow of the Royal Society of Chemistry. The ACS Division of Business Development and Management and the ACS Division of Industrial and Engineering Chemistry have sponsored this award. Dr Colacot would be receiving the 2015 national award at the ceremony held during the 249 th ACS national meeting that would take place in March 2015 in Denver, Colorado. 18 • September 2014
Ashland Gets Ringier 2014 Composites Technology Innovation Award Shanghai, China: Ashland Performance Materials recently received a Ringier 2014 Composites Technology Innovation Award for its non-sanding Maxguard GNJ sanitary gelcoat, which offers improved appearance and durability to manufacturers of sanitary products such as bathtubs and water closets. The award recognises significant contributions to the advancement of ChinaÊs composites industry through technical innovation, improved productivity, economic efficiency and market opportunity creation. Ringier awards are considered to be among the most prestigious in ChinaÊs composites industry. Maxguard GNJ gelcoat is specifically designed to deliver prime performance including excellent water resistance, high gloss retention, surface hardness and shortened manufacturing process time. „We are committed to delivering innovative products and unmatched technical expertise to help our composites customers grow and succeed in the marketplace,‰ said Winter Lai, UPR/Gelcoat product manager, Ashland Performance Materials, Asia Pacific. Gary Landsettle, VP, Ashland Performance Materials, Asia Pacific, added, „We see a number of exciting growth opportunities in ChinaÊs composites market and we look forward to providing our customers with leading-edge technology and service in the years ahead.‰
WorldÊs First Biocompatible and Non-toxic Antibacterial Plastic Rotterdam, Netherlands: Europe based Parx Plastics is starting the mass production of its biocompatible, non-toxic and non-leaching antimicrobial Sanipolymers. Parx Plastics was recently identified by the European Commission as one of the top tech start-ups of Europe with its technology derived from biomimetics to create antimicrobial plastics. Consumers are becoming aware that solutions adding an antibacterial property to touch surfaces are using hazardous substances. These substances or additives can be toxic for humans or have a disrupting impact on our environment, with the recent ban on Triclosan in hand soaps as an example. But Triclosan is also used in plastics and so are many other pesticides. The majority of these substances are leaching from the product to kill the bacteria, and they might end up on your food or the air you breathe. The technology developed by Parx Plastics is the worldÊs first antimicrobial solution for plastic without toxins or chemicals. It makes use of an essential trace element that is present in food and necessary in our daily diet for a healthy immune system and for building up hair, nails and skin. Absolute safety is guaranteed not only by the biocompatibility but also because the technology does not leach out. The antibacterial property is the result of an intrinsic change and not of leaching/migrating substances. The surface of a product becomes hostile to bacteria by means of a mere physical and mechanical action and TÜV laboratories prove it kills up to 99 per cent of the bacteria within 24 hours. Chemical Engineering World
CEW News Features
Innovating for the VUCA World ‘Powering the Future’ - the theme of Dow Innovation Day created a perfect setting for discussions around Dow innovations across key end user industries. The conference witnessed a strong presence of over 200 experts from diversified industries, researchers and scientists from multiple end user verticals.
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ipul Shah, President CEO and Chairman Dow India, kicked off the Innovation Day with the welcome address and briefed the guests about the achievements of company in the last two decades. DowÊs business in India has grown from a USD 10 million and a strong team of ten people in 1992 to close to USD 1 billion revenue employing over 900 people. „Dow India is in the process of transforming into a high-performance science and technology company by providing customised local solutions for the Indian market,‰ Shah said. The presentations were an eclectic blend depicting out of the box innovations developed by Dow. Dr A N Sreeram, Corporate Vice President ă R&D, The Dow Chemical Co USA, in his key note address touched upon innovations across Agrosciences, Packaging, Energy, Infrastructure and Transportation and Water. „We have a pan-India presence which includes four manufacturing plants, two established Centers of Excellence, three application development centers and three commercial offices. Staying close to customers helps us understand the market
trends and study their needs more diligently, which works as a win-win situation for both Dow and customers,‰ he added. Dr David Bem, Vice President - R&D, Dow Advanced Materials, Dr Bob Maughon, Global R&D Director, Dow Performance Plastics and Feedstocks and Dr Nilesh Shah, Senior R&D Director, Dow Consumer and Industrial Solutions from the international team shared insights into the latest innovations that Dow scientists were working for the future technologies. Dow also showcased diverse portfolio of innovative chemistry-based solutions across the key electronics and functional materials, coatings and infrastructure, agrosciences, performance materials, performance plastics and feedstock and energy that complemented the technical presentations. Dr Vilas Sinkar, Vice President ă R&D, Unilever, shared the concept of VUCA world and discussed the macro trends ă digitisation, living differently, demographic shifts and environmental stress that were impacting the FMCG companies. He
Audiences look on at the presentations at the first Innovation Day hosted by Dow India
22 • September 2014
Vipul Shah - Chairman, CEO and President, Dow Chemicals India during the inaugural address at the Innovation Day
went on to share that customer centric companies like the FMCG sector were under immense pressure to develop the product pipelines and get the new products to the market at a faster rate to get faster returns on investments. Rahul Gautam, Managing Director, Sheela Foams, Mahesh Gupta, Founder & Chairman, Kent RO Systems Ltd and Marzban Thanevala, Vice President-Marketing Innovations and Business Development, HUHTAMAKI -PPL further shared insights into various innovative ways their companies have adopted to meet the ever changing customer demand. The day ended with the panel discussion on ÂManaging Innovations in Dynamic EnvironmentÊ with Dow experts and the experts from other companies on the way research teams worked on building the culture of innovations taking failures in stride as a part of learning process. Shah moderated the panel discussion among Ralf Brinkman, President and CEO, Dow Europe GmbH, Larry Ryan, Business President, Energy and Water Solutions at The Dow Chemical Company, Raja Krishnamurthy, R&D Head, 3M Ltd, KBS Anand, Asian Paints and Dr Anil Biswas, Executive Vice President, Dr ReddyÊs Lab. Chemical Engineering World
Endura Chemical Press Ad_size: 210 mm (w) x 270 mm (h) Date: 02/09/14 OP CS job no: - Soho - 1079
CEW Features Lead Feature
The Market with Manifold Opportunities India has to become self-sufficient in its chemical requirements since the dependency on import will always put the nation on the back foot with regards to the vagrancies in the global market. Dr Raman Ramachandran, Head, South Asia and Chairman, BASF India disseminates his observation of the Indian Specialty Chemical Industry with the readers of CEW. the confidence of Ramachandran in the enveloping Indian market. Furthermore, in a recent conversation with CEW, the MD has cited the Tata Strategic Report as a gesture of his influence on the Indian specialty chemical arena. The same report has projected that the specialty chemicals market in the country will reach USD 60-70 billion by 2020.
Dr Raman Ramachandran Head, South Asia and Chairman, BASF
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he opportunities for the chemical industry in India are manifold. Today, India is the third largest market for chemicals in Asia and is expected to grow further. According to the Head of South Asia and Chairman of BASF India, with increasing purchasing power for all groups of the population, consumers want to buy longer lasting goods and goods that improve their quality of life and status. This offers the chemical industry a tremendous scope for innovations. Moreover, he also puts impetus on India becoming self-sufficient in its chemical requirements. This is a strategy that China has adopted very successfully. China is reasonably self-sufficient and hence has become an exporter. As per his analysis, as an importer, it always puts India on the back foot with regards to the vagrancies in the global market. Opportunity & Challenges BASF is very optimistic on India as a marketplace since it foresees a very bright future for the specialty chemicals market in India. This could be elucidated from 24 • September 2014
However, along with the positivity and optimism, Ramachandran has also identified certain predicament in the market. According to him, one of the biggest challenges are the lack of infrastructure and power shortage. Besides, ready availability of raw materials are some of the other main deterrents. He further pointed-out that these are the issues which are creating barriers for large scale direct investments. However, the man in charge of BASF expressed his buoyancy to these paltry matters by stating that these issues are easily surmountable with adequate government support and providing an additional boost to the R&D sector. Growth Drivers Ramachandran believes in the basic notion that the growing population would require resources which would ensure sustainable living. So, according to him, innovations based on chemistry will play a key role in three areas in particular; resources, environment and climate; food and nutrition
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India is the third largest market for chemicals in Asia and is expected to grow further.
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and quality of life. Amongst these themes, water will play an important role in ensuring a good quality of life and food and nutrition. He further cited the Frost & Sullivan data which projected that the Indian water and wastewater treatment market will reach ` 10,230 crore in 2016. So taking advantage of the opportunity in water segment, BASF is committed to grow its business in the water space. As part of its strategy, the company has also started working on expansion of its business beyond flocculants and coagulants in the industrial sector. Moreover, the company has identified the demand drive in the municipal and industrial sectors which is on water treatment and sewage treatment. According to Ramachandran, the Company will offer its products or technologies to the municipal sector through direct channels, OEMs or service providers for raw water treatment, dewatering of municipal sludge(s) and sea water desalination. Here BASF’s water treatment solutions would be able to further the vision of safeguarding a healthy future. Future Plans BASF’s growth and contribution to Asia Pacific will also develop along with the changing economies and demographics. According to Ramachandran, the company will continue its endeavor in providing solutions for the needs of the emerging middle class forming the base of the pyramide through solutions for affordable mass housing, food fortification, wind energy and water purification. These are in line with the four megatrends that the company has identified; resources, environment and climate; food and nutrition and quality of life. BASF is planning to enter India with the right customers base and later extend this further to other South Asian countries. Chemical Engineering World
Chemical Products Finder | November 2013 | 57
CEW Features Lead Feature
Growth at Center-Stage As India is poised to take its industrial growth to the next level, Dow India stays focused on making most of this opportunity with its path-breaking solutions in chemistry, customised for India. Rajiv Rao, Sales Director, Basic and Performance Chemicals, Dow Chemical International Pvt Ltd (Dow India) outlines Dow’s vision - Innovation for India, in India.
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he size of Indian chemical industry is about 3 per cent of the global chemical market. While the industry size may not be in proportion to the population share of India, the rising per capita income and consumption patterns point towards accelerated growth across the industry. The fact that the Indian industry is growing at a much faster pace than the global average of 3-4 percent speaks for itself. In the coming few years, we see majority of growth in sectors supporting infrastructure creation, consumer products, healthcare, energy distribution and water supply. The efforts on the part of central and state governments to provide supportive policy framework for chemical industry are now culminating in more and better manufacturing capabilities, fewer roadblocks in obtaining clearances and production of chemicals moving up the value chain. For Dow, this is an encouraging industry scenario to operate and grow in. Opportunities and Challenges Comparatively, lower per capita consumption is an opportunity by itself – there is a lot of potential for upward mobility. As the buying power and aspirations of the middle class grow, the opportunities in the market are increasing exponentially. Growth of generic drug manufacturing in conjunction with patent expiry, drive to increase agricultural output, increased consumer spending in FMCG sector, automotive and coatings sectors have provided the much needed impetus to the chemical industry.
As environmental regulations evolve in India, the changing regime is opening new avenues for chemical companies to innovate and place sustainable technologies in the marketplace. The challenges we face in India are very similar to our multinational peers – the complex bureaucratic system is not easy to navigate. Inadequate infrastructure, which is part of the opportunity here, can sometimes pose challenges in conducting day-to-day business. Many of the costs that add up in setting up business here are avoidable. Development of ports to ease out congestion, expressways of international standard enabling fast movement of goods, and implementation of GST should go a long way in enabling business in the country. 26 • September 2014
Rajiv Rao Sales Director - Basic and Performance Chemicals, Dow Chemical International Pvt Ltd
Growth Drivers As the economy opens up, the Indian marketplace is getting crowded with local and international companies vying for a share in the market. Innovation for India, in India would be the key differentiator - it will not only address specific needs of the consumer, but will also help in keeping the costs and environmental impact down. Indian manufacturers and exporters have already embraced the global standards and comply with sophisticated technical standards. These technologies of the future should also benefit India. Updating the Indian regulations accordingly, to include better, more sophisticated technologies at affordable cost should be the priority of the policy makers. For Dow, the key growth driver in India is the quality of our products and our capability to maintain uninterrupted supply to all our customers. We believe in being a compliant corporate citizen and giving back to the community in every way we can. This ethos of responsible care translates into our business and helps us maintain long-standing customer relationships. Future Plans India has always been one of the important markets for us. In the last few years, we have achieved strong growth numbers in this market. Our future plans focus on improving these numbers and maintaining market leadership for all our key products. Dow is now geared up to meet the needs of the Indian customers through highly efficient supply chain capabilities, unmatched product quality through manufacturing excellence, and shifting its focus from a product sale to providing holistic solutions to market needs. Chemical Engineering World
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CEW Features Lead Feature
A New Dawn in Waiting for Water Chemicals The industry has several challenges that include the need to invest more in research and create more awareness within senior management of end users to spend more on water since the return on investment is high. Tushar Jhaveri, CEO, Vasu Chemicals shares his perspective on the growth potential in the water treatment chemicals business.
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rowth rates in excess of past years are expected with the changes in the new policies and export promotion plans of the new government. The Indian chemical products are competitive in certain sectors and it is these areas where additional focus is required to ensure that we maintain our leadership position. Moreover, the specialty chemicals sector is also booming and several new innovative products are being offered by local manufacturers. Multinational chemical companies are also expanding operations in India. However, areas where Chinese products
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and medium size end users is up since water treatment chemicals are playing an important role to improve production efficiencies in all sectors. The industry also has several challenges that include the need to invest more in research and create more awareness within senior management of end users to spend more on water since the return on investment is high. Education programs for developing and mentoring water treatment professionals also need to be promoted. Overall this is going to
Water is not only a scarce resource but the cost to facilitate access to unsullied water is also on the rise, thus products that will improve water quality and performance will always be considered as indispensable.
Tushar Jhaveri CEO, Vasu Chemicals
have out priced us also need review and support of Government policies. Pharmaceutical intermediates and textile chemical market is improving and expected to grow further. Opportunities and Challenges in Water Treatment Chemicals There is continuous expansion and growth in this industry since water treatment is becoming more and more critical. Water is not only a scarce resource but its cost is also rising. Hence, products that will improve water quality and performance will always be needed. Furthermore, implementations of stringent environmental norms are also pushing the need to innovate and develop newer technologies and products in the market. Demand from large
28 â&#x20AC;˘ September 2014
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be a high growth industry and its growth will always benefit industry and society. Growth Drivers Environment regulations, availability and cost of water are the key issues that are responsible for this growth. Effective water treatment chemicals are also required to ensure asset life is preserved and heat transfer in plants is optimum for energy conservation. Future Plans The industry should focus to invest more in training of manpower and develop innovative products through in house research, particularly with simulation test rigs and predictive performance modeling. Chemical Engineering World
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CEW Features Lead Feature
Soda Ash Industries: A Victim of Policy Paralysis? In an exclusive interaction with CEW, N N Radia, Chief Operating Officer, Soda Ash, GHCL Ltd illustrates some of the major predicaments that the Soda Ash industry has been facing due to the prevailing Policy Paralysis and Anti Dump Policy.
N N Radia COO, Soda Ash, GHCL Ltd
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Chemical industry plays a significant role in the global economic and social development. It is a human resource intensive industry and generates huge employment opportunities. Chemical industry covers more than eighty thousand commercial products. M o r e o v e r, t h e g l o b a l chemical market size was estimated to be USD 3.7 trillion in 2012 and expected to grow at 4.5 per cent per annum over the next decade to reach USD 5.8 trillion by 2021.
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Natural Soda Ash Versus Synthetic Soda Ash The first and foremost challenge is the dilemma of making the right choice between natural soda ash and synthetic soda ash. Moreover, the prevailing cost disparity in the prices of natural soda ash which is comparatively far less than synthetic soda ash has killed competitiveness. Adding fuel to the plight is the dumping of soda ash by China and other natural soda ash manufacturing countries which further diminishes the competitiveness of Indian soda ash manufacturers. Raw Material versus Policy Paralysis High input cost of raw materials is the other deterrent factors in the progress of soda ash industry. Variation in season and meteorological condition and external demand of salt makes it costlier for soda ash industries. Besides, availability of good quality of limestone due to the stagnation in decision making for mining sector has forced the Indian industries to get limestone from abroad which is about four times costlier than domestic limestone. According to Radia, cost of energy in soda ash manufacturing is about 45 per cent of total production cost. This means that an increase in input energy cost reduces the competitiveness of Indian players versus Global players. Apart from that, the multiple government taxation on power makes the manufacturing of soda ash uncompetitive as compared to global players.
Logistics versus Pricing Most of the soda ash manufacturers are located in Gujarat. Distance between consumers and manufacturers increases the soda ash transportation costs. Average freight to customers in southern and eastern region from western region (Gujarat) is approximately USD 50 per MT whereas the average freight for imports ranges between USD 25 to USD 30 PMT. Due to this transportation cost, difference between domestic and imported soda ash, imported soda ash becomes attractive for eastern and south India based customers. To manufacture one MT of soda ash about 4-5 MT of raw materials is required. Hence transportation cost of raw material is significant. High diesel prices further aggravate the situation. Despite these demotivational factors, Radia is very optimistic on the Indian market. According to him, rising GDP and urbanisation will certainly lead to higher per capita use of products manufactured through soda ash. Moreover, supportive policy from the new government for mining, cheaper import of coal and labour laws will accelerate the pace of the industry. Besides, improved road and water ways will help in reducing cost of logistics. He further added that increase in demand of glass due to growth in Automobile sector and construction industry, growth of water treatment industry, mining, flue gas desulphurisation will help in growth of soda ash industry. Chemical Engineering World
CEW Features Lead Feature
Think Global & Act Local Vinod Saraf, Managing Director, Vinati Organics Ltd (VOL) strongly believes that in modern day practice the companies which do not improve their performance on par with the international standards will not survive.
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hink Global & Act Local - this was the reply from Vinod Saraf - the Founder and MD, VOL, when CEW tried to solicit his success mantra in chemical manufacturing. Certainly, the response was short and munificent but it contained some great gist for the chemical and petrochemical industry. With the very notion - Think Global & Act Local, Vinati Organics Ltd has integrated their manufacturing capabilities in such a way that every single manufacturing facilities of the company are of global size and efficiency but incorporated in such a way to go well with the local condition.
be believed, VOL has so far trained their manpower not only to face emergencies in operations but they also contribute to the profitability by continuous improvement in process and reduction in raw material and utility costs. Moreover, major efforts were made by the company on environmental issues. Saraf elucidates, further that in both the units, we have put recovery units to recover value added products from effluents. Besides, the company has not only been able to meet environmental standards but also create wealth from waste.
Vinod Saraf
MD, Vinati Organics Ltd The Manufacturing Facilities VOL has two facilities manufacturing specialty chemicals. In Mahad, the company produces Isobutyl Benzene (IBB), an intermediate for The customer expectations keep on changing hence bulk drug Ibuprofen. In Lote unit, it produces AcrylamidoTeritary Butyl SulphonicAcid (ATBS) to meet their requirements; companies need to make which is a Monomer used in many industries like small changes in existing facilities which may also water treatment, Acrylicfiber, enhanced oil recovery include new products in the same facility. etc. ATBS uses Isobutylene (IB) as one of the major raw materials which is usually a scarce chemical substance in India. Saraf still recalls the complexity Future Plans involved in importing IB at very high cost while The company has decided to add (PTBT) p-tert.butyl Toluene / (PTBBA) p-tert. explaining the uncertainty in the supply of IB. In ButylBenzoic Acid and its Methyl Ester at Mahad which will use raw materials order to overcome this predicament, the company like Toluene and IB and Methanol which are produced in Lote. Moreover it also has installed a unit for manufacturing IB in the same has plans to have value added products based on IB. This will further improve location. Saraf affirms that integration has helped our profitability and turnover. the company to overcome major bottleneck in operations and achieve higher efficiency. Conclusion Companies manufacturing value added products like specialty chemicals or drugs Thrust on Localisation and Sustainability face technical challenges. Their capital cost is not so high in absolute terms but In Mahad facility, the company had to reengineer it significant considering the unit production basis. Emphasis here is to meet end operations based on locally available raw material customer’s requirements as well as to meet statutory regulations like FDA and ie, chemical grade propylene against polymer grade GMP. Moreover, the customer expectations keep on changing. Hence to meet new propylene recommended by the technology licensor, requirements, these companies need to make small changes in existing facilities which is scarce and costly. Moreover, in Lote, it which may also include new products in the same facility. In order to make it has faced problems in sourcing of raw material - IB possible, companies go for multipurpose facilities which can be used to produce for which it has installed a new manufacturing unit. different products in the same plant. In such a case, operational efficiencies As far as the sustainability efforts of the company are concerned, it has two major contributors may be lower but it can be compromised as they have higher margins to offset manpower and environment protection. If Saraf is to lower efficiencies.
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34 • September 2014
Chemical Engineering World
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CEW Features Technical Article
NG - Fuelling Integration of Refining & Petrochemicals Refiners, not just in India but across the world, are working towards improving their Gross Refinery Margins (GRM). They are looking for technologies and exploring business dynamics to maximise their profits. This article explores some of the options available for refiners to enhance GRM and reduce carbon footprint with the use of Natural Gas (NG).
R
ising oil prices and weak fuel demand in recent past have made a significant impact on GRM. Historical data show that the refineries with bottom of the barrel processing facilities and integrated petrochemicals complex have performed well to stay ahead in the competition due to its greater flexibility to maintain healthy GRM. A robust refinery configuration which is flexible enough to process variety of crudes including difficult opportunity crudes along with integrated petrochemicals complex is the key aspect to sustain healthy margins. However, simple integration with refinery and petrochemicals complex may not be good enough in present scenario. Integration should be smart enough to address volatility of the market by ensuring healthy GRM and to minimise environmental impact by reducing carbon footprint. Use of natural gas as fuel addresses this issue to some extent by allowing recovery of valuable components from refinery off gases and facilitating release of good quantity of naphtha for valuable petrochemicals feedstock generation. It also enables production of more middle distillate from bottom of the barrel processing and helps reducing carbon footprint of overall complex. Price differential between crude and natural gas, especially in the countries where natural gas is available, makes it a hugely profitable proposition. Even for the countries, where both natural gas and crude are imported, it makes a case that needs to be looked into. Refinery Fuel Consumption and Generation A refinery consumes fuel gas and fuel oil produced from various refinery processes. No supplementary fuel is required for refinery operation. Generally, 38 â&#x20AC;˘ September 2014
naphtha is used as feed and fuel for Hydrogen Generation Unit (HGU) and Gas Turbines (GT). Typically, Process Heaters consume greater amount of fuel, followed by Utilities and Hydrogen Plant. Fired heaters in various process units consume about 40 to 50 per cent of fuel. Utility system including boilers and GTs consume about 30 to 40 per cent of fuel and HGU consumes about 15 to 20 per cent of fuel. Contribution of HGU includes both feed and fuel. Typically, a refinery with secondary processing facilities like Fluid Catalytic Cracking Unit (FCCU) and Hydrocracker Unit (HCU) consumes about 8 to 10 wt% of crude throughput as fuel including naphtha used in HGU and GTs. In case refinery is integrated with petrochemicals complex, which is highly energy consuming, fuel consumption is significantly higher. This fuel requirement is satisfied by fuel oil and fuel gas generated from various process units.
Fuel oil is mainly generated from Vacuum Distillation Unit (VDU) and FCCU main fractionator bottoms in absence of bottom of the barrel processing facilities in the refinery. Vacuum residue is generally taken through visbreaker unit to produce fuel oil. Generation of fuel oil can vary between 5 to 50 per cent of feed to VDU depending upon the type of crude processed while fuel oil from FCCU main fractionator bottom can vary between 4 to 6 wt% of FCCU feed. Fuel gas is generated from all hydrotreating units, MS block (catalytic reforming unit and isomerisation unit), FCCU, Delayed Coker Unit (DCU) and HCU. Crude Distillation Unit (CDU) can also be a source for fuel gas generation if light ends are present in crude. A typical contribution towards fuel gas generation from various process units in terms of wt% of total fuel gas generation are shown in figure 1.
Figure 1: Fuel Gas generation in a refinery
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CEW Features Figure 1 on the previous page shows that DCU, FCCU, MS block (Catalytic Reforming Unit + Isomerisation or Alkylation), CDU (in case light ends are present in crude) and HCU along with hydrotreaters (naphtha, kerosene, diesel and VGO) contribute typically about 30, 15, 18, 19 and 18 per cent respectively towards fuel gas generation from refinery. Many modern refineries have integrated petrochemicals complex to improve profitability. Significant amount of fuel gas is generated from naphtha cracker complex while a small amount of fuel gas is generated from aromatics complex (excluding catalytic reforming unit). Typically, about 16-17 wt% of feed is converted into fuel gas in ethane cracker while about 17-18 wt% of feed is converted into fuel gas in naphtha cracker. Fuel oil generation from ethane cracker is negligible while it can be as high as 10 wt% of feed for naphtha cracker. Petrochemicals complex is also a major energy consumer. Steam cracker consumes lot of power in its cracked gas compressors and refrigeration compressors. Typically, 600-620 kWh of power are required for one ton of ethylene production. Generally, naphtha cracker is net exporter of fuel gas and fuel oil while ethane cracker is net consumer of fuel gas. Para-xylene complex is net consumer of fuel gas or fuel oil and power. About 0.3 tons of fuel gas and 320-360 kWh of power are required for one ton of para-xylene production. Refinery products like fuel gas, fuel oil, naphtha and diesel are used to satisfy fuel and power requirement of steam cracker and aromatics complex. Natural gas can be utilised as fuel for an integrated refinery cum petrochemicals complex while maintaining flexible product objectives.
provides the opportunity to either reduce or eliminate fuel oil generation from refinery by utilising bottom of the barrel processing technology. So far, DCU is one of the most economical options for bottom of the barrel processing. Other bottom of the barrel processing technologies that are available and used presently offer lower yield of distillates and do not eliminate fuel oil generation completely. New technology like slurry hydrocracking, which is on the verge of commercialisation, promises to offer better distillate yield and minimum residue generation. However, our discussion is restricted to DCU only since it has a proven operational track record. Typically, distillate yield (combining naphtha and diesel) of about 65 per cent is obtained from DCU which may result in 10 to 12 per cent more distillate from refinery. Additional naphtha generated from DCU can be used as feedstock for naphtha cracker. Moreover, off gas from DCU contains good amount of ethylene, ethane and propylene. Ethylene and propylene can be recovered and used as petrochemicals feedstock after suitable treatment for impurities removal while ethane can be sent to steam cracker for production of petrochemicals feedstocks. Thus, replacing fuel oil with natural gas not only eliminates low value fuel oil generation but also enhances refinery
and petrochemicals integration along with high value middle distillate production. This change over ie, replacing fuel oil by natural gas in existing fired heaters requires careful evaluation for thermal, mechanical and hydraulics adequacy of existing hardware particularly with respect to burners, tube metallurgy, refractory, air preheater system etc. Natural Gas as Feed and Fuel for Steam Reforming: Hydrogen is one of the most important utilities in refinery. It is required to remove impurities like sulphur, nitrogen etc, from various refinery products and intermediate streams. Hydrogen is produced mainly by steam reforming of naphtha in refinery. Its requirement in refinery varies widely depending on crude processed and product specifications. Typically, 4 tons of naphtha is required as feed and fuel to produce one ton of hydrogen while about 3.5 tons of NG is required to produce one ton of hydrogen. Use of NG as feed and fuel for hydrogen plant will release a good quantity of naphtha which can further be utilised for producing value added petrochemicals feed-stocks. Switch over from naphtha to natural gas requires certain modifications in various sections of HGU; these are listed on the next page.
Use of Natural Gas in Refinery Natural Gas (NG) or Regasified Liquid Natural Gas (RLNG) can be used in refinery for various purposes such as fuel for process & utility heaters replacing fuel oil, feed and fuel for HGU replacing naphtha, fuel for GT and fuel for process heaters replacing fuel gas. Each of the above-mentioned cases is discussed below in detail. Natural Gas as Fuel for Process and Utility Heaters Replacing Fuel Oil: Use of natural gas as fuel replacing fuel oil 40 â&#x20AC;˘ September 2014
Figure 2: Different units producing Refinery off gases
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CEW Features Ć Feed Pumping/Compression and Preheating: Naphtha pumps, Naphtha vapouriser and superheater are not required while natural gas compressor may be required Ć Hydrodesulphurisation: If RLNG is used as feedstock, pre-desulphurisation is not required due to very low sulphur content of RLNG. Additionally, NG or RLNG being olefin free, there will be no threat of olefins to reformer catalyst. Ć Reformer Firing: Stoichiometric air requirement will be changed due to change in hydrogen to carbon ratio of fuel, and it will call for burner tip modifications. Ć High Temperature Shift (HTS) reaction, Steam Generation and Pressure Swing Adsorpotion (PSA): Lower load on HTS reactor and lower steam generation due to less firing are expected. PSA is generally not affected by this change over. Replacing naphtha with NG as feed and fuel for hydrogen plant not only helps the refiners produce more valuable products but also helps to reduce carbon footprint of the refinery. Typically, the changeover from naphtha to natural gas will help the refiners to reduce CO 2 emission from HGU by 25 per cent. Natural Gas as Fuel for Gas Turbine (GT): GT is the main work horse for power generation in the refinery. A part of the power requirement of the refinery is satisfied by steam turbines utilising the co-generation potential that exists to generate various levels of steam required in the refinery. The balance part of power requirement is satisfied by Gas Turbine. Generally, naphtha is used as fuel for GT. Typically, 0.25 tons of naphtha is required to generate 1 MWh power from GT. When naphtha is replaced by Natural Gas as fuel for GT, it releases significant amount of naphtha which can further be utilised for valuable product generation. About 0.2 tons of NG are required for 1 MWh power generation. This switch over also helps refiners to reduce CO 2 emission from GT by 25 to 30 per cent. Natural Gas as Fuel for Fired Heaters Replacing Fuel Gas: Fuel Gas is mainly generated from following sources of a refinery. 42 • September 2014
Ć Saturated gas from CDU Ć Off gases from hydrodesulphurisation/ hydrotreating units ă Naphtha Hydrotreater (NHT), Kerosene Hydrotreater (KHT), Diesel Hydrotreater (DHDT) and Vacuum Gas Oil Hydrotreater (VGOHDT) Ć Off gas from Catalytic Reforming Unit (CRU) Ć Off gas from FCCU Ć Off gas from HCU Ć Off gas from DCU Ć Aromatics Complex Ć Naphtha Cracker Complex Typical off gas yields from various refinery units, aromatics complex and naphtha cracker complex are shown in figure 2 on the previous page. Total fuel gas generation from refinery accounts for about 8 to 10 wt% of crude throughput whereas on integration with naphtha cracker and aromatics complex it can be as high as 15 wt% of crude throughput. Table 1 shows the valuable components present in off gases from various refinery process units, aromatics complex and steam cracker complex. Refinery which is processing crudes with light ends typically has a Saturated Gas Unit (SGU) to recover LPG. However, saturated off gas from this unit, primarily consisting of methane and ethane, still consists
of some quantity of propane. Ethane and propane from SGU off gas can be recovered in a cryogenic separation unit after suitable purification and can be fed to the steam cracker for production of ethylene and propylene. Hydrogen recovery from Refinery Off Gases (ROG) is an important aspect to reduce the size of Âon-purposeÊ hydrogen generation unit. This can be achieved by developing hydrogen balance model across the refinery, identifying constraints or flexibility of hydrogen usage and hydrogen pinch analysis for possible alternatives of hydrogen reuse from ROG. It should be noted that a careful techno-economic evaluation is required before implementing any project of hydrogen recovery from ROG. The reason behind is that, on one hand it reduces the size of the hydrogen generation unit and thus CO 2 emission, on the other hand it degrades the quality of ROG in terms of calorific value and reduces the opportunity of burning hydrogen to reduce CO 2 emission. However, for a larger hydrogen contributor, a dedicated recovery system is justified. CRU is one such source for Hydrogen recovery. Technip has developed a dedicated tool called HyN. DT for Hydrogen Management in order to help the refiners to optimise hydrogen recovery and size of Âon-purposeÊ hydrogen generation unit.
Source
Yield (wt% of feed)
CDU
0-2
Depending on presence of light ends in crude, source for ethane
CRU
10 - 12
Source for Hydrogen
FCCU
3-4
Source for ethane & ethylene
DCU
4-5
Source for ethane & ethylene
HCU
2-3
NHT
0.5
KHT
1
DHDT
2
VGOHDT
3
Used as fuel gas primarily
Aromatics Complex 5 (excluding catalytic reforming) Steam complex
Cracker 16-18
Source for hydrogen
Table 1: Refinery off gases with valuable components
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CEW Features Off gas from FCC and DCU contains good quantity of ethane, ethylene, propylene and some propane. Separate recovery of ethylene and propylene through cryogenic separation after suitable treatment may be economical if quantity of gas is significant. Otherwise a combined recovery section with cracker complex may be considered. Ethane and propane separated from off gases are sent to cracker for further production of ethylene and propylene.
Light naphtha to steam Middle Cut (C6-C7 cut) C7-C9 cut naphtha to cracking naphtha to MS aromatics complex Ć Enhanced ethylene production Ć Enhanc ed propy lene production
Ć
Enhanced gasoline production
Ć Ć
More PX production More benzene production
Table 2: Additional naphtha for petrochemicals production
Recovery of valuable components like hydrogen, ethylene, ethane etc from off gases significantly reduces fuel gas quantity in the refinery leading to requirement of external fuel like natural gas. In other words, use of natural gas as fuel for the refinery will help in recovering valuable components from ROG leading to enhanced refinery profitability. Change over from fuel gas to natural needs careful evaluation of existing hardware, specially fired heaters with respect to thermal, mechanical and hydraulics adequacy. Synergies between Refinery & Petrochemicals Use of natural gas as refinery fuel unleashes a host of opportunities in terms of synergies between refinery and petrochemicals complex. The availability of full range naphtha (C5-165 O C cut) as a result of utilising NG for steam reforming and gas turbines can be fruitfully utilised as feedstock for petrochemicals complex. From this full range naphtha, a portion of naphtha, ie, light naphtha (mainly C5) part can be utilised in steam cracker for production of ethylene and propylene while C7-C9 cut naphtha can be utilised for production of aromatics like benzene, toluene, para-xylene etc and middle cut can be blended in gasoline pool. Recent specifications of gasoline restricts aromatics content in gasoline thus restricting blending of reformate in gasoline pool and leading to use of alternate octane booster like isomerate and alkylate. Octane booster isomerate is produced by isomerisation of C5 stream of naphtha. However, if we use C5 stream to produce valuable products (like ethylene, propylene) in steam cracker, then alkylation unit can be considered for octane boosting. 44 • September 2014
Figure 3: Recovery of components from refinery off gas for petrochemicals production
Iso-butane reacts with olefins (propylene, iso-butylene etc,) to produce alkylates in presence of solid or liquid catalyst in alkylation unit. Generally FCC C4 cut is good feedstock to produce alkylates with Research Octane Number (RON) of 92 and above. Significant quantity of ethylene and propylene can be recovered from FCC and coker off gases. In addition, ethane and propane recovered from saturated gases ex-CDU and from FCC and coker off gases can be utilised to produce ethylene and propylene by processing through steam cracker. Hence, the steam cracker can be designed as dual feed cracker (both liquid and gas) to take advantage of refinery off gases and any surplus naphtha leading to more flexibility in operation. Technip designed steam cracker is capable of taking any feed from ethane to gas oil providing a great deal of flexibility. SPYRO, the proprietary software from Technip is first principle-based software
which is capable of predicting yield, run length etc accurately for any feed starting from ethane to gas oil. It is used by most of the ethylene producers worldwide to monitor and control cracking furnace performance. A great deal of synergy exists between refinery, aromatics complex and steam cracker complex. Off gases from FCC and coker containing good quantity of ethylene and propylene can be integrated with cold section of steam cracker. On the other hand, pyrolysis gasoline produced from steam cracker contains good quantity of xylenes and can be integrated with aromatics complex. Propylene produced from steam cracker complex and benzene produced from aromatics complex are the feedstocks for production of cumene and phenol which is the feedstock for producing bis-phenol and polycarbonates. Block flow diagrams given in table 2 and figure 3 show enhanced integration between refinery and petrochemicals complex when NG is used as fuel. Chemical Engineering World
CEW Features Reducing Carbon Footprint - A Bonus In addition to achieving a good synergy between refinery and petrochemicals complex, use of NG as refinery fuel helps in reducing carbon footprint of the refinery especially when fuel oil is replaced by NG. Typically, replacement of fuel oil with natural gas gives about 30 per cent reduction in CO 2 emission and replacement of fuel gas with natural gas gives about 5 to 10 per cent reduction in CO 2 emission through fired heaters. This is in addition to CO 2 emission reduction of 25 per cent in HGU and 25 to 30 per cent in GT that can be achieved by replacing naphtha with natural gas. A Case Study A case study is performed with a base case of refinery complex of 15 MMTPA with a steam cracker and aromatics complex. The refinery consists of CDU-VDU as primary unit, CRU and alkylation for MS production, FCCU and once through Hydrocracker Unit (OHCU) as secondary units and Delayed Coker Unit (DCU) is considered for bottom of the barrel processing. Hydrotreating of all products like kero, diesel, naphtha and VGO is considered to meet product specifications required for downstream units and to meet environmental regulations. Since light naphtha (mainly C5 cut), which is fed into naphtha cracker, is not available for isomerisation for boosting the octane number of gasoline, an alkylation unit is considered for the same. C4 cut from FCCU is the feed to alkylation unit. Light naphtha (C5 cut) from NHT and hydrocracker along with hydrocracker bottom is the main feed to naphtha cracker.
Feed/Product
Base Case Wt%
KTA
Wt%
Crude
15000
100
15000
100
Ethylene
490
3.3
805
5.4
Propylene
650
4.3
775
5.2
Butadiene
75
0.5
100
0.7
LPG
715
4.8
730
4.9
Gasoline
2050
13.7
2300
15.3
ATF
2640
17.6
2645
17.6
Diesel
4250
28.3
4285
28.6
Benzene
235
1.6
330
2.2
Para-Xylene
450
3.0
645
4.3
Coke
1025
6.8
1050
7.0
Sulphur
315
2.1
315
2.1
Fuel & Loss
2105
14.0
1020
6.8
Natural Gas
0
0
1225
8.2
Table 3: Comparison between Base Case and NG Case material balance
Hydrogen is recovered from CRU and naphtha cracker off gases through Pressure Swing Adsorption (PSA). Sulphur block includes Amine Treating Unit (ATU), Sour Water Stripper (SWS), Amine Regeneration Unit (ARU) and Sulphur Recovery Unit (SRU) as auxiliary units. Block flow diagram for base case refinery configuration is shown in figure 4 on the next page. An LP model is developed based on this configuration with maximisation of GRM as objective function with following basis. Ć Capacity: 15 Million Metric Tonne Per Annum (MMTPA) (~300000 BPSD) Ć Crude: 50% Arab Heavy and 50% Arab light Ć Desired Products: Ethylene, Propylene, LPG, Butadiene, Gasoline, ATF, Diesel, Benzene and Para-Xylene
Pyrolysis gasoline generated from naphtha cracker goes through aromatics separation unit where aromatics are separated and fed into para-xylene complex and raffinate is recycled back to naphtha cracker.
Base case (without supplementary fuel like natural gas) material balance is performed using this LP model and product yields are shown in table 3 under base case. With the same configuration of base case, LP model was rerun with natural gas as fuel replacing ROG and naphtha as feed and fuel for HGU and GT.
A butadiene extraction unit is considered within naphtha cracker complex.
The integration between refinery and petrochemicals complex is maximised by
46 • September 2014
NG Case
KTA
optimising refinery configuration in order to generate more value added products like ethylene, propylene, butadiene, benzene and para-xylene. Revised case (NG case) material balance is performed with natural gas as refinery fuel using LP model. A comparison of base case material balance and revised case material balance (NG case) is presented in table 3. For base case, a part of the heavy products like vacuum residue and FCCU bottoms are utilised for generation of fuel oil to satisfy fuel requirement of the complex. However, for natural gas case, all the heavy products are sent to DCU resulting in more distillates and a marginal increase in coke production. Fuel and loss are estimated based on total consumption of fuel gas, naphtha used for hydrogen generation and gas turbine and fuel oil consumption in boilers and heaters for base case. For natural gas case it is estimated based on natural gas and fuel gas consumption. Comparison between base case and natural gas case material balance shows that about 7 wt% of crude is converted into valuable Chemical Engineering World
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CEW Features
Figure 4: Base Case Refinery Configuration
Figure 5: NG Case Refinery Configuration
48 â&#x20AC;˘ September 2014
The article continues on page number 52 Chemical Engineering World
CEW Features Forward Focus
Can Responsible Care Thrive in India? In October 2012, the global Responsible Care community travelled to India for its annual leadership meeting and an opportunity to engage in dialogue with the country’s chemical industry leaders. During the course of these meetings, representatives of domestic companies and multinationals operating in India were able to network with their international peers and discuss the challenges and opportunities the chemical industry is facing in India. Debra M Phillips, Managing Director, Responsible Care and Value Chain Outreach, American Debra M Phillips Managing Director, Responsible Care and Value Chain Outreach, American Chemistry Council
50 • September 2014
Chemistry Council, writes.
W
hile Responsible Care has been a part of the Indian chemical industry for nearly 20 years, it can still, at best, be described as a work in progress. In order to fulfill its potential, chemical industry leaders in India - companies and their CEOs - need to re-commit themselves to Responsible Care and become an active part of the environment, health and safety excellence movement as its growing chemicals portfolio suggests it should be.
the acceptance of two new Responsible Care countries and programmes: Sri Lanka and Myanmar.
The International Council of Chemical AssociationsÊ (ICCA) Responsible Care Leadership Group (RCLG), which includes representatives of more than 57 industry federations, chose to meet in India last year as part of its efforts to support Responsible Care in key economies. In cooperation with the Indian Chemical Council (ICC), the RCLG held three days of meetings which included participation by a number of local industry leaders, Indian government officials and representatives of intergovernmental organisations such as the World Bank. A formal dialogue session between members of the RCLG and Indian CEOs allowed participants to explore the possibilities for growing Responsible Care in India. Highlights of the RCLG meeting included
In my opening remarks to the participants at the Mumbai conference, I took the opportunity to share the ICCAÊs concerns about the slow progress of Responsible Care in India. Despite two decades of membership in the Responsible Care community, ICCÊs efforts to date have not kept pace with its peers in other federations which adopted Responsible Care in the early 1990s. In fact, more recent adopters of the initiative such as the Dubai-based Gulf Petrochemicals and Chemicals Association (GPCA) have demonstrated that with strong leadership, broad member buy-in and a commitment of resources, significant progress can be made on Responsible Care in a short period of time. Given the essential position India holds as an emerging global
Prior to the Goa meetings, the ICC held a well-attended, one-day Responsible Care conference in Mumbai which featured speakers from domestic companies, multinationals and representatives of other national federations who shared their Responsible Care experiences and plans for the future.
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Features CEW chemical powerhouse and as a critical link in global supply chains, ICCA believes that it is imperative that Responsible Care in India begin making significant strides forward in the coming years. Concern about the status of Responsible Care in India is not limited to chemical industry insiders. Stakeholders in the UNEPÊs Strategic Approach for International Chemicals Management (SAICM) programme repeatedly inquire about the status of Responsible Care in India, citing the fact that only three Indian-based companies have signed the ICCAÊs Responsible Care Global Charter. These critics assert that Responsible Care has stagnated in one of the very places where it needs to be thriving. Stakeholders will continue to monitor the progress of Responsible Care in India and other countries to ensure that the programme is truly delivering important environmental, health and safety benefits, consistent with the commitments made in the Responsible Care Global Charter. How can the ICC and its members lead to improve implementation of Responsible Care in India? Based on experiences in other countries, the key to Responsible CareÊs success is sustained, active and visible corporate support. The Indian chemical industry must find Responsible Care champions from its most influential companies and company leaders need to engage their peers in a frank discussion about why Responsible Care is important to the success of their individual companies, the success of the Indian chemical industry as a whole and that of the larger global industrial community. Responsible Care is not a one-time activity, but rather a long-term culture of performance excellence that seeks to continually set higher expectations and achieve them. In a number of countries and regions, there are excellent examples of Responsible Care programmes that have adjusted and grown over time.
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“I implore Indian chemical industry leaders to begin to truly lead and join the global chemical industry community in a sustained commitment to performance exce llence through Responsible Care.” In the Americas and Europe, trade federations have repeatedly relied on CEO-led Task Forces to identify and propose improvements to Responsible Care and see these proposals through to full implementation. For example, here in the US, the American Chemistry CouncilÊs Responsible Care programme has undertaken three Strategic Reviews which over the past twenty years have transformed the programme from one which initially relied on company self-assessments and aggregate metrics reporting to one which required third-party certification audits and public reporting of individual company performance data. I encourage Indian chemical company leaders to come together and create a common vision and driving force for Responsible Care advancement in India. Leaders must set a strategic vision, employ a project management mentality, and dedicate appropriate resources to get this important programme in place, just as they would implement any infrastructure project in their own companies. Were ICC and its members were to embark on CEO-led review of Responsible Care in India, a good starting point for discussion might be to measure the programmeÊs progress against ICCAÊs Responsible Care Fundamental Features. The Fundamental Features identify eight required elements for all Responsible Care programmes. More importantly, ICCA has adopted five- and ten-year implementation milestones for each of the Fundamental Features which federations can use to benchmark progress since Responsible CareÊs adoption. In 2011, IndiaÊs Responsible Care programme was assessed against these fundamental features and it has fallen significantly off pace.
During the ICCA meetings India in 2012, there was considerable discussion about the benefits that Responsible Care brings to implementing companies. Companies benefit from implementing Responsible Care in many ways. But all benefits are derived from real, meaningful, sustained implementation of environment, health and safety performance programmes that are central to Responsible Care. In the US, an independent study was released in late 2012 showing that participation in Responsible Care reduces the likelihood of accidents by 69.3 per cent. Participation also was shown to reduce the likelihood of process safety by 85.9 per cent. These reductions in accidents due to Responsible Care in turn contribute to economically significant averted losses, with savings of about USD 61,000 per facility per year. In addition, the US government has granted liability protection to Responsible Care companies in the event of a terrorist act on a chemical facility or product in transit. IÊve been part of many discussions in the past two years with local and global chemical industry representatives who express a great desire to see Responsible Care thrive in India. I am certain that this sentiment is shared by many members of the Indian Chemical Council staff and their committee members. But the time for action is now. ICCA and its member federations want to see Responsible Care reach new levels of excellence in India and stand ready to lend support. I implore Indian chemical industry leaders to begin to truly lead and join the global chemical industry community in a sustained commitment to performance excellence through Responsible Care.
September 2014 • 51
CEW Features
Figure 6: Increased production for petrochemicals feedstocks
products like ethylene, propylene, LPG, butadiene, gasoline, benzene & para-xylene when natural gas is used as supplementary fuel for the refinery. Increase in production for these valuable petrochemicals feedstock is presented in figure 6. Figure 6 shows that the increase in production for ethylene, propylene, butadiene, benzene and para-xylene is 64, 19, 33, 40 and 43 per cent respectively which has a significant impact on GRM. In addition to it, there is a significant reduction in CO 2 emission. Estimated reduction in CO 2 emission is about 2.5 per cent for entire complex. This reduction can be achieved despite the increase in production of petrochemicals feedstocks which consumes additional energy. Conclusions Use of natural gas as refinery fuel unleashes a host of opportunities to make refining and petrochemicals business more efficient. It benefits integrated refinery cum petrochemicals complex in multiple ways. Ć Use of natural gas releases a good quantity of naphtha which is normally used as feed and fuel for steam reforming and gas turbines. This naphtha can further be utilised for producing value added petrochemicals feed-stocks like ethylene, propylene, para-xylene etc. Ć Use of natural gas as fuel for refinery gives the opportunity of recovering valuable components like hydrogen, ethane, ethylene, propylene etc. from refinery off gas. Ć Replacement of fuel oil by natural gas enables refinery to process complete vacuum residue in DCU for enhancing the distillate yield. In addition to above possibilities which help in significant improvement in GRM, use of natural gas as fuel also reduce 52 • September 2014
carbon footprint of a refinery significantly. Price differential between natural gas and crude and more importantly price differential between natural gas and petrochemical feedstocks like ethylene, propylene, butadiene, benzene and para-xylene will remain as key driver to consider natural gas as fuel for refinery to improve GRM through better integration between refinery and petrochemicals complex. Acknowledgement Authors are thankful to the management of TPKTI for their kind permission to publish this article.
References: (1) Tanmay Taraphdar, “Reducing carbon footprint - An integrated programme of process integration techniques lowers CO 2 emissions levels in refineries through energy savings”, PTQ, V 16, N°3, Q2 (2011), P 65 – 73. (2) Sanjiv Ratan and Roland van Uffelen, “Curtailing refinery CO2 through H2 plant”, ptq Gas 2008 The article was published in Petroleum Technology Quarterly (July,2012)
AuthorsÊ Details Tanmay Taraphdar Group Leader, Process & Technology Division, Technip KT India Ltd Email: ttaraphdar@technip.com M K E Prasad Senior Vice President Process & Technology Technip KT India Ltd Praveen Yadav Sr Process Engineer - Refining & Petrochemicals Process & Technology Division Technip India Ltd Chemical Engineering World
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CEW Features Guest Column
Doing It Differently Methanol-to-Olefins technology opens new, economical routes to light olefins from low cost feedstocks Amongst the largest volume petrochemicals in the world, olefins are building blocks for everything from packaging materials, home ware, piping and insulation, to synthetic rubbers and antifreeze. Honeywell’s UOP now has a revolutionary solution that produces olefins more economically than many traditional sources. The solution is MTO, writes Steve Gimre, Managing Director, UOP India Private Limited, A Honeywell Company.
B
y June of this year, ChinaÊs Wison (Nanjing) Clean Energy Co Ltd, has successfully produced more than 360 million pounds of light olefins at a plant in Nanjing, China, using UOPÊs breakthrough Methanol-to-Olefins (MTO) process technology. The plant, the first commercial-scale facility to use the UOP/Hydro MTO process technology, has been operating since September 2013 and is successfully meeting both quality and quantity expectations for light olefins. The Wison facility uses UOPÊs Advanced MTO process that combines the UOP/Hydro MTO process and the Total/ UOP olefin cracking process. The combination significantly increases yields and feedstock efficiency. The process converts methanol, which can be derived from low-cost raw materials such as coal or natural gas, into ethylene and propylene. MTO also offers flexibility in the ratio of propylene to ethylene produced, so operators can adjust plant operations to most effectively address market demands. Ethylene and propylene are two of the largest volume petrochemicals in the world. Ethylene is used in a variety of products including polyethylene (food packaging, house wares), polyvinylchloride (piping, construction materials), polyethylene terephthalate (bottles, films), and polystyrene (insulation, cups). Likewise, propylene is used in a variety of applications 54 • September 2014
including polypropylene (films, packaging, automotive components), acrylonitrile (synthetic rubbers), propylene oxide (antifreeze, polyurethane foams) and many others. Current Status of Olefin Manufacturing Nearly all of the worldÊs ethylene is produced via steam cracking technology. Steam cracking uses high temperatures (800 0C - 900 0C) and steam to crack and dehydrogenate hydrocarbons into ethylene and other valuable by-products. Propylene is one of the most important byproducts from steam cracking of propane and higher hydrocarbons. Approximately 55 per cent of the worldÊs supply of
propylene comes from steam cracking. Propylene is also supplied as a by-product from fluid catalytic cracking (~35%) and propane dehydrogenation (~5%). Over the past several decades, the manufacturing capacities for these chemicals have undergone remarkable transitions, with impressive growth in some regions and flat production in others (Figure 1). Two of the most important factors shaping the development of most chemical markets are regional demand and feedstock cost and availability. Driven mainly by the availability of low cost ethane, ethylene production
Figure 1: Ethylene capacity growth (by regions); (Source: IHS Chemical)
Chemical Engineering World
CEW Features capacity in the Middle East (ME) has grown significantly over the past 10 - 15 years. Similarly, after more than a decade of minimal growth, ethylene capacity in the Americas is increasing due to the availability of low cost ethane from shale gas and enhanced gas recovery technologies. The availability of low cost feeds can be an important driver for investments into new production capacity. The Asia Pacific region has also experienced tremendous growth in ethylene production capacity. However, unlike ME, this region does not possess an abundance of cheap ethane. With no other options available until recently, naphtha has been the predominant feedstock even though it has been up to more than five times more expensive than the ethane used in other regions. New technologies such as advanced MTO have the potential for changing the game by opening up new routes based on alternative, low cost feed stocks. The MTO Promise UOPÊs MTO process is a path-breaking innovation for producing ethylene and propylene from methanol. Since methanol can be made using a variety of different feedstock, MTO opens up an entirely new direction for the production of ethylene and propylene starting from low cost, alternative raw materials such as coal or natural gas.
Methanol is widely produced from natural gas or coal at locations with abundant reserves. By utilising methanol derived from these cost-advantaged raw materials, MTO enables low costs of production for olefins in regions that do not have large reserves of ethane. MTO can also help to fill the gap between propylene demand and supply from steam crackers and refineries by producing olefins at high ratios of propylene to ethylene. The conversion of methanol to olefins and other hydrocarbons products has been widely studied. Initial work in the 1970s and early 1980s focused on conversion of methanol to gasoline range products and employed ZSM-5 type zeolites. Selectivity of methanol to ethylene and propylene over ZSM-5 was generally low, with selectivities favouring heavier more highly-branched hydrocarbons and aromatics. This catalyst technology was utilised in the commercial development of the Mobil MTG Process. During the 1980s, a group of scientists at Union Carbide (which later became part of UOP LLC) discovered a new class of materials, Silicoaluminumphosphates (SAPO) molecular sieves. Of these, the discovery of SAPO-34 provided a technology breakthrough. SAPO-34Ês unique pore size, geometry and acidity created a more selective route for methanol conversion to ethylene and propylene with reduced heavy by-products.
Figure 2: Total Petrochemical MTO/OCP demonstration unit at Feluy, Belgium
A More Advanced Process In the early 1990s, UOP and Norsk Hydro A S formed an alliance to develop MTO technology. This collaboration with Norsk Hydro led to the development of the UOP/HYDRO MTO process. In developing the process, UOP built on its in-house Fluid Catalytic Cracking (FCC) experience for fluidised reactor and regenerator and known steam cracker art. Unrelated to MTO at the time, ATOFINA was at work in the 1990s developing an olefin cracking technology. Shortly after, in 2000, ATOFINA (which later became part of Total Petrochemicals and today of TOTAL Refining and Chemicals) and UOP formed a joint alliance to further develop olefin cracking technology. This collaboration led to the development of the Total Petrochemicals/UOP olefin cracking process. The Total Petrochemicals/UOP olefin cracking process has been integrated with the UOP/HYDRO MTO process. This combination of processes is the basis for Advanced MTO.
Figure 3: Advanced MTO process flow diagram
56 • September 2014
A major milestone for MTO commercialisation was the start up in 2009 of the semi-commercial, fully integrated MTO demonstration unit (Figure 2) in Belgium, which successfully demonstrated the performance of the integrated Chemical Engineering World
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CEW Features UOP/Hydro MTO process with the Total Petrochemicals/UOP olefin cracking process. How It Works The UOP/Hydro MTO process utilises a fluidised reactor and regenerator system to convert methanol to olefins using a proprietary SAPO-34 type catalyst. The process can be operated on crude or un-distilled methanol, as well as with pure (Grade AA) methanol. The choice of feedstock quality generally depends on project-specific situations because there can be advantages in either case. Figure 3 (on previous page) illustrates a simple flow diagram for the UOP Advanced MTO process. The methanol feed is preheated and then introduced into the reactor. The conversion of methanol to olefins requires a selective catalyst that operates at moderate to high temperatures. The reaction is exothermic so heat can be recovered from the reaction. Carbon or coke accumulates on the catalyst and requires removal to maintain catalyst activity. The coke is removed by combustion with air in a catalyst regenerator system. A fluidised bed reactor and regenerator system is ideally suited for the MTO process because it allows for heat removal and continuous catalyst regeneration. The reactor operates in the vapour phase at temperatures between 650 to 1000ĈF and pressures between 15 and 45 psig. A slipstream of catalyst is circulated to the fluidised bed regenerator to maintain high activity. The reactor effluent is cooled and quenched to separate water from the product gas stream. The product gas is compressed and then unconverted oxygenates are recovered and returned to the reactor. The reactor provides very high conversion so there is no need for a large recycle stream. After the oxygenate recovery section, the effluent is further processed in the fractionation and purification section to remove contaminants and separate the key products from the by-product components. Ethylene and propylene are produced as polymer-grade products and sent to storage. The C4 - C6 fraction can be sent to the OCP reactor where it is selectively converted to light olefins, the majority of which is propylene. Typically the propylene to ethylene ratio in OCP reactor effluent is about 4:1. The OCP product is separated by fractionation, with the C3 and lighter fraction sent to the MTO product recovery section and the residual C4 plus fraction used as a by-product fuel. MTO in Numbers In most regions of the world, either methane or coal is readily available at prices that make UOPÊs advanced MTO process a better economic choice than naphtha cracking. Investment in MTO can be staged by first constructing and operating the MTO unit based on purchased methanol and then later constructing the gasification and methanol synthesis sections. Likewise, existing methanol producers can use MTO integrate downstream and move into the light olefins market. 58 • September 2014
To date, UOP has licensed four MTO units, the first of which to come online was the Wison plant. All of these units are located in China and are based on either purchased methanol or coal. In total, more than 10 million tpy of combined ethlyene plus propylene production capacity from MTO technologies is planned to come on-stream in China by 2015. Shandong Yangmei Hengtong Chemicals Co Ltd, expected to start up later this year, will use the technology to produce 295,000 metric tons per year of ethylene and propylene, and Jiutai Energy (Zhungeer) Co., expected to start up in 2015, will use it to produce 600,000 metric tons per year of ethylene and propylene. Jiangsu Sailboat Petrochemical Chemicals is also building what is expected to be the largest single-train MTO unit in the world, producing 833,000 metric tons of ethylene and propylene per year. India ă What MTO Can Do For India, MTO can help the country meet its growing demand for olefins by using methanol derived from cheaper and more abundant coal, maximizing yields of high-value petrochemicals and reducing operating costs. Figures 4 and 5 depict the growth curves for the polyethylene and polypropylene industries in India. As is evident, the olefins market is propelled by domestic demand, and is expected to grow at a CAGR of ~10.5 per cent (till 2018). On the feedstock end, India has plentiful coal reserves, while the countryÊs natural gas and oil reserves are limited. Of IndiaÊs
Figure 4: Polyethylene (PE) demand growth in India; Source: Platts
Figure 5: Polypropylene (PE) demand growth in India; Source: Platts
Chemical Engineering World
Features CEW Naphtha
MTO
Cost
800 USD/MT
(Methanol feed 300 to 400 USD/ MT
1 ton of light olefin production
2 tons of naphtha
2.6 tons methanol
Capital investment
Double the investment of 1 MM MTA light a MTO based plant with a olefins plant is ~$1 similar capacity bn
of
Table 1: Methanol (through MTO) – Cost advantage over naptha
fossil fuel reserves, 93 per cent is coal, with crude oil and natural gas representing only 3 and 4 per cent, respectively. To utilise coal as a petrochemical feed stock, the first step is gasification of coal to synthesis gas. By using MTO technology, this synthesis gas can be converted into petrochemicals. This approach can help channel valuable crude oil imports toward fuels while supporting petrochemicals growth in India Olefin production would imperatively use either methanol or naptha as feedstock. Methanol however, has a distinct cost advantage over naptha: At a methanol price of 400 USD/MT, an MTO-based light olefins plant will have a feedstock cost advantage of 560 USD/MT of light olefins production. This advantage increases to 820 USD/MT of light olefins at a methanol price of 300 USD/MT. An MTO-based ethylene plant also produces twice as much propylene as a naphtha-based ethylene plant. Propylene traded at USD 1,396/MT (in April 2014) as against ethylene that traded at USD 1,254/MT (figures from PGPI). The growth rate of the price of propylene is also significantly higher than ethyleneÊs. Regional demand and the regional availability and cost of key raw materials are some of the most important factors shaping the development of petrochemical markets. Clearly, for regions with vast resources of coal such as India, MTO could provide long-term raw material security. The UOP/Hydro MTO process provides an economically-attractive route to convert cost-advantaged raw materials such as coal to high value-added olefins. MTO could work here as a potential game changer. UOPÊs Legacy This year UOP celebrates a century of innovation in the refining and petrochemical industries, with 80 years influencing IndiaÊs oil and gas sector. UOP entered the Indian market in the 1930s with its licensing of the Dubbs Thermal Cracking process to produce gasoline at the Digboi refinery in Assam, which operated in until 1999. Since then, UOPÊs technology solutions have continued to drive developments in the industry to give customers the means to economically produce materials that are in high demand. Chemical Engineering World
September 2014 • 59
CEW Features Technical Article
Protecting Integrity of Fired Heaters In order to eliminate the chance of any human fatalities or injur y in a plant, it is of utmost importance to maintain integrity of assets. This article highlights significance of Asset Integrity Management (AIM) programmes for fired heaters by leveraging Advanced Intelligent Pigging Inspection and Fitness-for-Service Software Technologies
R
efineries and chemical plants are complex operating facilities which are typically designed to operate continuously between scheduled maintenance turnarounds. Among a variety of operating assets within these facilities, fired heaters play a critical role in the dayto-day plant operation. Maintaining and protecting the operational integrity of these assets must remain a high priority for plant operators. Unexpected failures can quickly become costly, which drives the demand for an effective Asset Integrity Management (AIM) programme. Lack of an effective AIM programme onsite can elevate the risk of human fatalities or injury. For well over a decade plant engineers and inspectors have gradually integrated the use of ultrasonic-based intelligent pigging technologies into their AIM and inspection programmes. Intelligent pigging enables nearly 100 per cent inspection coverage of complex configured serpentine coils in convection and radiant
sections of fired heaters. This proven technology provides accurate inspection data allowing engineers to make critical decisions regarding the safe operation and necessary maintenance regimes for fired heaters. Continuous advancements in the technology have also increased the capabilities of these tools and extended these benefits to even more complex heater coils, including those which are joined via common header. The Plant Inspectors Challenge Accurately assessing the condition of fired heater coils has proven challenging due to several factors. Conventional Non-Destructive Testing (NDT) methods, such as manual ultrasonic (UT) or radiography (RT), are ineffective in accurately assessing 100 per cent of the internal condition of fired heater coils. The process is further complicated by serpentine coil lengths in excess of 1,524m (5,000Ă&#x160;), raised surfaces such as studs and fins, multiple short radius 1D x 180 0 return bends, and inaccessibility. Specially configured remotely operated autonomous internal inspection tools, commonly referred to as intelligent pigs, were developed in the 1990Ă&#x160;s resolving these challenges. This innovative technology enables complete coil inspection within the convection and radiant sections without the need to access confinement of the furnace box. The use of UT-based intelligent pigs has significantly improved inspection data quality and coverage area and has also significantly reduced safety risks attributable to refinery fired heaters.
Figure 1: Heater Coils
62 â&#x20AC;˘ September 2014
Intelligent Pigging Technology During a typical operation, the intelligent pig is transported through the interior of
the serpentine piping coil via a column of liquid (eg, water, diesel, glycol, etc.), which provides both propulsion and coupling for the ultrasonic transducers. The inspection data is stored electronically in onboard memory as the un-tethered intelligent pig rapidly travels through the piping coil. At the conclusion of an inspection run, the data is immediately downloaded onto a laptop computer. This provides immediate access to high resolution graphical images and quantitative test results. Anomalies such as internal or external corrosion, erosion, pitting, bulging, swelling, and other deformations are easily located and quantified while custom software provides the ability to view the entire coil in both two-dimensional (2D) and three-dimensional (3D) graphics. Asset Integrity Management Programme Conventional inspection practices previously used by refiners to determine condition assessment of furnace coil piping have proven time-consuming and costly, while providing only minimal inspection coverage, ultimately compromising the plants Fired Heater Asset Integrity Management (AIM) programme. The combined cost of lost production, scaffold erection, inaccessibility, piping surface preparation, and inspection labor quality varies widely. Furnace down times of several days or even weeks can be expected when conducting a typical coil inspection with manual inspection practices. Additionally, these practices provide limited inspection coverage and/or non-quantitative test results. Conventional NDT inspection methods for furnace piping coils typically consist of manually collecting UT spot readings at given increments along the piping coils axial length, typically at four 90 0 intervals Chemical Engineering World
CEW Features At the conclusion of evaluating a fired heater coil while applying all accessible inspection data in combination with API-579 / ASME FFS1, the output provides refinery engineers with the necessary confidence of making sound operating decisions regarding asset repairs or extending run times. Reliability engineers also have the option of integrating FFS/RLA software with their day-to-day engineering software packages to further enhance decision-making capabilities. Available software packages ensure no inspection data is unused, thereby providing further confidence to the end user.
Figure 2: 2D & 3D Graphics of Heater Coils
Conclusion Combining intelligent pigging and FFS/RLA software technology is key to a complete and comprehensive Fired Heater AIM programme. Technological advancements provide greater capability to refinery and chemical plant engineers, particularly those operating complex fired heaters. Inspections are completed quickly, minimising furnace down time and preliminary results are available within minutes after the data is downloaded from the intelligent pig. The results enable engineers to make real-time decisions concerning the return of the furnace to service. Utilisation of this system enables plant engineers to determine corrosion rates more accurately than ever before. The data is easily archived for direct comparison with future inspection data. Accurate corrosion rate information can improve run times, which results in increased plant throughput, efficiency, and reliability, as well as decreased risk of unplanned shutdowns and safety risks.
Figure 3: Integrating FFS/RLA software with enginnering software package allows enhanced decision making capabilities
around the circumference (ie, top, fire side, bottom, and refractory side), if access permits. In most cases, the convection section of fired heater coils is not inspected due to complete inaccessibility. On the rare occasion when the convection section of the heater coil is accessible, raised surfaces such as fins and studs prohibit the application of any external surface NDT inspection technique. The typical strategy for bare surfaced accessible piping requires the Non-Destructive Evaluation (NDE) technician to return to these exact locations year after year to gather comparison data. Repeatedly identifying these exact locations is difficult, inaccurate, and inefficient. The sparse amount of thickness data collected is then applied to insufficiently calculate corrosion rates, which the plant reliability engineers rely upon to make critical decisions involving current piping condition and remaining life. Remaining Life Assessment (RLA) Historically only limited inspection data was applied when performing complex calculations associated with determining Fitness-forService (FFS) and Remaining Life Assessment (RLA). With todayÊs computer horsepower and sophisticated software thereÊs no reason why 100 per cent of the inspection data collected is not applied when performing FFS and RLA calculations in accordance with the most widely used national standard, API-579 / ASME FFS1. 64 • September 2014
References: 1. API-573, Inspection of Fired Heaters and Boilers, Washington DC USA 2. API-579 / ASME FFS1, Fitness for Service, Washington DC USA 3. Paul, Ron (2008) NEXT Energy New Horizons – Out of Pipe Thinking, Chevron, San Ramon California USA. 4. Firth D., Hill T., Simmonds S., Keen D., Thomas C., (2007) Risk-Based Management of Refinery Fired Heaters, Bahrain 5. Roberts R., (2008) MENDT - Combining Both Ultrasonic Intelligent Pigging Inspection and Customized Remaining Life Assessment Software Minimizes Chance of Failure, while Maximizing Reliability in Fired Heater Serpentine Process Coils, Bahrain 6. Braun M., Roberts R., (2007), Refineries at Risk: Aging Infrastructures, PSM Concerns, and Capacity Requirements Drive Global Acceptance of New Inspection Technology for Fired Heaters, San Antonio Texas USA AuthorsÊ Details Richard D Roberts Vice President & General Manager Process Quest Integrity Group, LLC, USA Email: rroberts@questIntegrity.com Ashish Khera Director Allied Engineers, India Email: akhera@alliedengineer.com Chemical Engineering World
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CEW Features Interview
“It’s Time We Realised the Significance of Optimal Conservation and Efficient Use of Water Resources” Water is fundamental to life. The rivers that carry the waters are lifelines for overall growth of any nation. The water hence is to be conserved and harnessed sustainably. The question of maintaining sustainability of water is not only concerned with its quantity of availability with respect to time and space but also the measures that are to be taken for ensuring its quality, equitable distribution and efficient utilisation. In an exclusive email interview with Chemical Engineering World, S Masood Husain, Director General, National Water Development Agency (NWDA), Ministry of Water Resources, says that with the growing population and rising needs, the water availability in India will be under stress when considering its supply-demand scenarios, if appropriate measures including linking of rivers are not adopted timely in a phased and consultative manner. How do you evaluate the current water scenario in India? How serious is the threat of water scarcity? IndiaÊs average annual rainfall is about 1170 mm. Regional variations are ranging from 100 mm in Western Rajasthan to over 11,000 mm in Meghalaya in North-Eastern India. As a result, the country experiences flood and drought almost every year in one or the other region. Nearly a third of the country is drought prone while one eighth of the area is flood prone. Thus, the overall economic growth of the country depends on how effectively the flood and drought prone areas are developed and managed. Annual runoff potential of the country is estimated at 1869 Billion Cubic Metre (BCM). Utilisable water resources are assessed at 1123 BCM (surface water as 690 BCM and groundwater as 433 BCM). Since over 80 per cent of the annual rainfall and flood flows of rivers occur over a period of four to five months, it is necessary to conserve the resources during the period of its abundant availability by way of developing judicious mix of major, medium and minor storage cum diversion schemes at appropriate locations and link them with canals or tunnels, wherever feasible, for transferring excess flood waters to drought prone regions. 66 • September 2014
Further, the rainfall and river flow patterns of the country - due to global warming and climate change - can also affect the present availability of water resources. The per capita availability of surface water in India during the years 1991 and 2001 were respectively assessed at 2309 m 3 and 1902 m 3. It has also been projected that the per capita per year availability of surface water is likely to be reduced to 1401 m 3 and 1191 m 3 by the years 2025 and 2050 respectively. The skewed availability of water over the years may cause social, cultural and economical unrest.
The functions of NWDA were further modified in May 2011 so as to undertake the work of preparations of the DPRs of intra-state links also by NWDA.
Will you please brief us on some of the recent initiatives undertaken by NWDA towards water resource development? The NWDA was set up in July 1982 as an Autonomous Organisation under the Ministry of Water Resources, Government of India with the objective of establishing the feasibility of inter basin transfer of water under the Peninsular River Development Component of the National Perspective Plan (NPP) for water resources development. Later, in 1990 the studies related to Himalayan Component of the NPP were also entrusted to NWDA. In the Year 2006, NWDA was further mandated with the work of preparations of Detailed Project Reports (DPRs) of river link proposals under the NPP and preparations of Pre-feasibility/feasibility reports of Intrastate links as proposed by various states.
In addition to this, NWDA has also completed 33 pre-feasibility studies of intra-state links as suggested by the state governments of Maharashtra, Gujarat, Bihar, Odisha, Jharkhand, Rajasthan and Tamil Nadu and 2 DPRs of the intra-state links pertaining to the State Government of Bihar.
So far, NWDA has completed water balance studies of 137 basins/sub-basins and 71 diversion points; toposheet and storage capacity studies of 74 reservoir sites; and preparations of 32 pre-feasibility reports, 16 feasibility reports and 2 DPRs of link canal projects coming under the Peninsular Rivers Development Component of the NPP.
NWDA has been working intensively on developing water transfer links. IsnÊt it? Will you please elaborate on this concept? Yes, as per the concept of inter basin transfer of water, commonly known as interlinking of rivers, it is proposed to divert water from surplus river basins/sub-basins to water deficit ones by constructing dams/barrages at appropriate locations and interconnecting them with Chemical Engineering World
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CEW Features As far as India is concerned, there are successful experiences of about 10 existing river link projects, such as Periyar-Vaigai Link System, Parambikulam-Aliyar Project, Ghagra-Sarda Link Project, Indira Gandhi Canal Project, Sardar-Sarovar Scheme and Tehri Dam Project. link canal systems for providing the various benefits like irrigation, water supply to domestic as well as industrial uses, hydropower generation and flood control etc, on the basis of specific needs attached to each river basin/sub-basin.
Interlinking of Rivers (ILR) projects are developed to address the wide disparity in availability of water resources within a region with respect to others and growing demands of water resources, which are coming from various sectors.
Since the completion of feasibility study reports of river link projects, NWDA has been involved with concerted efforts for building up consensus amongst the concerned states. As a result, by now NWDA could complete DPRs of 2 inter basin water transfer links coming under the Peninsular Component, namely Ken-Betwa and DamangangaPinjal link projects. While the DPR of Par-Tapi-Narmada link project is in progress and scheduled to be completed by March 2015.
As far as India is concerned, there are successful experiences of about 10 existing river link projects, such as Periyar-Vaigai Link System, Parambikulam-Aliyar Project, GhagraSarda Link Project, Indira Gandhi Canal Project, Sardar-Sarovar Scheme and Tehri Dam Project. The implementation of ILR schemes can thus be further scaled up for overall development of the nation.
NWDA has also completed the DPRs of 2 intra-state link projects namely, Burhi Gandak-Noon-Baya-Ganga and Kosi-Mechi as proposed by the State Government of Bihar. NWDA is continuing with its efforts to arrive at consensus on the other remaining links. There are criticisms on environmental and ecological aspects of the river link projects in India. Will you please explain on this? As mentioned earlier, our country India experiences flood and drought situations almost every year simultaneously. It adversely affects the life and property including cultivated lands of the hazard stricken regions leading to huge human miseries and economical losses. The interlinking of rivers for transferring water from flood prone areas to deficit regions is an effective water resources management tool to deal with the simultaneous occurrence of flood and drought situations. Here, it may be noted that the river link project is not a new concept not only in India but also in many developed and developing countries in the world. In almost all the countries, the 68 â&#x20AC;˘ September 2014
The criticisms on environmental and ecological aspects of the ILR projects are mostly misinformed and not based on any scientific basis. This appears to be rather motivated based on apprehensions and conjectures. The environmental, socio-economic and ecological impacts of each link project are assessed in detail and corresponding management, monitoring and redressal measures are envisaged at the time of preparation of the DPR of the link project. The DPR of the first interlinking project, namely KenBetwa link involving the states of Madhya Pradesh and Uttar Pradesh, is ready for implementation after the statutory clearances are obtained. The project would provide annual irrigation to the tune of about 6.35 lakh hectares, drinking water supply to about 13.5 lakh population and 78 MW of hydropower generation. The implementation of the Ken-Betwa link project will greatly benefit the drought prone and economically poorest areas of Bundelkhand region in Madhya Pradesh and Uttar Pradesh. How effective has National Perspective Plan (NPP) been so far? As per the NPP formulated in 1980, it comprises of two water resources development components, namely
the Peninsular and Himalayan Rivers Development Components. The expected benefits with the implementation of all link projects under the NPP would be about 25 million hectares (Mha) of irrigation from surface water and 10 Mha from the increased use of groundwater, 34,000 MW of hydropower generation and other incidental benefits such as flood control, navigation, water supply for domestic and industrial sectors, fisheries, salinity and pollution control and release of environmental flows as and when needed. The broad approach primarily adopted in the NPP is that the existing uses of river basins/sub-basins have been kept undisturbed. Secondly, the water resources development under the existing legal and constitutional framework is assumed to be taken place fully by the turn of the century; development envisaged is within the frame work of all the existing agreements; and reasonable needs for the foreseeable future have been kept in view and provided for while planning the inter-basin as well as intra-state transfer of water. Finally, most efficient use of land and water in the existing irrigation and hydropower station has been kept as a principal objective to be achieved. It may be pointed out that the cooperation and understanding of the concerned riparian states are critical for making the NPP concept into reality. The current water resources development scenario in India has been constrained with limited availability of fresh water both with respect to quality as well as quantity and existence of competitions/conflicts for allocation/sharing of water for various sectors/states. Hence, central and state governments have to develop cooperative and sharing visions on the NPP concept for its effective implementation. NWDA hopes that the concerned state governments/ departments/stakeholders will realise the importance of optimal conservation and efficient use of water resources in the face of increasing demands, water scarcity and climate change scenarios. Read the complete interview on http://www. cewindia.com/interview.html
Chemical Engineering World
CEW Market Insights
Common Facility Centre to Boost R&D in Chemicals in Gujarat
G
ujarat Chemical Association (GCA) has planned to set up a Common Facility Centre (CFC) in Ahmedabad for R&D in chemical clusters. According to experts, the facility is likely to increase the chemical production capacities of Gujarat, where research and development in chemicals account for more than 50 per cent of the industrial production. Centre has already acknowledged GCA’s plan and ministry of micro, small and medium enterprises has given the approval for establishing the centre. The new facility will be coming up at Naroda Enviro Projects Limited, Odhav and as media reports suggest it will be called ‘Centre for R&D in Chemical and Allied Industries for Micro, Small and Medium Enterprises (MSME) Sector.’ The new centre will support scientific research and focus on a number of activities including design and development in chemical field. New product development, cost effective products technologies, reducing carbon footprint and boosting energy conservation will remain the core of the research activities.
Why Gujarat will continue to lead the Chemicals and Petrochemicals industry in India? • •
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The development is another positive initiative by the government to boost MSME sector in the state. The Gujarat government policy has provided enough support for development of micro, small and medium sized chemical & petrochemical industries in the state. In an column exclusively written for CEW earlier, Jaimin Vasa, President, GCA, has revealed that interest subsidy on loans for modernisation programmes, interest subsidy on eligible parameters, like sector, size, etc, venture capital and patent monetisation assistance, technology acquisition fund, support for vendor development, support for auxiliary industries for value-addition, cluster development in PPP mode, rehabilitation of sick units, etc, are some of the key policy features that have benefitted the industry in the state. According to the Industries Commissionerate, Government of Gujarat, Gujarat produces around 94 per cent soda ash, 80 per cent salt and 42 per cent caustic soda of the total production in India. Also, Gujarat contributes significantly to the country’s petrochemicals production (62%), chemicals production (51%) and pharmaceuticals production (35%). The chemical industry is today the largest and fastest growing component of Gujarat’s manufacturing sector. 70 • September 2014
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Gujarat is well-c onnected to major trade routes to Europe, Middle-East, East Asia and Australia. Gujarat has nearly 38 per cent (564 km) of the dedicated freight corridor passing through. Gujarat state, having one-fifth of countr y’s coastline (1,600 km) with 41 ports, second highest in the countr y. The state also targets to handling 40 per cent of the traffic through Indian ports by 2020. Gujarat is the only state in India organising the ‘Vibrant Gujarat ’ Summit a biennial summit organised to attract foreign investment for development of Gujarat aimed a t b r i n g i n g t o g e t h e r b u s i n e s s l e a d e rs, i n v e s t o rs, corporations, thought leaders, policy and opinion makers. This summit ser ved as a perfect platform to understand and explore business opportunities with the State of Gujarat. During these summits large-scale investments flow from the partner countries. Japan has a cooperation pact with the Union Government f o r 1 9 p ro j e c t s, o f w h i c h s e v e n a re p ro p o s e d i n Gujarat. In fast-industrialising zones of Dahej and Sanand in the state, t wo ‘Smart Cit y’ projects by Japan are proposed. Gujarat is the only state in India having concentration of petroleum, chemical and petrochemical estates around PCPIR. Out of the all the PCPIRs in India, Gujarat PCPIR has the benefit of rich natural resources and feedstock, chemical port and storage facilit y and PCPIR-specific infrastructure - effluent disposal pipelines, solid waste disposal sites. Gujarat is the only state to have better infrastructure like road, rail, por t, power, gas, water with planned up-gradation. Gujarat is the only state in India with Integrated State Wide G as G rid and hav ing 24 hours u n in te r r u p te d electricit y. Gujarat is the only state in the countr y to have LNG terminals (at Dahej & Hazira) Over and above it is clearly evident that Gujarat is definitely poised to become the global business hub of India. To progress continually, the Government of G u j a ra t i s c o n s ta n t l y i n t h e p ro c e s s o f i d e n t i f y i n g n ew ave n u e s o f i nve s t m e n t o p p o r t u n i t i e s n o t o n l y in the industrial sector, but in the chemical sector as well. Excerpts from Jaimin Vasa’s column
Chemical Engineering World
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Making the grade Stainless steel is the only metallic material that can meet all EU regulations on drinking water quality.
WATER TREATMENT SYSTEMS demand hygiene, corrosion resistance and resilience. For each combination, Outokumpu makes the grade. Very harsh environments may need the extraordinary qualities of duplex or super duplex stainless. But the wide range of austenitic and ferritic stainless offers grades for applications from drinking water to heating and process or wastewater. Stainless steel is the only metallic material that can meet all EU regulations on drinking water quality. It satisfies hygiene requirements, resists corrosion, and avoids the ion leaching or free organic compounds associated with some other metals or plastics. Stainless resists erosion corrosion, which can degrade other materials in some water treatment applications, particularly at high flow rates. This ticks the box for handling high sediment content. The corrosion-resistance of an austenitic grade with molybdenum, such as Outokumpu 4404 (316L) is the perfect fit where chlorine content is crucial, as in treatment of drinking water. With its mechanical strength and ductility, it is ideal for feed-water tubes and drainage lines and even marine environments. It is also a prime choice for process water, stainless tanks and cylinders for acidic or hard-water systems, and hygiene critical applications such as hospitals, where it must take regular chlorine-based disinfecting and cleaning. Read more: outokumpu.com/water-treatment
Dual-stabilized ferritic Outokumpu 4521 (ASTM 444) is well matched to use in heat exchangers, boilers and water heaters, as well as in solar water heating. It can also be used for storage tanks, tubes and drinking water pipes. The heat resistance of stainless piping in such applications means lower fire protection demands than for plastics that can burn or char.
And stainless grades are particularly useful in water distribution in multi-story buildings, offering life-cycle cost benefits and avoiding contamination or water discoloration problems than rival systems can develop in the long term. 74 â&#x20AC;˘ September 2014
Chemical Engineering World
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CEW Products Air Driven Boiler Tube Cleaner The tubes and piping of boiler heat exchangers and condensers must be kept clean in order to maintain 100 per cent production efficiency and to prevent damage to the boiler due to overheating. DBX Tools developed new pneumatic boiler and heat exchanger tube cleaner, which cleans tubes thoroughly by mechanical means. This air motor along with cutter or brush goes inside the tubes of vessels and cleans the tubes. This system consists of few moveable parts, easy to operate, faster, economical and versatile. It saves more manpower and time for handling tube cleaning job, gives polished inner surface, can clean straight and bent tubes (even U-bents) of any length from tube ID 25 up to 150 mm. Air pressure required is 6 kg. For details contact: DH Boiler Exchangers Tools Pvt Ltd 3101 Bhandup Indl Estate, Pannalal Silk Mill Compound LBS Marg, Bhandup (W), Mumbai 400 078 Tel: 022-66711682, 25948419, 25948120 Fax: 91-022-25948419 E-mail: dh.boilertools@gmail.com / info@dbxtool.com or Circle ReadersÊ Service Card 1
Gearmotors for Sliding Gates Gandhi Automations Pvt Ltd offers wide range of models for gates weighing from 300 to 10,000 kg. In case of power failure it can be manually operated. It is silient in operation. Built-in anti-jerk device prevents damage to the automatic system. MPS startup at maximum power permits motor to overcome any initial friction caused by ice, dust, etc. Motor protected by internal thermal switch. Obstacle detection causes the gate movement to stop if an obstacle is detected. Advanced electronic control unit permits operation time adjustment, particle opening, automatic closing, step by step control, stop safety reverse safety, etc. Self-test output activates the Secure-1 self-controlled safety device before start up of any movement of the halted gate. If functionality is correct the operation is confirmed and the movement is authorised. For details contact: Gandhi Automations Pvt Ltd Chawda Commercial Centre, 2nd Floor Link Road, Malad (W), Mumbai 400 064 Tel: 022-66720200, 66720300 | Fax; 91-022-66720201 E-mail: slaes@geapl.co.in or Circle ReadersÊ Service Card 2
Furnace Oil Heating Pumping Filtering Unit Vacunair Engg Co Pvt Ltd offers furnace oil heating pumping filtering unit with heating capacity in the range from 1 to 130 kW. Oil preparation which is of vital phenomenon for the efficient operation of low air pressure and pressure jet oil burners is available as a factory finished unit in duplex, semi-duplex and simplex versions comprises of electric oil heater fitted with renewable car tridge type heating element; and gear oil pump with motor, oil filters, ball valves, pressure regulating valves, instrumentation and interconnecting pipelines. Oil tank suction heaters is also available for the pre-heating of fuel oil in main storage tank and service tank to make easy flow of oil from the tank. It finds application in rolling mills, steel plants, ferrous/non-ferrous foundries, glass, silicate, ceramics, foundries, etc. For details contact: Vacunair Engg Co Pvt Ltd Nr Gujarat Bottling, Rakhial Ahmedabad, Gujarat 380 023 Tel: 079-22910771, 22910772 Fax: 91-079-22910770 E-mail: info@vacunair.com or Circle ReadersÊ Service Card 3
76 • September 2014
Chemical Engineering World
Small safety valve with big benefits Fainger LESER launches Type FL 237 This safety valve, Type FL 237, is a completely new design and extends the product range for applications that require compact dimensions. Your benefits:
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High quality stainless steel material Designed for all industrial applications Compact dimensions with high capacity
Very fast delivery time of two weeks ex works for standard configurations Read more about the new safety valve Type FL 237 on the Fainger LESER website www.faingerleser.com.
Head office in Mumbai
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Manufacturing facility in Paithan D-3, M.I.D.C. Paithan, Dist. Aurangabad, Maharashtra - 431 148, India Email: salesfl@faingerleser.com; ssc@faingerleser.com
CEW Products
Candle Filters
Condenser Tube Cleaner
SAP make candle filter provides pressure filtration as well as heel filtration in an enclosed and pressure tight housing. The filter media can be any type of cloth with a clean removal efficiency in the 1-5 micron range. As the cake builds up on the candle the efficiency improves to less than 1-micron. Cake discharge via back washing or blow back by gas. After discharge the cycle begins again.
To function efficiently, every tube of condenser must be kept clean in order to maintain production efficiency and to prevent permanent damage from overheating. DBX Tools developed new condenser tube cleaner consisting of a pneumatic or electric motor with water feeding attachment. The motor drive various cleaning tools by means of driven shafts and cutter brush. Water is supplied through the shafting by a feed attachment on the motor and is used to flush away the deposit removed by the tool. Best for removing extremely hard scale from straight tubes of condenser and heat exchangers from 9 to 28 mm ID.
It finds application in recovery of catalyst like nickel, platinum, palladium, etc; removal of activated carbon, charcoal in pharma plants; resin filtration; filtration of hazardous liquids; all types of polishing filtration; bleaching ear th removal in vegetable oil plants; etc.
For details contact: DH Boiler Exchangers Tools Pvt Ltd 3101 Bhandup Indl Estate, Pannalal Silk Mill Compound LBS Marg, Bhandup (W), Mumbai 400 078 Tel: 022-66711682, 25948419, 25948120 Fax: 91-022-25948419 E-mail: dh.boilertools@gmail.com / info@dbxtool.com
For details contact: SAP Filter Pvt Ltd Plot No: A-5, Sector 1, Vasai Taluka Indl Co-op Estate Ltd Goraipada, Vasai (E), Thane, Maharashtra 401 208 Tel: 0250-2458982, 2023040, 3208273, 2450366 Fax: 91-0250-2481095 E-mail: info@sapfilter.com / sales@sapfilter.com
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Ergonomic Machine Operation B&R offer new line of swing arm systems in wide range of variants and feature IP65 protection, allowing them to be placed optimally on machines. Multi-touch widescreen panels are available in sizes ranging from 18.5‰ to 24‰ with either HD Ready or Full HD resolution. The larger displays and higher resolution make it possible to include even more information on each screen. A 21.5‰ model in portrait format is also available. With optional side handles, it is easy to maneuver and operate these devices at the machine. Two system variants with analog resistive touch screens are also available in 4:3 format, allowing users to upgrade their operator hardware without having to modify their existing HMI applications in any way. These swing arm systems can be equipped with buttons, selector switches, key switches and an integrated E-stop button as needed. Thanks to an integrated RFID reader, individual access rights can be assigned to anyone from service engineers to system operators. Displays from the Automation Panel Series are available in 9 different swing arm models and can be equipped with additional switching elements as needed. For details contact; B&R Industrial Automation Pvt Ltd 8 Tara Heights, Mumbai-Pune Road Wakdewadi, Pune, Maharashtra 411 003 Tel: 020-41478999 | Fax: 91-020-41478998 Email: shyam.padwal@br-automation.com or Circle ReadersÊ Service Card 6
78 • September 2014
Chemical Engineering World
CEW Products O-Ring
Co-Mill Its low speed design applies an inherently gentle action to the product, achieving optimum particle granulometr y while generating limited heat, low noise and minimal fines. It is extensively used for even heat sensitive materials. Infeed chute can be customised to meet all process feed requirements. Swing away discharge should allow quick changeover of screen impellers, customised tooling for special applications. Also, allows for easy cleaning. Machine housing with super sanitary spindle assembly can also be modified for cleaning place operation. For details contact: Saan Engineers Pvt Ltd Plot R-841, TTC Indl Area, MIDC Rabale, Navi Mumbai 400 701 Tel: 022-27606242, 27606243 | Fax: 91-022-27606244 E-mail: saanengineers@saanengineers.com or Circle ReadersÊ Service Card 7
APPL offers wide range of O-ring as per standards or customers requirements. Their O-rings ensure accurate dimensions, glossy finish and invisible flash lines is absolutely defect free. These O-rings a r e ava i l a bl e i n s i ze ra n g i n g f r o m 2 . 0 0 m m I D a n d above in NBR, Neoprene, Butyl, EPDM, Hypalon, Viton, silicone rubber or any other rubber specified by the customer. Their O-rings are applicable for various industries. For details contact; Ami Polymer Pvt Ltd 303 Mahesh Indl Estate Opp: Silver Park, Mira-Bhayandar Road Mira Road (E), Mumbai 401 104 Tel: 022-28555107 | Fax: 91-022-28555378 E-mail: amipolymer@vsnl.com or Circle ReadersÊ Service Card 8
BMS Pumps Grundfos Pumps India Pvt Ltd (Grundfos India) offers the new range of BMS pumps for high flow and pressure applications, including reverse osmosis and ultra-filtration. The new range of BMS pumps are lightweight ultra-filtration booster module. Identifying the need that sustainable water treatment solutions require the pumping solution to be durable, cost-effective and offering trouble-free operation, the simple design and durable components of these pumps eliminate costly downtime. Combined with a permanent magnet motor, the efficiency of the pump has been improved by up to 5% and the weight reduced by more than 75%. This is in line with GrundfosÊ continuous endeavour to increase their productsÊ efficiency and sustainability. BMS pumps are used mainly in water treatment for applications such as: RO in domestic water supply systems; hospitals, laboratories as well as chemical, electronics and metal industries; ultra-filtration in chemical and galvanic industries; and painting workshops, metal and mineral industries. For details contact: Grundfos Pumps India Pvt ltd 118 Rajiv Gandhi Salai Thoraipakkam, Chennai 600 097 Tel: 044-45966800 | Fax: 91-044-45966969 E-mail: salesindia@grundfos.com or Circle ReadersÊ Service Card 9
80 • September 2014
Chemical Engineering World
CEW Products
Smart Water Activity Measurement The next generation of high quality water activity meters by Novasina with touch-screen combined with semi-temperature control and active sample temperature measurements, by an integrated infrared sensor, provide the highest possible reliability of measurements. All measurement data including the important protocols are stored on a SD card and can be transferred to a PC or printer. Special software is available for viewing results and analysis of the data. For details contact: Amkette Analytics Ltd ANM House, Plot No: A-141, Road No: 23 Wagle Indl Area, Thane (W) Maharashtra 400 604 Tel: 022-66141500, 66681500 Fax: 91-022-66681600 E-mail: info@anmalliance.com
FEP Encapsulated O-Ring APPLÊs Silicone, Viton and EPDM encapsulated O-rings with FEP encapsulation are designed to address the growing problem of sealing in the most hostile chemical and temperature environments. It combines the best qualities of FEP material on the outside with its chemical inertness and an elastomer on the inside for resilience. This unique combination forms a highly effective, long lasting seal for the most demanding applications. This O-rings comprises of FEP over Silicone, Viton or EPDM and can be used in temperatures from -75 to +400 oF (-60 to +205 oC) depending upon the choice of elastomer core. For details contact: Ami Polymer Pvt Ltd 303 Mahesh Indl Estate Opp: Silver Park, Mira-Bhayandar Road Mira Road (E), Mumbai 401 104 Tel: 022-28555107 | Fax: 91-022-28555378 E-mail: amipolymer@vsnl.com
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Titrator Hanna Instruments offers two new automatic titration systems utilizing 40,000 step dosing pump - the HI 903 Karl Fischer volumetric titrator and the HI 902C2 two channel potentiometric titrators. The HI 903 Karl Fischer volumetric titrator conducts moisture analysis, combining an ultra-precise titrant delivery system with a magnetic stirrer, sophisticated endpoint determination and background drift correction algorithm. The titrant delivery system is capable of dosing as little as 0.125 øL of titrant maintaining a minimal amount of drift rate. The HI 903 also features a unique anti-diffusion tip preventing unwanted diffusion of titrant into the solvent. These features allow for a 0.1% accuracy when measuring water content from 100 ppm to 100%. The HI 902 Potentiometric Titrator supports two analog inputs allowing sequential titrations to be performed with different sensors for the precise analysis of acid/base, ISE, Oxidation Reduction Potential (ORP), and complexometric reactions. The HI 902 uses the same 40,000 step dosing pump as the HI 903 for the precise dosing of titrant used in end point determination. Both titrators offer HannaÊs unique „Clip Lock‰ Exchangeable Burette system for quickly and easily swapping burettes with reagents used to perform different titrations. The other advantage of the Clip Lock Exchangeable Burette system is the ability to utilize burettes of different sizes (5, 10, and 25 mL) allowing for flexibility in the accuracy (0.1% full burette volume) and the minimum amount of titrant that is dosed. Each unit offers a large, easy to navigate colour LCD and can be connected to a PC using Hanna software. At the end of titration, all data is automatically stored in memory and can be copied via the included USB flash drive or through direct connection to a PC. For details contact: Hanna Equipments (India) Pvt Ltd Aum Sai Bldg, 3/4/5/6, 1st Floor,, Plot No: 23-C, Sector 7, Kharghar, Navi Mumbai 410 210 Tel: 022-27746554, 27746555, 27746556 E-mail: marketing@hanna-india.com or Circle ReadersÊ Service Card 12
82 • September 2014
Chemical Engineering World
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Products CEW Double Cone Blender The double cone blender consists of a two cone-shaped sections with 45 o slopes. The cone sections are welded at their wide ends to a centre band. The blender is mounted between two trunnions that permit the unit to tumble end over end. In operation, material is loaded to a fill level of 50 to 60 per cent of the blender’s capacity. The blender tumbles and the material in the vessel spread out. The transition area at the band between the cones prevents the material from sliding along the inner wall and instead causes the material to fold over itself. This provides gentle mixing with only very slight shear. The blender is ideal for powders of granules that degrade by attrition. The smooth transition area in the vessel also simplifies cleaning because there are no areas to trap particles and cross-contaminate batches. Contra rotary baffles with mechanical seals of both ends can be provided for critical mixing applications. For details contact: Saan Engineers Pvt Ltd Plot R-841, TTC Indl Area, MIDC, Rabale, Navi Mumbai 400 701 Tel: 022-27606242, 27606243 | Fax: 91-022-27606244 E-mail: saanengineers@saanengineers.com or Circle Readers’ Service Card 13
Field Intensity Meter M o d e l K M 8 2 8 is a n ew f ield intens ity meter from Kus amM e co. Th is m o d e l h a s LCD dis play and over range in d ica t io n f u n ct io n a n d c an ins pec t par tic ular objec ts o r d evice s t h a t ra d ia t e low frequenc y elec tromagnetic wave s. I t ca n b e u se d for power c ables, c omputer m o n it o r, TV, a u d io a n d vis ual, elec tromagnetic oven or a n a lo g o u s e le ct r ica l in s tallation. It’s meas ur ing range is 0 . 1 -4 0 0 m G, 1 -4 0 0 0 mG , 0.01-40 uT, 0.1-400 uT w it h a ccu ra cy ±(3 % rd g +3 digits ). The frequenc y range is 3 0 -4 0 0 H z. Th e sa m pling time of this meter is 0.5 se co n d . I t h a s a n e rg onomic des ign eas y to c arr y. It h a s a h o lst e r t o p reve nt the ins tr ument from damage d u e t o a ccid e n t a l fa ll. The power us ed is 9 V batter y. I t ’s o p e ra t i n g t e m p e ra t u re is 0 -5 0 0 C (3 2 -122 0 F) and relative humidity is ≤80% RH. Fo r d e t a i l s c on t a ct : Ku s a m E l e c tr i c a l I ndus tr i e s Ltd G-1 7 B h a ra t I n d l Est a t e, T J R o a d S ew re e (W ), M u m b a i 4 0 0 0 1 5 Te l : 0 2 2 -2 4 1 56 6 3 8 , 2 4 1 2 4 5 4 0 , 2 4 1 8 1 6 4 9 , 27750662 Fa x : 9 1 -0 2 2 -24 1 4 9 6 5 9 , 2 7 7 5 1 6 1 2 E -m a i l : k u s a m_ m e co @ vsn l. n e t / sa le s@ ku s am-mec o.c o.in or Circle Readers’ Service Card 14
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CEW Products
Metal Detector and Checkweigher Metal detector checks metal contamination and checkweigher checks and classifies weight variation in packed product finds use in food industry. A unique combination of metal detector and heckweighter with 100 product memory; diagnostics/statistic data avialable on screen.. For details contact: Technofour Electronics Pvt Ltd Gat No: 3 (PT), 5 (PT), 243 (PT), Kasurdi (Kheba) Khed Shivapur-Saswad Road Opp: Hotel Yogiraj Resort Post: Khed Shivapur, Tal: Bhor, Dist: Pune Maharashtra 412 205 Tel: 02113-305200, 305246 Fax: 91-02113-205250 E-mail: sales@tepl.co.in or Circle ReadersÊ Service Card 15
Rotary Vane Oil Sealed High Vacuum Pumps High vacuum pumps are available in single and double stage with directly coupled to motor flange or V-belt driven. The directly coupled to motor flange of the pumps are compact in size, evenly balanced with exceptional size to performance ratio. V-belt driven pumps are with air or water cooled in various capacities. It finds application in chemical, distillation systems, refrigeration plants, electrical, electronic components manufacturing, laboratory and air conditioning plants, etc. 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: 91-022-25664937 E-mail: indovac@yahoo.co.in or Circle ReadersÊ Service Card 16
Sliding Vane Pump Blackmer announce the availability of the XLW4A Model sliding vane pump. This 4-inch pump is an extension of BlackmerÊs XLW Series sliding vane pump line.XLW Series pumps have been designed to perform in the handling and transfer of a variety of abrasive liquids, including oxide primers, inks and paints, where wear-resistance is critical to pump operation. XLW Series pumps have also shown to be successful in applications such as vertical and horizontal bead mills, solvent recovery, tank-bottom recirculation, heat-treater supply, enhanced oil recovery, and crude- or hot-oil transfer. As with all XLW Series pumps, the XLW4A model features hardened rotor and shaft, liner, end discs and vanes for long life and optimized wear-resistance. These hardened internal parts allow the pump to be used with liquids featuring suspended abrasive particles up to 250 microns in size and at a concentration up to 25%. The XLW4A model can produce flow rates up to 190 gpm (719 L/min) at speeds to 350 rpm; handle viscosities to 20,000 SSU (4,250 cSt); operate at differential pressures to 150 psi (10.3 bar) and working pressures to 350 psi (24.1 bar); and handle temperatures up to 300ÀF (149ÀC). For details contact: Dover India Pvt Ltd ă PSG 40 Poonamallee By-pass, Senneerkuppam, Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle ReadersÊ Service Card 17
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Products CEW Complete Skid-mounted Chemical Dosing System Unique Dosing Systems offer dosing systems as per international standards and customer requirements. All components are calculated as per the discharge pressure of the dosing pump for safety precautions of the system. These skid-mounted dosing packages are used for chlorine dosing system, boiler chemical dosing, oil heating and pumping units and other such duties. The system incorporates single or compartment solution preparation tank; pressure relief valve; chemical dosing pumps single or multiple; pulsation dampener, interconnecting piping; instruments like pressure gauges, level gauges and level switches, sensors, etc; control panel including interconnecting cabling; and stirrer (agitator), valves and fittings. For details contact: Unique Dosing Systems F-1/3 MIDC, Ambad Nashik, Maharashtra 422 010 Tel: 0253-6695621, 6695341 Fax: 91-0253-6695341 E-mail: info@uniq2uesodisng.com / sales@uniquedosing.com or Circle Readersâ&#x20AC;&#x2122; Service Card 18
Habonim Line of Clean Ball Valves The 48 TuBore Series is the Habonium line of clean ball valves for the pharma and bioprocessing industries. These valves are designed for applications which require maximum flow capacity of minimum pressure drop, where sterility, cleanability and drainability are essential for faultless product quality. The 48 TuBore valve port matches tube ID dimensions, provides light shut-off and has exceptional performance in many servicc applications. A fully encapsulated body seal provides an improved seal under fluctuation temperatures and pressures. 48T Series offers rigid valve construction from bar stock to meet market demand for emission limitation and is designed in accordance with ANSI B16.34. For details contact: Jasubhai Engineering 64/A, GIDC Indl Estate, Phase 1 Vatva, Ahmedabad, Gujarat 382 445 Tel: 079-25831042 | Fax: 91-079-25831825 E-mail: Mumbai@jasubhai.com or Circle Readersâ&#x20AC;&#x2122; Service Card 19
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CEW Products Metering and Peristaltic Pumps Neptune offers its Series 7000 mechanically actuated diaphragm metering pumps specifically designed with water and wastewater applications in mind. The Series 7000 eliminates the use of contour plates on the liquid side of the diaphragm while the simple, straightthrough valve and head design allows for improved flow characteristics.
Low Air Pressure Oil/Gas/Dual Fuel Burners Low air pressure oil/ gas/dual fuel burners from Vacunair Engineering Pvt Ltd are excellent for high temperature furnaces for steel plants, rolling mills, ferrous nonferrous foundries, rotary furnaces, glass and silicate industry, ceramic and refractory furnaces and many more applications.
The Series 7000 is self-priming, provides superior performance, and has a max capacity range up to 300 gph (1,135 L/h) at 150 psi.
Low air pressure oil/gas/dual fuel burners from Vacunair Engineering are available with several added instruments for automatic operations and are available in capacity ranging from 10 to 500 litres/hr.
For details contact: Dover India Pvt Ltd ă PSG 40 Poonamallee By-pass Senneerkuppam Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com
For details contact: Vacunair Engg Co Pvt Ltd Nr Gujarat Bottling Rakhial, Ahmedabad, Gujarat 380 023 Tel: 079-22910771 Fax: 91-079-22910770 E-mail: info@vacunair.com
or Circle ReadersÊ Service Card 20
or Circle ReadersÊ Service Card 21
Modular Mechatronic Systems ACOPOSmotor sets new standards for decentralized motion control. With the ACOPOSmotor, B&R combines a servo motor and drive in one compact unit. Safety technology can also be integrated as an option. This gives developers more freedom when designing a machine and can save valuable space in the control cabinet. The ACOPOSmotor is connected to the drive network using a hybrid cable. This cable includes all necessary power and signal lines and establishes the connection to the POWERLINK network. ACOPOSmotor modules come in three sizes with torque ranging from 1.8 to 12 Nm. If needed, an optional fan assembly can provide a performance boost of up to 100%. I n a d d i t i o n t o t h e p r o v e n w i r e d s a f e t y f u n c t i o n s S T O ( S a f e To r q u e O f f ) a n d S S 1 ( S a f e Operational Stop 1), a network-based ACOPOSmotor module variant will also be available in the future. This will allow users to access the following functions (as with the ACOPOSmulti): STO, SOS, SS1, SS2, SLS, SMS, SLI and SDI. The ACOPOSmotor is fully compatible with the ACOPOSmulti drive system. This makes it possible for users to select the best-suited servo drive for each machine without having to do any additional engineering work. For details contact: B&R Industrial Automation Pvt Ltd 8 Tara Heights, Mumbai-Pune Road, Wakdewadi, Pune, Maharashtra 411 003 Tel: 020-41478999 | Fax: 91- 020-41478998 Email: shyam.padwal@br-automation.com or Circle ReadersÊ Service Card 22
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ChemTECH World Expo 2015
Chemical Industry Gorinchem
Dates: 28-31 January 2015 Venue: Bombay Convention & Exhibition Centre (BCEC), Goregoan, Mumbai Details: World meet of chemicals, petrochemicals, pharmaceuticals and process industry in India Contact: +91 22 40373636 Email: sales@jasubhai.com Website: www.chemtech-online.com
Dates: 2-4 Dec 2014 Venue: Gorinchem, Netherlands Details: Chemical Industry Gorinchem will be held for a period of three days in The Netherlands Organiser: Evenementenhal Gorinchem Contact: +31 183 680680 Email: gorinchem@evenementenhal.nl Website: www.evenementenhal.nl
Corcon 2014 Dates: 12-15 November 2014 Venue: Grand Hyatt, Mumbai Details: Corrosion Conference and Expo Organiser: Nace International Gateway India Section (NIGIS) Contact: +91 22 25797930 / 25797354 Email: kim.shah@nace.org Website: www.corcon.org
World PetroCoal Congress Dates: 15-17 February 2015 Venue: Convention Centre-NDCC, New Delhi Details: On sustainable usage of the non-renewable resources Organiser: Energy and Environment Foundation Contact: +91 11 2275 8149 Email: punit.nagi@ee-foundation.org Website: www.worldpetrocoal.com
China International Exhibition for Coating & Paintss Dates: 13-16 Mar 2015 Venue: Beijing, China Details: One of the leading trade fair for Coating & Paints industry in China Organiser: Sinostar Internationl Ltd Contact: +852 2865 0062 Email: info@sinostar-intl.com.hk Website: www.sinostar-intl.com.hk
Chem Bio Finland 2015 Dates: 18-19 Mar 2015 Venue: Helsinki, Finland Details: Exhibition for the chemical, laboratory and biotechnology products and services Organiser: The Finnish Fair Corporation Contact: +358 40 450 3251 Email: sales@messukeskus.com Website: www.messukeskus.com
India Chem
Middle East Coatings Show 2015
Dates: 9-11 October 2014 Venue: Bombay Convention & Exhibition Centre (BCEC), Mumbai Details: An exhibition on chemical, petrochemical and pharmaceutical sector Organiser: Federation of Indian Chambers of Commerce & Industry Contact: +91 11 23738760 / 23765081 Email: manoj.mehta@ficci.com Website: www.indiachem.in
Dates: 9-11 March 2015 Venue: Dubai International Convention & Exhibition Centre, UAE Details: An event for raw materials suppliers and equipment manufacturers Organiser: DMG Events Ä&#x192; ME & Asia Contact: +971 4 4380355 Email: info@dwtc.com; chrishamilton@dmgeventsme.com Website: www.coatings-group.com
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CEW Project Update
New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. Ć CHEMICALS Vasudha Pharma Chem is planning a chemical manufacturing project in village: Atchutapuram, district: Visakhapatnam, Andhra Pradesh. The project will be spread over 26-acre of acquired land. Work on the project commenced in August 2014 and is planned for completion in 2016. Sayona Colors, belonging to the Sayona Group, is planning an expansion of its dyes and colours manufacturing project in Navrangpura, district: Ahmedabad, Gujarat. The project will involve capacity expansion of products like synthetic organic dyes, food colours and cosmetic colours. The project is waiting for international collaboration. Punjab Chemicals & Crop Protection is planning a thiamethoxam manufacturing project in villages: Kolimajra and Samalheri, district: Mohali, Punjab. The project will come up at the companyÊs existing plant premises. The project is in planning stage. S K Solvochem Private Limited is planning a 1,500-TPA synthetic organic chemicals manufacturing project - dye and dye intermediates, bulk drug and intermediates excluding drug formulations, synthetic rubbers, basic organic chemicals, other synthetic organic chemicals and chemical intermediates at a cost of ` 20-million in village: Nimbua, district: Mohali, Punjab. The public hearing was held in January 2014. The project is waiting for environmental clearance. N u r a y C h e m i c a l s i s i m p l e m e n t i n g a fe r r i c c i t r a t e manufactur ing project at the existing unit in SIDCO Industrial Estate, Kakalur, district: Tiruvallur, Tamil Nadu. Civil, mechanical and engineering work is in progress and is scheduled for completion in Q4 2014. Equipment is already available. Lion Tapes Private Limited, a sister concern of Stretch Bands, Gujarat, is planning a 100-TPM synthetic organic chemicals manufacturing project in GIDC, Chitra Estate, district: Bhavnagar, Gujarat. As of October 2013, the project is waiting for environmental clearance. According to the MoEF sources, the project includes products like 40-TPM of Fast Red B Base, 20-TPM of Fast Bordeaux GP Base, 10-TPM of Fast MNPT (Red G) Base, 5-TPM of Fast Red 3GL Base, 10TPM of Fast Scarlet RC Base, 5-TPM of Fast Yellow GC Base, 5-TPM of Fast Orange GC Base and 5-TPM of Fast Red RC Base. The commercial waste generated from administration building would be disposed through sale to scrap vendors. The generated industrial wastewater will be treated in ETP and treated effluent will be discharged through common pipeline. 90 • September 2014
Ć MINING Barmer Lignite Mining Company, a JV between Rajasthan State Mines & Minerals and Raj West Power, a subsidiary of JSW Energy, is planning an expansion of the Kapurdi opencast lignite mining project from 3.75-MTPA to 7-MTPA in Kapurdi, district: Barmer, Rajasthan. The project cost is estimated to be ` 18,000-million inclusive of a new lignite mining project at Jalipa mines. The project is waiting for environmental clearance. Western Coalfields is planning the Penganga opencast coal mining project (3-MTPA and peak capacity is 4.5-MTPA) on 781-hectare of land in village: Wirur, district: Chandrapur, Maharashtra. As of November 2012, the project was submitted at the 59 th EAC (Thermal & Coal Mining Projects) meeting held on 6 th November, 2012. Central Coal Fields is planning 0.3-MTPA Ray Bachra underground coal mining project in district: Ramgarh, Jharkhand on a 1,215.45-hectare land. As of September 2012, the project was submitted at the 57 th EAC (Thermal & Coal Mining Projects) meeting held on 17 th September, 2012. Rajasthan Rajya Vidyut Utpadan Nigam is planning a 10-MTPA opencast Parsa East & Kanta Basan coal mining and 10-MTPA coal washery in Udaipur, district: Surguja, Chhattisgarh. As of August 2012, the project was submitted at the 55 th meeting of the EAC (Thermal & Coal Mining Projects) held on 28 th August 2012. Odisha Power Generation Corporation is planning the Manohar pur opencast coal mining project in distr ict: Sundergarh, Odisha. As of July 2012, the company is waiting for environmental clearance. Chhattisgarh Mineral Development Corporation is planning ÂSondihaÊ opencast and underground coal mining project in district: Surguja Chhattisgarh. As of July 2012, the company is waiting for environmental and forest clearance. Ć NON-CONVENTIONAL ENERGY Shri Shivsagar Sugar & Agro Products is planning an 18MW co-gen power project in village: Udpudi, district: Belgaum, Karnataka. The project will come up on the existing 150-acre sugar plant premises. The project is planned for completion in 12 months from zero date. Siddheshwari Paper Udyog is implementing a 6-MW rice husk-based captive power project in Kashipur, district: Udham Singh Nagar, Uttarakhand. The project is coming up with an expansion of its kraft paper-manufacturing unit. Civil work is nearing completion and machinery has been ordered. Chemical Engineering World
Project Update CEW Ć NON-CONVENTIONAL POWER IPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20-MW bagasse and rice husk-based integrated power project spread over 250-acre of land in village: Motipur, district: Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1-year from zero date. Ć THERMAL POWER Pashamylaram Common Infrastructure is planning a 1-MW coal-based cogen power project on 1.5-acre land in village: Pashamylaram, district: Medak, Telangana. The estimated cost of the project is ` 860-million inclusive of a common effluent treatment plant, which is also in planning stage. The project is waiting for environmental clearance. Rungta Mines is planning a 120-MW coal-based captive power project in district: Dhenkanal, Odisha. The project will come up along with an integrated steel project in the same location, which is in planning stage. Land acquisition is in progress. The project is in planning stage. Talavadi Cements, a subsidiary of Birla Corporation, is planning a 35-MW captive power project in village: Bari, district: Satna, Madhya Pradesh. JM Environet is the environmental consultant. The project is waiting for environmental clearance. The power generated will be used for the cement project to come up in the same location, which is in planning stage. VP Cements is planning a coal-based captive power plant (1ï40-MW in Phase I and another 1ï40-MW in Phase II) in village: Gundlakunta, district: YSR, Andhra Pradesh. Land acquisition is under progress. Both the phases are waiting for environmental clearance. The project will come up as part of its ` 16-billion 2-phase integrated cement project. Work on Phase I is expected to commence in 2015 and Phase II in 2017. Kanodia Cement, belonging to the Kanodia Group, is planning a 15-MW coal-based captive power project in Unit-I, Durgawati, district: Kaimur (Bhabua), Bihar. Land has been acquired. The project will come up along with an ordinary portland cement manufacturing project. The total cost of both the projects is Rs 900-million. The project is waiting for environmental clearance. Hira Electro Smelters, formerly known as RVR Smelters, belonging to the Hira Group, is planning a 20-MW waste heat recovery-based captive power project in Bobbili, district: Vizianagaram, Andhra Pradesh. The project is in conceptual stage. Work on the project is expected to commence in 2017. The project will come up along with a 50,000-TPA coke oven products manufacturing project. Jai Bhole Cement Combine, a group company of Zawar Sales, is planning a 72-MW (coal as fuel) and 10-MW (WHR as fuel) captive power project in Velabai, district: Yavatmal, Maharashtra. Equipment supplier is yet to be appointed. The project is waiting for environmental clearance. Work on the project commenced in March 2014 and is planned for completion in H1 2017. The project will come up as part of its ` 151-billion integrated cement project spread over 2,500-acre of acquired land. Ć POWER GENERATION Pashamylaram Common Infrastructure is planning a 1-MW coal-based co-gen power project at an estimated cost of ` 860-million inclusive of a common effluent treatment plant, which is also in planning stage in village: Pashamylaram, district: Medak, Telangana. The project is waiting for environmental clearance. Chemical Engineering World
September 2014 • 91
CEW Book Shelf Chemical Technology: An Integral Textbook Authors Price Page Publisher
: Andreas Jess, Peter Wasserscheid : ` 5,730 : 888 (Hardcover : Wiley VCH
About the Book : This textbook provides an integral and integrated treatment of industrialărelevant problems for students of both chemistry and chemical engineering. As such, this work combines the four disciplines of chemical technology ă chemistry, thermal and mechanical unit operations, chemical reaction engineering and general chemical technology ă and is organised into two main parts. The first covers the fundamentals, as well as the analysis and design of industrial processes, while the second section presents 20 concrete processes, exemplifying the inherent applied nature of chemical technology. These are selected so that they all differ with respect to at least one important aspect, such as the type and design of the reactor, the chemistry involved or the separation process used. As a result, readers will recapitulate, deepen and exercise the chemical and engineering principles and their interplay, as well as being able to apply them to industrial practice.
Unit Operations of Chemical Engineering Authors Price Page Publisher
: Warren McCabe, Julian Smith, Peter Harriott : ` 549 : 1152 (Hardcover) : Tata McGraw Hill Education
About the Book : In its seventh edition, the text still contains its balanced treatment of theory and engineering practice, with many practical, illustrative examples included. Almost 30 per cent of the problems have been revised or are new, some of which cover modern topics such as food processing and biotechnology. Other unique topics of this text include diafiltration, adsorption and membrane operations.
Process Flowsheeting Authors : A W Westerberg, A W Westerberg Price : ` 2,348 Page : 262 (Paperback) Publisher : Cambridge University Press About the Book : Process flowsheeting concerns the use of computers to stimulate and design chemical plant of all types, such as petroleum refineries, petrochemical complexes or even food factories. In this 1979 introduction to the topic the authors examine the role of flowsheeting in process plant design and look at the various techniques on which computer-aided systems may be based. For each one of these approaches the advantages and disadvantages are clearly stated and the four most important methods are described in detail. In each case the motivation for its development is analysed and its use is illustrated by a number of practical examples. Particular attention is devoted to the underlying technology of process flowsheeting systems, and an introduction to the analysis of degrees of freedom in flowsheeting and a guide to further reading are also included. 92 • September 2014
Handbook of Chemical Engineering Calculations, 4th Edition Authors Price Page Publisher
: Tyler G Hicks, Nicholas P Chopey : ` 7,500 : 768 (Hardcover) : McGraw-Hill Professional
About the Book: Fully revised throughout with new procedures, Handbook of Chemical Engineering Calculations, Fourth Edition shows how to solve the main process-related problems that often arise in chemical engineering practice. New calculations reflect the latest green technologies and environmental engineering standards. Featuring contributions from global experts, this comprehensive guide is packed with worked-out numerical procedures. Practical techniques help you to solve problems manually or by using computer-based methods. By following the calculations presented in this book, you will be able to achieve accurate results with minimal time and effort. Coverage includes: Ć Physical and chemical properties Ć Stoichiometry Ć Phase equilibrium Ć Chemical reaction equilibrium Ć Reaction kinetics, reactor design, and system thermodynamics Ć Flow of fluids and solids Ć Heat transfer Ć Distillation Ć Extraction and leaching Ć Crystallization Ć Absorption and stripping Ć Liquid agitation, etc
Chemical Engineering World
CEW Features
Company Profile
INTERGRAPH - THE POWER TO SEE Intergraph® Intergraph® Process, Power & Marine (Intergraph PP&M) has spent many years developing and offering integrated design, construction and operation solutions for the chemical industry. Intergraph’s SmartPlant® Enterprise software offers the largest set of market-leading solutions in the industry, from the schematic design of an asset through to physical modelling, materials management, construction management, fabrication automation and information management. At the centre of SmartPlant Enterprise software is Smart™ 3D. It provides a fully integrated design and manufacturing environment to support the design of integrated facilitates, be it plants, storage tanks, or other. Smart 3D can handle the dense and complex structural and outfitting designs required in modern designs.
Seamless data integration project software Intergraph SmartPlant Enterprise solutions, including Smart 3D, are delivered with out-of-the-box integrated architectures that seamlessly integrate the flow of information between them. Data and design parameters are entered only once into the authoring disciplines and re-used downstream. The out-of-the-box integration is a change management environment that facilitates publishing, retrieving, reviewing and comparing data and documents electronically between disciplines.
“Technip designers will definitely take advantage of 2014’s improvements around jacketed pipe design and deliverables extraction. One of the reasons Technip adopted Smart 3D was because of its integration with Intergraph’s 2D design tools. Smart 3D 2014’s Design Basis Viewer provides an easier way to compare and update the Smart 3D model with the data in SmartPlant P&ID, SmartPlant Instrumentation and SmartPlant Electrical.” Thomas Kerjouan, Technip France Smart 3D administrator. Smart 3D enables more efficient design, with better quality and design integrity than ever. In addition, upgraded Model Data Reuse (MDR) capabilities enables efficient reuse of design that is not possible in any other 3D CAD application. Users can reuse FEED or old designs with different catalogs and specifications, by leveraging Smart 3D’s unique rule re-use, tag renaming and specification interchange. Also, enhanced 3D interoperability capabilities enable the use of 3D data from multiple foreign CAD systems in conjunction with native Smart 3D models. Smart 3D is the only system in the world that allows interoperability with both graphics and data of foreign CAD models, making it an ideal solution for revamp and joint venture projects.
Real-time global work-sharing application for projects All enterprise applications, including Smart 3D, deliver global work-sharing capabilities, allowing companies to electronically share work internally or externally in real time. In addition to the schedule benefit of leveraging other offices, Intergraph’s worksharing capabilities improve quality by electronically enforcing all project or company standards across the globe and maintaining interface points within an application and between different discipline applications.
Efficient design Smart™ 3D is the most advanced and productive 3D design solution that effectively enables optimized design, increasing quality, interoperability and productivity, while shortening project schedules. 94 • September 2014
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Features CEW
Project planning software Smart 3D’s planning environment reduces the overall project schedule by allowing users to define physical boundaries and construction packages for the different modules/blocks at early stages of the project. These dynamic, multi-discipline definitions define the objects belonging to each block and the total volume, weight and centre of gravity for the module. The modules are further broken down into assemblies and sub-assemblies, containing detailed assembly orientations, installation sequences and work centre assignments. The definitions are made across a database and are not constrained by files or the plant breakdown structure, which enables them to be modified at any time to reflect fabrication/installation methodology changes.
Power facility lifecycle-management software SmartPlant Enterprise’s solutions include rule-driven design, relationally linked data between design disciplines, and complete visible management throughout the life of the offshore facility. “Empresarios Agrupados has used Smart 3D, SmartPlant P&ID and SmartPlant Instrumentation in a number of relevant combined cycle power generation plant and nuclear plant projects, experiencing productivity increases,” said Rafael Huete, IT department manager. “The company plans now to expand the use of the tool in projects in Africa and in the Middle East, while focusing on optimizing the implementation of SmartPlant Electrical Detailed and achieving further integration with other systems.”
Financial enterprise software for owner operators Reduce your capital expenditure (CAPEX) and improve your return on capital employed (ROCE) with Intergraph’s SmartPlant Enterprise for owner operators (SPO). The enterprise has been designed to help owner operators (O/O) address the issue of interoperabilit y by providing pre-packaged solutions that can be rapidly deployed, incorporating customer-specific requirements at low risk. SPO is built on the Intergraph SmartPlant Enterprise suite. Advantages of Intergraph’s SmartPlant Enterprise for owner operators’ software include the following: • Enjoy higher quality data, leading to less reworks during design and in the field • Reduce the risk of loss of critical asset intelligence due to a Chemical Engineering World
retiring workforce • Keep your maintenance data updated for auditability and ensure correct procurement of replacement parts • Realize significant savings on design time and costs • Improve facility safety with better configuration management and ensured data consistency Intergraph PP&M provides the future of engineering, today.
Intergraph Process, Power & Marine (PP&M) is a major provider of engineering software for the design, construction, and operation of process plants, ships and offshore facilities. Based on its extensive process industry experience, Intergraph® has developed the SmartPlant® Fusion package to deal with unstructured information challenges. For more information visit: www.intergraph. com/go/fusion. For more information, please refer to these whitepapers available at the website above: Understanding Information Challenges for Brownfield Assets and Greenfield Projects This white paper highlights the challenges in collating, organizing, and accessing unstructured information, particularly in brownfield plants, offshore facilities, and greenfield construction projects. New Approaches to Make Plant and Project Information Rapidly Available This white paper discusses a variety of new capabilities that are being made available by Intergraph and Leica Geosystems to enhance existing on-plant operation systems. SmartPlant Fusion: Technology and Capabilities This white paper discusses the technology platform being developed by Intergraph to solve the unstructured information challenges of the process, power, and marine industries.
Intergraph Consulting Pvt Ltd 1-8-446 and 447, S.P. Road Secunderabad - 500 003, Andhra Pradesh,India Tel: +91-9820983960 Email: indiasales@intergraph.com URL: www.intergraph.com/global/in/ September 2014 • 95
CEW Features Technical Article
THE BROWNFIELD INFORMATION CHALLENGE: UNSTRUCTURED LEGACY DATA Reducing costs, delays, risks and stress By Brad Broughton, Executive Director of Business Development, Intergraph Process, Power & Marine
Everyone in the industry would prefer to run a plant they have been involved with from conceptual design to commissioning, all handled by a single EPC contractor who has handed over a perfect set of data files. However, in practice, most of us have to function within plants that incorporate brownfield elements built in the past for another company, which are usually poorly documented. This legacy plant documentation is likely to be incomplete, unstructured and in a variety of formats, introducing a range of operational, safety and financial risks. Consequently, software for structuring and analyzing such documentation is a valuable tool for brownfield site operators.
W
hen acquiring existing facilities, the new owner/operator will often discover that the various contractors who were involved in engineering and construction over the years used different design and data management tools. Therefore, the information that exists is often in unintelligent formats like scanned documents, PDFs, and images. The files are often shared informally, resulting in duplicates scattered around in unofficial storage locations. Some documents might only exist in paper form. Leaving this information unmanaged leads to further duplication, fragmentation, and degradation of information integrity. (see Figure 1)
Costs and risks Trustworthy engineering data and documentation are essential for effective project delivery and safe, efficient operations. Every person involved in designing, constructing, operating, and maintaining a facility needs ready access to trustworthy information to perform their job effectively. Incomplete, unreliable and unstructured plant data exposes the plant owner/operator to significant risks. It is challenging to solve a problem on a plant or take a critical decision if inadequate information means that the root cause of problems is difficult to find, or if there are undocumented dependencies between systems.
Furthermore, when a brownfield plant is initiated after a turnaround there is likely to be a significant data disconnect between the main EPC contractor and the subcontractors working on the project. As a result, owner/operator personnel often set up their own data stores, leading to additional fragmentation.
Safety risks are even more important to consider. If owner/operators are not completely familiar with the details of their plants, how can they guarantee they are safe and achieve their zero hazards goal? Inadequate information can also pose challenges for maintenance and make it difficult to isolate equipment in an emergency. Similarly, if plant components are discovered to be substandard, all locations where they have been used need to be identified so that the components in question can be replaced. That requires detailed, up-to-date and easily accessible materials records.
This lack of reliable plant data also affects new-build plant elements. During this frenetic period, documents, drawings, and electronic files are distributed in boxes throughout the temporary construction offices and taken onto the site by craft workers. Some of the detailed information may only be in the heads of technicians or on scraps of paper somewhere. Whether this information is ever captured electronically is questionable.
Figure 1: Unstructured data scattered across various forms and file locations
96 â&#x20AC;˘ September 2014
An inability to quickly solve plant upsets can lead to unnecessarily long, costly production interruptions. Poor plant documentation can make it impossible to comply with health, safety and environmental regulations. This may lead to high fines and tense relationships with regulatory authorities. Solutions for dealing with unstructured, ever-changing data What is really needed is a single point of access to all plant data, be it historical or current, regardless of the format in which the data exists. We need a tool to bring organization and structure to unstructured information and make it easy to access. (see Figure 2) Such a tool should provide access to data in a wide range of formats and enable contractors and owner/operators to handle unstructured data more efficiently, thereby reducing associated risks. Chemical Engineering World
Features CEW
BOOST PRODUCTIVITY BY 30 PERCENT
INTERGRAPH® SMART™ 3D The next-generation 3D plant design Gain a competitive edge and accelerate projects with Intergraph Smart 3D, the first and only next-generation 3D plant design solution for the process, power, and marine industries. t Improve productivity: Smart 3D delivers up to 30 percent more productivity than any other system available today. t Ensure design integrity: Smart 3D automates repetitive tasks and automatically enforces design rules, meaning all designers work with the same rules in all locations. t Enhance interoperability: Smart 3D is the only system offering interoperability with both graphics and data attributes of third-party CAD models and native Smart 3D models.
© Intergraph Corporation. All rights reserved. Intergraph is part of Hexagon. Intergraph and the Intergraph logo are registered trademarks and Intergraph Smart is a trademark of Integraph Corp. or its subsidiaries in the United States and in other countries.
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September 2014 • 97
CEW Features
The key requirement is that the tool should help users find the information they need, even if initially they are not sure what they are looking for, or where to look for it. This means combining the strengths of computers (e.g. continuously scanning folders for new information) with those of skilled engineers (e.g. being able to quickly evaluate duplicates and revisions to pick the best master). One option for making data more accessible is to store files in hierarchical folders. However, such a hierarchy may merely lead to structured data rather than structured information which is actually useful. Instead, it would be better to adopt the „find what you need by what you know‰ concept. Users in different roles in an organization all know something different about the plant and the work they undertake in it. Hence, they will start looking for information from different starting points ă by tag number, unit number, discipline, document type, etc. An effective tool for accessing unstructured data should support this approach. Diverse data formats Plant data is likely to come in a variety of file formats: 2D and 3D CAD systems (e.g. AutoCAD ® and MicroStation), specialist plant design software, office software, PDFs, document scans, photographs, and laser scans. Ideally, the tool should provide convenient access to all these files. It should also allow the user to see the relationships between files and walk through the plant using photographs and laser scans which accurately represent the as-exists plant (which may well be different from the as-designed or as-built plant). Figure 3 shows how a web portal can give access to all information about a pump: the service manual, nozzle information, drawings, datasheets, P&IDs, as well as safety, purchasing, and maintenance data. The 3D laser scan is fully navigable and includes a measurement function. This comprehensive access to information makes it easier to assess issues affecting the pump and to plan maintenance or deal with emergencies without physically going into the plant.
Figure 2: Quick access to document thumbnails
Figure 3: WebPortal provides intuitive, single point of access to plant information
Figure 4: Charts, graphs and reports help you visualize the status of plant information
High definition laser scans are particularly useful in brownfield settings where the costs of surveying the as-exists plant and creating an accurate 3D model would be prohibitive.
identified locations and subsequently monitor relevant folders to check if new files are added.
Data management and reporting functions One would also expect plant information management software to have options to browse, query, sort, filter, and count information. These functions could be used for reports, cause and effect analyses, document quality assurance, etc. Reports could include tag lists, document lists, cross-reference lists, and lists of missing documents. (see Figure 4)
It is essential that documents and tag numbers are correctly linked. This provides effective access to information, helps to place everything in context and helps to determine the impact of proposed changes. The tool must also support multiple tag formats (e.g. as used by different contractors) and be able to identify tag numbers in CAD drawings and scanned documents, even if they have to be reconstructed.
Implementation In a brownfield environment those involved will have to cope with the existing data, which is likely to be spread across a network. When first installed, software should crawl through all files in
After the initial set up, an effective data management tool should immediately provide convenient access to the formerly unstructured plant data. This will save time and costs while improving safety and reliability.
98 • September 2014
Chemical Engineering World
CEW Ad Index Sr. No.
Client’s Name
Page No
Sr. No.
Client’s Name
Page No
75
28
Kevin Enterprise Pvt Ltd
Inside Cover I
29
Kirloskar Brothers Ltd
Beda Flow Systems Pvt Ltd
61
30
Kirloskar Pneumatic Co Ltd
11
4
BHS-Sonthofen (India) Pvt Ltd
59
31
Kishor Pumps Pvt Ltd
69
5
Bonfiglioli Transmissions
29
32
Kwality Process Equipment Pvt Ltd
35
6
Busch Vacuum India Pvt Ltd
41
33
Mazda Ltd
79
7
Chembond Chemicals Ltd
17
34
Mist Resonance Engg Pvt Ltd
77
8
Chempro Technovation Pvt Ltd
104
35
Paharpur Cooling Towers Ltd
19
9
ChemTECH + EPC World Expo 2015
60
36
PPI Pumps Pvt Ltd
79
10
Desmi Pumping Technology A/S
53
37
R K Dutt Concerns
73
11
Dover India Pvt Ltd
57
38
Rajdeep Engineering Systems (Pune) Pvt Ltd
73
12
EI DuPont India Pvt Ltd
47
39
Rasaii Flow Lines Pvt Ltd
55
13
Emjay Engineers
71
40
Rathi Transpower Pvt Ltd
69
14
Eureka Forbes Ltd
49
41
Refining & Petrochemicals 2015
99
15
Fainger Leser Valves Pvt Ltd
77
42
Seal Excel (India) PVt Ltd
67
16
Flexim Instruments Asia Pte Ltd
13
43
Specialty Chemical World Expo 2015
36
17
Fluorotech Engineering Works
71
44
SSP Pvt Ltd
31
18
Garnder Denver Engineered Products India Pvt Ltd
8
45
Super Industrial Lining Pvt Ltd
19
Glatt (India) Pharma Engineering Pvt Ltd
37
46
Suraj Ltd
67
20
Goodie International Pvt Ltd
65
47
Tecnimont ICB Pvt Ltd
45
21
Gopani Product Systems
Back Cover
48
Tranter India Pvt Ltd
39
22
H&R Johnson (Ind)
23
49
Uni Klinger Ltd
63
23
Hanna Equipments (India) Pvt Ltd
75
50
UNP Polyvalves (India) Pvt Ltd
25
24
Hi-tech applicator
7
51
Vega India Level & Pressure Measuremnet Pvt Ltd
15
25
HRS Process Sysstems Ltd
5
52
WaterEX World Expo 2015
81
26
ImageGrafix Engineering Services Pvt Ltd 85, 87, 89, 91
53
Zeeco Inc
27
Integral Process Controls India Pvt Ltd
1
Arvind Anticor Ltd
2
Atomic Vacuum Company (Exports)
3
100 • September 2014
43 Inside Cover II
3
9
27 Chemical Engineering World
Interview CEW
“Deliver Better Overall Economics than Existing Process Technologies”
Over dependence on fossil fuels is most likely to hamper the chemical industry where most processes are petroleum based. Providing the much needed solutions and being a widely-recognised technology leader, Genomatica has been developing novel manufacturing processes which allow its partners to produce the most extensively used chemicals in the world using alternative feedstock cost effectively and ensuring sustainability. In an email interaction with CEW, Dr Christophe Schilling, CEO, Genomatica, shares details on the company’s focus on innovation, its recently announced ‘nylon intermediates program’ and partnering with the likes of BASF, Novamont and more.
Chemical Engineering World
September 2014 • 101
CEW Interview The most recent survey results, announced in September attracted almost 1,000 responses from firms worldwide...results highlighted the continuing and strengthening interest in and movement toward greater sustainability in the mainstream chemical industry. Please apprise us of GenomaticaÊs performance in the last 5 years and share your thoughts on the future of bio-based chemicals market globally. Genomatica has delivered well on both technology and commercial milestones. Genomatica develops process technology for the production of the worldÊs most widely-used chemicals ă chemicals like butanediol (BDO), butadiene, and nylon intermediates (HMD, CPL, ADA). Our processes harness biotechnology ă using microorganisms that we purpose-engineer ă to convert alternative feedstocks (such as various sugars) into the desired chemical. They aim to deliver better overall economics than existing process technologies and greater sustainability. To do this, we first invested in our proprietary integrated biotechnology platform. Our platform lets us develop great process technologies more rapidly. Our platform combines computational modelling, experimental biotechnology, and process engineering capabilities. Using our platform, we commercialised our first process, for BDO, in less than five years ă a standout achievement in the industry. Our process has produced thousands of tons of product, been licensed by BASF and Novamont, and validated by many major firms. We are well along in our second process, for butadiene, which has gained USD 100 million in industry support, along with Braskem and ENI Versalis as partners. And we confirmed that our third program, for nylon intermediates, is well underway. Along with our platform, we have built a large body of intellectual property, which includes over 500 patents and applications. Our commercial milestones include the many large firms that have signed major agreements with us, and the products that are now making their way to end102 • September 2014
customers based on chemicals made with our processes. We also have been honoured with some of the industryÊs most notable awards, recognising our technology, innovation, milestones and potential for positive impact. Regarding the future of the industry, this is something we track closely. Through our many discussions with firms throughout the industry and also through a unique ongoing program we have run with ICIS, one of the worldÊs leading chemical and energy market information providers. The most recent survey results which were announced in September attracted almost 1,000 responses from firms worldwide and was one of the most extensive industry surveys to date. The results highlighted the continuing and strengthening interest in and movement toward greater sustainability in the mainstream chemical industry. Additional details on this survey can be found in GenomaticaÊs release, Sustainability Takes Firmer Hold in Mainstream Chemical Industry. The industry is more focused on R&D today; does Genomatica focus on innovation for its growth? Please elaborate on how much the company invests into research. Absolutely. In fact, we describe our headquarters as our ÂInnovation CenterÊ. A large majority of all Genomatica spending is allocated to R&D, including amounts received from our large partners as sponsors of select R&D programs. We speak regularly at conferences to share our work to advance the field, both in the underlying science and in the pragmatic work of scale-up, and delivery of processes that work in worldscale plants. More information on this is available on GenomaticaÊs website under the news section where the September 10, 2014 press release describes ă with numbers ă how continued innovation in
our underlying biotechnology platform has allowed us to further accelerate our process development work. Please tell us a bit more in detail about the recently announced Ânylon intermediates program.Ê We have been working on nylon intermediates for a while now ă and it is a natural target for our capabilities. The processes that we are developing aim to solve some real problems in the mainstream chemical industry, including addressing price volatility and limited supply sources of some current raw materials, and avoiding unwanted byproducts and waste streams. How did the adoption of GenomaticaÊs Âintegrated biotechnology platformÊ change the outlook for the company? Our platform is a unique and distinctive advantage for Genomatica ă and by extension, for our partners. It lets us more rapidly design and develop optimised process technologies, which means that we can get to market faster, and our customers can offer ÂbetterÊ,
GenomaticaÊs GENO BDO was developed using their platform and was notable for three reasons: The company reached commercialscale production in only five years. The process directly converts feedstocks to a chemical that is not naturally produced; and the thousands of tons of BDO produced to date continues to lead the industry in production of a high-volume intermediate chemical from renewable feedstocks. The BDO program required 27 months to reach over 50 grams per litre. Log on to http://www.genomatica. com/ for the complete press release. Chemical Engineering World
Interview CEW
Genomatica’s Headquarters also described as their ‘Innovation Center’
more sustainable versions of chemicals they may already sell, that much sooner. Recently, Genomatica was announced as the winners of 2014 Bioeconomy Leadership Award and green chemistry has become a buzzword today. Are there any other avenues besides butadiene and nylon intermediates that the company is looking at? Yes, and the 2015 World Economic Forum Technology Pioneer Award, too! Our technology ă and our intellectual property ă allows us to target many of the worldÊs most widely-used chemicals. We believe each of our first three lines of business represents a sizable opportunity which we are well-positioned to address. We will certainly be adding processes for more target chemicals, often in concert with and supported by major value chain partners with commercialisation intent. Could you please shed some light on the vision behind developing manufacturing processes which enable license partners to produce chemicals from alternative feedstock? Two ideas are represented here. We believe that allowing the chemical industry to harness ÂalternativeÊ feedstocks gives them important optionality. It can improve sustainability; allow for a differentiated and potentially more valuable and profitable offering; while also hedging against volatility in the oil and gas markets, both Chemical Engineering World
in supply and price. This is particularly true for those chemicals ă including C4s like butadiene ă that are primarily made as ÂbyproductsÊ at crackers; the switch to lighter feedstocks in many parts of the world can have large impact on entire value chains, and GenomaticaÊs onpurpose processes protect against that. Regarding enabling our licensees, that means that we are focused on supporting our partners, rather than competing with them. They know their markets, their applications, their customers; they know how to build and run plants. We can supply them with advantageous technology and they get to use it for competitive advantage. We both win. Genomatica has partnered with the big-wigs of the global industry viz. BASF, Novamont, Versalis, Braskem. Does the company plan to expand its reach through a partnership model alone? Partnerships are our focus, and we aim to be the Âbiotechnology partner of choiceÊ to the chemical industry. The centre of excellence and innovation. The company to turn to when major firms are looking to better understand how and where they can best apply what biotechnology is good at, with respect to chemical production ă and the company they know they can trust and which has a track record of delivering.
What has been the companyÊs approach in adopting new technology? What has been GenomaticaÊs experience like in India? We are always looking for how we can best incorporate and apply new technology and ideas. Regarding India: we think there are great opportunities and we invite partnering discussions. We believe that our process technologies can be used by producers to offer differentiated, more sustainable products; and by users of chemicals that want to back-integrate, and have assured supply, especially if current basic and intermediate ingredients they use are primarily supplied from other countries. There has been a big hue and cry about abolishing intellectual property (IP) rights for the global manufacturing sector to progress together. Can you please share your thoughts on this as Genomatica has a number of patents to its name? We have invested a very large amount of time and money to develop our intellectual property. By working with major firms that license our technology, they secure the rights needed to use that technology and they profit from it. The revenues that we earn this way help fund additional innovations that we all benefit from in following years. September 2014 • 103
8 â&#x20AC;˘ December 2013
Final Ad template amol.indd 8
Chemical Engineering World
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