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CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

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EVONIK HAS AMBITIOUS GROWTH PLANS IN ASIA AND INDIA IS MORE AND MORE ON THE RADAR NOW GLOBALLY.

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FRANK LELEK PRESIDENT - EVONIK INDIA REGION

CHRONICLING PROCESS INDUSTRY INNOVATIONS SINCE 1966

VOL.51 | ISSUE 1 | JANUARY 2016 | TOTAL PAGES 110 | US $ 10 | ` 150

Chemicals & Specialty Chemicals

Gujarat 2016 10-12, February 2016 Mumbai, India

Mumbai 2017 14-17, February 2017 Mumbai, India

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CEW Industry News IOCL to Upgrade Paradip Refinery to BS VI

Consultative Committee Meeting of MP’s on CIPET

Paradip, India: By April 2020, Indian Oil’s Praradip refinery in Odisha having a capacity of 15 million tonne per annum will have to invest ` 4,000 crore for upgradation and installation of new units which provide BS VI grade automotive fuel. At present the company is coming up with a plan as units will have to be set up by December 2019 making it crucial to invest at the earliest. The BS VI norms that were going to be implemented by April 2021 will now be implemented earlier by April 2020 by the Ministry of Petroleum and Natural Gas, Ministry of Environment Forests and Climate Change, Ministry of Heavy Industries and Ministry of Road Transport and Highways. IndianOil will be directly moving to BS VI from BS IV, which is to be implemented by 2017. A majority of the units at Paradip were commissioned in 2015-16. The refinery is set on a land area of 3344 acres and required an investment of ` 34,555 crore.

New Delhi, India: The Consultative Committee meeting of Members of Parliament attached to the Ministry of Chemicals and Fertilizers was held in New Delhi in December last year. The Minister for Chemicals and Fertilizers, Ananth Kumar chaired the meeting. Hon’ble Members, Virendra Singh, Rahul Shewale, Sudheer Gupta, R Gopalakrishnan and Mohammed Ali Khan took part in the meeting.

Henkel Appoints Hans Van Bylen as CEO Mumbai, India: Henkel has announced that CEO Kasper Rorsted, who has decided not to renew his current contract beyond 2017, will leave the company at his own request as of April 30, 2016. He served on the Henkel Management Board for 11 years, thereof 8 years as CEO. Effective May 1, 2016, Hans Van Bylen has been appointed as his successor. His successful career at Henkel started in 1984 and he serves as member of the Management Board since 2005, responsible for the Beauty Care business. The appointment to CEO already in spring will enable him to leading the development of the new strategy which Henkel will announce at the end of this year and driving its successful execution.

The successor of Hans Van Bylen as Executive Vice President Beauty Care will be announced in due course. “With the appointment of Hans Van Bylen as new CEO we have named a strong successor to the CEO position at an early time – as it is common practice at Henkel. Hans Van Bylen is an excellent choice as he has long-standing, international experience in managing brands and markets as well as a Management Board member at Henkel. On behalf of our governance committees and employees I wish Hans Van Bylen all the best and much success in his new role“, said Dr Simone Bagel-Trah, Chairwoman of the Supervisory Board and the Shareholders’ Committee.

BPCL Commissioned New Crude Distillation Unit Mumbai, India: Bharat Petroleum Corp (BPCL) has commissioned new crude distillation unit having a capacity of 6 million tonne at its refinery in Mumbai. This will take BPCL’s oldest facility’s capacity to 12 million tonne per annum. The fourth CDU unit required an investment of ` 1,419 crore and was completed on schedule. The modern technologies adopted in the unit will save as much as ` 128 crore for the PSU which will lower the fuel consumption annually by a large percentage of 30 per cent less compared to the present levels stated D Varadarajan, Chairman and Managing Director, BPCL. He added that among all the refineries in the country, the new CDU at Mumbai facility will have the lowest sulphur dioxide emission levels at 10.5 million tonne per day. Post the commissioning of the new unit, BPCL is to dismantle two older crude vacuum and distillation units which had been set up by Burma Shell in 1955 so that more land area is available for modernisation.

10 • January 2016

The subject for the meeting was Central Institute of Plastics Engineering and Technology(CIPET). A presentation was made before the Hon’ble members about the CIPETs. It was informed that centres of CIPETs are functioning at 28 locations giving various diplomas and degrees. It was informed that 80,000 students will undergo training in CIPET this year and the number is likely to go up to one lakh by next year. Hon’ble members were also informed that 11 more centres of CIPETs have been proposed.

Responding to various clarifications and suggestions by Hon’ble members, the Union Minister directed CIPET to start a Plastic Waste Management Consultancy to provide guidance on managing the plastic waste. A National Institute of Plastic Research will be set up which will undertake research in various fields particularly those relating to use of plastics in agriculture and common man’s life. The Minister said that the CIPET will set up a mobile exhibition which will go around the country informing people about plastics use and its waste management. CIPETs will also undertake hand holding and training for rag pickers. To overcome the loss inflicted to CIPET due to severe floods in Chennai recently, Ananth Kumar assured all support for its rehabilitation in the shortest possible time.

Petronnet Signs Deal with RasGas to Get LNG at Half-price New Delhi, India: Petronet LNG has signed a deal with RasGas to get fuel at almost half the cost than what are previously agreed upon. In 2015, the company will not be paying RasGas a penalty of `12,000-crore for lower off-take. Late in December 2015, RasGas and Petronet signed a sale purchase agreement which has been revised and according to it Petronet will get LNG at USD 6-7 per million British thermal unit (mBtu).

The new agreement is in effect from January 1, 2016 and is valid till 2028.

The previous contract signed by the two companies in 1999 stated that Petronet would get LNG at USD 12-13 per mBtu and buyers ended up paying higher price than that prevailing in the market as the previous contract did not allow any change in pricing.

This contract allows the price of the buyer to be based on the market dynamics based on the crude price linked formula. It is for a capacity of 8.5 million tonne per annum whereas the previous contract was for 7.5 million tonne per annum.

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CEW Industry News Aditya Birla Chemicals (India) Limited Merged with Grasim Industries Limited Mumbai, India: Aditya Birla Chemicals (India) Limited (ABCIL) has been merged today with Grasim Industries Limited (Grasim) from the appointed date of April 1, 2015 with all the requisite approvals for the Scheme of Amalgamation in place. With the merger becoming effective, Grasim’s standalone EBITDA for the six months ended September 30, 2015 stands increased from ` 728 crore (pre-merger) to ~ ` 883 crore (post-merger).

Grasim will issue 14.62 lakh equity shares to the eligible shareholders of ABCIL in the ratio of 1 (one) equity share of ` 10 each of Grasim for every 16 (sixteen) shares of ` 10 each of ABCIL. The share capital will increase from ` 91.88 crore to ` 93.34 crore. Grasim is the largest chlor-alkali manufacturer in India. The merger has consolidated its leadership.

The company’s installed capacity of caustic soda has risen from 453K TPA to 804K TPA. This merger has resulted in the geographical diversification of the Chlor-alkali Business of the company. It also enables the business to capitalise growth opportunities backed by Grasim’s inherent strengths.

Fertiliser Sector Expects 2 Million Tonnes Output in 2016 New Delhi, India: The fertiliser sector is expecting the output to increase to 2 million tonnes in 2016 so that the country’s dependence on imports is reduced and the subsidies are lowered by ` 10,000 crore. A few major initiatives that were undertaken in the fertiliser sector last year was mandating of neem coating of urea and opening of shut down plants to ensure India’s urea production makes it self-sufficient.

Although, the large sum in arrear subsidy may reach ` 45,000

by March 2016 which is a real concern. To make the process of gas availability and supply smooth and energy-efficient, the government has announced gas pooling and the new urea policy.

Ananth Kumar, Minister of Chemicals and Fertilizers believes that these initiatives will turn India into a new exporter of urea in the years to come.

To meet the domestic demand, India imports about 7-8 million tonnes or urea annually since the country produces about 22 million tonnes of urea annually. The government is trying to boost the controlled urea sector where the government made it mandatory for indigenous urea producers to turn 100 per cent of their production of urea into neem-coated urea. This could serve a dual purpose where it would ensure subsidy savings worth ` 6,000 crore annually and put a stop to the illegal diversion of highly subsidised urea for non-agricultural use.

12 • January 2016

Saudi Aramco and Lanxess sign JV Agreement New Delhi, India: Saudi Aramco subsidiary, Aramco Overseas Company, and Lanxess have signed a 50:50 joint venture agreement to create a new company for the development, production, marketing, sale and distribution of synthetic rubber used in the global tire industry, autoparts manufacturing and a wide range of other applications. Lanxess will contribute its existing synthetic rubber businesses to the joint venture. The businesses have 3,700 highly skilled employees, an established footprint of 20 production sites and 4 global research centres in nine countries across Europe, Asia and the Americas. In 2014 the business contributed approximately Euro 3 Billion to Lanxess group revenues. Saudi Aramco, through its subsidiary Aramco Overseas Company, will establish its stake in the new joint venture company via a share subscription and will bring financial stability, additional scale and resources, continued investment in technology, unrivalled opportunities to integrate with petrochemical facilities, and cost-competitive access to reliable feedstock supplies to the venture.

The Lanxess existing synthetic rubber businesses supply highperformance and versatile products used to produce high-quality synthetic rubbers for the global tire industry and functional components for the automotive, gas/oil exploration and production and mechanical, construction and cable engineering industries. The portfolio is complemented by reliable, high-quality and global technical service.

Industr y 4.0 Takes Centre Stage with Sag e Software at SME Forum Vashi, India: With a vision to drive value for India’s ambitious entrepreneurs, Sage Software Solutions Pvt Ltd set stage for their engaging Forum ‘Innovation For Growth’ to help SMEs devise an actionable plan to steer business growth. The forum brought experts from Sage Asia, Infomerics Valuation and Rating and IIICORP for a comprehensive curtain raiser on contemporary business enablers.

Navi Mumbai with its encouraging business environment and industrial infrastructure was chosen to be the primary host city for the forum. The event drew attendance from a diverse audience from banking, financial services, manufacturing, shipping and logistics at Hotel Tunga Regenza, Vashi. Through the forum of ‘Innovation for Growth’, Sage Software took the opportunity to present the most innovative business models and growth trajectories for the promising Small and Medium Businesses operating across Key Asian Markets. The evening also witnessed the launch of Sage X3, Version 7 ERP Solution in India. Browser based Sage X3 allows better access to real time data which is integral to an organisation’s growth strategy. Speaking on the occasion, Kumar Siddhartha, MD, Sage Software Solutions Pvt Ltd, India, said, “It is a proud moment for us as we showcase our solutions competencies.

With presence of Yaj Malik, our global champion on Industry 4.0 and GM for Sage Asia based out of Singapore & Sara Lua, our Sage X3 VP, Asia based out of Kuala Lumpur, visiting India to mark the launch of Sage X3 version 7, we aim to ignite the minds of the talented new aged business leaders of the country. Sage targets to leverage on its global best practices and develop various customer-centric initiatives and innovative solutions for SMBs in India.”

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CEW Industry News ElectroMech Celebrates the Handover of its 5000th Crane to Gamesa Pune, India: ElectroMech Material Handling Systems India Pvt Ltd achieved a new milestone by manufacturing the 5000th crane – 150 MT Gantry Crane. The landmark 5000th crane was handed over to Gamesa Renewable Energy Pvt Ltd, a global technological leader in the wind industry. Tushar Mehendale, Managing Director, ElectroMech along with N Ravichandran, Executive Vice President, Gamesa unveiled the magnificent Gantry Crane at the handing over ceremony.

Gamesa caters to the wind industry that requires huge components that are critical in various processes and require cranes which are highly technologically advanced and precise to handle the sensitive components. 1000 components are assembled together to make a turbine and placement of these parts is of utmost importance that requires high accuracy. After in depth study of material handling needs of Gamesa, ElectroMech customised an outdoor DG Gantry Crane with a unique feature of 360 degree rotating motorised hook that is suitable to withstand extreme climatic conditions.

Gamesa’s order coincided with ElectroMech achieving the landmark of 5000th crane manufactured at state-of-the art manufacturing facility at Pune. 150 tonne capacity Gantry crane offers fine control mechanisms and has a span of around 20 metres and height of lift as 19 metres.

HRS Showcases Energy Efficient Heat Transfer Solutions Pune, India: HRS Process Systems Ltd (HRS PSL) participated in the 5th AIA Industrial Expo organised by Ankleshwar Industries Association and Government of India from January 7-9, 2016 at DA Anandpura Sports Complex, GIDC Ankleshwar, Gujarat. The company showcased its wide range of innovative and energy efficient heat transfer solutions widely used in process industries like Chemicals, Pharmaceuticals, Petrochemicals and many more. Ecoflux Corrugated Tube Heat Exchangers (CTHE), HRS’ flagship product on display is based on corrugated tube technology developed by HRS for a range of processes like heating, cooling, condensation, chilling for various products, utility, steam, oil, water, and other heat transfer applications. HRS Funke Plate Heat Exchangers (PHE) are used for processes like water cooling, oxygen cooling and heat recovery. These heat exchangers have also proven to give enhanced benefits in terms of performance efficiency when integrated into Heat Exchanger based Systems. V Gokuldas, Managing Director, HRS Process Systems Ltd said, “Indian economy is poised for a decent growth in coming years and Gujarat with key sectors like petrochemicals, pharmaceuticals, chemicals, agro-chemicals and textiles is attracting lot of investments. The industry will need technologically advanced products and solutions, driven by the need for cost effective production and sustainable development. HRS has been at the forefront of energy efficient heat transfer technology and innovation for many sectors of the economy for more than a decade now.

Our application engineering and solutions have been well appreciated by customers. We are committed to our customers for quality product, performance satisfaction and efficient service.”

16 • January 2016

KSB Enhance Its Existing Range Of KRT Series Mumbai, India: KSB Pumps Limited, a leading manufacturer of pumps and valves in the transport and treatment of water and wastewater segment, introduced extension of its KRT series pumps by adding new hydraulics. In addition to its existing E & K hydraulics, ‘F’ (Free Flow) hydraulics with semi open impellers is added. With this addition now KRT series can handle higher flow and head combination in four different pump sizes. More than 28 motor combinations serve the wide range of operation and meets the customer requirements precisely. The major advantage of new F type hydraulics is that it can handle liquids containing solids up to size 100 mm. KRT pumps caters wide range of applications in waste water, sewage, water containing long fibrous and solid substances as well as fluids containing air and gas, raw activated and digested sludge, drainage water extraction, storm water, water transport in municipal, industrial and in commercial establishments. These pumps will be sold through KSB’s wide sales network available pan India and will also be backed with a strong aftermarket network of KSB’s own 4 service stations as well as over 150 authorised service stations.

Suttons Appoints New Chairman Widnes Cheshire, UK: Suttons Group, the Logistics and supply chain specialists, has announced the appointment of Graeme McFaull as Chairman with effect from January 4, 2016. Graeme will take over the role following the untimely death of the former longstanding Chairman, Michael Sutton, in May 2015. John Sutton, Group CEO, Suttons, said that the Group Board is unanimously agreed that Graeme McFaull is an ideal candidate to chair Suttons at this exciting stage in the company’s history. Graeme’s leadership abilities, coupled with his significant board experience and knowledge of our dynamic industry will be invaluable to the ambitious, competitive, global group that Suttons has become. Graeme has significant experience in the management and chairmanship of logistics and supply chain businesses. He understands the competitiveness of our industry and also has a strong empathy with our culture and commitment to serving our customers. We are delighted that he will be joining us. Formerly, Graeme was Chief Executive of European logistics company, Wincanton Plc, where he was instrumental in securing their position as a major force in European logistics.

Thyssenkrupp to Build Fertiliser Plant in Indiana, US Indiana, US: Thyssenkrupp Industrial Solutions (USA) has secured a contract from Midwest Fertilizer Company to provide engineering, procurement, construction (EPC) and related services to build a USD 2 billion nitrogen plant in Indiana, US. Construction on the plant is expected to start after finance closure, and to be complete by 2020. After completion, the plant will produce Ammonia. The project will be part funded by Midwest Fertilizer through USD 1.259 billion of tax-exempt debt the company has secured, which was facilitated by Posey County, Indiana under the Heartland Disaster Tax Relief Act of 2008. Fawad A Mukhtar, Chirman, Fatima Group, said: “We are confident that Midwest Fertilizer Company’s success will open up avenues for further progress and development in southern Indiana.”

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CEW Industry News Evonik Expands Venture Capital Activities into Asia Essen, Germany: Evonik has expanded its venture capital activities into Asia by investing in Chinese venture capital fund GRC SinoGreen Fund III (GRC III). Now the company is represented in the most important venture capital regions of North America, Europe, and Asia. GRC invests in private, green technology companies with unique strengths and substantial growth potential in Greater China. Target sectors include energy and resource efficiency, cleaner transportation, sustainability, and climate change mitigation and adaptation. GRC III has offices in Beijing and Taipei.

“By investing in GRC III, we are opening the door to the fast growing start-up community in Greater China. With GRC we have found a strong partner with a proven track record and with immediate relevance to our own business activities,” explained Bernhard Mohr, Head - Venture Capital, Evonik. Aside from Evonik, the investor base of GRC III includes the World Bank subsidiary International Finance Corporation, the development bank Netherlands Development Finance Company (FMO) and Shell Technology Ventures, the venture capital arm of Shell.

Investments in funds are an important element of Evonik’s venture capital activities. Previously, Evonik had invested in the European and North American venture capital funds Pangaea Ventures Fund III, Emerald Cleantech Fund III, and High-Tech Gründerfonds II.

Lanxess Completes Capacity Expansion for High-Performance Plastics Cologne, Germany: Lanxess has started up a second production line for high-performance plastics compounding at its facility in Gastonia, North Carolina, as planned. The new line represents an investment of about USD 15 million and doubles the site’s production capacity from 20,000 to 40,000 metric tons annually.

In the plant, the basic polymers polyamide (PA) and polybutylene terephthalate (PBT) are mixed and refined with special additives and glass fibre, according to client requirements, to make the highperformance plastic product lines Durethan and Pocan. They are used primarily in the automotive industry to manufacture lighterweight plastic components that can replace metal parts in vehicles, contributing to greater fuel efficiency and reduced emissions.

“This investment shows our strengthened focus on highperformance compounds and underlines our strategy to shift this business towards higher-value-added markets,” said Hubert Fink, Member of the Board of Management, Lanxess AG. In the coming years, Lanxess plans to further invest Euro 50 to 100 million for organic growth in its high-performance plastics business. “With the investments, we will be further balancing the capacities in our polyamide value chain and driving the globalisation of our engineering plastics business,” said Michael Zobel, Head, Lanxess’ business unit High Performance Materials.

18 • January 2016

King Salman & Chinese President Xi Jinping Inaugurate YASREF Refinery Riyadh, Saudi Arabia: The Custodian of the Two Holy Mosques King Salman bin Abdulaziz Al Saud, the King of Saudi Arabia and His Excellency Xi Jinping, the President of the People’s Republic of China jointly inaugurated the Yanbu Aramco Sinopec Refining Company (YASREF) refinery. The inauguration ceremony took place in Riyadh in conjunction with President Xi Jinping’s official visit to the Kingdom of Saudi Arabia. Established on January 14, 2012, YASREF is a joint venture between Saudi Aramco, which holds a 62.5 per cent share, and China Petroleum & Chemical Corporation (Sinopec), which holds a 37.5 per cent share. YASREF represents both companies’ focus on driving downstream growth across the entire hydrocarbon chain.

In conjunction with the inauguration, the YASREF joint venture partners, Saudi Aramco and Sinopec, signed a ‘Framework Agreement for Strategic Cooperation’ to enhance the competitiveness of the crude oil supplied by Saudi Aramco to Sinopec and to actively explore cooperation opportunities in key areas including oil and gas services, refining, chemicals, crude oil supply, sales, petroleum services, petrochemical services, technology development and promotion, and new energy.

HE Khalid A Al-Falih, Chairman of Saudi Aramco said, “The mutually beneficial relationship between China and Saudi Arabia has rapidly strengthened in the last two decades. China is the Kingdom’s largest trading partner and Saudi Aramco is proud to be China’s number one supplier of energy. YASREF, which is a partnership between Sinopec and Saudi Aramco, is part of Saudi Aramco’s strategy to expand and diversify its national and international investment portfolio.”

Dover Completes Acquisition of Tokheim Businesses Hamilton, USA: OPW announced that Dover Corporation has completed the acquisition of Tokheim Group SAS’s dispenser and systems businesses and they are now part of OPW. Tokheim is a leading manufacturer of fuel dispensers, retail automation systems and payment solutions. With a presence in Europe, Middle East, Africa, South America and Asia-Pacific, Tokheim is one of the most recognised brands in the retail fuelling industry. “Both Tokheim and OPW have been leaders in the retail fuelling industry for more than a century,” said David Crouse, OPW President. “By integrating Tokheim’s advanced line of dispensers and automation systems, the combined business will be able to offer our customers an unparalleled end-to-end fuelling solution.”

Tokheim is the fifth major acquisition for OPW in the past two-and-a-half years, and matches previous acquisitions (Fibrelite, KPS, Jump, Liquip) of category-leading brands outside the North American market. OPW’s deployment of this unique end-to-end solution strategy encourages customers to select and customise a fuelling system from OPW’s full line of underground storage tank equipment, piping and containment systems, and above ground products – including the newly acquired line of Tokheim dispensers and automation systems – fulfilling almost every equipment need for a fuelling station, while utilising just one supplier.

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CEW Industry News Gene Regulation Boosts Ammonia Production Tokyo, Japan: Research led by Tokyo Institute of Technology identifies a strategy for regulating genes involved in metabolic processes in cyanobacteria for enhanced ammonia production.

Nitrogen fixation in cyanobacteria metabolic processes may provide an important means for producing ammonia - a crucial ingredient in the chemical industry.

Regulating the cellular processes involved to optimise microbial ammonia production has been a challenge. Now researchers at Tokyo Institute of Technology have successfully demonstrated a gene regulation strategy for enhancing ammonia production in the cyanobacterium Anabaena strain PCC 7120 (A. 7120). The researchers first investigated the gene expression system in Anabaena using tetR promoter, which is regulated by tetracycline aTc - an antibiotic known to have a strong affinity to TetR. When a nitrogen-dependent tetR promoter was used, they observed a nitrogen-dependence in the amount of aTc needed to express the desired gene. Finally, for the production of ammonia, the researchers repressed expression of glnA with an antisense small RNA. The gene glnA encodes an essential enzyme glutamine synthase for nitrogen assimilation in cyanobacteria.

The antisense RNA - which represses it - was expressed under the control of the promoter previously used in this study, and tetR was expressed under the control of the nitrogen-dependent promoter.

They successfully observed increased excretion of ammonia when the expression of antisense RNA was induced. They conclude – these results demonstrated that the antisense repressors, used as the regulators of endogenous gene expression, may become useful tools for the production of desired substances in A. 7120.’

Idemitsu to Increase Production of SPS Resin XAREC Tokyo, Japan: Idemitsu Kosan Co, Ltd will increase its production capacity for syndiotactic polystyrene resin (SPS). SPS is an engineering plastic Idemitsu succeeded in synthesising in 1985 for the first time in the world using metallocene catalyst technology.

Idemitsu industrialised the product in 1997. SPS is low density engineering plastic and has high heat resistance, hydrolysis resistance, chemical resistance, and excellent electrical properties (high electric resistance, a low dielectric constant and loss).

Bonfiglioli & Carraro Enter JV agreement Regarding O&K Antiebstechnik Lippo di Calderara di Reno, Italy: O&K Antriebstechnik, specialised in the design and manufacture of gearboxes for high power machines and crawler cranes, passes under the control of Bonfiglioli. The Carraro Group maintains a 45 per cent share assuming a strategic role within the partnership.

According to this agreement, which sees two of the most historic Italian industrial families in the mechanical sector join forces, Bonfiglioli acquires 55 per cent of O&K Antriebstechnik GmbH for the amount of Euro 25.7 million. Carraro remains in the company with 45 per cent maintaining a strategic role as a key partner in the delivery of specific components. From the industrial standpoint, Bonfiglioli extends its range with products for higher power applications that can be exploited by its extensive sales network, whereas thanks to this operation, the Carraro Group will be able to further concentrate on developing innovative products – especially transmissions – specifically designed for agricultural and construction equipment.

“The agreement with Bonfiglioli is a great industrial story, which sees two Italian companies join forces in a real partnership approach with a view to mutual development”, said Enrico Carraro, Chairman, Carraro SpA. The transaction is subject to, among other things, obtaining the antitrust authorisations. Carraro will be reserved to the usual rights of governance to protect the minority, including the appointment of an administrator provided with some veto rights. As part of the transaction, the signing of several commercial and service agreements between O&K Antriebstechnik GmbH and both Carraro Group and Bonfiglioli Group companies is expected.

Praxair China Starts Up New Air Separation Plant Danbury, USA: Praxair, Inc has started up a large air separation plant in northern China for the Yankuang Guohong Chemical Co, Ltd facility in Zoucheng City. Yankuang Guohong Chemical Co, Ltd is a subsidiary of Yankuang Group, which has total assets of RMB 40 billion.

It is mainly being used for electric parts in automobiles (PCB connectors, high voltage components, and millimeter-wave radars) as well as for electrical and electronic parts, parts of home appliances, cookware for microwave ovens, and industrial film.

Through a long-term contract, Praxair’s 3,000-ton-per-day plant will efficiently and reliably supply on-site oxygen and nitrogen to Yankuang and replaces the existing customer-owned air separation units. Praxair’s industrial gases will be used in the coal gasification process for the production of methanol and downstream chemicals.

Idemitsu will increase the production capacity of the SPS manufacturing unit at its Chiba Plant (Ichihara City, Chiba), as new uses have been developed in recent years and demand for SPS is growing at an annual rate of approximately 10 per cent. The planned completion date is April 2016 and the production capacity will increase from the current 7,000 tons/year to 9,000 tons/year.

“Praxair’s world-class air separation plant is helping Yankuang achieve energy efficiency while providing enhanced safety and reliability performance. The success of this project is due to the strong cooperation between our companies, and we look forward to continuing a long and successful commercial relationship,” said Will Li, President, Praxair China.

20 • January 2016

Chemical Engineering World

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CEW Industry News Air Liquide Expands its Business to Colombia Paris, France: In the context of a contract with Coca-Cola FEMSA, the largest bottler of Coca-Cola products in the world and the largest beverage company in Latin America, Air Liquide will build and operate a new facility consisting of a carbon dioxide production unit and a cogeneration unit. This investment of around Euro 40 million marks Air Liquide’s entry into the Colombian industrial gas market. Under the terms of the agreement, Air Liquide will supply carbon dioxide as well as nitrogen, electricity, refrigerated water, compressed air and steam to Coca-Cola FEMSA’s largest bottling facility in Colombia, located in the municipality of Tocancipá, Cundinamarca, approximately 40 kilometres north of Bogotá.

Air Liquide’s new facility in Tocancipá is expected to begin commercial production in late 2016. Air Liquide’s new facility will employ at least 30 people. It will be located within the Permanent Free Trade Zone FEMSA Industrial Park. Additional carbon dioxide produced by Air Liquide’s facility will be available to the surrounding market. Latin America offers development prospects for Air Liquide. Air Liquide is well-positioned to meet the growing needs of the region, supplying products, services and technologies to help industry improve safety, efficiency and productivity.

Air Liquide also supplies industrial gases and utilities to two of CocaCola FEMSA’s major bottling facilities in Brazil, in the cities of Itabirito and Jundiaí.

Linde Selected By Gazprom for Major Gas Processing Project Munich, Germany: The Linde Group has been selected by Gazprom, Gazprom Pererabotka Blagoveshchensk and its general contractor NIPIgas as the licenser for cryogenic gas separation technology at the Amur Gas Processing Plant (Amur GPP), located in the far east of Russia.

Linde will engineer and supply units for ethane and natural gas liquids (NGL) extraction and nitrogen rejection, as well as for helium purification, liquefaction and storage. The plant is part of Gazprom’s project for the supply of Russian gas to China via the ‘Power of Siberia’ pipeline from eastern Siberian gas fields and will be built in five phases ending in 2024. When completed, the Amur GPP will be one of the largest gas processing plants in the world with a capacity of up to 49 billion cubic metres of natural gas per year.

Alexey Miller, Chairman of the Management Committee, Gazprom and Dr Wolfgang Büchele, Chief Executive Officer of Linde AG, also recently signed a strategic cooperation agreement stipulating the intention to cooperate and jointly carry out existing and future projects related to the natural gas value chain. The cooperation agreement covers process technologies, engineering and services related to the treatment and liquefaction of natural gas, as well as localisation of the respective equipment production in Russia.

Furthermore, the agreement also addresses the field of helium production, including the investment in, production and operation of helium plants.

22 • January 2016

Banking Sanctions on Iranian Petrochemical Export Lifted Teheran, Iran: The banking sanctions on Iranian petrochemical export have been lifted after receipt of money for the product exports from a Spanish bank. The Iranian Petrochemical Commercial Company (IPCC) account with a Spanish bank has been activated for first time with a European bank in the past five years. Mehdi Sharifi Niknafs, Executive Director, IPCC was quoted by the Mehr news agency as saying, “accordingly, the commercial contract between IPCC and the association of Spanish manufacturers was finalised.”

Niknafs further added, “On the basis of the reached agreements and receiving of official approvals the government and central bank of Spain, the limitations of receiving of money as well as export of products from various world countries were practically removed.” IPCC will now go ahead with the sale of petrochemical products, after the removal of restrictions on the sale after the preliminary agreement between the country and six world powers in Geneva. A meeting was held recently between the governor of the Central Bank of Iran (CBI) Valiollah Seif and top bankers, who discussed the actions that needed to be taken in preparation for the lifting of the sanctions, as well as the course of action to be taken post-sanctions. No official date has been declared for the lifting of sanctions. Iranian banks have been kept out of the global monetary system. Following the removal of the ban, banks will be able to transfer unlimited money in and out of Iran. The lifting of the sanctions also include several other benefits, and the move is expected to reconnect Iran with the Society for Worldwide Interbank Financial Telecommunication (SWIFT) financial-transactions system.

Clariant and CB&I to Design Plant in China Dalian, China: Hengli Petrochemical (Dalian) Refinery has awarded a contract to Clariant and CB&I to develop a propane and butane dehydrogenation unit in China. Under the deal, Clariant and CB&I will license and design the co-processing unit, which will be built in Dalian, China. CB&I will use its Catofin catalytic dehydrogenation technology to build the unit.

Clariant will provide its custom-made Catofin catalyst and heat generating material (HGM) to process 300,000 ton of propane and 600,000 ton of isobutane feedstock per year to jointly produce propylene and isobutylene. Upon completion, the project is said to become the largest single-train co-processing dehydrogenation plant in the world.Clariant’s Catofin process helps a plant to operate at the highest reactor pressure and temperature to produce propylene and isobutylene from propane and isobutene respectively.

The process is said to require less investment and operating costs.

Stefan Heuser, Senior Vice President and General Manager Catalysts Business Unit, Clariant, said, “We are very pleased to be part of this groundbreaking project for Hengli Petrochemical Refinery. The contract is further proof that our customers recognise and demand the technological and economical advantages of Catofin and HGM.” Chemical Engineering World

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CEW Technology News

Copper Deposition to Fabricate Tiny 3D Objects Zürich, Switzerland: A new 3D microprinting process allows scientists to easily manufacture tiny, complex metal components. The used technology was designed by ETH researchers years ago ETH researchers use a for biological research and has now been movable micropipette (blue) further developed for a completely different to manufacture tiny copper objects. (Visualisation: ETH application. This can be used to manufacture Zurich / Alain Reiser) even tiny, partly overhanging structures easily and in a single step. One day, this could pave the way for the manufacture of complex watch components or microtools for keyhole surgery, for example. In most existing 3D microprinting processes, overhanging structures can be achieved only through a workaround: during the printing process, a stencil manufactured beforehand is used as a placeholder under the overhang that is to be printed. The template must be removed once printing is complete. In the new technique developed by ETH doctoral student Luca Hirt of the Laboratory of Biosensors and Bioelectronics, the print head can also print sideways.

This means that overhangs can be printed without templates. The new technique is a refinement of the FluidFM system developed at ETH Zurich several years ago. At the heart of this system is a moveable micropipette mounted on a leaf spring, which can be positioned extremely precisely. Nowadays, FluidFM is used primarily in biological research and medicine; for example, to sort and analyse cells and to inject substances into individual cells. For three years now, the system has been sold commercially by the ETH spin-off Cytosurge. Read more on www.ethz.ch/en/news-and-events

Enabling Easier Isolation of Carbon Nanotubes Fukuoka, Japan: Manufacture of longer, thinner, and uncontaminated carbon nanotubes, and successfully isolating them, have been ongoing challenges for researchers. A newly developed method has opened up new possibilities in carbon nanotube development.

Researchers at Kyushu University’s Department of Applied Chemistry have developed a method for obtaining high-quality single-walled carbon nanotubes. The relatively mild process uses an outer stimulus to yield undamaged carbon nanotubes that are purer and longer, and even gives researchers the ability to sort nanotubes according to their structure and length. These can contaminate the nanotubes and are difficult to completely remove.

They also involve processes that could damage the nanotubes and impair their functionality. “Our approach involves introducing supramolecular hydrogen-bonding polymers, followed by simply shaking the mixture and changing the polarity of the solvent, rather than applying potentially destructive sonication or chemical modification,” says coauthor Naotoshi Nakashima. “In this way, we can obtain single-walled carbon nanotubes over two microns long that do a fine job maintaining structural integrity.” The new technique is particularly useful because of the mildness and selectivity of the newly designed hydrogen-bonding polymers used. The presence of fluorene moieties within them enables the specific recognition of and binding to single-walled carbon nanotubes, and specific sorting of tubes with a small diameter. Read more on www.eurekalert.org 24 • January 2016

High-Performance Material Polyimide with Angular Shape for 1 st Time Vienna, Austria: Using a new synthesis procedure developed at TU Wien, it is now possible to produce the extremely resistant material polyimide in the form of angular particles for the first time. Polyimides withstand extreme heat and chemically aggressive solvents, while being considerably less dense than metals. That is why they are very popular in industry, for example as an insulation layer on PCBs or in aerospace applications. However, it is precisely their high stability, which makes polyimides very difficult to process. Neither melting nor etching can be used to bring them into the correct shape. At TU Wien, a new synthesis method has now been developed which opens up completely new possibilities for this material class; it has been possible to produce angular polyimide particles for the first time using a technical trick.

“Small plastic particles are usually obtained as spherical objects,” says Miriam Unterlass from the Institute of Materials Chemistry at TU Wien.

However, roundish particles are poorly suited for many applications.

“Particle-containing liquids are extensively used as paints and protective coatings,” says Unterlass. “The geometric shape of the particles then determines how the particles are arranged and move within the liquid.”

There have been repeated attempts to give polyimide particles or similar materials an angular shape, but until now there has been little success.

Miriam Unterlass’ team at TU Wien has now tried a completely new approach. Read more about the research on www.tuwien.ac.at/en/news

New Method for Converting Solar Energy into Electrical Power Jerusalem, Israel: A new paradigm for the development of photobioelectrochemical cells has been reported by researchers from The Hebrew University of Jerusalem, in Israel, and the University of Bochum, in Germany. The design of photo-bioelectrochemical cells based on native photosynthetic reaction is attracting substantial recent interest as a means for the conversion of solar light energy into electrical power.

In the natural photosynthetic apparatus, photosynthetic reaction is coupled to biocatalytic transformations leading to CO2 fixation and O2 evolution. Although significant progress has been achieved in the integration of native photosystems with electrodes for light-to-electrical energy conversion, the conjugation of the photosystems to enzymes to yield photo-bioelectrocatalytic solar cells remains a challenge. Now, researchers report on the construction of photo-bioelectrochemical cells using the native photosynthetic reaction and the enzymes glucose oxidase or glucose dehydrogenase. The system consists of modified integrated electrodes that include the natural photosynthetic reaction centre, known as photosystem I, conjugated to the enzymes glucose oxidase or glucose dehydrogenase. Photoirradiation of the electrodes leads to the generation of electrical power, while oxidising the glucose substrate acting as a fuel. The system provides a model to harness the native photosynthetic apparatus for the conversion of solar light energy into electrical power, using biomass substrates as fuels. In contrast to numerous bioelectrochemical systems using electrical power to oxidise glucose, the present study introduces the implementation of the native photosystem to produce electrical power using light as the energy source. Read more on the research at new.huji.ac.il Chemical Engineering World

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CEW Technology News Graphene Oxide ‘Paper’ Changes With Strain

Cheaper Solar Cells With 20.2% Efficiency

Houston, USA: Rice researchers say material is more or less brittle, depending on how hard it’s pulled. The same slip-and-stick mechanism that leads to earthquakes is at work on the molecular level in nanoscale materials, where it determines the shear plasticity of the materials, according to scientists at Rice University and the State University of Campinas, Brazil. The Rice lab of materials scientist Pulickel Ajayan found that random molecules scattered within layers of otherwise pristine graphene affect how the layers interact with each other under strain. Plasticity is the ability of a material to permanently deform when strained. The Rice researchers, thinking about future things like flexible electronics, decided to see how graphene oxide ‘paper’ would handle shear strain, in which the sheets are pulled by the ends. Such deep knowledge is important when making novel advanced materials, said Chandra Sekhar Tiwary, a lead author of the new paper in the American Chemical Society journal Nano Letters and a Rice postdoctoral research associate. “We want to build three-dimensional structures from twodimensional materials, so this kind of study is useful,” he said. “These structures could be a thermal substrate for electronic devices, they could be filters, they could be sensors or they could be biomedical devices. But if we’re going to use a material, we need to understand how it behaves.” Read more on the research at news.rice.edu

Lausanne, Switzerland: EPFL scientists have developed a solarpanel material that can cut down on photovoltaic costs while achieving competitive power-conversion efficiency of 20.2 per cent. Some of the most promising solar cells today use light-harvesting films made from perovskites – a group of materials that share a characteristic molecular structure. However, perovskite-based solar cells use expensive ‘hole-transporting’ materials, whose function is to move the positive charges that are generated when light hits the perovskite film. EPFL scientists have now engineered a considerably cheaper hole-transporting material that costs only a fifth of existing ones while keeping the efficiency of the solar cell above 20 per cent. As the quality of perovskite films increases, researchers are seeking other ways of improving the overall performance of solar cells. Inadvertently, this search targets the other key element of a solar panel, the holetransporting layer, and specifically, the materials that make them up.

There are currently only two hole-transporting materials available for perovskite-based solar cells. Both types are quite costly to synthesise, adding to the overall expense of the solar cell. To address this problem, a team of researchers led by Mohammad Nazeeruddin at EPFL developed a molecularly engineered hole-transporting material, called FDT, that can bring costs down while keeping efficiency up to competitive levels. Tests showed that the efficiency of FDT rose to 20.2 per cent – higher than the other two, more expensive alternatives.

And because FDT can be easily modified, it acts as a blueprint for an entire generation of new low-cost hole-transporting materials. Read more on actu.epfl.ch/news

New Robotic Gripping Surface for Sensitive Devices: A Boost for Industry 4.0 Saarbrücken, Germany: Researchers at the INM have improved the adhesive force in their Gecomer structures up to 20 kg per 25 cm 2. Components with highly sensitive surfaces are used in automotive, semiconductor, display and optical technologies.

During production, these parts have to be handled repeatedly by pick-and-place processes. The proprietary Gecomer principle reduces the risk of surface contamination with residues, and of mechanical damage due to gripping. In their latest version, researchers at the Leibniz Institute for New Materials (INM) have improved the adhesive force in their Gecomer structures up to 20 kg per 25 cm2. Within these new findings, it will be possible to use the same gripper for heavy, robust and lightweight, sensitive devices. These innovations will open up new avenues for Industry 4.0. The researchers from the INM will be presenting their results at the International Nanotechnology Exhibition and Conference nano tech 2016, Tokyo, Japan.

“Ar tificially produced microscopic pillars, so-called gecko structures, adhere to various items. By manipulating these pillars, the adhesion can be switched on and off. Thus, items can be lifted and released quickly and precisely,” Karsten Moh from INM explains. “Our new materials add a new dimension to the handling of heavy devices which are sensitive, even in vacuum,” says Moh, “With the currently developed adhesion system, adhesive forces of more than 7.5 Newton per square centimetre can be achieved.

In our tests, the system has proved successful even after 15,000 cycles,” the technology expert Moh says. Read more on www. leibniz-inm.de 26 • January 2016

Thermal Cameras Snoop Beneath Surfaces To Reveal Materials’ Secrets Oak Ridge, USA: Scientists at the Department of Energy’s Oak Ridge National Laboratory are pioneering the use of infrared cameras to image additive manufacturing processes in hopes of better understanding how processing conditions affect the strength, residual stresses and microstructure of 3D-printed parts. This is just the latest application to build upon decades of expertise in IR cameras that have added scientific understanding to promising technological developments. In 1995, DOE’s Continuous Fiber Ceramic Composite program, led by ORNL, bought a high-speed IR camera—one of the first available for purchase outside the military.

ORNL researcher Ralph Dinwiddie used the new IR camera to help developers of tough, lightweight ceramic composites study how well these materials conducted heat and use the insight gained to optimise manufacturing processes. Since then, ORNL has acquired at least 10 additional IR cameras for use in a spectrum of other projects. The cameras have mapped changing temperatures as heat flows through objects from gears to artwork. “At first we just planned to use this camera to measure thermal diffusivity maps of composites,” Dinwiddie said of the 1995 purchase. “This would allow us to measure the constituent properties and to study how they changed due to the processing conditions.” Read more about the research on www.ornl.gov/news.

Chemical Engineering World

CEW Features

Frank Lelek, President - Evonik India Region

Evonik.

Power To Create.

Proximity to customers and joint search for solutions is one of the prime factors in our success 28 â&#x20AC;˘ January 2016

Chemical Engineering World

Features CEW 1. The global specialty chemicals demand is estimated to grow at 5.42 per cent in the period from 2015 to 2020 with Asia-Pacific being the largest market. Where does India stand as a growth driver and what is the kind of potential you see for the organisation on the global level and in India?

India will certainly outpace the global growth rate. Evonik is addressing that growth in potential markets by supporting our partners to continuously improve their offerings in the market.

We have an excellent technically trained sales team that can bring value to our customers.

2. How has Evonik fared in India in the last 5 years?

Evonik India has experienced a double digit CAGR in the last 5 years. We have a broad range of products globally and we represent most of the product range here in India. Evonik India has grown higher than the industry growth rate in the last few years. Evonik has ambitious growth plans in Asia and India is more and more on the radar now globally.

3. Which industries does Evonik specifically target in India and how do you see its market share increasing?

Evonik globally is addressing plenty of markets, the same in India. Specific markets are automotive, paint & coatings, construction, animal nutrition and healthcare, amongst others. In India, we strive to become the preferred partner for our customers, by providing innovative, bespoke solutions that cater to their specific needs. Proximity to customers and joint search for solutions is definitely one of the prime factors in our success.

With the acquisition of Monarch Catalyst, now Evonik Catalysts India Pvt Ltd, we are expanding our portfolio and overall now we have a broader range of products to offer to our customers ex local production.

4. The R&D centre in India was set up in 2002 and has become the Global Research Centre for formulation of pharma polymers. Does Evonik plan to create such a centre for other product Chemical Engineering World

lines? How much of its revenue is spent on R&D activities?

Several regions are under consideration to have research centres outside of Germany. On a global scale, Evonik plans to invest over Euro 4 billion in R&D over the next decade. Evonik intends to make tangible improvements to its innovative power, as innovations are to make key contributions to revenues and earnings in the future.

The company plans to significantly expand its innovation pipeline to keep up a steady flow of new products and solutions. The Evonik R&D pipeline is well-filled with some 500 projects, with even greater focus to come from strategic innovation management.

Promising innovation areas for Evonik include ingredients for the cosmetics industry, membranes, specialty materials for medical technology, food supplements and animal feed additives as well as composite materials.

5. In June 2015, Evonik acquired Monarch Catalyst in India. Does the company plan to make any more acquisitions for growing its presence in the country?

We see a multitude of opportunities for organic growth, innovation, acquisitions and investments into new projects in India and Evonik is working on increasing its footprint in a number of core businesses.

6. Which are the highest growing markets for Evonik besides India?

And what are its target markets in the future?

As part of our ambitious growth strategy, we are stepping up our presence in emerging markets. We define these as selected countries in Asia, South America, Eastern Europe, and the Middle East. In 2014, 78 per cent of our sales were generated outside Germany.

extent have the things eased out for the Chemicals business?

India is improving on the global rank on ease of doing business year by year but through very small steps. Evonik appreciates the improvements and actions that are being triggered by the central government. In daily business, there is still large room for improvements.

Since there is global competition for investments, and as other regions are not waiting for India to catch up, even more emphasis and efforts are required in that direction. Implementation of reforms is the key.

8. In 2007, Indian government made an announcement of setting up 5 Petroleum, Chemicals and Petrochemical Investment Regions (PCPIRs). Despite the announcement of 5 PCPIRs to promote the development of downstream petrochemical industry in India, Dahej is the only PCPIR which is operational as on date. For Indian industry to be competitive, how critical is it for India to put the planned PCPIRs in operation?

One of the key crucial issues in India is the raw material availability. The PCPIR concept is an important step in the right direction. It is the right model to attract investments since it should provide raw materials for the companies that want to invest in downstream technologies.

9. What is that one change in your view that can be the key enabler for India realise the projected growth of chemical industry to reach USD 215 billion?

Government support to improve competitiveness of India versus other countries/ investment destinations.

7. You mentioned ‘ease of doing business’ as a major challenge the last time CEW spoke to you. Since then, India’s rank has risen on World Bank’s ‘Doing Business 2016’ report. To what January 2016 • 29

CEW Features About Evonik India: Evonik India is headquartered in Mumbai and is part of Evonik Industries AG, world’s leading specialty chemicals company with around Euro 13 billion revenue and 33,400 people worldwide.

The group’s operation spans across India, Bangladesh, Nepal and Sri Lanka, with sales offices in Mumbai, Delhi, Chennai and Kolkata as well as a representative office in Bangladesh. All the 3 business segments: Nutrition & Care, Resource Efficiency and Performance Materials are represented in India. These are further classified into several business lines.

Evonik India has been making precipitated silica in India for more than 20 years at its subsidy Insilco Ltd. at Gajraula, Uttar Pradesh, although the majority of sales in this region are still via imports from other countries. The company achieved double digit growth rate in India in 2015, where it also operates the global centre for formulation development for its Healthcare business line in Mumbai.

devices, excipients for controlled drug release and regenerative medicine applications.

resource efficiency and globalisation. Our strengths include the balanced spectrum of our business activities, end-markets and regions.

Evonik concentrates on high-growth megatrends, especially health, nutrition,

Global Research Center in India 8 Applied Technology Labs : Interface & Performance Coating & Additives Silica Coating Solutions Silica Applications Amino NIR Functional Silanes Pharma Polymers, Mumbai Pharma Polymers Lab, Dhaka

Evonik strives to continuously strengthen its core businesses in India through sustainable investments. In June 2015, Evonik acquired Monarch Catalyst Pvt Ltd situated at Dombivli, Mumbai, now known as Evonik Catalysts India Pvt Ltd. This bolt-on acquisition in India complements Evonik’s leading positions in activated base metal catalysts and precious metal catalysts. All of Evonik’s future catalyst activities in India will be operated through the newly acquired company.

The key business areas of focus for Evonik India include specialty chemicals for healthcare, animal feed, automotive, paints & coatings, construction and personal care, amongst others. Evonik India also offers a broad range of bio-degradable polymers for medical 30 • January 2016

Chemical Engineering World

Chemical Products Finder | November 2013 | 57

CEW News Features

Having an Ace Up Your Sleeve in the Indian Market In an open conversation, Anil Shah, Managing Director, Bilfinger Water Technologies India Pvt Ltd talks to CEW about the history of the company, Johnson Screens’ acquisition by Bilfinger, the Indian market scenario and its importance to the company’s growth strategy and future plans.

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ilfinger is a multinational group with a varied portfolio of technologies to offer. The group company has a number of diversified businesses related to industrial services, construction, water technologies among others. Having a greater presence in Europe, the company entered the Indian market by acquiring Johnson Screens in 2013. From ` 48 crore in 2013-14, Bilfinger Water Technologies had a tur nover of ` 55 crore in 2014-15. It also strengthened its portfolio, and in the process, Bilfinger c o n s o l i d a t e d i t s bu s i n e s s e s r e l a t e d to water sector and named it Bilfinger Water Technologies.

Bilfing er’s Acquisition of Johnson Screens The acquisition was good for Bilfinger and Johnson Screens; Johnson Screens was a 110 years old company and had a strong brand name while Bilfinger has a global reach and this worked to their mutual gain. Although the company’s name has changed, Anil Shah, Managing Director, Bilfinger Water Technologies India Pvt Ltd, explains, “Bilfinger allowed Johnson Screens to retain its brand name as it was an established brand. We faced a few hiccups in the initial phase but now we are known as Bilfinger in the market.”

When talking about if Bilfinger also had a joint venture with Johnson Screens before it was acquired by the for mer, Shah informs, “Johnson Screens did not have a joint venture with Bilfinger before being acquired by it and the company has received good support from the parent

company. In fact, the Sanand facility has been sanctioned after the acquisition.”

Transfer of Technical Know-how Bilfinger planned on transferr ing the know-how from Ger many to India and brought 10 products from Europe. Before the acquisition, Johnson Screens offered 10 products which have now doubled after Bilfinger acquired it. Simultaneously, Bilfinger Water Technologies India sent a team of seven people who were trained in Europe and understood the workings of the products in detail. This allows the company to offer the ultimate contractors a complete package. Shah elaborates, “Here total solutions include everything from the technical support to the execution and we work with contractors where we are able to offer 8 of the 10 products that they require.”

Bilfinger’s Growth Strategy At Johnson Screens, since 2009, the company has been adding a few new products each year. Johnson Screens India was gaining technical know-how, product knowledge from Johnson Australia, Johnson USA or Johnson France. Shah takes pride in stating that the current p l a n t h a s a p r o ve n t r a c k r e c o r d o f implementing new products and bringing them to the market. Bilfinger too adopted a similar strategy and continued to add to the products that Johnson Screens already had.

Previously, we did not have the products but there was market potential in India; now we have an advantage as not many multinational companies have the technologies we offer and the Government of India is laying emphasis on recycling and clean potable water for all.” He further explains that the other territories under Bilfinger Water Technologies India are Bangladesh, Sri Lanka and Indonesia.

He concludes that impor ts from their facilities in Germany and Australia are possible but it is not cost-effective and this can be detrimental to the business. Shah quips, “Big conglomerates rate quality over price and would not mind the extra expense but that does not prove to be competitive in the long run.” Shah believes that the Indian market has great market potential and by 2019, Bilfinger hopes to reach ` 100 crore mark.

Potential Markets for Growth In India, Bilfinger has a high market share, as much as 70 per cent, for a majority of their products which are called ‘Water

We were able to double our revenue in the Water Technologies business thanks to the German technology... Previously, we did not have the products but there was market potential in India; now we have an advantage as not many multinational companies 32 • January 2016

Well Screens’ and it makes up for almost 40-45 per cent of the company’s revenue.

Shah shares, “We were able to double our revenue in the Water Technologies business thanks to the German technology that Bilfinger has brought in for water treatment, ETP, STP plants.

- Girija Dalvi Chemical Engineering World

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CEW Features Guest Column

A Week in the Life of Jane, a Combustion Engineer Emission performance and drive cycle measurements for diesel engine passenger cars have created a lot of ‘smoke’ in the media lately. The discussions highlight the importance of emission reduction and performance, and also reveal the great challenge of this work.

If some of the largest car manufacturers in the world struggle to meet the emission limits, it is evident that there is not an easy solution!

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missions are by-products of a chemical process, and to understand, predict and design compliant vehicles, the underlying chemical pathways need to be well understood. The purpose of this article is to introduce you to the tools available to make the job understanding and predicting chemistry easier and more straightforward. Let me tell you a story about Jane, a combustion chamber design engineer, and describe the daily challenges she faces.

Meet Jane!

Jane is a newly employed design engineer at CombustionCorp, a company that just started to use CFD for a major part of their development projects, the design of a combustion chamber being one of them.

Jane’s first assignment is to investigate and improve the design of a natural gas combustor. Using STAR-CCM+, she is able to quickly set up the geometry and the physics, opting for the standard Eddy Break Up (EBU) combustion model.

She decides that keeping it simple by just modeling one overall reaction is a good starting point as she is under a lot of pressure from her management to get the job done quickly. She obtains a flow and temperature field and verifies that the results obtained are accurate.

Next, she starts her design work with Optimate+, and she is able to quickly and automatically improve the design by optimising the fuel nozzle placement.

34 • January 2016

Karin Frojd, CD-adapco

And then, a few days later, a scientist from the lab tells her the combustor she is designing behaves differently for different qualities of natural gas. She wonders if she needs to consider a more complex approach and starts asking questions...

Why Does the Combustor Behave Differently for Different Natural Gas Qualities?

Different natural gas qualities contain varying amounts of larger hydrocarbons.

High quality natural gas consists mainly of methane, while low quality natural gas includes a few per cent of ethane, propane and butane. Larger hydrocarbons

break much more easily than methane, and hence low quality natural gas ignites faster.

How Does the Early Ignition Affect the Overall Combustion Behavior?

To understand this, Jane studies the chemical effects in an isolated environment, eliminating the influence of flow fields. She finds she can use DARS to accomplish this. DARS is a standalone tool from CD-adapco for analyses of chemical reactions in 0D and 1D idealised reactors. The tool can read and analyse chemical reaction schemes, for example for hydrocarbon combustion and catalytic processes in after-treatment systems.

Chemical Engineering World

CEW Features notes that under very lean conditions, the pure methane fuel speed is about 14 per cent slower than the lower quality fuel, indicating the high quality natural gas is more prone to lean blow-off.

To understand the behavior under diffusion combustion, she calculates a flamelet library for each fuel composition.

A flamelet is an idealised laminar diffusion flame, and a flamelet library is a set of flamelets for various scalar dissipation (mixing) rates.

She observes that the maximum temperature in the flamelet is about 30K higher for the low quality fuel under high scalar dissipation rate. This makes the high quality natural gas flame more prone to extinction; she notes that the extinction scalar dissipation rate is 41/s for the low quality fuel, and 35/s for the high quality fuel.

Figure 1: Case setup for chemistry analysis in DARS

Jane opens DARS and reads in the standard natural gas chemistry delivered with DARS. Then she connects a few different reactors to the read mechanism module: • Freely Propagating Flame: This module calculates the laminar flame speed, which is an important property for the flame propagation and thus the combustion behavior in a combustor.

The module also calculates species profiles and temperature in the flame.

• Constant Pressure: This module calculates ignition delay times as well as species profiles and thermodynamic properties of an auto-ignition event under homogeneous constant pressure conditions. It can also be used to calculate emission production.

• Flamelet Library: This module calculates the species and temperature profiles in a diffusion flame. It also calculates the extinction limit.

• Equilibrium: This module calculates equilibrium species and temperature.

For each module, Jane tries two different fuel qualities in DARS: • Pure methane to simulate very high quality natural gas, • Methane mixed with a few per cent of larger hydrocarbons (C 2-C 4).

38 • January 2016

She first calculates the laminar flame speed for a range of equivalence ratios. The laminar flame speed is the speed of a freely propagating flame under premixed conditions.

She finds that the flame speed is about 1 cm/sec faster for the low quality blend. She contemplates if this matters for her design...

What Does a Faster Flame Speed Mean for the Combustor?

Jane decides that this increases the risk of flashback in the combustor. She also

The extinction scalar dissipation rate is the mixing rate at which the diffusion flame is blown out. This indicates that blow-out is more common for high quality natural gas.

Jane calculates ignition delay times to understand the ignitability and to evaluate the tendency of pre-ignition in the mixing zone of the combustor. She creates a parameter sweep (called multi-run in

Figure 2: Laminar flame speed for high versus. low quality natural gas

Chemical Engineering World

CEW Features sets up the calculations and runs the library generation.

She creates a set of FGM libraries for varying natural gas mixtures and uses them in her CFD calculations, adding different fuel qualities to her Optimate+ optimisations. She finds a design which is also suitable for low quality natural gas and delivers it to the lab engineers for testing.

Figure 3: Flamelet temperature for low quality natural gas for various scalar dissipation rates ( green line: very low scalar dissipation rate, blue line: medium scalar dissipation rate, red line: scalar dissipation rate very close to extinction)

After this update, her colleagues are very interested in the varying behavior and want to understand why this happens.

How to Understand the Effect of Varying Fuel Mixtures?

To do this, she re-runs the homogeneous constant pressure reactor case with low quality natural gas and methane only, and checks the species sensitivity analysis.

The results for pure methane combustion look as follows: As expected, methane and oxygen are the dominant species for the combustion process. Then she plots the same sensitivity analysis for the low quality natural gas:

Figure 4: Ignitability for different natural gas qualities at initial temperature of 950K (blue line: high quality, red line: low quality)

DARS) with methane as fuel, sweeping over the full range of fuel-air equivalence ratios given the inlet temperature and ambient pressure.

After a few seconds, the calculations are finished, and she can watch the ignition of the mixture. She notes that the time-toignition is shortened by about 25 per cent for low quality natural gas, which gives an increased risk for pre-ignition in the mixing zone.

From the equilibrium calculations, she observes that the adiabatic flame temperature for low quality natural gas is about 5K higher than for high quality natural gas. Seeing the effect on the combustion behavior with only a very slight change in fuel composition, she understands she needs to continue the studies in the CFD simulations to quantify the effect on the 40 â&#x20AC;˘ January 2016

combustor behavior. She now needs to figure out how to do this and wonders...

How Do I Account for Different Fuel Blends in my CFD Calculations?

Jane figures out that she can do this by using the Flamelet Generated Manifold (FGM) model in STAR-CCM+, which includes the full detailed finite rate chemistry without compromising the speed of execution. The effect of different fuel blends is accounted for through the creation of one FGM library for each fuel blend. The FGM library is generated from detailed chemistry.

How Do I get an FGM Library for my Combustor Conditions for STARCCM+?

Jane finds out that she can use DARS for this as well. She opens her DARS project and drags an FGM library generation module to the workbench,

Propane constitutes only 1.5 per cent of the fuel blend, but still affects the combustion almost as much as methane.

Butane, which constitutes only 0.3 per cent of the mixture, also has a significant effect on the combustion. This shows that the larger hydrocarbons have a large impact. To understand the reactions behind this behavior, she checks their sensitivities. She notices that propane and butane dissociation are two very important processes, in addition to the oxidation reactions: Using the sensitivity analyses, plots on ignition delay times and the CFD simulations, Jane is now armed with all the material she needs to explain to her colleagues what happens during this process.

A while later, the lab engineer returns and asks her about emissions. For Chemical Engineering World

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CEW Features

Figure 5: Species sensitivities for high quality natural gas combustion

Figure 8: CO emissions as function of temperature and equivalence ratio

Figure 6: Species sensitivities for low quality natural gas combustion

Figure 9: CO mass fraction field in glass furnace simulation using the FGM combustion model.

Figure 7: Reaction sensitivities for low quality natural gas combustion

some load points, the CO emissions are unacceptably high. Is she ready for her next challenge?

How to Improve Emission Performance?

To better understand the CO emissions, Jane starts up DARS and runs a set of homogeneous constant pressure reactors under constant temperature, creating an emission map: In this map, she can see the CO production for different fuel-air equivalence ratios and different temperatures. Comparing to the mixture fraction and temperature flow field in CFD, she finds her combustor entering the CO yield area in some fuel rich zones close to the fuel outlet for the load range specified by her colleague.

She needs to improve the mixing in these zones, and thus sets a constraint on 42 • January 2016

the maximum equivalence ratio in these regions for the next optimisation loop.

doesn’t want to be pulled over for noncompliance. Longer computational time might just be a small price to pay.

She manages to decrease the CO with some efficiency penalty, and can study the trade-off between CO emission and efficiency. To further understand the CO yield, she adds CO to the post-processing species in her FGM library generation, and re-generates the FGM libraries. Now she can directly study the CO yield in her CFD simulation.

Finally, to fully understand the effects of detailed chemistry, she picks one of the cases and applies Complex Chemistry in STAR-CCM+ to perform a full CFD simulation with the chemical mechanism used in DARS. This serves as a good benchmark against the other combustion models. She convinces her manager that although these simulations take longer to complete, they will provide much better accuracy. After all, the company

Author’s Details Sabine Goodwin Director, Product Marketing CD-adapco E: sabine.goodwin@cd-adapco.com Chemical Engineering World

CEW Features Guest Column

How Can The Indian Chemical Sector in Gujarat Tackle The Slowdown?

The chemical industry is one of the largest and most diversified industries in the world.

It occupies a pivotal position in meeting basic needs and improving quality of life and it is important for the economic development of the country. The industry is the main stay of industrial and agricultural development of the country and provides building blocks for several downstream industries, such as textiles, papers, paints and varnish, soaps, detergents, pharmaceuticals etc.

T

he demand growth of the chemical sector is shifting to Asia Pacific region particularly to China, India and a number of Southeast Asian countries. China accounts for almost half of the chemicals sales in Asia followed by Japan and India.

India is the third largest producer chemical in Asia and eighth largest producer worldwide. Total production of the Indian chemicals industry 21.2 Million Tones during 2014-15. In India, Chemical Sector is most diversified, covering more than 70,000 commercial products. Indian chemical sector is very crucial for the economic development of the country.

According to industry estimates, with Asia’s share in the global chemical industry increasing from 31 per cent to 45 per cent and India has emerged as one of the focus destinations for chemical companies worldwide. The Indian chemical industry is highly diverse in structure with varied manufacturing bases and markets. Indian chemical sector has come a long way since its early days of independence. The sector has grown from a small-scale sector to multi-dimensional sector, which is taking on the challenges of globalisation. Indian chemical industry was a net importer in early 1990s but has now become a net exporter due to reduction in its imports, major growth in its exports in drugs/ pharma and biotech sectors and higher share of high tech product manufacture.

44 • January 2016

Specialty chemical industry is a knowledge driven industry. In India it has been growing rapidly over the last few years. Domestic demand of specialty chemicals is expected to follow an accelerated growth path. This demand is mostly driven by the strong growth outlook for end use industries. This along with increased adoption of specialty chemicals and newer usages can propel the growth further.

Today, Indian chemical industry holds a recognised position in the global map. Gujarat has been the leading state in terms of attracting investment for chemicals industry and Gujarat known as the ‘Petro Capital’ of India.

Gujarat contributes significantly to the

country’s petrochemicals production (62%), chemicals production (51%) and pharmaceuticals production (35%).

Gujarat produces about 91 per cent of India’s required amount of soda ash and gives the country about 66 per cent of its national requirement of salt. Gujarat produces around 6,600 types of chemical products and accounts for 18 per cent share in India’s chemical exports and over 80 per cent in dyes and intermediates’ production. Its business friendly policies have made it the first choice for investors.

The deteriorating global economic growth outlook and rising volatility in currency markets have dampened Indian exports.

The international market too has become stagnant and demand from markets such

Figure 1: Case setup for chemistry analysis in DARS

Chemical Engineering World

Chemical Engineering World

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CEW Features as Europe, South America, Egypt and Sri Lanka has fallen. Over and above, the slowdown in China and depreciation of its currency has further hit the chemical exports. Downfall in exports has hit the industry very badly.

India’s overall exports are projected by the commerce ministry to decline by 13 per cent from the previous year’s level to USD 270 billion in 2015-16, with a trade deficit of around USD 120-125 billion.

Exports of drugs and pharmaceuticals increased by 8.2 per cent but the growth of Chemical export was only 1 per cent in December 2015.

Many organic and inorganic chemicals were produced in mass in Chinese Taipei.

Also due to intense pressure faced

by Chinese chemical manufacturers, Government of People Republic of China have lowered the import and export taxes to boost the Chinese ailing chemical sector. Besides due to the low import duty structure prevailing in India, Chinese manufacturers are easily exporting various chemical products to India at below their normal value, which affected the domestic chemical industries in Gujarat very badly. The gradual reduction in duties of organic and inorganic chemicals over the years has affected the competitiveness of the sector. Further, the declining customs duty has made the sector vulnerable to imports and dumping.

Moreover, the domestic end-users prefer imported products to the Indian products because of their cheap price, this leading to disruption of the domestic industry.

The chemical industries in Gujarat, which mainly comprises of small and medium enterprises (SMEs), is also reeling under high costs amid dull market conditions.

The ability to connect science with innovation to help address many of our nation’s problems lies with this industry alone. With chemistry everywhere, this industry has developed and continues to develop a range of products from food to infrastructure to address everyday needs of the people. Sadly, world over, chemicals industry has acquired the reputation of being a ‘toxic industry’ and 46 • January 2016

a pollutant. In reality, it is the only industry to have consolidated answers to the world’s sustainability concerns also to beat the uncertainty in the market.

Since the global demand is not likely to get stronger in the near future, therefore, policy makers in India will have to adopt certain policy measures to counter the challenges faced by Chemical Industries in India.

First, with increasing competition worldwide, innovation remains crucial in finding new ways for the industry to satisfy its increasingly sophisticated, demanding and environmentally-conscious consumers.

Second, chemical industries has to improve the long-term export competitiveness, which will help exporters gain market share.

Otherwise, with economic recovery leading to higher imports, the trade deficit could widen.

Third, Central Government will have to focus more on internal drivers of growth to increase economic recovery.

Despite ample labour force, India is not a low-cost outsourcing option when compared with China and other emerging markets. This needs to change. By channelling available resources and exploring bio-based fuels, countries like Thailand and Singapore have emerged as hubs for the chemical industry without significant feedstock advantage or domestic demand.

Also Chemical industries in Gujarat have to focus more and more on research and development (R&D) activities as well as technological up gradation of their facilities.

The need of the hour is to improve productivity and not scale up production. Costs are rising, and it is difficult to pass the burden on to consumers, since the demand side is already weak. To surpass this situation, especially small and medium enterprises units need to spend more on R&D activity that will make production more economical, cost-effective and address the challenge of pollution concerns.

Thus, chemical Industries can be made globally competitive.

Focused growth and planning for the chemical sector would enhance our

global competitiveness further, increase domestic value addition, provide technological depth and promote sustained economic growth. In order to realise the growth envisaged above and leverage the India opportunity effectively, the chemical industry would also require significant investments in capacity creation, backward integration, technology development, alternative application of the chemical manufactured, creation of newer markets, access to feedstock and a larger pool of skilled human resources etc.

Innovation is important for chemical industry fortunes. In the past, product innovations have helped in developing products with multibillion dollar sales.

Therefore, innovation performance is a crucial determinant of competitiveness and national progress.

Moreover, innovation is important to help address global challenges. Domestic companies have built significant assets and have the opportunity to leverage them and will need to strengthen them further to withstand global competition.

India offers huge market for chemical companies. But, to achieve the goals of ‘Make in India’ initiative, the government has to create favourable conditions for global and local firms to invest in manufacturing facilities.

The chemical industry has many challenges in the 21 st century which must be overcome in order to remain at the heart of every major country. It is only through this that the industry can help society to maintain and improve its standard of living and do so in a sustainable way.

Author’s Details Jaimin Vasa President, Gujarat Chemical Association Chairman, MSME Committee, Gujarat Chamber of Commerce and Industry MD, Vasa Pharmachem Pvt Ltd E: jaiminvasa@gmail.com Chemical Engineering World

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CEW Features Interview

“Challenge Is To Implement Recycling And Reuse Measures In Economically Sustainable Manner” In light of the WaterEX Conference and Expo taking place at Chemtech Gujarat from February 10-12, 2016, Girija Dalvi interviewed A B Pandya, ex-Chairman, Central Water Comission and Chairman, Central Advisory Board – WaterEX Gujarat 2016 where he shared his views on how crucial recycling and reuse of water is in water management, Ganga Rejuvenation, tackling water woes with the burden of growing population among other important aspects.

1. Recycling and reuse of water are becoming more and more crucial in water management. What are the technologies that could create a balance between the desired demand and desired supply?

Recycling is becoming more and more important in view of our increasing urbanisation and industrialisation. We need to focus more and more on bringing the primary employment sector to industry than agriculture as it exists today. This is necessary to re-establish the economic viability of the agriculture as well as sustaining the economic growth to bring up millions above the poverty line through sustained employment opportunities. At present we have about 38 billion litres of sewage every day that amounts to 13.87 billion cubic metres of water, out of which a significant portion can be re-used if treated and will make a sizeable dent upon the freshwater requirements of the country as far as the process and cooling requirements are concerned and also will go towards reducing pressure on the water requirements for vegetable and other short term crops growth round the year.

The treatment technologies employing bio remediation and desalination hold promises for the solutions. Important need for any technology will have to be its economic sustainability at least during the operation and maintenance phase. Reducing the energy footprint of the technologies will also help to a great extent.

Apart from that, we will need to harness the surface water resources through strategic 48 • January 2016

storages and implementing the large scale programmes like Inter Linking of Rivers programme. The better harnessing of the surface water resources will lead to reduction on the stress on ground water and will also provide resilience against the climate change.

We need to holistically implement the recycling technologies with the long term vision of developing our water resources in a coupled fashion to achieve the desired balance.

2. Do you believe Ganga Rejuvenation can be as effective as the case of Rhine river in Germany or Thames in London? How can that be implemented as effectively as in the case of Rhine or Thames?

Ganga rejuvenation has the potential of becoming as effective as in the above cases provided we are able to bring in all the stakeholders to accept the same goal.

As far as the examples of Thames and Rhine goes, we need to appreciate that the hydrological context of the water availability in these rivers is entirely different than that existing in Ganga. In case of Rhine and Thames, the water availability throughout the year remains highly uniform as compared to Ganga, which being a monsoon fed river with predominant rainfall based flows, has a huge variation between monsoon and non-monsoon seasons. We should supplement the non-monsoon flows by strategic storages in the basin and attempt to improve the demand management by

increased efficiency of usage coupled with matching the same with reuse and recycling.

The challenge is to implement the recycling and reuse measures in an economically sustainable manner. There has to be a revenue model for operation and maintenance of the hardware assets created else the investments will not have a lasting effect. Annuity model is being tried out and time will tell the success of the same.

3. The growing population and changing demographics will add to the demand for water. How do you see the various states working internally to tackle their water woes? Is it possible to carry out collective efforts by the states for this?

Most of the states are aware of the need for a sustainable source of water for their growing needs. However, demands have grown at such a level that it is not possible for every state to be self-sustaining. All the river basins are spanning across units and it is necessary that there is an informed dialogue amongst the co-basin states so that the demand supply scenario in the basin is not adversely affected. Government of India is actively working towards assessment of basin level water resources and promoting the dialogue through basin level studies which can result in setting up of a river basin organisation amongst the participating states.

Chemical Engineering World

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CEW Features For an overall solution, ultimately, the interbasin transfers programme colloquially known as Inter Linking of River programme will have to succeed. Active efforts under the watchful eyes of the Supreme Court are on to generate the necessary consensus for implementing this programme in stages.

4. In your last interview with CEW, you had mentioned having efficient policies in place for improving quality of waste.

Has there been any significant progress on that front?

Improving the quality of waste water for enabling it to have other uses is being planned in case of Yamuna and some parts of Ganga basin. We still have to go a long way in this area as the same is falling in the domain of local bodies. The local bodies do not have adequate knowledge capacities and the finaicial health too does not permit them to take up the works on their own resources. Further handholding especially through the Urban development programmes is necessary.

The progress will have to come gradually as the awareness increases.

5. The Jurong Island Chemical Hub is a good example of how industries can thrive in the face of shortages of crucial requirements like raw materials, water, etc. Do you see such a scenario happening in India and how far in time?

Jurong Island is an ambitious development

by Singapore attracting investments in the range of USD 35 billion. It is apparent that the industry being setup there is being asked to depend upon the poor quality water as inputs by suitably treating it and also return an assured quality water back to the system. Extensive efforts through inviting problem specific consultancies and designs are being made in this direction. The efforts of reducing energy consumption in the membrane based treatment processes and using bio mimicking in the remediation processes are quite interesting and worth emulating.

Such a scenario can be replicated in the coastal regions of our country as reduced treatment costs of desalination can be beneficially exploited by using the residual 50 • January 2016

water emerging out of some of our nonperennial rivers and leaving appropriate quality water so that the marine environment is also not degraded.

6. A UN report published in 2014 states that by 2040, there would be no drinking water left in India and by 2025 almost 3.4 billion people would be living in ‘water scarce’ countries. How do you think we can bring about more awareness among the people of this grim situation and persuade a change?

The UN report does not paint a realistic picture as the overall quantum of water available annually is not changing drastically. The present concept of ‘use and throw’ will have to be abandoned in respect of our urban and industrial water supplies. At present there is considerable quantum water requirement for (almost 80% of the deployed water) for irrigation and agriculture purposes. We need to improve efficiency for this sector to make more water free for the drinking and industrial sector. The major constraint in the availability of the drinking water to the urban populations is the treatment and distribution networks. National water policy categorises the drinking water demand as the highest priority one but the lack of appropriate management and revenue models for the urban water supply make the last mile connectivity difficult.

We need to bring about a change in the mind-set of the consumers and make them amenable to pay for the resources used. Also, we need to improve land use management in our industrial and urban areas so that the specific quality demands of consumption by the livestock and population and the process water demands of the industry can be supplied out of different sources. A thrust towards treatment and use of poor quality water and technologies like low energy desalination will be useful in remote areas where the fresh water availability is naturally constrained.

7. Can setting up small effluent treatment plants in and around the Ganga region viz, the textile zone in Kanpur and Banaras save the industry from shutting down? What are the challenges you

foresee in setting up these plants and how can they be successfully resolved?

The effluent treatment plants will have to cater to individual communities and the size will depend on the size and output of the community concerned. There are about 118 towns and communities which are located in immediate vicinity of the main river stream of Ganga and their sizes are quite different.

In order to set up the plants, land is required for the same and also the plant has to be connected to its catchment area that it is planned to serve with a dedicated sewage/ effluent conveyance network.

These measures are location specific and will need to be handled as such.

In addition, it would be a good idea to set up industrial clusters catering to the specific type of industry eg, textiles. In that case, it will be possible to design the plant for the specific type of effluents emerging out of the industries in the cluster. There are specific legal provisions implemented through Central Pollution Control Act jointly administered with the State Pollution Control Board. Though the industries can be directed to maintain necessary facilities. Many industries have also come forward voluntarily offering the cooperation in this regard.

8. What is the ONE thing that you would actually like to see happening in India to give a boost to the chemical industry’s growth? If only you are given one choice.

I would like to see chemical industry to come up and reduce its footprint on the water quality area. The industry is primarily reviled and objected to on the grounds of water and air pollution that it created in its immediate vicinity. The industry needs to come up with economic zero effluent models for its clusters. The industry needs to look at the examples of Singapore industrial management and emulate the same. Chemical industry is a very vital component of our industrial growth as it produces a number of key ingredients required for the rest of the economy. The industry has to come out of its polluter tag by managing the water resources in an exemplary manner.

Chemical Engineering World

CEW Features Technical Article

Saving in the Air This paper shows and explains the different ways to efficient compressed air production and distribution to the end user and provides the insight of various production and distribution issues like correct generation pressure, efficient control of multiple compressors, leakages etc with example of their application in Indian Oil Corp Ltd (IOCL) - Gujarat Refinery.

C

ompressed air is widely used throughout industry and is often considered the ‘fourth utility’ in industries, other being power, water and steam. Almost every industrial plant, from a small machine shop to an immense pulp and paper mill, from small chemical plant to large oil refinery and petrochemical unit has some type of compressed air system. In many cases, the compressed air system is so vital that the facility cannot operate without it. In many industrial facilities, air compressors use more electricity than any other type of equipment. Inefficiencies in compressed air systems can therefore be significant. Energy savings from system improvements can range from 20 to 50 per cent or more in terms of electricity consumption. For many facilities this is equivalent to thousands, or even hundreds of thousands of rupees of potential annual savings, depending on the use.

may be known, but just not applied due to lack of knowledge about the financial savings possible.

Compressed Air Compressed air is one of the most important utilities used in industrial applications worldwide if not the most important. It has been in use for many years. The first known application is almost as old as Christian time scale. Over the years industry became used to the presence of compressed air. It is just there, a utility, very much comparable to electricity in a private household. But just like electricity, compressed air does have its costs. It is not as cheap as we think, in fact, it is one of the most expensive utility in a manufacturing plant. About eight horsepower of electricity is used to generate one horsepower of compressed air in electrical motor driven compressor. But despite the tremendous energy saving potential in compressed air production and distribution system, saving in compressed air system were hitherto not taken as seriously as it should have been taken. However, with the ever increasing cost of energy and awareness about the saving

A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality.

Many of the different levers for cost reduction

1. Leaks 2. Artificial Demand 3. Inappropriate Uses

Compressor Air Delivered by Compressors

1

2

3

4. Production

5. Heat Loss 85%

4 5

Electricity Consumed by Compressor

Delivered Compressed Air is only 15% Figure 1: A properly managed compressed air system can save energy, reduce maintenance, decrease downtime, increase production throughput, and improve product quality.

52 • January 2016

potential in this expensive utility, the scenario has changed in last couple of years. This is much more important considering the fact that only about 20-30 per cent of the energy given to generate compressed air is converted into usable energy at the point of end use. (See Figure 1 below)

Components of Typical Compressed Air System A modern industrial compressed air system is composed of several major subsystems and many sub-components. Major subsystem include air inlet filters, compressor, prime mover, control panel, intermediate and after air cooler, lubricant coolers, dryers, air receivers, air distribution network and end-user equipment like air tools, pressure regulators, pneumatic operated valves etc.

The compressor is the mechanical device that takes in ambient air and increases its pressure. The prime mover powers the compressor. Controls serve to regulate the amount of compressed air being produced. The treatment equipment removes contaminants from the compressed air, and accessories keep the system operating properly. Distribution systems are analogous to wiring in the electrical world—they transport compressed air to where it is needed.

Compressed air storage can also serve to improve system performance and efficiency.

Interestingly each and every component of this system has the potential and can contribute significantly in the energy saving plan of the system. (See Figure 3 on next page) Cost of Compressed Air Having the word ‘Air’ in compressed air, which is available for free, we often mistaken in realising the cost of compressed air?

There are three major components of the Chemical Engineering World

CEW Features compressed air cost namely capital cost invested for installation of facility, operating cost which is basically electrical energy as most of the compressors are electric motor driven and maintenance cost. Depending upon the size of the installation and operating hours of the system, proportion of these components varies slightly but still as shown in the fig about 70-95 per cent is the operation cost. (See Figure 2) Annual Operating cost of operating air compressors at IOCL Gujarat Refinery can be calculated by the fact that there are total 08 numbers of electric motor driven (832 KW each) compressor installed in the facility, out of which 04 compressors run continuously to meet the refinery plant air and Instrument air requirement. As per simple calculations, annual electricity consumption for operating 04 numbers of compressors considering motor efficiency as 85 per cent and 8760 hours of operation is: Annual Energy Consumption = 4 x 832 x (1/0.85) x 8760 KWhrs = 34297976.5 KWhrs Annual energy cost = 34297976.5 KWhrs x 4.55 ` /KWhr = `15.61 Cr Major Deficiencies in Compressed Air System • Finding the correct demand and system pressure requirement • Lack of integrated system for control of multiple units • Leakages at the end point and in the distribution system • Failure to store compressed air energy for use during peak demand periods • Severe fluctuation in pressure due to indiscriminate use of open blowing • Simple lack of maintenance, including neglect of dirty filter cartridges • Lack of efficient heat recovery mechanism Finding the Correct Demand and System Pressure Requirement A very important factor affecting the energy consumption of a compressed air system is the working pressure required. The pressure generated should always be such that to meet the minimum pressure requirement of the air operated equipment and also to meet 54 • January 2016

Figure 2: Cost Components of Compressed Air

the exigencies should there be any sudden requirement of the compressed air. This is easier to evaluate and implement the same in high volume networks than in small volume networks as the previous one has the higher surge observing capacity.

A rule of thumb for systems in the 100 psig range is, for every 2 psi decrease in discharge pressure, energy consumption will decrease by approximately by 1.0 per cent at full output flow. Additional incentive being reduced in consumption through unregulated use, leakages, open blowing etc which gives additional 0.6 -1.0 per cent reduction in energy consumption.

So, in total for every 2.0 psi reduction in discharge pressure energy consumption

will reduce by 1.6 - 2.0 per cent A 2.0 psi reduction in discharge pressure at Gujarat Refinery will result in annual saving of ` 28.0 Lakh (considering 1.8% reduction in energy consumption).

This is very much possible at Gujarat Refinery as we are generating air at 7.9 Kg/ cm2 (113 psi) and available pressure in most of the end user process units is in the range of 6.2 - 6.5 Kg/cm2 (88.2 psi - 92.5 psi).

All critical control valves and power cylinders installed in process units are designed for 4.5 - 5.0 Kg/cm2 instrument air pressure so surely there is scope of reduction of generation pressure by 2 - 4 psi without affecting the plant operation.

Figure 3: Components of Typical Compressed Air System.

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CEW Features Cost Of Leakages Diameter of Air Leak

Leakage Qty in CFM

Annual Electricity cost per CFM (0.157 KW * 8760 hrs.* ` 4.55/KWhr)

Annual Leakage Cost In `

1/16”

6.40

6258

40,051.00

1/4”

104

6258

6,50,832.00

1/2”

415

6258

25,97,070.00

1”

1661

6258

1,03,94,538.00

Minor Leakage – Big Menace A typical plant that has not been well maintained will likely have a leak rate equal to 20 percent of total compressed air production capacity.

Most common sources of leakage are Couplings, hoses, tubes, and fittings, Pressure regulators, Open condensate traps and shut-off valves and Pipe joints, disconnect, and thread sealants. In addition to being a source of wasted energy, leaks can also contribute to other operating losses. Leaks causes a drop in system pressure, which can lead to malfunctioning of all critical Instrument air operated control valves, power cylinders and other equipment. (See the table and the graph above)

See Table 1 on next page; All Figures Are in NM3/hr Total Air Leakage Rate = 3636.5 Nm3/hr or 2140.08 CFM

Air Leak Detection Since air leaks are almost impossible to see, it is difficult to detect even the bigger leakages let alone the small leakage which are equally important.

Annual Leakage Cost = ` 6257/CFM x 2140.08CFM = `1.34 Cr

The best way to detect leaks is to use an ultrasonic acoustic detector, which can recognize the high-frequency hissing sounds associated with air leaks. These portable units consist of directional microphones, amplifiers, and audio filters, and usually have either visual indicators or ear-phones to detect leaks.

To detect the air leakages and ascertain the amount of air leaking through an exhaustive air leak survey through ultrasonic detector was carried out in the year 2013 in Gujarat Refinery all over the compressed air network covering all process units, power plants, offsite and utilities section.

The number of leakage and amount of air leakage detected though this survey was an eye opener for all.

56 • January 2016

As a thumb rule, for any large motor driven compressor, 01 HP (0.7457 KW) can produce 4.5 - 5.0 CFM of compressed air at 100 psig pressure.

Cost of Generation of 01 CFM@100 psig = 0.7457/4.75 KW* ` 4.55/Kwhr Annual Cost of Generation of 01 CFM = 0.7457/4.75 KW* ` 4.55/Kwhr* *8760 hrs = ` 6258.00

So, at IOCL Gujarat Refinery annual saving of ` 1.34 Cr can be achieved by just plugging the leakages identified through ultrasonic leak detection.

Integrated System for Control of Multiple Compressor Units Compressed air system controls match the compressed air supply with system demand and are one of the most important determinants of overall system energy efficiency. Proper control is essential to efficient system operation and high performance. The objective of any control strategy is also to shut off unneeded compressors or delay bringing on additional compressors until needed. All units that are operating should be run at full-load, except one unit for trimming. Compressor systems are typically comprised of multiple compressors delivering air to a common

plant air header. The combined capacity of these machines is generally sized to meet the maximum plant air demand with a breakdown contingency. System controls are almost always needed to orchestrate a reduction in the output of the individual compressor(s) during times of lower demand. Compressed air systems are usually designed to operate within a fixed pressure range and to deliver a volume of air that varies with system demand.

System pressure is monitored and the control system decreases compressor output when the pressure reaches a predetermined level. Compressor output is then increased again when the pressure drops to a lower predetermined level.

The difference between these two pressure levels is called the control range. Depending on air system demand, the control range can be anywhere from 2 to 20 psi. In the past, individual compressor controls and nonsupervised multiple machine systems were slow and imprecise. This resulted in wide control ranges and large pressure swings.

As a result of these large swings, individual compressor pressure control set points were established to maintain pressures higher than needed. This ensured that swings would not go below the minimum requirements for the system. Today, faster and more accurate microprocessor-based system controls and variable speed compressors with tighter control ranges allow for a drop in the system pressure set points. Precise control systems are able to maintain lower average pressure without going below minimum system requirements.

At Gujarat Refinery there are total 08 compressors available for meeting the plant air and Instrument air requirement. These compressors are divided into section namely Chemical Engineering World

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CEW Features Unit

Leakage Big

Total

Medium

Small

DM Plant CGP-II

180.23

45.06

23.46

248.75

Compressor House

67.59

11.26

8.8

87.65

TPS Turbine

0

0

2.93

2.93

TPS Boiler House

67.59

33.79

18.57

119.95

CGP-II HRSG

0

5.63

11.73

17.36

DMp Plant CGP-I

45.06

45.06

45.96

136.08

CGP-I HRSG

22.53

16.9

11.73

51.16

CGP-I Compressor House

45.06

0

0.98

46.04

AU-I

157.7

22.53

28.36

208.59

AU-II

135.17

33.79

28.36

197.32

DHDS

0

0

9.78

9.78

HGU-II

0

16.9

12.71

29.61

AU-V

67.59

22.53

16.54

106.66

CRU

0

11.26

17.6

28.86

FPU-II

45.06

22.53

16.62

84.21

HGU-III

0

11.26

0.98

12.24

HGU-I

0

5.63

12.71

18.34

HCU

67.59

33.79

46.93

148.31

LAB

22.53

22.53

7.82

52.88

AU-III

22.53

16.9

10.76

50.19

UDEX

0

0

9.78

9.78

DHDT

45.06

16.9

9.78

71.74

SRU-I (OLD)

45.06

0

5.87

50.93

SRU-II (OLD)

0

11.26

1.96

13.22

ISOM PENEX

0

11.26

7.82

19.08

ISOM (NHT &NSU)

22.83

5.63

5.87

34.33

SRU-III

90.12

28.16

1.96

120.24

SRU-B

0

11.26

1.96

13.22

MTBE

0

0

0

0

FGH

0

0

0.98

0.98

VDU & BBU

225.29

56.32

10.76

292.37

CDU

135.17

11.26

6.84

153.27

FPU-I

0

5.63

8.8

14.43

VBU

90.12

39.43

24.45

154

DCU

22.53

22.53

11.73

56.79

FCC-LPG MEROX

0

0

0

0

ATF MEROX

0

0

0

0

COKER LPG MEROX

0

0

0

0

VGO HDT

22.53

5.63

4.89

33.05

MSQ

67.59

33.79

22.49

123.87

GANTRY – 5TH

202.76

61.96

46.93

311.65

GANTRY- 6TH

112.64

107.01

9.78

229.43

GANTRY-1/2

45.06

33.79

41.16

120.01

FCCU

135.17

11.26

10.76

157.19

TOTAL

2208.16

850.43

577.9

3636.49

Table 1: Leakages detected in various units of Gujarat Refinery

58 • January 2016

TPS & CGP-II with 04 compressors in each section. The outputs from these two sections are connected to common header. But the compressors were maintained at two different header pressures.

The basic problems with the old architecture were: • Non-existence of system wide control & monitoring of compressed air system • Two different set-points for two different headers • In case of increase in demand it may so happen that two different systems can give start command to two different compressors which will lead to simultaneous start of two compressor and availability of excess air which may result in unloading of running compressors and also opening of blowoff-valves which is highly undesirable in an efficient system.

• Continuous running of compressors at part-load. (See the old architecture of this system on next page)

In order to achieve the maximum efficient control of all compressors it was decided to integrate both these two system with a common setpoint. All these compressors were brought the common control network utilising the features of Ingersoll-Rand Air System Control Package (ASC). (See the new architecture of this system on next page) Features of the integrated System are: • Integration of the complete compressed air system • Energy management through base load and trim sequencing and/or load sharing; ASC controls the number of operating compressors, matching best efficiency with dynamic system demand • Time-based scheduling tool that enables virtually unlimited sequence change and compressor set operational combinations • Graphical interface – summary, setup and equipment-specific screen sets as well as object oriented graphics and dynamic icons made to represent the integrated system • Remote monitoring and communications – monitor from anywhere at any time and get real time data Heat Recovery from the Compressed Air During the compression process a high percentage of the consumed energy is transferred into heat. As much as 80 to 93 per cent of the electrical energy used by an industrial air compressor is converted into heat. In many cases, a properly designed heat recovery unit can recover anywhere from 50 to 90 per cent of this available thermal energy and put it to useful work like • Preheating boiler water • Makeup air heating • Supplemental space heating • Heating process fluids • Industrial process heating • Heat-driven chillers As a thumb rule, approximately 50,000 British thermal units (Btu) per hour of energy is available for each 100 cfm of capacity (at full-load). This value is based on 80 per cent recoverable heat from the compressor and a conversion factor of 2,545 Btu/bhphr.

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CEW Features The Old Architecture of the System

Set Point: 7.66 Kg/cm2

The New Architecture of the System

Set Point: 7.85 Kg/cm2

= [(796,170,470,40 Btu/yr)/(2644 Btu/Kg of MP steam) x (` 1.8/Kg of MP steam)]/ 0.85 = ` 637, 673, 24.31 = ` 6.37 Cr Conclusion As illustrated in this paper, compressed air system in overall has tremendous energy saving potential utilising the measures like optimisation of discharge pressure control, efficient use of individual machines in multi-unit system, plugging the air leakages and efficient heat recovery mechanism. On an average each compressed air system has approximately 33 per cent of energy saving potential. In addition to that, improving the performance of compressed-air system reduces plant wide energy costs. It can reduce downtime, increase production throughput, lower scrap rate, improve product quality, improve the plant reliability and create longer equipment life.

Figure 4

Energy Saving in Heat Recovery Energy Saving (Btu/year) = 0.80 x compressor bhp x 2,545 Btu/bhp-hour x hours of operation Gujarat Refinery has four compressors running at full load, each of 1116 bhp (832kw) with yearly running hours of 8760. So even if 80 per cent of the heat generated is recovered then the Energy Saving (Btu/year) = 0.80 x (4*1116) x 2545 x 8760 [= 796,170,470,40 Btu/year] The above heat generated can be used in Boiler feed water pre-heating, fuel oil pre-heating, air pre-heating, VAM air conditioning units etc. If we consider the case of fuel oil heating with hot compressed air instead of MP steam then Cost Savings (`/yr) = [(Energy savings in Btu/yr)/(Btu/unit of fuel) x (`/unit fuel)]/ Primary heater efficiency 60 â&#x20AC;˘ January 2016

Authorâ&#x20AC;&#x2122;s Details Bal Kishan Sharma Manager- Instrumentation Indian Oil Corporation Ltd - Gujarat Refinery E: sharma_bk@indianoil.in Chemical Engineering World

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Recycling Bio-Lubricants As An Avenue For ‘Second Life’ Market Opportunities Plugging the gap in industrial lubricants waste disposal early on in the value chain by incorporating ester-based solutions in our operation lifecycle

A

Snapshot of India’s Lubricants Industry Landscape India, with its GDP of approximately USD 1,825 billion (2012), is billed as the third-largest economy in Asia, following China and Japan. The drop in its economic growth rate to 5.3 per cent in 2013–2014, and change in government has had a ripple effect in the lubricants industry, which like in any major economy, is highly correlated to GDP given that the lubricants industry provides solutions for key industries ranging from automotive, aviation, agriculture, construction, steel, logistics and mining.

That said, overall lubricant consumption in India is expected to grow at an annual rate of 2.5 per cent over the next five years with the consumer segment seeing the fastest growth at a projected 6.6 per cent per year.

Advancements in infrastructure - roads, airports, power generation, and railways will continue lubricants’ economic influence and growing consumption locally.

Industrial lubricant is the largest market segment in India, accounting for over 54 per cent of the total market. Power generation, chemicals, automotive and other manufacturing, railways, marine, and metals are the leading end-use industries, together accounting for nearly 80 per cent of the industrial lubricant consumption.

The emergence of bio-based lubricants, advancements in the automotive technology, growth in green energy and increasing

62 • January 2016

appetite for higher valued products amongst end-consumers; are trends influencing the demand for environmentally responsible solutions.

Waste Oil and Leakages, an Interpretation For the purpose of clarity, it is fitting to provide some context to the definitions of ‘waste oil’ and ‘leakages’ used in this article.

Waste oil or used oil as defined by USA’s Environmental Protection Agency (EPA), is any oil that has been refined from crude oil, or any synthetic oil that has been used and is contaminated by physical or chemical impurities, as a result of use. This term typifies oil that is intentionally drained out of equipment.

Leakage on the other hand is when used oil is introduced into the environment, typically during the running of machinery or equipment. Terms such as ‘lost-in-use’ or ‘total-loss’ are also common and they all ascribe to ‘lubricants are lost to the ground forever’. Common leaks include twocycle engines, oils used for bar or chain, penetrating, rail and dust-suppressant; and wire-rope lubricants.

Waste and Leakage of Fossil-Based Products Is Often Irreversible In the USA, a Department of Energy (DOE) commissioned study estimated that almost 400 million gallons of used automotive oils and industrial lubricants are improperly

disposed of or illegally dumped into the environment in the United States each year, while the country’s EPA estimates the amount of used oil illegally dumped each year is the equivalent of two to three oil tanker-sized spills every month. This, just in the USA alone.

Specifically in India, the total loss of lubricants such as two-stroke engine oils and mould release agent account for 30 per cent and 28 per cent of the local market, respectively.

Yet another challenge confronting the Indian lubricants industry is the re-use or safe disposal of approximately 59 per cent of the lubricants that eventually become waste oil.

While about 66 per cent of such lubricants are re-used, the rest are simply burnt or dumped in water or land, affecting soil and waterways critical to the livelihood and health of many dependent on them.

With a recent poll by MachineryLubrication. com showing that ‘51 per cent of lubrication professionals’ work in facilities where waste oil is stored in large volumes’, in India, these startling figures call for urgent need to drive innovations in and the adoption of, ecofriendly lubricant products.

Mitigating Long-Term Impact of Lubricants with Bio-Based Additives Through Emery Oleochemicals’ business of manufacturing natural-based lubricant additives, we are increasingly aware of the regulatory, societal and environmental Chemical Engineering World

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CEW Features requirements lubricant formulators aim to address, while delivering on performance characteristics in bio-based additives equivalent to mineral-based solutions.

In my over 35 years of industry experience, I’ve seen innovations in biobased lubricants leapfrog with increased urbanisation. And in my opinion, given today’s availability of alternatives, businesses should be encouraged to consider waste avoidance/minimisation as the preferred choice (where possible) by incorporating bio-based solutions that also offer improved performance.

Sometime overlooked, I believe responsible businesses can dramatically influence waste and leakage issues when trying to achieve the following: a) Increasing equipment life: There is a direct correlation to growing economy and the increase in manufacturing and industrial demands. Now, with performance demands on industrial lubricants such as high operating temperatures and longer machinery runtime adds operational and yield pressures with almost no room for equipment downtime. Ester basestocks and additives not only address environmental impacts during leaks with its low toxicity, fast bio-degradation and nonbioaccumulative properties (and eventual disposal), they also provide: • reduced machine wear through reduced friction • high viscosity index • high load-carrying abilities • good anti-wear properties, and • low volatility and high ignition temperature Eventually, operators are able to efficiently use manufacturing resources (energy, less issues with wastewater and effluents, longer lubricant drain intervals) and reduce long-term costs. Additionally, on site challenges in dealing with waste oil and leakages are minimised with bio-based solutions that are readily bio-degradable ie, degrading minimum 60 per cent or more within 28 days according OECDtests as the fluid degrades completely 64 • January 2016

to CO2 and water before environmental damage occurs. b) Improved eco-system critical to local economy: Two industries that will quickly reap rewards of bio-degradable lubricants in India are the agriculture and fishing sectors, through reduced contamination of soil and water. In the case of the latter, the most significant global regulation passed to date is the Vessel General Permit (VGP), introduced by the USA’s EPA, where all vessels navigating to the country’s shores greater than 27 metres must be fitted with Environmentally Acceptable Lubricants (EAL). With far-reaching, positive impacts - shipping industry players are moving into incorporating ester-based lubricants into their operations. Esters, offering valueadd properties like superior lubricity, excellent low temperature behaviours and positive environmental impact, are expected to drive the demand for biolubricants, particularly in stern tube oils.

Also, in maintaining the quality of marine life, ester-based oil drilling muds used in offshore oil production are known to work well in extreme borehole conditions and deliver on rig yields.

On land, farming machinery typically see leakage of hydraulic fluids, and to this end, in order to minimise soil contamination; environmental regulations and consumer pressure in Europe have forced the conversion to more environmentally acceptable hydraulic fluids especially in sensitive areas such as waterways, farms and forests. Given that fossil-based oils that have migrated through soil or has reached ground water is subject only to anaerobic degradation and can take as long as 100 years, it is in the interest of Indian lubricant players (private or public sector organisations) to push the agenda of vegetable-oil based solutions integration not only into farming solutions but into automotive oils.

This is because landfills receive used oil filters and used quart motor oils bottles containing residual oils – driving the need to ensure nation-wide access to proper disposal methods

and grassroots initiatives to educate public on the damages and impact to an already limited availability of clean, drinking water. c) Increased worker safety and efficiency: Responsible businesses prioritise the handling and application of lubricants through all stages of its use and disposal.

From a worker safety perspective, plantbased lubricants are more attractive than their fossil-based counterparts because of their relative low toxicity, high flash point and low volatile organic compound (VOC) emissions. Bio-lubricants can be used as well as concrete release agents. Lab tests have also shown that in-soluble biolubricants were superior in performance and provided a better quality working environment when compared to the mineralbased release agents. They are reducing workplace hazards associated with oil mist and oil vapour that leads to dermatological and respiratory problems. Better working environment was also the case in spent biolubricant trials.

Renewable biodegradable ester oils are indeed gaining popularity especially because they are increasingly able to close the gap in performance compared to fossil-based lubricant products. Gradually, as bio-lubricants become more adopted and prove their mettle, there will be an added emphasis on waste oil disposal and reclamation initiatives. Efforts are currently made to further the processes of recycling bio-lubricants as an avenue for ‘second life’ market opportunities. This can undoubtedly add value to the primary product’s end-user by reducing disposal costs and creating extra dollars.

Author’s Details Mark Durchholz Global Business Director, Bio-Lubricants Emery Oleochemicals Chemical Engineering World

CEW Features Technical Article

Recovery of Ammonium Sulphate from Effluent Stream of Ammonium Sulphate Plant at GSFC- A Case Study Ammonium Sulphate (AS) is produced in GSFC plants with total capacity of 1,96,000 TPA. It also comes as a byproduct from caprolactam and methyl ethyl ketone oxime plants. Although it is a well known slow release nitrogenous fertiliser, a rich source of sulphur nutrient, it is also used as a raw material in chemicals, dyes and pharmaceutical industries. This article discusses the recovery of AS from effluent of ammonium sulphate plant.

B

ackground Effluents from fertiliser plants contain both nitrogen (N) and phosphorus (P) and are toxic to water bodies, if discharged untreated. These compounds inhibit biological process of cleaning toxic wastes.

The purification of wastewater/effluent which contain organic substances is as important as recovery of valuable product from the effluent. Conventional processes like biological treatment cannot remove all organic compounds, if substantial amount of N and P are present. When excess amounts of N and P are discharged, plant growth may be accelerated resulting in eutrophication in the receiving water bodies. Algae growth is stimulated causing blooms which are toxic to fish life and is aesthetically unpleasant.

Pretreatment of effluent and recovery of AS forms a very important waste control strategy for fertiliser plants. Such approach makes biological treatment easier and also gives economic returns in terms of recovery of valuable by-products. In ammonium sulphate plant of GSFC, AS rich effluent stream is purged out which contains significant amount of AS resulting in its loss and increase in water load in chalk pond. Typical characteristics of effluent include high chemical oxygen demand (COD) and unacceptable dark brown colour. The aim of the study was to recover the AS from effluent.

Treatment procedure The entire study was carried out at pilot plant of R&D in GSFC. Effluent was received at 6070°C having acidic pH around 2. It was cooled to room temperature by circulating chilled water in a reactor. Ammonia was added to

66 • January 2016

Figure: Recovery of ammonium sulphate from effluent

the effluent at suitable pressure till alkaline pH achieved to decrease the solubility of AS and thicken the ammonical crystal suspension.

Chilled water was circulated to increase the solubility of ammonia. Optimum ratio of ammonia and the effluent was established for recovery of AS crystals from effluent.

Conclusion A process for the recovery of 70-75 per cent ammonium sulphate crystals from effluent contaminated with organic compounds was proposed, resulting in substantial cost benefit. The recovery of AS also improves effluent quality to an extent suitable for biological treatment.

About 70-75 per cent AS crystals having purity of 97-98 per cent was separated by vacuum filtration. Ammonia can be recovered from the effluent after precipitation of AS crystals through alkaline solutions viz, sodium hydroxide, potassium hydroxide, calcium oxide or milk of lime. In our study, ammonia was recovered by using caustic soda solution.

Author’s Details Swati Jain N K Sanchapara K A Patel A S Sikdar R & D Centre Gujarat State Fertilizers and Chemicals Ltd Chemical Engineering World

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Auto Backflush Filters

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ilter Concept felt that industries were in demand of products which have less consumables changes out, easy to clean as well as there should be no concern of disposing off the products. By keeping these facts in mind, we have developed Auto backflush Self Cleaning filter which has many advantages compared to conventional Filter System like uninterrupted process, low operation and maintenance cost and easy to clean; which helps the organisation to fulfill environmental pollution control norms in India and across the globe.

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Features and Benefits • Simple operation of filtration • Easy process of Backwash / Back flush • Less wastage of water for cleaning • No consumable cost • Minimum manual intervention • Uninterrupted through out all time, even during back flushing • Can handle high suspended load Filter Concept Pvt Ltd 302, Aalin, B/H Jet Airways Office, Ashram Road, Ahmedabad, Gujarat, INDIA – 380014 T: +91-79-2754 1602 | F: +91-79-2754 0801 E: info@filter-concept.com W: www.filter-concept.com

Sawant Filtech Pvt Ltd

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As we attach great importance to efficiency, you can be sure that our products work costeffectively, profitably and environmentally friendly. Innovation is the central point of our work.

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68 • January 2016

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on Exchange (I) Ltd, a pioneer of water treatment in India with a legacy spanning over five decades, is recognised internationally as a premier company in water and environment management. We are among the largest environment solutions providers, one of very few companies worldwide with a complete range of technologies, products and services, which enables us to offer total solutions for every sector of the society. With sales, production and service footprints across the globe, we serve our markets with a sustained focus on customer satisfaction, technological innovation and dedicated service. Our capability to deliver comprehensive solutions with complete technical support makes us a partner to depend on.

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• Comprehensive 24/7 service support ensures high performance continuity Wealth of Expertise • Exports to Africa, Japan, Middle East, Russia, South East Asia, UK, USA and neighbouring countries • More than 1,00,000 installations worldwide • Over 1000 installations in the core sector - at thermal and nuclear power stations, fertiliser factories, refineries and petrochemical plants Extensive Infrastructure • All India infrastructure – production facilities, sales, service, dealer network and R&D centres • Largest service network in the water treatment industry in Asia • Global presence through overseas sales and service operations, subsidiaries and joint ventures Manufacturing State-of-the-art units spread across five states of India and in UAE, committed to built-in quality achieved by quality assurance systems, advanced manufacturing processes and continuous training in manufacturing practices, safety and quality issues.

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Hosur, Tamil Nadu ISO 9001 certified modern 11,000 sqft facility for fabrication and assembly of pre-designed packaged and pre-engineered water and waste water treatment plants; also for manufacture of water quality monitoring instruments.

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Verna, Goa ISO 9001 certified centre for membrane manufacture, produces world-class membrane products and systems for drinking and process water and non-water applications.

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Agent for vacuum pumps Mr. Jayant Joshi EMJAY ENGINEERS, AgentShubh for vacuum B/102, Saritapumps CHS, Near Shrikirshna Nagar, EMJAY ENGINEERS, Jayant Joshi (East), Appasaheb SidhayeMr. Marg, Borivali B/102, Sarita CHS, Near VacShubh Enterprises India LLP,Shrikirshna Mr. JayantNagar, Joshi Mumbai 400066 Appasaheb Sidhaye Marg, Borivali (East), B 102 Shubh Sarita, Appasheb Sidhaye Road Tel. 02228975275 | Mobile 9820047858 Mumbai 400066 Shree Krishna Nagar, Borivali (East) E-mail:electromech.engg.entp@gmail.com Tel. Mumbai 02228975275 Mobile 9820047858 400 066 E-mail:electromech.engg.entp@gmail.com Tel. 02228975275 | Mobile 9820047858 info@electromechengineering.com

1-800-266-1244

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drying specialist

ForBuilding, Details Contact: Taj 3 Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 For022-4037 Details3636, Contact: Tel: Fax: 022-4037 3635 Your vacuum drying specialist Email: industrialmags@jasubhai.com rd Taj Building, 3 Floor, 210 Dr D N Road, Fort, Mumbai - 400 001 rd marketing@italvacuum.com | Taj Floor,Fax: 210 Dr D N Road, marketing@italvacuum.com Tel:Building, 022-40373 3636, 022-4037 3635Fort, Mumbai - 400 001 Tel: 022-4037 3636, Fax: 022-4037 3635 Email: industrialmags@jasubhai.com italvacuum.com

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CEW Features

Company Profile

Kiron Hydraulics Needs Pvt. Ltd

T

he Czech factory of the German company CeramTec processes very abrasive Silicon carbide (SiC) for the production of technical ceramics. It was not easy for Iveta Formankova, production manager at CeramTec in Šumperk, to find a wear-resistant mixer for mixing and coating the very abrasive SiC during her search. She came into contact with Lindor through the Internet and discovered the existence of mixers with a ‘gentle touch’: a special mixing technique that exerts no force on the powder, which reduces wear to a minimum. During mixing a very even liquid coating is possible and a homogenous mass is quickly produced.

The process Technical ceramic materials are used in industry because of the very specific mechanical properties such as temperature resistance, wear-resistance, shape retention, insulation value, etc. The ceramic materials are often abrasive. Silicon Carbide is very abrasive and is therefore used as a grinding medium.

Iveta Formankova explains: “A spray drying installation produces the very abrasive SiC powder. The Lindor mixer then homogenises this SiC powder and coats it with an oil. In the following process pressing, sintering and machining take place to process this into components”.

Finally she wants to add “We discovered Lindor and their special mixers on the Internet and are very satisfied. The cooperation with Lindor was very good right from the start and the mixer functions without any problems.”

L4000 mixer with special configuration for very abrasive products The CeramTec mixer is of Lindor type L4000 (4000 litres useful mixing volume – approximately 2000 kg) and configured for this very abrasive material.

The most important property of the Lindor mixer for this application is that the actual wear in the mixer is minimal. Three elements create wear: an abrasive substance, movement and force. In this application there is plenty of abrasive substance present in the form of SiC. The movement is also present, though mainly in the form of the SiC particles rolling over the SS surface of the mixing drum and over one another. The force is however minimal so the wear is also ultimately minimal.

72 • January 2016

About CeramTec CeramTec is a company that has been producing technical ceramics for over 100 years. After having been part of the German Chemical group Hoechst in the 80s and 90s it became independent in 1996. The company now has around 3600 employees and branches in 17 countries. CeramTec serves the automobile, electronics, medical, energy and environmental technology industries as well as mechanical engineering. In Šumperk among other things gaskets (for example for ships, including the Queen Mary II), sprayers, burner components (up to 1600°C), bearing bushes, armoured elements, etc. are made.

More information www.ceramtec.cz.

on

CeramTec

can

be

found

on

Kiron Hydraulics Needs Pvt. Ltd 167, Readymoney Terrace, 3rd Floor, Dr Annie Besant Road, Worli, Mumbai – 400018 Contact No: +91-22-24936968/ 24937330 E:Sales@FPTindia.com Chemical Engineering World

4076

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Planex System: Multi-patented paddle vacuum dryer with ZeroFriction® planetary movement eccentric agitator

CosmoDry System: Paddle vacuum dryer with concentric agitator, fitted with a shaft dismountable in sections.

Agent for vacuum pumps

Your vacuum drying specialist marketing@italvacuum.com italvacuum.com

EMJAY ENGINEERS, Mr. Jayant Joshi B/102, Shubh Sarita CHS, Near Shrikirshna Nagar, Appasaheb Sidhaye Marg, Borivali (East), Mumbai 400066 Tel. 02228975275 Mobile 9820047858 E-mail:electromech.engg.entp@gmail.com

CEW Features

Company Profile

Poly Plast Chemi-Plants (I) Pvt Ltd

P

oly Plast Chemi-Plants (I) Pvt Ltd, is one of the Pioneers and leading manufacturers of high performance anti corrosive engineering plastic and fibreglass reinforced FRP/GRP equipments, which have got a wide application in all industries, where corrosion is main problem.

Poly Plast is fabricating chemical equipments in fiberglass reinforced plastics (FRP) and dual laminates in India since last 49 years. We are ISO 9001:2008 certified company.

Our history spans 49 years of dedicated quality supplies of FRP/GRP/thermoplastic equipments, pipes and fittings to the following spectrum of industrial segments: • Chlor-Alkali • Chemicals, Agrochemical and Pesticides • Bulk Drugs and Pharmaceutical Fine Chemicals • Acid Oil and Soap Industries • Pulp & Paper Industries • Ferrous & Non – Ferrous (Steel, Copper, Zinc, etc,) • Power Generation Plants The company has evolved to be a leading manufacturers of thermoplastic and thermoset equipments and piping having wide spread clientele throughout India and overseas countries like Denmark, Egypt, Saudi Arabia, UAE, Morocco, Malaysia, Bangladesh, Pakistan, Iran, Nepal, Oman, Singapore, Canada, etc.

We are working with following consultants and EPC Contractors: • TKIS India Pvt Ltd • Outotec • Larsen & Toubro Ltd (ECC Division) • Simon India Ltd • TATA Consulting Engineers Ltd • TOYO Engineering India Ltd • Technimont ICB Pvt Ltd 74 • January 2016

• • • • • • • • • • • • •

Aker Solutions JACOBS H & G Pvt Ltd SPB Engineering & Project Consultants Mott MacDonald Pvt Ltd Protech Consultants Pvt Ltd Gammon India Pvt Ltd Shroff & Associates (Engineers) Pvt Ltd Demech Consultants Aevitas Pharmagro Tech Pvt Ltd Chemtex Global Engineers Pvt Ltd Pipecon Consultants Pvt Ltd IBI Chematur Ltd Gunnebo India Pvt Ltd

We have two spacious and well equipped units of Poly Plast Chemi-Plants ( I ) Pvt Ltd at Bhiwandi and Khardi totalling approximately to 11 acres area.

Our testing facilities include a modern lab to test physical and mechanical properties of all input materials as well as final products. Our products are also subjected to destructive and non-destructive tests periodically.

Product Profile We design and manufacture the following equipments and systems in accordance with BS, ASTM, DIN and various other international standards as required by clients/consultants.

• Storage Tanks for Chemicals/Gasses, Reaction & Process.

• Ducting, Blowers and complete Exhaust systems.

• FRP/GRP Gratings, Pipes and Fittings.

• Vaccum Nutsche Filters and Scrubbers etc.

• Any other tailor made equipments/ components as per your requirement.

Poly Plast achieved its performance prominence in the field, by strict adherence to the quality in manufacturing, as well as by its commitment to serving client’s need with the services necessary to ensure the

performance of the equipments & piping system.

Poly Plast provides engineering, installation, logistics support and commissioning services as a part of its single point responsibility.

Poly Plast is also known for fast supplies and timely execution. Poly Plast, having more than 4 decades experience in the field, offers services to its customers by helping them to select proper material of construction, for their chemical and service conditions.

This way, many a time, a good amount of saving is made by our clients by choosing proper material of construction, at optimum economy scale.

In quite a few cases, costly conventional materials such as Titanium, Hastalloy-C, Nickel, Glass lined equipments etc. has been replaced and thus substantial saving is made by our customers. That is why we have been continuously patronised by our valued customers and as a result our sales turnover has increased by leaps and bounds.

Our excellent quality, competitive pricing, prompt customer service couple with an ongoing R&D process has been the hallmark of our products and services thereby earning a continued patronage of our esteemed clients/consultants.

Needless to say, we are on the approved list of all leading and reputed engineering consultants, EPC Contractors as well as several hundreds of end users.

Chemical Engineering World

Features CEW Company Profile

Proactive Engineering Services

P

roactive Engineering with a boost of ASNT Level II and III Engineers team is a leading manufacturer in Fabrication of Coded and non-Coded equipment’s on the basis of vast experience and certifications and approvals. Our main focus is to fabricate and manufacture errorless equipment’s & skid mounted systems, under observation of qualified and certified engineers. The accumulated wealth of knowledge and experience of working on different methods and standards of Fabrication with proper quality control, available at that time has put to good use for better equipment manufacturing along with upgraded technology: • ASME ‘U’ stamp accredited manufacturing workshop • Continual Quality Up gradation towards fabrication process • Best workmanship • A ‘ISO 9001:2008’ certified company • Equipment fabrication to be done under observation of ASNT Level II and Level III engineers • Systematic Approach, Quality Products, Transparent Business Relations, Appropriate Delivery period are the main features of ‘Proactive’ Fabrication of equipment’s passed through qualified engineers and complies towards best Products. These became a specialised field of operations for ‘Proactive’ customer-need of ‘single-point responsibility’, made it imperative for ‘Proactive’ to expand our field of operation from Manufacturing to a ‘Total Solution Company’. Utilised our expertise towards solutions for customer need and requirements.

We worked as an equipment manufacturing industry for various segments such as, oil & gas industries, pharmaceutical, fertiliser, distilleries, sugar, agro, and other chemical process industries. With the thrust on continuous up gradation and innovative ideas, coupled with sound basic fundamentals, ‘Proactive’ developed its own manufacturing industry. Sincerity, innovativeness, genuine concern for customer needs, reasonable costs and prompt services are the main texture of Proactive.

Today, ‘Proactive’ catering supply and services at following . . .

Manufacturing of equipments :Oil & Gas: Bio-CNG Plant Equipment’s, Odorising Tank, Gas to Gas Exchanger, Skid Mounted System.

Pharmaceuticals: Reactor, Kettle, Agitated and Limpet Coil Equipment’s, Condensers, Reboilers.

Fertiliser: Nitration Skid Mounted System, Chlorination Distillation System, Packed Column, Main Condenser, Evaporators, Sulphur Scrubber.

Chemical Engineering World

Other Chemical Industry: Shell and Tube heat exchanger, Multipurpose reaction systems, Scrubber, Stripper Column, Distillation Equipment.

Distillery Equipment, Malt Plant Equipment’s, Pot Still, Recovery Systems, Menthol, Acetone, Ethanol, Refinery, many more Tailor made Equipment and Cat-Walk Platform.

Capability to augment Third Party Inspection as and when needed.

Follow all the steps towards quality - raw material inspection by PMI • Raw material inspection by check test at approved laboratories for mechanical properties • NDE Test carried out as per QAP - RT, PT, VT, MT, UT • As per design, Hydro or Pneumatic test • Pre-delivery Inspection and Dispatches along- with proper quality dossier The company has established in 2012, well-equipped manufacturing facilities at Chakan Industrial zone – Pune India. ‘Proactive’ central co-ordination office set up at Warje Pune - India to carry out for coordination. A top-notch professional in different fields associates with us for mechanical design and engineering, process design, and work together to ensure smooth operations and customer comfort towards total solution. ‘Proactive’ has created a unique place for itself in the field of equipment manufturing for fabricated process equipment’s and skid mounted systems.

Proactive Engineering Services 705, Prestige Point, Wing-B Near RMD Sinhgad College, Pune-B’lore Highway Warje, Pune – 411 058.

M: +91 8805786706, +91 9860100004 E: dhananjay@proactives.net W: www.proactives.net January 2016 • 75

CEW Features

Company Profile

Remi Process Plant & Machinery Limited

W

e would like to introduce our selves as Remi Group consisting of several companies manufacturing wide range of products. Our range of products include agitators, stainless steel tubes/ pipes, motors, geared motors, laboratory instruments and consumer durables.

Remi Process Plant and Machinery Limited is engaged in the field of design, manufacture, testing and supply of agitators.

A brief introduction of our Company is given below.

We have established ourselves as the leader in the field of design manufacture, testing and supply of various types of energy efficient agitators for mixing liquids and liquid-solids.

Swivel Type side entry mixer

REMI is an approved vendor to all consultants in the country and also has a distinction of supplying critical agitators to the Indian process industry. We are in the field for more than three decades and our agitators have been working satisfactorily for years in all process industries.

We have so far designed, manufactured and supplied Agitators upto 225 KW capacities and with shaft length upto 19 metres. We also have the capacity and capability to design even higher than specified above.

Our Agitators have been working satisfactorily for years in the field of mineral and ore processing industries, polymer ,agro chemicals, oil drilling industry, refineries, petrochemicals, fertiliser, pharmaceuticals, paper chemicals, paint, breweries, food, dairy, effluent and water treatment plants, etc.

We have the distinction of supplying critical agitators to all type of Indian process industry 76 • January 2016

Figure 1: An automated breakthrough analyser

through international and Indian inspection and consultancy organizations like Engineers India Ltd, Uhde India Ltd, Aker Solutions, Jacob’s Engineering India Pvt Ltd, Toyo Engineering India Ltd, Technimont ICB Pvt Ltd, Technip India Ltd, etc.

Remi’s quality management system has been assessed and approved in accordance with the requirement of ISO 9001:2008 by Indian Register Quality System accredited By The Dutch Council For Accreditation (RVA) and has been awarded the Certificate of Approval

No. IRQS/ 1010331 for design, manufacture and supply of Industrial Agitators.

For any kind of assistance and enquiries, please feel free to contact us at: Remi Process Plants and Machinery Ltd Remi House, 11, Cama Industrial Estate Goregaon (E), Mumbai 400063, India T: +91-22-40589802/888 | +91-22-26853868 M: 09324802467 W: www.remigroup.com Chemical Engineering World

Features CEW Company Profile

Samson Controls Pvt Ltd (SCPL)

S

amson Controls Pvt Ltd (SCPL) is 100 per cent owned subsidiary of Samson AG, Frankfurt, established during 1964 as manufacturing unit for the following products :1) Globe Type Control Valve 2) Self-Actuated Pressure Regulating Valve 3) Self-Actuated Temperature Regulating Valve 4) Differential Flow Meter 5) Pneumatic / Electrical Analog Type Positioner SCPL imports following products from Associate companies of Samson AG. 1) Butterfly valves, Ball valves and Segmented Ball valves from LEUSCH GmbH 2) PTFE/PFA lined valves, butterfly and ball valves, Pigging systems from PFEIFFER GmbH. 3) Rotary Plug valves and Actuators from VETEC GmbH 4) Piston Actuators from AIR TORQUE SpA. 5) Ball valves for Petro chemical Applications from STAR LINE SpA. 6) Ceramic Ball and Gate Valves from CERA GmbH. 7) Engineering, low-power solenoid valves and limit switch units from Samsomatic GmbH 8) Diaphragm Valve for Aseptic application from SED Flow Control GmbH 9) On/Off, Critical/Non Critical, Manual - BALL VALVE,ON/OFF, Manual - Gate Valve, On/Off, Manual - Plug Valve, Manual and High Pressure Critical Globe Control Valve from Ringo Valves.

Samson AG, located in Frankfurt Main, established in 1907 to produce high quality control valves for worldwide distribution.

Samson AG has its presence in 50 countries with over 36 subsidies and 104 engineering and sales offices all over the world. Samson Chemical Engineering World

India (SCPL) has a manufacturing facility at Ranjangaon, Pune, Maharashtra. SCPL has 150 personnel including 9 field sales offices all over India. The project department supports worldwide projects of Samson and offer various services to EPC’s, PMC’s and other engineering companies.

Manufacturing Facilities: SCPL has state-of-the-art in house manufacturing capabilities. Our machine shop has several CNC, VMC, HMC, Drilling machines. We have phosphating, degreasing, statfield powder coating, stelliting and other facilities.

Quality Control SCPL an ISO 9001:2008 certified company is equipped for internal inspection, job inspection, final inspection with following test facilities:- hydrostatic pressure test, dyepenetration test, seat leakage test as per ANSI-B16, 104, for leakage upto class VI, Actuator cycle test, CMM, Magnetic particle test, Helium leak test facility by pressure test or by vacuum method, dynamic CV test etc.

Product Approval All the products SCPL produces for local market consumption are well received by Indian market. We produce products in line with Samson worldwide philosophy to have common design and construction.

Once the product is produced in India it is sent to our Principals for various tests and approval before we officially launch the product in Indian market. We follow drawings and manufacturing practices of Samson AG and thus, do not have separate design department. All products of SCPL are CE marked.

Department of Atomic Energy and its affiliated units, Bharat Petroleum Corporation Ltd, and its affiliated units, Hindustan Petroleum Corp Ltd, India Oil Corporation Ltd, National Fertilizers Ltd, Rashtriya Fertilizers and Chemicals Ltd, Indian Space Research Organisation & SHAR and Liquid Propulsion Space Centre, Tata Steel, Essar Steel, Jindal Steel, Bhushan Steel, Thermax, Praj, BHEL, Bharat Heavy Plates and Vessels Ltd, Akzonobel, Biocon, Teva, Ballarpur paper, Grasim, Bombay Dyeing Bayer, BASF and many more SCPL acquired approval from most of the Indian consulting and contractor’s organisations. To name a few:Engineers India Ltd, Uhde India Ltd, Kvaerner Powergas, Humphreys and Glasgow Consultants Ltd, Development Consultants Ltd, MECON, Ranchi, Technimont ICB Pvt Ltd, Project Development of India Ltd, Baroda and Noida etc.

SCPL has achieved double digit growth for the past few years and is proud of its quality, delivery and services.

SCPL products have been well received for several years by prestigious organisations like :January 2016 • 77

CEW Features

Company Profile

Shachi Engineering Pvt Ltd

W

e, Shachi Engineering Pvt Ltd an emerging in export business unit, takes pride to introducing ourselves as an ISO 9001-2008 certified company. Established in 1998, Shachi Engineering Pvt Ltd - currently associated as a partner in growth with more than 200 companies - has commendable achievements with over 350 installations across 5 countries. We are now entering the European Continent. Operating from Pune, our solutions encompass the entire range of services for chemical, dyestuff, fertiliser, detergent, pharmaceuticals, ceramics, enzymes, herbals, food and dairy industries. Our cumulative experience spans over more than three decades.

We are basically an EPC contractor with our own manufacturing unit at Pune. In addition to this, we have a number of dedicated, qualified and experienced engineers who are involved in design, engineering, fabrication, project execution, erection and commissioning.

We have supplied a number of spray drying plants, flash drying plants, multiple effect evaporators, conical mixers and large numbers of specialised equipment to a number of clients across India and abroad. We are also involved in renovating and upgrading of a large number spray drying plants, flash drying plants, multiple effect evaporators etc. Recently, we have expanded our manufacturing capability by adding few new equipment. We are in position to take additional work of design, engineering and fabrication of process equipment in stainless steel, carbon steel and any material as per the requirement.

The plants and equipment are customised as per the requirements.

78 • January 2016

Our Product Range Dryers • Spray Dryers • Spin Flash Dryers • Cage Mill Flash Dryers • Closed Loop Dryers • Continuous Fluid Dryers • Rotary Dryers • Integrated Fluid Bed Dryer (Cocurrent Flow, Counter-Current Flow, Mixed Flow)

Evaporators • Falling Film Evaporator • Rising Film Evaporator • Forced Circulation Evaporator • Agitated Thin Film Evaporator • Hybrid Evaporator

Spray Coolers • Open Loop • Closed Loop Turnkey Projects: • Zero Liquid Discharge Plant • Milk Powder Plant • Detergent Powder Plant

Allied Products • Mixers – Vertical Cone Mixer/Dryer (Nauta Mixer/Dryer) • Blenders – Ribbon/Online/Double Cone • CIP Systems • Duct Gas Burner For any kind of assistance and enquiries, please feel free to contact us at: Shachi Engineering Pvt Ltd Gat No. 271, Sr. No. 38, A/Po. Bhare, Tal. Mulshi, Pirangut, Dist.: Pune, 412115, Maharashtra, India.

T: +91 20 66546923/905 /936 F: +91 20 66546915 E: marketing@shachiengg.com W: www.shachiengineering.com Chemical Engineering World

Features CEW Company Profile

Sharplex Filtration

S

harplex was incorporated in year February 1993 with a determination to make a mark in Process Filtration Equipment, that are efficient and economical, catering to food, pharma, chemical, edible oil and fertiliser industries.

Sharplex offers the widest and most advanced range of process filtration equipments.

Sharplex recently set up a new state of art manufacturing facility in New Mumbai with a total area of 4500 sq metre. with latest engineering facilities. Filters manufactured in SS, SS 904L, Hastelloy, Titanium, Monel. The manufacturing facilities are approved by M/s Lloyd’s Registers for ‘PED’ (CE) jobs.

Sharplex also have another unit (Unit No.2) at B-21, Digha, Navi Mumbai having total area of 3500 sq. meter and is approved by many third party organisations.

Sharplex also supplied many filters under TUV Certification and with ‘CE’ marking.

Sharplex is equipped with full-fledged CAD centre, sophisticated facility for testing, all regulated by an uncompromised quality policy. Excellent designing skill enables us to offer wide varieties of equipments like vertical and horizontal pressure leaf filters, sparkler filters, polishing filters, candle filters, tubular centrifuges, spiral filter. Sharplex also supplies spare filter leaves for all size of Pressure Leaf Filters.

Applications: In Edible Oil Industry, filters are used for Bleaching Earth Filtration, Wax Filtration, Ni-Catalyst Filtration, Polishing Filtration etc.

In chemical and pharma industries, filters are used for syrup filtration, glucose/fructose filtration, molten sulphur filtration, catalyst filtration, activated carbon filtration, beverage filtration, fruit juice filtration, etc.

In paint industry, Sharplex Leaf Filters are used in alkyd resin filtration.

In viscose industry, Sharplex Candle Filters are used for sump zone filtration, spin bath filtration. In Petroleum Industries Sharplex Filters are used for amine filtration.

Chemical Engineering World

Export: Sharplex have their representatives in many countries and have exported filters to Egypt, Philippines, South Africa, Bangladesh, Kenya, Lebanon, Syria, Taiwan, Zambia, Nigeria, UAE, Turkey, Mexico, Norway, Belgium, U.S.A, Denmark, Bulgaria, Costa Rica, Monaco, Russia, China, Indonesia, Thailand, Sri Lanka, Ivory Coast, France, Israel, Romania, Slovakia, Croatia, Greece, Columbia, Uruguay, Iran, Pakistan, Jordan, Mozambique, Tanzania, Vietnam, Argentina, Malaysia, Netherlands, Singapore, Switzerland, Tunisia, Canada, Azerbaijan, Bahrain, Burundi, Colombia, Congo, Dominican Republic, Ecuador, Georgia, Japan, Italy, Kuwait, Madagascar, Mauritius, Nepal, Panama, Peru, Papua New Guinea, Poland, Qatar, Saudi Arabia, Spain, Syria, Uganda, Ukraine, Zimbabwe etc.

Sharplex Filters (India) Pvt. Ltd. Plot No. R-664, TTC Indl. Area, Rabale MIDC, Navi Mumbai – 400 701 T: +91-22-69409850 | Fax : +91-22-27696325 E: sales@sharplexfilters.com W: www.sharplex.com January 2016 • 79

CEW Features

Company Profile

Shridhan Automation

S

hridhan Automation manufactures Level Instrumentation for worldwide applications in oil & gas, offshore/ onshore, power, steel and mining industries. Our global sales and marketing reach covers UAE, USA, Northern Europe and Far East with diverse sales offices and representative offices.

Finesse in design and reliability are critical success factors for these custom built products. We entered the market with one version of ‘Magnetic Level Switch’. From then on we have been consistently performing in the market with an excellent product range and service backup. To catch up with the growth trend, Shridhan has also entered into the field of Level Measurement for highly critical applications along with the necessary product and system approvals to support.

We manufacture these instruments that are customised as per the application of the customer. Our team of qualified Engineers, Technicians and highly experienced employees constitute to form a superior solution provider to your level measurement needs.

Since 1987, these products were manufactured and marketed under the name ‘Shridhan International’. In 1998, the decision to move to an independent manufacturing facility to strive for the highest level of product quality was taken.

Since then, there has been no looking back.

Our continuous survey of the market and ability to add on products for any liquid level application with various techniques

has been our forte. An essential part of our activities in the last decade has been the systematic and gradual implementation of Quality Control and Quality Assurance Procedures and Programs for our products and systems which lead to enlarging our customer base around the world. In the coming years, we strive to be one of the most reputed brands in Level Measurement worldwide.

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Jasubhai Media Pvt Ltd

Registered Office: Taj Building, 3rd Floor, 210, Dr. D N Road, Fort, Mumbai – 400001, INDIA. Tel: +91-22-4037 3636, Fax: +91-22-4037 3635 Email: sales@jasubhai.com

80 • January 2016

Chemical Engineering World

Features CEW Company Profile

Swam Pneumatics, Noida

S

wam is a leading engineering company and global leader’s specialising in design, engineering, manufacturing, supply of rotary air and gas blowers, truck blowers, centrifugal fans, multistage centrifugal blowers, liquid ring vacuum pumps and compressors, dry screw vacuum pumps, mechanical vacuum boosters, acoustic enclosures, heat exchangers and related equipments.

Swam, a group known for technology, innovation and excellence, has acquired exceptional product design and development capabilities to meet stringent quality and performance requirements and confirm to the customers tough and diversified specifications.

At Swam, emphasis has been on innovative design, precision engineering, advanced technology, excellence in performance and quick responsiveness to customers.

With over three decades of experience, the company has adequately matured to execute different projects and is today represented in over 20 countries say USA, Canada, Mexico, UK, Latin America, China, Iran, Middle East, UAE, Singapore, Thailand, Malaysia, Indonesia, Zambia, Sudan, Sri Lanka, Pakistan, Vietnam, Nepal, Bhutan etc.

Our quality system has been accredited with ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 Quality Standards and procedures. The company’s head office and works are located at Noida near New Delhi, the capital city of India. The company has FOUR manufacturing plants equipped with CNC Machines and in-house testing facility up to 1000KW. Our highly motivated engineers and work force faces each contract with commitment to meet the client process specification and quality requirement. The company has Chemical Engineering World

executed many prestigious projects under the stringent quality compliance.

The company’s quality system is accredited with ISO 9001:2008, ISO 14001:2004, OHSAS 18001:2007 and is CE certified.

Product Testing and Quality Systems Swam, an ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 certified company and therefore quality and safety are always the priority to maintain desired standards.

Besides this all our products comply to international Standards and are CE certified.

The quality control is practiced at all levels in the organisation and in general the quality level is maintained through the established quality manuals and plants. This also follows the quality control manual and procedures drawn out for ISO-9001:2008 quality certification.

Swam has in-house testing facility for testing Blowers, Compressors, Vacuum Pumps, Centrifugal Fans etc, with a number of test

beds. Each product made to run for several hours as per the standard and codes before taken for painting and dispatch, varying voltage ie, the company has in-house testing facility up to 1000KW for voltages ranges up to 415V, 690V, 3.3KV, 6.6KV.

For any kind of assistance and enquiries, please feel free to contact us at: Swam Pneumatics Pvt Ltd C-2, Sector-3, Gautam Budh Nagar, Noida 201301, Uttar Pradesh, India T: +91-120-4696222/ 2527610/ 4696252/ 4696253/4696222/4276224 F: 91-120-2443283/4696200 W: www.swamatics.com January 2016 • 81

CEW Features

Company Profile

Teadit India

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ith more than 50 years of technology and experience in the sealing industry, TEADIT has manufacturing plants in Austria, INDIA, USA, Germany, Brazil, Argentina and China. It holds a worldwide distribution network spanning across 70 countries in five continents. Teadit is recognised as a world leader in the development and manufacturing of innovative fluid sealing products for the industrial segment. Its name stands for competence, quality and innovation and its products are known for their excellent performance and reliability even in the most demanding applications. “We must always innovate and try to become better to meet and exceed our market demands” says Carlos D Girão, Managing Director, Teadit India.

Production Plants in India Teadit has recently unified their two plants in Vadodara, Gujarat. Here they are manufacturing high quality and top grade gland packings as well as metallic and non-metallic gaskets. The two facilities with more than 50,000 ft² are adjacent to each other to enhance their efficiencies and managing capabilities.

Girão explains that the desire for a quality product and premium services is high, which is why the company had initially built plants in India and has now recently expanded into the metals operations.

In the past, Teadit has manufactured items such as gland packings and non-metallic gaskets. Now, however, these have been combined with the metals operations on their new facility in Vadodara. “We made significant investments over here from personnel, to equipment and inventory in order to bring a stronger focus on the end users.

Our plants have state-of-the art production equipment and capacity to respond fast to customers’ demands and urgencies. We want to become the reference for high quality fluid sealing solutions in the Indian market”.

Being a leader in the latest research and development trends is just one way that Teadit stands apart from their competitors. Teadit has a vast product line that includes structured PTFE and expanded PTFE joint sealants as well as gland packings, CNA fibre sheets, camprofiles, spiral wounds and double jacket gaskets among others. “Such a broad variety of products and the deep knowledge and understanding of the products allow us to specify the right solution for the customer’s needs instead of just offering one that is available”, says Akhilesh Pathak, Sales Manager - West India Region, Teadit. “We provide comprehensive technical support to our customers, including product information and technical data, installation instructions, product training and seminars, gasket bolting calculation tools, etc. This helps our customers and industry partners in diagnosing their different fluid sealing needs and challenges” he completes.

Teadit India plants are ISO 9001 certified. They have been recently registered with EIL and UDHE and are awaiting approvals from other well known consultants who had already audited the facilities.

Competing with New technologies Teadit leading edge products for Low Emission, Oxygen Service and Highly Abrasive Pump applications showcase its innovative profile and development capabilities. Their packing Style 2236 has a highly rated API 622 approval with 2ppmv average measurement throughout the whole test, as well as ISO 15848-1 Class A, API 607, TA-Luft, among others and they have recently developed Style 2238-OX for use on high demanding Oxygen Services.

82 • January 2016

For any kind of assistance and enquiries, please feel free to contact us at: Teadit India 381/382, Savli GIDC Estate Manjusar, Vadodara – 391775 Gujarat, India T: +91-2667-653871 E: mail@teadit.in W: www.teadit.in Chemical Engineering World

Features CEW Company Profile

Testo India Pvt Ltd

T

esto AG, is a world leader in design, development and manufacturing of electronic portable test and measuring instruments. Backed by more than 58 years of measurement engineering experience, Testo as a group is headquartered in Lenzkirch in the Black Forest region of Germany.

The company has been privately owned since inception. Today, Testo has 2500 employees, 30 subsidiaries and more than 80 representatives worldwide.

Established in 2006, Testo India Pvt Ltd, a 100 per cent subsidiary of Testo AG has shown phenomenal growth over the last seven years with its head office in Pune, 13 home offices in major cities and an extensive channel partners’ network across the country.

We are committed to provide best solutions and services to our Indian customers.

Our mission is to provide the best quality, service and value in the industry. In addition, Testo is recognised as the leading worldwide manufacturer of portable combustion efficiency analysers.

Testo has also become a major supplier for HVAC industries, refrigeration, airflow and environmental monitoring instruments for markets as diverse as chemical, food and beverages, pharmaceutical and biotech, steel and power, automotive industry and many others.

Our Motive: At Testo, we exactly understand the customer requirements; therefore, a central task is to pay constant attention to new technology and therefore our highest priority is Innovation.

We, as a market leader take everything concerned with the product seriously: service, support and availability. We commit – before sale, after sale and in all phases of application.

Chemical Engineering World

Products Testo India offers a wide product range that includes: • Portable Measuring Instruments & Systems for: Temperature, Humidity, Dew point, Pressure, Air velocity, RPM, Sound, Light, Compressed Air Flow • Data Loggers and Wireless Data Monitoring System • Portable Flue Gas Analysers for Combustion and Emission Analysis • Thermal Imagers for Predictive and Preventive Maintenance

serviced locally maintaining international standards. All calibrations are traceable to highly accurate international standards of the PTB Germany.

Testo offers quality standards and up to two years warranty on all its instruments. For more information, please log on to www.testo.in

For any kind of assistance and enquiries, please feel free to contact us at: Testo India Pvt Ltd Plot no 23, Sind Society, Baner Road, Aundh, Pune 411007, India T: +91 20 65600 203 F: +91 20 25850 080 E: info@testoindia.com W: www.testo.in

Service and Calibration: Located at our Head Office in Pune, Testo India has a high quality service and calibration lab accredited by Germany. Instruments of any brand/make can be calibrated and

We undertake calibration jobs for temperature: contact as well as non-contact, humidity, pressure, air velocity, RPM, sound, flue gas and dew point instruments of any brand/make.

January 2016 • 83

CEW Features

Company Profile

VEGA India Level & Pressure Measurement Pvt Ltd

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EGA Grieshaber KG is a worldleading supplier of level, switching and pressure instrumentation. With over 5 decades on our journey to achieve this strong position, the company always had one basic objective ‘the development of innovative, market leading products’.

Established in 1959 in the Black Forest, VEGA today employs over 1200 people world-wide, more than 600 of whom are at the company’s headquarters in Schiltach.

With a vision of establishing a global footprint and also looking at the growing market needs for level and pressure measurement instrumentation in the Indian sub-continent, VEGA Grieshaber KG in May 2011 formed the company VEGA India Level & Pressure Measurement Pvt Ltd in India.

VEGA India is a wholly owned subsidiary of VEGA Grieshaber KG with its head office in Pune Maharashtra. VEGA India will be responsible for the Marketing, Sales and Service of measuring instruments of VEGA Grieshaber KG Germany.

With a Team in India who will be technically and commercially competent and have extensive application and industry knowledge we strongly believe that we will be in a position to live up to the Global standards of the VEGA Grieshaber group.

VEGA India will provide comprehensive solutions to level and pressure measurement applications. Committed to the ‘VEGA SERVICE’, we offer instrumentation that not only excel in performance and quality, but is also backed up with years of experience gained in the industry.

In the coming future, VEGA India intends to start a assembly manufacturing of its devices in or around Pune. The modular or flexible 84 • January 2016

design concept called the ‘Plics’, helps reduce the manufacturing time and faster delivery of its products. This flexible possibility of combining sensors, process fittings, electronics and housing simplify instrument selection and project planning, cost reduction for the customer hence starts at the planning stage already.

Product Profile to be displayed / Showcased: Level Continuous Measurement: • Radar • Guider Microwave Radar (TDR) • Ultrasonic • Capacitive Level Switching: • Vibration • Capacitive • Radar • Conductive Pressure Measurement: • Process Pressure • Hydrostatic • Differential Pressure

Radiation Based : • Continuous Level • Density Measurement • Flow Measurement (WEIGHTRAC) Signal Conditioning Instruments Indicating Instruments Wireless Communication Separating and Protective Instruments Software & Accessories.

For any kind of assistance and enquiries, please feel free to contact us at: VEGA India Level & Pressure Measurement Pvt Ltd 3 B, 3rd Floor, Mutha chambers II Senapati Bapat Road, Shivaji Nagar Pune : 411 016 T: +91 20 41484148 F: +91 20 41494149 E: info.in@vega.com w: www.vega.com Chemical Engineering World

Features CEW Company Profile

Garlock India Pvt. Ltd

F

or more than 128 years, Garlock has stood at the forefront of fluid sealing technology. Garlock India Private Limited is located at Pune, Maharashtra to serve the customers faster.

Garlock is acknowledged as the global leader in high-performance fluid sealing products, committed to a culture of safety by making the world safer, sustainable and more reliable.

Our product range includes Gylon and Bluegard sheets and gaskets, premium grade rubber sheets and gaskets, metallic gaskets, spiral wound gaskets, mechanical seals, valve stem packing’s, braided packing, valve and pump diaphragms, klozure oil seals and bearing isolators, inflatable seals, expansion joints, high performance metallic seals etc.

Every Garlock product is specifically designed, constructed and tested to ensure a longer operating life, leading to lower cost, higher safety and real bottomline savings consistent with Life Cycle Costing (LCC) programs.

Our major area of working is oil and gas industries, fluid power industries, nuclear power and cryogenic industries, chemical, food processing and pharmaceutical industries, agrochemical and fertiliser industries, space and aeronautical industries, valve, pump and rotary equipment manufacturing industries, steel and cement industries, mining industries, pulp and paper industries, hydroelectric industries, wastewater and water treatment industries, power generation industries.

We have sealing products as per FDA norms certified as per various Chemical Engineering World

global norms including phthalate free products for food processing and pharmaceutical industries.

Garlock has wide range of pipeline products to be used for sealing as well as cathodic protections in the processing industry.

Garlock also provides Fugitive Emission Leak Detection surveys and bring down these emissions below 100 ppm levels with high performance special design valve stem packings.

Garlock THERMa-PUR metallic and nonmetallic gasketing products can handle challenging temperatures of 1000 OC.

With the most complete in-house testing facilities in the industry, Garlock can provide test verification documentation for your sealing solution, based on your specifications, or any industry or government standard.

Beyond offering you the widest available range of products for packing and sealing, Garlock enhances the value of its products with technical services and comprehensive training programs.

Customers who specify Garlock fluid sealing products get, at no extra cost, the high quality support needed to run a profitable and safe operation.

Garlock also offers Expansion Joint surveys in the plant and provide the solutions. Our newly developed ABRALINE style 404 best suit for highly abrasive applications typically found in power generation, fertilisers, mining and chemical industries.

With our dedicated team of application engineers, we can recommend, design, manufacture and supply any customised product to suite your application.

Our Application Engineering Department will partner with you to develop and test solutions for your toughest sealing applications whether you are in design stage for a new project or trying to solve an existing problem.

Garlock’s strong capability to research, development of new materials makes us serve new and challenging sealing applications of the industry.

For More details, please contact: GARLOCK India Private Limited, Plot No 21, “S” Block, MIDC, Bhosari, Pune, India- 411 026 T: +91 20-30616608 | F: +91 20-30616699 W: www.garlock.com January 2016 • 85

CEW Features

Company Profile

Lab Systems & Biotech (India) Pvt Ltd

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ab Systems & Biotech (India) Pvt. Ltd. is now a 24 years old experienced organisation that has been delivering Laboratory Solutions to various Industries like Pharmaceuticals, Biopharmaceuticals, Chemicals, Petrochemicals, Packaging, Research and Development Institutes etc.

The company had also slowly diversified itself in business of offering process solutions as the market also started moving towards online Real Time monitoring and measurements. Lab Systems & Biotech (India) Pvt. Ltd. is proud channel partners to the companies that are global leaders in their field of online process monitoring and measurement solutions. As the team of Directors of the company come from technical background, appropriation solutions are offered for optimum price to performance ratio .

The company is proud to have an association with ABB Limited for about 10 years now for promotion of their range of Process FT-IR/FT-NIR Solutions that are widely used by reputed companies like Reliance Industries Limited, Styrolution ABS, Dr Reddys Laboratories, Cipla Limited, Manali Petrochemicals Limited, Essar, GE etc, in India for various applications. The FT-IR/FT-NIR solutions is packed with patented interferometer design that offers the best in class Signal to Noise Ratio and highest Photometric Accuracy that allows real time quantification of various chemical properties both for Atline and Inline mode for all sample types like Powders, Liquids, Semi Solids, Gases etc. The Analysers from ABB Limited are also offered with communication and control devices that allows complete un attended operations to achieve high accuracy in process control that offers optimum productivity.

86 • January 2016

ABB make FT-IR/FT-NIR Solutions are also global benchmark for various space and satellite applications due to its maintainance free design and its high accuracy and reproducibility that offers cloning results that help us scaling the applications from laboratory to process.

Also, ABB make FT-IR/FT-NIR PAT solutions are globally acclaimed. ABB offers various ready to use solutions for various Industries like pharmaceuticals, chemicals, petrochemicals, packaging to qualify and quantify properties both at Lab Scale and in Production Process that helps customers optimise their productivity which in turn helps customer to inmprove on their top line and bottom line.

The vision of the company is to have sustainable growth through high quality low maintenance solutions to its customers that would offer excellent Return on Investments, that would surely bring a win – win situation. The ideology of company is crystal clear that there is no better business growth than a satisfied customer.

With of success story of 24 years of journey of offering analytical and process solutions, the company looks at still milestones to come.

With the Environment Ministries and Regulatory Authorities going more stricter on the compliance part to improve better synchronisation between Industries and green human living, Lab Systems & Biotech (India) Pvt Ltd also has played a vital role in helping their customers to comply with the latest guidelines of Central Pollution Control Board by offering Real Time Online Water Effluent Quality Monitoring and Stack Monitoring Systems again from one of the world’s leading companies.

The company is whole heartedly thankful to all its customers for their trust in the company by offering repeated valuable orders for various solutions. With the prompt after sales support and solutions through innovative ideas the company is always striving hard to be updated in offering solutions and support to the customer that would offer optimum price to performance ratio. The company strongly believes in expansion of business also through repeat order.

Lab Systems & Biotech India Pvt Ltd 329, Royal Palms, Mastermind, Phase IV Aarey Milk Colony, Goregaon (E) Mumbai - 400065 T: +91 22 3251 4134 E: info@labsystems.in W: www.labsystems.in Chemical Engineering World

Features CEW Company Profile

Carborundum Universal Limited (Cumi)

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USD 500 million company, CUMI was incorporated in 1954 as a tripartite collaboration between the Carborundum Inc, USA, the Universal Grinding Wheel Co Ltd, UK and the Murugappa Group, India. A pioneer in the manufacture of coated and bonded abrasives in India, CUMI has been an innovator in super refractory materials, electro minerals, industrial ceramics and ceramic fibers.

With customers in 43 countries across the globe, Carborundum Universal Limited (CUMI) is a one-point source for over 20,000 varieties of abrasives, electro minerals, ceramics and refractory materials, manufactured at 25 locations across Australia, China, India, Russia and South Africa.

All of CUMI’s manufacturing facilities are certified for international quality standards (ISO 9001:2000) and environment-friendly manufacturing practices (ISO 14001). Stateof-the-art facilities and strategic alliances with global partners have earned CUMI a reputation for quality and innovation. It is one

of the few manufacturers of abrasives and ceramics in the world with fully integrated operations, from mining, through fusion.

CUMI is equipped with a state-of-the-art Research and Development centre which works aggressively on product development and efficiency enhancement. Its in-house R&D and collaboration with leading research institutions have ensured market leadership in India and abroad. CUMI has, in place, manufacturing practices like Lean and Six Sigma to improve its cost competitiveness.

Power Distribution, Cement, and Mineral and Ore Processing industries. The division provides design and installation support in addition to product supply.

Industrial Ceramics division of CUMI is dedicated to manufacturing hi-tech ceramics for industrial applications. The products can be broadly classified into Wear ceramics, Engineered ceramics and Metalised ceramics.

The wide array of products serves a range of industrial applications: • Ceramic Tiles • Coal-based Power Generation • Coal Preparation Plants • Cement • Steel • Mineral processing • Chemical and fluid handling equipment • Defence (Personnel and Vehicle Armour) • Textile • Gas & Oil based boilers • Non-Ferrous Molten Metal • Power Distribution • Pulp and Paper

The industrial ceramics division specialises in the manufacture of wear limiting products, grinding media, liners and engineered ceramics catering to critical and demanding applications in the Armour, Ceramic Tile, Non-Ferrous, Steel, Power Generation,

Carborundum Universal Ltd Industrial Ceramics Division, Plot No 47 & 48 (Part), Sipcot Industrial Complex, Hosur – 635126.

T: + 91 4344 304748 M: +91 9445660961/ 9909974154

Grade

Salient Features

Products

CUMITUFF® 90

Excellent wear and abrasion protection properties

Standard and pre-engineered tiles, small / dimple tiles, isopressed components, lined equipment’s, rubberized ceramics

CUMITUFF® 92 CUMITUFF® CSP

Excellent wear and corrosion resistant for bulk application

CUMITUFF® 94

Metallised ceramics, excellent mechanical and di-electric strength

Metalized vacuum circuit breaker, metallised devices for electrical application

CUMITUFF® 95W

Good wear and corrosion resistant

Igniters and water pump seals

CUMITUFF® 98

Excellent ballistic performance

Armour for ballistic protection

CUMITUFF® 995

Excellent wear, corrosion resistant, outstanding ballistic performance

Body / vehicle armour, mechanical seals, textile ceramics, SOFC envelopes etc., and other engineering ceramics

CUMITUFF® 998

Very high purity, heat and corrosion resistant

Lab-ware, ferrules, furnace parts and components

CUMITUFF® YSZ / Excellent impact, wear and corrosion resistant tough ceramics MgSZ CUMITHERM™

Battery tooling, wire drawing dies, mud-pump liners, step cone pulleys

Excellent thermal shock resistance, non-wettability to molten non- Dosing tube, riser tube, sprue bushes, tap-hole ring and plug, ferrous metal and insulating ceramics spout and other non-ferrous melts holding and conveying parts

Chemical Engineering World

January 2016 • 87

CEW Features

Company Profile

G.A. Kiesel GmbH

G

A. KIESEL GmbH is a manufacturer with a long tradition founded in 1864.

Until today we have grown to a medium-sized family business with highest competence for pig cleaning systems, pumps, engineering and plant constructions.

KIESEL PIG CLEANING TECHNOLOGY consists of high quality components, e.g.

Fittings (Sending- and Receiving Stations, Product in- and outlets, Switches, Bypasses, Manifolds, Dosing Valves, Filling Valves, piggable loading arms,…), pipes, shaped fittings, pipe connections, mounting brackets/ sliders, pigs from DN 25 to DN 250 (silicone, PU, viton, …).

G.A. KIESEL GmbH offers solutions for transfer of emulsions, liquid chocolates, paints, chemicals, resins, adhesives, lubricants, liquids, cosmetics, pastes, creams, etc. by which multiple products or raw materials can be transferred from the same pipeline. Such solutions have been provided by Kiesel to various companies worldwide.

Pig cleaning technology is a cleaning technology for pipes, suitable for different branches of industry that need to convey high or low viscosity products so that common pipeline can be used to convey multiple liquids.

Principal advantages from KIESEL pig cleaning system: • no product loss: product is completely pushed out by pigs • higher productivity in each pipe because of the shortened time for product-change • low costs for cleaning by reduced use of rinsing agents • low waste management costs: reduction of mixture from product and rinsing agent 88 • January 2016

The Company G. A. KIESEL produces and supplies pigging systems successfully over 30 years for all industry branches.

We can offer solutions in fluid transfer: • to transfer multiple products in the same pipeline • to avoid foaming of products in pipeline.

• for complete recovery of product from pipeline • to reduce effluents generation and thereby bring down treatment costs.

• to optimize piping and storage Our branch-specific manufacturing make ever more possible to integrate the pig system with CIP-/SIP cleaning processes. With our high tech processing of stainless steel, we produce high precision apparatus, fittings, pumps and pipes, especially for the conveying-, pig-cleaning- and beverage-technology.

The KIESEL portfolio covers individual components up to complete systems accompanied by the most modern operational techniques for the following industries:

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degree of cleaning (for pharmaceutical/ biotech to chemical industry).

From simple manual pigging lines to fully automatic piggable distribution systems and specialized applications of dosage and small dosage (as small as 1 g).

Minimized product loss, as product is discharged (pigged) with the exception of a biofilm (1 μm) Lowest wear out of pigs by smooth pig movement (pig speed regulator) Replaces coupling stations for truck-/ ship-loading and unloading as well as manual hose distribution Smallest amounts (as small as 0,4 g) can be exactly dosed and added.

Almost no product loss due to dead room minimized fittings, distributors and pipes Shortest cleaning and maintenance periods Reduction of cleaning expenditure due to minimized usage of cleaning medias Space saving due to compact construction and low demand of pipe lines

- Industrial Pigging Systems for: • Chemical Industry • Paint, Lacquer and Varnish Industry • Petrochemical Industry - Hygienic Pigging Systems: • Cosmetics industry • Food / beverage / dairy industry • Chocolate and confectionery industry • Pharmaceutical and biotechnological industry Advantages of pig cleaning systems by KIESEL: • KIESEL specialized in industrial pigging application in the production environment (1 – 50 times a day).

• KIESEL implements worldwide pigging systems from the highest to the lowest

G.A. Kiesel GmbH Germany M: +91 83088 20242 E: s.pawar@kiesel-online.de W: www.kiesel-online.de Chemical Engineering World

Features CEW Interview

Converting Loss into Gains through Export I n t e r v i e w o f K L A r o r a , C h a i r m a n a n d M a n a g i n g D i r e c t o r, Kay International

1. Please share a brief history about the company and apprise us of the company’s performance in the last 10 years.

Kay International limited is an ISO 9001:2008, company with mastery in pressure and vacuum technology. Being a part of the forerunners of India’s post independence breed of entrepreneur professionals, I founded the company in 1966. Kay began its operation in 1966 as a micro unit with small infrastructure and after gradual improvement, currently the company is spread over an area of 45000 square metres at Haryana state industrial SIIDC in Rai and Kundli respectively, having 400 employees. The company is led by subject experts of the field of design and development, manufacturing and quality based at works and six sales cum service centres spanning across the industrial nodes of India. Kay is leading brand in the domestic market and the 4th largest blower manufacturer in the global market.

The gross income of the company increased from ` 190 million in 2005-06 to ` 500 million in the year 2014-15 with target gross income of ` 650 million in year 2015-16. The asset base of the company also increased many a fold with ` 17 million in year 2005-06 to ` 436 million in year 2015-16 with eye on ` 5000 million Vacuum Industry in India.

Addition of New Product The company has developed its own vacuum pumps technology which will add to the revenue of company during the year 201516. The infrastructural requirement remains the same for these product lines. The existing sales and service network will support us for Chemical Engineering World

these products with no increase in overhead cost. The vacuum product we develop and/or going to trade in are:The following products have been added in the current year which will help the company in due course - Dry Vacuum pumping Systems - Liquid Ring Vacuum Systems.

- Medical Air and Vacuum Systems - Power Sector Vacuum systems - Steel Degassing Vacuum systems - Chemical and Pharma Vacuum Systems These vacuum products have application in various industries some of them are listed below.

Key Users/market segment: - Chemical and Process Industries - Steel industries - Food industries - Waste Water Treatment industries - Coating industries - Pharma industries - Cement plant industries - Lightning industries - Semiconductor industries - Beverages industries - Wood industries Most of these are the industries in which we are already supplying our blowers for other applications so we do not foresee any difficulty in penetrating the market for the new product.

The total market for Vacuum Pumps in India is approx. 500 Crore and is growing at the rate of 20 per cent every year with present manufacturing capacity of approximately ` 200 crore only. The sales success story of few of the manufacturer show that they have

been achieving 100 per cent growth in their turnover every year for the last four years.

2. How does Kay International Ltd maintain its competitive edge especially with the tough competition in the Indian process equipment industry?

Our USP being the first, quality and close service support in India and abroad.

We were the first one to setup indigenous design and production of root type blower in India. All other companies competing with us or their promoters were a part of Kay at some point of time in the past.

Kay stands for quality. We use only brands like SKF and FAG in our blowers. We have very stringent quality control process and incur very high quality cost.

The country has been mapped by us into seven major industrial nodes and we have setup our own offices and service centres at all these hub centres.

3. What is the company’s growth strategy for the next 5 years?

We have already set ourselves on the expansion plans by establishing the second and third unit at Kundli industrial area in Sonepat on 6 acres of land making blowers and vacuum pumps with international standards.

The development stage of vacuum products is complete and the company is investing in the production of vacuum machines.

4. Which sectors are the highest revenue churners for Kay International Ltd and which are the sectors the company wants to enter into?

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CEW Features

Interview

These blowers have inescapable use in all industries with furnaces.

All such industries form a part of infrastructural development of the nation ie, industries like thermal power plants, steel plants and cement plants. Twin and Tri Lobe Roots blowers were never made in India after its independence. They were imported from western countries which was source of major foreign exchange loss to the country in its nascent stage. It is because of Kay that this loss to the nation was converted to gain by exporting the product and putting a total stop to import.

The Government of India has imposed a law that whosoever is going to set up an industry or even if he had Industry earlier, he will have to release polluted water in the main line after treatment. In order to follow this law, every industry has to install a water treatment plant in their factory. Now since the blower is a part and parcel of every water treatment plant, there is a huge demand from all industries to meet this new law.

5. Tell us more about Kay International Ltdâ&#x20AC;&#x2122;s memorandum with the South Korean Vaccum Technology giant.

Looking at the quality technology product offered at a competitive cost, many global industrial houses have approached us to shake hands with us. Talks were held with international consultants for joint venture with a South Asian country. It is because of the faith in our quality and productivity that we also have offers from premier South Asian companies for producing their design in India with their branding.

After a lot of deliberation and pursuance, we have established technical tie up with technology giant of South Korea on wide range of primary vacuum pumps and systems. Consequently this has now dragged attention of technology pioneers from Taiwan and other global engineering solution providers to have future tie-ups with us.

6. Kay International has its presence in which markets globally and which markets does it plan to target in the future?

Kay has predominantly been supplying all over the globe partially in direct role and majorly in indirect role through EPC companies and consultants. Kay is targeting Africa as major market in view of the infrastructure development. We have a competitive edge because of cost and so the markets of the American continent and Europe are also lucrative target.

7. What are the companyâ&#x20AC;&#x2122;s future plans?

There is great demand of good quality indigenous vacuum products and systems. The majority of machines are imported in this category. We wish to have joint ventures with foreign partners who are also into similar products. The new plant coming up in Kundli is being exclusively designed and developed for this purpose.

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Chemical Engineering World

Features CEW Interview

India - Developing Country... Needs Sustainable Infrastructure.

Girija Dalvi interviews Yatinder Pal Singh Suri, Country Head and Managing Director, Outokumpu India Pvt Ltd on how the company has performed in the last 5 years, its USP, importance of sustainability for Outokumpu, etc.

Q1. Please apprise us of the company’s progress in the last 5 years, globally and in India?

Outokumpu India – a subsidiary of Finnish steel major Outokumpu, the oldest and among the largest producers of stainless steel products in the world – has been present in India since 2006. We came to India with products and applications which were not present. The initial challenge was to create the market for these new age stainless steel products by enlightening the end user and educating the consultants and the decision makers on the competitive advantages they could derive. Although we have come a long way from that situation but we continue doing this even today since our advanced R&D set up keeps inventing new products and creating new applications every year.

We have expanded our presence in five locations ie, Mumbai, Pune, Baroda, Delhi and Chennai - all stainless steel intensive regions. The stainless steel intensity in the eastern parts of the country is nascent so we are not present there yet. Western India uses close to 52 per cent of the total stainless requirement, 32 per cent comes from the Delhi area and around 15 per cent comes from the South which is growing pretty fast now.

Ever since we started India operations, we are busy educating stakeholders, doing workshops, distributing informative corrosion and welding handbooks and technical specification pamphlets on our superior high end products like Duplex family as well as high performance grades of stainless steel. Oil storage, chemical storage, distribution pipelines, metro coaches, railway coaches, railway wagons, road and rail bridges, skywalks, chemical tanker ships, food processing and desalination are some of the areas where our high end grades are most relevant. Stainless steel rebar usage is another idea whose time has come for use in coastal and hilly regions.

Globally Outokumpu has established itself as a market and technology leader in the sectors using stainless steel.

Outokumpu’s presence in India is primarily relevant for high end grades and higher dimensions which are not manufactured in India. Being the oldest and largest stainless steel player in the world, India definitely needs Outokumpu innovations.

Each process stage sets its own special demands on the materials and therefore it is important that they are chosen with care. Here, we provide some guidance as to which grades are recommended for key oil & gas industry applications. For more specific information, we invite you to get in touch with an Outokumpu sales representative near you.

Q2. How has Outokumpu managed to maintain an edge above the competition in the country? What are its USPs?

Q3. How crucial is ‘Sustainability’ for Outokumpu and in which areas does the company bring in sustainability?

Chemical Engineering World

Sustainability has always been, and continues to be, a key element of our strategy. Outokumpu is a leader in environmental performance in the steel manufacturing segment. Stainless steel is 100 per cent recyclable, corrosionresistant, durable, hygienic material and the environmental impacts resulting from its use are almost non-existent.

Outokumpu stainless steel is a key component of sustainable solutions.

Outokumpu strongly believes that stainless steel is the key building block for a sustainable future, playing an important role in the sustainable development of global infrastructure. New business opportunities are emerging from humanity’s growing demands for clean energy and pure water. Renewable energy solutions such as solar power, biofuels and wind energy require components and materials that can be sustainably sourced and yield low life cycle costs. Stainless steel is an optimal choice in such areas.

We strongly believe that our integrated production routes, high proportion of recycled steel, energy efficiency and low-carbon energy sources have enabled us to systematically decrease our products’ environmental footprint, making us one of the global leaders in sustainable stainless.

India being a developing country with limited resources needs sustainable infrastructure. Our innovative sustainable products have made Indian end users January 2016 • 91

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Interview

competitive in the global markets and even the domestic industry has gained knowledge from the products and applications which India is not capable of offering currently.

Our in-house research and development on products and processes is the largest in the world and has led to development of many new grades and applications.

Being the oldest and emerging leader in stainless steel, we have so much to offer to India. The nation needs us and we are ready to do our best to build Stainless India.

Q4. Since the steel sector is a major contributor to India’s manufacturing output, how do you see the manufacturing sector growing in India especially with the investment coming in and the government promoting various infrastructure projects and initiatives like ‘Make in India’?

Stainless steel is the fastest growing segment of the metals industry, its applications are diverse and new applications are constantly being developed. The demand for the corrosion free metal is increasing in architecture, construction, high end industries including oil & gas, energy and shipping-related industries, railways, ports, infrastructure and automotive where corrosion is a serious issue. Indian stainless steel production is mostly in low end grades and applications. R&D is an area where India needs support from global leaders like Outokumpu so as to develop capabilities to Make In India for the world.

We are well established in the Indian market as a leader in stainless innovations. The local competition is emulating us in developing new grades locally. Our presence strengthens and enhances the capability of local players to fulfil the Make in India vision of the government. The Indian economy is 92 • January 2016

embarking on robust planning at the moment with strong positive indications.

India and USA have signed a vision statement which aims to make India corrosion free. This is a very healthy development which will support our efforts to eliminate corrosion in infrastructure and industrial applications with improved metallurgy products. It is an ongoing activity and there are visible successes and milestone achievements.

Q5. India’s consumption of steel is expected to increase by 7 per cent in FY 2015-16 which was higher by 2 per cent than the previous year. What could be the possible growth drivers for this increase?

Interestingly, the share of stainless steel production in overall steel production in India is more than 4 per cent, which is much higher than about 2 per cent share globally. But the per capita usage of stainless steel is very low. The stainless steel sector in India suffers from huge overcapacity and the emerging growth opportunities in infrastructure investments will lead to huge demand potential which should consume the overcapacity over the next few years. Even a growth of 1 kg per capita from the current level of 2 kg can mean a demand surge of one million tons of stainless steel.

If accelerated substitution strategy continues to replace carbon steel, a surge for corrosion free structures is definitely expected. Stainless Steel is quickly gaining popularity in terms of preference over the coated carbon steel applications due to its properties like corrosion resistance, aesthetics, low life cycle cost and health and safety aspects for humans and plants.

With aspirations to enhance the share of manufacturing component of GDP from 14 to 25 per cent, there is expectation

for steep growth in our per capita use of stainless steel. High end grades are also used for manufacturing of process equipment plants in oil & gas, chemical, refineries etc. Application areas being storage tanks for acids, chemicals, edible oils, food processing, dairy and beverages and the sugar industry. Carbon steel tanks corrode over a period of time and hence go through a maintenance cycle every five years. Even though stainless steel is 3 to 4 times more expensive than carbon steel but the life cycle cost will be lowest due to stainless steel having advantages in terms of its strength, resistance to corrosion, equipment safety and hygiene. Corrosion mitigation awareness and corrective steps would lead to steep growth in demand for high end stainless steel as well. All infrastructures particularly in the coastal areas will have to go for Duplex Stainless to neutralise high corrosive environment.

Q6. The Government of India has announced investments for modernisation and expansion of steel plants in India. What are Outokumpu’s strategies to remain competitive in the market?

Outokumpu welcomes announcements for new investments for modernisation and expansion of steel plants in the country and can extend support in enhancing local capability in qualitative aspects of stainless steel. The range of production capability of domestic integrated plants is rather limited at this point of time and they need to get ready to satisfy the increasing awareness and demand for high end advanced materials for the accelerated infrastructure growth.

We do believe in localisation which means that we are here to support and partner with downstream manufacturing and processing companies to manufacture world class downstream products. Local players stand to learn a lot from our R&D capability in terms of new products Chemical Engineering World

Features CEW Interview

and innovative applications to gain higher share in the emerging markets.

Outokumpu vision is to create a world that lasts forever and for sure, India is an important part of this vision.

Combatting corrosion in flowlines: CO 2, chlorides, H 2S, the formation of water condensate, as well as high flowrates and temperatures require the toughest materials, eg, LDX 2101 or 2205.

Outokumpu team in India is backed up by product specialists for each segment for our offerings to help customers get the greatest value out of using stainless steel on the project. Our R&D desk helps the engineers, designers and project owners in choosing the right grade of material.

Welded tubes for umbilicals: Welded stainless steel tubes have replaced seamless stainless tubes in recent years with LDX 2101, 2304, 2205, SAF 2507 offering good choices.

Being the oldest and largest stainless steel player in the world, we have positioned ourselves as the wise stainless men who are educating the domestic end users on new grades and applications and also giving new opportunities to the domestic mills to learn from us and upgrade their capabilities.

Q7. Please could you elaborate on the offerings Outokumpu has in the downstream petrochemical industry and please could you also share a few success stories?

We offer the broadest range of stainless steels to meet the exacting standards of todayâ&#x20AC;&#x2122;s petrochemical and oil and gas industry. Whatever oil and gas applications are onshore or offshore, upstream or downstream, we have the stainless steel to meet various needs.

Outokumpu stainless steel products have been used for decades in various oil and gas applications including flowlines, umbilicals, manifolds, heat exchangers, burners and flarers, structural components and safety systems As one of the largest suppliers of stainless steel for the oil and gas industry, we offer NORSOK approved Duplex and austenitic grades .

For subsea processes the areas, our stainless steel plays vital role: Chemical Engineering World

Ease of welding and top durability for wellhead equipment and Xmas trees As H 2S rises, risk of SSC or hydrogen embrittlement requires LDX 2101 or 2205, which are also formable and easy to weld.

Also possible are SAF 2507, 254 SMO, 1.4565 and 1.4529.

For topside construction the critical requirements areas are: Superior strength and minimum maintenance are required for blast, firewalls and living quarters where 1.4404/316L and 2304 offer the necessary properties, while 2205 is recommended for areas requiring even greater corrosion resistance.

True safety and cost-efficiency are needed for cable trays, stairs, tread plates and walkways. Although 1.4404/316L has become the benchmark, LDX 2101 and 2304 combine high mechanical strength and excellent corrosion resistance to form a far more economical choice.

For piping and related applications the functionality is critical in terms of: Extreme performance is vital for main process piping where extreme conditions require extreme measures, for which 2205, SAF 2507 and 254 SMO are perfect choice.

Enhanced corrosion resistance for oil and gas coolers is needed since many of

the tube heat exchangers in oil and gas coolers use seawater as a coolant. The enhanced corrosion resistance provided by 254 SMO or SAF 2507 are ideal.

The fluids in manifolds are just as corrosive as in main process piping.

When pressures are high, 2205 and SAF 2507 are perfect choices.

At higher temperatures and for better corrosion resistance, seawater piping with 254 SMO and 1.4529 have been highly successful in systems operating at up to 30 0C. Combined with 1.4565 for flanges or other parts prone to crevice corrosion, service temperatures can be increased.

Referring to some successful cases, for Al Shaheen oil field project in Doha , some of the pipes for sensitive sections in the top side equipment on the offshore platforms were exposed to very high corrosion, especially due to the aggressiveness of crude oil, the super-austenitic grade 254 SMO was used.

Gansu Lanke Petrochemical Equipment of China has extended the service life of its oil refineries from 1-3 months to 2 years and beyond by using Outokumpu grade 2205 duplex stainless steel in plate air-cooler and plate shell heat exchangers.

Sosta used Outokumpu 2205 duplex stainless steel coil to manufacture welded Duplex stainless steel flow-line pipes for a natural gas flow line at the Burhan West field in Oman. The project is developed

by Petroleum Development Oman.

In India too, looking at the diverse and on project experience of Outokumpu expertise, Outokumpu is in discussions with many local oil companies to opt for Duplex solutions. The outcome is very positive.

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Marketing Initiative

Accurate Dosing into Reactors Ensure Consistent Batches When synthesising chemicals and pharmaceuticals, even a small mistake can lead to serious consequences.

Continually dosing chemicals requires instruments with high precision and reliability – and safety cannot be compromised.

B

üchi AG Switzerland (buchiglasuster) is a leading global supplier of glass and metal reactor systems for R&D labs for full-vacuum and high-pressure applications.

The company also develops glass and glass-lined steel reactors for pilot plants and kilo labs with Good Manufacturing Practice (GMP) requirements.

The company found a single-source supplier in Mettler Toledo, which understood their complex requirements and could design, build and supply a complete system with full control. In addition, Mettler Toledo exper ts were available for installation, validation and training so that Büchi Glas Uster could then train their customers to operate the new equipment securely and efficiently.

The reactors include assistance-control and measurement systems to ensure precise measurement and control of different reaction parametres. This includes weigh modules and control terminals for precise dosing.

Safety and Compliance Safety is a critical issue for the chemical and pharmaceutical industries, especially when working with hazardous materials.

Mettler Toledo provides intrinsically safe products that are built especially for use in explosive environments.

Fast and Accurate Dosing Glass is the ideal material for processing a va r i e t y o f c o r r o s i ve m e d i a i n p i l o t plants, enabling visual control of changing chemicals and chemical reactions.

Pharmaceuticals and fine chemicals are produced in kilograms to be used for further trials or as active pharmaceutical ingredients.

It is crucial to have accurate and continuous dosing of chemicals for reactions under full vacuum and pressure in pilot plants.

The weigh modules and control terminals supplied by Mettler Toledo ensure fast and accurate continuous dosing and control of all reaction components.

Know-How and Service Excellence Customers not only expect products to be reliable, but they also expect them to be easy and safe to operate and to provide top-notch accuracy and precision.

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“We demand safe, reliable and compliant process instrumentation and control equipment, which allows us to produce high-quality reactor systems – and that is what we got,” says Daniel Heusser, Sales Director, Büchi AG. Th e haz ardous -area approved weigh modules are easily integrated into any reactor system thanks to their flexible and safe design, even in explosive environments.

SWB505 MultiMount The SWB505 MultiMount weigh modules let you add weighing capabilities to your process by converting a tank, conveyor or other structure into a scale.

• Designed for static and dynamic weighing applications.

• No compromise on safety – all safety features are standard, including FM and ATEX approvals.

• Highest level of weighing accuracy, thanks to rocker-pin design and metrologically approved load cells. www.mt.com/ind-multimount

Heusser says he appreciates Mettler Toledo’s professional support and deep understanding of their requirements along with easy maintenance and global availability of support.

“We have developed a successful long term relationship with the company because t h ey o f fe r h i g h - q u a l i t y p r o d u c t s t h a t help make our processes more efficient,” says Heusser.

Chemical Engineering World

CEW Products Electronic Speed Switches/Tachometers/ Anemometers Electronic speed switches/tachometers/ anemometers are non-contact type speed monitoring units for monitoring over-speed/ underspeed of any rotary or linear motion. The units are available as 2 part version (monitoring unit + sensor probe). The units are available for indoor and outdoor applications in different enclosure. The standard models are having a potentiometer for setting and a relay operates at preset value. Special purpose models are available with digital indication/4-20 mA output/RS-485 port and wide range of speed sensors (inductive/magnetic/optical). Speed sensing range from 0.1 to 10,000 RPM in more than 40 models. The standard models are RM 221, RM E21 and RM P261. Special models available for sensing wind-speed (anemometer), belt speed and belt loading. It is useful for safety of bulk materials handling conveyors.

For details contact: Jayashree Electron Pvt Ltd EL-34/EL-12, J Block, MIDC, Bhosari, Pune, Maharashtra 411 026 Tel: 020-27130529, 46901300 E-mail: sales@jayashree.co.in or Circle Readers’ Service Card 1

Filters & Strainers Cipriani Harrison’s filters and strainers made from SS-304 and SS-316 are highly polished and come standard with FDA silicone seals.

These filters and strainers consist of a housing with an inlet and outlet either inline or 90 o angle orientation. Inside the housing is the straining element that is fixed in such a way that the product flow is forced through it. This element consists of a backup tube and straining mesh. The housing with the element assembly inside it is then fitted between two stainless steel flanges by means of sanitary clamps and gaskets. These filters/strainers are 3A authorised.

For details contact: Cipriani Harrison Valves Pvt Ltd 1901, GIDC, Phase IV Vitthal Udyognagar, Vallabh Vidyanagar Gujarat 388 121 Tel: 02692-235082, 235182, 235282, 233243 Fax: 91-02692-236385 E-mail: info@harrisonengineers.com or Circle Readers’ Service Card 2

Sliding Vane Pump Blackmer has added the NPH and XH Series sliding vane pump models to its NP and X Series product families.

Both the XH Series pumps, which are designed to handle a wide range of non-corrosive and non-abrasive industrial liquids and petroleum products, and the NPH Series pumps, which are ideal for handling viscous or shear-sensitive fluids, feature the same performance characteristics as the NP and X Series models and are available in 2”, 2.5”, 3” and 4” (51 mm, 64 mm, 76 mm and 102 mm) sizes.

The feature that sets the NPH and XH Series pumps from the competition allows the user to choose between 90- and 180-degree porting. Not all other brands have the capability for 180-degree porting in all pump sizes, which gives the NPH and XH pumps a level of operational flexibility that gear pumps and other technologies do not possess.

Standard features on both the NPH and XH Series pumps include an internal relief valve that protects against excessive pressures; a smaller motor for less operational costs; high volumetric efficiency; symmetrical bearing support for extended life; high suctionlift capability that makes them suitable for pumping from underground tanks, bulk-plant service and aircraft refueling; self-priming and dry-run capability; and the unique sliding vane method of operation that results in high-level performance, energy-efficiency, trouble-free operation and low maintenance costs.

For details contact: Dover India Pvt Ltd – PSG 40 Poonamallee By-pass Senneerkuppam, Chennai 600 056 Tel: 044-26271020, 25271023 E-mail: sales.psgindia@psgdover.com or Circle Readers’ Service Card 3

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Products CEW Two-stage Helical Bevel Gearboxes Nord Drivesystems expands its latest Series of slim two-stage helical bevel gearboxes, adding a new smaller unit for output torques up to 50 Nm. The gear units are highly resilient and withstand large forces on the output shaft. The short-term overload tolerance is 275%. Mechanical blockages usually do not cause damage, but the drive can start right up again without service interruption. The new units are available for gear ratios from 3.58 to 61.88. They add a new size to the existing series that now comprises six sizes with output torques up to 660 Nm. NORD supplies the two-stage helical bevel gearboxes with hollow and solid shafts, single or double shafts, for foot or flange mounting and in open or enclosed designs. All versions feature high power density. By default, the gearboxes support reverse operation. NORD custom-configures motors, drive electronics, accessories, gaskets and lubricants for all industries. One of the options, for instance, is the heavy-duty corrosion-protection treatment nsd tupH for the enclosure.

For details contact: Getriebebau NORD GmbH & Co KG Getriebebau-Nord-Straße 1 22941 Bargteheide/Hamburg, Germany Tel: +49 45 32 / 2 89 -0 | Fax: +49 45 32 / 2 89 -22 53 E-mail: Joerg.Niermann@nord.com or Circle Readers’ Service Card 4

Interactive SmartAC Trane, a brand of Ingersoll Rand, offers Interactive SmartAC Web-gateway and Mobile App. Interactive SmartAC is a next generation smart gateway featured with multi-functions. It gives ease of control to every registered individual Trane Interactive AC enabling the control from anywhere through Interactive SmartAC App installed on a Smart Phone. The Interactive SmartAC application enables user to manage all functions, modes of operation and view various types of reports. Interactive SmartAC feature can also be retrofitted in all existing Trane Interactive AC lineup.

Interactive SmartAC supports multiple connectivity powered by industry leading technology. Features like Plug & Play style permits user to connect to network just by Powering ON the Gateway with no efforts for configurations.

The App will be available on Android and iOS platform. A single gateway will be able to connect 18 Trane Interactive AC through Internet. The Interactive SmartAC Web gateway comes with loads of exciting features and advance connectivity.

For details contact: Ingersoll Rand India Plot No: 35, KIADB Indl Area Bidadi, Bengaluru, Karnataka 562 109 E-mail: Contact-India@irco.com or Circle Readers’ Service Card 5

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January 2016 • 97

CEW Products Compensated Pressure Sensors

Air-operated Double Diaphragm Pump

The SM5500 Series is ideally suited for medical, automotive and industrial applications.

Offering improved performance over existing products on the market with either constant current or constant voltage excitation, the SM5500 Series or OEM pressure sensors consist of fully calibrated, temperature compensated pressure sensors in single in-line (SIP) packages. The SM5501/SM5502 are meant for pressure gauges of 5 to 100 PSI (0.345 to 6.8 bar) and are intended for constant current and constant voltage excitation respectively. The SM5551/SM5552 are for low pressures in the range of 0.15 to 3 PSI (10 mbar to 200 mbar). The SM5551 is meant for constant current excitation and the SM5552 is meant for constant voltage application.

Moniba Anand Electricals Pvt Ltd offers lightweight air-operated double diaphragm pumps (AODD) in capacity ranges of ½ inch from 0 to 2.5 metres3/ hr; 1 inch from 0 to 6 metres3/hr; 1-½ inch from 0 to 14 metres3/hr; 2 inch from 0 to 30 metres3/hr; and 3 inch from 0 to 45 metres3/hr. Maximum head is 70 3 metres /hr. Available in PP/PVDF/SS/aluminium. It is a self-priming pump, which can also run dry. It can handle solids from 2 mm to 10 mm in thickness. This AODD pump stops automatically on closing of discharge valve. There is no seal or motor involved. It can also be used as metering pump up to an accuracy of 3-5%. Any unskilled worker can operate or repair this pump. It finds application in handling abrasive adhesive, cement, ceramics, drilling, explosives, inks and dyes. food, oil and paint, pharma, plating industries, etc.

For details contact: Jupiter Integrated Sensor System Pvt Ltd A-401 & G-414-416 Kailash Indl Complex B/h Godrej Colony, Parksite, Vikhroli (W) Mumbai 400 079 Tel: 022-67551606, 25185474 | Fax: 91-022-25170867 E-mail: jupiterelectronics.co.in

For details contact: Moniba Anand Electricals Pvt Ltd 5 Saphire Bldg, Tirupati Park Opp: Professional Couriers, Sativalli Road, Village: Waliv Tal: Vasai (E), Dist: Thane, Maharashtra 401 208 Tel: 0250-6450425, 6450426, 6450427 E-mail: moniba83@gmail.com

or Circle Readers’ Service Card 6

or Circle Readers’ Service Card 7

Drum Pumps Shanbhag & Associates offers drum pumps of Lutz Pumpen GmbH & Co KG, 55 year-old German manufacturer of electric and pneumatic drum/container pumps. Indian customers include the leading consultants, EPCs, MNCs and many reputed companies across India in pharma, chemical, food, dairy, oil and gas, and other sectors. The Lutz concept allows the complete pump (drive motor and pump tube) to be used in different containers and liquids as long as both components are approved for use in the liquids. Lutz drum pumps can handle liquids which are aggressive, flammable, thin, viscous, hot or cold, hazardous to ground water and the environment, and vary with respect to their density. They are available in a variety of materials, equipped with electric (FLP or non-FLP) or with air motors adapted to the output requirements, for different voltages (AC/DC), explosion-proof for hazardous applications, pneumatically operated, with the required delivery rate and suitable sealing/sealless systems.

Pump tubes are available in varying lengths and are offered in a wide range of accessories permitting, eg, adaptation to problematic containers or operating conditions. Pump tubes are available with centrifugal, radial/axial impellers or with eccentric screw principle constructions. Tube materials are in PP/PVDF/Alu/SS-316 (Ti)/Hast-C. Drum pumps can be offered in sanitary and non-sanitary constructions.

For details contact: Shanbhag & Associates B-50 Nandbhuvan Indl Estate, Mahakali Caves Road Andheri (E), Mumbai 400 093 Tel: 022-40365700, 66926984 Fax: 91-022-40365712 Email: info@shanbhags.com or Circle Readers’ Service Card 8

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Chemical Engineering World

Products CEW Auto Backwash Filters Auto backwash self-cleaning filter is used for preliminary filtration of demanding application of various industries. It is useful for applications where suspended solid load is comparatively high and highly viscous material and slurry based filtration applications. Feature high filtration accuracy, stable filtrate quality and supply. Due to its own search and emergency operation function, self-cleaning filter can do automatic backwashing and can cope with volatile fluctuations without manual intervention.

Filtration equipment control system is unique and has a precise operation, which is to adjust back-washing pressure setting according to different sources and filtration accuracy in a flexible way. The system has high efficiency and strong recovery. Its cartridge can be used for longer period without replacement. During the backwashing process, each cartridge operates in turn and meanwhile the other cartridges continue the filtration process without being affected. It has a reasonable and compact structural design. No consumable material, low operation and maintenance cost, simple operation and management.

For details contact: Filter Concept Pvt Ltd 302 Aalin, B/h Jet Airways Office, Ashram Road Ahmedabad, Gujarat 380 014 Tel: 079-27541602 | Fax: 91-079-27540801 E-mail: info@filter-concept.com or Circle Readers’ Service Card 9

Corrosion Protection Equipment / Materials Electro Protection Services India Pvt Ltd (EPSIPL) an ISO 9001:2008 company manufactures in accordance with DNV-RP-B401 anodes which consists of a foundry and has design experience in providing/assisting corrosion engineers comprehensive cathodic protection (CP) for design, service work and corrosion testing and commissioning to the marine, offshore oil and gas industries pipeline, tank structures, mounted bullets, vessels, oil rigs, etc.This vast level of experience ensures EPSIPL fully understand and are able to supply corrosion protection equipment/materials in accordance with the most stringent requirements as demanded by the industry sectors. EPSIPL core business is to produce CP systems, which consist of sacrificial aluminium anode, zinc anodes and magnesium anodes.

EPSIPL provide all clients with high quality CP product like TR units, anodes, junction boxes, cables, reference electrodes surge diverter, polarization cell, backed up with documentation and certification.

For details contact: Electro Protection Services India Pvt Ltd Plot No: 6, 1st Floor, Cauvery Street Guruswamy Nagar Ext Sembakkam, Chennai 600 073 Tel: 044-22780677 | Fax: 91-044-22780688 E-mail: projects@epsipl.com or Circle Readers’ Service Card 10

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CEW Products M Pumps Shanbhag & Associates offers magnetic drive seal-less pumps in metallic, plastic and lined constructions from M Pumps of Italy, a unit of the Mischiatti Group. M Pumps is an ISO 9001 and ISO 14001 certified company manufacturing to API 610 and 685 as well as non-API pump standards. The pumps are offered in centrifugal, peripheral, sliding vane, self-priming, centre-line mounted, inline and vertical pump versions that find applications in oil and gas, chemical, pharma, industrial refrigeration, offshore platform, electronic, and galvanising and nuclear plant areas amongst others.Shanbhag also offer dry-running motor protection units, low flow pipeline sensors, temperature monitors on rear casing and ATEX certification for many models as optional / required features. M Pumps seal-less mag-drive pumps are available in 26 designs with over 350 basic models.

For details contact: Shanbhag & Associates B-50, Nandbhuvan Indl Estate, Mahakali Caves Road Andheri (E), Mumbai 400 093 Tel: 022- 40365700, 66926984 | Fax: 91-022- 40365712 E-mail: info@shanbhags.com or Circle Readers’ Service Card 11

Automatic Potentiometric Titrator / Karl Fischer Titrator Spectralab Instruments offers Automatic Potentiometric Titrator Model Agile and Karl Fischer Titrator Model Whiz, which are specially designed for titration having highaccuracy and reproducibility. These are with advanced microcontroller-based user-friendly design. It has user-interactive software in dialogue mode for ease of operation with protection against invalid entries. Some of the features include: online titration curve; connectivity to USB printer; auto burette recognitions; 7” TFT display with touch screen; online/ offline statistics; fast titration when end points are far from each other; D2896 and D4739 for TAN and TBN analysis for oil samples; and compliant to CFR 21 Part II, GLP/FDA and ASTM D664. These titrators are useful in chemicals, petrochemicals, pharma and biochemistry, environmental and water-pollution; and other industries.

For details contact: Spectralab Instruments Pvt Ltd W-446, Rabale MIDC, Navi Mumbai 400 701 Tel: 022-27644030, 27644031, 27644032 | Fax: 91-022-27644035 E-mail: marketing@spectralab.biz or Circle Readers’ Service Card 12

Seal less Magnetic Driven Pump Moniba Anand Electricals Pvt Ltd offers seal less magnetic driven pump in the capacity range of 5 LPM to 500 LPM; head range of 24 to 1 metre and electrical motor of up to 5 HP. Its front casing, rear casing and impellers are in glass filled polypropylene/PVDF/SS. Shaft is made of ceramic and guided in carbon filled Teflon bush.

These pumps do not have conventional mechanical seals as pump chamber is shielded by casing and impeller is operated by the magnets. Hence, these pumps are totally leak-proof. These seal less pumps are ideal for transfer of chemicals like acids, etc, totally eliminating outside contamination of liquid transferred.

It finds application in thin liquid, electroplating industries, metal finishing machines, ultrasonic cleaners galvanizing, anodizing/ plating plants, PCB plate making and coating, etching machines, spark erosion machines, etc.

For details contact: Moniba Anand Electricals Pvt Ltd 5 Saphire Bldg Tirupati Park Opp: Professional Couriers Sativalli Road, Village: Waliv Tal: Vasai (E), Dist: Thane Maharashtra 401 208 Tel: 0250-6450425, 6450426, 6450427 E-mail: moniba83@gmail.com or Circle Readers’ Service Card 13

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Chemical Engineering World

Products CEW Variable Speed Drives The Unidrive HS30 and HS70 variable speed drives, capable of output frequencies of 3,000 Hz, are perfectly suited to high speed applications frequently required for automotive and aeronautical engine and transmission line test equipment, machine tool manufacture and centrifuges for the food and beverage, and oil industries. Unidrive HS70 and HS30 are essentially designed with the same specifications as the standard Control Techniques Unidrive M700 and Unidrive M300 variable speed drives, however, unlike the Unidrive M models, HS30 and HS70 have been engineered specifically for high speed applications. Unidrive HS70 offers class-leading induction, permanent magnet and servo motor performance, with on-board real time Ethernet. It provides maximum control of high speed motors and incorporates an on-board Advanced Motion Controller and PLC. Different variations of Unidrive HS70 are available, including models with on-board Ethernet, RS485 and Dual Safe Torque Off (Dual STO). Unidrive HS30 is designed for applications that require cost-effective integration into safety systems and incorporates Dual STO and advanced Rotor Flux Control of open loop induction motors.

For details contact: Emerson Industrial Automation 117B Developed Plot Indl Estate, Perungudi, Chennai 600 096 Tel: 044-66918400 E-mail: tr.sathishkumar@emerson.com or Circle Readers’ Service Card 14

Distributed Servo Technology KOLLMORGEN expands its fields of application for the distributed servo technology with a significant increase in performance. The three-phase AKD-N Series now delivers currents up to 12-A – equivalent to a doubling of output to 4.8-kW. The AKD-C central rectifier units are also bringing more power. With 20-kW the compact devices are now also providing double the previous max continuous output of 10-kW. The short-term peak output for both devices is at just short of three times the nominal current.

With its distributed servo technology in Protection Class IP67, AKD-N enables KOLLMORGEN to incorporate drive functions on-site in a machine. This result in smaller switch cabinets, better options for modularization, drastically reduced cabling outlay and greater flexibility in construction. The AKD-N servo system from KOLLMORGEN therefore also supports fast and cost-efficient installation using single-cable connection technology and options to use the devices in conjunction with Ethercat for collecting I/O signals.

For details contact: KOLLMORGEN Europe GmbH Pempelfurtstraße 1 40880 Ratingen Germany Tel: +49.2102.9394.2195 E-mail: sandra.becker@kollmorgen.com or Circle Readers’ Service Card 15

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CEW Products Variable Frequency Drive

HFLR Liquid Resistance Soft Starter

PSD 300/VSD 300 indigenously designed variable frequency drive Series is of high performance general purpose inverters that incorporate space vector modulation and IGBT technology.

The output closely approximates a sinusoidal current wave form to allow variable speed control of any conventional squirrel cage induction motor and is equipped with most of user-friendly function and features to enhance in utility. PSD300/VSD 300 has easy to operate keypad for parameter setting. Speed selection, external control and facility to connect RS-232 serial port (optional). Minilec offers various advantages of indigenous design for different applications with suitable protection.

Manufactured with acquired technology of a field proven product, these are best starts to start a slipring motor. It operates on the principle of change in resistance of liquid due to current and temperature. Special models with sensing the difference in resistivity between liquid and its vapour are available. For higher rating of motors the resistance of liquid is changed by moving electrodes.

The liquid chemical is specialy designed to last long and is maintenance-free. Available up to 20 MW with rotor voltage up to 3,500 V.

For details contact: Minilec (India) Pvt Ltd S No: 1073/1-2-3, At Post: Pirangoot Pune, Maharashtra 412 111 Tel: 020-22922162, 22922354, 67920100 Fax: 91-020-22922134 E-mail: mkt1@minilecgroup.com or Circle Readers’ Service Card 16

Useful for compressors, crushers, ball mill, mixers, wire drawing, etc.

For details contact: Jayashree Electron Pvt Ltd EL-34/EL-12, J Block, MIDC Bhosari, Pune, Maharashtra 411 026 Tel: 020-27130529, 46901300 | Fax: 91-020-46901357 E-mail: sales@jayashree.co.in or Circle Readers’ Service Card 17

Ultra-high Torque Brushless Slotless Motor Portescap offers Ultra EC mini motor platform, the 22ECT brushless motor, designed specifically to deliver ultra-high torque in a compact size. With the unique coil technology and a patent pending multipolar rotor design, the 22ECT has been developed to be one of the most advanced and highest performing brushless slotless motors in its class. The 22ECT is specifically optimized for high continuous torque at low to medium speeds, maximizing power between 10 K and 20 K RPM. These motors are capable of delivering 2 times higher continuous torque than comparable BLDC motors of same size over the entire low speed range when used with gears. The 22ECT is constructed with an enhanced high-efficiency magnetic circuit that significantly reduces both iron and joule losses, the primary causes for motor stator heating. With max continuous torque up to 98.5 mNm and higher stall torque, 22ECT motors are ideally suited for use in applications such as industrial automation, power tools and robotics. Portescap succeeds in providing a high quality, long lasting and high performance brushless motor by optimizing the electro-mechanical motor design and material selection for 22ECT. Due to the multipolar design, these motors possess the torque capabilities of much bigger motors. Their low inertia design makes them an exceptional option for applications requiring fast stopping, starting and acceleration. The 22ECT is available in 60 and 82 mm length versions, with hall sensors and 3 different coils to match your speed and voltage requirements. Portescap is globally ISO 9001:2008 certified, and their production site in India is also ISO 13485, ISO14001:2004 and OHSAS 18001:2007 certified.

For details contact: Portescap Unit No: 2, SDF-1 SEEPZ-SEZ, Andheri (E), Mumbai 400 096 Tel: 022-42006200 | Fax: 91-022-42004036 E-mail: sales.asia@portescap.com or Circle Readers’ Service Card 18

102 • January 2016

Chemical Engineering World

It is time to Migrate to an advanced Structural Analysis Software

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Dates: 13-15 May 2017 Venue: Muscat, Oman Details: Designed to deliver key buyers to Oman’s growing refining and petrochemical industries creating a forum aligned with the government’s growth plans Organiser: OMANEXPO LLC Contact: Mr Ebrahim Taher Email: info@omanexpo.com Website: www.omanexpo.com

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The 2016 Automation Summit

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Dates: 27-30 June, 2016 Venue: Las Vegas, USA Details: Siemens Automation Summit – A User Conference. All areas of industrial automation will be covered including factory, process, motion, and drives.

Organiser: Siemens Industry, Inc Contact: +1 800 241 4453 Email: rich.chmielewski@siemens.com Website: usa.siemens.com/summit

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CEW Project Update

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

• CHEMICALS Saras Plywood Products is planning a 60-TPM urea formaldehyde resin manufacturing plant in New GIDC Gundlav, district: Valsad, Gujarat. The existing land area is 1.5 acres.

The estimated cost of the project is ` 7.5-million. Kalyan Industries is the equipment supplier. The project is waiting for environmental clearance. Civil work will commence in 3 months.

The project is planned for completion in this year. According to SEIAA sources, the company has proposed primary treatment plant followed by evaporator for treatment of industrial effluent and has also proposed a multi-cyclone separator.

FMC India is planning an expansion of its chemical manufacturing unit at IDA Patancheru, district: Medak, Telangana. The estimated cost of the project is ` 17.5-million. As of September the project was waiting for the environmental clearance.

According to MoEF sources, the plot area is 4.027 acres. The company proposes to manufacture 50-TPM of products as part of the expansion. Green belt on 33 per cent of the land area will be developed and maintained. Power requirement will be made available through SPCPDCL. The project will be completed within 2 years.

Globex Laboratories (R&D) proposes a pigments manufacturing unit at village: Dabhasa, district: Vadodara, Gujarat. According to MoEF sources, the project will come up in the existing land on 9,312-sq m. Kadam Environmental Consultants, Vadodara is the environmental consultant. The project will entail manufacture of 40-TPM red pigments, 40-TPM yellow pigments and 450TPM dilute phosphoric acid. Environment clearance has been obtained for the products – red pigments and yellow pigments.

Construction work has begun, as EC and NOC have been received. Effluents generated will be treated in effluent treatment plant having MEE. The company has applied for Amendment in Environmental Clearance dated 26 th September 2012 for change in fuel from LDO to agro waste briquettes and addition of one raw material, ie, phosphoric acid and generation of dilute phosphoric acid (25 per cent basis) as by-product.

Bohra Industries is implementing an expansion of its chemical and fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan on 14,500-sq m of existing land. The project will entail expansion of single super phosphate capacity from 400TPD to 600-TPD, granulated super phosphate from 200-TPD to 300-TPD and addition of new products namely 150-TPD triple super phosphate, 550-TPD synthetic gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid, 0.3-TPD potassium fluoride, 150-TPD H 2SO 4 and 0.3-TPD Sodium Tri Polyphosphate (STPP). Machinery has been ordered from 104 • January 2016

China. Civil work is in progress. The project is scheduled for completion in 2018.

Ami Lifesciences proposes expansion of its synthetic organic chemicals manufacturing unit (viz, pharmaceutical bulk drugs and drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district: Vadodara, Gujarat. The estimated cost of the project is ` 87.046-million. Environmental Consultant to this project is Envisafe Environment Consultants. According to MoEF sources, total plot area is 23,760-sq m (existing 10,270-sq m and 13,490-sq m for expansion). The unit currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM Carbomazepin and 12-TPM Oxacarbomazepin.

The expansion will involve addition of new products. Water requirement from ground water source will be increased from 34.53-cu m/day to 181-cu m/day after expansion. Effluent generation will be increased from 9.35-cu m/day to 79.5-cu m/day after expansion. Highly concentrated effluent will be sent to captive incinerator for incineration. Remaining effluent (70-m 3/day) will be treated in the ETP comprising primary, secondary and tertiary treatment. Treated effluent will be sent to CETP for further treatment. ETP sludge, inorganic residue and incineration ash will be sent to TSDF. Spent carbon, organic residue will be sent to incinerator.

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

The project is waiting for environmental clearance.

RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive power project in village: Kuranga, district: Jamnagar, Gujarat. Land acquisition is in progress. 85 per cent of land has been acquired. The project is waiting for environmental clearance. The entire project is planned for completion in 5 years from zero date.

Superhouse is planning an expansion of its chemical mixmanufacturing project from 200-kg/day to 500-kg/day in UPSIDC Industrial Area, district: Unnao, Uttar Pradesh. The product will be used in leather tanneries. The project will involve installation of containers. The project is in planning stage.

Stellar Chemical Laboratories is planning an expansion of its organic chemical manufacturing project from 7.1-TPM to 84.1-TPM in village: Derol, district: Panchmahals, Gujarat.

Chemical Engineering World

Project Update CEW Machinery is yet to be ordered. Work on the project is expected to commence after receipt of environmental clearances and the completion date is yet to be finalized.

• MINING Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi, district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated steel plant premises.

The capacity of the project is to be augmented from 0.70-MTPA to 5.70-MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental clearance and planned for completion in 1-year from zero date. According to MoEF sources, the expansion is based on heavy media cyclone (wet process) technology. The washery will produce washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about 58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers.

The proposed expansion will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced from its own power plant connected with the Grid Corporation of Odisha.

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

DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area is 42.50-hectare.

The estimated cost of the project is ` 55-million. The project is waiting for environmental clearance. Mining work is expected to commence soon. According to MoEF sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in riverbed and 9-m in agricultural field. Letter of Intent (LoI) for mining contract has been granted for a period of 9 years.

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

Karnataka Renewable Energy Development is planning a 10-MW solar power project at an estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Chemical Engineering World

Tumkur, Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of the project.

Maharashtra State Power Generation Company is planning a 50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company is scouting for land. Other details are yet to be finalized.

Azure Power India is implementing a 10-MW solar photovoltaic power project in taluka: Hiriyur, district: Chitradurga, Karnataka.

PPA has been signed with Bangalore Electricity Supply Company (BESCOM). Civil work and panel installation work is in progress.

Government of Odisha is planning a 20-MW solar power plant in Manmunda, district: Boudh, Odisha. Green Energy Development Corporation of Odisha is the nodal agency. According to reports, the nodal agency has identified about 120-acre of land at Manmunda for establishment of the project. The land has been allotted to the agency from the industrial park area earmarked by Odisha Industrial Infrastructure Development Corporation (IDCO). The EPC tender is for development of the power plant and maintenance for a period of 10 years. Apart from the Boudh project, the agency is in the lookout for additional land in Koraput, Kantamal and Bolangir areas for installing about 200-MW solar energy capacity.

ACME Solar Energy is planning a 30-MW solar photovoltaic independent power project at a cost of ` 2.4-billion in Chhattisgarh.

The company is a JV between ACME Cleantech Solutions, EDF Energies Nouvelles (EDF EN) and EREN, Luxembourg. PPA is yet to be signed with Chhattisgarh State Power Distribution Company Limited (CSPDCL). The project is in planning stage. The project is planned for completion in 1-year from zero date.

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

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

January 2016 • 105

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106 • January 2016

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January 2016 • 107

CEW Book Shelf Analysis, Synthesis and Design of Chemical Processes 4th Edition Authors Price Pages Publisher

: R. Turton, R. C. Bailie, W. B. Whiting, J. A. Shaeiwitz & D. Bhattacharyya : USD 125.26 : 1104 (Hardcover) : Prentice Hall

About the Book : This book presents design as a creative process that integrates both the big picture and the small details–and knows which to stress when, and why. Realistic from start to finish, this updated edition moves readers beyond classroom exercises into open-ended, realworld process problem solving. The authors introduce integrated techniques for every facet of the discipline, from finance to operations, new plant design to existing process optimization. This fourth edition adds new chapters introducing dynamic process simulation; advanced concepts in steady-state simulation; extensive coverage of thermodynamics packages for modeling processes containing electrolyte solutions and solids; and a concise introduction to logic control. ‘What You Have Learned’ summaries have been added to each chapter, and the text’s organisation has been refined for greater clarity.

Production Chemicals for the Oil and Gas Industry, 2nd Edition Author Price Pages Publisher

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About the Book : This book discusses a wide variety of production chemicals used by the oil and gas industry for down-hole and topside applications both onshore and offshore.

Incorporating the large amount of research and applications since the first edition, this new edition reviews all past and present classes of production chemicals, providing numerous difficult-to-obtain references, especially SPE papers and patents. The author then briefly discusses all chemical and nonchemical methods to treat the problem and provides in-depth descriptions of the structural classes of relevant production chemicals. He also mentions, when available, the environmental properties of chemicals and whether the chemical or technique has been successfully used in the field.

The Future of the Chemical Industry by 2050, 1st Edition Author Price Pages Publisher

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About the Book : Discussing the technological supremacy of the chemical industry and how it will adopt a leading position to solve some of the largest global challenges humans have even seen, this book details how the industry will address climate change, aging populations, resource scarcity, globality, networks speed, pandemics, and massive growth and demand.

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108 • January 2016

Industrial Catalytic Processes for Fine and Specialty Chemicals, 1st Edition Editors Price Pages Publisher

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