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Industry Focus: Fertilisers FERTILISERS: ALL EYES ON GOVERNMENT« Ÿ 24 ItÊs a Serious Business, Govt Must Pull its Socks Up Ÿ 26 Technological Advancements Will Pave the Way for Growth Ÿ 30 Will Bringing Urea Under NBS Make the Difference? Ÿ 36 Corrosion ă Tacking Challenges in Indian Fertiliser Industry Ÿ 40 Opportunities for EPC Players in Fertiliser Sector Ÿ 52
Special Section on Pumps & Valves
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EDITORIAL
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Jasu Shah Maulik Jasubhai Shah Hemant Shetty Mittravinda Ranjan (mittra_ranjan@jasubhai.com) D P Misra, N G Ashar, Prof. M C Dwivedi P V Satyanarayana, Dr S R Srinivasan, R B Darji, R P Sharma Bernard Rapose (bernard_rapose@jasubhai.com) Harshal Y Desai (harshal_desai@jasubhai.com) Arun Parab, Amol Patkar Abhijeet Mirashi Dilip Parab Brenda Fernandes V Raj Misquitta (Head), Arun Madye
VOL. 49 | NO.6 | JUNE 2014 | MUMBAI | ` 150 NEWS ɻ Industry News / 6 Technology News / 12
NEWS FEATURES ɻ Focus on Long-term Benefits, not on Instant Profits: Atanu Maity / 18
FEATURES ɻ FERTILISERS: ALL EYES ON GOVERNMENT… / 24
Place of Publication: Jasubhai Media Pvt Ltd
It’s a Serious Business, Govt Must Pull its Socks Up / 26
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Corrosion – Tacking Challenges in Indian Fertiliser Industry / 40
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Handling Tricky Situation with Ball Sector Valve / 62
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4 • June 2014
Will Bringing Urea Under NBS Make the Difference? / 36 – Guy Goves, President – Agri Business & Farm Solutions, DFPCL
Godfrey Lobo / V Ramdas 210, Taj Building, 3rd Floor, Dr. D. N. Road, Fort, Mumbai 400 001 Tel: +91-22-4037 3636, +91-22-4213 6400 Fax: +91-22-4037 3635 E-mail: godfrey_lobo@jasubhai.com, v_ramdas@jasubhai.com
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Technological Advancements Will Pave the Way for Growth / 30
– V P Sastry, CV Manian, NIGIS India Takes Pride of Place in Global Specialty Plastics Market / 50 – Dr Prakash Trivedi, Polymer SBU, Gharda Chemicals Ltd Opportunities for EPC Players in Fertiliser Sector / 52
SPECIAL ON PUMPS & VALVES Pump Material for Harsh Environments / 56 – Raimo Arola, Thomas Kraenzler, Sulzer Pumps – Volker Gatzert, Thomas Labahn, Schubert & Salzer Control Systems GmbH New Verderflex Dura 5 and Dura 7 Hose Pump Receives “Ringier Technology Innovation Award 2014” / 66 – Verderflex Centrifugal Pump Hydraulik Rerate - ROAD to RELIABILITY / 68 – Vishwanath Kulkarni, ITT Corp India Pvt ltd Complete Solutions for Valve Requirements / 72 – Intervalve India Ltd
MARKET INSIGHTS ɻ India Posed to Add Huge Desalination Capacities in 5 Years / 74
PRODUCTS ɻ / 80 EVENTS ɻ / 84 PROJECT UPDATE ɻ /85 BACK OF BOOK ɻ Ad Index / 87 Book Shelf / 88 Interview/ 89 “Leverage Talent and Experience Base to Focus on Specialty Chemicals” - Dr Raman Ramchandran, Head – South Asia & Chairman, BASF India Cover page image: Zuari Agrochemicals Ltd Disclaimer: The Editorial/Content team at Jasubhai Media Pvt Ltd has not contributed to writing or editing “Marketing Initiative.” Readers would do well to treat it as an advertisement.
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Chemical Engineering World
CEW Industry News Self-reliance in Fertilisers to be the Focus for Government: Ananth Kumar
Dharmendra Pradhan Takes Charge as MoS for Petroleum & Natural Gas
New Delhi, India: One of the key focus areas for the new government is going to be making India self-reliant in the fer tiliser sector, said Ananth Kumar after he took charge as the Minister of Fer tilizer and Chemicals on May 29. When talking of special economic zones he stated that petrochemical hubs would be set up in various parts of the country like Tamil Nadu, Assam and Ananth Kumar Odisha. Before the sowing of kharif or Minister of Chemicals summer crops begins, fertilisers would be & Fertiliser provided to the farmers. He further added that the governmentÊs long term policy would be to ensure that India does not depend on imports and becomes self-reliant in fertilisers.
New Delhi, India: Dharmendra Pradhan took charge in the Ministry of Petroleum and Natural Gas as the Minister of State (Independent Charge) on May 27.
Kumar said, „We are making a roadmap for the revival of closed urea units. Also, a new urea unit will be set up in Namrup in Assam and a new Single Super Phosphate (SSP) unit by FCI Aravali Gypsum Minerals India Ltd in Rajasthan.” Talking about neem-coated urea, he stated that the government would continue to work towards an action plan to improve its availability.
Nihal Chand is MoS for Chemicals & Fertilizers New Delhi, India: Nihal Chand has taken charge as the Minister of State for Chemicals & Fertilizers in New Delhi on May 28. The Minister said that he had been with his senior cabinet colleague Ananth Kumar, when he expressed the ministryÊs priorities and that he would work hard to achieve these stated objectives. Nihal Nihal Chand, Chand has been elected as a MP from the MoS, Chemicals & Ganganagar Constituency in Rajasthan in the Fertilisers Group recent Lok Sabha Elections. The 43 year old young BJP leader had earlier been elected to the Parliament three times and this is his fourth term.
Higher Gross Refining Margin Reported BYÏ#0#, Chennai, India: Chennai Petroleum Corporation Ltd (CPCL) has reported a profit in Q4 of FY 2013-14 because of higher gross refining margins. The refinery, a group company of India Oil Corporation, has seen a net profit of C 49.81 crore in Q4 ă which ended on March 31 ă as compared to the net loss of C 392.23 crore last year. The gross sale in the Q4 were C 14,608 crore against C 13,586 crore last year. As stated in the BSE filing, CPCL had a net loss of C 303.85 crore for the fiscal year which is much less compared to last yearÊs C 1,766.84 crore. In FY14, the gross sales touched C 53,923.7 crore (C 46,842.5 crore). About 2.8 million tonnes was processed during the last quarter. The gross refining margin stood at USD 1.96 per barrel (USD 0.08). 6 'QJA
Speaking to the media-persons after assuming the role, Pradhan said that his focus would be to meet the expectations D h a r m e n d r a P r a d h a n , M o S , of the poor and the middle-class people Petroleum & Natural Gas of t he count r y. „ T he peo pl e of the country have large expectations from the new government and this government is dedicated to the welfare of the poor. India needs to reduce import dependence and secure energy needs, so that it becomes self-reliant,‰ he said. Indian economy has an important role in the world economy, and the government would endeavour to make contribution to this effect. Pradhan would consult senior colleagues in the government and would like to formulate holistic policies, in tune with the guidance and vision of the Prime Minister, Narendra Modi. Earnest efforts will be made to bring back the economy on the track of progress and development. The issues, being dealt in the ministry, would be studied and discussed with senior officers, so that decisions could be formulated in the interest of the poor and the country.
RCF Shelves Plans of Setting Up Fertiliser Plant in Ghana New Delhi, India: Rashtriya Chemicals and Fertilizers (RCF) has put its plans of setting up a fertiliser plant in Ghana on hold as the country denied gas supply which was assured previously. It is an investment of USD 1 billion in total. A MoU was signed between India and Ghana to set up a urea plant which initially has a capacity of 1.2 tonnes per annum (tpa) in western GhanaÊs Shama district. The Indian government nominated RCF for this project as both, India and Ghana had to select a company from their side for the projectÊs execution. High level ministry officials and RCF officials paid a visit to Ghana in June 2013 for discussing the pricing and gas supply issues. Ministry sources stated that RCF has halted the project because assurance about gas supply as well as pricing was not given by Ghana government as those were the sole reasons why the company was interested. In India since 2007-08, the urea production has been stagnant at 22 million tonnes (MT). The current demand is at 30 MT and this is met through imports. DAIE?=H "JCEJAANEJC 4KNH@
CEW Industry News Lilleria Group and Fairmate Chemicals Plan JV in Kenya Ahmedabad, India: Vadodara-based companies Lilleria Group and Fairmate Chemicals plan on making a C 200 crore annual investment with the intention of acquiring a share in the construction chemical market in Kenya. Through the joint venture the companies plan to begin manufacturing in Kenya. Veer Rajesh Patel, MD, Lilleria Group, states that large amounts are being spent by Kenya on developing infrastructure which includes townships, residences and hotels. He said, „We will invest C 50 crore in the JV in next five years. There is a massive infrastructure and real estate boom in Kenya and there is huge demand for construction chemicals.‰
Production at ONGC Mangalore Petrochem to Start in July Mangalore, India: The production will be star ting at ONGC Mangalore Petrochemical Ltd (OMPL) around the end of June or early July. The aromatics complex is promoted jointly by Mangalore Refinery and Petrochemicals Ltd (MRPL) and ONGC. For some time now, pre-commissioning activities are going on. MRPL refinery would be supplying the feedstock to OMPL and the plant will produce 920,000 tonnes of paraxylene and 283,000 tonnes of benzene every year. In the Indian market, OMPL products would be useful in developing the downstream industries in the area around Mangalore. Besides that the company has plans of marketing for exports as well. The area of the plant is 442 acres and the company invested C 5,800 crore for setting up the plant.
Industry Wants Govt to Set Up C 560 Crore Fund -UMBAI Ï )NDIA To ensure that the chemical sector can reach its full potential, the chemical industry suggested the government to raise a chemical innovation fund of C 560 crore apart from creating a Council on Innovation. The CII National Committee has asked the government to take a look at the free trade agreements which stated that even after signing such pacts with numerous countries, India does not seem to benefit from it; while other countries have fared well. Nadir Godrej, Chairman, CII National Committee on Chemicals and MD, Godrej Industries, expressed that the government has to make certain that essential feedstock is available and economically priced for the specialty chemical industry. He also said that the government should facilitate quick implementation of GST (goods and services tax) so that transaction costs can be brought down along with sky-rocketing taxes. He added further that states should be considered when formulating policies.
Wa b a g S h i f t i n g f r o m Au s t r i a t o I n d i a f o r Cost-cutting Chennai, India: Rajiv Mittal, MD, VA Tech Wabag, said that the company would be having increased operations of their overseas business out of India because it wants to have lower costs and improved margins. Previously, all of WabagÊs international businesses were operated out of Austria, which happens to be the base of its parent company. But in the recent past, new subsidiaries which operate out of India proved to be better paying verticals. In 2013-14, more than 60 per cent of the companyÊs revenue came from their overseas business, which stood at C 2,230 crore.
Coal, Minning Could Revive Manufacturing: KPMG Kolkata, India: To encourage the manufacturing sector in India, tackling issues related to coal and mining industry as fast as possible is impor tant. According to S V Sukumar, Par tner & Head, Operations and Supply Chain, this is not only affecting this sector but has a cascading effect on other sectors and the whole economy. KPMG in its note stated that enhancing rail, road and por t infrastructure should be the shor t, medium and long ter m focus of the industry because the industry is facing a barrier in this area from the point of view of overseas and domestic movement. Sukumar also emphasised the need to employ more people. He fur ther added, „In India, planning has always been the weakest link for quite some years now. Given the many unpredictable factors associated with it, planning will have to be even more robust.‰
India has a solar power capacity of over 2,630 MW and wind power capacity of 20,000 MW. 8 'QJA
The Indian team supports WabagÊs business in Egypt, Nepal, Tanzania, Philippines, and Oman with regards to manpower, financials and technology. The team also provided support to big markets in South America. Human Resources, Treasury, Finance and Management Information Systems reporting will be brought here so that there is better control. Also, the company would have to pay one-fifth of the cost it pays in Europe.
Chemical Policy Draft would be Submitted to Govt Hyderabad, India: A draft of the national chemical policy would be submitted for the governmentÊs consideration by the Depar tment of Chemicals and Petrochemicals according to a top official. The purpose of this policy is to bridge the gap in export and import of chemicals by improving the domestic production, said Indrajit Pal, Secretary (Dept of Chemicals and Petrochemicals), under Ministry of Chemicals and Fertilisers. At an event organised by FICCI, he said, „We will be ready with the draft very soon. The new government has just taken over. Due to election code, we could not announce. We will submit it (draft policy) to the government soon.‰ The sector may even rise beyond the GDP growth. DAIE?=H "JCEJAANEJC 4KNH@
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CEW Industry News $ 2 . 5 b i l l i o n S e c u r e d by Tu r k m e n i s t a n fo r Petrochemical Projects
Materia and QAPCO Join Hands for Developing the Next Gen of Materials
Ashgabat, Turkmenistan: For financing the construction of a petrochemical complex in Turkmenbashi near the Caspian Sea, Japanese and South Korean export credit banks have agreed to finance Turkmenistan. A loan worth USD 2.5 billion has been secured by the country. A credit agreement has been made by the State Bank of Foreign Economic Affairs of Turkmenistan with Japan Bank of International Cooperation for USD 700 million and another with Korean Eximbank worth USD 1.8 billion for a period of 10 years to finance the plantÊs construction in the Balkan region of the country.
Pasadena, USA: As Qatar continues to grow its energy and industrial sectors and attempts to further optimise its hydrocarbon resources utilisation, research and innovation are set to propel the future success of these sectors. Research will support the development of new products using QatarÊs existing feedstock and natural resources and opens the door to new uses for energy products and derivatives such as petrochemicals.
The rest of the funding for this project would be done by Turkmengas which is TurkmenistanÊs national gas company. The contract for this complex was given to Toyo EngineeringÊs consortium which has Hyundai Engineering, Hyundai Engineering and Construction and LG International of South Korea. The project has been slated to be completed by 2018 and it will have a gas separation unit along with production units of ethylene and polypropylene. The gas separation unit will see 5 billion cubic meters capacity annually while the ethylene and polypropylene units will produce 400,000 tpa and 80,000 tpa, respectively.
Jacobs Gets Contract for Chlorine Dioxide Plant Pasadena, USA: Jacobs Engineering Group Inc announced on May 20, 2014 that it was awarded a contract by P.T. OKI Pulp and Paper Mills for the design and supply of an integrated c h l o r i n e d i ox i d e p l a n t fo r i t s p u l p m i l l p r o j e c t i n S o u t h Sumatra, Indonesia. Officials did not disclose the contract value, but revealed that when completed, the plant is anticipated to produce 172 metric tonnes of chlorine dioxide per day. The plant is scheduled to be commissioned in 2016.
HoneywellÊs UOP C3 Oleflex Process Technology Chosen by Guangdong Peng Des Plaines, USA: HoneywellÊs UOP LLC announced that Guangdong Peng Zun Energy Development Co Ltd has selected HoneywellÊs UOP C 3 Oleflex™ process technology to convert propane to propylene. This will be the first propane dehydrogenation project in the Southern Guangzhou region, which is a major trade hub for Southeast Asia located near Macau and Hong Kong. „The rise in disposable income for AsiaÊs middle and upper classes is increasing consumption of durable and nondurable goods made from chemicals and polymers derived from light olefins,‰ said Pete Piotrowski, Senior Vice President and General Manager, UOP Process Technology and Equipment business unit. 'QJA
To further this goal, Materia Inc. (Materia) and Qatar Petrochemical Company (QAPCO) have forged a par tnership, through a Memorandum of Understanding (MoU), to further reinforce their collaborative R&D efforts and to study the development of the next generation of materials produced from QatarÊs existing feedstocks. MateriaÊs exper tise and breakthrough catalyst technology combined with QAPCO resources will provide for the development of new products. Together, they will explore the possibilities to further optimise the use of QatarÊs natural resources, by studying how to ex t r a c t n ew p r o d u c t s f r o m Q A P C O Ês c u r r e n t fe e d s t o ck , w i t h t h e a i m t o m a x i m i s e t h e va l u e r e l a t e d t o Q A P C O Ês existing processes.
JV Agreement Between SABIC and SK Global for Production of PE Products Seoul, South Korea: SABIC and the Korean petrochemical company, SK Global Chemical, signed a 50-50 joint venture agreement for a total investment of USD 595 million to manufacture a range of high-performance polyethylene products using SKÊs cutting edge Nexlene solution technology. The joint venture, which is located in Singapore, is expected to operate a series of manufacturing plants, the first of which was recently completed by SK Global Chemical at its complex in Ulsan, South Korea, with an expected annual capacity of 230,000 tonnes. The plants will produce metallocene linear low density polyethylene, polyolefin plastomers and polyolefin elastomers that will meet the growing needs of diverse industries such as advanced packaging, automotive, healthcare, footwear and electrical & lighting. A second plant is planned for Saudi Arabia. Over time, production bases will be established worldwide. After the signing ceremony, Al-Mady commented, „We are happy to establish this partnership with SK Global Chemical and bring the best in advanced material science closer to our expanding customer base in Asia.‰
IndiaÊs chemical industry is estimated to reach USD
290 billion at CAGR of 15 per cent by 2017 . DAIE?=H "JCEJAANEJC 4KNH@
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CEW
Technology News Streaming of Videos Could Save Billions of CO 2 Emissions, Says Research Report
Enhanced Catalyst to Improve Petrochemical Production
Bristol, England: It has been proved through a new study that streaming videos would be positive for the environment as it would need less energy and emit less carbon dioxide as well when compared to using DVDs.
Zürich, Switz erland: W h e n c r u d e o i l i s r e f i n e d t o f u e l s and chemicals, help is at hand ă in the for m of so-called c a t a l y s t s. S c i e n t i s t s n ow p r ov i d e a r e fe r e n c e p a ra m e t e r for the perfor mance of an impor tant class of catalysts for petrochemical production.
The research was published in the Environmental Research Letters journal where the researchers state that modem devices like tablets and laptops are responsible for the improved environment. The reason for this is because these devices are energy efficient as compared to the DVD players. When complex HD content is streamed, the energy consumption and carbon emissions are quite high from this transmission of data. This research study was undertaken by researchers from Northwestern University, Chicago and Lawrence Berkley National Laboratory, California. It was estimated that in 2011 almost 2 billion kg of CO 2 could have been eliminated and about 30 petajoules (PJ) of energy could be saved if DVD viewing in US would have switched to streaming services. To read more about the research log onto http://iopscience.iop.org
Biomethane Hybridization to Make Thermosolar Plants More Sustainable Madrid, Spain: Concentrating solar power (CSP) technology could be easily commercialised if biomethane integration The thermosolar plant of Manchasol / Hysol in concentrating solar thermal power plants is done. This could bring down financial as well as environmental costs. Researchers belonging to the Hysol Project which ACS-Cobra company leads along with researchers from the Universidad Politécnica de Madrid conducted this study. Presently, the integration process of biomethane is being studied. The plans of constructing a pre-industrial plant are underway at the cluster of thermosolar innovation of Manchasol for ensuring process validation. A big problem the CSP technology faces is electrical generation as there is dependence on solar and seasonal cycles and weather conditions. The possibility of solar energy resources such as biomethane may enhance this technologyÊs financial viability. This can make 100% renewable electricity production possible. Read more on http://www.upm.es/ 12 'QJA
Zeolites are among the substances which can accelerate chemical reactions ă they are known as catalysts. Usually applied in pellet for m, the industr ial production of gasoline from cr ude oil without zeolites is inconceivable t o d a y. O n e o f t h e m a i n i n d u s t r i a l p r o b l e m s w i t h the use of zeolites is coke; a reaction side product which clogs the pores or block the active sites of the catalyst. Researchers are therefore working to make zeolite catalysts more resistant to such deposits, thereby delaying the need for regeneration and thus, extending the production cycles. Researchers from ETH Zurich headed by Javier Pérez-Ramírez, a professor of catalysis engineering, have now identified the relation between this resistance and the internal structure of a new class of zeolite catalysts combining a complex network of pores of various sizes. Log on to https://www.ethz.ch to read more.
Carbon-capture can be Improved with Patented Technology
Dr Jason E Bara shows a more efficient and cheaper method for capturing harmful emissions.
Alabama, USA: Less than a year after patenting a process that could improve stripping greenhouse gasses from industr ial emissions, a University of Alabama engineer ing professor was recently granted another patent that uses a different solvent to accomplish the same goal.
The newest method, patented by UA and Dr Jason E Bara, assistant professor of chemical and biological engineering, uses a form of liquid salt that could be swapped with chemicals currently used to scrub har mful emissions, such as carbon dioxide, or CO 2 , from industrial emissions. In a different patent granted in August 2013, Bara proposed switching currently used chemicals with a class of low volatility organic molecules. It is all par t of his research focus of showing different and possibly better, ways to capture harmful emissions. Read more on http://uanews.ua.edu/ DAIE?=H "JCEJAANEJC 4KNH@
CEW Marketing Initiative Sasol and INEOSÊs High Density HDPE JV at Final Investment Decision
Wacker Adds to Production Capacity of Dispersible Polymer Powders
Houston, USA: Sasol Chemicals North America LLC and INEOS Olefins & Polymers USA announced that they have reached final investment decision to form a joint venture to build a high-density polyethylene (HDPE) plant in LaPorte, Texas. The 50-50 joint venture will produce 470 kilo tonnes per annum of bimodal HDPE using Innovene™ S process technology licensed from INEOS Technologies. The ethylene required for the production of the HDPE will be supplied by Sasol and INEOS in proportion to their respective ownership positions.
Munich, Germany: Wa cke r C h e m i e AG i s ex p a n d i n g i t s p r o d u c t i o n c a p a c i t y fo r d i s p e r s i bl e p o l y m e r p ow d e r s i n Germany. The Munich-based chemical company is currently building a new spray dryer with an annual capacity of 50,000 metric tonnes at its Burghausen site, investing an amount of around Euro 20 million. The facility is scheduled for completion in the first quar ter of 2015 and will be one of the largest of its kind worldwide.
„This project will expand SasolÊs presence in the global chemical market and complement our North American growth strategy,‰ said Fleetwood Grobler, Group Executive - Global Chemicals, Sasol. INEOS will operate the HDPE plant at its Battleground Manufacturing Complex in LaPorte. Plant start-up is expected in the 2016 calendar year. The definitive agreements are in the process of being finalised, and all relevant permits have been obtained. As the plant will be debt financed, the investment decision is conditional on achieving financial close.
KBLÊs Lowest Life-cycle Cost Pump Receives Excellence Award Pune, India: Kirloskar Brothers Limited (KBL) has been conferred with the Award of Excellence at ACREX 2014. KBLÊs Lowest Life-cycle Cost (LLCTM) pump has been recognized as the most Energy Efficient product of 2013 at the ACREX Awards, held in New Delhi. Over 300 exhibitors enthusiastically participated in the competition that recognised excellence in four distinct categories such as Innovation, Indoor Air Quality, Energy Efficiency and Green & Sustainable. KBLÊs LLCTM Pump is a result of an innovative product development at the 100+ year old Kirloskarvadi facility. Factors such as corrosion and natural erosion have been considered while designing the LLCTM pumping system. The objective behind the breakthrough technology of LLCTM Pumps is to save additional energy costs and reduce the degradation cost. The cumulative reduction in energy consumption directly helps in saving cost and increases the overall profitability of an organisation.
KBL’s Lowest Life-cycle Cost Pump
14 'QJA
Wacker aims to meet the globally rising demand for dispersible polymer powders, which is driven by worldwide trends such as urbanisation, renovation and energy efficiency, as well as the increasing need for environmentally compatible dry-mix mortar products. With the planned production expansion, the group is creating the necessary capacity to reliably meet the market growth predicted by industry exper ts in the long term. „Wor ldwide, demand for high-quality dispersible polymer powders is rising par ticularly in residential construction and infrastructure measures,‰ said Arno von der Eltz, President, Wacker Polymers.
2014 World Cup Stadium Built with Sandvik Duplex Stainless Steels Frankfurt, Germany: SandvikÊs Sanmac® 2205 has been used in the construction of the iconic Estádio Jornalista Mário Filho stadium in Maracanã, Brazil. Hightex GmbH required duplex materials for a specific part of the roof of the stadium. With a tight construction deadline to meet, Hightex opted for hollow bars made from Sanmac® 2205 duplex stainless steel, chosen for the manufacturerÊs good price and fast delivery. The grade is a machinability-improved version of Sandvik SAF 2205™. The latter material accounts for more than 80% of applications of duplex stainless steel grades and is characterized by excellent machinability, high mechanical strength and good weldability. „We wanted to find a supplier of duplex stainless steel that could deliver quickly but also at a competitive price. We selected Sandvik on that basis and they were able to deliver on time as promised,‰ explained Vladimir Renner, Purchasing Manager, Hightex.
Hightex GmbH, Germany
DAIE?=H "JCEJAANEJC 4KNH@
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CEW Marketing Initiative National Technical Approval to OutokumpuÊs Lean Duplexes New Delhi, India: OutokumpuÊs lean duplex grades LDX 2101 ® (EN 1.4162) and LDX 2404 ® (EN 1.4662) recently received general approval AbZ (Allgemeine bauaufsichtliche Zulassung) by the German national building authority DIBt (Deutsches Institut für Bautechnik). This approval designed for the building industry means that manufacturers of building and construction components can use lean duplex grades and utilize their benefits without applying for a specific approval for the manufactured component. LDX 2101 ® and 2404 ® are OutokumpuÊs proprietary grades, d e v e l o p e d i n t h e g r o u p Ês r e s e a r c h c e n t r e i n Av e s t a , S w e d e n . T h e b e n e f i t s o f l e a n d u p l ex i n c l u d e ex c e l l e n t m e c h a n i c a l p r o p e r t i e s, c o r r o s i o n r e s i s t a n c e a s w e l l a s cost competitiveness. The approval covers lean duplex coil and plate products up to and including 30 mm thickness and bar products up to and including 40 mm diameter as well as all components manufactured from these materials. „This is an important milestone for the use of lean duplexes in building and construction, where lean duplexes have additional benefits. Leaner alloying together with added strength ensures highest value for money for our customers,‰ says Thomas Kirchhartz, Technical Sales Manager, Outokumpu.
Sustained Growth for Freudenberg in India Bangalore, India: The Freudenberg Group in India successfully withstood the challenging economic conditions in the region in 2013. Compared with 2012, sales rose slightly to C 1,128 crore. „The solid development of Freudenberg Group companies in India will have a sustainable positive impact on the entire group in the long-run,‰ said Dr Jörg Matthias Grossmann, Regional Representative (India), Freudenberg Group and CFO, Freudenberg Chemical Specialities at the press conference in Bangalore. In 2013, Freudenberg had a direct presence in 32 locations and employed 3,453 associates in India. In the 165th year of its history, Freudenberg was more successful than ever before on a global scale. In the 2013 financial year, the international technology group reported record sales for the fourth year in succession, on the previous consolidation basis totalling to approximately Euro 6,622.5 million. This represents an increase of almost Euro 300.8 million or 4.8 per cent.
Freudenberg Press Conference
Corrotherm International minimum manufacturing quantity of 250kgs. We can call on a wealth of industry expertise to help problem-solve and create innovative solutions for individual needs.
Jan Ward CEO Corrotherm
C
orrotherm International are a global distributor of heat and corrosion resistant nickel alloys in the form of pipes, fittings flanges plates and bars in trade name alloys Inconel Incoloy and Monel with over 100 alloys in the range. With offices in 10 countries Corrotherm understands market needs, delivers what customers want when they want it. We have the capability to supply from stock or to order with a
16 'QJA
The portfolio of alloys offered is continually updated and puts the company, and its customers, at the centre of any technological innovations and at the forefront of any new developments. Jan Ward, Corrotherm CEO, says: „With our expertise we can analyse client requirements and translate them into something mills can supply. We are also flexible enough to document and expedite jobs the way customers want so they fit their systems. We share our product knowledge through specially-tailored free seminars conducted by our metallurgist and mill technologist to create a forum for customers to discuss alternative solutions or ways of working. Our offer of flexible payments terms also gives
customers the confidence to place orders no matter what their timeframe requirements.‰ For more info, visit: www.corrotherm.co.uk
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CEW News Features
Focus on Long-term Benefits, not on Instant Profits: Atanu Maity Plastic machines manufactured by domestic manufactures are no ‘less efficient,’ and they are as good as the machines offered by global players, but the higher cost forces customers to go for second-hand machines, says Atanu Maity, President & CEO, Steer Enginering, who has recently been appointed to his current role.
P
olymer industry in India is now moving towards evolving as a major global player, and it will definitely be a key driver for companies engaged in manufacturing processing machines. „At present, there are around 200 players in the country, most of which are small and belong to unorganised sectors, and about 8,000 machines are sold in India every year,‰ Maity updates. Some of them certainly command respect worldwide in terms of technological advancement. He says that the share of processing machines namely for Extrusion, Injection Moulding and Blow Moulding & Others is about 30, 60 and 10 per cent, respectively. World-class Ability „Machinery manufacturers in India are building their machines following the design criterions and performance standards set by the best of the brands from Western Europe & North America with optimum quality, productivity, energy efficiency and reliability. Continued association with global technology leaders such as Battenfeld, Bausano, Italtech, Kuhne, Hosokawa Alpine, etc, through JV or technology license agreement, domestic manufacturers have remained par with globally offered technologies. Global players such as Toshiba, Milacron, ASB Nissei and Sidel are also present in India. These players have a manufacturing base in India, and produce machines having the latest technology in injection moulding and blow moulding for domestic market as well as for export.‰ He says that these domestically produced machines find acceptance in developing as well as developed countries such as North 18 'QJA
America, Europe, China, Japan etc. Few of the machine manufacturers such as STEER have their own R&D facilities and have global patents to their name. Cheaper Second-hand Machines But despite this fact, the share of imported machines, particularly second-hand machines and low-cost machines have increased in the country, Maity reveals. „Between 2002-03 to 2012-13, machines were added at CARG of 7.3 per cent. The growth of local machines was at 5.1 per cent CARG, whereas imports grew at 27 per cent CARG,‰ he adds. According to him, a large number of machines have been imported from China, but now with antidumping duty, direct imports from China have reduced, still these machines are arriving via other SE Asian countries, which enjoy FTA benefit. He further updates that industry has seen sizeable growth in past 5 years in tandem with our growing economy. Domestic manufacturers have 54 per cent share in the machinery market, while the share of imports is 46 per cent. Imports are mainly from far East on account of low price and shorter delivery period. Highlighting the reasons for popularity of second-hand machines, Maity explains that advancements in processing machinery
Atanu Maity
President & CEO Steer Enginering
for enhancing the energy efficiency and productivity have occurred in recent past. Under the compulsions to reduce the carbon footprint, processors in the developed world are replacing the older machines with new technology machines. Thus, used machinery from developed world is finding a way to developing world with an attractive price tag. Used ă aged machinery population -if allowed to increase- will definitely harm the industry in the long term, but at this juncture low cost machines are creating tough competition for major domestic machine manufacturers. Over past few years approximately 30 per cent of imported machines are second-hand.
The share of import till 2012-2013 (Nos.) 1999-2000
2005-06
2009-10
2012-13
Domestic
2,955
3,105
3,889
3,941
Imports
156
1,600
2,593
3,357
Indian Market
3,110
4,705
6,482
7,298
Installed Capacity
3,400
5,000
6,250
9,600
Share of Imports
5%
34%
40%
46% DAIE?=H "JCEJAANEJC 4KNH@
CEW News Features According to Atanu Maity the cost of production in India is higher due to following reasons Higher Input Cost: In order to bring domestic machines on par with global manufacturers technology components are imported from Europe, USA and Japan. Technology parts which are imported form on an average 25 per cent to 50 per cent of material costs. These imports attract ~8 per cent customs duty leading to increase in prices of finished goods, which in turns make the domestic products uncompetitive in comparison to global manufacturers. Taxes and Duties: Existing tax structures, duties, FTAs and regulations have created an unequal playing field between domestically manufactured goods and imported goods, imposing higher costs on domestic manufacturers. The current system of taxes leads to distortions to the detriment of domestic manufacturers. While the difference varies across states; the overall tax and duty structure can cause a 17 per cent cost disadvantage for domestic manufacturers. Further, certain automation equipment are required in the machinery for improving productivity, reducing wastage and improving quality levels. These automation equipment, which are currently covered under Tariff Heading 9031, are not manufactured in the country and attract an import duty of ~8 per cent. FTA: FTAs, in certain cases, are also creating an undue advantage for global competitors seeking to tap into Indian demand. If corresponding measures for creating a level playing field are not adopted, such as, lower duties for raw materials costs, domestic manufacturers will remain disadvantaged. Not only are manufacturers in these countries benefitting, but exports from other countries such as China are also routed through FTA countries to secure greater advantage over local manufacturers. Lack of Efficient Supply Chain: Quality and reliability of the product is decided by the quality of components put into its construction. Moreover, cost of the product is dependent on cost of parts from supplier. We need to develop efficient supply chain for cost-qualityădelivery using the cluster development programs. Lack of efficient supply chain also creates the necessity to carry high inventories & high inventory carrying cost. Lack of Skilled Manpower: Skilled manpower is in short supply in associate and supervisory category for processing industry as well as in machinery manufacturing. The education system in the current form and curriculum prevalent at institutes and universities does not create industry employable manpower, with the exception of diploma and degree in plastics stream conducted by some of the institutions. Modern Manufacturing Processes: Most manufacturers have not adopted modern manufacturing processes & systems such as forecasting, advance planning with use of ERP; all these causes longer delivery time of machinery. 'QJA
Disadvantage of Using Second-hand Machines „Second-hand machines are cheaper, but it will affect the productivity in the long run, for sure,‰ he adds further. „As the second hand machinery import is reported to be of older technology, the use of such machines is likely to impact the productivity, quality and competitiveness of domestic plastics processors. New technology machines help in achieving the fastest possible productions, continuous & smooth operation for long periods, low downtime, no major failures, maximum repeatability due to minimum rejections despite fine tolerances, low materials waste, minimal energy costs and long machine life span. These aged, second-hand machines consume greater energy, have greater variations in dimensions and due to this consume higher polymer per product,‰ Maity explains further. He exemplifies that a plastic cup produced using an old injection moulding machine with technology of 2000 or prior will consume 1.1KW/Kg and produce part which will weigh 16 gm in 9 sec. The same cup can be produced using latest technology machine in 8 sec, with part weight of only 14 gm and power consumption of 0.8 KW/kg. According to Maity, the cost of recent technology machines is higher by 30 to 40 per cent than the old technology conventional systems. Indian plastics processing industry is highly fragmented and majority of players are from small and tiny sector; low cost second hand machinery attract them instead of buying new technology machines which are relatively high priced. Also, many a time these processors find it difficult to obtain required funds from FIs and hence are more inclined to buy second hand machinery to meet the production requirement and deadlines. Steer EngineeringÊs Contribution When asked how well-designed are the machines manufactured by Steer Engineering to ensure higher output, better quality and less involvement of people, Maity educates that with around 25 global patents in various stages of approvals, Steer Engineering has developed technology and designs which provide overall improvement in product quality at lower cost due to higher output and less energy consumption. He says, „This improvement is due to special elements, shaft designs which are capable of higher torque, gearboxes that are suited for product requirement. Improved and special material of construction allows operation at higher rpm which not only improves output, but also reduces resident time of melt within extruder.‰ „SteerÊs strategy is to remain close to its customers and be alert to changes in the market in terms of volumes, technology and applications. Coupled with steady investments in R&D, the company would be ready with capacity and enhance the technological features of its products or the range of services required by our customers,‰ Maity concludes. - Harshal Y Desai DAIE?=H "JCEJAANEJC 4KNH@
CEW Features
FERTILISERS: ALL EYES ON GOVERNMENT... The growth of Indian fertilizer sector has been marred during the last decade which can be attributed to volatile energy costs, policy paralysis and very high dependence on raw material imports. The subsidies offered to the fertiliser industry too could not bring the much needed respite to bolster the growth of this sector. Manufacturers have been forced to carry subsidy burdens over stretched periods of up to 180 days and in some cases even 12 months, which severely impacts the operations and profitability. As a result of inadequate availability of raw material, India has almost 50 per cent of underutilised capacity. Though urea can be produced to certain extent from indigenous sources, our industry relies completely on potash and phosphate imports to produce phosphate based fertilisers. Any fluctuations in global supply chains have adverse impact on the Indian manufacturers. Sadly, despite being considered one amongst the largest agrarian economies globally, the fertiliser consumption is very low in India as compared to many countries like Bangladesh & Pakistan which have far lesser geographical spread in comparison. Nutrient Based Subsidy (NBS) scheme, launched in 2010 was a good move but was not extended to urea manufacturers and in the due course of 18 months the benefits of NBS have been partially neutralised, shares Suresh Krishnan, MD, Zuari Agrochemicals Ltd. With the new government in place, R Mukundan, MD, Tata Chemicals Ltd is optimistic about the improvement in policy regime during 2014 with implementation of NBS for urea and timely payment of subsidy bills. Setting up of Sovereign Wealth Fund (SWF) has been appreciated by the fertiliser industry but would require careful allocation of funds. Guy Goves, President, Agri Business & Farm Solutions, DFPCL is of the view that setting up joint investment fund to increase inorganic footprint through acquisition of raw material assets can go a long way towards securing long term supplies. Mukundan identifies technology stagnation as one of the major deterrents for the growth of the indigenous fertiliser sector. Internationally, fertiliser producers have deployed advanced technologies in their facilities, which enable them to be globally competent, whereas, over regulation and price control have refrained the investors from enter the Indian market.
GAME CHANGERS Acquire overseas assets to secure raw material supplies
Invest in technology up-gradation
Encourage investments in new technologies like coal gasification
Ensure prompt subsidy payments
Explore different business models - PPP and JVs etc to revive sick units Chalk out focused intent of Sovereign Wealth Fund Set up Joint International Fund for asset acquisitions
Extend NBS to urea Announcement of comprehensive National Energy Policy would benefit the industry at large; the government has also proposed policy changes in the oil & gas sector which would include introducing uniform licensing policy to facilitate E&P operators to work under the single policy regime. However, government will still require striking the balance in gas pricing, allocation and subsidies mechanism for the fertiliser sector to realise its true potential. The new government has given positive feelers to drive the growth of the fertiliser sector. However, this would require concerted effort on the part of policy makers and the industry to put the fertiliser sector back on a growth trajectory.
Adopt calibrated price increase of urea by 20 per cent minimum for next 4 years Remove 35 per cent cap on neem-coated urea
Gas allocation to urea & NPK fertilisers
- Mittravinda Ranjan 24 â&#x20AC;˘ June 2014
Chemical Engineering World
CEW Features ONE ON ONE
Itâ&#x20AC;&#x2122;s a Serious Business, Govt Must Pull its Socks Up The growth of Indian fertiliser sector has been saddled with various issues right from raw material deficit to market volatilities in gas prices to policy paralysis. This sector has gone through the most turbulent phase over the last decade. With the new government in place, fertiliser manufacturers are very optimistic about the growth of this sector and hoping that they take the much required initiatives to put the growth of this sector back on track. In an exclusive interview, with CEW, Suresh Krishnan, Managing Director, Zuari Agrochemicals Ltd, shares his views on these issues.
Please share an overview of the fertiliser consumption patterns in Indian market. The total consumption of urea last year was close to 30 million tonnes of which 23 million tonnes was produced locally and 7 million tonnes was imported. As far as the Diammonium Phosphate (DAP) segment is concerned, which is the larger Nitro Phosphate (NP) segment, India imported 3.2 million tonnes while the domestic production was 3.6 million tonnes. We also produced 7 million tonnes of Nitrogen, Phosphorous and Pottassium (NPK) in India. In a good year, India consumes about 30 million tonnes of urea and 20 million tonnes of NP and NPKs. NP and NPKs have seen a decrease in sales and production over the last two years largely due to two reasons - 1 st, the uncertain period of monsoons and 2 nd, pricing.
2013: Overview
Urea
Total consumption 30 MT Indigenous production 23 MT Imports 7 MT
DAP
Indigenous production 3.6 MT Imports 3.2 MT 26 Â&#x160; 'QJA
Consumption in the last 24 months has declined in India in this segment. Last decade has been very tough for Indian fertiliser sector, where the growth was saddled with various factors including the ones related with the policy. May we have your comments? Yes, it is true. Over the last 10 years, the fertiliser industry has had a challenging time. The one positive thing for the industry has been the introduction of Nutrient Based Subsidy (NBS) scheme in 2010. It was indeed a good move by the government. However, the benefits of NBS have been partially neutralised in the last 18 months.
The Indian fertiliser industry is very efficient as the cost structure of the industry is highly competitive when it comes to the conversion cost. However, feedstock price is one of the major reasons for the high manufacturing cost of the fertilisers. This is because the raw materials such as natural gas, phosphatic rock and potash required for manufacturing are not available in India. Hence, the industry is totally exposed to global prices of raw materials and foreign exchange fluctuations.
I must say that the fertiliser segment of our business in the last two years has not been able to hold on to profitability. However, our dominant market position, built over many years along with diversification into agri-inputs has stood us in good stead and allowed us to remain profitable.
Being a conduit, the industry needs to be paid on time, but somehow, it has been forced to carry the burden of subsidy in the books for a very long period. The primary principle of the fertiliser subsidy pay out being followed for the last couple of decades has been that the subsidy is released within a period of 45 to 60 days after the material has been produced and delivered.
Subsidy burden has been an ongoing debate for the fertiliser industry, but we have not yet reached a conclusion yet. What is your take on that? Let us understand very clearly that the industry is just a conduit to deliver subsidy, not being subsidised itself.
But we have noticed that the subsidy period has now increased stretching upto 180 days as well. There are certain elements of the subsidy which have not been paid for more than 12 months. This is exerting enormous pressure on the fertiliser industry. DAIE?=H "JCEJAANEJC 4KNH@
CEW Features What are your thoughts on the plans of the government to set up Sovereign Wealth Fund (SWF)? The SWF is a very good thought the government has come up with. I think the allocation of money should be far more serious here and the statement of intent should be very clear in terms of what kind of participation this fund will finally end up doing. One of the good ways of doing this would be to provide long term money to the Indian fertiliser industry wanting to invest and integrate in the upstream of this sector which means buying into mines and buying into resources which are being imported into India. For this, the quantum of money required would be more serious and the same will have to be truly long term. How have the overall dynamics impacted the performance of the company and what are the key strategic decisions that the organisation has taken towards maintaining positive growth momentum? As a long term growth strategy, we are going ahead with the backward integration for our DAP/NPK fertiliser segment and have planned investments of C 4000 crore in the Middle East (ME) to supply DAP to the Indian market. India is a net importer of finished fertiliser and 3.2 million tonnes of DAP was imported last year (which was about 7 million tonnes a few years back). Zuari Agrochemicals is a major supplier of DAP in IndiaĂ&#x160;s south and south western markets and it is now expanding in the northern part of India as well. This project is a strategic move in the direction of converting part of trade supplies into manufactured products for our markets. Currently, the project is in the planning stage with basic approvals already in place and feasibility studies are in progress. We are targeting to achieve the financial closure during this year and it would take another 3 years to commission the facility. Do you plan to set up urea ammonia based fertiliser units in the ME? The first and foremost criterion for setting up a nitrogenous facility is to locate a site where gas is available at a competitive price. It may be a good idea to set up such a plant in the ME but most of the recent gas finds or expected finds are seen 28 Â&#x160; 'QJA
largely in the African markets. There is no surplus gas available for investment in the ME, as per our information. India is setting up single phosphate greenfield project in Rajasthan. Is there a possibility of such projects elswhere in the country as well? In India, the Single Super Phosphate (SSP) manufacturing units have come up in the last two decades. However, the capacity utilisation of the local industry is not even 50 per cent today. The manufacturers have not been able to procure adequate material to run their plants at full capacity due to their location and their linkages for the supply of these raw materials. Today, even the local producers are importing rock phosphate. In this scenario, expecting a local project based entirely on local raw material to materialise is quite a challenge. Unless investments are made in the upstream, it will not be possible to have any new local projects based on local raw materials. I do not see any major change in the availability of local raw materials for the NP/NPK sectors in the near future. How do you propose dealing with the challenge of technology upgradation? The Indian industry has evolved over the last four decades as far as the ammonia urea manufacture is concerned. At any given point of time, India has always had projects which have been most competitive in terms of energy consumption and conversion cost. The overall efficiency and the input output ratio of any new plant to be set up in India will be far more competitive than what we have today. There is a good possibility for most of the units in India to be upgraded to the contemporary competitive global level. To achieve this, the Government of India must have a programme wherein they give incentives to the industry to modernise their technology and expand their capacity, resulting in ROI, which is beneficial both to the industry and to the government in the long term. This way, the government will be able to convert all the existing capacities to more competitive and efficient long term capacities over the next five years for the good of the Indian industry.
What are the corrective actions required to be taken to bolster the growth of fertiliser industry in the country?
Firstly, the government needs to have a long term strategy on handling subsidy. This has to be done keeping the global prices in mind. The government needs to decide what kind of subsidies it intends giving to the consumer at large and how it wants to target it. It is absolutely important for the government to have a clear position on this. Secondly, the government needs to look at correcting the MRP of urea in India. Currently, urea is priced at approximately C 5360 per tonne, which is not good for sustainability of fertiliser usage in India, as the overall NPK ratios need to be maintained for appropriate soil health. The third critical point is that the government needs to prepare a policy framework which encourages investment in this sector. It may be worth mentioning that this is one of the sectors which has not seen capital investments since the last 15 years. Fourthly, the trade aspect of this sector needs further opening up. Urea imports are still controlled. Similarly, while phosphatic fertilisers are imported, its export is again subject to government approval.
What would a perfect model for India? India is one of the largest fertiliser markets and the business environment for this sector is completely different from the rest of the world. Hence, there has to be an Indian model in place best suited to meet our needs. Other large countries such as the US have a different dynamics in terms of availability of raw materials and consumption drivers. Furthermore, other large consumption centres such as China, are still very comfortable in terms of availability of raw materials. It is essential to have a unique model for India as it is a big consumer with literally no availability of raw materials. Time has come for pooling of gas prices for the urea industry so that it can bring all manufacturers to a common platform, wherein all of them can compete, perform and extend the NBS scheme across all nutrients. DAIE?=H "JCEJAANEJC 4KNH@
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CEW Features ONE ON ONE
Technological Advancements Will Pave the Way for Growth A favorable regulator y environment that propels technological advancements is what we need to reinvigorate the fertiliser sector, believes R Mukundan, Managing Director, Tata Chemicals. Mukundan further shares views on how the new government should ensure the overall development of the fertilise sector in the country. He also questions the need for the New Investment Policy.
Please share some insights into the future-scenario if the government decides to double the gas price? Any gas price hike by the government must be supported by increased domestic production to ensure overall gains to Indian economy, hence the government should link price hike to increased production by domestic producer and they must be held accountable to meet with the committed production levels to address the growing demand and curb IndiaÊs import dependence. While the expected hike in gas price may lead to an increase in the subsidy burden for the government, it can look to offset the additional burden through higher royalty, profit sharing and tax collections from upstream operations expected in development of new gas resources. It will also benefit the overall economy by reducing expensive LNG imports. Further, the recent announcement by the government to promote a comprehensive National Energy Policy that focuses on development of energy related infrastructure, human resource and technology is a welcome move which would benefit a number of sectors, including the fertiliser sector. How is the Âgas price in US dollarÊ affecting the industry? In your view, 30 'QJA
what should be an ideal mechanism to calculate and fix the gas prices? The domestic gas price in USD was introduced five years ago; since then the rupee has depreciated by nearly 25 per cent. Due to the currency exposure, prices expressed in rupees have seen an increase, which in turn have led to higher working capital cost. The Fertilisers Association of IndiaÊs submission on the ideal mechanism to calculate and fix the gas prices is quite valid as high gas prices and further increase in fertiliser imports will push up international prices and will lead to increased outgo of foreign exchange. Therefore, there is merit in the domestic gas price to be billed in Indian rupees, not USD. Besides the glaring disparity in the price of feedstock, how are the issues ie, release of timely payment of subsidies, in-balanced usage of urea, low budgetary allocation to the industry affecting the Indian fertiliser sector? The countryÊs twin deficits, fiscal and current account, have reached levels that have prompted a wave of prudence by the previous government.
Against a requirement of C 1 trillion, the government allocated C 67,970 crore for the current fiscal. With arrears reaching as much as C 32,000 crore, the budgeted subsidy amounts are getting exhausted fast. As a result, firms are making up for delayed payments through borrowings, which are driving up interest costs. The problem of under-budgeting, especially when the urea subsidy bill is likely to bloat in the next fiscal, will need to be addressed. The huge price gap (50% to more than 100%) with complex fertilisers is leading to disproportionate usage of urea which requires the government to slowly rationalise urea pricing. Moreover, the low recover where in only one-third of the price is recovered from farmers are distorting the market and firms are reluctant to invest in new technologies. Policy regime for fertiliser business is likely to improve in 2014 with implementation of Nutrient Based Scheme (NBS) for urea and timely payment of subsidy bills by the new government. As a fertiliser company, how do you maintain the profit margins and
The Fertilisers Association of India’s submission on the ideal mechanism to calculate and łx the gas prices is quite valid as high gas prices and further increase in fertiliser imports will push up international prices and will lead to increased outgo of foreign exchange. DAIE?=H "JCEJAANEJC 4KNH@
CEW Features operating cost through balancing the subsidies offered to the fertiliser sector for gas and those to the farmers? As a fertiliser company, we have already stretched our efficiency to the best possible level. Delay in payment of subsidy is impacting our operations as well as profitability adversely. Inaction in the sector has weighed on our finances and share prices in the past three years. All these issues need governmentÊs attention. In fact in Q4 of FY14 even Tata Chemicals made losses in fertiliser business for the first time. May we have your comments on corrective actions and new measures that need to be taken immediately to attract investment in this sector by the industry as well as the policy makers? The natural gas prices should encourage investment in the upstream segment and boost domestic production of natural gas. However, the new government should look at putting in place a robust framework that enhances the accountability of domestic gas producers. In addition, the government should also look at enhancing the production efficiency by supporting the right technology and giving out incentives for efficient domestic production. New avenues such as coal gasification should also be considered as future source of fuel. The new government can adopt a few corrective actions such as deregulating the price of urea or inclusion of urea under ÂNBSÊ scheme, reviving sick and closed fertiliser units to boost capacity, and encouraging industry players financially to set up overseas facilities thus attaining self-sufficiency in urea production. What is your take on the planned move of Department of Fertilisers for creation of Sovereign Wealth Fund (SWF) acquiring fertiliser assets abroad? To what extent this
action would bolster the growth of fertiliser industry? Indian fertiliser companies rely entirely on imported potash and phosphate. Urea is the only fertiliser where the country can partly rely on domestic production, although availability of natural gas remains a major issue. In order to create long-term resource security for the country in the fertiliser sector, we believe that the new government should push for acquisitions abroad and the creation of a SWF for acquiring fertiliser assets abroad, on the lines of the China model. The government is already looking into setting up common overseas acquisition arms, and the need of the hour is to source resources like potassium, rock phosphate and urea from abroad. Access to raw materials and appropriate technology transfer would help in making the industry more sustainable. Technology stagnation has been cited as one of the constraints for the growth of Indian fertiliser sector. May we have your views on how this issue can be tackled in Indian context? Internationally, the fertiliser producing technology has progressed many folds with advancements focused at making plants more efficient. In India, deficit in technological advancements in the fertiliser sector is one of the biggest constraints for the growth. Overregulation and price control has resulted in the country not witnessing any significant investment. Due to a lack of clarity on returns and input cost pricing, no new urea plant has come up in recent years. In order to revive the industry, the new government would need to make the sector attractive for investors and create a conducive regulatory environment that propels technological advancements. This can only be done by removing price control and incentivising efficient producers.
The natural gas prices should encourage investment in the upstream segment and boost domestic production of natural gas. However, the new government should look at putting in place a robust framework that enhances the accountability of domestic gas producers. 34 'QJA
Your views on recent policy changes proposed for the fertiliser sector (Urea & Nutrient based) While a lot has been mentioned and talked about New Investment Policy for urea, I believe this is not the most important move government should focus on. In fact, we probably donÊt need New Investment Policy. The recommendation for the government would be to remove the 35 per cent cap on neem coated urea and make neem coated urea mandatory; extend NBS to urea; adopt a calibrated price increase of urea by at least 20 per cent every year for next 4 years; ensure prompt subsidy payments; focus on government to government contracts for investments in urea and other fertilisers assets overseas using SWF; focus on improving farm productivity by rejuvenating agriculture extension services and ensure priority allocation of domestic gas to domestic urea. As an immediate step, the new government can look at handing over the sick units to the public sector on nomination or make it open for the private sector. It can also be done through public private partnerships and joint ventures. Private sector participation will bring in much needed competition and improve efficiency. Further, the government should look at granting state owned companies more autonomy and focus on increasing efficiency as showcased by the Gujarat government. Over the last 10 years several stateowned companies such as Gujarat State Fertilizer and Gujarat State Petroleum Corporations have turned around due to such initiatives. There is a need to diversify the feedstock used by the industry rather than it being over-reliant on natural gas. With recent advances in coal gasification technologies, the competitiveness of coal-based fertiliser projects has improved substantially. A number of public-sector companies in India are coming together to revive fertiliser plants, which are also public-sector undertakings. DAIE?=H "JCEJAANEJC 4KNH@
CEW Features ONE ON ONE
Will Bringing Urea under NBS Make the Difference? Guy Goves, President, Agri Business and Farm Solutions, DFPCL, believes that the NBS has been good for the country, but not bringing urea into the NBS is one negative move which has impacted balanced fertiliser application. He says, countries like Bangladesh and Pakistan which have lower subsidies use higher fertiliser doses and have higher productivity.
Please share some insights into the future-scenario if the government decides to double the gas price? What should be an ideal mechanism to calculate and fix the gas prices? If this happens then for urea companies the subsidy would go up to the extent of the increase or the government may want to increase the price of urea to offset the increased subsidy burden - in all likelihood it would be the latter. It is quite possible that there would be surplus gas because in the power sector there would be fewer takers as the price increase is unaffordable. So, some of hte options can be, first, Fixing the price on a weighted average price for gas rather than simple average; second, working out the gas price on purchasing power parity with other nations; and third, excluding gas prices from the calculation as per the first point of those nations where gas is used for high end industrial uses like Japan. What are the elements affecting Âbalance application of fertiliserÊ? The glut in 2012-13 and the drought situation greatly impacted the fertiliser industry’s working capital as companies had to offer longer credit periods as well hold inventory for a longer period, and 36 'QJA
delay in subsidies further stretched the cash flows of these companies. Further, keeping urea out of the Nutrient-based Subsidy (NBS) has had an adverse impact on balanced application of fertiliser. Analysis has shown that wherever complex plants are situated the fertiliser application is more balanced. Urea should be brought under NBS. Low budgetary allocation to the sector leads to further delays in subsidies as more often than not subsidies run out half way through the year. All these factors ensure that this sector is not attractive to investments, yet the industry is one of the main drivers of food security which should be very high on the agenda of the government. As a fertiliser company, how do you maintain the profit margins and operating cost through balancing the subsidies offered to the fertilizer sector for gas and those to the farmers? We focus on operating cost and efficiencies as we have to compete in a competitive
market environment where market prices are concerned. Brand building and farmer connect give our products better salience in the market. Our Agri business and farm solution drive our ‘farmer connect’ to make our products the ‘choice’ of the farming community. What is the role of technology to strengthen the sector? The way I see it, technology would play a great part if we are to create competitive and sustainable agri ecology. Optimisation of land for better productivity, new seed varieties, sustainable water management, new and safer molecules in terms of crop care, mechanisation and improving the disorganised supply chain, should be some of the key drivers for agri growth. Most importantly, as the domestic markets are emerging, triggering a huge import requirement for products like apples and pears, our farmers should be enabled to access international markets through better know how and GAP certification so that they could
As a country we are dependent to the extent of 60 per cent on imports of nitrogen, 93 per cent on imports of phosphates and 100 per cent on potash to fulfil our needs; in this context the country should set up a joint investment fund to invest in projects abroad to ensure raw material security for the country. DAIE?=H "JCEJAANEJC 4KNH@
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CEW Features be globally competitive domestically as well. What are your expectations from the government? The government should move away from controlling the industry from the subsidy angle and instead give subsidies directly to farmers. Allow the fertiliser Industry to be more market oriented and competitive. As a country we are dependent to the extent of 60 per cent on imports of nitrogen, 93 per cent on imports of phosphates and 100 per cent on potash to fulfil our needs; in this context the country should set up a joint investment fund to invest in projects abroad to ensure raw material security for the country. The government should focus on sustainable agriculture in terms of water management and help set up structures to ensure that a competitive and productive environment is provided for the farming community. The single point agenda should be to make the Industry more market driven, give subsidies directly to the farmer and ensure that companies have a more market driven environment where competitive advantage is created through differentiation and economic cost structures. Reviving sick units should not be on the agenda, ensuring raw material security for gas, ammonia, phos acid should be high on the governments agenda along with improvement in farm productivity.
CEW had earlier interviewed K Rahul Raju, Managing Director, Nagarjuna Fertilzers and Chemicals Limited (NFCL) who shared insight into the challenges and possible solutions to transform the sector. Excerptsâ&#x20AC;Ś On gas pricing There is lesser interest in investments from gas producers in the country primarily because of slow decision making process and bureaucratic delays, and the second reason is not offering market driven prices to the gas producers. Though gas prices must be revised to incentivise the producers to implement the projects in order to step up gas production, the prices for the fertiliser industry could be maintained at a level to keep the indigenous manufacturers competitive against the imports. This is very important as India relies for 30 per cent of its urea supplies from the overseas market to meet the domestic demand. The CCEAâ&#x20AC;&#x2122;s decision to increase domestic gas prices is fair and the gas produced within the country cannot be compared with the imported RLNG. No country does that for survival of its end users. Once, the revised prices are implemented by the Department of Fertilizers (DoF), and ensuring that the Fertiliser Manufacturers are competitive by imposing extra customs duty for imported urea; the Industry will become efficient to survive against the global manufactures.
On price trends in ammonia and phosphates Ammonia and phosphate prices seem to be stable in the next couple of years, though there are some seasonal fluctuations in the same. We are banking on the Indian government to decontrol urea segment as they have done for the phosphate and potash segments. The subsidies by the government have to be decreased by increasing the price of urea which is currently very low and is being misused. On feedstock diversification from natural gas to coal gasification The technology for coal gasification for production of ammonia is available today in countries like China and few other European countries, and they are producing ammonia by using this technology. However, high ash content continues to be a major problem with Indian coal and using this would incur high capital cost and sizeable maintenance cost. Currently, the availability of coal from Coal India is also an issue and gas seems to be the best option for production of ammonia and urea for the Indian Industry. The interview was covered in May 2014 issue of CEW.
DFPCL Fertiliser Plant
38 Â&#x160; 'QJA
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CEW Features Technical Article
Corrosion – Tackling Challenge in Indian Fertiliser Industry Corrosion has continued to be a major concern for manufacturers of phosphatic and nitrogenous fertilisers due to corrosive nature of raw materials used in the production process. Industry runs high risk of encountering unforeseen downtimes due to damage caused by corrosion and result in heavy losses to the fertiliser manufacturers. The authors briefly review typical forms of corrosion observed in fertiliser plant and recommend measures to improve overall plant reliability.
I
ndiaÊs agriculture industry is a major consumer of phosphatic fertilisers viz, single and triple super-phoshates; and nitrogenous fertilisers which include ă ammonium sulphate, ammonium nitrate, di-ammonium phosphate, calcium nitrite and urea. Phosphate rock is the primary source of raw material to produce phosphatic grades. For nitrogenous fertilisers, hydrogen and nitrogen are the main raw materials for ammonia production. Typically, hydrogen (H) is generated by steam reforming of natural gas, while nitrogen is obtained through air liquefaction. The production process involves use of acids like phosphoric acid, nitric acid and sulphuric acid that are produced on-site (Figure 1).
Figure 1: A typical flow sheet of a fertilizer plant
40 • June 2014
Corrosion in urea manufacturing plants Corrosion is determined by temperature, process components and concentration of dissolved oxygen. Presence of contaminants may accelerate corrosion. Use of stainless steel (SS) lined carbon steel vessels in HP synthesis section and leak detection units (1, 2) can help mitigate the impact of chemicals on the process unit. Some of the typical forms of corrosion that occur in urea plant include Ć
Active corrosion is one of the most common forms of corrosion that can be prevented by exposing SS to carbamate solutions and passivated by the design amount of oxygen, else SS suffers severe thinning thus reducing longevity of the equipment
Ć Ć
Ć
Ć
Erosion corrosion Inter Granular Corrosion (IGC)is due to oxidizing action of oxygen containing urea carbamate solution, a low NH 3/ CO 2 ratio and segregation of impurities in sensitized SS. Any chloride ingress in the shell side of the stripper/carbamate condenser will initiate Stress Corrosion Cracking (SCC) on austenitic SS tubes, whereas duplex SS material resists SCC. Galvanic corrosion occurs in intercooler and after cooler of CO 2 gas cleaning circuit (3) , which in some cases have resulted in shutdown of the plant within six months. In one of the cases, AISI type 304 SS parts ă sealing strips, fins, demisters and the shell that were in contact with the duplex SS tubes suffered galvanic corrosion. Remedies reported are 304 SS for all parts of inter and after coolers; cool scrubber exit CO 2 gas to condense water and increase 0.8 per cent oxygen in CO 2 gas before entry into the intercooler for an effective passive film on SS.
Acid Attacks Phosphoric Acid (4): Level of impurities like fluorides and chlorides in phosphate rock decides the extent of attack downstream processes. Some of the reported failures include SCC and pitting/ crevice corrosion, thinning and leaks of phosphoric acid tanks and acid loading pipe cracking. Techniques such as Âredox adjustmentÊ or ÂMg additionÊ are reported to reduce corrosion. The process water Chemical Engineering World
CEW Features associated with by-product phosphorgypsum is acidic and corrosive. Nitro-phosphoric Acid(4): Used in manufacture of nitrate containing compound fertilisers. Temperature control to 700C and monitoring is critical to minimize corrosion in reacting rock phosphate in HNO3. Nitric Acid: Corrosion protection is through suitable austenitic SS. Aqueous Amine Solutions: Mono ethanolamine, di-ethanolamine or hot potassium carbonate solutions used for absorption of CO 2 in the process are corrosive, inhibited by V2O 5. Urea Ammonium Nitrate (UAN) (5) : Acidic nature of UAN makes it highly corrosive to CS, and results in Âsurface corrosionÊ when the ammonia levels are low. Accumulated corrosion deposits lead to crevice formation between/and eventually pitting. It is very important to control the level of ammonia when the surface is wet with UAN as excess ammonia of the order of 100 to 2000 ppm helps to mitigate the corrosion. Some of the control practices include: Ć Cleaning at least once in two years; recirculation of sludge during inbetween period Ć Use sloped bottom tank for removal of sludge (1) Monitor and maintain neutral pH, with ammonia levels >100ppm (2) Salt out condition causes corrosion if AN/Urea ratio is not between 1.2 to 1.4 (3) Use filmer or passivator type of corrosion inhibitor (4) Use coatings, linings , SS or plastics MIC Microbial Induced Corrosion (MIC): This is a perennial problem in fertiliser waste waters. Heat exchanger tubes show MIC leading to pitting and fouling (6, 7) . DAP-NPK in the effluents serve as nutrients for a) Fungus Aspergillus to produce corrosive organic acids, b) sulphates and low DO (dissolved oxygen), favorable to H 2 S production by Desulphovibrio desulphuricans, Clostridium perfringens, thus resulting in MIC. 'QJA
Improving Plant Reliability Current fertiliser production plants are very complex with individual units operating at various temperatures and pressures as per the licensor technology employed by the end-user. The plant availability and reliability is enhanced substantially by adopting following modern techniques: Ć HAZOP study: It is a design stage activity and continued at each stage when modifications, affecting the plant performance, are incorporated. It is a structured review of the Piping and Instrumentation Diagrams(P & ID) with the project group to ensure that adequate controls, instrumentation and interlocks are in place to take care of any process upsets, Ć Safety Integrity Level(SIL): Analysis of control system should be mandated to ensure that the critical loops in the plant are in conformity with International Safety Standards IEC 61508 & IEC 61511and to verify that the plantÊs safety functions meet the SIL requirements and to recommend possible mitigations if SIL standards are not complied with.
Potassium and chlorine deposits: Fertiliser manufacturers are now moving to use of biomass as an alternative source to derive the H requirement. Gasification of straw is one such source of H but poses the problem of corrosion due to the threat of high K and Cl deposits (8). Storage & Handling Corrosion in storage of fertilizer solutions can due to three main factors - decomposition or induced reaction to produce aggressive substances such as NH 3 or H 2 S, presence of chloride ions - including K or NH 4 Cl, or if acidic conditions prevail. Generally, in dry conditions, no corrosion is reported. Initially, moisture ingress results in caking, adding abrasive properties, in addition to corrosion. MOC like CS have limited resistance to corrosion while galvanized steels, aluminum and SS can withstand corrosion to a greater extent as compared to CS. Paints and coatings can generally improve equipment life. Tables 1, 2 & 3 describe the impact of corrosion on different materials of construction (MOC). Liquid fertilizers
Chemicals
Reactions with steel
Nitrogenous solutions
Ammonium nitrate, urea Slow reaction with steel, can be more rapid at welds and bolt holes, etc.
Phosphate solutions
Ammonium phosphate
Protective phosphate coat against nitrogenous solutions, in absence of acid conditions
Table 1: Corrosive reactions of liquid fertilizers (9)
Fertilizer
Corrosion rate, mpy Mild steel
Galvanized steel
Ammonium nitrate: Saturated /63% solution
50/15.2
10/11.2
Ammonium nitrate and chalk: Saturated /67 %
32.6/42.8
13.2/13.6
Compound fertilizers(0,24,24) Saturated solution 8
2.4
Controls in clean water
0.8
2.4
Table 2: Laboratory tests- Steel corrosion rates in fertilizers at ambient temperature (9)
Material
Corrosion Rate(mpy)
SS 304
0.01
Carbon steel
11.2
5052 Aluminium
5.28
Table 3: Material performance in commercial liquid fertilizers (9)
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CEW Features Ć
Ć
Ć
Ć
Ć
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Emergency shutdown (ESD) and proper start up of the plant. All plant personnel should be drilled into ESD procedures. Provision of Distributed Control System (DCS) and Advanced Process Control System (APC) should be provided to take care of inherent flexibility required in process operations, because of changes in quality and availability of feed stock, changes in process conditions. Selection of trustworthy and reputable vendors, who will work with the industry at all stages of plant change implementation, is critical. Provision for improving plant performance by incorporating corrosion monitoring techniques, which can form the basis for Residual Life Analysis and Aging Management programs. Typical examples of such activities will include provision of corrosion coupons, NDT testing programs, tested and reliable models to extract information out of corrosion monitoring devices. Complete understanding on the effect of materials selection on plant corrosion and hence its operation. Typical examples for a reformer section, urea plant and characteristics of FRP resin are listed here and comparison of MOC used in urea plant (Table 4). (1) Primary Reformer performance has been improved by change of tube metallurgy from HK-40 to Micro-alloys like Manurite 36M, Paralloy H39W. (2) Urea Stripper has undergone upgradation from Ti tubes to Zr tubes and to Sandvik 2RE69. FRP: In Âwet processÊ H 3PO 4 and H 2SO 4, typical MOC include high Ni alloy, rubber-lined CS, acid bricklined CS and resin coated CS. Choice is based on life expectancy and cost (Table 5). FRP with epoxy vinyl ester resin seems to be a suitable material for some equipment and piping and for abrasion resistant applications (gypsum slurry). Typical laminate is shown in Figure 2
44 'QJA
S.no.
MOC
Advantages
Disadvantages
1
Titanium
* Good passivation properties with less air
* * *
Susceptible to Erosion Difficult to Weld Expensive
2
Stainless Steel
* Immune to Erosion * Good Weldability
*
Large amount of passivation air required
3
316L-UG
* Excellent Weldability * Fair corrosion * Relatively less cost
*
Large amount of Passivation air required
4
25Cr-22Ni-2Mo * Excellent weldability * (2RE69)-Low to * Better Corrosion resistance zero ferrite. than 316LUG. *
Susceptible to SCC by chloride Expensive
5
Duplex Stainless * Good Weldability Steel * Excellent Corrosion (SAFUREX) Resistance * Passivation air is not required
Expensive
Table 4 Comparison of MOC for urea plants
Materials
Cost ratio
H2SO4ĈC/%
HCl C/%
Acid Chloride Salts
FRP -epoxy 1-1.5 vinyl ester
100/ 30
80/15
100ĈCAll conc.
2205 Stainless 1.88 Steel
30/ 30
60/1
65ĈCto 2000 ppm @ low pH
Alloy C-276
100 / 30
80/15
65ĈCto 50M ppm @ low pH
3.3
Table 5: Epoxy vinyl ester resin cost and chemical resistance comparison (11)
Exterior “Top Coat” or Veil as Required
2 Ply 1.5 oz./ft.2 Glass Mat 75% Resin 0.25 mm Veil 90% Resin
One Mat Ply or More for Corrosion Allowance as Required
Process Side
Mat Alternating with Woven Roving or Filament Winding as Required
Corrosion Barrier Portion (CB) 2.7 mm (100 mils) minimum E-glass or ECR glass
Structure Portion 6.4 mm (250 mils) minimum thickness
Figure 2: Typical Corrosion Resistant FRP Laminate Construction (11)
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CEW Features Adopting Risk Based Inspection (RBI) / proper Corrosion Monitoring Programs can lead to significant improvement in plant reliability and reduce annual routine shutdowns. Recommendations Ä&#x2020; Fertiliser manufacturers should develop methodology to maintain and optimise inspection programs for high corrosion risk to fertiliser plant equipment. Ä&#x2020; There is a need to compile the available data on corrosion in fertiliser industry since there is very limited data available.
References 1. Best Available Techniques for Pollution Prevention and Control in the European Fertilizer Industry. Production of urea and urea ammonium nitrate, EFMA 2000. 2. Fabrication of Construction Materials in Urea Manufacturing Plants . Deepak Juneja, Jitender Kumar, International Journal of Enhanced Research in Science Technology & Engineering, Vol. 2 Issue 9, September-2013, pp: (56-59).
28-31 January 2015, Mumbai, India
3. Corrosion failures of AISI type 304 Stainless Steel in a Fertiliser Plant. H. Shaikh et al. Engineering Failure Analysis, Volume 10, Issue 3, June 2003, Pages 329â&#x20AC;&#x201C;339. 4. Solutions to Corrosion Caused by Agricultural Chemicals : B. Eker1, E. Yuksel2, 1,2Trakya University, Tekirda Agriculture Faculty, Agricultural Machinery Department, 59030, Tekirda , Turkey. 5. Phil Bureman and Dr. Craig Meyers. â&#x20AC;&#x153;Take UAN Corrosion seriously.â&#x20AC;? Fluid Journal, Vol. 17, No.1, Issue # 63,2009. 6. Microbiological-InĂ?uenced Corrosion Failure of a Heat Exchanger Tube of a Fertilizer Plant. Journal of Failure Analysis and Prevention June 2014, Volume 14, Issue 3, pp 314-317. 7. Microbiological Characteristics of Wastewaters from a Nitrogen- and Phosphate-based Fertilizer Factory. Beatrice Nnene Uba , Bioresource Technology, 1995, Vol. 51, issues 2-3, pp 143-152 8. Ammonium Nitrate Fertiliser Production based on Biomass â&#x20AC;&#x201C;Environmental effects from a life cycle perspective., SerinaAhlgren,*, AndrasBaky, Sven Bernesson, Ă&#x2026;ke Nordberg, OlleNorĂŠn, Per-Anders Hansson , Bioresource Technology ,2008, 99, pp 8034â&#x20AC;&#x201C;8041 9. Anonymous, Corrosion control of agricultural equipment and buildings, http://www.npl.co.uk/ncs/docs 10. Improving Reliability of Fertilizer Plants,: S.C.Kar, Sr. Advisor &R.G.Rajan, CMD, Projects & Development India limited, www.pdilin.com/news/31. 11. The Use of FRP (Fiberglass-Reinforced Plastic) in Phosphate Fertilizer and Sulfuric Acid Processes. Don Kelley. Ashland Performance Materials 12. Inspection Manual for Fertilizers Industry. www.eeaa.gov.eg/ippg/.../ Fertilizers/Fertilizers%20english/Sec%202.doc
AuthorsĂ&#x160; Details V P Sastry Technical Committee NACE International Gateway India Section Email: cvmanian@gmail.com C V Manian Technical Committee NACE International Gateway India Section Email: vemuri.p.sastry@ril.com
46 â&#x20AC;˘ June 2014
Chemical Engineering World
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CEW Features Forward Focus
India Takes Pride of Place in Global Specialty Plastics Market Specialty plastics market is an extremely niche sector; the global volume of production is just 225 KMTA. Dr Prakash Trivedi, Polymer SBU, Gharda Chemicals Ltd throws light on the intricacies involved in specialty plastics, right from its properties, production to its application and market size. the conversion of monomers needs to be higher than 99.7 per cent.
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pecialty Thermoplastics are those which can withstand high temperatures, usually higher than 1700C for long periods. These usually have aromatic rings in chains, and therefore they have outstanding mechanical properties. Amorphous Polysulfone (PSU) with glass transition temperature (Tg) of 1790C is at their lower end and crystalline Polyether Ketone Ketone (PEKK) with melting point (Tm) of 3950C is at the highest end of specialty plastics. Production All specialty plastics are made using nucleaophilic or electrophilic substitution reactions on a single or two monomers at temperatures from ambient temperature to as high as 320 0C in an aprotic solvent. Getting reactive end groups capped and getting rid of bye-products, usually salts and solvent are as challenging as controlling chain structures and molecular weights (MW). Importantly, for higher MW,
Figure 1: Specific Flexural Modulus (MPa)
50 Â&#x160; 'QJA
While their overall production volume is low at about 225 KMTA, they make up with their higher prices starting at USD 6-10/Kg to USD 200/Kg and total business of USD 3.1 Billion. Major producers are Solvay, Ticona, Chevron Philips, BASF, Evonik, Arkema, Sumitomo and Gharda. Having such high temperature Tg & Tm, it becomes necessary that they be further processed into any shape using injection or compression moulding or extrusion techniques at temperatures approaching 4000C or even higher. Thus, processing machines parts should be capable of such high temperatures besides being able to withstand corrosion. Specialty plastics thus can be extruded into pipe, rod, plate shapes, as also film, fibers and cable insulation. They can be moulded into a large variety of shapes or blown moulded into bottles and jars. Properties Specialty plastics are meant to be used only where other plastics fail. Being generally of lower specific gravity (1.2-1.5), they are also preferred for metal replacement, when weight saving is a norm as in auto or aerospace. The amorphous plastics also show transparency making them a good substitute for glass. Their chief usage lies in applications, where resistance to corrosive chemicals and higher mechanical load at higher temperatures is important. They score over common
engineering plastics in all these aspects. For example, PEKK shows mechanical properties like tensile and flex strengths at 2500C, which are higher than those of polypropylene or ABS at room temperatures. The real beauty of these specialty plastics is in the substantial increase in properties when carbon fibre or to a lesser extent glass fibre is compounded with them. As shown in figure 1, Polyehter Ketone (PEK) with 40 per cent carbon fibre in its specific flex modulus equals to Aluminum and approaches to steel. Applications The applications for specialty plastics can be broadly divided into two basic categories; transparent like food trays, tapes, baby bottles, plumbing, etc and non-transparent with major engineering applications like seals, gaskets, bearings, cable sheathing and insulation and such others. Some of these plastics withstand high dosages of gamma ray making them most suitable for nuclear power plants and high temperatures up to 3000C, high pressures and chemicals (sour gas) making them useful in Oil/Gas exploration. Few companies and countries produce specialty plastics and India takes pride of place among them with Gharda (PEK, PEKK & PBI), Solvay (PEEK, PES) and Ralies (PEKK) having their production plants in Ankleshwar, Panoli in Gujarat since late 1990s. While today their Indian market is small at less than 10 per cent, it is a fond hope that in next 5-7 years, not only will they grow but India will also become an exporter of articles made from specialty plastics for real value additions. DAIE?=H "JCEJAANEJC 4KNH@
Chemical Engineering World
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CEW Features Guest Column
Opportunities for EPC Players in Fertiliser Sector For an EPC contractor, being engaged in a fertiliser plant is quite often a cherished desire, says K Shanker, Director - Onshore Business, Technip India Limited. In this insightful article, he futher elucidates different opportunities that lie ahead for EPC contractors in the fertiliser sector and assures that EPC contractors with superior technical skills will be in demand globally.
fertiliser plant challenges the engineering skills of a contractor with its requirement of a design system to withstand high pressure and vacuum, extreme temperatures ranging from minus 196 0 C to well over a 1000 0 C, corrosive and abrasive fluids in addition to a whole range of materials ranging from the ordinary carbon steel through stainless or alloy steels, duplex steels and on to the noble metals. This is why every EPC contractor looks forward to an opportunity to be involved in any aspect of building, modifying or revamping a fertiliser plant.
A
to improve plant Opex and get as close to the stoichiometric energy norms as possible. The prospects lie in the customary planned statutory shutdowns involving replacement and maintenance of defective material or equipment and statutory testing of equipment as well. With the mean time between statutory shutdowns increasing, the market for a plant opens up between 18 and 36 months. However, with plants situated worldwide and their planned shut downs varying over a year; this market becomes a constant annual feature for EPC contractors.
The fertiliser industry is a mature industry and has a very strong network both internationally and particularly in India which incidentally is one of the largest consumers of fertilisers in the world. As per the statistics, global nutrient demand was adequately supplied in 2013 with supply covered from production tonnage and important stock carry over in a few large consuming countries. Global production of ammonia, phosphate rock and potash totaled 234 Mt nutrients, has increased by 2 per cent over 2012. In 2013, global nutrient capacity grew at an aggregate rate of 5 per cent over 2012, adding close to 10 Mt nutrients. Internationally, today, the installed capacity of fertilisers both nitrogenous and phosphatic is greater than the demand.
While the above market for EPC contractors is an annual one, the same cannot be said for the lucrative expansion market that companies undertake either as brownfield or greenfield projects to enhance their existing production. To enter this market, one needs to know how clients set up these projects. In the international market, the general norm adopted by most clients is to start with a selection of technology and then go for a Bankable Feasibility Study (BFS) along with an AACE Class 4 estimate. If the study is acceptable, then a Front-end Engineering Design (FEED) along with a AACE Class 2 estimate is launched. On acceptance of the study an Invitation to Bid (ITB) is prepared and an EPC lumpsum tender process is put in place to select the EPC contractor who would eventually construct the plant.
The opportunities in the fertiliser market is mostly in the area of revamp 52 Â&#x160; 'QJA
As clients initially select a process licensor for their EPC projects, this field is generally restricted to EPC contractors who are Process Licencees of well proven Process Licensors. Thus the competition is generally restricted to about 3 to 4 EPC contractors to each bid. While this is the general norm of project execution in the international market, the Indian clients do not prefer the route followed by their International counterparts. The BFS is done by Indian clients itself based on their own experience and data bank. FEEDs are not in vogue in India and Indian clients generally develop their own ITBs and allow EPC contractors who are Process Licencees of different Process Licensors to take part in their EPC tender. With fertiliser capacity greater than the demand in the world today clients set up new additional capacity in case they have a long term access to feedstock to make the cost of production way below the international selling price of Global production of ammonia, phosphate rock and potash totaled 234 Mt nutrients , has increased by 2 per cent over 2012. In 2013, global nutrient capacity grew at an aggregate rate of 5 per cent over 2012, adding close to 10 Mt nutrients.
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The &+(0 gear pump can be used for a wide range applications from low to high viscosity. It is well suited for high temperature, vacuum inlet conditions and high discharge pressure. Applications can range from liquid metering to basic transfer tasks. Pumps of this type can be supplied without heating, electrically heated or jacketed. The available materials of construction and design options provided by WITTE RIIHUV RXU FXVWRPHUV PD[LPXP Ă&#x20AC; H[LELOLW\ This type of pump is also available as mini gear pump. 7KH &+(0 0,1, WDNHV Âż QH PHWHULQJ WDVNV ZLWK KLJK precision. Currently the smallest available pump has a VSHFLÂż F YROXPH RI FP3/rev. Smaller pumps are available upon request. CHEM MINI series can be RIIHUHG LQ VL]H FP3 UHY WR FP3/rev).
Esinger Steinweg 44a ' 8HWHUVHQ 7HO )D[ info@witte-pumps.de www.witte-pumps.de Our agents : Goodie International Pvt. Ltd. 2NKOD ,QGXVWULDO (VWDWH Phase-3, New Delhi Email : witte@goodie.in
CEW Features fertilisers or are ensured of government protection either by way of subsidies or import restrictions. Thus, we see plants coming up in western and northern Africa, Russia, the United States, Canada and the Middle East where such feedstocks are available at very attractive prices. As the fertiliser market for EPC contractors is therefore restricted to a regular replacement or revamp market and a limited expansion of EPC market, itĂ&#x160;s time to explore what opportunities are there for EPC contractors? In the former case, one need not necessarily be a Process Licencee of a Process Licensor and thus the field opens up to general EPC contractors. International contractors in this field must be ready to face stiff competition from local contractors who have general skills in the above type of work with an ability to offer the minimum shutdown at the lowest cost becomes the eventual winner. EPC contractors entering this field ought to be flexible to meet sudden additional requirement that generally crop up in such a market within a short notice period. Hence, they need to keep additional human resources and supply of materials over and above the planned resources for the work being tendered for. Projects are rarely due on a Lumpsum Turnkey (LSTK) basis and generally go by the unit rate basis way. In the case of the expansion market, qualified EPC contractors are generally asked by the clients to quote on a LSTK basis with all the risks of a contract loaded into the contractor side. The size of such market is slightly less than a billion USD in India and can go up to a billion and a half USD in the markets outside India. EPC contractors must be aware of the risks that they need to carry while executing such projects on a LSTK basis. Technically, the Engineering and Procurement part of
the EPC contract are well defined and pose no major risks to an established EPC contractor in this field. The risks are chiefly contributed by the construction perils and the contractual condition stipulated in countries where these plants are to be erected. These risks are broadly subjected to local laws that require a majority of the labour force being engaged from the country where the plant is erected, a general reluctance of erection contractors to take overall construction risk and one sided contractual conditions in favor of the client. Often it is seen that projects started on a promising note do not progress beyond the FEED stage as the cost projected as per AACE Class 2 or open book basis do not make the project viable. Projects are thus very often stalled. Hence, the EPC contractors interested to do business in this section of the fertiliser market should work closely with the clients. Design of the plant should be in sync with the clientsĂ&#x160; budget with a slight loss of plant flexibility, but without compromising on safety, quality, capacity and environmental norms. The fertiliser industry generally induces a wave in new plants being built. Quite often whenever there is growth in the Nitrogenous fertiliser industry, we see a subsequent setting up of Phosphatic plants as agricultural lands worldwide need a healthy and balanced input of Nitrogen, Phosphate and Phosphorus for good crop yields. The phosphatic industry generally has a cycle of 8 to 9 years to witness an expansion of its capacity. At the end of this cycle one sees a couple of complexes being built worldwide. With this peculiarity of the industry, it would be prudent for an EPC contractor to have the skills and track record to be capable of setting up both Nitrogenous and
Often it is seen that projects started on a promising note do not progress beyond the FEED stage as the cost projected as per AACE Class 2 or open book basis do not make the project viable. Projects are thus very often stalled unfortunately . Â&#x160; 'QJA
Phosphatic plants. Though the skill sets are completely poles apart, EPC contractors could keep their workforce active each year if they are capable of being involved in all section of the fertiliser industry as it generally takes 36 months to complete a major fertiliser expansion plant. It would also ensure that they are constantly in touch with the latest developments and trends in this industry. There is a third opportunity for EPC contractors in the fertiliser market and this pertains to the relocation of mothballed fertiliser plants to a new destination. Invariably apart from the relocation that involves judicious dismantling to maximise the use of existing material, clients also require the timely modification in the process as well to improve energy norms and at times marginal increase in capacity is called for. This indeed is exciting work for a true EPC contractor who specialises in fertiliser plant EPC work. However, EPC contractors need to have access to Process Licensors and be able to relocate and upgrade the plant in the shortest possible time. A major opportunity to utilise the inspection, construction and project management skills of the EPC contractor arises in such cases. The above three areas of the fertiliser sector therefore provide an EPC contractor with opportunities as indicated above. Since the fertiliser industry is mature and with capacity in excess of demand, contractors need to be alert to scout for various possible opportunities in this market. In the global market there are 9 major nitrogenous and 5 phosphatic plants expected to come up in 2014. In addition to this, there are 10 nitrogen and 4 phosphatic plants likely to be set up in the near future. EPC contractors with superior technical skills presenting out of the box solutions to address the requirements of the fertiliser clients both in Opex and Capex are definitely in great demand worldwide in the industry. DAIE?=H "JCEJAANEJC 4KNH@
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CEW Features Special on Pumps & Valves
Pump Materials for Harsh Environments Pumping corrosive fluids containing abrasive solids is a challenge. Sulzer can adapt pumps to such requirements by making the ideal choice of hydraulics and seals and by improving the materials used to produce the pump. Because it has its own foundr y, Sulzer can offer materials that are not easily available on the market. The company has developed a specific heat treatment procedure for steel that improves wear resistance, while leaving corrosion resistance nearly unchanged. Sulzer’s foundry in Karhula, Finland, manufactures stainless castings for pumps, mixers, and agitators.
S
ulzer supplies a variety of pumps that can operate in corrosive and abrasive environments, such as chemical or metal processes and demanding wastewater treatment. To ensure high reliability, research and development in the fields of fluid mechanics and materials technology as well as detailed knowledge of the applications and operating conditions are essential. Hydroabrasive wear and corrosion can significantly reduce the lifetime of pump components. One possibility to optimise operational life in such aggressive surroundings is the use of specially adapted hydraulics or seals. Furthermore, the selection of appropriate materials is the key to substantially extending the service intervals of a pump. Specialised Foundry Cast duplex stainless steels, as defined by ASTM International (the international standards organisation formerly known as American Society for Testing and Materials), are the materials mainly
56 'QJA
used today under corrosive and erosive conditions. When sourcing from commercial foundries, pump manufacturers are required to use these standard grades for their components. By contrast, Sulzer operates its own foundries in Karhula (Finland) and in Jundiaí (Brazil). This gives the company the option of developing alloys and methods for material treatment that commercial foundries do not offer. The foundry in Karhula supplies highquality, corrosion-resistant steel and special cast-iron castings primarily to the companyÊs own factories. Of the total annual production of some 30,000 castings, almost 90 per cent are made of corrosion-resistant duplex and super duplex cast steel grades. Making a Standard Material Better Even though duplex steel offers outstanding wear properties along with its corrosion resistance, some demanding applications require an enhancement. Precipitation
hardening is a specific heat treatment that can improve the characteristics of duplex steel without the need for expensive additional alloying elements. This heat treatment strengthens the material by allowing the controlled release of constituents that form precipitated nanoscale and microscale intermetallic clusters. However, it is not applicable to all duplex grades and bears the risk of impairing the corrosion resistance and the toughness of the respective material. Sulzer has examined several procedures for the precipitation hardening of duplex steel containing copper. By varying the copper content and the parameters of the heat treatment, Sulzer engineers have succeeded in improving the wear resistance of the material without undermining its corrosion properties and toughness. Proprietary Testing Knowledge Various process parameters, such as heating rate, heating temperature, dwell time, and cooling rate, influence the size DAIE?=H "JCEJAANEJC 4KNH@
CEW Features
Features CEW What is Duplex Stainless Steel?
Figure 1: The hardness and the toughness of the steel can be controlled by varying the precipitation hardening temperature and the dwell time.
and the distribution of the precipitates. The optimal control of these two characteristics provides the balance between the resulting increase in strength and the loss of ductility and toughness. Methods for the testing and characterisation of the material developed by the experts at the research unit Sulzer Innotec were used to optimise the parameters. The goal was to adapt the ASTM material A 890 Grade 1B (duplex steel containing some copper) to make it usable in challenging pump applications. During the materials development project, the several parameters were varied such as Copper content, Solution annealing temperature of the base material, Heating rate, Treatment temperature for precipitation hardening, Dwell time and Cooling rate Improved Hardness The testing clearly showed that there is only a small temperature range where hardness and toughness can be optimized. This temperature range is limited on both sides by the precipitation of harmful intermetallics (brittle metallic structures). However, within that process window, hardness and toughness can be tuned over a wide range by choosing the appropriate dwell time (Figure 1). Measured with a high-velocity slurry jet, precipitation heat treatment leads to a 58 'QJA
significant improvement in wear resistance compared with the reference material, which was only solution annealed. Corrosion testing of the precipitation hardened steel also showed only minor relative changes. Extending Pump Lifetime Sulzer has successfully used this heattreated material in cases where the pumped media are corrosive fluids that contain moderately abrasive solids such as pure salt crystals. For these applications, typically an Ahlstar process pump type WPP with wearresistant hydraulics is selected. The special material is used for pump impeller and side plate·because these parts are normally the most exposed to wear·or for all wetted cast parts. An exemplary application of a pump made from this new material is the second step of absorption in the fluor salts production, which is part of the production process of phosphoric fertiliser. As for most chemical processes, the performance of these pumps is critical for the production, and the requirements relating to their reliability are high. The pumped liquid is both corrosive and contains fine, abrasive particles.
The corrosion resistance of stainless steels is based on the presence of a substantial amount (>12 per cent) of chromium in the steel. It forms a protective film of chromium oxide on the surface that inhibits corrosion. By alloying other elements like nickel, molybdenum, nitrogen, titanium, and manganese, it is possible to achieve a wide range of mechanical and chemical properties in the stainless steels. Stainless steels are categorised into four groups according to their crystal structure: Ć Austenitic stainless steels (face centered cubic structure) Ć Ferritic stainless steels (body centered cubic structure) Ć Martensitic stainless steels (body centered tetragonal structure) Ć Duplex stainless steels (mixture of austenite and ferrite phases) The austenitic grades are most popular, but the duplex grades are the most important for industrial pump applications. Owing to their two-phase microstructure consisting of austenite and ferrite grains, duplex alloys combine the advantages of both steel groups. They are roughly twice as strong as purely austenitic stainless steels. They have significantly better toughness and ductility than ferritic grades. They exceed austenitics in their resistance to stress corrosion cracking. And these advantages are not associated with higher costs. Because of the increased yield strength, it is often possible to reduce the section thickness of components compared with designs based on austenitic grades. Furthermore, duplex stainless steels have a lower content of expensive nickel and molybdenum than their austenitic counterparts do, making them a cost-effective and weight-saving choice for many applications. Duplex steel combines two different phases: austenite (white areas) in a ferrite matrix (grey areas).
Improving Process Reliability A client who operates a fertiliser production plant wanted to replace DAIE?=H "JCEJAANEJC 4KNH@
Features CEW
Sulzer examined several procedures for the precipitation hardening of duplex steel.
the original pumps, which had an insufficient lifetime. These machines were sealed with gland packings. This type of seal works with a lubricating fluid and failed to seal the aggressive fluid dependably. Because the customer had had a positive experience with the Sulzer pumps being used in the first step of absorption, he entrusted Sulzer again with the replacement of the second-step pumps. Based on their experience with the pumps in first step of the absorption in the fluor salts manufacturing process, the Sulzer experts selected a WPP (wear resistant) pump with an open impeller and a dynamic seal. These seals operate very reliably with corrosive and abrasive fluids. The pumps are made from precipitation heat-treated material with a hardness of 300HBW. The chosen pumps operate close to their duty point, which is essential for efficient hydraulic operation. In this case, the combination of pump, fabrication material, and seal type·all well suited for the application·led to increased reliability of the overall process. This improvement reduced outage and increased the time between repairs. Following the successful installation of the first pump, several pumps·all made from specifically heat-treated steel·are now running in same fertiliser production line. (This article was previously carried in August 2013 Issue) AuthorsÊ Details Raimo Arola Material Specialist Sulzer Pumps Finland Oy Email: raimo.arola@sulzer.com
Thomas Kraenzler Manager Core Technology Materials Sulzer Pumps, Winterthur, Switzerland. Email: thomas.kraenzler@sulzer.com DAIE?=H "JCEJAANEJC 4KNH@
'QJA 59
CEW Features Special on Pumps & Valves
Handling Tricky Situation with Ball Sector Valve When an expensive control valve breaks down after three months only, a remedy is needed badly. But engineering resin producer Ticona had been having to live with this situation for considerable time due to their extraordinary producing process. Thinking outside the box was the way out. Using an “exotic” ball sector valve not only solved the problem, but also saves money.
T
he control valve was ready for scrapping after only three months. We are not talking about some cheap plug valve made from low-quality steel, but rather a valve made from high-quality Hastelloy C. This situation could not be tolerated for long, but the harsh conditions in fiber enforced plastic production at Ticona in Kelsterbach in Germany meant that abrasion and corrosion occurred on the body, tapered seat or plug after only a short time, leading to total failure. Lift valves of the type used until in the 1980s could not be considered because of the emissions regulations in „TA-Luft‰. Thomas Labahn, the person responsible for plant planning and EMC at Ticona in Kelsterbach, took a long hard look at the problem. This explains why he was very interested in a ball sector valve that he saw during a plant tour of the valve manufacturer Schubert & Salzer Control Systems. „As soon as they explained the
62 'QJA
control valve to me, a light went on in my head,‰ is how Labahn describes his Eureka moment. The fiber enforced plastics manufacturer conducted a parallel test of a ball sector valve from Schubert & Salzer and one from another manufacturer. The latter valve lasted precisely three weeks before seizing up. The Schubert & Salzer valve on the other hand, lasted the course: „The very first attempt was a major success. The valve lasted nearly ten months, almost three times as long as before,‰ explains Labahn. The trick: The valve is made from standard material (stainless steel) and only has hard chrome-plated (stellited) ball sector surfaces. This is the reason
why it is significantly less expensive than the previous valve made from Hastelloy. Furthermore, the damaged valve can be repaired and even costs a good deal less to buy than does the plug valve made from Hastelloy. Considering the numerous control functions in which these valves are used at Ticona under extremely challenging conditions, the saving potential is quite considerable. A small actuator is sufficient. After ten months in operation, only the holder of the seat ring had come loose, and the manufacturer is already working on a solution to this problem with an improved variant. „We found there was abrasion on the parts that were not stellated but came into contact with
The valve is made from standard material (stainless steel) and only has hard chrome-plated (stellited) ball sector surfaces. This is the reason why it is significantly less expensive than the previous valve made from Hastelloy DAIE?=H "JCEJAANEJC 4KNH@
CEW Features 1
2
(1) The ball sector valve opens the entire pipe cross section when it is open, (2) The actuator of the ball sector valve is relatively small
the medium,‰ describes Labahn. As far as the client is concerned, the reason for the longer service life is principally to do with the geometry: „The media flows through the ball sector element in a totally different way than in the plug valve,‰ explains Labahn. In future, completely stellated valves are expected to offer even greater improvements. Other important aspects in favor of using ball sector valves are their comparably light weight and relatively low actuator thrusts. The friction against the stuffing box seal in plug valves means they have a very high break-loose torque and this explains why they need powerful actuator thrusts. The torque with the ball sector valve, on the other hand, is relatively low and the actuators can be correspondingly smaller. A single action Wirematic actuator with a safety position is used on the valves. Furthermore, the valve does not get
blocked because the entire pipe cross section is left unobstructed when the ball sector is fully open. The fibre enforced plastics manufacturer is also happy when it comes to the control response: „In our case, the control accuracy that has been achieved is comparable to that of the plug valve we used to use,‰ reports Labahn. „We are planning to test using the ball sector valve as a manual valve as well soon,‰ declares operations assistant Volker Gatzert. The client anticipates this will result in greater ease of movement at the same time as saving space and weight. „ThereÊs not much room available where we use the valve,‰ describes Gatzert. However, it is a disadvantage that the unit is not built as a flange valve. Gatzert: „I think the manufacturer should consider designing a flange valve to open up a new and wider range of applications for its valves.‰
The modified equal-percentage operating characteristic (in operation, the differential pressure increases as the valve closes) combined with the outstanding rangeability of 300:1 mean that that valve can be used for most control tasks. 64 'QJA
COMPACT - Principle of the Ball Sector Valve The ball sector valve consists of a hemispherical shell - the ball sector that is held securely in the valve body using two large bearing stems. Part of the hemispherical shell is used for isolating, while the other has a hole with a diameter corresponding to about 80 per cent of the nominal size of the valve. The ball sector is turned through about 90Ĉ from fully open to closed. The shape of the opening cross section changes from completely round to elliptical in this case. This practically round shape for the flow opening reduces the risk of blockage when small control settings are made. The valve characteristic maintains almost the same percentage value with constant differential pressure. The modified equal-percentage operating characteristic (in operation, the differential pressure increases as the valve closes) combined with the outstanding rangeability of 300:1 mean that that valve can be used for most control tasks. The special connection of the valve body ensures that the differential pressure on the valve has little effect on the actuating torque. Ball sector valves are used as isolating and control valves for fluids, gases, turbid media and sludges, especially in the pulp and paper and chemical industry. Abrasive slurries of iron ore, coal, lime and fly ash are also controlled with this type of valve.
(This article was previously carried in August 2013 Issue)
AuthorsÊ Details Volker Gatzert Schubert & Salzer Control Systems GmbH Email:marketing@schubert-salzer.com
Thomas Labahn Schubert & Salzer Control Systems GmbH Email: info.cs@schubert-salzer.com DAIE?=H "JCEJAANEJC 4KNH@
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Marketing Initiative
Special on Pumps & Valves
New Verderflex Dura 5 and Dura 7 Hose Pumps receives “Ringier Technology Innovation Award 2014”
W
orld Pumps China, published by Ringier Trade Media Ltd, has announced Verder Liquids BV as the winner of the 2014 Ringier Technology Innovation Awards for the Pumps and Valves Industry. The Grand Awards ceremony was held at Shanghai Crowne Plaza on May 19, 2014. About 20 winning companies featured their innovative products and technologies across 5 categories: Centrifugal Pumps, Positive Displacement Pumps, Jet Pumps, Valves, Seals, Ancillary Products & Others. In the category Positive Displacement Pumps Verder Liquids BV received the award for a new and innovative hose pump: the Verderflex Dura 5 and Verderflex Dura 7. According to the jury prize
John Hoorneman (director Verder Liquids BV), received the “Ringier Technology Innovation Award”
winners develop, produce and market products and technologies which drive development in ChinaÊs pumps and valves industry. The Verderflex Dura 5 and Verderflex Dura 7 pump range are High Pressure Low Volume (HPLV) hose
pumps, dosing less than one (1) litre per hour at 5 or 8 Bar in a rugged hose. Benefits of the Verderflex Dura 5 and 7 HPLV include superior secondary containment, no more dry running problems and long life hoses reducing maintenance costs and increasing service intervals.
Case Study
Pumping Polyelectrolyte in wastewater treatment
A
n industrial waste water treatment company required a cost-effective solution to pumping polyelectrolyte. Existing helical rotor pumps were expensive to run and maintain; the Verderflex Dura Hose Pump offered the customer a dosing solution that offered long hose life and lowered maintenance costs.
The innovative flange design allows quick and easy removal and fitting. Ć The Dura provides longer hose life than conventional pumps Result
The Challenge An industrial wastewater treatment company required a cost-effective solution to pumping polyelectrolyte. The plant engineers approached Verderflex distributor, Global Pumps Australia for a solution to the following problems: Ć Ć
Ć Ć
The existing helical rotor pumps were expensive to run and maintain The replacement pump would have to be able to transfer liquid polymer, which is a thick, viscous liquid mixed with a 30% kerosene (hydrocarbon) carrier. The pump had to be compatible with the clientÊs existing system The hose would have to last a minimum of 3 months.
66 'QJA
Durapump
VerderflexÊs Dura Hose Pump has now been installed for more than 1 year. The customer has reduced their process downtime, improved their operational efficiency and reduced the overall maintenance cost after moving to peristaltic pumping technology.
Solution Global Pumps analysed the customerÊs current systems and the Verderflex Peristaltic Dura hose pump was selected for the following reasons: Ć
Peristaltic pumps have a low-shear operation; ideal for shear-sensitive products like polymers Ć The Dura has the ability to handle viscous liquids Ć The dosing capability is within 5% accuracy Ć A service is easy as the hose is only one wearable part in contact with the fluid.
Paul Dale Marketing
Verderflex Unit 3 California Drive, Castleford, West Yorkshire, England WF10 5QH DDI: +44(0)1924 221033 Fax: +44(0)113 2220291 Paul.Dale@verder.co.uk www.verderflex.com
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Small safety valve with big beneďŹ ts Fainger LESER launches Type FL 237 This safety valve, Type FL 237, is a completely new design and extends the product range for applications that require compact dimensions. Your beneďŹ ts:
High quality stainless steel material Designed for all industrial applications Compact dimensions with high capacity
Very fast delivery time of two weeks ex works for standard conďŹ gurations Read more about the new safety valve Type FL 237 on the Fainger LESER website www.faingerleser.com.
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New Functionality, Same Reliability New MasterďŹ&#x201A;exÂŽ I/PÂŽ Peristaltic Process Pumps â&#x20AC;˘ Accurate, washdown design â&#x20AC;˘ Handle aggressive solutions â&#x20AC;˘ Superior to conventional pumps! No valves to create blockages â&#x20AC;˘ Contamination-free, so your product does not come in contact with internal pump parts â&#x20AC;˘ Virtually eliminate maintenance with a brushless motor
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Special on Pumps & Valves
Centrifugal Pump Hydraulic Rerate- ROAD to RELIABILITY
7
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Complete Solutions for Valve Requirements
T
he Poonawalla Group is one of IndiaÊs most reputed, leading and respected business houses engaged in various diversified businesses such as, Engineering, Horse Racing & Breeding, Bio-tech, and Hospitality.
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CEW Market Insights
India Posed to Add Huge Desalination Capacities in 5 Years Indian clients and end users are becoming more adoptable to higher end solutions like sea water desalination technologies as these offer a very effective and long term water solution to Industries and municipalities, says
Sanjeev Sharma, Head of Marketing (India) at IDE Technologies.
D
esalination, in recent few years, has emerged as an Âefficient technologyÊ that is capable of removing salts, minerals from both saline and brackish water and making it suitable for human consumption. Couple of reports released earlier this year have indicated that India has installed more than 190 desalination plants by 2013, and that the desalination market has been growing progressively at a CAGR above 15 per cent over the last five year period which recorded revenues to the tune of USD 0.52 billion in 2013. While mentioning one of the reasons for the growth of the market, Sanjeev Sharma, Head of Marketing (India), IDE Technologies, says that the capital and operating cost for desalination have tended to decrease over the years significantly. Even though energy prices have increased, the desalting cost has been decreasing due to various factors like decrease in membrane cost, increase in recoveries, increase in process efficiencies and new innovative business models and finance structures. „The cost of obtaining and treating water from conventional sources on the other hand has tended to increase because of the increased levels of treatment being required and available water sources being more contaminated than even before,‰ Sharma explains. According to him, „The cost of desalinated water in India in last few years has been between 4.4-5 paise per liters (C 44-50/1000 liters) which includes cost of finance, plant, O&M cost and all other overheads and associated cost which is quite reasonable given the water scarcity in some parts of the country.‰ 74 'QJA
Figure 1: IDE has built 160 MLD MED ‘Reliance Jamnagar Project - India’s Largest Desalination Plant for Reliance Industries’ which is in successful operation for last more than 10 years.
Technology Trends When asked to explain about low temperature thermal desalination technology and membrane-based technology, Sharma, who has been associated with reputed names in water industry like Hyflux Ltd, Singapore & Driplex Water Engg Ltd in prior assignments, states that low temperature thermal desalination technology (MED) is a more accepted technology as far as India is concerned. Some of IndiaÊs largest desalination plants are working on this technology. Reliance (160 MLD Jamnagar project), Essar (65 MLD Vadinar project), Nuclear Power Corp of India (11 MLD MVC project) and Sanghi Cement (6.5 MLD
project) are some of the projects based on multiple effect technology. Currently, Reliance Industries is constructing a MED-based plant at their Jamnagar complex for a size of 72 MLD. The project has been ordered to IDE Technologies and is expected to be online in 20152016. „Membrane-based technology in last few years has been gaining an edge all over world and in India too. One of the main selection criteria for thermal or RO technology is availability of low pressure steam. For any process, oil and gas or other industry, where in steam is available, it is better to use thermal (MED) technology because of low operation and maintenance cost
“The cost of desalinated water in India in last few years has been between 4.4-5 paise per liters (C 44-50/1000 liters) which includes cost of łnance, plant, O&M cost and all other overheads and associated cost which is quite reasonable given the water scarcity in some parts of the country.” DAIE?=H "JCEJAANEJC 4KNH@
Name: ___________________________ Designation: ______________________ Company: ________________________ Address: _________________________ Pin Code: ________________________ Signature: ________________________
Chemical Engineering World
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VOL. 49
VOL. 49
ISSUE 5
FER TILIS ERS : ALL EYE S ON ItÊs a Serio GOV ERN us Busi MEN T« ness , Govt Tech nolo Ÿ 24 Mus t Pull gica l Adva its Sock ncem ents Will Brin s Up Ÿ 26 ging Urea Will Pave the Way Unde r NBS Corr osio for Grow n ă Tack Make the th Ÿ 30 ing Chal Diffe renc Opp ortu leng es in nitie s for India n Ferti e? Ÿ 36 EPC Play liser Indu ers in Ferti stry Ÿ 40 liser Sect or Ÿ 52
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Chemical Engineering World
FLUIDYME PROCESS FLOW TECHNOLOGIES Design & manufacture of
* Various Types of direct & gear driven Agitators, Agitators with mechanical seal & Gland packing. ● Modular design enables various mounting arrangements. (i.e. from open tank to closed tank.) ● High efficiency impellers designed for specific process applications. ● Efficient Chemical duty Totally Enclosed (TEFC or Explosion Proof Motors and Air Motor. ● Variable output speed by Variable Frequency Drive. ● Power range from 0.06 HP to 100 HP & onwards. * Agitators with reaction vessels, Pressure vessels. Dosing systems & Pilot plants. * High speed dispersers, Emulsifiers with hydraulically or pneumatically operated lifting lowering arrangement. * Drum Hoop mixer for mixing homogenizing viscous liquids. * Static Mixers with standard & custom design. * Drum press-out for liquid filling applications. E-2/4, Popular Prestige, Near Highway Bridge, Warje, Pune – 411 058, Maharashtra, INDIA. Telefax: (020) 25294091, 25293397, Mobile : 94220 09479, 98222 79409 E-mail: fluidyme@vsnl.net Website: www.fluidymetechnologies.com
CEW Market Insights of the MED process. For Municipal applications, however, it is recommended to use RO technology which does not use steam/heat in any form in the process,‰ Sharma elucidates further. Scope for Huge Capacities Desalination water technology is widely used in water scarce states such as Gujarat, Tamil Nadu, and Rajasthan. Sharma reveals that there are around 1,100 desalination plants functional in India. Desalination of sea water and brackish water is one the oldest, most feasible and identified solutions to counter the problem of water scarcity. Desalination primarily is a technology used to convert high saline water (sea water for example) into potable/ process applications and its usage is limited mainly to states having a large coastal line. „Gujarat, Tamilnadu, AP, Kerala, Maharashtra are main states which have seen desalination plants coming up in a big way and this trend will continue in the future, rather will be manifold,‰ Sharma predicts. He further says that landlocked states like Punjab, Delhi, Madhya Pradesh and others will not have any such desalination plants. Tamilnadu has recently announced 4 large size sea water desalination technology projects ranging from 400 MLD, 150 MLD to 100 MLD and this shows a clear increase in acceptance of SW Desalination technology as an alternative to conventional water resources. According to Sharma, „India is posed to add very huge capacities of desalination in the next 5 years; hence it may not be prudent to say that desalination has not picked up in a big way in India. India is currently in the list of 10 largest markets on desalination and will see a huge expansion in capacity addition.‰ Sharma believe that government support is essential to develop the infrastructure for desalination projects in the country. He avers, „India still is at a nascent stage when it comes to PPP modeling of projects. Government and political support is a must for more and more projects to come up in India on PPP basis. Ideally, state govenment and central government should have a desalination policy which can boost desalination in India to a big league. Government of Gujarat is working on 78 'QJA
Figure 2: Top ten desalination markets by expected contracted capacity. Source: GWI DesalData
desalination policy for the state and intends to have large size desalination plants in state to support the water demands and huge economic growth.‰ Environmental Impact Assessment While commenting on the protests against desalination projects from environmental groups and NGOs, Sharma explains that any desalination project or industrial project for that matter passes through strict environmental checks, controls and clearances in India and elsewhere too. Further, highlighting the significance of Environmental Impact Assessment (EIA), he adds, „Desalination projects require an Environmental Impact Assessment (EIA) study to determine the impact the project can have on the environment. The EIA considers all environmental parameters and criteria. It evaluates the potential impacts to air, land, and marine environments and also proposes mitigation measures to reduce environmental impacts.‰ The EIA report discusses the chosen desalination process, the emissions the process will generate, the implications the facility will have on the environment, the considerations to be made about the energy supply, the benefits the facility will have on the community and the proposed mitigation measures to reduce problems associated with the facility. „No project is given a go ahead until the project is
considered absolutely safe for environment and surrounding and beneficial for the society,‰ Sharma emphasises. Company Performance With more than 45 years of know-how and experience, IDE delivers end-to-end project solutions for its customers throughout the world. Leveraging superior thermal and membrane technologies, IDE specialises in the delivery and operation of various desalination and water treatment solutions. DEÊs desalination solutions make it affordable for municipalities and industries in arid regions to transform seawater into plentiful fresh water, whether for household/ drinking, agriculture and/or industrial use. Sharma reveals that to date, IDEÊs industryleading thermal and membrane desalination solutions have made it practical for about 400 customers in 40 countries to create enough fresh water to meet their needs: in fact, the installed capacity of IDE plants is over 3,000,000 cubic meters of fresh water per day, thereby alleviating distress and supporting regional development. „Through continual Âgreen-thinkingÊ technological advancements, IDE has achieved the industryÊs lowest energy consumption for all three dominant desalination technologies, while also reducing associated greenhouse gas emissions and waste,‰ he adds. - Compiled by Harshal Y Desai DAIE?=H "JCEJAANEJC 4KNH@
CEW Products Barcode Reader
Twin Screw Range of Pumps
Cognex DataMan 8050 Series handheld barcode readers, which are designed specifically for the pharma industry, with a rugged polycarbonate housing to handle harsh factory floor conditions and feature Cognex 1DMax+ with Hotbars barcode reading algorithms. The 210 mm x 115 mm x 85 mm readers feature a 752 x 480 global shutter sensor, integrated LEDs with near/far optics, and DataMan Setup Tool software, which enables imaging viewing, Java scripting, and data formatting options. DataMan 8050 reads all type of codes ă 1D, 2D and pharma code; helps in reading codes on the shipping cartons; and reads code on labels, packets, boxes and shipping cartons. The DataMan 8050 barcode readers are optimized for reading 1-D and 2-D label-based barcodes with the fastest performance
The pumping element comprises of two intermeshing screws rotating within a stationary housing. The pumping elements are supported by the bearings. The clearances between the screws are maintained by a pair of timing gears. The rotating screws in the pump casing and liner form transfer the fluid axially from the extreme ends to the center of the casing or vice versa, depending upon the direction of rotation of the screw spindles. Roto twin screw pumps are constructed around cast iron body with integral liner and in-line suction and discharge branches. Pumps can be configured both in internal bearing as well as external bearing design to suit liquid characteristics with the option for sump heating. External bearing pumps as a standard are with renewable liners and can be completely jacketed or made suitable for electrical tracing. Shaft sealing options are soft gland packing or mechanical seals conforming to API 682 with various flesh and quench plans. To suit liquid medium, a wide choice of construction materials are available.
For details contact: Cognex Sensors India Pvt Ltd Regus Level 6 Pentagon Towres P2, Magarphatta City Hadapsar, Pune, Maharashtra 411 028 Tel: 020-40147840 | Fax: 91-020-66280011 E-mail: info.in@cognex.com.
For details contact: Roto Pumps Ltd Roto House, 13 Noida Special Economic Zone Noida, Uttar Pradesh 201305 Tel: 0120-3043901 | Fax: 91-0120-3043928 E-mail: contact@rotopumps.com
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Productivity Boosting Tubes for Recuperator Applications S a n d v i k h a s t w o g r a d e s o l u t i o n s - S a n d v i k 2 5 3 M A a n d S a n d v i k 4 C 5 4 fo r o ve r c o m i n g t h e c h a l l e n g e s fa c e d by r e c u p e r a t o r t u b e s w h e n u s e d a t h i g h t e m p e r a t u r e a n d s eve r e corrosion conditions. Sandvik 253 MA is austenitic chromium-nickel steel alloyed with nitrogen and rare earth metals. Due to its high creep strength, very good resistance to isothermal particularly cyclic oxidation and combustion gases, good structural stability at high temperatures is ideal for use in metal industries such as iron and steel production, DRI, copper smelters, glass and petrochemical industry. The grade is also used in various industry segments because of its characteristics of handling temperatures up to 1,150ĈC and good weldability. While Sandvik 4C54 is ferritic, heat resistant, stainless chromium steel, characterised by extremely good resistance to reducing sulphurous gases very good resistance to oxidation in air, good resistance to oil-ash corrosion, molten copper, lead and tin. This grade is extensively used in the steel, metallurgical, glass, chemical industry and as thermocouple protection tubes. For details contact: Sandvik Asia Pvt Ltd Pune Mumbai Road, Dapodi Pune, Maharashtra 411 012 E-mail: shabareesh.nair@sandvik.com / tube.india@sandvik.com or Circle ReadersÊ Service Card 3
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DAIE?=H "JCEJAANEJC 4KNH@
CEW Products Double Planetary Mixer The double planetary mixer includes two blades that rotate on their own axes, while they orbit the mix vessel on a common axis. The blades continuously advance along the periphery of the vessel, removing material from the vessel wall and transporting it to the interior. After one revolution the blades have passed through the entire vessel, after three revolutions most materials have been mixed and after only 36 revolutions, the blades have contacted virtually the entire batch. Ross pioneered Change Can mixer design years ago. Today they offer many of their mixers including their PowerMix with this option. While one vessel is wheeled away for remote discharge and cleaning, another wheels into place to star t the next batch immediately. With no packing glands or bearings in the product zone, contamination is vir tually eliminated. Ross has patented the HV Blade design. This mixer is ideal for mixing and kneading viscous pastes or puttylike materials. Capacities from 200 ml through 1,500 litres. A wide variety of options include vacuum/pressure, thermal jacketing and sanitary designs. For details contact: Ross Process Equipment Pvt Ltd Gat No: 255, Chikhali-Moshi Road Bhoradewadi, Moshi, Pune, Maharashtra 412 105 Tel: 020-65111101, 65111102, 65111103, 65111104 E-mail: mail@rossmixers.in or Circle ReadersÊ Service Card 4
Microbioreactors
Laboratory Meter
Micro-Matrix offers an integrated, easy-to-use, and cost-effective technology platform for the rapid handling and growth of large number of microbial strains, clone libraries, mutant banks and cells. The system offers 24 independent bioreactors in a cost-effective microtiter plate footprint. pH and dissolved oxygen can be controlled in each individual bioreactor via gas and liquid addition. Temperature is controlled individually in each bioreactor by the integrated cooling and heating system. The microMatrix offers a true scale down of small-scale bioreactors. The bioreactorÊs square well cassette design is based upon the popular SBS-format microtiter plates, which seamlessly integrates into lab automation robots. The PC-based human interface offers simple, intuitive interaction for advanced process control in each of the 24 bioreactors.
Hanna Instruments offers edge, a full featured, affordable laboratory meter with revolutionary design features. edge measures pH, conductivity and dissolved oxygen: it is incredibly thin and lightweight, measuring only half an inch thick and weighing just 9 ounces; blending elements of portable meters and bench top meters into a seamless design. This versatile design allows customers to use edge as a benchtop meter, a portable meter or even attached to a wall to free-up valuable bench space in a laboratory. edge features a large 5.5‰ LCD with a wide viewing angle, capacitive touch keypad, dual USB ports, cradle with swivel arm electrode holder and an included wall mount. edge works with digital smart electrodes. These electrodes are nearly as advanced as the meter itself: featuring a built-in microchip that stores sensor type, ID, and calibration information that is automatically retrieved by edge once the electrode is plugged in. The electrodes have a 3.5 mm connector so customers do not have to worry about alignment and pins bending or breaking.
For details contact: Applikon Biotechnology BV Heertjeslaan 2, 2326JG Delft The Netherlands Tel: +/+ 31102083555 E-mail: info@applikon-biotechnology.com
For details contact: Hanna Equipments (India) Pvt Ltd Aum Sai Bldg, 3/4/5/6, 1st Floor Plot No: 23-C, Sector 7, Kharghar, Navi Mumbai 410 210 Tel: 022 27746554, 27746555, 27746556 E-mail: sales@hanna-india.com
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DAIE?=H "JCEJAANEJC 4KNH@
Products CEW Guided Wave Radar Transmitter
Trim Handling System
Magnetrol offers Eclipse Model 706 transmitter with Foundation fieldbus digital output communications. This is the first guided wave radar (GWR) transmitter to pass the Fieldbus Foundation testing using the latest Foundation fieldbus interoperability test kit ITK 6.1.1. This device offers all of the advantages of the standard 4-20 mA (HART) ECLIPSE Model 706, such as: improved signal to noise ratio (SNR); improved diagnostics (meets NAMUR NE 107); full complement of overfill-capable probes; etc.
Trim handling device is engineered to suck continuous trims of paper, plastic, laminate and the light material. It consists of high-efficiency fan for motive air, well designed venture and discharge cone. High velocity air from motive fan induces sufficient suction at suction nozzles to suck trims. Trims can be conveyed to waste collector, boiling or repumping tanks. All parts are specially designed for specific installation to consume optimum low power.
This new ECLIPSE Model 706 transmitter will contain the following Function Blocks: resource block; transducer blocks; analog input blocks; PID blocks; arithmetic block; input selector ; signal characterizer block; integrator block; etc. For details contact: Magnetrol International NV Worldwide Level & Flow Solutions Heikensstraat 6 - 9240 Zele - Belgium Tel: +32 (0)52 45 11 11 | Fax: +32 (0)52 45 09 93 E-mail: kgeerinckx@magnetrol.be
Vacunair Engg Co Pvt Ltd has designed a separator that can be placed near the main equipment. This reduces discharge pipe resistance and the power required can be reduced to half or less. This separator can be moved to the place of disposal. For details contact: Vacunair Engg Co Pvt Ltd Nr Gujarat Bottling, Rakhial, Ahmedabad, Gujarat 380 023 Tel: 079-22910771 | Fax: 91-079-22910770 E-mail: info@vacunair.com
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MGE-XS to Mini Gas Enclosure Line SEMI-GAS Systems offers Model MGE-XS to its mini gas enclosure product line. Created to store and deliver ultra-high purity process gases from small gas cylinders, this new Xturion™ custom gas system also incorporates automatic cylinder switchover capabilities to help minimize manufacturing down-time and operator interaction. With the addition of the new MGE-XS, SEMI-GASÊ MGE line now comes in two process models, each with two separate compartments housing two individual manifolds with separate purge inlets and vent outlets. The MGE-XS houses four process cylinders, providing two independent automatic switchover systems, in one compact package. While the original MGE-X houses two process cylinders and two dedicated purge cylinders. Ideal for customers who have low flow applications or are operating in limited space, the MGE-XS is small, measuring 69‰ high by 32‰ wide by 27‰ deep. For details contact: Applied Energy Systems 180 Quaker Lane, Malvern, Pa 19355; U.S.A. Tel:: (610) 647-8744 E-mail: mkasper@semi-gas.com / mkasper@appliedenergysystems.com or Circle ReadersÊ Service Card 9
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Dye+Chem Bangladesh Dates: 3-6 September, 2014 Venue: Dhaka, Bangladesh Details: Biggest show in Bangladesh for buyers and suppliers of dyes & chemicals Organiser: Conference & Exhibition Management Services Limited Contact: +65 6829 2144 Email: cems@cems-asiapacific.com Website: www.cemsonline.com Surface & Coatings Expo 2014
Speciality & Agro Chemicals America
Dates: 4-6 July 2014 Venue: Chennai Trade Centre, Chennai Details: Exhibit technology for cleaning, preparation, coating, painting of surface Organiser: Confederation of Indian Industry Contact: +91 44 4244 4555 Email: b.jeikrishnan@cii.in; businessfairs@cii.in Website: www.cii.in
Dates: 8-10 September, 2014 Venue: Charleston, USA Details: The 3 rd Annual Event for Agro, Specialty, and Custom Chemicals Organiser: American Chemical Marketing Contact: 1 215 882-9100 Email: tom.leahy@chemicalsamerica.com Website: www.chemicalsamerica.com
Watertech India 2014
RPTC
Dates: 10-12 September 2014 Venue: Pragati Maidan, New Delhi Details: Trade Fair for Water & Wastewater Treatment & Management Organiser: Messe Frankfurt Trade Fairs India Pvt Ltd Contact: +91 22 6144 5900 Email: rohit.rebello@india.messefrankfurt.com Website: www.watertechindia.com
Dates: 8-11 September, 2014 Venue: Moscow, Russia Details: Russia & CIS Refining Technology Conference & Exhibition Organiser: Euro Petroleum Consultants Ltd Contact: +7 495 517 77 09 Email: moscow@europetro.com Website: www.europetro.com
World PetroCoal Congress
ICIF, China
Dates: 15-17 Feb, 2015 Venue: Convention Centre-NDCC, New Delhi Details: On sustainable usage of the non-renewable resources Organiser: Energy and Environment Foundation Contact: +91 11 2275 8149 Email: punit.nagi@ee-foundation.org Website: www.worldpetrocoal.com
Dates: 11-13 September, 2014 Venue: Tianjin, China Details: The 13 th International Chemical Industry Fair 2014 for Chemical & Petroleum Organiser: China National Chemical Information Centre Contact: +86 10 6444 4135 Email: fany@icif.cn Website: www.chinaexhibition.com
India Chem
International Conference on Chemical Structures
Dates: 9-11 October 2014 Venue: Bombay Convention & Exhibition Centre (BCEC), Mumbai D e t a i l s : A n ex h i b i t i o n o n c h e m i c a l , p e t r o c h e m i c a l a n d pharmaceutical sector Organiser: Federation of Indian Chambers of Commerce & Industry Contact: +91 11 2373 8760; +91 11 2376 5081 Email: manoj.mehta@ficci.com Website: www.indiachem.in
Dates: 1-5 June 2014 Venue: NH Conference Centre Leeuwenhorst, Noordwijk, Netherlands Details: Conference to cover aspects of cheminformatics and molecular modeling Organiser: American Chemical Society, and other societies. Contact: +49 30 6128 8887 Email: iccs@mcc-pr.de Website: www.int-conf-chem-structures.org
84 Â&#x160; 'QJA
DAIE?=H "JCEJAANEJC 4KNH@
Project Update CEW New Contracts/Expansions/Revamps The following list is a brief insight into the latest new projects by various companies in India. Ć CHEMICALS Punjab Chemicals & Crop Protection is planning a thiamethoxam manufacturing project in Village Kolimajra & Samalheri, district Mohali, Punjab. The project will come up at the companyÊs existing plant premises. The project is in planning stage. S K Solvochem Private Limited is planning a 1,500 TPA synthetic organic chemicals manufacturing project - dye and dye intermediates, bulk drug and intermediates excluding drug formulations, synthetic rubbers, basic organic chemicals, other synthetic organic chemicals and chemical intermediates at a cost of C 20 million in Village Nimbua, district Mohali, Punjab. The Public hearing was held in January 2014. The project is waiting for environmental clearance. Nuray Chemicals is implementing a ferric citrate-manufacturing project at the existing unit in SIDCO Industrial Estate Kakalur, district: Tiruvallur, Tamil Nadu. Civil, mechanical and engineering work is in progress. The project is scheduled for completion in Q4 2014. Equipment is already available. Lion Tapes Private Limited, a sister concern of Stretch Bands, Gujarat, is planning a 100-TPM synthetic organic chemicals manufacturing project in GIDC, Chitra Estate, district: Bhavnagar, Gujarat. As of October 2013, the project is waiting for environmental clearance. According to the MoEF sources, the project includes products like 40-TPM of Fast Red B Base, 20-TPM of Fast Bordeaux GP Base, 10-TPM of Fast MNPT (Red G) Base, 5-TPM of Fast Red 3GL Base, 10 TPM of Fast Scarlet RC Base, 5-TPM of Fast Yellow GC Base, 5-TPM of Fast Orange GC Base and 5-TPM of Fast Red RC Base. The commercial waste generated from administration building would be disposed through sale to scrap vendors The generated industrial wastewater will be treated in ETP and treated effluent will be discharged through common pipeline. Numaligarh Refinery Limited is implementing a wax manufacturing project at a cost of ` 5,770 million in Numaligarh Refinery, district: Golaghat, Assam. The project is scheduled for completion in Financial Year 2013. The project envisages production of high value low volume paraffin and micro-crystalline wax utilizing inherent properties of North East crude. Engineers India and Axens of France have been selected as the process licencors for solvent de-oiling and wax hydro-finishing units.
Parawada, district: Visakhapatnam, Andhra Pradesh. As of September 2013, the project is waiting for Government approval. 1-(2-Phenylethyl) piperidin-4-one is used as an intermediate in the manufacture of chemicals and pharmaceutical drugs. This is a new product line in the existing plant. The company also plans to produce Amitriptyline HCl in the same unit in future. Resil Chemicals Private Limited is planning a specialty chemicals manufacturing project in Malur, district: Kolar, Karnataka. As of July 2013, land has been partially acquired. The project is in conceptual stage. Other details are yet to be finalized. Ć MINING Sri Venkatesh Granites is planning a colour granite mining project in Kamanpur, district: Karimnagar, Andhra Pradesh. As of December 2012, environmental clearance has been received. The project will come up on 4.56-hectare of leased area. Global Enviro Labs is the environmental consultant. Western Coalfields is planning the Penganga opencast coal mining project (3-MTPA and peak capacity is 4.5-MTPA) on 281-hectare land in Village Wirur, district: Chandrapur, Maharashtra. As of November 2012, the project has been submitted in the 59 th EAC (Thermal & Coal Mining Projects) meeting held on 6th November 2012. Central Coal Fields is planning the Ray Bachra underground coal mining project (0.3-MTPA) in district: Ramgarh, Jharkhand on 1215.45-hectare land. As of September 2012, the project has been submitted in the 57 th EAC (Thermal & Coal Mining Projects) meeting held on 17 th September 2012. Rajasthan Rajya Vidyut Utpadan Nigam is planning the opencast 10-MTPA coal mining and a 10-MTPA coal washery project in district: Surguja, Chhattisgarh. As of August 2012, the project has been submitted in the 55 th meeting of the EAC (Thermal & Coal Mining Projects) held on 28 th August 2012. Odisha Power Generation Corporation is planning the Manohar pur opencast coal mining project in distr ict: Sundergarh, Odisha. As of July 2012, the company is waiting for environmental clearance.
Ascent Pharma is planning a synthetic organic chemical manufacturing project at village Veraval, district: Rajkot, Gujarat. As of September 2013, the capacity of the proposed unit is yet to be finalized. The project is waiting for environmental clearance. Work on the project commenced in Q1 2014.
Chhattisgarh Mineral Development Corporation is planning ÂSondihaÊ opencast and underground coal mining project in Chhattisgarh. As of July 2012, the company is waiting for environmental and forest clearance.
Vasudha Pharma Chem Limited is planning a chemical manufacturing project - 1-(2-Phenylethyl) piperidin-4-one, in
Central Coalfields Limited plans expansion of its Churi Benti UGP coal mining capacity from 0.16-MTPA to 0.81-MTPA (coal)
Chemical Engineering World
'QJA 85
CEW Project Update in district Chatra, Jharkhand. As of June 2012, MoEF clearance has been received and the project is planned for completion in 2 years from zero date.
Tathagata Bio Energy Private Limited plans to set up 12-MW biomass power plant in Gaya, Bihar. As of May 2011, work on the project is under planning stage.
Zain Coke & Energy India is planning a 150,000-TPA metallurgical coke manufacturing project at a cost of C 450-million to C 500-million in Chickanthapura, district: Bellary, Karnataka. As of May 2012, the project is waiting for revenue and statutory clearance and is planned for completion in 10 months from zero date.
Ć THERMAL POWER Kanodia Cement, belonging to the Kanodia Group, is planning a coal-based captive power project in Unit-I, Durgawati, district : Kaimur (Bhabua), Bihar. The project is waiting for environmental clearance. Land has been acquired. The project will come up along with an ordinary por tland cement manufacturing project. The total cost of both the projects is C 900-million.
Calcom Cement India, belonging to the BK Group, is implementing the New Umrangshu limestone mining project in village New Umrangshu, district: Dima Hasao, Assam. As of April 2012, the mining work commenced in 2013. and machinery has been ordered. Jaiprakash Associates is planning limestone mining project in village Kothar, district: Satna, Madhya Pradesh. As of March 2012, the project is waiting for environmental clearance and the project completion date is yet to be finalized.
Hira Electro Smelters, formerly known as RVR Smelters, belonging to the Hira Group, is planning a 20-MW waste heat recovery based captive power project in Bobbili, district: Vizianagaram, Andhra Pradesh. The project is in conceptual stage. Work on the project is expected to commence in 2017. The project will come up along with a 50,000-TPA coke oven products manufacturing project.
Ć NON-CONVENTIONAL ENERGY Siddheshwari Paper Udyog is implementing a 6-MW rice husk-based captive power project in Kashipur, district: Udham Singh Nagar, Uttarakhand. The project is coming up with an expansion of its kraft paper-manufacturing unit. Civil work is nearing completion and machinery has been ordered.
Jai Bhole Cement Combine, a group company of Zawar Sales, is planning a 72-MW coal and 10-MW waste heat recovery based captive power project in Velabai, district Yavatmal, Maharashtra. Equipment supplier is yet to be appointed. The project is waiting for final approval of environmental clearance. Work on the project commenced in March 2014 and is planned for completion in H1 2017. The project will come up as part of its C 151-billion integrated cement project spread over 2,500acre of acquired land.
The Jeypore Sugar Company Limited is planning an expansion of its bagasse-based co-generation power plant from initial 0.5-MW to 8.5-MW in Chagallu Village, district: West Godavari. Andhra Pradesh. As of January 2014, the project will come up along with a new 120KLD grain-based distiller y. The project is waiting for environmental clearance.
Aditya Birla Nuvo is planning an expansion of its coal and lignite-based captive power project from 34.5-MW to 54.5MW at a cost of C 8,500-million (inclusive of viscose filament yarn project) at Indian Rayon unit at Veraval, district: Gir Somnath, Gujarat. The project is waiting for environmental clearance. The project is planned for completion in 2 years from zero date.
Savera Beverages is planning a 5-MW coal and bagasse-based captive power project in village H i r a n w a l i , d i s t r i c t : Fa z i l k a , P u n j a b. T h e p r o j e c t i s wa i t i n g fo r e nv i r o n m e n t a l c l e a ra n c e a n d i s p l a n n e d for completion in 6 months from zero date. 28-acre of land has been acquired. The project will come up along with a 100-KLD grain-based distiller y to produce extra neutral alcohol.
Cauvery Power Generation Chennai, an SPV promoted by the promoters of Kaveri Gas Power, is planning an expansion of its coal-based power project in villages Sirupuzhalpettai and Billakuppam, district: Tiruvallur, Tamil Nadu. The capacity will be augmented from 63-MW to 213-MW. The coal for the plant is impor ted from Indonesia and supplied by Coastal Energy. The project is in a conceptual s t a g e. T h e 6 3 - M W c o a l - b a s e d p owe r p r o j e c t s t a n d s commissioned since 2012.
Ć NON-CONVENTIONAL POWER IPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20-MW bagasse and rice husk-based integrated power spread over 250-acre of land in village Motipur, district: Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1-year from zero date. 86 'QJA
Jayaswal Neco Industries Limited is planning a 50-MW waste heat recovery-based independent power project in villages Dagori, Ameri Akberi and Udgaon, district: Bilaspur, Chhattisgarh. As of February 2013, Public hearing for the project is over. MoU is yet to be signed with the State Government. The project is waiting for environmental clearance and is planned for completion in 20 months from zero date. Chemical Engineering World
Ad Index CEW Sr No
Client’s Name
Page No
Sr No
Client’s Name
Page No
1
Ani Engineers
73
25 HRS Process Systems Ltd
2
Arvind Anticor Ltd
71
27 Integral Process Controls India Pvt Ltd
3
A t o m i c Va c u u m C o m p a n y ( E x p o r t s )
5 29
28 Intervalve (India) Ltd
9
Inside Cover I
29 Kirloskar Brothers Ltd
Inside Cover II
4
Beda Flow Systems Pvt Ltd
27
30 Kishor Pumps Pvt Ltd
69
5
BHS-Sonthofen (India) Pvt Ltd
59
31 KSB Pumps
17
6
Bonfiglioli Transmissions
23
32 Kwality Process Equipment Pvt Ltd
65
7
Busch Vacuum India Pvt Ltd
43
33 Leister Technologies
73
8
Chembond Chemicals Ltd
55
34 Mazda Ltd
81
9
Chempro Technovation Pvt Ltd
92
35 PVF World Expo 2015
61
10 ChemTECH World Expo 2015
63
36 Rasaii Flow Lines Pvt Ltd
57
11
67
37 Rathi Transpower Pvt Ltd
71
11
38 Ravel Hiteks Pvt Ltd
77
39 Robinson Cargo & Logistics Pvt Ltd
13
Cole-Parmer India
12 Desmi Pumping Technology A/S 13 Dip-flon Engineering & Co
7
14 Dover India Pvt Ltd
39
40 Ross Process Equipment Pvt
19
15 E I DuPont India Pvt Ltd
25
41 Simulanis Solutions Pvt Ltd
65
16 Emjay Engineers
69
42 Super Industrial Lining Pvt Ltd
17 Faab Industries
35
43 Suraj Ltd
77
18 Fainger Leser
67
44 Tecnimont ICB Pvt Ltd
41
19 Fluidyme Process Flow Technologies
77
45 Transflow Asia
45
20 Galaxy Thermoplast Pvt Ltd
79
46 Uni Klinger Ltd
47
21 Glatt (India) Pharma Engineering Pvt Ltd
37
47 UNP Polyvalves (India) Pvt Ltd
49
22 Goodie International Pvt Ltd
53
48 Verder India Pumps Pvt Ltd
15
49 Warade Automation Solutions Pvt Ltd
31
50 WaterEX World Expo 2015
60
23 Gopani Product Systems 24 Hi-tech Applicator Chemical Engineering World
Back Cover 51
3
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CEW Book Shelf Diffusion: Mass Transfer in Fluid Systems Authors Price Pages Publisher
: E L Cussler : USD 33.00 : 600 (Hardcover) : Cambridge University Press
About the Book : This second edition of a highly acclaimed text provides a clear and complete description of diffusion in fluids. It retains the features that won praise for the first edition--informal style, emphasis on physical insight and basic concepts, and lots of simple examples. The new edition offers increased coverage of unit operations, with chapters on absorption, distillation, extraction, and adsorption. New chapters on membranes and drug release broaden the bookÊs scope. The entire text is extensively illustrated, and many new worked examples and homework problems have been added.
H y d r a u l i c s o f P i p e l i n e s : P u m p s , Va l v e s , Cavitation, Transients Authors Price Pages Publisher
: J Paul Tullis : USD 122.81 : 288 (Hardcover) : Wiley-Interscience
About the Book : This comprehensive book addresses all hydraulic aspects of pipeline design. ÂHydraulics of Pipelines: Pumps, Valves, Cavitation, TransientsÊ incorporates many reallife examples from the authorÊs experience in the design and operation of pipelines. Topics covered include basic equations necessary to pipeline design, how to conduct a feasibility study and perform economic analysis, design considerations for pumps and valves, how to suppress cavitation, hydraulic transients, trapped air, and methods of numerical solution of governing equations (including applications to complex piping systems). The book includes twenty-five tables for easy reference, which are extensively illustrated.
Valve Selection Handbook, 5th Edition: Engineering Fundamentals for Selecting the Right Valve Design for Every Industrial Flow Application Editors Price Pages Publisher
: R W Zappe, Peter Smith : USD 96.67 : 399 (Hardcover) : Gulf Professional Publishing
About the Book : Valves are the components in a fluid flow or pressure system that regulate either the flow or the pressure of the fluid. They are used extensively in the process industries, especially petrochemical. Though there are only four basic types of valves, there is an enormous number of different kinds of valves within each category, each one used for a specific purpose. No other book in the market analyses the use, construction, and selection of valves in such a comprehensive manner. The book covers new environmentallyconscious equipment and practices, the most important hot-button issue in the petrochemical industry today, details new generations of valves for offshore projects, the oil industryÊs fastest-growing segment, and includes numerous new products that have never before been written about in the mainstream literature. 88 'QJA
Valve Handbook 3rd Edition Authors: Philip Skousen Price: USD 52.76 Pages: 496 (Hardcover) Publisher: McGraw-Hill Professional About the Book : Revised to include details on the latest technologies, Valve Handbook, Third Edition, discusses design, performance, selection, operation, and application. This updated resource features a new chapter on the green technology currently employed by the valve industry, as well as an overview of the major environmental global standards that process plants are expected to meet. The book also contains new information on valves used in the wastewater industry, Applying emergency shutdown (ESO) valves, recent changes to shutoff classifications, valves specified for the nuclear industry, the procurement process for the Nuclear Stamp (N-Stamp), the emergence of wireless technology and its application to current smart technology and characteristics of high-performance hydraulic fluid. Valve Handbook, Third Edition, covers: Valve selection criteria Manual valves Check valves Pressure relief valves Control valves Manual operators and actuators Smart valves and positioners Valve and actuator sizing Green valve technology and application Common valve problems Valve purchasing issues
DAIE?=H "JCEJAANEJC 4KNH@
Interview CEW
“Leverage Talent and Experience Base to Focus on Specialty Chemicals”
The specialty chemical market has a great scope for growth as several reports suggest. In the chemicals market in Asia, India is the third largest market. BASF has made their single largest investment to cater to this burgeoning sector through their Dahej project. In this exclusive interview, Dr Raman Ramachandran, Head – South Asia and Chairman, BASF India talks to Mittravinda Ranjan about how the company maintains its edge over their competition as well as the opportunities it wants to tap into in the Indian market. What is the progress of BASFÊs Dahej site? What role will this new plant play in BASFÊs growth strategy in Indian and global markets? The Dahej project, involving an investment of C 1,000 crore was broken ground in April 2012 and marks BASFÊs single largest investment in India so far. The new Dahej site will be an integrated hub for polyurethanes manufacturing and will also house production facilities for
Chemical Engineering World
care chemicals and polymer dispersions for the coatings and paper businesses. It will strengthen BASFÊs support to key industries such as appliances, footwear, automotive, construction, architectural coatings and personal care, as well as paper. Construction work at the Dahej site is on track and due for completion. May we have an R&D activities
overview of conducted
b y BASF in India? How do Indian operations support the international research activities? At BASF, innovation will play a key role to ensure our long-term business success with chemistrybased solutions to address global and regional challenges of resource, efficiency, food and nutrition and quality of life. Globally, our target is to have Euro 30 billion sales from
'QJA 89
CEW Interview innovations by 2020. BASF invested Euro 1.8 billion in R&D in 2013. As a part of an initiative to globalise R&D, it is targeted to spend 25 per cent of BASFÊs global R&D in Asia Pacific by 2020. India will also be an important part of this initiative. We currently have two R&D centers in India. Earlier this year, we established global R&D functions here in India at the Thane site focusing on organic synthesis, advanced process and formulation research, discovery chemistry for modern agricultural solutions and molecular modelling. With an initial investment of Euro 2 million, this new facility has been set up by BASF under its group company, BASF Chemicals India Pvt Ltd. Other than this, in India, BASF maintains a strong R&D presence through its sites in Mangalore and Mumbai, which are part of a global technology platform. Strategically located in close proximity to key production assets and customers, these facilities support close collaboration between research, development and business teams on site. The research projects are focused on catering to the global megatrends ă Resources, Environment & Climate; Food & Nutrition and Quality of life. As part of the global research platform, the Indian team collaborates with researchers all over the globe to work on new energy concepts, agricultural solutions, leather chemicals, specialty chemicals and the synthesis of intermediates for industrial applications. Many global specialty chemical companies have identified India as a big market for their products. Amidst high competition, how does BASF plan to maintain its edge? The opportunities for the chemical industry in India are manifold. Today, India is the third largest market for chemicals in Asia and is expected to grow further. With increasing purchasing power for all groups of the population, consumers want
to buy longer lasting goods and goods that improve their quality of life and status. This offers tremendous scope for innovations from the chemical industry. BASFÊs edge comes from our ability to innovate based on a deep understanding of global megatrends and specific customer needs and a non-compromising quality standard. Our long history in India, strong customer relations and local manufacturing foot print will also give us a competitive edge. As a company, we believe that it is important to have local manufacturing capacity in Asia for Asia. The local manufacturing sites will let us have a very clear cost positioning which will enable us to be competitive. And the most important reason for having a local manufacturing unit is to be close to the customer and understand the local market driven requirements and adapt and act on it promptly. Added to this, we have a very strong R&D capability which will enable us to bring products in the market quickly. How do you view the growth of specialty chemicals in India in terms of market and as a manufacturer? What are the biggest bottlenecks in your view for the specialty chemical manufacturers in India to compete at global level? With a growing demand in the chemical industry, I see a very bright future for the specialty chemicals market in India. This has been reaffirmed by the Tata Strategic Report which was released in 2013 on the specialty chemicals market in the country. This report says that the Indian market is bound to reach USD 60-70 billion by 2020. According to me, one of the biggest challenges we face is the lack of infrastructure and power shortage, ready availability of raw materials are some of the other main deterrents. Hence, large scale direct investments are difficult. But these issues are easily surmountable
As a company, we believe that it is important to have local manufacturing capacity in Asia, for Asia. The local manufacturing sites will let us have a very clear cost positioning which will enable us to be competitive. 90 'QJA
Specialty chemicals market is bound
USD 60-70 billion by 2020.
to reach
with adequate government support and providing an additional boost to the R&D sector. Water treatment chemicals market is already witnessing strong surge in demand across the entire Asia Pacific region. How do you see the competition in this market for BASF? What is your strategy to stay competitive? In 2050, more than nine billion people will live on our planet. Hence, the growing population would require resources which would ensure sustainable living. Innovations based on chemistry will play a key role in three areas in particular: resources, environment & climate; food & nutrition and quality of life. Amongst these themes, water will play an important role in ensuring a good quality of life and food & nutrition. Here BASFÊs water treatment solutions would be able to further this vision in safeguarding a healthy future. On a local front, according to data by Frost & Sullivan, the Indian water and wastewater treatment market earned revenue of over C 6,300 crore in 2011 and is estimated to reach C 10,230 crore in 2016. These statistics show that there is a strong demand for water treatment chemicals market and we have seen a surge in the number of multinationals working in this area. We are committed to growing our business in the water space. As part of our strategy, we are also working to expand our business beyond flocculants and coagulants in the industrial sector. In the municipal & industrial sectors, the focus is on water treatment & sewage treatment. We shall offer our products or technologies to the municipal sector through direct channels, OEMs or service providers for raw water treatment, dewatering of municipal sludge(s) and sea water desalination. Chemical Engineering World
Interview CEW Our range of products include highlyefficient ultrafiltration modules and costeffective, space-saving rack designs as the core components of water treatment plants, rounded off by the superb technical support it provides to its customers. All the companyÊs products are based on the in-house development of its patented Multibore® membrane technology, providing top-quality standards. The extremely small-pore (< 0.02 microns) filters of the Multibore® membrane reliably intercept not only particles, but also microorganisms such as bacteria and viruses, thereby providing a dependable source of clean water. Which are the other opportune areas for BASF in the Indian market? BASFÊs growth and contribution to Asia Pacific will also develop along with the changing economies and demographics. We will provide solutions for the needs of the emerging middle class forming the Âbase of the pyramidÊ through solutions for affordable mass housing, food fortification, wind energy and water purification. These are in line with the four megatrends, we have identified: resources, environment & climate; food & nutrition and quality of life. We will start to enter with the right customers in India and later extend this further to other South Asian countries. A recent paper by Frost & Sullivan indicated the strong growth that Middle East (ME) downstream chemical manufacturing industry until 2020 with strong emphasis on the specialty chemicals ă water treatment, paints & coatings, oil field chemicals etc, which are expected to grow at around 5.0 to 5.5 per cent CAGR. Since ME enjoys the feedstock advantage and is now highly focused on diversifying through value additions, where does that leave India in global competition? Yes, ME producers look at India as their home turf. But when the ME producers look at diversification, they need to look down the
value chain. This currently does not exist in the ME, primarily due to technology reasons and market reasons. The ME market is export oriented market and hence there is no captive demand. Vis-à-vis India, where the local players with their manufacturing units will continue to have a strong position by adapting the products to specific market requirements. How can India use its strong talent pool to counter the competition that would be offered by the ME in the years to come? ME, despite being rich in feedstock availability, requires expertise and the necessary manpower for execution of these projects. Currently a lot of Indian diaspora reside in the region and they are well equipped to take this MEÊs vision ahead. To counter this, India by having a local manufacturing unit can provide the requisite opportunity to retain the talent pool in the country. Additionally on a social front, Indians would be more willing to undertake activities in the country if provided the competitive benefits that would be provided in the ME. On the other hand, China ă being extremely cost competitive offers a strong competition to India. In your opinion, what kind of growth strategy should Indian companies adopt to get the much needed edge to be globally competitive? Priority should be on India to become selfsufficient in its chemical requirements. As an importer, it always puts India on the back foot with regards to the vagrancies in the global market. This is a strategy that China has adopted very successfully. China is reasonably self-sufficient and hence has become an exporter. From short to mid-term, this should be IndiaÊs strategy and that would generate market growth by being self-sufficient in its requirements. For example, it is crucial to set up petrochemicals units for products such as acrylic acids, oxo-alcohols etc, which India today imports
Innovations based on chemistry will play a key role in four areas in particular: resources, environment & climate; food & nutrition and quality of life. Amongst these themes, water will play an important role in ensuring a good quality of life and food & nutrition. Chemical Engineering World
Indian water and wastewater treatment market
earned
revenue
of
over
C 6,300 crore in 2011 and is
estimated to reach C 10,230 crore in 2016. In addition to this, Indian companies can leverage their talent and experience base to focus on specialty chemicals both for local and for export including contract manufacturing. This would require companies to develop international EHS standards, flexibility to cater to changing demands and a relentless focus on efficiency and economics. How is the shale gas revolution going to change the global market dynamics for the chemicals & petrochemicals industry? How do you see the impact on the global chemical supply chains in the years to come? And what would be its impact on India? Competitive raw material and energy costs are one essential criterion for the overall development of the chemicals and petrochemical industry. The recent rapid growth in the production of unconventional oil and gas such as shale gas in the US has led to a significant decrease of natural gas prices which in theory benefits the energy intensive industries. At BASF, we have taken steps to benefit from the low natural gas prices in the US. With competitive energy prices and a dynamic economic development, the United States and Asia Pacific are becoming increasingly attractive as investment countries for BASF. The shale gas revolution will definitely change the landscape, especially in the petrochemical industry. These changes are likely in the C1 ă methanol, methane ammonia and C3 methane to methanolpropylene areas. This implies there will be a shift in supply chain, which means there will be products manufactured in USA based on competitive feedstock. Needless to say, there will be a certain impact on India as well which, from todayÊs perspective, further needs to be quantified. 'QJA 91
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