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INDUSTRY WATCH - Chemical World
August 2011
EDITORIAL
The asset advantage
O
nly a few years ago, many manufacturing organisations were unable (mostly handicapped by technology constraints) to precisely quantify their risk exposure, and hence there was no sure basis to assess the quantum of risk they can endure to ensure the anticipated returns. Although things have not radically changed for better during this period, the good news is that today, thanks to available technology, an organisation has the ability to monitor some of the greatest risks to its asset reliability on a real-time basis. The point to be noted here is that it is not about minimising an organisation’s risk exposure; in contrast, it is to leverage the inherent risk for maximum gain in a competitive market. Moreover, the organisation’s keenness to establish a robust performance management system aided by process enablers, policies and contingency plans will play a vital part in realising the true potential of its assets as competitive differentiators. With increasing eco-awareness and rising disposal costs, it has almost become mandatory to include this aspect as part of an optimal asset management strategy. Besides, the investment part (mostly read as cost factor) in sustainable technology needs to emphasise on the potential value savings in the long run.
Business Insights Technologies Opportunities
Senior Editor : Manas R Bastia Assistant Editor: Rakesh Rao Senior Features Writer: Prasenjit Chakraborty Features Writer: Mahua Roy Correspondent: Avani Jain (Ahmedabad) Senior Copy Editor: Marcilin Madathil Edit Associate - Products: Paskaline Sebastian Art Director: Varuna Naik Chief Photographer: Mexy Xavier Senior Photographer: Neha Mithbawkar Photographer: Joshua Navalkar Senior Designer: Mahendra Varpe Production: Pravin Koyande, Dnyaneshwar Goythale, Vikas Bobhate Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Akshata Rane, Abhay Borkar Marketing & Branding: Jagruti Shah, Ganesh Mahale CEO-Publishing: Sandeep Khosla Associate Vice President: Sudhanva Jategaonkar Subscription: Sunil Nair, Distribution Head Email: sunil.nair@network18online.com, customercare@infomedia18.in Tel: 91-22-3003 4631/4633
Going forward, developing an ISO standard for asset management will add more strength in the quest to leverage physical assets to achieve the organisational strategic plan. For more insights into asset optimisation, especially in the context of chemical process industry, turn to ‘Sector Watch’. Now, let’s consider the bulk chemicals sector in India. Fragmented by nature, this is yet to achieve economy-of-scale as far as the global capacities are concerned; which explains its miniscule share in the global market. The writing is on the wall and it is the need of the hour to add operating capacity and enhance process efficiencies as per global standards. Also, this sector will do well with a clear focus on value-added downstream products. On the part of the government, it is important to rationalise the existing tax structure for providing a level-playing field as well as facilitating energy and raw materials at competitive rates. ‘Industry Update’ offers a detailed perspective into bulk chemicals and in particular, the way ahead. Read on…
Editorial Advisory Board Pothen Paul Executive Chairman, Aker Powergas Pvt Ltd D P Misra Director, TCE Consulting Engineers Ltd and Former Director General, ICC P D Samudra Executive Director (Sales) & Member of the Board, Uhde India Pvt Ltd
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August 2011 | Chemical World
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CONTENTS
30
LEADERS SPEAK Q “Our industry is poised to enter a new phase of growth and technology evolution” ...says Mark S Turowicz, Country Head, Honeywell Specialty Materials, and Managing Director, UOP India
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Q “The demand for large projects in India has doubled over the last two years” ...says Sabee Mitra, President, Emerson Process Management Asia Pacific
34
ROUNDTABLE 36
Bio-based feedstock: Is it a practical alternative?
FACILITY VISIT 38
Spraying Systems India: Showering customised quality solutions
SECTOR WATCH 40
Asset optimisation: Make every investment count
34
INDUSTRY UPDATE 44
Bulk chemicals: Aligning consolidation with capacity-building
MARKET INSIGHTS 48
Indian specialty chemicals sector: Towards making a global mark Dr Joerg Strassburger, Country Representative and Managing Director, LANXESS India Pvt Ltd
COATINGS CORNER 52
Emerging markets: Destination next for paint manufacturers Dr Mosongo Moukwa, Vice President - Technology, Asian Paints Ltd
SAFETY ZONE 56
Construction work near process plants: Step up measures, ward off hazards K N K Murthy, Consultant
36
MARKET SCOPE 58
Water-based adhesives: Binding sustainability with economy Courtesy: Frost & Sullivan Chemicals, Materials and Food Team, South Asia and Middle East
TECH TRACK Water management: Conservation through recycling Hans Birle, Project Manager - Water and Wastewater Treatment & Recooling Technology, Process Plant and Equipment Association
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TREND ANALYSIS Crossflow filtration: Optimising membrane technology Brad Milnes, Process Technology Leader, Koch Membrane Systems Inc
R EG U L A R S EC TI O N S
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Editorial .................................................... 11 National News ......................................... 14 National News - Report .......................... 18 World News............................................. 20 Tech Updates ........................................... 24 Project Updates ....................................... 26 Events Calendar ....................................... 72 Technology Transfer ................................. 74 Book Shelf ................................................ 76 Product Update........................................ 78 Product Index........................................... 89 Advertisers’ List ....................................... 90
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Cover photo shoot: Mexy Xavier
Highlights of Next Edition Sector Watch
: Analytical Instruments
Industry Update : Specialty/Fine Chemicals Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise
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Chemical World | August 2011
Details on page no. 27-28, 61-62, 68-71, 72, 88
NATIONAL NEWS
NEW PROJECTS
MARKETING STRATEGY
Clariant organises Leather Road Shows The second round of Leather Road Shows for Clariant in India concluded recently. The road show depicting the Spring/ Summer 2012 leather collection was held at Ambur, Vaniyambadi, Ranipet, Kolkata and Bangladesh. It aimed at making the leather manufacturers aware of the Customers checking the leather latest trends and innovations in samples at the Clariant Road Show leather fashion articles & the new product developments by Clariant. “Clariant fashion collection road shows are the first and unique in the industry, which have now become popular among our customers, as they get firsthand insights on the forthcoming trends and enable them to stay one step ahead in the industry. Our fashion predictions on leather articles and new development of products prepare customers to tackle the seasonal demand changes,” said R Kumaresan, Country Head – Leather Services, Clariant, India. The show also promoted new fashion predictions from Clariant for the Spring/Summer 2012 leather collections on cow, buff and goat leather. Tanicor RS36 Compact syntan & new oils & waxes and repolish systems were of prime interest at the show. It also provided a firsthand descriptive knowledge of the global colour trends and other new developments along with giving the opportunity to explore the leather fashion concepts and get a clear picture of the Spring/Summer 2012.
Paradeep Phosphates launches new projects worth ` 600 crore Buoyed by about 33 per cent jump in profits during 2010-11, fertiliser major Paradeep Phosphates Ltd (PPL) has launched new projects worth ` 600 crore to substantially raise capacities and efficiencies at its different plants. “In view of the growing demand for nutrients and other reasons, a host of new projects are underway for enhancing the capacity and efficiency of PPL’s plants for sulfuric acid, phosphoric acid and fertilisers,” said Sharad S Nandurdikar, Managing Director, PPL. Furthermore, additional residential and township facilities are at different stages of implementation. All these projects are expected to be completed in the next three years. “The estimated cost would be around ` 600 crore and on completion, the company plans to achieve a plant capacity of 15,00,000 tonne annually,” said Nandurdikar.
EXPORT
PRODUCT CATALOGUE
Indian chemical exports to double in next three years
Cole-Parmer launches its 5th Annual Catalogue for Indian market
According to CHEMEXCIL (Basic Chemicals, Pharmaceutical and Cosmetics Export Promotion Council), the apex trade promotion body of the chemical sector, chemical exports are expected to double up to ` 90,000 crore in the next three years. “In 2010-11, our chemical exports were worth ` 45,000 crore. Over the next three years, we expect to double up the exports,” said Satish W Wagh, Chairman, CHEMEXCIL. He further added, “Recently, the Prime Minister has constituted a task workforce on the chemical sector. Currently, the policy is being framed. We expect the government will offer a lot of schemes to boost production.” CHEMEXCIL, in co-ordination with the National Skill Development Council, will set up a skill development centre for execution of teaching programmes on skill development.
Cole-Parmer, a global leader with 50 years of experience in fluid handling, life science, general laboratory products, instrumentation and equipment, has launched its 5th Annual Catalogue for the scientific and process industry in the Indian market. The 272-page catalogue has numerous unique and new products as well as returning favourites. It is segmented into four key sections – fluid handling, laboratory essentials, process & laboratory equipment. This 2011 catalogue is similar to last year’s catalogue, yet also offers enhancements. It has more new products at competitive prices, and is designed to help customers in their product scale-up. The catalogue also has convenient dual pricing, featuring custom duty exempt prices and prices in Rupees, making it handy for users to set up supply contracts. Rakesh Aggarwal, Director - Operations, Cole-Parmer India, said, “We are working in an arena of customisation, where customers prefer to have solutions tailor-made to their application needs, and we offer this choice. Apart from the products listed in the catalogue, we have widened the horizon for the customer by offering this option of customisation to them through our catalogue, along with other exceptional services.”
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Chemical World | August 2011
NATIONAL NEWS
NEW FACILITY
ACQUISITION
UPL acquires 51 per cent stake in DVA Agro Brazil for $ 150 million The Mumbai-based agro-chemicals major United Phosphorus Ltd (UPL) has acquired 51 per cent stake in Brazilian firm DVA Agro Do Brasil (DVA Agro Brazil) for $ 150 million (about ` 663 crore). The balance 49 per cent would continue to be held by the existing shareholders, the company said in a statement. DVA Agro Brazil, with a net revenue of $ 130 million in 2010, is engaged in the production and marketing of crop protection products. It has a formulation plant in Brazil and is undergoing expansion. “UPL’s acquisition of 51 per cent will be against an immediate cash outlay of around $ 150 million, which will be accomplished through primary infusion of funds in DVA Agro Brazil and secondary purchase of shares from the existing shareholders,” the statement said. Jai Shroff, Chief Executive Officer, UPL, said, “This is the company’s second such acquisition in the Brazilian market.” According to Carlos Pellicer, General Manager, DVA Agro Brazil, the company intends to grow faster than the overall market over the next few years with the help of UPL.
Insecticides India to start Dahej facility by August 2011 Insecticides India Ltd, a leading agro-chemicals maker in the country, is aiming to commission its technical synthesis plant and R&D centre at Dahej by August this year. The plant, spread across 32 acres, is being set up with a total investment of ` 70 crore and would have a manufacturing capacity of 10,000 tonne per annum. “We have technical synthesis facilities located at Chopanki in Rajasthan and Dahej. At Dahej, we expect to start manufacturing monocrotophos technical from August onwards. We are awaiting final approvals to come from the regulatory authorities,” said Rajesh Agarwal, Managing Director, Insecticides India Ltd. Once the Dahej facility starts functioning, its manufacturing capacity for monocrotophos technical will rise to 12,000 tonne per annum, of which 10,000 tonne will come from Dahej. Insecticides India also aims to launch new products including fungicides. However, the company has already started manufacturing of formulations from Dahej plant.
EXHIBITION
FELICITATION
HITEX to organise its first Process Engineering Expo & Conference in Hyderabad
Dr Shah receives award from UDCT Alumni Association
Hyderabad International Trade Expositions Ltd (HITEX) – a PPP of Larsen & Toubro Ltd and Government of Andhra Pradesh – in partnership with Synergy Exposures and Events India Pvt Ltd is co-organising the maiden Process Engineering Expo 2011. A dedicated trade fair and conference pertaining to the process plant requirements, it will be held at the state-of-the-art international expo centre, HITEX Trade Fair Ground, Hyderabad from September 1-3, 2011.
The objective of Process Engineering Expo & Conference is to provide a platform to the equipment manufacturers, dealers and service providers in the process industry to showcase their prowess to technocrats, requirement initiators and decision-makers of the process industry. The Indian process industry has been on a steady growth path over the last few years, with the exponential increase in the demand for steel, cement, power, oil & gas, minerals, chemicals, etc. The future looks promising, and the quantum of growth is expected to grow manifold over the next 5-10 years. This creates a huge opportunity for the machinery and equipment manufacturers as well as service providers to this sector. The Process Engineering Expo is supported by nodal organisations like the National Small Industries Corporation, Cement Manufacturers Association of India, All India Mini Cement Manufacturers Association and Federation of Andhra Pradesh Chambers of Commerce and Industries.
Dr Kishore M Shah, Chairman & Managing Director, Sauradip Chemical Industries Pvt Ltd, and President, Indian Specialty Chemical Manufacturers’ Association, has been awarded the
Dr Kishore Shah (left) being felicitated
Distinguished Alumnus Award 2011 by UDCT Alumni Association. Dr Shah is a technocrat, author, consultant and an industrialist. He received his Ph.D. (Tech.) in Dyestuff in 1965 from UDCT (now ICT). He has also written several books that include Studies in Heterocyelic compound, Hand Book of Synthetic Dyes and Pigments, and Hand Book of Industrial Chemicals. In 1992, the then President of India, Dr Shankar Dayal Sharma, conferred Self-Made Industrialist Award ‘Udyog Patra’ on him.
August 2011 | Chemical World
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NATIONAL NEWS
STRATEGIC MOVE
NEW CENTRE
IKA India unveils its new application centre IKA India inaugurated its new Application Center (Lab & Ana and Process Technology) in Bengaluru recently, in the presence of around 30 wellknown technocrats from pharmaceutical & food industries and research institutes. S G Biligiri, President, Karnataka Drugs & Pharmaceuticals S G Biligiri lighting the inaugural lamp Manufacturers’ Association, inaugurated the Application Center (Lab & Ana), while Erhard Eble, Vice President, IKA Group, inaugurated the Application Center for Process Technology. Later, Suren Dixit, Managing Director, IKA India, presented an overview on IKA India’s roadmap. IKA India has developed the Center with modern facilities for testing and recommending devices & processes. Customers can undertake various studies regarding the suitability, efficacy, efficiency, tests and trials of the products being offered to them. Processes that revolve around stirring, shaking, dispersing, grinding, heating, analysing and distilling will be tested here.
Dorf Ketal Chemicals bidding for US-based Multi-Chem According to reports, Dorf Ketal Chemicals is eyeing US-based MultiChem for an acquisition. The first few rounds of bids saw valuations going over $ 500 million. The final binding bids are expected to be submitted very soon, in which Dorf Ketal may participate. Multi-Chem specialises in oilfieldbased chemical products and makes strategic sense for Dorf Ketal, which has a global presence and wants to expand its marketshare in the oilfield chemical space. The company has a turnover of $ 450 million and has been aggressive in terms of acquisitions. According to sources, the bid process for Multi-Chem is extremely aggressive, with large global players also participating in the bids.
INDUSTRIAL PRODUCT
ANNUAL GENERAL MEETING
Kemrock launches first indigenous industrial grade carbon fibre
DMAI’s 61st AGM held in Mumbai
Kemrock Industries and Exports Ltd (KIEL), one of the leading manufacturers of fibre reinforced polymer (FRP) composites, launched a range of carbon fibre products for industrial applications under the brand name JAITEC. The products were launched by Ashok Nayak, Chairman, Hindustan Aeronautics Ltd (HAL), during his visit to Kemrock’s facility. Appreciating Kemrock’s successful operations & commercial production of carbon fibre plant, Nayak said, “Initially, we were contemplating to have the prepreg manufacturing facility at HAL Bengaluru, considering the proximity of our other facilities. But I was highly impressed seeing Kemrock’s commitment & capabilities at its worldclass facility in Vadodara, which has made HAL decide to make prepregs at Kemrock, apart from the other grades of carbon fibre products.”
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Chemical World | August 2011
Dr K U Mistry addressing the gathering
The 61st Annual General Meeting of the Dyestuffs Manufacturers’ Association of India (DMAI) and Awards Presentation function were held recently in Mumbai. Dr K U Mistry, Chairman, Gujarat Pollution Control Board, was the chief guest. More than 100 members of the association, special invitees, guests & other dignitaries attended the meeting. Ram Ajekar, President, DMAI, thanked all the members for their excellent cooperation and support for tackling the various issues concerning the industry to the best possible extent. He said, “It would be wise to face uncertainties and grab opportunities in the present
difficult phase the industry is passing through. The global economy is still not out of the woods, as many European countries like Greece are facing economic crisis driven by unmanageable debts. Confusing signals from the US are also emerging.” Dr Mistry presented the Annual Awards for the year 2010-2011 for excellence in several categories like successful development of indigenous technology/process, domestic market, exports, pollution and safety, hazards control management, etc. Clariant Chemicals (India) Ltd has been awarded in two categories – ‘Excellent performance in the field of pollution control by a large-scale unit for the year 2010-2011’ and ‘Excellent performance in the field of safety & hazards control by a large scale unit for the year 2010-2011’. The awards were received by Edwin Lewis, Site Head – Kolshet, and Dr A L N Rao, Site Head – Roha from Dr Mistry.
NATIONAL NEWS
JOINT VENTURE
Granules India and Ajinomoto OmniChem form strategic JV Granules India Ltd, a vertically integrated pharmaceutical manufacturer, and Ajinomoto OmniChem, a leading producer of fine chemicals for the pharmaceutical industry, announced a joint venture (JV) to offer high-value active pharmaceutical ingredients (APIs) and intermediates to pharmaceutical companies. The new company, Granules OmniChem Pvt Ltd, will provide value through a unique contract manufacturing platform that will benefit through Granules’ technological capabilities, which offer high quality products through efficient processes and OmniChem’s extensive product portfolio & existing customers. Granules OmniChem will operate its facility in the Pharmacity SEZ zone in Vishakhapatnam (Vizag), Andhra Pradesh. The construction of the facility will commence by November 2011 and is expected to be completed by late 2012. The facility, which will have Capex of over $ 20 million, is expected to start production by January 2013. The company will initially focus on high-value, low-volume APIs and intermediates for existing customers, and will custom manufacture new chemical entities in the future. “The partnership will allow us, from day one, to focus on leveraging our core competency, which is offering high quality products and exemplary customer support with industry leading efficiency,” said Krishna Prasad, Managing Director, Granules India Ltd. INVESTMENT
IPL to invest about ` 300 crore on sugar plant in Bihar Indian Potash Ltd (IPL), a fertiliser company, is all set to invest about ` 300 crore to set up a sugar plant and distillery in Bihar. At present, IPL has five sugar plants in Uttar Pradesh with a total crushing capacity of 12,000 tonne of cane per day. “We will establish a sugar plant in Muzaffarpur district, in Bihar, along with a distillery to produce Indian-Made Foreign Liquor (IMFL), with an investment of ` 280 crore,” said P S Gahlaut, Managing Director, IPL. The company will soon start construction work on the sugar and distillery plant in Bihar. “While the sugar plant will have a capacity of 3,500 tonne of cane crushed per day, the distillery will produce 45,000 litre per day,” Gahlaut said. During the last fiscal, IPL established four sugar plants in Uttar Pradesh, taking its total plants in the state to five. Its sugar plants are situated in Meerut, Muzaffarnagar, Lucknow, and two at Gorakhpur. At present, the total sugar producing capacity of the company is around 12,000 tonne of cane per day (TCD), which would reach 18,000-20,000 tonne of cane per day after the Bihar plant becomes operational and with further capacity addition in other plants in the next three years.
August 2011 | Chemical World
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NATIONAL NEWS Report
IP training
GIIP aims at strengthening IPR awareness IPR is gaining unprecedented prominence across the process industry in India. However, lack of awareness and training makes it tough for professionals to gain a strong foothold in this arena. Global Institute of Intellectual Property (GIIP) comes forward as a training partner to the industry professionals to orient them about the nuances of IPR in India.
Mahua Roy
remaining 7,044 applications were filed by Indian residents. While this data does point to a large gap he introduction of a full-fledged product between the number of applications being filed by patent regime in India from January foreign applicants and those by Indian residents, 1, 2005, was a major milestone as far there has been an increase in the number of filings as the Indian Patent Law is concerned. compared to the previous years.” “Certainly, India has come a long way in the field IPR filings from chemical industry have also of establishing a patent system, which can boast increased in recent years. “Chemical inventions to be at par with the rest of the world. One of dominating the filings include polymers, textiles, the other relevant amendments agricultural chemicals like that took place in the Indian fertilisers/pesticides, textile dyes Patent Law was that of reversal and other specialty chemicals. of burden of proof in case of According to the data published process patent infringement. This by the Indian Patent Office, with has in fact impacted the chemical regard to the chemical industry, a patents in a big way,” elaborated total of 6,014 patent applications Atulya Nath, CEO, GIIP, a leading were filed in the year 2009-10 as Intellectual Property (IP) training compared to 5,884 in 2008-09. company, co-headquartered in In fact, BASF AG was ranked Atulya Nath New Delhi and San Jose, USA. among the top 10 patent GIIP has come forward filers in India with 222 patent to educate professionals about IPR. It has applications in the last financial year,” said Nath. put together unique international standard courses, conducted by Indian and international GIIP’s offerings IP practitioners, to provide comprehensive GIIP offers diploma, certificate, executive and knowledge about different types of IP-related corporate programmes to hone the skills of protection systems & their significance, technical professionals in the field of IPR, with infringement issues and strategies for focus on patents and patent process of the US, European and Indian jurisdictions. The institute commercialisation & management. has its academic affiliations with The University of IPR filings from India Washington (USA), Centre for Advanced Study & With many global companies setting up research Research in Intellectual Property, William Mitchell base in the country, the number of IPR filings College of Law (USA), Silicon Valley Seminar Inc from India has also increased. As Nath concurred, (USA), IIT Delhi (India), National Law University “According to recent data made available by the Delhi, Ministry of MSME, Ministry of IT, and Indian Patent Office, a total of 34,287 patent Council of Scientific and Industrial Research. Going applications were filed in the year 2009-10 in forward, GIIP plans to set up new learning centres India, of which 27,243 applications were filed at Pune, Hyderabad and Vadodara, and also launch by non-residents (foreign applicants) and the off-campus IP learning programmes.
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Chemical World | August 2011
WORLD NEWS
MEGA DEAL
ACQUISITION
AkzoNobel to acquire China’s leading specialty surfactant producer AkzoNobel plans to further enhance its manufacturing footprint in Asia by acquiring Boxing Oleochemicals, which is one of the leading suppliers of nitrile amines and derivatives in Asia. “This is an excellent opportunity, which couples our strategic ambition to accelerate growth in Asia with our commitment to locate production closer to our customers,” said Rob Frohn, Executive Committee Member, Specialty Chemicals, AkzoNobel. “Boxing’s leading market position in amines will complement AkzoNobel’s growing specialty surfactant business in Asia. The acquisition will also provide a strong local manufacturing operation in the region,” he added. Bob Margevich, Managing Director, AkzoNobel Surface Chemistry, said, “The demand for amines and derivatives is expected to increase significantly over the next few years, with a third of the Asian demand for amines coming from China alone. We plan to enhance the process capabilities and increase capacity at the Shandong site by introducing our state-of-the-art manufacturing technology. We will also introduce new products to the marketplace based on AkzoNobel’s product and application knowhow.” JOINT VENTURE
BASF and CSM to form JV for bio-based succinic acid BASF SE and CSM-subsidiary Purac have begun talks to form a joint venture (JV) to produce bio-based succinic acid. Under the JV, both the companies have been conducting research on this project since 2009. Techniques such as fermentation & downstream processing led to the development of a manufacturing process, which combines high efficiency with use of renewable substrates and the fixation of the greenhouse gas CO2 during the production. The employed microorganism, Basfia succiniciproducens, is a natural producer of succinic acid and can process a wide variety of
C3, C5 and C6 renewable feedstocks, including biomass sources. Bio-based succinic acid can be utilised for the production of bioplastics, chemical intermediates, solvents, polyurethanes and plasticisers. Gerard Hoetmer, CEO, CSM said, “Our company aims to be the first commercial producer in the market with a fermentation production capacity of 25,000 tonne, and we are already planning a world-scale plant with a capacity of 50,000 tonne to account for the expected demand growth.” The plant is expected to be in operation by 2013.
WATER TECHNOLOGY
Ecolab to buy Nalco for $ 5.4 billion Ecolab Inc (ECL), one of the largest makers of cleaning chemicals for hotels & restaurants, agreed to acquire Nalco Holding Co for $ 5.4 billion to add industrial water-treatment services. “We expect stronger growth than either company can achieve individually,” said Douglas M Baker, CEO, ECL. He estimates $ 500 million in additional annual sales growth from the merger. “It positions us well to meet the increasing demand for water and resolve water-scarcity challenges that the world is going to face,” Baker added. Erik Fyrwald, CEO, Nalco, who will continue to run Nalco units after the merger, said the decision to merge evolved from discussions with Baker about potential collaborations. Ecolab has indentified $ 150 million of cost savings from the combination, which was unanimously approved by both companies’ boards. Combined revenue of $ 11 billion will grow at the upper end of the 6 - 8 per cent rate that is forecast by both companies, Baker said. The transaction is valued at $ 8.1 billion, including assumption of $ 2.7 billion of net debt.
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Chemical World | August 2011
Dow and Saudi Aramco to develop chemicals complex in Saudi Arabia The Dow Chemical Company and the Saudi Arabian Oil Company (Saudi Aramco) have formed a joint venture, named Sadara Chemiacl Company, for developing a fully integrated chemicals complex in Jubail Industrial City, Kingdom of Saudi Arabia. Comprising 26 manufacturing units using Saudi Aramco’s project management & execution expertise, and utilising many of Dow’s industry leading technologies, the complex will be one of the world’s largest integrated chemical facilities. The complex will possess flexible cracking capabilities and will produce over 3 million metric tonne of high value-added chemical products and performance plastics. Total investment for the project, including third party investments, will be approximately $ 20 billion.
Andrew Liveris
Construction will begin immediately with all units expected to be up and running by 2016. “This premier partnership is designed to capture growth in the rapidly growing sectors of energy, transportation & infrastructure, and consumer products by creating a manufacturing hub that will provide a differentiated product slate and an advantaged cost position. Customers in emerging geographies such as China, the Middle East, Eastern Europe and Africa will benefit from a strong supplier with feedstock integration, inmarket commercial & supply capabilities, advanced technologies and resources to grow with their demand,” said Andrew N Liveris, Chairman and CEO, Dow Chemical.
WORLD NEWS NEW APPOINTMENT
Carlos Silva Lopes named Strategic Marketing Director for Dow Performance Materials Dow Performance Materials, a business of The Dow Chemical Company, has named Carlos Silva Lopes as Strategic Marketing Director for the business, which includes the specialty companies ANGUS Chemical Company and Acima Specialty Chemicals. In this role, Silva Lopes will lead all global marketing activities for a number of diverse markets – from personal care and paints & coatings to catalysts, metalworking fluids and life sciences. “Carlos brings a wealth of experience to his new role with his expertise in the areas of global business Carlos Silva Lopes marketing and value creation. I am confident that he will lead his team to ensure our portfolio remains competitive and meets customer needs – now and in the future,” said John Buckley, General Manager, Dow Performance Materials, and President, ANGUS Chemical Company. Silva Lopes joined Dow in 1990 for building product sales in Dow Portugal. Most recently, Silva Lopes served as the Global Marketing Director for Dow Fabric & Surface Care, a business unit of Dow Home & Personal Care.
FUEL TECHNOLOGY
Honeywell’s UOP and Exxonmobil to offer advanced fuel production technology UOP LLC, a Honeywell company, announced that it has formed a licensing alliance with ExxonMobil Research & Engineering Company (EMRE) to offer integrated solutions for the production of lubricant oils and high-quality fuels. The alliance brings together EMRE technology, used to produce lube base oils for use in motor oil, with UOP hydroprocessing solutions, which produce the high-quality feedstocks needed for lubricant production.
AGROCHEMICALS
Lonza to acquire Arch Chemicals Swiss pharmaceutical supplier Lonza Group Ltd will purchase biocides company Arch Chemicals Inc for $ 1.25 billion in an effort to strengthen its microbial control business. The combined businesses will create a bacterial-killing products division with sales valued at $ 1.6 billion. “The acquisition of Arch Chemicals is the next logical step in Lonza’s life-science-focussed strategy,” said
Stefan Borgas, CEO, Lonza. The global microbial control market is currently valued at approximately $ 10 billion and is growing at 4-6 per cent per year. The fastest growing microbial control markets are Brazil, India, China and South Africa. Lonza expects the deal to result in at least $ 50 million in savings within two years of the completed transaction. By the third year, Lonza expects the deal to boost sales by $ 40 million.
SOLAR ENERGY
DuPont acquires Innovalight DuPont has acquired Innovalight, Inc, a company specialising in advanced silicon inks and process technologies that increase the efficiency of crystalline silicon solar cells. The acquisition further strengthens DuPont’s position as a clear leader in materials for the solar energy market, enabling a broader & more integrated photovoltaic materials and technology offering from DuPont. DuPont exceeded $ 1 billion in revenue from sales in the photovoltaic market in 2010, and has set a goal to reach $ 2 billion by 2014. “DuPont and Innovalight share a commitment to innovation in materials that have a common purpose – to make solar energy more efficient & affordable,” said David B Miller, President – DuPont Electronics & Communications. Innovalight has developed innovative proprietary silicon ink products, process technology and a pipeline of anticipated products. Silicon inks used in conjunction with DuPont™ Solamet® photovoltaic metallisation pastes boost the amount of electricity produced from sunlight, enabling the production of superior selective emitter solar cells.
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Customers will also be able to access integrated process design solutions for EMRE fuel de-waxing technologies and UOP hydroprocessing solutions to produce high-cetane, ultra-clean diesel for cold climates in a single engineering package “By bringing together these two well-established portfolios, we are maximising solutions for our customers to produce more and better products from each barrel of crude,” said Pete Piotrowski, Vice President and General Manager, Process Technology & Equipment, Honeywell’s UOP. “The integration of EMRE and UOP technologies allows refiners to achieve impressive yields of dewaxed fuels and lube products while optimising their operating and capital costs.” UOP Unicracking™ hydroprocessing processes and catalysts upgrade crude oil to produce ultra-clean distillate products and lube oil feedstocks. operation.
WORLD NEWS
CSR INITIATIVES
PRODUCT SHOWCASE
Waters showcases advanced products at the American Association for Clinical Chemistry Annual Meeting Waters Corporation unveiled new technology solutions for increasing clinical laboratory efficiencies. MassTrak™ Online Solid Phase Extraction Analyzer providing automated sample clean-up, concentration & extraction, complemented by Waters® ACQUITY® TQD tandem quadrupole mass spectrometer for high-sensitivity quantitative analysis and MassTrak Immunosuppressants XE Kit – CE marked in accordance with the IVD Directive 98/79/EC for the quantification of tacrolimus (FK506; Prograf®) in liver and kidney transplant patients; and everolimus (Certican®). The company is also sponsoring two scientific workshops, which are designed to further the education of laboratory technicians, scientists and chemists responsible for developing, implementing and maintaining robust clinical assays. Each workshop features presentations from leading practitioners in the field of clinical chemistry, including Good Method Development and Validation Practices for Liquid Chromatography – Mass Spectrometry, Implementing LC/MS/MS in the Clinical Laboratory.
LANXESS raises sustainability profile LANXESS is raising its sustainability profile and joining the world’s biggest & most rapidly growing initiative for corporate social responsibility (CSR), the United Nations Global Compact. “We are delighted to now belong to the group of signatories that are promoting sustainability of the global economy through their entrepreneurial responsibility,” said Dr Axel C Heitmann, Chairman of the Board of Management of LANXESS AG.
RECOGNITION
AspenTech wins 2011 Supply & Demand Chain Executive 100 Award Aspen Technology Inc, one of the leading providers of software and services to the process industries, announced it has won a 2011 Supply & Demand Chain Executive 100 Award for an integrated supply and demand planning project. Using aspenONE Supply Chain software, a leading plastics and chemicals manufacturer increased the length of its scheduling horizon by 100 per cent and reduced maintenance over 80 per cent. The award from
Supply & Demand Chain Executive Magazine recognises 100 great supply chain projects. Blair Wheeler, Senior Vice President - Marketing, AspenTech said, “aspenONE Supply Chain software helps manufacturers become more demanddriven by integrating supply chain processes across business functions. By enabling supply chain best practices, AspenTech helps chemical companies meet customer demands with improved profitability.”
INDUSTRY FORUM
Rockwell Automation launches Biofuels Customer Advisory Council Rockwell Automation announced the launch of a Biofuels Customer Advisory Council (CAC) to provide customers with a forum to discuss their needs, challenges and industry opportunities. Rockwell Automation will utilise the customer feedback to guide and validate future strategies & product roadmaps for its Pavilion8 model predictive control and plantwide optimisation solutions. The 2011-2012 CAC is composed of representatives from a diverse group of industry-leading companies, including Cardinal Ethanol LLC, Golden Grain Energy LLC, Kansas Ethanol LLC, Marquis Energy LLC, Trenton Agri Products LLC, Western Plains Energy LLC, Western Wisconsin Energy LLC, White Energy LLC and Zilor Enterprises. As part of their participation, members will have the opportunity to preview new products and take advantage of beta-testing opportunities. “Rockwell Automation recognises the importance of obtaining customer input to create solutions that address my industry’s primary needs and goals,” said Jeff Painter, CEO, Cardinal Ethanol LLC.
Dr Axel C Heitmann
The Global Compact initiative was launched in 2000 by the then UN Secretary-General Kofi Annan. With its established principles in the areas of human rights, labour standards, environmental protection and anticorruption, the pact now numbers more than 8,000 participants from over 135 nations. Dr Heitmann stated that LANXESS has set itself clear targets in climate protection, among other areas. Between 2007 and 2009, the specialty chemicals company cut its direct greenhouse gas emissions by more than 50 per cent worldwide. The company aims to deliver a 10 per cent reduction in specific CO2 emissions and specific energy consumption for each business segment by 2015. Moreover, emissions of volatile organic compounds (VOCs) are also to be cut by 30 per cent worldwide by 2015.
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TECH UPDATES
KROHNE’s Viscoline offers better in-line measurement of process viscosity
GEA Niro collaborates with DTU to build a better spray dryer
KROHNE Inc has developed Viscoline Inline Process Rheometer, which provides in-line, continuous measurement of fluid viscosity for process control and monitoring applications. Viscoline is ideal for use wherever viscosity measurement is required for process or quality control. It is extremely adaptable and can be used for a variety of Newtonian or Non-Newtonian applications, including emulsions, cosmetics, shampoos, ketchup, yoghurt, sauces, cheese, paint, resins, oil, plaster, and many more. No mechanical process modification is required for accurate viscosity measurements. The innovative Viscoline uses patented technology based on mixing principles applied to pipes. Viscoline is simple and efficient, with all stainless steel construction, no moving parts and no in-situ calibration required. It enables continuous measurement with analog or digital outputs. The unit is extremely reliable, with a repeatability of 0.2 per cent, resolution to 0.1cP while meeting government policy on metrological traceability. Viscoline’s standard hardware configuration features two in-line mixer assemblies, a control box and an Operating and Maintenance manual. Since viscosity is flow dependent, KROHNE flowmeters are often supplied as part of the system.
GEA Niro is working hand-in-hand with the Technical University of Denmark (DTU) to simulate the fluid dynamics that take place within a full-sized spray dryer. This is done using a scaled down model with water instead of air. The process allows experiments to be performed at a laboratory level that would otherwise require full-scale equipment of several metre in all dimensions. The data gathered helps GEA Niro refine the development of its spray drying equipment and ensures that its technology keeps pace with, and sometimes drives its customers’ production needs. The laboratory equipment, financed by GEA Niro, looks impressive. Inside the scaled-down clear polycarbonate spray dryer containing swirling water, thousands of microscopic particles are turned alive by two green flashes from a laser. Meanwhile, a powerful computer shows a picture full of arrows, in different shapes and sizes, indicating the speed and direction of the flow. Thorvald Ullum, Fluid Mechanics Manager, GEA Niro, has been working on the development of spray dryers primarily used for powder production in food, chemical and pharmaceutical products for many years. “This research collaboration makes it possible for GEA Niro to optimise systems to be as compact and energyefficient as possible,” he said.
ABB’s gas analyser may reduce cost of ownership
Warwick Analytical’s procedure may detect fluorine accurately
ABB’s new combustion gas analyser reportedly offers lower cost of ownership: thanks to long-lasting components, reduced footprint and lower installation, maintenance and purchasing costs. This next-generation analyser can be used in process industries, hydrocarbon processing, power generation and utility boiler applications. Manufactured using a new ceramic-to-steel bonding process, the AZ20 offers improved resistance to thermal stresses and shocks compared to a conventional brazed design. It can be used in a wide range of applications subject to sudden variations in process temperature, as well as offering a gas tight bond throughout its operating temperature range. Featuring a revised sensor design and an increased choice of probe lengths up to 4 metre, the Endura AZ20 expands ABB’s offering to a new range of high temperature applications up to 800°C. The analyser benefits from a unique cell processing technique, which bonds the multilayered platinum electrode to the zirconia. AZ20 can be used in arduous applications subject to sulfurous and reducing atmospheres such as sulfur recovery processes, crematoria and industrial and clinical waste incineration.
Operating in an ISO 17025 and GMP compliant environment, Warwick Analytical Service (WAS) has developed proprietary analytical procedures to enable accurate and precise data to be produced for all types of samples including organic samples with trace levels of fluorine. From extensive method validation, typical results are within the ±0.3 per cent absolute limits considered acceptable for micro-chemical analysis. The WAS method can detect 0.01 ppm fluoride, which is equivalent to 0.02 per cent in a 10 mg sample. WAS has developed special procedures to remove interferences from samples containing boron, calcium or sulfur. Analysis of fluorine is carried out by combustion of an accurately weighed sample in a silica oxygen flask over an accurately measured volume of water and TISAB buffer solution. A fluoride ion selective electrode is used to directly measure the potential of a range of fluoride solutions. The potential of the combusted samples are measured under the same conditions. The concentrations of the sample solutions are calculated from the derived calibration curve. Sets of work typically include certified reference materials or organic analytical standards. Results from these standards and the electrode response are monitored to detect trends in the method.
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TECH UPDATES
Spraying Systems’ TankJet offers cost-effective cleaning solution
Michell Instruments develops intrinsically safe high-speed portable hygrometer
The new TankJet® 75 fluid-driven tank cleaner from Spraying Systems Co. provides thorough impingement cleaning of small tanks without the expense of high impact tank cleaners. The unit uses external gears to reduce nozzle speed for better impact and cleaning efficiency. Ideal for medium-impact cleaning of tanks, totes and intermediate bulk containers, the unit cleans tanks up to 30’ (9.1 m) in diameter. TankJet 75 features rotating solid stream nozzles that complete a 360° indexing pattern every 45 revolutions for complete coverage of the entire tank. The unit’s simple, self-cleaning, flow-through design enables easy maintenance and requires approximately five minutes for rebuilding. Units are available with a two-nozzle or four-nozzle hub and can be mounted permanently or moved from tank to tank with ease. TankJet 75 is ideal for cleaning chemical containers, dairy tanks and totes, food and beverage tanks, pharmaceutical tanks and process tanks. Spraying Systems Co. is the world leader in spray technology such as nozzles, systems, automated systems, fabricated components such as lances and research & testing. It offers complete tank cleaning solutions to optimise cleaning process.
The US-based Michell Instruments has introduced an intrinsically safe version of its portable MDM300 Series hygrometer. The new MDM300 I.S. is designed for natural gas quality monitoring, petrochemical processing, electric power generation operations and other hazardous area applications. By taking an innovative technical approach, continuous high-speed operation is now possible, thus increasing efficiency and reducing costs. The MDM300 I.S. is capable of operating at full line pressures up to 4500 psig, offering fast and accurate moisture content measurements in the field. Dew points to -60°C can be reached in less than 15 minutes with an accuracy of better than ±2°C, utilising Michell’s well-proven ceramic sensor technology. The MDM300 I.S. is completely self-contained including a fixed orifice sample system for low pressures. Higher pressures can be accommodated with a range of configurable external sampling systems. The rugged, ergonomic design of the MDM300 I.S. combines industrial durability with comfortable one- or two-handed operation. The intuitive menu and large, easy-to-press buttons enable the user to easily configure the instrument to display the required parameters even with gloved hands.
New X-ray camera can reveal secrets about how chemistry works
Chemists create molecular ‘flasks’ to control reaction
Designed to record bursts of images at an unprecedented speed of 4.5 million frames per second, an innovative Xray camera being built with STFC’s world-class engineering expertise will help a major new research facility shed light on the structure of matter. The unique device will be delivered to the billion-euro European XFEL (X-ray Free-Electron Laser) next year and will contribute to drug discovery & other vital research, once this facility starts operating in 2015. The go-ahead for continuation of the £ 3 million prototype collaboration contract for the camera’s construction has been confirmed following a visit to STFC by a delegation from the European XFEL’s Detector Advisory Committee. The decision to entrust construction of this crucial piece of equipment to STFC recognises the organisation’s outstanding capabilities in advanced microelectronics and the design of high-tech imaging devices (eg, for the Large Hadron Collider at CERN). Now under construction near Hamburg in Northern Germany, the European XFEL is a 2-mile-long facility that will use superconducting accelerator technology to accelerate electrons, which then generate X-ray flashes a billion times brighter Generation of X-ray laser than those produced by flashes in an undulator conventional X-ray sources.
One of the big challenges chemists continually face is finding new ways to control unwanted reactions or create conditions that promote desirable reactions and limit undesirable ones. Recently, researchers at New York University (NYU) demonstrated an ability to make new materials with empty space on the inside, an advancement that could potentially control desired and unwanted chemical reactions. Mike Ward, of NYU’s Department of Chemistry, and a team of researchers created molecular ‘flasks’, which are essentially self-assembling cage-like containers capable of housing other compounds inside them. These flasks may eventually allow researchers to isolate certain chemical reactions within or outside the flask. “We wanted to create frameworks to serve as the ‘hotel’ for ‘guest’ molecules, which can deliver the function independent of framework design. This makes it possible to separate chemicals based on size or perform reactions inside well-defined cages, which could potentially give more control over chemical reactivity and reaction products. Moreover, these frameworks may prove ideal for encapsulating a wide range of guest molecules, producing materials with new optical or magnetic properties,” said Ward. “By using geometric design principles and simple chemical precursors, Ward’s group has been able to construct relatively sturdy materials that contain many identically sized and shaped cavities,” explained Michael Scott, program director in the Division of Materials Research at NSF.
Courtesy: European XFEL
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PROJECT UPDATES
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the chemical and allied industries. Butyl rubber
Reliance Industries Ltd Project type New facility
Project news Reliance Industries Ltd (RIL) is planning to invest $ 450 million along with Russian petrochemical firm Sibur in setting up a butyl rubber plant at Jamnagar, Gujarat. The joint venture facility will have an initial capacity of 1,00,000 tonne of butyl rubber at RIL’s integrated refiningcum-petrochemical site in Jamnagar, and is expected to be commissioned by 2013. The plant will initially produce regular butyl rubber and is expected to manufacture other types of butyl rubber specialties in the future. The setting up of domestic manufacturing plant of butyl rubber will fulfill a long-standing demand of the Indian tyre and rubber industry and this investment is part of RIL’s vision to emerge as a significant global payer in the synthetic rubber business.
Project location Jamnagar, Gujarat
Project cost $ 450 million
Implementation stage Planning Contact details: Reliance Industries Ltd Makers Chambers - IV Nariman Point, Mumbai 400 021 Tel: 022-2278 5000 Telefax: 022-2278 5185 Email: tushar.pania@ril.com Caustic soda lye
Aditya Birla Chemicals India Ltd Project type Capacity expansion
Project news The ` 2,656-crore Aditya Birla Chemicals business is spread
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across India, Thailand and China. Currently it is planning capacity expansion of caustic soda lye from 220 tonne per day to 370 tonne per day. The unit is located at Sonbhadra, Uttar Pradesh.
friendly; gives high yield and generates minimum amount of by-products.
Project location
Implementation stage
Sonbhadra, Uttar Pradesh
Project cost Not known
Implementation stage Planning Contact details: Grasim Industries Ltd (Chemical Division) Industry House Ground floor 159, Churchgate Reclamation Mumbai 400 020 Tel: 022-2288 0480 Fax: 022-2288 0454 Email: kp.nair@adityabirla.com Hydrogen Peroxide
Gujarat Alkalies and Chemicals Ltd Project type New facility
Project news Gujarat Alkalies and Chemicals Ltd (GACL) and Evonik Industries are reportedly working on a new multi million dollar project in Dahej, Gujarat. The aim is to produce propylene oxide using the environment-friendly hydrogen peroxide to propylene oxide (HPPO) process. This route has clear advantages compared with the conventional production process for propylene oxide. Investment in the HPPO process is far lower, making it more economical. Moreover, the process is extremely environment-
Project location Dahej, Gujarat
Project cost Not Known Planning Contact details: GACL P O Petrochemicals Vadodara 391 346 Tel: 0265-223 2681/2 Fax: 0265-223 2130 Email: md@gacl.co.in Paints
Asian Paints Project type New facility
Project news Asian Paints Ltd will set up a new paint facility plant near Pune (Maharashtra) at an initial investment of ` 1 billion. The initial capacity of the new facility will be 1,50,000 tonne, which will be later scaled up to 4,00,000 tonne. The plant is expected to be operational by 2013.
Project location Pune (Maharashtra)
Project cost ` 1 billion
Implementation stage Planning Contact details: Asian Paints Ltd Asian Paints House, 6A, Shantinagar Santacruz (E), Mumbai 400 055 Tel: 022-39818000 Fax: 022-3981 8888 Email:proffice@asianpaints.com
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PROJECT UPDATES
Paints
Project location
Berger Paints India Ltd Project type
Roha
New facility
` 100 crore
assistance and supply of proprietary items for the project to UHDE India. The project is scheduled to be commissioned in June 2013.
Project news
Implementation stage
Project location
Berger Paints India Ltd has announced plans to ramp up production by investing ` 100 crore in greenfield project in the current fiscal and also double its installed capacity over the next two years. The company is setting up a greenfield project at Hindpur in Andhra Pradesh to manufacture synthetic enamels, acrylic emulsions, metal and wood paints, interior wall coatings, and exterior wall coatings.
Planning
Gujarat
Project location
New facility
Project cost
Project cost Contact details: Sudarshan Chemical Industries Ltd 162 Wellesley Road, Pune 411 001 Tel: 020-2605 8888/8046 Email: contact@sudarshan.com Sulfuric acid
Paradeep Phosphates Ltd Project type
Hindpur, Andhra Pradesh
Project news
Project cost
Paradeep Phosphates Ltd is mulling an investment of ` 500 crore to set up new plants and undertake major expansion work over the next three years. The company will invest ` 250 crore to set up a new 2,000-tonne per day capacity sulfuric acid plant.
` 100 crore
Implementation stage Planning Contact details: Berger Paints India Ltd 129, Berger House Park Street, Kolkata 700 017 Tel: 033-2229 9724 Fax: 033-2227 7288 Email: surajdas@bergerindia.com Pigments
Sudarshan Chemical Industries Ltd Project type New facility
Project news Sudarshan Chemical Industries Ltd is upgrading its manufacturing facility at Roha in Raigad district with an investment of ` 100 crore. The new plant will cater to the automotive coatings, plastics and cosmetic industry. The plant will also recycle 1,000 cubic metres of water per day. This pigment production plant is spread over 89 acre and includes a warehouse, R&D and application laboratory. Sudarshan has a range of organic, inorganic and pearlescent pigments and dispersions catering to the coatings, plastics, inks, cosmetics, textiles and construction Industries.
Project location Paradeep, Orissa
Project cost ` 500 crore
Implementation stage Planning Contact details: Paradeep Phosphates Ltd Pandit Jawaharlal Nehru Marg Bhubaneswar 751 001 Tel: 0674-239 3931 Fax: 0674-239 2631/1669 Email: connect@paraphos.com
` 1435 crore
Implementation stage Planning Contact details: GACL P O Petrochemicals, Vadodara 391 346 Tel: 0265-223 2681-2, Fax: 0265-223 2130 Email: md@gacl.co.in Synthetic rubber
Indian Oil Corporation Ltd Project type New facility
Project news Indian Oil Corporation Ltd (IOC) and its partners Marubeni Corp and Taiwan’s TSRC Corp will be investing ` 900 crore to set up a unit for manufacturing synthetic rubber for tyres. The three will build a plant at Panipat in Haryana by September 2012 for manufacturing 1,20,000 Tonne Per Annum (TPA) synthetic rubber from butadiene. The plant has been planned to benefit from the rising auto demand in India. The SBR would produce high-quality synthetic rubber used in the manufacturing of automotive tyres, conveyors and fan belts.
Project location Panipat, Haryana
Project cost Sodium Chlorate Crystals
` 900 crore
Gujarat Alkalies & Chemicals Ltd Project type
Implementation stage
New facility
Contact details: Indian Oil Corporation Ltd Indian Oil Bhavan G-9, Ali Yavar Jung Marg Bandra (East), Mumbai 400 051 Tel: 022-2642 7363, 2644 7528 Fax: 022-2644 3880 Email: kgwalani@indianoil.co.in
Project news Gujarat Alkalies & Chemicals Ltd (GACL) is in the process of setting up a project to manufacture 20,000 tonne per annum of sodium chlorate crystals for which it has awarded ` 1,435 crore towards engineering services, procurement
Planning
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LEADERS SPEAK
“Our industry is poised to enter a new phase of growth and technology evolution” …says Mark S Turowicz, Country Head, Honeywell Specialty Materials, and Managing Director, UOP India. He is responsible for local resource management and operational alignment with Honeywell Specialty Materials’ and UOP’s overall objectives & worldwide functional organisations. In conversation with Mahua Roy, Turowicz highlights the relentless contribution of Honeywell Specialty Materials towards sustainability and its plans for India.
The dynamic petrochemical sector in India A couple of decades ago, the oil refining and petrochemical industries in India comprised very different players. The refiners would simply provide the feedstocks to the petrochemical producers. The links in the value chain, from crude oil to the final petrochemical product, were distinct and value capture occurred at different places. Probably, the biggest change that has taken place over the last 20 years is that the thin lines between the Indian oil refining and petrochemical industries have almost completely disappeared. Reliance’s Jamnagar complex is the greatest example of this. Also, Indian Oil Corporation’s bold decision in the 90s to integrate refining and petrochemical projects has paid huge dividends to the corporation and the nation. Sophisticated technologies for the production of Linear Alkyl Benzene (LAB), paraxylene and Purified Terephthalic Acid (PTA), naphtha cracker olefins & others were rapidly embraced and assimilated. India may not be rich in expensive crude oil, but its rich talent understands that high-priced feedstocks must be processed with minimal waste and cost, even if this approach results in a slightly higher project capital expenditure.
Indians contributing to the robust R&D We are in the business of technological innovation. Investment in R&D is key to our survival and growth. India has a tremendous talent pool of gifted and innovative scientists & engineers. Some of UOP’s great technology developments over the last several decades were driven by scientists of Indian descent & training and this R&D talent was primarily based in our US facilities. In the late 90s, we decided to tap into this talent pool
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LEADERS SPEAK
directly. Our first step was to develop a world-class design engineering centre in India that has become an integral part of UOP’s global engineering efforts. Our logical next step is to establish an R&D centre of excellence, and we view India as an ideal location for this technology centre. We are now building our Technology Centre in Gurgaon, and plan to have it up & running by late this year.
mixed xylenes. This helped bring down the downstream cost of PET polyester made from p-xylene, besides making polyester fibre, garments, chips and film more affordable. Today, most of the paraxylene in the world is made using UOP technology, including in one of the world’s largest paraxylene production facilities in Reliance’s Jamnagar complex as well as in Indian Oil Corporation’s aromatics complex at Panipat.
Environment-friendly detergents
Complementing sustainability at refineries
Development of LAB, the key ingredient in the manufacturing of synthetic biodegradable detergents, is one of our major innovations. Till the late 60s, synthetic detergents were synthesised by reacting a propylene tetramer with benzene. The branched alkyl benzene product, when sulfonated, had good detergency, but was slow towards biodegradation that resulted in serious environmental problems. In 1968, we commercialised the first LAB complex, integrating four new technologies. The environmental need to phase out the much less biodegradable branched dodecylbenzene (DDB) helped quick acceptance of the new technology. Today, around 85 per cent of LAB made globally use UOP technologies, and India is the leading producer.
We hold the credit of innovating technologies such as UOP CCR Platforming™ process to meet the need for unleaded gasoline and the production of aromatics. More recently,
Towards optimising cost of PET In the 60s, Honeywell’s UOP took a novel counter-current moving bed adsorptive separation process, used to separate linear paraffins from hydrocarbon mixtures, from concept to reality. The n-paraffins, after dehydrogenation, are used in the production of LAB. In the 70s, we then extended this technology and developed Olex™ process to separate olefins from paraffin olefin mixtures through the development of shape selective zeolite adsorbents. In addition, by using another adsorbent developed by UOP, a process called Parex™ came into being to separate paraxylene from
I see a longterm potential in India’s refining and petrochemical industry. We see a continued growth in petrochemical demand that is driving rapid expansion in this sector. UOP pioneered and developed the UOP/HYDRO MTO process to produce olefins from methanol, which in turn is derived from coal or natural gas, providing alternatives to produce ethylene and propylene. We have also developed the UOP MaxEne™ process, which converts excess naphtha available in a refinery into a naphtha cracker feed, which can dramatically improve olefin yields and profitability. Another recent achievement is the technology to convert biological feedstocks into dropin transportation biofuels to support growing energy need and drivers for reduced emissions.
crudes over the long term. Our customers in India recognise this and have made investments in refining technologies that allow them to handle such crudes. We expect this trend to continue. However, it is important to remember that a majority of India’s refining capacity is among the most modern and technologically advanced in the world; so India is exceptionally well-placed to face the future. Another focus area is renewables, where India has access to a great amount of sustainable feedstock like biomass, jatropha and other indigenous, non-food plants. Honeywell UOP’s technology offers the opportunity for Indian producers to utilise these sources to increase energy supply, reduce dependence on crude oil and improve local economies. Additionally, an ever-growing population requires more polyester for durable clothing; and the packaging of liquids has predominantly moved to the use of PET bottles. Paraxylene is a raw material used in the production of both polyester and PET, so we are witnessing a growth in its demand.
Major challenges faced as a technology provider In my view, commercialisation of new technology is one of the major challenges that our industry is facing. In today’s financial environment, business leaders have become more risk averse and cautious. This is understandable, given that successful petrochemical projects require scale & huge investments, and companies are reluctant to commit this level of finance for a new project involving new technology. There are many potential clients waiting in line to be the second to commercialise a plant, but getting the first unit can be a challenge.
Efforts towards sustainability Major trends to focus on It seems that the world crude market will be dominated by heavy, sour
Honeywell’s UOP believes in investing in technology research to come up with solutions for the future. We were one
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LEADERS SPEAK
of the first to understand the drive for reducing pollution from transportation fuels, and we have been leaders in developing technologies to do so. In the 70s, our CCR Platforming™ process enabled refineries to produce lead-free gasoline and as a result, lead was removed from gasoline worldwide. We are now a pioneer in the conversion of natural oils, wastes and biomass to green transportation fuels (Green Jet Fuel™ and Green Diesel™). UOP has developed and commercialised technology for the production of Green Diesel Fuel™ as well as Green Jet Fuel™. In driving and flight tests, our fuel has proven to perform better than petroleum-based fuels, and it can provide net emissions reductions up to 85 per cent compared to traditional diesel and jet fuel.
UOP’s perspective on India I see a long-term potential in India’s refining and petrochemical industry.
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We see a continued growth in petrochemical demand that is driving rapid expansion in this sector. This demand also leads producers to look for new ways to improve the value that they provide to customers. Apart from that, going forward, we see many other opportunities for us in India, including collaborative R&D with key customers, alliances in catalyst manufacturing, and of course, in the further growth and expansion of the Delhi Engineering Centre.
Emerging trends and outlook Our industry is poised to enter a new phase of growth and technology evolution, but some problems remain, which need to be resolved on an urgent basis. The shift in product demand, tighter fuel specification, the need to maximise the products we get from a barrel of oil and the emergence of new alternative feedstocks will present challenges
for refiners around the globe, and ultimately drive new solutions. There is a great deal of change happening in the industry today. The real key for all players will be to maximise the yield of valuable finished products from every single barrel of oil processed. This will include new processing solutions and optimisation projects that deliver huge returns. We are bullish on the growth of petrochemical industry in India. India’s economic growth is driving energy consumption and the installation of new refineries & petrochemical plants. In addition to the domestic market, there is significant potential for India to become a world-leading export hub for refined products. India can do this, because it has the geographic advantage and necessary technical human capital. Though many may not realise this, the country has fairly advanced technology in most of its refineries.
LEADERS SPEAK
“The demand for large projects in India has doubled over the last two years” …says Sabee Mitra, President, Emerson Process Management Asia Pacific. After joining Emerson in 1995, he has held various positions in Emerson Process Management, including Business Leader for the PlantWeb and Asset Management Solutions business in Asia Pacific; Vice President of Rosemount Asia Pacific and President of Emerson Process Management Middle East & Africa. In an interaction with Prasenjit Chakraborty, Mitra highlights different aspects of the evolving process industry and Emerson’s contribution towards it.
Acquisition of the former Fisher Sanmar Ltd Integration of the former Fisher Sanmar Ltd has been part of Emerson Process Management’s ‘One India Strategy’ to provide complete automation products, solutions and services to our customers. The manufacturing capabilities include staging of process systems & engineering, manufacturing and servicing of instruments and valves. The acquisition enhances Emerson Process Management’s ability to support large projects in India. It also enables our Indian operation to export products, systems and services to high growth markets such as the Middle East and Africa.
Changing scenario in the Indian process industry Capital spending in the country is recovering. The demand for large projects in India has doubled over the last two years. This is part of a rebound in global demand for energy, industrial products and consumer goods. This has driven oil prices up, spurred power generation increases, stimulated exploration for natural resources, and increased production of pharmaceuticals & finished goods ranging from paper to plastics to metal products. India is one of the fastest adopters of new technologies in the automation space – for example, Emerson has over 100 process industry customers here using wireless technology. We are collaborating with customers in India and worldwide to commission smarter and more
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LEADERS SPEAK
efficient plants. We emphasise on support services and training to ensure that the workforce is knowledgeable in using modern tools like wireless and FOUNDATION fieldbus technology to operate the modernised facilities.
Specific plans for India Emerson has just completed manufacturing, engineering and solution staging expansion in Mumbai and Chennai for accelerating company growth to support improvement of customer facilities in these regions and throughout India. We plan to expand service and engineering staff to support our growing business. New technology will be developed, including more innovative customer solutions based on technologies including IEC WirelessHART, FOUNDATION fieldbus and Human Centered Design (HCD). Emerson’s goal in adapting these technologies is to reduce complexity in customer use of automation as well as helping towards unequalled improvement in business results. Use of support services with these solutions will elevate the knowledge and skills among engineers in India. Emerson combines process automation expertise and technology to support customers across industries in various parts of the world. Growth in India will come especially from oil & gas, power, chemical and electricity generation facilities.
Acceptance of WirelessHART product in India Emerson’s WirelessHART offering, named Smart Wireless, has proven its ability to fulfil customers’ requirements for simple, reliable and secure wireless communication in thousands of applications, working in concert with millions of installed HART devices and systems worldwide. Emerson’s Smart Wireless technology combines instrument and valve products into field networks to expand measurement and control across
entire process manufacturing facilities. The plant-wide digital networks provide continuous diagnostics that enable control room monitoring to predict failures and enable personnel to take corrective action to mitigate impact on operations. And, during automating new facilities or upgrading existing facilities, quick and easy Smart Wireless installation saves up to 90 per cent or more on installed cost and 75 per cent of implementation time as compared to wired technology. Because monitoring points in any plant constitutes almost 60 per cent of total points, the potential cost benefits that we can deliver in India will be immense. As a result, plants can monitor more to manage better, enabling improvement of units that were previously too costly to automate, or physically out of reach.
Automation is helping improve operational efficiency of plants in India by use of predictive maintenance and process control improvements. Emerging trends Automation is helping improve operational efficiency of plants in India by use of predictive maintenance and process control improvements. Helping to enable this, wireless technology is beginning to be used because it is flexible, easy and quick enough to implement, so as to allow upgrades during turnarounds or fullscale unit modernisation projects. It is especially valued for its expansion of predictive maintenance in facilities as wireless devices help in diagnosing the health of instrumentation as well as the process. In the not-too-distant future, Indian manufacturers may follow an emerging practice of installing a
wireless infrastructure throughout plants to even further ease the addition of new monitoring points by simply mounting and connecting more wireless devices into networks. Much more is happening, as facilities are adding Wi-Fi plant wireless networks to provide such functions as mobile worker capability, location tracking and safety mustering, and video for process monitoring & security applications.
Contribution of Global Development Center Process plants need integrated systems to deliver improved output at reduced cost. Delivering the needed efficiency, Emerson’s Global Development Center in Mumbai stages the company’s PlantWeb® digital systems that combine wired and wireless instruments & control valve products into best-in-class networks. These solutions increase reliability, safety and environmental performance of process plants.
Future plans in India Emerson’s strategy is to be as close to customers as possible to best support their needs for engineering, planning and start up of new or expanded facilities, and to provide support services for operations now and in future. We have been keenly locating and expanding our staging and manufacturing facilities to be closer to our suppliers and customers in the emerging markets. By doing so, we tend to improve our delivery and response times so that customers can achieve faster start-ups, shorter time to market, effective maintenance cycles and maximised production. We are optimistic that continued capital market expansion combined with our ongoing stream of customer-driven solutions will drive good growth and strong results for Emerson & its customers in India in 2011 and beyond.
August 2011 | Chemical World
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ROUNDTABLE
Bio-based feedstock
Is it a practical alternative? With the ever-increasing cost of producing petro-based products, the Indian chemical industry is compelled to explore feedstock alternatives. As a traditional agro-based economy, the country needs to develop appropriate strategy for producing chemicals from agricultural base in a viable manner, which can compete with chemicals produced from petroleum-based feedstock. But this can be achieved only by devising strategic plans through well-conceived R&D programmes, in a sustained manner. Avani Jain finds out from industry experts whether bio-based feedstock can serve as a feasible alternative.
Kirit Mehta, Former President, Chemical and Alkali Merchants’ Association Today, chemical companies are increasingly focussing on using feedstocks that have lesser impact on the environment and can save energy, besides being renewable. One of the major advantages of using bio-based feedstock is less pollution. Moreover, they ensure
energy-efficiency, as they can generate more calorific value at lesser cost. However, it is doubtful that they can in anyway replace the conventional source of energy. But, they surely possess the capability to minimise the usage of valuable fossil fuels. Also, regulatory compulsions need to be enforced and support should be provided to the small- and mediumlevel producers.
Laurent Labatut, CEO, DRT These days, companies have become more conscious about the strain (caused by human activity) on the environment, and many of them have started to change their approach. Using bio-based feedstock leads to a whole new approach going hand-in-hand with the recycling of byproducts, for instance. Consequently, one of the most significant advantages is to reduce the harmful impact on the environment. This allows the company to provide manufacturers with high quality
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natural ingredients (which are subjected to many regulations) and also creates a positive corporate image. In addition, the usage of bio-based feedstock brings down the operating costs. Bio-based feedstock, truly, has the potential to serve as an alternative to the traditionally available materials and is the future of chemical industry. Green or plantbased chemistry principles allow a strong development of the industry. Green chemistry is the key element of sustainability. It is also important to understand that it is not only about bio-based feedstock, but is mainly about preserving the environment.
ROUNDTABLE
Mukul B Malvi, Partner, TEXSPAN The use of renewable or bio-based feedstock has gained importance during the last ten years or so due to high prices of crude, and subsequent uncertainty about price and availability of petro feedstock. However, as seen in the last five years, changing & uncertain weather conditions have had a negative impact, and world over, bio-based raw materials’ yield went down and prices skyrocketed. Food security became an issue of utmost importance. Surplus stocks of grains & other food items became deficit and the food prices doubled in a year’s time. Bio-based raw materials became unviable in pricing and availability. Today, land availability for cultivation is decreasing and farms are
turning into human settlements. Therefore, unless more land for agriculture is made available and prices of food grain stabilised at reasonable level, we cannot think of using bio-based feedstocks for manufacturing of chemicals on a sustainable basis, as it will jeopardise the food security and result in high prices of items required on a daily basis. Thus, only those raw materials, which are not for human consumption, should be used as feedstock in the chemical industry.
Narendra R Mehta, Managing Director, Fibro Organic (India) Pvt Ltd The usage of bio-based feedstock in chemical industries is important because it has the potential for conserving the environment. It can provide a replacement to the non- renewable sources of energy being used in industries, if not completely, at least to an extent of 40-50 per cent. In order to increase the usage of renewable feedstock, there has to be proper R&D and an effective strategy in place. Not only industries but also the government should take steps for promoting the use of bio-based
feedstock. The government should provide incentives to those who use bio-based feedstock and put restrictions on companies using scarce fossil fuels. For instance, kerosene is used on a large scale in printing. Hence, people who are really in need of it feel deprived. So, industries must explore alternatives and not just stick to conventional ways of functioning.
Vijay Singla, Director (Works), IOL Chemicals and Pharmaceuticals Ltd The production of bulk chemicals from biomass can make a significant contribution towards solving two of the most urgent environmental problems, ie climate change and depletion of fossil energy. Also, in present times, non-renewable energy use and greenhouse gas emissions are reduced to some extent, due to the current state-of-the-art biotechnology, improved fermentation and downstream processing. Industrial biotechnology thus offers excellent opportunities for mitigating greenhouse gas emissions and decreasing dependence on fossil energy sources, and therefore has the potential to provide solutions to the various problems faced by the chemical industry today. Although the use of biomass has been limited, it has larger economic impact. Over the years, biomass
has been used in the areas of building, industrial products, and also in textile, paper packaging and pharmaceutical industries. Due to increasing oil prices and diminishing stocks, industries are reconsidering the use of biomass for a wide range of materials, because a major alternative for fossil is biomass. The use of biomass is likely to increase manifold in the near future. But in order to substantiate this need, there should be adequate investment on R&D of bio-based feedstock. There needs to be proper planning for collection, separation and utilisation of the same. Moreover, the government should provide subsidies for bio-based projects.
August 2011 | Chemical World
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FACILITY VISIT
Spraying Systems India
Showering customised quality solutions Offering an innovative product line comprising turnkey solutions for chemical processing, hygiene and pollution control, Spraying Systems India has evolved as a trusted partner to the industry. The company’s state-of-the-art manufacturing facility in Bengaluru aims at providing the best customised solutions to help chemical businesses grow.
Mahua Roy
Q
uality first! This is the industrywide demand, which is echoing throughout these days. With quality is linked brand loyalty and image. A trusted partner who can offer the commitment of delivering quality is what the industry is relentlessly on the look out for. This search ends for the chemical industry, with the product bouquet offered by Spraying Systems India. Also, without ignoring the operating cost containment, the products offered by this company optimise spray system performance for cost-efficient assistance in many chemical production applications. The Bengaluru facility of Spraying Systems India commenced commercial operations in 2003 from a 12,000 sq ft facility, to a facility that today is five times bigger (65,000 sq ft). “Through this facility, we serve the entire SAARC region. The new facility spanning 65,000 sq ft was established recently, in 2009. We handle the manufacturing of a few thousand different types of spray nozzles. These are multi-disciplinary and can find applications in almost all industries,”
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says Shridhar Bhat, Managing Director, Spraying Systems India.
The facility Apart from manufacturing, the company also handles the provisions of turnkey solutions for automation of sprays. “These days, the emphasis on hygiene acquires great importance. This is the reason why several companies are turning towards automated systems for spraying technology. Automation ensures that the product quality, consistency & reliability are maintained and there are minimum instances of contamination, which can be a possibility by manual application methods,” observes Bhat. Nozzles and spray technology systems provided by Spraying Systems India are efficiently designed to reduce operational costs and also improve product quality effectively. The spray systems find applications across diverse functions in a chemical processing plant.
Customised for chemical processing Process improvement and expense reduction are important elements for every business. Highly precise spray control, minimised coating
FACILITY VISIT
overspray, compact nozzles are product attributes, which aid the chemical processing industry in delivering costefficient operations. For chemical processing and production, proficient sprays for coating, humidification & dehumidification, etc are offered. Especially for the specialty and fine chemicals, customised sprays are offered, as well as those for chemical injections and desuperheating. Besides, an entire array of pollution control sprays is manufactured by this company. Highest grade of silicon carbide, Hastelloy®, Stellite® and other high performance alloys are utilised for most nozzles in addition to a wide range of metals and plastics. One of the most useful products manufactured by Spraying Systems is the CIP systems. From gentle rinsing to removal of the toughest of residues, the system can be used for tanks up to 30 m in diameter. “Stress is laid on waste reduction, cycle time, set-up time, as well as, increase in productivity,” asserts Bhat. The spray systems are designed to have an impact on sustainability as well, encouraging water conservation with minimum use.
These days, due to the emphasis on hygiene, more and more companies are turning towards automated systems for spraying technology. Automation ensures that the product quality, consistency & reliability are maintained and there are minimum instances of contamination, which can be a possibility by manual application methods.
Shridhar Bhat Managing Director
Spraying Systems India is a whollyowned subsidiary of Spraying Systems
Co, USA. It is a 74-year old company, headquartered in Chicago. Being the pioneer in this niche technology, it is evident that the company lays much emphasis on R&D towards providing better products continuously and consistently. “Our R&D vision and mission focus on quality. We emphasise on technology development to provide the same. Our full-fledged R&D team in Bengaluru comprise more than 20 qualified engineers who are working towards in-depth research, designing and manufacturing,” states Bhat. The outcome of this R&D team has led to the indigenous design and production of around 25,000 out of the 87,000 types of nozzles. “This customisation for the Indian markets serves around 80-90 per cent of our Indian customers,” says an elated Bhat. In addition, the compressed air spray systems were fully developed in India,
CNC machines used for manufacturing nozzles
Packaging and despatch unit
R&D focus
at the Bengaluru facility. This system takes care of the blowing off of the residual water, cooling, etc. Ongoing research activities are focussed on new application areas. “Our R&D activities undergo continuous improvement to provide more effective, efficient products. We also concentrate on serving new areas of application, which are relevant to the chemical processing industry to meet the exact requirements of our customers,” states Bhat.
Future vision Being operational in India since 1999 as a sales and marketing division, Spraying Systems India today has come a long way, pioneering spray technology solutions for the chemical industry. “Our vision is to become a ` 200-crore company by 2015. The capacity installed in the Bengaluru facility is in line with our vision,” informs Bhat. New products are lined up for the market, which the company is sure will elicit a positive response from the market. Incidentally, Bhat has been the very first employee of the company, since 1999. Reminiscing on the transformation this company has gone through, he concludes, “In the late 90s, it was a challenge to develop a market for such niche and technologically advanced products, which never existed in the country. Then we witnessed the proud moment when the commercial operations commenced at Bengaluru, and the first invoice from manufacturing unit was received.” (Photo by: Shrikanth S Y)
August 2011 | Chemical World
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SECTOR WATCH
Mention ‘cost savings’ in a project and you are bound to receive a thumbs up. But the true potential of a successful project can be realised only when the clause of asset optimisation is fulfilled. Futuristic technologies being offered by engineering, IT and maintenance experts are now enabling the industry to make the most of this.
Photo by: Mexy Xavier
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SECTOR WATCH
Safety and environment-friendliness is now a law. With stricter regulations now being imposed on the industry, PAM tools that complement the same need to be employed. Also, right training and education need to be provided at the basic levels for successful implementation of PAM.
Mahua Roy
R
emember using your notebook to the fullest, scribbling illegibly till the last page? Or jerking your pen relentlessly till the final drop of ink permitted you to write? These subtle habits of ‘asset management’ have made us realise its importance and why it is imperative to be incorporated and emphasised upon in projects. Once heavily endorsed and utilised by the developed nations, India is no more lagging behind in its adoption. As Bharat Gala, President, SNC Lavalin Engineering – India, puts it, “India has come a long way in the past 8-10 years. The largest refinery & petrochemical complex in the world is situated in India and most of the critical process-driven industries are growing as well. Such industries are investing more and more in engineering, project management, and Plant Asset Management (PAM) tools to optimise the use of existing assets along with boosting safety.” Global competitiveness is putting tremendous pressure on cost, quality and responsiveness in manufacturing. To succeed in this highly competitive arena, producers must keep pace with constantly changing needs and expectations from customers and end-users for innovative products and shorter lead-times.
Bharat Gala President, SNC Lavalin Engineering – India “Initially, PAM was never looked upon as a tool, it was considered as a luxury, adopted by very few players. But today, as the industry globalises and customised solutions become available to the industry, PAM is being highly accepted. Integration of technologies from inventory management to supply chain dynamics and real-time management of assets is equipping
Optimisation of material recovery in business cycle, where output of fabrics can be used as inputs again, needs to be realised. the industry personnel in planning future projects, training & orienting employees, planning & maintenance activities, etc,” explains Gala.
Being profitable and manageable
Is India ready for real-time asset management?
The incentive of obtaining higher Return on Investments (RoIs) motivates one to invest heavily in PAM. The customer dynamics towards PAM is changing and the industry is demanding futuristic technologies to maintain assets. The thrust of this maintenance focus is the early identification of faults and the suggestion of probable causes & corrective actions before the devices fail and cause unscheduled plant stoppages. Faults may be process discrepancies, or may be related to problems like vibration or lubrication failure, etc.
In order to be a class apart from the competition and achieve business advantage, it is critical for every
company to develop products, both quickly and to the highest possible quality standards. Service providers are acutely conscious of this fact, and thus reduce their time not only to develop new ideas but also in realising these ideas commercially. Thus, many industry-friendly real-time solutions are being provided, which are being heartily embraced by the process industry. “The Indian process manufacturing industry is in adoption mode for wireless technology. A few industry innovators have already adopted it; others are watching its implementation with keen interest. From a global viewpoint, WirelessHART (a wireless sensor networking technology) has earned international standard status (IEC 62591) and is being used in thousands of applications worldwide. While monitoring applications are dominant, the IEC 62591 wireless technology is designed to provide the full range of real-time management and control,” says Shailesh Naik, Business Leader - Asset Optimisation, Emerson Process Management India. Such real-time management and integration is being demanded extensively by the Indian industry.
Service providers & end-users need to communicate to establish reasonable expectations on service efforts and returns on investment. Services are an investment, but with the right plan, they can deliver significant value to equipment life, availability and profitability. Shailesh Naik Business Leader - Asset Optimisation, Emerson Process Management India
August 2011 | Chemical World
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SECTOR WATCH
Increased globalisation and after-effects of recession are forcing companies to continue to reduce costs and improve efficiencies of their operations without compromising on the increased demands of greater asset optimisation levels from the customers. Pradeep Kumar Gupta Practice Head - Ports, EPC, Manufacturing, IFS India Industry leaders are looking at streamlining the workflow of people and processes, not only among engineering and manufacturing units but across a whole organisation from the R&D function to the laboratory, then onto the pilot and, ultimately, the commercial plant. This thus drives more effective communication and helps to scale up from pilot to commercial plants quickly. It also helps generate data that process engineers may need to simulate ‘what if’ situations and identify bottlenecks in critical operations. “With increased availability of shared technologies and everincreasing involvement of government by way of defining user-friendly policies on technology usage, India has now
geared up to take on the challenges of remotely managing assets. It improves operational management by monitoring exceptions or failures, automated schedules for maintenance & replacement, remote access and scheduling of data. It provides faster information processing and shares it with the operations & maintenance workforce, management and customers,” voices Pradeep Kumar Gupta, Practice Head - Ports, EPC, Manufacturing, IFS India.
Demands of the chemical industry Decreasing product life-cycles, increasing customer requirements regarding quality, delivery time and flexibility on one hand, and the
Tips for better asset management R Implement proactive maintenance practices: Industry source NPRA has
statistics indicating that reactive maintenance costs 50 per cent more than planned maintenance. R Identify predictive maintenance improvements: Smart wireless technology based on the IEC 62591 international standard is a great tool. New wireless devices deliver diagnostics for management of the health of instrumentation as well as the process. Predictive diagnostics and process information are wirelessly connected to plant personnel who can make fast, accurate decisions based on the real-time information from plant assets. R Install (or optimise) asset management software: An effective asset management programme will provide predictive diagnostics and real-time equipment condition reports to maintenance & operations personnel so that work can be prioritised & planned while maintaining production. A comprehensive asset management solution will integrate predictive diagnostics from all types of assets (instrumentation, mechanical, electrical), so end-users have a complete understanding of their plant’s health and risks. R Perform the full range of predictive mechanical, electrical and instrumentation health monitoring: It is pivotal for ensuring maximum asset reliability and plant uptime. Source: Shailesh Naik, Business Leader - Asset Optimisation, Emerson Process Management India
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demand to increase profitability, on the other, require companies to consider minimisation of capital expenditure and investments. Keeping all these demands in mind, technologies are being customised to suit the industry needs. “Materials technology is one of the many areas targeted by the chemical industry for technology roadmapping activities. Effective materials selection is vital to the construction and operation of chemical reactors, furnaces, steam generators, heat exchange systems, separation systems, storage vessels, piping systems, etc in the chemical plant. Materials are critical to effective process control, and greatly impact the cost, longevity and reliability of equipment,” says Gupta. Apart from this, technologies related to asset visibility and ERP systems are also much in demand. “Advanced process control systems have become a necessity to have greater visibility and control on equipment more prone to vulnerability. Agile eco-friendly ERP applications having integrated asset optimisation tools coupled with techniques to achieve increased Overall Equipment Efficiency (OEE) have placed itself in high demand,” elaborates Gupta.
Efficient recycling With the increased sensitivity to environmental awareness and increasing disposal costs, it is especially necessary to consider this dimension to uncover an optimal strategy. Optimisation of material recovery in business cycle, where output of fabrics can be used as inputs again, needs to be realised. Recycling can be divided into four different forms: reuse, further use, recovery and reclamation. Recycling may be in-plant or cross-plant. From the perspective of sustainable development usually recovery is preferred to disposal. It is necessary to check whether the asset or its components can be used in another area or function economically,
SECTOR WATCH
technically and environmentally or as spare parts. If this is not possible, a recovery of the asset or components should be implemented. Only components that cannot be reused or recycled should be disposed.
Impediments to PAM implementation The mindset of the Indian industry is in a transitional phase right now. Commitment of high cost savings by the service providers is still not completely able to convince a majority towards bigger investments in PAM. “The biggest challenge we face is pertaining to price realisation. Most companies want to be totally convinced about value, and only then are ready to invest. We are constantly portraying the environmental aspect of investment in technology; and promoting sustainable technology that can help achieve cost savings also, in the long
run. Also, there is a perception that too much of technology is eating up jobs,” says Gala. Besides, in these times of a slightly cautious economic environment, larger investments into PAM become tricky. “Increased globalisation and after-effects of recession are forcing companies to continue to reduce costs and improve efficiencies of their operations without compromising on the increased demands of greater asset optimisation levels from the customers,” adds Gupta. Also, the industry needs to be well-informed about PAM strategies. “Lack of awareness regarding PAM technologies among end-users is a challenge. While service providers bring industry and application expertise, end-users need to have management and personnel commitment to implement the proposals that deliver the benefits of PAM,” says Naik.
In pursuit of success The perfect headstart to a profitable PAM environment is education and awareness, not just about technological advances, but also about environmental compliances. “Safety and environmentfriendliness is now a law. With stricter regulations now being imposed on the industry, PAM tools that complement the same need to be employed. Also, right training and education need to be provided at the basic levels for successful implementation of PAM,” says Gala. “Services are a different kind of solution. One cannot just install them in the plant and see immediate impact. Service providers & end-users need to communicate to establish reasonable expectations on service efforts and returns on investment. Services are an investment, but with the right plan, they can deliver significant value to equipment life, availability and profitability,” concludes Naik.
August 2011 | Chemical World
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INDUSTRY UPDATE
Bulk chemicals
Aligning consolidation with capacity-building At present, the bulk chemicals industry is running into rough weather. There are two main challenges the industry has to deal with – cheap import from China and issues related to economies of scale. Interestingly, if economies of scale are achieved, then the problem of cheap import could be addressed to a large extent. The industry is gradually realising this and has started taking corrective steps.
Prasenjit Chakraborty
T
he chemicals industry, which has been growing reasonably at a quick pace and contributing about 3 per cent of India’s GDP, still remains fragmented and highly dispersed. If one were to review the progress over the last two years, it has been a period of consolidation, with expansion of existing capacities and addition of new ones. The traditional major producers of bulk chemicals – North America, Western Europe and Japan – face challenges pertaining to feedstock availability, rising labour & energy costs and increasing environmental pressures. This has led to a gradual shift in the manufacturing base, benefitting countries like China, India and those in the Middle East. The inorganic bulk chemicals
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such as the caustic-chlorine & sulphuric acid and downstream products, have witnessed significant changes in terms of increase in existing capacities as well as emergence of new ones. Some of the major consumers of bulk chemicals have turned manufacturers for their captive requirements. The domestic chloralkali market has been threatened by cheaper imports. Moreover, weaker chlorine demand has driven most of the caustic soda manufacturers to operate at lower capacities and with reduced price realisations. Consolidation is seen in the industry, which is welcome, given the fragmented nature of the industry.
Economies of scale India is yet to reach the economies of scale as far as bulk chemicals industry is concerned. “This situation is amplified by the fragmented nature of this industry in India. Just to cite an example, we have around 45 units manufacturing 8 million tonne per annum of sulphuric acid, which is manufactured by a few large units in Europe or the US,” says K Vasudev, President - Aromatics Division and Bulk Chemicals & Intermediates Division, Atul Ltd.
INDUSTRY UPDATE
The industry typically faces challenges when it comes to availability of feedstock at the right prices; cheaper imports; slower adaptation of new technologies; logisticsrelated issues such as availability of improved infrastructure and freight costs. Although there have been improvement in all these areas, the pace of reforms has been slow and needs acceleration. According to H S Karangle, Director General, Indian Chemical Council, chemical industry is slowly coming out of the recession. And for bulk chemicals industry in particular, there are certain issues that need to be resolved to facilitate its growth. Barring fertilisers sector, bulk chemicals industry, mostly falls in the small- and medium-scale category. And this is one of the stumbling blocks to achieve economies of scale. Another reason is energy cost. “Many bulk chemical players are importing costly coal as a source of energy. Due to the high cost, domestic bulk chemicals manufacturers are not able to compete in overseas market. Low scale of operation is another reason for this. However, bulk chemicals industry is surviving because of the demand from the domestic market,” opines Karangle. Gradual reduction of duties from the sector is also hampering its growth. Dr Kishore M Shah, President, Indian Specialty Chemicals Manufacturers’ Association, strongly believes that the government should simplify the tax structure and the bulk chemicals industry should get energy/feedstock at competitive rates. “Since gas prices are shooting up, power that is generated from gas has become costly. Industry cannot afford interrupted power supply,” he points out.
Tough road ahead In recent times, two major segments, which have been hit due to increasing imports, mainly from China, are soda ash and caustic soda, resulting in lower capacity utilisation. “In case of
India is second after Japan to have converted 93 per cent of its caustic soda capacity to fuelefficient, green membrane cell technology, with plans to convert the balance capacities by 2012. Similarly, some of the soda ash manufacturers in India have world-class plants.
K Vasudev President - Aromatics Division and Bulk Chemicals & Intermediates Division, Atul Ltd caustic soda, with an existing installed capacity of 29.22 lakh tonne, the existing 36 producers recorded an overall output of 22 lakh tonne at an average of 77 per cent of capacity utilisation. This has forced the local producers to cut prices leading to a severe squeeze in their margins,” observes Vasudev.
Challenges for the industry R Availability of feedstock at the
right prices; cheaper imports; slower adaptation of new technologies R Bulk chemicals industry mostly falls in small- and medium-scale category R Pace of infrastructure development in the country is slow
The immediate and prompt way to protect the domestic industry is to urge the government to levy anti-dumping duties on imports. Some of the chemical imports from China include caustic soda, soda ash, carbon black, oxon-alcohols, phthalic anhydride and several other chemicals.
It is important to note that imported chemicals are cost-effective. That is why capacity utilisation for many chemicals in India is not hundred per cent. The reason for this being the gradual reduction of duty from the sector. “It is because whatever protection was given by the government in terms of duty to the domestic players earlier has been reduced considerably over a period. This provides an opportunity to China as its scale of operation is huge. That is why we are finding it difficult to compete in international market,” laments Karangle. According to him, providing protection on every front is not possible in the current circumstances. But wherever applicable, the government should apply anti-dumping duty; in this way the interests of domestic players could be served. Import from China is not the only hurdle. The real challenge, today, is to create world-class manufacturing capacities in line with the growing demand in the country. “It is in this direction that the government policies should become conducive in building capacities. In the case of China, government regulations mandate only
Many bulk chemical players are importing costly coal as a source of energy. Due to the high cost, domestic bulk chemicals manufacturers are not able to compete in overseas market. Low scale of operation is another reason for this. However, bulk chemicals industry is surviving because of the demand from the domestic market.
H S Karangle Director General, Indian Chemical Council
August 2011 | Chemical World
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INDUSTRY UPDATE
Investment in technology upgradation
large-scale projects in bulk chemicals for approval,” points out Vasudev. The overall infrastructure in the country is still inadequate, which also deters the growth. Another bottleneck is pertaining to the ability in manufacturing value-added downstream products made from bulk chemicals. Besides, assurance of feedstock for the sector is equally important. “Gas to the chemical sector is not guaranteed as of now. If we make provision for reserved gases for this sector, it would mean assurance of feedstock for the industry. If this materialises, we can expect investments in the sector,” opines Karangle.
Many of the chemical plants during the licensing era were built to cater to domestic requirements. Lower per capita consumption did not encourage setting up of bigger plants, as a result they were not comparable in scale to global chemical plants. The protection era did not call for any major technology upgradation. However, post-liberalisation reforms have resulted in rapid changes in terms of investment and upgradation of technology. “India is second after Japan to have converted 93 per cent of its caustic soda capacity to fuel-efficient, green membrane cell technology, with plans to convert the balance capacities by 2012. Similarly, some of the soda ash manufacturers in India have world-class plants,” says Vasudev. Caustic soda sector may be an isolated example in the entire industry. However, a closer look says only a few companies have invested in technology upgradation. Many are sitting on the fence and waiting for the right opportunity. When it comes to R&D, it is a low key affair for the bulk chemicals industry. Vasudev strongly believes that R&D contributions in this industry have to improve significantly in terms of new process development, improvement in process efficiencies, and new methods of effluent treatment & disposal. The major inputs expected from R&D would be on developing valueadded downstream products from bulk chemicals. “At present the bulk chemicals industry is spending around
Table 1: Usages of chlor-alkali products in different industries Hydrochloric acid Hydrogen Caustic soda Chlorine Hydrogenation Rayon and pulp industries Paper and pulp Amino acids Aluminium PVC Pickling Textiles Chloro-organics Ore benefaction Water disinfection Fertilisers Soaps and detergents Fertilisers Dye and pharma Refineries Refineries Petrochemicals Petrochemicals Dye and pharma Source: www.emt-india.net
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0.50 per cent to 1 per cent of its total turnover for R&D. It should be increased to around 4 to 5 per cent. Government support coupled with focus on R&D would take the industry to new heights, and this is the only way to compete with China,” exhorts Dr Shah. What restricts the industry to spend higher amount on R&D? The overall production of the industry is quite small, and perhaps restricts players to invest in R&D. “The scale of operation in the industry does not allow substantial R&D investments. It is justified when scale of operation is increased and export has substantial share in the total production,” categorically states Karangle.
Role of government The Government of India should encourage setting up of mega chemical industrial estates based on green technologies. These sites would definitely enjoy significant cost economies in terms of common utilities, common effluent treatment plants, storage facilities, proximity to ports, etc. Such estates have already been established in countries like China, Singapore, Thailand and those in the Middle East. “Needless to mention that caustic soda plants being a powerintensive industry, electricity and utility charges need to be rationalised, so as to enable them to compete at an international level,” opines Vasudev. As suggested by some of the industry experts, import duty for membrane cell plant should be reduced, since these are not available indigenously. Most importantly, there has to be a significant improvement in basic infrastructure facilities, including modernised ports, chemical storage terminals and common effluent treatment plants. Implementation of the Goods and Services Tax (GST) will undoubtedly eliminate the current complexities in tax structure prevailing at the Central and state level. When threatened by surging imports, domestic industry would
INDUSTRY UPDATE
seek government intervention by way of anti-dumping duties or safeguard duties levied on the imports into the country.
Towards attaining ‘bulk’y growth
At present the bulk chemicals industry is spending around 0.50 per cent to 1 per cent of its total turnover for R&D. It should be increased to around 4 to 5 per cent. Government support coupled with focus on R&D would take the industry to new heights, and this is the only way to compete with China.
According to Vasudev, the Indian Dr Kishore M Shah chemicals industry produces more President, Indian Specialty Chemicals Manufacturers’ Association than 70,000 products. Commodity chemicals continue to be the largest segment, followed by specialty, fine to achieve the economies of scale in the Indian manufacturers to build chemicals and agrochemicals. “The manufacturing and better efficiencies. world-class capacities, enabling inorganic chemicals industry including The industry would focus more on them to compete at international products such as caustic soda, improved operating norms, making level and protect the industry chlorine, sulphuric acid, etc is worth significant progress into value-added from the surging imports through $ 2.5 billion, and is expected to grow downstream products and addressing imposition of anti-dumping duties at a rate of 10 per cent,” he says. environmental concerns. One would or safeguard duties. Increase in per The industry is passing through a also witness a trend wherein major capita consumption is expected to consolidation phase. Take the example users would backward integrate further accelerate the growth of the of Aditya Birla Group’s recent move; to manufacture bulk chemicals chemicals industry in India. Looking at it has bought Kanoria Chemicals. themselves in order to have an assured the government’s move and industry’s This is a welcome step in view of the predictability of their input costs. willingness, it seems that the bulk fragmented and dispersed state of the It is anticipated that the government chemicals industry will emerge stronger industry. Consolidation is also necessary policies would be favourable for in the years to come.
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MARKET INSIGHTS
Indian specialty chemicals sector
Towards making a global mark India is becoming an export hub for specialty as well as knowledge chemicals. The re-engineering capabilities and the low cost of production make the country a favourable destination for sourcing activities from companies all over the world. However, the Indian chemical industry needs to mature far more on the infrastructure, innovation and safety fronts among others to be able to reign on the global platform. Courtesy: LANXESS India
Dr Joerg Strassburger
S
pecialty chemicals form an indispensable part of people’s lives and have a number of applications, be it in the construction of buildings, manufacturing of vehicles and so on. This implies that the potential for the Indian specialty chemicals industry would be triggered by a strong domestic demand, supported by the rising middle-class household consumption and increase in discretionary spending by these households. Also, the current level of penetration of goods in India is rather low; an increase in consumption of goods by the enduser industries like construction, automotive, tyre and agrochemicals will boost the growth of this sector as well. All these industries are growing at healthy rates currently. Experts believe that growth will be driven by four megatrends – rapid urbanisation, increase in mobility, growth in agriculture for fulfilling the food requirements of a growing population, and last but not the least, the need for adequate fresh water for industrial & domestic consumption. Here is an in-depth look at these factors. Urbanisation: By 2030, 40 per cent of India’s population will live in cities. This will lead
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to an increase in the purchasing power, and as a result in the consumption of goods among people. This would trigger demand for various specialty chemicals and related products. Mobility: Rapid increase in demand for automobiles is expected to result in a boom in the automotive industry, which is projected to grow by about 12-14 per cent during 2010-2012 period. Increase in mobility would generate more demand for tyres. Modern tyres rely on high-performance synthetic rubber to achieve superior qualities. Agriculture: With the overall increase in global population, the demand for food will increase, and hence the need to grow agricultural production. This can be possible through appropriate use of agrochemicals and other intermediates. Clean and safe water: There is lack of sufficient clean water across the planet. Population growth, pollution and climate change will make water as valuable as oil in the next few decades. Studies show that water demand will outstrip current supply by roughly 40 per cent in 20 years. The areas wherein optimisation of water as a resource would be required include purification of water, wastewater treatment, water treatment for industrial applications, among others.
MARKET INSIGHTS
Key demand drivers As Indian economy is witnessing a high growth rate in all segments, particularly driven by the burgeoning middleclass population; fiscal stimuli by the government and increased spending on infrastructure, there will be tandem growth in segments like automobiles, plastics, pharmaceuticals, construction, food processing, domestic and industrial appliances among others. This would trigger a high demand for basic chemicals, specialty chemicals and advanced intermediates from the chemical industry.
Challenges faced and the way ahead In India, a significant part of the chemical industry is unorganised and fragmented in nature, besides having small-scale operations. Most Indian companies lack a global platform for production, distribution and are ill-equipped to serve the needs of a global market. Lack of innovation is another key parameter that hinders the growth of the Indian chemical industry. Additionally, rise in the prices of crude oil in the recent past, surge in the cost of power and fluctuation in the exchange rates have also hampered the volume of exports. A consolidation in the industry, which creates strategically betterpositioned players, is required to attract investments, particularly in aspects like technology, environmentally safe production and to capture opportunities in the domestic & export markets. Environmental protection, health and safety issues are also key areas that chemical companies have to address with greater focus. In this regard, the chemical industry has a significant role to play in matters of compliance with rules & regulations; drafting of policies for internal & external stakeholders; adopting safe dumping practices; having transparent & audited governance; ensuring the highest safety standards in
manufacturing, packaging, distribution and handling, etc. On the infrastructure front, the government needs to build specialised chemical parks or mega clusters with common infrastructural support like continuous power supply, common effluents treatment system and improved logistics to facilitate import/export. India spends around 13 per cent of its GDP on logistics, which is higher than that in most of the developed countries. So, proximity of chemical parks to ports will reduce costs and the turnaround time. In addition, the state governments have to extend policy-led support and deliver on their commitments in order to invite more investments in their states. For exports, road transportation of finished goods from the manufacturing site to ports is expensive and is not safe due to bad roads, traffic congestion and the long time taken for clearance at the ports. So it is advisable to have Inland Container Depot (ICD) near every site for transfer of finished goods to ports by rail, which is safer, and costs involved would also be 2030 per cent lesser. For imports, single container fleet station for chemicals could be of help. At an industry forum, M Raman, Secretary to the Government of India, Department of Chemicals and Petrochemicals, assured that the Ministry is committed to the chemical
sector and also to meet the needs of energy, water & agriculture and stimulate growth in all these areas. Summing up, the need for public policy support, improvements in infrastructure, availability of continuous power supply, good connectivity to ports via road & rail, availability of feedstock, simplified tax structure and regulations, chemical parks with adequate facilities, availability of trained & skilled human capital, facility for single-window clearance for faster clearances of permits and approvals are the factors that call for attention from the industry to realise its true value potential in India.
Opportunities galore Given the fact that there is an increased consumption in the country from customer verticals, global chemical manufacturers are now keen to have presence in India. As a result, there have been significant investments from multinational companies (MNCs) in the country in recent years. On the other hand, Indian firms are now actively acquiring small and medium-sized companies in Europe and the US to be able to enhance their technology edge, improve their capabilities, expand their reach and penetrate those markets. Availability of an enormous talent pool in India makes it viable for companies to set up R&D units in India
End-user industries are triggering demand for specialty chemicals Courtesy: LANXESS India
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MARKET INSIGHTS
and foster innovation at a much lower cost. Continuous product and process innovation, performance improvement & identification of new modes of applications are key focus areas for the chemical industry to prosper in the long run. Organisations would need to build product leadership through rigorous innovation, continuous improvement and invention of new ways of meeting future needs of customers.
Outlook 2011-12 An important point to be noted here is that the projected growth of the Indian chemical industry has another key determinant – innovation. Innovations must be a fundamental aspect of corporate strategy (right through product conceptualisation, research and development, process improvements etc) and needs to be targeted at the specific needs of customers in specific markets. According to a survey conducted by the Boston Consulting Group (BCG), the number of executives who consider innovation as a top-three priority grew by over 10 per cent from 2009 to 2010. Targeted product innovations to satisfy customer needs are the key to solve global challenges and build a competitive edge. The BCG report also suggests that India is surfacing as one of the most preferred destinations for fostering research and development activities. Overall, the Indian chemical industry has attained a critical size and has the potential to build a $ 80-100 billion specialty chemical industry by 2020. The Asia-Pacific region now forms nearly 42 per cent of the global market for chemicals, clearly making it the largest contributor. It is evident that the growth will come from emerging markets, and this implies that India can leverage this shift in specialty chemical landscape. In addition, India has been increasing its export of chemical products in the recent years. Alongside the increase in exports of chemicals and the imports of crude oil, the demand drivers are strong and consistent, which lead experts to believe that the specialty chemicals industry in India would be on a fast growth track, if the framework is adequate. Dr Joerg Strassburger has been the Country Representative and Managing Director of LANXESS India Pvt Ltd since March 2005. He is responsible for the operations and development of LANXESS’ business units in India. Before this assignment, Dr Strassburger was Head of the Group Function Corporate Development at LANXESS AG, and was actively involved in developing LANXESS’ global strategy. He holds a doctorate in chemistry and a diploma in economics. For details, contact Rhituparna Mitra on email: rhituparna.mitra@lanxess.com
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COATINGS CORNER
Emerging markets
Destination next for paint manufacturers Paints and coatings companies world over, especially from the developed nations, are focussing on the emerging markets to expand their business, as studies reveal that these countries will be contributing the maximum towards the growth of the global economy.
Dr Mosongo Moukwa
T
he global economy is expanding at a fast pace. Although no one knows how long the present expansion will last, it is reasonable to expect several years of solid growth. In the past, growth phases have lasted seven to nine years. The present phase is different from the previous ones in the sense that, most of that growth will come from the fastest growing and largest emerging economies. Finding a CEO who is not evangelical about emerging markets these days is like finding a hen’s teeth. Because countries in emerging markets will contribute substantially to the global growth, it is little wonder that businesses are trumpeting their plans to expand in such markets.
Emerging countries At the moment, accounts for 65 GDP. Of the rest, Sachs identifies a
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the developed world still per cent of the global a new paper by Goldman number of large emerging
economies as the ‘growth markets’. Countries such as China and Brazil are expected to provide the lion’s share of global growth in the coming years. Going forward, by 2020, these markets will contribute a huge share to the growth boom. The US is the only country from the developed world that will deliver a significant portion to global growth. Japan and Korea get on to the chart, but no European country seems to make it. Countries such as Turkey and Indonesia will add more to global wealth over the next decade than Germany, France or the UK. However, these countries will only be able to deliver that growth within a freely trading world economy. The GDP growth in China is around 9 per cent, with the chemical industry growing at double-digits. India, with favourable demographics, is posting a growth rate of 7.8 per cent, but it still has to solve infrastructure and regulatory problems. Even if it does overcome these barriers, experts believe that growth will still not be as dynamic as in China because the country is more decentralised.
COATINGS CORNER
Paints industry Industry players are optimistic of doubledigit growth in Asia-Pacific region because of the demand from end-user industries such as steel, automotive, furniture and construction. The paints and coatings industry depends heavily on the end-user industries it serves. Positive growth is projected in those segments. Countries such as China, India, Vietnam and Indonesia are identified as high-growth countries where there are more opportunities for development of the paints and coatings market. However, the specific high-growth segments vary between countries. In India, the paints and coatings market has increased by approximately 15 per cent since 2009, reaching a market size of $ 3.8 billion in 2010. The market is expected to continue to exhibit double-digit growth between 2011 and 2013. Decorative and industrial coatings accounted for 63 per cent and 10 per cent of the total Indian paints and coatings market, respectively. Industrial coatings are expected to witness a higher growth rate compared to decorative coatings, owing to the increasing number of industrial facilities in India.
US and EU companies in emerging markets The US companies have been expanding in emerging markets, particularly China, for many years and some are reaping the benefits of those investments. Dow Chemical, a global chemical manufacturer, has seen its volume up by 27 per cent year-onyear. In China, its volume was up 46 per cent against 11 per cent in both North America and Europe. In 2010, Dow Chemical vigorously expanded its market in the Asia-Pacific region. It had made new investments in Thailand, Korea, China and Vietnam. Annual sales in emerging markets reached a record $ 16 billion. In addition, sales in the Asia-Pacific region, for the first time in history, touched $ 9-billion
35%
GDP shares (%) 2010 - World
30%
Asian pacific paints and coatings market 1% 4%
25%
3%
12% 10% 23%
20%
27%
12%
65%
5% 12% 11%
15% Emerging markets Growth markets Developed markets
10%
Decorative Marine Protective Wood Auto Refinish Can
15%
Other Powder Auto (OEM) Coil Source: Frost & Sullivan
Source: Goldman Sachs
Growth markets: China (9%) , Mexico (2%), Korea (1%), Turkey (1%), Indonesia (2%), Brazil (3%), Russia, (3%), India (2%)
5% 0% China
US
India
Brazil
Russia
Mexico
Japan
Korea
Turkey
Indonesia
Figure 1: Share of total GDP increase (%) 2010-2020
mark, an increase of 25 per cent. The company also has one of its largest research and development facilities in China, stressing the long-term strategic importance. Apart from the US companies, European companies are also venturing into emerging markets. For example, AkzoNobel, a global leader in paints & coatings and a major producer of specialty chemicals, is aiming to get half their sales from such countries in the next few years. According to the company’s annual report, the Dutch company was investing nearly all its money in emerging markets. Indeed, the company has put in place a series of investments. It just built a new multi-site in Ningbo, China. The facility is AkzoNobel’s largest ever investment outside of an acquisition and underlines the increasing importance of the world’s high growth markets as they look to establish themselves as the leading coatings and specialty chemicals company globally. One advantage European companies might have is the fact that their domestic markets are smaller than their American counterparts. This means that they are more used to getting a big part of their sales and growth from abroad, and are geared towards exports. Due to this, they tend to have decentralised management
models, something that should bode well in the emerging markets, with some exceptions. This also leads to some disadvantages. Put it simply, decentralisation makes Europeans good at adjusting well to each country, but leaves them with higher costs because they are slow to implement change across the company. Language and culture would tend to favour Americans, with US companies and universities better able to attract bright young minds from emerging markets. Some of them get deployed back to their countries after a few years of working experience in the US. European companies have increased their investments in emerging markets not just for production, but also for research. Some in Europe argue that such a move away from the continent can go on only so long before Europe’s own industrial base is harmed deeply. Some in the US share the same sentiment.
Vibrant mergers and acquisitions The paints and coatings industry itself has been witnessing a sea change. The industry is also facing major price increase in some key raw materials, and in some cases even shortage. One way out of this situation could be by controlling raw materials right
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COATINGS CORNER
Table 1: Market capitalisation: Chemical stocks had another strong year in 2010 Market Change Rank Rank Position in emerging markets Company capitalisation from 2009 2010 2009 ($ millions) 2010 Planned investments of Euro 2.3 billion ($ 3.2 billion) between 2011 and 2015. In China, it is planning expansion of its existing joint1 1 BASF 73,430 42.0 venture plant with Chinese oil and petrochemical giant Sinopec, by extending its acrylics value chain. Growth in emerging regions surpassed $ 16 billion in revenues for Dow the first time. Sales in Asia-Pacific topped $ 9 billion in the year, also 2 1 39,848 25.4 Chemical representing an all-time record. Invested in Thailand, China and Korea. PPG During 2010, it began construction of a new coatings resin facility in 6 6 13,485 39.0 Industries China and expanded the manufacturing. Announced a newly developed advanced technology to produce and 10 9 Celanese 6,414 38.4 expand the strategic acetate ventures in China. These actions will contribute to earnings growth in 2011 and beyond. Note: Based on share prices as on December 31, 2009, and December 2010. These are companies that generate more than half of their revenues through chemical manufacturing. Figures from companies that report in native currencies were converted to dollars and average annual exchange rates from the Federal Reserve.
at the source and monitoring the full value chain. With some exceptions, companies have never pursued this option. Take for example BASF, which makes pigments and urethane systems, as well as formulated paint for automobile and coil coatings. This is also the case for DuPont, which produces TiO2 and also formulate paints. Mergers and acquisitions will remain vibrant in the near term. After staying conservative during the downturn, companies have a lot of cash on their balance sheets, now that business has turned around. Rather than clamouring for special dividends and stock buy-backs, institutional investors that own chemicals stocks are encouraging companies to invest in growth. Only time will tell whether any of those transactions are big enough to reshuffle the Top 10 companies. But the push towards growth is likely to have an impact on the chemical industry for several years. To what extent this may change the scenario in emerging countries, no one knows.
Understanding local customers While Western companies are investing in emerging markets, higher domestic demand in emerging Asian
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countries encourages the growth of domestic players. More local players are expected to enter the industrial coatings segment, especially given the technology transfer that occurred during collaboration with multinational companies. The rise of domestic competitors will happen
The real threat to European and the US groups will be companies from emerging markets that might lack the technology but understand the customers. faster than most MNCs expect. Some local companies in some high growth markets have already established themselves. For example, Asian Paints has established itself as the leader in architectural paints in India. Today, it is ranks fifth globally in architectural paints. Multinationals aiming to garner a strong marketshare, a few years down the line, need to establish themselves now. Questions abound over how well European and the US companies understand consumers in emerging
markets. Customers in these markets have different needs than those in developed countries. Multinationals looking to capitalise on opportunities there should be ready to do business in hundreds of locations, not just in a handful of mega cities. This has tremendous implications on resources distribution and choice of business partners. Multinationals would do well, if they step up their innovation activities to meet the ‘really-demanding and price-sensitive’ needs of consumers in the emerging countries. Perhaps then, the real threat to European and the US groups will be companies from emerging markets that might lack the technology but understand the customers. Dr Mosongo Moukwa is Vice President (Technology), Asian Paints Ltd, Mumbai. He was Vice President (Global Technology), Reichhold, North Carolina. He holds a PhD from the Universite de Sherbrooke, Quebec, Canada and an MBA from Case Western University, Cleveland, Ohio. He is a member of the American Chemical Society, the Commercial Development and Management Association and the Licensing Executive Society. Email: mosongo.moukwa@asianpaints.com
SAFETY ZONE
Construction work near process plants
Step up measures, ward off hazards
Ascertaining safety at a construction site is a complex challenge, and more so, if it is located near a process plant where operations go on in full swing. Nevertheless, a safety culture is a must, if any hazard, be it in the process plant or the construction site, has to be averted.
K N K Murthy
U
ninterrupted plant operation and intermittent construction works of different magnitudes are the order of the day, considering the everincreasing demand for achieving the highest feasible productivity at optimal cost, better capacity utilisation, debottlenecking, technology improvement/upgradation, etc. Unlike the grassroots project work at a quite isolated and safe location, construction activities happening near operating plants pose additional risks, needing specialised redress philosophy, strategy and techniques. Some might ponder as to why one would opt for a construction site nearer to a fully operating process zone. The logic behind such a move could be attributed to significant factors such as: R Easy ‘docking’ strategy with the existing plant R Either shortage of required free land at ‘distant/ safer’ locations or conservation of available space for further expansion/installation of new units including downstream plants R Conservation of materials like cement & steel (for building/flooring/road, piping, support structure, etc) R Ready availability of infrastructural facilities required for execution of construction jobs like safe and convenient road access, storage/ handling area, electricity, water, steam, air, centralised workshop facility (for machining, fabrication, assembly), testing/calibration devices, etc
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R
Access to well-established safety systems/ procedures and practices (already in vogue) attributed to the safety concerns of the operating unit and possible extension of the same at construction site by ‘default’ R Existence of fully established administrative and welfare measures such as rest rooms, canteen, transportation, emergency assembly points, evacuation routes, etc, which can be shared with the construction personnel R Availability of fire fighting/rescue/first aid, transportation and emergency response facilities at a well-established process unit
The flip side The risk factors at a construction site near an operating unit outweigh all the aforementioned positive aspects. Severe domino effects of any type of hazardous situation prevailing at the operating zone could be detrimental to the construction activities or vice versa. Heavy movement of men and materials near to the process plant locations potentially make these plants vulnerable to risks. A few other problem areas include lack of awareness on process-related hazards among the construction employees; aggravation of process-specific risks due to inherent construction work-related perils; and poor, inadequate or improper communication strategy between operational & construction groups.
SAFETY ZONE
Lack of inspections, surveys and self-audits with reference to safety aspects either by the operating plant or project personnel; gaps in the effective compliance of control of work procedures especially ‘permit-towork’ system; usage of non-standard, sub-standard or worn-out items (tools/ tackles/equipment) being brought in by different types of construction agencies also pose several threats. This is not all, as non-compliance towards laid out statutory provisions (mostly due to ignorance, lack of awareness, negligence or poor training among concerned plant and construction personnel) needs to be looked into and resolved. Finally, the absence/ inadequacy/improper implementation of an emergency preparedness and response plan adds to the safety hazards.
Preventive measures Though there are several safety concerns, diligent adaptation of proactive steps will go a long away in addressing the risk factors. Some of the measures include formulation & dissemination of an exclusive construction safety policy by the company management, besides incorporation of the policy objectives in the tenders issued to all probable bidders for construction work. Appropriate selection of main or sub-contractors based on their experience and competency in safe execution of work, especially near
Safety challenges The issues related to safety governance at construction site are both unique and complex due to: R Varying work culture in the construction industry R Differing hazard rating based on the nature of the nearby process units, quantum of work R Pressure to cope with tough completion target schedules R Comparatively less organised set-up of construction workforce
process zones, and execution of risk assessment studies & compliance of recommendations based on rating will enable to ward off hazards. Moreover, checking, testing and certification of types of tools/tackles with higher vulnerability (all types of material handling equipment, machinery, tools and tackles) by the principal employer (logically those in charge of the unit under operation) need to be made mandatory. It is essential to identify & mark locations having hidden hazards such as live buried electrical cables, underground piping/storages in hazardous chemical service to ensure that the ongoing construction work does not create a risky situation (electrocution, release of toxic material, fire, explosion, environmental impact etc). Strict enforcement of ‘permit-towork’ system having constant linkage between the operating plant and project area; installation of gas/vapour detector sensors around the periphery of operating units to warn against any impending danger even after clearance of ‘permit-to-work’ at closeby construction sites can facilitate safe working environment. This is because such detectors can be hooked up with alarms/sirens and firewater sprinklers, which get automatically actuated when leakage concentration exceeds the specified limits. Initial review on the competency level of construction department personnel, periodical assessment of the safety standards and performance at construction site & implementation of time-bound corrective actions; execution of induction and job-specific training of construction personnel, evaluation & certification; deployment of safety officers from construction agencies and monitoring their performance through regular interactive meetings, site inspection, surveys, audits etc are other ways to tackle safety-related issues. Fast decision-making by operating plant in-charge to go for emergency shut down as warranted by any
warning or accident scenario especially from construction area is pivotal to redress any mishap. Safety surveillance on construction zones through self, internal and external audits followed by review of the time-bound compliance on recommendations; involvement of construction area personnel in both ‘onsite & off-site’ drills, mock-up exercises, etc; and compliance to the specific safety provisions/guidelines with reference to the latest statutes on Building & Other Construction Workers’ (Regulation of Employment & Conditions of Service) Act 1996 and Corresponding Central Rules 1998 will go a long way in ensuring safety.
Safety at its best An effective construction safety policy formulated and implemented by the principal employer, both at his unit and the new work site, coupled with a top-driven enforcement strategy could be among the best available options to ensure performance-based safety. K N K Murthy has been in the fertilisers and petrochemicals industry for 38 years and retired as Senior Manager (Safety) from Indian Petrochemicals Corporation Ltd, Vadodara. Currently, he works as a Safety Consultant and is attached to Mahatma Gandhi Labour Institute (MGLI), Ahmedabad. He has done pioneering works in various aspects like hazard identification, safety audits/ inspections/surveys, training, emergency preparedness planning, quality/environment standards (ISO), etc. He can be contacted on email: mohanaknk@yahoo.co.in
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MARKET SCOPE
Water-based adhesives
Binding sustainability with economy Globally, the need for sustainability has spurred every industry to shift towards environmentally viable options. For the adhesive industry, water-based products serve this purpose as they are ecofriendly as well as economical. Therefore, opportunities for manufacturers and distributors of water-based adhesives are immense.
Packaging tape which uses water-based adhesives Courtesy: Shehzhen Zhengxing Adhesive Product Co
A
growing segment characterised by low competition is how the water-based adhesive market can be described today. Water-based adhesives are adhesive monomers suspended in water, also referred to as adhesive emulsion. Their viscosity varies according to the solid content. Such adhesives mainly find applications in packaging, general construction, carpentry activities, etc. The Indian water-based adhesive market is primarily divided into two categories: acrylic emulsions and polyvinyl acetate (PVA) – the dynamics of both these segments is different. It was estimated at $ 360 million in 2010, with acrylic emulsions accounting for almost 80 per cent and PVA constituted the rest.
Market dynamics Acrylic emulsions are water-based dispersion on polymers or co-polymers of various acrylates. These emulsions are the preferred binders for high-performance water-based coatings, as they are easy to formulate and versatile. These are broadly classified into styrene acrylic emulsions, pure acrylic emulsions and vinyl acrylic emulsions. Styrene acrylic emulsion is mainly used in the mid-range paints segments, textiles and construction chemicals. The key applications of pure acrylic emulsions include premium quality
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paints, pressure-sensitive adhesives, tapes & labels, and for uses in textile and packaging industries. Vinyl acrylic emulsions are primarily used to manufacture economy grade paints. PVA adhesive, known as white glue or carpenter’s glue, is a rubbery synthetic polymer made through the polymerisation of vinyl acetate monomer. The solid content may vary between 40 and 45 per cent. In low quality adhesives, the solid content varies from 20 to 30 per cent. PVA adhesives are mainly preferred in wood adhesion, because of reduction in veneer peel, as well as for being more environment-friendly since they are water-based.
Competitive analysis The water-based adhesive market is organised and concentrated, with a handful of players. The dynamics of the PVA market is different from the acrylic emulsions market. Pidilite dominates the PVA adhesive market with a marketshare slightly less than half in revenue terms, followed by Jubilant. Pidilite’s Fevicol is one of the most reckoned brands all over India. Fevicol is considered synonymous with PVA adhesives, while Jubilant is more popular in North India with its Jivanjor brand. Huntsman and other smaller market players like Nikhil Adhesives comprise around 20 per cent of the share. Huntsman has a presence in the market with
MARKET SCOPE
its Karpenter brand. Other small-scale and local regional producers cater to specific areas in the country. In the acrylic emulsions market, the largest segment is styrene acrylic emulsion. The key players in this segment are Visen Industries Ltd and Rohm and Haas. Jesons Industries Ltd dominates the pure acrylates market in India, while Visen Industries is the largest organised supplier of vinyl acrylic emulsion. Courtesy: Pidilite Industries and Jubilant Industries
The ‘glum’ side Currently, there are few Occupational Safety and Health Administration (OSHA) requirements to monitor Volatile Organic Compound (VOC) concentration levels. Lack of any concrete regulations against the use of solvent-based adhesives is one of the reasons why these retain marketshare. Creating adequate awareness about the advantages of water-based adhesives would encourage many adhesive formulators to opt for their production. The PVA adhesive market is monopolised by Pidilite’s Fevicol brand. In this highly competitive market, it is therefore necessary for other companies to come up with innovative branding techniques. It is difficult for small players to spend on marketing and branding by squeezing their profit margins. Often, the manufacturers of PVA and acrylic emulsions do not have
20%
80%
Acrylic Emulsions Polyvinyl Acetate (PVA) Source: Frost & Sullivan
Figure 1: Indian water-based adhesive market: Split by chemistry, 280KT, 2010
a raw material manufacturing plant in India, since imports are more economical. The prices of PVA and acrylic emulsions depend entirely on raw material prices. Hence, the industry faces major fluctuations in prices that range anywhere between ` 35 and ` 80 per kg.
Emerging opportunities The PVA adhesive market is mainly dependent on the growth rate of the furniture industry, which in turn is primarily driven by the construction sector. While the PVA segment is expected to grow in future, it is predicted that new materials like glass, aluminium, PVC and steel, which are now being used for doors, windows & interiors, will affect the usage of wood or ply. PVA demand is likely to grow at a Compounded Annual Growth Rate (CAGR) of 6.5 per cent between 2009 and 2016. Having a strong distribution network is important for PVA adhesive manufacturers to maximise their reach across India. Any company entering the Indian PVA adhesive market has to first ensure that its distribution network is in place and that stocks are always available for consumers. In the acrylic emulsions market, maximum growth is expected from the pure acrylic emulsions segment – driven by the premium decorative paints application – that is expected to grow at an annual growth rate of around 16 to 17 per cent in the coming
years. Thus, there is an indication that the market will be able to sustain more players in the future. There is also immense scope for raw material manufacturers to set up a plant in India, which is likely to decrease the dependency of the acrylic emulsions producers on imported raw materials. Demand for vinyl acrylics has been replaced, to a large extent, by products such as styrene acrylic emulsions. It is expected that this trend would continue over the forecast period. The CAGR of acrylic emulsion during 2009 and 2016 is expected to be around 12 to 13 per cent.
Future outlook The Indian water-based adhesive market, valued at $ 360 million in 2010, is expected to reach $ 667 million by 2016. A key growth driver for this market is the development of construction and infrastructure sectors due to the increasing population. The demand for water-based adhesives is highly driven by the fact that they are economical as well as environmentally sustainable over the long term. With proper branding, efficient distribution channel, and adequate capacity to cater to bulk orders, the industry provides immense opportunities to adhesive formulators. Courtesy: Frost & Sullivan Chemicals, Materials and Food Team, South Asia and Middle East. For details, contact Anish Charles on email: anishc@frost.com
August 2011 | Chemical World
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TECH TRACK
Water management
Conservation through recycling Water recycling and the deployment of new water-saving systems will become increasingly important against the background of what are, in many countries, less readily accessible water resources. Here lies the importance of industrial wastewater treatment through the adoption of modern and sophisticated technologies, besides preventing contamination of water resources.
Hans Birle
L
ike climate change, rain forest destruction and overfishing, water scarcity is one of the most pressing environmental problems that need to be resolved in the 21 st century. Today, 1.2 billion people, nearly one in six of the world’s population, do not have access to clean drinking water. Worldwide, 2.6 billion people have no access to proper sanitary facilities connected to public water supplies and wastewater systems. As a result, the causes of over two-thirds of all illnesses in the developing world can be traced back to contaminated water. In the developing and under-developed countries, industrial wastewater is often discharged untreated into the water bodies, making a considerable contribution to the contamination of the environment. According to the United Nations Environmental Programme, $ 80 billion is invested worldwide in water projects every year. This amount must be doubled in the medium term, if there is to be any noticeable
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Chemical World | August 2011
improvement in water supply and wastewater systems, particularly in urban areas. The total worldwide market volume for civil works, machinery, plant and services in the water & wastewater sector is estimated to range from $ 460 to 480 billion. As usable resources of water are limited, it is absolutely essential that they be managed properly and protected from contamination. Conventional water and wastewater treatment systems are often unsuitable in emerging nations or arid regions because of varying climatic, geographical, social and economic conditions. Corresponding to the heterogeneous conditions worldwide, systems have to be developed that are adapted to meet people’s basic needs while conserving resources. Water resources cannot be protected or conserved without modern plant and technologies. Germany’s mechanical engineering and plant construction industry recognised this at an early stage and is developing reliable and economic procedures that contribute to conserving water resources.
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TECH TRACK
Need for a holistic approach Modern water management system pursues an integrated approach that involves a holistic view on water supply, process water treatment, wastewater disposal and water protection. The increasing scarcity of clean drinking water in many parts of the world requires that new approaches to technical water management be created. Existing technologies must, therefore, undergo continuous adaptation and development in order to rise to the challenges of providing suitable systems and processes for the areas facing water scarcity the world over. Novel sanitary concepts that allow the separation of uric, humic and greywater material have the potential of being feasible approaches. Concentrated, unmixed wastewater flows can be treated more easily and at lower cost; valuable substances can be separated; and the cleaned wastewater can be recycled for further use. Water hygiene-related issues are becoming increasingly important in metropolitan areas.
Treating industrial wastewater Industrial process water should be treated in decentralised facilities in accordance with local requirements. It is worthwhile to develop recirculating systems, if the energy input can be justified. Leakages of product or material residues from the production process, which have entered the water system can often be filtered out and fed back into the production process. The water consumption of existing production plant can be reduced. As a result, a smaller volume of water requires treatment, which can be accomplished with modified, state-of-the-art wastewater plant. Requirements vary greatly from area to area, depending on the availability of water resources and climatic conditions. Technologies and management must respond to these specific challenges.
Current market situation Exports are becoming increasingly important for German suppliers of innovative water technologies. The positive worldwide market trend mainly depends on two factors. One is the more comprehensive implementation of legal requirements in many parts of the world, particularly in Eastern Europe. The other is the positive global economic situation accompanied by increasing investment in production and infrastructure, which benefits the entire mechanical engineering industry. Water purification and wastewater treatment plant are important elements of local water supply and wastewater disposal services, and essential for many industrial production processes. In 2007, German manufacturers and suppliers of valves, compressors, fans and pumps for
August 2011 | Chemical World
63
TECH TRACK
water & wastewater systems, as well as plant, components & systems for water preparation, wastewater and sludge treatment achieved total sales of over Euro 4 billion. German exports were predominantly to the 27 EU states (Euro 1.585 billion, or 48 per cent), followed by Asia (Euro 576 million, 18 per cent) with the rest of Europe in third place at Euro 443 million or 14 per cent. Exports totalled Euro 3.250 billion, 81 per cent of production. The advanced engineering standard of German products combined with the continuing resolve to improve and develop them further is expected to help maintain the high reputation of
10%
43%
Water preparation, wastewater and sludge treatment systems & components Pumps Industrial fittings Fans & compressors Total value of production/sales: Euro 4.037 billion Source: Federal Statistical Office, VDMA 2007
Figure 1: German water & wastewater technology (Production/sales)
8%
7%
18%
Reducing consumption The greatest potential for reducing water consumption lies in preventing or minimising losses. Where irrigation for agriculture is concerned, which makes up 70 per cent of the world’s water consumption, evaporation losses can be reduced from 50 per cent to 10 per cent by the application of efficient irrigation systems. Losses through leaks of between 30 and 50 per cent from drinking water mains are the rule rather than an exception. In London about 900 million litre of drinking water seep away on a daily basis. In developing countries, the average loss of water through leaks is
28%
19%
5%
plant and processes made in Germany in the future.
48% 14%
EU 27 Rest of Europe Asia (without ME) Middle East (ME) North America Others
For industry, setting up recirculating systems is the key to sustainability because it reduces the need to extract water and minimises wastewater charges. 43 per cent, while European water networks lose between 15 and 30 per cent. Germany, at 8 per cent, is at the bottom end of the scale. Nevertheless, even here, water lost from derelict piping systems amounts to half a billion cubic metre every year – seven times the annual water consumption of metropolitan Berlin. Over Euro 13 billion would have to be invested to rectify this situation. Just cutting these losses will both reduce the consumption of water and save power because the transport of water alone constitutes up about 90 per cent of the water supply’s electrical power requirement.
Total value of exports: Euro 3.25 billion Source: Federal Statistical Office, VDMA 2007
Figure 2: Important export regions for German water & wastewater technology
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Chemical World | August 2011
Tying up water cycles Water is always circulating: it evaporates from the land & sea,
and returns as rain. Although the quantity remains constant, its quality is affected by the way communities and industries use it. Over-extraction, pollution, and wastage at an increasing scale disturb the natural circulation, even in countries with adequate resources. For industry, which consumes a substantial 24 per cent of the world’s water supply, setting up recirculating systems is the key to sustainability because it reduces the need to extract water and minimises wastewater charges. The treatment of unmixed flows with targeted recovery of water and water-borne substances is already pursued with state-of-the-art technologies in numerous industrial applications. Nevertheless, the changing environment requires that existing concepts and technologies be continuously developed and improved. Where drinking water installations are concerned, it is important that the high-quality water pumped into the system by the supplier does not deteriorate on its way to the consumer, and that measures to prevent microcontamination are installed. Depending on requirements, conflicting goals will manifest themselves, for example, the increased energy consumption, to achieve the higher levels of purification needed for water fit for reuse. In such cases, the aim must be to find the best solutions needed in each case, to continue developing proven technologies, and to test new systems. Hans Birle is the Project Manager for Water and Wastewater Treatment & Recooling Technology at the Process Plant and Equipment Association – a part of German Engineering Federation (VDMA). The water and wastewater engineering enterprises affiliated to VDMA supply components and systems for water supply and wastewater treatment solutions. Email: hans.birle@vdma.org
TREND ANALYSIS
Crossflow filtration
Optimising membrane technology Modern crossflow filtration technology has primarily evolved during the last 40 years, largely in step with the advancement of polymer chemistry. Durable, chemical-resistant polymers have made crossflow technology cost-effective.
Courtesy: Koch Membrane Systems Inc
Brad Milnes
M
any simple filtration processes use a dead-end technique – the flow of liquid to be filtered is directed perpendicular to the filter surface (Figure 1). This is effective when the concentration of particles to be removed is low or the packing tendency of the filtered material does not produce a large pressure drop across the filter medium. Some common examples of dead-end filtration are home water filters, vacuum cleaners and automobile oil filters. Typical industrial uses include the sterile filtration of water, beer and wine. In contrast, there are many process streams that have high concentrations of particles or macromolecules such as cells, proteins and precipitates that will rapidly compact on the filter surface when operated in a dead-end mode. Consequently, the filtration rate drops
quickly to an unacceptable level. In these instances, a crossflow membrane system provides the means to maintain stable filtration rates. The key to the design of a crossflow system is selecting a membrane geometry that suits the physical characteristics of the process fluid. Crossflow membranes can be provided in tubular, flat sheet, spiral wound, and hollow fibre configurations, each of which provides certain advantages for specific process needs. Virtually any membrane design can be applied on water-like liquids with low concentrations of suspended solids. But viscous streams and fluids with large amounts of solids can only be handled with membranes specifically designed for this purpose. In general, the more difficult a stream is to process, the higher the cost of a membrane system and higher the operating costs. Thus, an optimisation study is an important component of any potential crossflow installation.
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TREND ANALYSIS
Evolution of membrane technology The theoretical principles of crossflow filtration are derived from Fick’s law of diffusion, which addresses the migration of suspended solids/ macromolecules in a flowing stream towards a filtration surface, and the potential back-diffusion into the bulk stream. This premise forms the
Figure 1: Dead-end filter operation results in a rapid flux decline as particles accumulate
Figure 2: Crossflow operation with asymmetric membrane
Figure 3: Comparative dimensions
Figure 4: Relative size exclusion
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Chemical World | August 2011
basis for crossflow design – that the concentration of macromolecules at the membrane surface can be controlled as a function of the velocity of fluid flowing parallel to that surface (Figure 2). The design of a successful crossflow system relies on choosing a membrane geometry that can be installed & operated economically, provides consistent predictable results, and can be effectively cleaned using chemicals compatible with the membrane. Today, 98 per cent of crossflow installations utilise polymer-based membranes; inorganic materials such as ceramic are only selected in specific instances where pH, temperature, or cleaning chemistry prohibit the use of polymers. The goal of membrane technologists is to use appropriate polymer material, module configuration, system design and operating conditions to achieve the most economical process possible. At the heart of this effort is the selection of a membrane with the optimum separation characteristics.
Defining a specific membrane process Crossflow membranes are manufactured in a range of porosities tailored to address various applications. These span the range of salt removal from water to large particulate filtration in viscous fluids. Filtration ranges have been defined that correlate to physical aspects of the membrane process and the relative size exclusion involved (Figure 3). In addition to the choices of polymer and membrane geometry, pore size selection is an integral part of process optimisation. The membrane with the smallest pores is reverse osmosis (RO), which involves appropriately enough reversal of the osmotic pressure of a solution in order to drive water away from dissolved molecules. Strictly speaking, RO is not a size exclusion process based on pore size; it depends on ionic diffusion to effect the separation.
A common application of reverse osmosis is seawater desalination, in which pure water is produced from a highly saline feed stream. In applications such as this, RO serves a similar purpose to evaporation, yet provides better economics. RO is also used in many industrial processes including cheese whey concentration, fruit juice concentration, ice-making, car wash reclamation, and wastewater volume reduction. In each of these examples, the goal is either to produce a pure filtrate (typically water) or retain the components of the feed stream as the product. Because the osmotic pressure (a measure of the dissolved ion concentration) of many process streams is quite high, RO membranes must be designed to operate at pressures of 400-1200 psi (29-83 bars), which restricts the available membrane geometries.
Nanofiltration and ultrafiltration A natural extension of RO is nanofiltration (NF) – the most recent development on the crossflow frontier. NF functions similarly to RO, but is generally targeted to remove only divalent and larger ions, hence NF is also referred to as – selective rejection
Understanding Dalton Dalton is the scientific unit of measure of molecular weight, abbreviated Da. Daltons provide a method to precisely define the weight of a molecule based on an established standard – the carbon atom. The Dalton is formally defined as 1/12 the weight of a carbon atom and is roughly equal to one proton. One Dalton weighs 1.066 x 10-24 gram. It is a convenient way of representing the weight of atoms and molecules. The correlation between Daltons and microns is not exact because Daltons are a measure of 3-dimensional size based on atomic weight units and microns are a measure of 2-dimensional distance.
TREND ANALYSIS
reverse osmosis. Monovalent ions such as sodium and chloride will pass through a nanofiltration membrane (Figure 4), thus many of the uses of NF involve de-salting of the process stream. An example is the production of lactose from cheese whey; the NF process is designed to concentrate the lactose molecules while passing salts – a procedure that purifies and concentrates the lactose stream. In water treatment, NF membranes are used for hardness removal (in place of water softeners), pesticide elimination and colour reduction. NF can also be used to reclaim spent NaOH solutions. In this case, the permeate (filtrate) stream is purified NaOH, thus allowing reuse many times over. NF is an osmotic pressuredependent process; but due to the passage of monovalent ions, the net osmotic driving force required is less than RO. Operating pressures are lower and filtration rates are higher (Figure 5). Nanofiltration membranes typically operate in the range of 100600 psi (7-42 bars). In many instances, NF can be used in place of RO. Ultrafiltration (UF) is the next process on the pore size continuum. UF is not an osmotic process – the pores of UF membranes are larger and the method of rejection is primarily physical size exclusion. While RO/NF membranes are generally categorised by the degree of salt rejection under standard conditions, UF membranes are specified by a molecular weight cut-off rating (MWCO). The range of MWCOs for UF is generally considered to be 1,000-1,000,000 Daltons, which can be loosely correlated to pore size (roughly equivalent to 0.0050.1 microns). The major opportunities for UF involve clarification of solutions containing suspended solids, bacteria or high concentrations of macromolecules. These include oil/ water separation, fruit juice clarification, milk & whey production, automotive electrocoat paint filtration, purification
Figure 5: Crossflow applications
of pharmaceuticals, poly-vinyl alcohol and indigo recovery, potable water production, and tertiary wastewater reuse.
The design of a successful crossflow system relies on choosing a membrane geometry that can be installed and operated economically. UF membranes are manufactured in a much larger variety of configurations to address the wide range of applications. Many membrane geometries are available in part due to the fact that UF processes operate below 150 psi (10 bars) – some as low as 25 psi (2 bars).
Microfiltration The last process that pertains to crossflow technology is microfiltration (MF). MF is actually a hybrid, having its significant applications in simple dead-end filtration for water filtration, sterile bottling of fruit juices & wine, and aseptic uses in the pharmaceutical industry.
However, not all applications that benefit from the use of MF operate successfully in the dead-end mode; a large portion of the MF market has been captured by crossflow. The most common being clarification of whole cell broths and purification processes in which macromolecules must be separated from other large molecules, proteins and/or cell debris. Clarification of dextrose and highly-coloured fruit juices employ MF extensively as well. There are also large markets for MF crossflow filtration in wine production, milk/whey de-fatting, and brewing. As with UF, MF systems operate at relatively low pressures and there are a variety of membrane configurations commercially available. Brad Milnes is a Process Technology Leader for Koch Membrane Systems Inc in Wilmington, MA. He has been actively involved in membrane and process development in the Food and Life Sciences fields at Koch, and previously at Romicon, Inc in Woburn, MA, for more than 20 years. Koch provides an extensive line of MF, UF, NF and RO products in spiral, tubular and hollow fibre configurations to the water, wastewater and FLS markets. Email: bamilnes@kochmembrane.com
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ACE Products Products: Packaging machines, PP & PET strapping machines, Stretch wrap systems, Strapping machines, Shrink packaging machines, Packaging machines, Packaging materials, Polyolefin shrink films, Pallet stretch films, PVC cling films, BOPP tapes, Pre-stretch films W: www.acepackproducts.com Participating in: Rudrapur
Alstrut India Pvt Ltd Products: Aluminium profiles, Joining elements, Machine building accessories, Pipes & joints, Assembly lines, Conveyors, Flexible chain conveyors, Storage systems, Worktables W: www.alstrut.com Partici pating in: Rudrapur, Ahmedabad, Pune, Chennai, Indore
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Delta India Electronics Pvt Ltd Products: Switching power supplies, DC brushless fans, Power management solutions, Components, Visual displays, Industrial automation, Networking products W: www.deltaelectronicsindia.com Participating in:
Emtex Machinery Pvt Ltd Products: Lathe machines, Shearing machines, Press brake machines, Radial drill machines, Milling machines, CNC plasma cutting, Surface grinders, Welding machines, CNC lathe machines, Vertical machining centres, Air compressors & project engineering W: www.emtex.in Participating in: Rudrapur
Equifit Technoart Products: Aerosols, Speciality oils, Anti-seize compounds, Custom formulations, Metal working fluids, Metal treatment chemicals, Biodegradable degreasers, Synthetic greases & oils, PTFE/silicone/moly/ graphite greases W: www.equifitlubricants.com Participating in: Aurangabad
Gantner Instruments India Pvt Ltd Products: Manuals, Test controllers, Manuals ISM, Data loggers, Short manuals software, Manuals accessories W: www.gantner-instruments.com Participating in: Rudrapur
Grind Master Machines Pvt Ltd. Products: Tube polishing machines, Automatic buffing machines, Roll & cylinder superfinishing machines, Deburring machines, Diamond films & belts W: www.grindmaster.co.in Participating in: Rudrapur, Chennai
Heena Sales Products: Welding & cutting equipment Participating in: Ahmedabad
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Hi-Tech Robotic Systemz Ltd Products: Robotics, Artificial intelligence, Computer vision, Machine vision & related technologies, Developing solutions for industrial & military applications W: www.hitechroboticsystemz.com Participating in: Rudrapur, Pune
Integro Engineers Pvt Ltd Products: Power & soundproof acoustics, Electrical panels, Solar equipment, Mechanised industrial cleaning, Heat tracing, Hot & cold insulation contactors, Industrial products W: www.integrogroup.in Participating in: Rudrapur
Janak Enterprises Products: Metal cutting solutions, Nibbling cutting attachments & machines, Jigsaw attachments, Pipe cutting machines, Pipe chamfering machines, Pipe notching machines, Pipe & bar cutting machine, Teraspindles for fine engraving W: www.janakent.com Participating in: Pune
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Jyoti CNC Automation Pvt Ltd Products: CNC machines, Turning/turnmill centres, Vertical machining centres, Horizontal machining centres W: www.jyoti.co.in Participating in: Rudrapur
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Kruger & Brentt Facility Services Products: Wet & dry vacuum cleaners, Floor cleaning machines,Ultra-compact scrubbers, Buffing machines, High-pressurejet cleaners, Industrial sweepers, Truckmounted road sweepers, Cleaning equipment W: www.kbtechindia.com Participating in: Rudrapur
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UpdatE 3 Rudrapur 23-26 September, 2011 Gandhi Park
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Kushal Udhyog Products: Shot blasting machines, Spinner hangers W: www.kushaludhyog.com Participating in: Chennai
Mact Exim Llp Products: CNC machines, Lathe machines, Milling machines, Surface grinders, Bandsaw machines, VTLs, Planner milling machines, CNC press brakes, Hydraulic press brakes, Shearing machines, Plate bending machines, Boaring machines W: www.machtexim.com Participating in: Rudrapur, Ahmedabad, Pune, Chennai, Indore, Aurangabad
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EVENTS CALENDAR
National RUDRAPUR: Uttarakhand, Sept 23-26, 2011, Gandhi Park AHMEDABAD: Gujarat, Oct 14-17, 2011, Gujarat University Exhibition Hall PUNE: Maharashtra, Nov 18-21, 2011, Auto Cluster Exhibition Centre CHENNAI : Tamil Nadu, Dec 8-11, 2011, Chennai Trade Centre INDORE: Madhya Pradesh, Jan 6-9, 2012, Poddar Plaza, Nr Gandhi Hall AURANGABAD: Maharashtra, Feb 17-20, 2012, Garware Stadium India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.
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Process Engineering Expo & Conference 2011 International exhibition & conference on process plants & machinery; September 01-03, 2011; at HITEX Exhibition Centre, Hyderabad For details contact: Sambit Mund Sr. Manager - Marketing Hyderabad International Trade Expositions Ltd Near HI-TEC City, Madhapur Hyderabad 500 084 Tel: 040-2311 2121/22 Fax: 040-2311 2124 Email: sm@hitex.co.in
Automation 2011 International exhibition & conference dedicated to process automation, instrumentation & controls, factory automation, robotics, power plant automation, drives automation, bus & wireless technology, building automation, hydraulics and pneumatics; September 20-23, 2011; at Bombay Exhibition Centre, Mumbai For details contact: IED Communications Ltd 64 Mahendra Chambers D N Road, Mumbai 400 001 Tel: 022-2207 9567, Fax: 022-2207 4516 Email: ied@vsnl.in
Informex India Forum focussed specifically on the Indian specialty chemicals industry; September 22-23, 2011; at Holiday Inn, Mumbai For details contact: UBM India Pvt Ltd Sagar Tech Plaza A, 615-617
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Andheri Kurla Road, Saki Naka Andheri (E), Mumbai 400 072 Tel: 022-4046 1466 Fax: 022-4046 1477 Email: conferences-india@ubm.com
Fax: 022-2496 6631/32 Email: vishal.ganju@ficci.com
IPVS 2011 Industrial trade fair for pumps, valves and systems; November 11-13, 2011; at the Gujarat University Hall, Ahmedabad, Gujarat For details contact: Orbitz Exhibitions Pvt Ltd 101, Navyug Industrial Estate Sewri (W), Mumbai 400 015 Tel: 022-2410 2801/02, Fax: 022-2410 2805 Email: info@ipvs.in
CPhI INDIA 2011 International exhibition on pharmaceutical ingredients and intermediates; December 01-03, 2011; at NSE Exhibition Complex, Mumbai
Water Tech & Waste Tech Expo Trade show & conference on sustainable technologies for waste treatment and water management; September 28-30, 2011; at Gujarat University Hall, Ahmedabad For details contact: Exhiference Media Pvt Limited B-2 Basement, Kalyan Tower Near Vastrapur Lake, Ahmedabad 380015 Tel: 079-4003 9444; Fax: 079 4003 9431 Email: marketing@exhiferencemedia.com
Analytica-Anacon 2011 International trade fair and conference for analytical instrumentation, laboratory technology and services; October 12-14, 2011; in Mumbai
For details contact: CMP India (UBM India Pvt Ltd) Sagar Tech Plaza, A, 615-617, 6th Floor SakiNaka Junction, Andheri-Kurla Road Andheri (E), Mumbai 400 072 Tel: 022-6612 2600, Fax: 022-6612 2626 Email: deepalim@ubmindia.com
Hannover India Event showcasing process automation, material handling and renewable energy technologies; December 06-09, 2011; at Bangalore International Exhibition Centre, Bengaluru
For details contact: Imag Am Messesee 2, 81829 Munich, Germany Tel: +49 (0) 89 949 22 121 Fax: +49 (0) 89 949 22 350 Email: info@imag.de
For details contact: Hannover Milano Fairs India Pvt Ltd 603/604, Samarpan Complex New Link Road, Chakala Next to Mirador Hotel Andheri (E), Mumbai 400 099 Tel: 022-4005 0681/82 Fax: 022-4005 0683 Email: info@hmf-india.com
India Chem Gujarat 2011
PLASTINDIA 2012
Event focussing on specialty chemicals, fine chemicals, agrochemicals, colorants, dyes & dye intermediates with special emphasis on environment and green technology; October 13-15, 2011; at Mahatma Mandir, Gandhinagar
International plastics exhibition & conference; February 01-06, 2012; at Pragati Maidan, New Delhi
For details contact: FICCI Mumbai 33/B, Krisnamai Building Pochakanwala Road, Worli, Mumbai 400 030 Tel: 022-2496 8000, 2496 6633/39
For details contact: Plastindia Foundation 401, Landmark B, Suren Road Off Andheri Kurla Road Andheri (East), Mumbai 400 093 Tel: 022-2683 2911-14 Fax: 022- 2684 5861 Email: plastindia@vsnl.com
EVENTS CALENDAR
International ChemInnovations
OIL & GAS LIBYA 2011
Event focussing on chemical apparatus & plant installation, process technology, maintenance & QC; September 13-15, 2011; at George R Brown Convention Centre, Houston, USA
International exhibition and conference on petroleum exploration, production, refining and petrochemicals; October 17-20, 2011, Tripoli International Fairground, Tripoli
For details contact: The TradeFair Group Inc 11000 Richmond, Suite Houston, The US Tel: +1-214-3585359 Fax: +1-(832)-2421971 Email: efreer@che.com
Asia Pacific Coatings Show Symposium and international exhibition for the coatings industry; September 14-15, 2011; at Marina Bay Sands, Singapore For details contact: Kez Chen Westgate House, 120/130 Station Road Surrey, United Kingdom Tel: +44 (0)1737 855578 Email: kezchen@quartzltd.co.uk
CO2 Expo 2011
Exhibition dedicated to the climate and greenhouse emissions; September 14-16, 2011; at Fiera di Roma, Rome, Italy For details contact: Artenergy Publishing srl Via Antonio Gramsci, 57 20032 Cormano (MI), Italy Tel: +39 0266306866 Fax: +39 0266305510 Email: artenergy@zeroemission.eu
PEPP 2011 A business forum dedicated to polyethylene & polypropylene (PEPP) products, technologies and market; September 20-22, 2011; at Swiss么tel Zurich, Switzerland For details contact: Maack Business Services Moosacherstrasse 14 CH-8804 Au/Zurich Switzerland Tel: +41 1 781 30 40, Fax: +41 1 781 15 69 Email: mbspolymer@aol.com
For details contact: Dar Alarab Tel: +218 21 333 9141, Fax: +218 21 333 9142 Email: exhibitions@alarab.co.uk
ChemMash-Pumps 2011
chemicals, petroleum/energy etc; November 22-25, 2011; at Suntec, Singapore For details contact: Singapore Exhibition Services Pte Ltd No. 1 Jalan Kilang Timor #09-02 Pacific Tech Centre Singapore 159303 Tel: +65 62336638 Tel: +65 62336633 Email: events@sesallworld.com
A trade fair on chemical engineering and pumps; October 24-27, 2011; at Expocentre Krasnaya Presnya Fairgrounds, Moscow
Chemspec Middle East 2011
For details contact: ZAO Expocentr 1A Sokolnicheski Val Moscow 123100, Russia Tel: +7 (495) 255 37 23/33 Fax: +7 (495) 205 80 55 Email: centr@expocentr.ru
For details contact: Dmg World Media (UK) Ltd Westgate House 120/130 Station Road Redhill, Surrey RH1 1ET The UK Tel: +44 (0)1737 855000 Fax: +44 (0)1737 855475 Email: webmaster@ca.dmgworldmedia.com
INCHEM Tokyo 2011 Trade fair showing latest developments in chemical engineering; November 16-18, 2011; at Tokyo International Exhibition Center, Japan For details contact: Japan Management Association (JMA) 3-1-22, Shibakoen Minato-ku, Tokyo 105, Japan Tel: +81 (0)3 3434 0093 Fax: +81 (0)3 3434 8076 Email: convention@jma.or.jp
Saudi Petrochem 2011 International exhibition for chemicals and chemical technology industry; November 21-24, 2011; at Riyadh International Exhibition Centre, Saudi Arabia For details contact: Riyadh Exhibitions Co Ltd Olaya Road Postfach P O Box 56010 SA - 11554 Riyadh, Saudi Arabia Tel: +966 1 454 1448 Fax: +966 1 454 4846 Email: esales@recexpo.com
CIA 2011 An event focussing on latest progress on process control and automation in
Exhibition for performance and fine chemicals; November 28-29, 2011; at Dubai World Trade Centre, UAE
Digital Plant 2011 A plant lifecycle conference for the chemicals, power, oil & gas, offshore, and pharmaceuticals industries; December 05-07, 2011; at Woodlands Waterway Marriott Hotel & Convention Centre, Houston, USA For details contact: Daratech Inc 255 Bent Street Cambridge, MA 02141 The US Tel: +1 (617) 354-2339 Email: daratech@daratech.com
Chemical Process Plant and Machinery Middle East 2011 Exhibition and seminar for the chemical, petrochemical, chemical process technology and corrosion control industries; December 07-08, 2011; at Dubai World Trade Centre, UAE For details contact: International Expo-Consults LLC PO Box 50006, Dubai, UAE Tel: +971 (4) 343 5777 Fax: +971 (4) 343 6115 Email: iec@emirates.net.ae
The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Chemical World
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TECHNOLOGY TRANSFER
Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Activated carbon An Iranian firm is willing to offer activated carbon from coconut shells. Areas of application Food processing, pharmaceuticals, etc Forms of transfer Technology licensing
Cresyl phosphate / tri phenyl An Indian firm is offering consultancy for manufacturing plasticisers. Area of application Photo films, chemicals, plastic industry, etc Forms of transfer Consultancy
Ethanol An Iranian company is offering ethanol from molasses using the fermentation of sacharomyces cerevisiae. Ethyl alcohol is widely used for making many organic chemicals. Areas of application Chemical industry, energy industry Forms of transfer Technology licensing
Furfuryl alcohol technology An Indian firm offers technology for producing furfuryl alcohol from furfural by liquid hydrogenation as well as vapour hydrogenation, with a capacity of 6,000 tpa to 24,000 tpa. Areas of application Furan polymers, sealants & cements,
urea-formaldehyde, & phenolic resins and foundry cores Forms of transfer Consultancy, technical services, technology licensing
Phosphate esters An Indian firm is offering technology for manufacturing phosphate esters like tri butyl phosphate. Area of application Specialty chemicals Forms of transfer Joint venture
Sodium hydrosulfite An Iranian company is willing to manufacture sodium hydrosulfite using chemical compounds. It is widely used as a stripping agent in dyes and in chemical industry. Areas of application Chemical industry Forms of transfer Technology licensing
Sodium sulfide An Iranian firm is willing to offer sodium sulfide, which is used mainly in textile industry, paper mill, artificial silk and curriery. Areas of application Leather industry, textiles, curriery industries, paper mills, etc Forms of transfer Turnkey
Synthesis routes for organic chemicals An Indian firm is offering consultancy in design of synthesis routes for organic chemicals. Areas of application Pharma industry, speciality chemicals, plant protection chemicals, etc Forms of transfer Consultancy
Transformer oil unit An Indian company is willing to offer consultancy for making a transformer oil unit with domestic coal from its wastes. Area of application Transformers Forms of transfer Consultancy, technical services
Wasteless processing techniques An Indian company is willing to offer consultancy for waste-less processing techniques for the chemical & packaging industries. Area of Application Packaging industry, transformer oil manufacturing industry, chlor alkali projects Forms of transfer Consultancy, technical services
Share Your Technology Propositions The mission of Chemical World is to spread the technology culture. We offer you an opportunity to participate in this endeavour by publishing the best technology ideas. Technology developers/sellers are invited to furnish the techno-commercial details (with environmental benefits, if any) for publication in the Technology Transfer column of Chemical World. R&D organisations, technical consultancy organisations and individuals assisting small and medium enterprises may send the relevant literature, indicating the scope & services and the areas of specification. Contact: Chemical World Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: chemedit@infomedia18.in
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TECHNOLOGY TRANSFER
Technology Requested Calcium carbonate
Lime plant
A Saudi Arabian company needs the technical know-how for producing calcium carbonate from limestone. Areas of application Industries like chemical, textile, etc Forms of transfer Others
A group of businessmen in Zambia is interested in setting up an 800 t/d of quick lime and 200 t/d of hydrated lime plant. Areas of application Mining Forms of transfer Others
Glyoxal An Indian company is looking to switch the production technique for manufacturing 40 per cent glyoxal from its existing acetaldehyde based method to the MEG based glyoxal production. Area of application Pharma & textile Forms of transfer Others
Inorganic chemicals An Indian company is interested in seeking the technology & process know-how for production of potassium nitrate, chromium acetate, and magnesium hydroxide suspension. The company already produces inorganic chemicals and wants to add several other items. Areas of application Chemical industry Forms of transfer Others
Lime An Indian company seeks to adopt new cost-effective technologies, which can reduce carbon emissions and earn carbon credits, for manufacturing lime. Area of applications Quick lime and hydrated lime Forms of transfer Others
Manufacture of sodium hydrosulfite A company based in Pakistan is interested in establishing a joint venture for the manufacture of sodium hydrosulfite in Pakistan with either a Chinese or European manufacturer, who has the technological know-how and expertise in the field. Areas of application Industries like textile, paper and food Forms of transfer Others
Quaternary ammonium chloride An Indonesia-based company, is planning to diversify into manufacturing of quaternary ammonium chloride. It is seeking technology along with the supply of critical plant and machinery for the manufacture of the chemical 3-chloro-2hydroxypropyl trimethyl ammonium chloride that is produced from epichhlorohydrin. Areas of application Chemical industry Forms of transfer Technical knowhow, consultancy
Small-scale environmentfriendly chemical technology An Indian company is looking out for an economically viable smallscale environment-friendly chemical
technology useful in the textile sector as well as in pharmaceutical sector. Area of application Textile and pharmaceutical industry Forms of transfer Others
Solvent dyes An Indian company has recently installed a manufacturing capacity of 2,400 mtpa and is looking to diversify its product range by including various solvent dyes in its product portfolio. The company is seeking process consultancy for this project. Areas of application Plastics, petroleum, solvents, etc Forms of transfer Others
Sodium silicate and activated carbon A company from Thailand requires technology for manufacturing sodium silicate and activated carbon from rice husk & rice husk ash. Areas of application Manufacturing and construction industry Forms of transfer Others
Treatment of pollutants discharged during PTA production A Chinese organisation is looking for a recycling and pollution-free treatment technology to tackle the wastewater, exhaust gas, waste slag and noises generated in PTA production, thereby shifting from reduction of pollutant discharge to zero-discharge. Areas of application Chemical industry Forms of transfer Consultancy, technical services, etc
Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations Asian and Pacific Centre for Transfer of Technology (APCTT), APCTT Building , C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org
For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.
August 2011 | Chemical World
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BOOK SHELF
Prudent practices in the laboratory Compiled by: National Research Council of the National Academies (United States) Price:
This book by experts from academia and industry, with specialisations in areas such as chemical sciences, pollution prevention & laboratory safety, provides guidance on planning procedures for the handling, storage, and disposal of chemicals. It offers prudent practices designed to promote safety and includes practical information on assessing hazards, managing chemicals, disposing of wastes, and more. The updated edition responds to societal and technical developments that were driving significant changes in the laboratory culture and laboratory operations related to safety, health & environmental protection. This book serves as the leading source of chemical safety guidelines for people working with laboratory chemicals, research chemists, technicians, safety officers, educators and students. It also provides information on new topics such as emergency planning, laboratory security, handling of nanomaterials, and expanded discussion on environment, health & safety management systems.
Safe use of chemicals: A practical guide This book includes comprehensive instructions for those who work with potentially dangerous substances and also provides them with the information they need to avoid hazards associated with handling these chemicals. Besides, it contains information on industrial solvents, pesticides, metals, air pollutants, toxic gases and drugs, as well as other substances. Each chemical substance is concise yet thorough, and does not require advanced training to comprehend. For each chemical, this book provides the CAS number, IUPAC name, molecular formula, synonyms, uses & exposures, toxicity & health effects, the exposure limits, and methods of proper storage & disposal. Tables and appendices are included where appropriate. The different chapters of this book discuss specific chemical substances & their uses, toxicity, health effects on animals & humans, and the importance of taking precautions during use.
Author : T S S Dikshith Price : ` 5,300
Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958, Telefax: 022-2203 4058, Email: thadam@vsnl.com
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An invite that rewards as well...
Dear Reader, ‘Chemical World’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the chemical process industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Chemical World’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘Chemical World’ is the leading monthly magazine exclusively meant for producers and user fraternities of the chemical process industry (CPI). Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian CPI. Moreover, it offers a broader platform facilitating effective interaction among several fraternities of these industries by enabling them in reaching out to their prospective buyers & sellers through better trade contacts and more business opportunities. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,
Manas R Bastia Senior Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India
D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in
PRODUCT UPDATE
Liquid ring vacuum pump
Mechanical seal
Acmevac Sales offers liquid ring vacuum pump. The pump is available in both single and double stage. Its capacity ranges from 10 to 4000 cfm and can ultimately vacuum up to 720 mm. The sophistically designed liquid ring vacuum pump is silent in operation, as a result the silencer is fully eliminated. It finds applications in vacuum distillation, drying, concentration, degassing, crystallisation, gas evacuation, gas conveying, compression, chemicals, drugs, food, beverage, sugar, fertiliser, paper, metallurgy and allied process industries. The mechanical shaft seal design ensures adequate protection to the expensive shaft and provides ease in maintenance. These pumps are rugged in design, reliable in performance and is easy to maintain.
Technomech Engineering offers mechanical seals for chemical and process pumps, compressors, vacuum pumps, dewatering pumps, agitators, reactors, mixers, driers and process equipment with rotating shafts. These mechanical seals are available in various designs including multispring, single spring, teflon bellow, metal bellow, double mechanical & cartridge type. These are available in materials such as carbon steel, stainless steel, haste alloy, monel, tungsten carbide, ceramic and glass filled PTFE. These mechanical seals conform to ISO, DIN and API standards. They meet general as well as critical duties in chemicals, petrochemicals, fertilisers, paper, thermal power generation, ore processing, metallurgy, pharmaceutical, food, beverage, cosmetics, breweries and allied process industries.
Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-2837 5837, Fax: 022-2836 4977 Mob: 092233 88105 Email: acmevac@vsnl.com
Technomech Engineering Mumbai - Maharashtra Tel: 022-2678 5683 Fax: 022-2678 5683 Mob: 098672 09809 Email: technomech.seals@gmail.com
Chemical transfer pump Industrial oven Aero Therm Systems offers industrial oven. Each plant is individually designed to meet the specific requirements related to fuel, method of job handling, safety requirements and output. These ovens consistsof mild steel (stainless steel above 350째C), mineral wool insulation material (in conjunction with ceramic fibre above 550째C), panel mounted control gear with optional safety controls manual or powered door operation. The heating medium is gas, oil, direct or indirect fired, steam, thermic fluid and electrical. The industrial ovens are designed for use in industries such as aerospace, aluminium, brass, ceramics, electronics, chemical, ferrous metals, finishing, foundry, glass, motor rewinding, plastics, paint curing, powder coating, rubber and trade heat treatment.
Taha Pumps & Valves offers CFP series chemical transfer pump in SS 316 material to handle mild corrosive chemicals. The main features of these pumps are high efficiency, good performance and reliability. These pumps are available from 0.25 to 10 hp in different capacities in monoblock and bare pump design. All the wetted parts are made of graded SS 316 material. The sealing is by mechanical seal of different face combination of carbon, ceramic, GFT, silicon and tungsten. Pumps can be used for high temperature application up to 250oC. Special pumps are also available with casing steam jacketing and with flameproof motors. It finds application in different industries like chemical, petrochemical, steel plants, printing houses, pharmaceuticals and food processing.
Aero Therm Systems Pvt Ltd Ahmedabad - Gujarat Tel: 079-2589 0158 Fax: 079-2583 4987 Email: contact@aerothermsystems.com
Taha Pumps & Valves Surendranagar - Gujarat Tel: 02752-240 233, Fax: 02752-240 908 Mob: 098255 99415 Email: tahapv@yahoo.co.in
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Product Inquiry Card
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EASY STEPS TO GET PRODUCT INFO
Product Sourcing Just Got Simpler
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PRODUCT UPDATE
Evaporative cooling tower Gem Equipments offers evaporative Fibreglass Reinforced Plastic (FRP) cooling tower. The cooling towers are of vertical induced draft counter flow design, with uniform water distribution and optimum heat transfer. The tower casing is made of tough FRP and has sufficient structural strength to withstand high wind velocity and vibration. The fill is made of rigid Poly Vinyl Chloride (PVC) and is of honeycomb design with large contact surface area. The fill splits the air & water into several streams, increasing the time of contact and also transfers heat between water & air. Automatic rotary sprinkler system is made of nylon 66 material, with rotary head and sprinkler pipe, which distributes the hot water over the entire space of the filler. Sprinkler pipes are non-clogging, which require low pressure to operate and assure uniform water flow with minimal operating pump head. The performance of cooling tower greatly depends upon the water distribution over the fills. Gem Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-236 0013/0130 Fax: 0422-236 0523 Email: info@gemindia.com
Rubber diaphragm D K Industries offers rubber diaphragm for applications like pumps, valves, actuators, LPG valves, CNG valves, thermal actuators, gas diaphragm and pressure diaphragm. These diaphragms can be reinforced with fabric for higher strength. The dimensional tolerance of precision diaphragms is up to 0.02 mm (+/- 0.001 inches). Designing and manufacturing a rubber diaphragm is a science in itself and there are lot of factors involved to get the right diaphragm. Factors such as design, raw material, pressure and medium in contact are involved to get the right diaphragm. One can get customised diaphragm for specific applications. Diaphragms are available in approved materials like EPDM, nitrile, neoprene, viton and silicon. D K Industries Mumbai - Maharashtra Tel: 022-2678 9085, Fax: 022-2768 5063 Mob: 093222 81444 Email: dkindustries07@yahoo.com
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PRODUCT UPDATE
Sanitary pump
Bottom discharge centrifuge
Sri Pumps & Fittings Industrial Corporation offers sanitary pump. It is available in convenient design for quick and easy cleaning. The suction housing is equipped with an additional sanitary connection to accept flow bypass piping and valves. During CIP operation, cleaning solution passes through the pump, washing the internal parts thoroughly. Whereas, excess liquid is routed through the flow bypass line and is back into the piping downstream of the pump. Moreover, the pump offers clamp-style, DIN or ACME thread connections. It is ideal for any application where contamination must be avoided and frequent clean-up is required. The features include quick disassembly design for easy cleaning, no valves to clog or vapour lock, the ability to efficiently move viscous slurries and handle fluid temperatures up to 200ยบ F and solids up to 25 mm diameter. It finds applications in pharmaceutical, food processing, dairy, cosmetics and chemicals.
United Engineering offers bottom discharge centrifuge with cake scrapping arrangement for chemicals, pharma and process industry. The centrifuge is fitted with a cake scrapping arrangement, which can be motorised. It enables to scrap away even the stickiest or toughest cakes. The cake can be discharged through the bottom chute, which is provided along with the centrifuge. This results in reducing manual labour, less cake handling and uniform cake washing. The centrifuge is offered in vapour tight construction with nitrogen blanketing for hazardous chemicals. The CIP design with in-built cleaning nozzles ensures no product cross-contamination. The centrifuge is offered in three-point pendulum suspension and four-point inertia plate, which is mounted to suit the application. The centrifuge is available in MS, SS at point of contacts, complete SS and MS rubber/halar lined, with batch capacity ranging from 40 to 600 kg.
Sri Pumps Manufacturing Company Rajahmundry - Andhra Pradesh Tel: 0883-246 2990, Fax: 0883-243 0819 Email: info@sripumps.com
Electrolytic scalcium remover Ti Anode Fabricators offers electrolytic scalcium remover. The electrolytic scalcium remover produces oxidants in the water. The oxidant prevents corrosion, bio-fouling, scaling, microorganism growth and spread of air-borne bacteria. Scalcium remover has two main units and they are SPR & electro-chlorinator. SPR is used to remove the scales from the raw water and control the TDS available in the water. Whereas, the electro-chlorinator generates chlorine which takes care of bio-fouling and algae present in the water. O & M of the system is user-friendly, selfcleaning and self-calibration arrangement. Scalcium remover saves up to 60 per cent on operational cost by means of savings on chemicals purchase (no chemical injection is needed), lowers the usage of water & energy, and also reduces labour costs. Ti Anode Fabricators Pvt Ltd Chennai - Tamil Nadu Tel: 044-2278 1148, Fax: 044-2278 1362 Email: info@tianode.com
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United Engineering Enterprises Mumbai - Maharashtra Tel: 022-2308 3990 Fax: 022-2308 9445 Email: uenggent@gmail.com
Crate washing conveyor SS Engineers and Consultants offers crate washing conveyor. The special features of these crate washers include stainless steel body, selfcleaning individual tank filters, heavy construction design, stainless steel chain conveyance, hi-performance pumps, rotating spray jet nozzles, toughened glass windows and operational panel board with safety controls. The standard models include machines that range from 600 to 3,000 crates washing per hour. The hot air blowers and electric heaters are the additional equipment added. It finds application in food, pharma and chemical industry. SS Engineers & Consultants Rajahmundry - Andhra Pradesh Tel: 0883-242 6845 Fax: 0883-243 0819 Email: info.ssengrindia@gmail.com
PRODUCT UPDATE
Dry cooling tower Gem Equipments offers dry cooling tower to maintain the temperature of hot water at a particular level. This operates on the principle of heat transfer by a heat exchanger with extended fins. The fan is driven by an electric motor. The best quality imported OD copper tubes is used in level wound coils. Tubes are staggered in the path of airflow for better heat transfer efficiency. The return bends are die-formed from thick walled tubing, which is heavier than the standard tubing and is used in the rest of the coils. This provides toughness and durability, which is required in the most vital parts of the coils. The inlet and outlet headers are constructed of heavy wall steel pipes. Tubes are mechanically expanded for an optimum bond between tube and fin. A die formed galvanised steel frame provides stacking, shipping support, protection against tube damage during expansion and installation. Gem Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-236 0013/0130, Fax: 0422-236 0523 Email: info@gemindia.com
Sanitary ball valve Sri Pumps & Fittings Industrial Corporation offers sanitary ball valve. It is easy to install & maintain, and is equipped with positive loaded seals to provide leak-proof dependability. Full ported, straight-through ball valves free the flow path from any obstructions and as a result pressure drops across the valves. Ball valve is made of stainless steel and comes with an option of 304 or 316 SS. It has forged body with sanitary finish. Cavity flush feature allows natural flushing action within the valve cavity. Furthermore, it is a three-piece design with positive-backed seals. It has full port opening for unrestricted flow in the open position. The automatic (air operated) actuator is available in six designs with control top options. It finds applications in pharmaceutical, food, dairy, beverage, cosmetic and chemical industry. Sri Pumps Manufacturing Company Rajahmundry - Andhra Pradesh Tel: 0883-246 2990, Fax: 0883-243 0819 Email: info@sripumps.com
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PRODUCT UPDATE
Cartridge mechanical seal
Pallet washer
Technomech Engineering offers cartridge mechanical seals for chemical and process pumps, compressors, vacuum pumps, dewatering pumps, agitators, reactors, mixers, driers and process equipment with rotating shafts. It is self-contained unit consisting of a shaft sleeve, seal and gland plate. The unit is fitted on the pump shaft as a built assembly, and thereby eliminates the need for fitting. Cartridge seals are an attempt to overcome the fitting problems of conventional seals. It is offered in single and double form, and the gland plate is often fitted with various tapings to provide for flushing, cooling water injection and disaster control. It can overcome several limitations of the standard pump gland. The setting position of the seal is set by the cartridge design, but the seal unit should not be screwed to the shaft until the gland plate is secured to the pump. The design works to eliminate many of the common causes of seal failure.
SS Engineers offers pallet washer, which is designed for optimal cleaning of standard size pallets. Tank bottoms are sloped to large drains for easy tank cleaning. Work tunnel openings feature automatic doors, which remain closed unless a pallet is passing through, for an optimal thermal efficiency. Systems are available with power or manual conveyors, all feature fully adjustable side guide rails. Automatic water level control is provided within the wash tank. Level sensors are equipped with quick disconnect cords for easy maintenance. Spray nozzles are positioned to clean all surfaces of the pallet. No tools, quick disconnect couplers, caps and nozzles make maintenance as easy as possible. The blow-off system features a large air intake filter with dual disposable filters to prevent part contamination and protect the pressure blower itself. The fan is floor mounted for easy access.
Technomech Engineering Mumbai - Maharashtra Tel: 022-2678 5683, Fax: 022-2678 5683 Mob: 098672 09809 Email: technomech.seals@gmail.com
SS Engineers & Consultants Rajahmundry - Andhra Pradesh Tel: 0883-242 6845, Fax: 0883-243 0819 Email: info.ssengrindia@gmail.com
Centrifugal air blower Vacunair Engineering Co offers centrifugal air blower with fans of variable intel vanes. It is provided with high-pressure automisation/combustion air, which is in accordance with the requirements suitable for burners. It is offered with a design impeller fabricated in an aluminium/MS riveted high-strength construction that is fitted with a hub. Some of its features are: the minimum overhung and weight design for low starting inertia, dynamically balanced impeller, and different drives for direct coupled/mounted on motor shaft/vee belt. These blowers can be utilised in cooling, air knives, fluidising system, glass blowing, drying and various process systems. It has a capacity of up to 75,000 m3/hr and pressure of up to 1,500 mm WG. Vacunair Engineering Co Pvt Ltd Ahmedabad - Gujarat Tel: 079-2291 0771, Fax: 079-2291 0770 Mob: 099040 03010 Email: info@vacunair.com
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Chemical World | August 2011
Vacuum pump Acmevac Sales offers a wide range of vacuum pump, which is oil sealed rotary type. This series of vacuum pumps are rotary sliding vane, oil immersed type and are also available in single & double stage construction. These pumps are ideal for handling dry and clean air. The exhaust valve is designed in such a manner so that rapping noise can be eliminated. The unique construction of the pump totally eliminates the suction of air through the shaft seal. These pumps can also be operated with SAE-30 motor oil. It finds applications in chemical, pharmaceuticals, electrical, air conditioning & refrigeration, research, metallurgy and space research. The pumps are available in wide range of models with free air displacement, which ranges from 50 lpm to 10,000 lpm. Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-2837 5837, Fax: 022-2836 4977 Mob: 092233 88105 Email: acmevac@vsnl.com
PRODUCT UPDATE
Agitator mechanical seal
Multi-level inverter
Rotomech Engineering offers factory assembled double mechanical agitator seals for applications in mixers, agitators, rotary dryers, fermenters and reactors. These double-mechanical seals are designed for handling severe & hazardous fluids. The design incorporates bearings located very close to seal to avoid cantilever effect at seal area. A standard cooling jacket is provided in the seals to dissipate maximum amount of heat generated by the seal faces. Seals can be given without bearing, if equipment bearings are very close to seal area. These agitator mechanical seals are offered in shaft diameter of 20 to 200 mm; pressure of vacuum 12 bar (max), temperature from ambient to 200oC (max), shaft speed of 700 rpm (max).
Suvik Electronics offers H bridge multi-level inverter ‘N 5000’ for medium-voltage and high-power AC motor drives. Main features of this inverter are as follows: reduction of harmonic injection into the utility by means of specially designed multi-winding transformers; generation of near sinusoidal voltages with only low frequency switching; almost no common mode voltage; low dv/dt at output voltage; no significant over voltage on motor terminal even if the distance between inverter and motor is long. Applications are in power plants, incineration plants, sewage water treatment plants, oil pumping stations, etc. Some of its features are motor- friendly; power source-friendly; directly driven medium voltage AC motor; high performance; high reliability; high efficiency/high power factor; user-friendly maintenance; powerful and easy-to-use operation; and full range line-up.
Rotomech Engineering Mumbai - Maharashtra Tel: 022-2678 7163 Email: rotomechengg@mtnl.net.in
High-vacuum oil-seal rotary pump Joyam Engineers & Consultants offers high-vacuum oil-seal rotary pumps. These are oil-immersed, rotary vane type pumps. The inbuilt non-return valve prevents the back flow of air. Manufactured from graded material, all moving parts are precisely machined, ground and assembled with close tolerances. This results in increased efficiency and long trouble-free operation. These pumps develop maximum vacuum of 0.05 mm Hg in single-stage and 0.005 mm Hg in doublestage. Pumps operate at 500 rpm with the help of ‘V’ belt. These pumps are widely used in solvent extraction & recovery, sugar, oil refineries, distilleries, food processing, chemical, pharmaceutical, fertiliser, paper, textile, tube light & general lighting, printing etc. These pumps are suitable for various processes like vacuum filtration, distillation, vacuum crystallisation, vacuum impregnation, vacuum metallurgy, thin film coating, vacuum drying, dehydration, evaporation, deodorisation, de-gassing, moisture extraction, vacuum condensation, conveying, venting, etc. They have simple & rugged construction, trouble-free operation and low maintenance. Capacity ranges from 3 m3/hr (50 ltr/min) to 600 m3/hr (10,000 ltr/min). Joyam Engineers & Consultants Ahmedabad - Gujarat Tel: 079-2656 9533, Fax: 079-2656 2777 Email: joyam@joyamvactech.com
Suvik Electronics Pvt Ltd Gandhinagar - Gujarat Tel: 079-2321 2001 Fax: 079-2321 2006 Email: info@suvik.com
Fluoropolymer-lined valve Supremo Line & Control offers fluoropolymer (FEP, PFA and PTFE) lined SGI/WCB/SS valves. These products are manufactured for successful results with international quality for the chemical industry. Important features include: low co-efficient of friction, chemical inertness, non-toxic, non-inflammable, self-sealant, good weather resistance and zero water absorption. Supremo Line & Control Ahmedabad - Gujarat Tel: 079-2220 5282 Fax: 079-2220 5181 Mob: 097245 05282 Email: supremoproduct@gmail.com
The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of Chemical World
August 2011 | Chemical World
87
PRODUCT INDEX Engineering Expo Sl. No. E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12
Product
Pg. No.
E77
Actuators ................................. 70 Aerial work platforms .................. 70 Aerosols ...................................... 69 Air compressors & project engineering....... 68 Air coolers ................................... 69 Aluminium profiles ...................... 68 Anti-seize compounds ................. 69 Armatures ................................... 70 Artificial intelligence .................... 69 Assembly lines ............................. 68 Automatic buffing machines ....... 69 Automatic strapping machines & shrink packaging machines ...... 68 Automation technology ............... 70 Axle stands .................................. 71 Bandsaw machines.................. 70 Battery stackers ........................... 71 Bio-degradable degreasers........... 69 Blowers ................................. 68, 70 Boaring machines ........................ 70 BOPP tapes.................................. 68 Bow shackles ............................... 71 Brass anchors .............................. 70 Brass inserts................................. 70 Brushes........................................ 70 Buffing machines......................... 69 Bus technology & I/O systems...... 70 CAD products & services......... 68 Cargo lashings............................. 71 Chain pulley blocks...................... 71 Chain slings ................................. 71 Circular saws ......................... 68, 70 Cleaning equipment .................... 69 CNC lathe machines .................... 68 CNC lathes .................................. 71 CNC lathes accessories................. 71 CNC machines ................. 68, 69, 70 CNC plasma cutting..................... 68 CNC press brakes......................... 70 Coated abrassive flap wheels ....... 70 Components................................ 68 Computer vision .......................... 69 Controllers................................... 70 Conventional lathe accessories..... 71 Conveyors.................................... 68 Coventional lathes ....................... 71 Custom formulations ................... 69 Cutoff machines .......................... 70 Cutters ........................................ 68 Data acquisition ...................... 70 Data loggers................................ 69 DC brushless fans ........................ 68 Deburring machines .................... 69 Destructive holograms ................. 70 Developing solutions for industrial & military applications ....... 69 Diamond cutting & processing ....... systems........................................ 71 Diamond films & belts................. 69 Drill machines.............................. 68 Drills ...................................... 68, 70 Drum carriers......................... 70, 71 Drum lifters & tilters .............. 70, 71 Drum transporters ................. 70, 71 D-shackles ................................... 71 Electrical panels....................... 69 Energy management software ..... 70 Engine stands .............................. 71 Eye bolts ..................................... 71 Eye hooks .................................... 71 Fingerprint biometric attendance devices.................. 68 Flexible chain conveyors............... 68 Floor cleaning machines .............. 69 Gold purity (XRF) systems ...... 71 Grinders ................................ 68, 70 Hand & electric pallet trucks .. 71 Hand deburring tools .................. 70 Hanger-type shot blasting machines ...... 71 Hanger-type Y-conveyor shot blasting machines........................ 71 Heat guns.................................... 68
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Chemical World | August 2011
E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23 E24 E25 E26 E27 E28 E29 E30 E31 E32 E33 E34 E35 E36 E37 E38 E39 E40 E41 E42 E43 E44 E45 E46 E47 E48 E49 E50 E51 E52 E53 E54 E55 E56 E57 E58 E59 E60 E61 E62 E63 E64 E65 E66 E67 E68 E69 E70 E71 E72 E73 E74 E75 E76
Sl. No. E78 E79 E80 E81 E82 E83 E84 E85 E86 E87 E88 E89 E90 E91 E92 E93 E94 E95 E96 E97 E98 E99 E100 E101 E102 E103 E104 E105 E106 E107 E108 E109 E110 E111 E112 E113 E114 E115 E116 E117 E118 E119 E120 E121 E122 E123 E124 E125 E126 E127 E128 E129 E130 E131 E132 E133 E134 E135 E136 E137 E138 E139 E140 E141 E142 E143 E144 E145 E146 E147 E148 E149 E150 E151 E152 E153 E154 E155
Product
Pg. No.
Heat tracing ................................ 69 Heavy engineering steel fabrication........ 71 High-pressurejet cleaners ............. 69 Holograms................................... 70 Holographics security tapes ......... 70 Horizontal machining centres 68, 69 Hot & cold insulation contactors . 69 Hot stamping foils....................... 70 Hydraulic floor cranes.................. 71 Hydraulic jacking beams .............. 71 Hydraulic jacks............................. 71 Hydraulic lifting equipment ......... 71 Hydraulic lifts............................... 71 Hydraulic manual & electric pallet trucks................................. 70 Hydraulic manual & electric stackers ...... 70 Hydraulic multi-purpose toolkits .. 71 Hydraulic press brakes ................. 70 Hydraulic scissor trucks................ 71 Hydraulic spring dismantlers ........ 71 Hydraulic workshop presses......... 71 Indicators................................. 70 Industrial automation .................. 68 Industrial order pickers ................ 70 Industrial products....................... 69 Industrial sweepers ...................... 69 Jet pallet trucks....................... 71 Jigsaw attachments ..................... 69 Joining elements.......................... 68 KH-Instagram........................... 70 Laser cutting systems.............. 71 Laser marking & engraving systems ....... 71 Laser welding systems ................. 71 Lathe machines ..................... 68, 70 Lawn mowers.............................. 68 Lifting tackles .............................. 71 Light engineering components .... 71 LPG cylinder machines ................. 71 Machine building accessories ....... 68 Machine vision & related technologies ................................ 69 Machinery components ............... 70 Magnetic drill stands ................... 70 Maintenance platforms................ 71 Maintenance scissor lifting machines ..................................... 70 Manuals accessories .................... 69 Manuals ISM ............................... 69 Material handling equipment ...... 71 Material handling items............... 71 Material handling products ......... 70 Mechanised industrial cleaning.... 69 Metal cutting solutions................ 69 Metal treatment chemicals .......... 69 Metal working fluids ................... 69 Milling machines ................... 68, 70 Multi-doop controllers ................. 70 Multi-function units..................... 70 Networking products .............. 68 Nibbling cutting attachments & machines ..................................... 69 Packaging machines................ 68 Packaging materials ..................... 68 Packing holograms ...................... 70 Pallet stretch films ....................... 68 Panel meters................................ 70 Pins for earth-moving equipment ....... 70 Pipe & bar cutting machine......... 69 Pipe chamfering machines ........... 69 Pipe cutting machines ................. 69 Pipe notching machines............... 69 Pipes & joints .............................. 68 Planers................................... 68, 70 Planner milling machines ............. 70 Plate bending machines............... 70 Plate lifting clamps ...................... 71 Plung routers............................... 68 Pneumatic tools........................... 70 Polishers ...................................... 70 Polyester webbings ...................... 71 Polyolefin shrink films .................. 68 Portable auto lifts ........................ 71
Sl. No.
Product
Pg. No.
E156 Portable blast shot blasting machines ..................................... 71 E157 Portable hydraulic equipment ...... 71 E158 Portable meters ........................... 70 E159 Power & soundproof acoustics .... 69 E160 Power management solutions ..... 68 E161 Power tools ..................... 68, 70, 71 E162 PP & PET strapping machines ...... 68 E163 Precision automotive components ...... 71 E164 Precision components.................. 71 E165 Press brake machines................... 68 E166 Pressure blast shot blasting machines ..................................... 71 E167 Pressure washers ......................... 68 E168 Pre-stretch films........................... 68 E169 PTFE/silicone/moly/graphite greases........ 69 E170 Pulling lifting machines ............... 71 E171 PVC cling films ............................ 68 E172 Radial drill machines............... 68 E173 Ratchet lashings .......................... 71 E174 Ratchet liver hoists ...................... 71 E175 Recorders .................................... 70 E176 Robotics ...................................... 69 E177 Roll & cylinder superfinishing machines ..................................... 69 E178 Roller seats .................................. 71 E179 Round endless slings ................... 71 E180 Routers........................................ 70 E181 Sanders ..............................68, 70 E182 Scissor lifting tables ..................... 71 E183 Sensors........................................ 70 E184 Shearing machines ................ 68, 70 E185 Sheet metal machines ................. 68 E186 Short manuals software............... 69 E187 Shot blasting machines ............... 70 E188 Slings .......................................... 71 E189 Slotting machines ........................ 68 E190 Soft honing tools ........................ 70 E191 Software...................................... 68 E192 Solar cell scribing systems............ 71 E193 Solar equipment .......................... 69 E194 Speciality oils ............................... 69 E195 Spinner hangers .......................... 70 E196 Steel creepers .............................. 71 E197 Storage systems..................... 68, 71 E198 Stretch wrap systems................... 68 E199 Super blast shot blasting machines .... 71 E200 Super blast shot blasting machines .... 71 E201 Surface grinders .................... 68, 70 E202 Switching power supplies ............ 68 E203 Synthetic greases & oils ............... 69 E204 Tailor-made shopfloor material handling equipment .................. 70 E205 Tamper-evident holograms .......... 70 E206 Tele control engineering .............. 70 E207 Teraspindles for fine engraving.... 69 E208 Test controllers ............................ 69 E209 Thyristor power controllers .......... 70 E210 Toolroom machines ..................... 68 E211 Trading & machine shop ............. 71 E212 Transmitters................................. 70 E213 Transparent holograms................ 70 E214 Trolley jacks ................................. 71 E215 Truck-mounted road sweepers..... 69 E216 Tube polishing machines ............. 69 E217 Tumblast airless shot blasting machines ..................................... 71 E218 Turn buckles ................................ 71 E219 Turning/turnmill centres............... 69 E220 Ultra-compact scrubbers ......... 69 E221 Vertical machining centres .....68, 69 E222 Visual displays ............................. 68 E223 VTLs ............................................ 70 E224 Welding & cutting equipment .. 69 E225 Welding machines ....................... 68 E226 Wet & dry vacuum cleaners......... 69 E227 Wire rope clamps ........................ 71 E228 Wire rope slings .......................... 71 E229 Wire ropes................................... 71 E230 Woodworking machines .............. 68 E231 Workshop machines & accessories...... 68 E232 Worktables .................................. 68
PRODUCT INDEX Sl. No.
Product
Pg. No.
Sl. No.
Pg. No.
Sl. No.
Product
Pg. No.
Exhibition - Engineering Expo .... 27,32,61,
94
Non-return valve ............................... 5
68-71,88
95
Non-slam check valve-spring loaded ..... 83
50
Exhibition - Surface Technology 2011 .... 8
96
Non-IBR steam boiler............................ 43
Agitator mechanical seal ...................... 87
51
Exhibition - Water Tech 2011................. 4
97
Online B2B marketplace..............7, 89
5
Air blower ............................................ 33
52
Filter press....................................... 47
98
Pallet................................................ 85
6
Air pollution control equipment ........... 21
53
Fire tube steam boiler........................... 85
99
Pallet washer ........................................ 86
7
Air receiver ........................................... 21
54
Fluid ....................................................... 6
100 Piping system ...................................... 10
8
Analytical instrumentation ................... BIC
55
Fluid bed dryer ..................................... 83
101 Pneumatically actuated knife gate valve ...83
9
Automatic and contained discharge ..... 17
56
Fluoropolymer-lined valve ..................... 87
102 Polypropylene filter plate ...................... 47
10
Axial flow fan....................................... 83
57
Flush bottom ball valve ........................ 83
103 Polypropylene recess plate .................... 47
11
Bag filter.......................................... 43
58
Flush bottom plug valve ....................... 83
104 PP-recess chamber type filter press ....... 47
12
Ball valve .............................................. 83
59
Flush bottom ram valve........................ 83
105 Pressure and vacuum filtration ............. 17
13
Ball valve - Teflon-lined .......................... 5
60
Forged steel valve ................................. 83
106 Process heat exchanger .......................... 3
14
Bellow & dip-pipe................................... 5
61
FRP underground fuel tank................... 85
107 Process reactor ....................................... 3
15
Blower.................................................. 33
62
16
Boiler.................................................... 85
17
Bottom discharge centrifuge ................ 84
18
1
Acoustic hood ................................. 33
2
Actuated butterfly valve........................ 83
3
Actuated valve...................................... 83
4
49
Product
Gas conditioning and fire
108 PTFE lined valve & pipe fitting ................ 5
protection system ........................... 19
109 Reactor ............................................ 21
63
Gas detector......................................... 63
110 Reactor vessel ....................................... 50
Burner .................................................. 85
64
Gate globe & check valve-flanged end .....83
111 Rotary vacuum dryer .............................. 3
19
Butterfly valve - Teflon-lined ................... 5
65
Gear ....................................................... 6
112 Rotocone dryer ....................................... 3
20
Cake pressing .................................. 17
66
Gearbox........................................... 6, FIC
113 Rubber diaphragm ............................... 83
21
Cartridge mechanical seal ..................... 86
67
Gear motor ..................................... 6, FIC
114 Sampling valve-teflon lined .............. 5
22
Centrifugal air blower.....................83, 86
68
Gear operated knife gate valve ............. 83
115 Sanitary ball valve................................. 85
23
Check valve - Teflon-lined....................... 5
69
Gear pump........................................... 51
116 Sanitary pump...................................... 84
24
Chemical pump .................................... 51
70
Geared & flexible coupling ..................... 6
117 Silicone carbide heat exchanger.............. 3
25
Chemical tank ...................................... 85
71
GMP heat exchanger .............................. 3
26
Chemical transfer pump ....................... 78
118 Spherical paddle chopper dryer .............. 3
27
Chlorine valve globe type ..................... 83
72
GMP reactor ........................................... 3
119 Spiral cum helical gearbox...................... 6
28
COD analyser........................................ 63
73
Heat exchanger .................. 13, 21, 50
120 Spray analysis ....................................... 19
29
Columns & chemistries ........................ BIC
74
High-vacuum oil-seal rotary pump........ 87
121 Spray control ........................................ 19
30
Condenser ............................................ 21
75
Hot air & water generator .................... 85
122 Spray fabrication .................................. 19
31
Cone screw mixer ................................. 21
76
Hot air generator.................................. 43
123 Spray nozzles and accessories............... 19
32
Conical screw dryer ................................ 3
77
Hot water generator.......................43, 83
124 Steam boiler .................................... 83,85
78
HPLC ................................................... BIC
125 Strainer-teflon lined................................ 5
79
Hydrogenator/autoclave.......................... 3
126 Teflon lined valve & pipe fitting ...... 5
80
IBR steam boiler ......................... 43,85
127 Tefzel HHS isotactic PP material............ 10
81
Indirect air heater ................................. 83
128 Thermic fluid heater ................ 43, 83, 85
82
Industrial oven................................. 78,83
129 Thermoplastic valve .............................. 10
83
Informatics .......................................... BIC
130 Totally ingrated automation system...... BC
33 34 35 36 37
Container ............................................. 85 Continuous nitration system ................. 50 Continuous or batch filtration .............. 17 Crate washing conveyor ....................... 84 Custom moulding................................. 85
38
Dairy equipment ............................. 21
39
Damper ................................................ 21
84
Insulated box........................................ 85
131 Tray dryer ............................................. 83
40
Drum & carboy..................................... 85
85
IPVS trade fair & conference 2011 ....... 55
132 Turnkey project....................................... 3
Dry cooling tower................................. 85
86
Jacked ball valve ............................. 83
133 Turnkey system .................................... 19
Dual fuel burner ................................... 83
87
Lined valve & pipe fitting ................. 5
134 Twin shaft disperser ............................. 50
Dust collector ....................................... 43
88
Liquid ring vacuum pump .................... 78
135 UPLC ...............................................BIC
44
Electrical operating & discharge rod ...9
89
Material handling container ........... 85
136 Vacuum or hot gas drying ............. 17
45
Electrolytic scalcium remover ................ 84
90
Mechanical seal .................................... 78
137 Vacuum pump ..................................... 86
46
Empower............................................. BIC
91
Multi-stage cake washing ..................... 17
138 Vertical non-IBR oil-fired steam boiler... 85
47
E-safe fibre glass ladder.......................... 9
92
Multi-fuel fired IBR steam boiler ........... 85
139 Wafer-type check valve................... 83
48
Evaporative cooling tower .................... 83
93
Multi-level inverter................................ 87
140 Worm gear............................................. 6
41 42 43
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August 2011 | Chemical World
89
ADVERTISERS’ LIST
Advertiser’s Name & Contact Details
Pg No
Aerotherm Systems Pvt Ltd
83
Advertiser’s Name & Contact Details
Pg No
Fluidtech Boilers Pvt Ltd
43
Advertiser’s Name & Contact Details
Premium Transmission Ltd
Pg No
FIC
T: +91-79-25890158
T: +91-79-25840105
T: +91-20-66314100
E: contact@aerothermsystems.com
E: info@fluidltd.com
W: www.premiumtransmission.com
W: www.aerothermsystems.com
W: www.fluidltd.com
Balkrishna Boilers Pvt Ltd
85
Raj Process Eqpts & Systems(P) Ltd 21
General Engineering Consortium 83
T: +91-79-25894701
T: +91-80-23541808
E: info@balkrishn.com
E: gec1@vsnl.com
W: www.balkrishn.com
W: www.gecvalves.com
BHS-Sonthofen (India) Pvt. Ltd. 17
Hannover Milano Fairs India Pvt Ltd 8
T: +91-40-23315341 / 45
T: +91-22-40050681
E: neelesh@bhs-sonthofen.in
E: unmesh.mandpe@hmf-india.com
W: www.bhs-sonthofen.in
W: www.surface-india.com
T: +91-20-40710010 E: sales@rajprocessequipment.com W: www.rajprocessequipment.com Siemens Ltd
Dipesh Engineering Works
3
BC
W: www.seimens.com/chemicals Sintex Industries Ltd
85
T: +91-2764-253500
Heattrans Equipments Pvt.Ltd. 47
E: icontainers@sintex.co.in W: www.sintex-plastics.com
T: +91-22-26743719
T: +91-79-25840105
E: sales@dipeshengg.net
E: info@heattrans.com
Spraying Systems (India) Pvt Ltd
W: www.heattrans.com
T: +91-80-39853200 / 01
Elecon Engineering Company Ltd
6
E: ssipl@sprayindia.com
T: +91-2692-236469
Hi-Tech Applicator
E: infogear@elecon.com
T: +91-79-25833040
W: www.spray.com
W: www.elecon.com
E: hitech@ptfeindia.com
Uniphos Envirotronic Pvt Ltd
Engineering Expo
27;32;61;68-71;88
W: www.ptfeindia.com
T: +91-9819552270
HRS Process Systems Ltd
E: engexpo@infomedia18.in
T: +91-20-66047894
W: www.engg-expo.com
E: info@hrsasia.co.in
Ercon Composites
9
5
E: singhrv@unipos.com W: www.uniphos-she.com UNP Polyvalves India Pvt Ltd
W: www.hrsasia.co.in
E: ercon@ercon-india.com
T: +1800-200-4444 / 91-120-3911000
W: www.ercon-india.com
E: pr@indiamart.com
7; 89
E: mktg@polyvalve.com W: www.polyvalve.com Waters (India) Private Limited BIC
W: www.indiamart.com
T: +91-80-28371900
T: +91-11-45457777
Kwality Process Equipments Pvt Ltd 50
E: info@everestblowers.com
T: +91-220-2453438
E: waters_india@waters.com
W: www.everestblowers.com
E: pdmakwana@vsnl.net
W: www.waters.com
W: www.chemicalequipments.com
Witte Pumps & Technologies
Exhiference Media Pvt Ltd
4
10
T: +91-265-2649248
Indiamart Intermesh Limited
33
63
T: +91-22-6123500 13
T: +91-291-2741263
Everest Transmission
19
55
51
T: +91-11-41613643
T: +91-79-40039444
Orbitz Exhibitions Pvt Ltd
E: mmarketing@exhiferencemedia.com
T: +91-9323949693
E: witte@goddiesons.com
W: www.exhiferencemedia.com
E: harikrishnan@orbitexhibitions.com
W: www.witte-pumps.de
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Our consistent advertisers
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90
Chemical World | August 2011