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INDUSTRY WATCH - Chemical World
December 2010
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EDITORIAL
‘Treat’ing it clean
W
ith the spread in industrialisation, there has been an obvious byproduct in the form of effluent. More importantly, their treatment has been a big challenge for industries. Added to this are the scarcity of valuable freshwater resources, concerns about the eco-footprint of industrial wastewater discharge, and increasing regulatory norms for better environmental compliance. However, thanks to some of the latest technologies and processes (more specifically, the ‘green’ ones), it is now possible to provide means and methods for efficient & effective effluent treatment. In effect, it has led to an increase in investment towards effluent treatment methods. In this direction, the government’s move to set up Common Effluent Treatment Plants (CETPs) can go a long way in boosting the business competitiveness of chemical manufacturers, especially Small & Medium Enterprises (SMEs) that cannot afford effluent treatment in their individual units. Besides minimising environmental impact, CETPs can take cleaner production technologies to a higher orbit and thereby help the growth of SMEs in an eco-compatible manner. As per an estimate, the Indian water and wastewater market with revenue of around $ 4 billion, is growing at 8-10 per cent per annum. Moreover, there is a perceptible change in the industrial outlook with return on investment being given a priority while making decisions regarding
Business Insights Technologies Opportunities
Editor : Manas R Bastia Assistant Editor: Rakesh Rao Senior Features Writer: Prasenjit Chakraborty Features Writers: KTP Radhika Jinoy (Delhi), Mahua Roy Senior Correspondent: Shivani Mody (Bengaluru) Correspondent: Geetha Jayaraman (Delhi), Anwesh Koley (Delhi) Copy Desk: Meghanadan Sudhakaran Products Desk: Sudheer Vathiyath Assistant Art Director: Varuna Naik Chief Photographer: Mexy Xavier Design: Mahendra Varpe Production: Vikas Bobhate, Pravin Koyande, Dnyaneshwar Goythale, 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: Sunder Thiyagarajan, General Manager - Copy Sales Sheetal Kotawadekar, Senior Manager, Tel: 91-22-3003 4631/4633 Email: customercare@infomedia18.in
effluent treatment. In fact, there is an emphasis on evaluating lifecycle costs of technologies and the overall project cost as compared to the earlier practice of referring to capital costs as a primary basis while making purchase decisions. One of the recent trends in this space is the concept of Zero Liquid Discharge (ZLD) plant design instead of disposing wastewater to the environment. Such wastewater recovery methodologies for industrial applications hold high potential towards efficient and innovative management of entire water cycles for industrial applications as well as allowing businesses to save money, reduce environmental impact and meet legislation for discharge. The ‘Sector Watch’ offers some latest insights into the world of effluent treatment. On a related theme, the ultrafiltration technology can offer superior performance for the clarification of wastewater and process water, leading to better bottom lines and more eco-sustainable processes. However, there are several issues to be solved before this technology takes the centre stage. Turn to the ‘Industry Update’ and ‘Market Scope’ for more on it.
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 Ltd
Manas R Bastia Editor manas@infomedia18.in
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December 2010 | Chemical World
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CONTENTS
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LEADERS SPEAK “We foresee healthy market growth in the Middle East, Asia and Indian sub-continent” ...says William Yau, CEO, Borouge’s Marketing Company
32
FACILITY VISIT 34
DyStar India Pvt Ltd: Offering a rainbow of services
SECTOR WATCH 38
Effluent treatment: A must for ‘clean growth’
INDUSTRY UPDATE 42
Ultrafiltration: Separation with precision Dr G Arthanareeswaran, Asst. Professor - Dept. of Chemical Engineering, National Institute of Technology
38
MARKET SCOPE 46
Membrane filtration: ‘Sieving’ for a green future
COATINGS CORNER 50
Methyl methacrylate shortage: Facing the new reality Dr Mosongo Moukwa, Vice President - Technology, Asian Paints Ltd
SAFETY ZONE 54
Fall arrestor: Prime requisite for safe landing K N K Murthy, Consultant
PRACTICAL TIPS 62
Project management: A practical approach Deepak Makhijani, Proprietor, Geeta Consulting Services
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PREVIEW 66
HiTech Automation: Taking manufacturing to the next level
ADVERTORIAL 68
Engineering Expo Indore 2011: Investment ahoy!
CURTAIN RAISER EverythingAboutWater 2011: A technology forum with a difference
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REPORT Engineering Expo Pune 2010: Creating a perfect trade ecosystem
R EG U L A R S EC TI O N S
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Editorial .................................................... 17 National News ......................................... 20 World News............................................. 26 Events Calendar ....................................... 72 Product Update........................................ 78 Product Inquiry ........................................ 89 Advertisement Inquiry.............................. 91 Product Index........................................... 93 Advertisers’ List ....................................... 94
Highlights of Next Issue Sector Watch : Engineering, Procurement & Construction (EPC) Industry Update : Industrial Gases Market Insight : Highlights of Chemical Industry in 2010 Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise
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Details on page no. 11, 12, 29, 30
NATIONAL NEWS EXPANSION STRATEGY
LANXESS starts ion exchange resins plant in Gujarat
Narendra Modi, CM, Gujarat, is seen with Alex Heitmann and other dignitaries during the inauguration
Specialty chemicals group LANXESS inaugurated its new plant for ion exchange resins in Jhagadia, Gujarat. With an annual capacity of 35,000 metric tonne, this unit will manufacture products for industrial water treatment for the semi-conductor, pharmaceutical, food and the power industry. Overall, LANXESS NEW FACILITY
Lubrizol opens application centre in Mumbai The Lubrizol Corporation recently opened a regional applications and business centre in Mumbai to support its Advanced Materials business segment. This is an important milestone in the company’s geographic expansion plan in South Asia. The centre - which was inaugurated by Eric Schnur, President, Lubrizol Advanced Materials - will have a state-of-the-art development and applications laboratory, which will include development, formulation RECOGNITION
RIL ranks 20th among world’s largest chemical firms
Reliance Industries Ltd (RIL) has been named among the world’s top chemical companies in a global ranking - ICIS Top 100 Chemicals Companies. The company led by industrialist Mukesh Ambani has been ranked at 20th
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has invested around Euro 50 million in the site. The new plant is constructed on an area totaling 30,000 sq m. With its high-quality Lewatit ion exchange resins, adsorbers and functional polymers, LANXESS has more than 70 years of experience and expertise as a one-stop supplier of premium products for water treatment. These high-tech resins are used in the fields of water treatment in power generation, microelectronics and the drinking water & food preparation industries. The next stage of expansion for Jhagadia is planned for 2012. From then on, high-tech plastics from the SemiCrystalline Products (SCP) business unit will be produced at a capacity of 20,000
metric tonne per year. “India is preparing to become the third biggest market for engineering plastics after the US and China,” said Axel C Heitmann, Chairman, LANXESS Board of Management. LANXESS is also expanding its global research network and has signed a cooperation agreement with the leading Indian rubber research institute - Hari Shankar Singhania Elastomer and Tyre Research Institute (HASETRI) headquartered in Kankroli, Rajasthan. “With HASETRI’s acknowledged expertise, we will accelerate the development of our business in high-performance and safe tires on India’s rapidly growing market,” said Heitmann.
and applications testing capabilities in multiple personal-care & coatings applications as well as a pharmaceutical application development centre. The site will also support Lubrizol’s business in engineered polymers, which is well known in India for its FlowGuard® brand - a high performance engineered plastic widely used for hot and cold water delivery. Estane® thermoplastic polyurethane (TPU) is also a leading brand that has found acceptance globally in many applications including the transportation and sports shoe arenas. “Lubrizol has a long history of investing
in the South Asian market, particularly in India. We view this market as a great opportunity for Lubrizol Advanced Materials, and our new site represents an important step in what we intend to be a long-term effort focused on growth and investment in this region,” said Schnur.
position in the list, which was topped by German major BASF. RIL has been also named as the 8th biggest gainer in the list in terms of operating profits. The companies were ranked on the basis of their annual sales figures in the annual list released by ICIS Chemical Business magazine, which is published by ICIS, a global information provider for the chemical and energy industries. RIL was ranked 20 th on the basis of sales worth $ 12.3 billion last year, while top-ranked BASF had sales of $ 72.7 billion. While RIL is the only Indian company in the
top 20, another Indian entity, Tata Chemicals, has been ranked at 115th in a separate list of companies titled ‘Bubbling Under’, which did not make it into the Top-100. The report noted that the global chemical industry went through a year of turmoil in 2009, but RIL figured among the few companies on the list that bucked the trend. “The ICIS List of top players in the global chemical industry confirms that 2009 was a year of turmoil, but many companies have emerged from the downturn in solid shape,” it said.
Eric Schnur addressing the audience
NATIONAL NEWS NEW FACILITY
GEA Group inaugurates manufacturing unit in Pune
Pune plant
GEA Group, one of the largest product and system providers for food and energy processes in the world, recently launched its 3rd manufacturing facility at Chakan near Pune after Vadodara and Bengaluru. The group has revenues worth Euro SUBSIDIARY
Arch Chemicals Inc launches Indian subsidiary Arch Chemicals Inc is expanding its marketing presence and manufacturing capabilities in India with the formation of a new subsidiary – Arch Protection Chemicals Pvt Ltd (APCPL). Capitalising on the indigenous availability of raw materials and cost-effective production, APCPL QUALITY AND SAFETY
Intertek inaugurates safety testing laboratory
Intertek, one of the leading providers of quality and safety solutions, inaugurated SEMINAR
DyStar conducts seminar on resource management DyStar India Pvt Ltd has conducted a seminar on ‘Resource management: DyStar’s solutions’ to create awareness regarding resource management in the local textile industry. The seminar was conducted at The Astor Hotel, Kolkatta on November 20, 2010. DyStar is one of the leading names in
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4.4 billion and a presence in over 50 countries with global production and R&D centers. The Pune plant has been set up with an investment of over Rs 100 crore and a built up area of 6500 sq m. This new plant is aligned with GEA Group’s global manufacturing processes and quality standards. The Pune plant will manufacture Plate Heat Exchangers (PHE) of all types and will cater to India and Asia Pacific markets. K P Glockner, President, GEA PHE Systems said, “We have specifically located the plant in Pune
because of its proximity to Mumbai and availability of good infrastructure and manpower.” Mik Hansen, Regional Director - Asia Pacific, GEA PHE Systems, said, “We are optimistic about our new plant in India, as the Indian market is the second largest market for us in the Asia Pacific region. Our technologies are applied in dairy, food, chemical, petrochemical, refinery, pharmaceutical and biotech industries. We are capable of functioning as a total PHE product solution provider - covering design engineering and manufacturing.”
will offer novel biocide products and services that are tailored to meet the needs of Indian customers and climatic conditions. “Arch Chemicals is already supplying major international accounts in India with biocide products and our popular anti-dandruff agent, and we see tremendous opportunities here for further growth,” said Saravana Kumar, Country Manager, Arch India.
According to David Tierney, Global Business Manager for Building Products, India represents a strategic growth market for Arch Chemicals and our Industrial Biocides business.
its safety testing laboratory in Mumbai to provide enhanced testing services to its customers across diverse industries. Safety is crucial to any chemical process or unit operation. To help make these processes safer, Intertek’s Safety Testing Laboratory focusses on the safe handling of chemicals in powdered form and Process Safety Testing to define the characteristics of chemicals & their safe processing parameters.
“I have witnessed the Indian safety testing laboratory evolving over the last two decades from being an internal safety lab of Ciba to an outstanding, reputed, recognised and unique thirdparty service provider to the Indian manufacturing industry. This lab is a benchmark for safety testing and consulting in the entire APAC region,” said Dr Mara Beatrice Guzzetti, Head EMEA & APAC, Intertek Expert Services.
the textile dyes & chemicals sector, and is a total solution provider for textile supply chain. Rajesh Balakrishnan, President - South Asia, DyStar Group, reiterated the commitment of DyStar as the complete solution provider to the entire textile supply chain after the take over of DyStar by KDCL. Experts spoke about conservation of renewable resources by way of usage of high fixation & high
Saravana Kumar
Rajesh Balakrishnan lighting the lamp during inauguration
strength dyestuffs and role of multifunctional auxiliaries.
NATIONAL NEWS PRODUCT LAUNCH
Dow introduces innovative film resins in India
Dow Chemical International Pvt Ltd has launched a range of innovative film resins for use in food & specialty packaging, industrial & consumer packaging, and health & hygiene applications for the needs of film ANNUAL TARGET
Dupont expects $ 1 billion revenue in India DuPont Co, the third-biggest US chemical maker, recently announced that it expects its annual revenue from India to increase to more than 40 per cent reaching $ 1 billion by 2012, aided by agriculture, infrastructure and automotive products. Sales in India this year may climb to about FERTILISER
Tata Chemicals to offer customised fertiliser
R Mukundan
Tata Chemicals recently launched a customised fertiliser product to LOGISTICS
Aegis Logistics invests Rs 430 crore in India Aegis Logistic Ltd (India), one of the leading oil, gas and chemical logistics companies in the world, has decided to invest ` 430 crore in India for two projects in Pipavav and Halida. Anish Chandaria, Managing Director and CEO, Aegis Logistics Ltd, said, “We will invest around ` 430 crore in two oil terminal
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converters for new materials which offer better optics, improved toughness & faster processing opportunities. The new products include DOWLEXTM NG developmental (Next Generation) Linear Low Density Polyethylene (LLDPE) resins that take LLDPE performance to a new level and new ATTANETM NG Ultra Low Density Polyethylene (ULDPE) resins that allow the use of ULDPE in more demanding applications. “The South Asian region, particularly India, is an important long-term
strategic growth market for Dow. The launch of our new film resins here serves to reinforce our ongoing focus to the market in the region through driving innovations and offering differentiated services that meet the needs of our customers for next generation polyethylene solutions. Also, through leveraging our global technical capabilities, Dow looks to continuously enhance its products and services so that they provide value today and into the future,” said Sudjali Halim, Marketing Manager - Plastics, Asia Pacific.
$ 700 million from $ 500 million in 2009, as per Ellen Kullman, CEO, DuPont Co. The company has plans to set up a local research laboratory for which it has earmarked Rs 500 million and the expansion will be completed by the middle of next year. “Productivity is really the key to the future of agriculture in India. We are working to produce new varieties of hybrids in rice and corn
to increase productivity,” said Kullman. He presented a plan to increase the company’s earnings 20 per cent a year and sales at least 10 per cent.
improve crop yields. This product will be launched at Babrala, UP, where Tata Chemicals has its manufacturing plant. The company plans to expand the production of this product to two more units by next year. The plan for the customised fertilisers alone would need an investment of around ` 150 crore, said R Mukundan, Managing Director, Tata Chemicals. “This is over and above the
` 400-500 crore capex that we annually spend,” he added. Tata Chemicals has developed the product Paras farmoola for six key crops namely paddy, wheat, potato, sugarcane, maize and mentha. Customised fertilisers are crop and region specific which are typical to particular soil & plants that are aimed at a balanced distribution of nutrients in the field.
projects in which our major chunk of investment (around ` 400 crore) will go to APM terminals at Pipavav in Gujarat and ` 30 crore in the existing Haldia terminal where we propose to add an additional 30,000 KL to increase the present capacity of around 55,000 KL.” The company also plans to sublease a 100 acre of land for building a global oil and petrochemicals storage complex. Chandaria added,
“We have been supported by the oil majors in India for years in other ports in Mumbai and Kochi. They can use this facility for import & export of oil and petrochemical products.”
WORLD NEWS JOINT VENTURE
BASF and Ineos combine styrenics businesses
L to R: Callum MacLean (Member of INEOS AG Board), Martin Brudermüller (Member of the Board, BASF), Roberto Gualdoni, Jim Ratcliffe (Chaiman, INEOS AG) and Jürgen Hambrecht (Chairman, BASF SE)
SELL OFF
Harima Chemicals buys a part of Momentive Momentive Specialty Chemicals has signed a definitive agreement to sell its global Ink and Adhesives Resins (IAR) business to pine-based chemicals firm Harima Chemicals. “This business, much of which is based on pine chemicals technology, is a great fit with our existing company and will further extend our global presence in this sector. This investment highlights our FERTILISERS BUSINESS
K+S to acquire Potash One
The K+S Group, one of the world’s leading suppliers of standard and speciality fertilisers, has agreed to acquire Vancouver-based Potash One. The cash offer values Potash One at $ 430 million and is expected to close in GROWTH STRATEGY
LANXESS buys two businesses from Flexsys LANXESS has agreed to acquire two businesses from Flexsys, a division of the US based Solutia Inc to strengthen the portfolio of its Rubber Chemicals business unit. LANXESS will acquire the primary accelerator
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BASF and Ineos have agreed to combine their global styrenics operations into a new equally owned joint venture (JV), Styrolution, whose combine sales will be in excess of Euro 5 billion /year. The new company will be based in Frankfurt and will be headed by Roberto Gualdoni, currently a BASF employee. Christoph de la Camp, the current CFO of Ineos Nova, will be the CFO. The companies expect the JV to be formed by mid 2011.
The operations that are being combined into Styrolution are the companies’ styrene, polystyrene, acrylonitrile butadiene styrene, styrenebutadiene block copolymers and other styrene based copolymers as well as copolymer blends. As of January 1, 2011, BASF’s styrenics activities will operate as a separate company, which BASF named ‘Styrolution’. Ineos will transfer its activities into the new Styrolution group, as part of the proposed JV with BASF.
continuing focus on environmentally suitable technologies and products,” said Yoshihiro Hasegawa, President, Harima Chemicals. Momentive’s IAR business posted $ 278 million in revenues last year. The portfolio includes resins and additives for the graphics arts, adhesives, aroma chemical, synthetic rubber and specialty coating industries. The deal, which includes 11 manufacturing sites, is expected to close in the first quarter of 2011. Hexion Specialty
Chemicals was renamed Momentive Specialty Chemicals earlier this year after private equity management firm Apollo Management (New York) merged Hexion and Momentive Performance Polymers.
the first quarter of 2011. Potash One officials said that the deal mitigates risks to developing and funding its Legacy Project, a greenfield potash project in Saskatchewan (Canada) with an estimated production capacity of 2.7 million metric tonne . The mine, currently in the feasibility stage, is estimated to cost about $ 2.5 billion. “K+S is a highly qualified global leader with over 100 years of experience in the potash industry and a market capitalisation of
close to $ 13 billion; it has the technical & operational depth and the proven marketing & sales expertise to successfully bring Legacy forward,” said Paul Matysek, President and CEO, Potash One. Norbert Steiner, Chairman, K+S, said, “The deal complements our growth strategy to expand our potash capacities. Further, the new potash assets together with our existing domestic potash sites will enhance our international competitiveness.”
business as well as the anti-reversion agent Perkalink 900. The acquisition of the primary accelerator business requires approval from the relevant antitrust authorities. “The transactions clearly underline our commitment to maintain a reliable supply of high-quality chemicals to the tyre and technical rubber industries,”
Leverkusen site of LANXESS
said Luis López-Remón, Head - Rubber Chemicals business unit, LANXESS.
WORLD NEWS EPC CONTRACT
FPC awards Uhde India contract for linear alkyl benzene plant
Farabi Petrochemical Co (FPC) has awarded Uhde India a contract to design and implement its linear alkyl benzene expansion SPECIALTY CHEMICALS
Showa Denko and Air Water form joint venture Showa Denko and Air Water have agreed to establish a joint venture (JV) for the production of specialty material gases for the electronics industry. Showa Denko will have 51 per cent stake in the new JV, Showa Denko Air Water, while Air Water will hold the remaining. Demand for specialty material gases has steadily been growing, centering on Asian markets, ANALYTICAL INSTRUMENTS
Agilent expands LC/MS portfolio
Agilent Technologies Inc has introduced the Agilent 500 Ion Trap LC/MS, a MS/ GREEN COATINGS
Dürr builds eco-friendly paint shop in China As a general contractor, Dürr, a mechanical and plant engineering group, is building a new paint shop in Nanjing for Shanghai SVW - a joint venture between the Volkswagen Group and the Chinese SAIC Group
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project in Al Jubail in Saudi Arabia. Uhde India will render project management, detailed engineering, procurement, inspection & expediting and pre-commissioning services for FPC’s second linear alkyl benzene plant in Saudi Arabia. The US-based UOP is the licensor for the project, while Foster Wheeler is the project management consultant. The project is scheduled for completion in December 2011.
In 2006, Uhde India completed rendering EPCM services for the first phase of the project involving a grassroots 1,20,000 tonne per annum (TPA) N-paraffin and 70,000 TPA linear alkyl benzene plant. FPC is amongst the leading manufacturers of linear alkyl benzene and N-paraffin, heavy and light white oils in the Middle East. For Uhde India, the award will further consolidate its pre-eminent position as a leading engineering consultant for linear alkylbenzene plants.
for use in the production of solar cells, semiconductors, LCD panels and LEDs. The JV will establish a production unit and launch a wide variety of new material gases. The two companies will take the products from the joint venture and sell them independently through respective sales channels. The JV will initially install a 40 million tonne per year hydrogen selenide (H2Se) production facility within the premises of Showa Denko’s Tokuyama plant at Shunan, Japan, and the JV will start
producing H2Se at the plant in June 2011. Showa Denko and Air Water aim to quickly strengthen their joint operations, pursuing the possibility of expanding the JV’s product lines and establishing plants at best locations inside & outside Japan.
MS solution for chemical analysis, foodand product- safety testing, and other industrial applications. The 500 Ion Trap LC/MS is claimed to be a robust and reliable analytical instrument that offers routine, affordable MS, MS/MS, and MSn capabilities. The system can be ordered and operated with the complete line of Agilent LC products. With the choice of many ionisation modes and scanning techniques the new 500 Ion Trap is a flexible system
that can screen, identify and confirm compounds in a single experiment. The new system has advanced features which can make it an ideal choice for routine analytical applications. “The 500 Ion Trap LC/MS system fits perfectly into the Agilent LC/MS product portfolio. It offers the flexibility of routine, affordable compound identification and quantification that is ideal for many labs,” said Ken Miller, Marketing Director - LC/ MS Division, Agilent Technologies.
(Shanghai Automotive Industry Corporation). From plant technology to paint application and on to the control systems Dürr is providing a complete paint shop for SVW. Since environmental issues are also becoming increasingly important in China, SVW is counting on Dürr’s EcoDryScrubber – an alternative system to wet overspray
separation, requiring neither fresh water nor coagulation chemicals.
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CW_Dec _2010_ Engg Expo_Tab-2_30
An invite that rewards as well...
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LEADERS SPEAK
“We foresee healthy market growth in the Middle East, Asia and Indian sub-continent” …says William Yau, Chief Executive Officer, Borouge’s Marketing Company - a joint venture between Abu Dhabi National Oil Company (ADNOC) and Austriabased Borealis. A veteran in the chemicals industry, he is spearheading Borouge’s aggressive global growth strategy, especially in the highly dynamic markets of the Middle East and the Asia-Pacific regions. In this interaction with Rakesh Rao, Yau shares his views on the evolving global polymer industry and emerging opportunities in this sector.
Performance of the global plastics industry The world polyolefins (PO) market grew at a moderate pace of 2.7 per cent in 2009 dragged by sluggish demands in the US and Europe. The global PO demand, comprising polyethylene (PE) and polypropylene (PP), reached 114 million tonne in 2009, compared to 111 million tonne in 2008. The PO markets of Middle East, Asia-Pacific, Indian sub-continent, Central Europe, and South American regions, where the impact of the financial meltdown was less as compared to the US and Europe, performed exceptionally well. China’s import of polymers achieved a record level in 2009, boosted by massive government stimulus.
Key issues before the plastics manufacturers At Borouge, the most important challenge is to keep major investment projects on track and within budget. Till date, we have been successful at this and our people are focussed & committed towards our goals. Naturally, building a world-class, cross-
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LEADERS SPEAK
cultural & empowered organisation is important for us, and we are ensuring that we have the best people to take the company forward. For us, meeting our growing number of customers’ needs is also paramount. The year 2010 was important for us as our major expansion project in Abu Dhabi and the related logistics hubs in Asia & manufacturing facilities in China came on stream.
Emerging trends & opportunities The global PO market is changing dramatically in response to the fast advancing industrialisation and urbanisation trends in the emerging markets, as well as improvements in global communications & trade liberalisation. Investments are increasingly focussed on feedstockbased or high-demand growth regions, such as the Middle East, the Indian sub-continent and the Asia-Pacific.
Market potential Growth of PO consumption will be mainly driven by the rapid economic development of numerous transition countries in the Middle East, AsiaPacific, Indian sub-continent, Central Europe and South America. As these regions move towards more consumerbased economies, plastics usage, in general, will increase. Investments in export-oriented plastics converting capacities in many of these countries will also help fuel PO demand growth. Packaging, infrastructure and automobile sectors will continue to be the main drivers for the PO market, while pipe and telecommunications will also register high growth.
Future plans of Borouge Today, Borouge and Borealis have the capacity to manufacture over 5.4 million tonne PE and PP annually. Focussed on value creation through innovation, we will ensure that our customers throughout the value chain around the world can rely on
our superior products and security of supply. To enhance and optimise our service to our customers specifically in the Middle East and Asia-Pacific, Borouge has established logistics hubs in Abu Dhabi, Singapore and China. We are working closely with our customers and the market to develop robust supply chains that will meet their needs. In China, Borouge has invested in a manufacturing plant in Shanghai for the rapidly growing automotive & appliance markets in Asia, and we have also expanded our sales offices. A second plant is being planned in Guangzhou. The Indian sub-continent is being fed from our logistics gateway in the Middle East, and we are looking at improving our services to our strategic customers in the infrastructure, automotive and advanced packaging markets in this very important region. Committed to development in the region, we are continuing to support the development of polymer competence in the Indian sub-continent with undergraduate scholarships already offered at the IIT - Delhi, and ICT - Mumbai. In addition, through our ‘Water for the World’ initiative with Borealis, we will contribute to the lack of clean drinking water and basic sanitation in areas of need. Currently, Borouge is supporting the implementation of pipe systems in Pakistan, following the floods in the region. To meet specific customer application demands and to lead the way in the development of the next generation of plastics solutions, Borouge is building an Innovation Centre in Abu Dhabi, which will be completed by the end of 2011. In 2010, we trebled our annual production capacity in Abu Dhabi to 2 million tonne, and an additional 2.5 million tonne per year is scheduled for completion by the end of 2013 to create the world’s largest integrated polyolefins plant.
The Indian subcontinent is being fed from our logistics gateway in the Middle East, and we are looking at improving our services to our strategic customers in the infrastructure, automotive and advanced packaging markets in this very important region. Business in India & growth plans As an importer into the Indian subcontinent, we face significant challenges in meeting the needs of our customers. However, we are committed to growing our business in India. With our valueadded approach, we have the right innovative and value-creating solutions for the Indian PO market, and we will continue to be a long-term partner to them - now and in the future. Today, we have a well-established operation in India with sales office in Mumbai and team of sales & support personnel covering all Borouge application areas. We have a strong reputation in the market as an innovative, high-value PO supplier. Having targeted India for future business growth, the company will build on its position in the market and will continue to invest in appropriate local resources to meet our expectations.
Outlook for the global plastics industry We foresee a healthy market growth in the Middle East, Asia-Pacific and Indian sub-continent. These regions are becoming the global sources of PE. For example, in China alone, demand for PO is expected to grow at 6-8 per cent annually for PE, and 10 per cent for PP, until 2010. By 2015, China’s demand for PE and PP is expected to grow at 4-7 per cent annually. Further, we are also confident about the growth opportunities for Borouge.
December 2010 | Chemical World
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FACILITY VISIT
DyStar India Pvt Ltd
Offering a rainbow of services Constant innovations in product and process arenas have catapulted DyStar to an enviable position in the market. It has many firsts to its credit when it comes to product development. Moreover, DyStar’s services to the textile industry through Colour Solution International (CSI) Studio and Advanced Academy for Development of Textile Technologists (AADTT) have consolidated its position further in the market.
Prasenjit Chakraborty
M
erger of textile dyes business by Bayer and Hoechst, two reputed companies of Germany, gave birth to DyStar in 1995. It received further momentum when BASF, another German giant merged its textile dyes business into DyStar. It grew consequently into a complete solutions provider to the textile value chain through a series of acquisitions starting from Colour Solution International (CSI), a global leader in the colour forecasting and standards business, Yorkshire Dyes in the US, two European companies in the textile chemicals - Rotta Group and Boehme Group - to Texanlab, a leading company in India in the area of testing. In 2004, DyStar was acquired by Platinum Equity of the US, and the ownership further changed hands in 2010. Currently, the
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company is owned by Kiri Holding Singapore Pvt Ltd. In India, DyStar has its head office in Navi Mumbai and its sales offices are located in Delhi, Bengaluru, Tirupur, Ahmedabad, Tarapore, Vapi and Chandigarh. Products available range from fibre to finishing for processing of cellulosics, acrylic, polyamide, wool, silk, polyester and textile printing. The broad range of auxiliaries varies from spinning & weaving, pretreatment, dyeing, printing, laundry to finishing and coating. In the endeavour to further consolidate its position in the market, DyStar has established a plant at Ankleshwar in Gujarat.
Ankleshwar facility The plant is situated in the heart of industrial belt and was commissioned in 2008. It has a capacity to produce 600 tonne per annum (tpa) of pigment preparations, 4,200 tpa of
FACILITY VISIT
specialty chemicals, reactive and other dyestuffs using state-of-the-art technology. The quality control laboratory is well- equipped with Infra Red (IR) dyeing machines, spectrophotometers, Karl Fischer analyser and other equipment to allow quick access for checks and obtain prompt results. “Not only do we ensure the availability of raw materials in the plant, we also ensure that the good quality of supplies we receive from vendors are being well-maintained in the spacious warehouse that is located right next to the plant,” says Rajesh Balakrishnan, President - South Asia, DyStar Group, and Managing Director, DyStar India Pvt Ltd. The warehouse has a section for finished goods, which operates daily to ensure quick and timely despatch, thus providing quality services to the customers. It is also equipped with a wastewater treatment (reverse osmosis technology) facility.
Plant set-up The plant at Ankleshwar is spread over 25,000 sq m and is designed to standardise dyes using state-of-the-art technology that consistently gives quality products. There are two dry powder mixing units capable of producing 3,000 metric tonne (MT) high-quality dyes per annum. “Both units are equipped with auto-filling and weighing machines to ensure accurate weighing and safe working under a dust-free environment,” claims Balakrishnan. Similarly, the plant has two pigment emulsion preparation units equipped with vertical pearl mill, dissolvers and homogenisers. The units are capable of producing 600 MT high-quality pigment emulsions per annum. It also has textile auxiliary preparation units, which produce 1,200 MT high-standard products per annum. The plant follows the best manufacturing concepts as per the global DyStar manufacturing policy. “Our dry blending under inert atmosphere ensures that the product quality is wellpreserved and it is done under utmost safe conditions,” says Balakrishnan. In addition, to get quick quality checks and prompt results, a well-equipped quality control laboratory is installed in the plant. Not only that, ColorXPT® (web-based expert colour-matching system) in the laboratory also ensures that evaluation of samples are accurate. “All raw materials and products pass through stringent quality checks, which ensure that we maintain high-quality standards,” asserts Balakrishnan.
Safety first DyStar Ankleshwar plant maintains a high standard of safety. The plant has a well-spread network of fire-fighting facility including fire pond, auto-operated pumping system, sprinklers and smoke detectors. It also has a back-up diesel
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FACILITY VISIT
Rajesh Balakrishnan President - South Asia, DyStar Group
In addition to ambitious growth plans and expansions driven by our entrepreneurs, external factors such as increasing costs in China, political uncertainties and other factors have further catalysed growth of the textile industry in India. generator ensuring uninterrupted power supply to the critical equipment. Besides, the plant has a liquid nitrogen storage tank with a vaporiser, which ensures that safe blending of dry powder is carried out under an inert atmosphere. “Dry powders are packed in autofilling and weighing systems so that a dust- free atmosphere is maintained and manual handling is at minimum,” adds Balakrishnan.
times, meet stringent quality standards as well as environmental specifications,” says Balakrishnan.
Breakthrough innovations & services The company has many firsts to its credit. DyStar is the first company to develop a luminous reactive dye for cotton. The company also claims that it is the first to introduce liquid indigo for manufacturing denim. Some of the process innovations from Dystar are Luft-roto plus with Thies (economical & environmentally sound cellulose dyeing concept), Innodye/Innovat with Brazoli (flexible jet dyeing concept for reactive and vat dyes), econtrol with Monforts
Product range DyStar offers its customers a complete range of dyes, auxiliaries and services. Its range includes Levafix®, Remazol®, Sirius®, Indanthren®, Procion®, Mikethren®, Caledon®, Dianix® Telon® Supralan® Isolan® Realan® Astrazon® Imperon® Acramin®, Jetex®, Sera®, Evo® and Lava® brands. “Diversity, creativity and innovative strength are the cornerstones of our success. We will ensure that we remain a reliable and true partner for our customers in the future. We also co-operate with our customers to reduce costs, shorten lead
DSI Lab
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Packing area
(economical and environmentally sound continuous dyeing concept), Eeectrochemical dyeing with Thies (new dyeing process for vat, sulphur, and indigo dyes offering ecological and economic benefits), digital printing (comprehensive ink ranges and service for the digital printing of textiles), etc. Besides the wide range of dyes and auxiliaries, the CSI Studio located in Navi Mumbai offers the designer community, international & local brands, retailers and students the opportunity to work with a wide variety of colour standards, options and allied services. DyStar’s Texanlab (textile testing laboratory), which is also located in Navi Mumbai, provides complete services across the supply chain
Finished goods warehouse
from yarn to fabric, garments, home textiles, dyes and chemicals. Another significant step from DyStar India is the launch of AADTT. It was launched in collaboration with Alok Industries Ltd to offer opportunities to textile technologists from partnering institutes to develop their knowledge & skill and a career in the textile industry. “To capitalise on the growth opportunities in India, further investments into manufacturing, launch of new products, especially in auxiliaries, further development of our services, supporting more institutes & students through AADTT and setting up a Global Finishing Competence Centre are few of our immediate targeted milestones,” says Balakrishnan. Elaborating on the textile industry in India, he says, “The textile industry in India is well-supported by the Textile Ministry and aided by the government. It is poised to take a major share of the world textile and garment trade.” He optimistically envisions a colourful future for this industry. “In addition to ambitious growth plans and expansions driven by our entrepreneurs, external factors such as increasing costs in China, political uncertainties and other factors have further catalysed growth of the textile industry in India. A visible trend towards value addition as well as a growing awareness towards better quality has offered opportunities to reputed players like DyStar to play a dominant role in the textile value chain,” concludes Balakrishnan.
SECTOR WATCH
It may be more than just a prophecy that the Third World War would be fought for the reason of water. The sooner the industry realises the importance of this invaluable asset, it will not only earn accolades and applause but also be an integral part in presenting a secure future for the generations to come. To achieve this objective, the Indian chemical industry will have to adopt eco-friendly strategies to better its water and wastewater management techniques.
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SECTOR WATCH
Mahua Roy
C
hemical industry, in particular, has been at the receiving end for having consistently added to industrial pollution. But, the recent years have seen the industry taking more responsibility to change the outlook towards this issue by using better and greener technologies for production. This coupled with an increasing investment towards effluent treatment methods, show the change in attitude the chemical industry is harbouring. Even the government has taken various steps to solve the problem of effluent treatment being faced by chemical manufacturers, especially small & medium enterprises (SMEs). It has established Common Effluent Treatment Plants (CETPs) to make matters simpler for the SMEs.
Benefits of CETP According to Dr Hari Reddy, Director - R&D (Asia-Pacific), NLC Nalco, “CETP is one of the Best Management Practices, where the effluent from several different industries can be treated at a common plant.” He further adds, “This is becoming an important concept for small-scale industries, which cannot afford effluent treatment in their facility.” The Ministry of Environment and Forests (MoEF) has taken due
Dr Hari Reddy Director - R&D (Asia-Pacific), NLC Nalco
CETP is one of the Best Management Practices, where the effluent from several different industries can be treated at a common plant. This is becoming an important concept for small-scale industries which cannot afford effluent treatment in their facility.
notice of this fact and been at the forefront of promotion of CETPs in the country. To minimise environmental pollution caused by SMEs, cleaner production technologies and formation of waste minimisation circles are being encouraged in India. The MoEF has initiated a financial support scheme for CETPs to ensure the growth of SMEs in an environmentally compatible manner. The provisions of the scheme for fund support are as follows: R State government subsidy: 25 per cent of project capital cost R Central government matching grants: 25 per cent R Loans from financial institutions: 30 per cent of project capital cost R Contribution from SMEs: 20 per cent of project capital cost The concept of CETP was adopted as a way to achieve end-of-pipe treatment of combined wastewater to avail benefits of scale-of-operation. In addition, CETP facilitates reduction of number of discharge points in an industrial estate for better enforcement, and also makes available the skilled manpower for proper treatment of the effluent discharged. The growing problem of wastewater treatment is being widely acknowledged by end-user industries as well as the solution providers of effluent treatment. Manufacturers agree that the Indian chemical industry is open to acceptance of sophisticated technologies in line with the stringent government policies and harbour a responsible conscience towards the environment as well.
Present scenario “With a revenue of around $ 4 billion, the Indian water and wastewater market is growing at 8-10 per cent. While this segment is highly fragmented & unorganised, it is likely to mature in the future with large-scale private investments in infrastructure projects which will support new technologies with Joint Ventures
Sanjay Choudhary Chief Technology and Sustainability Officer, Tata Chemicals Ltd
With a revenue of around $ 4 billion, the Indian water and wastewater market is growing at 8-10 per cent. While this segment is highly fragmented & unorganised, it is likely to mature in the future with largescale private investments in infrastructure projects. (JV) between Indian companies and leading technology companies globally. This will accelerate maturity and support innovations,” foresees Sanjay Choudhary, Chief Technology and Sustainability Officer, Tata Chemicals Ltd. The change in outlook can be seen quite visibly in the industrial scenario. Return on Investments (RoIs) are being given a priority while making decisions regarding effluent treatment. “The Indian chemical industry is open to accepting better technologies as long as there are established references for their usage in similar functions. The purchase decisions are now evaluating lifecycle costs of technologies and looking at the overall project cost as against the earlier custom of using capital costs as a primary basis for purchase decisions. This has increased the acceptability of the budding technologies. Between performance, safety and lifecycle costs, the balance of the average Indian customer is inclined towards lifecycle costs as against the developed countries where the tilt is significantly towards performance and safety,” says Paresh Vora, Senior Manager, Siemens Water Technologies. But, there is still a long way to go to achieve the desired level of acceptance by the chemical industry. “It is difficult to convey the value of
December 2010 | Chemical World
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SECTOR WATCH
an effluent treatment programme in monetary terms to the customer since it is not a direct revenue for the customer and many smaller industries never realise the hidden value of such a programme,” says Dr Reddy.
New concepts As Choudhary effectively describes the current scenario, “Effluent treatment in the last decade has moved from the traditional outlook of being looked at as a burden to that of realisation of risks and opportunities alike with increasing interest in recovery & cost reduction. It is emerging as an important sector of growth and investment. The persistent and ongoing work by technologists and researchers over the years has resulted in many innovative concepts and ideas. This can be summarised as the Reduce, Recover, Reuse approach.” To meet the changing needs of the industry, effluent treatment solution providers are putting in constant efforts to upgrade their offerings. “Due to the awareness of limited access to good quality water, stringent regulations have been imposed by the government on industries that limit the amount of fresh water that a plant can withdraw and the quality & quantity of the wastewater it can discharge. These regulations and scarcity of water have made the industries move towards the concept of Zero Liquid Discharge (ZLD) plant design
Paresh Vora Senior Manager, Siemens Water Technologies
The purchase decisions are now evaluating lifecycle costs of technologies and looking at the overall project cost as against the earlier custom of using capital costs as a primary basis for purchase decisions. This has increased the acceptability of the budding technologies.
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instead of disposing wastewater to the environment,” voices Dr Reddy.
K Chakravarthy Vice President - Water & Waste Solutions, Thermax Ltd
Zero discharge: A reality! ZLD is a wastewater recovery methodology for industrial applications. The scarcity of valuable freshwater resources, concerns about the environmental impact of industrial wastewater discharge and increasing regulatory controls make a compelling case for recycling & reuse. Efficient and innovative management of entire water cycles for industrial applications
Changing approach towards wastewater treatment R Approaching
the effluent management to reuse the treated water rather than to discharge it by meeting the regulatory limits in view of increasing constraints on availability of water and the cost of disposal
R
Utilisation of one industry’s effluent to treat that of another in an integrated complex or chemical industry clusters, etc, and build an environmental supply chain mimicking the nature’s biological supply chain
R
Production of commercially valuable products from the effluent before reuse or disposal
R
Adoption of process integrations & intensification methods and cleantech & greentech road maps by leading chemical producers Source: Tata Chemicals Ltd
are heading towards ZLD, allowing businesses to save money, reduce environmental impact and meet legislation for discharge. ZLD evaporator systems for concentrating liquid waste streams allow the user to recover distilled water from waste streams, including: R Boiler, scrubber or cooling tower blowdown R Demineralisation waste R Flue gas scrubbing wastewater
Water reuse allows communities to become less dependent on groundwater and surface water sources. Additionally, water reuse may reduce the nutrient loads from wastewater discharges into waterways. This will eventually help in reducing pollution and preserving the resources. R
Landfill leachate, oilfield, mine and plant drainage R Reverse Osmosis (RO) concentrate R Metal finishing wastewater Crystallising systems for ZLD reduce wastewater discharge and, in many cases, these can allow chemical manufacturers to capture valuable byproducts. Typically, an evaporator or RO system is used to pre-concentrate wastewater. Crystallisation or evaporation then produces water for reuse as well as recovering specific salts. Thermal evaporative treatments for industrial wastewaters eliminate the liquid waste streams from a plant and allow the recovery of high-quality water for reuse. In many cases, this can reduce plant water consumption by 10-90 per cent. Using ZLD systems, it may also be possible to capture valuable byproducts, which may be sold to offset treatment costs. The potential risks associated with plant waste streams are also reduced.
Recycling for a better tomorrow Water recycling is becoming a necessity in today’s world. Under constant threat of climate change, explosive population growth and wastage of water, there is tremendous pressure on this basic & valuable resource. While industrial growth and unplanned water utilisation for
SECTOR WATCH
C Manoharan Head - Refinery, Essar Oil Ltd
To fully utilise our resources, liquid effluent is fully treated so that it can be reused in the refining process. This treated water is mainly utilised as service water in refinery operations and as fire water make up. agricultural usage have depleted ground water levels in many parts of India, the growth of urban clusters have put pressure on the available water. Increasing levels of sewage and industrial effluents have created the threat of pollution. “Water reuse allows communities to become less dependent on groundwater and surface water sources. Additionally, water reuse may reduce the nutrient loads from wastewater discharges into waterways. This will eventually help in reducing pollution and preserving the resources,” opines K Chakravarthy, Vice President - Water & Waste Solutions, Thermax Ltd. Also, oil refineries, which are said to be the major contributor towards water pollution, are adding to their responsible side today. “Since our refinery is located in an arid region of India where rainfall is scanty and unpredictable, it is imperative that we make use of every drop of water that is sourced through the costly desalination processes. To fully utilise our resources, liquid effluent is fully treated so that it can be reused in the refining process. This treated water is mainly utilised as service water in refinery operations and as fire water make up. We are also installing RO plants, which will enable Essar to treat this water further, to the extent that it can be used as cooling tower make up and boiler feed water,” says C Manoharan, Head - Refinery, Essar Oil Ltd. Besides, Essar has developed a green belt and planted more that 3,00,000 trees covering about 25 per cent of its refinery area. It has also carried out mangrove plantations and coral transplantation at its marine facility in co-ordination with the forest department. An ultra modern marine and environment laboratory is also being developed by Essar to closely monitor the marine ecosystem in consultation with National Institute of Oceanography. Such examples set by corporate India pave the way for not only growth in GDP but also manifold in respect and recognition across the globe. The day is not far when the laudable efforts of the Indian chemical industry will be cited by many as an exemplary foundation towards a cleaner, greener, brighter and better tomorrow.
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INDUSTRY UPDATE
Ultrafiltration
Separation with precision Ultrafiltration (UF) is a separation process used in the industry and research for purifying & concentrating macromolecular (103 - 106 Da) solutions. Efficient UF systems utilise membranes, which can offer superior performance for the clarification of wastewater and process water. Though it is in the early stages of development, the scope of UF is growing beyond the conventional applications. Courtesy: inge watertechnologies AG
Dr G Arthanareeswaran
I
ndia has joined the league of fast-growing economies, giving impetus to the industrial development in the country. There has been a vast change in the attitude of people on modern aspects like growth, Gross Domestic Product (GDP), environment, consumerism, etc. The growth in the chemical industry contributes immensely to the country’s economy, which is increasing by the day. However, this growth comes with a price. Rising industrialisation has resulted in an increase in waste generation by industries. Treating these wastes is a big challenge before the industries. New technologies and processes are continuously being developed to provide a method for efficient and optimised waste treatment. One of the most widely used techniques for water treatment is ultrafiltration (UF). UF is a process for separation of particles of size in the range 20-1000 A°. Large organic & inorganic complexes, small bacteria, virus and various industrial effluents containing economically important byproducts fall in this size range. The UF technique is utilised widely in the chemical industry across India.
Technological developments UF is a pressure-driven membrane separation process for separating particulate matter
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from soluble components in a carrier fluid (for example, water). The UF system has larger pores than in nanofiltration (NF) and RO systems. Hence, UF is a low-pressure membrane process used to separate highmolecular weight compounds from a feed stream. For example, raw water used in the chemical industry is pretreated using methods, which can range from mere activated carbon filtration to more elaborate processes like coagulation, clarification, filtration, chlorination and activated carbon treatment. The UF system is now gaining increased preference over conventional pretreatment methods due to the following advantages: R Replaces multimedia filters and clarifiers R Consistent water quality R Smaller space requirements R Improves downstream RO performance and reduces RO equipment size R Chlorine compatible; high/low pH resistant R Chemical-free treatment Membrane processes are now preferred over ionexchange because, besides ion reduction, these aid in removal of organic material and micro-organisms. Also, these are continuous processes and do not require storage and handling of acids & alkalis for regeneration. India has a huge potential for the growth of UF membrane technology, as currently it is being used for only a few applications. The
INDUSTRY UPDATE
UF technique will enable the industry to provide the customers with reliable, state-of-the-art and cost-effective water reuse systems. With the country and the industry facing major challenges in the availability of water, UF technology can provide useful contribution to the international environmental cause, as well.
Aiding water treatment UF is a complementary process to RO where dissolved salts are not removed from water. Thus, there is no change in the chemical composition of the water treated. The three main applications of this type of water treatment are as follows: R Water production where TDS of feed water is within limits, but clarity & disinfection is required R As a pretreatment technique to RO systems, to enhance life of the RO membranes and protect them from fouling. It is a single-step
process that eliminates settling, sand filtration and polishing cartridge filtration R Water purification for producing sparkling, crystal clear, safe drinking water without using electricity, chemicals and ultraviolet rays In India, UF is used for pretreatment of water in RO systems, as oil/water separator in petroleum industry, and for removal of organic contaminants in dye industry (Tirupur, Tamil Nadu). It is also used for protein removal & recovery of chromium in tannery plants and various industrial applications. It is estimated that the need for advanced wastewater treatment in this sector will increase by approximately 18 per cent each year. Shortage of process water in most parts of the country is also driving the need for recycling of wastewater.
Growth potential Currently, the industrial growth data claims a 10 per cent year-on-year
growth, thus presenting a huge opportunity for the chemical industry. At the same time, environmental concerns are increasing in India. Hence, there is a rising demand for separation technologies to treat industrial effluents. The membrane treatment, especially UF, comes as the preferred answer. The application of ultra-filters in industrial processes is on the rise, and this is evident with the growth of companies involved in membrane technology. Several MNCs like Pall, Aquasource, Millipore/ Amicon, Whatman and Osmonics have commenced Indian operations in the last five years with extensive growth plans. GE and Ramky Enviro Engineers Ltd (REEL) have also started to supply UF technology to industries such as pharmaceuticals, textiles, automotive, heavy metals and tanneries. Advantages offered by UF technology translate into cost savings and more environmentally sustainable
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INDUSTRY UPDATE
processes. Although the main focus of membrane development seems to be on purification of water (brackish, wastewater, etc) to potable standards, membranes can also be used in several ways for separating macromolecules (ie, protein purification), in controlled release systems (smart polymers for drug delivery & other applications) and in membrane reactors for production & purification of pharmaceuticals and other bio-products.
Solutions to find There are several issues in the way to adopting UF technology: R Membrane compaction results in a reduction in flux with respect to time, and it is observed that 40 per cent flux is reduced within 1 hr of membrane application. It is important, as UF operates at a relatively low pressure (less than 150 psi) than RO and NF R Membrane polymer degrades under extreme conditions of temperature, pressure and pH or chemical solvents. The cellulose membranes have the highest susceptibility to degradation, while Polyvinylidene Fluoride (PVDF) membranes are the least prone R Membrane fouling is a big challenge. Unfortunately, membrane fouling rarely occurs with a single foulant, and the presence of various inorganic & organic foulants complicates the process. It also reduces the membrane
Reasons behind popularity of UF R Simple in concept and operation R
Modular and easy to scale up
R
Low energy consumption and typically athermal
R
Greater efficiency for raw materials use and potential for recycling of byproducts
R
Equipment decreased
R
Does not involve phase changes or chemical additives
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life with decrease in performance and burden on running cost R Based on the usages, as in case of dairy applications, membranes must be disinfected daily and sterilised before every application for pharmaceuticals. But, these treatments disturb the pore configuration and effectiveness of the membrane
Economics of operations Currently, UF is used in a wide range of applications in food & dairy, pharmaceutical, biomedical, biotechnology, pulp & paper and various chemical industries in the treatments/ separation operations of various effluent streams and wastewaters. The detailed design, operation and economics are completely dependent on specific applications. The extent of applications are governed by certain state regulations, which vary geographically. The UF membrane system involves installation of two components – pump assembly and membrane module. In terms of the expenses involved, the cost of a pump is directly proportional to operation size. However, membrane cost first reduces with operation size; hence, the overall capital cost for very small operations is high, but reduces drastically with increase in operation size to an optimum level. The operation cost is directly proportional to operation size, and about only 5 per cent change is observed for large operations. The UF technology may be used as a microfiltration replacement, as several processes that had initially adopted the microfiltration technique achieved better results with UF and also utilised it as a pretreatment step for NF/RO to enhance their operational life.
Market forecast India has vast scope for treatment/ separation operations of a variety of
Courtesy: inge watertechnologies AG
effluent streams and wastewaters, as currently only 2-5 per cent of this is treated successfully. At present, there are several segments of the chemical industry that use UF in India, which are at a nascent stage, for example, production of ultrahigh purity chemicals, water for semiconductor applications, biotechnology applications, etc. Therefore, one can expect a growth rate of over 20 per cent in the demand for UF treatments. Another major factor responsible for extensive growth of UF is the growing middle class in the country. A large fraction of intellectuals from this section have positive views related to the environment, the country’s future and the growing economy. The pollution control laws in the country are far more stringent today than what they were in the 1990s. There are endless incidents and examples in the support of growth of the UF technology. Many MNCs dealing with membrane technology consider India as their operational hub, with extensive growth plans for South-East and Middle-East Asia regions. Though the demand for UF will increase in the country, one will have to wait to see how fast will be the growth rate. Dr G Arthanareeswaran is an Assistant Professor in the Department of Chemical Engineering of National Institute of Technology, Tiruchirappalli. His research specialties are development of ultrafiltration membranes, process integration & membrane technology, and application of membranes for water treatment. Email: arthanareeg@nitt.edu
MARKET SCOPE
Membrane filtration
‘Sieving’ for a green future With increasing focus on quality and safety, coupled with strict regulatory norms, ultrafiltration is becoming an automatic choice for many industries. Over conventional treatment systems, ultrafiltration offers several advantages such as compact design, reduced cleaning, reduced replacement of the membranes and low overall life-cycle cost. Naturally, many industries have opted for the method; but a closer look reveals that water & wastewater segments continue as major application areas. Courtesy: inge watertechnologies AG
Prasenjit Chakraborty
I
ncrease in population is leading to drinking- water shortages across the world, with many regions having little or no access to fresh water source. Hence, companies are looking at alternative sources (like seawater, wastewater, etc) to meet their demand for process water. One of the preferred methods of filtration and separation in desalination processes is Reverse Osmosis (RO) system, which requires pre-filtration. The use of ultrafiltration membrane systems for water filtration protects the RO elements from premature fouling and extends the service-life of the RO membrane. This cuts down the cost of RO desalination systems and is thus more economical to install. In addition, the usage of ultrafiltration equipment prior to RO reduces the chemical requirements for system operation. “Ultrafiltration delivers superior water quality compared to conventional treatment due to the defined, very fine pore structure. It continuously delivers good filtrate quality independent of feed water quality variability caused by, for instance, seasonal changes,” says Bruno Steis, CEO, inge watertechnologies AG. He further
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adds that the membranes’ compact design translates into a smaller system footprint, which becomes increasingly important to plants with limited space for expansion. Ultrafiltration technologies - from the family of membrane filters are proving to be a boon to technologists, as it offers separation range of approximately 0.001 to 0.1 micron range (10 to 1,000 A0). Ultrafiltration, when used in combination with other techniques like RO or nanofiltration, is capable of separating even minute impurities and dissolved molecules. “By conventional filtration methods such as depth filtration (as in sand bed filter) or surface filtration (as in rotary vacuum drum filter), particles of up to micrometre sizes can be filtered. While in ultrafiltration (as also in microfiltration and nanofiltration), particles of even nanometre size range can be filtered. So, particles either in suspension or solution mode can be separated by using ultrafiltration process,” says M V Rao, Managing Director, Fenix Process Technologies.
A trend-setter In the case of ultrafiltration, water and wastewater will continue to be the major
MARKET SCOPE
application areas. However, the emphasis on Green Chemistry and clean technologies will see ultrafiltration being increasingly used for process applications in the bio-pharmaceutical, food & dairy, beverage, textile dyeing, paper & pulp, oil & gas and specialty & fine chemical industries. While it is being used in the developed countries since several years, its demand is slowly increasing in the emerging economies. There are growing references in China, wherein the ultrafiltration systems are being used in RO plants for pretreatment during desalination process. According to Steis, majority of users in life sciences, pharmaceutical and Active Pharmaceutical Ingredient (API) are well-introduced to ultrafiltration in process purification/fractionation along with ion-exchange processes and other membrane technologies like nanofiltration. Steis says, “Ultrafiltration and nanofiltration are being increasingly used in thereupautic proteins, peptide chemistry and oncology, which are high-value products being developed by many Indian companies.” Of course, the process of adoption of such processes is still in the nascent stage in India. “Ultrafiltration has not yet become popular in the Indian
Bruno Steis Cheif Executive Officer, inge watertechnologies AG
Ultrafiltration delivers superior water quality compared to conventional treatment due to the defined, very fine pore structure. The membranes’ compact design translates into a smaller system footprint, which becomes increasingly important to plants with limited space for expansion.
chemical, pharma or bio-pharma industries. In the bio-pharma sector, its usage has begun but will take a long time to attain maturity,” opines Rao.
Maintenance challenges While ultrafiltration offers numerous opportunities in filtration & separation, maintenance is an issue that requires immediate attention. Rao says, “Achieving high flow-rate from a single unit is difficult. A variety of many identical ultrafiltration systems is used together to attain a reasonable industrial flow-rate. As the units of these systems are located close by, servicing or maintenance requires isolation of the entire lot.” Because membranes are of a single size, uniform diameter circular pores of straight-line configuration cannot be manufactured. Available membranes invariably get clogged by the solute/particle, which cannot be cleaned completely by backwashing, and therefore on prolonged use the membrane, even if it is mechanically not damaged, has to be replaced. Looking at the intensity of R&D in this arena, it seems that challenges related to membrane will soon be overcome.
Potential unlimited The membrane-based ultrafiltration is gaining importance in the market with rapid progress being made in material science research that is leading to the development of new materials used in this membrane. “High-quality (narrow-range pore size distribution, high strength, low fragility, chemically more inert) membranes are available at increasingly low cost, and consequently the usage of membrane processes using osmotic or externally applied pressure are increasing,” asserts Rao. Looking at the potential of membranes, different companies are coming out with innovative products making membrane-based ultrafiltration
M V Rao Managing Director, Fenix Process Technologies
High-quality (narrow-range pore size distribution, high strength, low fragility, chemically more inert) membranes are available at increasingly low cost, and consequently the usage of membrane processes using osmotic or externally applied pressure are increasing. more popular in the market. For example, inge watertechnologies AG’s membranes made of a modified, robust polyethersulfon (PESM). “The membrane’s patented Multibore® structure combines seven individual capillaries in a composite, resistant form. This honeycomb-like arrangement provides extraordinary stability, thereby precluding breakage of fibres,” claims Steis.
Exploring opportunities If the ultrafiltration membrane producers introduce more robust materials, wider chemical compatibility, lower prices to meet the technical and commercial needs of the Indian chemical industry, ultrafiltration will become the technology of choice. Increasing pressures from the green lobby and a proactive Ministry of Forests and Environment will be another growth driver for the ultrafiltration market. A good number of Indian membrane specialists at the leading government research laboratories as well as private players are developing ultrafiltration technology. This is likely to further bring down costs and increase viability to use this technology in the chemical industry. “So, it looks like an exciting and good future for the ultrafiltration technology,” concludes Steis.
December 2010 | Chemical World
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COATINGS CORNER
Methyl-methacrylate shortage
Facing the new reality Methyl-methacrylate (MMA), one of the key raw materials used in paints & coatings, has lately witnessed price escalation due to shutting down of some of the plants, and high demand from Asian countries. From the end-users’ perspective, the paints & coatings industry will have to compete for MMA with other sectors like LCDs, electronic equipment and automotive, which are experiencing high growth. Photo
DINODIA
Dr Mosongo Moukwa
S
ince May 2010, the world has been experiencing a shortage of MMA. This is because of shutting down of production facilities for economic reasons in Western countries and strong demand in Asia, particularly in Liquid Crystal Displays (LCDs) & other electronic equipment, automotive and mobile phone industries. The global capacity utilisation was 75 per cent in 2009, down from 81 per cent in 2008. MMA comsumption is estimated to have decreased by 6 per cent in 2009 from 2008. A worldwide growth in demand of 4 per cent/year during the past few years, combined with ongoing tight global supply and a rise in feedstock costs have prompted a bullish response from MMA suppliers. Downstream, this has affected the paints & coatings industry. Scarcity has bolstered prices. The demand is rising with global utilisation rates expected to gradually increase to at least 80 per cent by 2019. A growth rate of 5.1 per cent/year is predicted till 2014. However, some of the main engines of this recovery are also LCDs and electronic equipment in Asia. The paints & coatings industry will be competing with these industries for MMA.
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Prices increased from levels of $ 2,2502,300/tonne Cost and Freight (CFR) South-East (SE) Asia during mid-May in iso-tanks to around $ 2,430-2,480/tonne CFR SE Asia in mid-August for iso-tank cargos. Bulk MMA prices jumped from $ 2,130-2,180/tonne CFR SE Asia to $ 2,300-2,350/tonne CFR SE Asia during the same period. Downstream MMA derivatives, such as emulsions and acrylic cast sheet are facing huge difficulty passing on their costs.
Major applications MMA is a key intermediate chemical, due to its ability to undergo polymerisation and co-polymerisation. Polyacrylates, a family of clear and relatively durable thermoplastics, are the major source for the consumption of MMA. Today global consumption of MMA exceeds 3.7 million metric tonne (MT) per year, of which more than two million tonne is for MMA polymers. The other primary product of this industry is crude methacrylic acid (crude MAA), which is produced by similar technology but often in separate plant units. Production of crude MAA (for usages other than MMA) is around 20 per cent of the total production of MMA. Most applications of MMA monomers are through pure or almost pure homopolymers
COATINGS CORNER
(PMMA), a clear thermoplastic, which offers outstanding transparency and weather resistance. Within the PMMA consumption categories, the largest is for cast and extruded transparent acrylic sheet (PMMA sheet). Acrylic sheet is used for glazing, lighting, signage, displays, sanitary ware and miscellaneous applications. Its largest markets are in optical components of LCDs, mobile phone screens, outdoor sign boards. Over 80 per cent of MMA consumption is accounted for construction and automotive industries and by original equipment manufacturers. As shown in Figure 1, the global consumption of MMA in 2009 was estimated to be distributed as follows: acrylic sheets (35 per cent), moulding & extrusion (19 per cent), surface coatings (20 per cent), and others (26 per cent). By far, the largest emerging application of acrylics has been in LCDs and the enormous current & projected growth of large LCD screens for home theatre has been a major driver for MMA expansions, especially in Asia, where all the LCD manufacturing market now concentrates. The anticipated demand has been responsible for a spate of recent announcements for planned capacity addition by Lucite-Mistsubishi Rayon, Sumitomo, Degussa, etc. If this demand is not realised, there could be a risk of an MMA over-supply for years to come. The current trend, however, shows that LCD home theatre is replacing conventional CRT TVs at a much faster rate than anticipated.
MMA KTE 1996-2001 Global: 5% Asia: 8%
3000 2500 2000
2001-2006 Global: 6.5% Asia: 10% Europe: 5%
1500 1000 500
80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 Source: Lucite International, April 07, Freeflowmarket
Figure 2: Global consumption of MMA
MMA in paints
Surface coatings are the next largest consumer of MMA, for industrial solvent-based systems and increasingly, for water-based acrylic dispersions for domestic & industrial use. MMA provides a hard, glossy component in paint resins, where it is often combined with other acrylate and methacrylate monomers to form copolymers with appropriate properties, both for aqueous dispersion (latex) and solvent-based (acrylic lacquers & enamels) surface coatings. Non-acrylic co-monomers with MMA are also important in surface coatings, like the acrylic urethanes. Solvent-based systems were developed first, but the aqueous dispersions are now much more important, accounting for 75-80 per cent of MMA used in surface coatings. MMA is used in water-based acrylic dispersions for exterior masonry and wood coatings & semi-gloss emulsions for interior decorative coatings. These resins are essentially co-polymers of MMA, other methacrylates Acrylic sheet for glazing, fabrication, & acrylates, and 35% signs, lighting and sanitary ware comparatively low levels Moulding/extrusion compounds 19% automotive, medical and optical of acrylic acid &/or MAA Surface coatings, acrylic latex, 20% lacquers and enamels to provide hydrophilic Emulsion polymers, adhesives and components. Vinyl 7% polishes resins compete in these Impact modifiers and processing aids for 12% rigid PVC window and other profiles areas but do not match Mineral filled sheet, Corian acrylics for gloss and 5% (DuPont trade mark) weatherability. Demand Other polyesters and transesterification 2% growth for water-based Source: Lucite International acrylic paints depends Figure 1: Key application areas for MMA to some extent on new
building activity, but it is also sustained by maintenance usage & by increasing reluctance to apply solvent-based surface coatings on environmental grounds. The use of MMA in industrial coatings (trade paint) is primarily in the form of solvent-based acrylic resins. There is a growing usage of acrylic water-based industrial coatings. The total consumption of MMA for industrial surface coatings has been falling with the move towards high-solids and powder coatings, where polyesters are the preferred resin type. Original and refinishing acrylic topcoats for automobiles are still slow-growing markets for MMA.
Growth in Asia Global consumption of MMA has risen at 4.75 per cent CAGR between 1980 and 2006. However, rapid growth has been witnessed in the recent past. In 2008, Asia accounted for more than 50 per cent of global consumption of MMA. Its share is projected to rise further. It is estimated that the current capacity in Asia totals 1.8 million MT, expected to increase by 2,60,000 MT in 2011 (Figure 2). Demand in the US and Europe is expected to remain stable. In the long term, consumption of MMA polymers will be more in Asia with an expected growth of 5 per cent CAGR. The key drivers for the strong MMA demands are: LCD TVs and other electronic equipment, automobiles and mobile phones. LCDs and other electronic equipment: Growth in MMA
December 2010 | Chemical World
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COATINGS CORNER
Europe 6,70,000 tonne Q Mitsubishi (31%) Q Evonik Q Arkema
Asia 21,00,000 tonne Q Mitsubishi (41%) Q Sumitomo Q LG Q Asahi Kasei
USA 9,90,000 tonne Q Dow Chemical (48%) Q Mitsubishi Q Cyro
Q Q Q
One player accounts for 40% share of installed capacities in each of the three regions Combined share of top three players is in excess of 70% Asia is expected to account for more than 50% of expected global capacity of 3.8 million metric tonne by end of 2010
Q Q
Mitsubishi Rayon has become the global leader after the acquisition of Lucite in 2009 Mitsubishi Rayon will account for 37% of global capacities by the end of 2010. Its share is likely to increase to 42% by 2013 after its plant in the Middle East becomes operational Source: Asian Paints
Figure 3: Suppliers are highly consolidated in all three major markets
consumption due to LCD TVs is mostly enjoyed by Asia, with Japan, South Korea & Taiwan being major manufacturing hubs for LCDs. LG targets approximately 22.5 million units in 2010, an increase of around 6 million units (about 40 per cent) over 2009. Most of the demand for LCD TVs is emanating from emerging economies. Estimates suggest that demand for MMA is currently only 75-80 per cent of potential demand because of the economic downturn. If true, this can lead to fast-paced growth in the consumption of MMA. Automotive: The automobile industry in Europe is going through tough times as production is expected to drop by 25 per cent, because of the economic downturn and credit crunch. Overall in 2008, 18.4 million vehicles were produced, down 7 per cent in 2007. It is estimated that the overall vehicle production in 2009 has dropped drastically. In Asia, auto sales is expected to grow at more than 10 per cent CAGR till 2012. This may compensate for subdued growth in other regions. Most of the growth in volumes has been coming from developing countries. PMMA-led exports from South Korea surged 174 per cent year-on-year, as flat screen monitors for television and computers grew in popularity aided by
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strong demand from China and a slight recovery in global consumption. Demand for PMMA for automotive applications has also been on an uptrend, led by China, where car production and sales have remained buoyant despite the global economic slump.
Asia is the largest consumer of MMA, with its current installed capacity of 1.8 million metric tonne and an expected increase of 5,00,000 MT by 2014. Consolidation of suppliers Suppliers are highly consolidated in all three major markets (Figure 3). Asia is the largest consumer of MMA, with its current installed capacity of 1.8 million metric tonne and an expected increase of 5,00,000 MT by 2014. Mitsubishi Rayon accounts for around 40 per cent share of installed capacities in each of the three regions. It has become the global leader after the acquisition of Lucite in 2009, accounting for 37 per cent of global capacities by the end of 2010. The combined share of the top three players, Mustubishi, Dow and Evonik, is in excess of 70 per cent.
The world’s largest MMA plant (2,50,000 MT) is planned by SABIC along with Mitsubishi Rayon. The plant will be a part of a much larger chemical project, which with its low input & energy costs, will change the market dynamics. SABIC and Mitsubishi Rayon have agreed to set up a joint venture (JV) to manufacture materials used for cars, in a bid to compete with the US and European rivals including BASF. SABIC added a network of factories, manufacturing resins and thermoplastic sheets used in cars, roofs and lighting when it bought General Electric’s plastics unit in 2007 for $ 11.6 billon. The JV aims to produce specialty chemicals at a low cost and then selling the products in Asia.
Demand on the rise The availability of MMA in the paints & coatings industry is dictated by the demand of LCDs & electronic equipment, automotive & mobile phones industries, and this growth is taking place in Asia. The rules of supply and demand are dictated by the growth in these industries, as consumption of MMA outside paints and coatings has been growing at a rapid rate. Given the status of various growth drivers, suppliers in the Asian region may soon run out of capacity. Asian demandsupply situation is likely to remain tight despite over-capacity in the US, as hardly any supplier from this country has entered Asia. In India, domestic capacities of MMA & PMMA are limited, thus for many companies, there is a need to import to satisfy their demands. 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
Fall arrestor
Prime requisite for safe landing The manifestations of falls could be serious injuries, disabilities (full/partial/ permanent/ temporary), chronic ailments/illnesses like slip disc, brain haemorrhage or even fatality. A duly worn device of appropriate design, standard, quality and usage comfort is the only solution when the fall occurrence is imminent and inevitable. This article is an attempt to revisit the nuances of such vital personal protective equipment that can safeguard us. Courtesy: Gorbel Inc
K N K Murthy
M
ost of the times, people follow both proactive and/or reactive precautions while engaged in any type of work at heights or elevated locations. Still, fall incidents occur intermittently at buildings, construction sites, factory installations, repair/service shops, manufacturing units, material handling zones, overhead works, to name a few. A number of personnel are engaged in jobs ranging from apparently ‘simple & normal’ duties like changing an electrical bulb at the ceiling level to painting of a tall chimney. It has been logically inferred that an impact from only a 4-feet deep fall can be too serious or, at times, even fatal. In order to circumvent such eventualities, time-tested and fail-safe fall arrestors are readily available now-a-days. These can be broadly classified into two groups – pre-fall arrestors (exclusively preventive &
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engineered) and post-fall arrestors (add-on safety gadgets). Pre-fall arrestors include duly designed, constructed and regularly serviced/maintained devices such as: R Strong, load bearing and duly tested/ certified platforms/scaffolds, access stairs, ladders (portable as well as permanently installed), etc R Anchor supports at top and bottom R Hand and leg rails R Toe guards R Slip-resistant flooring R Half circle enclosures around tall (fully vertical) fixed ladders At the same time, post-fall arrestors come in two categories – passive and active.
Passive fall arrestors Safety nets are those that are commonly observed in circus trapeziums. In professional safety terminology, this is also known as
SAFETY ZONE
‘personnel nets’. These are used in large and open areas below the work locations like bridge constructions, long-term structural projects, etc. These provide protection against fall depth of up to 8 m below the work area and where the use of any other fall arrestors of active type is not feasible. The main advantage of using a net is that, no specific worker training is warranted. There are specific Indian and equivalent overseas standards applicable for the design of such nets. As a thumb rule, the mesh openings must not be larger than 15 cm. The net must be placed nearer to the work area, not below than 8 m (except in case of bridge construction where the highest work level could be measured from the lowest part of the bridge). And, periphery of the net must extend laterally outward of the structure under construction by atleast 2.4 m. The net must be
field-tested by dropping a 181-kg sandbag from a height of 8 m. The above-mentioned guidelines are as per the Occupational Safety & Health Administration’s (OSHA) regulations of the US.
Personnel nets are used in large and open areas below the work locations like bridge constructions, longterm structural projects, etc. These provide protection against fall depth of up to 8 m below the work area.
Another type of pre-fall arrestors is debris net, which is designed to catch falling trash such as dropped tools, foreign objects, falling concrete lumps and similar construction waste
materials. The strength and size of the mesh must be sufficient to catch or contain the estimated weight/ shape/size and impact of the objects likely to fall. Popular net sizes range from ¼ to ½ inch (6-8 mm) mesh. To catch large/heavy as well as light objects, the smaller mesh nets can be used in conjunction with larger mesh and stronger personnel nets. These net systems can also be used to catch personnel as well as debris. In this case, personnel nets can be deployed in conjunction with debris nets. The nets must be kept clear of debris to ensure the safety of any falling worker. In addition, there must be a readily available system to rescue the fallen worker from the net.
Active fall arrestors Popularly known as safety belts, these constitute a full-body harness and lifeline assembly. The latest version consists of a desirable, recommended
December 2010 | Chemical World
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SAFETY ZONE
Table 1: An indicative chart on important components of a standard and well-designed fall arrestor system & corresponding safety features as per OSHA guidelines
Component Safety feature Harness encompassing the torso (trunk) of human Designed to distribute the fall impact force over the shoulder-to-thigh area. body and attached to other parts of fall arrestor The generally accepted and optimum free fall distance is 0.6 m mechanism; fabric to be used is nylon/polyester R Positioning device should restrict free fall of less than 0.9 m R Be secured to an anchorage capable of supporting at least twice the potential impact of a person’s fall or 3,000 lbs, whichever is greater R Snap hooks should be a locking type designed to prevent disengagement Body belt of the same by ensuring good contact between snap hook and connecting member R Should be inspected prior to each usage for wear & tear, and the defective component should be duly replaced Portable, self-contained device fixed to an anchorage point above the work area is recommended. It is directly attached to the body harness. The line Lanyard (a short flexible rope, strap or webbing extends from the device, because movement distance increases and retracts connecting the wearer to the anchor) and as the person moves closer. When a fall occurs, the centrifugal locking retracting lifeline device mechanism is activated, preventing the fall. This device is ideal for usage on sloping roofs and angular structures. The extension limit varies between 2 and 90 m according to standard specification or customer demand Horizontal lifeline, an anchoring cable R Adequate degrees of slack - 227 kg per worker strength where falls up to 2 m are anticipated connecting to the retracting lifeline device, provides sliding facility, as the person is required R Free movement facility between 6 and 8 m of sliding distance without the need for detachment to move laterally Drop line – a vertical lifeline that extends from 16 mm diameter for nylon and polyester fabric; 24 or 9 mm diameter an independent anchorage point and to which for steel cable (depending on the material specification/quality), with a a lanyard is attached using a grabbing device minimum breaking strength of 2,449 kg – fabric could be nylon or polyester or steel Bolts, shackles, D-rings, snap hooks and metal links, which connect parts of the lifeline. About 1,800 kg static tensile strength is recommended. Hardware components These must conform to relevant Indian or equivalent overseas standards for reliability, integrity and strength and fully reliable optional feature of self-actuating/immediate stoppage of the ‘slip down movement’ of the lifeline, once it is engaged in case of an accidental slip/fall of the personnel, similar to the seat safety belt provided in automobile vehicles.
Rescue system Descent devices permanently installed or immediately available at workstations such as overhead crane cabs can be effectively used for bringing down injured personnel to the ground level. Collapsible cradles are snap-on accessories that may be used for cramped spaces in crane cabs and towers, but rigid stretchers must be made available to rescue personnel with bone injury/damage. Rescue workers can be brought down
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into confined spaces through lifelines to locate casualties, lift them and bring out safely. External actuated air winches can also be applied for such rescue work.
Better be safe than sorry There must be a well-formulated management policy on fall arrestor compliance – for normal work and emergency rescue actions. People must be adequately trained and demonstrated to use different types of fall arrestor mechanisms. Appropriate motivational schemes including enforcement routines must be in place, including ‘permit-to-work’ procedures. The equipment must be thoroughly maintained, serviced, certified and preserved to ensure ‘ready-to-use’ condition all the time.
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 is also a visiting faculty for industrial safety diploma courses and an accredited auditor/trainer for MGLI’s industrial assignments. He has done pioneering works in various aspects like hazard identification, risk assessment, safety audits/inspections/surveys, training, emergency preparedness planning, selection/development of need-based safety appliances, community awareness programmes, quality/environment standards (ISO), accident investigation/ analysis, etc. He can be contacted on mohanaknk@yahoo.co.in
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PRACTICAL TIPS
Project management
A practical approach The word ‘project’ can be used to describe an endeavour in which a number of tasks are performed to accomplish a particular objective. In usual context of project management, projects are undertaken by an organisation to achieve business objectives such as engineering, mechanical/ construction services or research for new product development. Large-scale turnkey can be managed by effective use of tools & techniques and team management.
Deepak Makhijani
I
n today’s scenario, there is a greater focus on managing projects in a short period within the budgets. Managing a project is different from managing a steady-state organisation. While a construction project has a distinct lifecycle, with a beginning and an end; a steadystate organisation runs continuously. Effective project management requires a clear concept and presence of an efficient project group within the organisation. The most important ingredients of project management are compatibility in interpersonal relations and clarity in mutual understanding & communication. Individuals involved in a project must clearly know what their responsibilities are, and also what is expected of them. The collective output of the people within an organisation in the form of expertise, experience and working system when seamlessly integrated, vastly adds to the efficiency of a project. Transforming the business need into a physical set requires efficiency & effectiveness of a series of processes, tools & techniques, and most of all, skills & experience. Together these culminate in what can be called World Class Project
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Management (WCPM). This requirement starts with the early identification of opportunities & business drivers and evolves into planning & execution. Project management is nothing but human management. The team leader (Project Manager) has to set the objectives of the project and align the team members to the daily targets. There is a human factor, which is critical and should be considered while the team members are assigned their roles and responsibilities. The team leader has to see that the members are assigned roles in line with their skill sets and are convinced about their job function & daily targets. Each team member has an established role and is held accountable for execution, while following the rules & regulations. This takes much of the guesswork out of executing the plan and establishes efficient & effective method to manage a project, regardless of the time constraints.
The Indian scenario In the current market scenario, most of the projects have tight schedules, and there is a need for effective team management. The local labour problems are a major hurdle in the execution of the projects. The petrochemical
PRACTICAL TIPS
companies have to comply with regulatory requirements such as Euro IV to meet the fuel emission norms. The pressure is on completing the project within the timeframe, and meeting the regulatory requirements. The cost reduction can be met by better product design, innovation & differentiation in application development and mobilisation of the available resources effectively to develop the product in minimum cost & time limits.
Impediments on the way Project management involves a series of changes. There are a lot of hurdles and hindrances in terms of successful completion of a project. It is to be noted that no project is ever completed on time & within the budget, and with the same staff who started it. Every new project taken up should support the respective company’s business goals. A project manager should always keep in mind that the project purpose
statement one wrote and understood will be seen differently by everyone else. Usually, the participants of the project are involved in the requirements of their department, and fail to concentrate on obtaining the companywide view for the project, which results in delay of the project commencement or unsuccessful completion. Some of the main challenges are: Inappropriate capabilities: Quite often, companies are required to take on a project without adequate manpower and/or expertise & people who do not have the necessary skill or motivation. This makes it difficult for project managers to get such people to perform tasks and deliver the project on time. Anxiety to grab business: In many projects, companies blindly accept terms from the customers, especially in relation to deadlines. As a consequence, people are forced to stay and work extra hours. As soon as the project development stage is over, some
people may withdraw from the project & the system test and implementation phase is affected due to lack of projects. Thus, the ‘hangover’ from the completed project remains unresolved. Manpower planning: People are suddenly pulled out of the project because their skills are required in some other projects. The issue is handled by training a junior level person as a backup. This arrangement is not always satisfactory and the customer sometimes expresses dissatisfaction about the back-up person’s quality of work. Insufficient training: Fresh recruits are often put on a project straight away. Quite often, people assigned to a project do not have the requisite training and lack expertise to play the roles they need to do. In addition, they have to interact with the customers without adequate understanding of the company values, vision, philosophy and other essential details.
December 2010 | Chemical World
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PRACTICAL TIPS
Top-down decision making: This is seen as a major hurdle, because team members do not buy into the ideas that are handed over to them. The big picture is not passed down and they are often unable to see how their portion of the work fits into the overall scheme of the project. The above challenges can be encountered with breakdown of the project into manageable tasks, anticipating the issues and pre-empting these with well-thought of actions. However, it is true that no project can be completed without encountering challenges and areas of issues. As Wolf’s law states – ‘It is not that things will necessarily go wrong, but rather that they will take more time and effort than you think if they were not to go wrong’.
A case study The following case study demonstrates the use of effective management techniques in a petrochemical company that undertook to comply with Euro IV norms. The project involved capacity expansion of the refinery. The project was at a location where the local labour problems are a major hurdle. The project had completion time-schedule of 10 months, and involved supply, installation, testing & commissioning of instrumentation works. The installation time-schedule was around six months and included impulse-piping works that required highly skilled welders and fitters. This
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was not an easy job knowing that the project was in a location where sourcing of local labour was expensive. The team leader had to assign the team members individual responsibilities and motivate them to complete the project within the time-schedule.
Challenges can be encountered with breakdown of the project into manageable tasks, anticipating the issues and pre-empting these with wellthought of actions. Project management is about managing people and it is important to keep people motivated and in line with the job responsibilities assigned to them. Technology and modern tools & techniques such as Microsoft Project/ Primavera 6 serve as drivers, however the key enabler is the spirit and motivation level of the team members, which may not be up to the mark. However, it is important to keep to optimal level and the same will be the key factor in the successful completion of the project. The team leader took note of the same and kept the team members charged up all the time as well as provided the required motivation by giving them incentives. The project plan was made and daily targets were assigned to the team members based on the daily targets;
and the actual progress v/s target was monitored. The shortfall due to constraints in project execution such as shortage of material/absenteeism of skilled manpower was monitored and the same was reported to the contract manager to make the shortfall good by arranging for additional manpower. The sub-contractors were motivated to complete the daily targets by working for extended hours by being offered suitable incentive schemes. A temporary shed was constructed to house the prefabrication of impulse/structural works. In order to minimise the burden of local labour, prefabrication of stanchion pipes/JB supports was given to a workshop outside the refinery. The customer/consultant was updated about the non-availability of work fronts and constraints faced for example, nonavailability of work permit was brought to their notice in the daily meetings. The customer took note of the requirements and provided the necessary help & cooperation to the contractor. The areas of concern such as nonavailability of tapping points/structural supports for tray installation were brought to the kind notice of the customer so that they could direct the other contractor to provide the work fronts. The contractor was able to successfully complete the project to the customer satisification and within the time schedule. Project management is a challenging task. But the above example shows that, any project can meet the time line & customer requirements, with proper team management and effective communication with the client/consultant. Deepak Makhijani is the Proprietor of Geeta Consulting Services. As a consultant, he has over 10 years of experience in execution and estimation of automation projects. He has successfully completed various oil & gas and petrochemical projects during his tenure with L&T Ltd and Siemens India Ltd. Email: geetaconsulting45@yahoo.in
PREVIEW
Mumbai | 17-19 Feb, 2011
Taking manufacturing to the next level With fast-paced changes taking place in the manufacturing sector, the need for automation cannot be undermined. With India catching up on the adoption of automation solutions, manufacturing will soon witness a dramatic change in the way it is being operated today. Aimed at offering automation solutions for the entire manufacturing fraternity, HiTech Automation Show is designed to provide a fertile ground for GenX manufacturing.
Shibani Gharat
W
hat are the few things that a future factory will have and must have beyond doubt? The answer lies in automation! It is automation that will drive manufacturing, growth, productivity, quality, innovation and technology. Supporting this, R Narayanan, Head – Discrete Automation & Motion Division, ABB India, avers, “Automation will be vital in helping manufacturing companies achieve economies of scale, global competitiveness and meet stringent quality/safety standards. Automation products, systems, solutions and services are designed to improve customers’ business, centered on increasing industrial productivity, while lowering environmental impact.”
Minimal human intervention The introduction of automation in Indian manufacturing has dramatically changed the speed & efficiency of production and delivery systems for the industry. It is a smart muscle that smoothly integrates and executes activities in an industrial environment. “An ideal factory in the future will have minimal human intervention, besides being increasingly environment-friendly,” says Shekar Viswanathan, Deputy Managing Director, Toyota Kirloskar Motor. Industrial automation has replaced human beings across industries. Automation proves to be an apt solution for jobs that require precision, speed,
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endurance and reliability. Traditional applications of industrial automation include material handling, assembling, painting, welding, packaging, palletising, product inspection and testing. Industrial robots are used in a diverse range of industries including automotive, electronics, medical, food production, pharmaceutical and machinery.
Increase in demand High efficiency and productivity have taken centrestage in today’s manufacturing scenario. To match the demands of increased quality at lower cost, several industries are opting for automation. “The demand for ERP/MIS integration with factory floor, which was more of theory, is fast becoming a reality. Process industries like steel, cement, refinery, petrochemical, power, etc, and discrete manufacturing industries like automobile, pharma, construction, food & beverage and rubber & plastics will continue to drive demand for automation,” says Narayanan. “Automation is the key to success. Typical automation capabilities, relative to the use of technological interventions such as advanced planning, measurement, robotics and MES, continue to grow. The focus of the emerging trends will be on reducing variability, increasing velocity & visibility, guaranteeing full compliance and increasing collaboration,” asserts Frank Khoshnoud, Sr VP & Head – Manufacturing, Retail & Distribution, Patni. Looking at such promising prospects, Network18 Group will be organising
HiTech Automation Show from February 17-19, 2011, in Mumbai, concurrently with HiTech Material Handling, under the umbrella show HiTech Manufacturing. HiTech Automation is a first-ofits-kind event showcasing the latest innovations under one roof. From factory automation, process automation & control systems, field instrumentation & smart sensors, robotics & drives, software solutions to hydraulic and pneumatics, the event will display the best among the new-age automation solutions. “HiTech Automation showcases the best and the latest in the industry. This show is a must attend for all small and medium enterprises. For those who will be a part of this extravaganza, the exhibition will provide tremendous networking opportunities and scope for business generation,” asserts Sudhanva Jategaonkar, Associate VP – B2B Publishing, Infomedia18, a Network18 company.
One-stop automation shop Displaying cutting-edge technology, breakthrough innovations and interactive demonstrations from the leaders in the automation industry, HiTech Automation Show has been designed to provide an ideal platform for the growth of the automation industry in India. HiTech Automation will help the entire automation industry converge into a single lucrative platform that will serve as a foundation for future growth of the industry and drive it towards a promising automated future.
Engineering Expo Indore 2011
Investment ahoy!
Acknowledged as the commercial capital of Madhya Pradesh, Indore is poised to become an industrial hub. Investments attracted by the region in the recent past have made it a strong contender for inclusion in the coveted category of commercial hubs of the country. Aiding the growth of commerce in the region are trade shows like Engineering Expo that not only provide a fertile platform for business augmentation, but also present a breeding ground for industry. Shibani Gharat
I
ndore, known for its rich historical heritage, is in the process of getting its name engraved in gold in the history of world manufacturing. The region that is the commercial capital of Madhya Pradesh (MP), is thriving with business opportunities than ever before. Thus, it can be said that footprints of royalty meet the velocity of business in this city.
Indore: A strategic choice Today, Indore has grown beyond measure with bulk of its trade coming from small, mid and large-scale manufacturing & service industries. The region has more trade & commerce to offer than any other citiy of similar stature within the country. Key business houses, including a bevy of foreign investors, have already made serious investments in concurrent projects that are ongoing in and around Indore. The industries, a major constituent of the Indore economy, contribute a considerable amount of revenue. The city has emerged as a major investment and industrial destination. Further, it is one of the fastest growing tier-II cities in India and is also in the process of becoming an IT hub with many IT companies flourishing in MP. It also has a thick concentration of conventional production and manufacturing industries. Prominent among
them is textile, which has been the backbone of the city’s industrial growth. Pithampur near Indore is one of the largest hubs of vehicle and automobile industries in India. Eminent industrial houses have commenced manufacturing operations in Indore. Some of the most important among them include Kinetic Honda, Onida Saka, Pratap Steel, Prestige Group, Bajaj Tempo, Bridgestone, Chirag, Ingots, Eicher Motors, Dhar Textiles, Larsen & Toubro, Indo German Tools, Hindustan Motors, Crompton Greaves, Pratibha Syntex, Kores India, etc. Harish Bajaj, Director, Atlas Radios, says, “New investments have helped the region immensely, especially the SMEs. They supply machinery and raw materials locally to various companies.” Atlas Radios is engaged in trading of electronic components, electronic meters, electrical items, home appliances, synthetic adhesives and such other items.”
Infrastructure growth Indore provides the industries with complete civic and industrial infrastructure. The industrial growth of this region has been phenomenal thanks to multinational and national companies choosing the city to set up their industries here. Time and again, these companies have reiterated that excellent infrastructure in the city makes them choose it for investment. A comprehensive industrial-friendly environment, supported by robust infrastructure, has resulted in exceptional industrial growth of this
Santosh S Garav Deputy Marketing Manager, Electronica Mechatronic System (I)
Engineering Expo-Indore has been a great experience for us. Last year, we booked machinery worth ` 2.5 lakh during the four-day event. We had also received more than 100 potential leads. part of MP. As the capital of the Holkar dynasty, Indore has always had an easy access to other prominent regions in India. Today, this region has proximity to almost all major towns in India, through a network of rail, roads and air. India’s first greenfield SEZ set up in Indore is an achievement for the State Government. Until now, 46 industrial units have been allotted land in Indore SEZ in which investment of ` 1,300 crore has been finalised and 20 units have already started their operations. Apart from Indore SEZ, Pithampur Industrial Park is MP’s first and unique industrial estate developed by a public sector undertaking, which assures reliable and superior infrastructure, estate management and supporting amenities. Around 7,500 people are engaged in this SEZ and nine units involving ` 650 crore are still under construction. The SEZ so far has recorded ` 1,300 crore worth of export business. The circuits of Pithampur-DharMhow have been selected as mega
Indore | 7-10 Jan, 2011 The Engineering Expo, organised by Infomedia 18, is one of the biggest engineering events in the country. The 2009-10 edition of the Expo saw business transactions worth over ` 150 crore. Launched in Ahmedabad in 2002, the event today boasts of huge visitor turnout. The Expo is a preferred destination for SMEs, manufacturing and engineering companies to transact, network, tie-up & exchange ideas for the growth of the industry. The Engineering Expo 2010-11 is scheduled to take place in four cities. After starting off at Pune in November, the Expo proceeds to Ahmedabad, Indore and Chennai in subsequent months.
investment region as per the Delhi Mumbai Industrial Corridor. Modal logistics hub at Pithampur, economic corridor on Indore-Pithampur airport road and water supply & sewerage project in Pithampur have been approved. All these projects would bring about revolutionary changes to the region’s economy.
Investment-friendly policies The industries in MP are resourcedriven at large. This is due to its natural wealth in the form of limestone, coal, soya, cotton, bauxite, iron ore, silica etc. Because of this, other industrial sectors are also emerging. Some of these include textile, cement, steel, soya processing and optical fibres. However, there is one exception to the resource-driven industrialisation policy. This exception is the region of Indore. In the past, the state of MP, as a result of its incentive policies, has been successful in developing a strong base in the auto, auto ancillary and pharmaceutical sectors. In the last few years, the state government has introduced many policies to encourage the development of
Indore. The MP State Industrial Policy, 2004, provides specialised packages for loss-making units. Several schemes are on offer with an aim to develop industries in Indore through a ‘cluster’ approach. The State Government has acknowledged textile, pharmaceutical, IT, auto components and food processing as priority sectors for the city. With the constitution of industrial clusters around Indore, its economic geography has expanded rapidly in the recent years. The major economic clusters around Indore are located in Kheda, Sanwer and Dewas along with Pithampur. With such tremendous prospects available, a platfom was required to bring about all the major players together for mutual benefits. This demand led to the introduction of Engineering Expo. Sudhanva Jategaonkar, Associate Vice President - B2B Publishing, Infomedia18, a Network 18 company and the organiser of Engineering Expo Indore, explains, “Engineering Expo is a platform that brings together participants from the entire manufacturing sphere. Acting as a one-stop-shop, this show immensely benefits the entire manufacturing fraternity. Indore has become a hot destination for investors, owing to all the support provided by the State Government. Trade in the region is booming, which in turn will help the industry. In the past, initiatives like Engineering Expo have proved to be principal platforms for this thriving industry to grow beyond measures.”
A platform for success Engineering Expo is an ideal manufacturing & engineering trade fair for displaying various products and services. It is one of the most preferred platforms to grow business, as selected by more than 1,000 companies that participated in the previous editions of the Expo. Past exhibitors like Atlas Radios are reaping huge benefits from their participation at the Expo.
Harish Bajaj Director, Atlas Radios
Engineering Expo has helped us spread awareness about our company and products among the new market entrants in the region. It has also helped business growth. Business generated through last year’s Engineering Expo has contributed to 10 per cent of our annual turnover. “Engineering Expo has helped us spread awareness about our company and products among the new market entrants in the region. It has also helped business growth. Business generated through last year’s Engineering Expo has contributed to 10 per cent of our annual turnover. This year, we are expecting to grow to 30 per cent,” Bajaj adds. “Engineering Expo Indore has been a great experience for us. Last year, we booked machinery worth ` 2.5 lakh during the four-day event. We had also received around more than 100 potential leads,” says Santosh S Garav, Deputy Marketing Manager, Electronica Mechatronic System (I), while speaking about its participation in Engineering Expo Indore last year. Highlighting the performance of Engineering Expo in helping the development of SMEs, Jategaonkar says, “The brand Engineering Expo is a brilliant example of a humble beginning and achievement of enviable feats over the years. The coming months look promising for the manufacturing sector, and we aim to provide more business development opportunities through our Expo.” Diverse industry presence, government support, infrastructure and Engineering Expo are the four pillars of growth for Indore’s industrial segment. Budding trade and commerce alongwith investors’ trust will make these pillars stronger.
CURTAIN RAISER
A technology forum with a difference With India ardently striving to meet the growing industry demands for water, a fast depleting resources, the industrial and domestic sectors have realised the need for wastewater recycling. Keeping this in mind, EA Water Pvt Ltd is organising the 8 th EverythingAboutWater Expo during January 6-8, 2011, in Mumbai.
T
he $ 15-billion Indian water industry stands at crossroads today. The demand for water from various sectors continues to rise despite depleting water resources. In this scenario, there is a huge scope for growth in water purification and recycling. Aiming to tap this opportunity, EverythingAboutWater Expo will be organised at Bombay Exhibition Centre, Mumbai. The event is considered to be one of the leading shows for companies and associations specialising in water treatment, wastewater management and related industries, to showcase their products and expertise under one roof.
Market for water treatment According to the organisers of this event, the total water and wastewater treatment market is estimated at about $ 420 million. A growth rate of 18 per cent annually has been recorded in several segments, with the industrial and drinking water segments experiencing high level of growth. Also, hundreds of small systemintegrators addressing local requirements have sprung up all over the country.
Key highlights R Product Launch Zone: All those curious to know about new
products being introduced in the market will find their answers at EA Water Expo 2011 R Dr H2O Pavilion: This is a discussion area where visitors will
interact with leading experts and independent consultants R EA Water Forum: This will give exhibitors an opportunity to make
a lasting impression while addressing a focussed audience R Best Stall Awards: To acknowledge the efforts of exhibitors in
stall designing & fabrication, EA Water has instituted this award, the evaluation of which will be based on concept, appearance, space planning, branding, product display and theme
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Expo offerings Around 350 exhibitors - which will include companies from the US, UK, Canada, Germany, Italy, Israel, Norway, Singapore and Thailand - are expected to exhibit their products at the Expo. The show, which is expecting 18,000 trade visitors and 900 conference delegates, promises to provide a platform for networking and interacting with leaders from the water sector. The event will feature a two-day international conference on the latest developments in seawater desalination technologies, training workshops on water reuse and recycling. It will also host a conference on non-chemical disinfection technologies - ozone & UV processes.
A water kingdom in itself! EverythingAboutWater Expo 2011 will offer attendees the access point to global technological advancements in the fields of water harvesting, water & wastewater treatment, water conservation, irrigation, wastewater recycling, desalination, etc, that are crucial for sustainable development of the industrial segment in India. The event will also offer industry players as well as government officials opportunities to analyse the market trends, and at the same time, obtain first-hand information on the latest technologies launched in the market.
Business Insights Technologies Opportunities
The ‘Catalyst’ of Growth for Chemical Process Industry
‘CHEMICAL WORLD’ is India’s leading monthly magazine for the chemical process industry. It delivers the latest and most relevant trends and technologies, highly useful articles and case studies, business strategies, views & visions of industry leaders and information on process industry machinery. It also comprehensively covers national & international current affairs, upcoming projects, events and other significant developments in the chemical process industry.
Other Business Magazines
Your Partner in Growth lnfomedia 18 Ltd., Ruby House, ‘A’ Wing, J K Sawant Marg, Dadar (W), Mumbai 400028. T : 91 22 3003 4650 F : 91 22 3003 4499 W : www.infomedia18.in E : b2b@infomedia18.in
EVENTS CALENDAR
National MUMBAI Concurrent Shows
INDORE
CHENNAI
Madhya Pradesh Jan 7-10, 2011
Tamil Nadu Mar 11-13, 2011
Maharaja Shivajirao School Grd, Chimanbaug
Chennai Trade Centre
India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.
For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 Fax: 022 3003 4499 • Email: engexpo@infomedia18.in
EverythingAboutWater Expo 2010 An international exhibition and conference on water & wastewater management; January 06-08, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Aarti Chopra EA Water Pvt Ltd A1/152, IGNOU Road, Neb Sarai New Delhi 110 030 Tel: 011-4310 0500, Fax: 011-4310 0599 Email: aarti@ewgroup.in
India Rubber Expo 2011 An exhibition for suppliers of raw material, synthetic rubber, additives & auxiliaries, and rubber manufacturing machinery; January 19-22, 2011; at Chennai Trade Centre, Chennai For details contact: All India Rubber Industries Association (AIRIA) 601, Pramukh Plaza, 6th Floor 485, Cardinal Gracious Road Chakala, Andheri (E), Mumbai 400 099 Tel: 022-2839 2095 Fax: 022-6710 3211 Email: info@allindiarubber.com
PU Tech 2011 A polyurethane (PU) exhibition & conference; March 09-11, 2011; at India Expo Centre - Expo XXI, Noida For details contact: Unitech Exhibitions Pvt Ltd 92/3, 2nd Main Road Gandhi Nagar, Adyar, Chennai 600 020 Tel: 044-2440 5493
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Fax: 044-2440 5492 Email: unitech@hathway.com
Maharashtra February 17-19, 2011 Bombay Exhibition Centre
One of the largest advanced design and manufacturing events in India featuring Machine Tools, Hydraulics & Pneumactics, Process Machinery & Equipment, Automation & Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.
For details Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4650 Fax: 022 3003 4499 • Email: hitech@infomedia18.in
Chemspec India 2011 An exhibition for performance & fine chemicals and organic intermediates; April 14-15, 2011, Bombay Exhibition Centre, Mumbai For details contact: DMG World Media Ltd 301B Court Greens The Laburnum, Sushant Lok Gurgaon 122 002, Haryana Mob: 098116 14144 Email: info@ca.dmgworldmedia.com
PVC 2011 The event will display the latest innovations in pumps, valves and compressors (PVC) for various industries; May 06-08, 2011; at Bombay Exhibition Centre, Mumbai For details contact: Conventions & Fairs (India) Pvt Ltd E 519, Floral Deck Plaza Central MIDC Road Opp SEEPZ, Andheri (East) Mumbai 400 093 Tel: 022-2839 8000, Fax: 022-2839 0502 Email: conventions@mtnl.net.in
IORS 2011 Symposium and international exhibition for oil & gas industry; September 0809, 2011; at Taj Lands End, Mumbai For details contact: Oil Asia Publications Pvt Ltd
530, Laxmi Plaza 5th Floor, Laxmi Industrial Estate New Link Road, Andheri (West) Mumbai 400 053 Tel: 022-4050 4900, Fax: 022-2636 7676 Email: oilasia@vsnl.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: Imag Am Messesee 2 81829 Munich, Germany Tel: +49 (0) 89 949 22 0 Fax: +49 (0) 89 949 22 350 Email: info@imag.de
SUGARASIA 2011 Exhibition showcasing cane sugar and downstream products such as distillation of molasses & ethanol, blending and power generation; November 21-25, 2011; at Pragati Maidan, New Delhi For details contact: Nexgen Exhibitions Pvt Ltd 1201 Pragati Tower, 26 Rajendra Place New Delhi 110 008 Tel: 011-4153 6990, Fax: 011-4153 6991 Email: nexgenservices@gmail.com
EVENTS CALENDAR
International Iran Chem Tech 2011
Chembio Finland 2011
The expo is devoted to materials and equipment & machinery for the chemical industry; February 07-10, 2011; at Tehran Permanent Fairground, Tehran
An event showcasing latest trends in laboratory products, biotechnology and chemical industry; March 22-24, 2011; at Helsinki Fair Centre, Finland
For details contact: Gohargodaz No.28 Sharifi alley North Razan st. Mirdamad blvd, Tehran 19119, Iran Tel: +98 21 22 22 52 05/22 92 30 88 Fax: +98 21 22 92 26 83 Email: info@gohargodaz.com
For details contact: Suomen Messut Messuaukio 1, PO Box 21, FIN-00521 Helsinki, Finland Tel: +358 9 150 91, Fax: +358 9 142 358 Email: info@finnexpo.fi
InformexUSA 2011 It will provide a meeting point for buyers and sellers of high-value chemicals; February 07-10, 2011; Charlotte Convention Center, Charlotte, The US For details contact: United Business Media Industrieweg 54, PO Box 200 3600 AE Maarssen, The Netherlands Tel: +31 34 65 59 444 Fax: +44 (0) 20 7921 8059 Email: jblack@cmpinformation.com
ISRACHEM 2011 An exhibition on industrial processing, chemical engineering, measurement control and instrumentation; February 22-24, 2011; Israel Trade Fairs Center, Tel Aviv For details contact: Stier Group Ltd 12, Tversky Street, Tel Aviv 67210, Israel Tel: +972 (0)3 5626090 Fax: +972 (0)3 5615463 Email: expo@stier.co.il
CIPPE 2011 An event for petroleum & petrochemical technology and equipment; March 22-24, 2011, New China International Exhibition Center, Beijing, China For details contact: ITE Group Plc 105 Salusbury Road London, NW6 6RG, The UK Tel: +44 (0) 20 7596 5000 Fax: +44 (0) 20 7596 5111 Email: enquiry@ite-exhibitions.com
Analytica Vietnam 2011 A trade fair and conference for analytical instrumentation, biotechnology, laboratory technology and services; April 07-09, 2011; at Ho Chi Minh City, Vietnam For details contact: Imag Am Messesee 2 81829 Munich, Germany Tel: +49 (0) 89 949 22 0 Fax: +49 (0) 89 949 22 350 Email: info@imag.de
FILTSEP 2011
May 18-19, 2011; at Exhibition Centre Westfallenhalle Dortmund, Germany For details contact: easyFairs - Brussels Rue Saint Lambert, 135 B-1200 Brussels, Belgium Tel: +32 (0)2 740 10 70 Fax: +32 (0)2 740 10 75 Email: europe@easyfairs.com
Oil and Gas Asia 2011 Asian oil, gas and petrochemical engineering exhibition; June 01-03, 2011; at Kuala Lumpur Convention Centre, Malaysia For details contact: Allworld Exhibitions 12th Floor, Westminster Tower 3 Albert Embankment, London The UK Tel: +44 (0)20 7840 2100 Fax: +44 (0)20 7840 2111 Email: info@oesallworld.com
Chemspec Europe 2011
A trade fair for equipment and technologies for filtration and separation; April 26-29, 2011; at Crocus-Expo IEC, Moscow, Russia
An exhibition for performance & fine chemicals and organic intermediates; June 15-16, 2011; at Palexpo, Geneva, Switzerland
For details contact: MVK - International Exhibition Company 1 Sokolnichesky Val Pavilion 4, Moscow 107113, Russia Tel: +7 (495) 995-05-95 Email: info@mvk.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
Dye+Chem Indonesia 2011 Exhibition focussing on all kinds of dyes and fine & specialty chemicals; May 1214, 2011; at Jakarta International Expo (JIExpo), Indonesia For details contact: CEMS Bangladesh House # 119, Unit- A3 Road-1, Banani Block-F Dhaka 1213, Bangladesh Tel: +880 2 8812713 Fax: +880 2 9894573 Email: cems@cemsonline.com
SCHÜTTGUT 2011 Industry forum for manufacturers of powder, granules and bulk solids;
PEPP 2011 A business forum dedicated to polyethylene & polypropylene (PEPP) products, technologies and market; September 20-22, 2011; at Swissôtel 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
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
December 2010 | Chemical World
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Engineering Expo Pune 2010
Creating a perfect trade ecosystem Reigning in the legacy of creating an ideal platform for profit, Engineering Expo Pune 2010 kept its promise of generating business, well beyond expectations. But even the envious ` 85 crore worth of business that the edition generated, faded in comparison to the prospects that it procured; not only for the visitors and the exhibitors, but also for the entire Pune region...
Sumedha Mahorey
B
ooming economy and buoyant industrial prospects reflect an unprecedented growth that India is all set to witness. With innovation as the guiding light, companies are putting their best foot forward to
strengthen tie-ups, establish strong networks and harness the most lucrative deals. Generating 8,123 business leads, the Pune edition of Engineering Expo provided an ideal ecosystem of growth to exhibitors and visitors. During the four power-packed days, from November 19–22, 2010, the Expo succeeded in
conveying the message that the time was ripe for the companies to reap maximum benefits and fructify potential business. The unveiling ceremony witnessed industry stalwarts vouching for the fact that India has emerged as a major trade economy and companies should make most of these opportunities. Through
Inspiring thoughts @ unveiling ceremony The four-day extravaganza began with an inspiring note from industry leaders on the critical importance of trade fairs in building a perfect ecosystem for growth. Here’s the glimpse of what the who’s who of the industry had to say…
The SME advantage that the Pune region enjoys should be pursued and leveraged for the bigger growth of the region. The developmental policies and the relentless work that has gone into making Pune region as a preferred choice for the manufacturing companies to establish their base here and grow is for all of us to see. But the need of the hour is to take these developmental work and policies to the next level to make our success a lot bigger and achieve a much higher success scale. Sadashiv Survase, General Manager, District Industries Centre, Pune
Trade shows are the best way to introduce your business to your customers. This is one place where you can meet all your customers at one go. In short, trade shows are the enabling vehicles to make success a surety. We grew our business only on trade shows, and my journey of being an inventor, an entrepreneur and now a proud part of a very successful organisation, would not have been so enriching without these trade shows being our enabling medium. That is the precise reason why I am here today. Farook Merchant, Chairman & MD, Messung Group of Companies
Design-led companies carry a distinct edge and are highly differentiated. Design helps improve your product & services, powers sustainability credentials that make people happy and has positive benefits on bottom line. Design innovation helps you move up the value chain and has become the new source of competitive advantage. With India positioning itself as an innovation-led manufacturing hub, design becomes a key strategic tool for enterprise success. Ashish Deshpande, Co-founder, Director & Head – Product Innovation, Elephant Strategy + Design 74
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their inspiring speeches, industry biggies reiterated the fact that trade fairs like Engineering Expo provide an ideal ecosystem for companies to put forth their innovative offerings for prospective buyers and aid in taking the growth trajectory forward. The awe-inspiring and thought-provoking insights of the leaders resulted in garnering business worth ` 85 crore with a total visitor footfall of 20,397. What added to the cheer was the presence of SMEs as well as government organisations along with multinationals, which provided a conducive atmosphere for the manufacturing ecosystem to grow and flourish.
Engineering Expo: A success story The Engineering Expo provided exhibitors the opportunity to reach out to global
giants who are visiting India to look out for prospective partners. Elaborating on the role of Engineering Expo in generating business leads, Pankaj Kanherkar, Senior Territory Manager, Aventura Components, said, “Engineering Expo has offered Indian companies a good opportunity to promote their products, especially at a time when MNCs are visiting our country. The Expo offers scope for tremendous exchange of ideas. We not only get inputs from customers but also from other participating companies, which help us upgrade and improvise our products to meet the demands of our clients.” With the vast expanse of products & services on display, the event proved to be a one-stop-solutions-shop for exhibitors & visitors alike. Some of the leading companies that showcased their
innovative solutions included Atlas Copco (India), Autotech CNC, Boge Compressed Air System, Igus India, Misumi India, Nilkamal, Tussor Machine Tools India and S&T Engineers, amongst others. Thus, weaving an entire industrial ecosystem on a single centrestage, the Expo opened up multiple lucrative opportunities for the industries in this region and brought to the fore the criticality of networking and understanding customers’ needs in a better way.
India has emerged as one of the fastest growing economies, but its growth story will be incomplete if the bottom of the pyramid is not a part of this story. So, while we should cheer for what we have achieved, we must also strive to make India’s success story a holistic one and that will only happen when there is enough & more networking platforms being created, and technology transfer happens more often. Engineering Expo is one such platform, so utilise it to the fullest. Raja Kochar, MD – India, Eaton Corporation
Since last year, we have worked very closely with the Engineering Expo team in providing clean and green power for the show. This Expo provides opportunities where one can see a variety of engineering products & services and that too, under a green roof. Events like this not only offer new business opportunities but also give boost to the overall economy of the region. As we travel to other locations with the Expo, our own understanding of our customer requirement is enhanced and this provides valuable inputs to our R&D team. Sanjay Jain, AVP – Sales, Kirloskar Oil Engines
This is the first time we are taking part in Engineering Expo and I must congratulate the organisers and the team for putting up this extraordinary show. The manufacturing sector is the probable growth engine of the Indian economy and as its economy progresses; the sector will have a bigger role to play. But as the economy and the sector progresses, there is a need to collaborate more than ever. Engineering Expo is the place where you can collaborate with the right companies and find right partners & products. Guy Amoroso, MD, 123 Insight India
Exhibitions and trade shows have been used as an effective marketing medium to find new customers, improve business relationships with existing customers, introduce new products & services, and deliver many other meaningful & tangible business outcomes. Engineering Expo is one such event that has become a principal platform for product launches and business growth for several SMEs in this region. Over the years, The Expo has helped foster trade & commerce in the region and has helped the local industry’s interface with prospective investors. Sandeep Khosla, CEO - Publishing, Infomedia 18 Chemical World | December 2010
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Delighted visitors
Growth phase
Maulik Desai, MD, Unique Industrial Services
S Chandrasekhar, Senior Manager (Western Region), S&T Engineers
I was expecting Engineering Expo to be organised on a much smaller scale. But the Expo was so well organised that it surpassed my expectations. I could easily find all the products I was looking for.
We are optimistic about the growth of our sector with increase in the number of start-ups. Various sectors like automobile, dies & moulds and component manufacturing are showing good performance. As a result, the demand for our machines will increase to match their requirements.
Santosh Patil Kulkarni, Manager, Ansys The Engineering Expo is good for the industry, especially the SMEs. I was able to get the products I needed. The good part is that there are electronics-related products available at the Expo.
Shireesh P Lawate, CEO, Parth Enterprises Engineering Expo has a wide range of engineering products on display. The organiser took steps to ensure that only quality visitors attended the show. To make it better, the Expo can be made more vertical-specific.
Animesh Kumar, AVP & Branch Head, Axis Bank My experience at Engineering Expo has been quite good. There were a number of engineering tools and forging products available at the exhibition. However, a better variety was needed. On the whole, the Expo was very informative.
D R Gadakh, Manager, New Aniket Packing Industries Engineering Expo was well-organised. The stalls were wellarranged and properly segregated.
8,123 are the total ads business le d generate
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Sohrab Daver, Executive Director, Masibus Automation and Instrumentation We have set up an additional system integration unit in our Gandhinagar plant and already have a manufacturing plant in Goa. We are expanding and plan to set up plants all over the country to keep pace with the manufacturing industry. We expect our company to witness a 30-40 per cent compounded growth in the next five years.
A P Singhal, MD, Emtex Marketing We are growing by 100 per cent in terms of turnover. We are also consolidating our market position by investing in new products.
Amit Shah, Manager - Sales, East India Bearing Co Our engineering products are unique in the world. While others produce ball or spherical bearings, we have split roller bearing equipped for the mining or steel industry. Companies using our equipment can reduce upto 90 per cent of downtime, thereby significantly improving shop floor efficiency.
itors 88% exhib showed to willingness h it partner w g Expo Engineerin again
eight Total w of the ry ne machi d in move 0 Kg 80,00
Business transaction of over ` 85 crore in 4 days
itors 235 exhib d participate ng ri e e in g n in E Expo Pune 2010
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Alluring alliances @ Engineering Expo Pune 2010
Demands trends witnessed
Arun Vijay, Director - Marketing, Autotech CNC
The need of the hour in the manufacturing sector is to upgrade existing technology to stay ahead of competitors.
Engineering Expo has helped us find a good number of references. We are a Pune-based company and most of our visitors were our clients. I am sure that if we participate in Engineering Expos held in other cities, we will definitely get a good response.
Prashant Joshi, Business Head, Hi-Tech Group We have participated in Engineering Expo to reach out to emerging markets like Pune, Ahmedabad, Chennai, etc, which are usually not covered by other trade exhibitions.
Preeti Nagarkar, Managing Partner, Mapyn
Milan Supanekar, Owner, Welding Technologies India
Pawan Wadhwan, Manager (Business Development), Sipcon Instrument Industries Nowadays, customers have become more demanding. They want the best product at the lowest cost. Therefore, companies should focus more on providing the highest quality products & services to their customers, at the lowest possible cost.
Nimesh Karlya, Director, Jay Equipment System
Engineering Expo has provided us a platform to display our products to our target customers. It gives us the chance to interact with customers and visitors, who give us valuable inputs on how we can upgrade our products.
Customers always track the market for the latest technology, high-quality and low-cost products. Hence, it is important that companies work on their branding and offer good quality products, which will enhance the company’s overall productivity.
Hemang K Ghelani, Product Manager – Control Components, Omron Industrial Automation
Dinesh Chaudhary, Director, Energy Mission Engineers
Engineering Expo helps us reach out to our customers. We look at the Expo as a marketing tool or a promotional activity to create brand awareness.
Customers want NC and CNC machines. This means that automation is in demand. At the same time, customers have also been demanding bigger and special machines.
rs 82% visito y p p were ha e with th nge product ra d e display
66% of the visitors have visited the Ex po in previous edit ions
s visitor 20,397 visited ing eer Engin Pune Expo
82% visitors were from Pu
ne
Chemical World | December 2010
77
PRODUCT UPDATE
Single-screw air compressor
Particle counter
Deep Pneumatics offers single-screw air compressor from Shanghai Feihe Industrial Group Co Ltd, Shanghai. With its unique structure and new technology of air end, singlescrew air compressor can help the customers to minimise maintenance cost, save energy and increase the value, in comparison to double-screw & reciprocating compressors. The single-screw air compressor is available between the range of 15 to 100 hp, pressure range from 7 to 12 bar, capacity range from 55 to 490 cfm, air-cooled & water-cooled. The company is planning to increase the manufacturing capability up to 480 hp with 2,275 cfm 7 to 12 bar, for air-cooled & up to 1,220 hp with 5,470 cfm, 7 to 12 bar pressure, water-cooled (electric & diesel engine driven, portable). Longer durability, high efficiency, energy saving, low maintenance cost, low noise, trivial vibration, reasonable structure, ideal balanced forces, high level of reliability, compact & simple construction etc, are the advantages of single screw over twin screw compressors.
MeasureTest Corporation offers ‘MET ONE 3445’ particle counter. With a 100-lpm flow rate, this new instrument can collect 1 m3 of sampled air faster in order to save labour costs and comply with the EU Annex 1 Guidance for Grade A areas. With flexible communication options and open communication architecture, this instrument can be seamlessly integrated into a central environmental monitoring system eliminating the need for manual recordkeeping. Intuitive operating commands & test wizard, rich user-interface software, ‘Long Life Laser™’ technology, and long continuous operation capability, enable the ‘MET ONE 3445’ to reliably perform clean-room validation testing & critical process monitoring within the shortest possible time. This device also features 21 CFR Part 11 compliance, easy data download, regulatory standard compliant analysis and reporting functions, strategically placed carrying handles & an easy-to-wipe down stainless-steel surface. The wireless option enables users to monitor the cleanroom without actually entering it.
Deep Pneumatics Pvt Ltd Ahmedabad - Gujarat Tel: 079-2280 3684, Fax: 079-2280 3684 Email: deeppneumatics@hotmail.com
Bottom discharge centrifuge United Engineering offers four-point bottom discharge centrifuge with scrapper in complete stainless steel construction and conforming to cGMP standards. The machine is mounted on inertia plates with antivibration mounts, ensuring that vibrations are absorbed, making it ideal for installations on higher floors. This also obviates the need for grouting or special foundation. The scrapper is hydraulically operated with bi-axial movement, making it possible to scrap hard and sticky cakes. The centrifuge can be offered in vapour-tight construction with nitrogen blanketing for hazardous chemicals. The CIP design with built-in cleaning nozzles ensures no product crosscontamination. The centrifuges are offered in batch capacities ranging from 5 to 600 kg. United Engineering Enterprises Mumbai - Maharashtra Tel: 022-2308 3990, Fax: 022-2308 9445 Email: pde_souza@hotmail.com
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Chemical World | December 2010
MeasureTest Corporation Mumbai - Maharashtra Tel: 022-2202 7982 Email: sheesh@mtnl.net.in
Pickling tanks EPP Composites offers pickling tanks for pickling process of MS and stainless steel coils/bars/pipes. These tanks are manufactured from PP and HDPE. This range of polishing tanks is made of premium quality material that makes them completely rustproof and chemical-resistant. These tanks are manufactured as per the international quality standard. Used for water purification, these polishing tanks remove the real contaminants like heavy metals, inorganics, bad taste and odour while leaving beneficial minerals in water. EPP Composites Pvt Ltd Rajkot - Gujarat Tel: 02827-287 059, Fax: 02827-287 063 Email: marketing@epp.co.in
PRODUCT UPDATE
Gear pump Maag Pump Systems offers ‘Vseries’ gear pump for handling high viscosity media in chemical/industrial applications. This is a discharge pump with special inlet geometry. It is ideal for all plant operators with difficult applications at low inlet pressures (vacuum) and high levels of viscosity (up to 4 million mPas), eg, resins, fats, silicones, sucrose, esters or prepolymers. It can be used at temperatures up to 350°C. The inlet geometry ensures even filling of the gears at low pressure to safeguard continuous production flow. Two versions are available. The gear pump with round inlet geometry is offered as variant one. On the second variant, the pump connection flange is omitted and the gear pump is directly connected to the reactor (sandwich design). Typical applications are in extractions from vacuum, thin film evaporators, handling highly viscous liquids (paste, grease, honey etc), liquids having viscosity lower than water, distillation processes, drug intermediates, residue transfers from reactors and speciality chemicals & polymers. Maag Pump Systems India Navi Mumbai - Maharashtra Tel: 022-2789 3645, Fax: 022-2789 4407 Email: satyagarinapally@maag.com
December 2010 | Chemical World
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PRODUCT UPDATE
Metal keyboards Solar Biotronic Laboratories offers metal keyboards using aluminium or stainless steel as the front surface. These keyboards can be used in factory shop floor, process control areas, petrol or diesel dispensing machine (petrol pumps), external locations etc. The metal keyboards operate at 30 mA, 0-24 V DC and in a temperature range of -10oC to +702 ptC. Solar Biotronic Laboratories Pvt Ltd Pune - Maharashtra Tel: 020-3011 6901, Fax: 020-3011 6905 Email: sales@sblindia.com
Ultrasonic cleaning chemicals Ashok Industry offers ‘Asfoclean-AD20’ series of ultrasonic cleaning chemicals. These chemicals are widely used in various types of ultrasonic cleaning equipment to remove different types of soil and contaminants such as oils, grease, lubricants, dirt, rust, scale etc, from metal & non-metal surfaces. Ashok Industry Mumbai - Maharashtra Tel: 022-6150 4150, Fax: 022-6150 4151 Email: sales@ashokindustry.com
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Chemical World | December 2010
PRODUCT UPDATE
Chemical transfer pumps Taha Pumps & Valves offers ‘CFP’ series pumps in SS 316 material for handling mildly corrosive chemicals and various other liquids in different industries like chemical, petrochemical, steel, printing, pharmaceutical, food processing etc. 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, tungsten etc. These pumps can be used for high temperature applications up to 250oC. Special pumps are also available with casing steam jacketing and with flameproof motors. Taha Pumps & Valves Surendranagar - Gujarat Tel: 02752-240 233, Fax: 02752-240 908 Email: tahapv@yahoo.co.in
December 2010 | Chemical World
81
PRODUCT UPDATE
Ultrafiltration system Ovivo India offers ‘OVIVO-TrisepTM’ ultrafiltration (UF) system. This is a robust flat-sheet and spiral-wound membrane. The UF system is operated in a cross-flow mode, thus reducing the chances of fouling, thereby maintaining the permeability of the membrane for a long time. Unlike hollow fibre membrane systems, which are prone to frequent breakage, ‘OVIVO-TrisepTM’ membrane elements are robust and are designed for effective aeration, backwash and purging. This UF system undergoes negative pressure operation, thereby eliminating compaction and higher TMP, which is generally seen in positive pressure systems. ‘OVIVOTrisepTM’ UF System has two product lines: ‘iSepTM’ and ‘SpiraSepTM’. The ‘iSepTM’ units eliminate the need for a process tank as they are skid-mounted ‘plug-and-play’ type. The ‘SpiraSepTM’ units are submerged UF systems which can be placed in an existing process tank and operated in a feed & bleed mode. The company also offers MBR, ‘AerostripTM’ - fine bubble diffusers, ‘JetaTM’ - grit removal systems, ‘Hybrid BNR’ - sequential batch reactor technology, ‘FlooBedTM’ - moving bed bioreactor technology and fine screens (up to 1 mm opening). Ovivo India Surat - Gujarat Tel: 0261-246 5972/73, Fax: 0261-246 2997 Email: info.in@ovivowater.com
Rotary vacuum pumps Acmevac Sales offers rotary vacuum pumps, series ‘LVV’. These are sliding vane, oillubricated type pumps. Design of the lubricating system positively feeds minimum quantity of oil to important points. Oil from the exhaust is baffled, collected and returned to the oil chamber. Heat-treated fibre vanes are used in these pumps in place of steel vanes. Advantages of these pumps are: silent running & negligible wear on stator, end covers and rotor slots. These pumps are driven by V-belt to give vibration-free and are fan-cooled. The complete unit with motor and base plate is suitable for mounting inside the equipment. All the models in LVV series can be modified to suit specific requirements. Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-2837 5837, Fax: 022-2836 4977 Email: acmevac@vsnl.com
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Chemical World | December 2010
PRODUCT UPDATE
Structured packings & internals Fenix Process Technologies offers structured packings and internals. These packings in sheetmetal and wire gauze provide high separation efficiency (low HETP) resulting in reduced column height and thus, cost saving. Available in standard & exotic metals at 450 & 600 crimp angles and surface areas of 60-1,000 2 3 m /m , these packings have low pressure drop and excellent wetting characteristics due to special surface treatment. High voidage gives lightweight and high vapour load. Low reflux ratios & pressure drop result in reduced energy costs. Very high contact area between the rising vapour and the down-coming liquid is provided by these packings, thus facilitating easy separation/purification of low boiling components at the top and high boiling ones at the bottom as desired products. These structured packings and column/ tower internals find use in sectors like chemical, pharmaceutical, petrochemical, dyes & intermediates, aromatics and other industries wherever miscible/azeotropic liquid-liquid separation is critical. Fenix Process Technologies Pvt Ltd Pune - Maharashtra Tel: 020-6630 4437/38 Email: shankar@fenix.in
December 2010 | Chemical World
83
PRODUCT UPDATE
Plate heat exchanger HRS Process Systems offers plate heat exchangers (PHEs). A PHE consists of a series of thin, embossed plates with passage opening. Each plate is fitted with an elastomeric gasket, which completely seals the flow gaps from the outside and forms the flow channels from inside. These plates are compressed together in a rigid frame to form an arrangement of parallel flow channels with alternating hot and cold fluids. Since the fluids are exposed to larger surface area, and the fluids are spread over the plates, it facilitates the transfer of heat, thus increasing the speed of the temperature change. This makes the unit compact compared to the conventional heat exchanger. The company offers various models of PHEs like gasketed, double-wall and semi-welded. The port size varies from 1� to 500 mm and surface area/plate from 0.04 to 3.0 m2. PHEs find application in various industries like power, steel, chemical, surface treatment, pharma, HVAC etc. The cladded plate heat exchangers are widely used in dairy and food industry. HRS Process Systems Pvt Ltd Pune - Maharashtra Tel: 020-2566 3581, Fax: 020-2566 3583 Email: mktcom@hrsasia.co.in
Fluoropolymer-lined valves Supremo Line & Control offers fluoropolymer (FEP, PFA, PTFE)-lined SGI/WCB/SS valves, pipes & fittings. 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 as approved by international food & drugs regulatory authorities, non-inflammable, self-sealant, good weather resistance and zero water absorption. Supremo Line & Control Ahmedabad - Gujarat Tel: 079-2220 5282, Fax: 079-2220 5181 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
84
Chemical World | December 2010
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Acoustic hoods...................................................... Air blowers ............................................................ Air breathing apparatus......................................... Air pollution control equipment............................. Air receivers........................................................... Air treatment......................................................... Air-cooled heat exchangers .................................... Air-cooled steam condensers ................................. Alu-cera polymer ................................................... Aluma coat............................................................ Aluminium oxide ceramic composites .................... Analytical instruments............................................ Antistatic lined pipes ............................................. Atex-compliant products........................................ Automatic filter press ............................................ Bag emptying equipment ...................................... Ball valves - Teflon-lined......................................... Ball valves-teflon lined ........................................... Bellows & dip-pipes ............................................... Bend ..................................................................... Big bag filling & emptying equipment.................... Blenders ................................................................ First Fold Here Blowers ................................................................. Bottom discharge centrifuge.................................. Bucket elevators..................................................... Bulk solid cooling and heating technology for chemicals ... Butterfly valves ...................................................... Butterfly valves - Teflon-lined ................................. Ceramic adhesive cement....................................... Ceramic electrical heater parts ............................... Ceramic plates ....................................................... Chain conveyors .................................................... Check valves - Teflon-lined ..................................... Chemical directory ................................................. Chemical dosing pumpS ........................................ Chemical process pumps ....................................... Chemical tanks ...................................................... Chemical transfer pumps ....................................... Chlorination plant.................................................. Chlorine cylinder/tonner emergency repair kit ........ Chlorine gas cylinder ............................................. Chlorine gas mask ................................................. Chloroscope .......................................................... Columns & chemistries .......................................... Condensers............................................................ Conditioners .......................................................... Cone screw mixer .................................................. Conical screw dryers .............................................. Containers ............................................................. Cooling tower ....................................................... Couplings .............................................................. Second Fold Here Crystallisers............................................................ Custom mouldings ................................................ Dairy equipment .................................................... Dampers................................................................ Desupereaters........................................................ Diaphragm valve.................................................... Dip pipes ............................................................... Drives .................................................................... Drums & carboys ................................................... Dust collectors....................................................... Empower............................................................... End cap................................................................. Exhausters ............................................................. Exhibition - Engineering Expo ................................ Exhibition - Everything About Water Expo 2011..... Exhibition - HiTech Manufacturing Show................ Feed water heaters ................................................
Feeding & metering equipment.............................. Fertilisers ............................................................... Filter cock .............................................................. Filter plates............................................................ Filter presses .......................................................... Filter press terminology.......................................... Fittings and valves ................................................. Flat high tension single-twin igniting electrodes..... Flow indicator........................................................ Fluoropolymer-lined pipes ...................................... Fluoropolymer-lined valves ..................................... Fluoropolymer-lined valves ..................................... Foot valve .............................................................. FRP underground fuel tanks................................... Gas conditioning and fire protection...................... Gas detectors ........................................................ Gear ...................................................................... Gear motor............................................................ Gear pump ............................................................ Gearbox ................................................................ Geared & flexible couplings ................................... Geared motor........................................................ GMP heat exchangers ............................................ GMP reactors......................................................... Granulators ........................................................... Grinding media ..................................................... Heat exchangers .................................................... Helical gearbox ...................................................... High pressure bellows............................................ Hoses .................................................................... HPLC ..................................................................... HRC fuse bodies .................................................... Hydraulic filter press .............................................. Hydrogenator/autoclaves ....................................... Impellers................................................................ Industrial ceramic .................................................. Industrial coolers ................................................... Industrial pumps.................................................... Informatics ............................................................ Insulated boxes...................................................... Level & pressure monitoring & safety components . Lined valves & pipe fittings .................................... Loading arms......................................................... Long neck pipe end ............................................... Magnet drive pumps ............................................. Manual filter press................................................. Material handling containers ................................. Mechanical vacuum boosters ................................. Membrane filer plates............................................ Membrane filter press............................................ Metal keyboards .................................................... Micro milling beads ............................................... Mill lining blocks ................................................... Mixers ................................................................... Monoblock pumps ................................................ Motors .................................................................. Multiple effect evaporators .................................... National Conference for Manufacturing SME ......... Non-return valves .................................................. Nozzles.................................................................. Pallets.................................................................... Particle counter...................................................... pH meter............................................................... Photoelectric sensor............................................... Pickling tanks......................................................... Plate heat exchanger ............................................. Plates & filter plates ............................................... Pneumatic conveying system components..............
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Pole ring...................................................... Pollution monitoring machines .................... Polymers...................................................... Polypropylene filter plates ............................ Polypropylene recess plates .......................... Power plant condensing packages ............... Process equipment....................................... Process heat exchangers .............................. Process reactors ........................................... PTFE-lined valves & pipe fittings ................... Pumps ......................................................... Reactors ...................................................... Receptacles.................................................. Recessed chamber filter plates ..................... Re-crystallised alumina tubes ....................... Reducers...................................................... Roots blower ............................................... Rotary feeders (rotary valves) ....................... Rotary sliding vane pumps ........................... Rotary vacuum dryers .................................. Rotary vacuum pumps ................................. Rotocone dryers........................................... Sampling valves - Teflon-lined ...................... Sand............................................................ Scalewatcher ............................................... Scoop.......................................................... Screw conveyors & feeders........................... Self-adhesive tapes ......................................
Service - SME loans...................................... Service control valves ................................... Showel ........................................................ Sight flow indicator ..................................... Sight flow meters ........................................ Silicone carbide heat exchangers.................. Silo safety components................................ Single-screw air compressor......................... Slipon flange ............................................... Smart Logistics Leadership Series ................. Software...................................................... Solid-liquid separation equipment ............... Solids discharging equipment ...................... Spade.......................................................... Special lined pipe......................................... Spherical paddle chopper dryers .................. Spiral-cum-helical gearbox ........................... Spray analysis .............................................. Spray control ............................................... Spray dryer project ...................................... Spray fabrication ......................................... Spray nozzles and accessories ...................... SS/MS teflon-lined flexible hose pipe ........... Steam jet ejector vacuum systems................ Strainers - Teflon-lined ................................. Structured packing ...................................... Structured packings & internals ................... Swivels ........................................................
Technical ceramic......................................... Tee .............................................................. Teflon sparger.............................................. Teflon-lined pipes ........................................ Teflon-lined valves........................................ Teflon-lined valves & pipe fittings................. Thermometer pocket ................................... Tri-lobe roots blowers .................................. Turbidity meter ............................................ Turbine bypass valves ................................... Turnkey projects........................................... Turnkey systems for dust suppression........... Twin lobe roots blowers............................... Two-stage vacuum pump............................. Ultrafiltration system ................................... Ultrasonic cleaning chemicals ...................... UPLC ........................................................... Valve actuators ............................................ Valves.......................................................... Ventilators ................................................... Vibrators & flow aids ................................... Washers ...................................................... Water faucet & tap parts ............................. Water ring vacuum pumps .......................... Worm gear .................................................. ‘Y’ type strainer ........................................... Yellow Pages................................................ Zirconia polycrystal ceramic .........................
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PRODUCT INDEX Product
Pg No
Acoustic hoods........................................... 65 Air blowers ...................................................... 65 Air breathing apparatus................................... 80 Air pollution control equipment.................25, 37 Air receivers ..................................................... 25 Air treatment ..................................................... 6 Air-cooled heat exchangers.............................. 13 Air-cooled steam condensers ........................... 13 Alu-cera polymer ............................................ BIC Aluma coat..................................................... BIC Aluminium oxide ceramic composites ............. BIC Analytical instruments...................................... 27 Antistatic lined pipes ......................................... 4 Atex-compliant products.................................. 41 Automatic filter press......................................... 9 Bag emptying equipment.......................... 41 Ball valves - Teflon-lined .................................... 7 Ball valves-teflon lined ..................................... 83 Bellows & dip-pipes ........................................... 7 Bend................................................................ 83 Big bag filling & emptying equipment ............. 41 Blenders........................................................... 41 Blowers......................................................63, 65 Bottom discharge centrifuge............................ 78 Bucket elevators............................................... 41 Bulk solid cooling and heating technology for chemicals............................... BC Butterfly valves................................................. 83 Butterfly valves - Teflon-lined ............................. 7 Ceramic adhesive cement.........................BIC Ceramic electrical heater parts ........................ BIC Ceramic plates ................................................... 9 Chain conveyors............................................... 41 Check valves - Teflon-lined................................. 7 Chemical directory ........................................... 81 Chemical dosing pumpS .................................. 80 Chemical process pumps ................................. 83 Chemical tanks ................................................ 81 Chemical transfer pumps ................................. 81 Chlorination plant............................................ 80 Chlorine cylinder/tonner emergency repair kit .. 80 Chlorine gas cylinder........................................ 80 Chlorine gas mask ........................................... 80 Chloroscope..................................................... 80 Columns & chemistries..................................... 27 Condensers ...................................................... 25 Conditioners .................................................... 41 Cone screw mixer ............................................ 25 Conical screw dryers .......................................... 3 Containers ....................................................... 81 Cooling tower..............................................6, 13 Couplings ................................................. FIC, 43 Crystallisers ...................................................... 37 Custom mouldings........................................... 81 Dairy equipment ........................................ 25 Dampers .......................................................... 25 Desupereaters .................................................. 37 Diaphragm valve .............................................. 83 Dip pipes ........................................................... 4 Drives ................................................................ 5 Drums & carboys ............................................. 81 Dust collectors ................................................. 41 Empower .................................................... 27 End cap ........................................................... 83 Exhausters........................................................ 63 Exhibition - Engineering Expo ..............11, 29, 47 Exhibition - Everything About Water Expo 2011 .........8 Exhibition - HiTech Manufacturing Show ....57-60 Feed water heaters .................................... 37 Feeding & metering equipment ....................... 41 Fertilisers.......................................................... BC Filter cock ........................................................ 83 Filter plates ........................................................ 9 Filter presses ................................................9, 79
Product
Pg No
Filter press terminology...................................... 9 Fittings and valves ............................................. 4 Flat high tension single-twin igniting electrodes ......BIC Flow indicator.................................................. 83 Fluoropolymer-lined pipes .................................. 4 Fluoropolymer-lined valves ............................... 84 Fluoropolymer-lined valves ............................... 81 Foot valve ........................................................ 83 FRP underground fuel tanks............................. 81 Gas conditioning and fire protection ....... 21 Gas detectors................................................... 45 Gear ................................................................ 67 Gear motor...................................................... 67 Gear pump ...................................................... 79 Gearbox........................................................... 67 Geared & flexible couplings ............................. 67 Geared motor .................................................. 61 GMP heat exchangers ........................................ 3 GMP reactors..................................................... 3 Granulators...................................................... 41 Grinding media............................................... BIC Heat exchangers............................ 16, 19, 25 Helical gearbox ................................................ 61 High pressure bellows........................................ 4 Hoses.............................................................. FIC HPLC................................................................ 27 HRC fuse bodies ............................................. BIC Hydraulic filter press .......................................... 9 Hydrogenator/autoclaves.................................... 3 Impellers..................................................... 83 Industrial ceramic ........................................... BIC Industrial coolers ............................................... 6 Industrial pumps.............................................. 43 Informatics ...................................................... 27 Insulated boxes................................................ 81 Level & pressure monitoring & safety components ... 41 Lined valves & pipe fittings ................................ 7 Loading arms................................................... 43 Long neck pipe end ......................................... 83 Magnet drive pumps ................................. 83 Manual filter press............................................. 9 Material handling containers ........................... 81 Mechanical vacuum boosters ........................... 63 Membrane filer plates........................................ 9 Membrane filter press........................................ 9 Metal keyboards .............................................. 80 Micro milling beads ........................................ BIC Mill lining blocks............................................. BIC Mixers.............................................................. 41 Monoblock pumps........................................... 83 Motors............................................................. 83 Multiple effect evaporators .............................. 37 National Conference for Manufacturing SME... 10 Non-return valves.........................................7, 83 Nozzles ............................................................ 43 Pallets ......................................................... 81 Particle counter................................................ 78 pH meter ......................................................... 80 Photoelectric sensor ......................................... 81 Pickling tanks................................................... 78 Plate heat exchanger ....................................... 84 Plates & filter plates ........................................... 9 Pneumatic conveying system components........ 41 Pole ring .......................................................... 83 Pollution monitoring machines ........................ 45 Polymers .......................................................... BC Polypropylene filter plates ................................ 79 Polypropylene recess plates .............................. 79 Power plant condensing packages ................... 37 Process equipment........................................... 55 Process heat exchangers .................................... 3 Process reactors ................................................. 3 PTFE-lined valves & pipe fittings......................... 7 Pumps .................................................79, 81, 83
Product
Pg No
Reactors...................................................... 25 Receptacles ...................................................... 43 Recessed chamber filter plates ........................... 9 Re-crystallised alumina tubes .......................... BIC Reducers .......................................................... 83 Roots blower ................................................... 79 Rotary feeders (rotary valves) ........................... 41 Rotary sliding vane pumps............................... 83 Rotary vacuum dryers ........................................ 3 Rotary vacuum pumps ..................................... 82 Rotocone dryers................................................. 3 Sampling valves - Teflon-lined .................... 7 Sand ................................................................ BC Scalewatcher.................................................... 53 Scoop .............................................................. 83 Screw conveyors & feeders .............................. 41 Self-adhesive tapes .......................................... 81 Service - SME loans ......................................... 35 Service control valves ....................................... 37 Showel ............................................................ 83 Sight flow indicator ........................................... 4 Sight flow meters ............................................ 43 Silicone carbide heat exchangers........................ 3 Silo safety components .................................... 41 Single-screw air compressor............................. 78 Slipon flange ................................................... 83 Smart Logistics Leadership Series ..................... 14 Software .......................................................... 15 Solid-liquid separation equipment.................... 41 Solids discharging equipment .......................... 41 Spade .............................................................. 83 Special lined pipe............................................... 4 Spherical paddle chopper dryers ........................ 3 Spiral-cum-helical gearbox ............................... 67 Spray analysis .................................................. 21 Spray control ................................................... 21 Spray dryer project........................................... 25 Spray fabrication.............................................. 21 Spray nozzles and accessories .......................... 21 SS/MS teflon-lined flexible hose pipe ................. 4 Steam jet ejector vacuum systems ................... 37 Strainers - Teflon-lined....................................... 7 Structured packing............................................. 4 Structured packings & internals ....................... 83 Swivels............................................................. 43 Technical ceramic......................................BIC Tee .................................................................. 83 Teflon sparger.................................................... 4 Teflon-lined pipes .............................................. 4 Teflon-lined valves ............................................. 4 Teflon-lined valves & pipe fittings ...................... 7 Thermometer pocket.......................................... 4 Tri-lobe roots blowers ...................................... 63 Turbidity meter ................................................ 80 Turbine bypass valves....................................... 37 Turnkey projects ................................................ 3 Turnkey systems for dust suppression .............. 21 Twin lobe roots blowers ............................63, 79 Two-stage vacuum pump ................................ 79 Ultrafiltration system................................. 82 Ultrasonic cleaning chemicals .......................... 80 UPLC................................................................ 27 Valve actuators .......................................... 41 Valves ........................................................41, 83 Ventilators ....................................................... 81 Vibrators & flow aids ....................................... 41 Washers ...................................................... 83 Water faucet & tap parts ................................ BIC Water ring vacuum pumps .............................. 79 Worm gear ...................................................... 67 ‘Y’ type strainer ......................................... 83 Yellow Pages ................................................... 88 Zirconia polycrystal ceramic .....................BIC
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover
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