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INDUSTRY WATCH - Chemical World
February 2012
EDITORIAL
The Budget beat
W
ith the Union Budget 2012 on the horizon, and more importantly, its likely upshots for the next fiscal, it will be pertinent to analyse with insight some of the recent developments – both globally and nationally – with potential to impact the chemical process industry value chain. In addition, it will be prudent to proactively prepare for the strategic scenario ahead. Let’s get started with the global scenario. The economic slowdown of recent times is primarily owing to sovereign debt issue in certain geographies rather than industry/ company-specific financial meltdown as was experienced in 2008-09. That said, there are good news as well as bad news. The good news is that the extent of the meltdown pulling down businesses may not be as globally widespread as it was the last time; hence, there will still be some emerging growth markets, albeit with a slow pace of progress. However, the bad part is that no one is clear about how long this business dampener will continue, and what if this malignancy spreads to other geographies. As far as India is concerned, the government’s policy paralysis seems to continue, with one of the crucial misses being the deferral in implementation of Goods and Services Tax (GST). However, things seem to be moving on this front, finally. The government has reportedly been able to obtain in-principle approval from all state governments on implementation of GST. Upon implementation, this long-pending reform will not only reduce business costs, but also improve government revenues. From a sectoral perspective, of late, there has been a global shift in the manufacturing value chain of chemicals and chemical process equipment, from West to East, primarily buoyed by mega trends sweeping the use of these in the latter part of the world. Also, the industry is witnessing increasing penetration of complete production systems along with application of advanced automation and innovative technologies, especially in the emerging economies to cater to a global market.
Editorial Advisory Board PothenP aul Former Chairman, Aker Powergas Pvt Ltd
Given this scenario, the forthcoming Union Budget will be an opportune moment for the policy-makers to make a decisive beginning, perhaps the second phase of economic liberalisation, and leave a long-lasting impression on the economy as well as the industry. Let the journey begin!
D P Misra Director, TCE Consulting Engineers Ltd and Former Director General, ICC
P D Samudra Executive Director (Sales) & Member of the Board, Uhde India Pvt Ltd
Manas R Bastia manas@infomedia18.in
February 2012 | Chemical World
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44 26 Cover visual: Mahendra Varpe
Special Focus: Oil & Gas
Insight & Outlook: Energy Management Energy efficiency ................................................................ 44 Efficient technology ........................................................... 46 Chemical industry in 2011 ................................................. 48
Natural gas .......................................................................... 26 Pipeline maintenance ......................................................... 28 Produced water treatment ................................................... 32
Coatings industry ............................................................... 50
Automation Trends
Interface - Soumen Kumar Roy, GM - HS&E, IOCL ....... 34
Traceability in manufacturing: Holistic tool to add value in supply chain .......................................................... 52
Interface - B Akala, Director, CBM Solutions India ......... 36
Energy Management
Roundtable .......................................................................... 38
SMEs in chemical sector: Imperative to inculcate best practices in energy usage ........................................... 54
In Conversation With
Policies & Regulations
Syed Jafry, Senior Vice President, ThermoFisher Scientific, and President, Asia-Pacific & South America .................... 20
Budget Wish List: Industry Voice
Interface - Sameer Bhatia Senior Director, Deloitte, India ......................................... 56
Strategy Industry-academia collaboration: Leveraging the best of both worlds ............................................................. 58
Tips & Tricks
Need for tax rationalisation to boost the sector................. 22
Facility Visit: HRS Process Systems Ltd
Lubricant selection: The pros and cons of synthetics and petroleum-based lubes ................................................. 62
Event Preview
Where precision is the hallmark ........................................ 40
Regular Sections Editorial ........................................................................ 5 News, Views & Analysis .............................................. 10 Technology & Innovation............................................ 18 Technology Transfer .................................................... 19 Projects ........................................................................ 63 Event List .................................................................... 65 Book Review ................................................................ 70 Products ...................................................................... 71 List of Products .......................................................... 85 List of Advertisers ...................................................... 86
Engineering Expo Aurangabad 2012: A majestic trade proposition ................................................................. 66
Event Report Engineering Expo Indore 2012: Transforming challenges to opportunities................................................. 68 Details on page no. 55, 64, 65
Highlights of Next Edition Special Focus: Safety & Maintenance Insight & Outlook: Specialty/Fine Chemicals
Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise February 2012 | Chemical World
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Business Insights Technologies Opportunities
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February 2012 | Chemical World
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NEWS, VIEWS & ANALYSIS
SPECIALT Y CHEMICALS
LANXESS invests ` 490 crore to expand Jhagadia facility Continuing its expansion strategy in India, the specialty major LANXESS recently inaugurated three new plants at its Jhagadia site in Gujarat to serve the growing domestic market. The company has invested around ` 490 crore (Euro 70 million) and created roughly 300 new jobs at the site. Its semi-crystalline products business unit started production at the site’s new plant for high-tech plastics. In addition, the material protection products business unit inaugurated a plant for biocides used in the construction industry. LANXESS subsidiary Rhein Chemie also started up a plant for release agents and additives used in the manufacturing of tyres and rubber products. Both plants were relocated from a former site in Madurai, Tamil Nadu. The
Dow inks pact with ICL affiliate for flame retardant
LANXESS officials at inaugural function
site already includes plants for ion exchange resins and rubber chemicals. Both started production in 2010. “LANXESS is heavily investing in the Indian subcontinent and this commitment has already paid off: We surpassed our 2010 sales already in the first nine months of 2011,” stated Dr Axel C Heitmann, Chairman of the Board of Management of LANXESS.
AGROCHEMICALS
Clariant strengthens innovation capabilities for crop protection sector in India In order to enhance local service and development support for crop protection sector in the emerging Indian market, Clariant’s Industrial & Consumer Specialties (ICS) Business Unit recently opened a new crop protection laboratory at its Kolshet site in Thane, near Mumbai. The new lab, which Christian Vang (Right) along with was inaugurated by Christian Vang, Head Dr Alexander Snell inaugurating the new lab of ICS, Asia-Pacific, Clariant, will focus on building a unique portfolio of crop protection guideline formulations, using Clariant’s ranges of emulsifiers, adjuvants, dispersing agents and new innovative chemistries derived from renewable resources. “Following the opening of the new personal care laboratory in October 2011, this new lab marks another milestone in our strategy to increase the service we offer to our valued Indian customers,” explained Dr Alexander Snell, Head of BU ICS India. RECOGNITION
Aker Powergas applauded for safety initiatives
Aker team with the award
Aker Powergas recently received an award towards the celebration of 10 million safe man hours on its project for Nagarjuna 10
Chemical World | February 2012
LICENSING DEAL
Oil Corporation Ltd (NOCL). The company is executing the engineering, procurement and construction management (EPCm) for the FCC and Merox units at NOCL’s 6 MMTPA refinery complex, located on 1600 acre at Cuddalore in Tamil Nadu, India. This is Aker Powergas’s first refinery project where the scope includes EPCm. At peak time, the Aker Powergas task force on this project consisted of 140 engineers
Dow Global Technologies LLC (DGTL), a subsidiary of The Dow Chemical Company, has signed a second license agreement for its polymeric Flame Retardant (FR) technology with Bromine Compounds Ltd, a company within the ICL Industrial Products (ICL-IP) segment. ICL-IP is a global leader in the production of flame retardants and has been granted a license to produce and sell the polymeric FR for use in extruded polystyrene (XPS) and expanded polystyrene (EPS) foam insulation products. A second licensee confirms global supply of the polymeric FR, validating and supporting the technology’s position as the new global industry standard flame retardant in the production of XPS and EPS foams. In March 2011, DGTL announced the invention and development of the polymeric FR - a stable, high molecular weight, non-PBT (persistent, bioaccumulative, toxic) substance with an enhanced environment, health & safety profile compared to current alternatives. The additive provides a fire safety solution for XPS and EPS foams enabling these thermal insulation materials to continue to meet the increasing demands for global energy efficiency regulations and sustainable building design.
and 20 onsite personnel for construction management. This venture will produce petro-products to international specifications and contribute in meeting the energy demands of Tamil Nadu. The shield was presented by P R K Rao, Executive Director – Finance, NOCL, and accepted on Aker Powergas’ behalf by the onsite construction management team. The function was also attended by S Ramasundaram, Managing Director and CEO, NOCL. Mahua Roy
NEWS, VIEWS & ANALYSIS
ENZYMATIC TECHNOLOGY
DISCUSSION FORUM
Novozymes and Sea6 Energy to explore ways to develop biofuels from seaweed
Chlor-alkali association organises power seminar
Novozymes has announced an exploratory Shrikumar Suryanarayan, Chairman, research agreement with the ChennaiSea6 Energy, said, “We are excited based Sea6 Energy to jointly develop a about our partnership with Novozymes process for the production of biofuels and look forward to developing an from seaweed. The research alliance will efficient enzymatic process to convert use enzymes to convert seaweed-based seaweed to sugar. Combined with Sea6 carbohydrates to sugar, which Energy’s offshore seaweed can then be fermented to cultivation expertise, these produce ethanol for fuel, fine conversion technologies chemicals, proteins for food, will offer a scalable and and fertilisers for plants. sustainable alternative to No vo z y mes wil l expensive and polluting research, develop, and fossil fuels, while providing manufacture enzymes for employment to coastal the conversion process, while communities and energy Sea6 Energy contributes its security for our country.” offshore seaweed cultivation Sea6 Energ y is technology. “Seaweed is a Different kinds of seaweeds currently carrying out trials natural complement to our efforts to convert for its seaweed cultivation technology other types of biomass to fuel ethanol. More in partnership with a few fishing than half of the dry mass in seaweed is sugar, communities around the coastal areas and the potential is therefore significant,” of South India. Novozymes’ Indian arm said Per Falholt, Executive Vice President will work closely with Sea6 Energy to and CSO, Novozymes. develop the conversion technology.
The Alkali Manufacturers’ Association of India (AMAI) will organise a seminar on ‘Open access & wheeling of power: Regulations & issues’ from February 16-17, 2012, in New Delhi to discuss matters relating to power. AMAI has invited experts from Central Electricity Regulatory Commission (CERC), power exchange companies, State Electricity Boards (SEBs), and chlor-alkali industry. The survival of chlor-alkali industry, which is power-intensive, depends on the availability of continuous power at lower cost. “The entire objective of this seminar is to crystallise ideas and work out suggestions, which could help the industry to get power uninterruptedly in sufficient quantity and at internationally competitive rates. This will not only help in the survival of the industry, but will give a boost to the industrial growth,” said the AMAI press release.
ANALY TICAL INSTRUMENTS
ANALY TICAL EQUIPMENT
Waters and NIBRT complete work on world’s first UPLC glycan database
US-based Brookfield Engineering plans to expand in India
Waters Corporation and Ireland’s National Institute for Bioprocessing Research and Training (NIBRT) announced the availability of the world’s first database for glycan analysis by UltraPerformance Liquid Chromatography® (UPLC®). Developed by Prof Pauline Rudd’s research team at NIBRT, the new GlycoBase 3+ Database is the first-ofits-kind repository of chromatographic retention positions expressed in glucose units for sets of glycan structures associated with a range of biotherapeutics. Now available for purchase, the database will be co-marketed worldwide by Waters and NIBRT. The GlycoBase 3+ Database is intended to give biopharmaceutical manufacturers a timely and powerful tool for confirming the structure of various glycosylated proteins. 12
Chemical World | February 2012
David Brookfield (left) and Sanjay Mehta, Co-founder, Amkette Analytics, at the new lab
Brookfield Engineering Laboratories, Inc, one of the leading global manufacturers of viscometers and rheometers for laboratory and industrial applications, is looking to target the online process control applications market for its products in India. The company wants to tap the industries such as pharma, food, chemicals, petroleum, etc. “Globally, there is a trend to move from lab to online analysis so as to reduce time for analysis. While we have supplied viscometers and rheometers for online applications in the US, we need
to explore overseas markets as well,” said Joseph Moi, VP - Brookfield Engineering Labs Inc. In its efforts to further expand its business in India, Brookfield Engineering recently opened an application lab in Thane (Maharashtra) in collaboration with Amkette Analytics, its distributor in India. David Brookfield, President and CEO, Brookfield Engineering Labs, Inc said, “Apart from the Indian market, the new lab will also serve our customers in West Asia, Africa and the ASEAN nations as a knowledge resource centre for viscosity, rheology and powder flow analysis.” While Amkette Analytics already offers Brookfield products for lab applications in India, the new lab, which is the only advanced application lab in South East Asia, will help it grow its business in online process applications as well. Rakesh Rao
NEWS, VIEWS & ANALYSIS
DYE INDUSTRY
FILTRATION AND SEPARATION
Dye and colourant industry working towards sustainability
Cole-Parmer to distribute ADVANTEC products in India
The Ecological and Toxicological Association of Dyes and Organic Pigments Manufacturers (ETAD), based in Basel, Switzerland, along with Indian Operating Committee (IOC) recently organised a one-day conference, in Mumbai. The seminar presentations stressed on the effects of dyes & colourants in the environment and health, and outlined various technological advancements in their safe manufacture, use and disposal. Eminent speakers included international and national experts from the industry including Dr Clemens Grund, VP-Technology, Dystar Colours Distribution; Dr Dileep Wakanker, Head-Corporate Product Stewardship, Clariant Chemicals India; Dr Peter Scheibli, Senior REACH ExpertTextile Effects, Huntsman; Reynold D’Souza, DGM (R&D), Sakata Inx; K P Nyati, CEO, SMI; Niraj Singh, Regional Product Safety Manager, Levis Strauss & Co; and Dr M U Rahman, General Manager (R&D and QA), Atul Ltd. Delivering the keynote address, Ravi Kapoor, President, ETAD and Managing Director, Heubach India, said, “The path to the growth of the dyestuff industry is challenging with regulatory, product safety and environmental issues playing a major role. It is these issues that ETAD seeks to address.” The seminars principally addressed issues like REACH, sustainability, waste management, Responsible Care, Nanopigments among others. Wakankar stressed the need for one standard method of testing of dyestuffs, to be uniformly followed by all labs.
Cole-Parmer has acquired authorised distribution rights in India for ADVANTEC’s wide range of filtration solutions for laboratory, research and process applications. ADVANTEC ’s products are used in a wide variety of scientific capacities and applications such as microbiological analysis, air/gas filtration and environmental monitoring. Specifically, ADVANTEC serves the pharmaceutical, public health, food & beverage, water analysis, healthcare, life sciences, and electronics industries. Because ADVANTEC manufactures its products to exacting standards, they are known for high product integrity. “ADVANTEC’s range of filtration products fits comfortably within Cole-Parmer’s own product range. It offers our customers an additional and valuable range of unique quality products that will enhance their processes and research,” commented Kashmira Nadkarni, Product Manager, Cole-Parmer India. Koichi Shiode, General Manager, ADVANTEC MFS Inc, added, “We are pleased to extend our partnership with Cole-Parmer to India, and are excited about the opportunity to introduce ADVANTEC’s high-quality products to the Indian customers.” Founded in 1917 as the first manufacturer of filter papers in Japan, today ADVANTEC is a global company with a focus on high-quality products for separation science.
Mahua Roy
APPOINTMENT
PETROCHEMICALS
Mike Barker is the new MD of Mott MacDonald’s India business
Honeywell’s UOP selected by Dow Chemical to provide technology for US petrochemical facility
Mott MacDonald, a global management, engineering and development consultancy firm, has appointed Mike Barker as Managing Director of its India business, taking over from Satyavrat Srivastava who has retired after 35 years with the company. Barker will be responsible for further developing Mott MacDonald’s position as one of India’s leading management, engineering and development consultancies in all sectors including energy, transport, water, buildings, industry, health and education. Barker has been with Mott MacDonald for almost Mike Barker 25 years and has worked on some of the most prestigious projects. Commenting on his appointment, Barker said: “India is a major country for Mott MacDonald and we are already working on some of the country’s most significant infrastructure projects. As the country continues to develop, it provides great business opportunities across all of Mott MacDonald’s key markets. In my role as managing director, I aim to build on the success that Satyavrat Srivastava has achieved over recent years, growing the business further, expanding our services and delivering solutions and support that contribute to our customers’ success.” 14
Chemical World | February 2012
UOP LLC, a Honeywell company, was recently selected by The Dow Chemical Company to provide technology for producing propylene at Dow’s Texas site. Dow will use UOP C3 Oleflex™ technology in a new propane dehydrogenation unit to convert shale gas-derived propane to propylene, a product used in the production of packaging, adhesives, coatings, cleaners and many other end-use applications. The facility will produce 7,50,000 metric tonne per year of polymer-grade propylene. The unit is scheduled to start up in 2015.
NEWS, VIEWS & ANALYSIS
INTERACTIVE FORUM
NOVEL MATERIAL
Manufacturing Summit for empowerment of SMEs
Evonik invests in fibre spinning plant for gas separation membranes
M Narendra inaugurating the summit by lighting the lamp. L-R: R K Dubey, Chandrakant Salunkhe and Ajay Shankar
The contribution of Indian small and medium enterprises (SMEs) in the economic development of the country cannot be overemphasised. In a fitting tribute to this, SME Chamber of India recently organised its national level annual flagship event titled ‘SME Manufacturing Summit 2012: Strategies and Initiatives for Sustainable Growth’ in Mumbai. The one-day summit was spread over three plenary sessions: Challenges and opportunities for SMEs, Strategies for better growth and Support services for better growth. While speaking on the occasion, the Chief Guest, M Narendra, Chairman & Managing Director, Indian Overseas Bank, highlighted the importance of Indian SMEs for the Indian economy and the challenges faced by this segment.
Ajay Shankar, Member Secretary, National Manufacturing Competitiveness Council (NMCC), Government of India, was the keynote speaker. In his address to the audience, he gave an overview of National Manufacturing Policy (NMP) that aims to take the growth of manufacturing sector to 12-14 per cent, create 100 million jobs, and increase the share of the sector in India’s GDP to 25 per cent from current 16 per cent by 2022. “For this, it is necessary to have a regulatory environment that supports high birth rate of new enterprises and also helps SMEs to scale up and grow fast,” he added. Other dignitaries present in this interactive forum of policy makers, bankers and SMEs included Kewal Handa, Managing Director, Pfizer Ltd; R K Dubey, Executive Director, Central Bank of India; Prashant Nagre, Chief Operating Officer, Fermenta Biotech Ltd; Jayesh Rambhia, President, The All India Plastic Manufacturers’ Association; Dr Rajendra Abhyankar, Former Secretary, Ministry of Foreign Affairs; and Chandrakant Salunkhe, President, SME Chamber of India. Manas R Bastia
Evonik Industries is setting up a plant for producing SEPURAN® hollow fibre membrane modules at its Schörfling, Austria, site. In particular, the novel membrane technology facilitates energy-efficient upgrading of biogas to biomethane. Biomethane is fed into the public natural gas grid. The new hollow fibre spinning plant will come onstream within 2012 to meet the growing demand on the biogas market. “With this investment, we are systematically strengthening our activities in the area of gas separation membranes proving our commitment to renewable energies by producing biomethane that can be fed directly into the grid. In contrast to other processes, our membrane technology needs no auxiliary chemicals; nor does it generate any solid wastes or effluents that would need to be disposed of,” said Dr Axel Kobus, Head - Fibres & Membranes Segment, Evonik Industries. The Evonik process is offered in the market by leading plant engineering and construction partners, and works cost effectively, even in relatively small plants.
EXHIBITION
SILICONE CHEMISTRY
Powder & Bulk Solids India to be held at Ahmedabad
WACKER signs partnership agreement with Spanish company
NürnbergMesse Group, jointly with Vogel Business Media, will be organising Powder & Bulk Solids India 2012, formerly known as Bulk Solids India, at Ahmedabad from March 1315, 2012. As the official representative of NüernbergMesse, the Indo-German Chamber of Commerce is supporting this event in India. Powder & Bulk Solids India 2012 will present basic processing technologies for powder and bulk materials, plant engineering and processing components, as well as a wide range of specialised products related to the chemical, food, pharmaceutical, cement, mining and ports industry.
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Chemical World | February 2012
WACKER, the Munich-based chemicals group, is strengthening its ties with Siliconas Silam S.A., a silicones compounder in Spain. The two companies recently signed an agreement to that effect. Under its terms, Siliconas Silam may sell readyto-use products made from WACKER Silicones are used in products such as silicone rubber base under its own label and turbocharger hoses bearing the supplemental slogan ‘Based on ELASTOSIL®’. Customers include the automotive, construction, cable and household goods industries. Siliconas Silam has been compounding and marketing WACKER products in the region for more than a decade. “The Spanish market is important for us, since we closely cooperate with local cable manufacturers and suppliers to the automotive and household goods sectors. Thanks to our long-term commitment and the support of our distribution partners, we have established a strong position there, especially in solid silicone rubber,” said Dr Bernd Pachaly, Head - Engineering Silicones Business Unit, WACKER.
TECHNOLOGY & INNOVATION
Rockwell Automation’s new power monitors to help achieve energy efficiency Two new Allen-Bradley power monitors from Rockwell Automation provide manufacturers with scalable, cost-effective insight into how, when and where energy is being used throughout the production process. The Allen-Bradley PowerMonitor W250 and 500 power meters offer users an opportunity to costeffectively drive energy monitoring further into their production processes compared to previous monitoring technology. “Many manufacturers are looking to gain deeper insight and data granularity of their industrial energy consumption. These two new power monitors allow our customers to drill down beneath facility or processlevel monitoring to collect data from specific energy-intensive applications without significant cost and effort,” explained Phillip Bush, Power and Energy Management Product Manager, Rockwell Automation. The PowerMonitor W250 power meter offers a self-generating wireless communications platform, ideally suited for applications located in areas where hard-wired networking is cost-prohibitive. The PowerMonitor 500 power meter features a large LCD display to view energy use information directly at the process being monitored without requiring any additional components. The wireless PowerMonitor W250 power meter is capable of measuring energy consumption at multiple metering locations, including remote or confined spaces such as ceilings, conveyor belts or outdoors. For smaller consumption and demand-monitoring applications, the PowerMonitor 500 power meter features an on-device LCD display in a small, panel-mounted footprint.
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Chemical World | February 2012
Grabner Instruments’ portable FTIR spectrometer offers better accuracy in fuel analysis Grabner Instruments, a subsidiary of AMETEK Inc, has introduced a new portable and highly versatile Fourier Transform Infrared (FTIR) spectrometer for the fully automatic measurement of gasoline, diesel and biofuel blends. The MINISCAN IRXpert is the first completely portable fuel analyser that combines superior scanning range and resolution with the advantages of mid-IR and near-IR spectroscopy for the highest measurement accuracy. More than 40 fuel parameters are automatically analysed. It has been designed as an intelligent, self-learning analyser that allows an unlimited number of new fuel parameters to be analysed at the push of a button. In the 1990s, Dr Werner Grabner, founder of Vienna-based Grabner Instruments, developed the IROX, the first portable FTIR spectrometer to measure the concentration of oxygenates in gasoline by mid-IR. With 20 years of expertise and feedback from customers around the world, the new MINISCAN IRXpert reflects a paradigm shift to a new level of quality in fuel analysis. The instrument houses a unique dual-cell design spectrometer that offers an extended wave length range from mid-IR to near-IR, superior resolution and the ability to analyse multiple fuels with a single instrument. Maximum measurement stability is guaranteed through a temperature-controlled measuring cell and density meter. High accuracy is ensured through the combination of information from the mid-IR and the near-IR spectrum.
WACKER develops tin-free, general-purpose adhesive sealant WACKER has developed a new generalpurpose adhesive and sealant for the household appliances, automotive and electronics sectors. Available under the name ELASTOSIL® N9111, the onecomponent silicone rubber compound is a tin-free formulation. It cures at room temperature in the presence of atmospheric moisture to yield a silicone, which has excellent heat resistance and good mechanical properties. The new adhesive constitutes a tin-free alternative to conventional room temperature-curing, one-component silicone rubber compounds. RTV-1 silicone grades are widely used in bonding, sealing and coating applications. They have become indispensable in many industrial sectors, including construction, automotive engineering, household appliances, electronics and textiles. The launch of ELASTOSIL® N 9111 extends WACKER’s range of condensation-curing silicone rubber compounds with a product, which offers new processing opportunities in the electronics and household appliances sectors. The new adhesive sealant, technically an alkoxy-curing RTV-1 system, is formulated with a tin-free catalyst. It is, therefore, ideal for applications in which organo-tin compounds act as inhibitors, and are thus undesirable.
TECHNOLOGY TRANSFER
TECHNOLOGY OFFERED As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Sodium hydrosulfite An Iranian company is willing to manufacture sodium hydrosulfite using chemical compounds. It is widely used as a stripping agent in dyes and chemical industry. Areas of application Chemical industry Forms of transfer Technology licensing
Sodium sulfide An Iranian firm is willing to offer sodium sulfide, which is used mainly in textile industry, paper mill and curriery. Areas of application Leather industry, textiles, curriery industries, paper mills, etc
Forms of transfer Turnkey
Synthesis routes for organic chemicals An Indian firm is offering consultancy in design of synthesis routes for organic chemicals. Areas of application Pharma industry, speciality chemicals, plant protection chemicals, etc Forms of transfer Consultancy
Transformer oil unit An Indian company is willing to offer consultancy for making a transformer oil unit with domestic coal from its wastes.
Areas of application Transformers Forms of transfer Consultancy, technical services
Wasteless processing techniques An Indian company is willing to offer consultancy for waste-less processing techniques for the chemical & packaging industries. Areas of Application Packaging industry, transformer oil manufacturing industry, chlor alkali projects Forms of transfer Consultancy, technical services
TECHNOLOGY REQUESTED Small-scale environment-friendly chemical technology An Indian company is looking out for an economically viable smallscale environment-friendly chemical technology useful in the textile sector as well as in pharmaceutical sector. Areas of application Textile and pharmaceutical industry Forms of transfer Others
Solvent dyes An Indian company has recently installed a manufacturing capacity of 2,400 mtpa and is looking to diversify its product range
by including various solvent dyes in its product portfolio. The company is seeking process consultancy for this project. Areas of application Plastics, petroleum, solvents, etc Forms of transfer Others
Sodium silicate and activated carbon A company from Thailand requires technology for manufacturing sodium silicate and activated carbon from rice husk & rice husk ash. Areas of application Manufacturing and construction industry
Forms of transfer Others
Treatment of pollutants discharged during PTA production A Chinese organisation is looking for a recycling and pollution-free treatment technology to tackle the wastewater, exhaust gas, waste slag and noises generated in PTA production, thereby shifting from reduction of pollutant discharge to zero-discharge. Areas of application Chemical industry Forms of transfer Consultancy, technical services, etc
Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations - Asian and Pacific Centre for Transfer of Technology (APCTT), APCTT Building , C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.
Share and Solicit Technology The mission of Chemical World is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer. Contact us: Chemical World, Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: chemedit@infomedia18.in February 2012 | Chemical World
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IN CONVERSATION WITH Syed Jafry
“We are committed to investing in the Asia-Pacific region for a long term” …avers Syed Jafry, Senior Vice President, ThermoFisher Scientific, and President, Asia-Pacific & South America. With varied stints in Glaxo Pharmaceuticals, General Electric and the present organisation, he has driven several top management roles across the US, Europe and Asia. Jafry was in India recently to commemorate over 30 years of ThermoFisher Scientific’s association with the country. Excerpts of his conversation with Manas R Bastia…
Tell us about the recent megatrends impacting the scientific discovery and analytical processes across chemical process industries in Asia-Pacific. ThermoFisher Scientific’s (TFS) capabilities of high-end instruments, general lab equipment, reagents and chemicals, software & services span a broad spectrum of industries such as pharmaceuticals, biotechnology, healthcare, chemical & process industries etc. Our global presence gives us large visibility to the life-cycles in different parts of the world. We are clearly witnessing our large pharma customers investing in R&D and expanding their manufacturing footprint within Asia, more specifically in China and India. At the same time, our large Indian customers are expanding rapidly through foreign acquisitions. Moreover, increasingly many pharmaceutical organisations are diversifying into life sciences. India has emerged as a major player in the manufacturing of pharmaceuticals, vaccines as well as healthcare services. The environment is conducive for R&D in these sectors, which is supported by a rich pool of scientific talent.
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How does TFS respond to the above in terms of solutions? We at TFS aim at providing world-class technology and technical support to all our customers. Our Asia-Pacific customers have access to the same technology and high standards that we offer our US or European customers. Our customers across Asia are keen to partner with us not only for the technology that we offer but they are highly interested in accessing our application assistance, technical support and value-added services. We have invested in many application support centres in Asia and three such laboratories are in India alone – to support our customers in areas of pharma R&D, drug discovery and food safety. Many of our Indian customers are expanding by investing in new R&D facilities. For such customers, we offer our value-added services starting with laboratory design and turnkey project assistance through a wide portfolio of laboratory furniture. We also offer an end-to-end solution by equipping these new labs with a complete range of highend equipment, consumables, software and services as per the customers’ requirements.
Asia-Pacific is the fastest growing region for us and we are committed to investing in the region for a long term. China and India continue to be our focus markets and we will continue to add resources in this region wherever required. We would like to be recognised by our customers as the leaders in serving science.
What is the agenda of this high-profile visit of the global corporate leadership team to India? TFS has been servicing customers in India for the past three decades through various legacy entities and brands. Incidentally, some of our equipment here are still working well after 20 years. The corporate leadership team is here to celebrate this long association with our Indian customers and thank them for their support. The leadership team is also using this opportunity to meet key opinion leaders in the various industry verticals to understand the changing market scenario in India and to learn about the expectations as well as future technological needs of our customers here.
Syed Jafry
What are the top three focus areas for TFS in India?
Which are the TFS products to be manufactured in India?
We are happy to see that the integration of the various divisions of TFS, which started in 2007, is now fully complete. We are now able to provide solutions to our customers for most of their scientific challenges. Our focus has always been on delivering our promise to our customers. With many new products being launched and our new acquisitions, we face this continuous challenge in integrating service and supply chain systems into one. But I am glad to inform you that we have recently invested in a common ERP system in India, which should help reduce a lot of complexities. Another focus area will be to align ourselves to the industry verticals that we serve, so that we communicate with our customers as a complete technology partner through comprehensive workflow solutions backed up with application support.
TFS already has a manufacturing site at Nashik where it manufactures gas chromatography instruments, and especially UV-Vis spectrophotometers – which are being exported all across the world. Recently, we have augmented this site to also assemble our liquid handling pipettes. We have an excellent pool of talent in India and the right environment to expand our manufacturing capabilities. We are currently looking at the viability of a few products to be redesigned, assembled and/or manufactured locally. We have also invested in a greenfield site at ‘Pharmez’ – a pharmaceutical SEZ near Ahmedabad, which provides complete logistics support for clinical trials. This is a state-of-the-art facility with complete environment control and clean rooms, and is already working with some top global pharmaceutical companies.
Which are the emerging verticals in Asia-Pacific with good prospects for your products and services? We see healthcare as one of the fastest growing verticals in Asia. Some other sectors such as industrial safety, environmental safety and food safety seem to be very promising in Asia in the near future. All these sectors are attractive to us as we are committed to our corporate mission, which is ‘to enable our customers to make the world healthier, cleaner and safer’.
What are the three key focus areas for you in driving the growth strategies of TFS? I would say, apart from all the plans that have already been mentioned above, product innovation, focus on customer satisfaction and continuous development of our people would be our priorities. Email: manas@infomedia18.in
February 2012 | Chemical World
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BUDGET WISH LIST Industry voice
Need for tax rationalisation to boost the sector The government is grappling with issues such as rising fiscal deficit, delay in roll out of some of the critical reform policies, uncertain global economy and its impact on India, etc. Rakesh Rao, Prasenjit Chakraborty and Mahua Roy interact with a few experts to know their suggestions for boosting the chemical industry and expectations from this year’s Budget. Diane Kelly, India President, Dow Corning We are hoping that this year’s Union Budget offers the necessary scope for positive enhancements in various industries; and initiatives oriented towards achieving growth in some of the new areas – renewable energy, high performance construction and infrastructure etc. It would also be interesting to see what policy reforms would be introduced, considering the current economic situation. We hope that these reforms are directed to achieve enhanced performance in industries that are steering their
efforts towards gaining a competitive edge. To give a boost to the chemical sector, initiatives should be taken to improve the current situation of industries across various verticals. Bolstering the industries with required resources, either through stimulus packages or reforms would be pertinent. Focus on innovative technologies would drive companies to look for enhanced solutions through specialty chemicals, silicones and siliconbased technologies. The variety of applications in silicones is vast and diverse. With proper directive from the Budget, more businesses would appreciate the importance of silicones in helping enhance product performance.
Rajesh Mokashi, Deputy Managing Director, CARE Ratings Ltd The Union Budget will be focussing more on getting back on the path of the Fiscal Responsibility and Budget Management (FRBM) and pay attention to the deficit numbers, which today have slipped due to adverse economic conditions. While the focus will be on garnering revenue from various sources, the thrust will remain on making expenditure more productive by channelling it in infrastructure. Sectors such as telecom, pharma, gems and jewellery, automobiles etc will continue to
attract attention as these are the sectors that can forge strong backward linkages with the rest of the economy. Given that the broad contours of taxation have been sort of set by the DTC and GST, which are not likely to be implemented this year, the Budget will be looking at improving the quality of the expenditure streams so as to produce more effective results. It will be interesting to see what are the growth numbers assumed in this Budget as it will set the tone for all other policies too. For chemicals, in general, rationalisation of the duty structure is important for industry growth and there is need to have incentives for chemical exporters through Duty Drawbacks.
Sanjay Upadhyay, VP - Finance & Company Secretary, Deepak Nitrite Ltd Inflation is one of the major concerns for the government at this point in time but a singular focus on inflation could hurt the country’s long-term growth trajectory. Further, heightened spending on welfare schemes will increase the fiscal deficit. We expect the government to drive a balance between focus on social welfare and industry. The government must also provide confidence to industry through clarity on its roadmap for implementation of fiscal and other reforms. A reduction in subsidies and government
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borrowing combined with some measure to help industry, given a fairly difficult and volatile year, would be appreciated. For the chemical industry, the government should rationalise the tax structure, relax rules regarding import of scarce raw materials/inputs, help promote manufacturing infrastructure and focus on enhancing roadways, ports and logistics. India is able to compete with countries like China in manufacture of fine & specialty chemicals due to superior quality and adherence to environmental norms. The Budget should make it easier for companies to grow their business and increase global marketshare.
Industry voice
Satish Wagh, Chairman, CHEMEXCIL In this Budget, I am looking forward to getting low-cost finance at the international rate, electricity at concessional rate and fillip for increasing capacity building. In many cases, Import Duty imposed on raw material is higher than that imposed on the intermediate products, wherein India has invested heavily to put up the manufacturing capacity. This poses threat to the domestic industry. Therefore, I urge the Finance Ministry to correct this
situation by imposing Custom Duty on intermediates. Also, the percentage of Duty Drawback, which replaced DEPB scheme, is much lesser than the actual duties paid by our manufacturers, and it is essential to increase the same.
U Shekhar, Managing Director, Galaxy Surfactants Ltd My expectations from the Union Budget are related to development of basic infrastructure to boost production, exports and logistics. This includes, most importantly, availability of adequate, reliable as well as quality power supplies across the country. The government needs to pay more attention towards a faster turnaround time of clearance at ports, thereby making exports smooth and easier. Also, I would like the government
to take steps to enhance efficiency and speedy transportation of goods across the country and abolition of octroi. Most importantly, for the chemical industry to flourish, speedier statutory clearances such as environmental clearances, are required.
V Gokuldas, Managing Director, HRS Process Systems Ltd I would expect some measures by the government to facilitate the investment scenario in the chemical industry – may be opening up of economy in a way in which foreign investments become little bit easier. At present, interest rate is not conducive to do business. Besides, Income Tax slab for professionals working in factories should be raised because current tax slab is not
matching with the inflation, thereby affecting them a lot. By rationalising the tax slab, revenue collection will be more than what it is now. We must get into GST regime quickly, because uniform tax structure will help everyone.
Vipul Shah, President, CEO and Chairman, Dow India The expectations from the forthcoming Union Budget are manifold. Announcements regarding ‘zero duty’ on import of chemicals, tax holidays for small- and large-scale players, self-assessment of imported chemicals would go a long way to provide a much-needed fillip to the chemical industry. Providing a clearer view of the policy roadmap, including fiscal incentives being in sync with the Indian government’s own
New Manufacturing Policy, rational corporate tax, simplified cess and duty structure would be a big positive for the industry. The government looks poised to implement GST during 2012 and bring much-needed relief to the players.
Dr Y R Singh, Executive Director, Alkali Manufacturers’ Association of India To reduce the cost of inputs for the chlor-alkali industry (which includes caustic soda, chlorine and soda ash), it is also important that interest rates are reduced and brought to international levels. To promote chlorine (Cl2) usage, government support is required to develop domestic ethylene capacity by providing incentives. Government should extend support to enhance allocation of railway rakes to soda ash industry on a priority basis
as all the soda ash plants are located in the coastal belt of Gujarat, while consumers are based in north, east and south regions. There is a need to encourage R&D for effective use of hydrogen as green energy like in fuel cells.
February 2012 | Chemical World
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SPECIAL FOCUS
OIL & GAS NATURAL GAS Key to solve the complex energy puzzle ............................................................ 26 PIPELINE MAINTENANCE Ensuring safe transit for fuel ............................................................................. 28 PRODUCED WATER TREATMENT Cost-effective solutions to the rescue ................................................................ 32 INTERFACE Soumen Kumar Roy, GM - HS&E, Indian Oil Corporation “Safety in retailing is highly challenging” .......................................................... 34 INTERFACE B Akala, Director, CBM Solutions India “The coal bed methane sector is expected to call the shots in future”.............. 36 ROUNDTABLE Should diesel price be deregulated? ................................................................... 38
February 2012 | Chemical World
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SPECIAL FOCUS Natural gas
Key to solve the complex energy puzzle Natural gas is viewed by many as clean, green fuel. No wonder that globally, countries are looking to increase the share of gas in their energy basket. Reliance Industries’ gas find in KG Basin and a number of government initiatives have raised hope for even India to join the race to fuel its economic growth with efficient energy source.
Rakesh Rao t is said that while 20th century was the era of oil, the 21st century belongs to gas. Corroborating this fact, the recently released ExxonMobil’s ‘The outlook for energy: A view to 2040’ report states that natural gas will become the world’s number two fuel as demand shifts to lowercarbon sources. Global demand for the least carbon-intensive fuels – natural gas, nuclear and renewables – will rise faster than the average rate. The report adds, “Oil will remain the world’s top energy source, led by 70 per cent growth in liquid petroleum demand in non-OECD (Organisation for Economic Co-operation and Development) nations. The fastest-growing major energy source will be natural gas, with global demand rising by about 60 per cent from 2010 to 2040.” Developed countries, such as the US and Europe, have already taken steps to move from coal to less carbon-intensive fuels such as natural gas, which is considered to be a clean, green
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fuel. “Natural gas is the cleanest hydrocarbon fuel available, and has the lowest carbon footprint – this is why it is often called a ‘bridge fuel’ as the world struggles to transition towards a lowcarbon future,” points out Andrew Ware, Director, Corporate Affairs & Communications, Cheniere Energy, USA – which (through its subsidiary, Sabine Pass Liquefaction LLC) has entered into an agreement with Gail India to supply liquefied natural gas (LNG).
Tanking up growth While the market for natural gas is expected to grow in every part of the world, according to ExxonMobil, the demand is expected to triple over the next 30 years in the non-OECD countries in the Asia-Pacific region. And significant amount of this raised demand will have to be met through imports via pipelines and LNG tankers. “Global natural gas demand is being driven by the needs of many developing countries to reduce reliance on petroleum products, which are expensive, and coal, which is dirty, for use in stationary uses like power generation and industrial facilities. India is no different. LNG provides an opportunity to globalise supply availability to countries that lack indigenous natural gas resources. Many believe that LNG will be the world’s fastest-growing fuel source over the next 30 years,” opines Ware. Following the global trend, the contribution of LNG in meeting soaring domestic energy demand has been rising in India. Shushmul Maheshwari, CEO, RNCOS (a market research firm), says, “Economics of energy generation, growing concern over environmental pollution, necessity of complete utilisation of natural resources, and the appropriate use of by-product gas emanating from crude oil operation are key factors driving LNG demand in India.” As industries look for low-emission fuel to propel efficiency and lower carbon footprint, demand for natural gas will witness steep rise in India. Maheshwari explains, “A number of industries are shifting towards natural gas. The inherent environmentfriendly feature, cost-effectiveness, and greater efficiency are the key qualities of LNG proving its utility in various sectors.”
LNG market While India continues to be one of the fastest growing economies in the world, the country’s energy needs are expected to treble by 2035 from 468 million tonne of oil equivalent (MTOE) to nearly 1405 MTOE. Natural gas will have to play a major role in driving economic growth in an eco-friendly way and help India achieve its goal for climate change. As the demand for natural gas rises, companies are scouting for resources (Indian as well as global) to supply gas. Though production of gas from domestic assets has increased in last three to four years, still it is not able to keep pace with the burgeoning demand. Hence, LNG is likely to fill in this gap. Companies such as Gail, Petronet LNG, etc have entered into contracts with global majors for supply of LNG. Experts
Natural gas
believe that India is ideally located to receive LNG supplies from West Asian countries. The increased absorption of natural gas by the user sectors such as power and fertiliser is likely to minimise the dependence on imported oil. Maheshwari says, “In the recent years, the consumption of LNG in India has increased more than that of any other fuel. The country has, in fact, seen a huge unmet demand for natural gas in the last few years, with the requirements of core sectors increasing.”
Pricing and availability While import of gas is increasing, the Government of India is taking steps to raise output from the domestic fields. Maheshwari says, “We cannot depend on imported gas for a long time, though importing of LNG is critical to cater to growing demand. Keeping this in view, the Indian government should encourage domestic production as locally produced gas would be advantageous in the long run. So, the government must focus on infrastructure development, and policy changes for the transportation of LNG.” At present, there are only two LNG terminals; that too located on the west coast. Due to high tariff and interstate taxes, the cost of LNG is highly uncompetitive as it is transported to far off locations from the importing terminals. “India had planned several terminals for importing LNG, but only two (Dahej and Hazira) are functional, and that too in the western coast. This makes LNG costlier, and its availability limited in other parts of the country,” notes Maheshwari. In order to improve gas supply in the country, Gail and Petronet have announced more investments to boost gas infrastructure. In fact, Petronet LNG Ltd is setting up LNG terminal at Kochi (which is expected to be commissioned this year) and is reportedly planning a terminal on the east coast at Gangavaram in Andhra Pradesh. Further, shipping and transportation of LNG account for 30-40 per cent of its total cost. While many countries
provide cargo support to their Table 1: Share of future energy supply in India (%) national fleet, no Indian company Year Coal Oil Gas Others fully owns an LNG vessel at present. 1997-98 55 35 7 3 Hence, to bring the cost further 2001-02 50 32 15 3 down, Maheshwari suggests that in 2006-07 50 32 15 3 the country’s interest, India should 2010-11 53 30 14 3 have its own fleet to carry this fuel 2024-25 50 25 20 5 of future. Source: India Hydrocarbon Vision 2025, The Ministry of Petroleum & Natural Gas In addition, there is a need to Global energy demand by fuel type (in quadrillion BTUs) include LNG under the purview of the proposed Goods and Services 250 2040 Tax (GST) to bring down the prices. 200 He says, “The recent proposal of the 2010 From its peak in 2025, coal will decline by government to include LNG in GST more than 10 per cent by 2040 150 Latin America and China are the biggest seems logical, and will definitely users of hydro power, which makes up over 80 per cent of total Hydro/Geo supplies benefit the country’s development. 100 On the other hand, if LNG comes 50 under declared goods, many state governments may incur loss as they 0 Biomass/ Wind/Solar Hydro/Geo Oil Gas Coal Nuclear cannot levy over 4 per cent tax.” Other Biofuels Source: ExxonMobil But experts believe that the initiative for uniform pricing of gas, certainly go up in India. However, the if implemented, will act as a booster for demand in near future depends on its industries to use cleaner fuel. “As said earlier, price sensitivity as compared to crude oil transportation adds to the cost of LNG and naphtha,” says Maheshwari. and makes it expensive. Thus, bringing As per the India Hydrocarbon Vision LNG under GST regime would eradicate 2025 of the Ministry of Petroleum & several inter-state taxes on transportation. Natural Gas, demand of about 391 million If implemented, the tax will encourage metric standard cubic meter per day uniform pricing of gas and use of cleaner (MMSCMD) of gas is expected between fossil fuel, besides providing level-playing 2020 and 2025. And a significant amount field and promoting competition among will be accounted by LNG. “In the Indian industries,” adds Maheshwari. energy sector, a significant demand-supply Ambitious growth targets gap exists that can be met via LNG. At With energy consumption centres present, the proportion of natural gas in shifting from developed regions to the country’s energy mix stands at just emerging markets, one will see countries 10 per cent while the global average is using more gas to propel industrial 24 per cent. By 2025, we can expect growth. Any disruption of energy supply India’s share to increase to 20 per cent,” in the world can have direct impact on opines Maheshwari. the Indian economy due to globalisation. Fossil fuels are expected to be major In order for gas to be used as primary contributors to India’s energy basket. source of energy, in addition to its lowDecisive climate change policies and emission credential, it has to be priced technological improvements in developing lower than the other resources. “The gas fields are likely to give a boost to prices have spiralled in the recent past natural gas industry in the country. Experts due to excessive demand from Japan (in believe that India has the potential to the wake of earthquake and tsunami that become the second-largest natural gas had led to shutdown of nuclear power consumer in Asia by 2015. Only time plants) and 17 per cent production drop will tell if we have succeeded in fuelling from KG-D6 field, India’s biggest deposit eco-friendly industrial prosperity. Email: rakesh.rao@infomedia18.in of natural gas. The demand for LNG will
February 2012 | Chemical World
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SPECIAL FOCUS Pipeline maintenance
Undoubtedly, pipelines are the arteries of the gas distribution system. Ensuring safety of pipelines by undertaking regular maintenance measures needs to be the topmost priority for gas companies.
Mahua Roy
I
ndian Petroleum Ministry has announced the addition of over 7,450 km of gas pipeline network over the next 2-3 years to ramp up its supply lines so that it can keep pace with the growing demand from the consumption centres in the country. The present natural gas transportation infrastructure in the country is around 10,800 km with a capacity to move 270 million standard cubic metre of gas per day. Managing this huge network smoothly and safely requires not only technology, but also an acquaintance with the highest ideals of safety. “Piping happens to be the most expensive single item of equipment in process industries. However, if there could be a flip side of the picture, accidents originating from piping itself have been detrimental to smooth operation, health & safety of personnel, preservation of assets and environment protection. Accordingly, its safe upkeep & maintenance hold 28
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the key for productivity,” aptly says K N K Murthy, Safety Consultant. Pipeline leakages are among the most dangerous hazards in the gas distribution system. In recent times, Indian gas companies have adopted global standards to keep up with the rising emphasis on safety, health and environment.
Identifying reasons for pipeline leakages Pipelines carrying gas are often close to areas having high density of population, or those areas which are highly environmentally sensitive. It is important to safeguard these pipelines with newer methods of on-line monitoring. However, one needs to be abreast with plausible reasons for pipeline leakages in order to be able to minimise damage quickly. “Fatigue failure, overpressure and unacceptable flow regime leading to erosion, are the major reasons contributing towards pipeline leakage,” says a spokesperson from ONGC. Besides, certain engineering factors too can contribute largely to pipeline
leakage. Summarises Murthy, “Using substandard material of construction, poor engineering design (lack or inadequacy of expansion/contraction flexibility, inadequate support, pressure/ vacuum/temperature relief system), poor installation (laying of ground level sleeper yards/elevated racks/underground installation) need to be avoided in order to prevent pipeline leakage.” However, this is not all. With growing terrorist activities across the world leading to uncertainties today, another major reason put forward for pipeline damage is sabotage. Experts agree that it is a matter of concern and are therefore investing heavily in timely and routine checks as well as advanced methods of immediate detection in case of leakage. Murthy adds, “Also, inclement weather pattern – saline atmosphere, humidity are factors that cannot be ignored.” Apart from sabotage, corrosion is also identified as a major reason. This has given rise to newer, specialised coatings being made an integral part of pipeline construction.
Pipeline maintenance
The inevitability of pipeline transfer as proven method for safer conveyance/ distribution of products up to the downstream processor or even end-user calls for effective maintenance and upkeep considering uninterrupted operation, safety and environmental protection with sustainability. K N K Murthy
Safety Consultant
Pipeline coatings for new construction and maintenance can ensure that pipeline exterior and interior perform safely and efficiently during their engineered design life. Nitin Mathew
Marketing Manager, Performance Coatings, AkzoNobel, India
Upcoming technologies Specialised coatings prove to be a boon for gas pipelines as a lot of factors pertaining to leakages can be addressed. For gas pipelines to homes, the gas service providers charge customers on
the amount of time used to transfer gas. It is thus a challenge to transfer more gas in lesser time. Leading names like AkzoNobel Coatings have developed advanced coatings, which help reduce coefficient of friction, and thereby fit the product deliverable. Pipeline coatings for new construction and maintenance can ensure that pipeline exterior and interior perform safely and efficiently during their engineered design life, observes Nitin Mathew, Marketing Manager, Performance Coatings, AkzoNobel, India. He adds, “This is achieved by the combination of protective coatings and cathodic protection to avoid high maintenance costs and potential environmental damage. It is necessary to offer tailored solutions for all environments and applications with single, double and triple layer coating systems that provide superior chemical, abrasion and corrosion resistance.” Such coatings provide external benefits like exceptional mechanical properties, long-term corrosion protection, excellent compatibility with cathodic protection, excellent adhesion to steel, as well as internal benefits like greater flow efficiency, easy inspection and pigging, corrosion protection & chemical resistance.
BEST PRACTICES IN OIL AND GAS INDUSTRY TOWARDS GAS PIPELINE MAINTENANCE R Hazard identification/risk assessment studies include Hazard & Operability (HAZOP), Hazard Analysis (HAZAN), Job Safety Analysis ( JSA), maximum credibility assessment etc, at conceptual stage, and incorporation of suggested recommendations during procurement of material, assembly and installation R Adoption of ‘condition monitoring’ techniques with respect to aspects like vibration/ fatigue/stress R Periodical monitoring of corrosion effects followed by failure analysis and timely rectification of defects in addition to replacement of segments, which cannot be repaired or set right R Safeguarding of lines against unauthorised access and intrusion R Regular patrolling of pipelines with reference to security/safety vigilance R Strict adherence to ‘Control of work’ procedures including ‘Permit-to-work’ system R Regular monitoring of flow regime/fluid properties to ensure adherence to desired specifications R Regular cleaning, pigging and periodical intelligent pigging R Contingency plan to be in place for repair and rehabilitation R Regular ‘Fitness for purpose’ assessment
Courtesy: K N K Murthy and ONGC
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Apart f rom coatings, newer technologies are being embraced by this industry. Murthy adds, “These include Supervisor Controlled & Administrated Data Acquisition (SCADA) system, which is fully automated and used for manning the terminal control rooms/receiving stations etc. It can be effectively applied to get warning against impending dangers like severe leakages, releases, emissions, domino effects etc. In addition, leakage/ spillage/emission detection instruments and warning systems using most advanced and sophisticated/accurate optical/nonoptical techniques are available.”
Proactive maintenance Putting forth a forward looking statement, the ONGC spokesperson says, “In the future energy basket, especially in the hydrocarbon sector, gas is going to play a more dominant role than oil or crude. This would entail development of a large network of gas pipelines across the country in near future.” As a result, investments in newer avenues of research in this field will have to be ensured. “New technologies such as intelligent pigging using satellite navigation, remote sensing for valve operations, ROW monitoring through satellites, multiple users and leak detection systems are essential. Besides, state-of-the-art security systems to check third party activities are equally important,” the spokesperson adds. A large number of factors will dictate the need for sophisticated methods of pipeline maintenance in future. With piped gas making inroads in the cities and rural areas as well, the magnitude of gas distribution is increasing manifold. “The inevitability of pipeline transfer as proven method for safer conveyance/distribution of products up to the downstream processor or even end-user (eg, cooking gas customers, gas bottling units etc) calls for effective maintenance and upkeep considering uninterrupted operation, safety and environmental protection with sustainability,” concludes Murthy. Email: mahua.roy@infomedia18.in
SPECIAL FOCUS Produced water treatment
Mahua Roy
T
he oil & gas (O&G) industry worldwide has been plagued by a lot of negative publicity with regard to its alleged irresponsibility towards the environment. However, with the changing times and outlook, this industry is striving hard to portray a better picture of itself. Right from changes in corporate strategies to production processes, every practice is being revisited. Produced water is one such area of concern. As per a recent report by Mumbai-based market research agency, Bharat Book Bureau, daily produced
WHAT IS PRODUCED WATER? Water that is trapped in underground formations, which eventually comes to the surface during exploration and production of oil & gas, is called produced water. It occurs naturally in formations where oil & gas are found. When extraction takes place, produced water is brought to the surface as a combined fluid with extracted oil & gas. This produced fluid generally comprises a mixture of either liquid or gaseous hydrocarbons, produced water, dissolved or suspended solids, produced solids (sand or silt), and recently injected fluids and additives that may have been placed in the formation as a result of exploration and production activities.
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water production volumes significantly exceed that of oil volumes, to the extent that 211 million barrels of water are produced by the industry worldwide daily as compared to around 85 million barrels of oil over the same timeframe. This poses a major business hurdle. As Kevin Cassidy, General Manager, Chemical and Monitoring Solutions – Water and Process Technologies, GE Power & Water, explains, “Water directly impacts a refinery’s ability to increase production rates. It is faced with increasing environmental challenges and regulatory pressures for pollution prevention. Source or influent, water must be treated for removal of suspended solids, organics,
similar problems, local conditions and requirements dictate that solutions need to be region-specific. The solution providers are cashing in on indigenous technologies to establish a brand equity and loyalty among O&G companies. This has resulted in making the total size of the market opportunity for final stage produced water treatment systems to be around $ 4.3 billion for the next five years, as per Bharat Book Bureau’s findings. The report also predicts that the size of the market opportunity for topside produced water re-injection systems is around $ 9.8 billion over the same period. Customisations and sophisticated technology aside, in the end, the O&G
The largest volume of waste generated by the oil & gas extraction operations is due to produced water. The efforts of environmentally conscious decision makers of today are being complemented by the solution providers of water management to present a responsible image of the oil & gas industry before the world. bacteria and any other impurities to protect plant equipment from corrosion, deposition and fouling.”
Choosing the disposal method Management of large quantities of produced water can prove to be extremely expensive, and can determine whether wells are profitable or not. O&G companies must, therefore, consider many different options for managing produced water. Customisation is what will work in the adoption of technologies. While O&G companies around the globe experience
companies always look for a costeffective solution. “Water treatment and management is a direct cost to oil companies, so any process improvement that lowers the cost will result in increased profits. The current situation of depleting oil resources is forcing oil companies to use more advanced oil recovery methods, resulting in higher energy prices as well as higher water treatment cost,” says Deepak Kachru, Assistant General Manager - Sales & Business Development, Aquatech. The key thus lies in engineering of a
Produced water treatment
technology-intensive, but equally cost-effective solution to manage produced water woes.
Solving complexities The complexity of the processes and variable quality feedstock pose challenges in design & operation of wastewater systems. The solution providers to the O&G industry are constantly developing newer means of cost-effective technology. However, certain challenges are faced by them when it comes to the adoption or acceptance of these methods. Arghya Roy, Industry Development Manager, Asia-Pacific Region, Nalco Water India, says, “The buying behaviour of chemical treatment programmes still remains commoditised. A proper Mechanical, Operational & Chemical (MOC) approach will help to achieve higher productivity and efficiency of the wastewater systems in the O&G industry.” The rapid industrialisation and sudden use of advanced technologies have made a lot of options available to the O&G industry. Industry watchers assert the need for constant orientation programmes to acquaint this sector with the latest developments in the field of process water treatment. “Currently the on-shore sites in India are not using any enhanced oil recovery techniques and the water produced with the oil is normally treated using separation techniques and then disposed off into deep wells. However, two important factors - increasing regulatory pressure and the need to enhance recovery of oil from existing wells – will require oil companies to look at reuse of the produced water as against disposal. Any reuse requirement will require water to be of a specific quality, suitable for the application, this will require adoption of more advanced and innovative methods to treat the waste. This is a gradual process and will take time,” says Kachru.
Tackling mature oil wells Quantities of produced water continue to increase throughout the entire exploitable lifetime of an oilfield to such an extent that oil and water production becomes almost inversely proportional by the end of the reservoir’s life. Dead wells invariably consist of more than 90 per cent produced water. Consequently, the industry has addressed the need for deeper research in this area. For tackling new field implementations, action is primarily taken to optimise the injection strategy of water, the sweep or to evaluate alternatives to water injection. But, for mature fields with high water production, it is too late for such actions. Thus, the research fraternity needs to concentrate on other options, such as reinjection, downhole separation, improved water cleaning or better water inflow control. Cassidy notes, “One must also consider whether or not one can afford a capital solution. This will help determine where the solution will focus – on equipment, chemistry or a combination of both.” Email: mahua.roy@infomedia18.in
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SPECIAL FOCUS Interface - Soumen Kumar Roy
“Safety in retailing is highly challenging” …says Soumen Kumar Roy, General Manager – Health, Safety and Environment (HS&E), Indian Oil Corporation Ltd (IOCL). A career spanning 35 years in Indian Oil, he is acquainted with the nuances and intricacies of this sector. He speaks with Mahua Roy about safety in the petroleum industry and disaster management strategies.
As the HS&E head, what are the top five ways by which you promote safety in the company? We are dealing with petroleum products that are highly hazardous, inflammable and need utmost safety in handling. As such, hazard identification, which is associated with petroleum products, is the topmost priority. Apart from fire, various other hazards are associated with this industry, such as release of toxic gases, pollution of sea and ground water, vapour cloud explosion, etc. It has been established that most of the accidents (almost 96 per cent) occur due to unsafe operations or equipment. Once the hazard associated has been identified, the second step is to train the employees towards mitigation processes. Training is a continuous process and is 34
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imparted in two parts – classroom & field training. All personnel entering the hazardous area are given safety briefing every day. Various safety slogans are displayed at prominent places at the installation. Third-most important issue is maintenance of equipment. The failure of equipment can cause huge catastrophes. As such, every equipment used, be it storage tanks, pipelines, vehicles carrying petroleum products etc, needs to be properly maintained. Four th comes mitigation preparedness. All installations handling petroleum products must be equipped with various safety and fire-fighting facilities such as fire hydrant lines, fire pumps, fire extinguishers, Personal Protective Equipment (PPEs), etc. A well-defined mitigation plan (Disaster
Management Plan), with duties and responsibilities of each individual in case of emergency has to be chalked out, and periodical mock drills & disaster drills have to be conducted at all installations. Finally, periodical safety audit (internal and external) must be carried out so as to understand the deficiencies in the safety system and taking corrective measures.
In all the oil & gas processes (E&P, refinery, distribution – pipelines, retailing), which is the most challenging area to implement safety? In my opinion, safety in retailing is the most challenging. The activities of E&P and refineries are carried out in confined areas. Moreover, they have dedicated and trained safety & fire-fighting personnel. In case of pipelines, it is a closed circuit, and danger associated is very less, if proper maintenance of pipelines is being carried out. However, in case of retailing, there are two major areas of concern – road transportation and retail outlets. The road transportation is being done through tank trucks. In most cases, it is difficult for the truck drivers to comprehend the hazards associated and various mitigation methods. Moreover, the attrition rate of drivers is high. As such, training new drivers is a time-consuming process. Further, the condition of roads in India is poor and often tank trucks meet with accidents. Apart from safety of handling petroleum products, road safety/safe driving is also an important factor. Similarly, in retail outlets, the products are being handled by untrained personnel. Moreover, another dimension to be considered is that of the general public entering the retail. It is necessary to raise awareness among public as well. There are several cases of accidents, which had occurred in retail outlets due to negligence of customers.
What is the current status of refinery safety in India? In India, all oil installations including refineries are guided by safety
Interface - Soumen Kumar Roy
standards issued by Oil Industry Safety Directorate (OISD), which is controlled by Ministry of Petroleum & Natural Gas, Government of India. These guidelines are well-prepared and based on API (American standards), NFPA rules etc. Moreover, all the refineries in India have dedicated safety and fire-fighting teams that are welltrained to handle any type of accidents. As such, I feel that refineries in India are safe.
You have been with IOCL for 35 years. Which was the most challenging incident you handled? The most critical incident I handled was at Kandla in 1994. A petrol (motor spirit) tank, while receiving the product from an ocean tanker, developed a small leak in the welded joints at the bottom. The bottom of the tank contained water, which started coming out. We were aware that over a period of time this
leak will increase and after the water gets drained, petrol will come out of the tank. Realising that the time was short to initiate emergency measures, we took following steps: R Called the Army (camping next to our Kandla installation) and they tried to stop the leak by placing sand bags near the leak, but the effort was unsuccessful R We made a temporary hose connection from the leaking tank to another tank for the transfer of oil and water mix, so as to reduce the extent of oil spill on the ground R We alerted nearby villagers through the public address system and requested them to leave the area and not to light any matches or smoke in the area R Ambulance, police, fire brigade were called and doctors were kept stand by near the installation R Electrical mains were switched off so that no electrical spark is
generated, which might ignite the petrol vapours When the oil started coming out from the tank, there was no other alternative than to allow the oil to spill on the ground. Around 75 per cent of the officers were engaged in the transfer of the oilwater to another tank by employing a portable flame-proof pump. We could salvage majority of the spill by resorting to continuous pumping. Water jets were sprayed on the surface of spilled oil so as to reduce the formation of vapours. After about 10 hours of efforts, the entire oil spilled on the ground could be salvaged and put into another tank. In the process, out of 5,000 kilolitre (kl) of petrol, we had salvaged 4,980 kl and only about 20 kl product was lost by way of vapourisation and soaking in the ground. We had averted a big catastrophe due to timely action by taking steps as per emergency response plan. Email: mahua.roy@infomedia18.in
February 2012 | Chemical World
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SPECIAL FOCUS Interface - B Akala
What are the opportunities with CBM resources in India? India is endowed with huge reserves of bituminous coal of paleozoic and tertiary ages within the CBM window at depths of nearly 250-1200 metre. Having the sixth-largest proven coal reserves and being the third-largest coal producer in the world, India holds significant prospects and resources for commercial recovery of CBM. This resource has been estimated to be more than 300 trillion cubic feet (TCF). Gas demand in India far exceeds supply. As an alternative to LPG, diesel and petrol, CBM has immense commercial prospects and is clearly emerging as one of the most viable and cleaner routes to India’s energy security.
to the well bore. In the process, natural gas resources may get depleted sooner, whereas CBM resources will prolong for many years. A stage may come, when the CBM industry can take over the natural gas industry.
What are the concerns regarding CBM produced water in India? The main concern is the very quantity of water that is produced in the process. Extraction of CBM involves pumping large volumes of water from the saturated coal seam in order to release the water pressure holding the gas in the coal seam. Another concern is the quality of CBM produced water pumped and its effect on the soil. The CBM production is still at a nascent stage in India. Though extensive
and reliable source of energy in the US, Canada and Australia. China and India are following the footsteps. The share of CBM is gradually increasing. With more shale gas discoveries pouring in, this sector is expected to call the shots. Production costs of CBM, being produced from comparatively shallow depths, are far cheaper than natural gas that is normally produced f rom much deeper reservoirs, both on- and off-shore. The economics will play a dominant role in CBM production. CBM being a low pressure gas, the production from wells is steady and prolonged for years. Some wells are reported to be producing even for more than 20 years.
The coal bed methane sector is expected to call the shots in future ‌says B Akala, Director, CBM Solutions India, and former CMD of Central Coalfields Ltd and Central Mine Planning & Design Institute Ltd (a subsidiary of Coal India Ltd). In an exclusive interaction with Mahua Roy, he elaborates on coal bed methane (CBM), which is an eco-friendly natural gas, generated during the process of coal formation.
Will coal bed methane become a major rival of traditional natural gas? It is difficult to say whether CBM will become a rival to the natural gas industry, till all the coal bearing areas of the country are explored for CBM and the Gas in Place (GIP) is known. But, it is emerging as a useful supplement to natural gas. There is no difference chemically or in the end use of both; the only difference is how they occur. While natural gas comes out by itself under high pressure, CBM is made to come out by pumping out the water that holds the gas and makes it travel 36
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data is not available on the quality of water pumped from the CBM wells in some of the coalfields, it is generally found and expected that CBM water is not so saline and, with simple care and treatment, can be put to use or safely discharged into the natural streams. But the issues of aquifer drawdown, recharge of the depleted ones etc will remain as challenges to be addressed, and solutions need to be found in the larger interest of environment.
What are the most exciting things about the industry? Worldwide, CBM is becoming an important source of energy. In recent decades, CBM has become a cheap
What is your outlook for this technology in India? Economically, the CBM process consists of extremely low-margin projects. In the initial stages, they look like losing ventures as the investments are high, and many would not dare to enter. But if selected and managed well, both technically and otherwise, a good project will produce large amount of gas for long periods, delighting the investors who had sleepless nights in the beginning. Besides making large profits, they are environment-friendly, thus producing clean energy. Email: mahua.roy@infomedia18.in
SPECIAL FOCUS Roundtable
Should diesel prices be deregulated? Globally, as crude prices continue to rise, considering a price reform for diesel is crucial at this point. The long-term development of the country is at stake, but there are short-term worries also to address. Mahua Roy presents viewpoints of industry experts on this issue.
P K Agarwal Energy Expert and Director, The Energy and Resources Institute
Kalpana Jain Senior Director, Deloitte Touche Tohmatsu India
Mukul Gupta Managing Director, Chemtreat India
I support deregulation of diesel prices. As a result of deregulation, all those bearing the burden of subsidies, viz national oil marketing companies (suppliers), Government of India, and upstream companies will benefit in the short run. And in the long run, economy as a whole will benefit. The other major pros of deregulation include reduction of fiscal deficit and, hence, improvement in macro-economic indicators of the country. It will develop a competitive market for diesel by enabling competition from private oil marketing companies. Also, it will cut out dieselisation arising out of artificially low prices of diesel. Deregulation of diesel price and, hence, full international price will force reduction in consumption by improving usage efficiency, cutting out discretionary consumption and stopping substitution of low-value fuels by diesel. Further, adverse impact of diesel on health and environment depends on quality of diesel, vehicles and their maintenance.
The Finance Ministry has worked out a plan to bring down the debtGDP ratio from 74 per cent to 65 per cent in three years; price decontrol can play an important role here. The deregulation of price is expected to increase the rate of inflation in short term as diesel serves as the major transportation fuel. There could be immediate price rise in commodities and other consumables. However, for long term it may be a good move because it will reduce our longterm debt and fiscal deficit. Our overall economy may become more stable in this case. Also, it would encourage efficiency in use of the fuel and cut wasteful consumption, which invariably happens with a subsidised product. Other means of directly supporting economically weaker sections of society in their fuel requirements will need to be put in place. Deregulation is expected to bring down inflation in the long run as the economy shall no longer carry the burden of subsidy.
I would fully support deregulation of diesel prices. The government is skeptical about this move considering its immediate impact on inflation. One of the main reasons for introducing regulation of diesel prices originally was to support the vulnerable sections of society. But effectually, by increasing the gap between petrol and diesel prices, the diesel subsidy is in fact incentivising purchase of diesel cars over petrol ones! In the recent past, the sale of diesel cars and SUVs has experienced tremendous growth. Besides, many automobile companies are announcing diesel variants. It is thus important to realise that a huge amount of diesel is actually consumed as a consumer transport fuel ie, for personal use. Why should they enjoy subsidy? It is a well-known fact that diesel is more polluting than petrol. Also, exposure to particulate matter in diesel exhaust can lead to acute heart and lung diseases. One can only imagine the long-term impact of this on health and the environment.
EDITORIAL TAKE Without doubt, deregulation of diesel will help the Indian economy in the long run. Responsible use of diesel can be expected. Also, since diesel exhaust can cause health and environment issues, one can expect lower use of diesel, if prices are deregulated. Most importantly, the fuel marketing industry will see a lot of activity. However, this deregulation needs to be introduced at a strategic time, keeping short-term inflation in mind. 38
Chemical World | February 2012
Photo: Joshua Navalkar
FACILITY VISIT HRS Process Systems Ltd
Where precision is the hallmark Introduction of line production concept coupled with other innovative measures in the plant is paying rich dividends to HRS Process Systems Ltd. The new steps, besides enhancing productivity, also ensure the quality of products. Since heat exchangers are being used across various industries, their demand is rising, thus opening up new growth avenues for the company. Prasenjit Chakraborty
A A view of the shop-floor
Technician on profile
visit to the HRS Process Systems Ltd’s plant located at Koregaon Bhima, 25 km from Pune city, underscores the significance of innovation and the returns it delivers. The plant, which manufactures all types of heat exchangers used across industries, is a one-stop shop for products, right from those that are traditional to highly-evolved ones. Two basic kinds of heat exchangers are used predominantly for industrial purposes – one being the shell and tube, and the other being plate type heat exchangers. In order to provide more efficient heat transfer solutions to sectors like chemical, petrochemical, pharmaceutical, fertilisers etc, HRS has come out with corrugated tube heat exchangers sold under the brand name ECOFLUX.
Productivity enhancement
Welding in progress
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HRS has implemented a unique kind of system called Pilot Production Cell in its plant. The basic reason for implementing the process is to see how it enhances the productivity. By doing so, it is evaluating line production manufacturing of heat exchangers. “The line manufacturing is a wellestablished concept in assembly shops,
typically for automotive or high volume production processes and for same kind of products. But for ‘customised’ equipment, fabrication is involved, and then it is imperative to carry out some modifications,” says V Gokuldas, Managing Director, HRS Process Systems Ltd. Fabrication requires a good study for implementation to be effective, because each stage has different input requirement. “So, we created the concept of production cell where heat exchanger manufacturing is defined in stages. After finishing one job, it goes to the next cell and so on till the final product is ready. Unlike in automotive industry, here welding is done, and sometimes cutting and grinding are also involved,” points out Gokuldas. In this pilot cell, all activities for manufacturing of heat exchangers are undertaken in one place, in a sequential manner, and space-wise layout is made. The important aspect to note here is people involved in manufacturing process are not moving, instead the materials are moving. The practice ultimately saves time and enhances the productivity. “In contrast, earlier everything was done in one area, and at one point of time, people involved in manufacturing needed to move for the next job. Now this is not required and the arrangement is like push-pull kind,” he points out.
HRS Process Systems Ltd
Segmentation also helps in quality because a team is only involved in one type of job. Daily production plan is prepared to enable the engineers & workmen carry out their respective work efficiently and with precision. “We implement ‘5S’ & ‘value stream mapping’ for the processes on shopfloor. Due to these productivity enhancement processes (PEPs), the major functions on shop-floor have been streamlined for a smooth product and process flow. This has helped reduce the idle time and distances on the shop-floor for material movement, besides controlling and eliminating any need for rework and similar wastes in the manufacturing process,” explains Gokuldas.
Manufacturing excellence The manufacturing facility, built to international standards, is spread over 4 acre with a 20,000 sq ft fabrication shop. The facility is designed for fabrication of heat exchangers – corrugated tube, shell and
Plate heat exchangers testing area
tube, plate type and heat exchanger-based systems – for process industry/food/fruit/ beverage processing. The capacity depends on size of units and can vary from about 80 to 250 heat exchangers per month. The facility is ISO 9001:2008 certified along with The American Society of Mechanical Engineers’ (ASME) ‘U’ stamp and The National Board of Boiler & Pressure Vessel Inspectors (NBBI) registration. ECOFLUX corrugated tube heat exchanger (CTHE) is an innovative product from HRS comprising corrugated tubes. These tubes enhance the efficiency of the heat exchangers, which not only helps to have a uniform thermal processing but also ensures that there is low fouling of heat exchanger surface. ECOFLUX CTHE is low maintenance heating equipment, with no spares requirement, and is thus ideally suited for the chemical and petrochemical industry. “Corrugated tube heat exchangers help user-industries reduce overall size of heat exchanger. Besides, it decreases fouling, which ultimately results in much higher performance. Even the technical advantages of the product are much better compared to shell and tube heat exchangers,” claims Gokuldas. Interestingly, the cost of the product is lesser compared to shell and tube heat exchanger for similar duty conditions. HRS also has patented UNICUS – an innovative scraped surface heat exchanger used for efficient heat transfer in viscous products/products with solids. This is a ‘no fouling’ heat exchanger, which can be used as an evaporator too.
Training for quality and safety
Hydrotest and packing area
Special heat exchanger assembly
All necessary safety aspects like shoes, helmets, eye masks, etc, as required for specific operations are in place. The ventilations (natural turbo fans) and lights are set up in a manner so as to make the working area more employee-friendly. For all employees, HRS conducts training programmes based on the product and market scenario. It also provides inhouse training on induction, design software, etc. Moreover, the employees attend training programmes organised by reputed institutes for soft skills and technical skills as and when required. At the shop-floor, the highest level
Heating equipment sector will witness a healthy growth in coming years, since such types of equipment find application across industrial segments. We want to be a globally preferred innovative heat exchanger company providing sustainable heat transfer solutions. V Gokuldas
Managing Director
of skill is required in the field of welding and, hence welders have to go through successive phase of training. “After passing several tests, they are allowed to weld on shop-floor. It is because any minor defect in welding could lead to catastrophe,” he says. The company has deployed automatic welding machines that help in improving quality and productivity. HRS considers its employees as the biggest asset. There are many employees who have been serving the company since its inception. Says Vikas Chandgude, Fitter, HRS Process Systems Ltd, “I have been working here since the last six years. I have improved my manufacturing skills significantly by working in this factory. Day by day, manufacturing process is evolving in this factory and I am getting acquainted with the latest techniques.”
On a positive note According to Gokuldas, heating equipment sector will witness a healthy growth in coming years, since such types of equipment find application across industrial segments. “Many new companies are being set up to address the growing demands of various intermediates that make up for a host of consumer durables. With buoyant growth in pharma and allied sectors, demand is going to build up for expansion in chemical process industry, and thereby all kinds of process equipment,” he asserts. About 40 per cent of the company business is from repeat orders and the trend is growing. “We want to be a globally preferred innovative heat exchanger company providing sustainable heat transfer solutions,” concludes Gokuldas. Email: prasenjit.chakraborty@infomedia18.in
February 2012 | Chemical World
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An invite that rewards as well... Dear Reader, ‘Chemical World ’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the chemical process industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Chemical World ’. Authors whose articles are published will be sent a complimentary copy of that particular edition. Published by Infomedia 18 Ltd, ‘Chemical World ’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the chemical process industry (CPI). Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian CPI. Moreover, it offers a broader platform facilitating effective interaction among several fraternities of these industries by enabling them in reaching out to their prospective buyers & sellers through better trade contacts and more business opportunities. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,
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INSIGHT & OUTLOOK
ENERGY MANAGEMENT ENERGY EFFICIENCY Exploring alternatives for a competitive advantage .....................44 EFFICIENT TECHNOLOGY Equipping for sustained power savings........................................46 CHEMICAL INDUSTRY IN 2011 Down, but not out .......................................................................48 COATINGS INDUSTRY Tough times ahead .......................................................................50
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INSIGHT & OUTLOOK Energy efficiency
Exploring alternatives
for a competitive advantage
Realising the dire need to become energy efficient, a few forward-looking chemical companies in India are trying to come up with captive and solar power projects. Another option could be to opt for easily available fuel in a particular region depending on project locations. Prasenjit Chakraborty
T
he Indian chemical industry is now witnessing a difficult energy scenario. This is because not only energy prices are steadily going up, thereby upsetting the economics of operations, but also there are problems in procuring energy sources such as coal and natural gas due to shortage conditions. According to N S Venkataraman, Director, Nandini Consultancy Centre, Chennai, when it comes to energy prices, there is little that the Indian chemical industry can do to influence it. “Considering the increasing cost of energy and India’s heavy dependence on import of energy sources such as coal, crude oil and natural gas, there is certainly distinct threat of various segments in the chemical industry losing marketshare in 44
Chemical World | February 2012
the competitive global market,” he points out. The current energy scenario calls for adoption of effective methods to become energy efficient, and subsequently become competitive in the market.
Cutting consumption Taking due cognisance of the above fact, chemical manufacturers have swung into action. Take the example of LANXESS. As part of its health, safety, environmental protection and quality (HSEQ) management system, the company undertakes environment-f riendly activities that are systematically monitored and optimised. Among other tasks, it promotes the sustainable generation and economical usage of energy at its sites, for example by switching over to one of the most efficient power plant technologies available – cogeneration. Furthermore,
the company invests in cutting-edge processes and plants designed to keep air, ground and water supplies clean. In doing so, LANXESS is utilising advanced economic tools such as emissions trading to finance climate protection projects. From the procurement of raw materials to production, logistics and the disposal of residual materials, LANXESS is working towards improving energy efficiency along the entire value-added chain. Cutting-edge technologies and processes help cut energy consumption, safeguard natural resources and save on costs at the same time. To continue improving the energy and resource balance of its production plants, LANXESS has introduced the XEnergy check system. The tool is used to systematically analyse the energy efficiency of individual plants, and thus indicate the areas where potential exists for further optimisation. This helps to ensure that energy use is managed efficiently at the production plants. In addition, the implementation of a global energy management system at LANXESS is due to be completed by the end of 2012. The goal is to cut specific energy consumption for each segment by 10 per cent by 2015 as compared to 2010 levels. Similarly, Atul Ltd has also taken steps in this direction. It measures and benchmarks consumption pattern, compares it with globally accepted norms, besides carrying out energy audit & energy balance programmes. “We have a well-structured team to look after energy management. The main objective of the team is to promote industrial energy efficiency, and thereby achieve substantial reduction in energy consumption. We examine availability of more energy-efficient processes, and equipment with higher efficiencies. Moreover, we realise the need to implement new technologies to bring in reduction in terms of energy and raw material consumption,” says K M Desai, Vice President (Technology), Atul Ltd.
Competitive strategies Cost reduction is a successful mantra used by companies in the wake of global
Energy efficiency
competition. Achieving energy efficiency by totally eliminating energy wastage and enhancing process efficiency is a important strategy to reduce manufacturing costs. “Energy cost generally constitutes 8 per cent of the sales price, which is equivalent to labour cost. The profit before tax (PBT) of the chemical industry may be about 5 per cent lower than the cost of energy. Therefore, energy cost reduction can play a significant role in increasing the profitability of chemical process industries (CPI),” observes Desai. Energy conservation is often interpreted as cut in energy consumption, but actually it is a cut in the misuse/waste of energy. “Successful firms concentrate on efficiency first, products second, and then on marketing and sales,” he asserts. Today, the industry is on the fast track on many fronts to find renewable solutions that can eventually supplement the use of petroleum-based resources. The most promising avenue of exploration is in the conversion of biomass such as corn, oilseeds and sugarcane into chemical raw materials. According to Dr Axel C Heitmann, CEO, LANXESS Group, “The renewable energy targets set by 66 countries – including Europe’s goal of using 20 per cent renewable energy by 2020 – coupled with enormous new research effort show that we mean business.” And more concentration in the area can lead to big business. McKinsey & Company predicts that the global biobased chemicals and pharmaceuticals market will reach between Euro 154 billion and Euro 300 billion by 2020. Many experts in chemical industry predict that in 10 years, as much as 20 per cent of this industry will be bio-based. However, energy efficiency alone cannot guarantee the competitiveness in the global or domestic market. There are several factors related to this such as demand-supply scenario, specification and quality of the product application development efforts, etc. “The production cost and product pricing are vital for achieving the market penetration. Besides, improvement of product quality, which is appropriate to the specific needs of the
consumers, is equally important,” exhorts Venkataraman.
Return on investment When players invest in new technology or equipment to become energy efficient, it is obvious that they will look for appropriate ROI and other benefits. The ROI on the measures for energy-efficiency drive is highly subjective and would vary among different types of industries. “Ingenious ways have to be found to launch such measures, keeping in view the investment and cost parameters. Investments can be justified only if they would result in reduced production cost and improve the economics of the project both in the short term as well as in the long term,” points out Venkataraman. The efficient
The current energy scenario calls for adoption of effective methods to become energy efficient, and subsequently become competitive in the market. combination of R&D efforts to modify the existing technologies or develop appropriate technologies, improve plant design and different shop-floor techniques is vital.
Supportive government policies Though government support and understanding can aid the Indian chemical industry in realising its energy-efficiency goal, currently the government’s participation in this area is inconspicuous. “There is really no worthwhile dialogue between the Indian chemical industry and the government with regard to the energy issues and related problems faced by it. The fact that the jatropha biofuel industry has not been adequately encouraged by way of providing reasonable pricing subsidy, and the little attention paid to algae biofuel
research indicate that the government is not initiating any appropriate policy measures in these areas at all,” laments Venkataraman. Clear understanding and co-operation between the Indian government and chemical industry are urgently needed. There is no indication that such developments are taking place.
Challenges and beyond It is difficult for the chemical industry to achieve energy efficiency to any significant extent in the short term. “There is no magic solution for this,” quips Venkataraman. The obvious solution is to optimise the use of energy and avoid wastage as well as reduce energy consumption in the process operations. “This calls for shortterm planning measures, particularly for optimising the process and shop-floor management practices,” he opines. Medium- and long-term strategy is to move away from the energy-intensive process technologies wherever possible. This calls for R&D efforts or acquisition of such technologies from abroad, which involve huge amount of money. “However, the success of R&D efforts in this direction is uncertain,” opines Venkataraman. The other strategies could include switching over to appropriate fuel depending upon the project location, availability of the fuel in the region and its price etc. Again such options can be limited. “While exploring such options, a few chemical companies in India have been trying to set up facilities for captive wind and solar power projects. However, the capacity utilisation of wind power project and its lack of reliability due to change in wind strength from time to time is a big limitation. In the case of solar power, the cost of production is an impeding factor,” he observes. In view of the limitations as mentioned above, and the growing need to be energy-efficient, it is now high time for the chemical industry to examine the feasibility of setting up appropriate nonconventional fuel projects such as jatropha biofuel, algae biofuel as well as wind power, solar power and biomass projects. Email: prasenjit.chakraborty@infomedia18.in
February 2012 | Chemical World
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INSIGHT & OUTLOOK Efficient technology
Prasenjit Chakraborty
C
hemical manufacturing involves transformation of organic or inorganic raw materials into products through chemical processes. Chemicals generally are classified into two groups – commodity and specialty. Commodity chemical manufacturers produce large quantities of basic, and relatively inexpensive, compounds in large plants, often built specifically to make one chemical. Since they make essentially equivalent products for general use in everyday consumer goods, sales are typically driven by price. Specialty batch or performance chemical manufacturers produce smaller quantities of more expensive chemicals that are used less
made,” points out Amit Kapur, Director, Everest Group.
The energy dynamics The chemical industry’s prime motivation for energy efficiency is controlling operating and production costs (eg fuel and raw material costs) in a competitive, worldwide market. According to Kapur, facility-wise approaches to energy efficiency, such as integrated heat exchanger networks to maximise the use of waste heat, are well-established in the industry. “While energy usage in chemical industry has increased in recent years, the sector has reduced energy consumption for heat and power per unit of output. Energy intensity (in terms of fuel consumption per ` value of shipments) has also decreased,” states Kapur.
energy efficient. “In the last three years, coal cost has risen by 28 per cent, fuel oil (FO) cost by 35 per cent and manpower cost by 20-25 per cent. However, profit margins are on the decline due to rising competition,” he points out.
Solutions provided Anticipating the demand for energyefficient equipment from the chemical industry, the equipment manufacturers have been focussing on bringing out relevant solutions for meeting the specific requirements of the customers. Today, a number of technological advances in steam systems enable chemical plants to run efficiently with minimal losses. The use of appropriate diagnostics can help in understanding energy consumption patterns in a plant to ensure that timely
In view of the prevailing volatile energy scenario, the equipment manufacturers have come out with solutions to help chemical industry become energy efficient. However, the extent to which these technologies will be leveraged remains to be seen, since majority of the players in the chemical sector belong to the SME category. frequently. As sales are based on product performance, controlling production costs may be of less concern than it is for commodity chemical manufacturers. The chemical industry uses energy both to supply heat and power for plant operations and as a raw material for the production of chemicals, plastics and synthetic fibres. Hence, energy management is gaining significance in controlling production costs. “Controlling production costs is crucial, which provides an incentive for energyefficiency improvements. At the same time, commodity plants often run continuously, typically shutting down for only a few weeks a year for maintenance. Thus, there is often a limited window of opportunity in which energyefficiency related improvements can be 46
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Management of energy aligns with a plant’s goals for higher profitability, controlled production costs and overall competitiveness. Once achieved, everyone stands to gain by excelling on these fronts. “However, without a sustained focus on energy management, savings from implemented energy conservation measures can easily be eroded. Additionally, a structured approach to energy conservation helps the plant to achieve the full potential for improvement and not just partial benefits,” says Pradyumna Madhusudan, Manager - Energy Service Division, Forbes Marshall. Volatile fuel prices and rising material & manpower costs in the wake of stiff competition make it absolutely essential for any chemical manufacturer to become
actions are taken to sustain savings. “We have been slashing fuel bills in the boiler house with our shell type boilers and efficiency monitoring packages to enhance boiler efficiency. In any process, steam is moved, used, depressurised, injected, throttled, condensed and its heat is reused. Our pressure reducing stations and process temperature control solutions ensure that steam is used at the right pressure and temperature at all times during the process,” claims Madhusudan. Issues like fuel changes, plant depreciation and new requirements crop up at any time. “Whenever there is a requirement for energy auditing of an existing plant and greenfield projects, our audit and consultancy services offer the ideal solution,” says Madhusudan. Hot water at a specific temperature is critical
Efficient technology SCOPE OF ENERGY SAVINGS Equipment retrofit/replacement Cleaner fuels Ranking: Medium Ranking: Medium Assessment: Major energy-efficiency gains are achievable Assessment: Coal represents a relatively small fraction of the through retrofitting or replacing steam system equipment (ie sector’s energy consumption, but it is an emission-intensive boilers, pipes, valves, traps, heat exchangers and preheaters). energy source. Though natural gas is the most viable substitute The primary barriers to equipment change are capital for coal, natural gas price trends are unlikely to make this an constraints, particularly in segments of the industry that are attractive opportunity for the industry. A substantial hardest-hit by rising energy costs. amount of energy requirements are currently met by waste and byproduct fuels, and there is a probability of increase in the use of alternative and waste fuels without Here viability of five primary Process improvement compromising environmental quality opportunities - cleaner fuels, Ranking: Medium However, hazardous waste permitting equipment retrofit/replacement, R&D, Assessment: Process optimisation requirements may inhibit energy increased usage of combined heat & is widely practised in the industry. recovery from waste fuels. power (CHP) or cogeneration and Process improvement (ie using an process improvement - for improving alternative process or path to produce environmental performance are ranked the same product) may require Increased CHP with respect to energy usage (low, technological advances or Ranking: High medium, or high). A brief assessment a breakthrough in a new Assessment: The chemical industry of the ranking is also provided, production process. meets a substantial portion of its including potential barriers. electricity demand through onsite power generation, primarily via cogenerating units R&D that also produce steam. Waste heat reduction Ranking: Medium and increased waste heat recovery (including the Assessment: Energy savings continue to be areas for use of waste energy streams in cogeneration) represents a industry research, be it membrane separation technologies, major opportunity for reducing energy losses, particularly for improved process control systems and process improvement organic chemical manufacturing. But, new CHP installations through catalysis. The sector also promotes research and face barriers in terms of utility rates and interconnection funding into coal gasification due to its interest in developing requirements, if electricity production is expected to exceed less expensive feedstock and fuel alternatives to natural gas. onsite demand. Source: Everest Group
for certain products. Giving the instance of Spirax from Forbes Marshall to elaborate this, Madhusudan adds, “Spirax Automatic and Instantaneous hot water generators are compact and deliver hot water at precise temperature. There are some areas from where the condensate is not recovered for fear of contamination. Spirax on-line contamination detection systems enable substantial energy savings and a better feed water quality.” Similarly, realising the shift of the industry towards energy-efficient solutions, Everest Group also offers solutions in this direction. “We are the largest producer of roots blowers in South East Asia having effective presence in wastewater treatment industry – Sewage Treatment Plant (STP) & Effluent Treatment Plant (ETP) – pneumatic conveying systems, aeration systems, aquaculture etc, to name a few,” claims Kapur.
Everest designs and manufactures solvent recovery systems to curb pollution. These systems not only play an important role in making the process eco-friendly but also in recovering precious solvents for reuse. “Most of the pharmaceutical processes have low boiler solvents, which are undesirable if expelled into atmosphere. On installation of solvent recovery system, most of the solvents can be recovered. The demand for such systems is growing exponentially due to increasing environmental awareness and corporate responsibility,” says Kapur. Besides, the company designs and manufacturers vacuum boosters for replacement of steam jet ejectors, extended shaft roots blowers configuration for applications requiring 100 per cent oil-free air like aeration in aquaculture farms, plating lines, STPs, etc.
On an energy saving mission No doubt, many equipment manufacturers have come up with innovative solutions for the chemical industry. However, it remains to be seen whether such solutions are adopted by the chemical manufacturers in India. This is because majority of chemical manufacturers in India fall under the SME category. “It is always a challenge for us to persuade SME players to go for energy-efficient alternatives,” laments Kapur. The real challenge is to make them understand the benefits of using such technology or equipment. But, with the growing need for conserving energy and curtailing manufacturing expenses, such technology will go a long way in achieving energyefficiency goals, if implemented to its best capacity. Email: prasenjit.chakraborty@infomedia18.in
February 2012 | Chemical World
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INSIGHT & OUTLOOK Chemical industry in 2011
While 2011 started on a high note for the chemical industry, the last quarter of the calendar year (CY) 2011 witnessed a slowdown in demand mainly due to global economic situation. However, growing demand for chemicals from the domestic market coupled with government’s initiatives to give a boost to this sector will encourage global majors to invest in India.
but not OUT Aashish Kasad
T
he contours of global economy are witnessing a sea change in the wake of the global financial crisis of 2008-09 and subsequent recurrence of rigid financial conditions in the markets worldwide. Given the significant global volatility, Indian economy has been mirroring the global growth over the past few years. After contracting in 2009, the world economy grew at an impressive 5 per cent during 2010 driven by a strong cyclical rebound in global industrial production and trade aided by significant government stimulus. However, global activity has continued to remain uneven with a sharp fall in confidence during 2011 and increasing downside risks owing to the crisis in Euro zone and slackening of the US recovery. In line with the global slowdown, the Indian economy grew by 6.8 per cent during 2008-09, significantly lower than average 9.47 per cent growth between 2005-06 and 2007-08. Subsequently, in line with the global recovery, Indian economy clocked GDP growth rate of 8 per cent and 8.5 per cent during 2009-10 and 2010-11 respectively. Amid rising global uncertainty, the Government of India has recently lowered the growth forecast for FY12 to 7.5 per cent, impacted by sustained monetary tightening by RBI and the lackadaisical 48
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global economic growth. During the past four quarters, India’s growth has been continually slowing down (8.3 per cent in Q4CY10 to 6.9 per cent in Q3CY11), curtailed by sluggish global growth.
Sustaining growth Despite these short-term hitches, Indian economy is poised to maintain its growth trajectory driven by favourable long-term factors that include growing middle-class population, a demographic dividend and significant proposed outlays on infrastructure cushioned by a robust regulatory and financial ecosystem. The economic growth over the past few years has led to the emergence and growth of India’s middle class, which is likely to fuel industrialisation and rapid urbanisation in the future. India also has one of the youngest populations in the world with a median age of approximately 26 years, which is likely to encourage future manufacturing investments in the country. The government is also likely to propose initiatives to support investments worth $ 1 trillion during the Twelfth Five-Year Plan (2012-2017). In fact, according to the Planning Commission, size of the Indian economy is expected to reach $ 10 trillion by 2025, thus becoming the thirdlargest economy in the world. A robust GDP growth rate, favourable government policies and initiatives as well as steady growth of end-user industries
are the key factors driving the growth of the chemical industry in India. During April 2010–February 2011, exports of chemicals increased 22 per cent to $ 7.5 billion. Chemical and chemical products have consistently outperformed the manufacturing and overall Index of Industrial Production (IIP) in the last five years.
Operational effectiveness The profitability margin for the chemical industry was the lowest in FY09 at 4.4 per cent and went up to 6.4 per cent during the FY-ended March 2011. Segments such as paints and coatings & agrochemicals have fared better than the average industry profitability margins in the last five years. The Indian paints industry traditionally grew at 1.5-2 times the GDP growth driven by domestic demand in both decorative and industrial paints. However, the profitability margins of the paints and coatings manufacturers have been affected in the recent past due to increase in raw material prices such as titanium dioxide and mineral turpentine oil. The PAT margins for the fertilisers industry increased in the last couple of years. The industry’s PAT margin improved to 4 per cent in FY10 and 5.7 per cent in FY11. Improved PAT margins have been driven by inter alia subsidy income of the industry.
Investing in India With an aim to optimise business portfolios as well as increase marketshare, joint ventures and acquisitions continue to be popular in the chemical industry. The Indian chemical industry has majorly witnessed 10 M&A (inbound and domestic)/JV deals (till December 10, 2011) at an estimated value of $ 511.8 million compared to 12 deals at an estimated value of $ 454.3 million in 2010. Unlike 2010, there has been some interest by private equity companies in the Indian chemical industry in 2011, which witnessed three deals this year. Since 1991, the chemical sector has been consistently ranked third among all
Chemical industry in 2011
sectors in India, in terms of the amount of foreign investment. Between April 2000 and August 2011, the FDI inflow in the chemical sector (other than fertilisers) has been $ 3.03 billion, representing 2.06 per cent of the overall FDI inflow. The sector (other than fertilisers) attracted cumulative foreign direct investment (FDI) of $ 398 million in 2010–11, representing a 6.5 per cent increase over the previous year. FDI inflows to the chemical industry have increased over the last few years, due to the robust Indian growth story accompanied by various incentives by the government, which has helped the development of the sector. Asia-Pacific’s chemical industry has shown the highest growth compared to other regions of the world in last couple of years. As industry participants globally anticipate growth of 8 per cent in AsiaPacific in the coming 3-4 years, chemical manufacturers are looking to set up new facilities, expand the existing ones or form new joint ventures, particularly in China and India. As a result, Indian players across different product segments have unveiled ambitious expansion plans in the next two to three years.
REACH implications Currently, one of the serious challenges faced by the Indian chemical industry is the impact of Registration, Evaluation, Authorization and Restriction of Chemical (REACH), the European community regulation on chemicals. The industry could face a major threat from the REACH legislation over the next decade. EU chemical exports are worth more than $ 2 billion per year to India. According to the Indian government, REACH already threatens 24 per cent of India’s chemical exports. The cost of registering a chemical varies between ` 0.33 million to ` 9.2 million, depending upon the hazardous nature of the chemical. As the compliance cost of REACH is high and also time-consuming, some of the Indian chemical manufacturers are opting out of the REACH registration
PAT margins for different product segments within the Indian chemical industry from September 2010 to September 2011 14% 12%
Fertilisers Agrochemicals Inorganic chemicals Petrochemicals Specialty chemicals Paints Industry
10% 8% 6% 4% 2% 0% Dec-10
Mar-11
Jun-11
Sep-11 Source: Prowess
process and do not intend to focus on the European market going forward. One of the other major problems for the industry is the shortage of globally recognised testing labs. Currently, India just has a dozen Good Laboratory Practice (GLP) approved labs, as certified by the EU and the Organization for Economic Cooperation and Development (OECD).
The road ahead The government initiatives will go a long way in ensuring the growth of the chemical industry. The newly approved Petroleum, Chemicals and Petrochemical Investment Regions (PCPIR) for Tamil Nadu, set up at Cuddalore and Nagapattinam, received Government support of $ 1.1 billion. Apart from this, the government has approved investments of around $ 34 billion in three states – Gujarat, Andhra Pradesh and West Bengal. Polyethylene capacity is expected to increase by 2.6 million tonne by 2015-16, which will increase its marketshare from 34 per cent in 2010–11 to 43 per cent in 2015–16 in the total polymer capacities. The demand for polymers is estimated to increase at a CAGR of 10–12 per cent in the next five years. The growth will be primarily driven by polyethylene, polypropylene and polyvinyl chloride segments, which together constitute around 92 per cent of the total polymer demand. According to estimates by industry analysts, the per capita consumption of plastics in India is expected to increase from 8 kg in 2010 to 27 kg by 2020. Complex fertilisers are expected to drive the fertiliser demand in the next five
years. The demand for complex fertilisers (excluding DAP) is estimated to grow at a CAGR of 16.4 per cent to 20.3 million tonne between 2009–10 and 2015–16. High growth in end-user industries such as construction, automotive, water treatment and paints and coatings as well as evolving customer needs are expected to drive the growth of the Indian specialty chemicals market. The Indian chemical industry faces some challenges, which can deter its growth rate. It needs to address issues such as availability of feedstock, simplified tax structure and regulations, improvement in infrastructure, continuous power supply, logistics costs and facility for single-window clearance of permits and approvals. In addition, India also faces significant competition from other emerging geographies such as China, Brazil and the Middle East with respect to new capacity additions and sourcing raw materials locally. Also, with an increasing trend towards green and sustainable products, Indian manufacturers will have to focus on developing environmentfriendly products by increasing their investment on R&D. Aashish Kasad is a Partner at Ernst & Young Pvt Ltd. She has over 15 years of experience in advising companies on international tax, transfer pricing, Indian income tax and regulatory matters in chemicals, health sciences, automotive and consumer product industries. For details, contact Padma Chourey on email: padma.chourey@in.ey.com
February 2012 | Chemical World
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INSIGHT & OUTLOOK Coatings industry
TOUGH TIMES AHEAD
The high rate of inflation, higher cost of capital, cut in fiscal spending to GDP and weak global capital markets are affecting several industries, such as construction and automotive segments. And, wreaking further havoc is the depreciating Rupee, which is likely to have a direct impact on the coatings industry. Dr Mosongo Moukwa
T
he Indian Rupee has been losing ground as the European debt crisis has been perplexing investors, pushing them to abandon emerging markets in favour of the perceived safety of the Dollar. Coupled with that, foreign investors who had invested in Indian stocks are pulling out money, and thus demanding Dollar that they can take back home, adding to the pressure on the Rupee. The Indian Rupee has been depreciating against the Dollar since July 2011. This is simply a matter of demand and supply. When people demand more of a thing while its supply is low, its price rises. When something is in excess supply in the market as compared to demand, its price falls. This holds true for currencies too. When supply of Rupee rises while demand falls, the value of the Rupee depreciates like it has been doing now. As the demand for Dollar keeps rising, its value rises too, and subsequently the Rupee faces a downward pressure.
Inflation and interest rates Another fallout of a weaker currency could be higher interest rates in the economy, with the help of which Reserve Bank of India (RBI) might want to fight off the pressure of depreciation in the value of the domestic currency. Currently, for example, RBI has opted to suck out the liquidity 50
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from the market to prevent speculative activity in the forex market. This has been achieved at the cost of a higher call money rate of over 9 per cent. Sustained absorption of liquidity could sooner or later reflect in higher interest costs for borrowers, which could in turn adversely affect the growth in investments and consumption. India is suffering from a inflationary pressure. A depreciating Rupee will add fuel to this. It will lead to high inflation, as India imports around 70 per cent of its crude oil requirement and the government will have to pay more for it in Rupee terms. Due to the control on oil prices, the government may not easily pass the increased prices to the consumers. Further, this higher import bill will lead to rise in fiscal deficit for the government and will push inflation. The coatings industry will have to pay more in Rupee terms for procuring raw materials, despite drop in global commodity prices, only because of a depreciating Rupee against Dollar. Those who are borrowers of Dollar will see their balance sheets impacted adversely. These companies will need more Rupees to repay their loans in Dollar. This will increase their debt burden and lower their profits. The corollary to this is that investors would avoid companies with high foreign debt.
Impact on the coatings industry The size of the Indian paint industry is estimated at ` 14,855 crore ($ 3.8 billion),
growing at more than 10 per cent. The organised sector constitutes 65 per cent of this value while the remaining 35 per cent is contributed by the unorganised sector. A large share of the industry imports are raw material inputs for the manufacturing of paints, and currency depreciation will affect it. Raw materials account for about 60 per cent of the total cost. As imports are traditionally denominated in foreign currency, Rupee depreciation will increase the cost of importing Dollar-denominated goods, and this will affect margins. The impact of Rupee depreciation on profitability of the industry depends on two considerations, the share of the total output value accounted for by the revenue growth of the industry and the share of the total inputs. As economic globalisation broadens and deepens, production processes increasingly draw on raw materials and intermediate inputs imported from other countries. This intra-industry trade accounts for a growing share of the global trade. The primary suppliers to the paint and coatings industry are producers of synthetic chemicals who manufacture emulsions/resins, solvents, and pigments, usually from petroleum and mineral ore
Coatings industry
feedstocks. A long list of suppliers is in the market, particularly for additives, emulsions/resins and pigments. Both pigment and emulsion/resin suppliers offer a significant amount of additives and driers. Global coating suppliers have long-term contract with raw material suppliers (rutile, resins, metals, additives) the world over, which give them an edge on sourcing.
Double whamming on raw material costs A depreciating Rupee is compounding the difficult economic and profitability situation of the coatings industry. The industry was already facing constraints in some key raw materials, and the depreciation of Rupee puts added pressure in an already difficult situation. Constraints are acute for the industry when it comes to titanium dioxide (TiO2), methyl methacrylate (MMA), butyl acrylate (BA), mineral turpentine oil (MTO), Hydroxyethylcellulose (HEC), which fall under the category of key raw materials. The price of TiO2, one of the key raw materials for paint, has already increased by more than 10 per cent in Asia and the price of acrylic acids has been fluctuating with the oil prices. Shortage is also experienced with MMA, an ingredient for production of emulsions. Suppliers are mostly foreign companies, and domestic capacity is limited. India GDP growth rate 10
10
9
9
8
8
7
7
6
6
5
5
Raw materials prices have been going up for the past few years, and it is estimated that input costs have already gone up about 15 per cent for the industry because of constraints on availability of raw materials. Price of TiO2 will go up further as the gap between demand and supply still exists, thus pushing the prices up almost every quarter. It has shot up by more than 10 per cent in the last one year. Another round of hike in the range of 2-3 per cent is expected in the future. Prices of emulsions, resins and solvents have been on an uptrend as a result of volatile crude prices. This coupled with the depreciation of the Rupee, one can sense the double whamming the industry will suffer.
The price of oil Sustained triple-digit oil prices could threaten the coatings industry, raising the price of all hydrocarbon raw materials. Earlier this year, when West Texas Intermediate (WTI) crude oil finally reached $ 100 a barrel, the highest it had been in more than two years, the industry proved to be more resilient than in 2008, when crude oil crossed $ 100 a barrel and most of the Western world was mired in recession. Can the industry sustain a continued high oil price? Oil is consumed significantly for transportation and power generation. Even when the price remains constant, this will cost the industry more. Even when the price of oil remains at $ 100 per barrel in the international markets, it will be more expensive to buy it because the Rupee has depreciated. Economists say they expect prices to remain high despite the relative weaknesses of the American and the European economies because global demand for oil is escalating and outstripping supply. There is a consensus that high prices will persist through 2012 because of the premise that the emerging economies are using a lot more fuel.
Painting the future
2008 2008 2009 2009 2010 2010 2011 2011
Source: Asian Paints
Experts believe that the paint and coatings market in the Asia-Pacific region will continue to improve because of the growth expected in the end-user
Indian paints and coatings market ($ 3.8 billion) 1% 4%
1%
4%
6%
13% 71%
Decorative Industrial Auto refinishes Powder
Automotive Marine Others Source: Asian Paints
segments of construction, commercial, public buildings and residential real estate. The buoyant economic conditions in most Asia-Pacific countries, especially in China and India, have had a bearing on the investment in these sectors and, thereby, on the paint and coatings market. Historically, the paints industry in India has achieved a growth rate of 1.5 times the GDP rate. In 2010/11, the decorative segment registered a growth of about 16 per cent by volume and 20 per cent in value terms. India is experiencing a bump on the road. International financial conglomerate Citigroup has revised its 2011-12 growth forecast for the Indian economy downward to 7.1 per cent from the earlier estimate of 7.6 per cent on account of the global slowdown and domestic factors like a tight monetary policy. This is still a good performance. Paint companies must be able to sustain those challenges. Some are already employing strategies to limit their exposure and be ready when the economy picks up again. Dr Mosongo Moukwa is Vice President (Technology), Asian Paints Ltd, Mumbai. He was Vice President (Global Technology), Reichhold, North Carolina. 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
February 2012 | Chemical World
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AUTOMATION TRENDS Traceability in manufacturing
HO
LI S
TIC
TO O
L T O A D D VA
E U L
IN
Traceability is not merely a process of tracking events in the supply chain; it is a method of being customercentric, enhancing service excellence and achieving commercial success by developing a genuine value chain. The time is right for companies to recognise that implementing traceability will identify the weak elements of the production system and also become an important tool for continuous improvement. Sunil Chaudhari
T
he need for manufacturers to focus on compliance and traceability initiatives is increasing significantly across the globe as commercial pressures grow to meet regulatory mandates. By mitigating the risk of product recalls, reducing manufacturing costs, and ensuring quality control through end-to-end traceability of processes, organisations will be able to successfully reduce inefficiencies within the supply chain. As defined by National Institute of Standards and Technology (USA), “Traceability of measurement requires the establishment of an unbroken chain of comparisons to stated references, each with a stated uncertainty.” Technology can be used to track system status (status tracing), analyse system performance (performance tracing) and support decision making (goal tracing). Software systems, for example, are designed to support the levels of strategy, planning, design and operations. There is a need for all these forms of traceability in manufacturing to provide a structured, holistic way of managing operations efficiently to meet commercial targets. In principle, traceability takes two forms. The first, known as product tracking, is the capability to follow the path of a specified unit of a product 52
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through the supply chain as it moves between organisations. Products are routinely tracked for inventory management and logistical purposes. The second, product tracing, is the capability to identify the origin of a particular unit and/or batch of product located within the supply chain by reference to records held upstream in the supply chain. Products are traced for purposes, such as product recall and investigation when complaints arise. One of the key objectives of traceability is to provide visibility across the supply chain. In a recent survey carried out by AMR Research, a Gartner Inc Company, on the expected business benefits of traceability, 41 per cent of respondents cited ‘achieve greater inventory visibility’ as being the most important business benefit. In order to best achieve this objective, events can be captured at various points in the chain, stored in a secure traceability network and then shared with trading partners.
Why traceability matters? Traceability is a critical requirement across the process industries for several reasons. The first is the need to comply with regulations. From January 2005 onwards, traceability has been a legal obligation in the European food sector. All food and feed business operators must have systems
P LY C H A I N P SU
in place to identify from whom they have received a food or feed item and to whom they have sold such an item. Another vital factor is the need for companies to use traceability to better manage customer relationships. By using it to reduce the time required to react to customer complaints, for example, organisations can typically ensure higher levels of customer satisfaction. Tr a c e a b i l i t y enables organisations to guarantee the origin of a product or raw material. As such, it also allows them to reduce the risks they face when an incident occurs by quickly searching impacted products and removing them from the marketplace as and when required. Traceability also enhances the quality of the process and, as a direct result, the quality of the service or solution being developed. In many organisations, process improvement opportunities are being lost because genealogical data is hard to attain. In this context, traceability helps organisations improve the efficiency and pertinence of quality controls, while at the same time reducing costs by decreasing non-conformities (deviations f rom specifications, standards or expectations).
Scoping out the challenge Currently, many organisations across the process industries, particularly those in the batch industries like consumer products, specialty & fine chemicals and pharmaceuticals, are still using manual approaches to traceability. While some automated point solutions exist, most users find traceability data by searching through old paper-based records in filing cabinets, log books and spreadsheets. Even in those organisations where some of the processes are automated, a considerable amount of manual intervention still takes place.This presents numerous problems to companies.
Traceability in manufacturing
They often need to keep a history of transactions, typically stretching back as many as ten years to comply with regulations, and this necessarily entails retaining a significant amount of paper. Most of these businesses keep a paperbased standard operating procedure document and mark up comments on it. There are many disadvantages to this approach. First, it is extremely expensive. Second, it introduces errors into the system both in the process and in the documents used to support it. Third, it brings little value to the organisation. It is mainly used for compliance purposes. Unlike data that is collected and stored electronically, it cannot easily be used to support continuous process improvement, carry out ‘what if ’ analysis and drive product efficiencies. While some organisations are now looking to digitise the process, the sheer weight of paper that will need to be moved before this can happen makes this a challenging task indeed. This is why it is important that data is not only analysed electronically, but also collected in the same way.
A myriad of applications Presently, automated traceability techniques are used across a broad range of applications. First, the approach can be employed to rapidly identify lots impacted by an incident by navigating ascendant and descendant links between raw material lots, intermediates and finished products. Second, it can help identify in which specific lots a particular product has been used. Third, automated techniques can be used to find which equipment items have been impacted by a given lot. Fourth, organisations are able to use records to find the history of a manufactured lot, typically including steps performed, relevant process variables and quality controls. Finally, it enables users to compare manufacturing and quality parameters both at different steps of the same lot and between the same steps of different lots.
Implementing an effective solution In order to fully support traceability through the process industries, tools need to be sophisticated enough to deal
A CASE IN POINT When a product is made from two raw materials – A & B, here is how electronic traceability techniques typically apply to a product development process: R Batches of raw material A are delivered by suppliers A via intake plant R Batches of raw material B are delivered by suppliers B via intake plant R These batches are processed in process plants A & B respectively R When processing is completed, batches A & B are pumped from process plants A & B to the continuous reactor via flow meters A & B and valves A & B R The reactor operates continuously and a plug flow model is assumed for simplicity R Product leaves the reactor and transfers to either of storage silos 1, 2 or 3 via valve and flow meters 1, 2 & 3 respectively R From the silos, the finished product is then shipped to customers Throughout this product development process, manufacturers need to have visibility about a broad range of issues. At any given time, manufacturers might sometimes need to know which batches of raw materials A & B made up lot 1 of the finished product; which supplier provided these batches; what material was in the reactor; where did it come from and where did it subsequently go? The problem with addressing these scenarios is how to handle material flow through the reactor itself. The batch concept is lost in the reactor, so a method is needed for enabling a trace to traverse the continuous flow region and link the reactor upstream & downstream batches. Using time models, it is possible to create the necessary linkage through the reactor from the process area to the silos area.
with a broad range of issues. They need to be able to collect different types of data electronically. In a typical product development process, this includes manual data from pallets, raw material scans and process automation data about temperatures and pressures used in the product development process. This will typically incorporate batch data, including details of product quantities, sources, destinations and times of despatch and arrival, and supply chain data typically relating to the distribution process. In addition, solutions will need to model certain interactions in order to capture relationships across the process, where materials are mixed together or where techniques, like plugged flow, are typically used. When all this disparate information has been collected, the information needs to be stored into a database and a user interface provided in order to navigate it quickly and easily. Detailed analysis software is also needed to analyse the data, evaluate issues, pinpoint their source and find the underlining cause. In this context, a software solution for traceability will address the core manufacturing function and the broader supply chain can be deployed across many process industries and easily integrated with many other systems. Solutions should offer the ability to collect and capture data and ‘interrogate’ it to find the source of problems across the manufacturing process. The additional benefit of such tools is that they successfully integrate with systems, including Distributed Control Systems (DCS), Laboratory Information Management Systems (LIMS) and Enterprise Resource Planning (ERP). When internal controls are tightened, the risks of defects escaping/entering the system will be significantly reduced. Sunil Chaudhari is the Country Manager, South Asia, at AspenTech – a leading software solution provider, which helps companies address traceability issues. Email: sunil.chaudhari@aspentech.com
February 2012 | Chemical World
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ENERGY MANAGEMENT SMEs in chemical sector
Imperative to inculcate
BEST PRACTICES
in energy usage A concerted effort coupled with costeffective solutions from the chemical process equipment manufacturers can provide a new dimension to the SMEs in chemical manufacturing and pave the path for them to embrace energy-efficient technologies.
Prasenjit Chakraborty
C
onvincing SME players to adopt energy-efficient alternatives has always been a challenge by itself. “However, the challenge persists only till cracking the first customer for any application. The others just follow. We work like business partners with our customers,” says Amit Kapur, Director, Everest Group. Any indigenous company understands the price implications faced by its customers in a developing nation and the need to ensure cost-effectiveness. There are companies, which have highquality manufacturing unit in India, and hence enjoy the benefit of lower cost of production. “Our management believes in forwarding these benefits/privileges to our customers, while not compromising on quality, performance and services at any time,” observes Kapur. Elaborating on the challenges faced by equipment manufacturers while convincing SME players to go for energyefficiency, Kapur states, “Probably, the most important issues for any industry today include better resource utilisation, reduction in process time, higher yields and better product quality.” The major concern today is ensuring low energy consumption per unit of product manufactured, and this objective is a major decision-making factor. “Innovation is the essence of the 54
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world today. Resources and market advantages do not matter much. Intellect and innovation do. The chemical and pharmaceutical industries in India are also experiencing the same. However, current demand patterns suggest tremendous growth potential,” he points out. In order to make SME players energy efficient, equipment manufacturers are providing customised solutions to them. “We provide customised quality products, maintaining the highest level of design and manufacturing standards, and sized appropriately to give the most competitive prices and maximum energy savings to our customers,” says Kapur.
Marketing strategies Effective marketing skills play an important role in convincing SME players to go for any new equipment or technology. Besides, the marketing team should find potential areas where products marketed by it can do wonders. The SME sector, by and large, prefers to operate with traditional technology. The reasons behind it are mindset and financial constraints. Against this backdrop, deciphering right information to SMEs is must. “Our marketing team constantly works on identifying areas where our products can revolutionise process. Having identified a niche, our technical team designs and develops products to suit the requirements,” says Kapur. Citing an example, he says that vacuum booster manufactured by Everest Group has found a niche in vacuum distillation processes in menthol industry
where it has provided huge improvements in processing efficiency. “We believe in diversifying our application engineering and earning out of satisfied customers rather than diversifying the product mix itself,” explains Kapur. In its endeavour to convince SME players to become energy efficient, Forbes Marshall conducts training programmes. “We have a training centre where we conduct training programmes. A large number of our customers attending these programmes are SMEs. We also work with industry associations like Confederation of Indian Industry (CII) to generate awareness on energy efficiency,” says Pradyumna Madhusudan, Manager, Energy Service Division, Forbes Marshall. The company also brings out several publications; for instance, the energy conservation tip compilations, which are widely distributed free of cost. “We have carried out a campaign where energy conservation tips are freely and widely circulated through email on a weekly basis. Besides, we have developed and distributed energy conservation tip posters,” he adds. Most importantly, Forbes Marshall has formed clusters for process industry where they benchmark the specific fuel consumption, and offer comprehensive solutions based on cutting-edge technology, yielding the lowest specific thermal consumption and best value for money. Similar steps by other companies would take SMEs to new heights as far as energy efficiency is concerned. Email: prasenjit.chakraborty@infomedia18.in
POLICIES & REGULATIONS Interface - Sameer Bhatia
The prime emphasis should be on enhancing domestic hydrocarbon production ‌asserts Sameer Bhatia, Senior Director, Deloitte, India, while delving on the different aspects of oil & gas exploration in India during an interaction with Prasenjit Chakraborty. Lack of quality geo-scientific data for the potential basins and blocks offered under New Exploration Licensing Policy (NELP) is a serious challenge to the Exploration and Production (E&P) sector.
Even after introducing NELP, the sector has not progressed as expected. Does this indicate a gap as far as government policy is concerned? I do not think there is a significant gap at the government policy level. It has evolved over a period, and continues to evolve rather well. Arguably, there are some issues around implementation, interpretation and scrutiny & audits, which adversely impact the pace of investments in this sector.
Oil & gas exploration segment in India needs bigger investments from global oil companies. What is your opinion on the same? India imports more than 80 per cent of its crude requirements, and close to a quarter of its gas requirements as liquefied natural gas (LNG). This exposes us to significant supply risks and price volatility. The prime emphasis for the country should be on enhancing 56
Chemical World | February 2012
domestic hydrocarbon production, to move towards its aim of achieving energy security. India has many prospective and underexplored sedimentary basins. Also the potential for unconventional hydrocarbon sources like shale gas and coal bed methane (CBM) do exist. This will require significant investments in E&P. India also needs global technology partnership to explore, develop and maintain complex fields.
Tell us about two most important challenges the oil & gas exploration segment in India is facing today. I think the biggest challenge facing the oil & gas exploration sector in India is the lack of quality and reliable geoscientific data for the potential basins and blocks offered under the NELP. Only about 22 per cent of our potential basins fall under moderately to well explored category, whereas around 34 per cent comes under poorly to completely unexplored. This is a big
challenge for global as well as large Indian E&P players in their evaluation of investments in this sector in India. Another challenge is that most of India’s potential reserves are in deep water and complex basins. Access to technology and expertise holds the key to success. The recent alliance of Reliance with BP is a case in point here. Ageing workforce and talent will be another major challenge in this sector, going forward.
What are the steps to be taken to make the segment more vibrant? A transparent and fair regulatory regime, which recognises the inherent investment risks in this area, and is also investor-friendly, will go a long way in giving a fillip to the E&P sector in India. The proposed Open Acreage Licensing Policy (OALP) should also generate a lot of interest among large Indian and foreign players. Email: prasenjit.chakraborty@infomedia18.in
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STRATEGY Industry-academia collaboration
Avani Jain
R
esearch is typically not a business or a profit centre but a long-term investment,which helps a company generate more revenue and profits. In India, till recently research was not taken up keenly in most companies – the knowledge that existed in the public domain was sufficient
partners and pursue ‘open innovation’, which include research institutes.” He further states, “There are currently three basic collaboration types that can be seen between industry and research institutes: first, collaboration between companies and research institutes for basic product research; second, collaboration where companies bring in new technology and research institutes help them to adapt
Leveraging the best of both worlds
The industry-academia collaboration is increasingly being viewed as a medium for accelerating the growth of the Indian chemical industry. On one hand, the industry can leverage on the capabilities of research institutes in the areas of new product development, design and process innovation to sustain its competitiveness. On the other, the institutes can reap several benefits, as students will be able to gain hands-on experience in the industry.
Science (IISc) and Council of Scientific & Industrial Research (CSIR) are having collaborations with many chemical and pharmaceutical companies. They are focussed on catering to the industry needs by upgrading the highly specialised courses to produce highly-qualified chemical engineers, scientists, technologists and pharmacists. Prakash Raman, Managing Director, Solvay Specialities India Pvt Ltd, notes, “There is no doubt that India produces good number of engineers but what is lacking is the quality and the skills required for the specific industry. This quality can be improved only through industry-academia collaboration.” He adds, “We are coming up with a Centre of Excellence, ie global R&D centre in Savli near Vadodara. The work will be completed in the first quarter of 2012. We have signed an MoU with the Government of Gujarat, ie, it will sponsor the university students to work at its manufacturing plant and R&D centre. This step will help in sharing the technology that we have with the state. This will also enhance the scientific and technical knowledge of students, as they will learn about the new technologies being employed by the company. This will not only give good exposure to the students but even the company will be benefited, as quality students will be absorbed by them.”
Role of research institutes for the business the company was engaged in. But this scenario seems to be changing now. In present times, universities and national research institutes play a major role in industrial development in terms of R&D. Narendra R Mehta, Managing Director, Fibro Organic (India) Pvt Ltd, notes, “Growing competition in the market forces companies to innovate their brands constantly. To be a successful brand requires large amount of resources and appropriate skills. It is now commonplace for companies to work with outside 58
Chemical World | February 2012
to the local conditions; and third, both research institutes and companies provide core expertise in complementary areas. Of the three, the first type is the most frequently observed.”
Strategising the concept Many companies have already resorted to industry-academia collaboration for better growth. Institutes like Institute of Chemical Technology (ICT), National Institute of Pharmaceutical Education and Research (NIPER), Indian Institute of Technology (IIT), Indian Institute of
The research institutes should send out researchers on a deputation basis to various companies in order to work in their labs for gaining experience on newer equipment so that the same can be put together in research teams for carrying out new process research as well as new product research. Research institutes should also welcome technical staff from industry to interact with their own researchers as well as use their equipment so as to foster closer relationships and encourage more industry-focussed research work, which can then be funded by industry with backing from their own support staff.
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Industry-academia collaboration
Further, research institutes play an important role in driving product innovation in the chemical industry, but they also need to keep few points in mind. Quality and timeliness are the two top criteria that research institutes need to bear in mind when aspiring to work with industry. In order to meet expectations of their stakeholders, industry functions on bedrock of process discipline and this factor plays a key role in defining any collaboration.
A win-win partnership Industry-academia collaborations can work, provided clear areas of co-operation are determined at the start of the projects. However, the challenges are many. Mehta notes, “First, R&D works only when there is a win-win situation for both the parties. Second, to be partners for R&D co-operation, both the parties need to have their strong areas either in research or with regard to other relevant aspects. Third, the two needs to be upfront and
clear about potential issues regarding intellectual property, and prepare possible solutions for these in advance. Fourth, for research institutes to be an interesting partner for collaboration, it needs to focus on identified strong areas and build its manpower committed to timely work and agreed cost. Thus, both sides need to renew their approach, if it has to become a continuous exchange. The key is that co-operation between industry and research institute is similar to a business transaction – it is an exchange from which each partner needs to benefit.�
Way to go The industry-academia collaboration has worked effectively in many developed countries such as Germany and the US as well as in developing countries like China. Major global corporations have already made it clear, and some have even declared it in their strategy that they are ready for collaboration for renewing their product portfolio. However, the
key challenges include the protection of Intellectual Property and government support to such initiatives so as to ensure that even small-scale industries are encouraged to utilise the efforts of such research institutes for carrying out cutting-edge research that otherwise would have been beyond their research. Thus, the industry-academia collaboration in the chemical industry has high probability of attaining success in the country as India is a major chemical manufacturing hub. This would be a phenomenal opportunity for the industry since in-house R&D set-up always involves extensive costs. Moreover, industry generally faces substantial shortage of research talent with the requisite skill-set and experience in advanced analytical researches, which can be easily addressed through such collaborations. Thus, the industry-academia collaboration can serve as a strategy for ensuring success and growth of the chemical industry in India. Email: avani.jain@infomedia18.in
February 2012 | Chemical World
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TIPS & TRICKS Lubricant selection
The pros and cons of synthetics and petroleum-based lubes Lubricants play a major role in maintaining equipment health in the chemical industry. Until synthetic lubricants came on the scene in the 1950s, most of the equipment used petroleum lubricants. While synthetics offer many benefits, petroleum lubes cost less. Hence, it is critical for maintenance personnel to select the appropriate lubricant by carefully evaluating the wide array of available choices.
S
election of lubricants should not be solely based on purchase price. Although synthetics are priced higher than petroleum lubes, they last longer than the latter. At the same time, petroleum-based lubes remain the best choice for certain applications. Hence, it is important to select right lubricants for a specific application. The tips mentioned below can help plant managers decide which lube is ideal for the required applications.
While petroleum-based lubes are obtained by refining crude oil, synthetic lubricants are developed after t h o ro u g h research, and their molecular structure is dependent on tailored, tightl y controlled chemical reactions. Hence, petroleum-based lubricants cost lesser than synthetics. Synthetic lubricants usually have a much higher flash point than petroleum lubricants, which translates to a lower risk of fire. For this reason, some insurance companies offer plants reduced cost on insurance premiums, if they switch to synthetic formulas. Synthetics have a good viscosity-to-temperature ratio. Synthetics may have better viscosity film strength than petroleum stocks at elevated temperatures (greater than 176째F/80째C). They are ideal for plant environments with extremely cold or hot temperatures.
Since synthetic lubricants are stable at high temperatures, they deposit less waste. The resulting decrease in equipment wear often results in fewer repairs and downtime. Because synthetic lubrication formulas reduce friction and transfer heat, they usually allow machine parts to operate more smoothly, meaning less horsepower and fuel is required to run the system. Synthetics are less likely to spark a fire than petroleum-based lubricants. This allows manufacturers to run equipment at higher speeds, resulting in more output. While synthetics offer many benefits, there are s e ve r a l a p p l i c a t i on s where petroleum-based lubricants shine. Because of their low initial cost, petroleum-based lubricants are the much more economical option in high-consumption applications.
S ynthetic lubes are ideally suited for operations that demand nearcontinuous duty (fewer oil drains means less downtime). Heavy loads also call for synthetic lubrication. Certain applications, such as natural gas processing, inevitably contaminate the lubricant being used. Because oil-based lubricants are less expensive, they are the superior choice in such settings. Some plants use machines that must spit out lubricants after only one rotation through the system. Therefore, petroleum-based lubes are always the economical option for these machines, which do not have lubricant reservoir. Neither synthetic nor petroleum-based lubricants f o r industr ial applic ations are meant to suspend dust and dirt. Therefore, in these situations it is more cost-effective to choose oil-based lubricants.
Reference: Petron Plus Global Inc (www.petronplusglobal.com) and Mar-Dustrial Sales Inc (www.mardustrial.com)
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PROJECTS
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the chemical and allied industries. Chlorinated polyvinyl chloride
Trience Specialty Chemicals Pvt Ltd Project type New facility Project news Trience Specialty Chemicals Pvt Ltd, a joint venture between Meghmani Organics Ltd and Japanese Mitsui & Company Ltd and Kaneka Corporation, will invest over ` 240 crore for setting up a chlorinated polyvinyl chloride (CPVC) manufacturing facility at Dahej in Bharuch district. The plant is expected to commence production in 2014 and will initially manufacture 20,000 tonne of CPVC annually, which can be increased up to 40,000 tonne per annum later. Project location Dahej, Gujarat Project cost ` 240 crore Implementation stage Planning Contact details: Meghmani House Shree Nivas Society Paldi, Ahmedabad 380 007 Tel: 079-2664 0668/669 Email: helpdesk@meghmani.com --------------------------------------------Liquid bulk storage facility
Vopak and Stolt-Neilsen Project type New facility Project news Royal Vopak and Stolt-Nielsen, two of the world’s biggest liquid bulk terminal operators, are planning a joint venture to build a new $ 120-million facility at Mundra Port, Gujarat. Vopak, the world’s largest liquid bulk storage provider, moved into the Indian market in July last year with the acquisition of Gujarat-based CRL Terminals, the owner of one of India’s largest vegetable oil and chemical storage facilities. Project location Mundra Port, Gujarat
Project cost $ 120 million Implementation stage Planning Contact details: Sudhish Pandey Vopak India, Unit no: 203, 3rd floor, Above Dolsun Jewels, 36 Turner Road, Bandra (W), Mumbai 400050 Tel: 022-6671 8884/6129 4800 Email: contactvopak@vopakindia.com --------------------------------------------LNG terminal
Gail India Ltd Project type New facility Project news Gail Gas Ltd, a wholly-owned subsidiary of Gail India, has joined hands with the Andhra Pradesh Government for setting up an LNG terminal and Floating Storage and Regasification Unit (FSRU) along the seacoast. Gail Gas will set up an LNG terminal and FSRU unit of 3.5-5 million TPA capacity in Kakinada or Visakhapatnam. The project would cost an estimated ` 5,000 crore to build. Project location Kakinada or Visakhapatnam Project cost ` 5,000 crore Implementation stage Planning Contact details: Gail India Ltd Petrochemical Marketing Group Gail Bhawan, 16 Bhikaji Cama Place, R K Puram, New Delhi 110066 Tel: 011-2617 2580, 2618 5624 Email: akdas@gail.co.in --------------------------------------------LNG terminal
Petronet LNG Ltd Project type New facility Project news Petronet LNG Ltd is planning to set up ` 4,500-crore LNG terminal at Gangavaram
in Andhra Pradesh with a capacity of five million tonne. Tracta Bel, a French company, has been appointed as the consultant to undertake the study for the third greenfield terminal. Dahej in Gujarat and Kochi terminal in Kerala are the other two greenfield terminals of the company. Project location Gangavaram, Andhra Pradesh Project cost ` 4,500 crore Implementation stage Planning Contact details: A K Chopra, GM (HR & PR) Petronet LNG Ltd 1st Floor, World Trade Center Babar Road, Barakhamba Lane New Delhi 110 001 Tel: 011-2341 3130 Email: akchopra@petronetlng.com --------------------------------------------Polyolefin
Mangalore Refinery and Petrochemicals Ltd Project type New facility Project news Mangalore Refinery and Petrochemicals Ltd, a subsidiary of ONGC, is considering the setting up of an 800-kilo TPA polyolefin complex for ethylene and downstream polymers such as HPDE, LDPE, LLDPE, and PP. The proposed polyolefin complex may also be considered for integration of the existing refinery to reduce capex and operating expenses. Project location Karnataka Project cost Not known Implementation stage Planning Contact details: Mangalore Refinery and Petrochemicals Ltd Kuthethoor , PO Via Katipalla Mangalore 575 030 Tel: 0824-2270400 Email: mrplmlr@mrplindia.com
February 2012 | Chemical World
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EVENT LIST
NATIONAL Paintindia International Exhibition and Conference
ChemProTech India 2012 International exhibition on chemical processing technology and equipment to be held concurrently with Chemspec India 2012; April 26-27, 2012; at Bombay Exhibition Centre, Mumbai
Trade show and conference for the paints and coatings industry; February 23-25, 2012; at NSE Exhibition Complex, Mumbai For details contact: S Mani, Colour Publications Pvt Ltd 126-A, Dhuruwadi, AV Nagwekar Marg Prabhadevi, Mumbai 400 052 Tel: 022-2430 6319, Fax: 022-2430 0601 Email: paintindia.2012@gmail.com
Lab Expo & Conferences Pune Industrial fair for lab equipment, technology and instrumentation; April 2022, 2012; at Auto Cluster Development & Research Institute Ltd, Pune For details contact: Harish Arora, Paramount Exhibitors 679, Phase 7, S A S Nagar, Mohali 140 110 Tel: 0172-2274801, Fax: 0172-2274803 Email: contact@labexposindia.com
Aquatech India Focussed trade show on advanced technologies for wastewater management;
AURANGABAD Maharashtra, Feb 17-20, 2012, Ayodhya Nagari Ground India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.
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
For details contact: Krunal Goda Koelnmesse YA Tradefair Pvt Ltd #1102, 11th Floor, DLH Park, Near MTNL Office, S V Road, Goregaon (W) Mumbai 400 062 Tel: 022-2871 5207, Fax: 022-2871 5222 Email: k.goda@koelnmesse-india.com
India Chem 2012
April 25-27, 2012; at Pragati Maidan, New Delhi
Premier tradeshow for the chemical industry in India; October 04-06, 2012; at NSE Exhibition Complex, Mumbai
For details contact: Sunil Chhibber Inter Ads-Brooks Exhibitions (India) Plot No 859, Phase-V Udyog Vihar Gurgaon 122 001 Tel: 0124-4524105; Fax: 0124-4381162 Email: info@interadsindia.com
For details contact: Mehul Tyagi, FICCI Federation House, 1 Tansen Marg New Delhi 110 001 Tel: 011-2376 5081/2373 8760 Fax: 011-2335 9734 Email: mehul@ficci.com
INTERNATIONAL Analytica Event to showcase technologies for analysis, quality control, laboratory technology; April 17-20, 2012; at New Munich Trade Fair Centre, Munich, Germany For details contact: IMAG AM Messesee-2,, Munich, Germany Tel: +(49)-(89)-9492 2121 Fax: +(49)-(89)-9492 2350 Email: info@analytica.de
For details contact: Nuernberg Messe North America, Inc 400 Interstate North Parkway, Suite 710 Atlanta, The US Tel: +1 (202) 462-6272, Fax: +1 (202) 462-1924 Email: info@american-coatings-show.com
World Gas Conference & Exhibition Event showcasing the latest in exploration, safety, refining, subsea production systems, drilling, transportation, etc; June 04-08, 2012; at Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia
American Coatings Show Symposium and technology showcase on coatings; May 08-12, 2012; at Indiana Convention Center, the US
For details contact: The CWC Group Ltd Regent House, Oyster Wharf 16-18
Lombard Road, London, The UK Tel: +(44)-(20)-7978 0037 Fax: +(44)-(20)-7978 0099 Email: exhibition@wgc2012.com
ACHEMA One of the leading international events on chemical engineering, environmental protection and biotechnology; June 18-22, 2012; at Messe Frankfurt, Germany For details contact: Messe Frankfurt Exhibition GmbH Ludwig-Erhard-Anlage 1, Frankfurt, Germany Tel: +(49)-(69)-7575000, Fax: +(49)-(69)-7575643 Email: rentalinquiries@dechema.de
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
February 2012 | Chemical World
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EVENT PREVIEW Engineering Expo Aurangabad 2012
AURANGABAD February 17-20, 2012 Ayodhya Nagari Ground
A majestic trade proposition Enter the land of the Marathas, which is slowly and surely transforming itself into a global investment hotspot. Globally known for its rich heritage sites, Aurangabad is traversing on a steadfast route to industrialisation and the results are for all to witness. The mushrooming presence of auto majors with hordes of component manufacturers has offered an alternative destination to manufacturing companies. Capturing this majestic proposition is the maiden edition of Engineering Expo Aurangabad. Slated to be held between February 17 and 20, 2012, this trade exposition promises nothing less than envious business deals… Prerna Sharma and Nishi Rath
E
xploring new markets and opportunities has been the backbone of the Engineering Expo since its inception. Having captured the manufacturing glory of regions such as Ahmedabad, Pune, Indore, Chennai and offering these regions a manufacturing push, it is now time to make foray into yet another emerging region abuzz with compelling prospects – Aurangabad. While the name connects with heritage sites like AjantaEllora, there is more to the glory of the region. History reveals that Aurangabad was developed as a trading hub four centuries ago. It lies on a major trade route that used to connect North-West India’s sea and land ports to the Deccan region. The city was a major silk and cotton textile production centre. A fine blend
ENGINEERING EXPO AURANGABAD STATS 200+ Exhibitors 10,000+ Expected visitors 5,000+ Products on display 1,00,000 sq ft Area 12 Cities to participate 66
Chemical World | February 2012
of silk with locally grown cotton was developed as Himroo textile. Paithani silk saris are also made in Aurangabad. Not to mention that, recently, the region created a buzz for placing the singlelargest order for Mercedes Benz cars in a single transaction in India – 150 Mercedes Benz cars worth ` 65 crore. There is more to it, the entry of Bajaj Auto inspired the likes of Volkswagen, Audi and Skoda to set up base in the region. The presence of the three auto companies, combined with proximity to the Pune auto hub (just four hours away) has also led to mushrooming of a huge component supplier base comprising Goodyear Tyres, Verroc, Endurance and Yash Birla Group company Birla Precision Technologies in the region. With many such budding prospects, organising a trade show makes perfect business sense. According to the proud organiser, Sandeep Khosla, Chief Executive Officer-Publishing, Infomedia 18 Ltd, “Aurangabad is witnessing a major boom largely because of the rapid growth in the automobile and pharmaceutical sectors. The overall industrial growth in the region is continuous and strong. It has truly become the favourite destination for those who are planning to invest in Maharashtra. This is our main intent to bring the industry to where the actual opportunities are. I am sure
that Engineering Expo, with its rich history of creating envious business leads, will be able to leverage on the burgeoning potential that the region possesses.” The edition is slated to be scheduled from February 17-20, 2012, at Ayodhya Nagari Ground.
The glory continues… To add on to the manufacturing competency, the city boasts of several reputed educational institutes. Aurangabad has a strong and robust education system. With a local university, over 10 engineering colleges and 25 graduate colleges, the availability of educated manpower is good. This provides the industry with a powerful workforce in the vicinity. The other advantages of Aurangabad include highly skilled labour and cheaper prices of land over Pune. Additionally, the industrial city falls on the railway line to Mumbai and has an inland depot for cargo. This makes it easy for export-oriented industries to transport heavy goods to Jawaharlal Nehru Port Trust. It also has excellent road connectivity through the Golden Quadrilateral and is serviced by all major airlines to the big cities of the country. The major industrial areas of Aurangabad include Chikhalthana MIDC, Shendra MIDC and Waluj MIDC. A new industrial
Engineering Expo Aurangabad 2012
Aurangabad has come a long way as compared to what it was a few years ago. Apart from the developing infrastructure what suits most businesses is the absence of octroi. Mangesh Agarwal
GM, Dürr Ecoclean India
belt, viz, the Shendra-Bidkin Industrial Park is being developed under DelhiMumbai Industrial Corridor (DMIC). Many renowned Indian and multinational companies, such as Wockhardt, Videocon, Siemens, SabMiller India, PepsiCo, Johnson & Johnson, Endress+Hauser, Crompton Greaves, MAN Diesel, etc, have established themselves in the industrial estates of Aurangabad. To this, SJ Gijare, General ManagerMaterial Handling, CTR Manufacturing Industries, adds, “Aurangabad today is a fast developing hub for sectors like pharma, automobiles (especially twowheelers) and electrical.”
Upbeat exhibitors Aiming to leverage the burgeoning potential, the participating companies at the maiden edition of Engineering Expo Aurangabad are all set to demonstrate their innovative offerings to the companies based in and around Aurangabad. Confirming the same, Nilesh Gandhi, Assistant Manager – Marketing, Auram Machines (I), says, “It is a platform for getting good visibility and some good business. Aurangabad is growing fast. A company like Bajaj has a huge plant here; the place has turned out to be one of the major automobile hubs. We will display drilling and tapping machines and launch a rapid tapping machine during the event.” Seconding his thoughts, Mangesh Agarwal, GM, Dürr Ecoclean India, observes, “We hope to get information about the market and introduce ourselves to Aurangabad. The region has come a long way as compared to what it was a few years ago. Apart from the developing infrastructure what suits most businesses is the absence of octroi. Companies
like Endurance and NRB Bearings are doing well here. We will be exhibiting industrial components cleaning machines (washing machines) – both water-based and chlorine solvent – with least cost per unit.” Gijare says, “We are looking forward to more publicity and visibility. Our stall at the Aurangabad Expo will be spread across 90 sq m – our largest stall till date. This time, we will display overhead maintenance and material handling equipment. Also, there will be a few product launches like electric pallet pluck-cum-stacker and barrel handling equipment.” On the other hand, Sammarth Loya, Director, Sammarth Overseas & Credits, says, “We are taking part in Aurangabad Engineering Expo because of the development the place has seen in the last couple of years. Apart from generating good business, we are looking forward to making buyers aware of our presence. We will exhibit roof ventilators and launch our new product aluminium heat insulation bubble foil.” Nawdeep Puranik, Managing Director, GKS Software Services, says, “Quality people should come and visit the Expo. The segments we are targeting include automotive and machinery. We provide engineering and reverse engineering services and will be displaying our recently launched 3D scanners used for reverse engineering. Aurangabad is on a developing high, and considered as one of the most important places when it comes to die casting and sheetmetal.”
Prosperous growth Going by the exhibitors’ sentiments, the maiden edition of Engineering Expo Aurangabad is well-poised to satisfy the thirst of companies, which are looking for new markets to expand their base. With this edition being the end of the 2011-12 season, it is surely going to leave a successful trail for other editions to follow. Email: prerna.sharma@infomedia18.in and nishi.rath@infomedia18.in
WHY AURANGABAD? Aurangabad, since the last few years, has grown to become a prominent major industrial hub, perhaps, only after Mumbai and Pune. The region already has a huge industrial presence with a large number of engineering services, auto ancillary and pharmaceutical research companies having facilities in the region. Significant corporate players in Aurangabad include Bajaj Auto, Videocon, Nirlep, Siemens, Garware Polyester, Skoda Auto India, Wockhardt, Shreya Life Sciences, Orchid Chemicals & Pharmaceuticals, Lupin, Atra Pharmaceuticals, Colgate-Palmolive, Endress+Hauser and Goodyear. The ever-evolving industrial scenario and the entrepreneurial spirit of the people have made Aurangabad grow into an industrial area of repute. A dominant player among the auto industry in Aurangabad is Bajaj Auto. Bajaj Auto initiated its production in Aurangabad in 1970s and was accountable for the changed industrial scenario of the city, owing to its massive investments and employment opportunities. Later, several ancillary units were set up in Aurangabad that gratified the spare parts needs of Bajaj Auto. These units have now transformed into large organisations themselves. Aurangabad has also emerged as a major pharmaceutical production centre. Looking at the booming opportunities, Network 18 is organising Engineering Expo in Aurangabad from February 17-20, 2012. All large, medium and small industries in manufacturing & servicing sectors can be a part of the Expo. Platforms such as Engineering Expo help foster trade and commerce in the region, hence inducing growth.
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EVENT REPORT Engineering Expo Indore 2012
INDORE January 6-9, 2012 Labh Ganga Convention Centre
Transforming challenges to
OPPORTUNITIES
In keeping with its commitment to manufacturing excellence and business networking, Engineering Expo returned to the heart of India. Apart from being a wide platform for cutting-edge technology, the fourth edition of Engineering Expo Indore surpassed its own standards in meeting expectations of exhibitors and visitors alike. Tiding over unprecedented challenges of change in venue and the ensuing logistics complexities, the Engineering Expo brand has emerged as fine steel through the test of fire. Annabel Dsouza
A
t the heart of India’s journey towards economic development lies the innovative entrepreneur and his never-say-die attitude that spells success for individual brands and companies as well as the community and nation at large. Celebrating and facilitating this spirit of business excellence
ENGINEERING EXPO INDORE 2012 AT A GLANCE 200+ Exhibitors 9,729+ visitors 5,000+ Products displayed 110,000 kg machinery moved 52,000 sq ft exhibition area
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Galaxy of dignitaries at the inauguration (L-R) R V Krishnan, C M Venkateshwaran, V Gokul Das, Sandeep Khosla, R Bhaskar and Asheesh Sharma
Esteemed dignitaries inaugurating the Expo. (L-R) Sandeep Khosla, M M Sharma, Omprakash Gupta, Sandeep Naolekar and Ajay Sevekari.
and dynamism, the fourth edition of Engineering Expo was held from January 6-9, 2012, at the Labh Ganga Convention Centre, Indore. During the four days of intensive networking, Indore’s burgeoning engineering industry received a further impetus in terms of information exchange and profitable partnerships. The Expo was inaugurated by eminent personalities from the city’s business fraternity that included Omprakash Gupta, President, MP Electric Merchants and Contractors Association; Sandeep Naolekar, Chairman, CII Madhya Pradesh State Council, and Managing Director, Darling Pumps Pvt Ltd; M M Sharma, General Manager, Indo-German Tool Room, Indore; Ajay Sevekari, Director, Bridgestone India Pvt Ltd; and Sandeep Khosla, Chief Executive Officer-Publishing, Infomedia 18 Ltd. The esteemed guests highlighted Indore’s emergence as a manufacturing hub and auto ancillaries sourcing base in
Central India. They also emphasised on the pivotal role played by trade shows such as Engineering Expo in supporting entrepreneurship and innovation in the region. Naolekar commented, “The fast-paced industrial growth in Indore will improve the employment avenues, and thereby raise the standard of living in Indore. Such Expos are vital for the competitiveness of industry, especially Small and Medium Enterprises (SMEs).” Sevekari added, “Engineering Expo will help local businesses to source world-class products and solutions. Exhibitors at this Expo can enhance their existing customer base by reaching out to the entire industry. Also, visitors at this Expo can expose themselves to latest technology and innovations, thereby promoting knowledge and idea exchange.” Further, Khosla said, “We look forward to further value-additions for an
Engineering Expo Indore 2012
even better experience and reach the target audience. We welcome large, medium and small industries in the manufacturing and servicing sectors to be a part of the Expo in this exciting journey.”
Rising relevance of Engineering Expo In recent times, tier II cities have emerged as the manufacturing backbone of industrialised India. “With global economic slowdown, Indian businesses are seeking a major industrial revolution. Madhya Pradesh, as the heart of India, is also looking at rapid expansion of its industrial base. Engineering Expo has provided a good platform to interact with the market leaders and update their technology know-how,” Gupta stated. With the IT sector inundating cities such as Indore, Raipur and Jabalpur, entrepreneurs are facing a challenging prospect to channelise the positive and robust young talent in the right direction to optimise production and customer satisfaction. Sharma revealed, “Engineering exhibitions can expose local vendors and distributors to international standards of product quality, delivery period and price competitiveness. On the educational front, we have been conducting several courses to improvise on the engineering and tooling skills of local talent to further boost the overall manufacturing excellence of Indore.” In its fourth edition, Engineering Expo Indore has evolved from being a mere meeting point for businesses from Madhya Pradesh and other parts of the country. Engineering Expo Indore 2012 showcased some of the latest machinery solutions and application-oriented products & services. Kalidas Bhangare, Director, Testo India Pvt Ltd, said, “Engineering Expo is one of the few large-scale exhibitions held in Indore. I am pleased to witness a healthy visitor turnout. Also, the level of awareness and understanding has evolved since the previous exhibitions. Today’s buyers are willing to pay a higher price for the right technology and this Expo offers us an
opportunity to convey our strengths to potential customers.” All successful businesses understand the crucial role played by exhibitions and conferences in fostering new opportunities. Engineering Expo has always been a platform for branding and interacting with suppliers, Original Equipment Manufacturers (OEMs), auxiliary service providers & end-users. Competitive acumen is another advantage offered by this Expo, which not only facilitates sales and marketing, but also supports decision makers in formulating future strategies. Amardeep Singh, Assistant Manager, Schneider Electric, opined, “At Expos such as this, we share common space with our competitors and collaborators. Apart from being a common platform for cutting-edge technology, exhibitors can showcase their unique advantages and deliver better product options to the industry. By facilitating intensive competition, trade exhibitions promote industrial development.”
Crossing the barrier Leaders like to say that ‘there is an opportunity hidden in every challenge’. In keeping with this maxim, this edition of Engineering Expo Indore was held at the futuristic Labh Ganga Convention Centre on the outskirts of Indore. This is the fastest developing area of Indore and is well-connected to other cities including the industrial hubs like Dewas, Pithampur, etc. The change in venue, in fact, proved to be a blessing in disguise for the exhibitors and visitors alike. Atanu Sengupta, Area Manager, Power Tool Division, Bosch Ltd, said, “The change in venue has certainly influenced the overall success of this Expo. In my opinion, this venue is the future of trade shows in Indore. The relative distance from Indore city has allowed technocrats to not only visit this exhibition, but also seek out quality products and learn more about globally competitive solutions.” The seamless relocation from the previous venue was executed through zealous efforts of the Expo team who ensured that this latest development reached all stakeholders through signage,
advertising and even a free shuttle bus service for the visitors from the previous ground to the new venue. V K Arora, Samarpan Engineering & Marketing Pvt Ltd, said “This is the second time we are participating in Engineering Expo Indore. There is good awareness among the student and industrial community. The change in venue has had a positive impact on the visitor turnout and we are receiving serious enquiries about our technology solutions.”
Visitors’ vistas The Indore Expo demonstrated its commitment towards networking not only for exhibitors, but also for visitors who travelled far and wide. Anuj Misra, CEO, APL Networks Pvt Ltd, commented, “It is heartening to witness an Expo of advanced standards in Indore. The quality of exhibitors and their products have helped us analyse various solutions according to our application and price offering. We are an IT consulting firm and currently looking out for security solutions for our offices in and around Indore. The exhibitors here have been warm and welcoming of our suggestions.” Likewise, Engineering Expo Indore enabled companies to collaborate and seek new opportunities, besides providing a learning curve in the areas of costcompression, quality circle, service improvement, energy-efficiency, etc. Varun Dalal, Director, Bluecoat Pvt Ltd, said, “I have recently set up my business in Indore and need to build a network for my company and its brands. I have visited several business exhibitions in other cities and Engineering Expo definitely meets existing standards in India.”
Future focus Engineering Expo Indore seemed to be a perfect culmination of the enterprising spirit of the local industry as well as business from across the nation. MP’s engineering industry earnestly awaits the next season, with renewed vigour and enhanced prospects as the Expo returns to Indore in January 2013. Email: annabel.dsouza@infomedia18.in
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BOOK REVIEW
Stilbenes Author: Gertz Likhtenshtein Price: ` 10,500 Stilbenes are diarylethenes, ie, hydrocarbons consisting of a trans or cis (E or Z form) ethene double bond substituted with a phenyl group on both carbon atoms of the double bond. These are important for the chemical industry, especially in dye and pharmaceutical manufacturing. This book acquaints the reader with the preparation and modern methods of investigation, via chemical and photochemical reactions, photochronism and non-linear effects. It also discusses the use of stilbenes as base for optical and measuring instruments, applications in industry, biochemistry and biomedicine, and as fluorescence-photochrome biophysical labels. This book will prove to be invaluable to students, professionals and academicians in the field of organic chemistry; molecular biologists; materials scientists; cell biologists as well as catalytic, medicinal and complex chemists, and those working with/on organometallics.
Accident/incident prevention techniques In the chemical industry, safety is an important topic of concern. The industry is making efforts to align the professionals (and would-be professionals) with the idea of safety. This book is an indispensable tool to delve deeper into this topic. This A-to-Z, hands-on guidebook addresses the responsibilities, principles, tools and techniques involved in accident investigation and loss control. The USP of this book is the provision of relevant applications of theoretical techniques described. It covers many accident prevention techniques, which have been in use by the safety community for years. The information and illustrations included in this book will allow the reader to develop and build a safety and health programme at the workplace. This book is applicable to a wide range of occupations since there are no risk-free workplaces. It is especially written for occupational safety and health professionals, who address these issues at work. It will also serve as an excellent source of study for training practitioners and students of this discipline.
Author: Charles D Reese Price: ` 4,815
Reviewer: Tejas Padte, Lecturer, Department of Chemistry, Ramnarain Ruia College, Mumbai
Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958, Telefax: 022-2203 4058, Email: thadam@vsnl.com
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PRODUCTS This section provides information about the national and international products available in the market
Video zoom instrument This video zoom instrument and measurement system provides a crisp and bright image in true colours showing minute details of the object under view. The precise X-Y movements of platforms scan a large object with ease and accuracy. It comes with a parfocal optics, which eliminates the need for refocussing every time the magnification is changed. The ergonomic design enables the user to work with it for hours without experiencing visual or physical fatigue. The video zoom instrument is available in various models, with 10 micron least count to automatic X-Y scanning. Lensel Optics Pvt Ltd Pune - Maharashtra Tel: 020-2747 4340 Email: lensel@vsnl.com
Ammonia gas detector The instrument is available as portable, wall-mounted, panel-mounted version with latest user-friendly microcontroller technology and with long-life electrochemical sensors. It accepts input of 4-20 mA/3-wire from toxic gas transmitter. The range, resolution, alarm setpoint, alarm control action, etc, are programmable by users. This instrument has high accuracy of 0.25 per cent with software linearisation. Easy online field calibration by user from the front keys is provided. Programmable latch/non-latch facility for relays and LED indication option is available. Ambetronics Engineers Pvt Ltd Mumbai - Maharashtra Tel: 022-2820 7768, Mob: 09323644415 Email: sales8@ambetronics.com
Rotary sifter This is a state-of-the-art non-vibrating dustproof continuous inline sieving machine. The rotating screw paddle feeder sifter is used for low density non-abrasive powders, especially for screening powders from 60300 mesh. Material is fed into a screw feeder with flat paddles, which rotates at a speed from 600-1500 rpm. The sifters have screening baskets of various sizes from 200 mm dia and 400 mm to 1200 mm long. The rotary sifter is used for screening non-abrasive powders from 60-300 mesh and can handle from 100 kg to 1000 kg/hr. Finex Sieves Pvt Ltd Vadodara – Gujarat Tel: 09376232820 Email: padmak@finexsieves.com
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PRODUCTS
Crate washing machine The continuous crate washing machine (type CrateWash) is made for cleaning of standard plastic crates. The crates washer cleans up to 100 pallets per hour and contains a separate prewash-zone and a final rinse-zone. The soiled crates to be washed are manually placed on the machine and conveyed by a chain conveyor into the wash chamber. The crates pass through high-pressure waterjet spray generated by nozzles having accurate spray angles for washing the pallets both externally and internally. This ensures optimum cleaning in the shortest possible timing. Flow Control Industries Mumbai - Maharashtra Tel: 022-3222 7296 Email: washsanitech@gmail.com
Flue gas analyser The Multilyzer NG flue gas analyser is an ideal solution for checking and servicing small and medium-sized heating systems according to the German BlmSchV guidelines. This can be used for CO concentration safety checks on gas-fired systems. This instrument can also be used for measurements and adjustments of solid fuel systems,
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in particular for pellets, as well as bivalent, modulating combined heating and power plants. The compact design allows the instrument to be equipped with any combination of up to six electrochemical cells. Afriso India Pvt Ltd Pune - Maharashtra Tel: 020-2551 4336 Email: nilkanth.jatar@afriso.de
Vacuum pool system The energy saver vacuum pool system is developed by integrating two vacuum pumps and a reservoir tank. This vacuum pool system is ideal for fluctuating processes. The system greatly improves the performance of such processes. Demand for air/vapour evacuation in certain kind of process applications fluctuates as the process parameters vary with time. The use of single vacuum leads to the fluctuation of vacuum, and constant vacuum cannot be maintained in the system. Energy saver vacuum pool system keeps the vacuum virtually constant. Joyam Engineers & Consultants Pvt Ltd Ahmedabad - Gujarat Tel: 079-2656 9533 Email: joyam@joyamvactech.com
PRODUCTS
Gas detector The Simtronics GD1 sets a new standard for toxic gas detection. Using a tuneable laser diode, the instrument delivers enhanced coverage and fail-safe detection. The performance improvement marks a genuine step change for safety systems and lifecycle cost savings. The gas detector is designed with features that provide an effective response to the detection of gas hazards in a wide range of industrial environments from offshore production facilities to wastewater treatment plants. At the heart of the detector is tunable laser diode that eliminates environmental effects from sun, rain and fog. Simtronics ASA Oslo - Norway Tel: +47-2264-5055 Email: mail@simtronics.no
Oven temperature controller The model PID-966 microcontrollerbased temperature controller (version 1.1) is incorporated with features taking into consideration the application of controlling the temperature of electrically heated oven in the industry. All the required variable aspects are met by this controller to suit any type of end-user or OEM application. The controller accepts J or K type thermocouple and displays the temperature over the full range with in 1oC accuracy. Depending upon the oven size and kilowatts of heaters, OEMs use the end controlling device as power contactor, solid-state relays or thyristor power pack. Libratherm Instruments Pvt Ltd Mumbai - Maharashtra Tel: 022-28963823 Email: libratherm@libratherm.com
Pallets These pallets are offered as per GMP and USFDA norms and are used for multifarious applications in different industries. Designed for optimal load-bearing capacities, the pallets are manufactured on state-of-the-art plants. The pallets have many outstanding features and can also be tailor-made to meet customers’ special requirements. Sintex Industries Ltd Kalol - Gujarat Tel: 02764-253500 Email: plastic@sintex.co.in
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PRODUCTS
Dock leveller The most advanced concept of the Campisa dock leveller is to have the whole drive unit contained in a wall box, which is installed on a wall inside the warehouse, at eye level, which allows for easy and economical maintenance, without the necessity to manoeuvre under the platform or inside the pit, where traditional power packs and controls are usually installed: an undoubtedly dangerous, dirty and uncomfortable operation. Depending on the type of installation, it can hydraulically power several dock levellers with only one console (drive unit); each dock leveller can be controlled separately by its own control pad. Gandhi Automations Pvt Ltd Mumbai - Maharashtra Tel: 022-6672 0200 Email: sales@geapl.co.in
Scrap lifting magnet This scrap-lifting magnet features highest lifting capacity and can handle tonnes of scrap continuously throughout the day. It is used in metalworking plants to hoist and transport steel parts, forgings, castings, plates, booms, channels, angles, rods and bars. The scrap lifting magnet saves time and effort because it can lift steel more quickly and conveniently than any other mechanical device. With a lifting magnet,
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there is no need to attach and secure lifting supports nor is it necessary to block up loads on the floor or to move for mechanical devices. It is applied to lifting and transporting magnet conductive materials. Electro Flux Equipments Pvt Ltd Chennai - Tamil Nadu Tel: 044-26181904 Email: marketing@electrofluxequipmentspvtltd.com
Hose reel The stainless steel hose reel is designed for heavy-duty use with a canvas reinforced rubber/Teflon braided stainless steel water hose. Using a heavy-duty internal spring, the reel quickly and easily rewinds the hose. The reel is provided with a ratchet assembly, which locks the reel when the desired length of hose has been pulled out. All hose reels are preset with enough force to fully retract the hose. The hose reel can be conveniently installed on the pillar, wall or ceiling, for easy access & maintenance and is offered in fixed or swivel designs. Cris Engineering Works Mumbai - Maharashtra Tel: 022-2685 9440 Email: roque_ferns@rediffmail.com
PRODUCTS
Bottom discharge centrifuge This centrifuge is fitted with a cake scrapping arrangement, which can be motorised or hydraulically operated to enable to scrape the stickiest of cakes. The cake is discharged through the bottom chute provided. This results in reducing manual labour, less cake handling loss and uniform cake washing. The centrifuge is offered in vapour-tight construction with nitrogen blanketing for hazardous chemicals. CIP design with built-in cleaning nozzles ensures no product cross-contamination. The centrifuge is offered in three-point pendulum suspension and four-point inertia plate mounted designs to suit application considerations. United Engineering Enterprises Mumbai - Maharashtra Tel: 022-2308 3990 Email: uenggent@gmail.com
Network sensor This is a rugged, self-contained pointto-point wireless network that provides reliable configured I/O for remote sensing and actuation. It is designed for process and assembly/manufacturing automation, agriculture monitoring, remote tank level management and wastewater treatment installations. Applications also include robotics, crosswalk signal actuation, machinery monitoring, rotating machinery and many others. Banner Engineering India Pvt Ltd Pune - Maharashtra Tel: 020-6640 5624 Email: salesindia@bannerengineering.com
Air velocity transmitter It is designed for accurate measurement of air-speed and gas flow between 0-40 m/s. The high-quality hot film sensor element is based on thin film technology and guarantees highest sensitivity even at low mass flows. Construction of the sensing head reduces to a minimum impact of the mounting angle on the measurement results. The transmitter can detect and measure even the smallest flow changes due to temperature variation, whereby resulting fluctuations of the output signal can be suppressed by the user with the help of software settings. E+E Elektronik GmbH Osterreich - Austria Tel: +43-7235-6050 Email: info@epulse.at
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PRODUCTS
Air clamp The MillHog air clamp is an air-operated cylinder that fits the small diameter welding end prep tools for use on tube and pipe up to 76.2 mm ID. It features a self-centering draw rod that rigidly mounts into the tube or pipe ID. The clamping mechanism employs clamp ribs that retract off the mandrel automatically to reduce friction and promote high reliability. It is capable of improving the cycle times between end-preps by as much as 600 per cent. The air clamp is used for fabrication shops processing individual tubes and tube sheet panels. ESCO Tool Massachusetts - USA Tel: +1-508-3594311 Email: matt@escotool.com
Gas detector The multi-gas detector (model XP 302 M) comes with inbuilt battery-operated suction pump. This portable detector makes simultaneous independent measurements of up to four gases - oxygen (O2), combustible gases (HC), hydrogen sulphide (H2S) and carbon monoxide (CO). A large, easy-to-see display shows the status of all four gases simultaneously. Temperature measurement and display function is also included. The backlight automatically lights in dimly lit places. This gas detector employs three or four gases and uses replaceable, pre-calibrated plug & play sensor cartridges. Prism Gas Detection Pvt Ltd Mumbai - Maharashtra Tel: 022-28778974 Email: prism@lpgsafety.com
Infrared temperature sensor The Thermalent CI infrared temperature sensor provides advantages of infrared temperature measurement in a compact, low-cost integrated sensor. Designed for easy integration into a standard four-wire system, the instrument can easily replace traditional contact probes with a type J or K thermocouple output or with a 0-5 V output application, which is susceptible to noise or requires a longer cable run. The infrared temperature sensor is designed to measure target temperatures ranging from 0 to 500째C. With water-cooling, the sensor can withstand ambient temperatures up to 260째C. MRK Engineers Chennai - Tamil Nadu Tel: 044-2478 0314, Mob: 09444668125 Email: ramakrishnan25@hotmail.com 76
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Electric chain hoist The streamlined, compact electric chain hoist comes in capacity ranging from 125 kg to 250 kg. This chain hoist is offered with conical rotor motor. The conical rotor motor is one hour rated and eliminates additionally mounted conventional EM brake. Specialised conical rotor motor makes the hoist compact, lightweight, and eliminates brake problems. The chain hoist is also offered with dual speed as optional. This load chain ensures safe lifting and longer life. Specially designed safety clutch protects hoist from overloading, over-hoisting and over-lowering. The hoist is suitable for production applications and offers trouble-free performance. Hafa Hoists Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-2769 4586 Email: hafa@vsnl.net
Ball valve The ball valve is offered in three-piece, twopiece and one-piece design with full bore and reduced bore with ends threaded, socket weld or butt weld, flanged to ANSI or DIN Std. It comes with a PTFE seat, which eliminates the need for periodic maintenance. The mirror finish ball ensures perfect matching with seats and gives long life. Blowout-proof stem and GFT packing eliminates gland leakages and reduces operating torque. The three-piece wafer-type design facilitates easy installation and inline maintenance at site of seals without dismantling the valve. The valve is provided with heating/cooling jackets to suit service conditions. Diamond Engineering Works Mumbai - Maharashtra Tel: 022-2685 3317 Email: diamondengg@rediffmail.com
Wear plate and wear pad Rollon Turcite-B wear plate and wear pad overcome the problems of wear in critical sliding surfaces of machinery. It is used in sugar mills, cement plants and other engineering applications. It is a modified bronze-sintered PFE material with inherent characteristics of self-lubrication, low friction and high load-bearing capacity. The wear-resistance property is enhanced by special wear-resistance additives. Turcite-B can withstand high working pressure of 115 kg/cm² and temperature of –218°C to +260°C. It is fungusresistant and not affected by weather/moisture and most chemicals. Rollon Bearings Pvt Ltd Bengaluru - Karnataka Tel: 080-2226 6928 Email: rollon@rollonbearings.com
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PRODUCTS
Salt spray corrosion testing system
Centrifugal pump
This is a proven system to make comparative or absolute study of corrosion resistance for different materials, surface coatings, viz, plating, painting, etc. Various components and assemblies of automotive, electrical, electronic, engineering and durable consumable products are subject to salt spray corrosion test to evaluate effect of corrosive atmosphere on their aesthetic and performance parameters. Based on these corrosion effects one can take corrosion inhibiting measures. Various corrosion tests mentioned in National & International Standards viz, IS: 9000 pt Xi, ASTM B 117, etc, can be carried out in this system.
The multi-stage horizontal centrifugal pump is a non-self-priming pump. All wetted parts, ie, impellers, diffusers, stage casings, etc, are made of corrosionresistant stainless steel. The pump is axial suction and vertical radial delivery-type with threaded ports. It has enclosed fan-cooled AC induction motor. Dynamically balanced rotors ensure vibration-free and noiseless operation. Salient features are: proven performance & durability, reliability & rugged in construction, stainless impellers & stage casings, energy efficient motors, sturdy & compact, noiseless & smooth operation, and ease in maintenance/zero maintenance.
Micro Supreme Auto Industries (I) Pvt Ltd Tel: 020-2693 2669 Email: bageshri.bhagwat@microsupreme.co.in
Aquasub Engineering Coimbatore - Tamil Nadu Tel: 0422-2642484, Mob: 09884326195 Email: atxcbe@eth.net
Digital indicator The model AI-501 digital indicator is available with programmable and modular inputs, supporting multiple input types of thermocouples, RTDs, voltage/current and two-wire transmitters. This indicator is suitable for measuring and displaying temperature, pressure, flow, level, humidity, etc with measurement accuracy of 0.3 per cent full scale. The dual display windows are convenient to set parameters and alarm points. Various dimensions are selectable. The indicator supports up to 4 loops of alarms including 2 loops of high limit alarms plus 2 loops of low limit alarms. Alarms can be outputted to different relays or share one.
Test tool The Fluke Color ScopeMeter test tool comes with automated test capability for Fieldbus, Profi Bus and other industrial communication protocols. Fluke 225C and 215C ScopeMeter test tools are designed for maintenance specialists who keep automation and process plant equipment operational. These instruments feature easy signal validation of all the critical signal parameters, like amplitude & noise and have floating and fully isolated inputs for true differential signal measurements on 2-wire differential bus systems.
Micon Automation Systems Pvt Ltd Ahmedabad – Gujarat Tel: 079-3090 0400, Mob: 09723462390 Email: info@miconindia.com
TTL Technologies Pvt Ltd Bengaluru - Karnataka Tel: 080-25251859 Email: tmidirect@ttlindia.com
Liquid paint
Nutsche filter
A range of liquid paints, varying from standard to highly specialised with superior performance, is used in automotive components and bus body builders, motors, pumps and valve components, electrical control panels and transformers, air compressors and pneumatic components, LPG cylinders. It is also used in air and water cooling radiators, wind energy fabrications, architectural/scaffolding equipment, textile machinery and accessories, steel furniture and storages racks, marine and offshore coatings. Speciality coatings, floor coatings (epoxy and polyurethane), marine coatings, miscellaneous coatings and thinners are also available.
This nutsche filter is a simple batch-type filter. It is a dish end type of tank with a filter plate fitted or bolted inside with flanges having a cloth as filter media. Filter plate is perforated to allow the filtrate. The slurry fed into the filter vessel is separated into filtrate and the residue in the form of cake on the filter cloth, which can be removed manually. The filter can be offered up to operating vacuum of 720 mm of Hg.
Titan HMG Paints India Ltd Coimbatore - Tamil Nadu Tel: 0422-2319841, Mob: 09600925850 Email: marketing@titanhmgpaints.in
EPP Composites Pvt Ltd Rajkot - Gujarat Tel: 0281-2361623, Mob: 09099072550 Email: marketing@epp.co.in
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PRODUCTS
Wastewater treatment system This wastewater treatment system employs pulsed electric field processing. The operations of a pulsed electric field (PEF) wastewater treatment system are based on the process of electroporation in cells to accelerate pre-digestion. This results in up to 80 per cent less solid waste output. The wastewater treatment PEF system destroys cell membranes by applying 1-20 microsecond, 35-50 kV/cm high voltage pulses at a frequency of up to 2 kHz to the wastewater stream. This system facilitates the anaerobic digestion process of cells and is available in sizes beginning from 10,000 lph and reduces the solid waste by up to 80 per cent. Diversif ied Technologies Inc Massachusetts - USA Tel: +1-781-2759444 Email: kempkes@divtecs.com
Drum dryer A range of drum dryers is available with quality standards and optimum effectiveness. This range is broadly accepted by prospective clients due to the fine efficient performance, robust construction and longer service life. The dryer is available as per customised specification and also at industry leading prices. Moreover, the range of dryers is manufactured using finest quality raw material sourced from reliable vendors after an appropriate inspection process. The range is manufactured using superior quality raw material and is used to convert liquid material into dry flakes. Tridev Industries Ahmedabad - Gujarat Tel: 079-2589 5865, Mob: 09978917299 Email: info@tridevindustries.com
Digital magnahelic gauge This digital magnahelic gauge is used for pressure/ vacuum measurement in the magnahelic pressure range. The instrument is capable of measuring differential pressure (two ports), gauge and vacuum measurement for all ranges. Also available is the standard pressure measuring range of 0 to 1, 2, 4, 5, 10, 40, 100, 400, 700 bar gauge pressure indicator and 0.0 to -760.0 mm hg vacuum range indicator. It finds applications in cleanroom pressure measurement, HVAC equipment, Hepa filters, boiler equipment, air handling units, etc. Ace Instruments Hyderabad - Andhra Pradesh Tel: 040-23078848, Mob: 09394030848 Email: sales@aceinstrumentshyd.com
February 2012 | Chemical World
81
PRODUCTS
Magnetic coupling
Swing check valve
This magnetic coupling is mainly used in providing solutions of leak proofing pumps and agitators handling hazardous and difficult-touse chemicals. The technology involves use of permanent magnets to transmit motor torque to the pump without contact. This enables sealing of the pump shaft hermetically, thus preventing leakage of fluid medium from the pump seals. It finds applications in isocyanate and polyol pumps in polyurethane machines, pharma and chemical process industries, food applications, biotechnology, industrial ovens and batching machines, bottom-mounted agitators for blenders and mixing vessels, etc.
The swing check valve comes in sizes ranging from 65 to 300 mm. This valve meets the design requirements as per BS 1868/API 6D/ ASME B16.34 and testing requirements as per API 598/EN 12266-1. Face-to-face and end-to-end dimensions (Dim A) conform to ASME B16.10; and drilling & flange dimensions conform to ASME B16.5, while butt weld end dimensions conform to ASME B16.25. To ensure long and trouble-free valve performance, seating surface is accurately machined, precisely aligned and perfectly lapped. Materials of construction are carbon steel and stainless steel.
BEDA Flow Systems Pvt Ltd Noida - Uttar Pradesh Tel: 0120-4329990, Mob: 09212289411 Email: info@bedaflow.com
Met-Flow Controls Pvt Ltd Hubli - Karnataka Tel: 0836-2332599, Mob: 09345886999 Email: info@metflowindia.com
High-pressure piston pump Electronic dosing pump The electronic dosing pump is available from 0-20 lph. It is compact in size and lightweight. The pump is diaphragm-type solenoid-operated pumps. The diaphragm is made of PTFE and backed by hyphalon. It can also be provided with automatic flow switches and level controllers. The pump is suitable for applications in water and wastewater treatment, fuel metering and other chemicals dosing in many process industries. Positive Metering Pumps (I) Pvt Ltd Nashik - Maharashtra Tel: 0253-2381993, Mob: 09326781757 Email: sales@positivemetering.com
The high-pressure piston pump and packages are ideal for transfer and supply of medium-to-high viscosity materials. This line of extrusion ram/pump packages includes single-post and two-post extrusion pump rams and complete ram/pump packages for 5gallon containers. Featuring superior down-force in a compact footprint, the new ARO ram/pump packages are especially suited to high-viscosity material applications including inks, caulks, mastics, lubricants and more in market segments such as automotive, automotive tier suppliers, printing, packaging and more. Ingersoll Rand Industrial Products Pvt Ltd Ghaziabad – Uttar Pradesh Tel: 0120-4389200 Email: brijesh_mulik@irco.com
Ribbon blender This ribbon blender is one kind of mixer to mix different powders. Horizontal mixer is precisely designed to maintain combination of three major dimensions is diameter, ribbon width and pitch. It is for effective distribution of very small amount of additive and assures homogeneity of final output. Powder is mixed in rotary as well as horizontal motion to get effective blending, which is achieved by designing perfect size of inner and outer ribbons. The ribbon blender is used to blend powder products in industries such as pharmaceutical, chemicals, dyes, pigments, agriculture, minerals, pesticides and food. Tridev Industries Ahmedabad - Gujarat Tel: 079-25895865, Mob: 09978917299 Email: info@tridevindustries.com 82
Chemical World | February 2012
Rotary evaporator The RV10 rotary evaporator is used for distilling a wide range of liquids. This has an attractive appearance backed by innovative features in the areas of safety, functionality and ergonomics. The evaporator automatically lifts the receiving flask out of the heating bath if the power cuts off. This means that the ongoing test and any distillate already produced are unaffected by the stoppage. The patented geometry of the IKA distillation condenser also provides a larger cooling surface area for distillation. The associated heating bath is ergonomic and safe. IKA India Pvt Ltd Bengaluru - Karnataka Tel: 080-2625 3925, Mob: 09845387684 Email: usha@ika.in
PRODUCTS
Hybrid stepping motor The PJPL series, a linear-type hybrid stepping motor, enables linear motion of motor shaft with a combination of threaded shaft and inner threaded rotor. It does not require any outside mechanical parts such as lead screw, wire or belt for linear motion, so the customers can design their system with simple mechanism. The stepping motor is available in two sizes, ie, 28 mm2 and 42 mm2. Both unipolar and bipolar windings are available. Typical applications of the motor are X-Y stage, syringe system or any other linear motion systems.
Nippon Pulse Motor Co Ltd Tokyo - Japan Tel: +81-3-38138841 Email: s-hagimoto@npm.co.jp
Tube cleaning system Brackett Green automatic tube cleaning system (ATCS) is a permanent and a cost-effective solution for reducing the efficiency loss of condensers and heat exchangers due to microfouling and scaling issues. This ATCS injects elastomer rubber balls slightly larger than the tube diameter into the water supply line. Cooling water flow forces them through the condenser tubes. As they pass through the tubes, the balls wipe the tubes clean of deposits and continually remove silt, scale and biological fouling. Eimco Water Technologies Surat - Gujarat Tel: 0261-2465972 Email: hiren.trivedi@glv.com
Laser particle size and shape analyser The laser particle size and shape analyser is available in wet and dry mode feeding. Low-cost particle sizers for small-scale industry and colleges, mid-range models for quality control, and top-of-the-line models for large-scale industry and research institutes are available. These analysers find applications in pharmaceuticals, cement, pesticides, battery material, graphite, petrochemicals, metallic powders, catalysts, etc. MeasureTest Corporation Mumbai - Maharashtra Tel: 022-2202 7982, Mob: 09869012701 Email: measuretest@yahoo.com
February 2012 | Chemical World
83
PRODUCTS
Reverse osmosis desalination system
Simulator
The PW series reverse osmosis desalination system is provided with the Aqua Pro 3 or 5plunger high-pressure pump, titanium head for maximum corrosion resistance, balanced drive for lowest noise and pulsation, ceramic plungers and nylon valves. The boost pump provides up to 50 psi of boost pressure to the filtration system. The system is equipped with easy-to-operate SS-316 high-pressure bypass valve, which controls the operating mode from cleaning/rinsing to water production and allows high pressure bypass for start-up and low pressure flushing without readjustment of regulating valve.
The simulator is an apparatus that provides (for testing purpose) conditions like those, which are encountered in real operation or replica of real plant with real-time data. Real-time simulators are offered for refinery: VDU, CDU, FCCU with emulated TDC3000 console, fertiliser: ammonia and urea plant simulation with emulated Yokogawa DCS console, power plant 210 MW on KWU and LMZ turbines.
Parker Hannif in India Pvt Ltd Navi Mumbai – Maharashtra Tel: 022-6513 7081 Email: parkerind@parker.com
Triangle Simulation Pvt Ltd Mumbai - Maharashtra Tel: 022-2409 5682, Mob: 09969074960 Email: triangle_simulate@yahoo.com
Hydraulic test pump Diesel and gasoline nozzles The FuelMaster and Big Mouth diesel and gasoline nozzles are designed for use on farm and consumer pumps. The lightweight Tensalloy aluminium FuelMaster diesel nozzle provides high flow capacity required by truck stops and terminal operations. Micro-touch valve provides smooth operation and exceptional flow control. Super tough nylon hose guard and holdopen clip and easy-to-change lockout style spout assembly are other important features. The lightweight Big Mouth diesel nozzle offers efficient refuelling. Dixon Asia Pacif ic Pvt Ltd Mumbai – Maharashtra Tel: 022-4093 1555 Email: salesindia@dixonvalve.com.au
Polypropylene and PVDF process pump The horizontal chemical process pump is made of polypropylene (PP). All contact parts are made of virgin copolymer PP with high wall thickness for better impact resistance and stability. The pump is centrifugal type. Rotating parts are dynamically balanced. The pump is available with ceramic, SS-316 or FRP shaft sleeve. Sealing arrangement is of PTFE gland packing or mechanical seal or as per the requirement. This pump is suitable for effluent treatment plants, filter press application, acid transfer, boiler de-scaling, pickling in steel plants, electroplating, etc. Moniba Anand Electricals Pvt Ltd Mumbai - Maharashtra Tel: 022-2857 3156, Mob: 09820046500 Email: mail@moniba.net 84
Chemical World | February 2012
The motorised hydraulic test pump comes in sturdy crankcase, completely sealed and made from graded cast iron. Heavy-duty bearings are used to provide support to the alloy steel, hardened and ground crankshaft at both ends. The lubrication of power-end parts and bearings are done by splash lubrication system from reservoir oil in the crankcase. Hardened stainless steel and ground plunger offer corrosion- and abrasionresistance for longer life. Dev Engineers Ahmedabad - Gujarat Tel: 079-26403839, Mob: 09824012742 Email: info@devpumps.com
PTFE/Teflon moulded components The range of PTFE/Teflon moulded components include: bushes, rods, sheets, bellows, O-rings, V-rings, mechanical seals, ball valve rings, gaskets, etc. These are available as per customers’ requirements or as per drawings and samples. The components are also available in all fillers of PTFE/Teflon, like glass, carbon, bronze and graphite. Supremo Polymer Industries Ahmedabad - Gujarat Tel: 079-55445181, Mob: 09327001998 Email: sales@supremopolymer.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
LIST OF PRODUCTS To know more about the products featured in this magazine, fax us on 022-3003 4499 or tear and post to us the ‘Product Inquiry Card’ by following the 5 easy steps given there. Alternatively, you may also write to us at michael@infomedia18.in or call us on 022-3003 4684, and we will send your inquiries to the advertisers/companies directly to help you source better. Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81
Product
Pg. No.
AC drive ...................................................... 21 AC motor .......................................................... 17 AC variable frequency drive .............................. 21 Accelerated ageing test ...................................... 37 Acoustic enclosure ............................................. 39 Agitator .............................................................. 11 Air clamp ........................................................... 76 Air pollution control equipment........................ 31 Air receiver......................................................... 31 Air treatment .................................................. BIC Air velocity transmitter ...................................... 75 Aluma coat ........................................................... 3 Ammonia gas detector ....................................... 71 Anaesthetic rotameter ........................................ 71 Analytical instrumentation................................. 29 Aqua gas chlorinator .......................................... 61 Autoclave gasket ................................................ 73 Automatic and contained discharge .................. 33 Automatic rescue device .................................... 21 Axial flow fan .................................................... 71 Bag filter ...................................................... 72 Ball valve ............................................................ 79 Ball valve - Teflon-lined...................................... 4 Batch disperser ................................................... 11 Bellows and dip-pipes .......................................... 4 Bio-diesel ........................................................... 37 Boiler.................................................................. 79 Bottom discharge centrifuge .............................. 75 Braided hose ...................................................... 73 Brake motor ....................................................... 17 Burner ................................................................ 79 Butterfly valve - Teflon-lined .............................. 4 Cable ........................................................... 73 Cake pressing machine ...................................... 33 Calorimeter ........................................................ 11 Centrifugal air blower ........................................ 71 Centrifugal pump............................................... 80 Check valve – Teflon-lined ................................. 4 COD analyser .................................................... 81 Column and chemistry ...................................... 29 Compositional and trace metal analysis ............ 37 Condenser .......................................................... 31 Cone screw mixer .............................................. 31 Continuous batch filtration ............................... 33 Controllers for furnaces ..................................... 21 Cooling tower ................................................. BIC Cords.................................................................. 73 Corona treater sleeve ......................................... 73 Crate washing machine ..................................... 72 Dairy equipment........................................... 31 Damper .............................................................. 31 DC motor .......................................................... 17 Dehumidifier...................................................... 75 Diesel and gasoline nozzles ............................... 84 Digital indicator ................................................. 80 Digital magnahelic gauge .................................. 81 Disperser ............................................................ 11 Distillation column ............................................ 76 Dock leveller ...................................................... 74 Drawer magnet .................................................. 76 Drum dryer ........................................................ 81 Drum-type magnetic separator .......................... 76 Dry vane pump .................................................. 39 Duel fuel burner................................................. 71 Dust collector ..................................................... 72 Electric chain hoist ....................................... 79 Electronic brake ................................................. 21 Electronic dosing pump ..................................... 82 Elevator controller ............................................. 21 Elevator door mechanism .................................. 21 Exhibition - Engineering Expo ................... 55, 64 Failure analysis ............................................. 37 FBD gasket ........................................................ 73 Filler compositional analysis .............................. 37 Filter press ......................................................... 74 Finishing machine ............................................. 76 Fire tube-type package IBR steam boiler .......... 79 Flameproof motor .............................................. 17 Flange mounting motor ..................................... 17 Flue gas analyser ................................................ 72 Fluid bed dryer .................................................. 71
Sl. No. 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162
Product
Pg. No.
FRP battery stand .............................................. 15 FRP cable tray ................................................... 15 FRP canopy ....................................................... 15 FRP grating ....................................................... 15 FRP ladder ......................................................... 15 FRP luminaries .................................................. 15 FRP piping ........................................................ 13 FRP poles & mast ............................................. 15 FRP profile ........................................................ 15 FRP storage tanks.............................................. 15 Fuel - diesel ....................................................... 37 Gas detector ................................................. 73 Gas detector system ........................................... 76 Gases .................................................................. 37 Gasket ................................................................ 73 Gear box ............................................................ 24 Gear motor ........................................................ 24 Gear oil .............................................................. 37 Geared motor..................................................... 17 Heat exchanger ................................31, 76, FIC Heating bath ...................................................... 11 Helical inline geared motor/reducer .................. 24 High-intensity roller-type magnetic separator ....... 76 High-pressure homogeniser ............................... 11 High-pressure piston pump ............................... 82 Hose reel ............................................................ 74 Hot plate ............................................................ 11 Hot water generator..................................... 71, 72 Hot-air and water generator .............................. 79 Hot-air generator ............................................... 72 HPLC panel ...................................................... 29 Hybrid stepping motor ...................................... 83 Hydraulic test pump .......................................... 84 IBR steam boiler .......................................... 72 Indirect air heater .............................................. 71 Industrial cooler .............................................. BIC Industrial ovens .................................................. 71 Inflatable gasket ................................................. 73 Informatics ......................................................... 29 Infrared temperature sensor ............................... 76 Inline disperser................................................... 11 Inline magnetic separator................................... 76 Inline shaft mounted helical geared motor/reducer ....24 Kneading machine ........................................ 11 Laboratory reactor ........................................ 11 Laboratory software ........................................... 11 Large diameter welded pipe .............................. 79 Laser particle size and shape analyser ............... 83 Light curtain ...................................................... 21 Lined valve and pipe fitting................................. 4 Liquid paint ....................................................... 80 Load cell ............................................................ 21 Load weighing device ........................................ 21 Lubes - engine oil .............................................. 37 Magnetic coupling ........................................ 82 Magnetic drum pulley........................................ 76 Magnetic stirrer ................................................. 11 Material identification ....................................... 37 Mechanical vibratory feeder............................... 76 Metallography .................................................... 37 Mill .................................................................... 11 Motor ................................................................. 17 Motor-driven dosing pump ............................... 61 Multi-desk vibrating screening machine ........... 76 Multi-fuel fired IBR steam boiler ..................... 79 Multi-stage cake washing .................................. 33 Network sensor............................................. 75 Non-IBR steam boiler ....................................... 72 Non-return valve .................................................. 4 Nutsche filter ..................................................... 80 Oil seal ........................................................ 73 O-ring ................................................................ 73 Oven temperature controller .............................. 73 Overband-type magnetic separator .................... 76 Overhead stirrer ................................................. 11 Pallets .......................................................... 73 Petrol & fuel oil ................................................. 37 Pilot plant .......................................................... 11 Piping system ....................................................... 6 Pneumatic and hydraulic accessory ...................... 8 Polymer characterisation .................................... 37
Sl. No. 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242
Product
Pg. No.
Polypropylene and PVDF process pump .......... 84 Polypropylene filter plate ................................... 74 Polypropylene recess plate ................................. 74 Power controller................................................. 21 PP-recess chamber-type filter press ................... 74 PP-recess chamber-type fully-automatic filter press ...74 Pressure and vacuum filtration .......................... 33 Pressure vessel .................................................... 76 Profile................................................................. 73 PTFE lined valve and pipe fitting ....................... 4 PTFE/Teflon moulded components ................. 84 Pump .................................................................. 39 Reactor ................................................... 31, 83 Reverse osmosis desalination system ................. 84 Ribbon blender .................................................. 82 Right-angled helical bevel geared motor/reducer ........24 Right-angled helical worm geared motor/reducer.......24 Roots blower ...................................................... 39 Rotameter .......................................................... 71 Rotary evaporator ......................................... 11, 82 Rotary sifter ....................................................... 71 Salt spray corrosion testing system ................ 80 Sample extraction products (Oasis) ................... 29 Sampling valve – Teflon-lined ............................ 4 SCR power controller ........................................ 21 Scrap lifting magnet........................................... 74 Seamless pipe ..................................................... 79 Sensor system ....................................................BC Shaker ................................................................ 11 Sheet .................................................................. 73 Silicone rubber sleeve......................................... 73 Silicone transparent platinum cured tubing....... 73 Simulator............................................................ 84 Slip ring crane-duty motor ................................ 17 Soft starters and digital starter........................... 21 Solenoid driven metering pump ........................ 61 Solid-liquid mixer .............................................. 11 Sponge ............................................................... 73 Spray dryer project ............................................. 31 Square ................................................................ 73 Stainless steel pipe ............................................. 79 Steam boiler ................................................. 71, 79 Storage tank ....................................................... 76 Strainer – Teflon-lined ........................................ 4 Strip ................................................................... 73 Suspension magnet ............................................ 76 Swing check valve .............................................. 82 TC gasket .................................................... 73 Teflon-lined valve and pipe fitting ...................... 4 Tefzel HHS isotactic PP material ....................... 6 Test tool ............................................................. 80 Testing machine ................................................ 37 Thermic fluid heater .............................. 71, 72, 79 Thermoplastic valve ............................................. 6 Thermostats & vacuum dryer/mixer.................. 11 Transmission fluid ............................................. 37 Transparent tubing ............................................ 73 Trap magnet ...................................................... 76 Tray dryer .......................................................... 71 Tube ................................................................... 79 Tube cleaning system......................................... 83 UPLC panel ................................................. 29 U-tube ................................................................ 79 Vacuum booster pump .................................. 39 Vacuum control equipment ............................... 61 Vacuum or hot gas drying ................................. 33 Vacuum pool system .......................................... 72 Vacuum system .................................................. 39 Valve .................................................................. 35 Variable area flowmeter ..................................... 71 Variable frequency drive .................................... 21 Vertical non-IBR oil-fired steam boiler ............ 79 Vibration motor ................................................. 76 Video zoom instrument ..................................... 71 Wastewater treatment system ........................ 81 Water wall membrane panel IBR steam boiler ..... 79 Wear plate and wear pad ................................... 79 Welded pipe....................................................... 79 Wood-fired four-pass thermic fluid heater ....... 79 Wood-fired thermic fluid heater ....................... 79
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover February 2012 | Chemical World
85
LIST OF ADVERTISERS
Advertiser’s Name & Contact Details Aeron Composite Pvt Ltd
Pg No 15
Advertiser’s Name & Contact Details Gem Equipments Ltd
Pg No BIC
Advertiser’s Name & Contact Details Raj Process Eqpts & Systems(P) Ltd
T: +91-79-65258500
T: +91-422-3267800
T: +91-20-40710010
E: info@aeroncomposite.com
E: sales@gemindia.com
E: sales@rajprocessequipment.com
W: www.aeroncomposite.com
W: www.gemindia.com
W: www.rajprocessequipment.com
Aerotherm Systems Pvt Ltd
71
Heattrans Equipments Pvt.Ltd.
T: +91-79-25890158
T: +91-79-25840105
E: contact@aerothermsystems.com
E: info@heattrans.com
W: www.aerothermsystems.com
W: www.heattrans.com
Aqua Services
61
T: +91-265-2331748
T: +91-79-25894701
T: +91-40-23315341 / 45 E: neelesh@bhs-sonthofen.in W: www.bhs-sonthofen.in
Bry Air (Asia) Pvt Ltd
IKA India Private Limited
W: www.bryair.com
13
E: salescbg@cppiping.com W: www.cppiping.com
71
Suraj Limited 11
W: www.surajgroup.com
W: www.ika.in
Suresh Enterprises 76
E: info@sevitsil.com
E: info@jkmagnetics.com
W: www.sevitsil.com
W: www.jkmagnetics.com
The Indian Electric Co T: +91-20-24474303 E: icemktg@indianelectric.com
E: info@jyoticeramics.com
W: www.indianelectric.com
W: www.jyoticeramics.com
E: cmflowmeters@vsnl.net
T: +91-250-2453438
W: www.cmflowmeters.com
E: pdmakwana@vsnl.net
Uniphos Envirotronic Pvt Ltd 83
Mazda Ltd
E: engexpo@infomedia18.in
T: +91-79-40007000
W: www.engg-expo.com
E: vacuum@mazdalimited.com
Entrepreneur
57
W: www.mazdalimited.com
Everest Transmission
39
New Amp & Ohm Applications Pvt.Ltd.
T: +91-22-6123500 E: singhrv@uniphos.com W: www.uniphos-she.com
35
Universal Corporation
E: samson7@vsnl.com W: www.samson-grp.com
21
UNP Polyvalves India Pvt Ltd
E: info@everestblowers.com
E: info@ampohm.co.in
E: mktg@polyvalve.com
W: www.everestblowers.com
W: www.ampohm.co.in
W: www.polyvalve.com
24
Waters (India) Private Limited
T: +91-79-25840105
T: +91-2692-231070
T: +91-80-28371900
E: info@fluidltd.com
E: infopbl@elecon.com
E: waters_india@waters.com
W: www.fluidltd.com
W: www.pbl.co.in
W: www.waters.com
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover
Chemical World | February 2012
6
T: +91-265-2649248
T: +91-40-64571792
Power Build Ltd
8
T: +91-22-23422238
T: +91-11-45457777
86
81
W: www.chemicalequipments.com
T: +91-09819552270
72
17
T: +91-253-2350120
Kwality Process Equipments Pvt Ltd
Fluidtech Boilers Pvt Ltd
73
T: +91-2762-224814 / 224240
T: +91-79-22870071
3
79
T: +91-79-27540720
E: process@ika.in
T: +91-33-24421456
55; 64
BC
W: www.siemens.com/chemicals
E: suraj@surajgroup.com
Jyoti Ceramic Industries Pvt Ltd
T: +91-22-67230600
Engineering Expo
Siemens
T: +91-80-26253900
Jaykrishna Magnetics Pvt Ltd
E: bryairmarketing@pahwa.com
CM Flowmeters India Pvt Ltd
FIC
75
T: +91-11-23906777
Chemical Process Piping Pvt Ltd.
W: www.shivatec-india.com
HRS Process Systems Ltd
W: www.hrsasia.co.in
33
37
E: gupta@shivatec-india.com
E: info@hrsasia.co.in
W: www.balkrishn.com
Shiva Analyticals (India) Limited T: +91-80-27971322
T: +91-20-66047894
E: info@balkrishn.com
BHS-Sonthofen (India) Pvt. Ltd.
W: www.samarthengineers.com
4
W: www.ptfeindia.com
79
76
E: sanjayraut21@hotmail.com
E: hitech@ptfeindia.com
W: www.aquaservicesindia.com
Samarth Engineers
31
T: +91-20-66300305
T: +91-79-25833040
E: aqua@aquaservices.co.in
Balkrishna Boilers Pvt Ltd
Hi-Tech Applicator
74
Pg No
29
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