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INDUSTRY WATCH - Chemical World
January 2013
EDITORIAL
2013: Tuning in to transformation!
A
fter the Mayan doomsday prophecy proved to be wrong (that had sounded the death knell for the world), the New Year rings in much hope and optimism. At this time of the year when most think about new beginnings, an important resolution could be to contribute towards a significant leap in the Indian chemical industry. However, as always, even this New Year comes with new challenges that need to be addressed swiftly and decisively. The troubles – especially the macro-economic ones – of our globally interconnected world seem far from over. With the European Union still sputtering to accelerate and the near- to mid-term economic forecasts for the Organisation for Economic Co-operation and Development (OECD) countries lacking the desired lustre, the emerging economies are most likely to continue their glorious growth march, albeit a bit slower, in the foreseeable future. The key points to be noted here are an increasingly interlinked world and the rising competitiveness of certain geographies to earn their share under the sun. Against this background, accompanied by country-specific competitive advantages as well as significant shifts in the impact of technology on the value chain spanning the feedstock suppliers to end-users with the manufacturers in between, the chemical industry is certainly not going to be the same this year. Rather than focussing too much on the drag factors, it is imperative to leverage growth drivers and chart an optimum course for the chemical industry and the Indian economy at large. Of course, the right set of policies will further help leverage the emerging opportunities and thus enable India to stay ahead in the race. According to the report ‘India’s New Opportunity – 2020’ prepared by a high level strategic group, the nation needs to accelerate its economic growth beyond the rates of 5-6 per cent per annum in order to be counted as a major economic powerhouse by the end of this century’s first quarter.
Editorial Advisory Board PothenP aul Former Chairman, Aker Powergas Pvt Ltd
While the importance of India’s demographic dividend cannot be overemphasised, it is high time to specifically focus on nurturing and offering the right skillsets required for an ever-evolving chemical industry. To achieve this, the time has come for a transformational shift. This calls for a shift from a mere compliance mindset to a commitment-driven focus on accomplishing goals and transforming ideas into actions with agility. Besides, superior efforts in improving the efficiency of organisations, building scale organically and inorganically, and harnessing some of the global best practices to improve operational excellence will further aid in this direction. On this note, here’s wishing all our stakeholders an eventful and enriching 2013!
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@network18publishing.com
January 2013 | Chemical World
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42 44 Insight & Outlook: Industrial Gases
28 Cover illustration: Sachin Pandit
Newsmakers of 2012 ......................................... 10 10 Special Focus: Wastewater & Effluent Treatment
Industrial gases ................................................................... 42 Steel industry ...................................................................... 44 Interface - Saket Tiku, President, All India Industrial Gases Manufacturers’ Association .................... 46 Propylene production .......................................................... 48
Wastewater treatment ........................................................ 28 Clean-in-place system ......................................................... 30 IT tools ............................................................................... 32
Automation Trends
Water management for SMEs............................................ 34
Radar level measurement systems: Cost-effective, reliable solution for process industry .................................. 50
Case Study - Marine toxicity tests ................................... 35
Energy Management
Roundtable .......................................................................... 36
Energy audit: Right means to enhance plant efficiency .... 52
Policies & Regulations
In Conversation With Vipul Shah, Chairman, CEO and President, Dow Chemical International Pvt Ltd .... 24
Facility Visit: Raj Process Equipments And Systems Pvt Ltd An integrated approach to offer quality process equipment .... 38
Implementing stringent safety norm: Time to go the ‘REACH’ way .............................................................. 54
Strategy Reducing water footprint: Adopting sustainable route to avert future scarcity .............................................. 56
Tips & Tricks Corrosion prevention: Effective ways to save chemical plant from rust formation ................................... 58
Event Preview
Regular Sections Editorial ........................................................................ 5 News, Views & Analysis .............................................. 16 Technology & Innovation ............................................ 21 Technology Transfer .................................................... 22 Projects ........................................................................ 61 Tenders ........................................................................ 64 Event List .................................................................... 66 Book Review ................................................................ 72 Products ...................................................................... 75 List of Products .......................................................... 84 List of Advertisers ...................................................... 85
Engineering Expo Aurangabad 2013: Leveraging market trends, expanding opportunities ............................ 68
Event Report Engineering Expo Ludhiana 2012: Exploring a horizon of opportunities .................................................. 70
Highlights of Next Edition Special Focus: Green Chemistry Insight & Outlook: Oil & Gas
Details on page no. 59, 66
Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise January 2013 | Chemical World
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Business Insights Technologies Opportunities
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January 2013 | Chemical World
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NEWSMAKERS OF 2012
ALTERNATIVE RESOURCES Novozymes and Sea6 Energy to develop biofuels from seaweed
LANXESS invests in BioAmber
( January) Novozymes signed an exploratory research agreement with the Chennai-based Sea6 Energy to jointly develop a process for the production of biofuels from seaweed. The research alliance will use enzymes to convert seaweed-based carbohydrates to sugar, which can then be fermented to produce ethanol for fuel, fine chemicals, food proteins, and fertilisers.
(February) LANXESS strengthened its commitment to renewable raw materials by investing $ 10 million in the US-based BioAmber Inc, as part of a private placement. BioAmber is a global leader in succinic acid produced from renewable resources such as corn. Together, the two companies have developed plasticisers, whose cost-effectiveness and safety profile make them sustainable alternatives to phthalate-containing formulations.
Enerkem begins ethanol production from waste at its demonstration facility in Québec
Three companies sign MoU to develop renewable feedstocks
( June) Enerkem Inc, a waste-to-biofuels and chemicals company, started initial production of cellulosic ethanol from waste materials at its demonstration facility in Westbury, Quebec. Vincent Chornet, President and CEO, Enerkem, said, “Enerkem has already produced cellulosic ethanol at its smaller scale pilot laboratory facility in Sherbrooke. ”
(August) Versalis (an elastomer producer), Genomatica (a renewable chemical technology provider) and Novamont (a third generation integrated biorefineries pioneer) signed an agreement to establish a partnership to enable production of butadiene from renewable feedstocks. Versalis will hold a majority interest in the joint venture holding company.
ANALYTICAL INSTRUMENTS Thermo Fisher Scientific opens facility in China
Parker Hannifin’s division inks pact with H2scan
(November) Thermo Fisher Scientific Inc opened its new facility in Suzhou, China, for the manufacturing of life sciences consumables and equipment. The facility expands the company’s global manufacturing footprint and establishes local production capabilities to meet increased customer demand in China and other Asia-Pacific markets.
(December) The Instrumentation Products Division (IPD) of Parker Hannifin Corporation, the global leader in motion and control technologies, has signed an agreement with H2scan Corp to become the exclusive manufacturer of co-branded process systems incorporating more than 11 different process monitors.
ENGINEERING & CONSTRUCTION Shaw to sell energy & chemicals business to Technip The Shaw Group Inc entered into a definitive agreement to sell substantial part of its energy & chemicals business to Technip – one of the leading global companies in project management, engineering and construction – for approximately $ 300 million in cash consideration.
ThyssenKrupp awarded FEED contract in Russia (May) ThyssenKrupp Uhde won a Front-End Engineering and Design (FEED) contract for a single-train polypropylene (PP) plant based on LyondellBasell’s Spheripol process technology for ZapSibNeftekhim LLC, a wholly-owned subsidiary of Sibur – a leading integrated gas processing and petrochemical companies in Russia, the CIS and Central and Eastern Europe.
Jacobs bags Reliance Industries contract
Foster Wheeler wins PMC contract by KNPC
(December) Jacobs Engineering Group Inc was selected by Reliance Industries Ltd (RIL) to provide engineering and procurement assistance services for the construction of a Mono Ethylene Glycol (MEG) plant at the Jamnagar refining and petrochemical complex in Gujarat.
(December) Foster Wheeler AG’s Global Engineering and Construction Group was awarded a project management and consultancy (PMC) services contract by Kuwait National Petroleum Company (KNPC) for its Clean Fuels Project at the Mina Al-Ahmadi and Mina Abdullah Refineries in Kuwait.
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Chemical World | January 2013
NEWSMAKERS OF 2012
INDUSTRIAL GASES Linde to construct plants for Sadara’s complex
Praxair starts up air separation plant in Peru
(April) The Linde Group and Sadara Chemical Company (Sadara) signed a long-term contract that will see Linde supply Sadara with carbon monoxide (CO), hydrogen (H2) and ammonia (NH3) at a chemical complex now being built by Sadara in Jubail, Saudi Arabia, which will be the world’s largest chemical complex ever built in a single phase.
(October) Praxair Peru, a subsidiary of Praxair Inc, started a new air separation unit (ASU) to expand Praxair’s supply of industrial gases to one of the largest producers of zinc in the world, in Lima, Peru. The ASU will supply additional capacity to meet the demand of one of the fastest growing economies in South America.
IT & AUTOMATION Siemens sells chemical and liquid feed product lines
AspenTech acquires PSVPlus
( July) As part of an ongoing and strategic product portfolio assessment, Siemens Industry Automation Division (SIAD) sold the assets, inventory, and associated trademarks for certain globally marketed chemical feed, liquid feed and flow meter product lines to Underground Solutions Inc (UGSI).
(September) Aspen Technology Inc, a leading provider of software and services to the process industries, acquired the PSVPlus software product from Softbits Consultants, Ltd. Energy, chemical, and engineering and construction companies use PSVPlus to model pressure relief scenarios and size pressure relief valves in process plants.
PETROCHEMICALS BASF to invest ` 1,000 crore in India
Dow to build ethylene plant at Texas
(April) BASF announced an investment of ` 1,000 crore to set up an integrated chemical manufacturing hub at Dahej, Gujarat, which will house production facilities for polyurethanes, care chemicals and polymer dispersions for coatings and paper. The start of production is planned in 2014.
(April) The Dow Chemical Company announced the construction of a new world-scale ethylene production plant at Texas, as part of its previously announced comprehensive plan to further connect its US operations with cost-advantaged feedstocks available from increasing supplies of US shale gas.
Williams Partners signs pact to buy Williams’ Gulf Olefins Business
Gulf of Guinea establishes methanol plant in Nigeria
(October) Williams Partners acquired Williams’ approximately 83 per cent undivided interest in the Geismar olefins production facility, as well as Williams’ refinery-grade propylene splitter for $ 2.264 billion and pipelines in the Gulf region.
(November) Gulf of Guinea Oil Exploration Ltd announced the establishment of a $ 700 million methanol plant in Nigeria in 2015. The plant, with a capacity of 8,50,000 metric tonnes of methanol productions annually will be the largest in West Africa.
PRIVATE EQUITY INVESTMENT Aurora Capital acquires DuBois Chemicals
Clariant divests three businesses to SK Capital
(December) Aurora Capital Group, a Los Angeles-based private equity firm, acquired DuBois Chemicals Inc, a leading provider of value-added specialty chemical solutions and services, from The Riverside Company. DuBois offers a broad range of proven and customised chemicals solutions predicated upon superior customer service and technical support.
(December) Clariant signed an agreement to divest its Textile Chemicals, Paper Specialties and Emulsions businesses to SK Capital - a private investment firm. The total consideration of the sale amounts to approximately CHF 502 million. Subject to regulatory approvals, the transaction is expected to close by the end of the second quarter of 2013.
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Chemical World | January 2013
NEWSMAKERS OF 2012
PUMPS & VALVES Dover’s Pump Solutions acquires Maag Group (February) Pump Solutions Group (PSG), a business unit within the Engineered Systems segment of Dover Corporation, has signed a definitive agreement to acquire the Maag Group headquartered in Zurich, Switzerland. The acquisition includes Maag Pump Systems, Automatik Pelletizing Systems and Maag Filtration Systems. Maag is a global leader in premium external gear pump technology.
Metso enters globe valve business by acquiring Valstone Control (March) The Finnish firm Metso acquired a globe valve technology and service company, Valstone Control Inc, in South Korea. The acquisition enables Metso to expand its offering for the oil and gas and power industries with globe valve technology that plays a key role in most critical processes with extreme pressures and temperatures.
HMS Group acquires Apollo Goessnitz
Swagelok acquires Innovative Pressure Technologies
( July) HMS Group agreed to acquire 75 per cent of Apollo Goessnitz GmbH, worldwide operating manufacturer of centrifugal pumps and system equipment, for Euro 25 million. The main products of Apollo Goessnitz are primarily used for specific applications in oil refining, offshore and onshore upstream, thermal power generation as well as chemical plants and water utilities, etc.
(September) Swagelok Company acquired the assets of Innovative Pressure Technologies (IPT) as part of its strategy to broaden the company’s offering of products and services for fluid system technology customers around the world. The US-based IPT is a manufacturer of quality high and medium pressure and sub-sea valves, fittings and fluid control devices used mostly in oil and gas, chemical/petrochemical and other applications.
SPECIALTY CHEMICALS LANXESS expands Jhagadia facility ( January) Continuing its expansion strategy in India, the specialty chemicals major LANXESS 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). Its semi-crystalline products business unit started production at the site’s new plant for high-tech plastics.
Flotek Industries signs supply agreement with Pioneer Natural (May) Flotek Industries Inc entered into a multi-year bulk chemical supply agreement with Pioneer Natural Resources Pumping Services LLC. The agreement provides that Pioneer will purchase 80 per cent of certain blended chemistries from Flotek for a period of three years with an option to extend the agreement beyond the initial term.
GFS Chemicals expands facility in the US
MWV Specialty Chemicals acquires Resitec
( June) GFS Chemicals Inc, a privately held specialty chemical manufacturer, announced plans to expand its Columbus facility to manufacture cerium intermediates to further back integrate its domestic production operations. Cerium has been in short supply due to China’s restrictive policy on rare earth mineral exports.
(November) MWV Specialty Chemicals, a division of MeadWestvaco Corporation, signed an agreement to purchase the remaining outstanding ownership stake of Resitec Industria Quimica Ltda, a Brazilian company that serves the Latin American pine chemicals industry. MWV and South Africa-based AECI Ltd have held a 50:50 JV in Resitec.
Momentive opens global R&D centre in Bengaluru
ALTANA acquires ChemCor
(November) Momentive Performance Materials Inc and Momentive Speciality Chemicals Inc – subsidiaries of Momentive Performance Materials Holdings LLC – have opened a new global research and development (R&D) centre and business headquarters for the India, Middle East and Africa (IMEA) region in Bengaluru. The new centrehas been built with initial investment of $ 4.35 million.
(December) The specialty chemicals group ALTANA signed a contract to acquire the business of Chemical Corporation of America Inc (ChemCor), a US manufacturer of specialty wax additives. The acquired business will be integrated into BYK USA Inc, which is based in Connecticut and belongs to the ALTANA Additives & Instruments division. ChemCor produces water-based wax products and specialty additives.
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Chemical World | January 2013
NEWSMAKERS OF 2012
SUSTAINABLE DEVELOPMENT Petronas and LanzaTech to recycle CO2
(October) LanzaTech, a producer of low-carbon fuels and chemicals from waste gases, and Petronas, the national oil company of Malaysia, will work together to accelerate the development of technologies to produce sustainable chemicals from carbon dioxide (CO2) and natural gas. The agreement blends Petronas’ experience and assets in the petroleum industry with LanzaTech’s gas fermentation technology.
LANXESS inaugurates wastewater treatment plant at its Madhya Pradesh site (November) LANXESS, the global leader in specialty chemicals having a manufacturing site in Nagda, Madhya Pradesh, opened a wastewater post treatment plant at its site. This plant, built with an investment of nearly ` 35 crore, will treat the discharge from the existing Effluent Treatment Plant in a manner that virtually no liquid effluent is discharged from the site.
MISCELLANEOUS Georg Fischer acquires Harvel Plastics
Ross Process moves into new plant in India
( January) Georg Fischer agreed to acquire Harvel Plastics Inc, the US market leader for industrial plastic pipes, for $ 50 million. This is another step in the implementation of Georg Fischer’s strategy to further expand its piping systems business worldwide. The company is the leading supplier in the North American market of polyvinyl (PVC) and chlorinated polyvinyl (CPVC) pipes for industrial applications.
( January) Charles Ross & Son Co relocated Ross Process Equipment Pvt Ltd (RPE) to a new state-of-the-art plant in Pune, India tripling the size of its previous facility. A fastgrowing company, RPE manufactures many Ross product lines including tumble blenders, ribbon blenders, planetary mixers, multi-shaft mixers, high speed dispersers, high shear mixers, as well as pressure vessels, tanks and other fabricated equipment.
AkzoNobel invests in new pulp chemical facility in Brazil (February) AkzoNobel announced plans to invest Euro 80 million in the construction of a new pulp chemical facility in Brazil. The plant, operated by the company’s Pulp and Paper Chemicals business, Eka Chemicals, will supply the Suzano Maranhão pulp mill. This is AkzoNobel’s secondlargest investment in Brazil in the past 12 months.
BASF to build formic acid plant in Louisiana (May) BASF announced its plans to build a state-of-the-art production plant for formic acid at its integrated ‘Verbund’ site in Geismar, Louisiana. The new plant will have an annual capacity of more than 50,000 tonne. It will be the only formic acid plant in North America.
Insecticides India forms JV with Japanese firm (September) In its endeavour to provide the latest technology to farmers, Insecticides India Ltd (IIL) formed a joint venture ( JV) with the Japan-based Otsuka AgriTechno Co Ltd (OAT) for R&D of new products. Under the terms of the JV, both the companies have agreed to establish a 4,000 sq m research centre in Bhiwadi, Rajasthan.
BKG Water Solutions acquires TIAMI (April) BK Giulini GmbH, a subsidiary of ICL Performance Products (ICL-PP), announced that its BKG Water Solutions division has acquired TIAMI Vattenkemi AB, one of Scandinavia’s largest water treatment companies. TIAMI, a privately-held company founded in 1991, is based in Göteborg, Sweden, and provides a comprehensive array of industrial water treatment solutions, including chemicals, equipment and services.
Solvay inaugurates research centre in India (May) Solvay has inaugurated its new Research, Development and Technology Centre at Savli, India. The centre will focus mainly on the development of high-performance polymers, organic chemistry, nano-composites and green chemistry. Housed in a new and high-performance sustainable building, it will employ over 200 researchers when fully operational.
Oxea expands carboxylic acids capacities (December) To better serve the continuously rising global demand for carboxylic acids, Oxea completed a significant expansion of its production capacities. The carboxylic acid units in Oberhausen, Germany, were successfully expanded by another 10 per cent of nameplate capacity. Additionally, Oxea is currently building another carboxylic acid plant in Oberhausen, and is expected to be completed in the first quarter of 2013.
January 2013 | Chemical World
15
NEWS, VIEWS & ANALYSIS
BUSINESS STRATEGY CAPACIT Y EXPANSION
Dow India to gain immensely from Sadara JV in Saudi Arabia
Raj Process’ fourth facility to be operational in May this year
Dow Chemical International Pvt Ltd At present, Dow India is investing (Dow India) is gearing up to take in developing infrastructure to receive advantage of Sadara Chemical Company products coming from Sadara. However, (Sadara), the $ 20-billion JV the company plans to offer between Saudi Aramco and value-added products, rather The Dow Chemical Company. than selling only chemicals. “India will be one of the largest “We want our customers to markets for the products from develop differentiated products Sadara complex,” said Vipul using our innovative solutions. Shah, Chairman, CEO and For this, we are looking to President, Dow India. invest at broadly three levels Sadara is constructing the – infrastructure, people and Vipul Shah complex, which will comprise new product development. 26 manufacturing units, and will possess We are currently building the infrastructure flexible cracking capabilities and produce in the country to ensure that product more than 3 million metric tonne of reaches the market. At the same time, we high-value performance plastics and are investing in skillset development of specialty chemical products. Sadara’s first people,” added Shah. The company is also production units will come on line in exploring applications that can be target 2015, and all units are expected to be up for products coming from Sadara plant. Rakesh Rao and running in 2016.
The Pune-based Raj Process Equipments and Systems Pvt Ltd is coming up with its fourth facility at Shirval, which is 60 km away from Pune. The plant is expected to be operational from May this year for which construction work is going on in full swing. Raj Process is one of the leading manufacturers of process equipment and turnkey plants serving the process industry for more than a decade. The new facility will be equipped with hi-tech equipment and advanced machineries such as CNC plasma, hydraulic plate bending machines, CNC welding and grinding, horizontal boring, CNC lathe and milling machines and many more. The new facility is spread over 14 acre and will provide employment to more than 1,000 people. The facility will manufacture boilers, dryers, evaporators, turnkey projects and heavy fabrications and other equipment. “Continuous increase in the demand for the process equipment and turnkey plants across the world has encouraged us to go with the new facility,” said Anil Pise, Managing Director, Raj Process Equipments and Systems Pvt Ltd. Prasenjit Chakraborty
ENVIRONMENTAL ISSUES
Panoli Intermediates receives closure notice from GPCB The Gujarat Pollution Control Board (GPCB) has issued a closure notice to Unit-II and Unit-III of Panoli Intermediates (India) Pvt Ltd based in Nandesari on the outskirts of Vadodara for discharging effluent in Mini river. The units had discharged effluent in an open field, which drained down into Mini river. The vigilance team conducted an enquiry and reached the source of the discharge after which the notice was sent. Rajen Trivedi, Regional Officer, GPCB, said, “The firm was required to channel the chemical waste to Common Effluent Treatment Plant (CETP) in Nandesari, but it discharged it instead in the river that passes in the area. As a result, water in the canal had become coloured.” He added, “The firm would be required to furnish 10 per cent of its Environment Management System (EMS) funds as bank guarantee to GPCB and a plan to take corrective measures before it is allowed to reopen the units.” Avani Jain
RECOGNITION
Dr K S Murthy to receive international award from UK-based organisation The Trustee Board of the UK-based Society of Dyers and Colourists Gold Medallists include Prof Ian D Rattee (also Perkin Medallist), (SDC) has decided to confer Silver Medal of the Society on Harry H Sumner (of ICI Organics and University of Manchester Dr K S Murthy, Technical Consultant, Pidilite Institute of Science & Technology), Dr K H Gharda Industries Ltd for his sustained support to the Indian (Chairman and Managing Director of Gharda textile industry. Dr Murthy will be presented with this Chemicals Ltd), etc. Commenting on the award, award at a function to be held in Bradford on April 26, Dr Murthy said, “I feel honoured to be given a small 2013. SDC is a world-renowned educational charity niche in this ‘hall of fame’ featuring such stalwarts, established in 1884 committed to the advancement of albeit at a different level. I am immensely pleased that science and technology of colour. The coveted SDC my work and years of committed efforts have been Dr K S Murthy annual medals and awards are bestowed ‘in recognition of recognised and acknowledged by SDC internationally, service to the society, outstanding contributions to the advancement rewarding me with this prestigious honour.” Rakesh Rao of the knowledge of colouration and technology’. Some past SDC
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Chemical World | January 2013
NEWS, VIEWS & ANALYSIS
GROWTH STRATEGY
Clariant to sell two more business units in 2013
GREEN CHEMISTRY
As a part of Clariant’s profitable growth strategy, the company is aiming to sell its leather services and detergents & intermediates businesses in 2013. To achieve the targets set for 2015, the company had announced in early 2012 to look for strategic options for the textile chemicals, paper specialties, emulsions, leather services and detergents & intermediates businesses. With the company agreeing to sell off textile chemicals, paper specialties and emulsions businesses to SK Capital, the US-based private investment firm, in December 2012, Clariant is planning to start the sales process for the remaining two businesses. “First, divestment (of leather services and detergents & intermediates businesses) is one of the possible options (however, it is our preferred option). We
Novel Spent Acid Management to expand operations
aim to start the sales process in the first quarter of 2013 and expect to find solutions by year-end 2013,” disclosed Dr Kai Rolker, Head - Corporate Communications, Clariant International Ltd. In order to achieve the targets set for 2015, Clariant is focussing on markets with future perspectives and strong growth rates, and on businesses that have a competitive position, resulting in strong pricing power. With regard to more divestments, Dr Rolker said, “Active portfolio management is part of our strategy and this includes M&A activities including divestments of any kind. But we have no specific plans for any further divestments. We are on track to achieve strategic targets for 2015.” Rakesh Rao
ALLIED SECTOR
Hitachi Hi-Rel Power’s new facility starts operation Hitachi Hi-Rel Power Electronics Pvt Ltd started operation at its new manufacturing facility in the Sanand-II Gujarat Industrial Development Corporation (GIDC) Estate recently. With this new factory now operating alongside its existing Gandhinagar plant, L-R: Hiroaki Nakanishi, Representative Hitachi Hi-Rel intends to enhance the lineand Executive Officer & President, up of industrial power electronics for use in Hitachi Ltd, Japan, and Piyush Shah, Managing Director, Hitachi Hi-Rel plants in fields such as power generation, Power Electronics Pvt Ltd steelmaking and chemicals. By increasing production capacity through the start of operations at the new factory, Hitachi Hi-Rel seeks to increase its revenue of the Indian market. At the same time, Hitachi Hi-Rel will strive to expand business with a view to exporting products to regions such as Middle East, Southeast Asia, Africa, etc.
Focussing on its vision statement, ‘Green chemistr y and green environment in Gujarat’, Novel Spent Acid Management aims to start new projects in this direction. J P Patel, General Manager, Novel Spent Acid Management, observed, “Keeping in mind the growing awareness about environmental issues among chemical companies, we will go for additional treatment facilities. We plan to increase the existing 7,000 sq mt area of gypsum yard to 10,000 sq mt. We are also going for additional neutralisation chambers so as to meet the requirements of more companies.” He added, “We plan to start hydrochloric acid treatment at the facility in addition to treatment of spent sulfuric acid. Besides, we are considering starting brick manufacturing, as gypsum obtained in large quantities can be used for the same. Incineration process for particular hazardous chemicals at this plant will also be initiated in future. The facility currently has 400 metric tonne neutralisation capacity, which will be expanded to 800 metric tonne in the coming years.” Avani Jain
AGROCHEMICALS BUSINESS
Insecticides India launches next generation termiticide Insecticides India Ltd recently introduced Milflex TC, which is a wooden structures and furniture. As the technology is advancing, so household termiticide. Backed with new generation technology, are the termiticides. This new product Milflex is also a termiticide Milflex TC offers good results against termites. The that provides a longer control and have several features.” effective chemical composition helps in controlling The product will be marketed first in North India. variety of pests such as termites, ants and other domestic “Looking at the success in the foreign countries, this bugs. It is effective and globally used to protect wood product has been launched in India. This has greater soil against the termites and borers. Rajesh Aggarwal, stability than competing molecules because in simple Managing Director, Insecticides India Ltd, said, “We are terms it is less affected by various factors such as soil strong in the termiticides segment, in the household as pH, UV light and soil moisture. We are looking forward Rajesh Aggarwal well as agriculture areas. Lethal is our flagship brand and to see the response, as this will be launched in northern is already a household name for years now. We already have Lethal markets first,” said V K Singhal, General Manager (Marketing), TC for pre- and post-construction treatment and Lethal RTU for Insecticides India Ltd.
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NEWS, VIEWS & ANALYSIS
PE INVESTMENT MARKET FORECAST
Propylene and butadiene supply may reduce in the US While the US ethylene industry is witnessing boom, thanks to the ongoing shale revolution, experts feel that it may lead to decrease in supply of other petrochemicals – namely propylene and butadiene. “The ongoing shale revolution is likely to reduce propylene and butadiene supply in the US. Propylene and butadiene are by-products produced during ethylene production from steam crackers. Ethane gives the highest quantities of ethylene as final product but produces negligible quantities of other by-products such as propylene and butadiene. Naphtha, on the other hand, yields significant quantities of by-products. The US basic petrochemical industry is already dominated by ethane feedstock, and additional ethane usage will further reduce the propylene and butadiene production,” said Ashok Pant, Senior Analyst – Petrochemicals, GlobalData, which recently brought out a report – titled ‘Petrochemical industry in the US: Abundant feedstock supply from the shale reserves to revive the US petrochemical industry’. According to the new report, increased investments in the US ethylene industry will see a rise in capacity from an estimated 26.137 million metric tonne per annum (MMPTA) in 2012 to 35.048 MMPTA by 2017 – an increase of just under 35 per cent. Rakesh Rao
SK Capital sees bright business prospects post-acquisition of Clariant businesses The US-based private investment firm, nylon chemicals sectors, as well as deep SK Capital Partners, which recently knowledge of the end-markets served signed an agreement to acquire Clariant’s by the businesses. The acquisition is three businesses (textile chemicals, paper consistent with SK Capital’s strategy specialties and emulsions), is banking on of acquiring niche market leaders these units to foster innovations and offer with strong brands, technologies and high-quality products in the market. Barry underlying growth trends, and actively Siadat, Managing Director, SK Capital supporting management in building Partners, commented, “These are good thriving businesses with sustainable global businesses with strong competitive advantages. technology bases, good brands In 2013, SK Capital is and excellent pedigrees. We are looking at more investments delighted to add them to our in the chemical space. “Yes, growing portfolio of technically we continue to look towards sophisticated materials serving adding good businesses the global markets. There with sound fundamentals, a are excellent short-term and strong technology base, and a Barry Siadat long-term prospects for these competitive manufacturing base businesses as we continue to deliver highserving specialty materials, chemicals and quality products and innovate new & pharmaceutical markets,” added Siadat. improved solutions for our markets.” With regard to opportunities in India, With a disciplined focus on the he said, “We believe India to be a good specialty materials, chemicals and place to invest. As logistics & energy cost healthcare sectors, SK Capital has and availability improves, India can be significant relevant experience gained an increasingly important player in the through both previous and current chemicals and materials industries.” Rakesh Rao investments in the textile, fibre and SUSTAINABILIT Y
TÜV SÜD moves CDM accreditation to India TÜV SÜD announced that it will manage the validation and verification of Clean Development Mechanism (CDM) projects from India. The Executive Board of the United Nations Framework Convention on Climate Change (UNFCCC) approved the relocation of the responsible entity from Munich to Pune. The Designated Operational Entity (DOE) located at TÜV SÜD South Asia has already started operations. “The relocation of the DOE to India marks an important step, which we are taking to cater to the newly industrialised countries (NICs) and the Asia-Pacific region for the CDM,” said Bratin Roy, Assistant Vice President, TÜV SÜD South Asia.
AUTOMATION SEMINAR
Emerson and IIT (BHU) host EDIFICE 2012 to encourage industry-academia collaboration Emerson, in partnership with the Indian Institute of Technology (IIT - BHU), Varanasi, recently organised EDIFICE 2012 – a twoday industry-academia interface programme to introduce students to technological advancements with direct applications in India’s core growth sectors and provide young engineering minds a platform to showcase their ideas. EDIFICE Sunil Khanna addressing the students 2012 was inaugurated by Dr Dhananjay Pandey,
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Director, IIT-BHU. The event included a panel discussion, which included speakers such as Dr R K Malhotra, Director (R&D), Indian Oil Corporation Ltd; Sunil Khanna, President and MD, Emerson Network Power India; Dr A S Prasad, Director - Project Pursuit & Solutions Business, Emerson Process Management India; and Anup Wadhwa, Director, Automation Industry Association.
NEWS, VIEWS & ANALYSIS
RECOGNITION PRODUCT LAUNCH
Rama Phosphates bags award second time in a row
WACKER introduces new silicone sealant in India The Munich-based WACKER group and its Kolkata-based silicones joint venture WACKER Metroark Chemicals Pvt Ltd recently introduced two new silicone sealant grades – WACKER Glazing Neutral and WACKER Weatherseal Neutral. Both grades are neutral-curing, one-part silicones, which offer better adhesion and weather resistance. Applications include perimeter sealing and glazing applications as well as weather sealing purposes. These sealants cure at room temperature with the help of atmospheric moisture and form a permanently flexible silicone rubber, which is suited for perimeter sealing and glazing applications as well as for weather sealing purposes. Both grades were developed exclusively for the Indian market. WACKER Glazing Neutral is especially suitable for glazing applications and for use on alkaline substrates such as concrete and mortar. It is also compatible with water-based and solvent-based coatings. On the other hand, WACKER Weatherseal Neutral is designed for interior as well as for exterior sealing applications.
J K Parakh (first from left) receiving the award from S K Jena
Rama Phosphates Ltd (RPL) was named as Best Performing SSP (Single Super Phosphate) fertiliser company in the country. The award was given by Ferliliser Association of India (FAI), New Delhi. RPL won the award second time in a row and this time the award was given to
RPL for outstanding performance at its Pune factory. J K Parakh, Chief Financial Officer, RPL, received the award from S K Jena, Minister of State for Chemicals & Fertilizers, Government of India, recently at Agra. RPL is an established market leader in SSP fertiliser industry in the country. Its three manufacturing units are strategically located at Pune in Maharashtra, Indore in MP, and Udaipur in Rajasthan as both Maharashtra and MP are major consumers of SSP while Udaipur is the only producer of rock phosphate, the basic raw material in the country. RPL’s Pune unit is in existence since four decades and is one of the oldest in the country.
SUSTAINABILITY CERTIFICATE
Tata Chemicals awarded ‘Sustainable Plus’ by CII Tata Chemicals Ltd (TCL) has been awarded the highly prestigious ‘Sustainable Plus’, world’s first Corporate Sustainability Label by the Confederation of Indian Industry (CII). Based on a methodology that is globally recognised and suited to Indian markets, the company has been recognised as ‘Sustainable Plus’ in the Platinum category by CII. ‘Sustainable Plus’ is a brand identity created by CII-ITC centre of excellence for sustainable development. The analysis of the recognition received enables companies to improve all aspects of performance such as reducing risks and costs, identifying market opportunities and improving competitive advantage. On receiving the certification, R Mukundan, Managing Director, Tata Chemicals, commented, “Tata Chemicals is committed to achieve the highest performance standards in the areas of sustainability, safety, service and quality. Each one at Tata Chemicals consistently works towards creating value for the organisation, community around and society in general. This recognition will energise us further in our continuous journey of sustainable development.”
MERGER & ACQUISITION
NEW CONTRACT
Kemira Oyj sells a part of ChemSolutions to Niacet
Aker Solutions awarded global frame agreement with Shell
In accordance with its strategy to focus on products and applications for water quality and quantity management, Kemira Oyj has signed an agreement to sell its food and pharmaceutical businesses together with its acetate-based chemicals business to the US-based Niacet Corporation. These businesses are a part of Kemira’s ChemSolutions segment. All shares of Kemira ChemSolutions BV, including the manufacturing site in Tiel (The Netherlands), will be transferred from Kemira Oyj to Niacet Corp. The other businesses of the ChemSolutions segment, including the chemical, feed and de-icing business, which are linked to Kemira’s formic acid production in Oulu (Finland), will stay within Kemira. The businesses sold have combined revenue of approximately Euro 50 million. The transaction is expected to close on January 31, 2013.
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Aker Solutions recently signed a frame agreement with Shell for the delivery of subsea umbilicals and cables globally. It estimates that the frame agreement could generate revenues between $ 200 and $ 400 million. The Enterprise Framework Agreement (EFA) with Shell is signed for the duration of five years with an option for an additional five years. Aker Solutions will deliver dynamic and static steel tube umbilicals for both shallow and deep water applications. Subsea umbilicals are deployed on the seabed to supply necessary control and chemicals to subsea oil & gas wells, subsea manifolds and any subsea system requiring a remote control. The EFA has a global scope. Shell’s subsea projects are primarily focussed on the Norwegian continental shelf, UK, Gulf of Mexico, West Africa and Brazil.
TECHNOLOGY & INNOVATION
Eriez’s new X-ray system provides better inspection for contaminants Eriez has introduced its E-Z Tec XR-pack X-ray inspection system. This X-ray inspection system has been specifically designed to provide unmatched protection for packaging applications. The state-of-the-art E-Z Tec XR-Pack X-ray inspection system exhibits better performance in identifying contaminants, scanning for missing or broken products, and mass inspection, to guarantee users’ product and packaging integrity. It effectively inspects for foreign objects (metal, glass, stone, bone and some plastics), count, seal integrity, weight, shape, item position and presence/absence of items.
Bayoxides from LANXESS helps manufacture high performance battery for electric cars Specialty chemicals group LANXESS has developed a range of iron oxides for the production of cathodes for lithium-ion batteries. Thanks primarily to their good morphological properties and high reactivity, the products are ideally suited for use in the e-mobility field. The latest development is the engineered iron oxide Bayoxide E B 90. The Bayoxide line includes special iron oxides with various particle sizes, crystal shapes and structures as well as purity grades to satisfy individual customer requirements. The products help manufacturers to produce high-performance batteries for electric cars. The pigments in the Bayoxide range have been developed for diverse markets, industries and requirements. The broad range includes products for the manufacture of airbags, brake pads and catalytic converters, pigments for toner used in copiers and laser printers, and adsorbents used for drinking water and wastewater purification, for example. Another very innovative application is the use of Bayoxides for the desulfurisation of biogas. The range is broken down into Bayoxide E pigments, which are produced on the basis of iron oxide pigments, and the Bayoxide C pigments, which are manufactured on the basis of chrome oxide. Like the pigments for colouring building materials or plastics, the Bayoxides also have a specific hue (red, yellow, green or black), but this plays only a minor role compared with the technical chemico-physical product properties.
AspenTech’s new software saves energy and optimises process
Features include tool-less disassembly for cleaning, unique beam geometry, compact 60-inch overall length, low profile design and auto learn for easy set up. Eriez also provides online remote support for this equipment. In addition to the E-Z Tec XR-Pack, Eriez also offers E-Z Tec XR-Bulk X-ray inspection systems for bulk flow applications. Its magnetic lift and separation, metal detection, x-ray, materials feeding, screening, conveying and controlling equipment have application in the process, metalworking, packaging, plastics, rubber, recycling, mining, aggregate and textile industries.
Aspen Technology (AspenTech), a leading provider of software and services to the process industries, announced the release of aspenONE V8 software, which delivers a new version of Aspen HYSYS; solids modeling functionality (acquired from SolidSim earlier this year) integrated within Aspen Plus; the new Aspen PIMS Platinum; a new version of Aspen Collaborative Demand Manager, and breakthrough innovations in advanced process control, energy and economic analysis. With aspenONE V8, new and occasional users become proficient faster, and experienced users can do more. This is critical for process industry companies facing workforce development and skills shortages. Usability and visualisation enhancements in aspenONE V8 also enable users to collaborate more easily, shortening project times and increasing productivity. With new Aspen HYSYS, the energy industry’s leading process simulator redefines simulation usability with a redesigned interface, streamlined workflow and interactive analysis. The new HYSYS makes it faster and easier to generate optimised process simulations for the hydrocarbon industry - from upstream to refining. Solids modeling is integrated within the simulation environment. The integration of recently acquired SolidSim technology into Aspen Plus eliminates silos between previously disparate solids and liquids modeling processes. This makes it possible to optimise all chemical processes together for the first time. The new ‘Activate’ feature in Aspen Plus and Aspen HYSYS, which are the industry’s first in process optimisation, allows process engineers to find energy and capital cost savings faster. Through activated energy, process engineers can quickly identify ways to change designs to reduce energy, saving design time and future operating cost.
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TECHNOLOGY TRANSFER
TECHNOLOGY OFFERED As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Activated carbon
Phosphate esters
An Iranian firm is willing to offer activated carbon from coconut shells. Areas of application Food processing, pharmaceuticals, etc Forms of transfer Technology licensing
An Indian firm is offering technology for manufacturing phosphate esters like tributyl phosphate. Areas of application Specialty chemicals Forms of transfer Joint venture
Ethanol An Iranian company is offering ethanol from molasses using the fermentation of sacharomyces cerevisiae. Ethyl alcohol is widely used for making many organic chemicals. Areas of application Chemical and energy industries Forms of transfer Technology licensing
Furfuryl alcohol technology
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 industries. Areas of application Chemical industry Forms of transfer Technology licensing
An Indian firm offers technology for producing furfuryl alcohol from furfural by liquid hydrogenation as well as vapour hydrogenation, with a capacity of 6,000 tpa to 24,000 tpa. Areas of application Furan polymers, sealants & cements, urea-formaldehyde, and phenolic resins & foundry cores Forms of transfer Consultancy, technical services, technology licensing
Sodium silicate recovery from rice husk ash
Precipitated calcium carbonate
Sodium sulfide
An Indian consulting company for the chemicals, minerals & food processing industries is offering precipitated calcium carbonate and turnkey projects for the same. Areas of application Plastics, paper, paints, rubber, inks Forms of transfer Consultancy, technical services
An Iranian firm is willing to offer sodium sulfide, which is used mainly in textile industry, paper mill, artificial silk and curriery. Areas of application Leather industry, textiles, curriery industries, paper mills, etc Forms of transfer Turnkey
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An Indian firm is offering technology to recover sodium silicate from rice husk ash. The technology claims to offer better ROI than other processing methods. Areas of application Chemical industry Forms of transfer Consultancy, technical services, turnkey, etc
Synthesis routes for organic chemicals An Indian firm is offering consultancy in design of synthesis routes for organic chemicals. Areas of application Pharma industry, specialty 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 waste. Areas of application Transformers Forms of transfer Consultancy, technical services
Zinc phosphatiser/rust converter (Ferphos) An Indian firm offers technology to produce Ferphos – a unique chemical formulation that acts as a zinc phosphatiser cum rust converter. Ferphos is an innovation and improvement over existing phosphating products/technologies practised around the world. Ferphos solution does not die, ie even after prolonged use, and does not require daily addition of chemicals and hence it results in zero effluence. Ferphos solution also acts as a rust converter when brushed on rusted iron products. It is an ideal substitute for sane/shot blasting. Areas of application All iron and steel products including aluminium, SS, GI products Forms of transfer Technology licensing
TECHNOLOGY TRANSFER
TECHNOLOGY REQUESTED Activated carbon and sodium silicate A company from Thailand requires technology for manufacturing activated carbon and sodium silicate from rice husk & rice husk ash. Areas of application Manufacturing and construction industry Forms of transfer Others
Glyoxal An Indian company is looking to switch the production technique for manufacturing 40 per cent glyoxal from its existing acetaldehyde-based method to the MEG-based glyoxal production. Areas of application Pharma & textile Forms of transfer Others
Inorganic chemicals An Indian company is interested in seeking the technology and process knowhow for production of potassium nitrate, chromium acetate, and magnesium hydroxide suspension. The company already produces inorganic chemicals and wants to add several other items. Areas of application Chemical industry Forms of transfer Others
Lime
Silica gel
An Indian company seeks to adopt new cost-effective technologies, which can reduce carbon emissions and earn carbon credits, for manufacturing lime. Areas of application Quick lime and hydrated lime Forms of transfer Others
An Indian firm is looking for new technology for manufacturing silica gel in which the wastewater discharge is minimum. Areas of application For various industries and most importantly breweries Forms of transfer Others
Phenolic and phenol formaldehyde resin An Indian company needs the technical know-how for producing phenolic and phenol formaldehyde resins. Areas of application Foundry, rubber adhesives, rockwool, abrasives, plywood, etc Forms of transfer Others
Quaternary ammonium chloride An Indonesia-based company is planning to diversify into manufacturing of quaternary ammonium chloride. It is seeking technology along with the supply of critical plant and machinery for the manufacture of the chemical 3-chloro-2hydroxypropyl trimethyl ammonium chloride that is produced from epichhlorohydrin. Areas of application Chemical industry Forms of transfer Technical know-how, consultancy
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
Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacific Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacific (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi - 110 016, Tel: 011-3097 3758 (Direct), 3097 3710 (Board), Fax: 011-2685 6274, E-mail: srinivasaraghavan@un.org, Web: 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, Network18 Media & Investments 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@network18publishing.com
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IN CONVERSATION WITH Vipul Shah
In order to become competitive globally, Indian companies need to invest in R&D …says Vipul Shah, Chairman, CEO and President, Dow Chemical International Pvt Ltd (Dow India). After joining Dow in 1988, Shah has served in various key leadership positions – globally as well as in India. In this freewheeling interaction with Rakesh Rao, he highlights the emerging trends in chemical industry and Dow’s plans to tap these opportunities. How is the current business environment for the global chemical industry?
Courtesy: Dow India
At present, the world is going through difficult times. Unfortunately, Europe is leading the way in this slowdown, along with other major economies such as China and the US. All these translate into low consumer confidence and hence affect the chemical industry adversely. I truly believe these are short term. Probably, in second half of 2013, the situation should improve. In early half of the year, one can
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Vipul Shah
expect China to stabilise. With election phase over, the US economy, which is already showing signs of improvement, will show better performance in 2013. China and the US will lead the recovery of the global economy. I think Europe will take long time to recover. Next 3-4 quarters will be tough, but long-term growth prospects are bright.
took off since land acquisition is one of the biggest hurdles. Out of the planned PCPIRs, only one in Dahej is operational. In some areas of fine chemicals, India is at the forefront. This segment does not require feedstock advantage, but needs human capital, which we have plenty. The industry needs to capitalise on this.
What about R&D initiatives? What about India? India has its own set of challenges. After long lull period with regard to policy making, in last three to four months, the Government of India has been seen taking some of the long pending policy reforms. These have led to buoyancy in investor confidence. As far as India is concerned, it has inherent market. The per capita consumption of any commodity chemical or performance material in India is the lowest compared to developed and other emerging markets. Low consumption base is driving the economy. So the only way to go is up.
What are the challenges before Indian chemical industry? Easy availability of low-cost feedstock is a challenge for the Indian chemical industry. The industry needs to find solution to this. Some of the strategies that can be adopted are import (wherever viable local alternative is not available), tie-up with countries that have huge feedstock resources, etc. Indian companies can establish base in regions such as Middle East for their feedstock requirement and target Indian market for value-added products. With duty structures today, it is possible. This way one can also resolve land acquisition challenge, which is one of the biggest hindrances for the industrial development. Moreover, when you do not have feedstock advantage, cluster concept is the only way forward. India should look at adopting consortium concept, which has been successfully implemented in other countries such as Thailand. The government’s policy of Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) is a step in the right direction. PCPIR can fuel growth, generate employment, save foreign exchange, etc. But, unfortunately it never
In order to become competitive globally, Indian companies need to invest in R&D. While sectors such as engineering and biotech are investing a lot in R&D, there has not been much investment done in fundamental research by Indian chemical manufacturers. Indians are extremely good in innovations in application side. We need to leverage on this. Our aim in India has been to ‘invent in India, for India’, and reach the masses in a significant way. One of the things that we are doing in India in last few years is getting the scientific pool of talent in the country. In last one to two years, we have been successful in developing products for Indian market from here. One of the biggest comfort customers have with companies like us is confidentiality maintenance. We maintain strict confidentiality with respect to customer IP.
How do you manage to get along with people having different cultural backgrounds? At core people are same. People want to be treated with respect. If you treat people with respect, they will do anything for you.
Which was the toughest business decision taken by you? As a part of strategy to rightsize commodity business, I had to take a call on shutting down Louisiana plant. That was probably the most difficult task that I have done. As a manager, you need to spend time and energy with the employees so that the tough decision does not become so tough.
Your mantra for success…
Which are the promising areas for Dow in India?
Keep it simple in terms of strategies. When you are rolling out a strategy, if employees do not feel part of that strategy you have lost it. Also, during tough times, it is important to communicate with people as often as possible because if you do not communicate, people will make up their own communication.
While we continue to consolidate our existing well-established portfolios in sectors such as automotive, packaging, coatings, etc, we would now focus on expanding businesses in underserved segments such as pharma, food, water, alternative energy, etc. We can offer sustainable solutions for energy savings and efficiency improvements in each of these segments.
majors, including Dow, have already transformed their business focus from basic chemicals to specialty chemicals. As part of transformation strategy, Dow has right-sized the basic chemicals portfolio to feed its performance chemicals business. In India, more than 90 per cent of portfolio is performance chemicals.
Most of Dow’s businesses have been based on performance chemicals. Why is it so? A company cannot be globally competitive, if it has basic chemical plant in every country since it incurs huge investment. Where there is easy availability of feedstock, such as Middle East, or protected market, companies will continue to produce basic chemicals. Many global
What is your target for India? To build organisational capability is our main aim. In India, consumerism is driving every thing. Half of our products in India can be easily classified under it. In India, our target for 2013 is to cross $ 1-billion turnover from over $ 900 million in 2012. By 2016, the company expects sales to touch $ 1.7 billion. Email: rakesh.rao@network18publishing.com
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SPECIAL FOCUS
WASTEWATER & EFFLUENT TREATMENT WASTEWATER TREATMENT Banking on novel technologies to save the precious drop .......................................................................28 CLEAN-IN-PLACE SYSTEM An in-built approach to optimise water usage ........................................................................................30 IT TOOLS Aiding the move towards zero liquid discharge .......................................................................................32 WATER MANAGEMENT FOR SMES A top priority to forge better business tie-ups .........................................................................................34 CASE STUDY - MARINE TOXICITY TESTS Ascertaining flow rate accuracy through multi-channel pump.................................................................35 ROUNDTABLE Is membrane bioreactor gaining traction in the chemical industry? ........................................................36
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SPECIAL FOCUS Wastewater treatment
Banking on novel technologies to save the precious drop The opportunities in the effluent treatment industry in India are growing exponentially with the rising conscientiousness in every sector regarding water conservation. Having grown 13 per cent between 2010 and 2013, it is today a ` 5,400-crore industry in the country.
Illustration: Sachin Pandit
Mahua Roy
A
t Indian Oil Corporation’s naphtha cracker project in Panipat, latest technology is being harnessed to recycle 150 million litre per day of water required for running the plants. And in Chennai, water-starved Chennai Petroleum Corporation Ltd (CPCL) had commissioned a 26.367 million litre per day reverse osmosis-based desalination plant to become self-sufficient and meet its daily water requirements. “The demand for water from the industry is expected to grow at a rate of 4-5 per cent CAGR over the next decade. However, the availability of water – ground and surface – is projected to decline over
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the same period. This calls for major focus on managing process water requirements by the industry to ensure a progressive drop in water consumption. This can essentially aid in bridging the demand-supply gap for water, going forward,” points out Alok Kumar Bhadra, Heavy Industry Marketing Lead, Asia-Pacific, Ecolab.
Towards optimistic growth As per an extensive market research by Frost & Sullivan (F&S), the capital expenditure by the industry on wastewater treatment plants alone, currently estimated at $ 100 million, is projected to increase by 300 per cent between 2011 and 2016. Also, the global market for wastewater treatment
equipment and treatment chemicals will increase at a 10.4 per cent CAGR to exceed $ 93 billion by 2016 from $ 57 billion in 2011. Besides, utility wastewater management in the country, which is currently estimated at $ 660 million, is projected to grow to $ 1,000 million by 2016. This includes wastewater network rehabilitation, new wastewater networks and wastewater treatment plants. The chemical and allied industries are at the forefront of this technology adoption. Considered as a polluting industry, the adoption of water management and optimisation strategies has increased manifold in the chemical sector. Other segments largely contributing to this growth rate are power generation, steel manufacturing, food & beverage processing and pharmaceuticals. “As the global population continues to boom, pressure will build on water resources that are already under massive strain, and in many regions the traditionally careless use of water will have visibly negative consequences. Industries are, therefore, becoming increasingly aware that water is a precious resource that needs to be managed in a sustainable way. Thus, technologies that promote more efficient use of water that is already available would need to be implemented,” adds Bhadra.
Opportunity areas brimming Treatment of effluent promotes reuse of water. This is an important opportunity area to cash upon. Industries such as specialty chemicals, food & beverages, and pharma require normal to ultrapurified water. This segment has business to the tune of ` 2,000 crore, growing at 15 per cent annually. According to government estimates, the total requirement for industrial water in 2025 will grow four-fold to 120 billion cubic metre from the current 30 bcm. The specialised wastewater treatment for industrial use, which is now a nascent business of ` 500-800 crore, will grow in the coming years, considering the pace of industrialisation in India. But this will
Wastewater treatment
depend on how strictly pollution control norms are enforced. Similarly, the industrial wastewater treatment equipment market, which has witnessed robust growth in the past few years, is expected to grow at a CAGR of 17.2 per cent. India is emerging as one of the fastest growing markets for water companies and manufacturing equipment required for water and wastewater treatment. “Wide-ranging applications of membrane technology in wastewater treatment unit operations, such as ultrafiltration (UF), reverse osmosis (RO), membrane bioreactors (MBR), along with advances in the use of specialty chemicals in industrial water treatment, will further assist market score gains in the upcoming years,” says Francis Brady, Team Leader - Process Technology, Koch Membrane Systems. According to the F&S report, power, petrochemicals, oil & gas and refineries were the key end-users of the industrial water treatment equipment. These industries made up an estimated 50 per cent of the industrial water treatment equipment market. Also, power, petrochemicals, oil & gas, refineries and pharmaceuticals were the key end-users of the industrial wastewater treatment equipment. These industries made up more than 57 per cent of the industrial wastewater treatment equipment market in 2010, the report added. Process water, as Thomas Kreuzer, Vice President – Marketing, inge GmbH points out, requires that the quality of water used is of the highest grade. “The Indian water treatment equipment industry is reasonably wellestablished and cost-competitive. The water treatment market is moving from chemical treatment and demineralisation technologies to greater use of membrane technology. The purity grade of process water required for the production or dilution of specialty chemicals can vary considerably due to the vast range of fine chemicals available and their production processes,” he states. Membrane filtration, which primarily finds application for reuse and purification
of water, can be used efficiently in this segment too. Depending on the feed water availability and nature, additional membrane technologies such as UF or micro-filtration may be incorporated as pretreatment technologies for RO. Brady observes, “RO can enable recovery and reuse of water or recover product from certain dilute product streams, thereby improving process yields.” The chemical industry worldwide is making concerted efforts towards reduction of waste and efficient water management. “Energy-efficiency of techniques coupled with cost-efficiency as well is much in demand. Streamlining R&D towards development of such technologies will see a lot of positive reviews,” says Brady. Besides, the use of chemicals to treat wastewater presents a huge opportunity. Demand for chemicals for wastewater treatment is expected to increase in 2012-13. It needs to be integrated with the mechanical and operational aspects of the plant to deliver sustainable results.
Industries are becoming increasingly aware that water is a precious resource that needs to be managed in a sustainable way. Thus, technologies that promote more efficient use of water that is already available would need to be implemented. Alok Kumar Bhadra Heavy Industry Marketing Lead, Asia-Pacific, Ecolab
to outsource operations and maintenance (O&M) for wastewater treatment plants to professional companies specialising in the skill-sets and competencies needed to run industrial wastewater plants to meet compliance norms consistently. This opens up a new, emerging market within the water space by providing value-added O&M services that are exclusive to wastewater management,” points out Bhadra.
Planning for the future
Opportunities exist largely in providing integrated solutions in the water treatment market. These solutions include performing feasibility studies, designing, technical consulting and providing operation and online maintenance services. Outsourcing as a new trend Opportunities exist largely in providing integrated solutions in the water treatment market. These solutions include performing feasibility studies, designing, technical consulting and providing operation and online maintenance services. Demand in matured regional markets will be driven by equipment replacements, technology upgradation, and introduction of new & innovative products. “Another recent trend observed among industry houses is
Approximately $ 63 million is the amount that will be put at risk, by 2050, if current water management practices are followed by industries across the world. This figure also translates to almost 1.5 times the size of today’s entire global economy. Such scary figures implore upon the industry to relook at the effluent treatment and water optimisation technologies. Moreover, it is also believed that 4.8 billion people (52 per cent of the world population) will live in water-stressed areas by 2050. The dynamic nature of wastewater will continue to challenge water professionals as industries progressively increase their production and capacity utilisation, while the regulatory norms for discharge become more stringent going forward. “With several greenfield project sanctions and export orders based on zero discharge, the wastewater treatment market will need a continuous flow of innovation, technology and best practices in the greater interest of human society and industry,” concludes Bhadra. Email: mahua.roy@network18publishing.com
January 2013 | Chemical World
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SPECIAL FOCUS Clean-in-place system
An in-built approach to optimise water usage Can safety and productivity go hand-in-hand? The answer to this question lies in the adoption of automated Clean-In-Place (CIP) systems, which are gaining traction in the process industry. CIP systems are one of the smartest ways towards optimised water management. Mahua Roy
C
lean-in-place systems are like an in-built washing machine for your equipment! Just like a washing machine, a CIP system is generally programmed with a variety of cycle types, depending on what equipment is being cleaned and what product is being manufactured. Safety and quality standards in sensitive industries such as pharma, food, etc, require effective and shorter cleaning times. CIP components that withstand higher temperatures and harsher chemicals are need of the day. The industry is seeing a lot of activity in the adoption of automated CIP systems, which definitely take a lot of manual work out of a cleaning operation. “These days, due to the emphasis on hygiene, more and more companies are turning towards automated systems for spraying technology. Automation ensures that the product quality, consistency & reliability are maintained, and there are
minimum instances of contamination, which can be a possibility by manual application methods,” asserts Shridhar Bhat, Managing Director, Spraying Systems India. CIP technology can be applied to any equipment in which contact by a liquid can be achieved by way of spraying or recirculation of water and aqueous cleaning solutions under pressures ranging from 25 to 80 psig. “Prior to cleaning a process system, it is economically beneficial to recover the residual product for many processing industries. This reduces downtime between product runs or when formulations are changed and recovery of the product is economically significant,” says Gabe Miller, Senior Technical Engineer, Sani-Matic. Let’s face it, time consumed in cleaning the process equipment is time spent not manufacturing the product; as a result, it directly translates to loss in productivity. A well-automated CIP system can make sure that the product is being protected
PRINCIPLES FOR CIP DESIGN o Reduce: CIP solutions can be reduced by implementation of liquid ring return pumps, which are self-priming, and the use of vortex breakers in process vessels to minimise the wasted hold-up volumes in the vessels during CIP. o Reuse: This allows wash detergents to be reused for multiple CIP cycles, rather than being discharged to drain after each use. Reuse tanks have been getting larger to recover higher quantities, and the use of conductivity sensors in the return lines allows the systems to isolate the phases of the solutions, increasing the recovery of wash detergents and rinse water. o Recycle: Food processes with higher solids, projectile recovery systems are being used increasingly to recover the residues in pipelines for reprocessing, prior to CIP. Source: Sani-Matic
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Chemical World | January 2013
efficiently by properly cleaning and sanitising all process equipment.
Optimising through process integration CIP systems are run using existing pumping systems to introduce a controlled amount of cleaning fluid into the equipment. The systems are commonly designed to clean using automated cycles, which normally include a pre-rinse, followed by a caustic or acidic chemical wash, and a postrinse, depending on the application. Such an ability to clean a processing system, which includes tanks, pumps, valves, filters, heat exchange units and process piping, without the need to disassemble all or part of that system, significantly reduces cleaning costs and minimises the handling of chemicals to provide a safer environment for plant personnel. These systems may be integrated into existing processing systems. “To accomplish CIP as quickly as possible, it is becoming more integrated with the process. There seems to be an increased interest in developing processes that are fully integrated with CIP to minimise changeover and sanitation time,” says Mike Sullivan, Marketing Manager, Watson-Marlow Pumps Group.
Efficient water management CIP offers significant advantages to manufacturing facilities towards efficient and reliable cleaning of process equipment and piping. Process improvement and expense reduction are important elements for every business.
Clean-in-place system
Today, the chief challenges confronting highefficiency CIP systems are making them more energy-efficient and environmentfriendly. That means using less water, heat, time and caustic chemicals. Shridhar Bhat Managing Director, Spraying Systems India
“Highly precise spray control, minimised overspray, compact nozzles are product attributes, which aid the chemical processing industry in delivering cost-efficient operations. The focus is on waste reduction, cycle time, set-up time, as well as, increase in productivity. The spray systems need to be designed to have an impact on sustainability as well, encouraging water conservation with minimum use of cleaning chemicals,” says Bhat. “To improve sustainability of cleaning processes, the most significant first step is to reduce the amount of water used for cleaning. By reducing the water required for cleaning, the chemicals needed to treat the equipment can be reduced accordingly, as well as the energy needed to heat and pump the solutions,” adds Miller. Reducing energy consumption and water usage, as well as improving employee safety, are also key drivers for sustainability. “One of the issues we routinely have with CIP is that customers want these systems to run for longer periods, at higher temperatures with more aggressive chemicals. This creates a lot of pressure on pumping systems, especially any pump with rubber components,” adds Sullivan. Altering the wash chemicals can also help reduce water usage significantly. For example, chemicals with lower alkalinity require a shorter rinse time and use less water, while chemistry that allows for lower wash temperatures reduces rinse water usage to cool equipment, thus saving energy.
The way forward Innovation is the key to overcome hurdles and kinks in current technologies. “Today, the chief challenges confronting high-efficiency CIP systems are making them more energyefficient and environment-friendly. That means using less water, heat, time and caustic chemicals. A promise of green technology using significantly less water, chemicals, energy, and most importantly, time required for a given CIP cycle, is the focus area for R&D in this field,” says Bhat. Modern automation systems need to be agile and flexible to take advantage of new technologies, while leveraging existing technologies to get the most optimal results out of existing systems and equipment. A properly automated CIP system should allow easy adjustments to cleaning cycles, without having to re-code anything in the system, and without the assistance of specialty technical resources. Email: mahua.roy@network18publishing.com
January 2013 | Chemical World
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SPECIAL FOCUS IT tools
Aiding the move towards zero liquid discharge
The goal that the process industry is trying so hard to achieve is to approach Zero Liquid Discharge (ZLD). Information Technology (IT) can play a unique role to make this possible. Several technologies are offered by the IT industry to tackle global water scarcity and move towards intelligent water management systems.
Mahua Roy
A
ccording to IBM estimates, leaks account for up to 60 per cent of water supplied, costing water utilities worldwide $ 14 billion every year. Wired water, ie the use of IT hardware, software, telecom, networking and services for water control, could become a $ 20-billion market, according to IBM. Water is one of the most abundant resources in the world. Ironically, it is fast becoming one of the most stressed resources. Access to clean water is a critical issue that affects economic activity, industrial development and business around the world. Technology advancements in recent times are allowing real-time device status alerts, event correlation and analytics, data trending; and the ability to detect patterns hidden in current and historical information drive real-time knowledge. This greatly aids organisations to make informed decisions.
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Towards ZLD “With rapid industrialisation in India, there has been steep increase in demand for potable as well as industrial water across the country in recent times. With the development of SEZs and other industrial hubs across the country, the demand is getting concentrated in select regions, thereby increasing pressure on the available resources in those regions,” says Naval Kishore Kadwani, Industry Technical Consultant, Nalco Water India Ltd. ZLD is one of the most efficient wastewater recovery methodologies for industrial applications. Drivers such as scarcity of valuable freshwater resources, concerns about the environmental impact of industrial wastewater discharge and increasing regulatory controls are making recycling & reuse of water an imminent option. Proper resource management has become crucial in chemical industry, as water is a critical resource that can affect its profitability. This is where IT expertise comes into picture.
Aiming for intelligent systems Cooling systems, irrespective of their size or design, come with multiple operational challenges. “Scaling, corrosion, fouling, and biological growth are threats, and all can impact water usage and cost. By using unique real-time monitoring, stress resistant chemistry, the industry needs 24x7 information about management capabilities in order to detect, determine and deliver improved results,” adds Kevin Cassidy, General Manager, Chemical and Monitoring Solutions – Water and Process Technologies, GE Power & Water. Intelligent and innovative management of water resources for industrial applications is heading more and more towards ZLD, allowing businesses to save money, reduce environmental impact and meet legislation for discharge. “With stricter pollution control norms in the country, the government is making it mandatory for industries situated near the urban areas to minimise or stop discharge of liquid waste in order to protect the environment. This requires that the industries need to install wastewater treatment plants, which can recycle most of the liquid waste and can then be reutilised inside the premises for relevant purposes,” says Kadwani.
Towards a smarter tomorrow Intelligent water management systems need to provide an integrated operating picture with robust real-time analytics, modelling and decision support capabilities. Water utilities can use advanced analytics to extend the lives of water infrastructure assets. “Identifying high-risk assets helps minimise water lost through leaks using preventive maintenance. By identifying accounts with potentially defective meters, water utilities can minimise lost revenue due to malfunctioning meters and save on the high cost of inspecting meters sequentially. In the short-term to intermediate-term, these capabilities allow organisations to take a proactive stance towards operations rather than reacting to situations as they arise,” says Cassidy. Email: mahua.roy@network18publishing.com
SPECIAL FOCUS Water management for SMEs
Mahua Roy
A
Industry and Federation of Indian Micro and Small & Medium Enterprises (FISME) was signed formalising co-operation with Europeans that would positively impact the efforts of SMEs for gaining access to green technologies. Several SMEs are identifying the key issues and acting upon the same. A court order was slammed at Tirupur textile cluster in January 2012 leading to closing down of approximately 494 dyeing units and 162 bleaching units. This had severely impacted the ` 12,000-crore textile industry. But as of December 2012, the Tirupur textile sector is one of the first clusters to achieve almost zero discharge in India. Membrane technologies coupled with RO are the best fit technologies for SMEs. The Common Effluent Treatment Plant (CETP) at Tirupur is trying to achieve zero liquid discharge by adopting the brine solution method in which the salt solution discharged after the Reverse Osmosis (RO) treatment and channelled back will be reused again in the units. Another method being used is nano membrane technology for selective evaporation of the dissolved salts in the effluent.
A top priority to forge better business tie-ups
s high as 70 per cent of industrial pollution load in India is contributed by SMEs, according to a World Bank study titled ‘India: Strengthening Institutions for Sustainable Growth, South Asia Environment and Social Development Unit’. To successfully compete in a challenging and dynamic business environment like the chemical industry, manufacturing and effluent treatment technologies need to be integrated and also, focussed. This is the reason why adoption of water management solutions is being witnessed in the SMEs in the chemical and allied industries. Although individually, the SMEs may not have a significant effect on the environment, together they exert a substantial impact. “Given their large numbers in emerging economies such as India, there is a growing need to address the issues of pollution and efficiency in use of energy and raw materials that these enterprises pose,” says Dr Suneel Pandey, Fellow, Centre for Environmental Studies, The Energy and Resources Institute. Another study by the Bureau of Energy Efficiency (BEE) reveals that Following the example the overall energy saving potential Being an unorganised sector, SMEs are of the SME clusters is about 72,432 responsible for causing pollution mainly tonne of oil equivalents (TOE), which is due to lack of awareness. The Central 27.4 per cent of the total energy consumption Government identifies this issue and has thus of SMEs. “In these days of critical water and given a bigger role to state government and energy crunch, the SME sector needs to collaborate and join hands for the adoption To target higher bottom line pollution control boards that provide the of technology in order to curb the pollution or lesser water footprint? This licenses to these companies. “For SMEs, the it is responsible for. Lowering the water question has been instrumental constraints on using environment-friendly footprint need not only involve incorporation in chalking out the strategies for technology to tackle water management of sophisticated technology, but it can also SMEs. As more companies now usually revolve around shortage of be majorly achieved by identifying potential prefer their SME vendors to be capital, limited access to technology, lack of awareness about the options for areas where water use can be minimised, environmentally responsible, a pollution control and prevention, etc,” says or simply, recycled and reused,” says Naval Kishore Kadwani, Industry Technical water management strategy can go Dr Pandey. With the visible difference a long way towards forging better seen in the case of big names in the Consultant, Nalco Water India Ltd. business relationships. industry that have throroughly benefitted Technology to be adopted out of technology adoption for water SMEs across the country have started to adopt greener technology. management, SMEs should consider emulating the same. As “Increased exposure to environment-friendly solutions is prompting India opens up to the idea of sustainability, vendor selection small companies to adopt green technologies and resort to nonincorporates this as a crucial point of shortlisting. “The chemical polluting modes of production. The route most often is collaboration. industry needs to step up its efforts towards development of Many Indian SMEs are entering into tie-ups with firms across sustainable products and processes by investing in technology the world to develop green manufacturing technologies and ecothat protects the environment and stimulates growth. Green friendly production processes,” says Dr Pandey. An agreement chemistry is the way forward,” adds Kadvani. Email: mahua.roy@network18publishing.com between the European Association of Chambers of Commerce and
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Case Study - Marine toxicity tests SPECIAL FOCUS
O Ascertaining flow
ceans make up a major part of water bodies on the earth and are also home to a large number and variety of life forms. Over the years, and especially in modern times, large-scale human activities have adversely affected
Simultaneously, sea water without toxicants is pumped into a separate chamber at a flow rate of 40 ml/min. After a predetermined time, the researchers take samples and conduct tissue analysis & enzyme studies to determine any damage to sea animals. With their results, they can
the application and the end-user’s requirements in detail and recommended the Ismatec multi-channel pump (7800112 and 78001-32), based on the accuracy and flow rates required. The planetary gear drives of this system (used with Tygon and Pharmed BPT 2 stop tubing and extension
rate accuracy through
multi-channel pump the marine life. The most significant ill effect has been pollution. Incidents of oil spills, industrial waste dumping, garbage disposal and accumulation of various toxic materials as wastes from many processes have polluted almost all the major aquatic bodies around the globe. Madurai Kamaraj University (MKU), a public university located in Madurai city in southern Tamil Nadu, has undertaken a toxicology study to understand the effect of heavy metal toxicants (such as copper, cadmium, lead, zinc, arsenic, chromium) and pesticides in sea water and analyse estimated damage to sea animals. Even though the causes for toxicants are different, MKU is primarily concentrating on the studies of marine pollution caused due to heavy metals and pesticides.
The challenge The experiment involves different reservoirs containing toxicants of interest at different ppm levels. Different concentrations of these toxicants are fed to sea animals in toxicants chamber. The flow rates are low and accuracy is critical as it defines the toxicant levels. The concentrations are typically 0.1, 1, 10, 100 and 1000 ppm. These toxicants are pumped at an approximate rate of 4 ml/ min to the animal chamber along with sea water, which is pumped at a rate of 36 ml/min.
With the objective of studying the effects of heavy metal toxicants and pesticides in sea water, the Department of Marine and Coastal Studies at Madurai Kamaraj University, India, incorporated Cole-Parmer’s multi-channel pump into its toxicology study. This provided better and faster results. Read on… determine the threshold level for toxicants. The main challenge in performing this study has been to obtain accuracy in the flow rates in different channels of the pump.
The pump enabled to achieve accurate flow rates, and offered variable flow rates that can be easily adjusted by the user. The solution The university contacted Cole-Parmer based on its previous experience and trust in the company’s capabilities, exceptional service, and technical support. The ColeParmer technical specialist discussed
tubing), along with an eight-roller pump head, clicks, go cartridge, and user calibration feature help achieve accuracy of flow rates in different channels. In all, the pump enabled to achieve accurate flow rates, and offered variable flow rates that can be easily adjusted by the user. Moreover, it requires low pump system maintenance; features flow rate and dispensing volume that can be calibrated, and provides high repeatability on all channels. Because the accuracy of the flow rate is good, this enhanced the users’ confidence. In summary, Dr C M Ramakritinan, Assistant Professor - Department of Marine & Coastal Studies, Madurai Kamaraj University, said, “We have been associated with ColeParmer since last 12 years and are receiving good support from product sales and services. We appreciate its approach and quick response including supply. Moreover, Cole-Parmer had helped us in executing our earlier projects successfully.” Courtesy: Cole-Parmer is a global leader in supplying fluid handling, life science, and general laboratory products, instrumentation, and equipment to the biotech, chemical, academics, environmental, food, industrial manufacturing and print industries. For details, contact Rajashri Lele on email: rajashri.lele@coleparmer.in
January 2013 | Chemical World
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SPECIAL FOCUS Roundtable
Is membrane bioreactor gaining traction in the chemical industry? Can zero liquid discharge become a reality for the process industry? As several technologies are evaluated for their efficacies, Membrane Bioreactor (MBR) technology is turning out to be a beneficial option for the industry. Mahua Roy talks to experts in the field and gauges the level of adoption of MBR technology.
Deepak Kachru Assistant GM - Sales & Business Development, Aquatech Systems
Vijay Singla Director (Works), IOL Chemicals and Pharmaceuticals Ltd
Dr Suneel Pandey Fellow, Centre for Environmental Studies, The Energy and Resources Institute
When it comes to the emerging economies, it is estimated that less than 5 per cent of wastewater is presently recovered. As regulations on the discharge of fluids into water bodies become more stringent, adoption level of MBR will increase. MBR is a key component for reaching towards ZLD plants. Some of the key opportunity areas in the chemical industry could be the Active Pharmaceutical Ingredients segment, wherein the potential for ZLD systems could be substantial in terms of volume of potential sites. The other segment could be fertiliser and chloralkali plants. Because of the large capital investment required for MBR systems and consequent high operational expenses, these systems are not seeing the desired demand at present. R&D in this arena has been directed towards finding alternatives to energy-intensive evaporator/ crystalliser systems.
Effluent treatment is not only crucial for controlling water pollution but is also a good source of energy recovery. Recycling of treated water is a value-added factor and reduces the abstraction of subsoil water. In last few years, many new technologies such as reverse osmosis, nanofiltration, membrane bioreactors, etc have been developed to treat complex/hazardous effluents. These help to conserve the resources as well as energy. MBR technology has a distinct advantage of treating a large volume of effluent with a small footprint that is ideal for most industries where availability of space is becoming a major constraint. If reuse is a major water quality goal, then MBR process is a major consideration. As the awareness about the benefits of MBR will increase among end-users, the maturity level to accept and actually use them will rise in India.
The cause of concern in the chemical industry is water pollution as the industry is highly water-intensive. The need to recycle wastewater and stricter environmental regulations make MBR system a viable solution for current and future wastewater treatment. The global MBR systems market is growing due to its ability to meet stringent effluent criteria along with its compact size and less operational cost as compared to other systems and equipment, which are used for wastewater treatment. Selection is based on an evaluation of various criteria, including packing density, investment cost, fouling tendency, cleaning and operating costs, and membrane replacement costs. R&D efforts need to be accelerated in this industry to push for costcompetitive products.
EDITORIAL TAKE Biotechnology has proven to offer cost-effective and cleaner alternatives to conventional effluent treatment processes that utilise chemicals. MBR is at the forefront of such measures. Though the cost factor limits its widespread adoption presently, research is being directed towards bringing down the expenses. Its advantages greatly align with the sustainability goals the industry is moving towards.
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FACILITY VISIT Raj Process Equipments And Systems Pvt Ltd
Prasenjit Chakraborty
R
aj Process Equipments and Systems Pvt Ltd is an ISO 9001 – 2000 company, with businesses in chemicals, pharmaceuticals & food process equipment and turnkey solutions. At present, Raj Group’s activities comprise designing, manufacturing and commissioning of spray drying plants, distillery plants and
Finished equipment
refineries, gas, critical high temperature & pressure vessels and reactors, material handling, bio-diesel and atomic energy,” says an elated Anil Pise, Managing Director, Raj Process Equipments and Systems Pvt Ltd.
Growing from strength to strength Raj Process’s first manufacturing facility was set up at Bhosri MIDC area in
into 12 metre length. All these machines help the company to provide better quality products to its customers. The plant manufactures mixer, dryer, evaporator, products for distillery plant, starch plant, boiler, equipment for food and pharma sectors etc. Interestingly, the Chakan factory has separate divisions such as mixer division, assembly division, distillery division and dryer & evaporator division. It also installed handling overhead and
Inspection of spray chamber
An integrated approach to offer quality process equipment The Chakan facility of Raj Process Equipments and Systems is one-of-its-kind, with separate divisions for manufacturing different products. The uniqueness of the plant is that it has all the fabrication processes in-house, which enables the company to manufacture products faster than its competitors. food processing plants. In addition, it also does large fabrication of vessels, reactors, heat exchangers, crystallisers, etc, as per customer or in-house designs. Last year, the company added new products in its product basket to cater to boiler and electrical & automation segments. In boilers segment, it manufactures package boilers, captive plant high capacity boilers, waste heat recovery boilers, among others. Similarly, in electrical and automation arena, it manufactures MCC panels, PLC panels, HT/LT panels, instruments and control panels. “Through continuous evaluation and upgradation of products, and quality systems & infrastructure, we are setting foot in unventured sectors such as
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Pune, which is spread over 22,000 sq ft. However, Bhosri facility is now converted as full-fledged R&D centre. “Our steady growth is due to our strong R&D. This year, we are investing more in this area, which is around 3-4 per cent from our total turnover,” says Pise. The growing business compelled the company to set up another factory at Chakan in Pune. The Chakan plant is spread over an area of 1,70,000 sq ft, of which carpet area is 1,10,000 sq ft. The facility has sophisticated machineries and fabrication equipment such as CNC plasma cutting, CNC welding, hydraulic bending, CNC milling, horizontal boring, special purpose milling, drilling and lathe having capacity to machine up to 4 metre
mobile crane facility up to 50 tonne. Raj Process has achieved ASME ‘U’ Stamp certification for Chakan plant. As far as inspection tests are concerned, it regularly conducts radiography test, ultrasonic test, die penetration test and hydro test. In its endeavour to provide quality products to customers, the company recruits only qualified welders. Not only that, each welder is engaged in welding only one particular product where his expertise lies. “By doing this, we ensure that our product is absolutely flawless,” categorically states Pise. Earlier, Raj Process used to outsource some components; however, at one point of time, the company realised that to ensure quality, service and delivery, it is
Raj Process Equipments And Systems Pvt Ltd
Advanced machine shop
imperative to have complete manufacturing under one roof. “We have more than 800 employees working under 40 production and 35 quality control engineers,” says Pise. Fabrication, which involves various activities such as pressing, rolling, bending, machining, is done in the factory. It means all facilities are available under one roof. “That is why we are making our job much faster than others. We can deliver a product in one month to our customers and our competitors take 45 days for the same product,” claims Nilesh Sonune, Manager - Works, Raj Process Equipments and Systems Pvt Ltd.
Turnkey projects Currently, Raj Process is focussing more on turnkey projects such as distillery plant, detergent powder plant, starch and glucose plant, gur and gum plant, Zero Liquid Discharge (ZLD) plant, etc. In addition, as mentioned earlier, the company also focusses on evaporating and drying systems, boilers, and mixers, among others. Given below are some examples of these. Distillery plant: Apart from potable purposes, alcohol today finds application in
Through continuous evaluation and upgradation of products, and quality systems & infrastructure, we are setting foot in unventured sectors such as refineries, gas, critical high temperature & pressure vessels and reactors, material handling, bio-diesel and atomic energy. Anil Pise Managing Director
Hardness testing of gear
a varied mix of industrial areas. “Here, we provide techniques and systems that bring out much higher quality of the product while effectively lowering production costs,” asserts Pise. The fermentation system offered by the company is designed by considering several crucial parameters, which helps to reduce losses of alcohol in fermentors and increases the yield of alcohol by controlling unwanted by-products. “We designed it in such a way that there is flexibility to operate continuously as well as synchronised mode of operation, depending on characteristics of feedstock,” claims Pise. Starch & glucose plant: One of the important aspects of starch processing or extraction is that starch is produced according to the requirement of the endusers depending upon changing reaction condition (temperature, pH, additives) and strict process control methods. To facilitate these aspects of starch extraction or processing, Raj Process has designed and developed starch processing equipment and plant that meet varied requirements in manufacturing plant. “Our advanced fabrication facilities, team of industry professionals and technical knowhow enable us to meet client’s specific requirements by developing customdesigned machinery,” claims Pise. ZLD plant: In the current scenario, ZLD systems have become necessary for many industries, which are generating liquid effluents. To address the problem, Raj Process’s ZLD plants offer features such as high steam and power economy, optimal space requirement, capacity range from 1 kl per day to 1,000 kl per day, PLC controlled systems etc. The
application areas are in industries such as pharmaceutical, distillery, chemical & dyes, paper and steel. Evaporation & drying: Evaporation systems are designed with consideration of higher fouling fluids, rugged operation, less maintenance and operating cost, easily stable with fluctuation on steam or feed side. For drying, the company offers rotary and spray dryer considering the suitability and nature of the product to be handled. “The dryers are highly efficient having low operating costs and easy to operate,” claims Pise.
Scaling new heights Raj Process is setting up another plant in Satara Road 60 km from Pune, which will be inaugurated in April 2013. Once completed, it will be the largest plant for the company. This plant will have ultramodern facility. In the first phase, it is investing ` 50 crore for the project. On the export front, currently, Raj Process exports its products to countries such as the US, Italy, UK, Malaysia, etc. Apart from Pune, it has marketing offices in Delhi, Ahmedabad, Hyderabad and Chennai. It also has branch offices in other countries namely Malaysia, Indonesia, Ukraine, Russia, Israel, UAE and Kenya. Plans are afoot to open offices in African countries as well. In its endeavour to become a world-class company, it is looking for joint ventures with some foreign companies. “We want to become one of the leading engineering MNCs within a decade, having a strong presence in domestic and global markets,” concludes Pise. Photo courtesy: Raj Process Equipments and Systems Email: prasenjit.chakraborty@network18publishing.com
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INSIGHT & OUTLOOK
INDUSTRIAL GASES INDUSTRIAL GASES Reducing operational cost with advanced technology ........................................................................... 42 STEEL INDUSTRY Amid course correction in industrial gases segment.............................................................................. 44 INTERFACE - Saket Tiku, President, All India Industrial Gases Manufacturers’ Association “It is difficult to fill the void created by the steel segment” .................................................................. 46 PROPYLENE PRODUCTION On-purpose technologies to bridge demand-supply gap ....................................................................... 48
January 2013 | Chemical World
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INSIGHT & OUTLOOK Industrial gases
Reducing operational cost with advanced technology The slump in the manufacturing sector has brought to the fore the importance of advanced technology for industrial gases manufacturers. The industrial gases sector is slowly moving towards investment in new technology, which will help reduce the overall operational costs. Courtesy: Hitech Industries Ltd
Prasenjit Chakraborty
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t is imperative for every manufacturing plant to maintain a fine balance between productivity and operational cost so that the end-product remains competitive in the market. The use of industrial gases in sectors such as steel, glass, effluent treatment, etc could help achieve that. Moreover, strict environmental norms had infused growth in industrial gases segment in the last two years. However, today things are not smooth for the industrial gases sector. This is because the consumption of industrial gases, by and large, depends on manufacturing sector, which is facing rough weather since last few months.
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According to R P Khator, Advisor, Bombay Oxygen Corporation Ltd, industrial gases sector is basically a supporting industry providing inputs to almost all sectors, be it manufacturing, research or healthcare. This industry by itself can neither enhance the demand of the base industries nor can it be a contributory factor in the slowdown process. “However, there is an effort by the gas industry to inject timely supplies of gases. Being a critical component in most of the manufacturing processes of the base industries, delivering the gases round the clock can help reduce large inventories at the user’s end. Efforts are also on to replace high pressure gas cylinders by liquid gases even in containers as small as 1,000 litre Porto Cryo type storage tanks, which obviously
renders better safety in handling the gases,” points out Khator. A lower labour cost and few replacements of spare parts in such liquid supplying system are added advantages. All these taken together could help the base industries to operate with comparatively lower working capital and less interest burden thereon. “These are some of the steps by the industrial gas sector, which may help in beating the slowdown of the core industries,” says Khator. Taking due cognizance of the situation, the gas manufacturers are going for consolidation and roping in new technology to address the escalating costs. D M Pillay, Managing Director, Peenya Industrial Gases Pvt Ltd, recommends, “In order to overcome the effects of slowdown, companies need to take measures such as
Industrial gases
consolidate & then go for expansion; cut down expenses by technology additions; ensure optimum output from manpower; lie low till the situation improves; avoid taking risk by giving nil credits and ensuring recovery in time.” Another biggest hindrance is erratic power supply, and it has to be noted here that the cost of power is high in India. To avoid this situation, many players are contemplating captive power units. “The industry is not on a roll for sure; old traditional gas units are already facing shut downs. With the government amending rules for gas cylinders and small and medium pressure vessels (SMPV), a lot more restrictions are coming our way for good and to make this industry safer, mature and updated. This will make sure that the fittest survives, especially in the SME sector,” points out Bhavneet Singh, Director, Hitech Industries Ltd. The industrial gases are highly inflammable in nature and the manufacturers belonging to SME sector should take steps to ensure safety of their workforce as well as plants. This is right time to do it as such steps will help them to compete in future. “Due to competition, many players (belonging to SME segment) are not taking steps to ensure safety. The current slowdown is hitting the gas industry big time. With overheads at a high, the selling rates of gases have lowered by 20 per cent minimum in past 5 years,” laments Singh.
On technology front The industry uses three different techniques to separate gases from the atmosphere. Cryogenic methods are the oldest and most widely used. Cryogenic separation relies on cooling and pressurising the
Being a critical component in most of the manufacturing processes of the base industries, delivering the gases round the clock can help reduce large inventories at the user’s end. R P Khator Advisor, Bombay Oxygen Corporation Ltd
air until it becomes liquid. With regard to the technology for manufacturing gases, India is still importing large and medium capacity cryogenic oxygen tonnage plants – from 100 TPD onwards, as indigenous technology has not fully developed. Some manufacturers are supplying higher capacity plants with most of the important components being imported such as compressors, aluminium exchangers, expansion turbines, cryogenic pumps etc. This technology could not be developed indigenously due to lack of demand of such plants and also because they are highly capital-intensive. Majority of industrial gases manufacturers in India belong to SME sector, and due to various constraints, they have not opted for such technology. A segment cannot grow, if there is no demand. However, globalisation and open markets have been leading to increased demand for industrial gases. Taking everything into consideration the industry should invite collaborations from developed countries for putting up plants for manufacturing the major components of large and medium capacity tonnage plants, which in turn can be exported. The industrial gases manufacturers must realise that the current slowdown in the manufacturing sector is not going to last forever. Moreover, the whole world is looking at India as one of the lucrative manufacturing bases in the world. “We have taken steps to take delegations to the US and other developed countries so that our members get acquainted with the latest technologies, manufacturing processes, best practices, etc. This will help them to induct latest machinery and implement best practices to their respective units,” says Saket Tiku, President, All India Industrial Gases Manufacturers’ Association.
Fresh air of opportunities On the brighter side, when it comes to smaller capacity plants of 6-10 TPD, India has developed the latest generation technology and many such oxygen plants are installed in different parts of the country and also being exported to various developing countries. These plants
With the government amending rules for gas cylinders and small and medium pressure vessels (SMPV), a lot more restrictions are coming our way for good and to make this industry safer, mature and updated. Bhavneet Singh Director, Hitech Industries Ltd
have low power consumption and hence the production cost of gases from such plants is economical. With regard to noncryogenic plants, India has a number of pressure swing adsorption (PSA) plants of various capacities, which are being manufactured indigenously. People associated with the industry strongly believe that with the influx of multinationals today, India must not face difficulty in gaining access to the latest technologies in industrial gas applications. The question is whether Indian players can afford the technology or not. Perhaps, the real problem arises in terms of handling the cylinders in small to medium enterprises and safety aspects related to accidental releases of high pressure gases in crowded places. More stringent execution of safety norms across various industries will lead to additional investments in modern technology and equipment that can substantially modify how to store, distribute and use industrial gases in India. In short span of time, the globalisation factor has brought in many significant changes in terms of technology, valueaddition, new product development etc in many sectors. The industrial gases sector has already witnessed some changes and other developments are in the pipeline. The factor that will drive the growth for industrial gases segment include rapid growth of manufacturing sector in India. And industrial gases increase production and at the same time reduce operational costs. A little more pragmatic approach in addressing safety issues and investing in technology will propel the segment to a new high. Email: prasenjit.chakraborty@network18publishing.com
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INSIGHT & OUTLOOK Steel industry
Amid course correction in industrial gases segment Industrial gases sector in India is highly dependent on the steel industry. However, since the steel industry is going through rough weather, the industrial gases sector is facing the brunt due to slump in demand. To address the problem, gas manufacturers are concentrating on other segments. But no segment is big enough to match the steel industry. The problem is indeed acute.
Courtesy: Praxair India
Prasenjit Chakraborty
T
he growth of the industrial gases segment is directly proportional to the growth of the manufacturing sector that needs industrial gases to carry out several operations. Looking at the need of the manufacturing sector vis-à-vis gas requirement, it has been found that the steel industry requires maximum industrial gases followed by other sectors such as glass, pharmaceutical etc. Most of the gas manufacturers set up their plants to cater primarily to the steel manufacturing industry. However, dwindling demand from the steel sector has put the industrial gases manufacturers in jeopardy. “The steel industry is the largest consumer of industrial gases consuming almost threefourth of the production. Its significance in the growth of the industrial gases industry
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cannot be ignored or underestimated as most of the capacities in the industrial gases sector are created to meet the demands of the steel industry. No other sector has been able to have this kind of impact on the growth of the gas industry,” points out R P Khator, Advisor, Bombay Oxygen Corporation Ltd.
Exploring new growth avenues Understanding the gravity of the situation, gas manufacturers are now exploring new avenues. However, it is difficult to match the volume the steel industry provides. Of late, beer manufacturers are using small quantity of nitrogen in the beer can to strengthen the wall of the can. However, the growth of the beer segment is not happening at a high pace in India. Similarly, usage of oxygen in portable cylinders for patients who need it at home has also increased; but again volume is a problem.
According to Khator, the entire industrial gas market is globally dominated by a few multinational companies. “They carry out research in various fields to explore new markets for industrial gases including in India,” he says. Some of the new areas being explored are use of helium gas in underwater exploration; hydrogen as an alternative fuel in the automobile industry; nitrogen and carbon dioxide for food preservation, cold grinding, animal husbandry for semen preservation, medical use, and space research etc. In addition, various types of gas mixtures are used in research, chemical analysis, special types of welding etc. In fact, environmental issues have provided momentum to the industrial gases sector. One of the applications wherein the increasing focus on environment has opened up new vista for industrial gases is its usage in waste effluent and sewerage treatment plants. Oxygen is used in such treatment for keeping the bacteria alive, thus preventing decay of organic matter, which pollutes water and the atmosphere. The enhanced use of carbon dioxide in various applications such as welding, soft drinks, food freezing etc, is also beneficial to the environment as otherwise it would be vented in the atmosphere as a pollutant. “With the advent of modern technology, many other sectors have opened up for high volume usage of gases in processing and manufacturing; and efforts are being made to open other avenues for consumption of gases, thus reducing the dependence on the steel sector,” opines Khator. The process industry has started to look for new areas for the usage of industrial gases but lot depends on the growth of the sectors and amount of gases such sectors consume. It seems the task is uphill. D M Pillay, Managing Director, Peenya Industrial Gases Pvt Ltd, says, “Industrial gas application or consumption is directly connected to steel production. Any reduction in steel production will make the big captive units liquid oxygen (LOX) surplus, which will find place in merchandise market resulting in flooding and price cuts, which can kill the smaller Air Separation Units (ASUs).”
Steel industry
Depending on one segment is always a risky proposition for any business; same is the case with industrial gases. There are players who have taken a balanced approach and moving forward. “Steel sector plays a vital role for gas industry, but one can never be dependent on single industrial line clients. Gases are used widely in pharma sector, lighting sector and railways. We cater to diverse clients, hence our sales figures are not affected much due to dwindling demand from the steel sector. Oxygen is the only gas consumed in mass quantity in steel industry. Besides oxygen, we are also dealing in nitrogen, argon, hydrogen, CO2 and helium. Slump in demand for oxygen is not a severe threat to us,” states Bhavneet Singh, Director, Hitech Industries Ltd.
Investment scenario With the general sluggishness in the manufacturing sector, the investment in the industrial gas industry has also been low during the last two years. The new capacities
already created in the last two to three years have resulted in oversupply, thereby putting lot of strain on margins and squeezing the profitability of a large number of industrial gas manufacturing companies. “Although few multinational companies are envisaging new investments in putting up large oxygen tonnage plants, they are reportedly moving slow in their implementation for want of sufficient demand of gases by the consuming industries,” points out Khator. Further, the unconsumed surplus production of captive oxygen plants creeping into the merchant market is also dampening the new investment scenario in the industrial gas industry. “The investment has reduced by more than 50 per cent due to unpredictable demand from end-users. On an average, an aggressive industrial gas unit invests around ` 4 crore each year and if returns are not guaranteed, how will they invest?” asks Singh. Players who have invested in the recent past are finding it difficult to recover the cost. “Last two years, many MNCs have tripled their production
and even the small players have made a sizeable investment. Now, everybody is struggling hard to recover this cost,” laments Pillay.
Addressing power problem Dwindling demand from the steel industry is not the only problem the industrial gases segment is facing. Power consumption and high capital investment are two important issues for the industrial gases industry. Power can be termed as a raw material for this industry but besides being expensive, its quality is also most unsatisfactory in terms of voltage, frequency fluctuations and interruptions in continuous supply. Statewise differences in power tariffs have also been responsible for the lopsided growth of this industry. This should be narrowed down for its healthy development. “Further, the continuous supply of power at concessional tariffs must be made available to the industrial gas manufacturing companies for their sustainable growth,” opines Khator. Email: prasenjit.chakraborty@network18publishing.com
January 2013 | Chemical World
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INSIGHT & OUTLOOK Interface - Saket Tiku
What steps are being taken by industrial gas manufacturers to beat the slowdown? The manufacturing scenario in India at present is not good. Earlier, the industrial gases industry used to grow around 19-20 per cent annually. But now the growth has plummeted, which is around 14-15 per cent. In order to beat the slowdown, the industry is going for more sophisticated units so that products could be manufactured efficiently. The prime raw material for manufacturing industrial gases is electricity, which is expensive in India.
which is around 20 per cent; health segment consumes 10 per cent and others such as food & beverage etc is around 10 per cent. We are trying to move into other sectors, which also require industrial gases. We have other areas where gas is being used like cryo-freezing. Now, industrial gases are also used in homecare product segment. Besides, India has substantial number of Chronic Obstructive Pulmonary Disease (COPD) patients where portable cylinders with oxygen could be given to the patients. We are trying for other sectors as well, but the problem is such segments are
provide them platform to interact with such companies so that our members come to know what is happening around the world. I, as the President of the organisation, give more emphasis to the safety of our workers. Our products are highly inflammable and that is why it comes under explosive department. In order to minimise accidents, we conduct safety workshops, where plant engineers and workers are trained on safety aspects in their own language (regional language). I am also taking initiative to take delegations to Europe, the US, etc. The purpose is to get first-hand
It is difficult to fill the void created by the steel segment ‌says Saket Tiku, President, All India Industrial Gases Manufacturers’ Association (AIIGMA). Speaking to Prasenjit Chakraborty, he highlights the difficulties faced by industrial gases sector due to shortage of demand from the steel industry and the steps taken to beat the slowdown.
The players in the industry are adopting latest equipment, which consumes less electricity. Our industry heavily depends on the steel segment; and if this segment is not doing well, then we are affected directly. Our focus is to reduce costs incurred on account of high electricity consumption, and that is why we are going for latest technologies. The industry is becoming more cost-effective because of competition in the market.
How is the demand from end-user industries? From the total production, steel and manufacturing (automotive, glass etc) sectors consume around 55-60 per cent of industrial gases, followed by chemical,
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not providing us much revenue. So, it is difficult to fill the void created by the steel segment.
What are your priority areas as the President of AIIGMA? Our Association represents almost all gas manufacturers of India and majority of them belong to the SME sector. Our association, apart from holding seminars, workshops etc, also provides platform to our members for networking. In India, we have more buyers compared to sellers. There are many companies from the US, China etc willing to supply products to our country. But as most manufacturers are from the SME sector, they do not have the means to reach them. So, we
information on technological innovation, safety issue, current trends, etc. Such visits will help the industry to implement new technology, best practices etc.
What is the investment scenario of the industrial gases sector? The year 2013 will not see much investment because of slowdown. However, in the last two years, the industry has witnessed investments to the tune of approximately Rs 9,000 crore. In my opinion, investment in 2013 will be around 25-30 per cent of what the industry had two years back. Linde is investing in a big way in India. Email: prasenjit.chakraborty@network18publishing.com
INSIGHT & OUTLOOK Propylene production
gap The propylene manufacturers are facing challenges, with the demand for propylene outpacing the current supply levels. Hence, they need to look at ways to improve output. And here is where on-purpose technologies such as propane dehydrogenation, olefin metathesis, methanol to olefins, among others, will offer practical solutions to this issue. And to know how read on‌ Anurag Srivastava
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thylene (C2) and propylene (C3) are the two most vital olefins used for the production of various industrial chemicals and polymers. Both C2 and C3 are co-produced in crackers and refineries; however, the ratio of the output depends on the type of feedstock used and the severity of cracking. If naphtha is used as a feedstock for the production of ethylene, the output of propylene remains substantial. However, gas crackers that process ethane gas produce more of ethylene than propylene and this is catching up as the current market trend. Most of the ethylene manufacturers in the US are currently moving to lighter feeds for the cracking of ethylene on the back of improved margins and feedstock security, due to abundant availability of shale gas reserves in the region. This is resulting in a reduced yield of C3, and consequently the total propylene production from ethylene crackers has been dropping significantly. With the demand for propylene outpacing the current supply levels, the supply assurance for propylene is becoming challenging.
Possible solutions In the Asia-Pacific region, where refineries still play a major role in the propylene production dynamics, Fluid Catalytic Cracker (FCC) represents a growing and a major share of total propylene capacity. North American
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and European markets, at present, have significant production of propylene from the existing refineries, but a lack of investment in new refineries and crackers, leaves no scope for improvement in the present scenario. In the Middle East, ethylene is given more importance than propylene and its downstream derivatives and hence, massive ethane-crackers are being built for major expansion of ethylene and other downstream products such as polyethylene. At present, just about 5-10 per cent of the global propylene comes from the purposive production techniques. Since the steam cracker expansion cannot keep pace with the propylene and polypropylene demand growth, various other alternatives need to be looked at for this purpose. On-purpose propylene technologies offer a solution.
The right strategy One basic approach that is being followed by many players in the industry is to enhance the FCC unit operation. By modifying the zeolite catalyst and other operating conditions in the existing FCC unit, the efficiency of the unit can be significantly improved and hence, this would result in increased yield of propylene. The only disadvantage of this method is that, the gasoline production is reduced significantly, by nearly 40 per cent of the previous yield. Hence, when the gasoline demand is high, the refiners would not be able to pump in the required quantities of gasoline into
the market. Lummus and Honeywell are the major firms that are licensing their proprietary enhanced FCC technologies. There are other technologies coming up in the market that provide a more direct solution and are relatively independent of the current crude oil market situation. The technologies currently prevalent in the market are propane dehydrogenation, olefin metathesis and methanol to olefins (MTO).
Propane dehydrogenation Propane dehydrogenation (PDH) uses propane gas as a major feedstock. The process employs a fixed bed of chromiaalumina catalyst to convert the propane gas into propylene. The main chemical reaction occurs during the gaseous phase at higher temperature levels (from around 500°C up to around 820°C) resulting in an endothermic equilibrium reaction. The PDH started gaining popularity since the discovery of shale gas reserves. At present, there are more than 12 propylene plants around the world using the PDH technology and a couple of more projects are underway. The major PDH licensors in the market are UOP (Oleflex), ABB Lummus (CATOFIN) & UHDE (STAR).
Ethylene to propylene: An interesting route Metathesis process involves the catalytic conversion of ethylene and butene-2 for the manufacture of propylene. Metathesis provides an opportunity to achieve the
Propylene production
olefin interchangeability by the rupture of the double bonds during the reaction and the formation of different olefins using the parts of the reactants. Olefin metathesis process can be included in a steam cracker to boost the production of propylene using the cracking exchange reaction of ethylene and butene-2. ABB Lummus currently licenses the maximum number of metathesis units across the globe.
Coal and natural gas: The most effective substitutes Methanol-to-propylene (MTP)/MTO technology has an encouraging future for producers who can get easy access to feedstocks such as coke, coal and natural gas. Natural gas is used for the production of methanol using the mega methanol process. The configuration of the process depends on the composition of the feedstock, which may vary from light natural gas (100 per cent methane) to oil-associated gasses. Coal is gasified for the production of syngas, which then is
used in the mega methanol process for the production of methanol, which in turn is used as a raw material for the synthesis of olefins. There are a number of coal gasifiers available in the market, the major ones being Mitsubishi, Shell, Lurgi, GE etc.
Embracing the feasible solution The most significant of the above methods is the propane dehydrogenation technology, which already supplies nearly 5 million MT of propylene globally. However, the price difference between propane and propylene acts as a major factor for the determination of the process economics and the seasonality plays a major impact in this regard. For example, during the winter season, when the demand for propane from the heating segment rises, it would not be that profitable for a propylene producer to use propane as a feedstock. A similar case exists for the olefin metathesis technology as well, since the price difference between ethylene and propylene would determine the profitability of any metathesis plant.
The demand for MTO/MTP is robust in areas where there is abundant availability of cheap feedstock such as natural gas and coal. Coal reserves of Russia, China and the US would prove to be the major hubs, going forward. However, the major stumbling block for MTP is the humungous investment cost. A gasification unit that includes the production of syngas through coal, production of methanol through syngas and synthesis of propylene through methanol together would cost close to $ 2 billion. A coal gasification/ gas reformation unit for the production of propylene would breakeven in about four years and six months for an annual capacity of around 600,000 MT, assuming it runs at around 80 per cent operating rate. Anurag Srivastava is the Senior Research Analyst at Beroe Consulting (I) Pvt Ltd, a procurement intelligence and customised market research company. Email: anurag@beroe-inc.com
January 2013 | Chemical World
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AUTOMATION TRENDS Radar level measurement systems
Cost-effective, reliable solution for process industry
Courtesy: Emerson Process Management
Radar systems serve as efficient tools in the area of level measurement for liquids and slurries. These find usage in numerous applications and process conditions as they are unaffected by changes in fluid properties, be it temperature variations, viscosity, density, pressure and vapour conditions, dielectric changes, turbulence, etc.
Guided-wave radar
Sarah Parker
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he emergence of radar has been an important advancement in the level measurement field. Radar represents a cost-effective, accurate solution that is immune to density and other process fluid changes as well as most vapour space conditions. Radar level measurement systems are available in
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contacting and non-contacting versions. Contacting type is generally a good fit for small spaces, and is an easy replacement for older technology such as displacers and capacitance probes. Non-contacting category is generally a better fit for dirty, viscous and/or corrosive applications and when agitators are present. Currently, contacting devices, called guided-wave radar (GWR), are slightly more prevalent, primarily because they are capable of
providing interface level measurement (eg oil and water), as well as standard direct level measurements. But both formats are now widely accepted by the process industry.
Contacting and non-contacting radars While GWR works in many conditions and is not dependent on reflecting a signal off a flat surface, some precautions need to be taken with respect to probe choice. Several probe styles are available, and the application, length and mounting restrictions influence their choice. Unless a coax-style probe is used, probes should not be in direct contact with a metallic object, as that will impact the signal. Twin and coaxial probes are susceptible to clogging and build-up. If the application involves liquids that tend to be dirty, sticky or can coat, then only single lead probes should be used. For such applications, devices offering signal quality diagnostics can help the user determine if the probe needs to be cleaned and allows maintenance to be scheduled only when needed. In general, GWR is not suitable for extremely viscous products where fluid flow is minimal. If GWR is used with very viscous fluids and is installed in a bypass chamber, the chamber should be heat traced and insulated to ensure fluidity. Furthermore, the connections from the tank to the chamber and the chamber’s diameter should be sufficiently large enough to allow good fluid flow. With non-contacting radar, process conditions and installation constraints all need to be carefully considered. Non-contacting radar requires a clear, unobstructed view of a liquid surface. It is also important that there is an unrestricted mounting nozzle. The measured surface needs to be relatively flat, not slanted. Non-contacting radar gauges can handle agitation, but their success will depend on a combination of the fluid properties and amount of turbulence. Dielectric properties will also impact the measurement. With low dielectric process fluids, much of the radiated energy is lost to the fluid, leaving very little energy to be
Radar level measurement systems
reflected to the gauge. If the liquid surface is turbulent, whether from agitation, product blending, or splashing, more of the signal is lost. So, a combination of low dielectric fluid and turbulence can limit the return signal to a non-contacting radar gauge. To overcome this, bypass pipes including self-contained chambers or stilling wells can be used to isolate the surface from turbulence.
High temperature applications In applications with extreme temperature and pressure conditions, it is important to select a heavy-duty process seal with multiple layers of protection and a flexible assembly to handle the stresses and the forces induced. This is to prevent leakages and ensure the safety and efficiency of any plant. When measuring liquids at high temperatures in a chamber, it is important to insulate and heat trace the chamber. Fluctuations in temperatures alter the density and volume of the product, which then affects the level in the chamber. Although radar technology is not affected by density changes, dielectric changes can have an impact. For boiler and feed water systems, where boiling water and high pressure saturated steam vapours are present, the returned signal from the surface becomes weaker as water temperature increases. If this is not taken into account, the saturated steam alters the propagation velocity of the radar signal and generates an error in the level reading proportional to the measured distance.
Interface applications Level and interface measurement has been successful with GWR but presents a separate set of challenges. The fluid with the lower dielectric must always be on top. The two liquids must have a dielectric difference of around 10, and the upper layer dielectric value must be known. Certain thicknesses of layers are also required for effective measurement to take place. Typical successful applications have a hydrocarbon-based fluid with a dielectric around 2 on the top layer and water-based fluid with a dielectric over 40 at the bottom.
Interface measurement applications, where the density of the two fluids is very close, or where emulsifier chemicals are used, can produce fairly large emulsion between the products. This may make the interface indistinct. Heavy and thick emulsion layers or liquid layers with similar dielectrics can pose a problem for GWR as the technology requires a distinct dielectric difference to detect the interface. GWR devices have proven to work, but success is difficult to predict. A manual adjustment of the interface threshold on the radar device may be required and a chamber/stilling well can help to minimise the emulsion. Radar often works well in open air or non-metallic tank installations. However, in some cases outside disturbances may interfere with the radar signal. Here it is important to select a radar device with high resistance to Electromagnetic Interference such as a GWR with a smart galvanic interface. For most open sump and well installations, an ultrasonic meter is a more cost-effective solution. However, should vapours be present, then a low frequency radar device is the preferred solution.
Overfill protection In critical level applications, it is necessary to use a minimum of two level technologies or devices and if the same technology is used, employ a voting scheme. Using technologies less influenced by process conditions, such as radar in combination with vibrating fork switches, is a good step to more accurate and reliable measurements. For radar, most failure modes relate to a loss of signal. High sensitivity normally results in high availabilities. High sensitivity is achieved by increasing the signal to noise ratio using technologies such as dual port and direct switch technology. Enhanced echologics – the ability to ignore false echoes – and smart software functions also improve the performance of the radar. Some GWR devices incorporate Reference Pulse Elimination software, which improves measurements in the near zone (high level areas), especially
for low reflective targets. However, above a certain level, the surface echo may not be visible at all in the waveform, but the echologics are used to monitor the changes in the signal as the level gets close to the top, adding an extra layer of protection. This supports the basic level signal and gives informative warnings that the tank is full, even if the level signal is lost.
Installation pitfalls A good installation is key to success with radar. When installing a new radar device, it is usually on an existing nozzle. This nozzle can sometimes be too tall or narrow for the instrument. It is recommended that users try to minimise the height of the nozzle used. Ideally, nozzles should be at least two inches, but no more than six inches high for GWR. For non-contacting radar, it is preferable that the end of the antenna extends slightly beyond the nozzle. Another installation problem is when the nozzle is positioned directly over a pipe, baffle or some other obstruction. The obstruction interferes with the radar beam and becomes the level measurement rather than the process medium in the vessel. As with all instrumentation, radar devices must be configured correctly in accordance with application needs. Special care must be taken when inputting thresholds for the radar signal. These will change depending on the medium being measured. For example, oil appears different to a radar device compared to water, and therefore requires very different threshold settings. However, today there are good set-up guides and functions such as measure and learn; so in most cases configuration is easily achieved in just a few steps. Sarah Parker is the Level Application Manager for the Rosemount Business Unit of Emerson and is located in Chanhassen, Minnesota, USA. She has been working with radar and other level products for more than 20 years. Email: sarah.parker@emerson.com
January 2013 | Chemical World
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ENERGY MANAGEMENT Energy audit
Right means to enhance
PLANT EFFICIENCY As the prices of feedstock and energy continue to rise with each passing day, it has become imperative for the chemical and process industries to adopt energy conservation measures to optimise overall efficiency of plants. Energy audit, which helps in understanding energy consumption pattern in a plant, can be the first step for achieving maximum energy efficiency. Avani Jain
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he chemical industry is now witnessing a difficult energy scenario. This is not just because energy prices are steadily going up, thereby upsetting the economics of operations, but also there are problems in procuring energy from sources such as coal and natural gas due to shortage. Besides raw materials, the energy cost is considered to be the second-largest operating expense in a chemical manufacturing plant. People believe that chemical industry is polluting by nature. Hence, effective energy management, which can reduce wastage and pollution, is important from energy and environment point of view. Energy management should be a continuous process and strategies should be reviewed annually and revised as necessary. The key activities involved in the process include having a formal energy management policy statement, specific and well-laid-out strategic approach, a dedicated energy management team, effective energy monitoring & reporting systems, etc. For successfully accomplishing all the above mentioned goals, performing energy audit is the primary step. Thus, chemical and process industries are undertaking energy audits to optimise plant efficiency.
Need for energy audit Energy audit is the first step towards
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attaining effective energy management. It consists of activities that seek to identify conservation opportunities preliminary to the development of an energy saving programme. To institute correct energyefficiency programmes, one has to know which areas in the establishment unnecessarily consume too much energy. Hence, conducting regular energy audit, which identifies where energy is being consumed more and assessing energy-saving opportunities will ensure maximum gains for a chemical plant that houses several types of energy-intensive equipment. Realising this benefit, many chemical manufacturers are conducting energy audit programmes. Bhupendra C Patel, Managing Director, Jemby Chem Ltd, notes, “In the present scenario, energy audit assumes utmost importance as the electricity prices are increasing each day. Energy audits help in pointing out the loopholes during processing. For example, if the belt of the motor is loose, then the motor will consume more energy. This can be identified during the energy audit and proper recommendations can be made in the report. Further, energy audit can help in identifying the appropriate type and size of motor to be used according to the process, thus reducing energy costs. Moreover, energy audits help in preventing any fault or accident in the long run.” Thus, with the ever-rising cost of energy (fuel, coal etc) and grid electrical
power, energy audit is a necessary step towards achieving optimum energy level. There are several reasons why a plant should ensure a periodic and comprehensive energy audit, some of which are mentioned below.
Advantage in abundance Energy forms a major component in production cost and will continue to increase its share in the processing plant as energy costs are rising every day. Thus, an energy audit can significantly and positively impact a plant’s profit & loss statement. Any chemical or process undergoes a change due to expansion, modification or modernisation – always presenting an opportunity for energy optimisation. An energy audit will, thus, reveal potential areas to save energy and improve efficiency. Energy being a topic of high interest, constant innovation takes place with regard to modernisation of equipment and retrofits for existing equipment. Energy audit enables a plant to understand continuous opportunities in a plant to achieve energy optimisation. Several energy-intensive plants may have a permanent energy manager within the company. However, there are several benefits of an external energy audit team. An external team is better equipped to achieve energy conservation and energy efficiency through energy audit, as it brings a focussed approach and past experience of several plants, which enables in benchmarking including successful
Energy audit
case studies of past implementations. It is generally believed that an energy audit in itself can actually save energy without further investments. This is because the energy audit report contains several key information about the plant such as energy consumption trend, energy calculations, areas for improvement etc, and, of course, the recommendations. It is assumed that the recommendations made in the energy audit report always require high investment but this is not true. In fact, in many cases, the measures stated have a payback of less than 18 months or in some cases 24 months, which is generally acceptable to the management. Energy audit in a plant creates awareness and a sense of urgency among the plant personnel, which in turn translates into further energy savings. It gives a positive orientation to preventive maintenance. This is mainly because although energy audit focusses primarily on energy optimisation, it also points out areas that can perform better with timely
maintenance, thereby reducing downtime and improving output. It is, thus, no surprise that several plants opt for a periodic energy audit to keep a check on the overall energy consumption and continually achieve energy conservation and efficiency. Patel avers, “These days majority of the companies including SMEs, MSMEs and the large corporates are undertaking energy audits to reduce their energy costs.� Energy audit is also a step towards green initiative as it results in achieving energy efficiency. At a higher level, it can go a long way in optimising the consumption of a nation’s natural resources. At the global level, an energy audit can be a small step towards reducing greenhouse gas levels.
Getting started A well-conducted energy audit would reveal the areas of wastage of energy and it would lead to suggestions for possible energy savings in all areas. Key
requirements for undertaking energy audit in a chemical company are as follows: o Availability of past data on energy consumption over a fairly long period of operation (3-6 months) o Details of basic production process and logsheet data o Fairly good understanding on part of audit agency of the alternative processes/fuels/utility sources and ability to carry out a magnitude of calculations; correlate vast amount of data; and comment expertly on the validity of the data Energy audit gives an understanding of the energy consumption with regard to the competitive scenario and allows a focussed approach towards finding endsolutions. Thus, regular energy audit and recommendations can be a useful tool to reduce feedstock and energy cost leading to economic gains for chemical manufacturers. Email: avani.jain@network18publishing.com
January 2013 | Chemical World
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POLICIES & REGULATIONS Implementing stringent safety norm
Prasenjit Chakraborty
T
he Union Ministry of Chemicals and Fertilizers has declared the need to create REACH-like legislation for promoting safer use of chemicals, in the interest of protection of human health and the environment, and to reduce the current number of chemical-related laws. REACH is a European regulation, a pioneer initiative in the world, dealing with the registration, evaluation, authorisation and restriction of chemical substances, which came into effect on June 1, 2007, in the European Union. After Europe, several countries have implemented REACH-like legislation and many are in the process of implementation. India
Dr Kishore M Shah, Chairman and Managing Director, Sauradip Chemical Industries Pvt Ltd, is strongly in favour of the implementation of REACHlike legislation in India. “We should implement REACH-like legislation in India because many countries have come out with such legislation. This type of legislation will benefit
The formulation of REACH-like legislation in India will prove beneficial in addressing issues pertaining to safety, quality, environment, etc. Such legislation will offer a level-playing field to Indian chemical industry. But before implementation, the infrastructure issue should be addressed properly. is also contemplating to introduce this type of legislation. Why India should implement REACH-like legislation? It is because the new legislation will help address shortcomings of the existing system and also provide a parameter on safety, toxicology, unhealthy competition, quality, etc, which will ultimately benefit the chemical industry.
The legislation will help the country’s overall manufacturing scenario as chemical manufacturers will be cautious on fronts such as toxicology, safety, environment etc. Once the quality aspect is addressed, export will automatically increase. Dr Kishore M Shah Chairman and Managing Director, Sauradip Chemical Industries Pvt Ltd
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The REACH-like legislation has myriad benefits. It will provide a direction to the chemical industry. It will also ensure quality and safety of products. the chemical industry of India,” he says. However, he sounds a note of caution and says that before implementing the legislation, there has to be thorough homework. “Preparation of data bank on chemicals is the first step in this direction. It has to be prepared without any flaw. Besides, it is essential to ensure proper infrastructure in terms of testing laboratories, adequate manpower, etc,” he asserts.
Taking the right direction The REACH-like legislation has myriad benefits. First, it will provide a direction to the chemical industry. Second, it will ensure quality and safety of products. Third, the legislation will address environmental issues. Speaking on business prospects, Dr Shah says, “Today, we are spending lot of money to get registration for REACH. It becomes difficult for the SME sector to export to the European countries. By implementing R E AC H - l i k e legislation, the country can earn more revenue, and at the same time, ward off unhealthy competition.” People associated with the industry feel that once the parameters for toxicology, safety, etc are determined, it would help the industry to scale new heights, because such standards are applicable for both the domestic industry as well as import. Serious players in the business will invest more to fulfill the criteria, and over a period, SME sector can also compete both on quality and cost fronts. “It will help the country’s overall manufacturing scenario as chemical manufacturers will be cautious on fronts such as toxicology, safety, environment etc. Once the quality aspect is addressed, export will automatically increase. Every country has introduced a system and it is time for us to emulate it,” asserts Dr Shah. The industry might face difficulties while implementing the new rule initially. It might see closing down of few small units, as it will be difficult for them to implement everything. But on a positive note, there is no doubt that such legislation will ensure survival of the fittest. Email: prasenjit.chakraborty@network18publishing.com
STRATEGY Reducing water footprint
Adopting sustainable route to avert future scarcity Reducing the water footprint is as much in the hands of the consumers as it is in the hands of the industry. The water footprint is a powerful tool to evaluate the sustainability of production and consumption as well as to identify response strategies. Projecting an enterprise as ‘water-positive’ significantly impacts its brand value too. Mahua Roy
G
lobal freshwater consumption quadrupled in the last 50 years. The pressure on global freshwater resources is increasing due to consumptive water use and pollution. The water footprint is a measure of human appropriation of freshwater resources, looking at both direct and indirect water use. The chemical industry and allied sectors are considered to be the biggest consumers of water among all industrial sectors. They are also the ones responsible for generating high volume and intensity of effluents.However, having opened up to the adoption of sophisticated technologies, along with realignment of strategies to cope with water scarcity, this industry has exemplified water management and optimisation. “As a major component of manufacturing, companies consider good water management strategic to their business and a key competitive advantage. It positively affects the bottom line, besides being good for the environment. The impact of manufacturing on the water
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supply is huge, and forward-thinking manufacturers are now looking at ways to have a ‘net-zero’ impact on the environment by creating a sustainable water supply in their efforts towards reducing their water footprint,” says Chaitanya Koranne, Chief Executive Officer, CRI Pumps Pvt Ltd. The past few years have seen the majority of chemical producers employ various measures to improve efficiency and attain self-regulated targets. “There are many ways to achieve water optimisation. Water is used in all areas of the manufacturing process. By capturing and reusing water for boiler feed water or utility water, manufacturers can help reduce their impact on fresh water supplies,” says Dr Suneel Pandey, Fellow, Centre for Environmental Studies, The Energy and Resources Institute.
Smart savings “With highly energy-intensive processes, chemical companies are among the largest consumers of water. Volumes of water consumption vary considerably from plant to plant, but water is essential throughout the production process, be it
for cooling, cleaning, dissolving, diluting, or for generating steam,” adds Koranne. A thorough review of production processes, improved maintenance programmes to reduce leaks & blockages, enhanced treatment of effluent, and heavy investment in water treatment facilities constitute a comprehensive water management strategy. Leak detection is a major emphasis area and can contribute to unprecedented amount of savings for a facility. A comprehensive report by Sensus, based on extensive interviews with utilities worldwide, found that, collectively, leaked water alone costs them an estimated $ 9.6 billion each year. Utilities across the world can save as much as $ 12.5 billion every year by using smart water networks that help in system performance improvements in leakage and pressure management, network operations, and water quality monitoring, the report stated. “Smart water networks can ease that pressure and save billions of dollars each year for utilities worldwide. These savings mean more than five per cent of utilities’ budgets could be reinvested
Reducing water footprint
to improve water networks and help address the global water scarcity crisis,” says Kevin Cassidy, General Manager, Chemical and Monitoring Solutions – Water and Process Technologies, GE Power & Water.
Relooking production process Water use in Indian industry is high due to a combination of factors including obsolete process technology, poor recycling & reuse practices and poor wastewater treatment. “Each and every industry knows where it is losing money or faces problems related to purity, profit and pollution. For instance, by replacing all liquid acid catalysed reactions and reducing the number of steps through use of catalysts or new routes will be an effective way to cut down water usage,” says Dr Pandey. Companies and clusters are coming forward to develop processes that can significantly reduce their water footprint right at the first stage, as a result the
cumulative effect is brought down drastically. For example, it is estimated that in order to produce coloured cotton T-shirts using reactive dyes and weighing about one kilogram in all, 2,000 litre of water gets consumed, right from farming to the final garment. In the wake of a rise in awareness among consumers in choosing sustainable textiles and garments, many textile machinery and dyes & chemical producers such as Clariant, Huntsman, Fongs, Dystar, Wacker etc, are introducing new technologies, which can help curb water usage as well as control pollution during the dyeing and printing process. Also, this is where biotechnology is also playing its part. DuPont’s biobased enzymes are being introduced as a replacement for traditional chemicals in cotton textile preparation, thus helping reduce water usage by 70 per cent and energy use by 27 per cent. A technology developed jointly by BASF and Dow will be used at the world’s first commercialscale hydrogen peroxide-to-propylene
oxide (HPPO) plant in Belgium. This will help to reduce both water consumption and waste, compared with the commonlyused chlorohydrin process.
The economic impact... Industrial conscientiousness is much triggered by slump in business. A blow will be felt when suddenly the impact of water scarcity will hit the economy of a country. “The limited availability of water in some areas will certainly lead to an increase in its price. This will then determine where new plants and expansions will be located, and can even lead to the closure of existing facilities in some countries,” adds Cassidy. Emerging economies such as India and China that are riding high on the wave of outsourced manufacturing will face the blow, as these countries suffer from mismanagement of water resources. So to continue its global expansion, the chemical industry has to realise that water is not an endlessly renewable resource. Email: mahua.roy@network18publishing.com
January 2013 | Chemical World
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TIPS & TRICKS Corrosion prevention
Effective ways to save chemical plant from rust formation It is estimated that process industry worldwide spends over $ 50 billion annually to combat corrosion, and this expenditure is expected to climb higher over the next few years. Selection of right material of construction (MoC) to manufacture chemical process equipment is one of the most important measures to inhibit rust and prevent corrosion.
M
any factors have to be considered when selecting engineering materials, but for chemical process plant the overriding consideration is usually the ability to resist corrosion. Here are few tips that may help machinery manufacturers to understand types of corrosion and the procedure of selecting materials for making equipment to prevent corrosion in the chemical plant.
1
Plant operators can use new inspection technology to assess corrosion deterioration in real time using the plant control and automation system. It allows the assessment of corrosion in much shorter time intervals with the ability to control and mitigate the rate of damage and more accurately factor in its true economic impact on plant operations.
2
One of the most important characteristics to be considered by the process designer when selecting a material of construction is corrosion resistance. The recommendation of materials should be based on the suitability for the process conditions.
3
If the corrosion of a material can be considered to be uniform, the life of the material in service can be predicted from experimentally determined corrosion rates. The corrosion rate will be dependent on the temperature and concentration of the corrosive fluid. An increase in temperature usually results
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in an increased rate of corrosion; though not always. The rate will depend on other factors that are affected by temperature, such as oxygen solubility.
4
Intergranular corrosion, which is the preferential corrosion of material at the grain (crystal) boundaries, can cause the catastrophic failure of equipment. The classic example of intergranular corrosion in chemical plant is the weld decay of unestablished stainless steel. Weld decay can be avoided by annealing after welding, if practical; or by using low carbon grades (<0.3 per cent C); or grades stabilised by the addition of titanium or niobium.
5
Corrosion rate and the form of attack can be changed if the material is under stress. For some combinations of metal, corrosive media and temperature, the phenomenon called stress cracking can occur. Stress corrosion cracking can be avoided by selecting materials that are not susceptible in the specific corrosion environment; or, less certainly, by stress relieving by annealing after fabrication and welding.
6
The term erosioncorrosion is used to describe the increased rate of attack caused by a combination of erosion and corrosion. If a fluid stream contains suspended particles, or where there is high velocity or turbulence, erosion will tend to remove the products of corrosion and any protective film, and the rate of attack will be markedly increased. If erosion is likely to occur, more resistant materials
must be specified, or the material surface protected in some way.
7
C o r r o s i o n is normally associated with aqueous solutions but oxidation can occur in dry conditions. Carbon and low alloy steels will oxidise rapidly at high temperatures and their use is limited to temperatures below 500Ë&#x161;C. Chromium is the most effective alloying element to give resistance to oxidation, forming a tenacious oxide film.
8
In order to select the correct MoC, the process environment to which the material will be exposed must be clearly defined. Additional to the main corrosive chemicals present, the factors that must be considered are temperature affects corrosion rate & mechanical properties; pressure; pH; presence of trace impurities stress corrosion, etc. The conditions that may arise during abnormal operation, such as at start-up and shutdown, must be considered, in addition to normal, steady state, operation.
9
A wide range of paints and other organic coatings is used for the protection of mild steel structures. Paints are used mainly for protection from atmospheric corrosion.
Reference: o Sapienza Universitaâ&#x20AC;&#x2122; di Roma Dipartimento Ingegneria Chimica Materiali Ambiente o International Society of Automation (ISA) Email: rakesh.rao@network18publishing.com
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Invites You To Indiaâ&#x20AC;&#x2122;s Largest
SME Gathering On Engineering &
Manufacturing
250+ participants | 20,000+ business visitors expected | 7, 250+ products on display Business transactions worth ` 80 crore expected | Spread over 15000 sq mtr Showcasing more than 30 diverse industry categories.
A URA N G A B A D 22 - 25 February 2013 Ayodhya Nagari Ground 10 am - 7 pm
Auto & Auto Components | Chemicals & Allied Products | Testing & Measuring Instruments Electrical & Electronics | Hydraulics & Pneumatics | IT Products & Services | Automation Instrumentation | Material Handling Equipment | Packaging Machinery | Wires & Cables Machine Tools & Accessories | Pipes & Fitting | Plastics & Polymers | Safety & Security Process Machinery & Equipment | Light & Medium Engineering
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Exhibitor Profile
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. Alphamethrin
Fertiliser
Tagros Chemicals India Ltd
Mangalore Chemicals & Fertilizers Ltd
Project type New facility Project news Tagros Chemicals India Ltd is planning to set up a new chemical plant at Bharuch in Gujarat. The project involves manufacturing of alphamethrin 5%, 20%, etc. Project location Bharuch, Gujarat Project cost Not available Implementation stage Planning Contact details: Tagros Chemicals India Ltd Jhaver Centre Rajah Annamalai Building IV Floor, 72 Marshalls Road Egmore, Chennai 600 008 Tel: 044-42007400 Fax: 044-28587873 Email: info@tagros.com,sales@tagros.com ---------------------------------------Fertiliser
Paradeep Phosphates Ltd Project type New facility Project news Paradeep Phosphates Ltd is planning to set up a new plant at Jagatsinghpur in Odisha. The project involves manufacturing of di-ammonium phosphate. Project location Jagatsinghpur, Odisha Project cost Not available Implementation stage Planning Contact details: Paradeep Phosphates Ltd Pandit Jawaharlal Nehru Marg Bhubaneswar 751 001 Orissa Tel: 0674-2393931 Fax: 0674-2392631, 2391669 Email: connect@paraphos.com
Project type New facility Project news Mangalore Chemicals & Fertilizers Ltd is planning to set up a new plant at Dakshina Kannada in Karnataka. The project involves manufacturing of micronutrients, fertigation products, soil conditioners, organic products, biofertilisers and agri fluids. Project location Dakshina Kannada, Karnataka Project cost Not available Implementation stage Planning Contact details: Mangalore Chemicals & Fertilizers Ltd Level-11, UB Towers UB City no 24 Vittal Mallya Road Bengaluru 560 001 Tel: 080-39856000/6500 Fax: 080-39855588 Email: homkt@mangalorechemicals.com ---------------------------------------Fertiliser
Bhilai Engineering Corporation Project type New facility Project news Bhilai Engineering Corporation Ltd is planning to set up a new plant at Bharuch in Gujarat. The project involves manufacturing of single super phosphate. Project location Bharuch, Gujarat Project cost Not available Implementation stage Planning Contact details: Bhilai Engineering Corporation Ltd Hathkhoj Village, Industrial Area Bhilai 490 026, Dist Durg Chhattisgarh
Tel: 0788-4088100 Fax: 0788-2285499 Email: becinfo@bec-group.com ---------------------------------------Inorganic chemicals
Rama Phosphates Ltd Project type New facility Project news Rama Phosphates Ltd is planning to set up a new plant at Udaipur in Rajasthan. The project involves manufacturing of single super phosphate. Project location Udaipur, Rajasthan Project cost Not available Implementation stage Planning Contact details: Rama Phosphates Ltd 51/52 Free Press House Nariman Point, Mumbai 400 021 Tel : 022-22834123, 22834182 Fax : 022-22049946 Email: rama@ramagroup.co.in ---------------------------------------Industrial gases
Praxair India Pvt Ltd Project type New facility Project news Praxair India Pvt Ltd is planning to set up a new plant at Jajpur in Odisha. The project involves manufacturing of oxygen. Project location Jajpur, Odisha Project cost Not available Implementation stage Planning Contact details: Praxair India Pvt Ltd Praxair House No 8, Ulsoor Road Bengaluru 560 042 Tel: 080-30576821/22 Fax: 080-25593499 Email: customercare_india@praxair.com January 2013 | Chemical World
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PROJECTS
Liquid pesticide formulations
Paint
Solvent
K P R Fertilisers Ltd
BASF India Ltd
Ashok Alco Chem Ltd
Project type New facility Project news K P R Fertilisers Ltd is planning to set up a new plant at East Godavari in Andhra Pradesh. The project involves manufacturing of liquid pesticide formulations. Project location East Godavari, Andhra Pradesh Project cost Not available Implementation stage Planning
Project type New facility Project news BASF India Ltd is planning to set up a new plant at Dakshina Kannada in Karnataka. The project involves manufacturing of automotive and industrial paints. Project location Dakshina Kannada, Karnataka Project cost Not available Implementation stage Planning
Project type New facility Project news Ashok Alco Chem Ltd is planning to set up a new plant at Raigad (Kulaba) in Maharashtra. The plant will manufacture diethyl phthalate. Project location Raigad, Maharashtra Project cost Not available Implementation stage Planning
Contact details: K P R Fertilisers Ltd D no 8-256, Tatanagar Balabhadrapuram, Biccavolu Mandal East Godavari Dist Andhra Pradesh 533 343 Tel: 08857-237367/477 Fax: 08857-237333 Email: kprfert@rediff.com ---------------------------------------Laundry detergent powder
Contact details: BASF India Ltd Shed 269B, 3rd phase Bommasundra Industrial Area Anekal Taluka Bengaluru 560 099 Tel: 080-27832447 Fax: 080-7832447 Email: investor-grievance-india@basf.com ---------------------------------------Pesticide
Procter & Gamble Home Products Ltd
Bayer Cropscience Ltd
Project type New facility Project news Procter & Gamble Home Products Ltd is planning to set up a new plant at Mahaboobnagar in Andhra Pradesh. The project involves manufacturing of laundry detergent powder. Project location Mahaboobnagar, Andhra Pradesh Project cost Not available Implementation stage Planning Contact details: Procter & Gamble Home Products Ltd G Plaza, Andheri East Mumbai 400 099 Tel: 022-28266000 Email: pg@corvoshandwick.co.in
Project type New facility Project news Bayer Cropscience Ltd is planning to set up a new plant at Sabarkantha in Gujarat. The plant will manufacture spiromensifen 240 Sc (Oberon 240 Sc). Project location Sabarkantha, Gujarat Project cost Not available Implementation stage Planning Contact details: Bayer Cropscience Ltd Bayer House, Central Avenue Hiranandani Gardens, Powai Mumbai 400076 Tel: 022-25711234 Fax: 022-25705940 Email: investor.relations@bayer.com
Contact details: Ashok Alco Chem Ltd Sharda Chambers Vithaldas Thackersey Marg Marine Lines Mumbai 400 020 Tel: 022-22000024 Fax: 022-22009456 Email: info@ashokalcochem.com ---------------------------------------Xylitol
Godavari Biorefineries Ltd Project type New facility Project news Godavari Biorefineries Ltd is planning to set up a new plant at Bagalkot in Karnataka. The plant will manufacture Xylitol. Project location Bagalkot, Karnataka Project cost Not available Implementation stage Planning Contact details: Godavari Biorefineries Ltd Somaiya Bhavan 45-47 Mahatma Gandhi Road Post Box No 384 Fort, Mumbai 400 001 Tel: 022-22858430 Fax: 022-22047297 Email: marina@somaiya.com
Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India Tel: 022 28666134 â&#x20AC;˘ Fax: 022 28013817 â&#x20AC;˘ Email: parmeet.d@tendersinfo.com
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TENDERS
Latest Popular Tenders brought to you by www.tendersinfo.com Oxygen analyser Org : Department of the Navy TRN : 13788374 Desc : Provision of oxygen analyser BOD : January 20, 2013 Loc : USA BT : ICB _______________________________________________
Proving vessel Org : Bharat Petroleum Corporation Ltd (BPCL) TRN : 14091638 Desc : Supply of proving vessel at BPCL Patna AFS BOD : January 20, 2013 Loc : Patna, Bihar BT : Domestic _______________________________________________
Heat exchanger Org : Aligarh Muslim University TRN : 14011658 Desc : Provision of heat exchanger MED BOD : January 20, 2013 Loc : Aligarh, Uttar Pradesh BT : Domestic _______________________________________________
Electronic chlorinator Org : Northern Railway (NR) TRN : 14060006 Desc : Provision of high capacity electronic chlorinator BOD : January 21, 2013 Loc : New Delhi BT : Domestic _______________________________________________
Liquid nitrogen generating plant Org : Department of Science and Technology TRN : 13914374 Desc : Supply, installation, commissioning, training of liquid nitrogen generating plant BOD : January 21, 2013 Loc : Pune, Maharashtra BT : Domestic _______________________________________________
Multi gas analyser Org : Delhi Technological University TRN : 14034529 Desc : Purchase of multi gas analyser with sensor BOD : January 21, 2013 Loc : New Delhi BT : Domestic (NCB) _______________________________________________
Hydro carbon detectors Org
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: Bharat Petroleum Corporation Ltd (BPCL)
Chemical World | January 2013
TRN : 14079558 Desc : Supply of hydro carbon detectors BOD : January 21, 2013 Loc : Bareilly, Uttar Pradesh BT : Domestic _______________________________________________
Liquid nitrogen generating plant Org : Agharkar Research Institute (ARI) TRN : 13900942 Desc : Provision of liquid nitrogen generating plant BOD : January 21, 2013 Loc : Pune, Maharashtra BT : Domestic _______________________________________________
Un-engineered hybrid vacuum ejector system Org : Bharat Petroleum Corporation Ltd (BPCL) TRN : 14126130 Desc : Provision of un-engineered hybrid vacuum ejector system BOD : January 21, 2013 Loc : Mumbai, Maharashtra BT : Domestic _______________________________________________
High pressure economiser coils Org : Chhattisgarh State Power Generation Company TRN : 14126176 Desc : Manufacture and supply of high pressure economiser coils; fully killed ERW air heater steel tubes BOD : January 22, 2013 Loc : Raipur, Chhattisgarh BT : Domestic _______________________________________________
Inlet cone and cylinders and tubes for usx-d type heat exchanger Org : Gail (India) Ltd TRN : 14079132 Desc : Supply of inlet cone and cylinders and tubes for usx-d type heat exchanger BOD : January 22, 2013 Loc : New Delhi BT : Domestic _______________________________________________
Automatic chlorination plant Org : East Central Railway TRN : 14001469 Desc : Provision of automatic chlorination plant at MGS 12 nos BOD : January 23, 2013 Loc : Vaishali, Bihar BT : Domestic
TENDERS
Latest Popular Tenders brought to you by www.tendersinfo.com Sulfur pelletisation package Org : Bharat Petroleum Corporation Ltd (BPCL) TRN : 14102749 Desc : Sulfur pelletisation package BOD : January 23, 2013 Loc : Kochi, Kerala BT : Domestic _______________________________________________
Granular base chlorination system Org : Military Engineer Services TRN : 14042121 Desc : Special repairs (M&O) for replacement of gaseous chlorination system with granular base chlorination system BOD : January 25, 2013 Loc : Chennai, Tamil Nadu BT : Domestic _______________________________________________
Process gas compressors, other equipment & process packages Org : Reliance Industries Ltd (RIL) TRN : 14081915 Desc : Supply and installation of process gas compressors, other equipment & process packages along with associated construction and modification works for onshore gas terminal BOD : January 25, 2013 Loc : Navi Mumbai, Maharashtra BT : Domestic _______________________________________________
Fertiliser mixing/granulating plant Org : Fertilisers and Chemicals Travancore Ltd TRN : 13873750 Desc : Supply of fertiliser mixing/granulating plant BOD : January 30, 2013 Loc : Kochi, Kerala BT : Domestic _______________________________________________
Spares for gas lift compressors Org TRN Desc BOD Loc
: : : : :
Oil India Ltd (OIL) 13950409 Provision of spares for gas lift compressors January 30, 2013 Duliajan, Assam
BT : Domestic _______________________________________________
Spares for gas compressors Org : Oil India Ltd (OIL) TRN : 13950408 Desc : Provision of spares for gas compressors BOD : January 30, 2013 Loc : Duliajan, Assam BT : Domestic _______________________________________________
Spares for gas compressors Org : Oil India Ltd (OIL) TRN : 13950407 Desc : Provision of spares for gas compressors BOD : January 30, 2013 Loc : Duliajan, Assam BT : Domestic _______________________________________________
Electro-chlorination plants and dosing pumps Org : South Eastern Railway TRN : 14120093 Desc : Supply, installation and commissioning of electrochlorination plants, dosing pumps etc at different stations in KGP-BHC section BOD : January 31, 2013 Loc : Chakradharpur, West Bengal BT : Domestic _______________________________________________
Refrigeration condensor unit Org : Central Railway TRN : 14020247 Desc : Supply of refrigeration condensor unit with complete associated equipment BOD : January 31, 2013 Loc : Mumbai, Maharashtra BT : Domestic _______________________________________________
Fluxless melting of magnesium alloys Org TRN Desc BOD Loc BT
: : : : : :
Hindustan Aeronautics Ltd (HAL) 14048050 Establishing fluxless melting of magnesium alloys February 02, 2013 Bengaluru, Karnataka Domestic
Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India Tel: 022 28666134 • Fax: 022 28013817 • Email: parmeet.d@tendersinfo.com
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EVENT LIST
NATIONAL AURANGABAD
HYDERABAD
Maharashtra, Feb 22-25, 2013
Andhra Pradesh, May 31- June 3, 2013
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
For details contact: Federation of Indian Chambers of Commerce & Industry Federation House, 1, Tansen Marg New Delhi Tel: 011-23738760/23738770 Fax: 011-2332 0714 Email: ficci@ficci.com
Network18 Media & Investments Ltd
Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. • Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@network18publishing.com
IP Summit 2013 The summit will address Intellectual Property Rights (IPR) issues across the countries in the globe, with a view to understand the operational dynamics and development perspectives both in principle and practice in IP; January 26-27, 2013; at Ahmedabad For details contact: Jatin Jani/Hasmukh Thaker Y J Trivedi & Co 2nd Floor, City Square Building University Road, Polytechnic Ahmedabad 380 015 Tel: 079-26303777 Email: events@yjtrivedi.com
India Water Expo An event showcasing an array of efficient water treatment processes, transportation, storage facilities, chemicals and other related equipment; February 01-03, 2013; Gujarat University Exhibition Hall, Ahmedabad For details contact: EA Water Pvt Ltd A1/152, IGNOU Road, Neb Sarai New Delhi 110 030 Tel: 011-43100568/500, Fax: 011-43100599 Email: shital@orbitz-world.com
World PetroCoal Congress An international event showcasing trends in refining technologies, extraction & drilling equipment, consulting services, natural gases and others; February 15-17, 2013; Convention Centre-NDCC, New Delhi
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Chemical World | January 2013
For details contact: Energy and Environment Foundation F1-F2, Pankaj Grand Plaza, Mayur Vihar - I New Delhi Tel: 011-24538318/22758149 Email:dranilgarg@ee-foundation.org
EverythingAboutWater Expo 2013 An international exhibition and conference on water & wastewater management; February 28-March 2, 2013; at Chennai Trade Centre, Nandambakkam, Chennai For details contact: EA Water Pvt Ltd A1/152, Neb Sarai IGNOU Road, New Delhi 110 068 Tel: 011-43100568, Fax: 011-43100599 Email: enquiry@eawater.com
ChemProTech 2013 An international event on chemical processing technology and equipment to be held concurrently with fine and specialty chemicals trade fair, Chemspec; April 11-12, 2013; at Bombay Exhibition Centre, Mumbai For details contact: Krunal Goda Koelnmesse YA Tradefair Pvt Ltd 1102, 11th Floor, DLH Park S V Road, Near MTNL Office Goregoan(W), Mumbai 400062 Tel: 022-28715207, Fax: 022-28715222 Email: k.goda@koelnmesse-india.com
Poly India A trade show for plastics and petrochemicals industries; April 25-27, 2013; at Chennai Trade Centre, Chennai
PetroWorld India An event showcasing novel technologies in oil & gas sector; August 22-24, 2013; Bombay Exhibition Centre, Mumbai For details contact: Siddharth Chibba Inter Ads Exhibitions Pvt Ltd Plot No 859, Phase-V, Udyog Vihar, Gurgaon 122016, Haryana Tel: 0124-4524200/4201 Fax: 0124-4381162 Email: siddharth@interads.in
analytica Anacon India 2013 International trade fair for laboratory technology, analysis, biotechnology and diagnostics; November 12-14, 2013; at Bombay Exhibition Centre, Mumbai For details contact: Avisha Desai Project Manager MMI India Pvt Ltd Lalani Aura, 3rd Floor, 34th Road Khar (West), Mumbai 400 052 Tel: 022-42554710 Email: avisha.desai@mmi-india.in
Chemical Expo A trade show for chemical equipment, environment & safety, plastic & packaging, electric & electronic, petroleum & gas, engineering and equipment; December 07-10, 2013, AIDS Ananpura, Ankleshwar, Gujarat For details contact: Better Deal 204, Concord Complex R C Dutt Road Alkapuri, Vadodara 390 007 Mob: 09979871798 Email: info@chemicalexpo.in
EVENT LIST
INTERNATIONAL Petrochem Arabia An exhibition and conference focussed on technological improvements and sustainability of the downstream and petrochemical industries; January 20-22, 2013; at Dhahran International Exhibition Center, Dammam, Saudi Arabia For details contact: Bme Global Ltd Waterfront Studios, 1 Dock Road, London, E16 1 Ag London, England, The UK Tel: +(44)-(207)-5119582 Email:info@bme-global.com
IndoGas 2013 Leading trade fair and conference on Indonesiaâ&#x20AC;&#x2122;s gas & oil industry; January 25-27, 2013; at Jakarta International Expo ( JIExpo), Jakarta, Indonesia For details contact: IEE Communications Jl. Kebon, Baru III, No. Jakarta, Jakarta Raya, Indonesia Tel: +(62)-(21)-83795203 Fax: +(62)-(21)-83795302 Email: indogas.committee@i-eec.com
Anaheim Convention Centre, Anaheim, California, USA For details contact: Informex Holdings, LLC 300 American Metro Blvd Suite 125, Hamilton, NJ 08619, USA Tel: +1 609 759-4700 Email: informex@informex.com
China International Agrochemical & Corp Protection Exhibition An exhibition focussing on latest developments in agro chemicals and crop protection technology; February 26-28, 2013; at Shanghai New International Expo Centre (SNIEC), Shanghai, China For details contact: CCPIT Sub-Council of Chemical Industry Building 16, Block 7, Hepingli, Dongcheng District Beijing, China Tel: +(86)-(10)-64275419 Email: contact@chinaexhibition.com
For details contact: World Promotion Centre 35 Abd Elhamed Awad St., 4th Floor, nasr City, Cairo, Al Qahirah, Egypt Tel: + (20)-(2)-22738278/22738279 Fax: + (20)-(2)-22738303/22738304 Email: info@wpcexh.com
InformexUSA 2013 Exhibition and conference bringing together buyers and sellers of chemicals, chemical technologies and related services; February 19-22, 2013; at
Kuwait Oil and Gas Summit & Exhibition An exhibition & conference focussing on the development, diversification and growth of the oil & gas industry of Kuwait; April 28-30, 2013; at Kuwait Regency Palace Hotel, Kuwait City, Kuwait For details contact: The CWC Group Ltd Regent House, Oyster Wharf 16-18 Lombard Road, London, England The UK Tel: +(44)-(20)-79780000 Fax: +(44)-(20)-79780099 Email: info@thecwcgroup.com
Petro.t.ex Africa Middle East Coatings Show An exhibition and conference on coatings and surface treatment; February 26-28, 2013; at Cairo International Convention Center, Cairo, Egypt
Gas Tech Cairo Focussed event showcasing latest innovation, technologies and developments across the gas value chain; February 04-05, 2013; at Sonesta Hotel, Tower & Casino Cairo, Egypt
No 889, 5th Floor, Thai CC Tower South Sathorn Road, Yannawa, Sathorn Bangkok, Thailand Tel: +(66)-(2)-6739970 Email: cba@cba.or.th
For details contact: Coatings Group Westgate House, 120/130, Station Road Surrey, Redhill, England, The UK Tel: +(44)-(1737)-855225 Fax: +(44)-(1737)-855034 Email: kezchen@quartzltd.com
Focussed event on refineries & oil and related technology; May 14-16, 2013; at Gallagher Convention Centre, Midrand, South Africa For details contact: Exhibition Management Services PO Box 650302 Benmore, Johannesburg, South Africa Tel: +(27)-(11)-7837250 Fax: +(27)-(11)-7837269 Email: director@exhibitionsafrica.com
Chemspec Europe 2013
Chemicals International Expo Thailand An exhibition focussing on latest developments in the areas of fine & specialty chemicals; March 19-20, 2013; at Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand For details contact: Chemical Business Association
An event dedicated to the fine and specialty chemicals industry; June 05-06, 2013, at MOC, Munich, Germany For details contact: Quartz Business Media Ltd Quartz House, 20 Clarendon Road Redhill, Surrey The UK Tel: + 44 - 1737-855000 Email: johnlane@quartzltd.com
The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Chemical World
January 2013 | Chemical World
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EVENT PREVIEW Engineering Expo Aurangabad 2013
AURANGABAD February 22-25, 2013 Ayodhya Nagari Ground
Leveraging market trends, expanding opportunities From being a mere tourist attraction centre to a manufacturing hub, Aurangabad’s journey has been glorious. The city has been growing at a healthy pace over the past few years and is expected to witness a rise in the years to come. Capturing this majestic proposition is the second edition of Engineering Expo Aurangabad. Slated to be held between February 22 and 25, 2013, this trade show promises to be the right connect between organisations and the growth forecasts… Nishi Rath
E
xploring new markets and providing the right platform for emerging opportunities have been the backbone of Engineering Expo ever since its inception. Having captured the manufacturing essence in regions such as Ahmedabad, Pune and Chennai while providing
Highlights of this edition 250+ expected exhibitors 20,000+ business visitors expected Business transactions worth
`80 crore expected 7,250+ products on display Spread over an area of more than
1,50,000 sq ft Showcasing more than 30 diverse industry categories
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them a manufacturing thrust, the second edition of Engineering Expo Aurangabad is all set to help one and all leverage on the opportunities and brighter prospects of this fast developing manufacturing hub. It all started when, Bajaj Auto Ltd entered Aurangabad in the 80s and was followed by Videocon. This move threw open a land of opportunities for Small and Medium Enterprises (SMEs) and the region’s growth prospects took an upward swing with major players like Skoda Auto, Varroc Engineering Pvt Ltd, Endurance Technologies Pvt Ltd, Man Diesel India, Can-Pack India and Siemens venturing into the region. Since then, SMEs have been contributing their fair share to the manufacturing sector here and thereby to the region’s growth. According to experts, Aurangabad is now one of the classic examples of efforts towards balanced industrialisation.
Growth of SMEs One of the favourite investment destinations, Aurangabad is known to be one of the fastest growing cities in Maharashtra. This has led to an array of business opportunities for SMEs
in the region. Aurangabad has over 3,405 medium and small scale units generating about 36,871 jobs with an investment of `404.86 crore. It is estimated that by 2020, these units will grow to 9,000, generating about 95,000 jobs with an investment of `1,050 crore. In this era of cost-competitiveness, when everyone is looking at controlling the overheads and reducing cost, existence of SMEs is a must. After all, SMEs help make the business models of Original Equipment Manufacturers (OEMs) more flexible. And with Aurangabad emerging as an attractive destination for auto giants, SMEs definitely have a great future here!
SEZs and IT: The growth catalyst The growth of Aurangabad can be traced to the time when Maharashtra Industrial Development Corporation (MIDC) started acquiring land to set up industrial estates. Today, Aurangabad boasts of Shendra, Chikalthana and Waluj MIDC industrial areas that are significant zones on the outskirts of Aurangabad. These areas, over the years, have witnessed a steady flow of investment and are home to both national and multinational players. The sectors that have attracted major investment in the region are automotive, engineering and pharmaceutical. In the last few years, the engineering and automotive sectors have significantly picked up, giving a boost to the entire industrial fraternity here. Aurangabad is the third city in Maharashtra after Pune and Nashik to offer an automotive cluster. Skoda Auto manufactures its models Superb, Laura and Yeti and also Passat and Jetta for Volkswagen and the A4, A6 and Q5 for Audi from its Aurangabad facility. Recently, Bajaj too launched its first four-wheeler manufactured in its facility in Aurangabad. Elaborating further, Chandrashekhar Patil, Partner, Veera Compressor, explains, “The presence of some major auto giants has helped SMEs bloom in Aurangabad. Although the market has been down for some time, we are looking forward to
Engineering Expo Aurangabad 2013
better times ahead. SMEs definitely have a bright future in this region and are poised for growth.” While the auto industry has made it big in Aurangabad, pharma giants like Wockhardt, Lupin and Glenmark have also made their presence felt. Going ahead, the IT industry has started taking baby steps in Aurangabad and the coming up of Software Technology Parks of India (STPI) has given it a further push. With Aurangabad sprinting towards additional growth opportunities and with the region successfully bagging major investments, it is only a matter of time when it will attract the attention of IT giants. Besides, with IT hubs such as Bengaluru, Pune and Hyderabad already reaching saturation, software professionals are looking for new avenues – a factor that could draw their attention towards Aurangabad. Aurangabad offers a lot of opportunities and is relatively costeffective as compared to other developing cities. As a result, not only professionals, but also medium-sized companies and first-generation entrepreneurs who want
Glimpses of previous edition 250 exhibitors 18,013+ business visitors from across India
17,000 business leads generated Business transacted worth
`70 crore 6,250+ products displayed from different industries
1,00,000 sq ft area occupied More than 1,10,000 kg machinery moved in for display
83% exhibitors got the expected visitors at the show
180+ delegations
to try their hands in this industry are considering investing in Aurangabad.
Engineering Expo: Harbinger of growth By marking its presence in promising regions, Engineering Expo has always believed in showcasing a region’s potential to the right audience. Highlighting the scope that Engineering Expo has provided for SMEs and MSMEs, Jeevan Deshpande, Proprietor, Samarth Machinery, exclaims, “Engineering Expo has provided us a good platform. It has become a motivation for traders here. The variety of machines displayed at the event depicts the might of this place.” Deshpande adds, “We were part of the first edition and were happy to find the right audience to connect with. Thanks to the Expo, we were able to convert these enquiries into good business. This year, too, we expect to make some good business.” Today, Aurangabad has become an emblem of an altogether different Maharashtra – the booming, increasingly urbanised, economic powerhouse. With huge industrial presence of significant corporate players, the city is buzzing with activity. Commenting on the value proposition of the Expo, Sandeep Khosla, CEO, Network 18 Publishing, says, “After 10 successful years of service to the industry, Engineering Expo today has established itself as India’s largest multi-location trade show on manufacturing. The Expo is a preferred destination for small and medium enterprises as well as manufacturing & engineering organisations to further their growth and that of the industry at large. For the 2012–13 season, we have eight editions spread across an equal number of locations of a rising India. Keeping our esteemed exhibitors and valued customers in mind, we have made elaborate provisions to offer a never before experience. These, we reckon, will add substantial traction to the industrial growth of the nation.”
New attractions in this edition o Panel discussion aims at providing a roadmap to infuse growth in the region o Institutional Buyer Involvement Plan to attract delegations from large corporate and major institutions o Improvised visitor profiling - profile, scan, filter and bring in visitors as per exhibitors’ requirements o Providing business networking support to exhibitors by leveraging Network 18 Publishing’s industry connect o Credit rating facilities for the benefit of exhibitors o Providing complete travel solutions for exhibitors o Offering logistics services to ensure smooth cargo handling, custom clearing, transport compliance, etc
First time exhibitors are also hopeful to attract target customers. Sharing the excitement of a first-time participant, Kusum Soni, Proprietor, Akshay Heaters, states, “We are participating in Engineering Expo for the first time and expect to interact with representatives from various engineeringbased companies from different regions/ states. We are hopeful that the event will be a great success with audiences from various engineering fields participating in the event.”
Promising future Aurangabad boasts of a strong brigade of young and enthusiastic first-generation entrepreneurs, who not only bring new ideas into implementation but also steer the region’s growth. With the enthusiasm and optimism about Engineering Expo Aurangabad riding high among this new brigade of entrepreneurs, the mega manufacturing show is set to provide a much deserved platform for developing business opportunities while leveraging the market trends. Email: nisi.rath@network18publishing.com
January 2013 | Chemical World
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EVENT REPORT Engineering Expo Ludhiana 2012
LUDHIANA December 21-24, 2012 GLADA Ground
they could have easy access to this manufacturing-friendly zone. Held at GLADA Ground, Ludhiana, during December 21–24, 2012, the event generated commendable enthusiasm among exhibitors. Visitors too were excited about the prospects of a show of such a magnitude being held in the developing industrial region of Ludhiana.
Exploring a horizon of opportunities
A grand opening
Generating tremendous response from the industry, Engineering Expo Ludhiana has proved to be a game changer for the machine tools industry in the region. Leveraging the vast potential and possibilities of the Punjab state, the Expo provided the perfect platform for accelerating business. Held during December 21–24, 2012, the Expo witnessed a wide range of business possibilities being unfolded. The four-day event received a robust response from the industry at large. A report…
Positioned to add positivities to the manufacturing and machine tools industry in and around Ludhiana, the Expo saw business deals worth `10 crore in the first few hours of the trade exposition and an order book outlook looking potent with big business deals for the exhibitors, thus benchmarking itself with the best in class trade shows.
L-R: Pravin Bansal, BJP – District Chief, Punjab; Hakam Singh Giaspura, Ex-Mayor of Ludhiana; Deepak Ballani, National Programme Officer, UNIDO-ICAMT; Mahendra Singh Dhakad, Programme Director, UNIDO-ICAMT; Harcharan Singh Golwaria, Mayor of Ludhiana; Sandeep Khosla, CEO, Network 18 Publishing; Anil Joshi, Hon’ble Industry Minister, Govt of Punjab; Sukhdial Singh, President, CLMTM
Anwesh Koley
A
round Independence in 1947, Ludhiana had a handful of machine tools units and some units that manufactured hosiery machines. Over a period, units producing bicycle and auto parts entered the scene. Eventually, there came about the need for machine tools to meet the growing demands for mother machines in the country. That is when entrepreneurs established machine tools producing units in Ludhiana. Today, Ludhiana has evolved to become one of the major producers of mother machinery in India. Led by
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manufacturing biggies, Ludhiana is fast emerging as a leading investment destination in the northern region of the country. Capitalising on this vast growth potential, the Ludhiana edition of Engineering Expo organised by Network 18 Publishing, emerged as an eye opener. Inaugurated amid incredible industry response, the maiden edition of Engineering Expo Ludhiana and Punjab Machine Tools Show (PUMTOS) stood tall with potential on the very first day. The Expo not only highlighted the potential of regions like Punjab in northern India but also made it evident to manufacturers how
Gracing the occasion and boosting the confidence of the industry, Hon’ble Minister of State for Industries and Commerce Shri Anil Joshi asserted, “We need a foolproof plan to promote the machine tools industry in Ludhiana. The Ministry is willing to extend all possible support to the machine tools manufacturers to set up business. We have the right pool of manpower available, but we need exposure so that our machinery is accepted not only in India, but across the globe.” The inaugural function was also attended by Ludhiana Mayor Shri Harcharan Singh Golwaria. Addressing the audience, he said, “A cursory look at
Engineering Expo Ludhiana 2012
the halls in the Expo clearly showed that the machinery available in Ludhiana can benchmark global quality. However, we are still heavily dependent on imported machinery. We need to reduce this dependence by spreading awareness about our machinery to the world.” The other dignitaries present at the inauguration included prominent industry stalwarts like SSS Dhillon, Director, MSME Development Institute; Mahesh Khanna, GM, District Industries Center; Mahendra Singh Dhakad, Programme Director, United Nations Industrial Development Organization-International Center for the Advancement of Manufacturing Technolog y (UNIDO-ICAMT ); Paramjit Singh, GM, Institute of Machine Tool Technology; Simarjeet Singh Bains, MLA; Deepak Ballani, National Programme Officer, UNIDO-ICAMT; Rajesh Jain, Sr Manager, National Small Industries Corporation (NSIC); Sukhdial Singh, President, Consortium of Ludhiana Machine Tools Manufacturers (CLMTM); Manjit Singh Matharoo, CEO, Matharoo & Matharoo Inc & General Secretary, CLMTM; and Sandeep Khosla, CEO, Network 18 Publishing.
Boosting industry sentiments While Ludhiana has seen a flurry of enthusiastic entrepreneurs and investments, there are areas that still need attention. Elaborating further, Matharoo added, “Of late, the machine tools industry in Ludhiana is suffering due to lack of exposure and a platform to demonstrate its credentials. However, with an event like the Engineering Expo, I am confident that we will successfully regain our lost ground.” The machine tools fraternity unanimously accepted that there was need for a platform, which can help the region showcase its industrial might. To this, Dhillon averred, “We need to organise similar events frequently in Ludhiana in order to bring our facilities and service providers together and discuss the
requisite improvements for this sector in the region.”
An innovative platform for business possibilities Visitors at the show were amazed by the variety of machinery on display and found the event to be best-in-class to interact with industry players. Amit Takkar, Director, Takkar Industries, exclaimed, “I visited this Expo for the first time and I am pleased with the arrangements. The variety of machinery on display was commendable. An event of this magnitude has taken place in Ludhiana for the first time; the local industry should take full advantage of this opportunity.” Another visitor, Abhishek Handa, Business Development Manager, Radeecal Communications, observed, “The Expo is appealing at first sight. Moreover, the companies exhibiting here are big names from the industry. I am quite satisfied with the overall arrangements at the Expo.” Pankaj Jain, Manager, Rexam Bright Solutions, another visitor, also shared similar sentiments. He stated, “An event of this stature and scale is taking place for the first time in Ludhiana and I am pleased to see the quality of machinery on display. The choice of venue is an important factor for such events and GLADA Ground is a perfect location to attract a large number of visitors. Such events should take place more often in Ludhiana.”
An event to reckon with The exhibition halls saw a large number of visitors of which many expressed their keenness to exhibit in the Expo next year. Also, the exhibitors received considerable enquiries for their machines and were highly optimistic about generating substantial business. Substantiating the same, C S Sidhu, Director – Technical, GR Cranes & Elevators, said, “We have received large number of enquiries at this event and expect most of these to convert into business. We have already sold machines to many customers.”
Highlights of this edition 250 exhibitors pan India Spread over more than
12,000 sqm 26,135 business visitors visited across India Business transacted worth
`195 crore
16,188 business leads generated 20,000+ products displayed from different industries More than 3,50,000 kg machinery moved in for display Another exhibitor, Robin Basant, Managing Partner, Basant Mechanicals, expressed, “The Expo plays a crucial role not only in business development but also in increasing profitability. Engineering Expo is considered to be an ideal platform for companies to foster growth through reach and awareness to their right target audience. Presented by Network 18 Publishing, Engineering Expo proves to be a perfect combination of a vast range of exhibitors, spacious venue, state-of-the-art amenities and humungous visitor turnout, which is crucial for exhibitors.” Didarjit Singh, Proprietor, Karam Chucks, who also exhibited at the Expo, said, “Personally, my expectations from Engineering Expo at Ludhiana were high and this Expo has lived up to my expectations. It has not only given us vast exposure, but also given us the confidence to launch some of our new products so that people who are not able to attend international shows, can find internal quality products in India.” Matharoo aptly concluded, “Engineering Expo is a great platform to showcase the industrial talent residing in smaller towns and cities of India. A place like Ludhiana has the skills to attract international manufacturers to India, and such Expos do a commendable job in assisting this.” Email: anwesh.koley@network18publishing.com
January 2013 | Chemical World
71
BOOK REVIEW
Chemistry of hazardous materials Author: Eugene Meyer Price: ` 5,190
This comprehensive book is designed to introduce basic chemistry concepts to personnel who deal with hazardous materials. It gives real world examples to explain concepts with a practical perspective. It also largely covers technical information and outlines Federal rules and regulations surrounding potentially hazardous materials, such as Occupational Safety & Health Administration (OSHA), Environmental Protection Agency (EPA), Global Harmonisation System (GHS) and Department of Transportation guidelines. Different variables involved in fire, oxidation, chemical leaks and spills and how to chemically clean them up as well as prevent the situation from worsening are detailed in the book. Topics also include chemistry of explosives, radioactive materials, biological agents, and many common organic & inorganic chemicals.
Engineering data on mixing This book comprises an elaborate compilation of the engineering data on mixing. The data on mixing is presented in a systematic manner to assist in design and analysis of agitated tanks, and to provide easier access to mixing data for various engineering activities. The book presents a variety of results for the experimental measurements of flow patterns in stirred tanks. It is useful for the prediction of flow patterns in tanks with different geometries, various types of agitators, and fluids of diverse physical and rheological properties, plus valuable data for the validation of results. Special chapters summarise a number of scale-up relations developed over the years for various systems. These include liquid, solid-liquid, liquid-liquid, gas-liquid, and solid-liquidgas systems. Special inclusion in this book is the chapter, which provides data related to multiphase processes, and most importantly, drop size and drop-size distributions and bubble-size distributions.
Authors: Reiji Mezaki, Masafumi Mochizuki and Kohei Ogawa Price: ` 15,000
Reviewer: Tejas Padte, Lecturer, Department of Chemistry, Ramnarain Ruia College, Mumbai
Available at: Sci-Tech Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai 400 053 Tel: 022-66970507/26735260, Telefax: 022-26735424, Email: scitechbooks@gmail.com
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Chemical World | January 2013
PRODUCTS This section provides information about the national and international products available in the market
Centrifugal PP monoblock pump
take Before taking delivery of any machine, one must help trials of the product for a short time. This will s. ivenes effect and ciency effi ct’s produ the determine
Sharayu Sawant (Director) Shruti Flexipack Pvt Ltd
The PCX M series Polypropylene (PP) monoblock pump is used for handling chemicals, loading and unloading tankers, acid pickling, etc. The casing, impeller and back plate are made of virgin moulded PP. The shaft is covered with high alumina ceramic sleeve and mechanical seal of teflon bellow type with GFT v/s ceramic seal faces. The pump eliminates the problem of pump and motor alignment generally faced in coupled type pumps. It also reduces chances of seal failure and provides long operating life. The pump comes with std. 415 V, 2900 RPM TEFC NFLP motor. The PCX M series pump is available in 1, 2, 3 and 5 HP models with capacity up to 40 m3/hr and maximum head up to 32 m.
Looking For A Specific Product? Searching and sourcing products were never so easy. Just type CW (space) Product Name and send it to 51818
eg. CW Pump and send it to 51818
Taha Pumps & Valves Surendranagar – Gujarat Tel: 02752 – 240233 Mob: 09825599415, 09825829875 Email: tahapv@yahoo.co.in, info@tahapumps.com Website: www.tahapumps.com
January 2013 | Chemical World
75
PRODUCTS
Air operated pump The air operated pump is used for handling viscous liquids (solvents, toxic fluids, oil, grease, etc). It provides hydro-static pressure testing with high pressure up to 500 bars. This is used for high pressure greasing. This does not need electricity as it runs on compressed air. Din-Tech Control Pvt Ltd Ahmedabad - Gujarat Tel: 079-22820008, 22821417 Email: info@dtcpl.in, Website: www.dtcpl.in
Block and pipe covering Block and pipe covering is made from hydrated calcium silicate reinforced with mineral fibres. The material has low thermal conductivity and is not affected by waterwettings. Standard size is 1000 x 500/900 x 600 and thickness is 25, 40, 50, 65, 75, 100 & 125 mm. Hyderabad Industries Ltd Hyderabad - Andhra Pradesh Tel: 040-3099900 Email: ak@hil.in, Website: www.hil.in
Magnetic driven pump The seal-less, magnetic driven pump is offered in centrifugal, peripheral, sliding vane, self-priming, centre-line mounted, inline and vertical pump versions. It is manufactured in metallic and non-metallic constructions. The pump finds applications in oil and gas, chemical, pharmaceutical, industrial refrigeration, offshore platform, electronic and galvanising and nuclear plant areas among others. To safeguard the pump, dry-running protection, temperature monitors on rear casing and ATEX certification are offered as options for many models. The seal-less magnetic driven pump is available in 26 designs with over 350 basic models. The wide range of pumps will help meet customersâ&#x20AC;&#x2122; exact process requirements. Shanbhag & Associates Mumbai â&#x20AC;&#x201C; Maharashtra Tel: 022-28346604, 28340071 Email: info@shanbhags.com, Website: www.shanbhags.com
Pallet washing machine Type PalWash pallet washing system is especially made for cleaning of standard plastic pallets. The system cleans up to 100 pallets per hour and contain a separate pre-wash zone and a final rinse-zone. Soiled pallets to be washed are manually placed on the machines and conveyed by a chain conveyor into the wash chamber. Flow Control Industries Mumbai - Maharashtra Tel: 022-32227296, Mob: 09833889965 Email: ludwig_vaz@rediffmail.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
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Chemical World | January 2013
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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
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: 022-27694586 Email: hafa@vsnl.net
Corrugated tube heat exchanger Ecoflux corrugated tube heat exchanger uses corrugated tubes instead of plain tubes. The tubes are corrugated to induce turbulence in both flows at lower velocities. This not only increases thermal efficiency but also eliminates product channeling. Product fluid channel is surrounded on both sides by the service fluid used for high viscous material. HRS Process Systems Pvt Ltd Pune - Maharashtra Tel: 020-25663581 Email: mktcom@hrsasia.co.in
January 2013 | Chemical World
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PRODUCTS
Automatic amino acid analyser
Pipe bevelling tools
The innovative automatic amino acid analyser AT 2433 combines the advantages of the classical ion exchange separation method with the modern technique of high performance liquid chromatography. The complete package of sophisticated instrumentation, a wide variety of prepacked and tested separation columns, combined with optimised ready-to-use buffer solutions and chemicals, creates the right answer for any routine or research problem in amino acid determination. With old fashioned step-elution systems, four and/ or five buffer solutions were needed. Now, due to the optimised buffer system, only two buffers for hydrolysates and three for the physiological sample are necessary. The buffer can be adjusted individually to the samples by varying the mixture of the buffer. The flexible design of each instrument allows the user to change all important parameters to fit the desired application from protein hydrolysates, physiological fluids to sugar analysis and biogene amines.
Pipe bevelling tools are fully portable for offshore pipelines and onsite use and can bevel at any degree of angle including precision ‘J preps’ for automatic welding. It is designed for long life and ease of use and requires no special operator training, all clamp to the pipe I.D., employ direct-drive bearing supported gears and use the EscoLock blade lock system with interchangeable cutter blades to bevel, face and bore simultaneously. A broad line of portable welding end prep tools for bevelling pipe ranging from 38 mm I.D. to 914 mm O.D. made of hard super alloys, offshore and in fabrication shops, is available with pneumatic, hydraulic and electric motors, depending upon model. They are suitable for bevelling stainless steel, super duplex and P-91 alloys.
Analytical Technologies Ltd Vadodara – Gujarat Tel: 0265 – 2253620 Email: info@hpcltechnologies.com, info@ais-india.com Website: www.analyticalgroup.com, www.hpcltechnologies.com
Hollow fibre ultrafiltration module Q-SEP hollow fibre Ultrafiltration (UF) modules contain UF membranes manufactured with an innovative cloud point precipitation method. This process ensures a high pore density along the length of the fibre and uniform pore size distribution in the membrane. Q-SEP modules deliver superior performance characteristics and product water quality that surpasses the quality from conventional UF modules, with low silt density index (SDI) and excellent rejection of bacteria and viruses. Q-SEP UF modules are made from a hydrophilic polyethersulfone material that provides high fibre strength and excellent low fouling characteristics, resulting in higher productivity. These hollow fibre membranes operate under low transmembrane pressure in an inside-out flow configuration for superior performance. Aquatech Systems Asia Pvt Ltd Pune - Maharashtra Tel: 020 – 66547000/7269 Mob: 09890343114 Email: waghn@aquatech.com Website: www.aquatech.com
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Chemical World | January 2013
ESCO Tool Massachusetts - USA Tel: (508) 429-4441 Email: matt@escotool.com Website: www.escotool.com
Reverse osmosis desalination system The PW series reverse osmosis desalination system is provided with the Aqua Pro 3 or 5-plunger 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. Parker Hannif in India Pvt Ltd Navi Mumbai – Maharashtra Tel: 022-65137081 Email: parkerind@parker.com
Dust filtration system The Dustkiller DK 500 captures fine particulates before they settle down on precision equipment. Dust is sucked by the centrifugal blower through the inlets on the top. Capacity is 500 cm³/hr, input voltage is 230 V ±10 per cent,with low noise and wall mounting with fixtures. Powertech Pollution Controls Pvt Ltd Bengaluru - Karnataka Tel: 080-23452156 Email: powertech@airtelmail.in
PRODUCTS
Facemask respirator The facemask respirator is used for dust filtration. It is convenient to carry in the pocket. The facemask respirator has a durable elastic band, which is soft and safe when it comes in contact with the skin. This mask is easy to wear, comfortable while talking and has breathing resistance. The product finds applications in various industries, such as cable, battery, PVC processing, heavy electrical, power and cement plants, ceramic, silica and glass. It is also used while laying cables, spraying paints, grinding, dusting, soldering and electroplating. Empire Trades Coimbatore - Tamil Nadu Tel: 0422-5377228, Mob: 09894232828 Email: ynajmi@indiatimes.com
Tray dryer This tray dryer is fabricated out of rigid angle iron frame with double walled panels insulated with compressed fibre glass and with a rigid door fitted with strong hinges. A control panel is fixed in front of the dryer to facilitate the operation easily. It has a large working space and is available, from mild steel and in good finishing outside with synthetic enamel colour and inside painted with heat resistant paint to resist temperature up to 300ยบC. A highly effective recalculating air system is provided in the tray dryer. The heated air is recalculated with fresh air in selected proportions for optimum drying. The system is designed so that the materials at the top and the bottom dry simultaneously. Jas Enterprises Ahmedabad - Gujarat Tel: 079-22743454 Email: info@jasenterprise.com
Air classifier This is a screenless machine for grading offline powder into distinct coarse and fine grades from 60 mesh down to 40 microns. The conventional vibrating screens have choking problems along with low capacity when used for fine powder separation. Also separation efficiency is reduced. The air classifier can be operated in closed circuit. Premium Vijimech Pvt Ltd Ahmedabad - Gujarat Tel: 079-40083450 Mob: 09712987467 Email: sales@vijimech.com
January 2013 | Chemical World
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PRODUCTS
Fractional electro-deionisation
are One should scan the market for products, which ed relevant, innovative, and have the latest and updat ts. emen requir ny’s compa the suit that technology
Amarpreet Singh (Sr. Manager – Services) Geo Informatics Consultants Pvt Ltd
With patented dual voltage technology, the Fractional Electro-Deionisation (FEDI) technology is the next generation EDI technology for production of high purity water. Developed taking into account the limitations of conventional EDI, FEDI improves the reliability of EDI for the production of high purity water for power and semiconductor applications. Unlike conventional EDI, FEDI stacks are able to tolerate hardness in the feed water. As a result, FEDI can be used after single pass RO without the need for softening or second pass RO, on most feed waters. FEDI’s dual voltage technology allows for a higher flexibility to inlet water conditions, thus lowering the risk of scaling and improving reliability. Aquatech Systems Asia Pvt Ltd Pune - Maharashtra Tel: 020 – 66547000/7269, Mob: 09890343114 Email: waghn@aquatech.com Website: www.aquatech.com
Hand tool Hand tool is used for operating on innumerable nuts/bolts and pipes. The tool is time-saving, user-friendly and can replace heaps of conventional tools. It has two spanners, which cover a size a/f 6 mm to 41 mm and can operate on more than 100 sizes of nuts/bolts. In the same way, the pipe wrenches can operate on various pipe sizes up to 2 inches (ø 60mm). All these tools are designed to operate in a slip-free manner. The tools are protected by Intellectual Property Rights. Solsons Exports Pvt Ltd Ahmedabad - Gujarat Tel: 09925152422 Email: solsons@solsons.com Website: www.solsons.com
Cage mill flash dryer This system has capacity that ranges from 10 kg/hr to 5,000 kg/hr. Due to low residence time in the range of 0.5 to 2 seconds in the flash dryers, heat-sensitive products can be easily dried without degradation. The cage mill flash dryers are compact, requiring less maintenance and user-friendly. Raj Process Equipments & Systems (P) Ltd Pune - Maharashtra Tel: 020-4071001, Mob: 09766441144 Email: sales@rajprocessequipment.com
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Centrifugal pump The pump has all contact parts, including casing and impellers, of corrosion-resistant silica epoxy construction. It is fitted with externally-mounted Teflon bellow-ceramic mechanical seals. Impeller shaft is cast integral with shaft and hence there is no chance of joint getting corroded. Heavy bearings are provided on the drive shaft. Resicast Mumbai - Maharashtra Tel: 022-26501971, Mob: 09820883985 Email: kfresi@rediffmail.com
Hybrid stepping motor The PJPL series linear-type hybrid stepping motors enable linear motion of motor shaft with a combination of threaded shaft and inner threaded rotor. The motors do not require any outside mechanical parts, such as lead screw, wire or belt for linear motion. These motors are available in two sizes: 28 mm² and 42 mm². Nippon Pulse Motor Co Ltd Tokyo - Japan Tel: +81-3-38138841 Email: s-hagimoto@npm.co.jp 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
Sl. No.
Product
Pg. No.
Acoustic enclosure ............................... FIC Agitator .................................................... BIC Air classifier................................................. 81 Air operated pump ...................................... 76 Allen CAP .................................................. 55 Allen CSK ................................................... 55 Alumacoat ..................................................... 3 Aluminium extrusion .................................. 57 Amino acid analyser .................................... 86 Anaesthetic rotameter ................................. 81 Analytical instrumentation .........................BC Atomic absorption spectrophotometer........ 86 Automatic amino acid analyser ................... 80 Automatic and contained discharge ............ 31 Ball valve .......................................... 13, 75 Basket centrifuge ......................................... 49 Bellow and dip-pipe ...................................... 4 Bend ............................................................ 75 Biospec-nano ............................................... 47 Block and pipe covering .............................. 76 Blower ......................................................... 45 Butterfly valve ....................................... 13, 75 Cage mill flash dryer ............................... 82 Cake pressing .............................................. 31 Centrifugal fan ............................................ 37 Centrifugal PP monoblock pump ............... 75 Centrifugal pump ........................................ 82 Ceramic adhesive cement .............................. 3 Check valve ................................................. 13 Chemical and pharmaceuticals.................... 76 Chemical pump ........................................... 79 Column and chemistries ............................BC Continuous or batch filtration .................... 31 Corrugated tube heat exchanger ................. 79 Decanter................................................. 49 Diaphragm valve ......................................... 75 Digital magnahelic gauge ............................ 76 Disc-bowl type centrifugal separator .......... 49 Dry vacuum pump ...................................... 81 Dry van pump ...........................................FIC Duralox.......................................................... 3 Dust filtration system.................................. 80 Electric chain hoist ................................. 79 Empower ....................................................BC Energy solution ........................................... 63 Engineering design ..................................... 63 Evaporator .......................................... BIC, 33 Exhauster..................................................... 45 Exhibition - Engineering Expo .................. 59 Facemask respirator ................................ 81 Fastener ....................................................... 55 Ferrous casting ............................................ 57 Filter cock ................................................... 75 Flow indicator ............................................. 75 Fluid .............................................................. 8 Foot valve .................................................... 75 Forged component ...................................... 57 Forged steel valve ........................................ 13 Fractional electro-deionisation .................... 82 FRP piping.................................................. 73 Fully threaded bar ....................................... 55 Gas chromatograph................................. 86
Sl. No.
Product
Pg. No.
Gate valve .................................................... 13 Gear .............................................................. 8 Gear box ........................................................ 8 Gear motor .................................................... 8 Geared and flexible coupling ........................ 8 Globe valve .................................................. 13 H.R.C fuse bodies.....................................3 Hand tool .................................................... 82 Hastelloy ..................................................... 13 Heat exchanger ........................................ BIC Heat transfer equipment ............................. 37 Hex bolt ...................................................... 55 High pressure blower .................................. 37 Hollow fibre ultrafiltration module ............ 80 HPCL production....................................... 86 HPLC ........................................................BC Hybrid stepping motor ............................... 82 Impeller.................................................. 75 Industrial machinery plants and equipment 76 Industrial pump ........................................... 53 Industrial valve ............................................ 57 Informatic ...................................................BC Innovasia 2013 ............................................ 83 Kamlok and drylok coupling.................... 53 Large diameter welded pipe ..................... 79 Laser particle size analyser .......................... 86 Lined valve .................................................. 13 Lined valve and pipe fitting .......................... 4 Loading arm ................................................ 53 Long neck pipe end .................................... 75 Machined component ............................. 57 Magnetic driven pump ................................ 76 Mechanical vacuum booster ........................ 45 Mixing and drying ...................................... 33 Monoblock high vacuum pump .................. 81 Monoblock pump ........................................ 79 Multi-stage cake washing ........................... 31 Nickle aluminium bronze ........................ 13 Non-ferrous casting..................................... 57 Non-metallic pump ..................................... 79 Non-return valve ..................................... 4, 75 Nozzle ......................................................... 53 Nuts ............................................................ 55 Oil seal high vacuum pump ..................... 81 Pallet washing machine ........................... 76 Pipe bevelling tools ..................................... 80 Pipe fitting end cap ..................................... 75 Piping system from polypropylene ................ 6 Plug valve .................................................... 13 Pole ring ...................................................... 75 Pollution control equipment .................... BIC Polypropylene process pump ....................... 79 Pressure and vacuum filtration.................... 31 Process gas blower....................................... 37 Product assemblies ...................................... 57 PTFE lined valve and pipe fitting ................ 4 Pump ............................................ 79, 81, FIC Pump for chemical equipment .................... 11 Pumping solution ........................................ 19 PVDF pump ............................................... 79 Receptacle .............................................. 53 Re-crystallised alumina tubes ........................ 3
Sl. No.
Product
Pg. No.
Reducer ....................................................... 75 Reverse osmosis desalination system........... 80 Roots blower .............................................FIC Roots vacuum pump ................................... 81 Rotameter .................................................... 81 Rotary dry vacuum pump............................ 37 Rotary gear pump........................................ 79 Rotary pump ............................................... 81 Scoop ..................................................... 75 Seamless pipe .............................................. 79 Self-priming mud pump ............................. 79 Self-priming sewage pump ......................... 79 Self tapping and machine screw ................. 55 Showel ......................................................... 75 Sight flow meter.......................................... 53 Silence flow package ................................... 37 Single-stage monoblock vacuum pump ...... 81 Single-stage vacuum pump ......................... 81 Slip-on flange .............................................. 75 Spade ........................................................... 75 Spiral cum helical gear box ........................... 8 Spray dryer ............................................... BIC Stainless steel pipe....................................... 79 Stainless steel and fastener .......................... 55 Steatite........................................................... 3 Strainer .......................................................... 4 Summit 2013............................................... 74 Super centrifuge .......................................... 49 Super duplex................................................ 13 Swivels ......................................................... 53 Tee ....................................................... 75 Teflon lined ball valve ................................... 4 Teflon lined butterfly valve ........................... 4 Teflon lined check valve ............................... 4 Teflon lined sampling valve .......................... 4 Teflon lined valve and pipe fitting ............... 4 Tefzel HHS isotactic PP material ................ 6 Thermoplastic valve ...................................... 6 Titanium ..................................................... 13 Tray dryer.................................................... 81 Tri-lobe roots blower .................................. 45 Truck blower ............................................... 37 Tube ............................................................ 79 Turned component...................................... 57 Twin lobe roots blower ............................... 45 Two-stage vacuum pump ............................ 81 ‘U’ tube ................................................... 79 UPLC .........................................................BC Vacuum booster pump ......................... FIC Vacuum or hot gas drying........................... 31 Vacuum pump ............................................. 81 Vacuum system .........................................FIC Valve ............................................................ 75 Variable area flowmeter .............................. 81 Vertical glandless pump .............................. 79 Washer ................................................... 75 Wastewater treatment system ..................... 79 Water faucet and tap parts............................ 3 Welded pipe ................................................ 79 Worm gear .................................................... 8 ‘Y’ type strainer ....................................... 75 Zirconox ...................................................3 Zircosil .......................................................... 3
BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover
Looking For A Specific Product? Searching and sourcing products were never so easy. Just type CW (space) Product Name and send it to 51818
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Chemical al W World | January 2013
LIST OF ADVERTISERS
Advertiser’s Name & Contact Details
Pg No
Acme Air Equipment Co Pvt Ltd
45
Advertiser’s Name & Contact Details
Fluid Energy Controls Inc
T: +91-79-25831985
T: +91-44-42083536
E: info@airequipments.com
E: sales@fecindia.com
W: www.airequipments.com
W: www.fecindia.com
Analytical Technologies Limited
86
T: +91-120-4236204
E: info@ais-india.com
E: info@foodpharma.in
W: www.ais-india.com
W: www.foodpharma.in 76
T: +91-2827-287658
E: sales@megamachineryindia.com
E: valve@gmengg.com
W: www.megamachineryindia.com
W: www.gmengg.com
31
33
G M Engineering
T: +91-2646-250025
BHS-Sonthofen (India) Pvt. Ltd.
53
Food & Pharma Specialities
T: +91-265-2253620
Anup Engineering
Pg No
13
Global Innovation Centre
T: +91-40-23315341 / 45
E: partners@innovasia.in
E: info@bhs-sonthofen.in
W: www.innovasia.in
73
Heattrans Equipments Pvt. Ltd.
T: +91-22-67230600
T: +91-79-25840105
E: salescbg@cppiping.com
E: info@heattrans.com
W: www.cppiping.com
W: www.heattrans.com
CM Flowmeters India Pvt Ltd
81
Hi-Tech Applicator
T: +91-33-24421456
T: +91-79-25833040
E: cmflowmeters@vsnl.net
E: hitech@ptfeindia.com
W: www.cmflowmeters.com
W: www.ptfeindia.com
Dev Engineers
79
E: info@devpumps.com
E: joyam@joyamvactech.com
W: www.devpumps.com
W: www.joyamvactech.com
Elecon Engineering Company Ltd
8
Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120
E: infogear@elecon.com
E: info@jyoticeramics.com
W: www.elecon.com
W: www.jyoticeramics.com
Engineering Expo
59
Parth Poly Valves Pvt. Ltd
19
57
Suraj Limited T: +91-79-27540720 E: suraj@surajgroup.com W: www.surajgroup.com
79
75
T: +91-09819552270
T: +91-79-22200198
E: engexpo@infomedia18.in
E: sales@parthvalves.com
W: www.engg-expo.com
W: www.parthvalves.com
Everest Blowers
FIC
Pentair Water India Pvt Ltd
11
T: +91-120-4199444
E: info@everestblowers.com
E: marketing.india@pentair.com
W: www.everestblowers.com
W: www.pentair.com Our consistent advertisers
Swam Pneumatics Pvt Ltd 37 T: +91-120-4696222 E: swamatic@airtelmail.com W: www.swamatics.com Toshvin Analytical Pvt Ltd T: +91-22-23015096 E: info@toshvin.com W: www.toshvin.com UNP Polyvalves India Pvt Ltd T: +91-265-2649248 E: mktg@polyvalve.com W: www.polyvalve.com
47
6
Waters (India) Private Limited BC T: +91-80-28371900 E: waters_india@waters.com W: www.waters.com
T: +91-11-45457777
Not applicable
Raj Process Eqpts & Systems(P) Ltd BIC T: +91-20-40710010 E: sales@rajprocessequipment.com W: www.rajprocessequipment.com
Shanbhag And Associates T: +91-22-28346604 E: info@shanbhags.com W: www.shanbhags.com
3
T: +91-2692-236469
Raajratna Ventures Ltd 55 T: +91-79-27561915 E: domestic@raajfasteners.com W: www.raajfasteners.com
83
Joyam Engineers & Consultants Pvt Ltd 81 T: +91-79-26569533
63
49
4
T: +91-79-26403839
Perennial Technologies Pvt Ltd T: +91-20-22953511 E: sales@perennial.co.in W: www.powerrental.co.in
Pg No
Real Centrifuges Asia Private Limit T: +91-20-24338642 E: centrifuge@vsnl.net
W: www.bhs-sonthofen.in Chemical Process Piping Pvt Ltd.
Advertiser’s Name & Contact Details
Y J Trivedi & Co T: +91-79-26308601 E: ama@amaindia.org W: www.amaindia.org
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BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover January 2013 | Chemical World
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