Chemical World - May 2012 by Infomedia18

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INDUSTRY WATCH - Chemical World

May 2012

EDITORIAL

Raising the competitive quotient elcome to the 8th Anniversary Edition of Chemical World! d As we raise a toast on this special occasion, it is time to thank our internal and external stakeholders who have made this journey so meaningful! Amid this, it is important to take note of the growing focus on the chemical sector in India. While many challenges remain â&#x20AC;&#x201C; ranging from price and availability of feedstock, regulatory reforms (both domestic and global), infrastructure development, et all â&#x20AC;&#x201C; to be surmounted, many of these have tremendous potential to lead the subcontinent into a golden era of infinite opportunities.

In fact, the present phase could be an inflection point in the annals of Indian chemical industry. As the global chemical industry gears up to double its size in the next 20 years and international companies strengthen their position in India through local production/ sales offices, some of the key demand drivers for base as well as specialty chemicals are being fuelled by the improving income distribution as well as growing rowing breadth and depth of the application areas in the country. Despite this optimistic projection, the big question facing Indiia today is regarding the way forward and in particular the competitiveness quotient. Hence, it will be prudent to strategise for the mid- and longg-term scenario well in advance, given the steady rise of Indian economyy and the multilateral implications thereof in the coming years. In order to ensure outstanding product, price and delivery, the need of the hoour is an integrated forward-looking chemical policy with the right mix of external regulation and professional self-regulation. This unique edition delves deeper into the above and moree such emerging avenues. Turn to Anniversary Speciall section n (with eight sub-sections and each representing a crucial facet of the chemical industry) to discern what an array of experts has to opine, not just on the latest trends and technologies but also on the future prospects and pitfalls. Team Chemical Worldd salutes the efforts extraordinaire of these achievers, which go far beyond the call of duty.

Editorial Advisory Board Pothen Paul Former Chairman, Aker Powergas Pvt Ltd

We believe that you will benefit from exploring this special edition as much as we enjoyed chronicling these highly informative pieces of actionable knowledge and much more. Have a good read d and do let us know your valuable feedback. Cheers!

D P Misra Director, TCE Consulting Engineers Ltd and Former Director General, ICC

P D Samudra Executive Director (Sales) & Member of the Board, Uhde India Pvt Ltd

Manas R Bastia manas@infomedia18.in

May 2012 | Chemical World

Guest Editorial

CONTENTS

“As an industry, we need to prioritise our sensitivity towards sustainability”

R Mukundan Managing Director, Tata Chemicals Ltd .................................. 10

“The chemicals industry needs to be recognised as a growth driver for the Indian economy”

Dr Joerg Strassburger MD & Country Representative, LANXESS India Pvt Ltd ..... 11

“India has the potential to become the location of choice for MNCs planning their investments in Asia”

Vinayak Pai Director – Operations, Aker Powergas Pvt Ltd ........................ 12

Cover visual: Mahendra Varpe

ANNIVERSARY SPECIAL

Feedstock .......................................................... 30 Research & Development ................................. 38

In Conversation With Safety, Health & Environment ............................ 44 “The government plans to increase R&D expenditure to 2% of GDP by the end of 12th Plan”

Human Resources.............................................. 52 Water Management ........................................... 60

K Jose Cyriac, IAS Secretary (Chemicals & Petrochemicals), Government of Indiaa ................................................................ 24

Regular Sections Editoriall ........................................................................ 5 News, Views & Analysis .............................................. 14 Technology & Innovation............................................ 20 Technology Transferr .................................................... 22 Event Listt .................................................................... 94 Book Review................................................................ w 96 Products ...................................................................... 98 List of Products ........................................................ 113 List of Advertisers .................................................... 115

Highlights of Next Edition Special Focus: Engineering, Procurement & Construction Insight & Outlook: Pollution Control

Policies & Regulations ....................................... 66 End-user Industries............................................ 74 Global Market .................................................... 84 Tips & Tricks Handling colourless gas: Safety tips for transporting spo ethylene .......................................................... 93

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

Note: ` stands for Indian rupee, e, $ stands s for US dollar and £ stands for UK pound, unless mentioned otherwise May 2012 | Chemical World

Business Insights Technologies Opportunities

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May 2012 | Chemical World

GUEST EDITORIAL R Mukundan

R Mukundan Managing Director, Tata Chemicals Ltd

As an industry, we need to prioritise our sensitivity towards sustainability

Chemical World | May 2012

ver the years, the chemicals industry has evolved from being a basic chemicals producing industry to one that offers innovative solutions. With increased investments in R&D, it is witnessing a significant growth in the knowledge chemicals sector, including the field of specialty chemicals. Approximately 13 per cent of total exports revenue is contributed by the chemicals industry, with a growth of 10-12 per cent per annum. The government is committed to the growth of this sector and has introduced many initiatives to build world-class infrastructure for this purpose. There has been the introduction of SEZs for the chemicals industry in a Public-Private Partnership (PPP) model, which will have common effluent treatment facilities and single-window clearance for new projects. As an industry, we need to prioritise our sensitivity towards sustainability. While larger organisations have taken concrete steps in this direction by making sustainability a part of their overall business strategy, SMEs too need to consider environment as an important stakeholder and build their business models based on aspects of sustainability. Consolidation of the highly fragmented chemicals industry will bring in a focus on sustainability. Policies and appropriate framework need to be introduced to aid players from the unorganised sector to consolidate in the larger organised sector. Government support in building specialised infrastructure for the chemicals industry like chemical transportation corridors, dedicated chemicals parks and clusters with the utility and waste management infrastructure will play an important role, going forward. This will enable economies of scale and linkages to markets & suppliers, bringing in overall cost-competitiveness for the sector. Dedicated Petroleum, Chemicals and Petrochemical Investment Regions (PCPIRs) were announced by the government recently. A speedy execution process and uniform policy deployment across the states would be critical differentiators for the sector to compete globally. Together with encouraging policies and framework, developing appropriate talent pool is another challenge, which all the stakeholders including the government will have to focus upon. It is also important to create a positive imagery for all the stakeholders to make it the most soughtafter sector. Publications like Chemical Worldd will play a prime role in creating the above favourable imagery for the industry and educate all stakeholders on current happenings in the sector.

GUEST EDITORIAL Dr Joerg Strassburger

n the backdrop of growth shifting from Western markets to the Asia-Pacific region, and India witnessing a surge in consumer-driven industries like construction, automotive, tyre, paints & coatings and agrochemicals to name a few, the country has the potential to build $ 80-100 billion worth specialty chemicals industry by 2020. Some of the key global megatrends that will drive the growth of the specialty chemicals industry are mobility, urbanisation and water availability. According to the International Organisation of Motor Vehicle Manufacturers, India was the sixth-largest vehicle maker in 2011. When it comes to urbanisation, India witnessed population growth rate of 17.64 per cent in the last decade. According to the â&#x20AC;&#x2DC;Water in India 2011â&#x20AC;&#x2122; report by India Infrastructure Research, the total demand for water requirement is expected to increase to about 813 billion cubic metre (bcm) by 2025. All these put pressure on the existing resources and create demand for new innovative materials and technologies that can provide a more sustainable solution for tomorrow. Specialty chemicals, in fact, offer solutions for challenges posed by these megatrends. India holds a lot of promise for the chemicals industry but not without some corrections that are imperative for its sustained growth. The challenges lie in the areas of infrastructure, manpower and support from the administration. The availability of continuous power supply and natural gas, access to common sewage and effluent treatment plants from the sites, good connectivity to major industrial clusters by highways, ports and airports are some of the quintessential infrastructure requirements that the industry currently needs to look at. On the raw materials front, higher cost and nonavailability of feedstock is often a handicap for scaling up operations. Since there are few sustainable chemical parks in India, availability of land is scarce for companies to set up plants. The potential of the Indian chemicals industry can be leveraged if the concerns are addressed. There is a projected increase of another 70 million middle-class households propelling the end-user industries. The chemicals industry needs to be recognised as a growth driver for the Indian economy by the policy makers, and decision-makers. On that premise, it also needs to draw the necessary support from the administration. This is where chemical publications can play a pivotal role in projecting the good work being done by different players in India, highlighting their issues and bringing forth the innovative solutions that the industry recommends.

Dr Joerg Strassburger Managing Director and Country Representative, LANXESS India Pvt Ltd

The chemicals industry needs to be recognised as a growth driver for the Indian economy

May 2012 | Chemical World

GUEST EDITORIAL Vinayak Pai

Vinayak Pai Director â&#x20AC;&#x201C; Operations, Aker Powergas Pvt Ltd, and Member, Board of Directors, Process Plant & Machinery Association of India

India has the potential to become the location of choice for MNCs planning their investments in Asia

Chemical World | May 2012

he chemicals industry in India is highly dynamic, and has high potential to be one of the pillars of the nationâ&#x20AC;&#x2122;s growth in the coming years. India has the potential to become the location of choice for multinational chemical manufacturers planning their investments in Asia. However, the downturn in the global economic sentiments and lack of clear government policy are some of the hurdles that need to be overcome. Our biggest priority is for investments to take place in this sector. The monetary policy of Reserve Bank of India to reduce the interest rates, thereby making reasonably priced debts available to the industry, will drive investments. Another imperative is to ensure that investments are large enough to take advantage of economies of scale. India is also a largely consumption-driven economy and if the domestic industry is given adequate policy backing, the larger and world-scale manufacturing facilities will become viable in India. However, the chemicals industry has to follow basic guiding principles, which will create a positive impression and strongly emphasise on safety & environmental aspects while designing plants. It is also imperative to invest in designing plants, which will deliver sustained quality products over a longer period of time. The other crucial point is to maximise the utilisation of the local capital goods industry. Though the Indian capital goods industry has to mature before it can become a partner of choice for the chemicals industry, there should be a sustained dialogue between the chemicals and capital goods industries to have a long-term plan for import substitution. This is precisely where the industry associations like Process Plant & Machinery Association of India (PPMAI) have to create an impact. It has to play the role of a facilitator to bridge the gap between the two industries. Forums where both the industries can get together and discuss openly the challenges each is facing will go a long way in addressing this issue. Business publications like Chemical Worldd also have an important role to play in this regard. Chemical industry, capital goods sector, EPC companies, industry associations and publications have a major role to play in driving the economic growth of the country. Having been part of this industry for the last 25 years, I am happy that things are moving in the right direction, and sustained efforts will further enhance the chances of Indian chemicals industry in being a world leader in the future.

NEWS, VIEWS & ANALYSIS

MARKET FORECAST EPC PROJECT

Methanol demand in India to pick up

Zuari Holdings selects Uhde India for NPK plant revamp

The demand for methanol in India is likely to witness high growth in near future as a result of booming end-user industries especially pharmaceuticals, automotives, paints & coatings, etc, according to experts. “Methanol in India, which accounts for around 2 per cent of the total Asian market, has been witnessing a strong demand from intermediate chemicals coupled with pharmaceutical and fuel sector. After China, India is currently the major methanol market in Asia,” said Mohan Krishna, Chemicals Analyst, GBI Research. According to a new report, Methanol Global Market to 2020, by GBI Research, China and the Middle East will benefit in the coming years from the burgeoning methanol market, potentially gaining gigantic revenue, thanks to the chemical’s multiple uses. Krishna added, “Growth in chemical intermediates is driving methanol demand in China, which constitutes almost 90 per cent of the Asia’s production. Automotive applications account for a major part of the methanol demand in the region. Similarly, availability of relatively

Zuari Holdings has selected Uhde India to render engineering services for the capacity augmentation revamp of their NPK-A plant in Goa. The scope of the contract includes detailed engineering, procurement, inspection and expediting, project management & planning, construction supervision and commissioning assistance services. The project is due for completion in the second half of 2013. Zuari Holdings (ZH), a company belonging to the Adventz group, operates a fertiliser unit consisting of ammonia, urea & complex fertiliser plants in Goa. ZH will deploy the Incro’s pipe reactor technology for the slurry granulation process, with which Uhde India has been associated for a number of projects involving leading fertiliser majors in India and abroad. In another development, ThyssenKrupp Uhde and the Mongolian Government reached an agreement on coal-to-liquids plant and heat recovery coke making plant in Mongolia. ThyssenKrupp Uhde and the representatives of the Mongolian Government signed two MoUs relating to the development, engineering and construction of both a coal-to-liquids plant and a heat recovery coke making plant.

cheap feedstock and motivation from Middle Eastern governments to branch out their oil-based economies to downstream derivative businesses and end-user sectors are likely to drive methanol consumption in the region.” Global methanol demand is expected to rise to 122.6 million tonne (MT) by 2020 from approximately 44.9 MT in 2010. A significant proportion of demand for methanol stems from the Asia-Pacific region, which accounted for 64 per cent of global methanol demand during 2010 and is expected to maintain this dominance in the future. While China will lead the methanol market in the immediate future, consumption is also rising in India. “According to GBI, we are expecting a healthy growth in Indian methanol market. But as the marketshare was relatively low when compared to China, methanol demand in India will play a significant part but not very critical in the Asia-Pacific region context,” commented Krishna. Rakesh Rao

POLYMERS

Sumitomo Chemical ties up with J P Plaschem for PMMA Sumitomo Chemical, Singapore, one of the leading players in the Indian polymethyl methacrylate (PMMA) market, has aligned with J P Plaschem Ltd to further consolidate its position in the country. The collaboration will provide a significant value-addition to the business of Sumipex PMMA, the acrylic resin from Sumitomo. Being the international marketing and sourcing division of J P Group, J P Plaschem represents reputed multinationals for promoting, marketing and distribution of various engineering polymers and sheets in India, Middle East, Russia, Europe etc.

ECO-FRIENDLY MANUFACTURING

OMNOVA India achieves ISO 14001:2004 certification OMNOVA India Pvt Ltd, manufacturer and supplier of synthetic rubbers and latices, has achieved ISO 14001:2004 certification from SGS UK Systems and Services Certification. The certification is applicable till February 22, 2015. It outlines that company production facility in Valia, Gujarat, has implemented and maintained an environmental protection management system. “Environment is a key performance focus of OMNOVA Solutions. Obtaining ISO 14001-2004 certification for our Valia plant is a great achievement and

Chemical World | May 2012

the result of our efforts to share the same worldwide corporate vision on environmental management,” stated Olivier Faussadier, Vice President & General Manager, OMNOVA Performance Chemicals - Europe, Middle East, Africa and India. He added, “By improving and monitoring our environmental performance, we demonstrate altogether: our corporate responsibility to attain a safe and healthy workplace, our contribution to safeguard the environment, and our commitment to customer satisfaction.”

Olivier Faussadier

NEWS, VIEWS & ANALYSIS

SUSTAINABILIT Y WATER TREATMENT CHEMICALS

Tata Chemicals retains Responsible Care® certification

LANXESS showcases latest water treatment solutions at Aquatech

Tata Chemicals Ltd (TCL) has retained to demonstrate their commitments to the highly recognised Responsible improve all aspects of performance, Care® certification from April 2012 to which relate to protection of health, March 2015, thus becoming one of the safety and environment. R Mukundan, first Indian companies Managing Director, to retain the Responsible TCL, commented, “Tata Care® certification for the Chemicals is committed second time in a row. This to highest standards of certification is given after a corporate citizenship and we comprehensive assessment continuously strive to achieve by the overseas assessors the highest performance standards in the areas of and permits TCL to use the Responsible Care® sustainability, safety, service logo until March 2015 and quality. The Responsible R Mukundan Care® certification for the and places the company in the list of the Indian Chemical Council’s second time in a row is a prized testimony (ICC) accreditation for manufacturing and of our efforts towards these values.” The International Council of distribution operations in India. Chemical Associations has established a Responsible Care®, which started in Canada in 1984 is a global voluntary framework for chemical manufacturing initiative, is practised today by high companies to adopt global Responsible performance chemical companies in 53 Care® core principles. Mahua Roy countries worldwide.This calls on companies

LANXESS showcased Lewatitt and Lewabrane product range at the recently held Aquatech India 2012 in New Delhi. These products, which are meant for water and wastewater treatment, are used in applications such as removal of fluoride & trace impurities; softening of water using ion exchange resins; ultra pure water purification; organic scavenging; removal of precious metals from wastewater; etc. “Aquatech offers us a good platform for demonstrating our expertise as a single-source supplier of ion exchange resins and RO membrane technology for this market,” said Jean-Marc Vesselle, Head - Ion Exchange Resins Business Unit, LANXESS AG.

LUBRICANTS

PERSONAL CARE MARKET

ExxonMobil exhibits lubricant portfolio at POWER-GEN

Dow Corning offers solution for haircare needs

ExxonMobil Lubricants Pvt Ltd showcased its comprehensive line of high-performance turbine oils and next generation of Mobil SHC-branded synthetic industrial lubricants at the 2012 POWER-GEN India & Central Asia Exhibition and Conference held in New Delhi. “ExxonMobil’s family of premium oils and maintenance solutions enable successful companies within the energ y sector to boost their productivity, reduce their energy consumption and increase profitability,” said Rupinder Paintal, General Manager - Industrial, ExxonMobil Lubricants & Specialties Company. ExxonMobil lubricants are expertly formulated to help reduce maintenance costs, extend oil drain intervals and deliver exceptional protection for key components, even under the extreme weather and load conditions common in many power-generating applications.

To meet the growing demand for haircare solutions that address individual haircare challenges, the XIAMETER brand from Dow Corning has expanded its range of silicone-based, performance-enhancing haircare materials with the introduction of XIAMETER PMX-1502 fluid. “Young or old, and anywhere in the world, consumers equate healthy-looking hair with general well-being. The challenge we are trying to address is meeting the increasing individual needs based on specific hair type, condition and desired style,” said Kevin Murphy, Global Market Manager, XIAMETER brand.

VALVE BUSINESS

UNP Polyvalves’ new unit to be operational soon In order to meet the growing demand within next three months. With this, we for corrosion-free valves, pipes and aim to increase our production capacity. pipe fittings manufactured Further, keeping in mind in advanced engineering the space constraints, the plastics, ie fluoropolymers manufacturing facility would & thermoplastic, UNP be divided into three floors, ie Polyvalves has set up another ground plus two floors.” manufacturing facility in The company has been Vadodara, Gujarat. Urmil providing solutions to almost Shah, Director, UNP every leading chemical and Urmil Shah Polyvalves (India) Pvt Ltd, petrochemical giant in India said, “We already have two plants in and is also exporting to other countries. It Makarpura GIDC and this would be has a wide product range in valves. the third plant, which will be operational Avani Jain

May 2012 | Chemical World

NEWS, VIEWS & ANALYSIS

ANALY TICAL TECHNOLOGY

Agilent introduces two products in India

RECOGNITION

Agilent Technologies Inc recently launched 4100 Microwave Plasma-Atomic Emission Spectrometerr (MP-AES) and 8800 ICP Triple Quadrupolee (ICP_QQQ) products in the Indian market. These products are in the field of elemental analysis. The 4100 MP-AES instrument requires no external cylinder or gas supplies, thus making it the first-of-its-kind elemental analyser that runs on air. Ideal for any elemental laboratory analysis, especially remote sites and mobile laboratory, MP-AES will cater to the needs of industries like petrochemicals, metals and mining etc. “We are launching the product in the Indian market because there is a need for such product,” said Dr P Siva Kumar, Country Manager, India, Life Sciences and Chemical Analysis, Agilent Technologies India Pvt Ltd.

Sustainable Biofuel Technology by Honeywell wins Award

The other product, 8800 ICP-QQQ, offers improved performance compared to single quadrupole ICP-MS, like consistent interference removal in reaction mode. ICP-QQQ also addresses high-end application requirements, with flexible analysis capabilities unavailable on single quadrupole machines. Dr Kumar said “The 4100 MP-AES will revolutionise the atomic spectroscopy market and give customers an alternative and more advanced technique. The 8800 ICP-QQQ Q will extend the boundaries in elemental analysis providing customers maximum flexibility in a range of novel reaction modes, delivering effective and consistent interference removal for problematic elements in difficult samples and high-end research.” Prasenjit Chakraborty

EPOXY SYSTEMS

Dow Formulated launches VORAFORCE TW W series Dow Formulated Systems, a business unit of The Dow Chemical Company, has launched DOW VORAFORCE TW W series of epoxy systems for fabricating composite pressure vessels for Compressed Natural Gas (CNG) and Liquefied Petroleum Gas (LPG). In combination with the DOW eCURE E modeling suite, the new systems help fabricators to optimise their processing so they can reduce energy consumption and waste while speeding up cycle times. The new systems enable the production of light-weight and durable composite cylinders with improved impact resistance, dynamic fatigue and low-temperature performance. Composite pressure vessels are also an attractive option powered by natural gas. Composite pressure vessels help reduce the weight of the vehicle and fuel tank, thereby reducing emissions and enabling better mileage. Adoption of vehicles powered by natural gas fuel by commercial fleets is paving the way for the broader use of these fuels in passenger vehicles as fuelling infrastructure is put in place in Europe, Asia-Pacific, North America and Latin America.

Envergent Technologies LLC, a Honeywell company, has recently been awarded a Sustainable Biofuels Award for its contributions toward sustainable biopower generation facilities. The award was presented in the category of Sustainable Biopower Generation Facility at the World Biofuels Markets, a leading event for the biofuels industry. The Rapid Thermal Processing (RTP) technology converts biomass into a clean-burning, nearly carbonneutral liquid biofuel that can be burned to generate heat or electricity, or further upgraded to other fuels. RTP technology works by rapidly heating biomass at ambient pressure to generate high yields of a liquid biofuel. It has been used in a number of projects worldwide using a variety of wood biomass sources for the generation of heat and power in regions such as Europe, Asia and North America. “As the demand for renewable fuels increases, Envergent is committed to innovation using sustainable resources and bringing relevant technology to the marketplace that will help reduce our dependence on fossil fuels and improve our environmental footprint,” said Dave Cepla, Managing Director, Envergent Technologies LLC. Mahua Roy

PROCESS INNOVATION

Krones to focus on valve and water treatment technologies at ACHEMA

Krones AG will showcase EvoGuard range of valves, plus its Hydroclassicc water treatment system, at ACHEMA 2012 –

Chemical World | May 2012

one of the leading global exhibitions for chemical engineering, environmental protection and biotechnology - to be held from June 18-22, at Frankfurt, Germany. EvoGuardd is a high-performance series of valves, manufactured in-house at Krones AG, which has already been successfully premiered in the beverage industry. It is also an attractive option for the chemical, pharmaceutical and biotech industries. At the ACHEMA, Krones AG will be exhibiting its entire series of valves: disk

valves and single-set valves for simple shutoff of pipes, double-seal valves as an affordable alternative for use in separating hostile media, plus double-seat valves for highly automated process sequences. The Hydroclassic RO O (Reverse Osmosis) water treatment system is a prefabricated unit that utilises membrane technology on the reverse osmosis principle. The aim now is to persuade customers in the chemical industry of the advantages offered by Krones’ Hydroclassic.

NEWS, VIEWS & ANALYSIS

PHOTOVOLTAICS E&P PROJECT

WACKER’s polysilicon facilities at Nünchritz come on stream

Aker Solutions to design world’s largest Spar platform

The Munich-based Wacker Chemie AG has officially inaugurated its new hyperpure polysilicon production facilities at its Nünchritz site in Germany. Overall, WACKER has invested some Euro 900 million in the facilities. Initial production began at the facilities in fall last year, and the startup phase is now virtually complete. The Polysilicon deposition at the Nünchritz site plant is expected to reach its full nominal capacity of some 15,000 metric tonne per year within the next few weeks. All in all, WACKER is ramping up its total capacity for polysilicon to around 52,000 metric tonne by the end of 2012, making it one of the largest producers worldwide. With the new polysilicon site currently under construction in Charleston (Tennessee, USA), WACKER’s total annual production capacity will rise to around 70,000 metric tonne by 2014, strengthening its position as a leading producer of high-quality semiconductor- and solar-grade silicon.

Aker Solutions has been awarded a Front-end Engineering and Design (FEED) contract from Statoil to design the world’s largest Spar platform for the Aasta Hansteen field development in the Norwegian Sea. With a total hull length of 193 metre and a draught of 170 metre, the Aasta Hansteen Spar platform will be the largest of its kind. A Spar platform is a cylinder shaped floating offshore installation. The Belly-Spar concept is an exclusive Aker Solutions design. The ‘belly’ refers to the increased diameter on part of the circular shaped hull, where the condensate storage tanks are located. This gives the Aker Solutions’ Belly-Spar its characteristic shape. “The Belly-Spar concept is a result of the innovative spirit and culture among our engineers, who have come up with the right solutions for the challenging conditions on the Aasta Hansteen field,” informed Valborg Lundegaard, Head - Engineering Business Area, Aker Solutions.

APPOINTMENT

Eric Herman is the new Global CCO of Damco Eric Herman has taken over as the new Global Chief Commercial Officer (CCO) of Damco, the logistics arm of A P MollerEric Herman Maersk Group that provides innovative logistics solution for the chemicals industry worldwide. He will take overall responsibility for Damco’s global commercial activities. Herman has 19 years of experience and a strong execution record. Commenting on the appointment, Rolf Habben-Jansen, CEO, Damco, said, “I am happy to have Herman on board. He will be a strong addition to our commercial as well as global leadership team.”

Chemical World | May 2012

POLYMER TECHNOLOGY

Honeywell’s UOP selected to provide technology for propylene production in China UOP LLC, a Honeywell company, has been selected to provide key technology to produce propylene in China. Zhangjiagang Yangzi River Petrochemical Co Ltd will use Honeywell’s UOP C3 Oleflexx process technology to convert propane to propylene. The project is the ninth propylene project Honeywell’s UOP has announced since the beginning of 2011, helping meet the growing demand globally. “UOP’s combined Oleflex projects will help increase propylene production by nearly 5 million metric tonne globally

in the next three years,” said Pete Piotrowski, Senior Vice President and General Manager - Process Technology and Equipment, Honeywell’s UOP. The new unit, expected to start up in 2014, will produce 6,00,000 metric tonne of propylene annually at its facility in Zhangjiagang City, Jiangsu Province, China. Honeywell’s UOP will provide the engineering design, technology licensing, catalysts, adsorbents, equipment, staff training and technical service for the project.

WATER TREATMENT TECHNOLOGY

KMS to display novel membrane filtration systems at ACE 12 Koch Membrane Systems Inc (KMS) will present its flagship products for the water and wastewater market in the forthcoming ACE12, the American Water Works Association’s Annual Conference & Exposition to be held from June 10-14, 2012, at the Dallas Convention Center. KMS, known for its innovative membranes and membrane filtration systems, will display the latest generations of the TARGA II Hollow N membrane bioreactor (MBR) system. Fiber Ultrafiltration system and the PURON The TARGA II HF F system offers a cost-effective, safe, high-quality water solution for a variety of ultrafiltration applications, from drinking water to seawater pretreatment, industrial water treatment, and tertiary wastewater treatment. The cornerstone of the TARGA II HF system is intelligent process controls to handle variations in water quality and flow with minimal operator intervention, reduced chemical use, and improved energy efficiency. The PURON PSH18000 MBR module offers up to a 25 per cent capacity increase from previous PURON N generations, as well as a 10 per cent lower aeration requirement and a 10 per cent greater surface area than competitive products.

TECHNOLOGY & INNOVATION

HART-based pressure transmitter helps reduce maintenance cost United Electric Controls (UEC) has launched TX200H H which is a HARTbased smart pressure transmitter designed for panel or direct process mounting. The transmitter provides simplified field adjustment while reliably communicating asset management data utilising the latest HART 7 specification. A flexible 10:1 turndown allows users to range the transmitter as application requirements change while reducing inventory levels through model reduction. Real-time diagnostics also reduce maintenance costs by reporting device health status and process performance, alerting users to potential problems to troubleshoot before escalation occurs. Integrating TX200H into most process systems is simple. Since HART communication is superimposed over the 4-20 mA signal, TX200H H can use existing wiring as an upgraded, drop-in replacement for a standard analog 4-20 mA transmitter. A user may easily communicate with TX200H H utilising a handheld device or a PC equipped with commercially available software. UEC’s smart pressure transmitters may be used to safely monitor and control a variety of process applications, but are ideally suited for upstream oil & gas applications. ATEX/ CE compliance and cULus approval assure that most worldwide hazardous requirements are met.

Measurements in hazardous areas made easy with FCI’s flow meter Fluid Components International (FCI) has developed ST100 0 series thermal mass air/gas flow meter, which is available in a remote mountable configuration that is ideal for applications in hazardous areas or hard-to-reach locations. Remote mount flow meters are ideal for equipment crowded plants or hazardous factory areas where combustible or toxic gases may be present near the transmitter’s electronics. The ST100’s 0 remote mount transmitter, with optional digital display, can be mounted up to 1000 feet (300 metre) away from the flow sensor using interconnecting cable. Besides, it is user-friendly and versatile, storing up to five unique calibration groups to accommodate broad flow ranges as well as differing mixtures of the same gas and multiple gases, obtaining up to 1000:1 turndown. The optional, patent-pending SpectraCal Gas Equivalencyy calibration method lets users select and switch between 10 common gases. Setting a new industry benchmark for process and plant air/gas flow measurement instrumentation, the ST1000 series flow meter offers the most feature-rich and function-rich electronics available today. It offers better flow sensing performance to deliver unsurpassed adaptability and value, meeting plant gas flow measurement applications for today and tomorrow. The creation of the ST1000 series air/gas flow meter was facilitated by discussions with a wide range of instrument, process and plant engineers, who wanted more comprehensive measurement information as well as the flexibility to adapt to future plant and process control technology they might deploy. The ST1000 is the first thermal mass flow meter featuring a migration path to tomorrow. It continuously measures, displays and transmits the industry’s most extensive array of parameters. It is available with 4-20 mA analog, frequency/pulse, alarm relays or digital bus communications such as HART, Fieldbus, Profibus or Modbus. The ST1000 flow meter adapts as necessary to a plant’s changing needs or desire for upgrades with a plug-in card replacement that can be changed out by plant technicians in the field, taking ‘never obsolete’ to a whole new level. It features a unique graphical, multivariable, backlit LCD display/readout that brings new meaning to the term ‘process information’. It also provides the industry’s most comprehensive information with continuous display of all process measurements & alarm status, and the ability to interrogate for service diagnostics.

Grabner Instruments’ new vapour pressure tester gives competitive edge Grabner Instruments, a subsidiary of AMETEK Inc, has upgraded its portable vapour pressure tester, MINIVAP VPXpert. After extensive testing, the company has released a new method to test Liquefied Petroleum Gas (LPG) up to 1000 kPa pressure. This method is included with all new analysers. “The MINIVAP VPXpertt is the best deal for customers. We are continually improving our analysers by adding new, thoroughly tested methods and features, to give our customers a competitive edge in terms of costs and ease of use,” claimed Dr Oliver Sauer, Director, Marketing & Sales, Grabner Instruments.

Chemical World | May 2012

Since its market introduction in 2009, MINIVAP VPXpert has rapidly become the best-selling vapour pressure analyser, taking the lead in innovation from its predecessors, the MINIVAP VPS S and VPSH. H It is a fully configured ‘all-in’ analyser, ready for testing gasoline (ASTM D6378, D5191), V/L ratio (ASTM D5188), ASTM D6377 (crude oil) and ASTM D6897 (LPG up to 1000 kPa). MINIVAP P is claimed to be the world’s first automatic mini-vapour pressure tester that eliminated operator bias and tiresome sample handling that, up to then, had been associated with vapour pressure testing.

TECHNOLOGY TRANSFER

TECHNOLOGY OFFERED As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Sodium hydrosulfite An Iranian company is willing to manufacture sodium hydrosulfite using chemical compounds. It is widely used as a stripping agent in dyes and chemical industry. Areas of application Chemical industry Forms of transfer Technology licensing

Sodium sulfide An Iranian firm is willing to offer sodium sulfide, which is used mainly in textile industry, paper mill and curriery. Areas of application Leather industry, textiles, curriery industries, paper mills, etc

Forms of transfer Turnkey

Synthesis routes for organic chemicals An Indian firm is offering consultancy in design of synthesis routes for organic chemicals. Areas of application Pharma industry, specialty chemicals, plant protection chemicals, etc Forms of transfer Consultancy

Areas of application Transformers Forms of transfer Consultancy, technical services

Wasteless processing techniques An Indian company is willing to offer consultancy for waste-less processing techniques for the chemical & packaging industries. Areas of application Packaging

industry, transformer

Transformer oil unit

oil manufacturing industry, chlor alkali

An Indian company is willing to offer consultancy for making a transformer oil unit with domestic coal from its wastes.

projects Forms of transfer Consultancy, technical services

TECHNOLOGY REQUESTED Small-scale environment-friendly chemical technology An Indian company is looking out for an economically viable smallscale environment-friendly chemical technology useful in the textile sector as well as in pharmaceutical sector. Areas of application Textile and pharmaceutical industry Forms of transfer Others

Solvent dyes An Indian company has recently installed a manufacturing capacity of 2,400 mtpa and is looking to diversify its product range

by including various solvent dyes in its product portfolio. The company is seeking process consultancy for this project. Areas of application Plastics, petroleum, solvents, etc Forms of transfer Others

Sodium silicate and activated carbon A company from Thailand requires technology for manufacturing sodium silicate and activated carbon from rice husk & rice husk ash. Areas of application Manufacturing and construction industry

Forms of transfer Others

Treatment of pollutants discharged during PTA production A Chinese organisation is looking for a recycling and pollution-free treatment technology to tackle the wastewater, exhaust gas, waste slag and noises generated in PTA production, thereby shifting from reduction of pollutant discharge to zero-discharge. Areas of application Chemical industry Forms of transfer Consultancy, technical services, etc

Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations - Asian and Pacific Centre for Transfer of Technology (APCTT), APCTT Building , C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.

Share and Solicit Technology The mission of Chemical Worldd 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, d Infomedia 18 Ltd, â&#x20AC;&#x2DC;Aâ&#x20AC;&#x2122; Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: chemedit@infomedia18.in

Chemical World | May 2012

IN CONVERSATION WITH K Jose Cyriac

The government plans to increase R&D expenditure to 2% of GDP by the end of 12th Plan …avers K Jose Cyriac, IAS, Secretary (Chemicals & Petrochemicals), Government of India. This assumes great significance at a time when the Indian chemicals industry seems set for a big leap into the next orbit of value creation. Manas R Bastia caught up with this seasoned bureaucrat – with splendid service record in several senior positions in the Government of Kerala and the Government of India – on an array of focus areas including the draft National Chemical Policy 2012; the government’s plans to augment capacity, R&D and skilled human resources; the progress of PCPIRs; among others. Excerpts of the conversation… Photo courtesy: Elite Plus Business Services

Where does India stand todayy amid mega g consolidation in the global g chemicals and petrochemicals industry? India has witnessed consolidation in certain areas of petrochemicals (eg, Indian Petrochemicals Corporation Ltd with Reliance Industries Ltd). Indian companies are also acquiring foreign companies or entering into joint ventures to ensure continued availability of feedstock/raw material resources. For instance, Tata Chemicals has acquired a British company in the field of inorganic chemicals. Global companies such as Mitsubishi, GE, DuPont, Dow Chemical, Rhodia, Total etc have entered Indian market through 100per cent wholly-owned subsidiaries, joint ventures, etc. India is also keeping pace with the global trends.

What do yyou foresee as the opportunities pp and challenges g for value creation in the Indian chemicals industry? The main opportunities for the Indian industry include the large and growing domestic market, with a young

Chemical World | May 2012

population having increasingly high disposable income, rising consumerism, educated and trained workforce, and growing trade pacts with ASEAN countries, Korea, Japan, etc. There is a boom in the construction, automobile and telecommunication sectors, all of which provide opportunities for high-end value-added products from chemicals and petrochemicals sector. The challenges stem from infrastructure constraints, availability of feedstock, high cost of capital, increasing trade barriers, stringent environmental regulations, etc.

Please elaborate on the draft National Chemical Policyy 2012. Will it have REACHlike provisions for India? The draft National Chemical Policy 2012 aims at facilitating the growth and development of chemicals sector in India. The policy comprehensively discusses the various issues involved in a holistic manner, and accords high importance to R&D, technology upgradation, safety & sustainability, pollution & environmental aspects, effluent/waste disposal & treatment,

K Jose Cyriac

NATIONAL CHEMICAL POLICY 2012: BROAD OBJECTIVES

o Increase investments in the sector through facilitating capacity additions and ensuring availability of necessary feedstock and quality infrastructure o Increase the domestic demand and per capita consumption of chemicals o Adoption of cluster approach and encourage development of ancillary industries around them o Facilitate access to the latest technologies o Promote research and development o Promote human resource development

and green chemicals. The draft policy is posted on the Department of Chemicals & Petrochemicals (DCPC) website at www.chemicals.nic.in. The policy is still at a draft stage and any provision for a REACHlike legislation will emerge after deliberations with stakeholders.

What is the governmentâ&#x20AC;&#x2122;s g action p plan to tackle the growingg menace of dumping g in India? In compliance to the WTO framework, India has implemented antidumping and safeguard regulations. These regulations provide protection to the domestic industry within the international trade norms. The government proactively responds to issues raised by the industry and provides protection to domestic industr y, wherever justified. For instance, anti-dumping duties were imposed on caustic soda, polyvinyl chloride, polypropylene, phthalic anhydride etc after due examination and process of law. Decisions are taken on a case-to-case basis; the government does not have a general position on this.

What are the governmentâ&#x20AC;&#x2122;s g measures to neutralise the mountingg internal transaction costs as well as input costs? The problem in power and energy is not the cost, but availability. Cost of finance has always been high in India, but this is more than set off by other input costs. Capital equipment costs are also not higher than elsewhere. Notwithstanding this, the government has re c o g n i s e d inadequate infrastructure as a major constraint on rapid growth. It has, therefore, emphasised the need for massive expansion in investment in infrastructure, based on a combination of public and private investment, the latter through various forms of PublicPrivate Partnership (PPP). The total investment in infrastructure, which includes roads, railways, ports, airports, electricity, telecommunications, oil and gas pipelines and irrigation, is estimated to have increased from 5.7 per cent of GDP in the base year of the 11th Plan to around 8 per cent in the last year of the Plan. A large number of PPP projects have taken off, and many of them are currently operational in both the Centre and States. Further, the government has come out with the Petroleum, Chemicals and Petrochemical Investment Regions (PCPIR) Policy, which aims at promoting investment in chemicals and petrochemicals sector through creation of excellent infrastructure that would provide a conducive and competent environment for setting up businesses.

What is the latest p policyy status on making g available Indiaâ&#x20AC;&#x2122;s natural gas g as feedstock for chemicals industry? The availability of natural gas is shrinking and the government has identified the following areas as priority sectors: fertilisers, power, LPG and City Gas Distribution (CGD). However, the policy also visualises that higher fractions (C2, C3 and C4) are to be extracted from natural gas for

their use in value-added chemicals & petrochemicals, before being deployed for other sectors.

How is the government g planning p g to encourage g diversification into bio-based feedstock in India? Ethanol (ethyl alcohol) is an important bio-based feedstock used by the chemicals industry. In India, almost the entire ethanol is produced from sugarcane molasses. Hence, ethanol production in India is heavily dependent on production of sugar and sugarcane, which fluctuates due to their cyclic nature. Ethanol is mainly used as raw material for chemicals industry, potable alcohol and also for the Ethanol Blended Petrol (EBP) Programme. Currently, the availability of ethanol is limited in the country and is insufficient to meet the requirement of different sectors. The government, under the Sugar Development Fund, provides soft loans to sugar mills for setting up ethanol projects to improve their viability via value-addition to their by-product, namely molasses.

How is the DCPC gearing g g up p to facilitate significant g investment in capacity p y creation, higher g R&D expenditure p and skilled human resources? The major players such as Reliance Industries, Indian Oil Corporation, Oil and Natural Gas Corporation, Hindustan Petroleum Corporation, Haldia Petrochemicals, Gail India Ltd etc have invested in petrochemical projects. These companies are also expanding their capacities that are likely to materialise during the 12 th (2012-17) and the 13 th (2017-22) Five-Year Plans. Such investments will drive the downstream processing investments. The government plans to increase the total expenditure in R&D to 2 per cent of GDP by the end of 12th Plan. This could consist of about 1 per cent in the public sector and 1 per cent in the corporate sector,

May 2012 | Chemical World

K Jose Cyriac

including Public Sector Units (PSUs). Further, my Department has framed a Scheme for setting up Centres of Excellence (COEs) in the field of petrochemicals. Presently, two COEs are being set up; by Central Institute for Plastic Engineering and Technology (CIPET), Chennai, and National Chemical Laboratory (NCL), Pune. The Department plans to set up more COEs in the 12th Five-Year Plan. The government plans to increase the percentage of the workforce, which has received formal skills through vocational education and training from 12 per cent at present to 25 per cent by the end of the 12th Plan. This would mean that about 70 million more people have to be imparted formal skills in the next five years. For this, support to the National Skill Development Corporation (NSDC) would have to be significantly enhanced and State Skill Development Missions in all States would have to be fully operational and effective during the 12 th Plan.

Chemical World | May 2012

Similarly, Industrial Training Institutes (ITIs) and Industrial Training Centres (ITCs) need to be strengthened and upgraded. PPPs in financing, service delivery and provision of workspaces and training of trainers need to be promoted. Further, CIPET, under the aegis of the Department, is an accredited premier national institution devoted to Academic, Technology Support & Research (ATR) activities for the growth of plastics & allied industries in the country. It offers a blend of specialised academic programmes in the field of polymer science & technology and provides qualified human resources to the industry. Every year, CIPET trains about 10,000 students through long-term programmes and about 20,000 trainees through short-term programmes with hands-on experience with the most modern sophisticated facilities in design, CAD/CAM, tool room, plastics processing and plastics testing & quality control.

How do you y rate the progress of PCPIRs so far? The PCPIR model is based on the rationale that substantial investments by the anchor tenant in the refinery and cracker segments will lead to other investments in the chemicals and petrochemicals sector including downstream segments. While some of the PCPIRs have been making substantial progress, some others are not. The Department has identified the weaknesses and is working on a strategy to overcome these.

Your message g for the industry on the road aheadâ&#x20AC;Ś Sectors such as automobile, electronics, telecommunication, real estate constructions, agriculture, pharmaceuticals, textiles etc are driving the demand for the chemicals and petrochemicals sector. Herein lies a great opportunity for Indian and foreign investors alike to exploit the vast potential that the country offers. Email: manas@infomedia18.in

ANNI AN NIVE VERS RSAR AR A RY SP SPEC ECIA IAL L

FEEDSTOCK

HUMAN RESOURCES

Crudee oi Crud oill su supp pply ly:: Di Dive vers rssif ifyi y ng ressou ourc r es ttoo rc hedg he dge ag agai ains nstt ri risi sing ng ccos ost. t... t. .... .. .... ...... .. ........... ................... .... ...................... 300

Chemical inssti titu tute t s: N Nurtu tu uri rin ng ski ng kill ll-s -set ett ffor tomorrowâ&#x20AC;&#x2122;s ind to dus u trr y ne need eds. ed s... s. ............. .............. . ........... .... ............... .. .... . ...... 52

Reene newa wabl ble resource ces: s: R Ren enew ewin ing th thee en ener e gy f turee off India....... ....................................... fu .............. .... ....... ............... 322

Talent reteen enti tion tion on: Cr Creati t ngg a new ti w dim imen e siion through CS SR st sttrrateegy ... .... ... .. . ....................... .... . ...... .. . .. . .. .... .................. 54

Prabhakar ka Nair, Head Head - Busi Busines ne s Develop lopmen mentt Asia Asia,, Lanz LanzzaT aTe Tech ch NZ Ltd

LN NG supp pply ly:: Ca ly Ca US provide low-cost solution?........... Can . ... . .. 34

Rooun undt d ab dt able able le: Is Is ind dus ustr t ytr y accad a emia partnersh hip help he lpin i g to in t tac ackl ac klle ta kle tale l ntt sho le hort hort r agge? e?.. .............. . ........ ....... . .. ........... ............ 58

Roundtable: Is natural gas an ideal feedstock?....... ............... 366

Roun Ro undt dtab dt aab ble le: Ar Are ch chem em mic icaal al m man anufac an uffactu ure r rs rs tak akiin ing right meeasures es to en ensure r wor orkk-li k-li l fe f bal alance? l ?....... ........................... 59 ?.

RESEARCH & DEVELOPMENT

WATER MANAGEMENT

Basic research: Building foundation for innovative solution ...... ......................................................... 38

Wastewater treatment: Technologiies ttoo co cons nsser n e ve v the precious drop ........................................ . ... .... . .. .......... . .. . ........... 60

Collaborative research: The way forward to create a win-win situation................................................. 40

Optimising water usage: Innovative solutionss to bridge demand-supply gap........................ . ......... . ....... ....... ......... 62

Roundtable: Can India evolve as the global hub for research?....... ............................................................ 42

Roundtablee: Is I recycled water a viable option for or p pro rocessing?........................ . .... .... .................. .................. . 64 64

SAFETY, HEALTH & ENVIRONMENT

POLICIES & REGULATIONS

Safe processing: Effective risk management for boosting investments ..................................................... . 44

Duty rat atio iona nalisation: Ti Time me ffor or a pragmatiic ap approach..... .................. .... .... .... . .................................... 66

KNK Murthy, Consultant

Product stewardship: A cradle-to-grave tool to reduce environmental impact of chemicals ..................... . 48 Roundtable: Can green chemistry principles be effectively used in production processes?......................... . 50

National Che hemi mica c l Policy: Timely imple l me ment ntat atio ion n key to accelerrat atee in indu dust stry ryâ&#x20AC;&#x2122;s progress...................... . ..... ....... .... .... .... . . 67 Vipul Shah, President ent,, CEO CEO & Chairman, Dow Chemical Internat na ion ional al Pvt Pv Lt Ltdd

Chemical clusters: Enhancing ind dusstr tryy competitiveness............................................... . ... .... ......... .... . .... .... .... .... 68 Policy reforms: A booster dose for growth....... .................... 70 Roundtable: Should India have REACH-like regulation?....... ............................................... 72

Chemical World | May 2012

ANNIVERS AN SAR ARY Y SP PEC CIA IAL L

GLOBAL MARKET Uncertain bu usi sine ness ss eenv nvironmeent nt:: Trran ansf ansf sformi f mi ming ngg chal ch alle leng ngees iint ntto op opporttun u it itie tiees ...... .................. ...... .......................... 84 BRIC BR IC CS co coun untr tries: s:: Adv dvantage India?.................................... . 86 Chem Ch emic icall exp xp ports: On a voyage to explore n w oppoort ne r unities................................................................. un n . 90 Inte In t rffacce - Robert Duane Dickson, te Prin Pr inci in c pall, l, Delloi oitt t e Consulting LLP “ he wor “T orld ld wil illl lo l ok towards India for major b eakthr br hrou ouugh ghs” ss””.......................................................................... 92

END-USER INDUSTRIES Fine che F hemi mica c lss: Lu ca Lucr crrat ativ ivee oppo iv oppo op p rtunittie iess in the h offing.......................... . ... ......... ....... ................. ...... .... .... ..... .... .... .... .... .... ......... .... 74 Auto Au tomo m tiive ves: s: A Acc ccel cc eller eler erat atin at ingg th in the grow wth of chemi of mica call secttor or..... . . ... . .... ......... ............................. .. ......... . ............... ...... 75 Bu uil i di ding ng & consttructtio ion:: Lay ayin ingg a st in strong foundaati tion on ffor or ffut uture....... ............. ............. ................. . .............. ........... 76 Home Ho mee & per e so sona nall ca care re:: Th Thee ne next xt b biig ig tthi hing hi ng forr sp fo s eciaalt l y ch c em emic ical als. s... .... ....... ....... . .......... .... .... .... .... ...... . ......................... 78 78 Text Te xtil iles es: Kn Kn ing a value proposition ... Knitti . .. .... ....... .... .... .. .... .... ....... .... .... .... .... .... .... 80 Interfac acee - Ma Manish hD Doshi, Prres esid iden den nt, t Indian Drug Manufactur urer ers’ s’ Ass ssoc ocia iati tion on “The “T he IIndian chemicals industry is reegi g ster erin i g si sign gnif ific ican antt grow o th iin n kn knowledge chemicals sector”................................ .... .... ..... 82

May 2012 | Chemical World

FEEDSTOCK Crude oil supply

Diversifying resources to hedge against rising cost Majority of Indian chemical manufacturers are dependent on naphtha, the prices of which have soared in the last few years. While alternatives (gas, coal-to-liquid, bio-based raw materials, etc) are being explored, the industry will have to put in place a comprehensive policy for feedstock sourcing to be globally competitive.

Rakesh Rao

asy availability of feedstock is one of the most critical things for the survival of chemicals industry. It is more important for a country like India, which has to import nearly 70 per cent of its crude oil (the main raw material for feedstock in chemicals industry). After the sharp dip post-slowdown, the prices of oil have been moving north on the global index. This has adversely affected the Indian chemicals industry. Shushmul Maheshwari, CEO, RNCOS E-Services Pvt Ltd (a market research firm), says, “Over the years, the rising crude oil prices have significantly affected the margins of chemical manufacturers as the industry is highly dependent on energy, and raw materials used in it are mainly petroleum-based. In fact, the increase in raw material costs is faster than the pace at which chemical manufacturers can raise

Chemical World | May 2012

prices. Thus, the situation is placing the commodity chemical and petrochemical pricing under severe pressure.” If India has to emerge as one of the leading trade partners in the global chemicals industry, then it has to ensure feedstock availability. Opines Aashish Kasad, Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd, “Non-availability and higher costs of raw materials are often discouraging factors for chemical manufacturers to scale up manufacturing operations. It is imperative that feedstock and fuels be available at international prices for the Indian chemicals industry to be more competitive. Therefore, there is a need for zero import duty on naptha and hydrocarbons such as ethane and propane, which are the raw materials for manufacturing a wide range of organic chemicals. India should have a plan to secure its feedstock from feedstock-rich countries with competitive supplies.”

Diversify sourcing To a large extent, India is dependent on Gulf countries for its crude oil requirements. Current political turmoil in Gulf countries and sanctions against Iran are having adverse impact on the crude supply to India. Some experts argue that India should explore non-Gulf countries to meet its crude oil requirement. But there is a challenge. Traditionally, India has been importing all its crude oil from Gulf countries and hence, majority of refineries were built to treat this crude. Hence, to treat other types of crude, companies will have to invest in new technology. Maheshwari elaborates, “India should continue to import crude oil from Gulf countries instead of exploring the nonGulf countries, which have less proximity to the Indian sub-continent. Also, by-andlarge Indian refineries are technically designed to process Gulf crude.” Another option for Indian chemical manufacturers is setting up manufacturing base in other countries (Gulf, Brazil, South Africa, etc) where cost of feedstock is low and end-user industries are growing. The strategy to move closer to feedstock is proven and many of the global majors have adopted it. But, can Indian companies emulate the success of these global majors? Kumar Kandaswami, Senior Director, Deloitte Touche Tohmatsu India Pvt Ltd, answers, “A large number of global majors have gone closer to the feedstock. Therefore, this is quite a proven strategy. That said, while setting up such operations, it must be carefully thought through. Some of the parameters that will come into play are the scale, ability to find customers for the increased capacity; ability to manage logistics if the customer profile does not change; the portfolio of products that are sought to be manufactured; pipeline of future products; and ability to manage new manufacturing environments. Therefore, the choice to move close to the feedstock would be driven by one or more of these factors. This may not always be the answer for a relatively small-sized company, operating a small portfolio of products, with a small, captive customer base.”

Crude oil supply

BOOSTING FEEDSTOCK AVAILABILITY o Reduce import costs of feedstock, and discourage export of naphtha o Secure feedstock supply from oilrich countries o Diversify feedstock requirements o Scout for alternative sourcing for gas o Coal-to-chemical technology can be explored, but will require huge investment o Incentivise research for bio-based raw materials

Is alternative feedstock the answer? Rising crude oil prices have forced chemical manufacturers to look at other alternatives. And gas tops this table. “Certainly, chemical companies have already started using gas as feedstock in India. Conventionally, naphthabased crackers provide feedstock to the industry, but nowadays, due to high naphtha prices, they are being substituted by new gas-based crackers,” points out Maheshwari. However, gas availability and pricing are big challenges to overcome. “I do not see a major shift towards using gas as a feedstock. Globally, naphtha continues to be the major source (accounting about 70-75 per cent) for petrochemicals, followed by gas (about 15-20 per cent) and rest from coal-to-chemical & biofeedstock. And this will not change in the next 10-15 years. Of course, there

In future, the usage of renewable feedstocks is expected to increase on the back of rising crude oil prices and the government’s initiatives to promote the substitution of petroleum requirements. Shushmul Maheshwari CEO, RNCOS E-Services Pvt Ltd

are exceptions such as the US where increasing availability of shale gas gains shares,” points out Dr Alexander Keller, Partner, Roland Berger Strategy Consultants GmbH. In order to diversify their feedstock needs, global chemical majors are investing in bio-based raw material technology. In India, this is still in the early stage of development. “Renewable feedstocks (bio-based feedstocks) are being used in the Indian chemicals industry as an alternative to petroleumbased feedstocks, but they are at a nascent stage of development. In future, the usage of renewable feedstocks is, however, expected to increase on the back of rising crude oil prices and the government’s initiatives to promote the substitution of a percentage of its petroleum requirements,” opines Maheshwari.

Coal, the stored energy Experts believe that if crude stays at above $ 80-90 per barrel, then coal-tochemical is a viable option. Although, there is a clear potential for coal-tochemical with current crude prices at $ 100-110 per barrel, there are many challenges. Dr Keller points out, “First, coal-to-chemical technology is still not a matured technology. Second, coal-tochemical project requires multi-billion dollar investments. At the same time, it is environmentally challenging, eg the technology requires large quantity of water. In many places, while coal availability is not an issue, finding water is a problem. So coal-to-chemical is a solution, but it cannot be the only source for feedstock.” With large reserves of coal, India can look at coal-to-chemical as an attractive alternative. In India, two blocks were awarded for coal-to-liquid projects to Tata Group (in joint venture with South Africa-based Sasol Synfuels Pty Ltd) and Jindal Steel & Power Ltd with Lurgi, in Orissa. “This is a positive step for such complex technologies to take root in India. These multi-billion dollar projects, although having made significant progress, are still in the initial stages of

Globally, naphtha continues to be the major source (accounting about 70-75 per cent) for petrochemicals. And this will not change in the next 10-15 years. Dr Alexander Keller Partner, Roland Berger Strategy Consultants GmbH

development as they are long gestation projects. One of the major challenges before these companies will be selecting appropriate technology for utilising the local coal, which is characterised with higher ash content than what is found globally, for these projects. Many other Indian companies have also evinced interest in coal-to-chemicals projects, but one has to wait and watch the results of these two projects,” opines Pratik Kadakia, Principal, Roland Berger Strategy Consultants Pvt Ltd.

Securing supply for future Although feedstock diversification is an option that can be explored, Indian chemical companies will continue to depend on naphtha for their requirements. Given the fact that India will be dependent on imports to meet its feedstock requirements even in future, the ideal strategy will be to optimise resources by using state-of-the-art technology. “While India continues to be one of the leading importers of crude oil, the refining capacities that are coming up are based on the competitiveness of Indian refiners vis-à-vis global counterparts making us competitive in the export of petroleum products. So the learning from this is if we continue to invest in latest technologies and world-scale infrastructure & operations, the chemicals industry will flourish in India as the market is definitely here. With the refining capacity that will get commissioned, it will continue to meet the domestic requirement of naphtha for now and the future,” concludes Kadakia. Email: rakesh.rao@infomedia18.in

May 2012 | Chemical World

FEEDSTOCK Renewable resources

Towards empowerment

Renewing energy g future India

Emphasising heavily on renewable resources is the biggest priority for the Ministry of New & Renewable Energy in India. In this backdrop, the chemicals industry is best suited to tackle the challenges pertaining to dearth of nonrenewable resources. Friendly government policies and measures are needed to imbibe deeper execution of this plan. Prabhakar Nair

uring the next 20 years, while global energy demand will grow by more than 40 per cent, the International Energy Agency (IEA) strongly projects that more than 75 per cent of energy will still be supplied by fossil fuels. Solutions can be devised if the challenges and opportunities are considered in the same vein. Very intricately, the chemicals industry is inextricably linked to the energy industry. India is one of the leading investors in clean energy, particularly solar and wind power. The country has also developed innovative solutions for its large rural population who do not have easy access to the grid power. These include solar cookers, solar lighting and rural electrification schemes based on bioenergy. The rural

Chemical World | May 2012

electrification schemes being pursued in some of the emerging regions are a clear example of localised solutions that are better enabled by use of renewable sources like solar or biomass than by conventional grid supply. The imminent question that arises is: How do we get more alternative sources of energy into the current energy pool? How do we change the energy mix such that no more than 60 per cent of the global pool is supplied by fossil fuels by 2035? A likely solution could be continued investment in the clean tech industry. India is aggressively moving towards becoming a global clean tech powerhouse and ranks fourth among the G20 nations in terms of clean tech investment. In 2011 alone, it racked up investments of $ 10.3 billion in the sector, a growth rate of 52 per cent that dwarfed the rest of the worldâ&#x20AC;&#x2122;s significant economies (source BNEF).

India has taken serious cognisance of the need to grow its chemicals industry as a whole and has a national Five-Year Plan (2012-2017) perfectly in place for this industry. This plan will enable the country to develop its entire chemicals sector including infrastructure, IT, specialty chemical development and exports, and thereby allow India to expand its current (3 per cent) access to the $ 4 trillion-worth global chemicals market. A part of this plan is to evaluate the use of renewable feedstocks to produce chemicals. For example, producing chemicals using precursors such as ethanol that could be derived from renewable sources. The Indian chemicals industry needs to launch an industry-wide initiative to include robust renewable R&D development and deployment strategies to ensure that all avenues for renewable chemical production are explored. India is already investing heavily in R&D to develop fuels from a variety of feedstocks and pathways.

Friendly measures The bilateral agreements that the United States Department Of Energy and the Indian Ministry of New and Renewable Energy have in place to facilitate increased co-operation between the US and Indian firms in the green spectrum are aimed at providing support towards developing green chemicals industry in India. Besides, dramatic growth rates for green chemicals are expected during the coming decade. National Energy Policy in India is an important driver for the growth of alternative energy solutions and it serves to set the objectives for the implementation of new energy solutions by the industry. However, it needs to be remembered that effective energy solutions will be those that address energy needs at a local level. Prabhakar Nair is Head of Business Development Asia, LanzaTech NZ Ltd. For details, contact Smriti Kulkarni at skulkarni@perfectrelations.com

FEEDSTOCK LNG supply

India plans to diversify its Liquefied Natural Gas (LNG) imports. While new destinations are being explored for gas to meet the domestic need, the US could emerge as one of the low-cost, long-term suppliers of LNG in near future. Rakesh Rao

he boom in shale gas in the US may turn out to be a blessing in disguise to Asian countries, particularly India, which are scouting for gas supply to meet their energy needs. Record production from shale deposits has driven down gas prices in the US – making it one of the lowest in the world. Unlike oil, natural gas market is still in the early stages of development; in other words, gas prices are still not uniform across the globe. But this could change with global gas market integrating.

WHY THE US? o India is exploring LNG from nontraditional suppliers such as the US and Australia o Record production of shale gas in the US has lowered the cost o US companies are exploring markets to export gas o For India, cost of LNG supply from the US can be lowest o India can bargain with other LNG suppliers to lower the cost

Chemical World | May 2012

Looking beyond Gulf countries Even India, which traditionally used to source gas from Gulf countries, is seriously looking at the US. Gail India, the country’s largest gas supplier, became the first Asian buyer of US natural gas in December 2011 when it signed a 20-year deal with Sabine Pass Liquefaction, LLC – a subsidiary of Cheniere Energy Partners LP – for supply of 3.5 million tonne per annum LNG. “Yes, the contract between Cheniere and Gail is the first time that Cheniere, or any other US company, has sold LNG to India under a long-term contract,” asserts Andrew Ware, Director, Corporate Affairs & Communications, Cheniere Energy. With excess supply of gas in the domestic market, the US companies are looking for export of gas to emerging economies such as India. “Cheniere is bullish on growth in Indian LNG demand, and we foresee great potential for more contracting between US and Indian counterparts in the future,” Ware adds. Even companies from Australia are gearing up to explore the Indian LNG market. The fourth-largest exporter

of LNG in the world, Australia is the third-largest LNG exporter in the AsiaPacific region having exported 18.9 million tonne of LNG in 2011 worth around $ 11.1 billion. While Australia has been supplying LNG to China and Japan for quite some time, it is now eyeing to strengthen its foothold in India as well. Similarly, Russia’s Gazprom is also expanding its footprint in the Asian markets – particularly India. “Gazprom and Indian oil & gas companies are developing their co-operation on various business directions, including supplies of LNG to India. Under estimates of independent experts, gas consumption in India may increase around 70 per cent by 2020 compared with current volumes. This market is quite promising for Gazprom, which plans to build export facilities as part of its Eastern gas programme. In 2009 and 2011, Gazprom exported 10 batches of LNG amounting to a total of 650,000 tonne to India,” according to an official of Information Directorate, Gazprom.

Pricing, the deciding factor Prices of LNG in India are at $ 13.65 per million British thermal unit (mBTU) this year, according to the US Federal Energy Regulatory Commission (FERC). Traditionally, long-term prices of gas are linked to oil. With crude oil prices above $ 100 per barrel, the cost of LNG (after addition of cost of shipping, regasification, pipeline tariff and local levies) is likely to be about $ 17-20 per mBTU. On the other hand, as per the contract with Cheniere, the price of LNG will be based on Henry Hub (HH) from the US market, which is generally lower by $ 2-3 per mBTU compared to that based on oil index (Brent/JCC) from other sources. Ware explains, “LNG supply from the US offers portfolio diversification for Indian buyers. LNG has historically been purchased under long-term contracts linked to oil prices, and this contract structure remains dominant in the global industry. Due to high

LNG supply

($ 100+) oil prices, this oil linkage requires Indian companies to pay high prices for their LNG. Cheniere is offering a new contract structure to the LNG industry. For the first time, LNG would be purchased at prices linked to the HH in Louisiana, which is the index point represented by Nymex natural gas futures contracts. This contract structure would provide Indian buyers exposure to the largest traded natural gas hub in the world. Diversifying risk while lowering purchasing costs is a good proposition for all LNG buyers, including companies in India.” Similarly, Indian companies may find Australian LNG to be priced a bit too high with gas prices in the US declining. Ware adds, “America’s natural gas prices are now the lowest in the world due to the ‘shale revolution’ that has been gaining momentum in recent years. The US now has an estimated 100 years worth of natural gas due to advances in drilling technology pioneered by the domestic industry that has unlocked vast resources in shale fields across the US. The US natural gas production is at record highs, and prices are now approximately $ 2.50/mBTU (~$ 15/barrel oil equivalent), at 10-year lows, due to oversupply. This creates compelling value for energy companies in India.”

Booming gas economy Many developing countries, including India, are realising the benefits of gas to reduce reliance on petroleum products, which are expensive, and coal, which is considered to be polluting. With domestic production of natural gas on decline, demand for LNG is likely to increase manifold in near future in India. Ware says, “We anticipate significant future growth in Indian LNG demand to meet both the needs of India’s expanding economy and increase the rate of penetration of natural gas within the economy’s fuel mix. India and China represent the fastest-growing natural gas markets in the world. India has long struggled with a shortfall in availability of natural gas supplies as feedstock for its fertiliser units. Natural gas will also play a critical role as a fuel in expansion and upgradation of India’s power industry, and to wean reliance on coal for power generation.” LNG can provide an opportunity to globalise supply availability to countries that lack indigenous natural gas resources. Many believe that LNG will be the world’s fastestgrowing fuel source over the next 30 years. And many Indian companies will look forward to contracts similar to GailCheniere to boost gas supply for the domestic industry. Ware opines, “Cheniere will continue to engage with LNG buyers in India and seek out good partners for future LNG projects. Our free on board (FOB) contract arrangement with Gail represents a good model for the relationship – Cheniere is responsible for making and delivering LNG to Gail’s vessels at the Sabine Pass terminal, after which Gail is free to take its LNG cargo wherever it chooses.” Email: rakesh.rao@infomedia18.in

May 2012 | Chemical World

FEEDSTOCK Roundtable

Is natural gas an ideal feedstock? With volatile crude oil pricing and uncertainty in the international markets, conventional fossil fuel sources for the chemicals industry are running the operations under tough conditions. The entire downstream process trickling down to end-products experiences a steady inflationary impact. In such times, how effective can natural gas be as a feedstock? Mahua Roy talks to experts and gauges the situationâ&#x20AC;Ś

B Akala Former Chairman & Managing Director, Central Coalfields Ltd

Soumen Kumar Roy General Manager â&#x20AC;&#x201C; Health, Safety and Environment, Indian Oil Corporation Ltd

N Anand Senior Manager - Marketing, Aker Solutions Pvt Ltd

Crude oil, natural gas and coal are the usual feedstocks for chemicals industry. But natural gas is the fuel of preference that powers most chemical and refining processes because of the simplicity in the process associated with ease in handling, cleanliness and comparatively cheaper handling cost. Cheaper natural gas would mean cheaper ethane for chemical producers, giving them an advantage. Increasingly volatile oil prices have had a knock-on effect on naphtha, which has swung wildly in the past five years. Natural gas has innumerable uses in chemicals industry and new applications are being developed every day. With the prevailing shortage situation of natural gas in many countries, coal-to-chemicals technologies are d developing l i quickly i kl and d use off coall and ethane is expected to grow rapidly for economic reasons.

Natural gas contains about 89-90 per cent methane. Hence, it cannot be used as feedstock for petrochemicals. However, it can be used as feed in fertilisers as well as hydrogen generating plants and in furnaces & boilers. The economic benefit of using natural gas as feedstock depends upon the cost of natural gas (delivered cost) vis-Ă -vis cost of alternative feedstock. Presently, the delivered cost of natural gas is lower in India as compared to naphtha or other fuels. Natural gas as a feedstock is commonly found as a building block for methanol, which in turn has many industrial applications. Environmental benefits through lower carbon emission will be there using natural gas, if it replaces heavier fuel in furnaces or is used as feedstock in hydrogen generation. Technological T h l i l improvement i may b be required in chemicals industry on case-to-case basis to use natural gas.

Natural gas is the cleanest of all the fossil fuels. Reliable and continuous availability of natural gas poses one of the greatest challenges to the industry to develop new technology and improve R&D spends to develop new processes for better utilisation of gas. Syngas, which could be derived out of natural gas, provides substantial opportunities to develop various downstream products. However, manufacturers are presently looking at producing syngas from coal, which is not a clean source. It is essential to address areas of concern to facilitate a switch over to natural gas supply. To take care of future requirements arising out of greater demand and usage of natural gas, a sustained programme would be required from research and process know-how companies to innovate and d d develop l cleaner l technologies h l i to harness the potential strength of natural gas.

EDITORIAL TAKE Considering the economical and environmental benefits provided by natural gas over conventional fossil fuels, it needs to be considered seriously as an alternative by the chemicals industry. The fertiliser industry has been implementing this strategy and is showing successful results. To ensure an exemplary sustainable future for the chemicals industry, natural gas needs to be employed as a source of feedstock.

Chemical World | May 2012

RESEARCH & DEVELOPMENT Basic research

Building foundation for

chemicals industry, basic research involves analysing the subject at the molecular and fundamental level, to understand its impact at the macro level.” Basic research is not intended to yield immediate commercial benefits. However, in the long term it is the basis for many commercial products and applied research. Pure research is mainly carried out by chemical institutes like Institute of Chemical Technology (ICT), IITs, National Institute of Pharmaceutical Education and Research (NIPER), Indian Institute of Science (IISc) and Council of Scientific and Industrial Research (CSIR). It is seen that academicians have a strong ability to analyse the various problems faced by the industry and solve these in the conceptual domain. This is an expertise, which industry lacks and here the role of research assumes high importance. Dr Y R Singh, Executive Director, Alkali Manufacturers’ Association of India, notes, “Basic research assumes importance in the chemicals industry as it forms the basis for growth. Through basic research activities, companies get to know about new technologies, atomised processes etc, which can help them in developing new products and reducing cost & energy consumption.”

Fundamental benefits

Universities and research institutes have always been the source of new ideas for the chemicals industry in India. The basic or fundamental research carried out by them has opened new avenues for the industry; but at present, not much is being done to promote such activities. The need of the hour is that the concerned authorities including the government and chemical companies in India should put their best foot forward. Avani Jain

esearch and development in the chemicals industry can act as a long-term investment enabling an organisation to drive innovations and improve productivity. It enables the company to have a leadership position in leveraging the new technology for offering higher value. Research can

Chemical World | May 2012

also help cater to the constant demand for improvement in quality, bring down costs, and create more value. Research can be basic or applied. Pure, basic, or fundamental research is carried out to increase understanding of fundamental principles. Dr Anand Mohan, Assistant Professor - Department of Chemical Engineering, Indian Institute of Technology (IIT) Hyderabad, notes, “In the

New knowledge is the primary product of fundamental research. The industry gets to know about innovations and improvements about existing products. Chemical companies can use this knowledge to produce new products and satisfy customers. Pure research generates new ideas, principles and theories, which may not be immediately utilised, despite being the foundations of modern development. Moreover, the economic returns from fundamental research can be considerable, far in excess of the initial costs of the research. Despite the benefits, there are few challenges as well, while promoting basic research activities. Dr Mohan notes, “Not many academicians and institutes want to take up fundamental research as it is timeconsuming and there is no glamour attached to it as compared to applied research. Thus,

Basic research

to find a dedicated person is a challenge.” Further, institutes are often involved in academic or pure research, which may not have applied aspect to it. But this situation can be improved by entering into industryacademia collaboration.

Promoting basic research activities In order to provide a boost to the chemicals industry in India, it is important to facilitate the growth of basic research activities. Dr Singh notes, “The first step in this direction is providing adequate funds for supporting fundamental research. The actual costs of basic research are high. Modern research requires increasingly sophisticated equipment and technologies. Thus, the government and the industry should come forward and fund such research projects.” Often, basic research is carried over a long period of time, ie it does not give immediate results. Dr Singh says, “The authorities and the industry must

be ready for such long-term investments and should not stop the funding in the middle of a task as seen in many cases. The companies should also realise this fact and fund such researches.” He adds further, “Not only the government funding is required but proper direction is also needed by the institutes. The skilled manpower is available in plenty but there is no one to guide them in carrying out the different researches. So steps should be taken to improvise such a situation.” It is crucial to spread technologies produced by universities or national laboratories widely to private sector so that they can benefit from it and the researcher’s work is recognised. Also, companies should facilitate and invite researchers on deputation basis to work in their labs to gain experience on newer equipment so that this knowledge can be used in carrying out new process as well as new product research. Further, they should also actively scout for opportunities

to commercialise technologies developed within the institutes. The main hurdle today in carrying out fundamental or basic research is lack of proper infrastructure and mechanism. Dr Singh comments, “The government should set up national chemical labs so as to provide the much-needed technology and process to carry out the basic research activities.”

Future prospects The basic research being undertaken by many researchers at universities and national research institutes, and around the world, not only provides results that are valuable but are intellectual assets that can be shared by all the segments of the industry. The practical application of such research has the potential to drive innovations in the chemicals industry. Thus, adequate steps need to be taken to promote basic research in this sector in India. Email: avani.jain@infomedia18.in

May 2012 | Chemical World

RESEARCH & DEVELOPMENT Collaborative research

Avani Jain

The way

from research institutes have good theoretical and fundamental knowledge, which they can apply effectively so as to provide innovative solutions to the industry and resolve all their problems.”

he chemicals industry se veral off ers opportunities for players to collaborate for improving competitiveness. Players could come together and reap benefits like reduced costs, Role of research better knowledge and greater institutes marketing power. Out of the Research institutes play an several forms of collaboration, important role in driving product industry-institution partnership innovation in the chemicals for knowledge development/R&D industry but they also need to is slowly gaining momentum in consider a few factors. Quality The industry-academia collaboration for and timeliness are the two top the country. R&D is increasingly being viewed as a way The Indian chemicals criteria that research institutes of accelerating the industrial growth in the industry can leverage the need to bear in mind when country. Through this collaborative strategy, potential of research and aspiring to work with industry. educational institutions as a While defining the role the chemicals industry too can leverage on source of intellectual capital as of research institutes when the capabilities of academic institutes in well as future human capital. It collaborating with the industry, the areas of new product development and can collaborate effectively to A Prathap Reddy, Managing design & process innovation to sustain its establish research programmes for Director, Balaji Amines Ltd, competitiveness. application research in educational atio i nal notes, “Research institutes note shou uld welcome technical staff institutes. This is espeecially from industryy to interact with their own critical to the knowledgee segment in researchers as well as use their equipment the industry. so as to fostter closer relationships and The need for collaborration encourage in ndustry-focussed research In India, till recently there was no need work, which h can then be funded by for research in most compaanies – the industry with backing from their knowledge that existed in thee public own support staff.” domain was sufficient for the There are currently business the company waas three basic collaboration engaged in. But that seems types that can be seen between industry and to be changing now. It is research institutes. Firstly, now commonplace for h coollaboration between companies to work with outside partners and purrsue ‘o p e n companies and research institute for basic udes research product research. Secondly, collaboration innovation’, which inclu where com mpanies bring in new institutes. In present times, the universities utes play major technology an nd research institute helps and national research institu role in the industry in terms of R&D. them to adap pt to the local conditions. Thirdly, both h research institutes and Dr Kirti Chandra Saahu, Assistant Professor - Department off Chemical Ch l companies providing core expertise in to undertake applied research but this is Engineering, Indian Institute of complementary areas. Of the three, the Technology (IIT) Hyderabad, notes, “At first type is the most frequently preferred. not possible until and unless there is strong present, in India, the technology and fundamental/basic research to support it. process required for performing research Challenges posed on the way In order to carry out fundamental research, Industr y-academia collaborations is traditional and outdated. Further, India companies have to involve professionals from the institutes who have the required is also lagging behind in fundamental can work, provided clear areas of research activities. Companies directly want knowledge and skills. The professionals co-operation are worked out at the start

Chemical World | May 2012

forward to create a win-win situation

Collaborative research

of a project. However, the challenges are many and the major among them is huge investments. Dr Sahu notes, “Investments in fundamental research are huge and often companies are not interested in making long-term investments as they want quick results. For example, one has to wait for few years to see good results from research but the companies shy away from that. The scenario is different in other countries where companies actively involve themselves in fundamental research. However, slowly and gradually, the situation is changing in the country.” The other key challenges include the protection of intellectual property and government support to such initiatives so as to ensure that even small-scale industries are encouraged to utilise the efforts of such research institutes for carrying out cutting-edge research that otherwise would have been beyond their reach. Apart from this, for an effective collaboration, there are other requirements

as well. First, to be partners for R&D co-operation, both the parties need to have their strong areas either in research or with regard to other relevant aspects. Second, the two needs to be upfront and clear about potential issues regarding intellectual property, and prepare possible solutions for these in advance. Third, for research institutes to be an important partner for collaboration, it needs to focus on identified strong areas and build its manpower committed to timely work and agreed cost. Thus, both sides need to renew their approach, if there has to be continuous exchange. The key is that co-operation between industry and research institute be similar to a business transaction – it is an exchange from which each partner needs to benefit.

Way forward Given the benefits of industry-academia collaboration, in future, it will be critical in emerging areas such as biotechnology. Another bold step could be the privatisation

of some of the institutions in full or part creation of private research companies that run laboratories or undertake contract research for companies. The educational institutions could also partner with the chemicals industry by offering courses and conducting research proactively. Reddy concludes, “The industryacademia collaboration has high probability of attaining success in the country as India is a major chemical manufacturing hub. This would be a phenomenal opportunity for industry since in-house R&D set-up always involves extensive set-up costs and HR costs. Moreover, industry generally faces substantial shortage of research talent with the requisite skill-set and experience in advanced analytical researches but this collaboration will help the industry in this aspect also.” Thus, the collaborative strategy will definitely go a long way in ensuring growth of the chemicals industry in the country. Email: avani.jain@infomedia18.in

May 2012 | Chemical World

RESEARCH & DEVELOPMENT Roundtable

Can India evolve as the global hub for research? With chemical companies realising the importance of research and development (R&D), many steps are being taken by them as well as the authorities for promoting such activities. So, can India become a global hub for research? Avani Jain delves deeper into the issues and analyses the steps that need to be taken to achieve the objective.

Jaimin Vasa President, Gujarat Chemical Association, and Managing Director, Vasa Pharmachem Pvt Ltd

Bhupendra Patel Chairman - Gujarat Region, Chemexcil, & Managing Director, Jemby Chem Ltd

Mukul B Malvi Partner, TEXSPAN

India is lagging behind in R&D activities compared to other nations. However, a few proactive measures can make India a global hub for R&D. First, we should establish chemical sector council for innovation having representatives from the government, chemical companies, industry associations and reputed research institutes. Second, we should establish an autonomous $ 100-million chemical innovation fund to encourage commercialisation of innovations. Third, we should develop regional clusters and innovation centres in universities dedicated to chemicals industry. Fourth, collaboration agreements with foreign countries will enable us to develop capabilities in chemical product and process innovation. Finally, we should establish Chemical Innovation Council, which will recommend d and dh help l government iin creation of dedicated fast track court to handle IP issues.

While the US and Japan remain leaders in innovation, there is an increasing shift of R&D activities to Asian countries. Growth of technological capabilities in this region is the prime factor. Over the past two decades, India has emerged as a global hub for product research. Not only have multinationals set up their own R&D operations in India and partnered with local enterprises but Indian multinationals are also leveraging the talent pool for cuttingedge development. The teams based in India today are in a position to lead and collaborate with R&D teams across the globe to help define an organisationâ&#x20AC;&#x2122;s leadership position in their respective domains and in the industry as a whole. However, care must be taken to continue to nurture this ecosystem. Academia and industry must continue to co-operate closely l l to understand d d each h otherâ&#x20AC;&#x2122;s h â&#x20AC;&#x2122; requirements and deliver the same in a mutually beneficial environment.

There is good scope for R&D activities in the country but the companies are not willing to invest in this. India has potential in terms of availability of skilled manpower but the funds are not available. Further, even the technology required for such activities is not adequate. The industry-academia collaboration is also at a nascent stage. Whereas in the US, projects are sanctioned by the government in this regard and industry provides funds to universities to carry research process, in India, this concept is still not developed. There is a good scope for such collaborations in India. In my opinion, it will take a long time for India to become a global hub for research as the industry is not motivated to indulge in R&D activities and innovation. Thus, industry should start taking interest in R&D activities; and industryacademia d i collaboration ll b i should h ld be b promoted, so as to make India a global hub for research.

EDITORIAL TAKE In order to ensure the overall development of the industry, it is essential to develop long-term strategies for sustaining innovative R&D initiatives. However, at present, one of the biggest problems facing the chemicals sector is lack of fund and technology required to perform research and development activities. If these issues are resolved, then India can definitely become a global hub for research.

Chemical World | May 2012

SAFETY, HEALTH & ENVIRONMENT Safe processing

K N K Murthy

important aspect of enhancement of productivity through more dependence on safety. Social liabilities/commitments on safety, occupational health surveillance, pollution controls, responsible care etc are also to be addressed seriously. Industries do face constraints in inventory management of hazardous materials (maintaining optimally minimum

ndustrial occupations pose additional hazards when new scientific principles, engineering and technologies are applied as part of development or improvement process or for progressive growth. Among all industries, chemical manufacturing and allied functions are extremely vulnerable

layout by way of segregating/distancing bulk storages (both raw materials and finished goods) from hazardous zones. Moreover, safer storage patterns such as provision of emergency containment/ treatment facilities against spillages/ leakages/emissions etc, and creation of marketing outlets/terminals etc, away from high hazard-intensive operating plants/facilities also help.

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While new advancements in every industry spell good news for its growth, they also come with the baggage of additional hazards or new hazards hitherto unknown or undiscovered, especially in the case of chemicals sector. Hence, it is vital to tighten the safety belt not only to avoid workplace hazards, but also to attract huge investments in the chemical arena.

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quantity) due to fluctuating market situations and uncertainties. This problem can be resolved by adopting phased-out delivery schedules of raw materials of high hazardous nature, safer location/plant

Whyy workplace p safety is important to attract investments in the chemical arena? India is a preferred destination for chemical business considering the prevailing good work culture, resources, professional management capability/competence, availability of skilled, committed manpower, industrial peace and harmony. Accordingly, it is important that manufacturers give importance to safety. Worldwide, the performance of any manufacturing unit is gauged based on the following parameters: A. Ability to sustain highest quality B. Ensuring the delivery of desired quantity C. Commitment to extend best service â&#x20AC;&#x201C; both pre- and post-dispatch D. Integration of safety at all phases of business entrepreneurship and management Any aspect of delinking with respect to D will adversely affect A through C.

Chemical World | May 2012

There are various factors hindering safe processing. Non-availability of required number of qualified, experienced, skilled personnel at different levels including professionals at senior level is a serious problem with respect to safe operation/upkeep of all types of chemical processing units. There exists a wide gap with regard to the knowledge base on different chemicals being used and resultant process hazards & risk management capabilities. Sometimes the race for job completion against tough targets and time-frames pose add on/ external risk factors. Absence/ inadequacy of the contribution of independent centralised/facilitation ser vice functions like technical wings, R&D, corrosion monitoring/ inspection, structural design, condition monitoring, rotary equipment upkeep/ maintenance, preventive/predictive maintenance of mechanical/electrical/ civil and instrumentation system can be detrimental to safety management. Poor response with reference to needbased training/retraining system for employees is a major concern. Lukewarm attitude to emergency preparedness and response plan execution can decelerate safety governance. Last but not the least, companies are faced with the tough task of compliance against

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New hazards that can manifest into high-intensive operational risks are being seen. The main causation factors could be faster reaction rate, less retention time, adoption of higher temperatures/ pressures/flow velocities, risks emanating out of high reactivity/non-compatibility/ releases etc. emissions/energ y Optimisation and integration of safety with productivity can be considered as a viable and proven option to circumvent such situations. This takes care of the

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Current scenario and challenges

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to high toxicity, corrosiveness, reactivity, fire/explosion etc, besides most of the safety concerns faced in other industries as well. All these threats need specific risk management techniques and strategies. They can be chosen from a variety of options and application flexibility.

Effective risk management for boosting investments

Safe processing

MISHAPS DUE TO HAZARDOUS CHEMICALS Following are some of the recent accident cases (indicative) involving units handling hazardous chemicals: o Serious fire in a hydrocarbon storage terminal of a leading refinery unit (loss of property and business interruption) o Fire involving natural gas (conveyed through pipeline) at a dairy industry (loss of life, property and business interruption) o Leakage of chlorine from a gas cylinder storage zone located near a national harbour o Fire at a rivulet bed where oily wastes from a refinery were being dumped (no report of loss of life or property except violation of pollution-related statutes) o Runaway reactions involving organic and inorganic chemicals (loss of life and property) o Fires/toxic emissions involving road/rail tankers hauling materials like petroleum products/ammonia

stringent statutes, which have come up after major disasters like Bhopal gas tragedy.

Workplace safety vis-à-vis efficient production targets In industrial circles, there used to be in existence certain myths for a long time (still persistent among few) that: o Compliance efforts to fulfill safety norms decelerate production and efficiency considering the extra time/resource mobilisation o Extra cost is to be borne for implementing required safety measures, which cannot be justified in terms of appropriate payback Both the above arguments can be brushed aside if the work methods/ systems are improved upon. In fact, proper planning, preparation

Chemical World | May 2012

and compliance of safety measures save a lot of time, expenditure and even embarrassment at times. On the contrary, the loss of time or profit reduction encountered due to any untoward incident could be more detrimental for higher productivity.

Reducing workplace hazards The attempt must be commensurate with choice of proven, inherently safe technology, process, adherence to best design/engineering standards, choice of right material of construction, good construction and craftsmanship followed by smooth operation, upkeep of plant and equipment, preventive maintenance, periodical examination, checking and certification. Good engineering practices include structural integrity, reliability, control of noise/vibration/corrosion, inspection, fire proofing, installation of electrical fittings/fixtures/accessories as per area classification, static dissipation etc, to name a few. Usage of appropriate personal protective gears followed by inspection, surveys, monitoring, audits, motivation, enforcement and accident reporting/investigation/retrieval of information will go a long way in managing workplace hazards.

Revisiting the ‘human element’ From time immemorial, the human element factor has been doing rounds as the ‘ single’ and the most significant aspect of accident causation theory, which could be logical considering the involvement of humans being more prevalent in any type of accidents. However, it is commonly observed that the application of the human element theory especially after an accident tends to be shifted exclusively towards the person at the fag end of the chain – mostly victim. This is unfortunately a reactive or sometimes knee jerk response; in the process one loses sight of various other factors – again human – but pertaining to specific and focussed elements such as the

persons in charge of employee selection/ placement/super vision/training/ enforcement of system, upkeep of work area/design of equipment/maintenance, safety system management etc. Then there is the question whether there could have been an attribute to the execution of one’s assigned roles/ responsibilities, which could have helped prevent the incident at source. In most of the accidents, it could be proved that any one or more of such key links in the chain of events could have been the contributory factor for the final occurrence per se. While considering human element, it is important to accept people, who may be error-prone at various degrees, but can be trusted to be more errorresistant, user-friendly, etc, rather than always being dependent exclusively on human intervention, involvement, attitude, aptitude, behaviour etc.

Safety as business booster In the current scenario of financial uncertainties, competitiveness and highly speculative market environment at global level, safety can definitely play a catalytic role to enhance business viability. In the prevalent situation, where India is being seen as a viable option among many investors (both local and overseas), a deep-rooted safety culture will enhance their confidence level - it being an indispensable element in total loss prevention/reduction/ control of hazards. K N K Murthy has been in the fertilisers and petrochemicals industry for 38 years and retired as Senior Manager (Safety) from Indian Petrochemicals Corporation Ltd, Vadodara. Currently, he works as a Safety Consultant and is associated with Mahatma Gandhi Labour Institute, Ahmedabad. He has done pioneering works in various aspects like hazard identification, safety audits/inspections/surveys, training, emergency preparedness planning, quality/environment standards (ISO), etc. He can be contacted on email: mohanaknk@yahoo.co.in

SAFETY, HEALTH & ENVIRONMENT Product stewardship

Design, Development & Product Launch

DISPOSAL & RECYCLING

A cradle-to-grave tool to reduce environmental impact of chemicals

SUPPLY CUSTOMER USE

Product stewardship is a product-centered approach to reduce the environmental impact of manufactured products. There is a drive to put in place policy framework to promote chemical safety around the world. So are Indian chemical manufacturers prepared for this?

MANUFACTURE STORAGE, PACKAGE & DISTRIBUTION

Rakesh Rao

oday, probably one of the most important things in the minds of chemical manufacturers is safe handling and use of substances. In their endeavour to strengthen their Environment, Safety and Health (ESH) policy, companies are adopting product stewardship strategy. Product stewardship is the management

WHY GO FOR PRODUCT STEWARDSHIP? o Though not mandatory now, it will be critical in future o Global obligations will result in stringent chemical legislations in India o Post-2020, most countries will have tighter control over chemicals being supplied o Knowledge of chemical’s safety profile is a must for environment protection

Chemical World | May 2012

code for assuring safe handling and use of chemicals, throughout each chemical’s lifecycle, that is from R&D, design, manufacturing, marketing distribution, use, recycling and disposal of chemical products. While product stewardship is a wellestablished concept globally, in India it is now gaining importance. “The concept of product stewardship is definitely gaining importance in India. Though the acceptance is low at present in small to medium enterprises, most of the big players are adopting strategies for product stewardship. Multinational companies such as Dow, BASF, Clariant, etc have dedicated set-up for product stewardship. On the other hand, most of the Indian chemical manufacturers are still more focussed on process safety and the concept of product stewardship is still nascent among them,” says Dr D M Wakankar, Vice Chairman & Chairman – REACH Committee, Chemexcil.

Meeting global obligation As a result of lack of strong legislative requirements for chemicals in India,

companies have not taken product stewardship seriously. But this is likely to change with the upcoming international movement called ‘Strategic Approach to International Chemicals Management’ (SAICM), which is a policy framework to promote chemical safety around the world. “According to this UN initiative, to which India is a signatory, by 2020 all countries will have to put in place chemical management programmes. For this, India will have to frame several legislations, which could be related to restrictions, bans, control on certain chemicals, imports, etc. All these form a part of product stewardship, which will become indispensable over a period of time,” says Dr Wakankar. Because India has this obligation towards SAICM, he feels that chemical manufacturers in the country will have to gear up to product stewardship initiatives.

Know ‘thy’ chemicals With globalisation, the supply chain has become highly complex. Hence, Indian chemical manufacturers will have to take proactive steps to achieve product stewardship. Dr Wakankar suggests, “First of all, our knowledge about synthesised products is restricted. SMEs play a big role in Indian chemicals industry and manufacture & export lots of goods. However, fundamental knowledge about the product profile (ie, chemical composition, impurity profile, safety aspects, etc) is scarce. To compete globally

Product stewardship

with other chemical manufacturers, one needs to enhance these capabilities.” To regulate chemical manufacturing, it is important to know exactly the number of chemicals being manufactured in the country and how much. Whether they are hazardous or not? What is their safety profile? To know these, most of the developed countries have in place what is called as chemical inventory. Dr Wakankar says, “Inventory will have to be the starting point of everything. Unless you have inventory, you would not know which and what quantum of chemicals are being manufactured and imported. Hence, inventory is always the beginning for any legislation in any country.”

inventory. In this meeting, it was decided that Chemexcil will take a lead and prepare a model inventory based on which the actual inventory will be developed. Dr Wakankar discloses, “We have already started the work and have so far covered 4,000 substances. In about two to three months, the model inventory should be ready. Then we will present this jointly to the Ministries of Environment & Forests, and Chemicals & Fertilizers. Government then has to take this forward, since inventory cannot be implemented without the legislation.” Normally, when inventory is published, anything that is not mentioned in it cannot be manufactured or imported.

Getting future-ready Chemical inventory: Work in progress In January 2012, there was a meeting organised by Department of Chemicals and Petrochemicals (DCPC), Government of India, to discuss the status of chemical

If India has to meet the SAICM obligation, then it has to finish the chemical inventory at the earliest as this will be the basis for framing other legislations. Dr Wakankar says, “Most of the developed countries have their inventories in place. We do not have

the luxury of time as developed countries had (since they started the process quite early) and hence, we have to do multiple things at the same time and with double the speed. If we have to adhere to the 2020 deadline of SAICM, then chemical inventory has to be put in place by 2014 at the latest.” Post-2020, most countries, including India, will have stringent legislations in place to regulate chemicals. Hence, Indian chemical manufacturers will have to start the work on product stewardship in right earnest to be future-ready. “Once legislations come into force, chemical manufacturers will start looking into impurity profile, safety aspects, classification & labelling, etc about the products. And if a manufacturer is unable to fulfill any of the legislative requirements, then the company will not be able to sell/manufacture this product. Hence, product stewardship is going to be critical for doing business in future,” concludes Dr Wakankar. Email: rakesh.rao@infomedia18.in

May 2012 | Chemical World

SAFETY, HEALTH & ENVIRONMENT Roundtable

Can green chemistry principles be effectively used in production processes? The optimism of Dr Paul Anastas and Dr John C Warner, who put forward the 12 principles of green chemistry, is seen to be rewarded by the efforts of the chemicals industry. Mahua Roy speaks with experts in this field who decode the stipulations of green chemistry by extrapolating them from the lab to the production area.

Dr Swapan Kumar Ghosh Director, Nova Surface-Care Centre Pvt Ltd

Dr Pintoo Ganguly General Manager – Laboratory Operations, Sigma-Aldrich India Ltd

Dr G D Yadav Vice Chancellor, ICT, Mumbai

With scientists and engineers being more involved in providing solutions, it is important for academicians to use the principles of basic green chemistry and work upon it to provide solutions, which are practically possible to implement. As it is not easy to bring about a radical change, incremental amount of green changes can be looked into. All businesses ultimately aim at maximising the profitability. A new, greener process will not be feasible unless it provides some advantages over current processes and is sufficiently profitable to shifting from the conventional facilities. Green chemistry needs the engagement of a wide cross-section of the scientific community to enable it to deliver and within a stipulated timeframe. A concerted research drive by academia, government and industry iis needed d d to develop d l a wide id range of reliable, green methodologies that will be available as and when needed.

The chemicals industry has been striving to make better products with improved properties and applications. The industry is aware of its responsibilities towards sustainable development. Though much has been achieved, lot more is possible if the society at large supports companies and incentivises organisations that make products the ‘greener’ way. The cost focus should be coupled with the focus on waste reduction, recyclability and reuse. Easy access to affordable technologies will enable a large number of SMEs to graduate towards cleaner technologies. Academia all throughout has played a key role in the development of chemistry and technologies including development of green chemistry. Greener ways of production are the requirement of the h times i and d it i has h to be b taken k up to ensure a brighter future for the chemicals industry.

Sustainability rests around three important pillars – economic, environmental and social. But it is a known fact that the industry does not adopt new ways of manufacturing unless there are strict legislations defined. Unless there are tax incentives or monetary benefits achieved through the practice of green chemistry, the industry does not feel motivated enough to implement greener processes. Use of safer chemicals and processes in every sector is possible. Especially the dyestuff, intermediates and agrochemicals industry needs to implement process re-engineering towards greener routes. Green chemistry or engineering should be employed to develop environmentally benign technologies, which are not energyintensive. It is the duty of the academia d i on iits part to iintroduce d green chemistry programmes in their syllabi.

EDITORIAL TAKE The most inevitable question that needs to be answered is: can greener methods be cost-efficient? Resolution of this long-standing debate can convince chemicals manufacturers to adopt green chemistry in their production process. The key lies in considerable investments in R&D efforts to make sure that new routes of process engineering suit the practicalities of the industry, and most importantly, are cost-competitive.

Chemical World | May 2012

HUMAN RESOURCES Chemical institutes

Nurturing skill-set for tomorrow’s industry needs Attracting excellent talent to the chemicals industry has become as tough as predicting the trend of crude oil prices. An industry that offers a wide range of challenging deliverables and strategies, why is it losing out the battle to glamorous fields like IT, services and even media? The nurturing of talent needs to happen right at the stage when the minds of young chemical engineers and scientists are impressionable. Mahua Roy

ndia is seeing numerous investments in the chemical, petrochemical and oil & gas industries. As the chemical technologies for these become more intricate, demanding high level of expertise for designing and operation, it is an obvious fact that without an adequate number of knowledgeable employees, several technology-related industrial functions cannot be carried out at adequate standards. The problems appear to be centred at the level of education and training provided to the engineers, technicians and scientists in India.

G Gaikar, Bharat Petroleum Professor of Chemical Engineering, and Head, Department of Chemical Engineering, Institute of Chemical Technology (ICT), Mumbai. If one would look only with a quantitative viewpoint, India has a colossal figure of technologists, engineers and technicians to boast of. Companies are increasingly finding it difficult to get reasonably talented and knowledgeable engineers, technicians and scientists for investigative and skill-oriented functions like R&D, design & estimations and consultancy functions. While quantitative availability of manpower is certainly met with, the problem is at quality level.

Quality over quantity? There have been an sudden spurt in the number of engineering colleges, technical institutions and higher science research institutes all over India. Several students successfully complete their coursework every year and the number is much more than what is required in India. “Technical education in the country is booming today, with almost 1.5 million engineers graduating every year,” says Prof Vilas

Chemical World | May 2012

What does the chemical industry want? Chemical engineering is a highly sciencebased discipline, and changes in other areas have started affecting the ‘technical expertise or competence’ requirement. The industry now expects the candidates to have working knowledge of design software. “The chemicals industry is known for its diversity with areas ranging

from petroleum refining, petrochemicals, polymers, fuels, to steel & mining and specialty chemicals. Chemical engineers by their training, however, can settle comfortably in any of these fields once the basic principles are learnt and employed properly,” says Prof Gaikar. The basic expectations of the chemicals industry from new talent are technical expertise, leadership qualities, willingness to take initiatives, and excellent interpersonal communication skills. But in the last few years, soft skills are becoming a major requirement.

Nurturing talent for tomorrow One of the most common problems faced by the freshly graduated candidates is their unemployability because of lack of training in practical aspects and multidimensional nature of engineering discipline. If the potential of these engineers is to be used to the fullest extent, practical training is a must. “It may be difficult for the chemicals industry to provide training to every graduate. But if teachers are given training by the industry, with some sustenance stipend, it would help in imparting useful

Chemical institutes

knowledge to the next level of students,” suggests Prof Gaikar. He further adds that the offering of courses or part-time lectures by experts in industry can help in the transfer of knowledge and expertise to the students. “Also, the industry can probably offer internships to the most deserving candidates; challenge them with more difficult problems and nurture their talent for entrepreneurship & innovation,” says Prof Gaikar.

environment,” says Prof Gaikar. The most difficult first step is to attract the talent to take up a career in chemical sciences and chemical engineering. “Chemical companies can participate in the process by sharing the best practices at the undergraduate level in association with the educational institutes,” suggests Prof Gaikar. In addition, industry experts can add value by participating in curriculum revisions; writing to universities explaining tomorrow’s needs so that curriculum is shaped well in advance.

Serious industry participation is needed

Academia playing its part

Now is the time for serious industry participation, beyond just monetary funding. “An important aspect is generating interest among students towards science, and chemicals industry is ideally suited to exhibit application of science for producing materials of interest to society. The industry needs to demonstrate clearly the care it takes to avoid negative impact of its operations on the surrounding

Many institutes such as ICT, Indian Institutes of Technology (IITs), Council of Scientific & Industrial Research (CSIR), are well-equipped with some of the world-class facilities and look for collaborative activities. “Academic R&D labs should not be viewed as service labs to provide analytical services. PhD candidates take a major risk when they embark on a journey into unknown. This

atmosphere can be used to attract industry talent to work in academic laboratories on joint projects. This will bring greater responsibility in academic circles with respect to time-bound deliverables. On the other hand, young PhDs can bring new outlook and fresh ideas in analysing the situation,” quips Prof Gaikar. Besides, academia can also offer refresher courses to industry personnel, as a continuation of education programme. “New theoretical foundations are being built with heavy emphasis on miniaturisation, high speed computational facilities and on-line optimisation. Research students are the cheapest labour of highest intellectual capacity and available to work on projects at the minimum cost,” says Prof Gaikar. He also opines that if talented candidates exist in industry, they can come back to the academia to impart knowledge, as there is in fact a dearth of talented teachers in engineering profession. Email: mahua.roy@infomedia18.in

May 2012 | Chemical World

HUMAN RESOURCES Talent retention

Creating a new dimension through CSR strategy In a recent survey conducted by GlobeScan, a prominent international market research agency, 83 per cent of employees in G7 countries said that their company’s positive corporate social responsibility (CSR) reputation increases their loyalty. Emulating such values is driving companies in India too to seriously orient their strategies towards CSR as a mode for talent retention.

Mahua Roy

he attitude towards a strong CSR policy is evidently missing in India. Considering the size of the chemicals and petrochemicals industry, the efforts towards the mission of ‘giving back to the society’ are few. Apart from the laudable endeavours by a handful of large players, a lot remains to be done on this front. Traditionally, the chemicals and petrochemicals industry has been plagued with the image of being a polluting industry. To contribute towards a

Chemical World | May 2012

positive image, the chemicals industry, as a whole, needs to build up on the lost trust. Emphasising on sturdy CSR initiatives is one of the best places to begin.

Addressing attrition Another real world problem that the chemicals industry is facing is that of talent crunch. Right from highly qualified and experienced R&D professionals to production engineers, it is exposed to a number of challenges arising out of attrition. More so, as the young workforce enters the industry, the HR policies

need to be crafted taking into account the mindset of the new talent. “There is inadequate focus on career anchoring among youngsters, which poses challenge for the organisation. Also, lack of mobility is an area of concern as there is a huge gravitation towards city jobs,” puts forth B Sudhakar, Chief Human Resources Officer, Tata Chemicals Ltd.

Gluing CSR and talent retention together Application of CSR policy can help the chemicals industry address the problem of both attrition, and engage employees to contribute towards betterment of the society. “If an organisation’s CSR programme is genuine and positive, and it believes in total involvement, then the company definitely helps in building a positive feeling. People like to work for companies that share their values,” opines B Ramakrishnan, Managing Director, Marine & Protective Coatings, Akzo Nobel India Ltd, and Head, Performance Coatings plant, Bengaluru. Whether through reduced attrition costs or increased employee productivity, the HR benefit of CSR cannot be overlooked. Anecdotally, CSR improves morale, reduces turnover, and generally leads to more satisfied employees. Promoting the benefits of why ‘doing good’ is important in society has always been a tough task. This is where the role of senior management comes into the picture. Regular interactions with employees orienting them regarding the greater good obtained are essential. And not just culturisation, individual involvement of senior management makes a huge difference. “There is a direct correlation between management time invested in young talent and the output from them. Personal demonstration of the leaders makes a lot of difference to the youngsters,” says Sudhakar.

Risks, responsibilities and rewards In order to put forth a strategic CSR policy in place, weighing the risks, responsibilities and rewards becomes

Talent retention

important. From putting forward imminent regulatory changes to other such serious and relevant issues, companies must consider what risks they face and how CSR might help mitigate exposure to those risks. If the cause taken up by the company somehow aligns with the ideology of the company, the CSR exercise makes even more sense. Responsibilities arise out of new wave of expectations surrounding corporate involvement in the community. Whether from consumers, media, NGOs or even employees, there is visible pressure being put on chemical companies to be active and engaged in society. And most importantly, rewards arise out of gaining reputation, loyalty and credibility as a responsible sector. “Our current and ex-employees feel proud and happy to be associated with the CSR programmes. We have established a CSR model that has been extended to different geographical areas and wider sections of the society,” quips Ramakrishnan.

Chemical World | May 2012

Looking beyond immediate numbers In a world where business decisions need to be justified through sound reasoning, quantitative measurements, and tangible benefits, coupled with Excel sheets and Powerpoint presentations, expecting immediate return on investments (RoIs) is not the way to go. Heads of chemical companies should be mindful of where, when and in what form CSR investments pay off, and should not expect miracles overnight or over a quarter. “Encouraging volunteerism to inculcate care and trust dimension in the employees, which also helps them contribute to the society at large, is a factor that cannot be neglected,” adds Sudhakar. The bigger picture lies in the development of a responsible pool of citizens created by the corporate sector. Although some noticeable benefits of CSR may be seen, the larger picture and justification out of investments will be visible only in the long run. An effective

plan of CSR can not only boost the commitment of current employees, but also attract talent in the future. “Employees and potential employees reflect the values of the wider community and are influenced by those issues & concerns that are readily communicated in their communities and society. CSR programmes, when appropriately communicated, demonstrate the actualisation of values,” adds Ramakrishnan.

Imbibing the right culture It is an obvious fact that if a chemical company is involved in blatant, or even subtle depletion of the environment or natural resources, or embroiled in an embarrassing financial scandal, the employees will probably be less enthusiastic than if one believed one’s company is involved in ‘saving the world’. However innocent or raw the statement sounds, fatter paychecks can never compete with the repute of a company. Email: mahua.roy@infomedia18.in

HUMAN RESOURCES Roundtable

Is industry-academia partnership helping to tackle talent shortage? One look at the research scientists in a renowned international institute, one is bound to see an Indian name in the list. But closer home, the chemicals industry is facing real talent crunch. Isn’t this the right time to relook at the academic scenario and revamp the procedure of chemical education? Mahua Roy finds out…

Vinayak Pai Director – Operations, Aker Powergas Pvt Ltd

Ravi Kapoor Managing Director, Heubach Colour Pvt Ltd

Mukul Gupta Managing Director, Chemtreat India Ltd

In the chemicals and petrochemicals, or even the allied EPC industry, there is a definite resource gap for skilled manpower. There needs to be a structured top-driven approach to address this issue. Fortunately, the government has identified this problem and is driving solutions to this issue through the National Skill Development Council. Rather than working on piecemeal basis, the government and the industry should join hands and prepare a holistic approach to address this issue. A lot of data needs to be generated to actually quantify this gap and work out programmes to fill this gap. The industry is in the best position to do this and then tailor-make training programmes at all levels. The government can steer this programme and provide funds as required. i d Sh Short-term and d llongterm targets need to be identified and tracked for effectiveness.

Sourcing highly skilled talent has become a critical issue for the chemicals industry in India. Chemical engineering or chemistry is not usually the first choice for students, except those few students choosing highly reputed institutes, which are known for these fields. The Indian education system needs to be revamped in order to address this issue. Global practices, especially those in Germany need to be studied deeply and a relevant model should be adopted that is customised towards Indian environment. A three-tier system comprising healthy involvement from academia, industry and the government is looked forward to. The academia can train from the theoretical aspect; the industry would support practical training while hil the h government needs d to come forward with feasible funding to support these causes.

The Indian chemicals industry has a good record in management expertise – the availability of skilled and qualified chemists & chemical engineers are at par with the world. However, local talent deserting Indian industry is becoming a major problem. In view of this, the industry and authorities should create an exciting situation for Indian talent to flourish in the country. There is a need to provide infrastructure for innovation to flourish as it will stop the brain drain and migration of talent to other developed countries. The academia needs to focus on training students who are ready for industry and provide good interface for fruitful collaborations. Partnership between industries and academia is a must for transforming ideas into new products. Thus, Indian chemicals industry should leverage the h potential i l off education d i & research h centres and intellectual resource as well as human capital.

EDITORIAL TAKE The chemicals industry is one of the most prestigious in India. In order to sustain its reputation, academia-industry partnership needs to build strategies together. These two facets are interdependent and co-existent. It is more of a symbiotic relationship. The sooner the two works together as one entity, the faster will the real issue of talent crunch be solved.

Chemical World | May 2012

HUMAN RESOURCES Roundtable

Are chemical manufacturers taking right measures to ensure work-life balance? Long working hours, frequent expeditions, stringent deadlines – these words would seem highly familiar to an employee in the chemicals industry, which is facing a talent crunch. So what is the status of HR practices that are looking to tackle talent retention? Mahua Roy examines the efforts of leading companies.

Bharat Gala President, SNC Lavalin Engineering India Ltd

Rohit Thakur Director & Head of Human Resources, GE Energy, India

Lakshmi Nadkarni HR Country Leader India, Dow Chemical International Pvt Ltd

The demands of the chemicals industry create the need for a fastpaced workplace with high standards for excellence in a growing sector. In order to succeed, we need to ensure the well-being of employees. This includes a balance between work and personal time. In order to ensure this, the corporate values of an organisation need to reflect a focus on employees, their personal growth, career development, and general well-being. We know that this is important to all our employees, regardless of age, and we promote it across our workforce. Our employees work hard to meet the high standards we have set for ourselves. The company needs to care about the health and safety of employees. When it comes to the stressful demands of the EPC sector, work-life balance ensures that h employees l are happy h and productive, which allows us to do a better job for our clients.

Our experience shows that worklife balance has become more of an element of work-life flexibility rather than work-life balance. With a flexible work culture, the employees work in an environment where they feel comfortable; where employees are treated equitably and managers are empowered to create an open, supportive and responsive environment, and where requests are approved based on business and customer needs. Our successful initiative has been well-received by employees. It helps our company to retain talent and create a competitive advantage at a time when finding qualified job candidates can be a difficult challenge as it provides our employees flexibility in setting their own schedules to meet business needs as well as their own personal needs. d IIt h helps l people l to b be more productive specially those who have long commutes.

Work-life balance is broadly defined as a satisfactory level of involvement or ‘fit’ between the multiple roles in a person’s life. Its importance has increased with the demanding 24x7 work culture. Taking cognisance of this importance, we are empowering our leaders and employees to work together to develop worklife solutions that effectively help employees manage their professional and personal responsibilities. The young workforce of today is aware of this concept and respects companies, which enable them to gain that balance, making it one of the important driving factors of consideration for them. The chemicals industry is a highly sensitive one, where employees need to be responsible enough to deliver safe and optimum results. Even a marginal error could lead to disastrous results. di l H Hence, iit iis critical ii l that employees are provided with an environment that helps them thrive.

EDITORIAL TAKE Regarded as one of the highly stressful industries, the chemicals & petrochemicals industry is facing an inevitable challenge of talent crunch. Thus, one of the critical issues facing the industry is that of talent retention. One of the best ways to achieve this is by providing a work-life balance, which would help create, most importantly, sound unstressed life for the individual.

May 2012 | Chemical World

WATER MANAGEMENT Wastewater treatment

Rakesh Rao

n April 26, 2012, something unusual happened at Mangalore Refiner y and Petrochemicals Ltd (MRPL). For the first time, the twodecade old refinery had to go for a total shutdown due to shortage of water supply. Surprisingly, the region where it is located receives plenty of rainfall. So what was the reason? Experts claim that the cause of the problem was mismanagement of water by the government authorities. If this could h happen to a region that h receives above b average rainfall, then one could imagine the scenario in areas where rainfall is scanty. No wonder, water conservation

the new but proven technologies being used for effective treatment of industrial wastewater in India,” says Nilesh Tantak, Senior Applications Engineer, Aquatech International Corporation. One of the major trends witnessed in the recent times is the increased adoption of hybrid technologies to treat complex wastewater and effluents. Hoshang Subawalla, Business Leader, Water & Process Technologies, GE Energy, India, elaborates, “The industrial market has seen adoption of hybrid technologies like chemical treatment/pretreatment in addition to equipment technologies such h as MBR MBR, reverse osmosis (RO), (RO) Zero Liquid Discharge (ZLD), etc for wastewater reuse. In many cases, the industrial markets are opening up for the

process/specialty chemicals too. These solutions have been driven by increasing need for conserving and reusing water in industrial processes.” Though the adoption of hybrid technologies is low, it is slowly picking up pace. “In India, a key challenge would be the ‘slow’ adoption of newer technologies. Water policies need to be directed towards reduction of the nonrevenue water and adoption of latest technologies. These drivers will generate the push towards reuse and recycling of water,” says Subawalla. GE offers water & process technologies providing integrated d solutions l to serve energyand water-intensive industries such as mining, metals, refinery, petrochemicals, power and food & beverage.

Technologies to conserve the precious drop has gained importance in all the sustainability reports of chemical majors.

Moving towards hybrid solution The water situation is more critical for countries such as India and China, which have large population and where agriculture accounts for a major share of GDP. Hence, industries have a moral obligation to minimise usage of water and treat effluents. To achi h i eve this objective, ch hemical manufacturers in India are adopting novel wastewate ter te treatment technologies. “Industry is embracing newer technologies with an objective to maximise recycling of treated effl flue fl u ntt back into their process. Sequencing Batch Reactor (SBR), Moving Bed Bioreactor (MBBR) and Membrane Bioreactor (MBR) are some of

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Water Wa W ate t r scarcity scarcity iss ev eevident vidden ent ent across India. Henc Hence, nccee,, to reduce dependence on municipality for the su su supply of water, cchemical hemical manufacturers are adopting adop opting op novel technologies to treat wasttewater and reuse itt inn wastewater t ei th their e r facility.

“Our products include equipment such as membranes, MBR and s stems, and treatment chemicals sy & services for effluent, cooling, b iler and wastewater applications. bo We offer specialty chemicals used in the process, wastewater, metal removal and cooling applications. Increasingly, the environmental awareness, social responsibility and operational cost savings through adoption of these chemical technologies are driving the growth in this sector of the water business,” adds Subawalla.

So S olving the comp co mple l x waste problem Often the effluent from chemicals industr y contains various types of chemicals, which cannot be treated by a specific

Wastewater treatment

technology. Hence, manufacturers have to adopt the ideal strategy for ensuring effective effluent treatment. Tantak says, “In general, for specific chemical contaminants that may pose challenge to biological treatment technologies, the inside battery limit treatment within process unit itself is the norm. For instance, spent caustic waste stream originating in refinery and petrochemical plants is treated via wet air oxidation system before it is allowed to be discharged to central wastewater treatment plant.” However, the discharge standards in near future may aim towards certain refractory chemical contaminants – dioxins, polychlorinated biphenyls (PCBs), heavy metals, etc – to achieve very low levels in parts per billion (PPB). “This may require addition of specific advanced treatment technologies such as Advanced Oxidation Processes (AOP), advanced chemical precipitation processes as polishing treatment to meet trace level discharge standards. These technologies are also available in the market but their use may require piloting for specific application before adopting on commercial scale,” opines Tantak. Experts feel that the global developments in the wastewater sector are not different from what India is experiencing right now. However, the shift in wastewater treatment is towards the concept of ZLD. “This has led to process and system design with equipment such as MBR, RO, ultrafiltration (UF) and evaporators with chemical treatment/pretreatment. Increasingly, the shift in chemicals is towards polymers, which are much easier to handle; metal removal applications for environment; and process & specialty chemical applications for specific needs in the different industries. The industry is definitely seeing the adoption of hybrid technologies with chemical treatment/ pretreatment in addition to MBR, RO, ZLD, etc for wastewater reuse,” adds Subawalla.

Taking proactive steps The chemicals industry, one of the leading consumers of water, is responding by using less water and reducing emissions of pollutants into rivers. Take the example of recently established carbon disulfide (CS 2 ) production plant in Dahej of Indo Baijin – a joint venture between Indofil Industries and Shanghai Baijin Chemical Group (SBC). “The green technology adopted by Indofil Industries for its Dahej plant results in 25,000 tonne (estimated) carbon credits per year and can be traded in carbon exchanges. The technology also recycles 300 cubic metre of water everyday. These measures not only help protect the environment and reduce carbon footprints, but also increase the bottom line of the company. The new technology has a time tested 99.5 per cent sulphur-to-product conversion, which means Indofil would be minimising wastage of raw materials,” claims R K Malhotra, Chief Executive and President, Indofil Industries Ltd. The company plans to expand its water management strategy to other manufacturing units. Malhotra adds, “Keeping in mind the outlet of wastewater, where human habitation might be present downstream or close to its vicinity, it becomes pertinent for chemicals industry to adopt effective treating technologies. Indofil Industries is committed to adopting green technology and encourage sustainable development across all its plants. We will use water recycling technology in all other plants and projects of Indofil after the success in Indo-Baijin project in Dahej. However, this would be done in phases over a period of time.”

Save every drop With more and more companies taking steps to optimise the usage of water, wastewater treatment solution providers are looking to invest in India and bring leading global technologies into the country. Subawalla opines, “GE currently sees wastewater as an

WATER CONSERVATION SOLUTIONS o Water scarcity is driving chemical companies to use novel wastewater treatment technologies o Chemical manufacturers are making significant investments to use water efficiently o Usage of hybrid technologies (ie combination of chemical treatment with equipment technologies such as MBR, MBBR, etc) is on the rise o Water recycling is gaining importance o There is a shift towards the concept of Zero Liquid Discharge

important and high growth area for the industrial and municipal sector. Water scarcity/stress in many areas of the country and regulation enforcement along with the ‘comparatively’ better/ newer technology adoption in industries would be a driver for wastewater treatment in this sector.” Speaking about the future scope of wastewater treatment market, he says, “Technologies for treatments are wellproven and, more efficient and ‘leaner’, less energy consuming technologies are making new inroads. MBR, SBR, MBBR are few such technologies, which are finding prominence in wastewater treatment. The adoption of these technologies in the industrial sector and the municipal sector will define the scope of the wastewater treatment.” Water is already a scarce resource in all parts of India. Intense competition with human needs makes this a sensitive social factor, and there is no question that industry will be a third priority in any allocation, after community and farming needs. Hence, chemicals industry will have to take a lead in offering solutions to water scarcity problem, and also to find ways and means to efficiently use the world’s most precious liquid. Email: rakesh.rao@infomedia18.in

May 2012 | Chemical World

WATER MANAGEMENT Optimising water usage

Innovative solutions to bridge demand-supply gap The fast depleting water resources has brought to the fore the need for effective water management across industries. Effective management of water in the process industry can address demand-supply gap to a large extent. Increased focus on water treatment is also instrumental in bringing new technologies to the market. by the industry to ensure a progressive drop in specific water consumption for bridging the demand-supply gap for water, going forward,” points out Alok Kumar Bhadra, Managing Director, Nalco Water India Ltd.

Tips to conserve water

Prasenjit Chakraborty

ffective water management is the buzzword in every industry. It is mainly because of gradual depletion of water, which makes industries cautious and forces them to adopt strategies to address the problem. Hence, today, water and wastewater treatment market is growing by leaps and bounds. Looking at the dynamics of the chemicals industry, effective water management is a must and will provide myriad benefits to the industry as well as nature. “The demand for water from the industry is expected to grow at a rate of 4-5 per cent compounded annual growth rate (CAGR) over the next decade. However, the availability of water (ground and surface) is projected to go down over the same period. This calls for major focus on managing process water requirements

Chemical World | May 2012

With increasing population and urbanisation, the demand for water, especially domestic water, is on the rise. “It is difficult to bring down the demand for water in the area of agriculture, which comprises over 70 per cent of consumption and feeds the growing population. The challenge lies within the industry to reuse and recycle water by adopting latest technologies and best practices aimed at conservation, and meet the increasing discharge limitations with regard to quality and quantity,” says Bhadra. Technology and innovation will play a major role in the Indian market to overcome the challenges of rapid industrialisation and the progressive scarcity of water resources. “Automation and control technologies to manage ‘more with less’, plus technologies for better management of unit operations in municipal water, sea water, surface water, wastewater, will be extremely crucial in optimising water usage costs effectively,” points out Bhadra. With the advancements in materials science, nanotechnology and information technology, it is likely that there will be new developments in the area of membrane filtration, disinfection/ oxidation methods, ion exchange resins, adsorption technologies, as well as water management methods utilising information and telecommunication

technologies with remote monitoring and control capabilities. Nanofiltration and nano-size based membrane filtration are the most quickly developing novel technology, in terms of both quality and quantity of treating wastewater. Even though ultrafiltration and reverse osmosis (RO) techniques are gaining popularity in wastewater treatment markets for their performance in tertiary treatment, nanofiltration remains midway between the two as this technology is proven to be efficient in terms of better particle removal and also with lesser operating pressure than RO.

Business drivers Among the various treatment technologies available, there has been a discernible shift from the conventional methods towards advanced technologies like RO membrane technology and use of ion exchange resins. These technologies are mainly used for recycling processes. As the world is facing energy crisis, there is a demand for energyefficient water treatment technology. Eco-friendly biotechnology also would be a cost-effective clean technology for wastewater treatment. Besides, forward osmosis technology removes difficult waste and pollutants from industrial waste streams. No doubt, the water management arena is also witnessing remarkable changes. “The outlook is positive as the key business drivers for the industrial water market in India are firmly in place and projected to intensify in the mediumto-long term, attracting investment in talent, technology and infrastructure, by both the government and the private sector,” asserts Bhadra. Email: prasenjit.chakraborty@infomedia18.in

WATER MANAGEMENT Roundtable

Is recycled water a viable option for processing? Water scarcity is not a dreaded dream any more, but a reality. Water recycling is one of the possible solutions to solve this challenge. Rakesh Rao interacts with some experts to know the feasibility of water recycling in the Indian chemicals industry.

Hoshang Subawalla Business Leader, Water & Process Technologies, GE Energy, India

Nilesh Tantak Senior Applications Engineer, Aquatech International Corporation

R K Malhotra Chief Executive & President, Indofil Industries Ltd

Water recycling is a function of water availability, cost of water and regulatory environment. As all these drivers for recycling are shaping up in India, recycling certainly is a viable option for the chemicals industry. Water availability is getting scarce; industrial water charges are climbing higher or are beginning to be charged (which used to be free or at a nominal cost); and regulations & enforcements are becoming more stringent, especially for waterintensive industries such as steel, power, chemical etc. Recycled water has numerous applications depending on the level of treatment/removal achieved. Most of the current applications for recycled water include gardening, and non-drinking flushing applications. However, with the added dd d fil filtration/treatment i / process, this water can also be used for the production application.

There is little doubt that water recycling is a viable option. Scarce fresh water resources and rapidly deteriorating quality of water resources due to discharge of untreated or non-compliant treated effluents are the prime compelling reasons for Indian chemicals industry to adopt effective technologies for treating wastewater. Industry is pursuing several cost-effective options to recycle their treated effluent to reduce its dependence on the dwindling fresh water supplies. Aquatech has successfully implemented treated effluent recycle system in several chemical manufacturing facilities in India. It is possible to use the recycled water in production process. This requires additional polishing treatment steps, for example, second pass RO, mixed bed demineralisation unit i or electro l deionisation d i i i (EDI) to meet specific process water quality requirement.

Water recycling is not an option but a must for the chemicals industry in India as availability of potable water is becoming scarce for human consumption and agriculture. Also, the industry has to treat effluents in order to recycle water and achieve zero wastewater discharge so as to obtain Environmental Clearance (EC) from Minister of Environment & Forests (MoEF) to set up the project and for expansion. Hence, it is the responsibility of an ethical corporate to adopt all possible measures to try and reduce consumption and wastage of fresh water. At the new Indo-Baijin project, we have adopted technology to channelise used water through cooling plants. Its primary utility here will be of heat transfer, without much relevance for its pH balance. b l Thus, Th by b reusing i water, we would be utilising it several times in the production process.

EDITORIAL TAKE Forced by stringent environment regulations coupled with growing awareness about water recycling, chemical manufacturers in India are looking to use recycled water in their facilities. Given the slow adoption rate, the government should facilitate the process by giving adequate sops for water recycling technology.

Chemical World | May 2012

POLICIES & REGULATIONS Duty rationalisation

Prasenjit Chakraborty

he chemicals industry in India strongly feels that if the government rationalised the current duty structures, it could reach new heights in terms of competition, exports, etc. According to Satish Wagh, Chairman, Chemexcil, the Government of India is giving incentives to farmers under Vishesh Krishi & Gram Upaj Yojana (VKGUY ) for export of castor oil (industrial feedstock) whereas the value-added products like sebacic acid are not incentivised. “This situation discourages the entrepreneurs from manufacturing value-added products. China is the biggest buyer of Indian castor oil,” he says.

incompetitive in the international market compared to Malaysian and Indonesian manufacturers. This is causing a serious threat to the survival of the Indian soap industry,” laments Wagh.

Excise Duty Hike in Excise Duty and Service Tax ultimately results in price increase at the final consumer level. “This will be more predominant in case of products where benefit of CENVAT cannot be availed. With inflation already reigning high, the disposable surplus with the Indian consumer is already under pressure,” points out H S Karangle, Director General, Indian Chemical Council. Further in view of current duty levels, imports from overseas countries have

materials required for the manufacture at BCD levels of 7.5 per cent,” rues Karangle. According to him, there is an Export Duty on phosphorous in China whereas on the finished product based on phosphorous the duty is lower or nil. Such proactive step from the Chinese government ultimately helps the industry there to grow. India needs to have its own measures in this regard. It seems that the government is now realising the gravity of the matter and its affect on the industry. “Some initiatives are being taken; however these need to be examined for compatibility with WTO,” says Karangle. According to him, insufficient infrastructure development in existing chemical clusters and energy & finance,

Time for a pragmatic approach The absence of pragmatic duty structure is costing chemicals industry in terms of competition, level-playing field etc. It is time for the government to examine the duty structures in other countries and the benefits they offer to their respective chemicals industry. It is still not too late to emulate what other nations have done for good. In case of oleochemicals (soaps and detergent industry), countries like Indonesia and Malaysia impose an Export Tax on palm oil, which is a basic raw material for soap noodles. “Added to this, India levies additional Customs Duty on import of palm oil meant for industrial use. Also, it is mandatory to import adulterated palm oil for industrial use (so that it is not diverted into local market). All these add to the cost of Indian soap manufacturers making them

Many of the products are facing the problem of inver ted duty structure making them less competitive vis-àvis imports. This is particularly more apparent in the case where India has signed Free Trade Agreement. H S Karangle Director General, Indian Chemical Council

Chemical World | May 2012

increased and Indian manufacturers need to reduce price to match the landed price of imported goods. This also puts pressure on the margins and affects the industry. Price increase due to these tariffs will surely have adverse impact on the chemicals industry. In many cases, Import Duty imposed on raw materials is higher than that imposed on the intermediate products. It is quite detrimental as India invested substantially to put up the manufacturing capacity. “Many of the products are facing the problem of inverted duty structure making them less competitive vis-à-vis imports. This is particularly more apparent in the case where India has signed Free Trade Agreement (FTA), eg Thailand,” points out Karangle. Hydrogen peroxide is a case in point. “Hydrogen peroxide when imported as per the recent Notification No.127/2011 dated 30-12-2011 has the Basic Customs Duty (BCD) at 2.5 per cent. Whereas manufacturers have to pay Import Duty on the ingredients/key raw

which are linked with Central & State tariffs are the reasons for India losing out to other countries.

Pragmatic duty structure For level-playing field for the chemicals industry, it is imperative to understand that every stakeholder is now part of the global economy as barriers are now being dismantled. “Thus, we have to be globally competitive,” exhorts Karangle. While Indian technical manpower and manufacturing skills have been substantially upgraded, now it is time to sincerely look into costs vis-à-vis other countries. “The various costs, the major elements like energy (this cost is almost controlled by the government), labour reforms etc are government-centric. Thus, the government has to play a proactive role. Also, there is a need to support R&D, which will be the backbone for sustained growth of the chemicals industry,” asserts Karangle. Email: prasenjit.chakraborty@infomedia18.in

POLICIES & REGULATIONS National Chemical Policy

Recently, the Department of Chemicals & Petrochemicals, under the Ministry of Chemicals & Fertilizers, Government of India, has come out with Draft National Chemical Policy (NCP). The thrust of this policy is to underscore the imperative that sustained adoption of technology upgradation would offer viable options in overcoming developmental challenges across multiple sectors. Vipul Shah

hemistry touches millions of lives every day and helps address many of the world’s most challenging problems such as ensuring adequate potable water, renewable energy generation & conservation and increasing agricultural productivity. In India, the chemicals industry is one of the fastest growing, critical sectors that accounts for almost 13 per cent of the GDP. With a market size worth more than $ 100 billion, it helps sustain the 7 per cent plus GDP growth of our economy by contributing ~ 3 per cent to it. Hence, a policy specific to the chemicals industry like the Draft NCP is the need of the hour for better regulation and functioning.

Cohesive policy For the NCP to be effective, it should be aligned to the country’s National Manufacturing Policy (NMP) and more importantly, supplement the already announced concept of Petroleum, Chemicals and Petrochemical Investment Regions (PCPIRs) in 2007. In order to give a boost to the Indian chemicals industry, the policy should

ey to accelerate industry’s progress also make concrete recommendations for adopting: o A cohesive approach to address all relevant legislations given that the chemicals industry endures a large number of legislations (both Central and Local) governing it. Instead of merely stating an intention to adopt legislation similar to that of REACH or setting up a centralised body – Indian Chemical Agency – the policy needs to iterate the timeline within which these need to be adopted o Stricter mechanism to ensure safe disposal of chemical waste o Concrete steps towards addressing high power costs/captive power costs/ land acquisition costs and associated risks/taxes, levies and duties/lack of infrastructure/financial support and incentives for the industry. These are real issues plaguing the industry for a while now o A roadmap for consolidation of SMEs into bigger units – how much and by when. Incentive guidelines should be provided for the SMEs so that they can see the benefit of consolidation o An industry-friendly duty for feedstock products and uniform pricing mechanism for importing feedstock o A mechanism to provide financial incentives to players who are migrating from obsolete technology to green state-of-the-art technology o Leveraging the Free Trade Agreements with several blocs by reducing the customs tariffs and signing definitive amount of import/

export of chemicals as part of the agreements o The final policy should also clearly specify the role and accountability of the government, various bodies, industries and others to ensure complete backward and forward integration o In the context of sustainable development, accepting that sustainability today is a reality, the policy has to have a special emphasis on green technology through the Technology Acquisition and Development Fund (TADF). This will result in a positive move in the direction of a sustainable eco-friendly manufacturing industry

Let’s get started! The current draft does attempt to cover all points such as bringing in fresh investment, developing infrastructure, providing financial incentives and tax benefits & state-of-the-art-technology. Having said that, the need of the hour from this draft policy is a concrete, realistic and doable approach, with specific timelines to get the goals off the ground. Vipul Shah is the President, CEO & Chairman, Dow Chemical International Pvt Ltd. He provides leadership and geographic oversight for implementing Dow’s geographic business objectives and reinforcing the company’s new portfolio and transformational operating model. For details, contact K Balaji on email: balajik@dow.com

May 2012 | Chemical World

POLICIES & REGULATIONS Chemical clusters

The chemicals industry in India is growing at a rapid pace. It forms the backbone of the industrial and agricultural development in India and provides building blocks for downstream industries. In order to further add impetus to this growth, and provide a boost to the SMEs in the sector, chemical clusters have been formulated and they have yielded positive results. Avani Jain

oday, there is an urgent need to build better infrastructure and provide adequate power/water to support industrial growth. The chemicals industry faces various challenges related to safe transportation of products. Infrastructure is also inadequate with respect to proper storage facilities, and for seamless exports. Investments are needed to develop roads, railways, waterways, ports, warehouses, etc to support the overall industrial growth. Further, chemical units are dispersed throughout the country due to incentives offered by the respective State Governments. Thus, there is a need to form clusters with provision of common infrastructure facilities to address the constraints of common effluent treatment, transport linkages, including roads, power supply, water facilities, etc.

A c l u s t e r- b a s e d approach will help the government in providing basic amenities to all the industries in a particular area and this will encourage planned development in the State, besides giving a boost to the chemicals industry there. Jaimin Vasa and MD, Vasa Pharmachem Pvt Ltd

Chemical World | May 2012

Cluster development Industry clusters are establishments where several players set up plants around an area to reap the benefits of co-location. Some of the major benefits of chemical clusters include sharing of resources to reduce costs, proximity of suppliers/buyers, thereby improving co-ordination across players and availability of trained & industryspecific skilled manpower. Jaimin Vasa, President, Gujarat Chemical Association, and Managing Director, Vasa Pharmachem Pvt Ltd, says, “A cluster-based approach will help the government in providing basic amenities to all the industries in a particular area and this will encourage planned development in the State, besides giving a boost to the chemicals industry there.” There are various benefits of a chemical cluster. The major being that it will provide a boost to SMEs in the sector, which do not have adequate funds, infrastructure and technology. Further, clusters can work to obtain clearance from regulatory agencies in export markets for the entire cluster. Companies can get easy access to common services like power, transportation infrastructure, legal services for patent and intellectual property rights-related queries, and a well-equipped laboratory for quality checks as well as compliance-related issues. This will also save transportation costs of companies by easily connecting

them with the key raw material suppliers, giving them tremendous logistics benefits and operational flexibility. Further, the clusters can set up their own common waste disposal plants like the effluent treatment plants etc.

Government initiative The Government of India has developed ‘Industrial Cluster Upgradation scheme’ to facilitate the growth of the industries including the chemicals. The proposed scheme primarily focusses on developing and upgrading industrial infrastructure at existing clusters. The overall objective of the scheme is to influence efficiency and enhance competitiveness of industries located in such clusters. The scheme covers areas such as infrastructure support, market intelligence, technology transfer, human resource development etc.

Gujarat: A success story The presence of mega-estates in chemical manufacturing at several industrial clusters in Gujarat has helped growth and expansion of the industry by providing an appropriate business ecosystem. Chemical clusters especially at Ankleshwar, Panola, Vapi, Vatva, Jhagadia, Dahej etc have facilitated rapid development. Vapi is one of the country’s largest chemical clusters. It comprises majorly small and medium players. It consists of about 1,300 industrial units, of which about 1,900 are involved in chemical and pharmaceutical processing.

Chemical clusters

The Petroleum, Chemicals and Petrochemical Investment Region (PCPIR) – a specially delineated investment region planned for the establishment of manufacturing facilities for domestic and exportdriven production of chemicals and petrochemicals – at Dahej is spread over an area of 453 sq km of brownfield area in the coastal belt of the Gulf of Khambhat. With a capacity of 22 million metric tonne per annum (MMTPA), it is in the vicinity of the Dahej port. The PCPIR offers scope for future expansion possibilities to augment capacities to 30 MMTPA for catering to LNG, dry bulk and liquid chemicals. Thus, with the development of clusters like PCPIRs and SEZs, Gujarat has created world-class infrastructure facilitating the progress of the chemicals industry.

Issues to be addressed While everything seems positive about the chemical clusters, the government

needs to keep few points in mind. Vasa notes, “There should be effective effluent disposal scheme in the chemical clusters. This is to ensure clean environment in the chemical zones. The government needs to ensure that everybody gets access to common amenities like basic infrastructure, water and power supply. Further, efforts should be made to shift the existing chemical companies to chemical clusters, as this will help them to better utilise the facilities that are meant for them.”

Networking at its best The chemicals industry in India is well-established and has recorded a steady growth over the years. It offers a wide scope for development that contributes positively to economic growth and regional development. The outlook for the industry is bright with positive developments anticipated in various chemical sub-sectors. In order to promote investment in this sector

and make the country an important hub for both domestic and international markets, the government has decided to set up chemical clusters so as to attract major investments, both domestic and foreign. The chemical clusters would reap the benefits of networking and greater efficiency through the use of common infrastructure and support services. They would have high-class infrastructure, and provide a competitive environment conducive for setting up businesses. Further, the chemical clusters need to leverage individual capabilities and unique selling points to attract businesses. Clusters need to be projected as a single destination for potential buyers of chemicals catering to the needs of all buyers. Thus, it can be said that the chemical cluster can aid in growth of chemicals industry and can be a viable option for the industry. Email: avani.jain@infomedia18.in

May 2012 | Chemical World

POLICIES & REGULATIONS Policy reforms

Rakesh Rao

ccording to the Planning Commission, Government of India, size of the Indian economy is expected to reach $ 10 trillion by 2025, making it the third-largest economy in the world. This has prompted many chemical companies to increase their investments in India. “Increasing per capita consumption, strong domestic demand, high growth rate of end-user industries such as automotive, construction, textiles and paints & coatings and high number of working age population makes India a preferred investment destination,” says Aashish Kasad, Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd. In order to further increase investors’ confidence, government is taking a number of initiatives. Kasad observes, “As per the draft manufacturing policy recently approved by the Cabinet, it targets an increase in the share of manufacturing in GDP to at least 25 per cent by 2025 (from current 16 per cent). The growth in the chemicals sector is also expected to be boosted by government policies such as 100 per cent FDI,

consolidating multiple legislations governing the chemicals industry into one integrated legislation and cover the entire lifecycle of chemicals. It should also focus on removing redundancy associated with multiple regulatory bodies. Integration of chemical legislation will simplify the regulatory structure, avoid duplication as well as make the entire process more efficient.” In addition, she feels that the government should provide a single window clearance for development of infrastructure facilities to boost chemical sector, including settingup of special duty free zones, export promotion zones and new chemical investment regions. “To be competitive in the export market, export-linked income tax incentives akin to those granted to the erstwhile export-oriented units should be introduced,” she adds. Fo r sustainable growth, it is

According to Siddharth Paradkar, Principal, Tata Strategic Management Group, India should do the following to increase the flow of investments: o Provide incentives to international players for setting up large petrochemical plants – enabling availability of feedstock for downstream products o Policy initiatives like the PCPIRs and National Manufacturing Investment Zones (NMIZs) need to be pushed to strengthen the infrastructure for the industry o Simplify and expedite approvals, land and especially environment

demanding tax reform for quite some time. Diane Kelly, India President, Dow Corning, says, “Taxation laws that are rolled out and implemented are important and affect the way companies make investment decisions. From a macro-level standpoint, it is also necessary for the inflation and interest rates to be monitored and regulated by the concerned authorities and statutes. In summary, creating an environment to encourage manufacturing growth would determine the investments that companies make in any geography.”

and its electrical power supply. Any stimulus in this field would be extremely beneficial to the chemicals industry and could attract additional investment. Another point worth consideration is the efficiency of administrative processes. While we have always been pleased with the forthcoming assistance provided by local authorities, streamlining and speeding up approvals could help highlight India’s attractiveness as a preferred investment destination.”

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ia Ind , d an em ifold. d Building stic e man e confidence b om g d s can Favourable market n i ris nefit d with proactive coupled n e a b policies can result in faster growth ives orms, t a i it l ref n of the industry. As Dr Wilhelm i ent ctura Sittenthaler, Member-WACKER m ern e stru v o Executive Board, rightly says, s g mor u o h i n e c e s s a r y can be no question that India “There r it , va rs. W h t for the business is one of the most attractive countries w jo gro al ma environment to allow for foreign investments in Asia. So, c i m ic economies of scale to be there actually is little room for ono chem c e l y a accessible for companies with growth If at all, India should improvement. h b t al glo plans. For this, industry has been try to further enhance its infrastructure f he

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special duty-free zones, establishment of export promotion zones, Customs & Excise Duty cuts, formation of Petroleum, Chemicals & Petrochemical Investment Regions (PCPIRs), etc.”

Long way to go In spite of this, experts feel that India has to undertake number of structural reforms urgently. Kasad says, “Government should focus on

Chemical World | May 2012

Email: rakesh.rao@infomedia18.in

POLICIES & REGULATIONS Roundtable

Should India have REACH-like regulation? REACH legislation, enacted by the European Union, aims to protect human health and environment from the hazardous effects of chemicals. Many other countries are adopting a similar policy to retain their position in the global market. In this interaction with industry experts, Rakesh Rao finds out the feasibility of implementing REACHlike regulation in India.

Dr D M Wakankar Vice Chairman & Chairman â&#x20AC;&#x201C; REACH Committee, Chemexcil

Diane Kelly India President, Dow Corning

Pratik Kadakia Principal, Roland Berger Strategy Consultants Pvt Ltd

I object to the basic phrase â&#x20AC;&#x2DC;REACH-like legislationâ&#x20AC;&#x2122;. Why do we want to imitate somebody? We have to understand our scenario, capabilities, etc and frame a legislation, which is appropriate for our country. This statement arises from the fact that there is a general feeling that REACH is a trade barrier. The question is should we look at chemical legislation as a trade barrier or as an instrument of safety for human beings and environment? That REACH is a trade barrier is an argument, which is debatable and cannot be fully supported. Had it been a trade barrier, then European chemical companies would not have been asked to do the same thing as the non-European companies. In India, there is significantly low awareness about chemical hazards. I strongly feel that we should h ld have h strong llegislation il i iin place, but in no case should we imitate REACH.

Yes, regulatory reforms are important to India just as in any other economy to provide the necessary structure and bring in discipline to the way business is conducted in the country. However, this is a continuous improvement process, which does not stop at merely introducing regulations. Considering the necessity of and the benefits from such regulations, it is pertinent to ensure that companies are compliant with such norms across all sectors. At Dow Corning, as any ethical company would do, we strive to follow and be compliant to the regulations and norms. If the compliance is not uniform, it can put us at a time/ cost disadvantage. Hence, it is necessary that the regulations l i that h are rolled ll d out have an in-built mechanism to track compliance.

Globally, there is a drive towards sustainability and chemical companies have become environmentally conscious. While there is an agreement in the Indian chemicals industry that manufacturers should act responsibly, there is also the need to differentiate such responsible companies through an Indian equivalent of Responsible Care Certification. Policy or regulation should be such that companies (both Indian as well as MNCs), who are complying and acting responsibly, should be incentivised for growth and not treated at par with those who do not. A certification of this kind could be effective. We definitely require strong legislation since there is a need to have a control on environmentally hazardous chemicals. Having said that, the regulation should be fframed d after f holding h ldi consultations l i with all the stakeholders and drawing a thorough action plan.

EDITORIAL TAKE At present, there are no specific Indian legislations pertaining to registration of substances, restrictions on hazardous substances, etc. Hence, there is an urgent need to have stringent legislation to monitor and control the movement of hazardous chemicals. The legislation need not be on similar lines as REACH, but it has to ensure safe use of chemicals for protection of human health and environment.

Chemical World | May 2012

END-USER INDUSTRIES Fine chemicals

Lucrative opportunities

in the offing

Specialty chemicals are gaining prominence in end-user industries like construction, automotive, textiles, etc. This is mainly because such chemicals provide customised solutions, enhance energy efficiency, etc in different industries. Specialty chemicals have been able to provide solutions in various instances, which until recently were seen as challenges. Potential unlimited

Prasenjit Chakraborty

pecialty chemicals form the key constituents of various solutions for end-user industries like cars, paints, leather finishes, textiles, agro-produce, household goods and consumer durables, construction, among others. Hence, these industries play an important role in the growth of the chemicals industry in India. Of late, growth in disposable income of people has further widened the scope for specialty chemicals. This is because, now more and more people are buying cars, changing cell phones frequently, using value-added paints for various requirements, etc. All these have ultimately helped the specialty chemicals segment to grow. When it comes to India, it is the volume that is accelerating the growth of specialty chemicals. Hence, the end-user segment is crucial. In the recent past, the market has seen increasing focus of MNCs like LANXESS, Clariant, Dow Chemical etc in the Indian market. Again the focus differs for different companies.

Chemical World | May 2012

Let us have a look at what construction industry offers for chemicals, especially specialty chemicals sector. Construction chemicals encompass a large range of products for application in every type of construction. The chemicals are used internally in concrete as well as for purposes such as protection, repair and maintenance of structures. The growth of automotive, construction and textile industries calls for more investments in manufacturing facilities. As these facilities grow, they require more concrete, concrete curing compounds, specialty floorings, protective coatings for structures, grouts for machinery foundations, water-proofing solutions, anticorrosive coatings, coatings for water treatment plants, heat-resistant structures, etc. “Construction of durable structures is absolutely not possible without the correct usage of construction chemicals. Therefore, with the growth of industries and construction, the construction chemicals industry will by default augment its own growth,” points out Sunny Surlaker, Head-Admixtures Division, MC-Bauchemie (India) Pvt Ltd.

Growth on fast lane In the recent past, the automotive market has seen the launch of both luxury as well as cars meant for mid-segment in India. And such companies are registering a healthy growth as well. The booming automotive industry augurs well for the specialty chemicals sector, as these chemicals are used in significant amount in automotives. “Chemicals touch human lives in all its spheres right from the beginning of the day till the time we go to bed, and hence the end-user industries that are directly related to the basic needs, ie food, clothing and housing will be lucrative for specialty chemicals segment in India,” points out Ravi Vadiya, Head-SOM & Coatings, India Sub-Region, Clariant Chemicals (India) Ltd. For any segment, with the change in the technology, the products are getting more and more customised, hence, it is more like a solution provider. The growth of end-users market is directly proportional to the growth of the specialty chemicals. Email: prasenjit.chakraborty@infomedia18.in

END-USER INDUSTRIES Automotives

Prasenjit Chakraborty

he automotive industry has impressively improved on performance and the supporting technology in the last decade. Specialty chemicals have played a crucial role to make these advancements possible. For example, high performance rubber for tyres, plastic alternatives to metal parts that help reduce the weight of the car, light-weight leather for seat covers all contribute in different ways towards improving the fuel efficiency, safety and comfort of a car. “Innovative chemicals also improve drivers’ comfort and safety in the form of antifreeze and other fluids, rubber tyres and hoses, plastic dashboards, and the coating of a modern car. Through our rigorous research and innovation, we are now a frontrunner in offering these solutions for future mobility,” claims Dr Joerg Strassburger, Managing Director and Country Representative, LANXESS India. According to Shailendra Deshpande, Director, Commercial, Dow Corning India, the automotive industry is important for the growth of the specialty chemicals sector because it uses various chemicals in different forms at many different levels of the value chain. For example, automotive paints use chemicals to give particular properties like mar resistance and lustre. Sealants made of silicones are used for wind screen and rear screen sealing and gasketing applications. Adhesives help assemble components. The foams used in the seats need chemicals for processing and for incorporating special properties. Fabrics and finishes in the car use chemicals for treatment to resist soiling and reduce noise. The engine, transmission, brakes and other parts need specialty lubricants to reduce wear and sealing compounds & rubber gaskets to prevent leaks. Electrical wiring needs rubber insulation, motors need lubrication, and electronic hardware needs chemical-based potting and encapsulation solutions for keeping them in working condition in the harsh automotive environment. Safety devices such as seat belts need specialty lubricants for reliability, and airbags also need special chemical treatment/coating to function properly when they are used.

Modern technologies widening the scope There have been many changes in the automotive industry that have widened the scope of chemicals usage. Diesel is becoming attractive as a fuel. “Now we have diesel engines, which are less polluting, give more fuel efficiency and are more silent. This

DRIVING DEMAND o Innovative chemicals enhance drivers’ comfort o Adhesives help assemble components o Special chemical treatment required for airbags o Need to reduce the existing gap between chemical manufacturers and automotive designers

Accelerating the growth of chemical sector

Specialty chemicals find applications in automotive manufacturing in the areas of safety and comfort, fuel-related issues etc. However, there exists a gap between chemical manufacturers and automotive designers. Once the gap narrows down, the acceptance of specialty chemicals in the automotive sector will be more. change in fuel presents many challenges to automotive designers, which they are solving by way of using specialty chemicals. The temperature in the engine and under the hood has increased, and hence designers are using special lubricants, sealants and gaskets, which can withstand higher temperatures in and around the engine,” points out Deshpande.

The road ahead Chemicals have a major role to play in the success of the automotive industry. Specialty chemicals will help the automotive designers to meet new design requirements for more fuel efficiency, safety and reliability. “Specialty chemicals can help design vehicles that would be a pleasure to drive, will require less servicing and will have less impact on the environment,” points out Deshpande. With more innovations in the specialty chemicals, the reliance is bound to grow between the chemical and automotive industries, and the market is bound to grow in the years to come. “This will be largely driven by the growing middle-class population and increasing purchasing power of the consumers. The automotive sector will steadily propel the demand for specialty chemicals and advanced polymers. Prospects for vehicle manufacturing (automotive and all forms of mass transport) and greater use of high-performance materials are on the upswing,” sums Dr Strassburger. Email: prasenjit.chakraborty@infomedia18.in

May 2012 | Chemical World

END-USER INDUSTRIES Building & construction

Laying a strong foundation for future

AAgainst Ag ga st the tthhe backdrop bacckkdr drop op of of increasing ncrea e s ngg ffoocuss on focus on infrastructure, frraastr ct cturre, e, the the he coo str construction trucct on chemicals che he ca ca s segment seegg entt caa scale can sca e new sca sc ew heights. hheeigghhtts. Taking Takk ng dduue cognisance due coggnn sance co ce ooff th tthis h s fact, faacct, t, coomppa es aare companies re co coming o ng ng oout utt w withh innovative noov t ve ssolutions. o utt o s Ho H However, ow weeve ver, er,r, lack ackk ooff awareness awar aw are es ess ab ess aabout bo t usage sag age off such s ch chemicals cchhe ca s iss hampering ha ppee nngg the growth the grow gr owtthh of of the the segment, segm se gme t, t, and andd hence itt iss imperative he hence mpppeera ra vvee ttoo create crrea e ttee aw r ess ab awareness about bo t th ttheir he r bbe benefits. eneef ts ts

Prasenjit Chakraborty

he focus on building and road construction will favourably impact the growth of the construction chemicals industry. With the advances in concrete technology and new construction chemicals impacting the types of concrete being produced today, the industry is set for major leaps ahead. Other popular systems are injection and membrane technologies to cater to every type of water entry problems and soil stabilisation. Roads, airports, railway terminus, bus depots, sea ports are civil constructions and are required to be built in India at a rather rapid pace. “Specialty chemicals could impart great value to achieve this humongous task by making cement to rapidly set, buildings to be anti-fungal and anti-bacterial, steel and seaports to be

Chemical World | May 2012

made anti-rust, airports to be made less inflammable, railway station buildings less noisy and roads non-chippy by usage of various eco-friendly chemicals,” points out Ravi Vadiya, Head-SOM & Coatings, India-Sub Region, Clariant Chemicals (India) Ltd. A few examples can be halogen-free flame retardants and ecofriendly bio-degradable additives/waxes.

Role of modern technology According to Vadiya, due to shortage of land mass, the cities in India are growing vertical. “High-rise buildings need top quality exterior paint, durable up to 7 years, with high light fastness, weather fastness, sea salt spray fastness, as cost of repainting of such high-rise buildings is phenomenal. Specialty chemicals help in achieving these desired qualities,” he points out. Modern technology and construction practices do impact the chemicals industry.

For eg, today, waterproof concrete is the next big trend in the field of construction. “We would need to adopt the latest material technology for production of waterproof concretes. If we manipulate the properties of concrete itself, we can prevent water entering the concrete, protecting the reinforcing steel against water and aggressive media. We can achieve this using a combination of a dense aggregate packing factor along with high performance PCE-based admixture technology, next-generation materials like silica-fume or aluminosilicate slurries and highly specialised latest generation integral water-proofing compounds that work on process of Dynamic SynCrystallization (DySC) technology,” explains Sunny Surlaker, Head, Admixtures Division, MC-Bauchemie (India) Pvt Ltd.

Taking concrete measures According to Surlaker, commercially, the construction chemicals industry size is pegged at roughly ` 2,000 crore. Experts predict the industry to grow to ` 5,000 crore in next five years. “This growth can only come, if the industry joins hands to promote awareness among constructors and endusers. Ultimately, the users should believe that use of such chemicals would provide them with clear advantages,” he says. The biggest opportunities to the industry would come by increasing awareness, standardisation of products, training for right usage and creating a commercially a level-playing field. The awareness and standardisation coupled with proper training will help grow the industry manifolds. “Chemicals/specialty chemicals shall always play an important role in improving the quality of construction industry. In India, we still do not have buildings/infrastructure fully stable against earthquakes, tsunamis, hurricanes or other natural disasters. Chemicals industry can play a significant role in balancing these factors along with civil engineering industry by making use of natural sources such as sunlight (through solar cells), water (through rain harvesting) and natural wind energy (through scrubbers/ purifiers) towards achieving this milestone,” concludes Vadiya. Email: prasenjit.chakraborty@infomedia18.in

END-USER INDUSTRIES Home & personal care

The next

BIG THING for

SPECIALTY CHEMICALS According to a research report by TAM Media Research Pvt Ltd, FMCG categories constituting personal care, household products (and which also include food and beverages) accounted for 40 per cent of television ad volumes in 2011. This does not even include print, digital, outdoor or other non-broadcast media. The boom in the Home and Personal Care (HPC) industry reflects the impending spurt of the specialty chemicals industry, which make the HPC industry the hero it is today! Mahua Roy

alk into a retail store and you can subtly hear the ‘Buy Me!’ cry once you pass the shampoo aisle. With numerous variants to suit all kinds of hair in Indian conditions, and maximum benefits promised by a particular brand, the shampoo aisle is one of the most stocked polated to and sought-after. This can be extrap other HPC categories including homecare, haircare, oral care, dishcare and laun ndry care. Chemexcil puts this industry at a staggering ` 2,00,000 crore, and it is set to grow 15 per cent year-on-year in the next five years. Besides food & beverage, the personal care industry is directly aligned with the population dynamics of a country. And dian since almost 50 per cent of the Ind population is around 25 years of age, the HPC industry is all set to takee care of this generation! w, Big international players like Dow Cognis Clariant, Huntsman, BASF-C have already established their baase in the country to cater to this exxciting industry. At trade fairs customissed for the HPC industry, representativees from these companies exclaim how eveen SMEs are keen on collaborations with these giants i towards product development. This is a good sign for the revolutionisation of the domestic HPC industry. But it is the specialty chemicals, which are responsible for making your favourite shampoo turn your hair like Rapunzel’s. Be it the metallic salts of fatty acids used to make the soaps, or the high-end

Chemical World | May 2012

cosmeceuticals that combine the beautyrelated properties of cosmetics with the functional benefits of pharmaceuticals, chemicals (whether natural or synthetically synthesised) are an integral part of personal care products. Specialty chemicals are widely used as active ingredients in the form of

emollients, foaming agents and stabilisers. Their performance characteristics like thickening, foaming, imparting smoothness and conditioning are the key functionalities sought in several personal care products. Here’s examining the top 4 upcoming areas where specialty chemicals are set to transform the HPC industry!

1. Facecare: Fairness creams According to AC Nielsen, the fairness cream market in India stands at ` 2,200 crore. Besides, a niche sector is springing out of this figure - that of special men’s fairness creams. Attracting the atten attention of big and small players alike, thoough valued at just ` 186 crore, it shows a staggeringly high growth rate of 31 per cent. The category of fairness is not solely related too receiving the fairness attribute. “The coonsumers want added properties alongg with static fairness; they want the rresults to be rapid and visible; and they want long-term authentic fairrness,” quips Farooq Alam, Reegional Marketing Manager Ind dia, Dow Personal Care. Other imp portant features expected are those of anti-ageing, acne cleansing, etc. T This has led to development of sevveral technologies revolving around nanotechnology for delivery systems as well as microencapsulation, microem mulsions involving specialty chemicalls. “Besides, these ingredients must contain the t ‘green’ factor, ie, they need to be enviroonment-friendly products, derived mainly from f vegetable sources,” adds U Shekhar, Sh kh Managing Director, Galaxy Surfactants Ltd. It is quite evident that the skincare industry in the developed markets is close to saturation. Meanwhile, emerging economies such as India offer a lucrative market for large multinationals. As per a recent study by the Confederation of Indian Industries (CII), the overall Indian

Home & personal care

skincare market has been increasing for the last two years and has recorded a growth rate of 20 per cent in 2010.

2. Haircare: Conditioning/antidandruff The haircare market is anticipated to grow at a 20 per cent CAGR during 2011-2014 to reach around ` 208 billion by 2014, as projected by market research firm, RNCOS. The upcoming sub-sectors seen here are that of hair conditioning as well as anti-dandruff attributes. “The sudden growth in the number and sophistication of professional haircare salons has made this category lucrative and is seeing a lot of activity,” adds Alam. But the challenge lies in making the final product affordable keeping in mind the target audience of using various salons as distribution channels. The haircare market is seeing differentiated products with non-ionic ingredients, which are replacing traditional silicone, giving superior hair conditioning properties. “The need for mild (soft, less

toxic, suitable for everyday use) products is increasing. Two to three decades back, one used to apply shampoo maybe once a week; today it is used once a day,” notes Shekhar. This can be attributed to the innovation brought about by specialty chemicals.

3. Kitchencare: Stain removal According to Alam, dishcare is an area where he sees traffic of requests from the FMCG industry to deliver better attributes. “Liquid dishcare is an exciting area, which is quite nascent at this stage in India,” he adds. Liquid dishcare agents add to convenience, which is what the consumer of today really wants. India has been traditionally exposed to multipurpose surface cleaners. Designing a surface cleaner that specifically targets hard surfaces is the next big thing to look out for. “A small amount of activity is brimming in this space. And soon, it will develop into a full-fledged category with institutional clients like hospitality in the rope,” adds Alam.

4. Laundrycare: Stain removal Laundry detergents are another sector, which is catching the attention of specialty chemical manufacturers. “Tough stain removal, care (of the colour) and antiredeposition are the attributes demanded by consumers,” notes Alam. Another term called ‘functional whiteness’ is doing the rounds in this industry, where other properties apart from just whiteness are desired by consumers, for eg, fragrance and anti-dullness post washes. This is also leading to product reformulations. This trend is catching on quite rapidly among specialty chemicals manufacturers. “Manufacturing technologies have to focus more on ‘concentrated’ products. This is where the marketing campaigns of such products are to be directed. For example, these days the promotional activities of detergents stress on the usage of only 1-2 spoons. So, it all depends on how one packs more power into a product,” sums up Shekhar. Email: mahua.roy@infomedia18.in

May 2012 | Chemical World

END-USER INDUSTRIES Textiles

amylase and catalases,” says Ganesh. Apart from removal of impurities, value-adding processes are done on the substrate with the use of dyes (colouring chemicals) and process chemicals in dyeing and finishing chemicals. Chemicals and dyes have also been extensively used in non-apparel segment such as industrial textiles, agro textiles, sports textiles, geo textiles, etc.

Technologies further enhance scope

Knitting a value

PROPOSITION

Chemicals can add value to textiles right from reducing the process time to saving energy. Besides, these also enhance look and feel of clothes. Chemicals and dyes have been extensively used in different segments like industrial textiles, agro textiles, sports textiles, geo textiles, etc.

Textile printing, for example, is one such area where modern technology has expanded the scope and capability of chemicals. “In the colour industry, inkjet printing (digital printing) is the latest innovation and was considered to be of great academic/research interest due to its large production volumes, low costs and high production speeds etc. These are usually difficult to achieve with traditional inkjet printing as the traditional inkjet printers for textiles tend to be slower than screen printing systems. Digital printing is slowly finding its way,” he says. With increased usage of digital printing machines, there is a rise in demand for the inks and additives, thus opening new horizons for textile chemicals industry.

Entangling issues Prasenjit Chakraborty

hough the agriculture industry enjoys the apex position contributing to the employment of around 52 per cent of the total workforce, textile manufacturing accounts for 14 per cent of the total industrial production and contributes to nearly 30 per cent of the total exports. The textiles industry is dependent on chemicals industry, as textile dyes and chemicals add value to the garment. The textiles industry is registering a sturdy growth of around 9-10 per cent and the chemicals industry as a whole is growing at a healthy rate of 12.5 per cent. “With the growth of developing countries, the average world per capita fibre consumption currently is at about 10-11 kg. Thus, textiles play a major role in the growth of the

Chemical World | May 2012

chemicals industry,” says V R Sai Ganesh, Deputy General Manager – Business Development, DyStar India Pvt Ltd.

Role of chemicals in textiles The Indian textile industry is mainly dominated by two major substrate types, cotton and polyester. Other substrates are viscose, linen, wool and silk, etc. Cotton, in its raw form, contains impurities and to ease the spinning and weaving processes, additives such as fibre/yarn lubricants & sizing chemicals are added. For the removal of natural as well as added impurities/additives, processes such as desizing, scouring and bleaching are carried out. “These processes involve use of bulk chemicals such as sodium hydroxide, hydrogen peroxide, acetic acid, etc; and specialty chemicals such as wetting agents, detergents, novel chemicals, sequestering agents, stabilisers and enzymes such as

Cotton is the most preferred choice for consumers. “The dyeing technology most commonly used on cotton is reactive dyeing. Reactive dyeing requires high amount of water and energy to wash off the process, to remove unfixed reactive dyes from the textile in order to achieve high wash fastness; it also consumes high quantity of basic chemicals such as common salt (sodium chloride) and soda ash,” he says. In this direction, specialty chemicals manufacturers are offering solutions to help reduce both water and energy consumption during the process. “The market demand will veer towards multifunctional chemicals that have lesser load on ecology. There will also be tremendous growth in chemicals, in terms of technology that help reduce water and energy consumption, making production more economical,” sums up Ganesh. Email: prasenjit.chakraborty@infomedia18.in

END-USER INDUSTRIES Interface - Manish Doshi

chemicals are generally characterised by their innovative aspects in the form of developing new products or modifying existing ones, besides developing new process technologies to produce such products.

How pharmaceutical industry in India is boosting the growth of the chemicals industry? The Indian pharmaceutical industry is growing at a phenomenal double-digit growth rate and is one of the largest in production volume globally. Also, our manufacturers are continuously engaged in innovating and formulating newer combinations of APIs for providing better therapeutic medicines at affordable costs. This growth and innovation has to be supported by the continuous supply of bulk drugs, intermediates etc. Although the drug industry constitutes only about 15 per cent of the Indian chemicals industry today, the chemicals industry is also growing and has been focussing on modernisation, which in turn is helping the pharmaceutical industry.

Photo: Joshua Navalkar

Elaborate how modern technologies are widening the scope of chemicals in the pharmaceuticals industry with an example. With increase in investments in R&D, the Indian chemicals industry is registering significant growth in the knowledge chemicals sector such as pharmaceuticals, biochemicals etc. The industry, especially the API, has evolved from being a basic producer of chemicals to an innovative one to produce environment-friendly technology

The Indian chemicals industry is registering significant growth in knowledge chemicals sector â&#x20AC;Śsays Manish Doshi, President, Indian Drug Manufacturersâ&#x20AC;&#x2122; Association (IDMA). In conversation with Prasenjit Chakraborty, he touches upon issues such as the transformation of Active Pharmaceutical Ingredients (API) sector, competition from China, and the need to modify existing laws, among others. What vital role does chemicals and specialty chemicals play in drug manufacturing? Chemicals, inorganic and organic (commodity chemicals), have entered every sphere of human life and India is no exception. End-user industries are many, be it plastics and petrochemicals, drugs & pharmaceuticals, dyes & pigments, pesticides & agrochemicals, fine & specialty chemicals, or fertilisers. All manufactured drugs are organic or inorganic. Specialty chemicals constitute the higher value-end of the chemicals business. These

Chemical World | May 2012

and products. Many API manufacturers in India have adopted differential manufacturing technologies through in-house R&D and collaborations. For example, Arch Pharmalabs Ltd, a Mumbaibased producer of APIs entered into a strategic collaboration with Codexis Inc, a US-based biosciences company to implement its biocatalyst technology for manufacturing APIs and intermediates at room temperature, shortening process development timelines and substituting use of certain hazardous chemicals, thus decreasing overall environmental impact. This advanced technology resulted in a 20 per cent cost differential vis-Ă -vis conventional methods of production.

What are the areas that remain a challenge for the chemical manufacturers as far as drug manufacturing is concerned? The recent trends of globalisation has seen an erosion of API manufacture in India, mainly owing to the unhealthy competition

Interface - Manish Doshi

from China due to dedicated large volume production plants sponsored by the State. Thus, there is an urgent need for creating and increasing capacities of APIs and basic chemicals, to maintain our exports and affordability in domestic healthcare. The API industry requires whole-hearted support from the government in terms of realistic costing and price controls. Also, strong support from Indian formulators in sourcing their API requirements indigenously will make a significant difference to our hard hit API manufacturers. One important aspect that contributes heavily to the cost of manufacturing is effluent treatment. The government should create more Common Effluent Treatment Plants (CETPs) in collaboration with private sector, near the industrial estates. The API plants should not only meet â&#x20AC;&#x2DC;Schedule Mâ&#x20AC;&#x2122; standard, but also meet WHO-GMP standard. For this, assured funding at low rate of interest and easy repayment schemes are necessary for

upgradation or setting up of new units. The support by Central Government for the development of the API industry should be in co-ordination with state financial institutions.

What steps need to be taken to address these challenges? The environmental laws are stringent and almost in line with those applicable to the chemicals industry. The laws should be modified taking into account the smaller tonnage of APIs as compared to the chemicals industry in general, and also the extent to which the API pollutes the environment. Our regulator should align with the regulatory procedures of USFDA and EDQM by sending inspectors for site inspection at overseas manufacturing units; thereby the number of manufacturers from China and other countries dumping APIs in Indian market will be curtailed. Indigenous manufacturing through fiscal and other methods need to be encouraged. A

lower tax regime for locally produced APIs is perfectly TRIPS compatible. Setting up a dedicated API & Basic Chemicals Fund (ABC Fund) of about $ 700 million to develop small & large API manufacturing facilities is imperative. Land should be provided at cheap rates for dedicated API plants as Small-scale Industries (SSI) and the first generation entrepreneurs require support from governments, both Central and State, to procure land at reasonable prices on long lease. Entrepreneurs must be encouraged to tie up with universities and research institutes for development of APIs; simultaneously these institutes must be provided with incentives to put up incubators & pilot plants to enable first generation entrepreneurs, either small or big to successfully complete their R&D projects at a pilot plant level at lower cost, which will reduce their risks and encourage them in putting up facilities confidently. Email: prasenjit.chakraborty@infomedia18.in

May 2012 | Chemical World

GLOBAL MARKET Uncertain business environment

Transforming challenges into opportunities Industry observers believe that uncertainty in the global economy is here to stay at least for another two to three years. Hence, it is important for Indian chemical manufacturers to devise strategies to survive in this period by focussing on long-term goals and product innovation.

Rakesh Rao

he current uncertainty in the global economy is casting dark shadows on the Indian chemicals industry. With the traditional markets such as the US, Europe, etc not providing ample exports opportunities, Indian chemical manufacturers are exploring strategies to survive in this unfavourable global market. Giving insights into this, Kumar Kandaswami, Senior Director, Deloitte Touche Tohmatsu India Pvt Ltd, says, “There are still high growth markets among the emerging economies. Admittedly, they are relatively smaller in size compared to the traditional consuming markets, somewhat evolving and where most of the global manufacturers are focussing their attention on. Therefore, while there

Chemical World | May 2012

REACH regulation, as per which companies exporting to any European country has to be REACH-compliant. While industry has been urging for incentives for becoming REACHcompliant, the financial aid is not forthcoming. Aashish Kasad, Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd, adds, “REACH registration is compulsory and costly for Indian companies exporting products to Europe. Moreover, for products to be REACH-compliant, it takes substantial investment to reformulate chemicals. Government should provide weighted deduction on expenses incurred with respect to REACH compliance, to incentivise chemical exports to European Union countries.”

Depreciating Rupee

are opportunities, it is also true they are competitive as well. Frankly, India will be an attractive market for some time to come – it may be worthwhile to think of niches one can serve or increasing marketshare.”

Bolster exports to Europe With developed markets implementing stringent regulations, exports to these countries have added additional cost. A case in point is European Union’s

The value of Indian Rupee has been sliding down against the Dollar since August last year. While Rupee depreciation is good for exporters, it increases the input cost for manufacturing. So how can Indian chemical manufacturers (with large exposure to overseas market) devise strategy for this? Kandaswami answers, “If one is talking about companies with large exports, the problem of currency fluctuations is somewhat evened out. The problem is probably larger for companies that are import-focussed in the current context and where they are not able to pass on the additional costs to their customers. The obvious solution would be to build a portfolio that balances these risks. That said, it is not something a company can achieve overnight. Larger companies with wider product/market portfolios would be in a better position to deal with such situations.”

SURVIVAL TIPS o o o o

Keep a close eye on cash flows in these times It is important to create a niche for your products Exploring other developing markets where consumptions are still low Survival will depend on the strength of the product or the value proposition and not just on the market growth rate o Do not emulate others. Devise your own strategy based on the strength of the products

Uncertain business environment

It would be critical for chemical manufacturers to have in their portfolios products that are unique and offer attractive value propositions to their target customers. Kumar Kandaswami Senior Director, Deloitte Touche Tohmatsu India Pvt Ltd

industry to learn a lot from its pharma counterpart. “Indian pharma sector has managed to create a strong presence in these developing markets; a large part of which has come from inorganic bolt-on acquisitions. These markets are growing and several end-user sectors present interesting opportunities,” he adds.

Entrepreneurs need to be careful in pursuing growth. It is important to keep a close eye on cash flows in these times and least on topline growth. Navroz Mahudawala Founder, Candle Partners

On African safari Scouting for new destination With dwindling exports to developed markets, chemical companies can explore other developing markets. “Significant portion of chemical exports are from dyes & pigments and agrochemicals into the US and EU markets. There is definitely a need for the industry to diversify into new markets like AsiaPacific and Middle East, which currently have lower levels of consumption,” says Siddharth Paradkar, Principal, Tata Strategic Management Group. To increase their export basket, Indian firms are drawing up strategy to expand into emerging markets such as Brazil, Russia, South Africa, etc. Though this strategy appears good, Kandaswami feels that this may not be enough. He adds, “Most manufacturers are pursuing opportunities in the emerging economies vigorously. In many cases, they are willing to invest in buying marketshare. This is a game for big players with financial strengths. In such situations, smaller companies are the first casualties. In the final analysis, it will emerge that the determinant of longevity is the strength of the product or the value proposition and not just the rate at which the market grows.” Navroz Mahudawala, Founder, Candle Partners, advises Indian chemicals

There is definitely a need for the industry to diversify into new markets like AsiaPacific and Middle East, which currently have lower levels of consumption. Siddharth Paradkar Principal, Tata Strategic Management Group

Experts feel that if political crisis across African continent ends, then it could be a land of golden opportunity for Indian chemical companies as it has abundant natural resources. But Indian companies will have to offer better value proposition through their innovative marketing strategy as it is a highly competitive market. Kandaswami adds, “The whole of African chemical market is probably less than the size of India in terms of Dollar value of sale – it is said that the top 10 sub-Saharan countries add up to something like $ 35 billion. Each one of the countries would represent a pretty small volume – except for countries like South Africa and Nigeria. This volume is likely to grow over the coming decade, particularly, if the downstream sectors take root there. Clearly, it is the market for the future.” He adds, “The trick would be to identify the right time to tap into these markets – frankly, some of them are too small and difficult to enter into at this time. It must be remembered that all global major manufacturers would be looking at Africa with the same level of interest as the Indian manufacturers.”

The survival instinct In this uncertain global financial scenario, one needs to remember the golden rule: Cash is king. Mahudawala says, “In the current times, it is important to look at the domestic market and consolidate one’s presence. Also, entrepreneurs need to be careful in pursuing growth. It is important to keep a close eye on cash flows in these times and least on topline growth.” For small and medium enterprises, it is critical to devise long-term strategy to sustain growth. Kandaswami says, “If

one goes on the basis, a large number of chemical manufacturers in India are likely to be medium sized. It is important to recognise that playing the cost game with commoditised products gets difficult to sustain over a period of time.” In the coming years, there is likely to be excess capacity for certain periods of time, particularly, if China’s – and of other large consuming countries – consumption slows down. “First, it would be critical for chemical manufacturers to have in their portfolios products that are unique and offer attractive value propositions to their target customers and to keep the new product pipeline healthy. Second, it is important to build a supply chain and product portfolio that help manage the cyclical risks of the downstream sectors or economies. Three, cost is a burning issue – there are a number of controllable costs along the entire supply chain that can be taken out,” suggests Kandaswami. Most importantly, this is a strategyintensive sector – given the fact the structural rigidity and costs are built up on the basis of assumptions of what may be the likely future scenario. Therefore, it is absolutely critical to define a sensible growth strategy. Kandaswami recommends, “Often, one sees companies trying to do what the industry leader may be doing, little realising that the internal realities of these two could be different. So, companies should be sure they are adopting the right strategies – there is no sense in a small/medium manufacturer banking on strategies that are appropriate for a large company simply because they are not sustainable. The reverse is true too – a large company may struggle to do what a small start-up is able to achieve successfully.” Email: rakesh.rao@infomedia18.in

May 2012 | Chemical World

GLOBAL MARKET BRICS countries

Advantage India?

Though India lags behind other BRIC (Brazil, Russia and China) nations in terms of infrastructure, its increasing working population will trigger big investments from the leading global chemical companies. Whether India will lead the race to become leading investment destination for global chemicals industry, is something worth watching. Rakesh Rao

ccording to the Global Competitiveness Report 2011-12 by the World Economic Forum, India was ranked 56 th among the most competitive economies globally. Among the other BRICS nations, India continues to rank at par with South Africa (50th) and Brazil (53rd) and ahead

of Russia (66th), but its gap with China is widening. China currently ranks 13th and the difference between China and India has increased six-fold between 2006 and 2011. “Poor infrastructure and comparatively poor availability of feedstock are some of the challenges faced by the Indian chemicals industry,” observes Aashish Kasad, Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd.

$ Million

FDI in Indian chemicals industry

1000 500 0

749

198

390

205

FY05

FY06

FY07

Chemical World | May 2012

229 FY08 Year

FY09

362

398

FY10

FY11

Source: Ernst & Young Pvt Ltd

India raring to go The biggest advantage India possesses over the other BRICS nations is the working age population. Kasad says, “By 2030, India is expected to have the largest working age population in the world. Between 2010 and 2030, India is expected to add 241 million people in working age population while Brazil and China are estimated to add only 18 million and 10 million people, respectively, during the same period.” The confidence is echoed by many multinational companies (MNCs). Diane Kelly, India President, Dow Corning, says, “India stands out for the advantages it offers companies in terms of the availability of and access to a well-educated population of professionals. The fact that language is not as much of a barrier as it is in many other emerging economies makes it easier to grow business in India. As a market, the large and growing middle class offers to companies the scope to understand specific needs and identify potentially unique opportunities to serve the market with better focus and clarity.”

BIG TICKET INVESTMENT o In April 2012, BASF announced its plan to invest Euro 150 million ($ 195 million) to set up a new chemical production site at the Dahej PCPIR located in Gujarat o In January 2012, Kuwait’s Al-Qabela Al Watya decided to invest around $ 7.6 billion (`` 400 billion) to develop a refinery in PCPIR near Visakhapatnam o The US-based Huntsman Corporation plans to invest ` 2.50 billion ($ 50 million) in India over next two to three years for expansion of existing facilities and acquisitions Source: Aashish Kasad, Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd

BRICS countries

With Asia’s growing contribution to the global chemicals industry, India is becoming one of the preferred destinations for investment for the chemical companies globally. Aashish Kasad Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd

Yes, definitely, agrees Dr Wilhelm Sittenthaler, Member, WACKER Executive Board. “India’s booming market offers significant growth opportunities for chemical companies around the world. According to analysts, India’s GDP will increase around 7 per cent this year, making it one of the fastest expanding BRIC economies. In terms of volume, India is already the third-largest producer of chemicals in Asia today,” he adds.

Knowledge-driven business The availability of skilled workforce having knowledge about chemistry is an added advantage. Dr Sittenthaler says, “One of India’s advantages is its technology-mindedness and its thirst for knowledge. Indians are technologysavvy people who want to bring in a lot of newness to the country. India provides an inspiring and fruitful environment for innovation and technology. The country also has a lead in important industry branches such as information technology and pharmaceuticals.” Except China, India has a cost advantage in several sectors of chemicals vis-à-vis the BRICS nations, believes Navroz Mahudawala, Founder, Candle Partners – a boutique investment bank

India has always been one of the preferred destinations for multinational companies. Innovation is critical to the success of the chemicals industry in India. Diane Kelly India President, Dow Corning

Chemical World | May 2012

with focus on lifesciences and chemicals. He adds, “Our skills in chemistry and our ability to do difficult chemistries in record times are attributes that other countries do not possess.” The signs that Chinese economy may be heading for a slow growth in GDP (compared to earlier years) in 2012 can provide additional advantage to India. Siddharth Paradkar, Principal, Tata Strategic Management Group, observes, “Over the next 5 years, China is expected to grow at a rate of around 7.5 per cent as against India at the rate of 7-8 per cent. There has already been significant investment into China and now it is time to look at India.”

Propelling growth According to Kasad, “With Asia’s growing contribution to the global chemicals industry, India is becoming one of the preferred destinations for investment for the chemical companies globally. High growth rate of the enduser industries, rising per capita income, availability of skilled manpower and easy access to local and international markets have propelled global chemical manufacturers to invest in India.” Most of the global chemical majors have been present in India for quite some time; hence they understand the market requirements much better today. “Indian chemicals industry has several decades of experience and most chemical MNCs have done well in the country and have profitable operations. There is keenness to invest further in the years to come,” opines Mahudawala. Low penetration of chemicals in India is also seen as an advantage to bolster demand. Dr Sittenthaler says, “Our strategy in emerging countries has always been to create markets and to grow the business. On a relative scale, the per capita consumption of chemicals in India is still less than 10 per cent and it is even less in the specialty chemical field such as silicones. So what comes as the first challenge is creating awareness and demand. The way we do it is by strengthening

India’s booming market offers significant growth opportunities for chemical companies around the world. In terms of volume, India is already the third-largest producer of chemicals in Asia today. Dr Wilhelm Sittenthaler Member, WACKER Executive Board

and expanding the relationship to our customers and by establishing technical centres in order to provide best possible local customer support.”

Flowing investments According to Kasad, between April 2000 and August 2011, the foreign direct investment (FDI) inflow in the chemicals sector (other than fertilisers) has been $ 3.03 billion, representing 2.06 per cent of the overall FDI inflow. The sector (other than fertilisers) attracted cumulative FDI of $ 398 million in FY11, representing a 9.9 per cent increase over the previous year. The Indian chemicals industry is expected to grow at a rate of about 12 per cent to reach revenues of $ 240 billion by 2020. There is no doubt that it will continue to occupy top slot for investment among global chemical majors. Kelly says, “India has always been one of the preferred destinations for multi-national companies. Innovation is critical to the success of the chemicals industry in India. At Dow Corning, we work towards developing innovative solutions in conjunction with Indian customers. It is vital for chemical companies to have the market and customer intimacy for developing solutions that are sustainable for growth. Government reforms would certainly propel the attractiveness of India as a preferred destination. But relying completely on the reforms without development of innovative solutions in-house may not be the best possible approach to success.” Email: rakesh.rao@infomedia18.in

GLOBAL MARKET Chemical exports

On a voyage to explore new opportunities In exports, depending only on traditional markets is not an ideal situation. The reason: A slowdown or uncertainties in these markets can have a huge impact on the domestic industry. During the last economic recession, growth in chemical exports was witnessed more in non-traditional markets. For overall growth in chemical exports, both government and the industry have to take the right steps. Prasenjit Chakraborty

t is indeed the need of the hour for the Indian chemicals industry to spread its wings to newer export markets. The traditional markets for India include the US, Japan, European Union – basically all the developed countries where production/ consumption has stabilised. Moreover, there is a shift of manufacturing base from the developed world to the developing countries such as India, Vietnam, China due to the availability of skilled manpower and competitive production facilities. “The Indian chemicals industry constitutes only one per cent of the total international trade,” says Satish Wagh, Chairman, Chemexcil. It is interesting to note that during the economic nosedive in the recent past, the exports to traditional markets suffered

drastically whereas our exports to focus markets viz Latin American countries, ASEAN, Africa etc registered double-digit growth. “Therefore, in order to increase our marketshare in international trade and sustain growth, both indigenously and on export front, we should explore newer markets,” he opines.

Current scenario Chemicals industry is an important constituent of the Indian economy. “The total investment in Indian chemicals sector is approximately $ 60 billion and total employment generated is about one million,” says Wagh. According to him, the export performance of dyes and dye intermediates panel for the period April 2010 to February 2011 was $ 3,148 million as compared to $ 2,411 million of the corresponding period last year, registering an increase of 30.56

Statistics of chemical exports from India in the last five years (in ` crore)

Dyes Dye intermediates Pigments Inorganic chemicals Organic chemicals Agro chemicals Cosmetics Soaps p & toiletries Essential oils & perfumes p Castor oil

2005-06 5718 741 843 1344 4897 2546 1258 265 681 940

2006-07 7657 1548 1264 1639 5989 2048 1455 273 821 1090

2007-08 8945 1225 1287 2252 6024 2923 1650 209 899 1276

2008-09 2009-10 8333 8368 1214 1220 1496 1500 3712 3892 7958 8248 4304 4390 2671 2771 354 454 1416 1506 2129 2178 Source: Chemexcil

Chemical World | May 2012

per cent. The pigments and intermediates sector have good scope for exports. If current trends are any indication, then emerging markets will continue to dominate on the export front. “Asia and other emerging markets will continue to lead the world in volume gains, with China and India showing the most significant increases. Chemical manufacturers in the emerging markets witnessed 5.4 per cent production increase in 2011. It is expected to be 6.2 per cent in 2012 and 7.5 per cent in 2013. The chemicals industry outlook indicates modest growth over the next several years, depending on certain factors, including strengthening domestic demand and improvement in exports,” points out Pravin S Herlekar, Chairman & Managing Director, Omkar Speciality Chemicals Ltd. According to global consulting firm, McKinsey, the Indian specialty chemical exports is projected to grow at 22 per cent every year from $ 7.5 billion in 2005-2010 to $ 13 billion in 2013. Further, India’s specialty chemicals industry is expected to grow at 15 per cent by 2015, almost double the growth of the global specialty industry.

Bottlenecks in export Indian chemicals industry forms the backbone of industrial and agricultural development of India and provides building blocks for downstream industries. The industry comprises both small- and largescale units. The fiscal concessions granted to the small-scale sector in mid-eighties

Chemical exports

led to the establishment of a large number of units in the small-scale industries (SSI) sector. “Currently, the industry is in the midst of a major restructuring and consolidation phase. With the shift in emphasis on product innovation, brandbuilding and environment-friendliness, this industry is increasingly moving towards greater customer orientation. Even though India enjoys an abundant supply of basic raw materials, it will have to build upon technical service and marketing capabilities to face global competition and increase its share of export,” points out Herlekar. Further, volatility of inputs like crude oil and natural gas prices has been the major roadblock for the chemicals industry, indirectly factoring a negative impact on the bottom line of the companies. According to estimates, the spike in the prices of crude oil has eroded 12-15 per cent of the overall revenues of the industry. “The industry faces shortage of feedstocks like naphtha, liquid natural gas etc. Due to high input material cost, the chemicals

produced by chemicals sector are not competitive,” points out Wagh. Apart from this, the chemical plants in India, with the exception of few, are not of global capacity and thereby cost of production becomes high. Wide dispersion of industries leads to high logistics cost.

The right approach Players in the industry strongly believe that India has the potential to become a global chemical exporter, if the government and domestic players rise up to the challenge. The Indian chemicals industry is standing at a critical juncture, where immense growth opportunities coupled with intense competition are acting as major drivers behind the dynamic growth being witnessed in certain segments. “The key success factors needed for the industry are lower cost of feedstock and availability, value chain access, technology, capital investment as well as access to growing markets,” observes Herlekar. Cluster approach and provision of common

infrastructure facilities in the clusters such as roads, common effluent treatment plants, power etc, for the units to have plug in and plug out approach could help a lot in this direction. Indian chemicals industry can deliver on an accelerated growth phase, provided a clearly defined vision along with a strategic roadmap is developed by the government to enable it. “If this is not done, we may see the growing market increasingly being served through manufacturing done outside India. Various segments of the chemicals industry (such as organic chemicals and specialty chemicals) have their own unique set of challenges. The industry can grow only if these segments overcome their challenges and move swiftly along the growth path. Besides, the sector has been facing a major stumbling block in terms of procedural hurdles from various government departments like Customs and Central Excise,” laments Herlekar. Is it not time to give a serious thought to all these? Email: prasenjit.chakraborty@infomedia18.in

May 2012 | Chemical World

GLOBAL MARKET Interface - Robert Duane Dickson

Do you think the current uncertainty in Europe and other developed countries will work in Indiaâ&#x20AC;&#x2122;s favour with more investments coming into the country? Certainly, more investment will flow into India, if it can further develop itself as an attractive investment destination, and develops as expected as a market. The situation in Europe is a challenge for all countries producing chemicals and materials considering the imports of Europe.

How is the current chemical trade between the US and India? How could it be given further boost? Trade between the US and India could be improved by stronger trade partnerships and open innovation. Both countries have good transportation infrastructure. They also have complementary resources, be it materials or manpower. Acceleration will come when the collaborations become more common and open. I also expect to see growing Indian investment in the US assets, which will act as a catalyst for further growth

Currently, feedstock diversification is a major initiative by companies around the world. Do you think it is time for India to shift to gas? Shifting to gas is easier said than done. It certainly makes sense to move to a more balanced feedstock profile and to deeply explore biological routes to chemical feedstocks.

The world will look towards India for major breakthroughs â&#x20AC;Śsays Robert Duane Dickson, Principal, Deloitte Consulting LLP. In conversation with Prasenjit Chakraborty, he emphasises on opportunities offered by the Indian chemicals market, feedstock situation, current uncertainty in Europe, and trade prospects between India and the US. How is the Indian chemicals industry shaping up? The Indian chemicals industry is well-supported by effective engineering and science education system. The world will look towards India for major breakthroughs. From the market perspective â&#x20AC;&#x201C; the ever-increasing needs of a growing population and a surging economy will drive the need for advancements in agriculture, collection and processing of biomass into energy or chemical feedstocks, advanced and distributed fresh water and wastewater systems, and materials for affordable housing. India has the education, the markets and the technology competency to develop world-class solutions.

Chemical World | May 2012

Which are the two important factors preventing global companies from investing in India? India does not have a strong track record when it comes to honoring contracts, and that worries investors. The permitting process and perceived corruption documented in the past is also a lingering concern. There is also lack of adequate infrastructure in parts of India, which adds to their woes.

What is the scope for India in emerging regions like Africa and Latin America? India has so much potential to develop and export advanced materials and technologies based on resolving climate issues, new modes of transportation, affordable systems for healthcare and the like. India has many of the same opportunities and challenges as Africa and South America. I think agriculture, scarce water/wastewater, and renewable energy needs in India, if solved, would be transportable to Africa and South America. Email: prasenjit.chakraborty@infomedia18.in

TIPS & TRICKS Handling colourless gas

Safety tips for

TRANSPORTING ETHYLENE Ethylene is a colourless gas having a faint, slightly sweet odour. It is practically insoluble in water. Cold ethylene gas is heavier than air and may travel a considerable distance to a source of ignition. Cryogenic ethylene weighs approximately 4.7 pound per gallon at its boiling point at atmospheric pressure.

thylene is not significantly toxic by inhalation, but high concentrations may be anaesthetic or may cause asphyxiation via displacement of air. Contact with cryogenic ethylene and concentrated cold ethylene gas may cause frostbite. Ethylene is transported as a compressed gas or cryogenic liquid and used for a variety of applications, including refrigeration and for making plastics and organic chemicals. Containers of cryogenic ethylene may rupture violently if exposed to fire or excessive heat for sufficient duration. One of the products of combustion includes carbon monoxide. Hence, it needs proper care during transportation. Some of the factors to be considered while transporting ethylene gas are mentioned below.

Persons who work with ethylene cr yogenic or respond to emergencies involving cryogenic ethylene must be trained for its proper and safe handling and in accordance with applicable federal, state and local laws & regulations.

All employees who work with hazardous chemicals, including cryogenic ethylene, must be trained in accordance with the Occupational Safety and Health Administration’s (OSHA) Hazardous Materials Communication Standard (29 CFR §1910.1200).

Employees should h ld b be provided with information and training on the hazards of cryogenic ethylene, methods for detecting releases, and protection from exposure. The materials safety data sheet (MSDS) is an important source of information. It contains information on health, safety, fire and protective measures.

All personnel responding to hazardous material incidents, including cryogenic ethylene, must be trained in accordance with OSHA’s standard on Emergency Response (29 CFR §1910.120 [q]). Responders should be provided with information on the hazards of cryogenic ethylene, methods for detecting releases, methods of protection from exposure, isolation distances and options for mitigation.

Cryogenic ethylene is transported in specially built tank cars. These tank cars are insulated and vacuum-jacketed to keep cryogenic ethylene in a liquid state.

Cr yogenic ethylene is transported in class Department of Transportation (DOT)-113 tank cars. All class DOT-113 tank cars are constructed as a tank-within-a-tank. Each tank car is protected by one or more pressure relief valves and one or more rupture (frangible) discs.

Each E h tankk car transporting cryogenic ethylene must be in compliance with all applicable regulations, including markings and placards, the amount of material loaded, transit times, vacuum level, pressure relief valve retest, and rupture disc change out.

shipment of Each cryogenic ethylene must have a shipping paper describing it as ‘Ethylene, Refrigerated Liquid, 2.1, UN1038’, and some indication of the total quantity, such as ‘1 Tank Car (T/C)’, as appropriate (49 CFR §172.201).

For any shipment made under the provisions of a DOT Exemption, the shipping papers must state the exemption number, as ‘DOT-E’ followed by the number of the exemption, unless specifically excepted in the exemption (49 CFR §107.101(g)(2)).

1 10

For both loaded and residue shipments in tank cars, the shipping papers must include the notation, ‘DOT-113; Do not hump or cut off car while in motion’. Additionally, for residue shipments in tank cars, the shipping papers must include the notation, ‘Residue: Last contained’, before the shipping name (49 CFR §173.203(e) (1-2)). Reference: www.lyondellbasell.com Email: prasenjit.chakraborty@infomedia18.in

May 2012 | Chemical World

EVENT LIST

NATIONAL AHMEDABAD

PUNE

CHENNAI

LUDHIANA

Gujarat, Oct 5-8, 2012

Maharashtra, Nov 2-5, 2012

Tamil Nadu, Nov 22-25, 2012

Punjab, Dec 21-24, 2012

INDORE

AURANGABAD

RUDRAPUR

Madhya Pradesh, Jan 11-14, 2013

Maharashtra, Feb 1-4, 2013

Uttarakhand, Feb 23-26, 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 Infomedia 18 Ltd

Ruby House, 1stt Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. • Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in

India Oil & Gas Review Summit 2012 International conference and exhibition showcasing latest trends in oil & gas industry; September 06-07, 2012; at Hotel Taj Lands, Mumbai For details contact: Oil Asia Publications Pvt Ltd 530, Laxmi Plaza, Laxmi Industrial Estate New Link Road Andheri (W), Mumbai 400 053 Tel: 022-6681 4900, Fax: 022-2636 7676 Email: oilasia@vsnl.com

Automation 2012 Conference and exhibition showcasing latest technologies in the fields of factory automation, process automation and control systems, robotics & drives, field instrumentation & smart sensors bus technologies, software solutions, wireless technologies, etc; September 07-10, 2012; at NSE Complex, Mumbai For details contact: IED Communications Ltd 64, Empire Building D N Road, Fort, Mumbai 400 001 Tel: 022-22079567, Fax: 022-22074516 Email:arokiaswamy@iedcommunications.com

Informex India 2012 A tradeshow for bringing together buyers and sellers of chemicals, chemical technologies and related services; September 12-14, 2012; at Nehru Centre, Mumbai For details contact: UBM India Pvt Ltd

Chemical World | May 2012

Sagar Tech Plaza A 615-617, 6th Floor Andheri-Kurla Road Saki Naka Junction, Andheri (E) Mumbai 400 072 Tel: 022-6612 2600, Fax: 022-6612 2626/27 Email: info.india@ubm.com

India Chem 2012 Premier tradeshow for the chemical industry in India; October 04-06, 2012; at NSE Exhibition Complex, Mumbai For details contact: Mehul Tyagi, FICCI Federation House, 1 Tansen Marg New Delhi 110 001 Tel: 011-2376 5081/2373 8760 Fax: 011-2335 9734 Email: mehul@ficci.com

Watertech Expo & Conference An event to be held concurrently with Wastetech, Cleantech and Pollutech focussing on technologies for waste, wastewater and recycling; November 02-04; at Ahmedabad For details contact: Exhiference Media Pvt Ltd B-2 Basement, Kalyan Tower Near Vastrapur Lake, Ahmedabad 380 015 Tel: 079-4003 9444, Fax: 079-4003 9431 Email: marketing@exhiferencemedia.com

Indian Petrochem 2012 An interactive knowledge forum for manufacturers, traders, buyers, technology licensors, consultants, strategists, financial intermediaries and investors; November 08-09, 2012; in Mumbai

For details F d il contact: Sahil Shah Elite Conferences Pvt Ltd 606, Bhagyalaxmi, Kennedy Bridge, Mumbai 400 004 Tel: 022-2385 1430 Fax: 022-2385 1431 Email: sahil@eliteconferences.com

CPhI India 2012 International exhibition on pharmaceutical ingredients, machinery, equipment,, outsourcing and bio-solutions; Novemberr 21-23, 2012; at Bombay Exhibition Centre, Mumbai For details contact: UBM India Pvt Ltd Sagar Tech Plaza A 615-617, 6th Floor Andheri-Kurla Road Saki Naka Junction Andheri (E) Mumbai 400 072 Tel: 022-6612 2600 Fax: 022-6612 2626 Email: info.india@ubm.com

IPVS 2012 A trade show for industrial pumps, valves and systems; December 14-16, 2012; att Auto Cluster Exhibition Centre, Pune For details contact: Orbitz Exhibitions Pvt Ltd 202, Navyug Industrial Estate T J Road, Sewri (W), Mumbai 400 015 Tel: 022-2410 2801 Fax: 022-2410 2805 Email: shital@orbitz-world.com

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: 011-4310 0568/ 0572 Fax: 011-4310 0599 Email: enquiry@eawater.com

EVENT LIST

INTERNATIONAL Chemistry Oil & Gas 2012 Specialised exhibition on cutting-edge products and technologies, equipment and materials for the chemical, oil and gas industries; May 15-18, 2012; at the Roofer Soccer Arena, Belarus For details contact: Olga Akulinina ZAO Technics and Communications Post Box 34, Minsk, 220004, Belarus Tel: (+375 17) 306 06 06 Fax: (+375 17) 203 33 86 Email: chemistry@tc.by

Dye+Chem Indonesia 2012 Trade show for dyes and fine & specialty chemicals; May 31-June 3, 2012, at Jakarta International Expo, Jakarta For details contact: PT CEMS Indonesia 2608, Grand Kartini 57 Jalan Kartini Raya, Jakarta, Indonesia Tel: +(62)–(21) 7003 3233 Fax: +(62)–(21) 3042 5226 Email: contact@cems-dyechem.com

World Gas Conference & Exhibition Event showcasing the latest in exploration, safety, refining, subsea production systems, drilling, transportation, etc; June 04-08, 2012; at Kuala Lumpur Convention Centre, Kuala Lumpur, Malaysia For details contact: The CWC Group Ltd Regent House, Oyster Wharf 16-18 Lombard Road, London, The UK Tel: +(44)-(20)-7978 0037 Fax: +(44)-(20)-7978 0099 Email: exhibition@wgc2012.com

Chemspec Europe An event dedicated to the fine and specialty chemicals industry; June 13-14, 2012; at Gran Via Exhibition Centre, Barcelona, Spain

For details F d il contact: Quartz Business Media Ltd Westgate House, 120/130 Station Road, Redhill, Surrey, The UK Tel: +44-1737-855000 Fax: +44-1737-855034 Email: michellebaalham@quartzltd.co.uk

ACHEMA One of the leading international events on chemical engineering, environmental protection and biotechnology; June 18-22, 2012; at Messe Frankfurt, Germany For details contact: Messe Frankfurt Exhibition GmbH Ludwig-Erhard-Anlage 1, Frankfurt, Germany Tel: +(49)-(69)-7575000 Fax: +(49)-(69)-7575643 Email: rentalinquiries@dechema.de

Petrochemical Asia 2012 The event will focus on solutions to overcome feedstock challenges and the latest processing technologies; June 20-21, 2012; at Conard, Bangkok, Thailand For details contact: Clarion Events Pte Ltd 78 Shenton Way #20-03 Singapore 079120 Tel: + (65) 6590 3970 Fax: + (65) 6223 9198 Email: info@clarionevents.asia

Dye+Chem Bangladesh 2012 Trade show for dyes and fine & specialty chemicals; July 11-14, 2012; at Bangabandhu International Conference Centre, Dhaka, Bangladesh For details contact: Conference & Exhibition Management Services Ltd House – 119, CEMS House Unit A3, Road – 1, Banani Block – F Dhaka – 1213, Bangladesh

Tel: T l + (880) –(2) (2) – 8818111 Fax: + (880) –(2) – 8811788 Email: cems@cemsbangladesh.com

ICIF China 2012 An event to facilitate the growth of petroleum & chemical industry of China and also to encourage international exchange & cooperation; September 10-12, 2012; at Binhai International Convention & Exhibition Centre, Tianjin For details contact: CCPIT Sub-Council of Chemical Industry Bldg. 16, Block 7, Hepingli Beijing 100013, China Tel: + (86)-(10)-64222898 Fax: + (86)-(10)-84292180 Email: mokai@ccpitchem.org.cn

Gastech 2012 Focussed event showcasing the latest innovations, technologies and developments across the gas value chain; October 8-11, 2012; in London, the UK For details contact: Paul Sinclair, Sales Director DMG Events Northcliffe House, 2 Derry Street London, W8 5TT, The UK Tel: +44 203 180 6576 Fax: +44 203 180 6550 Email: paulsinclair@dmgevents.com

TOG Expo 2012 Event focussing on latest technologies in the oil and gas industry; October 16-18, 2012; at Pavilion 58, Tripoli International Fair, Tripoli For details contact: WAHAexpo Company Ben Ashour Road PO Box 83433 Tripoli, Libya Tel: (00) (218)-(21) 7269417 Fax: (00) (218)- (21) 362 2360 Email: hanan@wahaexpo.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

May 2012 | Chemical World

BOOK REVIEW

Wastewater treatment plants: Planning, design, and operation Author: Syed R Qasim Price: ` 995

Wastewater treatment has become an integral part of the chemicals industry, which has to deal with hazardous effluents. The plants should be so designed that the effluent standards and reuse objectives, and biosolids regulations can be met with ease and at reasonable cost, keeping in mind the regulatory stipulations as well. The design should incorporate flexibility for dealing with seasonal as well as long-term changes in wastewater quality. Engineers, scientists and financial analysts can definitely utilise principles presented lucidly in this book from a wide range of disciplines: engineering, chemistry, microbiology, geology, architecture, and economics to carry out the responsibilities of designing a wastewater treatment plant. The objective of this book is to present technical and non-technical issues that are most commonly addressed in the planning and design stages for wastewater treatment facilities. Topics discussed include facility planning, process description, process selection logic, mass balance calculations, design calculations and concepts for equipment sizing. Theory, design, operation and maintenance, troubleshooting, equipment selection and specifications are integrated for each treatment process. Thus, delineation of such information for students and practising engineers is the main purpose of this book.

Standard methods for examination of water & wastewater Water conservation is one of the major areas of concern across all industries. Water is critical for various processing requirements in the chemical industry. This book deals with water analysis and remains a trusted source of accurate, proven methodology for analysing natural waters, water supplies, and wastewaters. The 22nd edition is powered with new content and most of the sections are updated. It guides the user towards safety and quality management with excellent experimentation techniques discussed in detail. The book provides methods for measuring biological, chemical, and physical attributes of water, and offers guidance for choosing the best-suited among available methods for specific elements and compounds. It will help professionals in the field of environment management, production, as well as laboratory experts and students.

Edited by: Eugene W Rice, Rodger B Baird, Andrew D Eaton, Lenore S Clesceri Price: ` 15,675

Reviewer: Tejas Padte, Lecturer, Department of Chemistry, Ramnarain Ruia College, Mumbai

Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958, Telefax: 022-2203 4058, Email: thadam@vsnl.com

Chemical World | May 2012

PRODUCTS

This section provides information about the national and international products available in the market

Cooling tower

Energy saver

This evaporative Fibreglass Reinforced Plastic (FRP) cooling tower is of vertical induced draft counter flow design with uniform water distribution and optimal heat transfer. The tower casing is made of tough FRP and has sufficient structural strength to withstand high wind velocities and vibrations. The fill splits the air and water into several streams, increasing the time of contact. Automatic rotary sprinkler system is made of nylon 66 material; rotary head and sprinkler pipe distribute the hot water over the entire space of the filler. Sprinkler pipes are non-clogging, require low pressure to operate and assure uniform water flow with minimal operating pump head. The performance of cooling tower greatly depends upon the water distribution over the fills. The water is distributed evenly through a wide spray angle without any dry pockets.

Sensor-based energy saver (model ACES) automatically switches the air-conditioners On and Off when the temperature in the room is achieved. There is a 3-minute compressor protection time interlock between each On/Off operation. The existing air-conditioner has a crude non-sensitive thermostatic control, which senses the grill temperature to switch the air-conditioner On/Off, whereas ACES has a precision sensor, which can be placed, in any part of the room to switch the air-conditioner On and Off. This helps in maintaining the comfort temperature in most used part of the room.

Gem Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-2363800, Mob: 09366631697 Email: sales@gemindia.com Website: www.gemindia.com

Vacuum pumping unit

External shunt The MECO-V external shunt is used for DC ammeters. End blocks are made from electrolytic copper extruded sections ensuring high electrical conductivity and perfect contacts. The resistance element is made from manganin, which has low PPM, thus ensuring highly reliable and stable readings. A unique soldering system ensures that the shunt does not get over heated. The external shunt has current rating from few mA to 6,000 A and a voltage drop of 50/60/75 mV. It conforms to IS:1248, DIN:43703 and BS:89 standards. Goliya Electricals Pvt Ltd Mumbai - Maharashtra Tel: 022-24149657 Email: geplmumbai@mtnl.net.in Website: www.goliya.com ya

Gautam Enterprises Mumbai - Maharashtra Tel: 022-2875 0421 Email: gautament@vsnl.net Website: www.gautament.com

This vacuum pumping unit consists of twin lobe pumps as fore pump and rotary vane pump as backing pump. The fore pump picks up oil necessary for its lubrication from the backing pump. The exhaust from the fore pump is connected to the suction side, which gives advantage of high pumping speed at higher vacuum. The pumping units are highly energy efficient and consume less power than conventional single vacuum pumps. These are of compact design and are mounted on the base frames. Applications include vacuum distillation, evaporative concentration, vacuum drying, vacuum coating, degassing, gas evacuation, sintering, brazing, metallurgy and heat treatment. Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-28375837 Email: acmevac@vsnl.com Website: www.acmevac.com

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 98

Chemical ical Wo World | May 2012

PRODUCTS

Heat exchangers The range of heat exchangers include fixed shell and tube type, floating, full double expanded and double tube sheet type. These heat exchangers are used for various applications in industries, namely, fertilisers, chemicals, petrochemicals, pharmaceuticals and other allied segments. Capacity of the heat exchangers ranges from 1 to 150 sqm of heat transfer area. Kwality Process Equipments Pvt Ltd Thane - Maharashtra Tel : 0250-6417968 Email: sales@chemicalequipments.com

Steam cleaner The steam cleaner is environmentfriendly and operates without any chemicals. The heating output is 1500 W, tank capacity is 1L, steam pressure is 3.2 and the dimensions (LxWxH) are 380x254x260 mm. Steam is an ideal alternative to conventional cleaning methods. During cleaning, the steam penetrates into the microscopically tiny spaces between the dirt and the surfaces it clings to and removes even the most stubborn dirt particles. This ensures that the dirt is easily removed from hard-to-reach areas so that one can achieve hygienic cleaning results without any scrubbing or polishing. Karcher Cleaning Systems Pvt Ltd Noida - Uttar Pradesh Tel: 0120-4661800 Email: kritika.batra@karcher.in

Electronic dosing pump The electronic dosing pump is available from 0-20 lph. It is compact in size and lightweight. The pump is diaphragmtype solenoid-operated pumps. The diaphragm is made of PTFE and backed by hyphalon. It can also be provided with automatic flow switches and level controllers. The pump is suitable for applications in water and wastewater treatment, fuel metering and other chemicals dosing in many process industries. Positive Metering Pumps (I) Pvt Ltd Nashik - Maharashtra Tel: 0253-2381993, Mob: 09326781757 Email: sales@positivemetering.com

May 2012 | Chemical World

PRODUCTS

Fasteners and steel metal components The fasteners and sheet metal components are useful in plastic injection-moulding machines and rubber industries. The components include full thread spindle, HTS hex head bolt, nuts, washers, spiral pin, plugs etc. These materials are offered as per ISO, DIN, IS, BS, JIS and ASTM standards. The materials are made from MS, carbon steel, alloy steel, stainless steel, brass, copper, PVC, nylon, fibre and spring steel. These components are used in hydraulic-pneumatic pumps & valves, electrical, electronics, machine tools, materials handling equipment, home appliances, washing machines, refrigeration and air-conditioning plants, etc. Zenith Industrial Products Mumbai - Maharashtra Tel: 022-28470806 Email: zenith@zip-india.com Website: www.zip-india.com

Level control switches These are RF admittance-type solid & liquid single-point level control switches. The RF admittance absorption measurement principle use sensing probe employing driven shield, coat guard circuit and corresponding threeâ&#x20AC;&#x201C;element probe. Three-element coat guard technology ignores material build-up on the probe. These are suitable for high dusty environment. MTS Engineers Pvt Ltd Ahmedabad - Gujarat Tel: 079-26400063 Mob: 09879495924 Email: sales@mtsengrs.com

Mass spectrometry systems The Agilent 5975E GC/MSD is a bundled system, which provides outstanding value for routine analysis. These systems consist of 7820A GC, C 59755 series GC/MSD, PC loaded with MSD ChemStation software and printer. An optional A automatic-liquid sampler and 150 vial tray, 7693A or Headspace sampler can be added for increased productivity. Agilent Technologies India Pvt Ltd New Delhi Tel: 011-51496664 Email: cag_india@agilent.com

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PRODUCTS

Dry cooling tower The dry cooling tower maintains the temperature of process hot water at a particular level. This operates on the principle of heat transfer by a heat exchanger with extended fins. The fan is driven by an electric motor. Tubes are staggered in the path of airflow for better heat transfer efficiency. The return bends are die-formed from thick walled tubing, which is heavier than the standard tubing and is used in the rest of the coils. This provides toughness and durability, which is required in the most vital parts of the coils. The inlet and outlet headers are constructed of heavy wall steel pipes. Tubes are mechanically expanded for an optimum bond between tube and fin. A die-formed galvanised steel frame provides stacking and shipping support and protection against tube damage during expansion and installation. Gem Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-2363800 Mob: 09366631697 Email: sales@gemindia.com Website: www.gemindia.com

Liquid ring vacuum pump The liquid ring vacuum pump is available in both single and double stages with capacity that ranges from 10 to 4000 cfm and ultimate vacuum is up to 720 mm Hg. It is silent in operation due to which silencer is totally eliminated. Its mechanical shaft seals design ensures adequate protection to the expensive shaft and provides for ease of maintenance. This leads to minimal time required for servicing, cutting down time to the barest minimum. This pump is rugged in design, reliable in performance and easy to maintain. It finds applications in vacuum distillation, drying, concentration, degassing, crystallisation, gas evacuation, gas conveying & compression etc in chemicals, drugs, food, beverage, sugar, fertiliser, paper, metallurgy and allied process industries. Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-28375837 Email: acmevac@vsnl.com Website: www.acmevac.com

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PRODUCTS

Reactor liquid sampler This reactor liquid sampler is for bulk drugs/ Active Pharmaceutical Ingredient (API). The sampler is equipped with aseptic valves, controllers, piping and container for sample collection. The system requires vacuum line for sample extraction and nitrogen line for purging. The unit mounted on top of the reactor extracts liquid sample from reactor through dip pipe under vacuum or pressure of reactor. All wetted parts are made of Stainless Steel (SS) 316 & elastomer chemical resistant Ethylene Propylene Diene Monomer (EPDM). The design is aseptic with no product contamination and the end connection can be triclamped or flanged. The system is equipped with a control panel. The application lies in chemicals, pharmaceuticals and petrochemicals industries. Industrial EquipWash Inc Mumbai - Maharashtra Tel: 022-26797941, Mob: 09869231815 Email: iewi@mtnl.net.in Website: www.iewi.net

Vacuum pump The vacuum pump by ITALVACUUM is equipped with new lubrication system LubriZero that has zero non-reusable oil consumption. This allows the use of synthetic oils, which is particularly suitable for chemical and pharmaceutical processes, such as drying, distillation, reaction and crystallisation. This vacuum pump ensures absolute safety of the process and the operators; operation is simple in nature and is completely reliable during the difficult operative conditions. The nominal capacity ranges from 80 to 3800 m3/h and the oil consumption is 10 g/h. Emjay Engineers Mumbai - Maharashtra Tel: 022-28975275, Mob: 09819982801 Email: electromech.engg.entp@gmail.com

Lubricant additives and reactive surfactants The ADEKA lube S series is an organo-molybdenum compound developed with original technology by ADEKA Corporation. These additives can reduce friction and help save fuels, minimise metal wear & extend machine life. The additives give good lubricity performance even under severe conditions, prevent degradation of oil, and extend oil life. Adeka India Pvt Ltd Mumbai - Maharashtra Tel: 022-40263301 Email: info@adekaindia.com

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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, like cable, battery, PVC processing, heavy electrical, power & cement plants, ceramic, silica and glass. It is also used while laying cables, spraying paints, grinding, dusting, soldering and electroplating. Empire Trades Coimbatore - Maharashtra Tel: 0422-537 7228, Mob: 09894232828 Email: ynajmi@indiatimes.com

Furnace curtain The high-temperature silica fabric withstands temperature as high as 1,000°C. Because of its capacity to withstand high temperature, it offers better performance than silica glass fabric, which can withstand much lower temperature (around 400-500°C). The fabric is also coated with aluminium foil and silicon rubber. It can also be used as a furnace curtain for covering open/ exposed area of the furnace. During the manufacturing process, the loom is provided at top of the curtain and a steel wire is passed through the loom. This curtain is also made in the form of a hanging strip. Urja Products Pvt Ltd Ahmedabad - Gujarat Tel: 079-22872277, Mob: 09825688244 Email: info@urjafabrics.com Website: www.urjafabrics.com

Wear plate and wear pad Rollon Turcite-B B wear plate and wear pad overcome the problems of wear in critical sliding surfaces of machinery. It is used in sugar mills, cement plants and other engineering applications. It is a modified bronze-sintered PFE material with inherent characteristics of self-lubrication, low friction and high load-bearing capacity. The wear-resistance property is enhanced by special wear-resistance additives. Turcite-B B can withstand high working pressure of 115 kg/cm² and temperature of –218°C to +260°C. It is fungusresistant and not affected by weather/moisture and most chemicals. Rollon Bearings Pvt Ltd Bengaluru - Karnataka Tel: 080-2226 6928 Email: rollon@rollonbearings.com

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PRODUCTS

Basket centrifuge These are products for handling highly corrosive and foodgrade chemical for full vacuum to 25 kg/cm² press and up to 250°C temperature. Halarcoated basket centrifuge is suitable for bulk drugs, fine chemicals and pesticides. An industrial advantage of the halar coating is its smooth surface. FDA approved and non-sticky property apart from chemical resistance, it is available from 14” laboratory machines to 24”, 35” and 48”, three pendulums or up to inertia plate construction. Elasto Polymer Processors (Gujarat) Pvt Ltd Rajkot - Gujarat Tel: 0281-2361623 Email: epp@sify.com Website: www.atikagroup.com

Tray dryer This tray dryer is fabricated out of rigid angle iron frame with double walled panels insulated with compressed fiber 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 300ºC. 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 E mail: info@jasenterprise.com

PTFE/Teflon moulded components The range of PTFE/Teflon moulded components include: bushes, rods, sheets, bellows, O-rings, V-rings, mechanical seals, ball valve rings, gaskets, etc. These are available as per customers’ requirements or as per drawings and samples. The components are also available in all fillers of PTFE/Teflon, like glass, carbon, bronze and graphite. Supremo Polymer Industries Ahmedabad - Gujarat Tel: 079-55445181 Mob: 09327001998 Email: sales@supremopolymer.com

104 Chemical World | May 2012

PRODUCTS

Turbine blowers These are designed to suck or to compress gases/non-explosive air mixtures. These are absolutely oil free with air flow capacities that ranges from 42 to 1100 m3/hr with maximum vacuum up to 500 mbar and maximum pressure is up to 550 mbar. These are light-weight due to Al construction and have 100 per cent oil-free non-pulsating continuous air flow. These blowers require practically zero maintenance and have silencers on both suction as well as discharge ports. These find applications in areas such as pneumatic conveying systems, industrial vacuum cleaners, printing & paper handling, air pollution monitoring equipment and dental suction equipment. Shree Siddhi Vinayak Industries Thane - Maharashtra Tel: 0250-2845 8372 Email: response@minivacpumps.com

PVC cable tray The rigid PVC perforated cable tray is an ideal replacement to MS tray. This PVC tray is not affected by any corrosive chemicals and is waterproof. It can be used outside for prolonged periods as it is UV stabilised to resist ultraviolet rays of sun. It is available in width ranging from 50 mm to 300 mm, flange heights of 25 mm and 50 mm and with a standard length of 2.9 m. The cable tray is lightweight and maintenance-free. Supreme Electroplast Industries Mumbai - Maharashtra Tel: 022-2887 3428, Mob: 09820306252 Email: supshitl@vsnl.com Website: www.supshitl.com

Hybrid stepping motors These 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 mmÂ˛ and 42 mmÂ˛. Nippon Pulse Motor Co Ltd Tokyo - Japan Tel: +81-3-38138841 Email: s-hagimoto@npm.co.jp

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PRODUCTS

Vacuum pumps

Ultra-filtration systems

These Minivac SVL series of low vacuum pumps are sliding vane type direct/belt driven vacuum pumps mounted on common base frames. These are compact in size, vibration free and hence can be mounted inside the machines. These attain maximum vacuum levels up to 29” of Hg and capacities range from 50 to 2000 Lpm. The specially treated vanes give advantage of silent operation, reduces wear and tear on stator. The unique design of lubrication system positively feeds minimum required oil to all rotating and frictional parts. These are useful in many applications like capsule filling/capsule printing machines and pharmaceutical machineries, packaging/labelling machines, screen printing/plate making and vacuum chucking.

These ultra-filtration (UF) systems are of robust flat sheet and spiral wound membrane. The UF systems are operated in a crossflow mode, thus reducing the chances of fouling and maintaining the permeability of the membrane for a long time. These systems undergo negative pressure operation, thereby eliminating compaction and higher TMP.

Shree Siddhi Vinayak Industries Thane - Maharashtra Tel: 022-28458372 Email: response@minivacpumps.com

Vibro sifters These vibro sifters are ideal for gradation and separation of dry powder, granules and semi-solids and liquids. The modular design clings easily with fitted clamp and is suitable for a wide range of materials. Less power consumption, variable flow pattern and the dust-free arrangement leads to free sieves. Bombay Pharma Equipments Pvt Ltd Mumbai - Maharashtra Tel: 022-28594877 Email: bombaypharma@vsnl.net

Digital flow meters These paddle wheel insertion-type digital flow meters are unique 2-in-1 combination, wherein the rotameter measures flow rate vertically. The water meter counts total horizontally and measures both the aspects. It is economical and used to match up with international standards. No external power supply is required. MTS Engineers Pvt Ltd Ahmedabad - Gujarat Tel: 079-26400063 Mob: 09879495924 Email: sales@mtsengrs.com

106 Chemical World | May 2012

Ovivo India Surat - Gujarat Tel: 0261-2465972 Email: info.in@ovivowater.com

Dust filtration systems The Dustkiller DK 5000 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 voltage 500 cm³/hr, input 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

Digital indicator The model AI-501 digital indicator is available with programmable and modular inputs, supporting multiple input types of thermocouples, RTDs, voltage/current and two-wire transmitters. This indicator is suitable for measuring and displaying temperature, pressure, flow, level, humidity, etc with measurement accuracy of 0.3 per cent full scale. The dual display windows are convenient to set parameters and alarm points. Various dimensions are selectable. The indicator supports up to 4 loops of alarms including 2 loops of high limit alarms plus 2 loops of low limit alarms. Alarms can be outputted to different relays or share one. Micon Automation Systems Pvt Ltd Ahmedabad – Gujarat Tel: 079-30900400, Mob: 09723462390 Email: info@miconindia.com

` `

PRODUCTS

Cage mill flash dryers These have capacity that ranges from 10 kg/ hr to 5000 kg/hr. Due to low residence time in the range of 0.5 to 2 seconds in these flash dryers, heat-sensitive products can be easily dried without degradation. The cage mill flash dryers are compact, requiring less maintenance and are user-friendly. Raj Process Equipments & Systems (P) Ltd Pune - Maharashtra Tel: 020-4071001 Mob: 09766441144 Email: sales@rajprocessequipment.com

Salt spray corrosion testing system This is a proven system to make comparative or absolute study of corrosion resistance for different materials, surface coatings, viz, plating, painting, etc. Various components and assemblies of automotive, electrical, electronic, engineering and durable consumable products are subject to salt spray corrosion test to evaluate effect of corrosive atmosphere on their aesthetic and performance parameters. Based on these

corrosion effects, one can take corrosion inhibiting measures. Various corrosion tests mentioned in National & International Standards viz, IS: 9000 pt Xi, ASTM B 117, etc, can be carried out in this system. Micro Supreme Auto Industries (I) Pvt Ltd Tel: 020-26932669 Email: bageshri.bhagwat@microsupreme.co.in

Polypropylene and PVDF process pump The horizontal chemical process pump is made of polypropylene (PP). All contact parts are made of virgin copolymer PP with high wall thickness for better impact resistance and stability. The pump is centrifugal type. Rotating parts are dynamically balanced. The pump is available with ceramic, SS-316 or FRP shaft sleeve. Sealing arrangement is of PTFE gland packing or mechanical seal or as per the requirement. This pump is suitable for effluent treatment plants, filter press application, acid transfer, boiler de-scaling, pickling in steel plants, electroplating, etc. Moniba Anand Electricals Pvt Ltd Mumbai - Maharashtra Tel: 022-28573156, Mob: 09820046500 Email: mail@moniba.net

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PRODUCTS

Ribbon blenders

Airless paint spraying pumps

These light-duty blenders are useful for easy mixing of powder components and are low-shear mixers, most commonly used for solid/ solid, solid/liquid mixing and when high shearing force is not required. The counter flow helicoids flight mounted on shaft ensure gentle mixing. Blades are designed for triple action mixing to suit end-product characteristics.

These pumps are suitable where better paint finish, gloss of paint and aesthetic results of the machine are prime requirements. The pumps give high output of paint and thus save time, manpower, paint & cost by giving high efficiency. It is also possible to spray high build paints for anti-corrosive painting with airless pump.

Raj Process Equipments & Systems (P) Ltd Pune - Maharashtra Tel: 020-4071001 Mob: 09766441144 Email: sales@rajprocessequipment.com

Synco Industries Ltd Jodhpur - Rajasthan Tel: 0291-2741571 Mob: 09829022258 Email: synco_2000@yahoo.com

Centrifugal pumps

Twin screw pumps

These pumps have all contact parts, including casing and impellers, of corrosion-resistant silica epoxy construction. The pumps are fitted with externallymounted 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.

These pumps consist of one set of shafts – one driving and one driven with two screws mounted and keyed onto each shaft. Liquid entering the pump is divided into two parts, each part going to the outer end of screws. These hold a given volume of fluid, moving axially as the screws rotate.

Resicast Mumbai - Maharashtra Tel: 022-26501971 Mob: 09820883985 Email: kfresi@rediffmail.com

Fly ash dryer systems These systems are used to dry the wet fly ash with 20-25 per cent moisture by weight, by utilising waste heat generated from the clinker production process or by hot air furnaces. The exhaust hot air from the cooler or hot gas generator installed are around 300° to 350°C and made to pass through the dryer, along with wet fly ash. The dryers are designed to have sufficient retention time for the fly ash to get dried by bringing down the moisture to less than 2 per cent. Sabash Engineering (Chennai) Pvt Ltd Chennai - Tamil Nadu Tel: 044-24732900 Email: welcome@sabashengg.com

110 Chemical World | May 2012

UT Pumps & Systems Pvt Ltd Mumbai - Maharashtra Tel: 022-32992488 Email: info@utpsl.in

Sample preparation plates Ostro sample preparation plates represent a novel approach for removal of phospholipids from biological samples. It removes up to 30 times more phospholipids. With its proprietary, patentpending design, it is specifically created to overcome the hurdle by offering a solution that removes multiple families of phospholipids. Waters (India) Pvt Ltd Bengaluru - Karnataka Tel: 080-28371900 Mob: 09342160313 Email: padmini_satish@waters.com

PRODUCTS

Welding fume extractors The Fumekillerr welding fume extractors are fitted with self-balanced extractor arms that are ideal for capturing and controlling all types of welding fumes. Unlike mechanical filters, these work on the electrostatic filtration principle. Filter modules are washable and reusable. There is no replacement cost of the filters. Powertech Pollution Controls Pvt Ltd Bengaluru - Karnataka Tel: 080-23452156 Email: powertech@airtelmail.in

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 predigestion. 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

Air classifiers These are screenless machines 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 machines can be operated in closed circuit. Premium Vijimech Pvt Ltd Ahmedabad - Gujarat Tel: +079-40083450, Mob: 09712987467 Email: sales@vijimech.com Thee info foormaation n publlis ished in thiss secttion is as per thee dettails furniished d by the respectivee man nufacctureer/disstribu utor. In any casee, it does no n t re repressen ent th he view ws off Chemical World

May 2012 | Chemical World

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An invite that rewards as well... Dear Reader, ‘Chemical World ’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the chemical process industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Chemical World ’. Authors whose articles are published will be sent a complimentary copy of that particular edition. Published by Infomedia 18 Ltd, ‘Chemical World ’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the chemical process industry (CPI). Well W supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian CPI. Moreover, it offers a broader platform facilitating effective interaction among several fraternities of these industries by enabling them in reaching out to their prospective buyers & sellers through better trade contacts and more business opportunities. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

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D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in

LIST OF PRODUCTS

Sl. No.

Product

Pg. No.

Sl. No.

Product

Pg. No.

Sl. No.

Product

Pg. No.

AC/DC gear box......................................... x 41

Compositional & trace metal analysis ............. 43

Food processing machinery............................. y BC

AC/DC electric motor..................................... r 41

Condenserr ...................................................... 102

Foot valve ......................................................... 79

Accelerated ageing test..................................... t 43

Continuous or batch filtration ......................... 35

FRP battery stand ............................................ 17

Acoustic enclosure ............................................ 63

Conveyorr ........................................................ 103

FRP cable tray.................................................. y 17

Agitatorr ............................................................ 13

Cooling towerr ............................................. 23,98

FRP canopy...................................................... y 17

Agitator tank............................................ k 45, 102

Crane .............................................................. 104

FRP grating...................................................... g 17

Air classifiers .................................................. 111

Dehumidifierr .............................................101

FRP handrail & fencingg .................................. 17

Air cooled heat exchanger................................ r 23

Diaphragm valve ........................................ 77, 79

FRP ladderr ....................................................... 17

Air freightt .......................................................... 8

Digital flow meter.......................................... r 106

FRP luminaries ................................................ 17

Air pollution control equipment...................... t 19

Digital indicatorr ............................................. 106

FRP pole .......................................................... 17

Air-cooled steam condenserr ............................. 23

Disperserr .......................................................... 13

FRP storage tankk ............................................. 17

Airless paint spraying pump .......................... 110

Distillation column .......................................... 49

FRP structural profile ...................................... 17

Allied service ...................................................... 8

Dry cooling towerr .......................................... 101

Fuel - diesel...................................................... 43

Anaesthetic rotameterr .................................... 103

Dry vacuum pump ........................................... 99

Fully automatic filter press............................... 56

Analytical instrumentation ............................ BIC

Dry van pump .................................................. 63

Furnace curtain............................................... 103

Aqua gas chlorinatorr ........................................ 91

Dryerr ................................................................ 47

Gas .......................................................... 43

Automatic and contained discharge ................. 35

Dust collectorr ................................................... 26

Gas plant.......................................................... t 21

Bag filterr ............................................... 26, 97

Dust extraction system ..................................... 97

Gaskett .............................................................. 77

Ball check valve ................................................ 77

Dust filtration system..................................... 106

Gear box ................................................... 41, 104

Ball valve .................................................... 77, 79

Electronic dosing pump .............................. 99

Gear motor....................................................... r 41

Basket centrifuge............................................ 104

Empowerr ....................................................... BIC

Gear oil ............................................................ 43

Batch disperserr ................................................. 13

End cap ............................................................ 79

Gear pump ....................................................... 81

Bath & circulatorr ............................................. 33

Energy saverr ..................................................... 98

Goliath crane.................................................. 104

Bellow & dip-pipe ............................................. 4

EOT/HOT crane .......................................... 104

Goods liftt ....................................................... 104

Bend ................................................................. 79

Etallographyy ..................................................... 43

Heat exchangerr .................. 19, 45, 99,102, FIC

Biodiesel ........................................................... 43

Evaporator............................................ r 27, 37, 49

Heat transfer equipmentt .................................. 73

Biospec-nano .................................................... 57

Exhausterr.......................................................... 39

Heating bath .................................................... 13

Blenderr ........................................................... 102

External shuntt .................................................. 98

Heating element............................................. t 100

Blowerr .............................................................. 39

Facemask respiratorr ...................................103

Heating solutions ........................................... 109

Bulk bag filler................................................. r 103

Failure analysis ................................................. 43

High pressure blowerr ..................................... 104

Bulk bag unloaderr .......................................... 103

Fasteners and steel metal componentt ............ 100

High pressure homogeniserr ............................. 13

Bush ................................................................. 77

FEP/PFA/PVDF material............................... 77

Hot air generatorr ............................................. 26

Butterfly valve ............................................ 77, 79

Filler compositional analysis ............................ 43

Hot plate .......................................................... 13

Cage mill flash dryerr ..................................109

Filter cockk ........................................................ 79

Hot water generator......................................... r 26

Cake pressingg ................................................... 35

Filter press ........................................................ 56

HPLC ........................................................... BIC

Calorimeterr ...................................................... 13

Fitting............................................................... g 77

Hybrid stepping motorr .................................. 105

Centrifugal fan ........................................... 73, 97

Flame proof hoist........................................... t 104

IBR steam boiler......................................... r 26

Centrifugal pump ...................................... 41,110

Flash dryer........................................................ r 47

Impellerr ............................................................ 79

Chain pulley blockk ......................................... 104

Flexible screw conveyor.................................. r 103

Industrial heating elementt ............................. 100

Check valve-teflon lined .................................... 4

Flow indicatorr .................................................. 79

Informatic ...................................................... BIC

Chemical pump.............................................. 104

Flow verturi tube ............................................ 102

Inline disperserr ................................................. 13

Column & chemistries .................................. BIC

Fly ash dryer system ....................................... 110

Jib crane ....................................................104

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

eg. CW Pump and send it to 51818 May 2012 | Chemical World

113

LIST OF PRODUCTS

Sl. No.

Product

Pg. No.

Sl. No.

Product

Pg. No.

Sl. No.

Product

Pg. No.

Kneading machine ...................................... 13

Pressure and vacuum filtration......................... 35

Solid-liquid mixerr ............................................ 13

Laboratory reactorr ...................................... 13

Pressure vessel .......................................... 45, 102

Spade ................................................................ 79

Laboratory software.......................................... 13

Process gas blower.......................................... r 104

Spin flash dryerr ................................................ 47

Large diameter welded pipe ............................. 99

PTFE lined valve & pipe fitting........................ g 4

Spray cooler...................................................... r 97

Level control switch ....................................... 100

PTFE/Teflon moulded components.............. 104

Spray dryerr ................................................. 49, 97

Lined valve & pipe fittingg ................................. 4

Pump ....................................63, 81, 99, 104, 111

Stainless steel pipe............................................ 99

Liquid ring vacuum pump ............................. 101

Pumping solution..................................... 55, 102

Steam cleanerr ................................................... 99

Long neck pipe end ......................................... 79

PVC ................................................................. 41

Storage tankk ..................................................... 49

Lube-engine oil................................................ 43

PVC cable trayy ............................................... 105

Strainer-teflon lined ........................................... 4

Lubricant additives and reactive surfactants .. 102

PVDF pump .................................................. 104

Swing check valve ............................................ 77

Magnetic stirrerr .......................................... 13

PVDF valve ...................................................... 41

Teflon lined valve & pipe fitting g ................... 4

Mass spectrometry system.............................. 100

Reactorr ............................................ 19, 53, 71

Tefzel HHS isotactic PP material ..................... 6

Material identificaton system ........................... 43

Reactor liquid samplerr ................................... 102

Testing equipmentt ........................................... 43

Mechanical vacuum booster............................. r 39

Reducerr ............................................................ 79

Mill ................................................................. 13

Ribbon blenderr............................................... 110

Mini vac pump ............................................... 100

Rod ................................................................. 77

Mixing & drying........................................ g 27, 37

Roots blowerr ............................................ 63, 111

Monoblock high vacuum pump ....................... 99

Rotameterr ....................................................... 103

Monoblock pump ........................................... 104

Rotary atomiserr ................................................ 47

Monoblock vacuum pump ............................... 99

Rotary dry vacuum pump................................. 73

Monorail trolleyy ............................................. 104

Rotary evaporatorr ............................................. 13

Motor driven dosing pump .............................. 91

Rotary gear pump..................................... 81, 104

Motorised chain pulley block......................... k 104

Rotary pump .................................................... 99

Multi stage cake washing................................. g 35

Sack tip station ..........................................103

Non-metallic pump....................................104

Salt spray corrosion testing system ................ 109

Non return valve .......................................... 4, 79

Sample preparation plates .............................. 110

Non-IBR steam boilerr ..................................... 26

Sampling valve-teflon lined ............................... 4

Oil lubricated vacuum pump ......................105

Scoop ................................................................ 79

Oil seal high vacuum pump ............................. 99

Scrubberr ........................................................... 97

Oval wheel flow meterr ................................... 105

Seamless pipe ................................................... 99

Overhead stirrerr ............................................... 13

Self priming mud pump................................. 104

Petrol & fuel oil.......................................... 43

Self priming sewage pump ............................. 104

Pharma temperature control .............................. 8

Sensor system .................................................. 51

Pilot plant......................................................... t 13

Shaker............................................................... r 13

Vacuum pump .....................................99,102,106

Pipe ................................................................. 77

Sheet................................................................. t 77

Vacuum pumping unitt ..................................... 98

Pipe fittingg ....................................................... 41

Showel .............................................................. 79

Vacuum system ................................................ 63

Pipingg ............................................................... 65

Silence flow package ........................................ 73

Valve ........................................................... 77, 79

Piping system ..................................................... 6

Silicone FBD gaskett ........................................ 69

Variable area flowmeterr ................................. 103

Plant & machinery .........................................BC

Silicone rubber braided hose ............................ 69

Vertical glandless pump ................................. 104

Plastic masterbatch ........................................... 89

Silicone rubber compound ............................... 69

Vibro sifterr ..................................................... 106

Plug valve ......................................................... 77

Silicone rubber cord ......................................... 69

Washer....................................................... r 79

Pole ring........................................................... g 79

Silicone rubber corona teater sleeve ................. 69

Water ring vacuum pump .............................. 111

Polymer ........................................................... 43

Silicone rubber extruded gasket & profile ....... 69

Wastewater treatment system ........................ 111

Polypropylene and PVDF process pump ....... 109

Silicone rubber moulding................................. g 69

Wear plate and wear pad ............................... 103

Polypropylene filter plate ................................. 56

Silicone rubber sheett ........................................ 69

Welded pipe ..................................................... 99

Polypropylene process pump .......................... 104

Silicone rubber sponge ..................................... 69

Welding fume extractorr ................................. 111

Polypropylene recess plate ................................ 56

Silicone rubber tubing...................................... g 69

Wire rope hoistt .............................................. 104

Powergas solution............................................. 45

Slipon flange .................................................... 79

Y type strainer............................................. r 79

PP-recess chamber type filter press ................. 56

Solenoid driven metering pump....................... 91

Zircoatt ......................................................... 3

BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside Cover

114 Chemical World | May 2012

Thermic fluid heaterr ........................................ 26 Thermoplastic valve ........................................... 6 Thermostat & vaccum dryer / mixerr ............... 13 Transfer trolley............................................... y 104 Transmission fluid............................................ 43 Tray dryer....................................................... r 104 Tri lobe roots blowerr ....................................... 39 Truck blowerr .................................................. 104 Tube ........................................................... 77, 99 Turbine blower............................................... r 105 Twin lobe root blowerr ............................. 39, 111 Twin screw pump .......................................... 110 Two stage vacuum pump ......................... 99, 111 Ultra-filtration system ................................106 UPLC ............................................................ BIC Vaccum control ........................................... 91 Vacumm cleaner............................................. r 111 Vacuum booster pump ..................................... 63 Vacuum or hot gas drying................................ 35

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Acme Air Equipment Co Pvt Ltd

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103

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104

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Fluidtech Boilers Pvt Ltd

FIC

Joyam Engineers & Consultants Pvt Ltd 99

T: +91-2762-224114

BHS-Sonthofen (India) Pvt. Ltd.

T: +91-265-2331748

Arctic India Sales

27; 37

103

T: +91-2752-241479

Aqua Services

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T: +91-22-66915901

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Pg No

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T: +91-40-23315341 / 45

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E: neelesh@bhs-sonthofen.in

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May 2012 | Chemical World

115

LIST OF ADVERTISERS

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Pg No

Kwality Process Equipments Pvt Ltd

Advertiser’s Name & Contact Details

Samarth Engineers

Pg No

102

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Suraj Limited

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109

111

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Toshniwal Instruments (Madras) Pvt Ltd

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E: gupta@shivatec-india.com

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Prayag Polytech Pvt Ltd

100

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Shri Vishnupumps

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105

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100

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Parth Poly Valves Pvt. Ltd

104

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Techno Industries T: +91-79-25830742

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P P I Pumps Pvt Ltd

Satyam Industries

Pg No

E: info@toshvin.com 102

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Siemens

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Supremo Polymer Industries

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Waters (India) Private Limited

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116 Chemical World | May 2012

Our consistent advertisers

W: www.polyvalve.com

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W: www.siemens.com/chemicals 19

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E: vishnupump@rediffmail.com

BIC