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UNDERMINING POTENTIAL?

ome facts: World Bank predicts that mining is poised to expand considerably over the next 20–30 years. India produces as many as 86 minerals, which include 4 fuels, 10 metallic, 46 non-metallic, 3 atomic and 23 minor minerals. The total value of mineral production in India (excluding atomic minerals) during 2009–10 was estimated at `1,27,921.42 crore, which shows an increase of about 4.61% over that of the previous year. This figure is on the ascent and is expected to be huge by the end of 2012. The Indian mining industry market is set to attain a size of US$36.2 bn by 2016, according to a report recently

released. Mining retains the position of being the most talked about topic and deliberation among the populace, though not necessarily concluding with any concrete outcomes. While the reasons for the attention are well known (the sheer prospects & profits involved), the misdoings and mishandlings involved in this sector, given the scope & the dangers involved, attract bad press. The outcome: the business-to-business community, the value chain, the suppliers and vendors’ community face the adverse impact of the negative publicity—a concern that needs to be addressed and sorted. All this becomes all the more relevant as India ranks among the world’s Top 5 nations for its core competency commodity reserves of coal and iron ore. While India is the world’s third-largest producer of coal, fourth-largest producer of iron ore and the fifthlargest producer of bauxite, only 10% of the country’s landmass has been explored, primarily due to significant bureaucratic obstacles. It is more than established that the Indian mining sector has a goldmine of profits and prospects. However, there are some hurdles as well that the sector needs to watch out for. In many countries, including India, governments are seeking a greater take from the sector through a wave of new requirements, such as mandated beneficiation, export levies and limits on foreign ownership. Projects around the world have been deferred or delayed because of the degraded risk/reward equation. Then again, global skills shortage, infrastructure access, cost inflation, capital project execution, social licence to operate, price & currency volatility, capital management & access, and fraud & corruption are some worrying factors that can stall the growth of this sector. A bright spot, however, is the increasing number of Indian companies venturing overseas to secure stable, long-term supplies of minerals, such as coal and iron ore, in a bid to meet the fast-rising domestic demand. While the demand outlook remains strong, mining and metal companies too remain nimble and sure-footed in how they manage these fast-changing risks. Now is the time to promote the optimal utilisation of India’s mineral resources for its industrial growth and socio-economic development, through scientific exploration, sustainable mining practices and geo-scientific research & development. Considering the mineral potential of India, the contribution of the mining sector in the GDP should increase. The mining sector needs to play a major role if India has to realise its cherished growth figures. The importance of the sector in the growth of GDP in mineral rich countries indicates the opportunities available…but are we then undermining our potential?

Archana Tiwari-Nayudu archana.nayudu@network18publishing.com

CONTENTS SPECIAL FOCUS: Pumps And Valves

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Mining Processes And Stages Mapping The Life Cycle Of A Mine The production operations in mining tend to be separate and cyclic in nature, although the trend in modern mining and tunnelling is to eliminate or combine functions. In order to increase the continuity of extraction, production cycle and certain auxiliary operations must be performed. Here are the major stages and processes that comprise the whole of the mineral production via the mining process.

EDITORIAL Undermining Potential?

STRATEGY 146

Innovating Profitably The 10 Best Practices For Success

NEWS, VIEWS & ANALYSIS 36

EQUIPMENT WATCH

Latest Happenings In The World Of Manufacturing

150

The All New JCB 3DX Backhoe Loader An Earthmoving Achievement!

TECHNOLOGY & INNOVATIONS 42

Technology Update Cutting-edge Solutions

IN CONVERSATION WITH

Pg 44 AUTOMATION TRENDS 139

Robotics In Nuclear Fuel Cycle Automating The Atomic World

ENERGY MANAGEMENT 142

Increasing Efficiency Saving Energy = Saving Money

POLICIES & REGULATIONS 144

Financing SMEs In The ‘Interest’ Of SMEs

‘Operational improvement is critical for companies to achieve competitiveness in all its KPIs’ Filippo Mantegazza, Chairman of the Board, Solving Efeso International SA

HIGHLIGHTS: OCTOBER 2012 ●

Special Focus: Material Handling ● Insights & Outlook: Defence ● Special Edition: Investment Destination: West Bengal

CONTENTS SPECIALS IN THIS ISSUE SPECIAL FOCUS Pumps and Valves

INSIGHTS & OUTLOOK Mining

Open Page

Pumps: 10 Growth Commandments The Doctrine Of Growth

Emerging Trends Expectations 2012 For Global Mining Sector

Uranium Mining Nuclear Energy: Towards Attaining Self-reliance

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National Policies On Mining A Guiding Light For Indian Mining

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Five Discourses Of Valves The Controlling Authority

Mining Of Fuels Fuelling Power Into Indian Mining

Overviewing Some Major Mineral Ores Minerals: The Essential Elements Of Growth

FDI In Mining A Goldmine Of Business Opportunities

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Indian Coal Scenario Overview A Resource-full Reserve

Mining Equipment Enhancing Mining’s Efficiency Quotient

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Safety In Mining Mining’s Achilles Heel

Mergers, Acquisitions And Joint Ventures Envious Deals To Deliver Demands

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Environmental Effects Of Mining Is The Eroders Of Earth Tag Justified?

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Global Mining Deals 2011–12 Empowering Nations

PRODUCT UPDATE

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EVENTS LIST

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New Launches Latest Products In The Offing

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TENDERS

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Pumps & Valves Latest Products In Pumps & Valves

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Mining Latest Products In Mining

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General Products Rolling Out The Best In Class

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International Products Showcasing Products In A Global Arena

PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

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ADVERTISERS’ LIST Advertisers’ List In Chronological Order

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MANUFACTURING SECTOR MAY RECORD LOWER GROWTH IN Q2: FICCI The manufacturing sector is expected to register lower growth during the July–September quarter of the current financial year as compared to the previous quarters, mainly due to the rupee depreciation and slowdown in demand, according to a survey by the industry body FICCI. The manufacturing sector, which constitutes over 75% of the factory output, did not perform well as it grew a meager 2.5%, as against 6.3% in May 2011. According to the survey, which drew responses from 418

manufacturing units and associations, 46% respondents expect that the sector’s growth would be low in the second quarter of this fiscal. On the other hand, only 42% respondents said that the depreciation has helped them to improve their exports. Rupee depreciation has presumably affected the sector’s competitiveness severely over the last few months, said FICCI’s quarterly survey on manufacturing. “Rupee depreciation has led to increased cost of their imported raw materials and inputs by 5–25% in the

INDIA TO SET UP TWO MANUFACTURING HUBS IN SRI LANKA India is all set to come up with two manufacturing hubs in Sri Lanka, which will act as supply chains for companies based in India. Both the countries have decided to double their bilateral trade to $10 billion by 2015–16 from the current volume of $4.8 billion. Union Commerce and Industry Minister Anand Sharma informed, “India and Sri Lanka have agreed to set up Manufacturing Special Economic Zones for investment linked to manufacturing auto components and

engineering goods. We will also set up a pharma manufacturing hub in the island nation.” The manufacturing hub will be set up in Trincomalee, known for its natural deep-water harbour. The location for the pharma hub is yet to be identified. The Commerce and Industry Minister also announced giving preferential access to Sri Lanka to the Indian market. The manufacturing hubs will help in value-added exports to India.

SAIL TO OUTSOURCE DEVELOPMENT OF TWO VIRGIN MINES The Steel Authority of India Ltd (SAIL) has decided to outsource the development of two huge virgin iron ore mines at Rowghat in Chhattisgarh and Chiria in Jharkhand. Rowghat, which will have a capacity of 14 million tonne per annum (mtpa) and Chiria, 15 mtpa, are crucial for SAIL’s capacity expansion. The company has decided to develop these two mines through mine developercum-operators. It would cost `1,000–1,200 crore each for developing Rowghat and Chiria mines, and if the method is successful, SAIL’s investment for mine development would be reduced

by around `2,500 crore. The public sector steel major has earmarked an investment of `15,000 crore for expanding its existing mines and developing virgin mines. SAIL, which would increase its capacity to around 24 MT by the end of next year from the existing 14 MT, would require 39 MT of iron ore by the end of 2013. A railway line is also being laid from Dalli–Rajhara to Rowghat, which would cost `700 crore. Environment clearance and first-stage forest clearance have also been received for Chiria mine in Jharkhand while land acquisition is still under way.

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last few months,” said the survey. The depreciation of the rupee has affected some sectors such as automotive, electronics, capital goods, chemicals and textiles. According to the survey, “The demand conditions remained subdued in the economy for the manufacturing sector in Q2 compared to the previous quarters.” The survey also said that the capacity utilisation in Q2 has remained low. Moreover, the growth in manufacturing exports was expected to be low in Q2 as against the previous quarters.

SIEMENS BAGS NMDC PROJECT A consortium led by Siemens VAI Metals Technologies has received an order from the National Mineral Development Corporation (NMDC) Ltd for the supply of a complete LD (BOF) steelmaking plant. The order volume for the consortium amounts to approximately €290 million. The steel plant will be built at Nagarnar, Chhattisgarh, as part of an integrated production complex with an annual capacity of approximately 3 million tonne steel. The project is scheduled for completion by mid2015. NMDC had already ordered a sintering plant from Siemens for the Nagarnar project site, according to a company release. The Nagarnar integrated steelmaking plant is part of a national programme to increase the steel production capacity of India. Siemens will be in charge of the design and the ‘turnkey’ supply of the steel plant, including two LD (BOF) converters, two 175-tonne desulphurisation plants (HMDS), two ladle furnaces and an RH degassing plant. The ‘turnkey’ project scope of supply also includes material handling systems, primary & secondary de-dusting systems, a gas recovery plant & a water treatment plant.

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AAM ANNOUNCES NEW MANUFACTURING FACILITY IN CHENNAI American Axle & Manufacturing Holdings, Inc (AAM) recently announced the grand opening of its Chennai Manufacturing Facility (CHMF), located in the industrial park of Mahindra World City. Cliff Owens, CHMF Plant Manager, will oversee the facility’s manufacture of highly engineered driveline products for the region. Products manufactured at the facility include a family of front and rear axles for commercial vehicles. “We are extremely pleased to celebrate the grand opening of AAM’s third regional manufacturing operation in India,” said John J Bellanti, Executive VP – Worldwide Operations, AAM, adding, “The Chennai

Manufacturing Facility will allow us to leverage AAM’s track record of world-class quality, delivery, reliability and outstanding warranty performance while furthering AAM’s global expansion in emerging markets.” “Profitable growth in India is a key component of AAM’s global business strategy,” explained Anand M Ganguly, MD, AAM India. “Chennai Manufacturing Facility reflects AAM’s commitment to India while allowing us to provide advanced technology products for current and potential new customers throughout the region. The facility is strategically located in proximity to our OEM customers,” he emphasised.

BMM ISPAT TO SPEND `6,700 CRORE ON HOSPET PLANT EXPANSION BMM Ispat Ltd is adding capacity at its Hospet plant at a cost of `6,700 crore for expanding its capacity to 3 million tonne steel per annum. The promoters will bring `2,500 crore as their share and the balance will be debt financed by a consortium of 16 banks led by the State Bank of India. The company is adding capacity adjacent to its existing facility and has plans to focus on producing long products, alloy steel for the automobile sector and increase captive

power production to 675 MW from the current 235 MW capacity. According to the company, after the capacity addition is completed in 2014, BMM will be a 5-million tonne per annum company. The company, located at Hospet, in Karnataka’s Bellary district, currently produces 2.5 million tonne of pellets, one lakh tonne of TMT bars, seven lakh tonne of sponge iron for domestic market and 235 MW of captive power.

KIRLOSKAR LOOKING FORWARD TO SET UP PLANT IN ODISHA Kirloskar Brothers Ltd (KBL), the flagship company of the $2.5-billion Kirloskar Group, is keen to set up a valve and pump manufacturing unit in Odisha. KBL is a global fluid management solutions provider & a leading manufacturer and exporter of centrifugal pumps & valves. The core businesses of KBL are large infrastructure projects (water supply, power plants and irrigation), project & engineered pumps, industrial pumps, agriculture and domestic pumps,

valves, motors & hydro turbines. The company is scouting for a suitable location in the state to set up the manufacturing plant. Odisha has attracted investments worth `12.08 lakh crore across sectors till the end of 2011, grabbing 10.04% share of the overall investment in the country estimated at `120.34 lakh crore. The state has bagged the top slots in manufacturing and mining sectors with a share of 17.5% and 31.2%, respectively, of the total investments.

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BOC INDIA TO INVEST `5.4 BILLION TO BUILD TWO NEW AIR SEPARATION PLANTS BOC India (BOCI) Ltd, a member of the Linde Group, recently announced that it had been awarded a major long-term industrial gases supply contract by Tata Steel Ltd. Tata Steel is progressing with the first phase of its greenfield integrated steelworks in Kalinganagar Industrial Complex, Odisha, which will become operational in 2014. BOCI will invest `5.4 billion to construct two large air separation plants—each having a capacity of 1,200 tonne per day (tpd)—to supply gaseous oxygen, nitrogen and argon to meet the production requirements of Tata Steel’s new steelworks. The air separation plants, which will be commissioned in 2014, will also produce liquid gases to meet the growing demand for gases in the merchant market. Commenting on the same, SK Menon, MD, BOCI, said, “Our new contract with Tata Steel represents a great strategic win for BOCI, given the fast-rising importance of the Kalinganagar industrial complex as a massive steel production hub in India. BOCI also intends to establish an extensive pipeline network through the industrial complex to meet the gas demands of the various steel production units operating there, and our latest agreement with Tata Steel will enable us to take steps forward in this direction.” Speaking about the project, HM Nerurkar, MD, Tata Steel, informed, “We are pleased to be working with BOCI in our new facility in Kalinganagar. Our new 3 million tonne per year (mtpy) steelworks, which will expand to 12 mtpy in the medium term, will be the first new major greenfield blast furnace-based steelworks built in India in the past 15 years.”

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PTC TO ACQUIRE SERVIGISTICS PTC recently announced that it has signed a definitive agreement to acquire Servigistics, Inc—developer of an innovative suite of Service Lifecycle Management (SLM) software solutions—for approximately $220 million in cash. Pending regulatory approval and satisfaction of other customary conditions, the transaction is expected to be completed in September 2012. The acquisition will greatly enhance PTC’s existing portfolio of SLM solutions, which, today, includes robust capabilities in the areas of warranty and contract management, service parts definition and technical information, including mobile delivery. Servigistics is recognised as a technology leader in complementary areas, such as service parts planning, management

and pricing, field service management, returns & repair management and service knowledge management. “Over the past few years, Servigistics has earned a reputation for innovations that help companies maximise their global service businesses through increased profitability, cash flow and customer loyalty,” commented Jim Heppelmann, President and CEO, PTC. SLM helps manufacturers and their service network partners optimise the customer experience by ensuring that service is systemically planned, delivered and analysed to continually improve performance & maximise customer value. Yet, few manufacturers have either a coordinated strategy or an integrated technology suite needed to capture this new market opportunity—

DUBAI TO PLAY IT BIG ON SOLAR POWER Dubai Municipality plans to use solar technology to reduce its consumption of traditionally produced electricity and water by 20% over the next five years. The municipality has signed up with a UAE Government programme to retrofit buildings with systems designed to save energy. As part of its overall energy strategy, the Dubai Supreme Council of Energy has identified a number of measures that can easily be implemented to conserve energy and water. Dubai has managed to curb the rising costs of utility provision by drawing up a programme to moderate the consumption of electricity and water. This has enabled the Dubai Electricity and Water Authority to postpone the construction of a large-scale power plant—the 1,500-MW Hassyan project.

JSPL TO INVEST `1 LAKH CRORE BY 2020 TO RAISE CAPACITY Jindal Steel and Power Ltd (JSPL) plans to invest `1 lakh crore to expand its capacity to 20 million tonne per annum (mtpa) in the next eight years. The company is in the process of expanding the capacity of its Raigarh plant to 7 mtpa. New capacities at Angul in Odisha and Jharkhand will also come up. The company will have 20-mtpa production capacity by 2020. Its Raigarh plant has three-mtpa capacity and the company is planning to commission the first phase of its 6-mtpa plant at Angul in Odisha by 2013–14. The company is also

constructing a greenfield plant of similar capacity in Jharkhand. The company has already initiated the process to acquire land and other regulatory clearances to expand the Chhattisgarh plant to 7-mtpa capacity. According to company sources, expanding the capacity by four mtpa will take 4.5 years. JSPL envisages `17,000–18,000 crore investment for expansion of the Raigarh plant alone. The company is also in the advanced stages of securing an iron ore mining lease from the Chhattisgarh Government to feed its expansion at Raigarh.

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with many manufacturers realising as little as 25% of the total service value in their products’ service lifecycle. “At Servigistics, we share PTC’s vision for helping to transform the way companies execute their service strategies,” said Eric Hinkle, President and CEO, Servigistics. “We anticipate that our clients will reap great benefits from the synergies of this shared vision and we are pleased to help PTC secure a strong technology & thought leadership position in SLM,” Hinkle added. In connection with this acquisition, PTC is increasing its previous preliminary FY’13 non-GAAP EPS target of $1.70–$1.80 by a range of $0.02–$0.05. PTC expects to draw on its credit facility to finance this transaction.

KESHUB MAHINDRA STEPS DOWN AS CHAIRMAN OF M&M At the 66th annual general meeting of Mahindra & Mahindra (M&M) in Mumbai, Keshub Mahindra addressed shareholders for the last time as Chairman of the company. A Director for 64 years at M&M and Chairman for 48, Keshub Mahindra, officially resigned from the Board of the Company. He will now take over as Chairman Emeritus. Keshub Mahindra joined the Board of the Company in 1948 and was elected its Chairman in 1963. Under his Chairmanship, the Mahindra Group grew from a manufacturer of automobiles to become a federation of companies operating in a range of businesses. He successfully created business alliances with global majors, laying the foundation for the emergence of the Group as an Indian MNC. The Board has unanimously appointed Anand Mahindra as the Chairman & MD of the Group.

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NTPC TO SPEND `1.38 LAKH CRORE ON CAPACITY ADDITION The country’s largest power producer, National Thermal Power Corporation (NTPC), is looking to spend more than `1.38 lakh crore over the next few years on projects with a total capacity of over 27,000 MW. The state-owned power producer plans to shell out `47,169 crore for capacities that are currently being constructed, involving 12,428-MW generation capacity. Another `91,353 crore will be spent for projects ‘under award/tender/ planning’, with a total capacity of 15,100 MW. Together, the capital expenditure would be `1,38,522 crore for establishing 27,528 MW additional capacity. Some of the upcoming projects of

NTPC are Mauda II, Vindhyachal IV and V (all having 1,000 MW capacity), 800-MW Kudgi, 1,320-MW Barh-I, 500-MW Rihand-III and 800-MW Koldam. For the April-June quarter of the current fiscal, the company has declared 2,320 MW of new commercial generation capacity. NTPC aims to have an additional capacity of 14,038 MW in the current Five Year Plan (2012–17). And of the projected total, 2,160 MW has already been commissioned till July 31. By 2032, the company expects to have an installed capacity of 1,28,000 MW. Presently, the NTPC Group has a total installed capacity of 39,174 MW.

ISA EMPHASISES ON THE NEED FOR INCREASING AUTOMATION The International Society of Automation (ISA), Bangalore, recently organised a seminar on ‘Automation, Robotics and Remote Handling Technology in the Nuclear Fuel Cycle’ at Bangalore, as part of its mission to spread, encourage & enhance the industrial knowledge of automation. KV Kasiviswanathan, Raja Ramanna Fellow and Former Assistant Director, Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, explained wider possible applications of the automation technology developed at IGCAR, such as remote monitoring, that had not been considered so far. The remote data collection devices are connected to a management/control centre over serial or Ethernet, depending on factors such as distance and the type of management system used.

TOYOTA TO BEGIN ENGINE PRODUCTION AT BANGALORE PLANT Japanese auto major, Toyota to Invest $500 Million in Brazil Toyota, would begin engine production from Japan’s automobile manufacturer Toyota is all set to invest 1 billion reais ($500 million) to set up its manufacturing facility an engine factory in Brazil. The new project, in Bangalore. Shekar which will be located in Sao Paulo, will create Viswanathan, Deputy MD 600 new jobs, and would promote the level of – Commercial, Toyota local production of Corolla and Etios—two of Kirloskar, informed that the Toyota’s car models. production would start from The plant, Toyota’s third in Brazil, will generate August 2012. Toyota plans 1,700 direct jobs, with an anticipated production to manufacture about one capacity of 70,000 cars annually. Toyota lakh engines and 2.40 lakh currently employs over 4,000 people in Brazil. transmission units from the facility. Toyota Kirloskar is announced it would set up an engine a joint venture between Toyota Motor plant & expand its transmissions unit Corporation and Kirloskar Systems, to cater to Etios & Etios Liva—two of Bangalore. its latest sedans. Toyota Kirloskar had earlier

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HONEYWELL TO UPGRADE CONTROL & SAFETY SYSTEMS AT ITS SURINAME REFINERY Honeywell recently announced that it has been selected by Staatsolie Maatschappij Suriname NV— the state-owned hydrocarbon and sustainable energy company—to upgrade the safety and control system at its Suriname refinery to its Integrated Control and Safety System (ICSS) solution. The upgrade is being designed & implemented in the context of the Suriname Refinery Expansion Project, which will double the capacity and expand significantly the range of products & fuels, with a special focus on satisfying the domestic transportation market. The project is being managed by Saipem as the main contractor responsible for engineering, procurement, modules prefabrication and construction management. Developed on the strengths of Honeywell’s Experion Process Knowledge System (PKS) architecture, ICSS is an allencompassing safety solution providing robust and secure control for critical applications. Built to offer simplified operations, integrated process control and safety controllers, ICSS will equip Staatsolie with best in class compliance, reliability and safety for its refinery production units. The upgrade includes the expansion of Honeywell’s Alarm Management System, Operational Insight Software and OPC Desktop Historian solutions currently installed at the site. This suite of tools will provide Staatsolie with automatic monitoring of system changes, a platform for cross-departmental collaboration and enable the communication of information from data sources to any client application in a standardised format.

CUTTING-EDGE SOLUTIONS

DUAL-PORT ETHERNET/IP I/O ADAPTERS HELP IMPROVE USER EXPERIENCE the end device versus the switch. With no need for unnecessary switches and cabling, users can reduce design time and simplify implementation. The ring also adds a measure of redundancy that is very effective when a connection fails—as a single network failure, such as a cable break, will not lead to the failure of other devices in the ring. A DLR network can recover in less than three milliseconds for 1749 FLEX I/O Dual-Port EtherNet/IP Communication Adapter a 50-node system. During this Module time, the connection between the programmable automation controller USPs and the I/O device is not interrupted. • The new EtherNet/IP adapters support a Device-Level Ring (DLR) The adapters also support the daisytopology, which provides a robust network infrastructure and ensures chain topology for applications that extremely fast recovery time while keeping implementation costs down. involve devices located far from CPU • DLR infrastructures are connected at the end device versus the switch. sub-systems. With no need for unnecessary switches and cabling, users can reduce The adapters (1794-AENTR design time and simplify implementation. and 1794-AENTRXT for extreme environments) that are compatible with the Rockwell Software products support a Device-Level Ring (DLR) the dual ports, users can also leverage include RSLogix 5000 programming topology, which provides a robust the adapters to display diagnostics via software version 16 & higher, and network infrastructure and ensures a simple web browser. This, in turn, RSLinx version 2.58 & higher. The extremely fast recovery time while helps reduce troubleshooting and adapters also can connect up to eight keeping implementation costs down. downtime. FLEX I/O modules. DLR infrastructures are connected at The new EtherNet/IP adapters achine and original equipment manufacturers, system integrators and end users with demanding applications look to simplify network design while maintaining resiliency. The new Allen-Bradley FLEX I/O dualport EtherNet/IP adapters from Rockwell Automation achieve this goal. The adaptors help OEMs connect machines to their end customers’ IT infrastructures using a single network. With

GE TESTS INTERIOR PERMANENT MAGNET TRACTION MOTOR THAT WILL ENHANCE THE TRAVEL RANGE FOR ELECTRIC & HYBRID VEHICLES E researchers have tested the prototype of an interior permanent magnet traction motor expected to enhance the travel range for electronic vehicles and hybrids. The traction motor is a component of the propulsion system that converts electrical energy into motion to drive hybrid and electric vehicles. According to Ayman El-Refaie, Electrical Engineer, GE Global Research’s Electrical Machines Lab, the company has always strived to build robust and efficient motors for hybrid and electric vehicles. “We have built a motor that is substantially more powerful than what is commercially

USPs • GE’s traction motor delivers higher power density, acceleration and energy efﬁciency in a smaller frame at a lower cost. • It reduces the fuel consumption on electric vehicles and their hybrids. • GE’s traction motor has almost twice the temperature tolerance of conventional hybrid-electric motors. • It also does not require a separate cooling system. available now, while improving efficiency by up to 5%,” El-Refaie informed. The development is part of the four-year, $5.6-million US Department of Energy (DoE) project on electronic vehicles and hybrids. “This technology is scalable & flexible

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and can be leveraged in a number of capacities,” added El-Refaie. It has been fully tested in the lab and demonstrated for DoE. However, further testing for reliability is required before commercial production commences.

FILIPPO MANTEGAZZA

DEFINE OPERATIONAL EXCELLENCE In today’s times, a company has to maintain a long list of Key Performance Indicators (KPIs) in order to gain an edge in the market. Operational improvement or operational excellence is critical for a company to achieve competitiveness in all the KPIs it follows. There are various important techniques and concepts that are followed to achieve operational excellence like Total Quality Management (TQM), developed in Japan. Besides, many companies opt

CREDENTIALS Born in Milan in 1951, Filippo Mantegazza is a Plant Engineer and a graduate from Milan Polytechnic. He has also earned a degree from MIT in Production Planning. He founded Efeso Consulting in 1979, an International consulting company focussed on operations improvement. He has been serving as Chairman of the Management Board, Solving Efeso, since 2007 and looks at the overall business activities of the company. He has also authored many publications.

Operational improvement is critical for companies to achieve competitiveness in all its KPIs Filippo Mantegazza, Chairman of the Board, Solving Efeso International SA, in an interaction with Arindam Ghosh, shares his thoughts on various critical subjects ranging from the importance of operational excellence to key requirements for developing the theory, and highlights his contribution to develop the ‘World Class Operations Management’ approach to achieve operations performance improvement. Excerpts… for Six Sigma to achieve excellence in quality. Additionally, we have the philosophy of Lean. These are not just theories, but part of your systems that need to be implemented continuously in order enhance your capability & performance level. For a company to reap the benefits from these concepts, the entire organisation needs to come forward and play a proactive role in implementing these techniques.

MANTRA TO GAIN A COMPETITIVE EGDE Operational excellence plays a critical role in transforming the entire supply chain of a company and in creating a big impact on cost & quality. It further strengthens the ability of the company and allows it to react quickly & work according to the changing market situations. If a company has expertise in understanding its market, it will remain highly competitive and sustain itself in the market in the long term.

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It is very critical to understand that in today’s time, it is not merely enough to be good enough; what you really need is to know the market and be better than the competition. Operational improvement enables a firm to raise the competitiveness and provide substantial, tangible and lasting gains.

KEY CONSIDERATIONS FOR COMPANIES There are two major factors that

FILIPPO MANTEGAZZA

a company needs to consider for achieving operational improvement. Firstly, a company needs to develop and build a strategy based on thorough research of the market conditions it wants to operate in. It is important to understand that a company cannot afford to do everything everywhere, as every market has unique features, characteristics and requirements. It needs to be very selective in its offerings. Secondly, companies need to engage themselves with the local elements of the market. This will allow them to develop a deeper understanding of the market & its behaviour and react quickly & adapt itself according to the changing market scenario.

NEED TO ADOPT A LOCALISED APPROACH Implementing a localised approach is the key to success for any global company that wants to enter a market. If a company wants to enter India, it needs to adopt an India-specific approach. This has to be developed based on customer preferences, local culture, etc., of each region. If the global company has strong local knowledge, it can flourish its business in a short span of time and will be competitive under any market condition. This is vital, because if a company cannot remain competitive, it cannot survive for long.

DEVELOP WORLD CLASS OPERATIONS MANAGEMENT APPROACH For the last 30 years, I have been involved in many projects for making various companies achieve operational excellence. I have worked on various topics linked to operations improvement like cost reduction, performance improvement, etc. After working for so many years, we have developed and implemented the World Class Operations Management (WCOM) approach. It was designed jointly in co-operation with Fuji Consulting, the Japan Institute of Plant Maintenance and

Richard J Schonberger, a world-class manufacturing guru. WCOM has been developed to help companies improve operations performance on a global scale. The approach is based on Japanese methods and ideas, but with a Western approach. The implementation of WCOM has led several large companies, such as Volvo, Fiat, Unilever, Pirelli, Tetra Pak, Heineken, to win some of the most exclusive awards for operations excellence, like Quality Award, JIPM Award, EFQM Award, etc.

India is a lucrative market. The current phase of economic instability is temporary, given that the Indian market is governed by strong economic fundamentals. If you compare India and China, India has a strong advantage in terms of a large Englishspeaking workforce. Moreover, in terms of costs, it is very competitive globally. However, in terms of doing business, China has a big advantage as it offers state-of-the-art infrastructure.

INDIA’S POSITION AMID ECONOMIC INSTABILITY

Companies that are operating globally, especially our clients, are highly aware of the importance of operational excellence. Such companies have been following several techniques to achieve this. With the ever-growing globalisation and the resulting competitiveness, the Indian companies also understand the importance of operational excellence. This is where the role of Solving Efeso comes in. We will help in expanding the business of our customers not only in India, but also globally, by making them achieve operational excellence. The combination of our strategic and operational teams will widen the scope of opportunities for our clients.

Our clients have been coming to India, as it offers a huge market and is currently one of the fastest growing countries. Additionally, the labour costs are comparatively lower here. Our clients have been enjoying a high growth rate in terms of expanding their business operations in the country.

HELPING COMPANIES ACHIEVE OPERATIONAL EXCELLENCE

INITIATIVES REQUIRED

UP CLOSE & PERSONAL Your Passion… My work drives me. Your Hobbies… I like sailing and skiing. Your Mentor... There have been quite a few individuals from whom I have learnt a lot. However, I would like to name two people who have greatly influenced me; Antonio Roversi and Guido Granata. Antonio Rosersi motivated me to become a consultant and Guido Granata, my professor, has always been a huge source of inspiration.

Companies come to India because they see a huge business opportunity in the country. Besides, excellent infrastructure will play a key role in further encouraging companies to enter the country. With regards to infrastructure, I have observed that the country has been taking several steps to improve its infrastructure. A modern and advanced infrastructure is vital for improving the productivity and efficiency of the supply chain movement, as it will ensure rapid expansion of the business. At the same time, a company needs to develop innovative strategies to remain competitive in the market. arindam.ghosh@network18publishing.com

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SEARCH September 2012 Ad Name: Peantair

Pg No. 47

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PUMPS AND VALVES I

Scenario

The global business of pumps and valves has crossed the market cap of US$75 billion, while the Indian business, which is growing at an average of 5.5% per year, has been pegged at around US$3 billion. Pumps: While the US will remain the largest purchaser of pumps for the next five years as per the demand trends, China will remain the largest growing country with the largest growth rate; it will build nearly half of the world’s new coal-fired plants in the next five years. Centrifugal pumps, with more than 50% of the total sells, will remain at the top as compared to the submersible pumps having 10% of the total sells. Valves: In the valve industry, China is at the top of the list with 15% growth rate; this trend is likely to continue owing to the investments made in the country. The global demand has been rising at 5.4% annually and is expected to have a market cap of $94 billion by the end of 2016. The valves industry, so far, is dominated by the conventional valves with 60% shares of the total, but the rising demands of automotive valves will overturn the data by the end of 2020. The East-West Pipeline project has kept the demand for gate valves and ball valves in double digits, while plumbing and other control valves have found applicability in drip irrigation and sprinkler irrigation, oil & gas, power generation, mining, water reticulation, sewage and chemical manufacturing.

Industry leaders

Pump Industry: The industry leaders in this segment are Kirloskar Brothers Ltd, Tecumesh Products (India) Ltd, BHEL, Ingersoll-Rand, Elgi Equipment, CRI Pumps, Sharp Pumps, Aqua Sub Pumps, Suguna Motors & Pumps, Texmo Pumps, Grundfos Pumps, ITT Corporation India, Heidelberg ProMinent Fluid Controls Valve Industry: The industry leaders in this segment are Audco India Ltd (AIL), L&T Valves, Peco Valves, Precision Valve India Ltd, BHEL, Sealmech Valves, Brightech Valves.

Key Sectors

The key sectors are oil and refineries, water treatment, irrigation, agriculture, hydropower, solar power, pulp & paper industry, sugar industry and power industry. The key demands are likely to come from water treatments, domestic water circulation and the power sector. Canada and a few European countries have also raised the demand for Indian pumps and valves in the pulp & paper industry over the last few years.

In the News

Interstate Natural Gas Association of America (INGAA) has estimated that North America would add 19,000 miles (31,000 km) of oil pipelines at a cost of $31.4 billion by 2035 as production surged 50% to 12.7 million barrels per day The US shale oil revolution cannot be stopped, but it could be delayed by a potential shortfall of 10-tonne valves and giant pipeline pumps ITT Corp’s adjusted quarterly profit handily beat market expectations on strong sales of components to the US mining, chemical and industrial sectors as well as emerging markets, sending shares up as much 15% in morning trade As per the research done by UK micro fluidics experts, the valve industry will soon be able to add the next-gen flavour with advancements done in nanotechnology like ‘plug and play’ micro fluid system.

Expectations

The are huge expectations from the US shale oil projects worth US$20 billion, Canada-Bakken-Ohio two pipeline projects, Indian pipeline projects, power sector, irrigation and water treatment sector.

Compiled by Suprita Anupam

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PUMPS AND VALVES

PUMPS: 10 GROWTH COMMANDMENTS: The Doctrine Of Growth ........................................52 FIVE DISCOURSES OF VALVES: The Controlling Authority ...........................................................62

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PUMPS: 10 GROWTH COMMANDMENTS

ling opel w t h r p the gr o een e r a p i d d u s t r y b e few pump manufacturers from China hav d s . T h m p i n y i s mps u s e h o l t h e p u i n d u s t r ing u and India were able to convert others’ p r o d ood, s and h ourage n pump nufactu DP, l b losses into their profits. What made ping d u s t r i e h a s e n c e I n d i a er ma h t h e G t a m u this possible? How did Indian firms h n t p e i les ost all dustries . But th d to ot pace wi ustr y s c i r succeed in reaping the benefits t d ven pare e e p e in d alm er in owth from a gloomy scenario? The Like r behin and oth this gr en com ng to k l help th o i answer is simple. Indian fact e basic ce with high wh still tr y that wil of th atch pa t on a ile it is dments firms focussed on meeting to m ainly no dia. Wh omman late. the requirements of companies, cert ors in In he Ten C s to emu i.e., they worked on making their products sect resent t or other more quality & cost conscious. They also worked f we p hmark towards making their products future ready. benc To compensate for the overall losses, the global slowdown

SUPRITA ANUPAM

or centuries, Indian pump manufacturers have made significant contributions towards ‘pumping up’ the growth prospects of almost all sectors in India. Having won accolades and awards the world over, the Indian pump industry has now become a synonym for merging quality with lower cost—owing to the magnanimous contributions made by the top manufacturers that have become representatives of the Indian pump industry. While the pump industry has more than 500 manufacturers yielding out 1.5 million pumps every year, the rest are still serving the domestic demand without meeting the quality standards. This presents a challenge to the Indian pump industry – it MUST get organised!

SWITCH OVER TO THE GLOBAL SCENARIO… America, Europe and Asia have almost equal shares in the pump market, but the fortunes of the pump industry in these towering nations are plagued by the global economic slowdown. In the Asian Continent, China, India, Malaysia and Japan are the major contributors to the pump industry with the top three companies of the world holding 20% shares of the pump market, while the top 25 companies owning 50% shares. Although China will demonstrate the largest growth rate owing to the large investments made in all the sectors and applications from semiconductor ultrapure water to boiler feedwater, the US will continue to dominate as the top purchaser of pumps for the next few years. Despite the global downturn from 2009 onwards, a

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also fuelled the ‘collaboration trend’ among companies, which increasingly started to look at collaboration as the perfect strategy to expand their product range, ensure their availability and enhance market size. Needless to say, the pump industry worldwide also benefitted from this trend. Substantiating the same is a study conducted by the Confederation of Indian Industry (CII). According to the study, Indian pump manufacturers are currently exporting their products to more than 70 countries. The Indian pump industry has attracted foreign investments and also successfully captured the domestic market by way of collaborations with local companies. Simultaneously, a few Indian companies also expanded business across the globe by acquiring foreign companies as well as forming joint ventures (JVs). One such company is Kirloskar Brothers Ltd (KBL). Elaborating further, Subodh Srivastava, AVP & Business Head – Distribution Sector, KBL, avers, “KBL is the only Indian company that has acquired many foreign pump companies such as SPP Pumps (UK) and Braybar, Africa. We have also collaborated with Ebara to provide a specific type of pump solutions. In this way, we are expanding the global possibilities rather than only consuming the local market.” KBL has also set up a JV with Copeland. The bane called recession proved to be a boon in disguise. By creating an environment that fostered a mixed economy for the first time, it taught companies a valuable lesson— build on market strength—and thus provided companies a long-term solution for sustainability. The key standards behind this sustainability were: Easy availability of talent Dynamic market strategy Low innovation and technology risks High performance with recommended quality standards.

PUMPS: 10 GROWTH COMMANDMENTS

THE 10 COMMANDMENTS Big gaps among manufacturers inhibit the Indian pump industry from having a strong and powerful association that can propel it from all directions, by taking the necessary

steps. Industry experts, consultants and associations set the doctrine straight for the pump industry. Here’s profiling the 10 commandments that will guide the pump industry to a better and fruitful existence…

THOU SHALT FOCUS ON DEMAND witness futuristic demand from the solar The Indian pump market share— energy sector. Apart from these sectors, including organised and unorganised few others like pulp & paper industries of countries such as sectors—comprises 4% of the approximately $35-billion Canada and Malaysia have also increased the demands for global market of the pump industry. While the early Indian pumps—particularly centrifugal pumps and, in some cases, market consumption was limited to catering to domestic submersible effluent pumps. water supply (like pumping water from wells and irrigation), Centrifugal pumps still remain on the top even though the ‘liberalisation’ has helped shape the pump market as per it has several drawbacks. Despite being inefficient at high the global standards, i.e., from oil refineries to mines and steel pressure, these pumps continue to record the strongest growth mills. Nonetheless, the major demand for pumps continues and account for 50% of the total pump sales. Submersible to come from the power sector and water treatment industry. effluent pump, submersible domestic pumps and progressive Indian firms altogether produce more than 1.5 million pump share 5%, 4% and 1% of the total sales, respectively. pumps worth $1 billion. And the demand trend in exports The key importers of centrifugal pumps include the US, has risen with buy-back contracts keeping technological & the UK, Singapore, Chile, Ghana, the UAE, Egypt and economic competence in the industry. With the quality Germany. Fortunately, perception rising across the imports show positive the world, the demand India has not yet explored all the variations in their demand has risen locally as well possibilities of better water trends. For instance, as globally. Power/energy management. There is lots of wastage in the form of rainwater German importers of and the water management and mountain water. America and pumps basically belong sectors are fuelling the Europe, on the other hand, focus a lot on saving to chemical industries, pump demands by more every drop of water. That is where the demand for pumps while Asian importers than 45%. This trend is rises as it includes irrigation, industrial and domestic water circulation. The demand for pumps is likely to come from the primarily deal with oil likely to continue with the power sector, particularly from hydro power. and refinery firms. This power crisis and erratic Subodh Srivastava, AVP & Business Head – Distribution Sector, Kirloskar variation encourages the availability of water in Brothers Ltd pump manufacturers to the country. In addition, work more strongly on demands from big quality and customisation. Discussing the demand trends, infrastructure projects, sewage treatments, power generation Prasanna Kumar Rao, MD, Heidelberg ProMinent Fluid (thermal, nuclear & hydropower and pumped storage), Controls India Pvt Ltd, informs, “For the last two years, oil & natural gas sector, refineries, fertilisers, lubricants we managed to get more than 30% growth, but, this year, and petrochemicals sector, mining & metal ore refining it seems difficult. Undoubtedly, the year has not been good sector, steel, pulp and paper, utility sector, agriculture & for the pump industry, but the global slowdown has slowed irrigation, fisheries and aquaculture are also increasing the down our business.” demands. “We export to as many as 30 countries either through Commenting on the same, Srivastava remarks, “India ProMinent subsidiaries or directly in few countries like has not yet explored all the possibilities of better water Myanmar, Bangladesh, Bhutan and Sri Lanka. ProMinent management. There is lots of wastage in the form of India is faring much better than China and Malaysia. We are rainwater and mountain water. America and Europe, on the still confident of achieving double-digit growth,” Rao says, other hand, focus a lot on saving every drop of water. This adding, “ProMinent India alone fulfils the 30% demands is where the demand for pumps rises as it includes irrigation, of the total dosing pumps, sugar, pharmaceutical and industrial and domestic water circulation. The demand for electroplating industries. Recently, we supplied our entire pumps is likely to come from the power sector, particularly dosing pump system packages to Siemens while working on from hydro power.” a project of Torrent Pharma.” Srivastava further indicates that the pump industry might

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PUMPS: 10 GROWTH COMMANDMENTS

THOU SHALT CUSTOMISE PUMPS TO RIDE HIGH ON APPLICATIONS Yes, there is indeed a variety of pumps, but each one has some drawbacks against some or the other application. Moreover, pumps can only be operated at certain operating points. The operating point—which is usually arrived at by calculating cross-point of head flow curve and system curve—decides the operational temperature, speed, load & efficiency (for example, a centrifugal pump increases system resistance and reduces the flow). Hence, the required operating point must be carefully calculated in order to avoid any drop in efficiency. Additionally, customisation with technology improvements has enabled the manufacturing of applicationspecific pumps. New application trends are growing in both closed loop pump storage projects and open loop pump projects; earlier the shift was more towards closed loop. Over time, with improvement in heat pump water technology, the corresponding applications have also risen. Besides, residential applications have also grown. For instance, Lowra has designed a new submersible grinder pump for residential applications. The new DOMO GRI has been designed to deliver domestic sewage, liquids containing solids or fibres, and wastewater from residential buildings to the sewer

mains or a pressurised sewer network. The applications have extended their purview from watermill or windmill to irrigation, water supply, gasoline supply, air-conditioning, refrigeration, chemical movement, sewage movement, flood control, marine services and infrastructure projects among others. Some application-based customised pumps include: Floating SVI pump, new application for immersible pumps: In high-pressure application areas such as irrigation, where the water is found in a reservoir or holding tank, it becomes difficult to find a cost-effective solution to supply water to sprinkle heads. Traditional submersible pumps are incapable of handling the kind of high power required, while the borehole pump adds to capital costs. The new Lowara SVI immersible pump provides a ray of hope. The pump is mounted on a pontoon—floating on the water—and moves up & down depending on the water level and with a certain operating range. This gives the user a number of pump options to meet sprinkle head requirements. CEB vertical pump for autogas application: CEB vertical tank pump, a replacement of submersible design pump, can be retro-fit into most of the common tanks. In the first stage,

Rising applications are plunger pumps, split case pumps, turbo flow multi-stage Water treatment: This includes four kinds of industrial water pump, self-priming chopper pumps, submersible pumps and treatment, viz., boiler feedwater treatment, process water so on. treatment (like beer manufacturing), cooling water treatment Emission control and fuel cell: Ogura Industrial Corporation’s (water before recirculation) and wastewater treatment. air pumps were initially designed as superchargers for gas Pumped storage projects: A few sites by NHPC have been and diesel engines. However, it was observed that the pumps marked where pumped storage projects may take place in can be better utilised as future. It is said that using emission-control devices for pumped water to store diesel engines and to reduce electricity costs less than parasitic load on fuel cells. $100 per kilowatt-hour and is The air, pulled via a pair of highly efficient. The projects rotors, is trapped in the form will need high-pressure, highof pockets formed in between capacity pumps. the rotors and housing and is Some of its advantages are 33% energy savings, tapping pumped from one side to the groundwater—a more stable Figure 1: Pumped hydro power project work ﬂow other. Thus, by working as energy source—and no Courtesy: http://www.consumersenergy.com an emission control device, requirement for any other supplemental heat. Geothermal air pumps help reduce unburned gases from reaching the heat pumps can be either earth-coupled or water-sourced. tailpipe by injecting oxygen into the exhaust stream to Power applications: In a power plant, various kinds of pumps burn the hot exhaust gases. While working in a fuel cell are used for different applications. The major applications application, these pumps control air, water and hydrogen include ash handling, boiler applications, coal handling, going into the fuel cell to generate electricity. The air pumps are driven by brushless motors fed directly by those cooling tower applications, emission, pressure boosting and fuel cells. water service. The kind of pumps utilised for these applications

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PUMPS: 10 GROWTH COMMANDMENTS

an NPSH impeller and side channel stage are located at the bottom of the tank by means of an extension pipe. It operates under flooded suction, while one to three side-channel stages are placed below the discharge flange in order to produce the required pressure with less power consumption. This process has been optimised with better designing of

two-poles hydraulic system. The uses of this Sterling SIHI CEB pump are for loading and unloading of liquefied gases under boiling conditions offering several advantages over traditional pumps such as low NPSH, effective priming and continuous operation, pressure generating as well as a stable curve and magnetic coupling shaft sealing.

THOU SHALT EXPLORE AND ENCASH TECH POSSIBILITIES For the past few years, the Indian pump industry technology trends have been revolving around lean production, just-in-time production and accuracy. To achieve these, there is an emphasis on materials, material coating, energy saving, precision casting, die-casting, sintering and deep drawing. As is the case with the development of other industries, pump technology development is driven by market demand. The basic guidelines directing the technology trends include: Long life cycle: As long as the plant lasts Lowest possible operating expenditures: Lowest possible energy consumption, without any local operators, easy to remove and install Highest possible reliability: Meantime between failures above 50,000 hours Less sensitive or protected against misuse: Able to run dry or handle gas/liquid transients Environment friendly: Leakage-free, easy to decontaminate and easy to recycle. The need to meet all these parameters leaves very little room to renovate the basic technology of pumps. Discussing the scope for improvement, Rao expounds, “In motordriven pumps, there is not much scope for improvement.” To cater to the same, “in electronic hosing pump, we have designed advanced electronic control equipment to make the system much more accurate. ProMinent has also designed an entirely new kind of electronic dosing pumps. In India, we have also developed a new plasma pump,” he adds. However, to include the above-mentioned directing guidelines, one must consider the following: To ensure that pumps have a longer life, the parts that come in contact with water must use the newly developed coatings, duplex steel, plastics (like Poly-Aryl-EtherKetone or PAEK) or ceramics and titanium. The frequency controller must be used to self-adjust pump performance with the lowest energy consumption. The pump must avoid any oil lubricant, shaft seals and base plate coupling. There should be early failure detection or tele-monitoring systems to detect the problems in advance without having any real downturn. The pumps should have wide performance range. However, a ‘smart pump’ that performs all the above-

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mentioned guidelines costs much more than conventional pumps—a factor that deters customers from investing in them. Moreover, the overall lifecycle with high performance of these pumps is not guaranteed. Leaving the discussion aside, let us take a look at some of the recent developments that could change the architecture of the pump (for the better) in the coming years. Variable speed technology: The recent sophisticated variable speed technologies have allowed OEMs to create smaller machines offering higher uptime, greater accuracy and functionality. Revolutionary rotary piston machines: Physicist and inventor Wolfhart Willimczik has created a rotary piston machine without bearings in the power train. The friction in these machines has been significantly minimised to the extent that they are able to run without any lubrication— even at higher pressure. Geyser pump: The geyser pump technology has been in existence for as long as the airlift pump. However, the Geyser Pump Tech Co attracted the industry’s attention only after the technology received the patent in December 2000. Geyser pump, with its improved design over the airlift pump, has eliminated the small bubbling. Instead, it holds the supplied air for a while and instantly releases a big bubble to the riser pipe. New insulin pump technologies: The next-generation insulin pump technology and Continuous Glucose Monitoring (CGM) technology is still in the testing phase and is likely to hit the markets over the next few months. It is based on the Veo technology that has already been approved in Europe. Meanwhile, the Animas Vibe, an insulin pump with a built-in DexCom CGM, which is in its testing phase, has demonstrated 99% accuracy. Gas-fired heat pump technologies: The US Department of Energy and Oak Ridge National Laboratory are working on these projects. The idea behind the project was to encourage the usage of environment-friendly gases in ACs and refrigerators instead of using ozone-depleting gases. Other recent advances include progressive cavity pump technology, concrete pump technology, vacuum pump, pumping hydrogen with electron beam technology and adaptive gas pumping by controlled timing of active microvalves in peristaltic micropumps. Commenting on GE’s

PUMPS: 10 GROWTH COMMANDMENTS

advances on this front, Subrajit, Head – Turbomachinery Aerodynamics Lab and Aerodynamics & Acoustics Lab, GE, Bengaluru, says, “Current research in the turbomachinery lab

is focussed on developing higher efficiency, power-dense, wider operating range steam turbines, compressors, pumps & next-generation seals for rotating components.”

THOU NEED TO THINK ABOUT SUITABLE REPLACEMENTS metallic friction and wear solutions The ever increasing demand for pumps called CeraComp® material. pump reliability, performance, low This innovative ceramic-matrix composite delivers vibration levels and better efficiency over a wide range of dramatic benefits over traditional silicon-carbide materials operating points has prompted the need to search for new with superior fracture and wear resistance—expanding materials for pumps that can be used in place of cast iron/ the reliability of seal-less pumps by virtually eliminating stainless steel. But they are application specific and hence, the risk of catastrophic failure. CeraComp® is capable of materials must be looked at only after considering all the withstanding temperatures over 1,100°F (600°C), physical and chemical properties of the composites as well exceeding the upper limit of polymeric and elastomeric as fluids to be used. composites, and maintains outstanding chemical Polymer-based composites resistance, thereby achieving improved durability and GE Oil and Gas has introduced a new material. Though longer component life. According to Jonathan Pledger, the use of materials like Poly-Ether-Ether-Ketone (PEEK) VP and GM — PetroChem & Power – Greene, Tweed as wear components in centrifugal pumps is not new, & Co, “The capability of the new CeraComp® is truly this composite material can cover many new applications. game changing for the petrochemical & power industries. The American Petroleum Institute (API), in its journal, This exciting new material will maximise plant production has outlined a list of possible polymer-based composites capabilities by keeping pumps running longer with that can be used as possible alternatives to metals as wear reduced maintenance requirements.” parts. Though the cost factor, tolerance and efficiency under high pressure are still seen as big hurdles, there are a few Silicon carbide: This material has gained wide equally good benefits like accuracy and wide application acceptance as plain bearing within pumps. It diminishes possibility—the biggest one being variable desired speed unwanted frequency to some extent. over a wide range of operating points with long life cycle. Dependent application areas: Composite material GE Oil and Gas has been offering few composite materials property must be constant throughout the pumping. for centrifugal pumps such as PEEK thermoplastic. The Applications where new materials can be considered as ratio of resins fillers and the carbon fibre, however, can vary replacements are centrifugal pumps (in a few apps), as per the requirements. submersible pumps and immersible pumps. Before using these materials as wearing Non-metallic wear part materials elements in pumps, the following must be Material Temperature limits Limiting pressure differential Application considered: Min Max Chemical compatibility: Does the fluid to -30°C 135°C 2,000 kPa (20 bar) (300 psi) Stationary PEEK be used for pumping show any kind of parts Chopped carbon fibre filled chemical activity with the composite -30°C 230°C 35,00 kPa (35 bar) (500 psi) or Stationary PEEK material? Continuous carbon 14,000 kPa (140 bar) or rotating Temperature: Working temperature range fibre wound (2,000 psi) if suitably supported Abrasives: How much abrasion resistance Polyamide Need information relative to experience do they have? Stationary Carbon graphite Thermal expansion: Co-efficient of linear parts -50°C 285°C 2,000 kPa (20 bar) (300 psi) Resin impregnated expansion -100°C 150°C 2,750 kPa (27.5 bar) (400 psi) Babbit impregnated -195°C 400°C 3,500 kPa (35 bar) (500 psi) Nickel impregnated Fillers: Carbon fibres, glass fibres and Copper impregnated -100°C aramid fibres, depending on thermal Non-metallic wear part materials, which are proven to be compatible with specified expansion and other design parameters process fluid, may be proposed within above limits. Water absorption: By what percentage do Such materials may be selected as wear components to be mated against a suitably selected they absorb water and what’s their saturation metallic component, such as hardened 12%Cr steel or hardfaced austenitic stainless steel. level? Materials may be used beyond these limits if proven application experience can be provided, and if approved by the purchaser. Ceramic composites: PetroChem & Power Courtesy: GE Oil & Gas; Figure 3API 610 9th ed. - Table H.4 – Greene, Tweed & Co has provided non-

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PUMPS: 10 GROWTH COMMANDMENTS

THOU NEED TO UNDERSTAND THE WIRE-TO-WATER EQUATION A majority of the pumps used are centrifugal pumps and to improve their efficiency, the following key factors must be analysed: Effect of speed variation: In a centrifugal pump, peripheral velocity is directly related to the shaft rotational speed. Hence, keeping the impeller diameter fixed, variation of rotational speed alters the pump performance. The rotodynamic pump performance parameters of flow, head generated, power absorbed and variation have been shown in the figure. The flow rate must be calculated by taking all these variations into account.

strategy can improve pump efficiency by 4%â&#x20AC;&#x201D;which is enough to save around $3 billion annually. Pump control by varying speed: Speed variation changes duty point. In the systems where speed reduces with friction losses, the operating point remains constant. But in a high static head situation, a small turn down can result in a big reduction in flow rate as well as pump efficiency. It should be noted that the drop in pump efficiency during speed reduction in a system with static head, reduces the economic benefits of variable speed control. Hence, it is apt to select the pump in accordance with the system curve intersection of full-speed pump & efficiency such that efficiency will increase as the speed is reduced and then decrease. Pumps in parallel switched to meet demand: It is another efficient method to improve the efficiency where static head is in high proportion, as the system curve is usually not affected by the number of pumps that are running. If the closed valve heads of different

Figure 2: Pump performance Curves

Effects of impeller diameter change: The efficiency of a pump varies when the diameter is changed within a particular casing. This is because changing the impeller diameter creates a proportional change in the peripheral velocity. Net Pump Suction Performance (NPSH): This is something that must be taken care of while designing the pump to avoid undesirable effects of cavitation, noise and vibration. The exceeding pump suction pressure is expressed in terms of head of liquid and is referred to as Net Positive Suction Head Available (NPSHA). However, the value of Net Positive Suction Head Required (NPSHR) is defined as the onset of cavitation. When there is a drop of 3% NPSHR compared to the cavitation-free performance, a prolonged operation might lead to damage.

IMPROVING EFFICIENCY With the above factors taken into account, a dynamic flow

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Figure 3: Effect of pump speed change with a system with high static head Courtesy: Bureau of Energy Efficiency

pumps are similar, it would be a wise decision to run different pumps in parallel. In this way, a large number of different flow rates can be achieved without affecting the optimum pump efficiency of individual pumps. Other Methods: The other methods to improve performance include optimising start-stop control, flow control valve, bypass control, fixed flow reduction and variable speed drives.

PUMPS: 10 GROWTH COMMANDMENTS

THOU SHALT FOCUS ON SAVING ENERGY Minor upgradations, such as eliminating standby periods and trimming the impeller diameter by 75%, can save a considerable amount of energy. The cost of saving energy does not always cost

Harvest Energy Conservation Opportunities in Pumping Systems Ensure adequate NPSH at site of installation Ensure availability of basic instruments at pumps like pressure gauges, flow meters Operate pumps near best efficiency point Modify pumping system and pumps losses to minimise throttling Adapt to wide load variation with variable speed drives or sequenced control of multiple units Stop running multiple pumps—add an auto-start for an online spare or add a booster pump in the problem area Use booster pumps for small loads requiring higher pressures

as much as presumed. The following table indicates some solutions that can help save energy by pumping under the Best Efficient Performance (BEP).

Symptoms that indicate potential opportunity for energy savings Symptom

Likely reason

Best solutions

Throttle valve-controlled systems

Oversized pump

Trim impeller, smaller impeller, variable speed drive, two-speed drive, lower RPM

Bypass line (partially or completely) open

Oversized pump

Trim impeller, smaller impeller, variable speed drive, two-speed drive, lower RPM

Multiple parallel pump system with the same number of pumps always operating

Pump use not monitored or controlled

Install controls

Constant pump operation in a batch environment

Wrong system design

On-off controls

High maintenance cost (seals, bearings)

Pump operated far away from BEP

Match pump capacity with system requirement

THOU OUGHT TO DISPOSE OF GRACIOUSLY Pumps provide safe disposal of wastes— be it wastewater or other unwanted byproducts—by keeping the product safe and secure. However, the pumping solution to the waste disposal is product specific. Peristaltic pumps, lobe pumps, Archimedes screw pumps, jet pumps, diaphragm pumps and centrifugal pumps are best utilised for the purpose. Vacuum transfer & pumping: More often, wastes contain hazardous gas or materials that need to be transferred via vacuum. These vacuum transfer & pumping systems minimise the need to enter into tanks or vessels to carry out cleaning. While the application of this technology does not always provide the complete solution, it can significantly reduce the man hours needed

in the vessel and thus reduce the possibility of exposure to hazards and risks. Besides, the vacuum transfer pumping system provides emission-compliant engines, integral bunds and noise suppression and enhanced atmospheric protection. Waste-to-green: A majority of Indian plant operators dispose of the waste by selling, recycling or simply disposing. Global engineering and technology corporation, Metso, provides automation technologies based on peristaltic dosing pumps that can maximise a plant’s incineration capacity while keeping combustion and steam production stable. A suitable pump solution can automate the process and with the waste-to-green idea, it can solve the energy problem to some extent.

THOU OUGHT TO DESIGN WITH CARE While pumps are chosen because of their mechanical performances, one needs to realise that along with their brilliant mechanical performances, these pumps also bring with them several disadvantages in the form of corrosion, friction and high-pressure pump failure. There is, therefore, a need for special designs, which will cater to the containment of pressure and fluid sealing to minimise corrosion and friction.

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These are usually not taken into account during their design stage, and, as a result, pose bigger threats later. Take, for instance, the pump failure in the NHPC power project in Himachal 2006 that claimed six lives. As the process of industrialisation and modernisation gathers momentum in the wake of globalisation, the demand for pumps and its connecting parts is expected to enhance. Hence, extra caution needs to be exercised during

PUMPS: 10 GROWTH COMMANDMENTS

the selection stage itself. One needs to opt for the right Essential parameters of pump design Fluid Nature and composition, concentration, pH, aeration, impurities, type of pump design for the desired pumping service to chemical additions, suspended solids, variations with time obtain reliability as well as profitability in the present Temperature Minimum, maximum and normal; any possible thermal shocks competitive industrial market. To ensure the same, here Pressure Range, including vacuum are some of the factors that need to be kept in mind: Flow Volume with time, velocity including any local turbulence Operation Continuous, intermittent, standby While designing a pump size, its size and the Contamination Effect on fluid of any corrosion products which may be produced pressure required for moving the fluid must be taken Requirements Reliability required, minimum life, ease and cost of maintenance into consideration. One must also take into account the chemical and physical nature of the fluid. instance, centrifugal pumps can be horizontal, vertical: in line, vertical: submerged or canned. The horizontal design Distribution of flow or pressure should be designed in is not usually self-priming and can lose prime if air/ such a way that erosion and cavitation is minimal. vapour is present. Besides, it has poor performance on An alloy with good foundry characteristics must be selected viscous liquids. In case of vertical: in line, bottom bearing for parts of the pumps that come in contact with water. becomes contaminated. Hence, it is advised to go with A compatible wrought alloy must be preferred for items the symptoms in advance rather than replacing it later such as shafts and stems. after a disaster actually takes place. Each pump design comes with some disadvantages. For

THOU SHALT KEEP THE MANUFACTURING COST LOW Cost and compatibility are the key factors behind sustainability. As the cost of materials rise over time, technology & innovation will help keep the cost of manufacturing low. Elaborating further, Prasanna says, “In India, we have developed a new plasma pump that is much more economical. We are now selling it to China, Brazil, Germany and Italy, among other countries. For instance, we can now deliver a pump that costs €750 in Germany, for € 250.” Apart form the pump’s cost, the operational cost must also be considered. To lower the operational cost: Activate the timer at the required intervals: This will automate the process with complete control without spending too much on control. Keep the intake grates clear of debris: Clogged drains require the pump to work harder, which uses more energy. Hence, it is important to backwash your filter appropriately.

Optimise the pump size as per the requirement: Also, keep the impellers’ diameter short. Operational cost has a lot to do with frictional power loss: Frictional power depends on the rate of flow, pipe size, length of the pipe and properties of the pumped liquid. Optimising them will bring down the operational cost. Compute the annual and life cycle cost: Compare it with the projected cost. Working on the gap will help bring the cost down. Evaluate pumping costs for a couple of pumps: Also, try to accommodate the pipe size with the lowest overall life cycle cost, particularly in systems dominated by friction head. Look for how to reduce the friction factor: Thermoplastic or epoxy-coated steel pipes in accordance with applications can reduce friction by more than 40%, thereby saving much of the operational cost

THOU SHALT NOT DO ANY WRONG AND BESEECH THE SAME The Indian pump industry has its own set of issues that need to be sorted out in time by the government, if the industry has to be brought back on track. Every hour, there is a pump failure in the country. However, the culprit here is not the quality of the pump, but quality of power. Besides, the poor quality of power has given rise to unnecessary costs, viz. stabiliser and other support control systems that are as costly as the pump itself. Additionally, there are other minor issues—like Form ‘C’—which are threatening the growth prospects of the pump industry. “By filling Form ‘C’, you can avail around 2% rebate over VAT, which is 14.5%. But it is not easily available and costs you much

more time, manpower and productivity,” says Prasanna. Resolving the issues of the pumps industry will, in turn, help resolve several other connected issues. For instance, in almost all the metros, there is huge scarcity of water supply that can only be met by using more and more pumps. The increasing use of pumps will also offer a boost to the agriculture and irrigation sector, which are the lifeline sectors of the country. However, for this to materialise, the government needs to intervene. suprita.anupam@network18publishing .com With inputs from Bureau of Energy Efficiency

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FIVE DISCOURSES OF VALVES

Valves are inherently present in all the applications we use in our day-to-day lives. Strangely, we hardly ever notice them. From nuclear, hydro, or thermal power to the tap water we use in our daily life, all the mechanical pressures are handled and controlled by valves. Here’s a look at the various aspects of valves that can be considered as ﬁve ‘discourses’ of the Indian valve industry...

SUPRITA ANUPAM

alves, as accessories regulating the flow of fluids (both liquids and gases), have been in existence for centuries. Romans were the first to invent valves in 25 AD. However, it was only by 1775 that it started taking the shape of an industry as the demand for more and more pressure valves from a growing steam industry began to increase. Initial globe valves were designed using cast iron or alloys brass and bronze. In the modern times, a number of technical advancements have been made in terms of steel valves, pressure-seal bonnets and corrosion-resistant valves to fulfil the requirement of regulating 100-octane aviation fuel. But are these technical advancements sufficient? The global demand in the valves industry has been rising at 5.4% annually and is expected to reach a market cap of $94 billion by the end of 2016. At US$1.6 billion, the Indian valve industry is growing at over 10% per year. This trend is likely to continue for the next 5–10 years owing to the huge investments made in the pipeline, power, water, oil and refineries. However, this is not enough when compared to China, which is showing a steady growth of 14.7%. Like all other industries, the valves industry too faced a slowdown during recession. However, it still managed to grow at 10–12% because of its versatility in not only serving various industries, but also in terms of product range. The

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growth of the Indian valve industry is dependent on the growth of other industries, such as infrastructure, electric power, gas, oil, refinery, chemical industry, pharmaceuticals, petroleum, etc. Elaborating on this, Anand Radhakrishnan, CEO, Amrutha Technologies and Valve Solutions, informs, “Although the Indian economy has been growing at a steady pace, there have been many bottlenecks in the implementation and execution of new projects announced over the last two years in the oil & gas and energy sector. This holds true for most of the public sector projects. Even though there are many projects announced from time-totime, they are not sufficient to sustain the energy needs of a large country like India.” The valves industry, so far, has been dominated by conventional valves (60% of the total), but the rising demands for automotive valves will overturn the data by the end of 2020. The East–West Gas Pipeline Project of Reliance has maintained the demand for gate valves and ball valves in double digits. At the same time, plumbing and other control valves have found applicability in drip irrigation, sprinkler irrigation, oil & gas, power generation, etc. Exports and expectations are on the rise. These need to be encashed graciously while ensuring that the quality is as good as the expectations. The following five ‘discourses’ will help you understand the valves industry better…

FIVE DISCOURSES OF VALVES

BLESSED ARE THOSE WHO DO IT RIGHT

Indian exports have been rising at 20%, but is it enough? Statistics reveals that the domestic market is growing at 10% with imports registering a 6.4% growth. Hence, the actual export figures are not the same as projected. German and Italian manufacturers/suppliers are the major countries from where India is importing its valves as they offer the best quality. However, some Indian manufacturers copy their products’ design as well as logo in a bid to capture their market. As per the data released by German Engineering Federation, the valve industry has been badly affected by illegal imitations, with 14% of the manufacturers being affected. Actuators’ manufacturers are the next most seriously affected business. The Federation’s survey also shows that a large percentage of the imitations and counterfeits originate from China; 71% of the affected companies named China as the country where the imitations originated, followed by Taiwan (12%), India (11%) and South Korea (10%). The ‘imitation’ tag hurts the business prospects of manufacturers in

these countries. However, this certainly does not imply that these countries are void of manufacturers that focus on quality. India has manufacturers like L&T and BHEL that are extremely concerned about quality. But these form a marginal percentage of Indian valve manufacturers. Nonetheless, India has managed to attract foreign investments. To this, Radhakrishnan adds, “There is a growing interest among foreign valve manufacturers to set up manufacturing plants in India close to the foundries they have been sourcing from, due to stringent environmental norms on foundries in other countries. Their products are exported and find ready acceptance in the international market through their well-established global distribution channels. As far as the organised sector is concerned, home-grown valve manufacturers, like AIL, Virgo and BDK Valves, are finding a strong market share in the global valve industry market.” Valves are used in critical applications. Therefore, it becomes very important that the quality of materials used to manufacture them must be application oriented.

BLESSED ARE THOSE WHO SUPPLY TO THE DEMAND when compared to their Chinese “We have an app for that,” famously counterparts. Commenting on the said the late Steve Jobs. Before same, Hemlata Joglekar, ESE Manager, Alfa Laval India, releasing the first iPhone, Jobs had some 15 amazing explains, “An economical and effective process is about models from which the actual iPhone was selected. two things—simplicity and control.” Though Apple has applied all those designs for patents for the sake of just what they did, they did not bring it Though the Indian valve exports are growing at 20% to the market. The reason: ‘Boom’ presenter, Steve Jobs, per annum, they are still not able to encash on the believed in ‘not giving alternatives, proportional demand that has been but in giving the best’. While we shifted to Asian countries, which The sectors where Indian valve merely state ‘necessity is the mother have a stronghold on almost half of manufacturers are still lagging include of invention’, he actually did it. the world’s valve market. The major hydrocarbon processing, which Demand and applications are very reason behind it is that the Indian requires a robust design to prevent closely correlated. Both rely on each valve industry is unorganised. cavitation and ﬂashing, intelligent other. It is up to you how to use Barring a few manufacturers, others valve positioner market and special it. Jobs first created a product and have not explored the demands valve demands like counterbalance then, went on to create a demand that might come from outside the valves & nuclear power valves. for it—be it an iPhone, iPad or an country, even though they have the iPod. This instance can be looked necessary certifications. at from the point of view of the valves industry. Unlike The following organisations govern the international the European countries, particularly Italy and Germany, valve industry: Indian valve manufacturers wait for the demand to rise, American Petroleum Institute (API) i.e., they just follow the trend. This is where they lag Manufacturer Standardisation Society (MSS)

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FIVE DISCOURSES OF VALVES

American Society of Mechanical Engineers (ASME) International Organisation for Standardisation (ISO) American Water Works Association (AWWA) Instrument Society of America National Society of Corrosion Engineers (NACE). Having ISO 9001 and ISO 14001 certifications makes manufacturers eligible to sell their products across the globe. However, there are certain application-specific organisations, like AWWA, which give manufacturers an added edge. These applicationspecific organisations ensure that a particular valve design fulfils the application requirement. Therefore, obtaining these certifications definitely gives manufacturers an edge in terms of encashing on application-based demands. The size of valves varies from 0.1 mm to 5 m, and

so do their applications. Further, there are one, two, or three-port valves, V-notch ball control valve bodies, eccentric-disk control valve bodies and eccentric-plug control valve fitting the requirement. The market sector that these capture include wastewater, home plumbing systems, heating ventilating and air-conditioning, fire-conditioning, general industry, power, oil & gas and refinery. Here, the sectors where Indian valve manufacturers are still lagging include hydrocarbon processing, which requires a robust design to prevent cavitation and flashing, intelligent valve positioner market and special valve demands like counterbalance valves & nuclear power valves. Analysing the demand possibilities can be the key factor to develop new applications that might fuel the valve industry exponentially.

BLESSED ARE THE DISCIPLES OF TECHNOLOGY With smart-bus and fieldbus controls and new designs like tripleoffset butterfly valves, metal-seated ball valves, improved materials—high Cr/Mo alloys, superalloys, extended life seating and hard facing overlay welding technology, technology advancements have been made not only in valves’ design and material, but also in the complete system including bonnets, actuators, trim materials, gaskets and exotic—high and superalloys. The valve response depends on the flow speed and actuating type, whether hydraulic, pneumatic or electric. As compared to others, pneumatic valves indicate a speedy and good response. This is one of the important areas of valve research, particularly in the field of nuclear power, where a response delayed by even a millisecond can result in losses amounting to `10-50 lakh. Currently. there are technological advancements in the fields of: High-temperature alloys Advanced computer control and actuation Fugitive emission control Packaging of bigger valves with diameter in metres Bigger valves fitting. Here, the focus of the technology is on stemless valve technology, their applications, butterfly valves, cryogenic valves & their applications, digitalisation of valve actuators and positioners. Stemless valve technology: Unlike traditional valves, stemless valve technology secures fluids, vapours and

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toxic & hazardous fluids from any leakage, thereby saving the environment. Seamless valves can withstand high pressure and are capable of providing torques up to 6,000 inch-lbs while opening and closing under the harshest of conditions. One example of such a valve is MagBall™ Valve, which caters to aerospace, cryogenic, fuel cells and petrochemical industries. Magnetic valve technology: Developed by Big Horn, the magnetic valve technology combines the proven ball and ball seal technology with new magnetic stemless valve actuation. The technology provides uniform levitation valve actuation, smooth low-turning torque, fill-safe magnetic interlock, improved safety, 360° rotational cartridge with longer seal life offering minimal flow loss. Digitalisation of valve actuators and positioners: A weak response and fluid leakage from the best ergonomic and robust valves forced manufacturers to reconsider the accuracy of actuation & positioning. Companies such as ABB, Yokogawa, Festo, etc., have digitalised the valve actuators and positioners, thereby providing a host of benefits in process plant applications, such as hydrocarbon. Thus, this smart technology is able to control multiple air-operated valves. Though some benefits from the technology are yet to come, the uniqueness of the technology lies in accuracy, better troubleshooting and easy handling. Smart ValveTM monitoring system: The system

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Pg No. 65

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FIVE DISCOURSES OF VALVES

consists of a SMART ValveTM wear-monitoring sensor wire between reinforcing cords and wear rubber to alert maintenance personnel if the tube needed to be replaced. Low-power solenoid valves: These valves have been developed as pilot valves to open and close larger ball or butterfly valves or on control valves for fail-safe air release in case there is a loss of power. It may find applications in refining upstream, oil & gas, chemicals, pharma & life sciences, food & beverage and power. There is further scope for R&D in sliding-stem control valve technologies and rotary shaft control valve technologies. As per Radhakrishnan, “Innovation in the valve industry will move seamlessly along with new process designs by the licensors in the global market. There has been a lot of innovation in valve

automation along with some valve trim improvements to offer solutions to specific process applications in the downstream manufacturing plants.” He adds, “As the competition in the valve industry continues to grow with over 5,000 valve manufacturers in India, there is much pressure on the cost of the finished products. Manufacturers need to move closer to foundries, where skilled labour and power are available in abundance. The introduction of automation in the manufacturing process can also drive down costs. As far as alternate materials are concerned, there has been some exposure to plastics PolyPropylene valves, given their strength to withstand corrosion. Carbon composites are at an early stage of development and much needs to be done.”

BLESSED ARE THE BELIEVERS OF ENERGY EFFICIENCY

There are loads of internal and external factors that affect the performance of valves. The countable parameters are dead band, actuatorpositioner design, valve response time, valve type and characterisation, valve sizing, etc. The competition has forced companies to produce highest quality and efficient valves. Controlling the process control variables written above, one can manage to get the best efficiency for a given application. Further, efficiency has a lot to do with energy savings, which is now connected with green initiatives. Expatiating further, Radhakrishnan comments, “As far as energy-saving techniques for the valve industry are concerned, I would give core focus to air compressors. Compressed air is the highest energy drainer. Only 5% of electrical energy is converted to compressed air that is used to drive pneumatic tools and other instrumentation equipment. Some basic techniques are to ensure low inlet air temperature—increasing the inlet air temperature by 3°C increases power consumption by 1%, while reducing discharge pressure by 10% saves energy consumption by up to 5%. Finally, leakage from a half-inch diameter hole from a single compressed air line working at a pressure of 7 kg/cm2 can drain almost `2,500 per day.”

BLESSED ARE THOSE WHO VALUE TIME & MONEY

ASME and API standards are the universal guidelines to test (shell test & seat test) as per product type, size and class in the medium of air or water. Though this ensures longevity with quality, ultimately it is the circumstances that demand proper maintenance of valves. Further, it is always better to repair in time than to replace later, as repairing valves cost only 5–35% of the replacement cost. Besides, repairing saves time as well. Repairing can be on-site and off-site. On-site repairing is less time consuming and less expensive. The machines and instruments that are required for on-site repairing include: VALVA VSK-Tools VSK-TOP SEGMENTS VSA SL HSS TD TDF TSD FLM KS SM ENT LS

Portable grinding and lapping machine for valves and flanges Special tools for grinding conical seatings Conical top segments Portable high-speed grinding machine for valves and flanges Portable gate valve grinding and lapping machine Portable high-speed gate valve grinding machine Portable turning machine for working sealing seats and drill holes Portable turning machine for working flanges Portable gate valve turning machine Stationary face lapping machine Grinding table for wedges and disks Stationary grinding and lapping maching Tilt tables Special tools for working metallic lens type gaskets and tube ends Courtesy EFCO

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MINING AND MINING EQUIPMENT

In the News

Aureus Announces Settlement of Weaju Legacy Mining Claims Aureus Mining Inc has signed an agreement to acquire certain legacy mining rights from Weajue Hill Mining Corporation. The legacy mining rights are situated in the Weaju area, covering only 1.7 sqkm of the total 457 sqkm. Class A Mining Licence was granted by the Republic of Liberia to Bea Mountain Mining Corporation, a wholly owned subsidiary of Aureus. American International Ventures settlement options with Bruner Mine to Patriot Gold American International Ventures, Inc optioned the Bruner Mine to Patriot Gold on April 1, 2009, for eight annual payments totaling $315,000 and a balloon payment due on AIVN in April 2016, in the amount of $1,185,000. In addition, AIVN retained a 1.5% NSR wherein, PGOL has the option to purchase 1% of the NSR for an additional $500,000. Green Technology Solutions: Could Canada Be the ‘Next Big Thing’ in Lithium Mining? Rising global demand for lithium-ion batteries drives lithium prices higher and higher. Green Technology Solutions is exploring new opportunities in what could be the world’s next lithium hotspot— Canada. Lithium mining activities have recently drawn significant investing interest to Canada’s mining industry. Nova Mining acquired mining concessions in Saskatchewan, and Canada Lithium Corp is exploring an open-pit mine and processing plant in Quebec. GTSO could be the next company to capitalise on the worldwide boom in demand for lithium. That demand is being driven by increasing usage of lithium-ion batteries in everything from Apple iPads to electric vehicles. Some industry veterans predict that the demand for the metal could increase 20% this year over that of the previous year.

Joint Ventures

Klondike Gold Corp: JV Sets the Stage for Placer Gold Production on Indian River Project Under the terms of a newly signed joint venture agreement with privately held Yukon Inc, Klondike Gold Corp’s Indian River Project’s construction work is under way. Klondike Gold entered into the Joint Venture (JV) with Yukon Inc to further explore and develop the Indian River mining project. The fully permitted placer gold property lies within the Indian River Valley—Yukon’s largest gold producer in the recent years—and is accessible by road from Dawson City. China to develop three mines in North Korea North Korea has signed a deal with China to jointly develop three mines in the North as the cash-strapped country steps up attempts to earn hard currency from overseas. The deal is the first foreign investment deal announced by the Beijing unit, which is run by the Committee of Investment and joint venture in charge of luring overseas capital and investment into the North. The joint North-China mining venture also illustrates growing exports of underground resources from the North to China, its closest ally and a major source of foreign currency.

Emerging technologies

McGuinty Government will test a thin spray-on lining that helps keep broken rock safely in place Ontario is investing in innovative new technology that will help strengthen Sudbury’s position as a world mining leader. Through the Northern Ontario Heritage Fund Corporation, the Canadian Mining Industry Research Organisation will test a thin spray-on lining that helps keep broken rock safely in place in deep underground mining. The new product could become an important tool in ensuring the health and safety of underground workers. Emerging Tech: Reality Mining Reality Mining is defined as the ‘collection and analysis of machine-sensed environmental data pertaining to human social behaviour in order to identify predictable patterns of behaviour.’ This mobile technology has tremendous potential to comprehend the pattern of human life, in understanding of ourselves, organisations & society, and by analysing digital traces through sensors in mobile phones, cars, security cameras, RFID readers, GPS technology, etc.

Compiled by Prateek Sur

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MINING AND MINING EQUIPMENT

MINING PROCESSES AND STAGES: Mapping The Life Cycle Of A Mine .....................................70 EMERGING TRENDS: Expectations 2012 For Global Mining Sector ..............................................76 MINING OF FUELS: Fuelling Power Into Indian Mining ..................................................................85 INDIAN COAL SCENARIO OVERVIEW: A Resource-Full Reserve ...............................................88 URANIUM MINING: Nuclear Energy: Towards Attaining Self-Reliance ..........................................92 OVERVIEWING SOME MAJOR MINERAL ORES: Minerals: The Essential Elements Of Growth ..96 MINING EQUIPMENT: Enhancing Mining’s Efficiency Quotient ...................................................108 SAFETY IN MINING: Mining’s Achilles Heel .................................................................................110 ENVIRONMENTAL EFFECTS OF MINING: Is The Eroders Of Earth Tag Justified? ....................116 NATIONAL POLICIES ON MINING: A Guiding Light For Indian Mining .....................................122 FDI IN MINING: A Goldmine Of Business Opportunities .............................................................124 MERGERS, ACQUISITIONS AND JOINT VENTURES: Envious Deals To Deliver Demands .......130 GLOBAL MINING DEALS 2011–12: Empowering Nations ..........................................................134

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MINING PROCESSES AND STAGES

The production operations in mining tend to be separate and cyclic in nature, although the trend in modern mining and tunnelling is to eliminate or combine functions. In order to increase the continuity of extraction, production cycle and certain auxiliary operations must be performed. Here are the major stages and processes that comprise the whole of the mineral production via the mining process. PRATEEK SUR

he mining processes involve many stages— from exploration and site development to reclamation. The steps that contribute directly to mineral extraction are called ‘production operations’. These constitute the production cycle of operations. The ancillary steps that support the production cycle are termed as ‘auxiliary operations’. The unit operations of mining are the basic steps that are used to produce mineral from the deposit, while the auxiliary operations are used to support them. During the development and exploitation stages of mining, when natural materials are extracted from the earth, remarkably similar unit operations are normally employed. The production cycle employs unit operations that are

normally grouped into rock breakage and materials handling. Breakage generally consists of drilling & blasting, while material handling encompasses loading or excavation and haulage (horizontal transport), and sometimes hoisting (vertical or inclined transport). The basic production cycle consists of the following unit operations: Production cycle = drill + blast + load + haul

PROSPECTING Prospecting—the first stage in the utilisation of a mineral deposit— involves searching for ores or other valuable minerals (metallic or nonmetallic). Mineral deposits may be located either at or below the surface

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of the earth, using both direct and indirect prospecting techniques. The direct method of discovery, normally limited to surface deposits, consists of visual examination of either the exposure (outcrop) of the deposit or the loose fragments (float) that have weathered away from the outcrop. Geologic studies of the entire area augment this simple, direct technique. With the help of aerial photography, geologic maps and structural assessment of an area, the geologist gathers evidence by direct methods to locate mineral deposits. Precise mapping and structural analysis plus microscopic studies of samples also enable the geologist to locate the hidden as well as surface mineralisation. The most valuable scientific tool employed in the indirect search for hidden mineral deposits is geophysics, the science of detecting anomalies using physical measurements of gravitational, seismic, magnetic, electrical, electromagnetic and radiometric variables of the earth. The geophysics methods are applied with the help of aircraft and satellites, on the surface of the earth, and beneath the earth by using methods that probe below the topography. Geochemistry, the quantitative analysis of soil, rock & water samples, and geobotany, the analysis of plant growth patterns, are also employed as prospecting tools.

EXPLORATION The second stage in the life of a mine, i.e., exploration, determines as accurately as possible the size and value of a mineral deposit, utilising techniques similar to but more refined than those used in prospecting. The line of demarcation between prospecting and exploration is not sharp; in fact, a distinction may not be possible in some cases. Exploration is generally limited to surface and sub-surface locations, using a variety of measurements to obtain a more positive picture of the extent and grade of the ore body. Representative

MINING PROCESSES AND STAGES

deposits to prepare for underground samples may be subjected to chemical, EXPLOITATION mining. In either case, certain metallurgical, X-ray, spectrographic or Exploitation, the fourth stage of preliminary development work, such radiometric evaluation techniques that mining, is associated with the actual as acquiring water and mineral rights, are meant to enhance the investigator’s recovery of minerals from the earth. buying surface lands, arranging for knowledge of the mineral deposit. Although development may continue, financing and preparing permit Samples are obtained by chipping the emphasis is on production. Usually, applications & an Environmental outcrops, trenching, tunnelling and only the required development is Impact Statement (EIS), is generally drilling. In addition, borehole logs done prior to exploitation to ensure required before any development could may be provided to study the geologic that production, once started, can be take place. When these steps have been and structural make-up of the deposit. continued uninterrupted throughout the completed, the provision of a number Rotary, percussion or diamond drills life of the mine. The mining method of requirements—access roads, power can be used for exploration purposes. selected for exploitation is determined sources, mineral transportation Diamond drills are more favoured as mainly by the characteristics of the systems, mineral processing facilities, the cores they yield provide knowledge mineral deposit and the limits imposed waste disposal areas, offices and other of the geologic structure. The core is by safety, technology, environmental support facilities—must precede actual normally split along its axis; one half concerns and economics. Geologic mining in most cases. Stripping of is analysed, while the other is retained conditions, such as the dip, shape and the overburden will then proceed if intact for further geologic study. strength of the ore & the surrounding the minerals are to be mined at the An evaluation of the samples enables rock, play a key role in selecting the surface. Economic considerations the geologist or mining engineer to method. Traditional exploitation determine the stripping ratio, i.e., calculate the tonnage and grade, or methods fall into two broad categories the ratio of waste removed to ore richness, of the mineral deposit. S/he based on locale, viz., surface mining recovered may range from as high as estimates the mining costs, evaluates and underground mining. Surface the recovery of the valuable mining includes mechanical minerals, determines the excavation methods such By planning the mine for subsequent development, mine environmental costs and as open pit & opencast planners can enhance the value of the mined land and help assesses other foreseeable (strip) mining, and aqueous convert it to a use that the public will consider favourable. factors in an effort to reach methods such as placer & a conclusion about the profitability solution mining. Underground mining 45 yard/tonne (38 m/tonne) for coal of the mineral deposit. The crux of is usually classified in three categories, mines to as low as 1.0 yard/tonne (0.8 the analysis is whether the property is viz., unsupported, supported and caving. m/tonne) in metal mines. Some nonjust another mineral deposit or an ore metallic mines have no overburden body. For an ore deposit, the overall to remove, as the mineral is simply RECLAMATION process is called ‘reserve estimation’, excavated at the surface. Development The final stage in the operation of that is, the examination and valuation for underground mining is generally most mines is reclamation, the process of the ore body. At the conclusion of more complex and expensive. It of closing a mine and recontouring, this stage, depending on the results requires careful planning and layout of revegetating and restoring the water & obtained, the project is developed, access openings for efficient mining, land values. The best time to begin the traded to another party, or abandoned. safety & permanence. The principal reclamation process of a mine is before openings may be shafts, slopes or the first excavations are initiated. In adits; each must be planned to allow other words, mine planning engineers DEVELOPMENT passage for workers, machines, should plan the mine keeping in view The third stage—development— ore, waste, air, water and utilities. the reclamation process. The mine involves the opening up of a mineral Many metal mines are located along planning should help in minimising deposit for exploitation. With it begins steeply dipping deposits, and, thus, the overall cost of mining plus the actual mining of the deposit, now are opened from shafts, while drifts, reclamation, and not just the cost of called the ‘ore’. Access to the deposit winzes & raises serve the production mining itself. The new philosophy in must be gained either by: areas. Many coal and non-metallic the mining industry is sustainability, (1) Stripping the overburden, which mines are found in nearly horizontal that is, the meeting of economic and is the soil and/or rock covering the deposits. Their primary openings environmental needs of the present deposit, to expose the near-surface ore may be drifts or entries, which may while enhancing the ability of future for mining be distinctly different from those of generations to meet their own needs. (2) Excavating openings from the metal mines. While planning for the reclamation surface to access more deeply buried

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MINING PROCESSES AND STAGES

Stages In The Life Of A Mine Stage/(Project Name)

Procedure

Prospecting (Mineral Deposit)

1–3 years Precursors To Mining Search For Ore • Prospecting Methods Direct: Physical Indirect: Geophysical, Geochemical • Locate Favourable Loci (Maps, Literature, Old Mines) • Air: Aerial Photography, Airborne Geophysics, Satellite • Surface: Ground Geophysics, Geology • Spot Anomaly, Analyse, Evaluate

Exploration (Ore Body)

Defining Extent And Value Of Ore (Examination/Evaluation) • Sample (Drilling Or Excavation), Assay, Test • Estimate Tonnage And Grade • Valuate Deposit (Hoskold Formula Or Discount Method): Present Value = Income - Cost • Feasibility Study: Make Decision To Abandon Or Develop

2–5 years

$1–15 million or $0.20–1.50/tonne ($0.22–1.65/tonne)

Development (Prospect)

Mining Proper Opening Up Ore Deposit For Production • Acquire Mining Rights (Purchase Or Lease), If Not Done In Stage-2 • File Environmental Impact Statement, Technology Assessment, Permit • Construct Access Roads, Transport System • Locate Surface Plant, Construct Facilities • Excavate Deposit (Strip Or Sink Shaft)

2–5 years

$10–500 million or $0.25–10.00/ tonne ($0.275–11.00/tonne)

Exploitation (Mine)

Large-scale Production Of Ore • Factors In Choice Of Method: Geologic, Geographic, Economic, Environmental, Societal Safety • Types Of Mining Methods Surface: Open Pit, Open Cast, etc. • Underground: Room And Pillar, Block Caving, etc. • Monitor Costs And Economic Payback (3–10 years)

10–30 years

$5–75 million/yr or $2.00–150/tonne ($2.20–165/tonne)

Reclamation (Real Estate)

Post-mining Restoration Of Site • Removal Of Plant And Buildings • Reclamation Of Waste And Tailings Dumps • Monitoring Of Discharges

1–10 years

$1–20 million or $0.20–4.00/tonne ($0.22–4.40/tonne)

of any given mine, there are many concerns that must be addressed. The first of these is the safety of the mine site, particularly if the area is open to the general public. Office buildings, processing facilities, transportation equipment, utilities and other surface structures must be removed before reclamation could begin. The mining company is then required to seal all mine shafts, adits and other openings that may present physical hazards. Any existing high walls or other geologic structures should be demolished to prevent injuries or death due to geologic failures. The second major issue to be addressed while reclaiming a mine site is the restoration of the land surface, the water quality and the waste disposal areas so that long-term water pollution, soil erosion, dust generation, etc., do not occur. The restoration of native

Time

plant species is often a very important part of this process, as the plants help build a stable soil structure and naturalise the area. It may be necessary to carefully place any rock or tailings with acid-producing properties in locations where rainfall has little effect on the material and acid production is minimised. The same may be true of certain heavy metals that pollute streams. Planning of the waste dumps, tailings ponds and other disturbed areas will help prevent pollution problems. However, remediation work may also be necessary to complete the reclamation stage of mining and satisfy the regulatory agencies. The final concern of the mineplanning engineer may be the subsequent use of the land after mining is completed. Old mine sites can be converted to wildlife refuges, shopping malls, golf courses, airports,

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Cost/Unit Cost $0.2–10 million or $0.05–1.00/tonne ($0.05–1.10/tonne)

lakes, underground storagel facilities, real estate developments, solid waste disposal areas and other uses that can benefit society. By planning the mine for subsequent development, mine planners can enhance the value of the mined land and help convert it to a use that the public will consider favourable. The successful completion of the reclamation of a mine will enhance public opinion of the mining industry and keep the mining company in the good graces of the regulatory agencies. The fifth stage of the mine is thus of paramount importance and should be planned at the earliest in the life of the mine. prateek.sur@network18publishing.com With inputs from Pawan Raj Gandhi, ASE, Rajasthan State Mines and Minerals Ltd; Shivendra Panthi, Mines Operating Manager, Infrastructure and Mines India Pvt Ltd.

EMERGING TRENDS

Despite tough economic conditions, the global demand for mining products is generally increasing. This presents both opportunities and challenges for mining companies. Due to signiﬁcant risks, such as dwindling global reserves, increasing project complexities, increasing government interventions and changing requirements from key stakeholders around environmental & social issues, meeting demand is a critical issue for the mining sector. Increasingly, more and more mining explorations are being located in remote and politically unstable regions of the world, which are often plagued with high rates of unemployment. These problems require the governments of various nations to take proactive steps to better manage the mining sector. Amid all these happenings, here are certain developments that we can expect to witness in 2012… PRATEEK SUR

GROWTH AND GLOBAL DEMAND WILL CONTINUE TO DRIVE MERGERS AND ACQUISITIONS (M&As) AND JOINT VENTURES (JVs) Emerging nations have become the key drivers of economic growth and urbanisation. It has been estimated that the world’s middle class will increase to 4.88 billion in 2030 from the present 1.85 billion. Since urbanisation is highly resource intensive, it will hugely increase the demand for steel in the near future, with the demand for mid and late-cycle commodities expected to spike over the long term. This does not even take into consideration agricultural minerals or thermal coal, which are also essential ingredients of urbanisation. Continued demand from developing markets is likely to spur further M&As and JVs across all resource sectors, with an especially intense focus

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on early-cycle commodities. Traditional miners, as well as steelmakers and other industrial verticals, will increasingly seek acquisitions in the light of continued challenges with supply. However, the cost of exploration is rising, largely due to the following factors: New mining discoveries have been difficult to come by despite large investments in exploration. The cost of organic mine development has continued to increase due to rising energy, transportation & labour costs. Cost pressures have been further exacerbated by foreign exchange volatility.

EMERGING TRENDS

FINANCIAL BUYERS WILL GRADUALLY BEGIN TRANSACTING IN THE MINING SECTOR, ALTHOUGH THERE WILL BE A FEW DEALS Financial buyers have traditionally been less than enamoured with investing in the mining sector, and with good reason. Mining investments are typically accompanied by: Illiquidity and high capital expenditure requirements over long hold periods (10+ years between typical discoveries to commercial operations) Regulatory, environmental and sovereign risks Concentration risk (via single asset, single commodity, single geography, etc.) Price risk. None of the above-mentioned problems is congruent with the classic ‘buy–hold–sell’ model that many private equity firms subscribed to during the first decade of this millennium. However, the present global economic slowdown, characterised by anaemic growth in the West, low interest rates, volatile public markets and bullish longterm sentiment for resources, has prompted PE funds and Sovereign Wealth Funds (SWF) to pause and reconsider their investments in the mining sector. It has been observed that some of the world’s leading private equity firms and SWFs are attempting to ‘figure out how to make mining investment work’. However, with most financial buyers still in the investigative phase, the mining sector has not yet seen significant capital inflows from SWFs or private equities. At the same time, there are some encouraging signs to show that the tide is slowly turning. Some recent deals involving financial buyers are China Investment Corporation’s 2009 investments in South Gobi Resources, PT Bumi & Teck Resources, Blackrock & First Reserve supporting Glencore’s deal for Umcebo Mining in 2010 and Temasek’s investment in Inmet Mining in 2010. The following deals amply prove that financial companies are showing a continued interest in mining: Qatar Holding LLC (‘Qatar Holding’), a global investment house founded by the Qatar Investment Authority, is investing in and financing European Goldfields. It provided a $600-million, seven-year loan (secured against European Goldfields Greek gold assets) plus a $150-million unsecured loan with equity participation. The equity participation includes the issuance of warrants to allow Qatar Holding to acquire equity at a pre-determined price. In addition, Qatar Holding conducted two separate transactions, acquired 9.9% of the undiluted share capital of European Goldfields and entered into a call option agreement allowing for further acquisition of company shares. Taurus Minerals Ltd, a company formed at the direction of CGNPC Uranium Resources Co Ltd and The China– Africa Development Fund (an equity development fund), has acquired Kalahari Minerals, which holds an indirect

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interest in the world’s third-largest known primary uranium deposit, the Husab Uranium Project in Namibia. Beijing-based private equity firm Origo Partners PLC, one of the largest buyout investors in the Mongolian natural resource sector, collaborated with Dutch commodity trading giant Trafigura in a joint coal and iron ore mining venture in Mongolia. The JV, Trafigura– Origo MGL, will invest in a number of already identified coal and iron ore exploration projects in Mongolia with the objective of targeting further high-grade deposits with the potential for significant export volumes. The industry expects that financial buyers will continue to move into the mining sector, albeit in an extremely cautious and calculated manner. Specifically, it can be expected that: SWFs will seek out opportunities to invest non-controlling stakes in both pre-development and producing projects. The SWF value proposition, ceding cash without takeover, may be attractive for cash-hungry developers in growth markets with few financing options. SWF partners may also be of interest to small and mid-size producers who are not interested in tapping public markets (a process that can be expensive and highly restrictive). Large Western funds (those with sufficient resources to allocate to the mining sector in a diversified portfolio) will continue to evaluate the mining sector in 2012. These potential buyers will need to find projects at or near production, in stable jurisdictions and with strong management teams. With this aim, financial buyers will compete with public equity markets, strategic buyers and state-backed entities—all of which frequently place a higher value on companies and projects. Relative to the oil & gas industry, large-scale (greater than $100 million) private equity has been relatively inactive in the mining and metals industries. With regard to SWFs, industries view the commodity market as strategic and, with respect to future commodity, demand and potential low-cost debt, are willing and able to pay higher prices than traditional private equity. The competitive environment for targets may also prompt pension or hedge funds to: Utilise debt-like instruments to protect against downside risk and earn preferred returns Target resources that do not require multi-billion-dollar, follow-on investments in infrastructure (as can be the case with iron ore) Focus on resources with unique drivers and lower risk profiles. For example, thermal coal can be considered in the energy sector; fertiliser minerals can be considered in agriculture sector Carefully monitor the market to identify projects that do not have a ‘logical strategic buyer’.

EMERGING TRENDS

WESTERN BUYERS WILL BE FORCED TO FIND BUSINESS MODELS THAT MAKE THE GROWTH MARKET DEALS ‘WORK’ The Western miners lag behind their growth market counterparts with regard to transacting in the higher risk emerging, developing and frontier regions. This has to be changed if the Western mining titans want to remain dominant through the next decade. Roughly three quarters of the known reserves are believed to lie in countries outside the developed market economy countries. Gaining market and board acceptance for transactions in growth markets will pose a significant challenge. Deals in these markets, in general, have a notorious history of being value destructive. A recent PwC study showed that over 50% of all deals in growth markets that enter detailed diligence fail to complete. The study also showed that postdeal failures are expensive, with buyers losing an average 50% of their initial investment. Smaller mining entities, in particular, may have difficulties effectively managing operations in these markets. The following strategies might help the West adapt to this new paradigm: Pursue multi-faceted partnerships with governments and other miners. In addition to safeguarding against postdeal ‘surprises’, these relationships can be an important source of future deal flow. While partnerships are

important, 50–50 JVs should be avoided. They can be tricky when consensus or exit is required. Re-tool risk-evaluation strategies. There are no ‘perfect investments’ in frontier markets. Risks need to be assessed in order to take ‘calculated risks’. (Security risks are high across Sub-Saharan Africa, for example, but identification of a protected pocket may mitigate this risk). Consider spinning off higher risk assets into a separate entity to insulate slower growth and lower risk project portfolio (although this strategy introduces financing challenges). Identify specific political risks that miners will be up against and prepare the company’s board & shareholders for the same. If transacting in an environment where there is a high risk of instability with regard to taxation and royalty schemes, it is better to engage local advisors on these matters & engage them early. As appropriate, revise the negotiating approach by appreciating that ‘first-world standards’ may be foreign in developing markets. Contemplate what the exit options will be. Is a sale to another strategic buyer possible if collaborating with a local firm/government? What kinds of deal is the region seeing?

AN AFRICAN RENAISSANCE Africa will emerge as one of the most important mining M&A geographies in the future, and 2012 is going to be just the start of its superiority in mining activities. Unparalleled resource potential and an increasingly investor-friendly climate are two key drivers in this development. The political climate in Africa is also improving. Transparent and efficient mining policies are being formulated and even calls for participation by local capital & government have increased. The interest in investing, even in countries as difficult as Zimbabwe, is evident. Also, relatively high commodity prices, increasing competition from Chinese investors (and elsewhere), and less policy pressure from donors have helped to shift negotiating leverage to the African governments. Many countries are also more stable and better governed than in the recent past, when the threat of war, unrest, or systemic regulatory uncertainty deterred all, except but the most risk-tolerant investors, who often received highly attractive terms. The revival of African mining is obvious from the number of new projects covering a range of commodities. Copper: A number of projects, both greenfield and brownfield, evenly spread in the various parts of the

continent, are in the pipeline and will be ready for production within the next couple of years. Uranium: The Namibian uranium boom continues and considerable new supply, from mostly greenfield projects, is projected before 2015. Niger will also expand its production. Some other countries that are joining the foray are Botswana, Zambia and Tanzania. Iron ore: West Africa is the emerging hot spot in iron ore mining. Greenfield projects in Sierra Leone, Guinea, Liberia and Congo are well on track to create a new global iron ore centre. Coal: Three countries dominate the coal sector—South Africa, Mozambique and Botswana. South Africa is the leading producer. Mozambique will increase its production considerably in the next couple of years. However, Botswana has a lot to do as the necessary infrastructure is not yet fully in place. Therefore, while M&As and JVs in Africa will continue apace, companies would be well-served in understanding the new terms that they are likely to encounter when doing deals in the continent. prateek.sur@network18publishing.com With inputs from PwC India

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MINING OF FUELS

Fuelling POWER into Indian Mining India is at a critical juncture, poised for stupendous growth. And if this opportunity is not to be jeopardised, it is vital that we take appropriate steps to ensure there are sufﬁcient resources of energy to power India’s growth story. Though the present per capita power consumption is low in India, the growing population will increase it tremendously. In fact, by 2020, India needs to increase its installed generation capital from 138.73 GWe to 417 GWe. Also, the share of nuclear power has to increase from 4,120 MWe to 20,000 MWe by 2020. Therefore, it becomes very important that we increase the requirement for coal, oil & gas and uranium accordingly.

PRATEEK SUR

ndia faces a number of power constraints, and the primary reason for this is the huge increase in the population, which has decreased the per capita availability of power fuels like coal, oil & gas and uranium. India has inadequate coal reserves and that too of low calorific value. Moreover, opaque government policies also put an additional strain on the coal mining sector. In the oil & gas sector, India again has inadequate reserves, forcing the country to import nearly 70% of its fuel requirement. Coupled with this, India also has a complex geo-political environment, making the situation more difficult. Moving over to the hydroelectric fuel resources, India has very limited geographically suitable sites for hydroelectric power generation. And erratic monsoons & the fact that the prime demand areas are miles away from the hydroelectric powergeneration sites further complicate this situation. Moreover, developing the hydroelectric resources adversely affects the ecology and also leads to the displacement of a vast population. In addition, the non-conventional

fuel resources have limited scope as the present technologies are inadequate. And the poor capacity factor and the diffused location of resources further complicate the fuel situation of India. Therefore, an overview of the availability of power fuels in India becomes important.

COAL Coal is a fossil fuel that is used primarily for electric power generation and for producing steel. To mine coal, miners have to go into the earth. However, many coal seams are located close to the surface, which makes the extraction of this resource easier. Surface Mining It typically uses a method called ‘strip mining’, which is usually more costeffective than underground mining and requires fewer workers to produce the same quantity of coal. Here, workers use huge earthmoving equipment, such as power shovels or draglines, to scoop off the layers of soil and rock covering the coal seam. Once the coal is exposed, it is broken by using explosives. Smaller shovels are then used to lift it from the ground and load it into trucks.

Underground Mining It is used when the coal deposit lies deep below the earth. Tunnels are first dug deep into the earth where the coal is located. Depending on where the coal seam is in relation to the surface, tunnels may be vertical, horizontal or sloping. Entries are constructed so that miners can get themselves & their equipment to the ore and carry it out, while, at the same time, allowing fresh air to enter the mine. Once dug to the required depth, a mine’s tunnels interconnect with a network of passageways branching in many directions. Using the roomand-pillar method, miners remove sections of the coal as they work the coal seam from the tunnel entrance to the edge of the mine, leaving columns of coal in place to help support the ceiling together with long steel bolts. This process is then reversed, and the remainder of the ore is extracted, as the miners work their way back out. Longwall Mining In the case of longwall mining (a form of underground mining), selfadvancing roof supports, made of hydraulic jacks and metal plates, cover the area being mined. As coal is removed, the entire apparatus advances,

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MINING OF FUELS

allowing the ceiling in the mined area to cave in as the miners work back towards the tunnel entrance.

oil or gas is found, otherwise the site is abandoned. Similar techniques are employed in offshore drilling, except that the drilling equipment is part of a steel platform that either sits on the ocean floor, or floats on the surface and is anchored to the ocean floor. Advancements in directional or horizontal drilling techniques, which allow increased access to potential reserves, have had a significant impact on drilling capabilities. Drilling begins vertically, but the drill bit can be turned so that drilling can continue at an angle of up to 90°. This technique extends the drill’s reach, enabling it to reach separate pockets of oil or gas. Extracting Oil And Gas Once the drilling reaches the oil or gas reserve, extraction can begin as the natural pressure forces the oil or gas up

is controlled by the Uranium Corporation of India Ltd (UCIL), which has operations in Jaduguda, Bhatin, Narwapahar, Turamdih and Domiasiat mines. The company has OIL & GAS uranium recovery plants at Rakha, The oil & gas extraction produces the Surda and Mosaboni. UCIL is poised petroleum and natural gas that are to develop what has been identified as extensivley used as fuel. They are also one of the world’s highest grade nearthe raw materials for plastics, chemicals, surface ore bodies situated at Domiasiat medicines, fertilisers and synthetic in the West Khasi Hills. Domiasat fibers. Decaying plants & animals has reserves estimated to contain as become trapped under impermeable much as 10,000 tonne of uranium. rocks for millions of years under Studies by the Uranium Institute extreme heat & pressure, preventing estimate that India produces nearly their dispersal. This creates a pocket of 200 tonne of uranium per year. The oil. Similar processes produce natural uranium ore mining and processing gas, which can be found mixed with industry of the country began at oil or in separate deposits. Finding Jaduguda in 1968. It has demonstrated and extracting the oil & gas in these impressive growth during these years pockets is the primary function of this with four operating mines and meeting industry segment. the entire nuclear fuel requirement of Preparations Before Extraction the country. The country Small crews of specialised Seismic prospecting—a technique based on measuring the now has a definite plan workers search for geologic time that sound waves take to travel through underground for multi-phase expansion formations, on land and formations and return to the surface—has revolutionised oil of the nuclear power at sea, which are likely & gas exploration. programme, with selfto contain oil or gas. through the drill hole to the wellhead, reliance in raw materials being the Sophisticated equipment and advances where it enters separation and storage basic drive. The uranium mining in computer technology have increased tanks. If the natural pressure is not industry is fully geared up to meet the productivity of exploration. great enough to force the oil to the the challenge of uranium fuel demand Maps of potential deposits now are surface, pumps may be used. In by undertaking uranium mining made using remote-sensing satellites. some cases, water, steam or gas may and processing activities. Several new Seismic prospecting—a technique be injected into the oil deposit to uranium ore-mining projects are in based on measuring the time that improve recovery. The recovered oil is the pipeline. The technologies of sound waves take to travel through transported to refineries by pipelines, mining, processing and tailings’ underground formations and return ships, barges, trucks or railroad. disposal have also undergone to the surface—has revolutionised oil Natural gas is usually transported to improvement by following global & gas exploration. Computers and processing plants by pipeline. While oil advancements in these fields. advanced software analyse seismic data refineries may be many thousands of provide three-dimensional models of miles away from the producing fields, sub-surface rock formations. Another WHAT THE FUTURE HOLDS gas processing plants typically are near method of searching for oil & gas is It will not be an exaggeration to say that the fields, so that impurities such as based on collecting and analysing core fuels are indispensable for the economy water, sulphur and natural gas liquids samples of rock, clay and sand in the of all nations. However, the extensive can be removed before the gas is piped earth’s layers. usage of fossil fuels has placed the to customers. The oil refining industry Processes Involved In Extraction environment in a state of compromise. is considered a separate industry, and After scientific exploration studies Therefore, we need to review our its activities are not covered here, even indicate the possible presence of oil, a legislation and develop renewable though many oil companies extract as well must be drilled to prove the same. resources as alternatives. However, until well as refine oil. A well site is selected and a derrick—a the time it happens, we will have to tower-like steel structure—is installed continue to use fossil fuels. to support the drilling equipment. A URANIUM hole is drilled deep into the earth until The country’s uranium production prateek.sur@network18publishing.com

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INDIAN COAL SCENARIO OVERVIEW

India stands 8th in terms of total world coal resources, 4th in identiﬁed reserves and 3rd in terms of annual coal production. As assessed by the Planning Commission, the demand for coal during 2010–11 was 572 Mt. The demand for power, steel and cement in a developing country is closely related to its economic growth, as steel and cement production depends on coal. It is very important to provide coal of adequate quantity & quality to power, steel and cement sectors. Therefore, coal mining becomes very important for a country’s development. Here, we present an overview of coal mining in India. he major coalfields of India are mainly distributed along the river valleys of Damodar, Sone & Mahanadi, Pench & Kanhan and Wardha & Godavari rivers. Peninsular India has 69 major coalfields, while the Northeastern region has 17. The bulk of the coal reserves are confined to the South-eastern quadrant of the country, i.e., in the states of West Bengal, Jharkhand, Orissa, Chhattisgarh and Madhya Pradesh. The Geological Survey of India has estimated the coal reserves of the

country at 285.8 billion tonne (Bt)–up to the depth of 1,200 m, as on March 31, 2011. Of the 285.8 Bt, ‘prime’ coking coal reserves comprise of 5.3 Bt, while medium & semi-coking coal reserves and non-coking coal reserves comprise of 28 Bt and 250.8 Bt, respectively. Most of these resources occur in the Gondwana rocks and the balance in the tertiary formations. The present lignite reserves in the country have been estimated at around 39.7 Bt, most of which occur in Tamil Nadu. Other states where lignite deposits have been located include Rajasthan, Gujarat, Kerala, Jammu &

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Kashmir and the Union Territory of Pondicherry. Indian coal has high mineral content (ash) unlike Pennsylvanian and Carboniferous coal of America and Europe, respectively. The Jharia coalfield is the main source of prime coking coal for India, while superior grade non-coking coal reserves are generally available in Raniganj coalfields of West Bengal, Central India coalfields of Madhya Pradesh and Talcher coalfields of Orissa.

COAL RESOURCES At the time of Independence in

INDIAN COAL SCENARIO OVERVIEW

Image by Coal producing Piparwar mine

Deposit characteristics widely vary from coalfield to coalfield. In some areas like Jharia and Raniganj coalfields, high concentration of superimposed seams (sometimes as high as 40 in number) pose great challenges to mining operations. The presence of a large number of thick seams, though a blessing for opencast mining, is a major problem for underground mining. Moreover, steeply inclined seams have only marginal reserves. Then, there are geological inconsistencies, like faults, folds, washouts, etc., that tend to reduce the mining potential of the coal deposits. Intrusions such as dykes & sills often lead to operational problems and quality deterioration.

1947, the coal mining operation was primarily in the private sector and the total coal production in the country was nearly 30 million tonne (Mt) per year. It remained primarily in the private sector up to 1971–73 and the production had reached nearly 72 Mt per year only. From 1972–73, the government nationalised the entire coal industry and then made massive investments in the sector. As a result, India now ranks as the third largest coal producer of the world, next only to China and the US. In India, the mining depths of the coalfields are quite shallow, barring a few mines in Jharia and Raniganj coalfields. About 87% of the coal resources of the country lie within the depth range of 600 m. It is expected that the total amount of the coal reserves will improve considerably if we increase the depth of exploration.

The government is removing controls on industry & trade and is reducing the tariff on import. It is also permitting private investment and is allowing majority shareholding by private/foreign sources in PSUs. Nearly all Indian coal seams are prone to spontaneous heating. The incubation period varies from two to 12 months. However, compared to the other parts of the world, the coal seams in India produce less gas emission.

COAL INDUSTRY IN INDIA Coal India Ltd (CIL) is the largest Public Sector Undertaking (PSU). It has eight subsidiaries, viz., Bharat Coking Coal Ltd, Central Coalfields Ltd, Eastern Coalfields Ltd, Western Coalfields Ltd, South Eastern Coalfields Ltd, Northern Coalfields Ltd, Mahanadi Coalfields Ltd, and Central Mine Planning & Design Institute Ltd. The Singareni Collieries Co Ltd (SCCL) is a coal-mining company jointly owned by the Government of Andhra Pradesh and the Government of India. The Singareni coal reserves stretch across 350 km of the PranhitaGodavari Valley of Andhra Pradesh with proven geological reserves of 8,791

Mt. SCCL is currently operating 13 opencast and 37 underground mines in Andhra Pradesh. The Coal Mines (Nationalisation) Act, 1973, was amended with effect from June 9, 1993, to allow coal mining by both private and public-sector companies for captive consumption for the production of iron & steel, power generation, coal washing and other such end uses, which would be notified by the government from time to time. Cement production has also been allowed as an end use with effect from March 5, 1996, for captive mining. However, the restriction of captive mining does not apply to the state-owned coal/mineral development undertakings, like CIL, SCCL, Neyveli Lignite Corporation (NLC), etc., and the Mineral Development Corporations of the various State Governments.

COAL PRODUCTION Coal production achieved in the country during 2010–11 was 533.07 Mt, while it was 523.16 Mt during 2009–10, showing a CAGR of 1.91%. About 80.86% of the total coal production in the country comes from the collieries of CIL. CIL is also the biggest supplier of coal in the country as indicated in Table 1. Table 1: Anticipated Coal Production — 2012–13 (In Million Tonne) Name of the Coal Company Production CIL 570 SCCL 58 Others 125 Total 753

COAL PRODUCTION BASED ON TECHNOLOGY Both opencast and underground mining are prevalent in India. In 2009–10, opencast mine production grew by 5.54% to reach 457 Mt. In the case of underground mines, the production was 58.60 Mt in 2009–10

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INDIAN COAL SCENARIO OVERVIEW

Table 2: Production of Coal and Its Share by Type of Mining Type of Mining Opencast Underground Total Production Production 433.7 58.97 492.75 2008–09 Share (%) 88.03% 11.89% 100% Production 457 58.60 515.6 2009–10 Share (%) 88.63% 11.37% 100% Growth (%) as shown in Table 2.

PRIVATE COAL MINING IN INDIA The government’s strategy to allow coal mining by stand-alone companies that have tie-ups with steel, cement and power companies for coal supplies will become operational in the coming months. Coal Ministry and Law Ministry officials confirmed that those mining companies that have supply contracts with authorised users, viz., steel, cement & power companies can have mining rights to the coal blocks reserved for confined users, even without amending the Coal Mines (Nationalisation) Act, 1973. The move will give a further push to coal production and will play a pivotal role in meeting the country’s future demand.

5.54%

-0.5%

generation, coal preparation (washing) and production of iron, steel & cement. The government has already appointed a Screening Committee under the Ministry of Coal to allocate identified coal blocks for captive mining to the above categories. Hundred blocks have already been identified, and several companies given permission to operate such blocks. Apart from these, there are numerous investment opportunities in the transfer of new technology, manufacture of equipment/spares, construction of road (both approach and arterial) in coalfields, building raillines, major repair workshops/spares depots, environmental protection,

AREAS OF INTEREST FOR INDIAN COAL MINING COMPANIES Powered support Longwall/shortwall Continuous miners in room and pillar system Roof bolting systems Application of light bolting machines in bord and pillar development galleries Mechanised depillaring of coal seams developed on bord and pillar system Prediction of strata behaviour in the extraction of the developed pillars by caving method Design of roof support to permit mechanised depillaring Use of road haul dumper,

Table 3: COAL PROJECTS [in ` Crore (€ Million)] (Approximate Figures) Particular

BE 2009–10

RE 2009–10

BE 2010–11

Coal Sector Projects under Implementation

INVESTMENT OPPORTUNITIES PSUs have dominated the coal production in the country since 1973– 74. However, with the opening up of the economy since 1991, the scenario has significantly changed. This is because huge investments are required to meet the increasing demand for coal by power & other industries. The government is looking at the private sector to fill the gap. The government is removing controls on industry & trade, reducing the tariff on import and allowing private investment and is even allowing majority shareholding by private/ foreign sources in the PSUs. The Coal Mines (Nationalisation) Act, 1973, has also been amended to allow privatesector participation in coal mining as captive mines for companies engaged in opening new units for power

4.67%

joint ventures for opening new mines, for leasing of equipment, ancillary & infrastructure developments, in auxiliary industries and in the development of ports & for handling imported coal.

Minell Expansion

320.77(49.34) 323.57(49.78) 224.11(34.47)

Barsingsar Mine

50(7.69)

27.71(4.26)

37.73(5.8)

Project under Formulation Mine lll AAP

0.05(0.007)

0.01(0.0015)

0.02(0.0030)

Jayamkondam Mine AAP

83.90(12.90)

0.47(0.072)

0.23(0.035)

Bithnok Mines Project AAP

0.50(0.0769)

0.05(00.769)

0.18(0.027)

0.24(0.036)

0.16(0.024)

0.18(0.027)

Hadla Mine project

Palana Lignite Mines AAP Gujarat Mines AAP

0.35(0.053)

0.02(0.0030)

0.03(0.0046)

8.10(1.24)

0.01(0.0015)

0.37(0.0569)

1.00(0.1538)

3.63(0.5584)

5.50(0.8461)

1.35(0.20)

0.00

Science & Technology

3.00(0.461)

0.72(0.11)

2.85(0.438)

Geological Investigation

3.81(0.586)

6.15(0.94)

4.80(0.73)

Other Completed projects

51.79(7.69)

23.39(3.59)

36.57(5.62)

Expansion for existing mine l & lA AAP Talabira ll & lll AAP Riri Mine

Total

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524.09(80.44) 386.89(60.11) 312.57(48.06)

INDIAN COAL SCENARIO OVERVIEW

Nearly all Indian coal seams are prone to spontaneous heating. The incubation period varies from two to 12 months. However, compared to the other parts of the world, the coal seams in India produce less gas emission.

coal; upgradation of coal needed for power plants Improved hydraulic stowing techniques using river sand, crushed overburden, fly ash and other locally available materials.

NEW COAL PROJECTS IN INDIA continuous miner Application of mobile-powered supports (crawler mounted) in depillaring by caving method Road headers Coal conveyor systems Simple and cost-effective transport system for men and material in inclined roadways Ventilation system in mines Coal-handling arrangements High-speed loading equipment Advanced geological exploration techniques to prove faults with small throw (less than 5 m); in-depth range of 20–300 m Communication system in underground mines Application of information technology in mining activities Simple methods for beneficiation of

Lanco Infratech Ltd is setting up a 1,320 MW coal-based power unit PNC Infratech Ltd to set up 660 MW coal-based power unit Bharat Coking Coal Ltd is setting up a 2.5-Mt per annum coal washery at Dugda Maharastra State Power Generation Co Ltd to set up a 1,320-MW coal-based power unit on PPP basis Era Infra Engineering Ltd plans to set up a 2,640-MW coal-based power unit at Rajauli CIL offers 447 Mt of coal to power utilities. More projects have been displayed in Tables 3 and 4.

REGULATORY FRAMEWORK OF COAL INDUSTRY IN INDIA The coal industry in India is regulated

Table 4: New Mines Planned by SCCL in 12th Plan, 2012–17 Mine

Year of Opening

Capacity (LT)

Adriyala

2011–12

28.1

JVROC-2

2012–13

40.0

RKPOC-I

2013–14

25.0

Abbapur OC

2013–14

6.0

Kistaram OC

2014–15

20.0

Jallaram OC

2014–15

22.8

Jangedu UG

2014–15

8.0

Khairagura UG

2014–15

10.0

Kasipet – 2 UG

2014–15

5.4

KK6&7

2014–15

8.0

KKOC

2016–17

17.5

IKOC

2016–17

12.0

Mahadevapur OC

2016–17

10.0

Peddapur

2016–17

10.0

KTK-9 UG

2016–17

27.0

Reconstruction of existing UG mines

2012–13

3.0

largely by the following provisions: The Coal Mines (Nationalisation) Act, 1973 to nationalise the coal sector Mines & Minerals (Development & Regulation) Act, 1957 to regulate exploration and exploitation of minerals The Coal Bearing Area (Acquisition & Development) Act, 1957 to facilitate acquisition of coal bearing land Environmental Protection Act, 1986 to conduct mining operations in an environment-friendly manner.

LIBERALISATION OF POLICY REGIME The main thrust of the liberalisation policy is to open up the statutory and regulatory regimes in order to promote Table 5: FDI in Mining Sector Year FDI in FDI in (April– ` Crore € Million March) 2008–09 161.09 24.78 2009–10 829.92 127.68 2010–11 357.42 54.98 2011–12 436.61 67.17 Total 1,785.04 274.61 investment in the coal sector. Table 5 indicates the FDI inflow in the sector. The recent policy initiatives have been in the following direction: Captive mining by power, steel and cement industry allowed FDI allowed up to 100% in power and coal mining sectors Creating a competitive market for selling coal Progressive reduction of customs duty on coal and heavy earthmoving machinery imports Introduction of contract mining. Rajesh Nath, MD, VDMA India; Dipanjan Paul, Business Analyst, VDMA India. With inputs from Coal Directory of India, Ministry of Coal Annual Report, Report on the Overview of Coal Mining Sector in India— VDMA and SCCL & CIL websites. E-mail: vdmaindia@eth.net

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URANIUM MINING

PRATEEK SUR

holds the potential for commercial he outstanding uranium mining operations. Thus, growth of the Jaduguda in Singhbhum Thrust Indian economy Belt (also known as Singhbhum during the last Copper Belt or Singhbhum Shear decade has led Zone) was the first uranium to a significant rise in the deposit to be discovered in the demand for energy resources. country in 1951. It is a zone Of all the available options of intense shearing and of possible energy sources deep tectonisation with less for making the energy supply than 1 km width and is known secure and robust, nuclear for a number of copper deposits power has acquired a special with associated nickel, molybdenum, place. Therefore, India has bismuth, gold, silver, etc. It extends started working on developing its in the shape of an arc for a length of nuclear programme soon after attaining about 160 km. independence. India’s three-stage This discovery of uranium paved Atomic Energy Programme is based the way for intensive on robust and commercially exploration work in the successful Pressurised Heavy With the formation of Atomic Energy Commission in whole country and soon a few Water Reactors (PHWRs), 1948, India made a humble beginning of its inspiring more deposits, like Bhatin, operated by indigenous Atomic Energy Programme. Consequent to this Narwapahar and Turamdih, natural uranium. The recent development, it was felt that the country must have were brought to light in this developments in international indigenous resources of basic raw materials, such as area. Other deposits like civil nuclear co-operation uranium, thorium, etc. As a result, Rare Metal Survey Bagjata, Banduhurang and have provided India great Unit (later renamed as ‘Atomic Minerals Directorate Mohuldih are being taken opportunities for enhancing for Exploration and Research’) was formed by the up for commercial mining its nuclear power capacity Government of India to locate good uranium deposits operations. Some of the through the import of fuel. in the country. During that period, the emphasis other areas like Garadih, However, to safeguard the of search was on the existing mineral belts and Kanyaluka, Nimdih and country’s Atomic Energy geologically favourable areas of the country. Nandup in this belt are also Programme, the ideal path known to contain limited for generating nuclear of the country and go a long way in uranium reserves with poor grades. power should be through the use easing the uranium supply situation. Apart from discoveries in the of indigenous uranium. Uranium However, some of the uranium mines Singhbhum Thrust Belt, several Corporation of India Ltd (UCIL), a under operation (in Jharkhand) for the uranium occurrences have also been Central Government-owned public last four decades are depleting, thereby found in Cuddapah basin of Andhra sector undertaking, has the mandate generating concerns about future Pradesh. These include Lambapurto mine and process uranium ores in supply and sustained production. Peddagattu, Chitrial, Koppunuru, India to meet the fuel requirement Tummalapalle, Rachakuntapalle. In of PHWRs. Over the years, UCIL the Mahadek basin of Meghalaya, has marched towards maximising INDIA’S URANIUM DEPOSITS sandstone-type uranium deposits like the production of uranium. Many Association of uranium with copper Domiasiat, Wahkhyn and Mawsynram operating units have been expanded and gold was already known in some provide near-surface flat ore bodies & new facilities have been built for parts of the world. Based on this amenable to commercial operations. maintaining an uninterrupted supply analogy, known copper and gold Some areas in Rajasthan, Karnataka of fuel. Some projects of critical reserves of the country were extensively and Chhattisgarh also hold the promise importance for augmenting the investigated. The pioneering work of holding some major deposits. uranium production are in different brought to light many uranium stages of implementation. Their occurrences in Singhbhum Thrust Belt successful completion shall create newer (in Jharkhand, formerly part of Bihar) URANIUM MINING OVER THE YEARS... benchmarks for the uranium industry and it became evident that this belt The uranium mining in India made an

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URANIUM MINING

exciting beginning with the formation of UCIL in 1967 under the Department of Atomic Energy. Since then, the uranium industry of the country has recorded phenomenal growth in the production and upgradation of technology. UCIL launched its operation with the commissioning of an underground mine and oreprocessing plant at Jaduguda (1968). Subsequently, underground mines at Bhatin (1987), Narwapahar (1995) and Turamdih (2003) were commissioned. All these units are within 25 km of Jaduguda. Keeping in view the nationâ&#x20AC;&#x2122;s endeavour to expand its nuclear energy infrastructure (20,000 MWe by 2020 from the present capacity of 2,770 MWe), new uranium mines are being opened by UCIL not only in the Singhbhum Thrust Belt, but also in other parts of the country.

URANIUM ORE PROCESSING IN INDIA The processing of uranium ore is an integral part of the uranium mining industry. Therefore, the upsurge in mining activity has necessitated the expansion of the existing plants and construction of more new oreprocessing plants. Some examples of such plants are an operating plant at Jaduguda, new plants at Turamdih, Seripalli & Domiasiat and a prospective plant at Tummalapalle.

CHALLENGES Uranium deposits in India are generally small, lean in tenor and complex in nature of mineralisation. With the globalisation of the Indian economy, it has become imperative to develop these deposits in a cost-effective and eco-friendly manner assimilating the worldwide developments in science and technology. To meet the timely requirement of uranium, the construction activities need to be accelerated. Increasing ore production from new mines calls for some innovative approaches for physical beneficiation of valuable uranium-

bearing minerals, which will reduce the volume of ore transportation and processing. The plants with a shorter processing route need to incorporate measures to maximise the re-use of water, high recovery of the product and minimum discharge of effluents. In the field of tailings management, longterm stability of tailings restricting the movement of contaminants, the need to strengthen the embankment system, maximum reuse of effluents and reclamation of the existing ponds are some of the challenging areas for continuous research and improvement. Rapid progress has been made in some of these areas by absorbing technology through fundamental transformations.

Some important uranium mines in India Operating mines in Jaduguda, Bhatin, Narwapahar and Turamdih mines New mines in Jharkhand at Banduhurang, Bagjata and Mohuldih New mines in Andhra Pradesh at Lambapur-Peddagattu New mines in Meghalaya at Domiasiat Prospective mines at Tummalapalle uranium deposit and Rohili uranium deposit

NEW DEVELOPMENTS Using integrated software (for survey, geology and mine planning) helps in quickly establishing the configuration of ore body and assessing the potential of the deposit. Standard modules of mine layout have been developed with minor variations to accommodate the sitespecific geology. Similarly, standard modules and parameters for different processing activities are in place for implementation with site-specific modifications. This has considerably cut downtime in planning, awarding contracts for construction, drawing up specifications for equipment and procurement. Uniformity in procedures for different studies like environmental

assessment, feasibility, detailed project report, etc., has helped in reducing the pre-project period. Standardisation of the layout and equipment has brought in significant cost advantage in the field of maintenance management and inventory control. Mining in India has come a long way from conventional operations to trackless mining, progressively emulating and absorbing global technologies. In the existing mines, pneumatic equipment is systematically being phased out with the introduction of more energy-efficient electrohydraulic and dieselâ&#x20AC;&#x201C;hydraulic equipment. New mines are being planned with provisions to automate all strenuous mining activities avoiding direct handling of radioactive ore at every stage of operation. Underground ventilation system, strata control measures, etc., are being simulated before field trial and implementation. The bulk ore assaying system with automatic grade estimation is undergoing continuous improvement. The countryâ&#x20AC;&#x2122;s dedicated mining research institutes have identified some of the thrust areas like cutting technology in place of conventional drilling & blasting, use of electronic detonators, environmentfriendly explosives, etc., for future development. Keeping in view the worldwide technological progress in ore processing, some major strides have been taken towards absorbing expertise and adapting cutting-edge technology through radical innovations. A number of steps have already been taken to implement the precipitation of uranium peroxide (UO4.2H2O) using hydrogen peroxide in place of magnesium diuranate (MgU2O7). This will prevent co-precipitation of other metals, ensure higher purity in product and control many environmentrelated problems. New plants with simpler and shorter processing routes are being envisaged. Use of modern, energy-saving & efficient equipment and concept of central control room

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URANIUM MINING

are expected to be some of the distinctive features of new plants. Resolving the process know-how for alkaline leaching is the emerging area for further research and development, which can make the huge resource of Tummalapalle area exploitable. A dedicated state-of-the-art facility has been created at Jaduguda to pursue rigorous laboratory investigation/pilot plant studies in line with the above requirements. The research institutes of the country are also actively participating in time-specific projects for finding breakthroughs in uranium mineral beneficiation, bio-leaching, bio-beneficiation, etc.

MANAGING THE URANIUM TAILINGS Uranium tailings management has attracted the interest of public and regulatory bodies of the country resulting in wide-ranging research and development on the subject. The new tailing ponds are being developed with sound embankment system and

impermeable artificial liner to prevent any seepage of effluent. Various laboratory studies are being conducted to implement Thickened Tailings Disposal (TTD) system at Seripalli. Remediation of the existing tailings ponds at Jaduguda is being taken up on priority. Ecorestoration with suitable soil capping and vegetation are being addressed by various premier research institutes. Efficacy of microbial leaching of tailings and microbial modifiers are also being looked into. Leaching characteristics of the tailings under different physicochemical environment, studies pertaining to the migration of contaminants into the adjoining environment, modification in tailings texture for minimising dispersal of radon are some of the critical areas for research in new tailings ponds of the country.

SCOPE FOR EXPANSION Attaining self-reliance in the energy resources is the first priority of the

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countryâ&#x20AC;&#x2122;s nuclear power programme. The government is committed to increase the contribution of nuclear power to the total power generation capacity of the country. Accordingly, the Department of Atomic Energy has strategically designed the countryâ&#x20AC;&#x2122;s nuclear power programme. The uranium industry of India has shown an extraordinary uptrend during the last decade. The industry is expected to expand further, keeping with the phenomenal growth in the nuclear power generation. Apart from supplying the raw material for nuclear fuel, the uranium mining industry of India has a great potential to contribute towards the development of infrastructure, mining technology and employment generation. prateek.sur@network18publishing.com With inputs from Ramendra Gupta, Chairman & MD, Uranium Corporation of India Ltd and AK Sarangi, Superintendent (Geology), Uranium Corporation of India Ltd

OVERVIEWING SOME MAJOR MINERAL ORES

Minerals: The Essential Elements of Growth The metallic and non-metallic ores, such as iron, copper, gold, platinum, magnesium, limestone, bauxite, lead, gypsum, opal and zinc are used in many industrial purposes. Gold and platinum are primarily used in jewellery and high-end electronics, iron is used to produce steel, copper is the main component of electrical wiring, lead is used in batteries and zinc is used to coat iron & steel to reduce corrosion and as an alloy to make bronze & brass, and so on. Let us get an overview of their mining processes, uses, etc., of some such minerals. PRATEEK SUR

etals usually do not occur in pure concentrated form, but in small traces in rocks called ‘ores’. Indistinguishable from regular rocks to the untrained eye, some ores contain only a fraction of metal. As a result, a massive amount of rock must be extracted from the ground in order to obtain a usable amount of metal. As a result of this, and because metal & non-metal ores are less common than the fuels like

coal, uranium and oil & gas, metal & non-metal mines can be much larger than coal mines and operate in more extreme environments. For example, while coal mines are rarely more than a few hundred feet underground, gold mines can be over a mile below the surface. Like coal and uranium ores, metal ores are mined in both surface and underground mines, depending on where the ore deposit is located. In addition to strip mining, surface ore

mines also use the open-pit mining technique. These mines are huge holes in the ground that are mined by blasting rock from the sides and bottom with explosives, carrying out the debris in trucks, and then repeating the process. Open-pit mines can be dug hundreds of feet deep and several miles wide. Underground mining is less common, and is used only when rich veins of ore are discovered or mineral prices are high enough to justify the added expense.

Platinum Platinum is a very rare mineral and its cost is double that of gold. It is usually found in igneous rocks, which have iron and magnesium also. It is also found in thin layers with minerals like copper and gold. It is mined through both surface and underground mining. Some platinum is also mined through placer mining. Earlier, platinum was considered as inferior to silver and used to be discarded. As it is usually found in gold mines, platinum is also known as ‘white gold’. In the US, it is usually mined along with copper and gold. The major platinummining countries are South Africa, Russia, Columbia, the US and Canada.

USES Platinum is used to manufacture surgical instruments, chemical equipment, jewellery and catalytic converters for cars. It can be moulded into any shape, and, hence, it is used

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in wires and items that have to be bent.

METHODS OF MINING Platinum Group Metals (PGMs) are extracted by narrow reef method, where hand-held pneumatic drills are used to make holes in the reef. The ore-released blasting is taken out with the help of scrapers attached to wenches and transported to the surface. The most popular mining methods are new mechanical and hybrid mining. One mining procedure consists of drilling either by pneumatic drills/newer specialised drilling equipment and then cleaning the ore from the mine using low-profile vehicles known as Load Haul Dump (LHD). Large amounts of platinum are obtained from the mines located in the Far East Russia and the Norilsk–Talnakh mine, using open-pit, strip and underground mining procedures. In Zimbabwe, platinum

OVERVIEWING SOME MAJOR MINERAL ORES

was found in 1925 near Great Dyke.

TOP PLATINUM PRODUCERS South Africa is the world’s largest producer, where platinum is mined from Bushveld Igneous Complex—a large igneous

intrusion spread in area of 370 km. It was estimated that this massive ore deposit was formed 2,000 years ago. Here, the PGMs are discovered in three distinct layers known as reefs and the main source is the Merensky Reef, first opened in 1925.

Magnesium Magnesium is the third most used metal, followed by iron and aluminium. Magnesium derives its name from ‘magnesite’, a magnesium carbonate mineral. The British chemist Humphry Davy isolated magnesium in 1808 by electrolysing damp magnesium sulphate, using mercury as a cathode. The first industrialised production of magnesium began in Germany in 1886 by Aluminum und Magnesium fabrik in Hemelingen, Germany. Aluminum und Magnesium fabrik later became the constituent of the chemical industry conglomerate IG Farbenindustrie, which, during 1920s and 1930s, invented a process for manufacturing huge quantities of molten and fundamentally water-free magnesium chloride, now called the ‘IG Farben process’.

MINING AND CONCENTRATING Both dolomite and magnesite are hauled out and concentrated

by conservative methods. Carnallite ore is taken out and is separated from other salt amalgams by solution mining. Another excellent example of naturally occurring magnesium ore is brines that occur in the ocean and large ponds by solar radiation.

EXTRACTION AND REFINING Magnesium is a powerful chemical reagent and reacts readily with both oxygen and chlorine. This means that to extract the metal from its ores is an exhaustive procedure and requires high-end technologies. Commercial production of magnesium uses two completely dissimilar methods: electrolysis of magnesium chloride and thermal reduction of magnesium oxide. Electrolysis is a cheaper means of production, and, it accounts for nearly 75% of the world magnesium production.

Opal Opal has been a mystery for centuries. No two opals look alike. The word opal was derived from the Greek word opallos, which means ‘to see changes of colour’. Opal is a precious gemstone, which is formed from non-crystalline silica gel. It consists of 6–10% water. The small silica spheres in opal are arranged in a regular pattern. It generally measures 5.5–6.5 on MOH’s hardness scale, with pearls measuring 4–5 and diamonds 9–10.

DEPOSITS Australia accounts for nearly 95% of the world’s reserve of opal. A small quantity is also found in Mexico, Brazil and the US. In Australia, the major opal-deposit regions are New South Wales, South Australia and Queensland. Lightning Ridge, New South Wales, is famous for its glorious black opal, where it was first discovered in the late 1880s. White Cliffs is Australia’s oldest commercial opal

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OVERVIEWING SOME MAJOR MINERAL ORES

field, first mined here in 1889. For nearly 30 years, White Cliff opal fields produced opal for the world market. Opal mines are concentrated in Yowah, Quilpie, Eromanga and Jundah regions of Australia. Coober Pedy is famous for white or milky opals. Andamooka is one of Australia’s most famous opal fields, having produced some of the most beautiful pieces of opal. The opal fields in and around Andamooka produce top gem, crystal, light opal and some dark opal.

METHODS OF MINING Opal usually occurs in both sedimentary and volcanic rocks. There are various methods of opal mining. Sink a shaft: The simplest form of opal mining is by sinking a shaft with a pick and shovel. A shaft is sunk straight down until some promising ‘opal dirt’ is discovered. The shaft’s length could be as short as 3 m or as long as 20 m. As opals are usually frail, it is extracted with the help of a handpick or screwdriver.

Open-cut mining: The open-cut method involves using heavy machinery to remove large amounts of opal dirt for inspection. This method is more expensive and is mostly used to search for boulder opal in Central Queensland, Australia. Noodling: It is the practice of sifting through rejected mullock heaps for small pieces of opal inadvertently discarded by miners. Many people, living near the opal fields, rely on noodling to earn a living. They usually sift through the waste by hand, using a rake and sieve. Some have also taken to large-scale machine noodling, by making large amounts of opal dirt move on a conveyer belt under ultra-violet light, which helps in easy detection of the precious opal. Puddling and rumbling: A puddler is a large mesh-lined drum attached to a motor. This device rotates and turns the clay into sludge as water is pumped into the drum. The sludge escapes through the mesh. A related technique is dry rumbling.

Gold USES Gold has been widely used throughout the world as a vehicle for monetary exchange. It is used extensivley to make jewellery. However, as pure gold is soft, it is usually alloyed with base metals before being used in jewellery. Gold also finds usage in medicine.

MINING Earlier, gold used to be mined using different methods like panning, cradling, dry blowing, shaft mining, puddling and dredging. It was very difficult to find gold in those days, as there was no proper mining equipment. Discovering gold was more a matter of luck than good judgment. Nowadays, open-cut mining and underground methods are generally used to mine gold. Panning: It is one of the oldest techniques for separating gold from rock. It was introduced by Isaac Humphrey at Coloma in 1848. The Mexicans also developed their own panning technique, using a flat dish called batea. Panning is a very slow process, even for the most skillful miners. In a single day, one miner can wash only 50 pans in a 12-hour workday and obtain only a small amount of gold dust. Rocky material is loosened with pick and shovel. Then, the material is carefully washed & swished around a shallow metal pan. As the water separated the particles of dirt, rocks and pebbles, small deposits of gold sink to the bottom of the

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pan. This yields only small nuggets. Cradle (Rocker): This method was introduced by Isaac Humphrey. Cradling involves a wooden box with a handle on one side and a ridged bottom covered with Hessian cloth. Large pieces of rock were sorted through and discarded if they did not yield any gold. Finer rocks & pebbles are washed with water. This method is more successful than panning as greater amounts of gravel and dirt can be examined. Dry blowing: This method is not very effective. It was adopted in some regions like Kalgoorli in Western Australia. Two pans were used for dry blowing. Fine, dust-like material was poured from a pan that was held high, into the second pan positioned on the ground. As the material was poured down, the wind blew away the dust and fine particles of rock, while the tiny nuggets of gold fell into the pan below. While the method was sound in theory, the winds meant that tiny particles of gold could also be blown away along with the rest of the dust and dirt. Shaft mining: It is one of the popular methods for gold mining. Here, miners dug a shaft up to 50 m deep. This method is only adopted when a prospector is confident that there is enough gold in a particular place. Puddling: Here, small amounts of clay are dumped in a large container filled with water. On being stirred with wooden stake, clay dissolves and gold particles sink to the

OVERVIEWING SOME MAJOR MINERAL ORES

bottom. However, this method does not yield much gold. Dredging: Here, a huge bucket is placed in front of the dredge that will scoop vast amounts of sediment from the riverbed. The sediment is then carefully sifted and sorted. for gold. Open-cut mining: In this method, rocks that are on surface are removed. The mine is thus excavated in a series of layers, known as ‘benches’. Benches allow trucks and other large vehicles to enter the site and allow drilling & ore sampling at different levels. The rocks that are removed with the help of machines are crushed and sifted through for gold. This method is very profitable as the removed rocks will at least have 3–4 grams of gold per tonne. However, mining companies must take proper safety measures at regular intervals to reduce the risk of rock falls in the mine.

Underground mining: Underground mining is used to mine gold found below the surface. This method is very costly and also dangerous. Here, a shaft is sunk into the ground that could be 1,000 m deep. Horizontal tunnels, known as ‘stopes’, are dug at various depths and the miners work along these to access the gold. Vehicles access the various levels of the mine through a spiral tunnel called ‘decline’. As mineshafts become deeper, the risk of caveins or collapses increases. Therefore, underground mines must operate under strict safety protocols regarding the way the mineshafts are dug & constructed, the methods of support for the walls & ceiling of the mine and the use of special machines to provide adequate ventilation & lighting.

Zinc Zinc is found in igneous and metamorphic rocks. Some important ores of zinc are sphalerite, franklinite, willemite, zincite, smithsonite, hemimorphite and hydrozincite. Some of these ores are fluorescent.

USES Zinc is used in paints, for coating steel, automotive parts, electrical fuses, batteries, roof gutters, pennies, rubber, deodorant, etc. An important use of zinc is in the galvanising process.

MINING Zinc ore is mined using underground and surface mining or a combination of both. After the ore is mined, flash smelting is performed where the ore is heated to make zinc oxide. The zinc ends up as powder. Zinc ore is chiefly mined in China, Australia, Peru, Canada and the US (Alaska, Tennessee and Missouri).

MEANWHILE, IN INDIA... India is a major zinc producer. Most of these deposits are located in Rajasthan, and are being developed by Hindustan Zinc Ltd—the country’s largest zinc producer. The company presently operates seven mines and fours smelters spread across Rajasthan, Andhra Pradesh, Bihar and Orissa.

Lead/Galena Galena (PbS2) is the main ore of lead and silver. Galena is found combined with zinc, copper and silver. Sometimes, it also occurs as a byproduct of the mining of the other minerals. Lead is obtained on melting the ore. Galena is found in igneous and sedimentary rocks.

Oklahoma and Missouri), Germany, Peru, Mexico, Zambia and England.

USES Lead is used in the manufacture of bullets, batteries, gasoline, and welding solder. It was earlier used in paints, dishes and cups until it was found that it was poisonous.

MINING Galena is extracted through underground mining. The major zinc-producing countries are the US (Texas,

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MEANWHILE, IN INDIA... Domestic demand for lead is about 1,70,000 tonne/

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OVERVIEWING SOME MAJOR MINERAL ORES

year. The total primary smelting capacity in the country is 89,000 tonne/year, consisting of 65,000 tonne/year (HZL) and 24,000 tonne/year (Indian Lead Ltd). HZL’s smelters are located at Chanderiya, Rajasthan (capacity: 35,000 tonne/year) and Visakhapatnam, Andhra Pradesh (capacity: 22,000 tonne/year). However, the Tundoo smelter (capacity: 8,000 tonne/year), which also produces silver, has been shut down as it was faring very poorly. The smelter at Visakhapatnam has also been closed for some time because of environmental concerns by the Andhra Pradesh

Government. Visakhapatnam was a loss-making unit and the costs of installing environment-friendly equipment would be prohibitive. HZL is in the middle of raising its annual lead-smelting capacity by 50,000 tonne. Indian Lead Ltd has two units, one in Kolkata and the other at Thane, near Mumbai, each with a capacity of 12,000 tonne/year. Both units treat imported concentrates. Binani Industries possesses a 25,000 tonne/year lead recycling plant (from batteries) at Wada in Maharashtra under the name of Binani Lead.

Bauxite/Aluminium Bauxite is the basic raw material in the aluminium manufacturing process. India is naturally endowed with large deposits of bauxite. The captive bauxite mines in Jharkhand, Chhattisgarh, Maharashtra and Orissa provide the raw material to the alumina refineries located at Belgaum in Karnataka, Muri in Jharkhand and Renukoot in Uttar Pradesh. The mines follow modern mining methods with stringent environmental controls including extensive re-greening of mined land and proactive participation in the sociological development of the communities around.

AREAS OF GROWTH The three main growth areas for aluminium in India are the automobile, electrical wiring and food packaging sectors. India is a major producer of bauxite and has substantial reserves of high-grade ores. Reserves are estimated at 2,600 Mt, and are expected to last over 350 years at an anticipated consumption of 7 Mt per year. Proven and probable reserves are estimated at 1,200 Mt, making the country fifth-largest producer, after Australia, Guinea, Brazil and Jamaica. India’s reserves account for 7.5% of the world’s total deposits. However, the aluminium capacity is only 3%, indicating the scope and need for new capacities in the country.

TOP PRODUCERS Nalco (National Aluminium Company) is India’s largest integrated bauxite mining and alumina smelting company. Most of its operations are located at Damanjodi in Orissa. Nalco is expanding its bauxite production to 2.5 Mt per year and its alumina capacity to 1.5 Mt per year. Other major producers include Hindalco, INDAL (Indian Aluminium Company), Balco (Bharat Aluminium Company, owned by the Indian Government and Sterlite Industries) and Malco (Madras Aluminium Company). INDAL’s bauxite mines

at Panchpatmali in the Koraput district, Orissa, produce approximately 2.5 Mt per year. In June 2003, Sterlite Industries India Ltd (SIL) commenced work on its `40.0-billion bauxite-mining and alumina-refinery project at Lanjigarh in Kalahandi district, Orissa. Considered as one of the largest greenfield projects in the country, it will comprise a 1-Mt/year alumina refinery with associated bauxite mining facilities. The refinery can be expanded to 1.4 Mt/year and is based on 150 Mt of bauxite committed by the Orissa Government for the project. The bauxite is of high quality (around 47% alumina content). It is expected that almost half the total alumina produced in the refinery will be exported and the rest used for domestic consumption. The power requirements for the venture are to be met through a new 100-MW power station, to be built as part of the project. Sterlite has drawn up plans to increase Balco’s refining capacity from 1,00,000 tonne/year to 3,34,000 tonne/year, and Balco has signed a `10.0-billion syndicated debt arrangement facility with a bank consortium led by ABN Amro Securities. Separately, Vedanta Resources has allocated US$800 million, from the US$1.0 billion it raised in London, for expanding Balco’s aluminium smelting capacity, from 1,50,000 tonne/year to 5,00,000 tonne/year by March 2006. Hindalco’s aluminium smelting capacity was about 3,10,000 tonne/year. However, its `18.0-billion brownfield expansion project, completed in August 2003, has raised this to 3,45,000 tonne/year. Hindalco plans to raise its smelting capacity further, to 3,60,000 tonne/year, and its alumina refinery capacity to 7,00,000 tonne/year. Hindalco has acquired 96% stake in Indian Aluminium Co (INDAL), formerly owned by Alcan of Canada, and the Hindalco– INDAL combine now accounts for over 70% of India’s market for aluminium.

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OVERVIEWING SOME MAJOR MINERAL ORES

Limestone India has abundant reserves of limestone. Limestone of different grades is mined from Pannedam limestone mine through surface mining and selective operations.

USES Limestone is an important mineral and is used to manufacture cement, lime, steel, glass, etc. Limestone of varying grades occurs in sedimentary and crystalline rocks. While the high-grade deposits are directly utilised for manufacturing cement and lime, the other varieties are blended with the high-grade deposits & made more usable. However, as limestone resources are depleting,

it is important that we explore and exploit all grades of limestone. The intensity of spectral reflectance/absorption of limestone or carbonate minerals helps in determining the chemical composition and purity of the mineral. Pure limestone reflects the visible and Near Infra-Red (NIR) energy, while Short Wave Infra-Red (SWIR) energy in the 2.35-Âľm region will be absorbed. The depth of absorption in the SWIR region will depend on the concentration of carbonates in the mineral. Hence, it is possible to quantify the purity of a limestone deposit by analysing the visible and carbonate absorption SWIR bands in a satellite image.

Phosphogypsum USES Phosphogypsum is important for producing fertilisers. As the Indian economy is dominated by agriculture, the fertiliser industry has a pivotal role to play. However, only about 35â&#x20AC;&#x201C;40% of the requirement of raw material for phosphatic fertiliser production is being met through indigenous sources. For the rest, the country has to import rock phosphate, phosphoric acid and fertilisers.

MEANWHILE, IN INDIA... The major activity of Rajasthan State Mines and Minerals Ltd (RSMML) is the mining of rockphosphate ore.

RSMML operates one of the largest and fully mechanised mines in the country at Jhamarkotra. Rock phosphate mines at Jhamarkotra & Kanpur Group of Mines are complex deposits. Mining these rock phosphate deposits is far more difficult than in most parts of the world. Despite the complexities of the deposit, excellent results have been achieved by continuous innovations. With an annual rock handling capacity of about 20 million tonne, Jhamarkotra is probably the largest opencast mine in India outside the steel and coal sectors. It contributes 98% of rock phosphate production of India.

Copper USES The major applications of copper are in electrical wires (60%), roofing & plumbing (20%) and industrial machinery (15%). Copper is mostly used as a metal, but when a higher hardness is required, it is combined with other elements to make alloys (5% of total use), such as brass and bronze. A small part amount of copper supply is used to produce

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compounds for nutritional supplements and fungicides in agriculture. Machining of copper is possible, although it is usually necessary to use an alloy for intricate parts to get good machinability characteristics.

MEANWHILE, IN INDIA... Copper mining is constrained by the lack of good quality

OVERVIEWING SOME MAJOR MINERAL ORES

ore and by the fact that average metal content in Indian ore is only 1% as against the world average of 1.5%. India has an estimated copper resource of 730 Mt averaging 1.17% copper. However, the copper business in India has suffered a setback because of the explosive growth of mobile cellphone networks and the emergence of ‘wireless-in-loop’ (WLL) telephony. The landline phones (until recently a government monopoly) had been the largest consumer of copper in India. The dramatic fall in the prices of optical fibre also impacted adversely on copper offtake and, despite improved demand for transformers, switchgears, motors & alternators, this has not been adequate to offset the reduced demand in the telecommunications sector. As a result, domestic consumption of copper in India last year grew by only 3-5%. Out of this, only 185 Mt of ore with an average grade of 1.21% copper is under mining lease held by state-controlled Hindustan Copper Ltd. Until 1998, Hindustan Copper has been the only producer of copper concentrate in India. Since then, several smaller companies, including Sikkim Mining Corporation at Rangpo and Hutti Gold Mines in Karnataka, have been producing copper concentrates. Hindustan Copper will now be largely relying on its Malanjkhand mines at

Madhya Pradesh, which has grades of 1.42 % copper. Birla Copper, the copper division of Hindalco Industries, completed the de-bottlenecking of its copper smelter at Dahej in 2002 and since then has a rated smelting capacity of 1,50,000 tonne/year (actual capacity is 1,85,000 tonne/year). Birla Copper produces Grade-A quality copper as per the specifications of the London Metal Exchange. Its profitability has been dependent on the concentrate treatment and refining charges it receives. Its acquisition of the Nifty mines (located in the eastern Pilbara region of Western Australia) from Straits (Nifty) Pty Ltd has enabled Birla Copper to become an integrated copper producer. The acquisition also gives Hindalco greater control over the value chain since mine production and represents 75–70% of the value of copper. Nifty has a mine production capacity sufficient to yield 27,500 tonne/year of cathodes and possesses a large undeveloped sulphide resource. Total resources at Nifty amount to 148 Mt averaging 1.3% copper, and a feasibility study for exploiting the sulphide ore was scheduled for completion. Birla has also acquired a 50% interest in the Maroochydore Exploration Project, and is exploring the possibilities for acquiring additional mining capacity.

Iron ore USES Iron is the world’s most commonly used metal. Steel, of which iron ore is the key ingredient, represents almost 95% of all metal used per year. It is used primarily in structural engineering applications, maritime purposes, automobiles and general industrial applications (machinery).

TOP PRODUCERS Mining iron ore is a high-volume low-margin business, as the value of iron is significantly lower than base metals. It is highly capital intensive, and requires significant investment in infrastructure, such as rail to transport the ore from the mine to a freight ship. As a result, iron ore production is concentrated in the hands of a few major players only. World iron production averages two billion metric tonne of raw ore annually. The world’s largest producer of iron ore is the Brazilian mining corporation Vale, followed by Anglo-Australian companies BHP Billiton and Rio Tinto Group. Another Australian supplier, Fortescue Metals Group Ltd, has helped bring Australia’s production to the second position in the world.

The seaborne trade in iron ore was 849 million tonne in 2004. Australia & Brazil dominate this trade, with 72% of the market, and BHP, Rio Tinto Group & Vale control 66% of this market. In Australia, iron ore is extracted from pisolite ‘channel iron deposit’ ore derived by mechanical erosion of primary banded-iron formations and accumulated in alluvial channels, such as at Pannawonica, Western Australia; and the dominant metasomatically-altered banded iron formation-related ores such as at Newman, the Chichester Range, the Hamersley Range and Koolyanobbing, Western Australia. The global consumption of iron ore is growing at 10% per annum on an average with the main consumers being China, Japan, South Korea, the US and the European Union.

MEANWHILE, IN INDIA... The total recoverable reserves of iron ore in India are about 9,602 million tonne of haematite and 3,408 million tonne of magnetite. Madhya Pradesh, Karnataka, Jharkhand, Orissa, Goa, Maharashtra, Andhra Pradesh, Kerala, Rajasthan and Tamil Nadu are the principal Indian producers of iron ore. prateek.sur@network18publishing.com

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MINING EQUIPMENT

PRATEEK SUR

n today’s globally competitive mining environment, companies have to face many challenges, such as workplace safety, managing the complexities of environmental & regulatory requirements and enhancing financial performance through improved processes & cost controls. One of the significant factors that contribute to both operational cost and production capacity is the heavy mining equipment that keeps the ore moving every day. The operating and maintenance costs of mining equipment not only represent a large proportion of a mine’s operational expenditures, but can also affect a mine’s profitability. Current estimates show the operating costs of 360-tonne haul trucks and 80-yard cable shovels is more than $500 per hour and is this figure is increasing by the day. On an average, a truck that is taken offline for a shift has a financial production impact of $35,000, which can become much more that that for a shovel. Also, the ability to extend the operating

life of a $5,000,000-haul truck or a $17,000,000-shovel can affect the profitability of a mine significantly. Strength and durability are the two most important factors for choosing any type of mining equipment. Cost is also an important consideration while selecting mining equipment. With escalating operating costs and limited resources, mining companies need to monitor the performance of operators and their heavy mobile equipment. To prevent the production downtime, it is critical to accurately diagnose any performance issue before it adversely affects the profitability.

REDUCING THE MAINTENANCE COST Equipment maintenance costs represent between 30% and 50% of direct mining expenditures. Most often, mining companies employ traditional preventive and reactive maintenance programmes for critical equipment, which take up most of the technicians’ time. As a result,

other assets are often maintained less frequently or are allowed to run to failure. Besides, the limited availability of skilled maintenance personnel makes it difficult, if not impossible, to optimise preventive maintenance programmes for all equipment. Equipment monitoring systems provide a real-time bridge between OEM interfaces and maintenance staff. They allow technicians to manage the health of critical assets and implement an effective conditionbased maintenance methodology.

REQUIRED SHIFT A condition-based maintenance methodology is one in which maintenance is applied to an asset based on the current condition or health of the equipment and the impact of poor performance on business & operational goals. By adopting a conditionbased maintenance methodology, maintenance personnel can remotely diagnose problems and improve service levels, reduce emergency & field maintenance and improve Key Performance Indicators (KPIs), such as Mean Time To Repair (MTTR), Mean Time Between Failures (MTBF), availability and utilisation. Maintenance

Mining equipment keep the ores up and running. The longer the mining equipment stays intact without breaking, rusting, losing effectiveness or requiring too much maintenance, the better it is for keeping the mining costs low and increasing the productivity with minimal input costs. This ultimately leads to easier access to the mined products, which, in turn, helps in the economic growth of a country. Therefore, it is very important to know how to prolong the life of mining equipment.

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Courtesy: Caterpillar

Enhancing Mining’s Efficiency Quotient

MINING EQUIPMENT

of equipment health, operator performance and maintenance processes. Regardless of its vendor, technicians can monitor and manage any type of field equipment, allowing for easy integration and the continued use of existing assets. Monitoring systems can be seamlessly integrated with maintenance management, dispatch and Enterprise Resource Planning (ERP) systems to optimise communications and workflow in all layers of the mining organisation.

strip or area mining, quarrying, contour mining, mountaintop removal and placer mining. Some examples of the opencast mining equipment are rock drills, drifter, paving breaker, dth hammer, wagon drill, slim drill LD-4, pneumatic crawler drill, TCT drill steel grinder and cross bit grinder. There are excellent mining equipment available for sub-surface mining processes, SOLUTIONS OFFERED such as shaft mining, drift mining, New advancements in equipment borehole mining, slope mining and monitoring technology enable timehard rock mining. Similarly, there are constrained technicians and engineers special mining equipment for deep to discover, diagnose and act on a underground mining processes, such as fault before it results in production TYPES OF MINING EQUIPMENT longwall mining, continuous mining, downtime or serious damage to the In the past, miners used to excavate blast mining, shortwall mining and equipment or operator. By remotely minerals and metals by using simple retreat mining. Some examples of the accessing onboard equipment data, hand-held tools. However, modernunderground mining equipment are personnel can immediately view day mining equipment are powered mucking machine, slurry pump, exhaust and analyse equipment & operator mainly by electricity and hydraulic fan, air mover, cement injection pump, performance through a variety of energy. And with the introduction pneumatic power pack, turbo light, dashboards, user-defined KPIs and of automation, today’s mining world spare parts for Atlas Copco Drifter alarms to facilitate immediate action. enjoys the benefit of many types of BBC-120F, Simba Junior, BMS-46 This is accomplished through mining equipment. There are various Feed Motor, BSP 10 Pneumatic Rod monitoring systems that identify types of mining equipment available. Catcher, Atlas Copco Cavo data patterns that are Strength and durability are the two most important factors 310 Loader, etc. Using the often precursors to the for choosing any type of mining equipment. Cost is also an right mining equipment development of faults and important consideration while selecting mining equipment. is essential for increasing can, therefore, be used as productivity. For example, the use of predictors. Once developing abnormal Some of them include industrial large mining equipment in surface conditions are detected, technicians shredders, drilling equipment, blasting mining maximises the recovery through who can take appropriate actions equipment, drill rigs, hammers, mine the excavation of one or more coal seam to prevent the abnormalities from winders, blasting machine, mining deposits in the large area surface mines. escalating to serious issues are alerted. locomotive, well-drilling machine, etc. While equipment monitoring is not Some examples of mining equipment new to the mining industry, traditional that are used extensively in mining IT IS IMPORTANT TO KNOW YOUR methods, unstable technology and operations include hard hats, clothing/ MINING EQUIPMENT WELL the extreme mining conditions have gear, ventilation fans, rock dusters, Mining is a very dangerous process. If often plagued the effectiveness of earth movers, water jet pumps, and a wrong equipment or tool is used for a these first-generation solutions. These so on. A mining light system is an specific mining purpose, it might lead rudimentary monitoring systems not important mining equipment used to disaster. Therefore, it is important only presented integration challenges, for all mining processes. It increases that everybody involved in the mining but were also unreliable because of the efficiency & speed of mining operation must know exactly how limited data throughput, chronic data operations and guarantees optimum to use their mining tools properly. loss, inflexible software and a lack of results. A mining light might consist Each worker should be properly and OEM standardisation by equipment of a heat sink, LED or laser, magnetic thoroughly trained to use every part of manufacturers. In contrast, presentswitch or a focussing cone. The mining mining equipment they will be using. day mining equipment monitoring excavators using advanced technology Also, the workers should be educated solutions, such as The MineCare® help in reaching the international level about the safety measures in using the System or Matrikon™ Mobile of performance in mining processes. mining equipment. Equipment Monitor, are designed to There are mining equipment reduce mobile mining equipment costs available specifically for surface-mining With inputs from David Fisk, Director – through the real-time management processes, such as open-pit mining, Mining Solutions, Matrikon personnel can now monitor the entire mining fleet and receive early warnings of developing problems, prompting action to reduce negative impact on operations. This ultimately leads to vital equipment spending less time on the shop floor and more time in the mining field.

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SAFETY IN MINING

Mining’s

Achilles

Heel

Working in mines is hazardous because of the possibility of ﬁre, ﬂood, explosion and collapse of the mine roof. Such disasters affect the miners & their families as well as those staying in the nearby areas. Whether it is underground mining or surface mining, safety should always be the top priority. Though the government has laid out various rules & regulations for the safety of the miners, mining is still proving to be Achilles’ heel not just for the government, but also for the miners and mine owners. PRATEEK SUR

located above the ground. Air flows afety has long been a AN OVERVIEW OF THE MAJOR MINING only in one direction, making circuits HAZARDS major concern for the through the mine such that each main mining sector, especially Mining ventilation is a significant work area constantly receives fresh in underground mining. safety concern. Poor ventilation air. Spraying water in coal mines also The Courrières mine exposes miners to harmful gases, heat helps to keep dust levels down. By disaster in Northern France on March and dust inside sub-surface mines, spraying the machine with water and 10, 1906—Europe’s worst mining which can cause injury, illness and filtering the dust-laden water with a accident—resulted in the death of death. The concentration of methane scrubber fan, miners can successfully 1,099 miners. Another major mining and other poisonous gases in the trap the dust. accident at the Benxihu Colliery in mines can generally be controlled by Gases in mines can poison the China killed 1,549 miners on April dilution (ventilation), their capture workers or displace the oxygen in the 26, 1942. before they enter the host air stream mine, causing asphyxiation. While mining today The Government of India has started taking adequate steps Therefore, it is important has become substantially towards ensuring the safety of miners. The number of mine for miners to continually safer than what it was accidents in India has reduced from 222 in 1975 to 90 in carry gas-detection earlier, mining accidents 2004 and that of fatalities from 664 to 99 during the same equipment that can detect still occur. For example, period. common gases, such as in China, as per the CO, O2, H2S, CH4, and also calculate government reports, about 5,000 (methane drainage), or isolation (seals miners die in various mining accidents and stoppings). the percentage lower explosive limit. each year, while other reports have Rock dusts, including coal dust and All production should stop if the suggested a figure as high as 20,000. silicon dust, can cause long-term lung concentration of the inflammable Examples of some recent major problems, including silicosis, asbestosis gases present reaches 1.4%. As newer mining accidents include the and pneumoconiosis (also known as technologies, such as nanotechnology, Ulyanovskaya Mine disaster in Russia in ‘miners’ lung’ or ‘black lung disease’). are being introduced, gas detection 2007, the Heilongjiang Mine explosion A ventilation system is set up to force will become more easier. in China in 2009 and the Upper a stream of air through the working Methane gas is a common source Big Branch Mine disaster in the US areas of the mine. This air stream is of explosions in coal mines, which can in 2010. generated by large mine fans, usually potentially initiate more extensive coal

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may result in heat-related illnesses, including heat stroke that can prove fatal. The presence of heavy equipment in confined spaces also poses a risk to miners. Despite modern improvements to safety practices, mining remains dangerous throughout the world. Modern mines use automation and remote operation, such as automated loaders and remotely operated rock breakers, to improve the safety of miners.

THE SITUATION IN INDIA

or partings in between the seams Accidents have also occurred due to inaccurate knowledge of the working of water bearings Suitable techniques for establishing the thickness of the barrier & the partings and for detecting the voids & the working of abandoned water bearing need to be developed Roof fall and side fall in the mine roadways are major causes of accidents in underground mines in India Suitable support system with roof bolters for bord & pillar workings is required A well-established technology/ method for hard roof management, both for extraction/depillaring and development workings, may be explored Techniques based on numerical modelling for subsidence prediction & control are required The communication in Indian coal

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FACT

The Government of India has started taking adequate steps towards ensuring the safety of miners. The number of mine accidents in India has reduced from 222 in 1975 to 90 in 2004 and that of fatalities from 664 to 99 during the same period. Also, more than 50% of the mining accidents in India are due to inundation, followed by gas explosions. In underground mines, sidewalls & roofs may also fall, resulting in major accidents. In surface In China, as per the government reports, about mines, slope failure of 5,000 miners die in various mining accidents dumps is also a major each year, while other reports have suggested cause of accident. a ﬁgure as high as 20,000. Examples of some The safety, welfare recent major mining accidents include the and health of mine Ulyanovskaya Mine disaster in Russia in 2007, workers are regulated the Heilongjiang Mine explosion in China in by the Mines Act, 2009 and the Upper Big Branch Mine disaster 1952, and the rules in the US in 2010. & regulations framed under this Act. These regulations are administered mines is primarily based on CDS, by the Directorate General of Mine signalling or telephone system. Safety (DGMS) under the Ministry Telephones are located at strategic of Labour and Employment. Safety points in underground mines. This in coal mines is monitored by the system has the inherent limitation various committees starting from unit as wires have to be laid down at level to company board, including specific points and a direct two-way representatives of various trade unions communication is not possible. & DGMS. The safety situation is also Advanced wireless communication reviewed at the government level by technology for direct communication the Union Coal Minister. from surface to underground and vice versa may be a better alternative SAFETY ISSUES IN UNDERGROUND The advanced communication MINES system should be able to transmit voice, data, video-telephony, realMost of inundation accidents occur time production information and due to the failure of barrier pillars

FAC T

dust explosions. Therefore, rock dusts, such as limestone dust, are spread throughout coal mines to diminish the chances of coal dust explosions and limit the extent of potential explosions, in a process known as ‘rock dusting’. Coal dust explosions can also begin independently of methane gas explosions. Frictional heat and sparks generated by mining equipment can ignite both methane gas and coal dust explosions. For this reason, water is often used to cool rock cutting sites. Miners utilise heavy equipment to break through extremely hard layers of the earth’s crust. These equipment, combined with the closed workspace that underground miners work in, can cause hearing loss. For example, a roof bolter can reach sound levels of up to 115 dB. Combined with the reverberant effects of underground mines, a miner without proper hearing protection is at a high risk of hearing loss. By age 50, nearly 90% of the US coal miners have some hearing loss, compared to only 10% among workers not exposed to loud noises. Roof bolters are among the loudest machines, but auger miners, bulldozers, continuous mining machines, front end loaders and shuttle cars & trucks also cause excessive noise in the mines. Since mining entails removing dirt and rock from its natural location, creating large empty pits, rooms and tunnels, cave ins as well as ground & rock falls are a major concern in mines. Modern techniques for timbering and bracing walls & ceilings within sub-surface mines have reduced the number of fatalities due to cave-ins, but ground falls continue to represent up to 50% of mining fatalities. Even in cases where mine collapses are not instantly fatal, they can trap mine workers deep underground. Cases such as these often provoke high-profile rescue efforts, such as when 33 Chilean miners were trapped deep underground for 69 days in 2010. High temperatures and humidity

SAFETY IN MINING

and images of everything in sight. track machinery & personnel provided by the Central Government Data, other than that required for deployed in the underground and the various state governments. the purpose, is automatically mining This also includes bettering the available for different applications rescue equipment, which is a prime Mine fires and explosions are at any time such as that for requirement for saving the lives of critical for Indian mines. Suitable monitoring open-pit slopes of high the miners trapped in the mine at any techniques such as mine fire walls and internal dumps. given point. There are procedures and mapping by thermal infra-red techniques for locating & rescuing the remote-sensing method may be New techniques, some of which are trapped miners in surface used to detect fire and sub-surface mines. Suitable technology may Rock dusts, including coal dust and silicon dust, can cause These procedures be explored for detection long-term lung problems, including silicosis, asbestosis and need to be followed & measurement of pneumoconiosis (also known as ‘miners’ lung’ or ‘black with complete precision. conductor temperature lung disease’). The technology has to in mine trailing cables be kept up-to-date with the latest to prevent premature insulation given below, can considerably advancements so that there should not failure leading to electrocution and reduce the dangers associated with be even a single fatality in or around fire hazards fly-rocks, inadvertent blasting, the mines. The provision of rescue set fumes, etc. These techniques up and services for the mining industry include: SAFETY ISSUES IN SURFACE MINES needs to be bettered all over world. - Digital Energy Control System Slopes of mines, stockpiles and - Pyro-Breaking Capsules (PBC) overburden need to be monitored - Threshold Blasting Technology. for their stability. prateek.sur@network18publishing.com Laser imaging system can be used With inputs from Rubin Sariwala, Deputy in geological mapping, stockpile RESCUE SERVICES GM, Indian Mines and Miners Association survey and pit development surveys. In the recent times, many advancements and Rakesh Mahant, Chief Analyst, NRS This system collects measurements have been made in the rescue services Consultants.

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ENVIRONMENTAL EFFECTS OF MINING

Is the Eroders of EARTH tag justified? The processes involved in mining operations have a negative impact on the environment. This negative effect continues even after the mine is no longer in operation, further aggravating the situation. As a result, most of the nations are now adopting various regulations to moderate the negative environmental effects and after-effects of mining operations, and provide the perfect solution for the same. Here’s taking a look at the various environmental effects of mining and analysing whether justice has been done to nature. PRATEEK SUR

he environmental impact of mining includes erosion, formation of sinkholes, loss of biodiversity and contamination of soil, groundwater & surface water by chemicals used in mining processes. In some cases, forests in the vicinity of mines are cut down for storing the debris from mining. Besides damaging the environment, the leakage of chemicals also adversely affects the health of the local population. As a result, some countries have made it mandatory to follow environmental and rehabilitation

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codes, thereby ensuring that the mined area is returned close to its original state. Besides, some mining methods may have significant environmental and public health effects. Additionally, mining exposes hillsides, mine dumps and tailings dams. Their erosion and resultant silting of drainages, creeks and rivers significantly impact the surrounding areas, a prime example being the Ok Tedi Mine environmental disaster in Papua New Guinea. Besides, mining disturbs and destructs farmlands, grazing lands, ecosystems and habitats and also causes noise, soil and visual pollution.

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WATER POLLUTION Mining can have adverse effects on the surface and groundwater if protective measures are not taken. It can result in unnaturally high concentrations of some chemicals, such as arsenic, sulphuric acid and mercury over a significant area of surface or subsurface. In addition, runoff of soil and rock debris—although non-toxic—also destroys the surrounding vegetation. Also, the dumping of tailings overburden—mine-induced erosion into the river system or in forests is the worst option here. Submarine tailings disposal is a better option (if the soil is pumped to a great depth). If no forests need to be cleared for storing the debris, then land storage and refilling the mine is even better. Large amounts of water produced from mine drainage, mine cooling, aqueous extraction and other mining processes can contaminate the area, including the groundwater and surface water. To avoid these harmful effects of mining, it is important that mines are well regulated, with hydrologists and geologists taking careful measurements of water and soil to exclude any type of water contamination

ENVIRONMENTAL EFFECTS OF MINING

environmental hazard.

metals. There are severe health effects caused by burning coal. According to the reports issued by the World Health HEAVY METALS Organization in 2008, pollution caused Another example of environmental by coal particulates has been estimated problems with mining is dissolution to shorten approximately 10,00,000 & transport of metals and heavy lives annually worldwide. metals by run-off & groundwater; Oil Shale for example, the Britannia Mine, a The oil shale industry also causes former copper mine near Vancouver, land, water and air pollution. It British Columbia. Tar Creek— also causes problems in waste an abandoned mining area in management, caused by the extraction Picher, Oklahoma, which is now an and processing of oil shale. Surface Environmental Protection Agency mining of oil shale deposits causes superfund site—also suffers from heavy the usual environmental impacts of metal contamination after water in open-pit mining. In addition, the mine containing dissolved heavy combustion and thermal processing metals, such as lead and cadmium, generate waste material, which must leaked into local groundwater. be disposed of along with harmful Long-term storage of tailings and atmospheric emissions, including dust can lead to additional problems, carbon dioxide, a major greenhouse as they can be easily blown off the gas. Experimental in-situ conversion site by wind. It occurred at Skouriotissa, processes and carbon capture & an abandoned copper mine in storage technologies may reduce some Cyprus. of these concerns in future, but may ACID MINE DRAINAGE raise others, such as the pollution of AMD, or Acid Rock Drainage DEFORESTATION groundwater. (ARD), refers to the outflow of acidic For opencast mining, the overburden, Mountaintop Removal Mining water from (usually abandoned) metal which may be covered in the forest, Mountaintop Removal mines or coal mines. Mining (MTR), also Apart from mines, other Sea turtles depend on sandy beaches for their nesting, and known as Mountain Top areas where the earth sand mining has led to the near extinction of gharials (a Mining (MTM), is a form has been disturbed (e.g., species of crocodiles) in India. of surface mining that construction sites, subinvolves the mining of the summit or divisions, transportation corridors, must be removed before the mining can summit ridge of a mountain. In MTR, etc.) may also contribute ARD to commence. The resulting deforestation entire coal seams are removed from the environment. The liquid that may lead to species extinction if there the top of a mountain, hill or ridge drains from coal stocks, coal-handling is a high level of local endemism. by removing their overburden, and facilities, coal washeries and coal re-stacking the overburden back on waste tips can be highly acidic, and ENVIRONMENTAL HAZARDS CAUSED the ridge to reflect the approximate is treated as ARD. It occurs naturally BY DIFFERENT TYPES OF MINING original contour of the mountain. in some environments as part of the Coal mining The excess overburden that cannot be rock weathering process. However, The environmental impact of the coal replaced on the ridge-top is moved the situation is exacerbated by largeindustry includes issues such as land into neighbouring valleys. It is the scale earth disturbances characteristic use, waste management and water & predominant method of coal mining of mining and other large construction air pollution caused by coal mining, in the Appalachian Mountains in the activities, usually of those rocks that processing and use of its products. In Eastern US. The process involves contain abundant sulphide minerals. addition to atmospheric pollution, coal blasting with explosives to remove The same type of chemical reactions burning produces hundreds of millions up to 400 vertical feet (120 m) of and processes may occur through of tonnes of solid waste products mountain to expose the underlying the disturbance of acid sulphate soils annually, including fly ash, bottom ash coal seams. Excess rock and soil formed under coastal or estuarine and flue-gas desulphurisation sludge, laden with toxic mining byproducts conditions after the last major sea which contain mercury, uranium, are often dumped into nearby level rise, and constitute a similar thorium, arsenic and other heavy that could be caused by the mine’s operations. In the US, the government has made it mandatory for mining companies to follow the government’s environmental regulations while operating. They are encouraged to follow non-toxic extraction processes such as bioleaching. If the project site becomes polluted even after following these steps, mitigation techniques such as Acid Mine Drainage (AMD) should be carried out in which contaminated water is pumped to a treatment facility that neutralises the contaminants. The five principal technologies used to monitor and control water flow at mine sites are: - Diversion systems - Containment ponds - Groundwater pumping systems - Sub-surface drainage systems - Sub-surface barriers.

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ENVIRONMENTAL EFFECTS OF MINING

done illegally. occur combined with ordinary sand. valleys, in what are called ‘holler fills’ However, sand mining causes or ‘valley fills’. erosion and impacts the local wildlife. Peer-reviewed studies show that WHAT THE FUTURE BEHOLDS? For example, sea turtles depend on MTR has serious environmental A better and safer future for mining lies sandy beaches for their nesting, and impacts, including loss of biodiversity in making mines more environmental sand mining has led to the near and toxification of watersheds, which friendly. For this to happen, proper extinction of gharials (a species of mitigation practices cannot successfully environment management steps should crocodiles) in India. Disturbance of address. There are also adverse impacts be taken. The used mines should be underwater and coastal sand causes of MTR procedure on human health duly filled up after the full extraction turbidity in the water, which is harmful that result from contact with affected and should not be just left abandoned. for sea organisms, such as corals, that streams or exposure to air-borne toxins Effective steps should be taken for and dust. reforestation of the mined Sand Mining area. This would reduce the The environmental impact of the coal industry includes Sand mining is used problems of environmental issues such as land use, waste management and water & air to extract sand, mainly degradation such as soil pollution caused by coal mining, processing and use of its through an open pit. Sand erosion. Therefore, there products. is also mined from beaches, must a balance in the need sunlight. It also destroys fishes, inland dunes and dredged from ocean mining processes so that justice is done causing problems for people who beds & riverbeds. Sand is used to make to nature. depend on fishing for their livelihood. concrete and also as an abrasive. It is Besides, removal of physical coastal also used to replace eroded coastline. prateek.sur@network18publishing.com barriers, such as dunes, leads to the Sand mining is also used to extract With inputs from Shireen Tyrewala, flooding of beachside communities, minerals such as rutile, ilmenite and Assistant Professor, Department of Chemistry, and the destruction of picturesque zircon, which contain the industrially Annakurim University and Val Krammer, beaches harms tourism. Though sand useful elements titanium and Visiting Assistant Professor – Department of mining is regulated by law, it is often zirconium. These minerals typically Science and Technology, University of Madras

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NATIONAL POLICIES ON MINING

A Guiding Light

For Indian Mining As India is endowed with vast mineral resources, the mineral industry is an important segment of the Indian economy. The country produces as many as 84 minerals comprising of four fuels, 11 metallic, 49 non-metallic and 20 minor minerals. The mining sector in India is largely dominated by the public sector; however, the government is now seeking a phased withdrawal of its participation from the non-strategic metal sector in order to encourage private sector players. Here, we discuss some policies and regulations that can strengthen the mining sector of the country and help it function more efﬁciently. PRATEEK SUR

he government had approved the new National Mineral Policy, 2008, on March 13, 2008. The new policy enunciates measures to streamline and simplify the procedures for granting mineral concessions, develop a sustainable framework for optimum utilisation of the country’s natural mineral resources for the industrial growth in the country, and, at the same time, improve the life of people living in and around the mining areas, which are generally located in the backward and tribal regions of the country. Apart from these, the National Mineral Policy has enunciated several policy measures that seek to strengthen the framework/institutions supporting the Indian mining sector, which includes the Indian Bureau of Mines, Geological Survey of India and State Directorates of Mining & Geology. The new policy spelt out measures to optimise the scientific mining and exploration of the country’s mineral resources. Some of the important measures are:

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The existing Mines and Minerals (Development and Regulation) Act, 1957, will be replaced. The draft Act has already been posted for suggestive amendments from the public. In order to ensure implementation of the non-legislative policy initiatives given in the National Mineral Policy, 2008, the Ministry of Mines has also constituted an Implementation Committee in June, 2009, to oversee the implementation of the action points of the National Mineral Policy. The new National Mineral Policy enunciates measures like assured right to next stage mineral concession, transferability of mineral concessions and transparency in the allotment of concessions, in order to reduce delays that are seen as impediments to investment and technology flows in the mining sector of India. Other features of the policy include: - It recognises that minerals are valuable natural resources as they are the vital raw material for infrastructure, capital goods

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and basic industries. The development of the extraction and management of minerals has to be integrated into the overall strategy of the country’s economic development. - The exploitation of minerals has to be guided by long-term national goals and perspectives that are dynamic and responsive to the changing global economic scenario. - It also recognises that the country is blessed with ample resources of a number of minerals and has the geological environment for many others being a part of the ancient Gondwanaland, which includes parts of Australia, South Africa and Latin America. - The policy lays out that the guiding strategy for the development of any mineral should keep in view its ultimate end users in terms of demand and supply in the short, medium & long terms. This would be market oriented. However, a disaggregated approach in

NATIONAL POLICIES ON MINING

respect of each mineral will be adopted and a mineral-specific strategy will be developed to maximise gains from the comparative advantage that the country enjoys. Moreover, mineral development will be prioritised in terms of import substitution, value addition and export, in that order. - Conservation of minerals shall be construed not in the restrictive sense of abstinence from consumption or preservation for use in distant future, but as a positive concept leading to the augmentation of reserve base through improvement in mining methods, beneficiation and utilisation of low-grade ore and rejects & recovery of associated minerals.

MINE DEVELOPMENT AND MINERAL CONSERVATION The National Mineral Policy lays down that the mine development and mineral conservation, as governed by the rules & regulations, will be on sound scientific basis, with the regulatory agencies, viz., Indian Bureau of Mines (IBM) and the state directorates, closely interacting with R&D organisations and scientific & professional bodies to ensure optimal mining plans. Conditions of mining leases regarding size, shape & disposition with reference to geological boundaries and other mining conditions shall favourably predispose the leased areas to systematic & complete extraction of minerals. Also, the regulatory agencies will be suitably strengthened through capacity-building measures. The Implementation Committee has directed IBM to prepare detailed guidelines for mine closure, best practices and the actual process of obtaining approval from IBM for the mine closure plan, detailing the socioeconomic aspects of mine closure, long-term impacts, costs involved, etc.

The same has been incorporated in the IBM Restructuring Report. In this context, IBM has constituted Working Groups to: - Suggest incentives to be given to mine operators to promote the adoption of mechanisation, computerisation and automation - Develop a plan for the collaboration of private sector institutions and jobs in the field of mineral beneficiation - Develop a legal and institutional framework for zero waste mining and strengthening of mechanisation of mining - Evolve guidelines for operating small deposits in a scientific and efficient manner safeguarding vital environmental and ecological aspects.

MEASURE TO CONTROL ILLEGAL MINING All state governments have been requested to computerise the system for collecting royalty and issuing transport permits on the basis of the Online Royalty Pass System implemented by Code Solutions, a Division of Gujarat Narmada Valley Fertilizers Co (GNFC) Ltd. All state governments have also been requested to include representatives of railways, customs, ports, and, in the case of iron oreproducing states, representative of the Ministry of Steel in the State Coordination-cum-Empowered Committees set up in the state, for better monitoring of the transportation and export of ore. To reduce delays, they have been asked to send a list of mineral concession cases pending with the Ministry of Environment & Forests for clearances. The state governments have also been asked to impose the â&#x20AC;&#x2DC;Special Conditionâ&#x20AC;&#x2122; under Rule 27(3) of Mineral Concession Rules, 1960, for ensuring that all the mining lease holders assess the resources in their leases as per the UNFC. Besides, the state governments have been

requested to be more actively engaged in improving the quality of mineral administration by taking the following steps: - Increasing personnel at railway sidings - Removing restrictions on loading of ores in sidings not used optimally - Improving security features of the transit passes (for this purpose, the system of a single permit per rake would need to be implemented) - Taking action against overloading of trucks, which is a substantial factor in royalty evasion besides being responsible for deteriorating road quality in mining areas and increasing transport inefficiency - Putting in place in-motion weigh-bridges and modernisation of check gates - Bettering enforcement through intelligence sharing, enforcement squads, joint inspection, mining cells in police organisation, etc. - The Ministry of Mines has directed all the state governments to start the process of registering end users, constitution of Special Cells in State Police, use of satellite imagery to track down illegal mining, hologram marking/barcoding of transport permits, etc. - The state governments are also planning to set up special camp at sites and deployment of Home Guards in areas where there have been complaints about illegal mining. In addition, the Rule 45 of Mineral Conservation and Development Rules has been amended on February 9, 2011, to bring traders, stockists, exporters and end-users dealing with minerals under the purview of the regulation. This will ensure endto-end accounting of minerals, thus obviating scope for illegal mining. prateek.sur@network18publishing.com With inputs from Indian Bureau of Mines, Department of Mines, Ministry of Minerals and Mines, Government of India

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FDI IN MINING

A Goldmine of Business

Opportunities

India has become one of the most promising markets in the globe. Its technical and skilled human resources are among the ﬁnest in the world. The private sector is the lifeblood of economic activity in India, which is energetic and spirited. The middle-class population of India is greater than the population of the US or the European Union, which provides India a key place in international competition. Under the new economic policy, India provides an open and liberal economic atmosphere and offers considerable scope for FDI, joint ventures and collaborations. The policy formulated by the government has removed all the unnecessary rules and has created a liberal environment for foreign investors to facilitate FDI inﬂows under the automatic route. PRATEEK SUR

ccording to the World Bank, the mining industry is poised to expand considerably over the next 20–30 years. Developing nations, such as India, play an increasingly important role in this expansion on the demand side (as the population and economies grow), as well as on the supply side (given the shifts in the exploration and mining development investments). Today, the mining sector is one of the largest employers in India and hires more than one million people, i.e., around 4% of the Indian workforce. India produces as many as 86 minerals, which include four fuels and 10 metallic, 46 non-metallic, three atomic and 23 minor minerals. The total value of the mineral production in India (excluding atomic minerals) during 2009–10 was estimated at `1,27,921.42 crore—an increase of about 4.61% over that of the previous

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year. This figure is on the ascent and is expected to become huge by the end of 2012. To a great extent, the mining sector has flourished due to the continuously increasing demand from industrial production, agriculture, high-tech sectors and merchandise producers in more than 100 countries. Among these 100 countries, 50 can be called ‘mining countries’ because: The sector immensely contributes to the export earnings of these countries It serves their large domestic markets It employs millions of workers from these countries.

SCOPE OF FDI FDI plays a vital role in improving the economy of the country and is a crucial element to help local industries survive in the global market. FDI inflow provides strength to the Indian economy and therefore, concerted

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efforts are needed at the regional, national and international levels in order to attract FDI inflows for the growth of the Indian economy. In order to analyse FDI in the mining sector, we need to first examine the opportunities, challenges, responsibilities and recommendations, among other factors. Since the last two decades, India has been an attractive and profit-oriented market for investments. In this scenario, FDI has been an easy path for investors to enter the market. Though factors such as vast consumer market, a big retail sector and huge aggregate demands have attracted FDI, there are some ‘depressing’ factors that make FDI in the mining sector difficult. Some of these ‘depressing’ factors include inadequate domestic supply, weak infrastructure, lacking technological background, political instability, low GDP, poor management skill, underpar investment promotion strategies,

FDI IN MINING

confused outlook of the government towards investment, ailing local industries, inadequate finance and unemployment. The government, investors and producers should work towards creating a healthy economy. It needs to draft a favourable legal framework for FDI policies in India. Also, there needs to be adequate policies to maintain quality and prices of goods. Additionally, preference should be given to technology exchanges between the host and guest countries. It is important to note that FDI plays a vital role in improving the economy of the country and is a crucial element to help local industries survive in the global market. FDI inflow provides strength to the Indian economy and therefore, concerted efforts are needed at the regional, national and international levels in order to attract FDI inflows for the growth of Indian economy.

ADVANTAGES OF FDI

FDI IN COAL SECTOR

FDI decreases the production cost of goods and services. Elimination of transaction and transporting cost between the host & guest countries is possible under FDI. The role of FDI in job creation and conservation is found to be more favourable for the host country. A good inflow of FDI creates new employment opportunities in the industries and market sectors of the host country. The FDI inflows also encourage the transfer of technological expertise and professional education between different countries. FDI increases the industrial productivity of the host country. With the increase in output, the home country can boost its export. It also helps in bridging the deficit between import and export. FDI improves the GDP of the host country, leading to a healthy economy. Better GDP rate improves the living standards of people in the host country. FDI enhances the competition at the global level. The FDI inflow develops the efficiency and sustains the growth rate of the developing countries. FDI also encourages regional development of a developing country. FDI releases broad opportunities in the traffic of goods and services in India. FDI helps in upgrading the existing old processes with new technologies. Also, developing countries can implement advanced technology in industrial and IT sectors by inviting FDI. Foreign firms are nowadays investing large amounts in joint ventures with India. In order to position themselves better in the Indian market, they spend large amounts on quality and distribution of the product. FDI increases the level of competition in the host country. This results in the availability of economicallypriced and good-quality products and services. FDI has also created a large number of employment opportunities by developing industrial units in various parts of India. It has also been seen that FDI encourages domestic producers. They become more efficient and are able to withstand competition from local as well as outside markets. It results in enhancing the economic growth. Finally, FDI can also provide large supplies of products and services by implementing advanced infrastructure & technologies in industries. It helps in increasing the purchasing power of low-income people in the host country.

Private Indian companies setting up or operating power projects as well as coal/lignite mines for captive consumption may be allowed 100% foreign equity, provided that the coal/ lignite produced by them is meant only for captive consumption in power reviewed its policy on FDI and decided generation. Full foreign investment Policy to infuse funds, technology and to permit it under the automatic route in the equity of an Indian subsidiary managerial expertise in the sector. The for coal and lignite mining for captive of a foreign company or in the equity FDI policy in the mining sector had consumption by power projects, iron of an Indian company for setting up been gradually liberalised during the & steel, cement production and other coal processing plants in India may be next few years. In 1997, the automatic eligible activities permitted as per allowed subject to the conditions that approval route for investments such an Indian subsidiary involving foreign equity or the Indian company: participation up to 50% in The FDI cap for exploration and mining of diamonds & mining projects and up to Shall not do coal mining precious stones has been increased to 100% under the 74% in services incidental Shall not sell the washed automatic route with effect from February 2006. to mining was introduced. or sized coal from their the provisions of the Coal Mines Also, the FDI cap for exploration coal-processing plants to the (Nationalisation) Act, 1973. and mining of diamonds & precious respective parties. stones has been increased to 100% Also, private Indian companies under the automatic route with effect that are engaged in the exploration or MINING AND FDI from February 2006. With this, FDI mining of coal and lignite for captive The Indian Government had, in a in the mining sector for all non-atomic consumption for iron, steel and cement pragmatic manner, opened up the and non-fuel minerals have now been production may be allowed 100% mining sector to FDI in 1993 after the fully opened up to 100% through the foreign equity. The government has announcement of the New Mineral

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FDI IN MINING

to the displaced people.

with the help of FDI. India is an over-populated country; and the infrastructure facility is not much MINING: AN EXCITING SECTOR FOR developed. Supply has become weak POTENTIAL INVESTORS RECENT DEVELOPMENTS and inflation also keeps on increasing. Of late, there has been an emphasis Clearly, the mining sector in India Hence, there is a need for good by the Indian Government to is an alluring venture with the investment policies and a peopleensure that the legal licence to mine government leaving no stone unturned welfare outlook while inviting FDI. is also accompanied by a social to make it more investor friendly. FDI has now become an important licence to mine. A draft bill, Mines There are proposed amendments and part of the Indian economy without and Minerals (Development and decisions in the pipeline that may have which the present status of economy Regulation) Bill, 2010, envisages the far-reaching consequences for the could never be maintained. setting up of a National Today, the mining sector is one of the largest employers in To compete at the Mining Tribunal that can India and hires more than one million people, i.e., around 4% international level, help check independently, all of the Indian workforce. local businesses survive, decisions, indecisions and upgrade old technologies and primarily delays in its application. It further potential investors. The contribution to increase the number of employment proposes that if the state governments of mining and quarrying sector to opportunities in the mining sector, want to grant forest areas for mining, it GDP in 2009–10 (April–September) FDI has a key role to play. is mandatory to consult the panchayats was `31,808 crore—an increase of of the tribal areas. It has also been 8.7% over the figure of the preceding proposed that 26% of the profits from period. Clearly, mining in India is an prateek.sur@network18publishing.com mining should be shared with the exciting sector for potential investors. With inputs from Akash Meshram, Assistant people who are displaced because of By the end of 2012, this growth will Professor – Department of Commerce and the projects. If companies do not make become far more clear. Rekha Meshram, Head – Department & profits, they would need to pay an The path of economic growth Assistant Professor – Department of Commerce, amount equal to the mining royalties and development certainly navigates NH College, Bramhapuri District, Chandrapur. automatic route, including diamonds and precious stones.

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MERGERS, ACQUISITIONS AND JOINT VENTURES

Envious Deals to Deliver Demands The numbers of Mergers & Acquisitions (M&As) and Joint Ventures (JVs) in mining have cooled down in the second half of 2011 and the early half of 2012. Although the sector has seen one or two big deals, M&As and JVs involving base metal companies have dwindled as economic uncertainty curbs global demand and softens prices. However, deals relating to gold mining are capturing a higher percentage of the minimal M&A activities in mining. PRATEEK SUR

lobally, the growth in Mergers and Acquisitions (M&As) and Joint Ventures (JVs) in mining had begun to slack in the latter half of 2011. As the crises in European and US economies forced companies to adopt a wait-andwatch stand, the situation remained the same in the first half of 2012. The only sector that has seen the most aggressive consolidation in the form of JVs and M&As is the metallurgical or met coal and iron ore industries. This has largely been facilitated owing to the large global steel producers seeking to secure their access to the raw materials. Coal sector deals in the US alone drew many global companies into M&A activities to a much greater degree. While China, too, is showing signs of becoming a more sophisticated & confident acquirer, African copper

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assets appear to be high on the country’s agenda. In this situation, the depressed stock prices of many small mining companies are encouraging acquisitions by big ones, as they often believe that small companies are specialised at what they do. Therefore, many large companies prefer to acquire the best early-stage projects of the small companies rather than develop their own exploration and development capabilities. Unsolicited bids with large premiums have also become prominent M&A activities. Cameco’s $479-million takeover of the Hathor Exploration in August 2011 (subsequently acquired by Rio Tinto) is one example that represented a 40% premium. Stillwater Mining also paid a 290% premium to buy all the outstanding shares of Peregrine Metals. Another feature of the M&A

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activities is the increasing number of interlopers that are jumping into the already announced deals. For example, the Inmet and Lundin merger attracted Equinox Minerals, Minmetals Resources & Barrick Gold as interlopers. However, the case ended up with Inmet and Lundin abandoning their merger and Barrick buying Equinox. Timmins Gold was also an interloper in the AuRico Gold/Capital Gold transaction—a role that AuRico itself played in the deal between Northgate Minerals and Primero. In addition, a few transactions spawned spin-off companies to develop properties that were unwarranted by the acquirer and particularly desired by the target. When Quantum Minerals first acquired Antares Minerals, a company called Regulus Resources was created to develop Antares’ 50% interest in the

MERGERS, ACQUISITIONS AND JOINT VENTURES

ENVIOUS DEALS AND ACQUISITIONS COAL Alpha Natural Resources has beat fellow American Arch Coal to acquire Massey Energy for $8.5 billion— the highest valued mining target in 2011. Subsequent to a failed divestiture attempt, Whitehaven recently announced the acquisition of fellow Australian miners Aston and Boardwalk for $3 billion. The deal creates Australia’s largest independent coal explorer. Against a backdrop of crashing equity prices, Rio Tinto and Mitsubishi have teamed up to acquire a minority stake in Australia’s Coal & Allied for approximately $1.5 billion. Mongolia Mining has signed a $464-million deal to buy fellow Mongolian coal miner QGX. The deal is the largest ever Mongolian M&A transaction. Bumi PLC has announced that its proposed acquisition of 75% of PT Bumi Resources Minerals will not proceed due to market uncertainties.

COPPER Australia’s Equinox Minerals has been acquired by Canada’s Barrick Gold for C$7.3 billion. The offer trumped Minmetals’ C$6.3 billion offer and has resulted in Equinox retreating from its hostile bid for Lundin Mining (which resulted in the death of a friendly merger between Lundin and Inmet mining). KGHM Polska Miedz has announced the acquisition of Canada’s Quadra FNX Mining for C$3.5 billion—the largest ever overseas acquisition by a Polish company. Japanese industrial conglomerate Mitsubishi Corporation has acquired a 24.5% stake in Anglo American Sur for $5.4 billion in November 2011. The deal blocked Chile’s Codelco from acquiring 49% of Anglo’s Chilean copper unit (via its option to do so) and ignited a cross-continent legal battle. In another cross-continent battle, this time for African copper resources, China’s Jinchuan Group—an emerging market giant, has offered $1.3 billion to acquire South African copper miner Metorex, trumping a bid by Brazil’s Vale. Chinese Minmetals Resources has extended three offers to Africa-focussed Anvil Mining—the most recent of which valued the company at $1.3 billion.

GOLD Eldorado Gold has acquired fellow Canadian European Goldfields for C$2.5 billion. The transaction, which was motivated by a desire to secure European Goldfields’ assets in Greece and Turkey, was the largest gold deal of 2011. US-based Newmont Mining Corp has acquired Canada’s Fronteer Gold for C$2.3 billion in order to gain three exploration and development projects in Nevada, which are expected to contain 4.2 million ounces of gold. Newmont spun off the remaining 11 projects into a new company, Pilot Gold. In one of the largest-ever transactions led by a Chinese gold producer, Shandong Gold Group has announced a

$1-billion unsolicited bid for Brazil’s Jaguar Mining. The hostile offer has prompted Jaguar to initiate a strategic review process to explore alternatives. The bid represented the highest premium ever offered in cash (nearly 79%) for a gold miner (>$500 million). Canada’s White Tiger Gold and Century Mining have entered into a business combination. The combined entity emerged as a diversified intermediate with multiple properties in various stages of production and development in Canada, Russia and Peru. Northgate Minerals and AuRico Gold have entered into a share exchange of approximately $1.5 billion. The deal has resulted in the creation of a leading intermediate producer, with a strong foothold in Canada and Australia.

IRON ORE US-based Cliffs has acquired Canada’s Consolidated Thompson for $4.7 billion. Cliffs sought out Consolidated Thompson’s coveted Asian customer in order to expand beyond its largely North American steel-making customer base. In a sign that the buyer base for mining deals is expanding, Russia’s VTB Capital, the investment business of VTB Group, has acquired Russia-based iron ore producer OAO for $2.5 billion. Chinese conglomerate Hanlong Mining has acquired Australia’s Sundance Resources for A$1.44 billion. Sundance’s projects span the Republics of Cameroon and Congo. The estimated cost to develop the projects, including the construction of a deepwater port and railway, is in the range of $4.7 billion. The Steel Authority of India has won the rights to develop an iron ore concession in Afghanistan (the latter was the latest in a series of deals aimed at opening up the country’s mineral resources to regional powers). As part of the deal, the Indian consortium proposed setting up mines and a steel plant in the war-torn country. The Techint Group, the second-largest steelmaker in Latin America, has agreed to pay $2.8 billion for a 27.7% voting stake in Brazil’s Usinas Siderurgicas de Minas Gerais SA (Usiminas). Usiminas is the largest flat steel producer in Brazil with 9.5 million tonne of crude steel capacity. It has facilities near the main consumers of steel in Brazil and iron ore mines in the Serra Azul region. With a strong but volatile outlook for the sector, the global mining and metals industry is focussed on future growth through expanded production, without losing sight of operational efficiency and cost optimisation. The sector is also faced with the increased challenges of changing expectations in the maintenance of its social licence to operate, skill shortages, effectively executing capital projects and meeting government revenue expectations. Collated from PwC India

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has been estimated to increase, it remains constrained by environmental regulations. Moreover, the rate of growth is anticipated to be slower than the demand, thereby resulting in an estimated coal shortfall of 142 million tonne in 2012. Indian downstream metal operations continued to attract inbound investment. While not many significant deals of this nature were completed during 2011, JSE announced that it is looking to increase its stake in JSW from 14.9% to 24.9% in order to access the Indian market. Additionally, the National Mineral Development Corporation (NMDC) and Russian steel company Severstal are jointly developing a steel plant in India. While this represents one of the

of over 20 banks—reportedly the largest loan of its size in India since 1952. The proceeds will be used for constructing a 1-million tonne per annum (mtpa) alumina refinery with a 75-MW co-generation captive power plant at Lanjigarh, and a 1.60-mtpa aluminium smelter with 1,215-MW captive power plant at Jharsuguda in Orissa in Eastern India. Moreover, India’s IPO market is also subdued, mirroring the caution and unfavourable conditions seen in many markets of the world. There were just two small-scale new listings in the sector this year, Vaswani Industries and Readymade Steel India. Challenging equity market conditions MEANWHILE, IN INDIA... have also reportedly impeded the In 2011, a number of aspiring IndiaIndian Government’s ability to based mining and metals companies meet ambitious privatisation targets continued to target M&As to sustain this year. SAIL growth and become global India is the world’s third-largest coal producer, and although and Hindustan players in their own right. production has been estimated to increase, it remains Copper have deferred Despite this, outbound constrained by environmental regulations. Moreover, the issues of new equity. investment slowed in 2011 rate of growth is anticipated to be slower than the demand, with many deals struggling thereby resulting in an estimated coal shortfall of 142 million to be completed. This was POTENT WITH PROSPECTS tonne in 2012. largely due to different Coal and iron are likely largest investments in India’s steel asset valuation expectations and to remain the focus of mining market, it is also likely to bring the intense competition, rather than a loss M&As during 2012, although other latest steel-making technology to India of appetite for acquisitions. commodities, including copper and and thus motivate the Indian mining The largest deal to be completed in zinc, will also be targeted. Indian industry to reach newer levels. 2011 was Vedanta Resources’ increased companies are likely to continue looking stake in Cairn India, bringing its total to Indonesia, Australia and Africa for investment to 58.5%. While this is not growth opportunities, increasingly RAISING THE CAPITAL strictly a mining deal, as Cairn India opting to acquire outrightly rather Indian borrowers also faced some is an oil & gas producer, it adds scale than through off-take agreements. of the highest borrowing costs in to, and diversifies, Vedanta’s energy More domestic consolidation is 2011. Essar Steel reportedly paid operations. With the exception of the expected during 2012 within mid-size 13.4% interest on a $224-million domestic oil & gas deals, coal remains Indian steel companies in the hope of emerging market investment grade the most targeted commodity by the increasing scale and better positioning bond maturing in 2018—the highest Indian mining and metals companies, themselves against squeezing margins. coupon in the sector. The rising representing 94% of India’s outbound Companies also expect to see more cost of borrowing may impede the investments during 2011. To this, inbound investment in the steel market, expansion & acquisition ambitions of Anjani Agrawal, Partner and National with Asian steel giants POSCO and India’s mining and metals companies. Leader – Metals & Mining, Ernst & JSW showing an interest in accessing In an effort to rein in currency and Young India, adds, “Urbanisation, the India’s market potential. This can inflation pressures, the Reserve Bank need to build infrastructure and the potentially lead to the development of of India has raised its prime lending demand for automotives & consumer India-based greenfield steel projects. rate to 8.5% in last year, in a series of goods continue to fuel Indian mining rate rises over the past year. and metals investment.” In a positive sign, Vedanta prateek.sur@network18publishing.com India is the world’s third-largest Aluminium closed a $3.6-billion With inputs from PwC India, KPMG India coal producer, and although production project finance facility with a syndicate and Ernst & Young India Rio Grande project. Similarly, Pilot Gold was a new company created to develop 11 residual exploration projects when Newmont Mining bought Fronteer Gold. Australia was the most targeted geography. Coking coal assets continued to be in demand, although a number of deals could not be completed during 2011 primarily due to strong competition from Chinese investors. The need to move quickly on the decreasing number of goods projects around the world has also led to more joint bids than the industry has seen in several years.

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GLOBAL MINING DEALS 2011–12

Empowering Nations Mining, a venture that requires drilling, blasting, excavation, loading, crushing and conveying of an ore right from the bottom of the earth to the final processed product that comes out of a factory, is one of the most important factors that drives the nations in the present era. Every government tries to invest in and better its mining capabilities so that it helps the nation in its development. Here’s profiling a list of some of the sector-wise mining ventures happened in the last fiscal year 2011–12. ALUMINIUM Year 2011 saw 10 deals with a cumulative value of $6.5 bn and an average deal size of $654 mn, as compared to the sector average of $161 mn. The deal value was largely driven by Norsk Hydro’s acquisition of Vale’s aluminium assets for $4.9 bn to secure long-term supply of high-quality bauxite. British Petroleum’s divestment of its non-core business, Arco Aluminium, to a consortium of Japanese companies for $680 mn was the second largest deal in the sector. Transaction activities are expected to increase in 2012. Rio Tinto Alcan has announced that it plans to divest or close 13 of its assets. As aluminium prices in late 2011 and early 2012 are close to the marginal cost of production, it would seem that acquirers looking to the medium term could become active in the coming year while assets are cheap. China is expected to see producers consolidate and rationalise costs, potentially through closures.

COAL Coal is currently one of the hottest areas for Mergers & Acquisitions (M&As). In 2011, there were 161 deals either targeting coal or undertaken by coal companies. These deals had a cumulative value of $42.1 bn and an average size of $261 mn as compared to the sector average of $161 mn. In 2012, there are $18 bn worth of incomplete coal deals in Australia alone. In 2011, power utilities, steel companies and governments continued to integrate raw materials in order to manage supply and price risks. Consolidation in the North American coal market dominated acquisitions, while Indonesia, as well as frontier regions such as Mozambique and Mongolia, showed significant growth. The next two years promise to provide a supply imbalance in favour of thermal coal miners. Investors who want to benefit from the strong Chinese demand may look to coal reserves of Indonesia and Mongolia. On the other hand, those that want to take advantage from the imbalance in the Indian coal sector may focus on Australia and Indonesia. Aston Resources and Whitehaven Coal have announced a merger of equals that, along with the purchase of unlisted Boardwalk Resources, will create a $5-bn Australian coal company. Gloucester Coal has entered into a merger proposal with Yanzhou Coal Mining Company and its wholly owned Australian subsidiary, Yancoal Australia. Steel and power companies will continue to integrate into coal to help manage price and supply risk. Looking at 2012 and beyond, it is expected to see more deals in frontier markets.

COPPER In 2011, high prices, strong emerging markets demand and constrained mine supply were the major drivers of deal activity in the copper sector. Despite softness in price, copper still trades at more than double its marginal cost of production, thereby providing very attractive cash margins. As a result, junior explorers and miners emerged as prime takeover targets for bigger producers, particularly those looking to expand output capacity immediately. The biggest deal during the year was the acquisition of Africa-focussed copper miner, Equinox Minerals, for $7.4 bn by Barrick Gold. In Chile, Japan’s Mitsubishi Corporation acquired a 24.5% stake in Anglo American Sur for $5.4 bn. Interestingly, Chilean state-owned Codelco is currently disputing the acquisition by Mitsubishi, based on an option it had to acquire up to 49% of Anglo American Sur. Rio Tinto’s additional stakes in Ivanhoe Mines for a total $1.8 bn was aimed at gaining greater exposure to Oyu Tolgoi mine in Mongolia, which is expected to be the world’s biggest copper mine outside of Chile. The year 2012 may well see even further increase in Rio Tinto’s ownership of Oyu Tolgoi. This deal, together with smaller deals targeting Pakistan, Papua New Guinea and the Philippines, highlight the growing interest in untapped/high-risk regions to meet the need for copper supply growth. Canadian companies were the most active copper acquirers in 2011, completing 45 deals with a total value of $8.6 bn. Domestic activity dominated Canadian deals, with the majority involving junior miners and explorers. Japan completed two

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GLOBAL MINING DEALS 2011–12

large deals with a total value of $6.1 bn. It is expected to see an increasing number of deals targeting Latin America and Africa, as these regions account for the majority of potential copper supply. Acquisitions by sovereign interests for resource security are expected to be a continuing trend.

GOLD Strong demand and continued high prices may persist in 2012 and beyond. Gold deals were again driven by consolidation to access new growth and increase market share, with over half of the gold deals targeting domestic reserves and market share. Russia attracted the top deal by value—Kazakh Gold Group acquired Polyus Zoloto for $8.4 bn. Faced with limited growth options, major gold producers may increasingly look to diversify into copper, while maintaining their gold exposure. Barrick Gold closed the second largest gold deal of the year with its acquisition of copper producer Equinox Minerals for $7.4 bn. The strange disappearance of much of the gold premium during 2011 has made gold companies comparatively more attractive than in the previous years. This could also encourage more transactions to be done for cash. It is expected that deal activity will increase in 2012–13, mostly from transactions involving smaller M&As of equals and the disposals by majors of non-core holdings.

IRON ORE Strong demand and high prices were significant deal drivers, especially during the first half of 2011. Steel companies and governments are seeking new sources of raw materials in order to manage supply price risks. For a number of iron ore companies, deals were driven by the need to secure future reserves and achieve economies of scale for production, as well as spreading costs associated with infrastructure. The largest deal in 2011 was Cliffs Natural Resources’ $4.1-bn purchase of Consolidated Thompson Iron. This deal highlights the continued interest in Canada as companies seek to find new resources. Australia, too, remained a favoured destination both for inbound and domestic activities. In 2012, deal activity in West Africa is likely to increase as greater political certainty attracts more players to the region, even though this production will not reach the market until 2015 at the earliest. Steel companies will continue to integrate into raw materials to help manage price and supply risk. As an alternative way to gain greater off-take, steelmakers are also likely to become a new infrastructure funding source.

NICKEL The overall deal value increased 62% year-on-year to reach $1.5 bn, while the number of deals fell by almost a quarter. The larger nickel deals tended to focus on increasing stakes or taking over entire mining companies, while smaller deals focussed on securing minority stakes and supply security. The biggest deal was completed when Norilsk Nickel’s subsidiary, Stillwater Mining, acquired Peregrine Metals in Canada for $387 mn. It is expected that 2012 transaction activity will remain steady, but low in comparison to other base metals. Expected restraints on nickel prices means that transactions will be trying to lock in lower cost production via economies of scale or other synergies. Deals are likely to centre on expanding positions in existing nickel mining regions, along with significant laterite deposits in countries such as Australia and Canada.

POTASH/PHOSPHATE The rebound in potash demand was aggressive in 2011 and resulted in CanPotex and Belarus Potash virtually being sold out of potash by the third quarter of 2011, despite record production by Potash Corporation of Saskatchewan in the second quarter. In 2011, there were 21 deals either targeting potash or undertaken by potash companies. These deals were dominated by Russia’s consolidation of Silvinit and Uralkali. The merger made Uralkali the second largest producer of potash in the world. After Russia, Canada was the most sought after destination for potash M&As. There is also a growing interest in Africa. In the Republic of the Congo, China-based Evergreen Industries acquired TSX-listed MagIndustries for $119 mn, in order to gain access to the Mengo Potash Project. There is also interest in potash projects in Brazil and Saudi Arabia. The long-term demand fundamentals for potash and phosphate by the fertiliser sector are strong, largely due to population growth, changing diets, declining arable lands, the need to increase yields and historic under-application of fertilisers. There continues to be noteworthy exploration in Africa, particularly in the Danakil Basin, extending from Eritrea southward into Ethiopia. Vale’s project to produce phosphate rock in Mozambique is in the feasibility stage, with estimated

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production capacity of two million tonne per year. Canada’s outlook is also positive with Potash Corporation of Saskatchewan planning two new mines. On a less positive note, financially troubled Belarus looks poised to sell a stake in state-owned Belaruskali. As signalled by BHP Billiton’s increasing investment in potash and phosphate, the large global diversified miners will increasingly look to grow their portfolio exposures to these fertilisers. As such, the companies should expect some transformational deals over the next few years.

SILVER, LEAD, ZINC Global economic uncertainties and the possibility of another recession have led to renewed interest in silver. Zinc and lead deals have been driven by the need to secure long-term supply and achieve economies of scale. Nyrstar completed two zinc deals aggregating $979 mn when it acquired Canada’s Farallon Mining and later Breakwater Resources, thereby securing supply in low-risk jurisdictions. Hindustan Zinc, a unit of Vedanta Resources, acquired Anglo American Zinc for $1.3 bn. Anglo American Zinc comprises the Skorpion Mine in Namibia, the Lisheen Mine in Ireland and a 74% interest in Black Mountain Mining in South Africa. It is expected that deals in silver will continue as it is seen as a ‘safe haven’ commodity. Zinc and lead will also continue to be attractive where integration of mining and smelting operations provides scale & cost efficiencies. There will be high demand from emerging markets like China and India in 2012. More strategic joint ventures are expected, as smaller companies look for ways to minimise project risk and increase access to capital and operational capabilities, especially for companies focussing on emerging and developing silver projects. As seen in 2009, canny buyers of lead and zinc assets reaped handsome rewards in 2010 when there were concerns of global economic growth. A similar scenario may well be played out in 2012. Countries with high-grade deposits, such as Peru and Mexico, are the likely destinations of choice for future deal makers.

STEEL Market and price volatility is a big driver of deals in the steel sector as steelmakers seek to protect margins and remain competitive. Raw material prices have surged, and, in some cases (for example, when raw materials have to be imported), can account for up to 70% of the overall costs of goods. The biggest deal in 2011 was the acquisition of 15% of Brazilian niobium producer CBMM for $2.0 bn by a consortium of Chinese steelmakers and Chinese state-owned investment company, CITIC Group. In the US, the Renco Group acquired the North American assets of Severstal for $1.2 bn and OneSteel acquired Altasteel in Canada and Moly-Cop in Chile for $932 mn. The acquisition of Baffinland Iron Mines in Canada by ArcelorMittal and investment partner Nunavut Iron Acquisition for $514 mn highlights the move upstream into raw materials by steelmakers. The pending deal between Nippon Steel and Sumitomo Metal will create the second-largest steel producer in the world. The Chinese sector may consolidate further if the recent decline in steel prices adds impetus to government policy to further consolidate high-cost Chinese steelmakers. Increasing demand from emerging markets will see an increase in strategic joint ventures by global steelmakers with players in those markets. It is expected that the excess steelmaking capacity in North America and Europe may be progressively shut down and most new expansions may take place in Asia and the BRIC countries.

URANIUM The uranium sector experienced an uncertain first half of 2011, with deal volumes impacted by the fallout of the Japanese nuclear disaster. Despite market uncertainty in 2011, a number of large deals were completed. The largest was Atomredmetzoloto’s (ARMZ) acquisition of Mantra Resources, via its Canada-based subsidiary, Uranium One, for $981 mn. The Russian company was seeking to secure uranium reserves in Africa. The majors will continue to be active, with Rio Tinto completing its $620-mn acquisition of Hathor Exploration in 2012, BHP Billiton proceeding with its Olympic Dam expansion and the accumulation of assets by ARMZ. The Rio Tinto takeover of Hathor has generated a lot of interest in the highly concentrated global sector. The deal has given Rio Tinto a foothold in Athabasca Basin, which is already home to many other uranium-mining companies. The Australian Government’s recent decision to sell uranium to India confirms India’s emergence as a powerful customer. Time will tell whether the decision by Germany and others to cease development of nuclear power stations will stand up to energy security issues. The current uncertain environment for uranium will see acquirers seeking to take advantage of this disconnect between supply fundamentals that, in turn, leads to undervalued companies. Collated by Prateek Sur with inputs from Ernst & Young India.

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ROBOTICS IN NUCLEAR FUEL CYCLE

Automating the ATOMIC WORLD India has seen several developments pertaining to automation in atomic reactors. However, considering the developments in this ﬁeld in countries such as Japan, the US and other European countries, it is clearly evident that there is still scope for much more when it comes to high-temperature sustainable robots, real-time path planning, etc. An innovative development system with a judicious mix of young, senior, academic and research & industry personnel is essential for the speedy implementation of the targeted goals. obotics, automation and remote handling technologies play a crucial role in almost all facets of the nuclear fuel cycle, such as fuel fabrication, reactors, fuel reprocessing, In-Service Inspection (ISI) & repair, PostIrradiation Examinations (PIE), isotope production, etc. The phenomenal advancements in this fascinating area have been due to the various necessities—unique to the nuclear industry—to reduce the radiation exposure during handling operations and technologies required to facilitate remote inspection of inaccessible areas of nuclear reactors/ plants or to facilitate remote repair/ refurbishments of operating plants.

FUEL FABRICATION In the field of fuel fabrication, robots and automation are essential to increase the productivity as well as to facilitate the inspection of inaccessible remote locations. The automation of Non Destructive Examination (NDE)

in the fuel fabrication line results in significant performance enhancement in terms of cost, time and efficiency. Higher productivity and yield could be achieved in these plants with augmented automation and inspection concepts. These could include modern concepts like ‘intelligent processing’, where feedback from inspection could be given to the process for online correction, thereby achieving ‘zero defect’ concepts. Further, these concepts also facilitate higher levels of documentation of critical components like fuel pellets, end plugs and fuel pins, among others. These documentations help in accurately estimating the life of these components in reactors and also act as effective tools to take corrective actions in the fabrication procedures based on the feedback from operating experiences. A field that requires immediate attention is the thorium fuel cycle— the third stage of India’s nuclear energy programme. Since the fission of U232 results in high radiation levels, large-scale fuel fabrication using U233

in the thorium fuel cycle will be possible only if the fabrication facility is fully automated. Robotics and automation are the best choices for the speedy closure of fast breeder reactor fuel cycle, by way of reprocessing/ re-fabrication of short-cooled fast breeder reactor fuels.

FUEL REPROCESSING In fuel reprocessing, the current concepts of automation need to be augmented for increasing the reliability and productivity of the plants. The introduction of rugged automation concepts with the possibility of robotic or remote dismantling/repair capabilities will greatly facilitate the plant layout that is more structured and not dependent on the reach of conventional master–slave manipulators (MSMs). Reprocessing/ re-fabrication using advanced concepts, like pyrochemical or pyrometallurgical methods, is only possible in an automated manner. Large-scale waste management of highly active waste streams is always

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ROBOTICS IN NUCLEAR FUEL CYCLE

better done using automated concepts; for example, the waste immobilisation by vitrification. Decommissioning of highly contaminated glove boxes, reprocessing plant components, reactor internals, etc., also require advanced robotic concepts for remote handling and automation. ISI and repair of nuclear reactor/ reprocessing plants are some other challenging areas that require immediate attention. In case of remote inspection of the nuclear plants in service, automated and robotic inspection techniques allow faster inspection with accurate & reliable detection of defects. It is also possible to size the defects by employing such methods. It also helps in archiving the test results/data for future analysis and interpretation. In fact, the NDE aided by automation and robotic systems is key to achieve economy in design, manufacture, operation & life extension of components and plants. A number of such systems & gadgets have been successfully developed indigenously in the Department of Atomic Energy (DAE) and are being utilised for Pressurised Heavy Water Reactor (PHWR) coolant channel inspection, core shroud inspection of Boiling Water Reactors (BWR), etc. At Indira Gandhi Centre for Atomic Research (IGCAR), Kalpakkam, a number of ISI devices have been successfully developed and deployed for inspecting reprocessing plants. Currently, efforts are underway for developing a remote-controlled robotic device that can work at an ambient of 1500C. This device, which is nearing completion, can be deployed to the narrow inter-space between the main reactor vessel & the safety vessel and can perform a number of visual & NDE checks, where the temperature at the time of inspection will be 1500C. The device has a number of state-ofthe-art features for remote navigation, safe deployment & withdrawal and high-temperature inspection devices. In the past, considerable

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advancements were made in the development of remote handling equipmentâ&#x20AC;&#x201D;starting from low-end MSM, articulated versions to higher capacity rugged duty manipulators and modular three-piece advanced versions. Servo-controlled manipulators with large volume reach and moderate handling capacities have been also developed and inducted into service. However, this area requires very special attention to fulfil Indiaâ&#x20AC;&#x2122;s third-stage nuclear vision, by inducting advanced MSMs of leak tight version, higher capacity advanced servo manipulators coupled with remote vision and perception systems. Such systems are essential in all areas of nuclear fuel cycle, such as reprocessing, remote fuel fabrication, waste management and PIE among others.

NEED OF THE HOUR Many challenging and key areas of robotics in the nuclear realm require

for tele-presence using vision, tactile & feedback sensors and advanced instrumentation for remote operation. Another area that requires collaboration from academia is the development of advanced concepts for hyper-redundant manipulators, like spine manipulators. The robotic vision for quality control in automated transfer lines is to be introduced in remote and automated fuel fabrication. In case of robots for rescue operations, real-time path planning during the search is vital for the navigation of the robot and an optimal path planning strategy involving coordinated motion of multiple rescue robots need to be addressed. The key elements in achieving these challenging goals are through critical reviews of the evolving designs and pooling together the combined experiences in the industry along with the experimentation & analysis done by academicians and researchers. Increased participation of

Nuclear Power Reactors of India Power Stations Narora Atomic Power Station Rajasthan Atomic Power Station Tarapur Atomic Power Station Kakrapar Atomic Power Station Kudankulam Nuclear Power Plant Madras Atomic Power Station Kaiga Nuclear Power Plant

Location Narora, Uttar Pradesh Rawatbhata, Rajasthan Tarapur, Maharashtra Kakrapar, Gujarat Kudankulam, Tamil Nadu Kalpakkam, Tamil Nadu Kaiga, Karnataka

active participation from academia, R&D institutions and the industry. Some key issues are the development of standardised radiation-hardened electronic systems, feedback elements and tactile & vision sensors. Importantly, artificial intelligencebased control systems and advanced instrumentation for process automation need to be developed. In remote and automated fuel fabrication, complete automation assisted by robotic systems with tactile sensing hands requires to be implemented. This will include associated developments in the field of advanced control and analysis systems

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Date of Establishment January 1, 1991 December 16, 1973 October 28, 1969 May 6, 1993 November 20, 1988; Operational on January 14, 2004 January 24, 1984 November 16, 2000

industries in the design and manufacture of innovative concepts are essential for translating the R&D experience into production. An innovative development system with a judicious mix of young, senior, academic, research and industry personnel are essential for speedy implementation of the targeted goals. KV Kasiviswanathan, Raja Ramanna Fellow, Outstanding Scientist and Ex-Associate Director, Indira Gandhi Centre for Atomic Research Department of Atomic Energy, Kalpakkam. kvkasi@gmail.com, kasi@igcar.gov.in

INCREASING EFFICIENCY

Saving Energy = Saving Money Recently, the country witnessed the worst power outage when three major grids that supply electricity tripped. Nineteen states and more than 600 million people found themselves without electricity. The power crisis also majorly affected the industrial production in 11 states. It reinforces the fact that we need to work towards increasing energy efﬁciency. Industries should start adopting various methods for increasing the energy efﬁciency in their respective facilities. Here, we discuss some simple steps that can prove to be very resourceful for companies. NISHI RATH

SE ENERGY-EFFICIENT APPLIANCES

SELECT THE MACHINES PROPERLY Increasing efficiency and taking measures to reduce the amount of energy that a motor requires can directly impact the bottom line of your business. By replacing inefficient motors with premium efficient motors equates to significant cost savings over the life of the motor, not to mention the additional benefits in terms of reduced downtime and increased productivity and reliability.

An example of an energyefficient appliance is the LED. It has longer operational life than the conventional bulbs. It also reduces power consumption. A properly designed LED circuit can achieve as high as 80% energy efficiency, as compared to a compact fluorescent lamp or an incandescent bulb. Although LEDs are more costly, the cost will be offset over time in terms of energy cost savings and lower maintenance cost.

REGULAR MAINTENANCE Routine & regular maintenance of various equipment & buildings is a must. Inspect and patch leaks, clean or replace air filters, check fan belts, lubricate motors, pumps & fans, clean condenser coils and make sure that refrigeration seals are airtight. Well-maintained equipment runs more efficiently, reducing energy costs and extending the life of the equipment.

REPLACE OLD APPLIANCES Old appliances tend to be less energy efficient, as they were not designed to be so, or they are no longer in their optimal working condition. Replacing them is the best possible option. At the same time, a careful balance has to be made between energy conservation and waste reduction. If there is a real need to replace your old appliances, do consider sending them for recycling. In this way, some of their recyclable parts can be re-channelled to make new products. Also, it is important to get the model of the correct size and capacity as oversized or undersized appliances usually operate inefficiently.

GO FOR TECHNOLOGY Install switch plate occupancy sensors or motion detectors. These will automatically switch off the lighting when no one is present and switch it on when people return. However, these should be installed in places where

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EMPOWER EMPLOYEES it is capable to ‘see’ an approaching person’s motion.

DESIGN & MATERIAL OF BUILDINGS Consider the design and the materials used to build an office/facility. Using insulating materials will help to keep the temperature within the building at the desired level, regardless of the conditions outside. When there is a need to air-condition multiple rooms/ chambers at the same time, multi-split units are generally more energy efficient than separate single-split/ window units.

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Having a project leader to look after energy conservation can prove to be a good idea in the long run. He can form his own team from every department to keep a check on the whole system. These employees can be experts on motors, water/steam, electricity, lighting & heating, etc. Training the employees will make them aware of the importance of energy efficiency. It may help to have a Lean Six Sigma expert to suggest ways to enhance efficiency. nisi.rath@network18publishing.com

FINANCING SMEs

SMEs are the engines of a country’s growth, and, so, their development is highly critical. India has about four million SMEs registered with the government, of which, only 4–5% have been able to secure ﬁnancial support through institutional funding. To help SMEs prosper, there is a lot that needs to be done. Supportive government policies and initiatives by banks and other ﬁnancial institutions will help this ‘growth engine of a country’ smoothly chug along the path to progress. ARINDAM GHOSH

loans. Such a scenario is detrimental to process, VK Bansal, Executive Director, MEs form the backbone the growth of SMEs in the country. Global Small and Medium Businesses of the Indian economy Chamber of Commerce, Industry and are truly playing a and Services, explains that when a critical role in driving INTEREST RATES: A MAJOR CONCERN borrower applies for financial support the country’s economic Given that business activities are to banks or other authorised agencies, progress. Currently, SMEs account heavily dependent on credit, what is he needs to go through a cumbersome for 8% of the country’s GDP, 95% even more striking is that the interest of overall industrial units, rate for securing financial 45% of the manufacturing assistance from banks and India needs to create a ‘level-playing field’ in terms of the interest rates. This, in turn, will lower the financial burden on other financial institution output and 40% of all SMEs and will significantly contribute to their development. exports in the country. is quite high. In India, a However, factors such company is required to pay as high interest rates, difficulties in documentation process. In many cases, an interest rate of about 11–14% based availing easier finances and lengthy & proper guidance is not provided to the on the amount it borrows from the complicated documentation processes borrower while filling these forms. In authorised agencies. Commenting on are preventing the growth of SMEs. the process, he is not able to furnish the role of Global Small and Medium all the necessary details, which, in turn, Businesses Chamber of Commerce, Elaborating on some of the challenges delays the entire process for availing Industry and Services in making faced by SMEs in this expansion

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FINANCING SMEs

easier finances available to SMEs, largest financial supporters to the country, Global Small and Medium Bansal states that their institution is a SME sector in the country. However, Businesses Chamber of Commerce, ‘facilitator’. “If required, we also help due to lack of awareness, SMEs Industry and Services has planned to companies furnish all the documents remain unaware of the various sectoropen 25 centres across the country to the banks as per the requirement,” friendly schemes. Discussing the steps within the next two years. he adds. “Presently, there are about required to increase the awareness Each of these centres will have four million SMEs registered with levels, Bansal opines that there is a a team of experts who will guide the government. As per industry need for awareness programmes to prospective borrowers on how to secure estimates, only 4–5% of them have educate the firms about the various finances from authorised agencies. successfully secured financial support existing schemes offered by the banks. “The services will be available free through institutional funding. The “Banks need to be more responsible and of charge,” informs Bansal, adding, rest are highly dependent on personal play a sensitive role for the borrowers,” “Though the financial requirement has sources for covering their financial he says, adding, “Establishing to be provided by the banks, we will requirements,” continues Bansal. proper channels of communication, try our best to help SMEs smoothly One of the biggest differences especially from banks, will play a avail financial assistance. We may also between India and other countries critical role in terms of facilitating interact with the bank on their behalf, is the ‘rate of interest’, highlights access to credit for borrowers.” if required.” Bansal. While in other countries it is Besides, there is also a need to The body also plans to organise somewhere between 3% and 5% (in increase the scope for credit while more events across the country, which European countries, it is about 2% facilitating finance for MSMEs. will bring all the lenders and borrowers and in China, the interest rate is about Currently, banks thoroughly review together on the same platform. Bansal 3–4%), in India, it is in double digits. and analyse the financial health explained that the aim of these events Therefore, India needs to would be to increase the create a ‘level-playing field’ awareness levels of the SMEs account for 8% of the country’s GDP, 95% of overall in terms of the interest industrial units, 45% of the manufacturing output and 40% of borrowers on the various all exports in the country. rates. This, in turn, will schemes that are offered lower the financial burden by banks. They can on SMEs and will significantly compare all the schemes and finalise of a company and based on its contribute to their development. on a lender and scheme that best meets study, it assigns them credit ratings. their requirements. It would also give These ratings enable the lenders to the lenders an opportunity to extend easily assess the reputation of the WHAT THE GOVERNMENT HAS DONE? their reach. prospective borrower or the company The government is taking active steps Many lending institutions, like in the market and enable them to to smoothen the flow of credit for the Corporation Bank, have pledged to take decisions accordingly. Further, MSME sector in the country. The approve the loans for SMEs in 15 on many occasions, these lenders also Government of India and SIDBI have days of receiving the request from consult with credit rating agencies to set up the Credit Guarantee Fund the borrowers. However, the approval help them determine how to structure Trust for Micro and Small Enterprises would vary depending on the case. and approve the loan to them. Giving (CGTMSE) with an aim to make Elaborating on what State Bank a perspective from the credit rating finances available to borrowers. of India has done to help SMEs agencies, Kritika D Monga, Deputy CGTMSE would strengthen the credit on this front, Punarvasu, Assistant Manager – Business Development, delivery system and facilitate the flow Manager, State Bank of India, ICRA Ltd, said that the interest rates of credit to the sector by eliminating says, “In terms of offering better benefit varies in the range of 0.25–1% the hassles of collaterals and thirdservices to our customers, State Bank of depending on the ratings issued for a party guarantee for MSMEs. Under India has opened various SME company by the agency. Additionally, the initiative, free credit facility has branches across the country with a focus the government can look to adopt been extended by eligible institutions to cater to the needs and requirements international practices for lowering to all new as well as existing SMEs of the SME customer only.” the interest rates. This, in turn, will with a maximum credit cap of `100 After all, SMEs are critical to come as a huge boost to the growth of lakh. All the public sector banks have support the growth of the country, he the sector. been following these norms. thoughtfully concludes.

MANDATORY INITIATIVES

STEPS TAKEN

Banks are gradually emerging as the

To fuel the growth of SMEs in the

arindam.ghosh@network18publishing.com

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INNOVATING PROFITABLY

The

Best Practices for Success Consistent innovation leading to proﬁtability is what corporate India needs. There are no limits to the possibilities of the human mind. “Microsoft’s only factory asset is the human imagination,” wrote Frank Moody, the New York Times Magazine writer. Corporations that adopt innovation as a way of life never need to compete. Theirs is the path where no one has gone before—the path that leads to untold success. nnovation has the power to turn problems and inconveniences into profitable elements for a business. The mightiest of modern organisations have been built in a few years only through the power of information and human mind. Helping human imagination in developing creative solutions will be the secret to success. Innovation can be seen in every field and every sector. When the first pre-paid telephone cards were introduced in Japan, it was heralded as the best innovation of the year. It was an example of a simple innovation offering tremendous benefits, to both the consumers as well as the telephone companies. Innovating continuously is the need of the hour. However, this will not happen through mere rhetoric. An ‘innovation initiative’, which embraces everyone from the doorman to chairman, will create a culture of

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innovation. This initiative is for those who are willing to dive in and stay on the course of a long-term organisational development intervention. However, Indian companies have to overcome many hurdles before they achieve this goal. Lack of interest in investing resources for building a culture of innovation and a certain reluctance in installing the innovation tools are some of the big problem areas for the Indian companies. Creativity may be, as Plato called it, a ‘divine madness’. But if you want practicable innovations to give results, there needs to be a method to the

FORTUITOUS INNOVATION It was observed that elephants dragging logs in the jungles of Assam were returning with oily muck on their legs. This led to the discovery of oil reserves in the state—an excellent example of fortuitous innovation.

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madness. It is a fine balance, which involves taming the crazy idea to suit the business. The findings about the Indian brand of innovation reveal many gaps, which have been discussed in the book, ‘Innovate Happily’. Each innovation initiative needs to be tailormade to bridge the gaps in the selected company. Here’s how you can create a general framework for improving the ‘innovation quotient’ of your organisation. The structure should provide for sustained, long-term efforts to build an innovation culture. Two-day laboratories/seminars are not impactful enough to create this culture. In the words of Shekhar Arora, Executive Director – HR, Ashok Leyland, what we need is ‘365 days of innovation’. The process of building a safe, nurturing climate has to start from the top. Every participant has to become aware of the verbal, tonal and nonverbal innovation landmines that lie

INNOVATING PROFITABLY

buried in the existing culture, waiting to blow up new ideas. An even more important aspect of an initiative is installing the thinking tools. Every employee should learn and practice the tools, which form the foundation of innovation. Their regular practice and use in meetings can make generating and taming of new ideas an everyday occurrence. Thinking tools are not an occasional indulgence. They need to become the oxygen of the corporate existence. Here is a blueprint for an innovation initiative.

FORTUNE AT THE BOTTOM OF THE PYRAMID

“I consider constraints as a source of innovation. I believe in fortune at the bottom of the pyramid,” said Ravi Venkatesan, Former Chairman and Corporate VP, Microsoft India. The biggest challenge is cost. As an example of finding fortune at the bottom of the pyramid, Microsoft has created computers with five mice instead of one mouse per computer for rural schools. It has also created a computer that 10 people can share, which provides the additional benefit of learning to work as a team. Moreover, a split screen makes it easy for people to work on different problems at the same time. Such innovations have reduced the cost of access. Then, there is the problem of language. Many people do not speak English, and therefore Windows is now available in 14 languages—another example of innovation.

CREATE INCUBATORS FOR INNOVATION

into cash flow. We have experienced that in our company.”

DREAM BIG, BE FREE Let’s dream and dream big. Let’s change the world. Let’s have a high tolerance for failure, as fear for failure discourages people from trying. Curiosity has no genetics, nationality or gender bias; therefore, people should be free to explore and innovate. We then remove the escape button,” said Mariwala. Just like the Greek leader who burnt all the boats and bridges once his army was on the enemy territory. This meant that his force was infused with a do or die attitude. There was no way back. The only way forward was victory. Companies should also follow a similar path for encouraging innovation. Mariwala explained, “We are driven by our concern for the environment and preventive natural good health. To us, a customer is a person with constantly rising aspirations. Our suppliers are our partners in business.” “The idea is first incubated in an Incubation Cell. They report directly to me for two years. It is dismantled once their role is complete. Today, for example, the Kaya Skin Clinic is a flourishing new business. Each of my product teams identifies their

Nurturing

Stimulating

Sustaining

Reinstating

Harsh Mariwala, Chairman Innovation development cycle and MD, Marico Industries, innovation agenda as part of strategic believes that spreading the message of planning,” informed Mariwala innovation should be part of corporate when discussing the procedure for social responsibility as innovation can encouraging innovation at Marico build the nation. Innovation flourishes Industries, further adding, “We believe in an open and empowering culture. in orbit shifting innovation. To be “We give a new business idea to a team acceptable, innovation should translate and empower them to implement it.

BUILD THE YOUNG EXECUTIVES SYSTEM

When Ramaswamy Seshasayee, CEO, Ashok Leyland, found that young executives at Ashok Leyland felt alienated at times by the legacy system and red tape, he came up with a comprehensive Young Executives System (YES). Ashok Leyland, championed by the redoubtable team of Arora and Kalpana Ganesh, Head – Organisation Development, has created an efficient youth organisation with its own website to share ideas, sometimes directly with the CEO. They were given the responsibility to come up with a budget. They were also involved in creating a model truck. Both tasks were concluded with huge benefits, further affirming the importance of innovations.

TRANSFORM SPECTATORS INTO PARTICIPANTS

Another example of innovation is that of Tata Steel, Jamshedpur, which saved `700 crore merely by turning the whole population of the town into participants. B Muthuraman, MD, Tata Steel, speaks about their programme ‘Manthan Ab Shop Floor Se’, which means churning the energies of the shop floor. Every few weeks, workers from different departments, apart from management (except facilitators), get together for a three-hour meeting. These worker-driven gatherings have spawned hundreds of innovations that are rewarded at the ‘Innovation Exhibition’, where the workers also get to talk about their work to Ratan Tata, Chairman, Tata Group.

MAKE YOUR PRODUCT EXCITING FOR CUSTOMERS AND EMPLOYEES

Naina Lal Kidwai, one of the most powerful women of corporate India,

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INNOVATING PROFITABLY

opined, “Innovation is the key!” The HSBC Bank Branch at Flora Fountain, Mumbai, seems to be a hot spot for out-of-the-box thinking. The 35,000-strong workforce with an average age of 30 craves change and innovation. “The worst thing we can do is shut them out. They believe in themselves, they are so passionate about their ideas. They need to know where the idea is going. Just generating ideas is not enough!” emphasised Kidwai. Her ideas on innovation are interesting. “One needs to be able to generate ideas, grow them and finally disengage from them when the time comes!” It reminds one of good parenting. Nurture the baby, help it grow and finally, let it go! And the last may be the toughest!

Among some innovations that help the employees, especially new employees, bond with the bank are ‘New Employee Induction Roadmaps’, also called the ‘Jungle Book’. Then, there are a lot of other employee-fun activities, such as ‘Treasure Chest’, ‘Holi’, ‘Dilwalla’ and ‘Heroes Day’, among others. Employees are urged to play the lead, play to win, think beyond the possible and speed forward together. Customers too can look forward to an unusual experience at the bank. The bank is not a branch, but a mall. There are Saturday surprises that include food and ice creams for visitors. There is a charity sale as well. NGOs sell their products at the bank. All festivals call forth decoration and celebrations. There is a ‘May I help you?’ desk, and

Key Elements Of An Innovation Initiative Stimulating Identify people to be included in innovation initiatives

Help in selecting projects for creative problem solving Make available teams to work on projects

Nurturing Officially recognise the teams and scope of activity Schedule presentation for top management Provide a budget Organise innovation symposiums Provide space and time for innovation spirals to meet Mentors to help solve organisational hassles

Sustaining Start a Minds’ Power Club to meet once a month Give innovation awards

Reinstating Communicate the results of innovation initiative

Celebrate good ideas Prepare reports and publish success stories Use the innovation club for self-development

Have annual awards for best teams Name master innovators

Have a series of tests that can lead to create learning sets as thinking tools Provide common Persuade everyone to Create an office Develop a game plan facilities centre use Innovation Tools for development of keeing in mind the innovation, with time, cost and staffing representation on the parameters Board The innovation Evolve new processes Coach regularly through Have a problem bank from where participants chief should be to suit local conditions verbal, written and senior, qualified and can take up problems visual communication charismatic enough to to hone up their skills sell his/her ideas Reward small successes Provide means of Train and empower communication across problem owners or the organisation: champions intranet, open house, e-newsletters, etc. Provide counselling by Provide a consultant’s an expert for teams to support Top management to organise innovation provide support forums Top management’s approval and support

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Have a 52-week programme on innovation

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a special lounge to give high-net-worth individuals an extraordinary experience. This is presided over by a relationship manager.

FOCUS ON MARKETS IGNORED BY OTHERS

“Empowering people is the most effective way to create profitable companies,” stated R Thyagarajan, Founder and Chairman, Shriram Group of Companies. He brought workers into management and spent a lot of time with them. His methods are simple: Cut out all non value-added activities Engage each worker, including the contract labours, by uniting them for a common cause. The company decided to focus on truck operators, whom no one wanted to deal with, and considered them as financial partners. They collect no collateral. Elaborating on the procedure, Thyagarajan said, “We help them develop the business because we are co-creators of value. We give truck operators a vision for themselves. We treat them with respect. We support schools for drivers. We support AIDS prevention with the Melinda & Bill Gates Foundation. We try to deal with their total credit needs. And we are rewarded with total loyalty!”

BE A GOOD CORPORATE CITIZEN

Rana Kapoor, Founder, MD & CEO, Yes Bank, focusses on knowledge banking. The bank has utilised the domain knowledge of its customers for its further growth. For example, industries have financial products created by industry experts. An agricultural expert with core knowledge of the field helps the bank create financial products for this core sector. The whole banking process of Yes Bank has an unusual sustainability model, with the business focus being people, planet and profit, instead of profit, profit and profit. The bank believes in responsible banking. Its

INNOVATING PROFITABLY

model for sustainable investment banking has resulted in creating a bank for the poor.

DO NOT BENCHMARK: BE THE BENCHMARK

INNOVATE HAPPILY MANTRAS Innovation is taking interesting ideas and transforming them into usable solutions for business problems. Innovation is about transformation. Imagine a block of ice. It is cold, solid and transparent. However, it does not remain a block of ice forever; it melts and ﬂows. If you heat it, it boils; if you keep heating, it becomes airborne by taking the form of steam. Add pressure and the steam can rotate turbines to generate power. To resolve all problems, analyse men, material, machinery, methods, markets and money. The ‘6M’ is both a template and a blueprint to generate new ideas. The innovation process means problem statement, idea generation, incubation, analysis and implementation. Do not be afraid to ask questions even if it makes you look ignorant—nobody is expected to know everything. Happy communities can happen only when people stop being selﬁsh and start working together to solve each other’s problems. Every day, each of us should work on Making Things Better (MTB), so that we become a nation of problem solvers rather than a country of problem creators. Life is the greatest guru. Learn from it. Get rid of what is not divine, just as one has to get rid of all the extra marble in a block to make a beautiful statue. Do not be a victim of ‘hurry sickness’. Wait till your soul catches up with your body.

A start-up with five people and with an investment of `10,000, Infosys has now grown into a $3-billion company with 90,000 people. S Gopalakrishnan, CEO and MD, has the peaceful air of a corporate yogi. He said, “Infosys has to innovate to meet the needs of the new emerging markets—India and China—with more than two billion people whose rising expectations have to be met. Products have to be created for this market. We can learn from the mistakes of the developed and mature economies. We can start on a much higher platform, without repeating the mistakes they had made!” the area of water management. Ensuring buy-in from key people He emphaised that we need to create Replacing metal pumps with The engineering challenge. When benchmarks for the world, instead practically unbreakable concrete pumps, everyone heard that the Swiss could of following the benchmarks created Kirloskar has created long-lasting not do it, the virus of self-doubt by it. According to him, “Indians are systems. Illustrating their contribution became rampant. This was content with small improvements. to the agricultural operations of Laos, overcome by the infectious They are afraid to think global or about Alok Kirloskar recalled, “Six years ago, confidence of the top management. the quantum changes that innovation the rice economy of Laos was bad. We Watch manufacturers, in the past, is all about. We are restricted by the provided them with a unique system of were prone to copy the technology modesty of our dreams, the poverty pump sets that could be mounted on from other companies. Since the of our aspirations. It is this lack of boats. This helped the country produce 1950s, Indian companies had confidence that stands in the way a rice surplus in 2005–06.” never manufactured a watch all by of our becoming a world themselves. From 1992, An ‘innovation initiative’, which embraces everyone power.” He echoed the Titan started to attempt to from the doorman to chairman, will create a culture words of the German CEO break this trend. The Edge of innovation. This initiative is for those who are of the Indian business in was the result of a willing to dive in and stay on the course of a long-term Alcatel, “Indian engineers do close collaboration organisational development intervention. not have the confidence to between manufacturing, differ from their European clients, to technology and SLIMMER THAN THE BEST: THE go beyond the brief, to question status research teams. The challenge was to COMPETITIVE EDGE quo. That is why their products lack create a watch that was delicate as well “It cannot be done!” said the Swiss the originality that only a confident as tough enough to face the challenges watch makers. In the watch industry, dissent can create.” of daily wear. It is one of India’s major the Swiss are the ultimate court of product innovations, putting us on the appeal. However, the way the Titan world map! Watches produced Edge, the world’s SIMPLICITY IS THE KEY These 10 ideas can create an slimmest water-resistant watch, is Kirloskar has used simpler methods ecosystem and a culture that can make a lesson in persistent and patient and technologies to move towards innovation thrive in a company. problem-solving innovations. It was greater technological complexities. an example of an Indian company’s Earlier, the company used to refusal to give up. However, there were buy outdated technology from Dr Rekha Shetty, Author of best-sellers many challenges in the way, such as: multinationals. But now, it has become ‘Innovate Happily’ and ‘The Happiness Quotient’ one of the most successful players in Instilling self-confidence in the team Email: rekhashetty123@gmail.com

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THE ALL NEW JCB 3DX BACKHOE LOADER

An EARTHMOVING achievement! Vipin Sondhi, MD & CEO, JCB India, with the company’s all new JCB 3DX backhoe loader.

JCB India’s recent launch, the all new ‘JCB 3DX’ backhoe loader, aims to deliver better economics to its customers. With beneﬁts such as ensuring 20% lower fuel consumption in excavation activities—which will result in fuel savings of `2.25 lakh per year at the current diesel prices—this new-generation machine is certainly economical and efﬁcient. ARINDAM GHOSH

s part of the company’s expansion plans, JCB India, the country’s largest manufacturer of construction equipment, has recently launched the company’s all new ‘JCB 3DX’ backhoe loader. The move is aimed at helping the company further strengthen its grip on the market. The machine will be developed at JCB India’s backhoe manufacturing facility— the world’s largest—at Ballabgarh, Haryana. Speaking on the occasion, Vipin Sondhi, MD & CEO, JCB India, said, “With one out of every two machines sold in the construction and earthmoving sector being a JCB, the company aims to create new markets by foraying into new territories as well as give the best possible rate of return for our customers. This machine will perhaps do just that.”

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ECONOMIC & EFFICIENT The all new JCB 3DX is highly versatile. It ensures 20% lower fuel consumption in excavation activities, which will result in fuel savings worth `2.25 lakh per annum at the current diesel prices. This feature makes the machine one of the most fuel-efficient backhoe loaders available in the market. JCB further says that the machine is able to perform 25% more work per litre of fuel and also ensures 20% higher output per hour. It is powered by JCB’s 76 HP ‘ecoMax’ engine—an in-house developed system.

ERGONOMICALLY DESIGNED The new equipment has been ergonomically designed with 20% more cabin space keeping in mind the requirement of the operator. It has been provided with a new brake linkage system to ease braking effort

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by the operator. Also, its small turning radius makes the machine turn quicker, thereby ensuring more productivity in the loading cycle. It is also fitted with power track steering rod system for equal turn steering and quick response with less operating force for smooth and easy manoeuverability.

AFTER-SALES SUPPORT With a network of 57 dealers and over 430 outlets spread across the country, coupled with the company’s highly trained service engineers, JCB offers good after-sales support to all its machines. It also runs Operator Training Schools for conducting various training programmes for operators. The machine offers the best return on investment for customers and has the best resale value. arindam.ghosh@network18publishing.com

NEW LAUNCHES This section gives information about products, equipment and services available in the market. If you know what you want. . . refer to Product Index on Page 202 to find it quickly

ROTARY VANE OIL FREE VACUUM PUMPS

inivac RVD & MVC series of oil free vacuum pump direct coupled/ belt driven & monobloc vacuum pumps mounted on common base frames. These are compact in size, vibration free & hence can be mounted inside the machines. These attain maximum vacuum levels up to 25â&#x20AC;? of Hg & capacities range from 50 Lpm to 2000 Lpm. Use of imported graphite vane give advantage of prolonged vane life, silent operation & reduces wear & tear on stator. These are useful in many applications like capsule printing machines & other pharmaceutical machineries, packaging/ labeling machines, screen printing/ plate making, book binding/ folding machines, vacuum chucking etc.

Shree Siddhi Vinayak Industries Plot No.19, Kashimira Indl. Estate, Off. Western Express Highway, Post-Mira, Dist: Thane-401 104. Tel / Fax: 022-28458372 / 28457073 Email: response@minivacpumps.com Web: www.minivacpumps.com

CHEMICAL RESISTANT DIAPHRAGM VACUUM PUMPS

hemical Resistant Diaphragm pump are the best suited oil free vacuum option for laboratory & pilot scaled application. Typical applications for Chemical Resistant diaphragm pumps include evacuating chemically aggressive gases and vapors from such equipment as rotary evaporators, vacuum drying cabinets and centrifugal concentrators. Most importantly, diaphragm pumps are oil-free, for vastly reduced service demands compared with oil-sealed pumps. They eliminate the water waste of

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water-jet aspirators, and the contaminated waste-oil disposal of rotary vane pumps. The diaphragms are available in various options of materials like EPDM, neoprene, viton & teflon coated neoprene rubber. These vacuum pumps are available in the range of 15 lpm to 33 lpm generate a maximum vacuum of 30Torr. Chemical resistant vacuum pumps are supplied with 3phase fl ame-proof motors also.

Sri Vishnu Pumps Mfg. Co. 19A, Plot No.19, Kashimira Indl. Estate, Behind Kashimira Police Stn., Post Mira, Dist. Thane-401104. Tel / Fax: 022-28458372 / 28457073 Email: vishnupump@rediffmail.com Web: www.minivacpumps.com

3 PHASE HEAVY DUTY INDUSTRIAL VACUUM CLEANERS

LOWTECH offers highly sophisticated range of industrial vacuum cleaners to suit all industrial applications. All the models are available in powder coated mild steel, partial SS & complete stainless steel constructions. Vacuum cleaners are built on sturdy trolleys & supplied with various accessories & fi lter options including HEPA to suit different industrial applications in textile, food, pharmaceuticals, wood-working, engineering and electronics industries. They are equipped with high efficiency primary cyclone separators with secondary separators as cartridge fi lters/ bag fi lters. These are also available for wet & dry applications. These are also modified for complete wet handling systems for extraction of machine coolants & swarf separation.

BLOWTECH Row House No.2, Om Balaji Heights, Near Ramdev Park, Mira Road (East), Dist.Thane-401107. Tel. fax: 022-28458372 / 28457073 Email: response@vacuumcleanerindia.com Web: www.vacuumcleanerindia.com

NEW LAUNCHES

SLIMLINE RELAY

n todayâ&#x20AC;&#x2122;s high-tech world it has become inevitable that control panels will progressively reduce in size, forcing us to do a lot more in a lot less space. Connectwell brings you the right solution to such problems in the form of Slim Relays for switching and control applications. Conventional Relay Modules occupy about 25 mm per channel but with Slim Relays the same can be achieved in just 6 mm. They come with the additional benefits like being absolutely modular and din rail mountable. Th is is what we at Connectwell call sensible switching ... These Slimline Relays are available in the following three variants: A. 1 CO Electro-Mechanical Relay are available with input voltages of 5, 12, 24, 48 VDC with a contact rating upto 6A @ 250 VAC (or 30 VDC) B. 1 NO DC in - DC out Solid State Relays are available with input voltages of 5, 12, 24, 48 VDC with a contact rating upto 4 A @ 30 VDC C. 1 NO DC In - AC Out Solid State Relays are available with input voltages of 5, 12, 24 VDC with contact rating upto 2 A @ 380 VAC

Connectwell Industries Pvt. Ltd. D-7, Phase-2, M.I.D.C.,

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NEW LAUNCHES

Dombivli - 421 204, India. Tel.: +91 251 3980 600, 3980 700 Fax: +91 251 3980 700 connect@connectwell.com www.connectwell.com

MINIVAC SIDE CHANNEL VACUUM PUMPS & COMPRESSORS (TURBINE BLOWERS)

hese are designed to suck or to compress air / gases / nonexplosive air mixtures. These are absolutely oil free with air flow capacities range from 42 to 1100 m3/ hr with maximum vacuum up to 500 mbar & maximum pressure up to 550 mbar. These are light weight due to Al construction & having 100% oil free non pulsating continuous air flow. These pumps/ blowers require practically zero maintenance & are having silencers on both suction as well as discharge ports. These are useful in many applications like pneumatic conveying systems, industrial vacuum cleaners, electroplating industries like hot dip galvanising, oxy-generation in aquariums/ fi sheries, air feeds to industrial ovens & burners, printing & paper handling, air

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NEW LAUNCHES

pollution monitoring equipments, dental suction equipments etc. For further information contact:

Shree Siddhi Vinayak Industries Plot No.19, Kashimira Indl. Estate, Post-Mira, Dist: Thane-401 104. Tel / Fax: 022-28458372 / 28457073 Email: response@minivacpumps.com Web: www.minivacpumps.com

2500 AMP ACB PANEL

The function of this panel is to make energy distribution safer, minimise maintenance cost and reduce installation time.

Deep Automation Plot No-E-60, S.G.M. Nagar, N.I.T. Faridabad-121001 Haryana Tel: 0129-4056729 Mob: 09873671946 Email: automation_deep@yahoo.com Web: www.deepautomation.in

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VERTICAL MULTISTAGE INLINE PUMPS

SWAL Vertical Multistage lnline Pumps are suitable for a variety of applications from pumping of potable water & chemicals, which comes with various pump sizes and various numbers of stages to provide the flow and pressure required. Its applications include water treatment, ultra-fi ltration system, reverse osmosis system, softening, ionising, de mineralising systems, distillation systems, separators, swimming baths; water supply, fi ltration and transfer at waterworks, distribution from waterworks, pressure boosting in mains, pressure boosting in high rise buildings & hotels; industries, pressure boosting system, process water system, washing and cleaning systems, vehicle washing tunnels, fi re fi ghting systems; liquid transfer, cooling and air-conditioning systems, boiler feed and condensate systems, machine tools (cooling lubricants); irrigation field irrigation (flooding), sprinkler irrigation, drip-feed irrigation. Nominal flow rate is 1 15 m 3/h with pressure bar up to 23 Kg/cm 2 , with pump efficiency up to 72%. It is available in various material versions according to the pumped liquid. Series OCR in Cl, OCRI in AISI 304 and OCRN in AISI 316 grade.

Oswal Pumps Limited Oswal Estate, NH-1, Kutail Road, P.O. Kutail-132 037,

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Distt. Karnal, Haryana Tel: +91-184-6616600 (30 Lines) +91-1748-257701-04 Fax: +91-1748-257700 Email: munishrai@oswalpumps.com Web: http://oswalpumps.com, www.oswalpumps.co.in

PTFE LINED VALVES

luoropolymer FEP, PFA, PTFE, lined SGI/ WCB/ SS pipes, valves and fittings are offered using technical knowhow and raw materials for appropriate application of the resin for successful results with international quality for the chemical industry. Features are low co-efficient of friction, chemical inertness, non-toxic approved by international food & drugs regulatory authorities, non-infl ammable, self-sealant, excellent weathering resistant, zero water absorption, etc.

Supremo Line & Control Ahmedabad, Gujarat Tel: +91-079-22205282 Email: supremoproduct@gmail.com Web: www.supremoproduct.com

PUMPS & VALVES

VALVE SENSOR

he UVS 610 valve sensor allows partial discharge (PD) measurements to be conducted in liquid-insulated power transformers. The PD sensor is inserted into a power transformer through the vent of the oil drain valve. Used with a UHF converter, the UVS 610 is connected to the MPD 600 measuring system. A useful scale on the slide-rod ensures that the device is correctly inserted into the oil drain valve. Partial discharge measurements in high frequency ranges are conducted inside the tank of a power transformer. Th is ensures a more sensitive detection of partial discharges.

OMICRON Energy Solutions Pvt Ltd New Delhi, Tel: +91-011-47151234 Email: info.india@omicron.at Web: www.omicron.at

CUTTING VALVES

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hese cutting valves enable longer production runs resulting in increased production of parts. These are very compact, lightweight design allows the valves to be placed closer

PUMPS & VALVES

together for greater versatility. The new stems deliver greater performance for longer production runs with many on-off cycles. Six stainless steel springs increase reliability and production and the compact design enables close stacking of the cutting head.

Karolin Machine Tool (KMT) Pvt Ltd Mumbai, Maharashtra Tel: +91-022-28572494 Email: bhavin.mavani@kmt-waterjet.com Web: www.kmt-waterjet.com

VALVE

he size ranges from 1” to 8” (25 mm to 200 mm), the material of constructions is CI to IS 210 Gr.FG 200 and the operation is manually handle wheel operated. The sleeve is of neoprene, nitrile or as per one’s requirements. The working condition is 150 PSI at max 150 degree. The end connection is of fl anged end and the fl anged is as per BS 10 table D or as specified by one’s

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requirement. The top body and bottom body is made of cast iron, stem is SS AISI 410, the stem bracket is M.S, gland, bracket and hand wheel is made of cast iron.

M Kumar Technocrates Ahmedabad, Gujarat Tel: +91-079-27540287 Mob: 9898114242 Email: info@amtechvalves.net Web: www.amtechvalves.net

GATE VALVE

his knife gate valve features non sliding motion, avoid sliding contact between body & gate enables the flushing of media from the valve interior. Bottom edge of the gate (knife edge) allows the tight shut off even when solid particles settle at the bottom of the body. A wide variety of hardened trim options are available for the gate, seat and wear ring. Knife gate valve is a unidirectional valves & bidirectional valves. The operation is manually operated, gear operated, pneumatic, hydraulic or motorised actuator operated.

M Kumar Technocrates Ahmedabad, Gujarat

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Tel: +91-079-27540287 Mob: 9898114242 Email: info@amtechvalves.net Web: www.amtechvalves.net

PLASTIC FLAP LOADED FOOT VALVE

he new range of plastic fl ap loaded foot valve is most popular due to its friction-free low coast design. It is gives better linear flow of water in suction lines than CI foot valves. These products exhibit some of the distinguished features, like durability, friction free design, corrosion resistance, leakage-proof and dimensional accuracy. Technical specifications include standards as per IS:10805:1986 of BIS, thread as per IS:554:1985 of BIS, body test pressure at 0.5 MPa, seat test pressure at 0.02 MPa, normal bore size 21/2” and 3” (65 mm and 80 mm), and materials of construction: PP body, PP strainer, and PVC washer.

Arti Products Rajkot, Gujarat Tel: +91-0281-2388908 Mob: 09428155144 Email: arti_product@sify.com Web: www.artiproducts.in

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PNEUMATIC CYLINDER VALVE

he Y-type angled pneumatic cylinder valve is used for process control application. Th is valve is used for on/ off application to control steam, water, coolants, air, gas and light oil at line pressure up to 10 bar. The actuator is pneumatic cylinder-type with pressed stainless steel. It is available in sizes ranging from ½” to 2” bsp with 2 way and 3 way investment casted body. The valve fi nds application in pharmaceutical machinery, textile dyeing machinery, air-drying equipment, autoclaves, automobile industry and automatic process control applications.

Madho Controls Pvt Ltd Thane, Maharashtra Tel: 022-2588 3252 Mob: 09820066046 Email: madho@vsnl.com Web: www.madhocontrols.com

PNEUMATIC VALVE

he valve is pneumatic controlled with vertical actuator that is usually supplied with DIN-SMS-IDF union. Construction features include, choice of materials and hygienic concept of SPF valves, which makes the valves suitable for

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use in sectors where hygiene is indispensable. The pneumatic valve meets a wide range of applications in dairy, food, pharmaceutical and chemical industries.

Sri Pumps & Fittings Industrial Corporation Rajahmundry, Andhra Pradesh Tel: 0883-242 6845 Mob: 9440868551 Email: sripumps@yahoo.co.in Web: www.sripumps.com

LIQUID CONTROL VALVES

he pilot-operated liquid control valves are specially design for liquid service. These valves are so designed that by providing different combination of pilot arrangement the valves can be used for various types of functions, like on-off, pressure reducing, pressure relief, flow control, pump bypass, non-return, etc. The liquid controls valves conforms the seat leakage in class VI of ANSI B 16.104 and are available up to size of 16â&#x20AC;? in the fl anged end to ANSI class 150 and 300 with temperature range up to 220Â°C maximum.

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Brightech Valves & Controls Pvt Ltd Ahmedabad, Gujarat Tel: 91-079-22902911 Mob: 09426055442 Email: info@brightechvalves.com Web: www.brightechvalves.com

BALL VALVE

his ball valve comes with pneumatic rotary actuator. The valve is of on/off type with screwed, fl anged, socket weld, tri-clover end in three-piece design. It is available in SS-304 and SS-316 investment castings and is fitted with double-acting pneumatic rotary actuator that operators through 90-degrees angular movements of ball valve or butterfl y valves. Pneumatic actuator is mounted directly on the shaft of the valve. The actuator is supplied with solenoid valve mounted on it. It is available in different sizes up to 4â&#x20AC;? to control fluids such as steam, chemicals, oil, air, and water.

Madho Controls Pvt Ltd Thane, Maharashtra Tel: 022-2588 3252 Email: madho@vsnl.com Web: www.madhocontrols.com

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GOLIATH CRANES

he single girder and double girder Goliath cranes conform to IS:807-1976, IS:3177-1977, IS:3938-1983 and IS:4137-1963 wherever applicable. These cranes are manufactured up to 50 ton capacity and for 40 m span. Grabbing cranes are designed to suit indoor or outdoor location and can also be supplied with grab buckets, electromagnets. Goliath cranes are designed to run on forged steel wheels running on L-type housing on anti-friction roller bearings. These cranes are suitable for control from floor, by means of pendant controller or from the driverâ&#x20AC;&#x2122;s cabin by means of master controller or through radio remote control.

Elmech Engineers Mumbai, Maharashtra Tel: 022-2352 1798/2710 Email: eddycranes@vsnl.com Web: www.elmechengineers.com

WALL CONSOLE CRANES

he wall console cranes can slide horizontally along a track on the wall. The girder can reach up to 10 meters, and loads can be lifted up to 20 meters. Such features allow the wall console cranes to squeeze into the tightest assembly line, warehouse, or other industrial area. Th ree end carriages work together for a stable and balanced crane. Steel girders ensure strength and painting resists corrosion over the life of these systems.

Konecranes India Pvt Ltd Pune, Maharashtra Tel: +91-020-40047470 Email: india.sales@konecranes.com Web: www.konecranes.com

FLOOR CRANE

he floor crane has load-lifting capacity of up to 1000 kg, hook lift up to 8 feet from ground level, and boom length up to 5 feet. It is hand pump and power operated. The crane is widely used in various industries, like plywood, laminated sheets, ceramics, paper lamination, plastic moulding,

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MINING

packaging, automobiles, rubber moulding, textile, pharmaceutical, etc. The floor crane is also used in rack storage systems and container loading.

Hydro Mech Engineers Ahmedabad, Gujarat Tel: 91-079-25890771 Mob: 09825019905 Email: info@hydromech.in Web: www.hydromech.in

EOT CRANES

he rational structure of the crane is of box construction adequately designed and reinforced by stiffening ribs. It is connected with bridge trolley, which is moved by motors, coupled up with speed reducers. The crab carriage is in steel section. It comprises of special crane duty motor, connected to speed reducers and is coupled to a grooved steel drum. Electromagnetic brakes are used to control the smooth lifting of weight. AC drive is also provided (on demand) for smooth operation of long travel. The

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hook is equipped with a forged steel forked revolving hook. Wire rope is of 6 x 37 construction.

Friends Engineering Works Udaipur, Rajasthan Tel: 91-294-2492200, 91-294-2494379 Mob: 09829042424 Email: info@friendseng.com Web: www.friendseng.com

LIFT GOLIATH CRANE

his unique special type goliath crane has with 12 tonne lifting capacity. It has a 180 m lift with 20 m span that includes a hoisting speed of 25 m/min. Th e crane can be used for lifting and shifting of blusted muck through bucket with openable gate at the bottom. It can be used for transportation of steel ribs for shaft up to 180 m deep. It can also perform all activities from ground level to 180 m deep shaft, including transferring of loader/ JCB/ BOBcat for loading of muck in the bucket.

Century Crane Engineers (P) Ltd Faridabad, Haryana Tel: +91-0129-4048863 Email: century@centurycranes.com Web: www.centurycranes.com

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MINING

ALUMINIUM CRANE SYSTEM

hese XA aluminium light crane system applies the strength and low weight of aluminium to every light material which needs to be lifted. Handling low loads is of up to 2 metric tonne across a wide variety of rail types, it is a robust, cost-efficient solution. An anodised aluminium surface ensures the long-term durability of the system purchase. The modular design, requiring no welding or painting, greatly reduces downtime during installation, expansion, or upgrade.

Konecranes India Pvt Ltd Pune, Maharashtra Tel: +91-020-40047470 Email: india.sales@konecranes.com Web: www.konecranes.com

GRABBING CRANE

his grabbing crane is suitable for ceramic and other industries to handling various raw materials. The crane can lift up to 3 tonne capacity in one single scoop. Crane that

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can handle loaded grab of desired capacity is also offered. In addition, all types of fl ameproof and explosion-proof cranes to gas groups I, IIA, IIB and IIC as per IS:2148 are also available. Nonsparking track wheels are manufactured from non-ferrous materials. The crane is suitable for petrochemical plants, oil refi neries and mining.

Aarco Kolkata, West Bengal Tel: +91-033-2379736 Email: guptarun@123india.com

PALLET TRUCK

he model AGHL-100 high-lift pallet truck is specially designed for raising pallets to medium heights up to 800 mm. Th is pallet truck is used for stacking 2 to 3 pallets. Pallet used in the hydraulic hand high lift trolleys is used in various types of work in plant and maintenance shops. Technical specifications include capacity of 1000 kg, minimum height of 90 mm, overall width of 560 mm, fork

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MINING

width measuring 152 mm, fork length of 1220 mm, and raised height of 800 mm.

Agromec Meerut, Uttar Pradesh Tel: +91-0121-2440660, 91-121-3098766 Mob: 09313159058 Email: agromec@vsnl.com Web: www.agromecindia.net

HYDRAULIC PALLET TRUCK

iger hydraulic pallet truck is of high quality engineering and heavyduty construction. It is an economical solution for handling heavy loads. The frame is made of heavy duty formed steel, jig welded and forks of double fl anged pressed steel which gives maximum strength. Ram and pump plunger of the hydraulic cylinder is grounded to high precision and hard chrome plated which reduces wear and resists from corrosion. Special safety valves are provided for smooth lowering of load and a dual overload safety valve is provided to

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MINING

protect the truck from damage due to overloading.

Ferro Foundries Pvt Ltd Mysore, Karnataka Tel: +91-821-2402376,+91-0821-3048000 Mob: 09845120878 Email: info@ferrotiger.com Web: www.ferrotiger.com

HYDRA TRUCKS

he model model TL-4M Truckman hydra trucks (also called die loader) is efficient and ideal material handling equipment, designed for quick loading and unloading of press tools or machine parts, crates, oil drums, components, etc. Pump is manually operated and is of double acting type complete with oil tank with release valve capacity of 500 to 1000 kg. Lift maximum from the ground level is 1400 mm. Lowered height is 140 mm. Platform size is 700 x 700 mm. The unit is mounted on polymer wheels for easy movement and long life. Applications are in tool rooms, godowns, engineering units and chemical and petrochemical industry, automotive industry, etc.

Textile Machinery Manufacturing Company Ahmedabad, Gujarat

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MINING

Tel: 91-079-22941389 Mob: 094284 07325 Email: truckman@eth.net Web: www.truckmanindya.com

MACHINE HANDLING PALLET TRUCK

he model AGMH-500 hydraulic machine handling pallet truck is ideal for transportation and installation of heavy machines in the plants. The capacity of the pallet truck is 5000 kg. Fork length is available up to 1650 mm. The overall width is up to 1150 mm because of which heavy and large machines can be handled by inserting two trolleys from both the sides. The pallet truck has multi-purpose hydraulic lifting trolley that ensures safe handling of machines for commissioning and transferring of plants. Platform on forks are provided for greater stability.

Agromec Meerut, Uttar Pradesh Tel: +91-0121-2440660,+91-121-3098766 Mob: 09313159058 Email: agromec@vsnl.com Web: www.agromecindia.net

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GENERAL PRODUCTS

TRI-LOBE ROTARY BLOWERS

he advanced technology next generation Axcel TR series Tri-Lobe blowers are suitable for air/gas applications. It is ruggedly built and can work under tough conditions, high transmission loads and higher operating speeds with capacities up to 65,000m 3/hr and pressure up to 1.1kg/cm 2 in single stage/ up to 2.2kg/cm 2 in multi stages. The computer generated new millennium series rotor lobe profi le optimises high volumetric efficiency, minimises slip losses, lower power consumption and thus are energy efficient.

A K Ahuja (AGM-Projects) Swam Pneumatics Pvt. Ltd. C-2, Sector-3, Noida, UP - 201301

have rigid heavier structure with IS 25 grade casting, 60 degree true slant bed, precision A2 series cartridge spindle, heavier LM rails, blocks & ball screws for axes, linear toolings with more X-axis travel. TIZONA I can turn jobs having diameter 100 x 150 length and TIZONA II is for diameter 200 x 250 length jobs. TIZONA has the latest CNC controller with 8.4” TFT colour display, USB interface and many more useful features. It is equipped with suitable power chuck, lubrication & coolant system, air-conditioned electric panel with quality components, tool holders, etc. TIZONA CNC Chucker Series is designed to turn various chucking components with minimum cycle time. The gang tooling works adeptly without delaying the turret retraction and indexing, thus it eliminates the unproductive nonmachining time. These machines are best suitable for precision components in mass production with optional integration of bar feeder, bar puller, autoloader, automation line, tooling solution, etc.

TIZONA I & TIZONA II CNC TURNING CHUCKERS

vermark Automation Pvt Ltd is one of the most dynamic growing companies in CNC machine manufacturing having productive design and very good manufacturing & testing facilities. The company’s sister concern Accurate Machine Tools offers the fi nest machines in the industry. Avermark offers TIZONA I & TIZONA II CNC Turning Chuckers, which

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Avermark Automation Pvt Ltd Veraval (Shapar) – 360 024. Dist. Rajkot Tel: +91 2827-253677/88 Mob: +91 98242 22448 Email: sales@avermark.com Web: www.avermark.com

GENERAL PRODUCTS

FIRE ROLLING SHUTTERS/ FIRE DOORS

ndiaâ&#x20AC;&#x2122;s No. 1 entrance automations & loading bay equipment company Gandhi Automations offers fi re rolling shutters/ fi re doors: constructed of galvanised or stainless steel in a variety of gauges, slat designs and fi nishes for unsurpassed strength, durability and style. Wide ranges of styles meet or exceed industry fi re safety testing standards including UL, FM and ULC. The doors are also compliant with all NFPA-80 standards. Door closes automatically under governor control after separation of fuse link. UL-listed brush-type smoke gaskets satisfy smoke retardation requirements. Additional safety options include the fi re SentinelTM timedelay release device photoelectric or ionization-type smoke detectors, with or without heat detector. Additionally available uninterruptible power supply for use with motor-operated doors allows door closure by central alarm or smoke detector under motor power. 2 â&#x20AC;&#x201C; 4 hours Fire rated resistance. Compliant with BS 476 part 22/UL/FM/REI 120.

Gandhi Automations Pvt Ltd Mumbai, Maharashtra Tel: 022- 66720200/66720300 (200 lines) Fax: 022-66720201 Email: sales@geapl.co.in Web: www.geapl.co.in

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GENERAL PRODUCTS

CYLINDRICAL PHOTOELECTRIC SENSOR

he CY series cylindrical photoelectric sensor has a M18 thread size for convenient mounting in industries. It has a long sensing range up to 12 metre throughbeam type, 3 metre through retro-reflective type and 120 mm through diff use-reflective type. Th is sensor has a wide product range with DC supply type 10 to 30 V DC and AC supply type 24 to 240 V AC. It is used in industries such as ceramic, packaging, pharmaceuticals, food processing, automobiles, textile, plastics and many more.

Lubi Electronics Ahmedabad, Gujarat Tel: +91-079-22205471, Mob: 09825569559, 09327497006 Email: info@lubielectronics.com Web: www.lubielectronics.com

ROLL TURNING LATHE MACHINE

he roll turning lathe machine is rigidly designed and suitable for heavy jobs. Th is lathe machine combines all the features which are expected in roll turning lathe machines with great efficiency and is ideal for all sliding, surfacing and screw

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cutting operation. Its important features include hardened & ground bedways, plano type one-piece solid bed, raw material used is selected and fi rst grade quality. Its main spindle is hardened and ground with double grinding. All screws are made from bright steel with gunmetal screw nut, Turcite-B coated in saddle & surface guideways. It has a full norton gearbox.

Premier Lathe Manufacturing Co Rajkot, Gujarat Tel: 91-0281-2387556 Email: info@premierlathe.co.in Web: www.premierlathe.co.in

LATHE MACHINE

he Max series medium-duty type lathe machine is compact and offers better value for money. Th is machine features simplicity, robustness and longer working life. It rotates the workpiece on its axis to

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GENERAL PRODUCTS

perform a variety of operations, like cutting, sanding, knurling, drilling, etc. The machine is sturdy and easy-to-use and assures optimum return on investment. It is highly versatile and durable. The medium-duty lathe machine is built using modern technology to assure enhanced functioning. Th is lathe machine is useful for precisely machining relatively hard objects.

Bhavya Machine Tools Ahmedabad, Gujarat Tel: +91-079-40087900 Email: info@bhavyamachinetools.com Web: www.bhavyamachinetools.com

COPPER ENAMELLED WIRE

his is manufactured using EC grade copper rods that are extruded or drawn by dies of special size and are further repeatedly coated with enamel. Various varieties of enamelled copper wire comprise polyester, polyesterimide and self-solderable wires. For example, polyesterimide overcoated with polyamide-imide enamelled round copper wire, class 200; modified polyester enamelled round copper wire, class 155; polyester enamelled round copper wire, class 130; all in the range of 4.06-0.091 mm (8-43 swg). Polyestermide enamelled round copper wire, class 180, in the range of 4.06-0.091

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mm (8-43 swg). Self solderable polyurethane enamelled round copper wire, class 155 & 180, both in the range of 0.813 mm to 0.091 mm (21 swg to 43 swg).

Jalan Wires Pvt. Ltd. Mumbai, Maharashtra Tel: 022-61451600 Email: sales@jalanwires.com Web: www.jalanwires.com

WIRELESS DATALOGGER SYSTEM

he Testo Saveris Radio probes and measures temperature & humidity and saves the recorded measurement data sending to the central base at regular intervals. If a limit value is exceeded, a radio link is established immediately. In free field, the transmission path is approximately 100 m at a frequency of 2.4 GHz.

Testo India Pvt. Ltd. Pune, Maharashtra Tel: +91-020-65600203 Mob: 09375346186 Email: apatankar@testoindia.com Web: www.testo-india.com

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MOTOR PROTECTION RELAY

his displays various parameters, trip count and trip data on 8-digit alphanumeric display, and has separate LEDs for individual fault indication. Th is is a four user programmable output relay, its built-in self-supervision & self-testing feature helps maintenance. Th is provides easy operation by 5 push buttons. RS485 Port for serial communication with â&#x20AC;&#x2DC;MSCOMâ&#x20AC;&#x2122; user-friendly software.

Larsen & Toubro Ltd. Mumbai, Maharashtra Tel: +91-022-67054902 Email: karthikm@lntebg.com Web: www.lntebg.com

ELECTRIC MOTORS-D

he range consists of 0.12 HP to 425 HP. These have dynamically balanced rotors, corrosionresistant frames and end-bracket hardware. These have high-efficient stator laminations with superior low loss CRNGO steel and are designed for 50 0 C ambient temperature for the entire range.

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These have stainless steel rating plate and six terminal constructions across the range. These have compatible AC drives & software starter range.

BCH Electric Ltd. Barakhamba Road, New Delhi - 110001 Tel: 011-2331 6029/6539 Email: bilmkt@vsnl.com Web: www.bchindia.com

SLIPRING MOTOR STARTER-D

he slipring motor starter Magnastart inducer consists of three coils wound on specially shaped steel cores. Eddy currents in these cores are refl ected in the windings as impedance that is dependent on rotor frequency. Comprehensive thermal protection prevents any possibility of damage. Smooth acceleration to full speed reduces electric stress in the motors.

JSL Industries Vadodara, Gujarat Tel: +91-0265-3054631 Email: jyotiltd@jyoti.com Web: www.jyoti.com

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MOTOR PROTECTION RELAY

icrocontroller-based motor protection relay PD-MMPR-303 uses the state-of-the-art microcontroller-based measurement techniques for providing protection for motors up to 75HP. The comprehensive protection features of the relay make it ideal for motor protection. The heart of the relay is microcontroller-based reliable hardware with special algorithms to calculate the tripping time. The relay continuously monitors the three-phase currents to build the thermal replica of the motor. Th is thermal replica is used to protect the motor against thermal overloads.

Prok Devices Pvt. Ltd. Bengaluru, Karnataka Tel: +91-80-26760718 Mob: 09845033226 Email: prokdvs@vsnl.com Web: www.prokdvs.com

ELECTRIC WIRE ROPE HOIST

he electric wire rope hoist is available from 0.5â&#x20AC;&#x201C;50 tonne capacity range with a maximum height of lift of 200 mtr in accordance with Class I, II, III & IV heavy-duty specification as per IS:3938-1983. Th is wire rope hoist is manufactured offering foolproof electro-mechanical brakes operating on conical rotor motor principles. The brakes are far superior to electro-hydraulic thrustor

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brakes offered by most other manufacturers. All hoists have high torque, crane duty, 40% CDF, Class-F insulated conical motors suitable for 150 starts/hour. Brakes are provided in hoisting as well as cross traversing motion.

Eddycranes Engineers Pvt. Ltd. Mumbai, Maharashtra Tel: +91-022-23522710 Email: eddycranes@vsnl.com Web: www.eddycranes.com

ELECTRONIC SAFETY SENSORS

he RSS-36 electronic safety sensors are equipped with RFID technology, with different variants, each with different coding possibilities. These sensors also feature all the well-known advantages of the CSS technology. A second version only accepts the target, which was taught during the fi rst start-up. In the third version, the teach-in process can be repeated any number of times.

Schmersal India Pvt. Ltd. Pune, Maharashtra Tel: +91-020-26741000

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187

GENERAL PRODUCTS

Mob: 09595457878 Email: info-in@schmersal.com Web: www.schmersal.in

LATHE CHUCK

he Rota-S plus lathe chuck has an optimised wedge bar drive system and an improved lubricant system to ensure consistently high clamping forces from the new lathe chuck. Since higher speeds and cutting speeds are possible, users can apply more efficient cutting materials, which shorten the manufacturing time. An optimised drive allows fast, comfortable and repeat accurate jaw changes. Th is lathe chuck is fully compatible, and already existing base jaws can be used in it. Its unique three-fold jaw safety device prevents operating errors. It has located an indicator pin at the chuck circumference, which displays the individual clamping status. Protection sleeve system and expansion arbor are categorised as additional equipments.

Schunk Intec India Pvt. Ltd. Bengaluru, Karnataka Tel: +91-080-40538999 Mob: 09741211766

Amit Kapur, Director, Everest Group, New Delhi, India. Network 18 Publishing is a critical partner in promoting our solutions. They are at the forefront of delivering industry editorial content while offering leading-edge multi channels (online portals, newsletters, magazines, Yellow Pages, etc.) that enable us to effectively increase our brand awareness.

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GENERAL PRODUCTS

Email: info@in.schunk.com Web: www.schunk.com

EXTRA HEAVY-DUTY LATHE MACHINE

he Balaji series VGH geared-head extra heavy-duty lathe machine has height of centre 267 mm, length of bed up to 6,095 mm and admit between centres up to 5,000 mm. Main spindle hollow is 80 mm and the main spindle nose is A2-8 type. Dynamically balanced spindle runs at vibrationfree motion at 1,200 rpm. All gears are made of 20MN CR5 material and fully induction hardened and teeth grinding. The Norton gearbox cuts any metric, modules and pitch (DP). Bed is made from graded cast iron and fl am hardened up to 400 BHN diameters.

Vinit Engimech Pvt. Ltd. Rajkot, Gujarat Tel: 91-281-2312091 Email: vinit@blalajilathe.com Website: www.balajilathe.com

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189

INTERNATIONAL PRODUCTS

NICHROME SEALING WIRE

his is a new line of nichrome resistance wire coated with DuPont Teflon to create a non-stick surface for use at high temperatures. The nichrome wire provides a non-stick surface in a variety of plastics and packaging processing applications and is capable of 260째C continuous and 316째C intermittent use. Th is is suitable for use in a wide range of packaging, sealing, shrink wrapping, plastic sheet & styrofoam cutting, and acrylics bending equipment.

Applied Plastics Co, Inc - Massachusetts - USA Massachusetts, Massachusetts Tel: 781-7621881 Email: davering@appliedplastics.com Web: www.appliedplastics.com

GE Fanuc Automation Europe SA, Germany Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com

MINIATURISED SENSOR SYSTEMS

he CarboSen miniaturised sensor systems are used for detection of fl ammable gases, such as CO, H2 or CxHy. These systems consist of a sensor unit, sensor housing and sensor electronics. The sensor electronics enable temperature compensation during operation. Th is design can be used at temperatures up to 450째C.

SPINDLE MOTOR

he Fanuc spindle motor BetaiI series is a high performance motor suited to spindle axis of machine tools. High efficiency & low heat generation is achieved by

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SPINDLE HRV control. Optimised winding design & effective cooling structure enables high power and high torque. The compact size of the motor is an added advantage.

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Lamtec GmbH & Co KG Walldorn, Tel: 6227-605240 Email: info@lamtec.de Web: www.lamtec.de

SEARCH September 2012 Ad Name: Sanyo Pg No. 191

SEARCH September 2012 Ad Name: A plus Pg No. 192

INTERNATIONAL PRODUCTS

DIGITAL FIBREOPTIC SENSORS

n addition to MEGA power, the FS-N Series (FS-neo) introduces unprecedented setup ease with one click operation. Salient features include: newly released water-resistant fibre sensor amplifiers; IP66 standard; complete setup with just one click (new); automatic maintenance (new); high power reduces labour hours; 250x conventional model; detects wire as small as Ă¸0.6 um; and ambient-light resistance: 30,000 lux.

Keyence Singapore Pte Ltd Lobby G, Singapore Tel: +65-6-63921011 Email: info@keyence.com.sg Web: www.keyence.com.sg

ROBOCUT

his machine has highperformance CNC coupled with digital servo technology. It has a high-rigidity casting and a thermal insulation structure. It is incorporated with twin-servo wire tension control, advanced AWF2 enabling safe unmanned operation, customised Fanuc PC FAPT Cut

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193

INTERNATIONAL PRODUCTS

programming software & Servo water level control for stable cutting. It comes with a 15-inch LCD touch panel & an USB I/O. For high precision, it has an upgraded AI pulse controls 2 & fi nish cutting generator.

GE Fanuc Automation Europe SA, Germany Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com

ROBODRILL

t is a small machining center with spindle taper size No. 30 for milling, boring, drilling and tapping. Th is machine is characterised by Nano CNC system, HRV control, AI contour control which implements high-speed, high-precision machining by reading 200 blocks in advance for acceleration/ deceleration control & high acceleration positioning. It has a synchronous built-in servo motor installed. The number of blocks to be read in advance can be increased, thereby enabling up to 1,000 blocks to be read in advance for acceleration/ deceleration control. Th is enables high-speed, high precision machining without feedrate variations even for a program consisting of super-minute line segments. Additional 1-axis control can be added to enable simultaneous contour control of up to 4 axes. Spindle is directly

194

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INTERNATIONAL PRODUCTS

coupled with its motor. Least maintenance due to grease sealed bearings. The high speed and high precision ball bearing is used for the high-speed spindle.

GE Fanuc Automation Europe SA, Germany Germany Tel: +49-352-7279 79213 Email: ingo.kaiser@gefanuceur.ge.com

MILLING HEADS UNITS

he gears and axis are all made from SCM415, and have heat-treatment and precise girded to JIS 1 level. Most of components are lubricated by auto-pump and auto-injection. High precision, low noise and vibration free, each model has different speed for machining and some models also could be used for drilling. These milling heads most equipped on plano milling machine for vertical and horizontal milling or the retrofit work shop.

Para Mill Precision Machinery Co Ltd Taichung City, Taiwan Tel: +886-4-26800678 Email: para-mill@umail.hinet.net Web: www.paramill.com

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195

INTERNATIONAL PRODUCTS

CNC GRAPHITE MACHINING CENTER

his closed bridge type-high speed CNC Graphite Machining Center has patent design on its structure, as its super structural rigidity is combined with advanced technologies. It has a 30000 RPM high speed spindle, resulting in high quality graphite electrode performance. The Graphite Dust Suction & Filtration System (GDSFS) results up to 99% dust disposal efficiency. The dry type GDSFS is implied here. It has high efficiency dust-collecting equipment & incorporates zero wear-out draught fan function.

Hsiu Fong machinery Co. Ltd Taichung City-Taiwan Tel: 886-4-22792121 Email: sales@surefirst.com.tw Web: www.surefirst.com

STEEL BARS

hese bars are processed with centerless grinding & hard chrome plating after cold drawn. The bar is abrasion-proof & corrosion-proof. These are hard chrome coated where thickness is minimum 20 microns. Standard length of mass product is 3000 mm -6000 mm.

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INTERNATIONAL PRODUCTS

Fu-Long Metal Industrial Co., Ltd. Taoyuan Hsien-Taiwan Telephone: 886-3-4852858 Fax: 886-3-4787597 Web: www.flweb.com.tw

SPECIAL ALLOY SURFACE COATINGS

he special alloy surface coating is a new processing method over welding of nickel based alloy on the thread surface. Features include: evenly gardened surface with 1 m/m thickness; hardness does not decrease under normal temperature; corrossion-resistance & especially suitable for PVC material; and the hardened surface is 2 or 3 times more wear-resistant than conventional threaded rods.

Jiuh Kang Enterprise Co, Ltd Tainan, Taiwan Tel: +886-6-2534783 Email: jiuh_kang@yahoo.com.tw Web: www.plasticmachine.com.tw The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

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197

EVENT LIST

NATIONAL

4-6 October 2012 INDIA STEEL 2012 Focus: Technology, machinery & equipment in the steel industry Where: Bombay Exhibition Centre, Mumbai Mob: 91 9899392930 Email: kamal@ficci.com

ABROAD

30 October 1 November 2012

3-5 October 2012 POWER-GEN ASIA Focus: Power generation Where: Impact Exhibition & Convention Centre, Bangkok, Thailand Tel: 44 1992656634 E-mail: mathildes@pennwell.com

WIRE & CABLE INDIA 2012 Focus: Developments in wire & cable Where: Bombay Exhibition Centre, Mumbai Tel: 91 011 2697 1745/1056 66 E-mail: sawhneyr@md-india.com

NATIONAL

1-5 November 2012

21-24 November 2012

ENGINEERING EVOLUTION Focus: Industrial Machinery Where: Ahmedabad Education Society Grounds, Ahmedabad, Gujarat Tel: 079 40092078 Fax: 079 25895904 E-mail: admin@andestrade.in

INDUSTRIAL AUTOMATION INDIA 2012 Focus: Industrial Automation Application Where: India Expo Center, Greater Noida, India Tel: 022 40050681 Fax: 022 40050683 E-mail: tushar.alekar@hmf-india.com

ABROAD

21-24 November 2012 EMAF EXPO 2012 Focus: Industrial Tools & Machinery Where: Feira International do Porto, Portugal Tel: 351 229981472 Fax: 351 213826734 E-mail: fernando.reilima@exponor.pt

NATIONAL

14-16 December 2012 IPVS TRADE FAIR & CONFERENCE 2012 Focus: Industrial pumps, Valves & systems Where: Auto Cluster Exhibition and Convention Centre, Pune, Maharashtra Tel: 022 2410 2801/02 Fax: 022 24102805 E-mail: harikrishnan@orbitzexhibitions.com

ABROAD

11-14 December 2012

5-8 December 2012

AUTOMECHANIKA SHANGHAI Focus: Repair & Maintenance Equipment Where: Shanghai New International Expo Center, Pudong, Shanghai Tel: 86 21 6160 8555 Fax: 86 21 5876 9332 E-mail: info@china.messefrankfurt.com

MANUFACTURING INDONESIA SERIES 2012 Focus: Manufacturing machinery, equipment, materials & services and chemical processing Where: Jakarta International Expo, Jakarta, Indonesia Tel: 65 2333 6777 Fax: 65 6233 6768 E-mail: enquiry@iemallworld.com

EVENT LIST

NATIONAL

ABROAD

8-13 January 2013

4-7 January 2013

VIBRANT GUJARAT GLOBAL TRADE SHOW Focus: Manufacturing & technology Where: Helipad Ground, Gandhinagar, Gujarat Tel: 079 2325 6009, 2325 0492 / 93 Fax: 079 2325 0490 E-mail: indextb@indextb.com

ELASIA 2013 Focus: Electrical, Lightings & Power sector Where: Triupra Vasini, Palace Grounds, Bengaluru, Karnataka Tel: 080 43307474 Fax: 080 22352772 E-mail: info@triuneexhibitors.com

7-10 January 2013 ARABIA ESSEN WELDING & CUTTING Focus: Manufacturing Industry Where: Dubai World Trade Centre, Dubai, United Arab Emirates Telephone: 49 20172440 Fax: 49 2017244248

NATIONAL

ABROAD

14-18 February, 2013

15-17 February, 2013

VCCI EXPO Focus: Industrial and Allied products Where: Naulakhi Compound, Vadodara Tel: 0265 - 2642291, 2636262, 2636969 Fax: 0265 - 2638050 E-mail: info@vcciexpo.org

IETF MANUFACTURING Focus: Manufacturing Industry Where: Pragati Maidan, New Delhi Tel: 0124)-4014060 / 4014061 Fax: (91)-(124)-4014088

5-7 February, 2013 EXPO MANUFACTURA 2013 Focus: Manufacturing Productivity Where: Cintermex, Monterrey, N.L., 64010, Mexico Tel: 52 (81) 8369 6969 Fax: 52 (81) 8369 6911 E-mail: info@cintermex.com.mx

ABROAD

6-7 March, 2013

19-21 March, 2013

19.-22 March, 2013

DESIGN & MANUFACTURING SOUTH Focus: Technology Where: Orange County Convention Center, Orlando, US Tel: 310-445-4200 E-mail: info@cancom.com

ELECTRONICA&PRODUCTRONICACHINA2013 Focus: Materials processing, production related services Where: Shanghai New International Expo Center Tel: +86-21-2020-5503 Fax: +86-21-2020-5688 E-mail: dong.yongfa@mmi-shanghai.com

AMPER 2013 Focus: Electronics, automation Where: Brno Exhibition Centre Tel: +420 221 992 144 Fax: +420 221 992 139 E-mail: kurdiovsky@terinvest.com

AHMEDABAD October 5-8, 2012

PUNE November 2-5, 2012

INDORE January 11-14, 2013

CHENNAI November 22-25, 2012

AURANGABAD February 1-4, 2013

LUDHIANA December 21-24, 2012

RUDRAPUR February 23-26, 2013

Tel: 022-30034651 • E-mail: engexpo@infomedia18.in • Web: www.engg-expo.com

Latest Popular Tenders brought to you by www.tendersinfo.com CONTROL AND INSTRUMENTATION SYSTEM AND PLC Org : Department Of Atomic Energy TRN : 11931609 Desc : Design, fabrication, inspection, tightening trials, dispatch, erection and commissioning of automated bolt tightening system with nut feeding system and indexing arrangement with PLC BOD : September 03, 2012 Loc : India BT : Domestic competitive bidding CENTRIFUGAL PUMPS Org : Public Health Engineering Department TRN : 11943121 Desc : Supply of centrifugal pump set BOD : September 03, 2012 Loc : India BT : Domestic competitive bidding INVERTER Org : North Central Railway TRN : 10568732 Desc : Supply of static inverter BOD : September 03, 2012 Loc : India BT : Domestic competitive bidding MOTORS Org : Chittaranjan Locomotive Works TRN : 11819945 Desc : Supply of motor set for traction motor BOD : September 05, 2012 Loc : India BT : Domestic competitive bidding TELESCOPIC CRANE Org : Indian Railways TRN : 11686562 Desc : Design, supply and commissioning into service of high-capacity diesel hydraulic microprocessor controlled telescopic jib breakdown cranes BOD : September 09, 2012 Loc : India BT : International competitive bidding

TRANSFORMER Org : Chittaranjan Locomotive Works TRN : 11874372 Desc : Supply of transformer main 5400 KVA complete BOD : September 12, 2012 Loc : India BT : Domestic competitive bidding CNC UNIVERSAL LATHE MACHINE Org : Indian Ordnance Factories TRN : 11820722 Desc : Supply of conventional alignment lathe 10 m BOD : September 12, 2012 Loc : India BT : International competitive bidding CNC HORIZONTAL MACHINING CENTRE Org : Diesel Locomotive Works TRN : 11776223 Desc : Supply of CNC horizontal machining centre BOD : September 25, 2012 Loc : India BT : Domestic competitive bidding

PROJECT SUN EDISON’S BANKURA 5-MW SOLAR POWER PLANT DEVELOPMENT PROJECT Org : SUNEDISON LLC12500 Baltimore Project Type : N/A Project News : Setting up a 5-MW solar power plant Loc : India Project Cost : $25 million Contact: SUNEDISON LLC12500 Baltimore Avenue Beltsville, MD 20705, US. Tel: 443-909-7200 Fax: 443-909-7150 Details should include the Address with Pin Code, Tel No, Fax No, Email and Website

Org: Organisation’s Name, TRN: Tendersinfo Ref No, Desc: Description, DSLD: Doc Sale Last Date, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.

INFORMATION COURTESY: TENDERSINFO.COM 1, Arch Gold, Next to MTNL Exchange, Poisar, SV Road, Kandivali (W), Mumbai - 400067, Maharashtra, India Tel: +91-22-28666134 • Fax: +91-22-28013817 • Email: parmeet.d@tendersinfo.com

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PRODUCT INDEX Looking For A Specific Product? Searching and sourcing products were never so easy. Just type SRCH (space) Product Name and send it to 51818

eg. SRCH Pump and send it to 51818 Product

Pg No

Abrasive 153 Abrasive blast cleaning 170 AC gear motor 4, 185 AC servo 65 AC servo motor 4, 185 AC variable frequency drives 16 AC/DC panels 167 ACB panel 157 Accessories 8 Acoustic enclosure 119 Actuators 59, 196 Adaptor 187 Adhesives 179 Aerobridge installation & maintenance 189 Agitator seals 120 Air operated diaphragm pumps 118 Airport equipments & service provider 189 Ait/water flow switches 59 Alarm annunciators 99 All gear lathe 170 All geared auto feed pillar drilling machine 178 All geared planning machine 181 Allen cap 195 Allen CSK 195 Alloy steel cold drawn seamless straight pipes/tubes 166 Alu-cera polymer 7 Aluminium bronze 175 Aluminium casting 184 Aluminium crane system 171 Aluminium oxide ceramic composite 7 Aluminum extrusion 186 Analog timers 205 Annunciator 75 Auto feed radial drilling machine 178 Autoclavable gaskets 196 Automatic grinding machine 193 Automatic rolling shutter 21 Automatic weighing 189 Automation 19, 20, 153 Automobile bearing 159 Automotive automation - engine & transmission assembly 143 Autophoretic coating 154 Axial flow fans 157, 166 Ball bearing 94, 127, 168, 173 Ball check valve 165 Ball screws 94 Ball valve 128, 160, 165, 167, 180, 213 Balls 171 Batch production machine 172 Battery operated pallet trucks 121 BBL brake motor 71 BBL/KEC flame proof motor 71 Bearing 94, 102, 105, 159, 168, 173 Bench type drilling machine 169 Benchtop presses 161 Bend 180, 218 Blackening / bluing salt 176 Blow down valves 180 Blowers 194 Blowers & Fans 157

202

Product rod

Pg No

Boiler compound & scale remover 176 Boring machine 181 Bottle cap torque testing systems 41 Braided hose 196 Brake motors 46 Brushes 179 Building automation 20 Bushes 94, 165 Butterfly valve 160, 163, 165, 180, 213 Cabinet and v-series cooling technology 47 Cable carrier 102 Cable conduits 23 Cable connector 102 Cable gland 49; 87; 167; 179 Cam followers 180 Capacitance & tan delta testers 185 Carbide 187 Carbide tools 187 Carbon steel cold drawn seamless straight pipes/ tubes 166 Cargo systems & sort equipments 189 Cast/extruded 169 Casting 155, 184 Castors 160 Cbm/pdm services 154 Centre drill 187 Centreless grinding machine 133, 183 Centrifugal air blowers 157 Centrifugal pumps 39 Chain 102 Chain hoist 182 Chain pulley block 114 Check & needle valves 158 Check valve 160, 180, 213 Cheese head slotted screw 190 Chemical & industrial pump 197 Chemical process pumps 187 Chemical pumps 184 Chemical resistant diaphragm vacuum pumps 152 Chromatsing chemicals 176 Chuck 187 CI Casting 181 Circuit breaker analyzer 185 CNC bic CNC cutting machines 20 CNC cylindrical external grinding machine 133 CNC external grinding machine 133 CNC grinding machine 193 CNC hydraulic turret punch press 186 CNC internal grinding machine 133 CNC laser cutting machines 20 CNC lathes 27 CNC machines bic CNC oxy fuel cutting machine 20 CNC plasma cutting machine 20, 186 CNC press brake 186 CNC synchro press brake 186 CNC tooling 187 CNC turning center bic CNC turning chucklers 178

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Product

Pg No

CNC vertical machining center bic Coating machines 20 Coating plants 20 Coating systems 20 Cold galvan 154 Collet 187 Collet chuck 187 Combination screw with washer 190 Component handing system 143 Compressed air division 189 Compressed air system fittings 217 Compressors 157, 161 Concept line wall mounted enclosure 47 Connector 8, 14, 77, 102 Construction electric hoists 107 Container pumps 118 Contrast/color scanner 95 Control cabinet 77 Control damper 196 Control panel 77 Control system 77 Controller 157, 161 Conventional phase failure relays 205 Conventional precision lathes 27 Conveying blower 157 Conveyor 160 Conveyors and automation systems 21 Coolant pumps 79 Cooling systems 191 Cooper chromium zirconnium 175 Copper chromium 175 Copper enameled wire 182 Cords 196 Corrosion inhibitors 176 Counter 75, 205 Coupling element rubber 188 Crabs 114 Crane 84, 107, 114, 141 Crane drives 182 Crane duty motors 46, 174 Crimp testers 41 Cross connection acc 8 Current injectors 185 Cushion dock shelters 21 Cutting machines 20 Cutting valves 160 Cylindrical grinder 183 Cylindrical photoelectric sensor 180 Cylindrical roller bearing 159 Cylindrical sensors 95 Dampers 196 Dampers for centre 166 Deep groove ball bearing 159 Degreasing / cleaning agents 176 Dehumidifiers 181 Demagnetiser 194 Deoxidized copper 175 Diaphragm vacuum pumps & compressors 163 Diaphragm valve 165, 180 Diaphrgms 193 Didactic equipment for training 77 Digital frequency meters 183

Product

Pg No

Distribution board 10 Dock levelers 21 Door - pvc flap 21 Door - pvc strip 21 Door - rapid flexible 21 Door - rapid roll up 21 Door - sectional overhead 21 Door â&#x20AC;&#x201C; telescopic 21 Dosing pump 157 Double drum & triple drum magnetic separator 194 Double shaft gear box 164 Double sheet monitoring 95 Drawer magnets 194 Drill chuck arbor 187 Drill chucks 189 Drill mill 187 Drilling machine 169, 178 Drills 169, 178 Drive motor 184 Drives 185 Drum pumps 118 Drum type magnetic separator 151 Dry vacuum pumps 175 Dry van pump 119 Dryers 156 Dusters & circuit cooler 179 Electric high torque actuator 59 Electric motors 184 Electric wire rope hoist 107, 186 Electrical & maintenances contractors 189 Electrical cad/cae software 101 Electrical measuring instruments 167 Electrical product 16, 49; 87; 167; 179 Electro mechanical servo systems 161 Electroless nickel plating 154 Electronic dosing pump 157 Electronic process controls instruments 177 Electronic safety sensors 187 Electronic timer 28-35, 75 Electronica india 2012 115; 207 Electronics fair 115; 207 Electronics product 49; 87; 167; 179 Electropnematic positioner 153 Element shrink disc 180 Elmcbs 17 EMI/RFI shielding 179 Encoders 185 Encon products 154 End cap 180 End clap/shop 8 End mills 187 End plate 8 Energy meter 75 Engineering & consultancy services 25 Engineering plastic plug & socket 28-35 Engineering plastics 169 EOT cranes 107, 169 EOT jib crane 84 EOT/HOT cranes 114 Epoxies 179

PRODUCT INDEX

Product

Pg No

Evaporator 156 Exhausters 194 Exhibition 115; 207 Exhibition - AutoMach 2013 208 Exhibition â&#x20AC;&#x201C; IMTMA - AMTTF 82 Exhibition - VCCI 2013 22 Exhibition - Wire & Cable India 2012 26 Extruding 155 Factory automation 20, 185 Fail safe assembly system & consumer automation 143 Fasteners 195 Fbd gaskets 196 Fbe & nylon coating 154 Fep/pfa/pvdf material 165 Ferrous / Non-ferrous casting 186 Fiber laser cutting machine 214-215 Fiber optic amplifier 95 Filter cock 180 Filters 176 Filtration 176 Filtration nets 176 Finishing & thermal spray coating. 170 Fire doors 179 Fire rolling shutters 179 Fire safe ball valve 160 Fittings 165 Flame proof hoist 114 Flame proof motors 46 Flange mounting motor 71 Flash dryer 156 Flat high tension single-twin ignit 7

Product

Pg No

Floor crane 168 Floor plate 181 Flow indicator 180 Flow meters 118 Flow switches 59 Fluid connectors 182 Flush bottom ball valve 160 Flush bottom valves 180 Flux & flux remover 179 Fmcg & auto comp 143 Fogged steel valve 213 Foot valve 180 Force & pressure calibration & testing equipment 41 Force & torque gauges 41 Forged components 186 Forged steel gate 158 Forged steel valves 180 Forging 8 Forked photoelectric sensors 95 Freewheel-oneway-clutches 180 Frequency meters 167 Front casing 184 Fuel burners 157 Fully threaded bars 195 Furnace automation 48 Gang drill machine 169 Gantry crane 84 Gap frame press 203 Gas springs 24 Gaskets 165, 193, 196 Gate valve 160, 162, 180, 213

Product

Pg No

Gear box 6, 46, 114, 164, 185, 201 Gear motor 6, 201 Gear pumps 182 Geared & flexible couplings 201 Geared drill machine 169 Geared motor 6 Gears 164, 201 Glass 125 Glass screen cleaner 179 Glide wheels 160 Globe 158 Globe valve 160, 180, 213 Gluing systems 113 Goliath crane 107, 114, 168 Gomet bearings 127 Goods lift 84, 114 Grab buckets 107 Grabbing crane 171 Gravity die castings 184 Grinder 133 Grinding machine 111, 125, 133 183, 193 Grinding media 7 Grinding tool for hard material 111, 125 Handling system module 77 Hard chorme plating 154 Hast alloy 213 Head screw 184 Head washer 184 Heat exchangers 192 Heat resistance coating 154 Heat shrink tubing 49; 87; 167; 179

Product

Pg No

Heat treatment salt 176 Heating element 176 Heating equipment 192 Heavy duty CNC 160 Heavy duty cylindrical bearing 127 Heavy duty lathe machine 170 Helical gear box 46 Helical geared motor 46 Helical inline geared motors / reducers 6 Helical speed reducer 164 Hex bolts 195 High alumina wear resistant ceramic tiles 7 High carbon chrome. 171 High carbon steel balls 171 High efficiency standard motors flame proof motors 174 High intensity rare earth magnetic separator 151 High intensity roller type magnetic separator 151 Hipots (high voltage testers) 185 Hoists 107 Hold back 180 Hopper magnets 194 Horizontal CNC machines bic Horizontal machining center bic Horizontal spindle rotary table surface grinder 133 Hoses 182 Hosphating chemicals 176 Human machine interface 16 Hump magnet 194

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203

PRODUCT INDEX

Product

Pg No

Hydra trucks 176 Hydraulic centerless grinding 183 Hydraulic components 217 Hydraulic cylinder 166, 182 Hydraulic cylindrical grinder 183 Hydraulic cylindrical grinding machine 133, 183 Hydraulic hose pipes 172 Hydraulic manual pallet trucks 121 Hydraulic pallet truck 175 Hydraulic press 203 Hydraulic press break 186, 214-215 Hydraulic sealing solution 188 Hydraulic seals 129 Hydraulic shearing machine 186, 203 Hydraulic surface grinding machine 193 I/p transducers 153 Imaging & vision systems 20 Impeller 180, 184 Induction heaters 138 Induction motors 79 Inductive proximity switches 23 Inductive switches 95 Industrial automation products 16 Industrial ceramic 7 Industrial electric power distribution system 10 Industrial fans & blowers 166 Industrial grinding & cutting 155 Industrial heating element 176 Industrial pumps 162 Industrial service 105 Industrial shoes 73 Industrial vacuum cleaners 152 Industrial valves 163 Inline drum type magnetic separator 151 Inline helical geared motors 174 Inline shaft mounted helical geared motors / reducers 6 Instro maintain controls panels 177 Instrumentation & control 12-13 Instruments 183 Insulating material solutions 66 Insulating oil tester 185 Insulation resistance testers 185 Interface modules 8 Interface modules acc 8 Internal grinder 183 Internal grinding machine 183 Inverter duty motors 174 Invertors 65 Isolator 137 Isolators and dbs 17 J eastomer extrusion pump 197 Jacketed ball valve 160 Jib crane 114 Junction box 47 Kamlok & drylok couplings 162 Kec ac motor 71 Kec dc motor 71 Kec slipring crane duty motor 71 Keyless transmission element 180 Knife edge gate valves 180 Knurled bolt 190 Large diameter welded pipes 177 Large helical 174 Laser cutting 218 Laser shaping 111, 125

204

Product

Pg No

Lathe chuck 188 Lathe machine 170, 181, 189 Led 23 Led signal tower light 28-35 Level controllers 99 Lift goliath crane 170 Lifting magnets 194 Limit switch 28-35, 153 Lined valve 213 Liquid ceramic coating 154 Liquid control valves 166 Liquid pumps 118 Liquid ring vacuum pump 157 Lldpe tubes 217 Load break switches 23 Loading arms 162 Long neck pipe end 180 Low pressure die casting 184 Lubricants. 105, 179 Lubricated plug valve 128 Machine handling pallet truck 177 Machine interface 65 Machine tool 48 Machined components 186 Magnet cup 184 Magnet drive pumps 184, 187 Magnet pumps 184 Magnetic coolant separator 151 Magnetic pulley 194 Magnetic racks 194 Main & sub-system assembly automation 143 Marker plotter 8 Markers 8 Marking solutions 18 Material handling 48 Material handling equipment 121, 189 Mcb 137 Mcbs 17 Measuring instruments 167 Measuring sensors 95 Mechanical press brake 186 Mechanical seals 120 Mechanical seals for process equipments 120 Mechanical vacuum boosters 194 Medium duty lathe machine 170 Mesh 176 Metal cutting tool 5 Meters 167 MGN brake motor 83 Micro plc 65 Micro switch 28-35 Mill lining blocks 7 Mini sensors 95 Modular plc 65 Molding 155, 196 Monitoring 161 Monoblock high vacuum pump 175 Monoblock pump 79, 187 Monorail trolley 114 Motion control 65, 113 Motion control products 185 Motion technologies 211 Motor 46, 71, 79, 187 Motor protection circuit breaker 23 Motor protection relay 184, 186 Motor testing systems 41

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Product

Pg No

Motor/pump protection relays 99 Motorized chain pulley block 114 Motorized metering pump 157 Mounting bracket 8 Mounting rails 8 Multi-level car parking systems 189 Multimedia union 24 Multiport ball valve 160 Multistage centrifugal air blowers 157 Needle roller bearing 94, 127 Nickel silver 175 Nickle Aluminium bronze 213 Non lubricated plug valves 128 Non return valve 180 Non-ferrous castings 184 Nozzles 162 Nuts 195 O ring 129, 184 Ohms meters 167 Oil 157 Oil seal high vacuum pump 175 Oil seals 164, 193 O-ring chevron set strip 188 O-rings 193 Over band magnetic separator 151 Over crank shearing machine 186 Oxy fuel cutting 186 Packaging net 176 Packaging paper pulp 48 Paint remover 176 Pallet truck 172 Panel 167 Panel bender 218 Panel bender & material handling 218 Panel bending machine 214-215 Panel meters 183, 205 Parallel shaft helical gearbox 164 Parallel shaft helical geared motors 174 Partition plate 8 Pbegl geared motor 71 Pedestrian & rider operated counter balanced pallet trucks 121 Peening 170 Pen heads 190 Permanent magnetic chucks 194 Permanent magnetic drum pulley 151 Permanent magnetic drum type separator 194 Pf controllers 183 Phase failure relays 99, 205 Phase monitoring device 75 Philips combination pointed screw 190 Philips combinations screw 190 Philips csk screw 190 Philips pen head 190 Phosphorus bronze 175 Photoelectric switches 81 Pid controllers 177 Pillar drill machine 169, 178 Pillow block bearing 159 Pilot lights 23 Pipe 165 Pipe tube fittings 217 Piping system from polypropline 55 Piping systems 217 Piston rod 182 Planetary gear boxes 164 Planner machine 160, 181

Product

Pg No

Plano milling machines 160 Plano-miller 181 Plasma cutting machine 214-215 Plastic flap loaded foot valve 163 Plat truck 160 Plate bending machine 186 Plate magnets 194 Plcs 185 Plug valve 128, 165, 213 Plugs and sockets 23 Plumbing pipes & fittings 217 Pneumatic components 217 Pneumatic control valves 180 Pneumatic cylinder valve 164 Pneumatic valve 164 Pneumohydraulic 161 Pole ring 180 Polyacetal 169 Polymer production pump 197 Polynets 176 Polypropylene 169 Polyurethane 169 Position transducers 81 Potentiometers 81 Potting + encapsulating 179 Power 161 Power line transducers 183 Power magnet 194 Power press 186, 203 Power systems 191 Power tool 153 Precision component 105 Precision steel 111, 125 Precision switches single & multiple 23 Precision universal cylindrical machine 183 Press brake 172 Press brake machine 203 Presses 161 Pressure sensors and indicators 41 Printed circuit boards 99 Printing 48 Process automation 113 Process automation and control equipment 77 Product assemblies. 186 Production and processing equipment 192 Productronica india 2012 115; 207 Profiles 196 Proline modular enclosure 47 Protective polymer coating 154 Prototyping materials 179 Proximity sensor 28-35 Proximity switches 81 Ptfe 154, 165, 180 Ptfe lined valves 158 Ptfe/teflcon 169 Pull stud 187 Pump seals 120 Pumps. 39, 79, 118, 119, 157 162, 175, 182, 184, 187, 188, 197, BC Punch multiple holes. 172 Punching 218 Punching laser cutting 214-215 Punching sheering machine 214-215 Punching-shearing system 218 Pure water fittings 217

PRODUCT INDEX

Product

Pg No

Push buttons 23 Quality control valves 59 Radial drilling machine 178, 181 Rccb 137 Reamers 187 Rear casing 184 Rear cylinder hydraulic press brake 203 Receptacles 162 Reducer 180 Relays 205 Remanufacture and repair 105 Right angled helical bevel geared motors / reducers 6 Right angled helical worm geared motors / reducers 6 Rod 165 Roll forming machine 214-215 Roll turning lathe machine 180 Roller bearing 94, 173 Roots blower 119, 162 Roots vacuum pumps 175 Rotary actuator 59 Rotary air lock valve 180 Rotary atomizer. 156 Rotary dampers 24 Rotary gear pumps 182 Rotary joints & unions 24 Rotary pumps 175 Rotary shaft seals 129 Rotary sliding vane pumps 187 Rotary switches 23 Rotary vane oil free vacuum pumps 152 Rotating unions 24 Rubber parts 193 Rubber products 164 Rust preventive 176 Rust removers 176 Safety controls 161 Safety protection devices 23 Safety shoes 73 Safety valves 163 Scable ties 49; 87; 167; 179 Scada 185 Scoop 180 Scr bess power regulator 177 Sealing system 182 Seals 105, 164 Seamless pipes 177 Section 196 Sector ball valve 160 Self aligning ball bearing 159 Self tapping & machine screws 195 Sensor solutions 113 Separator plate 8 Servo drives 16 Servo motors 16 Servo systems 191 Sewage pump 79 Shaft mounted speed reducers 164 Shaping machine 181 Shearing machine 203 Sheet 165, 196 Shock absorbers 24 Shovel 180 Shunts 167 Side channel blowers 157 Side lock adaptor 187 Sight flow meters 162

206

Product

Pg No

Sight glass 180 Silicon brass 175 Silicon bronze 175 Silicon rubber sleeves 196 Silver copper 175 Single converter isolator modules 177 Single limit switches 23 Single shaft extruder gear box 164 Single stage monoblock vacuum pump 175 Single stage vacuum pump 175 Siphon systems 24 Sleeve bearings 127 Slimline relay 153 Slip ring motor starter 185 Slipon flange 180 Small size ball bearings 127 Smps 75 Sockets & switches 8 Soft starters 99 Solderless terminal 49; 87; 167; 179 Solid carbide drill 5 Solid carbide drill with ic 5 Solid carbide mill 5 Solid carbide reamer 5 Solid carbide reamer with IC 5 Solid carbide special drill 5 Solid carbide special mill 5 Solid carbide special reamer 5 Sorting systems & automation 189 Space sector 143 Spade 180 Special application motors 174 Special bearing 159 Special pointed screw 190 Special purpose machines 160 Special tools 187 Specialized chemicals 179 Spherical roller bearing 159 Spherical roller thrust bearing 159 Spin flash dryers 156 Spiral cum helical gear box 201 Sponge products 196 Spray dryers 156 Spray guns 189 Spring testers 41 Sprockets 164 Square 196 Stacking system 214-215 Stainless steel 171 Stainless steel fasteners 195 Stainless steel pipes 177 Steam engineering products fic Steam jacketed ball valves 128 Steam jacketed plug valves 128 Steel 105 Steel balls 171 Steel industry 48 Steel mill duty & flame proof cranes 107 Steel tube 182 Stepper motors 185 Strainer 160, 180 Strips 196 Super duplex 213 Super precision bearings 127 Superior hard anodizing 154 Surface grinder 193 Surface grinding machine 193

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Product

Pg No

Surface plate 181 Swing check valve 165 Switch 3, 137 Switchboard meters 167 Switchgear 3 Switchgear applications 66 Swivels 162 Tachometer 75 Taper plug valves 128 Taper roller bearing 159 Technical ceramic 7 Tee 180 Teflon bush 184 Tefzel hhs isotactic p.p material 55 Temperature controller 75, 205 Temperature indicator 205 Tensile testing 41 Tensioner nut 180 Terminal blocks 8 Testers 167 Thermoplast extrusion pump 197 Thermoplastic valves 55 Thrush ball bearings 127, 159 Time switch 75 Titanium 213 Tooling for edm / wedm / vmc-s / hmc-s 214-215 Tools 187 Torque 41 Torque motors 174 Torque tool testers 41 Track rollers 180 Trade show 115; 207 Transfer trolley 114 Transformer ratio meters 185 Transformer winding resistance testers 185 Transformers 167 Transmission 153 Transparent sleeves 196 Transparent tubes 196 Tri lobe roots blowers 194 Tricover gaskets 196 Tri-lobe rotary blowers 178 Trim handling systems 157 Trolleys 160 Trunion mounted ball valve 160 Tubes 165, 177 Tubing accessory 77 Turbine blowers 154 Turned components 186 Turret punching machine 214-215 Twin lobe roots blower 162, 194 Twist drills 187 Two stage vacuum pump 162, 175 U & v seals 193 ‘U’ tubes 177 Uhmw-pe 169 Ultrasonic sensors 95 Vacuum booster pump 119 Vacuum pumps 161, 175 Vacuum system 119 Vacuum/pneumatic recovery system 170 Valve 77, 128, 160, 161, 163 165, 180, 187, 196 Valve positioner 153 Valve sensor 160 Valve terminal 77

Product

Pg No

Vane damper 157 Velocity & feed controllers 24 Vertical boring machine 181 Vertical multistage inline pumps 158 Vertical turning lathe 160 Vertical turning machine 181 Very low frequency hipots 185 Vibrating reed type 167 Voltage/current/power monitoring relays 99 Wafer type ball valve 160 Wall console cranes 168 Washer 180, 196 Washer head screw 190 Waste and water treatments 48 Water faucet & tap parts 7 Water ring vacuum pump 157 Water ring vacuum pumps 162 Water softening compound 176 Water treatment 192 Water valves 163 Weighing applications 48 Welded pipes 177 Welding equipments 189 Wheel barrows 160 Wheels 160 Winches 84, 107 Wind mill gear box 201 Wiper 188 Wiper o-ring 188 Wire connector 49; 87; 167; 179 Wire rope hoist 114 Wireless data logger system 183 Work holding devices 190 Worm drive hose clamps 197 Worm gear 201 Worm geared motors 46 Worm reducer gear box 164 Worm reducers 164 Xylan coating 154 ‘Y’ type strainer 180 Zinc flake coating 154 Zirconia polycrystal ceramic 7

INTERNATIONAL PRODUCTS Product

Aluminum CNV graphite machining center Coil spring Concrete energy savings Digital fibreoptic sensors Energy efficiency solutions Milling heads units Miniaturized sensor systems Nichrome sealing wire Robocut Robodrill Special alloy surface coatings Spindle motor Steel bars Wave spring

Pg No

195 196 171 43 193 43 195 190 190 193 194 197 190 196 171

ADVERTISERS’ LIST

To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at search@infomedia18.in or call us on +91-22-3003 4640 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

A Plus Projects Technology Pvt Ltd T: +91-20-25630620 E: sales@aplusprojects.biz. W: www.aplusprojects.biz

192

Bry Air (Asia) Pvt Ltd T: +91-11-23906777 E: bryairmarketing@pahwa.com W: www.bryair.com

181

Electromech Material Handling Sys P Ltd T: +91-20-66542222 E: getcranes@emech.in W: www.emech.in

Academy For Conservation Of Energy T: +91-265-2325034 E: info@syguruace.com W: www.syguruace.com

154

C&S Electric Ltd. T: +91-11-30887520-29 W: www.cselectric.co.in

137

Champkraft Machine Tools T: +91-2752-241881 E: champ1@sancharnet.in W: www.solcogrinder.com

133

Electronic Automation Pvt Ltd T: +91-80-42802345 E: sales@eaplindiamail.com W: www.eaplindia.com

Classic Polymers & Resins T: +91-22-24465251 E: sales@classicpolymers.co.in W: www.classicpolymers.com

169

194

Allied Electronics Corporation T: +91-22 61953699 E: allied@vsnl.com, W: www.aecconnectors.com

CNP Pumps India Pvt Ltd T: +91-22-25818400 E: sales@nanfangpumps.com W: www.nanfangpumps.com

Amsak Cranes Private Limited T: +91-44-26273486 E: sales@amsakcranes.com W: www.amsakcranes.com

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

Accent Control Pvt Ltd T: +91-22-25822141 E: info@accentsensors.com W: www.accentsensors.com Acme Air Equipment Co Pvt Ltd T: +91-79-25831985 E: info@airequipments.com W: www.airequipments.com

Confederation Of Indian Industry T: +91-124-4014060-65 E: rachna.jindal@cii.in W: www.bsxindia.com

208

ANI Engineers T: +91-2752-241479 E: anivarya@sancharnet.in W: www.anivaryapumps.com

182

Apex Industries T: +91-2764-291085 E: pateldineshn@gmail.com W: www.industrialcoatingsindia.com

154

Ashok Industry T: +91-22-26232133 E: manisha@ashokindustry.com W: www.ashkindustry.com

176

Associated Toolings (India) Pvt Ltd T: +91-33-26530657 E: atipl@cal3.vsnl.net.in W: www.atipl.com

158

Austin Engineering Company Ltd E: sales@aecbearings.com W: www.aec-bearings.com

173

143

Durga Bearing Pvt Ltd T: +91-22-6876073 E: inquiry@durgabearings.com W: www.durgabearings.com

127

Avasarala Technologies Limited T: +91-80-26083300 E: marketing@avasarala.com W: www.avasarala.com

171

Eddycranes Engineers Pvt Ltd T: +91-22-2352 2710 E: eddycranes@vsnl.com W: www.eddycranes.com

107

Ballkings T: +91-161-2534501 E: ballkings@ballkings.com Baumer India Pvt Ltd T: +91-20-25286833 E: mbhalerao@baumer.com W: www.baumer.com

113

Elecon Engineering Company Limited T: +91-2692-236469 E: infogear@elecon.com W: www.elecon.com

201

Connectwell Industries Pvt Ltd T: +91-251-2870636 E: connect@connectwell.com W: www.connectwell.com Control Engg Co T: +91-33-2248 0192 E: ceco@cecoelectronics.in W: www.cecoelectronics.co.in Dr. Dinesh & Ramesh Engr. Pvt Ltd T: +91-79-25893704 E: hpatel@drecasting.com W: www.drecasting.com DSM India Pvt Ltd T: +91-20-66430813 E: ojas.mehta@dsm.com W: www.dsmep.com

184

Everest Blower Systems T: +91-11-45457777 E: info@everestblowers.com W: www.everestblowers.com Farmax Machines Private Limited T: +91-80-28435034 E: skr@farmax.in W: www.farmax.in Festo Controls Ltd T: +91-80-22894100 E: info_in@festo.com W: www.festo.com

141

119

214-215

Flosteer Engineers Pvt Ltd T: +91-79-65435676 E: info@flosteer.com W: www.flosteer.com

180

Flow Chem Industries T: +91-79-27712102 E: flowchem@flowchem.com W: www.flowchem.com

160

Fluid Energy Controls Inc T: +91-44-42083536 E: sales@fecindia.com W: www.fecindia.com

162

Forbes Marshall Pvt Ltd T: +9120-27145595 E: bgaikwad@forbesmarshall.com W: www.forbesmarshall.com

FIC

G L Brothers T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com

189

G M Engineering T: +91-2827-287658 E: valve@gmengg.com W: www.gmengg.com

213

G R Polynets T: +91-2692-230484 E: srpatel@grpolynets.com W: www.grpolynets.com

176

G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in Gandhi Automations Pvt Ltd T: +91-22-66720200 E: sales@geapl.co.in W: www.geapl.co.in

Our consistent advertisers

212

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ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Gelco Electronics Pvt Ltd T: +91-79-22200902 E: info@gelco-world.com W: www.gelco-world.com

205

Ingeco Gears Pvt. Ltd. T: +91-2717-651551 E: info@ingecogears.com W: www.ingecogears.com

164

Knowell International Pvt Ltd T: +91-33-22304627 E: hktrading@vsnl.com W: www.knowell.co.in

168

Goliya Electricals Pvt Ltd T: +91-22-24120456 E: geplmumbai@mtnl.net.in W: www.goliya.com

167

Inventum Engineering Co Pvt Ltd T: +91-22-26730499 E: inventum@vsnl.com W: www.inventumindia.com

138

Lan Marketing Pvt Ltd T: +91-22-27893645 E: jai@lanengg.com W: www.maag.com

197

Goliya Instruments Pvt Ltd T: +91-22-24149657 E: goliya@mtnl.net.in W: www.goliyainstruments.com

183

Jagdeep Foundry (Regd.) T: +91-1871-242750 E: jagdeepfoundry@rediffmail.com W: www.jagdeepfoundry.in

181

Larsen & Toubro Ltd T: +1800-233-5858 E: cic@lntegb.com W: www.larsentoubro.com

Grundfos Pumps India Pvt Ltd T: +91-44-24966800 E: salesindia@grundfos.com W: www.grundfos.in

.BC

Jaibalaji Control Gears Pvt. Ltd., T: +91-44-26251279 E: dchandramohan@jaibalaji.firm.in W: www.jaibalaji.firm.in

28-35

Larsen & Toubro Ltd T: +91-22-67525656 E: ss-ccd@lth.lthindia.com W: www.larsentoubro.com

Heattrans Equipments Pvt.Ltd. T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com

186

Jaykrishna Magnetics Pvt Ltd T: +91-79-22970452 E: info@jkmagnetics.com W: www.magneticequipments.com

151

Liberty Shoes Ltd T: +91-1748-251120 E: warriors@libertyshoes.com W: www.libertyshoes.com

Heidelberg Prominent Fluid Controls T: +91-80-23578872 E: prominent@hpfcindia.com W: www.prominentindia.com

157

Joyam Engineers & Consultants Pvt Ltd T: +91-79-26569533 E: joyam@joyamvactech.com W: www.joyamvactech.com

175

Hensel Electric India Pvt. Ltd. T: +91-44-24541669 E: henselelectric@vsnl.com W: www.hensel-electric.de

Hi-Fab Engineers Pvt Ltd T: +91-22-40766555 E: info@hi-fab.com W: www.hi-fab.com

120

Hiflon Polymers Industries T: +91-79-25857182 E: sales@fluoroplastind.com W: www.fluoroplastind.com

188

Hindustan Motor Mfg Co T: +91-22-42500500 E: sales@hindmotors.com W: www.hindmotors.com

174

Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in

102

Indian Machine Tool Mfgr’S Asso, T: +91-80-66246600 E: imtma@imtma.in W: www.imtma.in

Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120/338 E: info@jyoticeramic.com W: www.jyoticeramic.com

Jyoti Cnc Automation Pvt. Ltd. T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in

.BIC

K.P.Mondal & Sons. T: +91-33-26530673 E: kpmondalandsons@gmail.com W: www.kpmvalves.com

163

Kamal Valves Pvt Ltd T: +91-288-2673239 E: kvpl_ad1@sancharnet.in

128

Kiran Manufactures T: +91-281-2388372 E: info@nagmanilathes.com W: www.nagmanilathes.com Klipco Pvt Ltd T: +91-22-28684221 E: klipco@mtnl.net.in W: www.klipcoclips.com

Libratherm Instruments Pvt. Ltd. T: +91-22-42555353 E: libratherm@libratherm.com W: www.libratherm.com

177

Luthra Pneumsys T: +91-09821128362 E: rl@pneumsys.com W: www.pneumsys.com

217

M+V Marketing - Leuze Electronic T: +91-80-40854444 E: manish.sahay@leuze.in W: www.leuze.in Machbow Products T: +91-22-25784069 E: machbow@gmail.com W: www.machbow.com

184

Maco Corporation India Pvt Ltd T: +91-33-24758371 E: rdutta@macocorporation.com W: www.macocorporation.com

170

Macro Tech Equipment Pvt Ltd T: +91-33-24666261 E: info@macrotechcal.com W: www.macrotechcal.com

121

197

Makson Machines Pvt Ltd T: +91-278-2446437 E: makwana_eng@yahoo.com W: www.makwanaeng.com

178

Our consistent advertisers

214

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ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Marks Pryor Marketing Technology T: +91-20-66743300 E: info@markspryor.com W: www.markspryor.com

Messe Dusseldorf India Pvt Ltd T: +91-11-26971745 E: DughL@md-india.com W: www.md-india.com

MGM-Varvel Power Transmission (P) Ltd T: +91-44-64627008 E: ravik@mgmvarvelindia.com W: www.mgmvarvelindia.com

Minilec (India) Pvt Ltd T: +91-20-66524695 E: mkt1@minilecgroup.com W: www.minilecgroup.com

Mitcon Consultancy Services Ltd T: +91-20-25533309 E: deepak.zade@mitconindia.com W: www.mitconindia.com

Mitsubishi Electric (I) Pvt. Ltd. T: +91-124-4630300 E: Shinji.Mizoguchi@asia.meap.com W: www.mitsubishielectric.asia/india/

MMI India Pvt Ltd T: +91-22-42554700 E: bhupinder.singh@mmi-india.in W: www.electronica-india.com Moulik Rubber Industries T: +91-22-40037863 E: moulikrubber@gmail.com W: www.moulikrubberindustries.com NI Systems India Pvt Ltd T: +91-80-41190000 E: ni.india@ni.com W: www.ni.com

115; 207

193

12-13

NIA Controls T: +91-250-2480916 E: ncvasai@gmail.com W: www.tscindia.com

196

NMTG Mechtrans Techniques Pvt Ltd. T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

180

Oil Seals Mfg Co Pvt Ltd T: +91-22-22047943 E: omcoseal@rediffmail.com

164

Advertisers’ Name & Contact Details

Pg No

OSG India Pvt Ltd T: +91-20-66304407/08 W: www.osg-india.com

155

Oswal Pumps Ltd. T: +91-184-6616600 E: munishrai@oswalpumps.com W: www.oswalpumps.com

P P I Pumps Pvt Ltd T: +91-79-25832273 E: sales@ppipumps.com W: www.ppipumps.com

162

Parth Poly Valves Pvt. Ltd T: +91-79-22200198 E: sales@parthvalves.com W: www.parthvalves.com

180

Patels Airflow Ltd T: +91-79-40200800 E: info@steeltubeindia.com W: www.steeltubeinida.com

166

Pentair Technical Products India Pvt Ltd T: +91-80-28454640 E: contact.marketing@pentair.com W: www.pentairtechnicalproducts.com

Pinnacle Engineering Enterprise T: +91-2752-230552 E: mail@pinnaclegrinder.com W: www.pinnaclegrinder.com

193

Pitroda Utility Industries T: +91-2752-243795 E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com

183

Advertisers’ Name & Contact Details

Pg No

Progressive Engineers T: +91-22-32944289 E: info@progressiveengineers.net W: www.progressiveengineers.net

179

Raajratna Ventures Ltd T: +91-79-27561915 E: sales@raajfasteners.com W: www.raajfasteners.com

195

Rapid Controls Pvt Ltd T: +91-11-28115349 E: info@rapidcontrols.in W: www.rapidcontrols.in

Ravel Hiteks Pvt Ltd T: +91-44-24963241 E: sales@ravelhiteks.com W: www.ravelhiteks.com

188

Ravi Electronics T: +91-79-65722609 E: sales@fluconautomationinc.com W: www.fluconautomationinc.com

153

Renu Electronics Pvt Ltd T: +91-20-27292840 E: info@renuelectronics.com W: www.renuelectronics.com

Rexello Castors Pvt Ltd T: +91-22-40917777 E: rexello@gmail.com W: www.rexello.com

160

Rittal India Pvt Ltd - Eplan Div. T: +91-22-39527200 E: info.eplan@rittal-india.com W: www.eplan.in

101

Power Build Ltd T: +91-2692-231070 E: infopbl@elecon.com W: www.pbl.co.in

Robin Precision Products Pvt Ltd. T: +91-2827-287631 E: info@bloodtools.com W: www.bloodtools.com

187

Precihole Machine Tools Pvt Ltd T: +886-3-329-9968 E: pshtech@gmail.com W: www.peei.com.tw

Rotomotive Powerdrives India Ltd. T: +91-2692-230173 E: info@rotomotive.com W: www.rotomotive.com

Precision Brearing Pvt. Ltd T: +91-79-65412051 E: sales.india@znlbearings.com W: www.znlbearings.com

159

Salvagnini Machinery India Pvt Ltd 218 T: +91-80-32214123 E: riddish.jalnapurkar@salvagninigroup.com W: www.salvangninigroup.com

Premier Engineering Technics Pvt Ltd T: +91-22-26852233 E: sales@premiertechnics.com W: www.premiertechnics.com

189

Sanyo Denki Singapore Pte Ltd T: +91-44-42038472 E: info@sanyodenki.in W: www.sanyodenki.com/ad/search1201

191

Our consistent advertisers

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215

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Sarabsukh Enterprises T: +91-1871-223893 E: sarabsukhbatala@yahoo.co.in W: www.sarabsukhmachines.com

160

Suhner India Pvt Ltd T: +91-80-27831108 E: automation.in@suhner.com W: www.suhner.com

153

Senor Metals Pvt Ltd T: +91-288-2730251 E: info@senormetals.in W: www.senormetals.in

175

Sumitron Exports Pvt Ltd. T: +91-11-41410631 E: sumitron@vsnl.com W: www.sumitron.com

Shachi Engg Pvt Ltd T: +91-20-66546900 E: shachi_engineering@vsnl.com W: www.shachiengg.com

156

Superflex Engineers T: +91-09998882404 E: superflexengineers@yahoo.com

172

Shailesh Sales Corporation T: +91-281-2461102 E: info@shaileshmachines.com W: www.shaileshmachines.com

203

Supremo Line & Control T: +91-79-22205282 E: supremoproduct@gmail.com W: www.supremoproduct.com

Shree Siddhivinayak Industries T: +91-22-28458372 E: minivacs@hotmail.com W: www.minivacpumps.com

161

Siddhapura Engineering Works T: +91-278-2428054 E: drills@dataone.in W: www.siddhapuradrills.com

169

105

Tox Pressotehnik India Pvt Ltd T: +91-20-66538300 E: rnamboodiri@tox-in.com W: www.tox-de.com

161

182

165

Trident Precision International T: +91-11-41425326 E: trident.sales@tridenthydraulics.com W: www.trident-precision.com

166

Suraj Limited T: +91-79-27540720 E: suraj@surajgroup.com W: www.surajgroup.com

177

Trident Products Pvt Ltd T: +91-124-4300626 E: trident.sales@tridenthydraulics.com W: www.hydrauliccylinder.co.in

Suresh Enterprises T: +91-2762-224814 E: sevitsil@sancharnet.in W: www.sevitsil.com

196

Tussor Machine Tools Ind P Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com

49; 87; 167; 179

Sushma Industries T: +91-80-28397463 E: marketing@sushmaindustries.com W: www.sushmaindustries.com

Synco Industries Ltd T: +91-291-2742077 E: mail@synco.co.in W: www.synco.co.in

170

SKF Group W: www.skf.com

SYP Engineering Co Pvt Ltd T: +91-22-28489969 E: syppumps@gmail.com W: www.sypco.co.in

118

Taha Pumps & Valves T: +91-2752-240233 E: tahapv@yahoo.co.in W: www.tahapumps.com

187

Techno Industries T: +91-79-25830742 E: info@technoind.com W: www.technoind.com

114

Tee-Vee Tools & Engineering Industries T: +91-250-2023363 E: teeveetools@gmail.com

190

171

SNF Sales Corportation T: +91-09325021277 E: snfsales8989@gmail.com

211

Sonal Magnetics T: +91-79-22872349 E: info@sonalmagnetics.com W: www.sonalmagnetics.com

194

Spareage Seals Ltd T: +91-22-25800972 E: sales@spareage.com W: www.spareage.com

129

Spares & Components Co T: +91-22-28836879 E: sudhir@spco.in W: www.spco.in

Pg No

Timken Engineering India Pvt Ltd T: +91-80-40053100 E: ruchir.agarwal@timken.com W: www.timken.com

Siemens Ltd T: +91-22-27623727 E: motors.in@siemens.com W: www.siemens.com

Smalley Steel Ring Company T: +847-719-5900 E: info@smalley.com W: www.smalley.com

Advertisers’ Name & Contact Details

Teknic T: +91-22-26592392 E: teknic@vsnl.com W: www.tecknic.co.in

Sri Vishnu Pumps Manufacturing Co T: +91-22-28458372 E: vishnupump@rediffmail.com W: www.minivacpumps.com

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The Indian Electric Co T: +91-20-66865200 E: iecmktg@indianelectric.com W: www.indianelectric.com

Strategi Automation Solutions Pvt Ltd T: +91-22-66926217 E: sales@strategiautomation.com W: www.strategiautomation.com

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Theeta Electricals Pvt Ltd T: +91-124-4387400 E: sales@theeta.com W: www.theeta.com

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Tyrolit India Superabrasive Pvt. Ltd T: +91-80-40953259 E: subrahmanya.kumar@tyrolit.com W: www.tylolit.com

111

Udeyraj Electricals Pvt Ltd T: +91-22-66916181 E: udeyraj@udeyraj.com W: www.udeyraj.com

185

Unipunch Toolings Pvt Ltd T: +91-44-26253436 E: unipunch@vsnl.com W: www.fabmachinesindia.com

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UNP Polyvalves India Pvt Ltd T: +91-265-2649248 E: mktg@polyvalve.com W: www.polyvalve.com

Vacunair Engineering Co Pvt Ltd T: +91-79-22910771 E: info@vacunair.com W: www.vacunair.com

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Vadodara Chamber Of Commerce & Indus. 22 T: +91-265-2642291 E: info@vcciexpo.org W: www.vcciexpo.org Weldor Engineering Pvt Ltd T: +91-281-2360242 E: weldor@weldor.com W: www.weldor.com

186

Wendt India Ltd T: +91-4344-405500 E: vijayvernekar@wendtindia.com W: www.wendtgroup.com

125

Western Material Trading (Shanghai) Co., Ltd. T: +86-21-5876-1508 E: tao.cheng@wmt-china.cn W: www.wmt-china.cn

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Our consistent advertisers

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Vol 15 No 09

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