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CEW Industry News
India to Build Petrochemical Complex in Iran Soon
New Delhi, India: India proposes to establish Special Economic Zones
(SEZ) in Iran, Turkmenistan and Myanmar as part of the National
Democratic Alliance government move for Reverse SEZ in oil-rich
countries with dedicated exports back to the country, according to Union
Minister for Chemicals and Fertilizers Ananth Kumar. Minister said that
India had formed a joint venture with Rashtriya Chemical Fertilizers
and Gujarat Narmada Fertilizers Corporation and had several rounds
of meeting with Iran, the latest being in January this year. Negotiations
were on for fixing the price of gas and on terms of contract.
He said that the proposed natural gas-based petroleum plant-cum-
petrochemicals complex would be established in the port city of Chabahar.
The Minister had had two levels of discussions in this regard with the
Ambassador of Iran, Indian Ambassador to Iran and Minister for External
Affairs Sushma Swaraj to hasten the process.
Plastic Market in India has Huge Growth Potential,
Says Hansraj Ahir
Mumbai, India: According to an official statement, Minister of State for
Chemicals and Fertilizers Hansraj Gangaram Ahir said that the Indian
plastic and petrochemical sector has a huge potential for growth and
there is a need for free trade agreement (FTA) and duty inversion to
make cost of manufacture in the country cheaper.
He was attending the inauguration of PolyIndia 2016 at the Bombay
Exhibition Centre on January 28. The three-day exhibition on plastics
and petrochemicals was themed Indian Plastic and Petrochemical sector:
Potential for Global Manufacturing Hub.
The MAGIC Begins
Pune, India: The Union Minister for Science & Technology & Earth
Sciences, Dr Harsh Vardhan, inaugurated a unique MAGIC [Modular,
Agile, Intensified & Continuous] Process Lab at CSIR-National Chemical
Laboratory (CSIR-NCL) Pune last evening.
While inaugurating the facility he announced that ?The MAGIC processes
and plants will bring about a paradigm shift in the way in which India?s
Fine and Specialty Chemicals industry will operate in the future. Over
the past three decades, the global fine and specialty chemicals industry
has shifted manufacturing base from the western world to countries like
India and China.
The MAGIC processes developed in CSIR-NCL can radically change
currently practiced process technologies into modern processes that are
cleaner, greener, safer, compact, scalable and economical. As a result,
the MAGIC processes have the potential to transform the country into
a global powerhouse in this important sector, thus enabling the country
to increase its contribution to global production of chemicals from the
current levels of 3 to 5 per cent over the next few years.
6 February 2016
CIPET, Govt, of Karnataka to set up Advanced
Polymer Lab
Bengaluru, India: The Central Institute of Plastic Engineering
&Technology (CIPET) has signed a memorandum of understanding
(MoU) with the Karnataka Government to set up an Advanced
Polymer Design and Development Research Laboratory-cum-High
Learning Centre at Bengaluru.
The MoU was signed in the presence of Union Minister of
Chemicals and Fertilizers Ananth Kumar, Karnataka Chief Minister
Siddaramaiah and other dignitaries. An official press release said
the laboratory was being set up at an estimated investment of Rs.
87 crore. The State Government will allot the land for the centre
and also share 50 per cent of the project cost.
The centre will act as a multi-functional one-step facility with
specialization in product development in the polymer sector.
It will also conduct R&D, product tests and evaluations and
commercialization of technology.
G D Yadav, Vice Chancellor, IICT Mumbai Selected for
the Padmashri Award
Mumbai, India: G D Yadav, vice chancellor of Indian Institute of
Chemical Technology in Mumbai has been selected for Padmashri
awards for this year.Yadav was born in a hamlet in the Radhanagari
tehsil in the Kolhapur district. He completed his education till
class VII in the village.
After completing his basic education, he went to Mumbai for higher
studies and completed chemical engineering from the University
Department of Chemical Technology (UDCT), in Mumbai in 1974.
He then worked for green technologies and did further research
in nanotechnology and biotechnology.
He has made innovative contributions to green chemistry and
engineer ing, catalysis science and engineer ing, chemical
reaction engineering, biotechnology, nano-technology and energy
engineering. He has supervised 83 doctoral candidates and 88
students pursuing their masters.
India Suspends Agreement with ACRON
New Delhi, India: India has shelved its plan to buy 30 per cent
stake in Russian fertilizer producer ACRONs USD 2-billion potash
mine project due to valuation issues. In December 2014, the two
parties had signed an agreement to buy 30 per cent stake in
ACRONs potash mine project. Potash is a decontrolled fertilizer
and government pays fixed subsidy on it. As per the proposal,
India was represented by an NMDC-led consortium of four state-
run companies and one cooperative
Chemical Engineering World
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CEW Industry News
CFCL Technologies Arm to Sell off its Business
Mumbai, India: Chambal Fertilisers & Chemicals - subsidiary
company - CFCL Technologies arm have entered into agreements
for sale of some of its business. ISGN Corporation, USA has
entered into a stock purchase agreement to sell and transfer its
entire shareholding in its wholly owned subsidiary - ISGN Solutions
Inc, USA to Firstsource Group USA, Inc.
Further, ISG Novasoft Technologies has entered into a slump sale
agreement to sell and dispose-off part of its business / undertaking
i.e. Business Process Outsourcing business to Firstsource Process
Management Services, India as a going concern on slump sale
basis.Chambal Fertilisers & Chemicals is one of the largest private
sector fertilizer producers in India. It has three divisions catering
agri products, shipping & textiles.
No Price-hike for Fertilizers in Next Four Years
New Delhi, India: During his visit to Fertulizer Corporation of In-
dias Karimnager plant, Union Minister for Chemicals and Fertil-
isers Hansraj Gangaram Ahir has said that the prices of fertiliz-
ers such as urea and DAP (Di-ammonium phosphate) will not be
increased for next four years.
Speaking on the occasion, the Minister said all the eight fertilizer
plants of national stature which were closed down during the
previous UPA regime will be reopened.
The Minister also mentioned that the works on six plants have
already begun, and Prime Minister Narendra Modi will re-com-
mission the FCI factory in Ramagundam during the second week
of next month.
GSFC is Exploring Global Markets for Nylon-
6 Fibres
Vadodara, India: Gujarat State Fertilizers & Chemicals Ltd
(GSFC) is exploring global export opportunities for its Nylon-6
fibres GUJCON-CRF and GUJCON-PRF.
At the launch of the products in Hyderabad, GSFC Chairman
and Managing Director Sudeep Kumar Nanda said that GSFC is
revolutionising the business of fertilisers and industrial chemi-
cals and has innovated and pioneered yet another revolutionary
product GUJCON-CRF and GUJCON-PRF.
GSFC aims to leverage opportunities in construction and infra-
structure sectors in India and overseas markets and exploring
opportunities of export of its products to African countries, Gulf
countries including UAE and Dubai, Sri Lanka, Canada.
8 February 2016
GoI to Set Up 100 CIPET
New Delhi, India: Union Ministry of Chemicals and Fertilizers decided
to set up 100 Central Institutes for Plastic Engineering and Technology
(CIPET) in India. The decision was taken in order to meet the need of
skilled manpower in the petrochemical sector or plastic processing
industry. The announcement in this regard was made by Minister of
Chemicals and Fertilizers Ananth Kumar at the occasion of National
Awards for Technology in Innovation in Petrochemicals and downstream
Plastics Processing Industry.
Currently, CIPETs are present at 28 locations in India. Department
of Scientific and Industrial Research (DSIR) recognizes CIPET as a
scientific and research organisation in the area of Plastics Engineering
and Technology.
Evonik, ICT Mumbai Ink R&D Pact
Mumbai, India: Evonik Industries and the Institute of Chemical
Technology (ICT), Mumbai have sealed a strategic partnership agreement
for the purpose of exploring research topics together, closely in selected
fields in the future. Evonik and ICT research partnership agreement
includes Provision of scholarship funds for masters degree and PhD
students; Collaboration in research and development projects in the
field of chemical science; Financial support for internships for master,
bachelor and PhD students; Sponsor lectures and/or presentations
by representatives of Evonik at ICT and vice versa. The expansion
of innovation activities in economically attractive regions supports
Evoniks growth strategy. The goal is to strengthen local customer
competitiveness with technological services as well as research and
application techniques that fit local needs.
South Africa Opens up Opportunities to Indian
Chemical Companies
Johannesburg, South Africa: A number of South African industrial
houses are struggling to succeed and hence looking to sell equity, cre-
ating an opportunity for Indian companies to pursue acquisition, says
Debajit Shome, Director of multinational Union Colours. Shome was ad-
dressing a networking meeting organised by the Indian Consulate-Gen-
eral here for a delegation of 61 members of the Basic Chemicals, Phar-
maceuticals and Cosmetics Export Promotion Council (Chemexcil).
South Africa has long been the leader in chemical production for the
continent, but producers are currently facing poor domestic demand
and a volatile exchange rate that hampers exports, which has led to a
decline in output since 2013, Shome explained. Chemexcil Chairman
Dr B R Gaikwad urged members of his organisation to heed this call and
the offer of further assistance from the Consul-General if they wished
to pursue. Highlighting the Make in India campaign as one which is
intended to produce in India for consumers across the globe, Gaikwad
also urged South African manufacturers to use the opportunity of growing
their businesses by partnering with India.
Chemical Engineering World
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CEW Industry News
SMEs to Emerge as Key Players in Export Growth
of Chemical industry
Mumbai, India: Small and medium enterprises are expected to play
a vital role in the export growth of chemical industry, said Union
Commerce Minister Nirmala Sitharaman. She was presenting
CHEMEXCIL awards to the winners of export performance in
various categories during the last four years. She stressed the
need to have a strategy to enhance expor t competitiveness
of SMEs through capacity building, cheaper credit and better
marketing. The minister said the central government has initiated
an all out efforts to nurture budding entrepreneurs across sectors.
Indian Organic Chemical Industry Outlook to 2019
New Delhi, India: A report titled India Organic Chemical Industry
Outlook to 2019 - Driven by Consumer Preferences and Integrated
Production of Chemicals provides a comprehensive analysis of the
various aspects such as market size of the overall organic chemical
market with a focus on methanol and phenol markets. The market
is further segmented into consumption and production, end user
industry analysis, import and export and competitive landscape of the
major players operating in methanol and phenol market. Investment
opportunities, recent trends, drivers and macro economy factors have
also been discussed in the market intelligence.
In India, six major organic chemicals, namely, Methanol, Aniline, Alkyl
Amines and its derivatives like Formaldehyde, Acetic Acid and Phenol,
have contributed a major proportion to the domestic Organic Chemic
industry. The production of organic chemicals market has increased
marginally at a CAGR of 3.8% over the years during FY2009-FY2014.
This growth has been registered also on account of abolishment of
Industrial Licensing for various sub sectors except the hazardous
chemicals and reduction in the list of reserved chemical items for
the production in small scale sector. Poor infrastructure, high cost of
feedstock and under-utilization of installed capacities have acted as
a major hurdle in the achievement of optimum operational capacities
of plant and machinery. Ensuring feedstock availability, stringent
government regulations against cheap imports, skilled manpower
and innovating new applications of organic chemicals are the major
factors that would drive the growth of this market in the next five years.
New Plastic Pipe Plant for CRI Pumps
Chennai, India:To cater to the east and south Indian markets, CRI Pumps
has opened a plant at Hosur to make non-metallic plastic pipes. The
company had been transporting pipes from its plant in Gujarat to markets
in south India leading to the freight cost working out to almost eight per
cent. Hence, it was decided to have a manufacturing unit at Hosur. The
company had invested ` 125 crore in pipe-making plants at Gujarat and
Hosur. It had expanded capacity at the Gujarat plant to 20,000 tonnes
a year. The Hosur plant also had a similar capacity. Turnover from the
pipe-making units in 2016-17 is expected to be ` 150 crore, according
to G Soundararajan, Company Vice Chairman.
10 February 2016
CIL Q3 Profit Surges by ` 500 Crores
Mumbai, India: Coal India reported a nearly ` 500 crore increase
in net profit, which touched Rs.3,718.30 crore as compared to
` 3262.50 crore a year ago. Total income has increased to `
20,953.40 crore from ` 19,944.90 crore. This performance came
on the back of a 10.7 per cent growth in coal supplies. CIL supplied
137.90 million tonnes between October and December 2015.
The third quarter witnessed production of 143.9 million tonnes with
the company holding its production tempo at 373.51 million tonnes
in the nine months of 2015-16 against 342.38 million tonnes on
a year-on-year comparison, with a 31.13 million tonnes increase
in absolute terms.
Nippon Paint to Strengthen its Market Presence
in South
Chennai, India: Japanese paint manufacturer Nippon Paint is
planning to become a dominant player in the southern market by
end 2019. The expansion plan includes increasing the production
volume, introducing more water-based products, penetrating
into Tier-III cities of southern states and rolling out skill training
programme for painters.
Nippon Paint has a facility at Sriperumbudur with capacity to
produce 7,000 kilo litre per month. Currently, it operates at 35
per cent of its capacity.
GSFC Awards EPC Contract to Simon India
New Delhi, India: Simon India Limited, a leading EPC company
and a part of Adventz group, has won a significant contract from
Gujarat State Fertilizers & Chemicals Limited (GSFC) for their
Caprolactum Quality Project (CQP). The project is for installing
new distillation unit of 50,000 MTPY capacity to enhance quality
of Caprolactum produced in old plant and will be set up in GSFCs
existing Fertilizernagar complex in Vadodara, Gujarat.
Simon India has been awarded this project on EPC basis against
competitive bidding. The scope of work includes extended basic
engineering, detailed engineering, procurement, supply, erection &
construction and commissioning assistance. The project is slated
for completion in Q1-2017.
The Bhoomipujan & Foundation stone laying ceremony of the
CQP project was recently performed by the Honble Chairman &
Managing Director - Dr S K Nanda, IAS in an impressive function
held at Fertilizernagar complex.
This is the second contract awarded to Simon India Limited by
GSFC and reiterates trust in Simon Indias capabilities.
Chemical Engineering World
CEW Industry News
Safety Data Base for Registered Chemicals
Maryland, US: Researchers at Johns Hopkins Bloomberg School of
Public Health, US, have created a safety database on 10,000 chemicals
registered in Europe for predicting the toxicity of many of the 90,000
or more other substances in consumer products.
With the database, explained online in the Alternatives to Animal
Experiments journal, the researchers aim to help regulators,
manufacturers and scientists by providing idea about whether
chemicals, for which little research is done, are harmful or not. The
database, created on the basis of 816,000 research studies, also
inclu includes information about the hazardous nature of the surveyed
chemicals to the humans.
EU Exit would Cause Great Loss to UK Chemical
Market
London, UK: The chemical industry in UK could face a EUR 7
billion loss of exports if the country chooses to withdraw from the
European Union (EU) without signing a new Free Trade Agreement
(FTA), according to a report by trade credit insurance group Euler
Hermes. In addition, the report has warned that the machinery
and equipment industry would face a loss of EUR 3.5 billion and
the automotive industry would face EUR 3 billion loss, if new
FTA is not agreed. The UKs chemicals, automotive, machinery,
and equipment sectors are known to be highly dependent on the
European market.
Bertin Technologies to Install Second Sight at
Saudi Aramcos Jazan Refinery
Dhahran, Saudi Arabia: Petrofac, a leading service provider to
the international Oil & Gas industry, awarded a contract to Bertin
Technologies, a subsidiary of CNIM group, to supply, install and
commission a pioneering gas leak tracking system, Second Sight,
at the Saudi Aramco owned Jazan refinery.
This system opens up a new era in gas detection methods for
the Oil & Gas industry. Bertin Technologies has achieved a
major breakthrough by customizing its own gas imaging camera.
Initially developed for defense and civil security applications,
Second Sight has been adapted to IECEx hazardous area and
Saudi Aramco standards. To enhance the level of safety on site,
Bertin Technologies will provide a turnkey solution that detects
and monitors explosive gas clouds.
The Second Sight solution has been selected by Saudi Aramco
and Petrofac because it offers several benefits that complement
conventional gas detection methods. It provides, in real time, a
complete scene visualization. In the case of an alarm activation,
it localizes the leakage source and direction of the explosive gas
cloud in the vicinity.
14 February 2016
Topsoe Wins Iranian Methanol Plant Contract
Chabahar, Iran: Denmark-based technology, catalyst and services
supplier Haldor Topsoe (Topsoe) has secured a contract from Badr-
e-Shargh Petrochemical Complex to provide licenses, engineering,
proprietary equipment, materials and catalyst for a new methanol
plant to be located in Chabahar, Iran.
It will be the first plant in a new industrial zone in Chabahar area.
The company has also decided to open permanent offices in
Tehran with an expectation to tap the petrochemical and refinery
business in Iran.
Report Forecast Strong M&A in Chemical Industry
New York, USA: A Deloitte Global report has stated that strong
mergers and acquisitions (M&A) activity in the chemical sector
will continue this year. According to Deloitte Touche Tohmatsus
(Deloitte Global) 2016 global chemical industry mergers and
acquisitions outlook, companies are showing more interest in
acquisitions to grow and provide greater shareholder value.
Chemical sectors, such as fertilisers and agriculture chemicals,
have already diversified this year, and industrial gases are also
expected to see strong M&A activity.
Deloitte Global M&A chemicals and specialty materials sector
leader Dan Schweller said: Higher deal volumes are likely as
companies use M&A as a tactic to deliver growth to counter
challenging business conditions, which are expected to continue
in these segments.
Axiall Turns Down Westlake Chemicals Offer
Atlanta, Georgia: Chemicals and building products manufacturer
Axiall has turned down a revised USD 1.41 billion acquisition offer
from Westlake Chemical. The US-based company called the bid
an opportunistic effort to buy its vinyl assets at a cheaper rate.
In the unsolicited cash-and-stock bid, Westlake offered to buy all
the outstanding common shares of Axiall for USD 20 per share,
constituting USD 11.00 in cash and 0.1967 shares of Westlake
stock. Westlake offered its bid to buy Axiall last week. After
reviewing the proposal, the company unanimously rejected it.
Westlake said that previously it had offered USD 11 per share in
cash and 0.1967 of its stock for each Axiall share.
Axiall president and chief executive officer Timothy Mann
said: We believe that Westlakes proposal is an opportunistic
attempt to take advantage of challenging public equity market
conditions, and significantly undervalues Axialls assets and its
long-term prospects.
Chemical Engineering World
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CEW Industry News
New Dispense Technology for Agricultural Use of
Chemicals
Cambridge, UK: A new spray technology that shoots a targeted
droplet with incredible accuracy could cut agricultural use of
chemicals by more than 99 per cent, according to Niall Mottram,
head of agrifood product development at developers Cambridge
Consultants. The technology has the potential to not only
save farmers money, but also help protect the environment by
dramatically reducing the amount of chemicals that are applied.
The system uses advanced machine vision algorithms that can
differentiate between healthy and diseased crops, and then apply
a droplet only to the crops that need it.
Andritz Starts up Semi-chemical Pulp line with
Green Liquor Pulping Technology
Moscow, Russia: International technology Group Andritz has
started up the pulp line delivered to JSC Arkhangelsk Pulp and
Paper Mill (APPM) at the Novodvinsk mill, Russia.
The new line features Andritz green liquor technology for efficient
pulp cooking, refining, and washing and produces 1,000 t/day
of semi-chemical pulp for the production of corrugated board
from birch and aspen, as the company says in the press release
received by Lesprom Network. Semi-chemical pulp is produced
in a combination of mild chemical treatment and subsequent
mechanical treatment in which the fibers are liberated from the
wood matrix.
A major advantage of the Andritz green liquor technology, which
is mainly applied for hardwoods and enhances the fiber quality
substantially, is the efficient and easy recover y of cooking
chemicals in the adjacent kraft mill. Thus, no additional process
steps are needed for chemical recovery.
ChemChina to Acquire Syngenta
Beijing, China: Chinas gover nment-owned China National
Chemical Corporation (ChemChina) has agreed to buy the Swiss
agrochemical and seeds company Syngenta for USD 43 billion.
The decision to sell 100 per cent of Syngentas equity came
after the companys board unanimously approved ChemChinas
bid. ChemChinas offered USD 465 per share in cash, and an
additional special dividend of Sfr 5 (USD 4.91), which will be paid
immediately before closing the deal.
The deal is yet to receive anti-trust reviews and approvals from
relevant countries. Upon completion of the deal, ChemChina will
retain the operations, management and employees of Syngenta.
Syngenta will retain its name and will continue its operation from
its existing headquarters in Basel, Switzerland.
16 February 2016
Environmental Products and Services Files
Lawsuit against Miller Chemicals
Pennsylvania, USA: An environmental cleanup company, Environmental
Products and Services, has filed a USD 6.9 millionfederal lawsuit against
Adams County, US, based company Miller Chemical and Fertilizer.
Environmental Products alleged that Miller Chemical has not paid the
group fully for the cleanup work it carried out following a fire that killed
numerous fish in June last year, reports PennLive.
During last years incident, a Miller Chemicals warehouse located in
Radio Road, near Hanover, US was burned down, incurring around USD
20 million in property loss to the company.
State and county officials claimed that the fire-fighting and cleanup
measures carried out for days had polluted nearby water bodies and
killed thousands of fish. Due to the contamination, fishing, boating
and swimming were prohibited in the nearby waterways, where the fire
occurred, for around a month. The lawsuit filed in US Middle District
Court has mentioned that Miller Chemical hired Environmental Products
to help in proper recovery efforts and to initially provide equipment and
labour support.
Optima Chemical to Expand at DuPont Plant
Belle, USA: As West Virginias chemical industry waits to see how the
proposed merger between DuPont and Dow Chemical plays out, one
company is wasting no time opening up shop in the Kanawha Valley.
Optima Chemical, a Georgia-based company, announced last June that
it had bought two units at the old DuPont chemical plant in Belle. Seven
months later, the companys employees are busy bringing those sections
of the aging plant back to life. In December, Optima received preliminary
approval from the West Virginia Economic Development Authority for a
USD 2.25 million government-subsidized loan to buy new equipment
and to upgrade existing infrastructure at the plant, some of which hasnt
been used for more than five years.
Bertschi Opens New Plant at Jurong Island
Drrensch, Switzerland: Swiss chemical logistics firm Bertschi
Holding has inaugurated its USD 45 million Jurong Island Chemical
Cluster (JICC) facility in Jurong Island, Singapore.
With its first facility in South-East Asia, Bertschi aims to provide
chemical logistics, processing services, and lean supply chain
solutions to specialty chemical makers located along the islands
Ethylene Oxide corridor.
The manufacture of specialty chemicals has grown recently in Jurong
Island, which is mainly known for its refineries and petrochemical
complexes. Bertschi aims to provide specialised logistics services
to those manufacturers from the companys new facility.
Chemical Engineering World
CEW Industry News
Green Biologics Named in the 2015 Global
Cleantech 100
Gahanna, Ohio and Abingdon, England: Green Biologics Ltd, a UK
based industrial biotechnology and renewable chemicals company, has
once again been named to the prestigious 2015 Global Cleantech 100,
produced by Cleantech Group, a leading global research and advisory
firm. Green Biologics was recognized for its Clostridium fermentation
platform, which converts a wide range of sustainable feedstocks into
high performance green chemicals such as n-butanol and acetone for
use by the growing consumer and industrial products industries. The
Global Cleantech 100 is a comprehensive list of the private companies
poised to make the most significant impact on the cleantech industry
through innovative and promising technologies aimed at addressing
tomorrows clean technology challenges. The list is collated by sifting
through thousands of nominations and combining proprietary Cleantech
Group research data, with weighted qualitative judgments, and specific
inputs from a global 100-person Expert Panel.
Air Products Builds ASU Trains for Shaanxi
Future Energy Chemical
Yulin, China: Air Products has brought online its four air separation
unit (ASU) trains built for Shaanxi Future Energy Chemical in Yulin City,
Shaanxi Province, China. The trains are equipped with air compressors,
as well as design and technology advancements to improve energy
efficiency, while helping Shaanxi reduce operational costs. The project
was initially announced in December 2011. Together, the units are capable
of producing 12,000t of oxygen and nitrogen, and compressed dry air
per day for Shaanxis coal chemical plant. Air Products industrial gases
Asia on-site business development vice-president Phil Sproger said: The
successful execution of this world-scale project is another testimonial of our
leading position in large air separation and excellence in safety, reliability
and technology.
TV SD Supports Iranian Manufacturers and
German Importers in Dealing with REACH
Munich, Germany: Trade sanctions against Iran have now been lifted
and companies are building new business relationships. TV SD
is supporting Iranian chemical product manufacturers and German
importers in implementing the European chemicals regulation, REACH.
Chemicals, petrochemicals and extractive metallurgy are major
industrial sectors in Irans economy. Now that the trade embargo has
been lifted, Iranian manufacturers can export their chemical products
to the European Union. However, they must observe the provisions of
the European chemicals regulation, REACH. Under the terms of the
regulation, importers must register any substances produced in volumes
over the limit of 1 t/a per substance within specific deadlines, explains
Dr Dieter Reiml, REACH expert at TV SD Industrie Service GmbH.
Manufacturers can also commission an Only Representative outside the
European Union to carry out registration on their behalf. This option has
advantages for the entire supply chain, advises Dr Reiml; for example,
importers no longer need to register as downstream users.
18 February 2016
Idemitsu to Expand Xarec Resin Production
Capacity
Tokyo, Japan: Japan-based Idemitsu Kosan is all set to increase its
production capacity for syndiotactic polystyrene resin (SPS) Xarec.
Idemitsu started production of the low-density engineering plastic SPS
on an industrialised scale in 1997. The company said it will increase the
production capacity of the SPS manufacturing unit at its Chiba plant due
to increasing demand for the product at an annual rate of around 10 per
cent. The production capacity is set to increase from the existing 7,000t
per year, to 9,000t per year. Completion is set to take place in April.
Praxair Introduce Ozone Technology for Water
Treatment
Mumbai. India: In power plants and the chemical and petrochemical
industries, cooling towers determine final heat transfer rates on associated
equipment. During operation, cooling towers are generally exposed to
the ambient conditions from atmospheric microflora as well as impurities
and sunlight. This process is prone to microbiological activity leading to
adverse effects like heat exchanger fouling, loss of cooling efficiency,
microbial influenced corrosion and severe localized metal loss due to
acid build-up. Conventional microbial control offers many solutions and
the choice depends on water chemistry, types of organisms, compatibility
with treatment chemicals, system design, permits and cost limitations.
Praxairs ozone technology harnesses the powerful biocide action of
ozone to decrease and nearly eliminate microbial growth. Praxairs
treatment reduces the need for chemical additives to be added to the
cooling tower water. Ozone not only removes and prevents the growth
of these organisms but also reduces the contaminant levels through
direct oxidation. Contrary to conventional halogen-based biocides, ozone
does not produce unwanted by-products such as halocarbons. The
blowdown rates are also lowered due to lower water losses and lower
chemical dosage.
Schwarze-Robitec to Present NxG 2.0 at the
International Trade Fair Tube 2016
Cologne, Germany: During the Tube 2016, visitors to the Schwarze-
Robitec booth will have the opportunity to find out more about intelligent
tube bending solutions. The CNC-controlled system NxG 2.0 allowed
us to tie a total package together that consists of software and hardware
and that will undoubtedly improve the tube bending production in the
not so distant future, says Bert Zorn, General Manager of Schwarze-
Robitec. With the objective to get the bending technology ready for
Industry 4.0, the company integrated fundamental modules into the new
control system. In addition to a new operating concept, and besides
standard statistical information about the bent component, the further
development of the high-performance NxG makes it also possible
to record and evaluate process data. Integrated sensors provide
information about wear parts to arrive at conclusions such as the
maintenance requirement of the machine. The advanced software uses
icons displayed on the desktop, and its new graphical user interface
ensures process reliability and intuitive operability.
Chemical Engineering World
CEW Technology News
G S P C B R e p o r t N e g a t i v e R e s u l t fo r N a n o
Oxidation Technology Lab Trials
Panaji, India: The Goa State Pollution Control Board (GSPCB)
has found lab trials conducted using the nano oxidation
technology, which promises to treat any kind of water for all
pollutants, to be unsatisfactory for using it to clean up larger
streams of polluted water bodies like the St Inez creek. However,
it is recommendatory for industries to adopt such technology
in their effluent treatment plants and for hotels in their sewage
treatment plants.
The technology was offered by Ozo Nano Sciences, a Bangalore-
based firm, which approached the GSPCB last month with the
proposal to clean up the polluted St Inez creek water. The
company claims to remove toxic or non-degradable material
from water.
It also claims the removal of pesticides, petroleum ingredient
and VOCs (volatile organic chemicals) by just adding liquid
incinerator into the polluted water that also neutralises bacteria,
reduces chemical toxicity and precipitate heavy metals.
INTERSECT16 Held at Karaikudi
Karaikudi, India: A three-day National Technical and Research
Symposium on Electrochemical and Chemical Technology
2016 (INTERSECT16), a national-level technical symposium
and cultural event was organised by the Electrochemical
Technologists Association (ETA) in the Council of Scientific and
Industrial Research-Central Electrochemical Research Institute
(CSIR-CECRI) from February 4 to 6 at Karaikudi, Tamil Nadu.
Inaugurating the conference, M Jayachandran, acting Director,
CSIR-CECRI, said that he always felt happy to work with
young minds as they came up with fresh ideas and advised the
delegates to interact freely with scientists and take up projects
at CECRI.
Ramesh Babu, Dean, Centre for Education-CECRI, explained
the unique B.Tech. (Chemical and Electrochemical Engineering)
programme offered at the institution. V Ramamoorthi, retired
Dean and Professor, AC Tech., Anna University, Chennai,
emphasised the role of electrochemical engineering in the
present era. Electrochemical engineering was the need of
the hour, he said and cited various real-life applications.The
conference was a great opportunity for young minds, they said
adding the technical symposium was being conducted with a
team of B.Tec.h and research scholars of CSIR-CECRI. It had
events such as oral presentation, poster presentation, science
quiz, workshops on instrumentation, online competitions and
designing competitions, they said.
20 February 2016
IICT Researchers Introduce Advanced Water
Purification System
Hyderabad, India: A team of researchers lead by Dr S Sridhar,
the Principal Scientist for Indian Institute of Chemical Technology
(IICT) in Hyderabads Membrane Separations Group, introduced
a promising water purification systems work on membrane
filtration, remineralisation and pressurised reverse osmosis
techniques that allow 1,000 litres of pure drinking water to be
generated per hour, at the cost of just 4 paise per litre (and a
one-time investment of around ` 3 lakhs) thats safe from fluoride
and arsenic, two of Indias biggest water pollutants. The pilot
projects have a capacity of around 6,000 litres per hour.
The team has also developed nano-filtration and ultra-filtration
techniques for water that has a plethora of uses, including
generating medical-grade water.
Hybrid Technology to Create Biorenewable Nylon
Iowa, USA: Engineers at Iowa State University have found a way to
combine a genetically engineered strain of yeast and an electrocatalyst
to efficiently convert sugar into a new type of nylon. Previous
attempts to combine biocatalysis and chemical catalysis to produce
biorenewable chemicals have resulted in low conversion rates. Thats
usually because the biological processes leave residual impurities
that harm the effectiveness of chemical catalysts. The research group
has created genetically engineered yeast - a microbial factory, - that
ferments glucose into muconic acid. By applying metabolic engineering
strategies, the group also significantly improved the yield of the acid.
Then, without any purification, Tessonniers group introduced a metal
catalyst - lead - into the mixture and applied a small voltage to convert
the acid. The resulting reaction adds hydrogen to the mix and produces
3-hexenedioic acid.
ClearRefining Technologies, Ninth Wing Capital Join
Hands for Modular Near-zero Emission Refineries
New York, USA: ClearRefining Technologies, LLC, and Ninth Wing
Capital, LLC, has announced its partnership to establish modular
near-zero emission refineries in major metropolitan areas around the
globe to provide a clean alternative diesel fuel, known as GDiesel,
that meets and exceeds government fuel standards. PGA Tour
Professional Billy Hurley III has also agreed to become the first brand
ambassador for GDiesel. Over 40 million gallons of clean diesel fuel
have already been delivered to the Las Vegas and Reno markets,
including power generators at a local PGA Tour event there. GDiesel is
demonstrating tremendous success in lowering vehicle maintenance
costs by almost 50 percent; dramatically reducing both regulated
and unregulated emissions; and increasing by 12 per cent vehicular
miles per gallon, according to Peter Gunnerman, Managing Partner
of ClearRefining Technologies, the newly-formed parent company of
Advanced Refining Concepts, LLC.
Chemical Engineering World
CEW Technology News
Aqdot Bags EUR 5 Million of Fund
Cambridge, UK: Cambridge-based chemical company Aqdot
has closed a EUR 5 million Series A funding round led by
Imperial Innovations Group. Parkwalk Advisors, Cambridge
Enterprise the University of Cambridges commercialisation
arm and Providence Investment Company also participated in
the round. Founded in late 2012, Aqdot, a spin-out company of
the University of Cambridge specialises in producing intelligent
encapsulation technology.
Bright Future for Organic Solar Cells
Wako, Japan: Although the amount of energy that organic solar
cells can generate from sunlight is lower than conventional
cells, experts say that there is room for improvement, with many
arguing they could be an effective tool for slashing carbon dioxide
emissions, in part, due to their pliable nature.
Normally, solar cells that people imagine are ones on the roof
that are heavy and firm (but) organic solar cells are very light
and flexible, so they can be set up in places where it would be
physically impossible to install regular solar panels, said Itaru
Osaka, a senior research scientist developing organic solar cells
at the state-backed Riken institute.
Organic solar cells are made from organic compounds or
polymers, while regular cells are made primarily of silicon. A
silicon-based solar panel weighs about 15 to 20 kilograms and is
heated at hundreds of degrees Celsius during the manufacturing
process, which actually results in greenhouse gas emissions.
Osaka said organic solar cells are made by thinly coating the
polymers on various materials, such as plastic, so they are light.
Also, the cells can be crafted at temperatures of less than 100
degrees, making them more environmentally friendly.
Scientists Invent Process to Directly Convert CO2
from Air into Methanol
California, USA: Scientists at the University of Southern
Californias (USC) Loker Hydrocarbon Research Institute have
invented a process to directly convert carbon dioxide (CO2) from
the air into methanol at comparatively low temperatures. The
research has been led by GK Surya Prakash and George Olah
of the USC Dornsife College of Letters, Arts and Sciences and
is a part of the greater attempt to reduce the amount of CO2 in
the atmosphere.
The effort also aims to use clean energy to convert greenhouse
gas into its flammable sources. Methanol can be used as the
internal combustion engines fuel, and as a fuel for fuel cells,
as well as raw material to make various petrochemical products.
22 February 2016
Chinese Scientists Make Fertilizer from Potato
Effluent
Lanzhou, China: Scientists in China have developed a way
of making fertilizer from waste water discharged by potato
processing plants, solving a pollution problem which has held
back Chinas potato ambitions.
China sees potatoes as a new staple food to ensure food security,
but protein-rich water discharged by starch processors, a major
buyer of the spuds, has been blamed for polluting rivers and
lakes. Lius team has developed technology that can halve the
chemical oxygen demand (COD) of the effluent by removing
starch, fiber and protein. The processed water does not need to
be dumped either, because of its high nitrogen, potassium and
phosphorus content make it a perfect irrigation water.
New Addition to the Periodical Table
North Carolina, USA: Four new chemical elements with atomic
numbers 113, 115, 117, and 118 have been formally added to the
periodic table, completing the tables seventh row.
The additions have been made following the verification of the
discoveries of the elements by the International Union of Pure and
Applied Chemistry (IUPAC). Scientists in Japan, Russia and the US
discovered the elements, which are the first to be included in the table
since 2011. Elements 114 and 116 were included in the table in 2011.
All the four elements are super heavy, lab-made, and very radioactive,
with which scientists will be able to create even heavier and synthetic
elements in times to come.
Boston Collage Researchers Introduce New
Cross Coupling Chemical Reaction Method
Boston, USA: Researchers at Boston College have developed a
new type of cross coupling chemical reaction method, with the help
of a third reactant.
The reaction has been developed on the basis of a Nobel Prize-
winning technique, which is known to be one of the most complicated
tools available to research chemists. The 2010 Nobel Prize in
chemistry has the subject of transition metal catalysed cross-coupling
reactions. One of the major components of the reaction is known as
Suzuki-Miyaura coupling, which unites two kinds of reactants, one
donor electron and one acceptor electron. The process, developed
by professor of chemistry at Boston College James P Morken and
his team, uses transition metals to develop a different cross-coupling
process that merges two electron donors by reacting with the electron
acceptor. The team reported in the Science journal that the resulting
conjunctive reaction occurs efficiently and offers a high-degree
of selectivity.
Chemical Engineering World
Introducing
a new world class!
VEGA, the world market leader in radar level measurement will
soon be presenting a new star in the galaxy of sensors. Get ready
for the technology of the future. Look forward to a new generation
full of innovative possibilities. Well keep you updated!

www.vega.com
CEW News Features

Purita is working towards the vision of being a

complete water management and solutions company
Started business catering to cooling water treatment programme with its first ever Chlorine Dioxide System for one
of the largest Power Generating Stations in India in 2005, Purita Water Solutions Pvt Ltd has extended its reach into
other sectors like Refinery, Petrochemical, Steel, Fertiliser etc with top-10 companies ruling in these sectors spanning
with nearly 30 happy clients, says Ravindra Wadel, Chairman & Managing Director, Purita Water Solutions Pvt Ltd.
He shares his view on the companys Indigenous Technologies and Precursor Chemicals for Cooling Water, Drinking
Water, Wastewater & Water Recycling applications for various sectors with CEW.

E
stablished in 2005, Purita Water Solutions
Pvt Ltd started business catering to
cooling water treatment program with its
first ever Chlorine Dioxide System for one of the
largest Power Generating Stations in India with
1600 MW installed capacity and cooling water
flow rate of nearly 1,80,000 m3/h. The system
was engineered, designed, supplied, installed
and brought to successful commissioning & in
operation from Year 2006 onwards. We were
privileged to manage the plant O&M from its
commissioning date until today which is quite
rare as customer showed continued faith in
Puritas capability, says Wadel.
Further, we have extended our reach into
other sectors like Refinery, Petrochemical,
Steel, Fertiliser etc and we are proud to have
worked with top-10 companies ruling in these
sectors spanning with nearly 30 happy clients,
Wadel explains.
Indigenous Technologies and Precursor
Chemicals
With a highly experienced team of professionals
& experts, Purita offers alternative disinfection
using environment friendly Chlorine Dioxide
technology replacing hazardous Gas Chlorine
& related chemical applications in Cooling
Water, Drinking water, Wastewater & Water
recycling applications, says Wadel.
We have launched our UniQu Design with
portable (system on trailer) systems in 1 kg/h
to 48 kg/h requirements. These systems are
pre-wired and ready to use for on-site in-situ
Chlorine Dioxide generation, Wadel continues.
Purita is a leading manufacturer of Precursor
C h e m i c a l s i . e . C H L O R AC T I V 2 5 0 9 ,
26 February 2016
CHLORACTIV 3109 which are essential
raw material required for the production of
Chlorine Dioxide. We have increased our
reach by offering Japanese world class water
& wastewater treatment chemicals for various
applications. Hence, we can cover the entire
spectrum of water conditioning and treatment
program including systems and services,
reveals Wadel.
Success Stories
Purita has achieved many first to its credit by
offering technology which is actually replacing
the hazardous application of chlorine for
water & wastewater. Our first installation
for a power station was based on techno-
economic benefit by which our customer
reduced the operation & maintenance costs
by nearly 40 per cent from their earlier budget
and additionally our environment friendly
technology provided way for Chlorine Dioxide
use. In consequence our client also benefitted
in reducing their time by nearly half in their
planned outage and hence offered more
operating life to the power station. Many of
our clients have benefitted from this useful
technology and we would like to maintain
our niche in the segment by constantly
upgrading and innovating our designs,
says Wadel.
Growth Drivers
Water has always been essential and precious
resource which has been underutilised in
our country putting pressure on Government
to subsidise the water distribution and last
last 10- 15 years, we have seen continuous
evolvement and efficient use of water and
its resources. The more & more use or
reuse of water and achieving nearly ZERO
Liquid discharge is becoming a common
phenomenon and basic requirement in
industry, says Wadel.
We have been part of water & water waste
business throughout and we really see a
good future ahead for the segment to grow.
However, as the growth showing north, we have
also competition increasing and hence in our
opinion, technology edge and related products
would find its way into this highly competitive
and growing segment, adds Wadel.
Purita will strive to retain its leadership
position in Chlorine Dioxide business and
eventually enter into other segments of water
& wastewater businesses.
Association with Singapore Research
Institution
Purita believes in innovation and we have been
closely working with Singapore based research
institute as a continuous evolving process. Our
gain from this research is to upgrade our design
and safety standards to match with internally
acceptable standards, reveals Wadel.
Future Plan
Working towards a vison of being a complete
water management and solutions company,
Purita is aiming to bring the best water
conditioning and treatment program technology
effectively for an environment friendly future.
Chemical Engineering World
CEW Features
Guest Column

The Criticality of Managing Supply Chain Energy Efficiently

Companies today are being energy efficient. There is considerable awareness about going
green and reducing carbon footprint. However, one aspect that they might be overlooking
is the energy spent in the various links of the supply chain. If one can manage supply
chain energy efficiently, carbon footprint reduces drastically, says Shaik Asad Parwez,
Head, Supply Chain, Racold Thermo Ltd.

O
ver the period there has been
a shift in the perspective of the
supply chain process. The focus
has been shifted from reducing cost to
reducing carbon footprint. The modern
day manufacturers are looking at ways
to reduce carbon emission. They have a
broader target of reducing cost using the
energy efficiently, reducing the wastage
having better productivity etc.
In the coming years if the organisations
think out of the box and in collaboration
with the supply chain of the other
organisation, then there are opportunities
of reducing the carbon emission using the
best technology generating better profits.
Piggy Bank issues: Where and What
to Save?
In supply chain there is a great scope
for promoting energy efficiency, reducing
costs & decreasing the environmental
footprint of consumer goods. The energy
& commercial efficiency can be achieved
by engaging leading companies to identify
high quality suppliers. There can be a
single supplier for many companies and
he would do the manufacturing activity
of all the companies under the same
roof. The supplier will follow the SOP
for each and every company as defined
by them. This will create sector-based
collaborations for improving supply chain
energy efficiency by assembling groups of
peer manufacturer within a supply chain
and using benchmarking and process
capability analysis and best practice
30 February 2016
sharing to identify and improve energy
efficiency and industry competitiveness.
The cost of the goods will decrease
as the supplier will get the benefit of
bulk purchasing of raw material, 100
per cent utilisation of the plant capacity
and energy to run the plant, elimination
of wastage etc. On the other hand
companies can also reduce the carbon
footprint by initiating certain practices on
the distribution front.
Today, most of the companies operate
out of dedicated facilities and have a
dedicated logistic supplier taking care
of operations. The companies can also
look for 3PL suppliers who can handle
multiple account from the same facilities
hence the concept of shared resources
can be utilised by doing so the company
can reduce the overall logistics cost
as the warehouse facility, manpower,
transportation, electricity are on sharing
basis and this will also reduce the
carbon footprint.
Tips of Energy Saving
Organisations need to list down their
desire of reducing energy costs through
supply chain management. They also
need to be aware of the regulations to
follow and permits to take to ensure that
all personnel involved in the process of
Supply chain teams have centralised and are managing the complexities
of global supply chain. Supply chain network design incorporates
variety of factors ranging from production purchase, warehousing,
inventory and transportation.
supply chain management are following
steps for efficient energy utilisation.
These are some of the initiatives we at
Racold Thermo take up to ensure the
reduction of electric energy usage:
Provide sufficient ventilation in the
plant
Introduce air ventilators for effective
exhaust system
Use transparent sheets on the roof for
proper sunlight
Use induction lamp instead of MHL
etc.
Solar water heaters for heating water
Solar panels for generating electricity
which can be used in production line
From a futuristic point of view, the
companies need to engage leading
manufacturing companies to identify
high-quality suppliers for pilot supply
chain energy efficiency improvements.
They can also create one or more sector-
based collaborations for improving supply
chain energy efficiency by assembling
groups of peer manufacturers.
There are several leading companies that
follow a regulated process to ensure an
energy efficient supply chain keeping
those in mind, companies must follow suit.
They need to see the larger picture an
Chemical Engineering World
CEW Features
In a country like India where there is a different tax structure and rules order to adhere to the regulations and
and regulation for doing business in each and every state. In order to permits involved we have to increase the
operations in various states increasing
adhere to it the companies are forced to maintain warehouse in each
the cost of operations and carbon
and every state. footprint even though you can manage
energy efficient process and organisation Keep measuring the results, with less locations thereby reduced
is loved by the people, and with the that will help improve the carbon footprint as with each increased
saving costs operations can be improved. entire process location we incur additional layer of
It is a win-win situation. warehouses, transportation, and other
Reducing Carbon Footprints/Carbon related infrastructure and all these
Reducing Costs through Supply Chain Emissions lead to increased carbon footprint for
Management the environment.
Companies have realised that carbon
Supply chain teams have centralised and management in the supply chain plays
are managing the complexities of global VAT for doing local billing.
a vital role. Working in partnership can
supply chain. Supply chain network design CST billing is costly as the liability in
improve vehicle utilisation and reduce
incorporates variety of factors ranging on the company in case C Forms are
carbon emissions for all the companies.
from production purchase, warehousing, not submitted.
Appended below are few essential steps
inventory and transportation. It has Road permits for different states.
towards reducing carbon footprints:
driven many companies to redesign Octroi etc.
Using right metrics for carbon
and reconfigure their supply chains, Stock transfers between
management like improving
resulting to reduction in costs and giving locations to balance the
communications with suppliers to
effective outcome. inventory levels.
deliver performance
Optimise truckloads
Supply chain can examine ways to reduce With the advent of new tax regime GST
Utilise non-polluted/environment
costs by coordinating transportation business will become simpler and thereby
friendly vehicles
inventory and vendor strategies. For the companies can do business in the
Utilise rail or multimodal transportation
example: most cost effective manner with lesser
Delivering as per the vendor/ Optimise warehouse space utilisation, number of locations thereby helping
customers requirements, will avoid e.g. vertical storage reduce the overall carbon footprint.
adding up to the costs of back-and-
forth transportation Regulations and Permits involved in the
Understand the customer/vendors Process of Supply Chain Management
needs and define the supply chain In a country like India where there is a
strategy different tax structure and rules and
Getting a clear understanding of the regulation for doing business in each
process first and then only define the and every state. In order to adhere to
systems it the companies are forced to maintain
Using multiple suppliers avoids costly warehouse in each and every state.
delays in receiving products Doing business is complex. Hence in

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32 February 2016 Chemical Engineering World

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CEW Features
White Paper
The Enlightened Plant: How an Automation System
Delivers New Insight to Plant Operations
Industry teams today must comprehend and leverage a massive volume of information delivered by control
technologies. A process automation system can inform and enlighten plant personnel at all levels with context-
rich information. Last in a series of three, this paper explains the new operational insight that can be delivered
to plant operations after meeting basic needs for reliable, secure performance.
T
his paper focuses on how modern,
process automation systems
can enhance existing control
technology. The goal is not just to inform
plant personnel, but to enlighten them with
context-rich information delivering new
levels of operational insight for operators,
systems engineers, project engineers,
maintenance technicians, safety team
members, and managers.
Information without context is noise.
When surveyed, many of todays process
industry engineers and operators indicate
that they have all the information they
need, but want help in figuring out what to
do with it. The best way to filter that noise
is to ensure that each plant function has
clear, up-to-date information that enables
safe, successful operation of the business.
Although each job role operates within
multiple contexts, automation systems
can assist process plants most in the
following areas:
Increasing production value
Reducing costs of raw materials
and energy
Improving plant safety and security
Improving environmental integrity and
regulatory compliance
Empowering the plant workforce
This paper, the third in a series of three,
focuses on how automation system
users can adjust to information overload
and can incorporate new tools that will
help them to simplify tasks in a more
complex environment. The other papers
in this series include The Future-proof
34 February 2016
Plant: Impact of Evolving Operations,
Technology, and Workforce Changes
and The Protected Plant: How an
Automation System Mitigates Risks to
Operational Integrity.
Operational Adjustments
Plants will continue to grow larger and more
complex. Operators will struggle to handle
the increased load. More instrumentation
will need to be managed, more data will
need to be processed, and, as a result, the
potential for more human error will grow.
Unlike their predecessors, who viewed a
panel board to determine at a glance what
was going on in the plant, modern operators
rely on workstation screens. They access
and absorb much more information at a
faster speed. More steps are required
in order to properly assess and resolve
a problem.
Modern systems will be designed to counter
this gap between system complexity and
human operator capability. For example,
new situational libraries based on
modelling tools provide operators with the
content they need to adjust set points or
otherwise respond with maximum speed.
Pre-configured templates can improve
operator effectiveness, shorten response
time, reduce human error and fatigue,
and ensure that all actions are consistent
with company procedures, policies, and
strategies. In addition, critical information
can be displayed on smart phones and
tablets for operation from almost anywhere,
at any time, depending on the process
and the intrinsic safety parameters of the
devices involved.
Enhanced Engineering Tools
Remedying production problems based
on root-cause analysis is a key role
that systems engineers play while
increasing production value and managing
constraints. Their work environment
comprises a large variety of systems, each
of which may be from a different vendor
and each of whose technologies may be
changing rapidly. These engineers need to
understand those systems well enough to
diagnose production problems quickly, and
then scale immediately to make necessary
improvements. Timing is critical. They no
longer have the time to analyse detailed
sequential flow charts, ladder logic,
function block diagrams, or structured text
to determine what is really taking place
in the system. These are abstractions of
the actual process and in many cases,
abstractions not created by the engineer
who encounters them. Intuitive, easier-
to-use interfaces are required for these
engineers to complete their tasks.
One approach that offers engineers a
means for addressing these challenges
is based on an enhanced version of
Scientific Apparatus Manufacturers
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tools that are especially popular in the
power industry. These tools present a
more accurate representation of the
relevant proportional-integral-derivative
(PID) blocks and data flows. Such an
implementation can also include dynamic
filters, which help engineers focus more
directly on the control mode in which they
are working. Users report that the intuitive
modelling of such SAMA tools, combined
Chemical Engineering World
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CEW Features
with the dynamism built into them, can
reduce engineering workloads by as much
as 60 per cent.
Project Engineering Productivity
Project engineers must deliver new and
major upgrades on time and on schedule.
They need real-time awareness of
changing requirements and need to assess
the cost of the technology required.
Their productivity improves when they
can access an automation system that
decouples the configuration layer from
the runtime layers, enabling significant
portions of the system to be configured
and tested in the cloud. This speeds
project delivery by enabling engineering in
the context of a hypothetical future state.
Such a system also supports engineering
workbench and project management tools,
which can be deployed in the cloud to
enable project engineers to work in real-
time collaboration with colleagues around
the globe.
Downtime Control
Maintenance technicians working to
minimise downtime are also challenged
with increasing volume and complexity
of information. Systems generate an
unprecedented quantity of alarms. The
systems that the technicians work on are
sourced from many different vendors who
use multiple protocols to communicate
and who provide unique toolsets and
instruction manuals.
One solution is a maintenance response
centre that can display maintenance
alert dashboards comparable to the
alarm management systems that
operators use. When maintenance alerts
sound, the dashboard helps technicians
determine where to start drilling deeper
into procedures, inventory and other
information they need to solve the problem.
Integration of workflow management helps
maintenance technicians synchronise their
activities with others who may be working
on, or be affected by, a problem.
Security Enhancement
Safety team members must secure the
plant from safety breaches and cyber
36 February 2016
attacks and must do so at the lowest
cost, but without the slightest increase
in risk exposure. As discussed in The
Protected Plant: How an Automation
System Mitigates Risks to Operational
Integrity, the second white paper in this
series, the role that a modern system plays
in maintaining the operational integrity of a
plant includes safety.
When a process automation system
combines with a safety system, those
managing plant controls can work with
enhanced information regarding how and
where emergency shutdown capability is
being deployed throughout the plant. To
change these deployments, they go to a
separate interface or request modifications
from an engineer dedicated to the safety
system but they have the information
they need to work in full awareness of
the safety protection levels in operation.
Dashboards can provide further context on
a companys risk profile and provide users
the maximum flexibility of an integrated
experience without jeopardising safety.
Managing in Context
For plant executives and managers, the
future will demand more on-the-spot
decision-making that could have serious
implications for plant profitability, safety,
and security. Managers will guide the
setting of strategies and polices that
will make these decisions easier, but
they must be confident that the entire
plant is executing accordingly. A future-
ready automation solution must provide
an effective perspective across the
enterprise, facilitating better and faster
business decisions.
A modern system should provide all
components necessary to integrate
execution of plant strategies at every level.
A template of the operator situational
awareness library, for example, could
display real-time monitoring of performance
against one or more of the objectives
mentioned earlier, such as reducing raw
material or energy costs (see Schneider
Electric white paper How Human Machine
Interface (HMI) Impacts Business
Performance in Industrial Sites for more
information regarding the situational
awareness concept). Maintenance alerts
could be programmed to prioritise based
on achieving those same objectives. An
operator interface could warn of safety
risks that might be introduced by changes
in operations, and workflow engines could
connect all relevant functions.
In addition to the individual productivity
improvements that a new system can bring
to each function, aligning everyone on the
same strategic page yields unmatched
competitive advantage to those companies
that implement it. Some of the references
at the end of this paper provide more detail
on how that alignment can be achieved.
Object Model Future-Proof Benefits
Many of the applications that will be
needed to manage the future have not yet
been developed or even imagined, which
is why it is critical to build on an open yet
secure system platform. Much like the case
with smartphone or tablet apps, adherence
to common object models means users can
benefit from future managing applications
still to be developed. The more closely
these applications adhere to the standards,
the more easily users can incorporate and
benefit from them.
In addition to simplifying the delivery
of advanced tools and critical run-time
applications, a component object-based
architecture and layered design can
enable easy plug-in of applications built
to open computing standards, such as the
following:
a. Simulation, modelling and software,
which supports operator training,
real-time online optimisation, and
multivariable process control
b. Enterprise manufacturing intelligence,
which delivers real-time insight into
trends in production and operation
c. Corporate energy management, which
helps management deal with fluctuating
energy costs and supply
d. SCADA applications that are customised
for well-field, pipeline, water/
wastewater, and other applications
e. Enterprise asset management software,
which reduces costs through improved
diagnostics, inventory management,
Chemical Engineering World
 Unit II : Plot No. 4/18, Sector No. 10, PCNTDA, Bhosari,
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CEW Features
and preventive and predictive maintenance
f. Mobile applications, which deliver real-time procedure guidance
to field workers and enable real-time reporting

Conclusion
In the final analysis, automation does not solve problems; people ` VOL. 49 NO. 3 March 2014 US $ 10 ` 150

do. While a future-ready, future-proof process automation system

can deliver tremendous competitive and protective benefits,
the real strength of the control system is in its application, not
its technology. That application is in the hands of the people
who use it.

Automation has traditionally meant replacing human activity. Now, EPCM Special
recent advances in automation technology and the demands of the 28-31 January
rry 2015, Mumbai, India
ChemTECH World Expo 2015
28-31 January 2015, Mumbai, India

future have moved the industry into a new age. It is an age in which
automation is not replacing operational roles or dumping raw data
on people in the plant. Instead, it is enlightening plant personnel
with the context-rich information they need, and thus helping them
perform their roles better, more safely, and with greater gain for
themselves, their employers, and the consumers of their products.

References
1. Martin, Peter G., Walt Boyes, and Kaoru Maruta, Real Time
Control of the Industrial Enterprise, New York, NY: Momentum
Press, 2013.

2. Martin, Peter G., Bottom-Line Automation, 2nd ed., Research

Triangle Park, NC: International Society of Automation, 2006.

3. Martin, Peter G., Real-Time Strategic Empowerment for

Improved Profitability, white paper, Invensys Operations
Management, 2012.

4. Martin, Peter G., Real-Time Profit Control: Driving Profitability

in the Dynamic Industrial Environment, white paper, Invensys
Operations Management, 2011.

Authors Details

Dr Peter G Martin
Vice President Strategic Ventures
and Marketing
Schneider Electric

Grant Le Sueur
Director Product Management
Schneider Electric
38 February 2016 Chemical Engineering World

Technical Article
What Unnecessary Risks are You Taking?
What would you think if you saw someone using a shopping trolley as a car jack? Or a newspaper and sunglasses
as an improvised welding mask? You would probably ask yourself why anyone would put themselves in that kind
of danger. Here, the author explains why companies should never take any chances, especially where testing
and analysis are concerned.
S
trict Legislation
The Dangerous Substances
and Explosive Atmospheres
Regulations (DSEAR) of 2002 and the
Explosive Atmosphere Directive (ATEX
137) set the minimum requirements
for protection against risks from fire,
explosions and similar events arising
from dangerous substances used
or present in the workplace. The
legislation introduced more rigorous
testing for operators, including
regular and representative analysis of
thermal fluids.
Respecting The Dangerous Substances
and Explosive Atmospheres Regulations
(DSEAR) guidelines helps companies
identify early warnings regarding process
problems, helps maintain a safe and
efficient working environment and save
costs. Preventative maintenance and
Preventive maintenance and frequent testing helps
maintain a safe and efficient working environment, save
cost and extend the life of thermal fluid.
Chemical Engineering World
frequent testing can also help extend the
life of thermal fluid. More importantly,
a timely reaction to early warnings can
help you avoid replacement of costly
equipment and even save lives. In
environments where the risks are so high,
no expense should be spared to ensure
legislation is respected and thorough
efforts are made to keep employees and
premises safe.
What Risk?
In a nutshell, the dangers caused by
the lack of preventative maintenance
are rooted in the degradation of thermal
fluid. Over time, heat transfer fluid breaks
down through a process called thermal
cracking. The fluids molecules are
broken down into smaller particles and
several types of fractions are released
from this chemical reaction. The first side
products of thermal cracking are light
ends that have a low boiling point and are
very volatile.
The second category of thermal cracking
decomposition products are heavy
ends, which recombine to form heavy
polyaromatic molecules that usually
cause fouling of the heat transfer system.
As a result, carbon molecules will stick to
the system internals and reduce process
efficiency, unless cleaned and flushed
in time.
It is crucial to remember that thermal
fluid does not go from being fit for use
to needing replacement overnight.
There is a grey area where fluids can be
managed against what specialists call
the degradation curve. Degradation is
steady if a system is operated properly.
Features CEW
Only as the fluid approaches the end
of its practical working life, there is a
gradual curve which eventually drops
off very sharply. This sudden change in
the quality of thermal fluids is one of the
reasons why regular and preventative
maintenance is so important.
Diluting the thermal fluid by topping up is
a cost effective and durable option only
while the fluid is in the early part of the
degradation curve. After the condition of
the fluid has significantly deteriorated,
dilution is no longer a viable alternative.
It would have the same effect as putting
a new torch battery into a two battery
torch alongside a battery that has already
been used for some time. It would not
be a long term solution and would result
in the system not operating at optimum
capacity. That being said, the best thing
to do when the thermal fluid reaches the
end of its lifespan is to flush and clean
the system, prior to refilling it with a fresh
charge of heat transfer fluid.
Hot, Closed and Circulating
Despite the clarity of existing legislation
and the dangers of neglecting thermal
fluid analysis, companies often fail to
perform the sampling DSEAR requires
and carry out irrelevant tests, including
lube oil tests. These are sometimes non-
applicable and do not always provide the
necessary information.
Sample methodology is crucial incorrect
sampling give inaccurate flash point
results, which can have very dangerous
consequences. Unless the fluid samples
are collected when the oil is hot and
circulating, they will reveal artificially
February 2016 39
CEW Features
It is crucial to remember that thermal fluid does not go from being fit for use to needing replacement overnight
high flash point values. This incorrect
sampling will lead to the conclusion
that the system is safe, when in reality
it might not be. Inaccurate samples
can have negative consequences,
including decreased energy efficiency,
unmanageable flash points and a
dangerous working environment with risks
of explosions.
The sample also needs to be closed so
that no potential atmospheric particles
can contaminate it or distort the results.
An open sample would also allow light
ends to flash off to the atmosphere,
instead of remaining in the sample, which
produces unreliable readings.
Test Often and Well
Frequent sampling is crucial. DSEAR says
manufacturers must show they are taking
appropriate measures to mitigate health
and safety. GHT encourages its clients
to perform the eleven point test at least
twice a year, every three months ideally,
and even more frequently than that in
some applications.
Finally, testing in an accredited lab,
in the correct conditions is the key to
getting accurate results. As with general
maintenance, identifying a problem
early helps avoid complications without
excessive cost or efforts.
40 February 2016
Best Practice Sampling
After the samples have been taken correctly,
the interpretation of data is essential
and this is where Global Heat Transfers
experience and eleven-point test takes
the best-practice cake. As opposed to
most companies, that only provide a
seven point test, GHT looks in detail at
key data to ensure the results completely
reflect reality.
might seem intimidating, but the
The three main checks that Global Heat
Transfer focuses on are carbon level
and amount of insoluble particles, a
closed flash point test and the acidity
level (TAN).
The Ramsbottom Carbon Residue test
(RCR) is a method of calculating the
carbon residue in a fluid. If the carbon
level (heavy ends) is too high, build-ups
can occur, which will reduce the efficiency
of the system, make pumps work harder
and result in higher running costs for
the company.
Global Heat Transfer performs both
types of flash point measurement: open
and closed cup. The Pensky-Martens
closed flash test involves the heating of
test specimens in a covered brass cup at
regular intervals until a flash point that
spreads throughout the inside of the cup
is identified. The temperature at which
this spread takes place is the samples
flash point. Because closed cup tests give
lower flash point values (between five and
ten degrees Celsius difference), they are
a better approximation to the temperature
at which the vapour pressure reaches the
lower flammable limit. To ensure final
result accuracy, a Seta open cup flash
test is also performed on the fluid sample.
An acidity level test identifies the amount
of additive depletion, oxidation or acidic
contamination, in a thermal fluid sample.
The acid number is determined by the
amount of Potassium Hydroxide (KOH)
base required to neutralise the acid in
one gram of an oil sample.
These three main areas of testing are
complemented by additional checks,
including appearance, viscosity, water
and ferrous content, particulate quantities
and fire point testing. The data from the
eleven tests forms the basis of a holistic
analysis based on trend data, which
results in an accurate thermal fluid
evaluation. Parameters for action, caution
and satisfactory levels are the key factors
when conducting the result analysis.
The complexity of thermal fluid testing
importance of the process cannot be
stressed enough. Respecting legal
regulations, performing preventative
maintenance and frequent testing are the
best ways to ensure your company is not
taking any unnecessary risks. Otherwise,
you might as well be using newspaper
and sunglasses instead of personal
protective equipment.
Authors Details
Andy Burns
Technical Business
Manager
Global Heat Transfer
carolinel@globalgroup.org
Chemical Engineering World
 Features CEW
Technical Article

Process Intensification - An Insight

The concepts of Process Intensification (PI) in chemical industry has started evolving quite strongly in the
past 15 years with interestingly novel hardware and software applications being reported in bio-processing and
fine chemicals. This article talks about the need for PI and its advantages. Principles and Barriers of Process
Intensification are also discussed.

T
he process economies of chemical
industry are fraught with two
major challenges namely, capital
investment and operational expenses.
While one could be reduced at the cost
of the other, simultaneous reduction in
both the costs would result in an optimal
solution. Improving process efficiency
to lower the equipment volumes and
simultaneously combining a number
of unit operations in an equipment
would bring down associated capital
investment. Process Intensification
typically addresses these aspects of cost
optimisation either by miniaturisation
of equipment or by synergizing various
process steps. Process Intensification
(PI) can be defined as a set of innovative
technologies that focuses on minimisation
of plant profile thus reducing capital
costs and their integration to achieve
high capacity, reduced footprint (area),
increased selectivity and enhanced heat
and mass transfer rates. 1 It involves
constant miniaturisation and integration of
engineering methods and equipment. 7 Its
approach towards design of sustainable
chemical processing plants is based
on four dimensions namely, structure,
energy, synergy and time. 2
column packed with catalyst. 1 In the 10 th
Annual Research Meeting of Institute of
Chemical Engineers (IChemE) on process
intensification held in the same year, the
first research paper from South Africa
was based on intensive underground
processing of gold ore. 3 A total of 16
papers concerning the fields of mineral
processing, heat transfer, chemical
reactor and plant design with control were
presented in the aforesaid meeting. 3 On
a commercial scale, Eastman Chemicals
set up a reactive distillation tower in
1980s with multifunctional capabilities
reducing 80 per cent energy requirements
as compared to conventional operations. 4
Throughout the next two decades, mostly
within United Kingdom, a lot of improvised
versions of PI sprung up utilizing the
concepts of centrifugation, enhanced
heat transfer based on spatial domain
and micromixing. In 1995, the first full
conference on PI for chemical industry
was organized in Antwerp, Belgium by
UK-based BHR Group, a technology
organization in fluids engineering. 2
Towards late nineties PI technologies
were developed in research labs across
the world such as microreactors in USA
(Massachusetts Institute of Technology)
and Germany (Institut fur Mikrotechnik,
Mainz), high-gravity processing in
China (Beijing University), compact heat
transfer in France (Greth CEN Institute)
and centrifugal adsorption in The
Netherlands (TU Delft). 5 The concepts
of PI in chemical industry has started
evolving quite strongly in the past 15
years with interestingly novel hardware
and software applications being reported
in bio-processing and fine chemicals. 5,6
Why Process Intensification?
The cardinal principle governing process
intensification has been improved

The term, Process Intensification was

introduced in 1960s by an East-European
publication on Metallurgy. In 1983,
Prof. Colin Ramshaw, widely regarded
as the father of process intensification
(PI), developed first set of innovations
related to the subject in separation
processes. 1,2 His work analysed the effect
of high gravity field in distillation and a
hybrid strategy to combine separation
with reaction processes in a single Figure 1: Main advantages of process intensification

Chemical Engineering World February 2016 41

CEW Features

Source of Energy Intensified Element Intensification changing the kinetics

Factor* Improving conversions & selectivity
Avoiding unwanted side products
High gravity field Reaction time 1000
Improving number & frequency of
Static electric field Interfacial area (by emulsification) 500 collisions
Microwaves Reaction time (for liquid-phase 1250 Better understanding of equipment
catalytic reaction) & flow geometry for improved
Ultrasound irradiation Reaction time 25 orientation of molecules in the
Supersonic flow Gas-liquid mass transfer coefficient 10 moment of collisions & their energy
Capacity (for fluidized-bed reactor) 2.25 Designing uniform products with
minimum waste
*Reported possible improvement (as number of times) in comparison to conventional technology Macroscopic residence time
Table 1: Process intensification effects of the alternative sources and forms of energy 10
distribution, reduction in dead
zones & bypassing
Technologies Benefits Commercial Meso & micro-mixing
Feedstock Capital cost Energy implementation*
cost requirements 2. Optimizing driving forces & maximizing
Reactive distillation 20-80% 20-80% >150 specific area
DWC distillation 10-30% 10-30% >100 Improving transport rates
across interfaces by maximizing
Reverse flow reactor >20% Low >100
interfacial area from millimetre to
Microchannel reactor Yes Yes Only in fine the micrometre scale of channel
(for small scale) chemicals and dimensions
pharmaceutical Maximizing driving force
sector (concentration difference) not
*In terms of number of units commercialised6, 9 always required
Table 2: Process intensification in petrochemical industry and their benefits 9

3. Maximizing synergistic effects from

utilisation of molecular interactions
under optimised conditions of driving
forces and synergistic effect of different
unit operations. While gradient-
free temperature and concentration
profiles are achieved with reduction
in residence time, 2 lower pressure
level can be maintained with minimum
energy requirements thus ensuring high
level of safety in chemical plants. The
combination of different unit operations
results in better process control with
lower degrees of freedom. 2 Adopting PI
techniques results in nearly 20 per cent of
total plant cost. 1 Operating costs largely
comprise of the consumables, process
utilities and level of plant maintenance.
These parameters can be optimised with
improved output yield and turnaround
time achieved through PI techniques.
The opportunities offered by PI are
summarised as shown in Figure 1 on the
previous page.
Table 1 summarises various alternative
sources and forms of energy that can
be utilised for PI technologies in order
42 February 2016
to attain gross efficiency enhancement
of chemical and biochemical processes. 8
PI gains momentum in commercial
operations for reduced requirement
for consumables as well as waste
management. The benefits of reduction in
plant economics and energy requirements
as achieved in the petrochemical industry
have been summarized in Table 2 by
the researcher from Shell Technology
Solutions, The Netherlands. 9 As per an
European publication 10 in 2008, the overall
energy savings across industrial sectors
(namely bulk & fine chemicals and food
processing) on use of PI technologies
such as multifunctional equipment, micro-
reactors, microwaves and high gravity
field (spinning tube reactor) is estimated
(on current trends) to reach nearly
100 x 10 15 Joules per year by 2050.
Principles of Process Intensification
The major principles that drive the
process intensification are as follows:
1. Maximizing effectiveness of intra &
intermolecular events
The processes not limited by their
inherent kinetics but governed by
partial processes
Multifunctionality on the macroscale
Reaction-cum-separation by
removing products from the reaction
environment
Process intensification differs from process
optimization (defined as performance
improvement of existing concepts) and
process system engineering (defined as
multi-scale integration of existing and
new concepts). Table 3 on the next page
gives brief description of each process.
Barriers to Process Intensification
While several PI technologies have
achieved success on a lab scale, they
are still at infancy as long as their
industrial applications are concerned.
The industrial adoption of PI is faced with
several barriers:
Lack of in depth knowledge and know-
how in PI among process engineers
Inadequacy in pilot scale facilities for
PI for the existing production lines
High stakes (both technical and
financial) in prototype development
Chemical Engineering World

as well as in retrofitting of existing
process
Lack of awareness among the top
management about the potential
benefits of PI technologies
Non-availability of process control
systems catering to novel PI modules
The R&D efforts in chemical industry
primarily focus on new products
(chemistry) and much less on the new
manufacturing methods (chemical
engineering). The chemical manufacturers
are not interested in developing novel
types of equipment or processing
techniques and simultaneously the
equipment manufacturers and engineering
companies are not sufficiently active in
process intensification.
Other barriers include high cost to retrofit
PI technologies in current plants thus
increasing the risks of commercializing
breakthrough technology. Scaling up of PI
techniques from lab to pilot to commercial
scales poses major challenges. PI
technologies warrant long development
path, which calls for effective IP
cooperation among various R&D labs,
universities and industries.
Process Intensification Select
Technologies
The technology application for PI broadly
includes micro-reactors, simulated
moving bed reactor, oscillatory baffled
reactor, tube-in-tube reactor, reactive
distillation, membrane or ultra-sound
Process Optimisation
Aim Performance
improvement of existing
concepts
Focus Model, numerical method
Interdisciplinary Weak (interface with
applied mathematics)
Table 3.0: Basic Features of Three Areas of Chemical and Process Engineering
Chemical Engineering World
Features CEW
Figure 2: Broad technology applications for process intensification. 7
crystallization and compact heat the plant. It involved elimination of a
exchangers. PI has been successfully few number of condensers and reboilers
applied for scale-up of continuous involving the sub-mixtures that resulted
reactors and also for alternative retrofit in a reduction of 23 per cent in energy
methods for existing processing plants. costs when compared to the existing plant
Figure 2 presents common classification design layout. 11
for PI technologies as suggested by
Stankiewicz and Moulijn. 7 Numerous case Micro-reactors: Micro-reactors is a class
studies elaborate the advances in PI of chemical reactors at sub-millimeter
over the past three decades that started level that can achieve reduced volume,
off with the reactive distillation process higher product selectivity and higher
developed in 1983. 1,2 reaction rate. 2,5 It helps in complete mixing
even for highly viscous fluids at large flow
The merits of reactive distillation include rates. Alternative reaction pathways are
reduced equipment size thus lowering made possible due to higher heat and
capital cost, less energy use, and higher mass transfer rates and precise control of
reaction volume under consideration. 5,12
product yields. 4 Recently, M. Errico et al.
Figures. 3 (a) and (b) (shown on the next
suggested a retrofit to existing distillation
page) are schematic representations of
systems through thermal coupling
pioneering attempt on an integration of
technique to minimize physical size of
automated process controls and micro-
reactors for homogeneous catalysis. 13
Process Systems Process
Engineering Intensification
Typical applications include catalysis,
Multi-scale Development of new steam reforming, organic synthesis
integration of existing concepts of process
and multiphase reactions. 13,14 A recent
and new concepts steps and equipment
example has been the use of cross-flow
Model, software Experiment, micro-channel reactors for reversible
phenomenon, polymerization at 90 oC to form poly(vinyl
inter-phase butyral), a high-demand product for
Modest (mostly Strong (chemistry the manufacture of safety glasses in
applied mathematics & catalysis, applied automobile industry. 13 It involves viscous
and informatics, physics, mechanical fluids such as poly(vinyl alcohol) and
chemistry) engineering, n-butanal in presence of acid catalyst.
materials science, Conventionally the batch process has
electronics etc.) lower rate of reaction with a product yield
of 20 to 30 per cent (expressed in terms
February 2016 43
CEW Features
Figures 3: (a) Schematic view of microreactors as printed circuit boards 14 (b) Numbered-up approach of multiple
microreactors 14 (c) Comparison of product yield (% in terms of acetalisation degree (AD) or butyral group content) for
the reversible polymerization reaction at a mass concentration ratio of n-butanal to PVA of 0.8 and an aging time () of
3 hours 13
Figure 4: (a) Schematic process flow diagram of a typical membrane distillation unit (b) Variation of total solids content
(TDS) in pre-filtered brackish water samples at feed side for different types of membrane material (PP22 and TS22) at
temperature difference of 20 oC 16
of butyral group content) resulting in
precipitation problems and phase change.
On using 1000 m length x 500 m wide
micro-channels made of stainless steel
and PTFE (Teflon) in cross-flow pattern
submerged in water, a well-controlled
reaction takes place at 50 oC within less
than 56 seconds and the product yield
has been reported as high as nearly 75
per cent after an hour of aging. 13
The optimized flow-rate at 5 per cent
PVA solution for a maximum limit of
80 ml/min resulted in good mixing
performance as shown in Figure 4.0 (c). 13
The resultant process optimisation for
catalyst can lead to reduction of working
capital for different utilities. Some of its
major limitations include insignificance
of gravity forces, scale formation due
to material incompatibility and micro-
fabrication costs.
44 February 2016
concentration. Membrane distillation at
Membrane Distillation: Role of
membrane technology in enhancing mass
transfer efficiencies has been significant
by reduction in capacity and energy
requirements. It is a hybrid technique
combining membrane separation and
conventional distillation. 7 Desalination
units based on osmotic pressure
difference cover nearly 60 per cent of
existing plants all over world. 15
But their performance suffers due
to brackish feed water with high salt
content. Recently, direct contact
membrane distillation with conductive
heat transfer is reported to have
achieved nearly 100 per cent inorganic
salt rejection with no additional energy
consumption. 16 The technique developed
by Hickenbottom and Cath for feeds with
very high total dissolved solids (TDS)
utilises temperature and flow reversals
on alternate basis to control variations
in water flux and salt concentration
profile. It uses a thin Teflon (TS22)
active stratum and polypropylene (PP22)
support layer of overall thickness 175 m,
effective surface area 89 cm 2, pore size
0.22 m and porosity of 70 per cent. The
pre-filtered water is fed at 1.6 Lits/min
at 50 oC and the distillate is highly pure
water devoid of non-volatiles collected at
room temperature.
Reduced distillate conductivity estimates
the quantitative reduction in salt
lower temperature difference of 20 oC over
ambient resulted in higher water flux and
salt concentration at membrane interface
of TS22 membrane as shown in Figure
4.0. Cold feed water at 15 oC is used at
periodic interval to reduce scaling thereby
lowering membrane maintenance costs. 16
An intensification factor of 16 in terms of
surface area requirements in comparison
to conventional evaporation ponds for
concentrated salt solutions has been
possible. The above technique when
integrated with low grade heat sources
and environment tax benefits, can
achieve high-quality water production at
an optimized cost of USD 0.57 per cubic
metre of pure water produced. 16
High Gravity Processing: The
application of high gravity field using
a high-speed rotor allows counter-
current gas-liquid flow through a rotating
packed bed where one of the phases is
fed continuously. It requires minimal
area requirements, less maintenance,
reduced equipment weight and provides
short contact time over rotor packing with
enhancement in heat and mass transfer
rates. 5 The need for de-aerated seawater
in oil fields for re-injection purposes to
avoid blocked pipe-works near oil-bearing
rocks could be met through high-gravity
processing (Higee) technique. Otherwise
a conventional vacuum stripper of 3 m
diameter and 10 m height with large
auxiliaries would be required to reduce
oxygen content to parts per billion (ppb)
concentration level. 17 To achieve effective
momentum transfer to feed seawater
Chemical Engineering World

Figure 5: Schematic Diagram of Higee Unit
(500 m 3/hour), the requisite minimum
pressure is of 2.2 bar for Higee deaeration
operation. The energy requirements for
Higee technology primarily depends on
the process time required for tip speed
of rotor to be nearly equivalent to liquid
velocity over radial direction.
An intensification factor of 1000 in terms of
oxygen concentration in treated seawater
samples is estimated. 17 Use of 400 RPM,
2.8 m length, 1.0 m diameter rotor with a
cost-effective packing of reticulated metal
foam reported a reduction of 90 per cent in
energy consumption. Major drawbacks in
this virtual separation column with evenly
spread bubbles maintained throughout 10
mm thick packing are the resultant high
pressure drop and backmixing problems.
Spinning Disc Reactor
Spinning Disc Reactor (SDR) technology
finds application where the problem of
backmixing as in stirred tank reactors
and higher energy requirements as in
high-gravity field process reactors are
eliminated with the utilisation of thin liquid
film formation specific to its spin disc
design. It focuses on the intensification
of spatial domain to obtain uniform mixing
in laminar region (assumed) and very
short residence time. 5,18 A typical SDR
design involves a liquid film of micrometer
thickness over a spinning disc that is
subject to high circumferential velocity
(up to 1000 RPM) over spiral grooves
under an inert atmosphere, mostly
nitrogen below 1 bar pressure. 16 Coolants
such as ethylene glycol or water are used
to maintain disc operating temperatures.
An example is a multiphase reaction
for development of an alkyl cyanate ion
Chemical Engineering World
Figure 6: (a) Operating principle of spinning Disc Reactor (SDR) (b) Comparison of particle size distribution between plant
material obtained from conventional batch process and that from spinning disc reactor (SDR) 18
intermediate (Darzens reaction) useful
in drug development. It occurs within
a second at 20 oC with less than 0.1
per cent impurity when compared to an
operating temperature of 0 oC with nearly
1.5 per cent impurity in conventional
batch reactors. 18
Another reaction demonstrated in SDR
is based on re-crystallization of like
mesylate salt solution using hot acetic
acid in tert-butyl methyl ether (an anti-
solvent) to form an active pharmaceutical
ingredient useful for various formulations.
PTFE coating over the spinning disc
provides better control of particle size
distribution with a maximum limit of
3 m as illustrated in Figure 6 (b) and
prevent mass clusters. 18 Some of the
major limitations include control of
turbulence of thin liquid film, process
stability, maintaining vacuum conditions
and material compatibility.
Compact Heat Exchangers
Compact heat exchangers (CHE) provide
increased available heat transfer area to
exchanger volume thus lowering size and
capital cost.5 Its values range between
300 to 700 m 2/ m 3 for liquid phase and
even higher for gas phase. Typical
examples include plate or plate-fin heat
exchangers and hybrid combination of
reactors and heat exchangers fabricated
on printed circuit boards for enhancement
of heat transfer rates. 19 This class of heat
exchangers finds applications in heating,
Features CEW
ventilation and cooling (HVAC) systems
and heat pumps. 19 During the last decade,
two notable CHE designs evolved namely,
Compabloc from Alfa Laval, Sweden and
Marbond heat exchanger from Chart
Marston, UK. 1,19,20 Compabloc is a laser-
welded plate heat exchanger comprising
corrugated plates with an alternate
cross-flow pattern at high turbulence
with multi-pass arrangement as shown in
Figure 8 (b) on the next page.
A reduced plant footprint is achieved
by an intensification factor of 3.5 when
compared to conventional shell-and-tube
heat exchangers for the same thermal
load. On industrial implementation,
Compabloc technology has been utilized
for an evaporator unit in ammonium nitrate
production plant in Slovakia from 2001
onwards that resulted in enhancement of
heat transfer rates, lower fouling problems
and a large reduction in energy consumption
(~5 MW) for steam. 20 Marbond heat
exchanger, almost of the size of a lap-top
has been developed with hydraulic channels
of sub-millimeter diameter and high voidage
making it suitable for multiphase chemical
systems. A significant reduction in capacity
by about 95 per cent can be achieved when
compared to existing conventional shell-
and-tube heat exchangers if corrosion-free
environment is maintained. 19 Some of the
demerits of CHE technology include poor
involvement of inertial forces, high pressure
drop on use of highly viscous fluids and
fouling problems.
February 2016 45
CEW Features
Figure 7: Comparison of different heat exchanger types in terms of hydraulic diameter (in mm) and area density (in m 2
per m 3) 19. PHE: Plate heat exchanger, S+THX: Shell-and-tube heat exchanger, PFHE: Plate-fin heat exchanger, PCHE:
Printed-circuit heat exchanger
Figure 8: (a) Comparison of Alfa Lavals Compabloc and conventional shell-and-tube heat exchangers for the same heat
transfer duty (b) Section view of Compabloc heat exchanger 20
Conclusion
Process intensification offers an effective
approach in optimizing raw materials, land,
utilities, energy input and capital costs
resulting in efficient operating conditions
for significant reduction in working capital
and simultaneously maximizing output. The
minimization of physical size of the plant
by PI helps in better process control and
sustenance of overall plant inventory. The
recent advances in PI concepts in chemical
reactors, membrane separation and heat
exchangers infer the quality of research work
being carried out across the world. There
is a need to address environmental issues
associated with innovative PI technologies
such as control over carbon footprint10,
accumulation of unwanted by-products and
46 February 2016
their disposal methods. One of the feasible
options could be the induction of renewable
energy sources like solar, wind or bio-energy
in PI technology applications to further offset
CO2 gas emissions and energy consumption.
While addressing cleaner aspects of process
technologies, PI strategies in reducing energy
consumption (both temperature & pressure)
and enhancing product yield would also improve
safety concerns of the chemical industry. In
India, dedicated efforts on micro-reactors
and membrane separation are underway
at various Government funded academic
institutions and research laboratories. On
analysing the energy use data, it is estimated
that the Indian chemical sector could have
reduced energy consumption by more than
20 per cent in 2014 by adopting overall plant
intensification in existing units.10,21,22 Presently,
the major challenges exist in the commercial
implementation of several PI technologies that
have evolved over the past three decades.
The primary reason hindering adoption of PI
technology by industries could be attributed to
an apprehension on delay over achievement
of production targets accompanied by a risk
of loss in market share. To ensure specific
production requirements and smoother
implementation of PI, industries need to
partner with R&D or academic institutions at
an early stage with investment in research to
succeed commercially.
References:
1. Costello Rocky, Process intensification -
think small, Innovations in Pharmaceutical
Technology, 2012, 126-132.
2. Process Intensification, An online M.Sc.
Course offered by TU Delft, The Netherlands,
2012.
3. Proceedings of 10th Annual Research
Meeting of Institute of Chemical Engineers
(IChemE) held at University of Manchester
Institute of Science and Technology
(UMIST), Manchester, UK, 1983. http://
archive.icheme.org
4. Harmsen Jan G, Reactive distillation:
The front-runner of industrial process
intensification: A full review of commercial
applications, research, scale-up, design
and operation, Chemical Engineering and
Processing: Process intensification, 2007,
46, 774-780.
5. Staankiewicz Andrej, Moulijn Jacob A, Re-
engineering the chemical processing plant,
Marcel Dekker, USA, 2004, ISBN: 0-8247-
4302-4.
6. Excerpts from H. L. Roy Memorial Lecture
delivered by K V Raghavan, at Chemcon
2015, Indian Institute of Technology,
Guwahati, India.
7. Stankiewicz A I and Moulijn J A, Process
intensification: transforming chemical
engineering, Chemical Engineering
Progress, 2000, 96(1), 22-34.
8. Stankiewicz A, Energy Matters: Alternative
sources and forms of energy for intensification
of chemical and biochemical processes,
Chemical Engineering Research and Design,
2006, 84 (A7), 511-521.
9. Harmsen Jan, Process intensification in the
petrochemical industry: Drivers and hurdles
for commercial implementation, Chemical
Engineering and Processing: Process
Chemical Engineering World
 Features CEW
intensification, 2010, 49, 70-73.
10. Reay D A, The role of process intensification in cutting greenhouse gas
emission, Applied Thermal Engineering, 2008, 28, 20112019.
11. Errico M, Rong Ben-Guang, Tola Giuseppe, Turunen Illka, Process
intensification for the retrofit of a multicomponent distillation plant-An
industrial case study, Industrial and Engineering Chemistry Research,
2008, 47, 1975-1980.
12. Worz O, Jackel K P, Richter T., Wolf A, Microreactors, a new efficient
tool for optimum reactor design, Chemical Engineering Science, 2001,
56, 1029-1033.
13. Xi Yan Lin, Ji Song Zhang, Guang Sheng Luo, Process intensification
of the synthesis of poly(vinyl butyral) using a microstructured chemical
system, Industrial and Engineering Chemistry Research, 2015, 54,
3582-3588.
14. Jensen Klavs F, Microreaction engineering-is small better?, Chemical
Engineering Science, 2001, 56, 293-303.
15. Drioli E., Stankiewicz A. I., Macedonio F., Membrane engineering in
process intensification, Journal of Membrane Science, 2011, 380, 1-8.
16. Hickenbottom K. L., Cath Tzahi Y., Sustainable operation of membrane
distillation for enhancement of mineral recovery from hypersaline
solutions, Journal of Membrane Science, 2014, 454, 426-435.
17. Peel J., Howarth C. R., Ramshaw C., Process intensification: Higee
seawater deaeration, Chemical Engineering Research and Design,
1998, 76, 5, 585-593.
18. Oxley P., Brechtelsbauer C., Ricard F., Lewis N., Ramshaw C.,
Evaluation of spinning disk reactor technology for the manufacture of
pharmaceuticals, Ind. Eng. Chem. Res., 2000, 39, 2175-2182.
19. Reay D. A., Compact heat exchangers, enhancement and heat pumps,
International Journal of Refrigeration, 2002, 25, 460-470.
20. Official website of Alfa Laval Corporate AB, Lund, Sweden. Available
online at: http://www.alfalaval.com
21. Industrial Energy Consumption in the UK, UK Department of Energy &
Climate Change, 2015.
22. Energy Statistics 2015, Central Statistics Office, National Statistical
Organisation, Ministry of Statistics and Programme Implementation,
Government of India.

Authors Details

Raghu Krishna Moorthy

B.Tech (Hons.) - Government Engineering College, Calicut
Currently studying M.Tech at NIT-Trichy
raghukmoorthy@gmail.com

Sangeeta Baksi
Scientist in TIFAC
sangeetabaksi@gmail.com

Soumitra Biswas
Adviser/Scientist-G in TIFAC
soumitra2000@gmail.com

Chemical Engineering World February 2016 47

CEW Market Insights

Water Treatment Additives Market to Hit

35.2 Billion USD by 2020

A
ccording to the report, the water treatment additives market
is estimated to reach USD 35.2 Billion by 2020 at a high
CAGR. Published by IndustryARC, the report states that
high rates of Industrialisation in APAC coupled with Government
regulations driving the Global Water Treatment Additives Market to
reach USD 35.2 Billion by 2020

The key factors driving demand for water treatment additives

are the demand for clean water, rapid industrialization,
environment, government policies and increasing population.
The market has been segmented into the type of additives
being used which include scale inhibitors, corrosion inhibitors,
oxygen scavengers, Defoamer, biocides, organic polymer
and others.
The organic polymers segment accounted for a market share of
around 26 per cent in the global revenue and 25 per cent in the
global volume as of 2014. Scale inhibitors have an equal revenue
share as organic polymers but the volume share is slightly
higher at around 29 per cent. With increasing water scarcity and
government regulations upon safe water usage, the requirement
of water treatment additives has been increasing. The investment
opportunities in developing countries tend to increase in future and
there is scope for new entrants in the market.
The Water Treatment Additives Market in 2015 was USD 26.4
Billion according to research conducted by IndustryARC, and
is dominated by Asia-Pacific (APAC) with more than 35 per cent
market revenue share. Asia-Pacific is the most encouraging market
for water treatment additives owing to the increasing demand from
countries such as China and India, and is estimated to reach 38 per
cent of the global market by 2020. China, among all the countries is
the most promising market with rising demand for water treatment
sector due to severe water shortages resulting from large population
and water pollution caused by rapid economic growth. The global
market revenue is estimated to reach USD 35.2 Billion by 2020 with
a CAGR of 5.9 per cent during the forecast period 2015-2020.
Water treatment is the process of removal of existing water
contaminants from water that becomes fit for its desired end-use
such as drinking, industry or medicinal purposes. Usage of water
treatment additives is necessary to achieve an optimized process.
They have a wide range of applications in pulp and paper industry,
power industry, Oil and Gas industry, food and beverage industry,
water industry, wastewater industry, electronics, chemicals
and others.
48 February 2016
Figure 1: Water Treatment Additive Market Share by Geography, 2014 (%) (Source: Industry
ARC Analysis)
Market Overview, Market Landscape, Market Forces, Strategic
Analysis, etc are some of the points the report covers from
the additive market. It also covers the additive market by type
of water treatment, by type of additives, by application and
by geography.
Water treatment additives are used to treat drinking
water, industrial water and wastewater and also
public utility waste water. The key factors that led to
increasing demand for water treatment additives are
the demand for clean water, rapid industrialization,
environment, government policies and increasing
population. The consumption of water treatment
additives depends on source of water and the quality
of water depends on hardness, pH and alkalinity.
Organic polymers and biocides are the major additives
that are used in water treatment processes. Organic
polymers are used to purify low quality water either for
drinking or industrial purposes. Oxygen scavengers
are formulated to combat the effects of oxygen related
corrosion in industrial boiler systems to reduce
maintenance costs, maintain boiler efficiency and
equipment life. The efficacy of the water treatment
additives depends on dosage rate and duration of the
additives presence in water.
Source: Industry ARC
Chemical Engineering World

Producing Bio-Rubber with Bio-Butadiene
from Sugars
V
ersalis (Eni), a European producer in the polymers
and elastomers industry, and Genomatica, a leader in
bioengineering solutions have successfully advanced to pilot-
scale production of bio-butadiene (bio-BDE) from fully renewable
feedstock. Versalis used this bio-BDE to make bio-rubber,
specifically, bio-polybutadiene (bio-BR). These accomplishments
represent a remarkable milestone for the rubber industry, by
enabling an improved technological and sustainability footprint; and
to the broader industry for butadiene, one of the most widely-used
chemicals in the world, with over ten million tons produced per year.
The success of this innovative undertaking results from a newly-
developed process for the on-purpose production of butadiene
which uses various types of sugars as feedstock, rather than the
traditional use of hydrocarbon feedstocks. The project started with
the establishment of a technology joint venture between Versalis
and Genomatica in early 2013. The joint venture with Versalis
having the majority stake has developed a complete process to
make bio-BDE and plans to license the resulting technology. The
joint venture uses the proven and complementary strengths of both
companies. Versalis and Genomatica together determined that
1,3-butanediol (1,3-BDO) was the most suitable intermediate to
produce bio-BDE.
Genomatica applied its whole-process systems approach to
bioengineering to develop a microorganism that produces 1,3-BDO
in a way that enables cost-efficient, scalable fermentation, recovery
and subsequent process operations. Versalis leverages its industrial
process engineering and catalysis capabilities, plus expertise in
overall polymer production, to purify the 1,3-BDO, dehydrate it and
then purify the resulting butadiene. Versalis has produced several
kilograms of butadiene from 1,3-BDO made in 200 litre fermenters
at their research centres at Novara and Mantova, and then made
bio-polybutadiene, at the Ravenna R&D centre, using both anionic
and Ziegler-Natta catalysis. Initial testing of the bio-BDE and bio-BR
demonstrates good compatibility with industry standards. Versalis is
continuing to test the bio-BDE within its other proprietary rubber and
plastics downstream technologies such as SBR (Styrene-Butadiene
Rubber), SBS (Styrene-Butadiene-Styrene Rubber) and ABS
(Acrylonitrile Butadiene-Styrene). The accomplishments demonstrate
the common vision of the partners on the potential of this project:
access to on-purpose butadiene from renewables will establish a
competitive advantage and will ensure a strategic raw material from
alternative feedstock, contributing at the same time to drive a greater
sustainability profile for downstream applications in the plastics and
rubber businesses.
Chemical Engineering World
Market Insights CEW
Global Synthetic & Bio-based Butadiene Market is Likely to
Reach USD 23.45 Billion in 2023
Last year, a report by Transparency Market Research has suggested
that the Global Synthetic & Bio-based Butadiene market is anticipated
to reach US$ 23.45 Billion by 2023, expanding at a CAGR of 4.9
per cent between 2015 and 2023. Butadiene is one of the major
petrochemical and holds significant importance in end-user industries
such as automotive and tire. High demand from tire and automotive
industries is driving demand for synthetic & bio-based butadiene
during the last few years. Butadiene derivatives such as SB rubber,
ABS, and butadiene rubber are used in the processing of tires and
automotive parts. SB rubber products such as S-SBR and E-SBR are
primarily consumed raw materials in the production of tires. These
materials provide low rolling resistance and better grip, thus resulting
in reduced CO2 emissions and improved fuel economy. Rise in demand
for ABS in Asia Pacific, especially in China and Southeast Asia, is
another key factor propelling growth of the market for synthetic &
bio-based butadiene.
Furthermore, development of innovative technological processes for
the production of bio-based butadiene is likely to fuel the butadiene
market in the near future. However, volatility in raw material prices
coupled with stringent environmental regulations are expected to hinder
the market growth during the forecast period. Synthetic butadiene was
the largest product segment, accounting for a significant share of the
global synthetic & bio-based butadiene market in 2014. Synthetic
butadiene is produced from a mixture of C4 feedstock and is further
processed to obtain derivatives such as ABS, SB rubber, and SB latex.
These derivatives are employed in tire and automotive industries.
Bio-based butadiene is likely to be the fastest-growing product
segment of the synthetic & bio-based butadiene market in the next
few years. Stringent regulations are primarily boosting growth of the
bio-based butadiene market. Alignment towards eco-friendly and cost-
competitive production is estimated to drive the market growth during
the forecast period. In terms of demand, butadiene rubber has been
dominating the synthetic & bio-based butadiene market in the past
years. Butadiene rubber is primarily used in tire production; however,
it is also used as an additive in plastics such as polystyrene and ABS.
SB rubber accounted for the second-largest share of the synthetic &
bio-based butadiene market in 2014. SB rubber is a synthetic rubber
obtained through copolymerization of butadiene and styrene and is
used in the production of tire and its products. ABS and adiponitrile
are considered to be among the fastest-growing application segments
of the synthetic & bio-based butadiene market. A similar trend is
anticipated to continue during the forecast period.
February 2016 49

Customized solutions-High Vacuum LRVP
T
he Toshniwal HIGH VACUUM LRVP
is utilized primarily in production of
fine chemicals, pharmaceuticals wet
process like distillation, drying, evaporation
and reaction under vacuum. Depending on
process condition, it can be operated with
once-through/ closed loop circulation for
service fluid. In the closed loop circulation
system allows to re-use the condensate
which are recovered from suction gas without
external contamination.
STANDARD CONFIGURATION
The standard Toshniwal HIGH VACUUM
LRVP system composed of Liquid ring
pump with closed loop circulation system
for service liquid, a special spiral coil heat
exchanger mounted vertically for vapor /
liquid separation and a collection tank. A
special post condenser with clean condensate
recovery tank provided. Also included are
all connecting pipe / flanges and control
instruments including thermometer, vacuum
gauge are mounted on a single steel
structure base.
The combination of Double stage LRVP, Gas
ejector, roots pump can obtain oil-free low
residual pressure and each component is
optimally designed with correct staging ratio
for perfect fit.
Variport Liquid Ring Pump- Pompetravaini
Italy- Hydro pack compact Vacuum packages-
ensure full recovery of service liquid - No
contamination of central cooling water-
variported vacuum pump can work entire
pressure range 1013 mbar - 33 mbar unlike
conventional double stage vacuum pump
which has limitation in working pressure range
Variport offer minimal water consumption and
an innovative impeller design that assure
extremely quite operation and extending its
life even under harsh condition
Shut off vacuum less than 10 mbar with
air ejector
50 February 2016
Marketing Initiative
Shut off vacuum less than 5 mbar with
Roots vacuum pump
Oil free vacuum pump
Can work under corrosive media upto
3.5 pH
Wide range of sealing medium like
water ,oil and solvent etc
Environmentally safe
Roots Pump: It is provided with inbuilt
bypass (Over flow) valve suitable for
high pressure operation. The benefits
are Roots / Booster pump can be started
at the same time as the backing pump,
and Roots / Booster is protected from
overloads resulting from inadvertent
operation at high pressure.
poor degassing, and process interruption
Gas Ejector: The suction pressure
The solution is Hybr id LRVP since it
range of liquid ring pump will be further
can provide required high vacuum under
reduced by pre connected gas ejector.
polluted process situation.
T h e c o n t i n u o u s i n f l o w o f m o t i ve -
gas prevents liquid ring pump from
Product Distillation: Oil Ring Pumps
operating cavitations range The motive
generally are used in wet process pumps
fluid of gas ejector is part of the gas
to handle vapours along with air load which
exhausted by the Liquid Ring Pump.
leads to oil contamination drop in vacuum,
frequent replacement of consumables etc
Waste Oil Purification: The criticality
to get required lower operating pressure
of the application is to handling sticky
(example 10 mbar).In order to provide
material emanating during recuperation.
required high vacuum under polluted
All kind of vacuum systems including
process situation, Toshniwal Hydrid LRVP
dry pump fails for these application, but
is the best solution.
Hybrid LRVP with sealant as purified oil is
the solution, the oil as sealant in regular
interval being replaced by fresh oil.
Toothpaste Degassing: Tooth paste has
to be degassed to remove entrapped gas
content before packing.
Authors Details
Since suction of air has to be done in
p r e s e n c e o f h i g h d e n s e wa t e r va p o r Toshniwal Instruments
,evacuation need to be handled by Liquid (Madras) Pvt Ltd
ring pump during initial phase and Double 267, Kilpauk Garden Road
stage vacuum pump during final phase. Chennai - 600010
Contact: +91 44 26445626, 26448983
Tooth paste mist entering into vacuum E: sales@toshnwial.net
system, and oil contamination resulted in W: www.toshniwal.net
Chemical Engineering World

Electromech Engineering Enterprises
(Third Party Inspection Agency)
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e are in the field of Third
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Ltd, Glenmark Generics Limited, Shasun
Phar maceuticals Limited, Cheminova
India Limited, Apcotex Industries Limited,
Syngenta India Ltd, Nitrex Chemicals India
Ltd, Orchid Chemicals & Pharmaceuticals
Ltd, and Emcure Pharmaceuticals Ltd, to
name a few.
We follow ASME, TEMA & API codes
for Pressure Vessels, Heat Exchangers,
Storage Tanks, Valves, and Pumps etc. We
can support you with engineers who are
trained in NDT methods like Ultrasonic,
Liquid Penetrant Test and Radiography
with Level II certification.
We a l s o p r o v i d e fo l l o w - u p s e r v i c e s
right from Drawing stage till completion,
involving material identification, stage
fabr ication, visiting sub vendors and
a s s i s t a n c e w i t h m o n t h l y ex p e d i t i n g
reports, vendors reports and inspection
reports. We would be pleased to associate
with you as our esteemed client. We hope
you give us an appointment at a mutually
convenient time, so that we can discuss
the above mentioned services at length.
SCOPE OF WORK
Stages of Inspection for Reaction Vessel
Heat Exchanger / Pressure Vessel.
Approval of detailed fabr ication
drawings submitted by the vendor after
detailed discussion with the client
Chemical Engineering World
Marketing Initiative
Preparing of bar chart after discussing mention below. Several types of equipment
with the vendor and the client are frequently inspected by us at various
Material identification based on Mill / vendor locations and our team is well
manufacturing certificate or testing at conversant with it. These equipment are
laboratories Blower, Centrifuges, Pumps, Glass lined
Stamp transfer on all pressure & non reactor, FRP Tanks, Sparkler filters, Tray
pressure parts (parts coming in contact dryer, PP & PVDF lined fittings, Conveyor,
with process fluid) ANFD, FBD, Nauta mixer, Double cone
dryer(RCVD), Blender, Co-mill, Pipe &
Approval of welding procedure
Tube inspection, Pipe fittings, Explosion
specification & welders qualification
test cladded plate etc.
Witness of all physical tests at various
NABL approved testing laboratories
All set up of long seams & circ-seams,
nozzles set up, Manhole hand hole &
pads set up
C h i p - b a ck D P Te s t a f t e r o n e s i d e
welding
Review of Radiography films & witness
of Ultrasonic test & Liquid Penetrant
test as per requirement
Tube sheet inspection of drilled holes,
ligaments, grooves and layout
Mock up test of tube sheet to tube
joint for pullout load test & detecting
minimum leak path
Air running trial with dummy support
for checking alignment, assembly of
agitators and to assure the Vibration,
Noise level within acceptable limits
Hydraulic test at specified pressures
Pneumatic test of mechanical seal at
working pressure
R u n n i n g t r i a l i n s i d e t h e ve s s e l a t
working pressure
Contact Details
Final dimensions and visual inspection
Final inspection after pickling and
Mr Jayant Joshi
passivation of Stainless steel and
B- 102, Shubh Sarita, Appasaheb Sidhaye
painting of carbon steel parts
Marg, Shri Krishna Nagar, Borivali (E),
Packing & supporting of agitator shaft PIN: 400066
inside the vessel & dispatch instruction. T: +91 22 2897 5275
Submission of final documents M: +91 98199 82801, +91 91676 62735
E: info@electromechengineering.com,
We have experienced engineers to carry E: divya@electromechengineering.com
out inspection of specialized equipment as W: www.electromechengineering.com
February 2016 51

A Revolutionary Vacuum Drying Philosophy
Planex System : A multi-patented paddle dryer with ZeroFriction planetary movement eccentric agitator.
I
talvacuum, one of the most known
manufacturers of vacuum dryers and
va c u u m p u m p s fo r t h e p r o d u c t i o n
processes of chemical, pharmaceutical
and cosmetics industries, has recently
introduced on the market an innovative
h o r i zo n t a l p a d d l e d r ye r. I t i s P l a n ex
S y s t e m , a m u l t i - p a t e n t e d m a c h i n e
which is conquering the most demanding
operators from all around the world, by
guaranteeing results that were unthinkable
till now with conventional systems, both
horizontal and vertical.
Designed to dry wet feed from filtration and
centrifuging processes Planex System
i s i d e a l fo r t h e p r o d u c t i o n o f a c t i ve
pharmaceutical ingredients (API), fine
chemicals and intermediates.
The major added-value of Planex
System is the eccentric agitator with
two independent movements that can
simultaneously revolve around its own
axis and rotate tangentially to the
drying chamber.
The combined rotations of the agitator
and its small size compared to the drying
chamber diameter, ensures the perfect
mixing of the entire batch, and allows
consuming at least three times less energy
than conventional dryers with a concentric
agitators. This means a threefold reduction
in mechanical and thermal stresses on the
batch being dried . As a result, even the
most delicate and temperature-sensitive
products are treated with maximum care.
But there is more. The Planex System
control software allows to automatically
command the agitator movements with
the Stop & Swing program. In this way,
the agitator swings back and forth, thus
remaining all the time immersed in the
product, and guaranteeing its continuous
52 February 2016
mixing. This approach is par ticular ly
effective when processing small batches.
Moreover Planex System , thanks to
its agitators ZeroFr iction planetar y
movement, prevents the product from
being rubbed against the drying chamber
walls and thus heating up due to friction,
a typical problem in conventional paddle
systems. In addition, the rotation of the
paddles tangentially to the chamber
w a l l s , c o nvey s t h e p r o d u c t i n t o t h e
small clearance between the agitator
and the chamber surface, preventing
lumps for mation and guaranteeing
an even more effective dr ying and a
controlled final particle size distribution,
w h i c h i s i m p o s s i bl e t o a c h i eve w i t h
conventional dryers.
The minimum clearance between agitator
profile and chamber walls not only prevents
p r o d u c t bu i l d u p s, bu t i t a l s o m a ke s
discharge significantly easier. In addition,
there is a specific automatic program
fo r t h e d i s c h a r g e o p e r a t i o n s. T h e s e
operations are even more effective thanks
to the pendulum movement of the agitator
(the agitator pendulum movement), which
swings by 90 degrees in the discharge
area. As a result, the amount of product
left in the Planex System chamber after
discharge is truly minimal, averaging less
than 1 per cent of the volume.
Planex System also features outstanding
loading flexibility. The system is available
with total volumes ranging from 150 to
3,200 liters. Maximum loading capacity
depends on the product to be processed,
and can vary from 15 to 80 per cent of the
chamber volume. The system can meet all
the production needs of the pharmaceutical
and chemical industries, as it is capable
of processing small amounts of product as
well as large batches.
Marketing Initiative
Planex System is safe for operators, the
environment and the product, because it is
designed and manufactured in compliance
with European Union ATEX Directives
and CE marking requirements, as well
as with the increasingly stringent US
FDA standards and cGMP Current Good
Manufacturing Practice Regulations.
Manufacturing Materials
All the parts of Planex System that come
into contact with the product are made
of AISI 316L stainless steel, but other
weldable materials such as Alloy C-22
and AISI 904L are available on request.
The drying chamber walls, the agitator
shaft and the access hatch are heated
by diathermal fluid circulation to prevent
c o l d s p o t s t h a t c o u l d c a u s e s o l ve n t
condensation or product buildup. Internal
surfaces of the drying chamber are lapped
or electropolished to optimize corrosion
resistance, reduce adhesion and friction
on the product, improve powder flow
behavior and facilitate cleaning operations.
The shaft of the agitator is complete with
a double mechanical seal system, studied
to guarantee the perfect vacuum tightness
and the absolute purity of the dried batch,
avoiding any risk of contamination of the
product. The mechanical seal may be of
conventional type with wet flushing or run
dry with nitrogen immission.
Cleaning
Planex System is designed and developed
to make cleaning operations outstandingly
fast and effective. This is an important
consideration for any machine, and one
that is absolutely essential for a dryer
that customers from all around the world
have selected for its versatility and ability
to be used in multi-product assets. Ease
of cleaning, in fact, means that all the
operations involved in washing the interior
of the dryer, removing the internal parts,
Chemical Engineering World

insp ecting the u nit an d clea ning t he
exterior are simple and straightforward.
Inter nal washing: The fully accessible
chamber interior, with no hard-to-reach
zones or areas that could trap product
residues, ensures that the entire dryer can
be perfectly cleaned. To make the washing
operation even more effective, the dryer
is equipped with an efficient C.I.P. system
with retractable rotating washing head.
Equipping Planex System with the C.I.P.
washing unit not only guarantees perfect
cleaning, it also provides significant
savings: the agitators off-centered position
enables it to rotate during washing, thus
reducing the amount of liquid needed.
Inter nal par ts removal: Thanks to its
special structure, the agitator can be
readily disassembled into removable
sectors, thus making cleaning operations
even more effective. This is an exclusive
feature that makes Planex System a one-
of-a-kind dryer: in conventional systems,
the agitator is made of a single structure
and removing it requires the use of bulky
equipment and long system downtimes.
Internal inspection: The big front-opening
hatch provides full access to the entire
drying chamber. Other advantages include
the agitators off-centered position. This
allows the operator to have more room to
work, making it even faster and easier to
carry out swab testing.
External cleaning: The exterior of Planex
System is also easy to clean. The entire
machine is housed in a sealed external
casing (cGMP particle-free configuration)
which encloses the insulation and all
electrical, hydraulic and pneumatic circuits.
In addition, no support to the machine
is present in the clean room, as the
dr ying chamber is flange-mounted on
the wall. In this way the chamber exterior
can be cleaned quickly and effectively,
avoiding product accumulations in slots or
junctions. These features, combined with
the partitioning approach, permit clean
room installation, so that the clean area
Chemical Engineering World
Marketing Initiative
can be pressurized and kept separate from c. no build up
the technical area d. guaranteed final particle size
4. Ideal for processing also small batches,
Pilot Trials thanks to the automatic Stop & Swing
In its factory Italvacuum has a range of program
pilot systems which allow to carry out 5. Easy total discharge thanks to:
semi-industr ial scale dr ying tests on a. minimum clearance between agitator
customers products. During pilot trials, paddles and fully machined dr ying
product samples can be taken for analysis chamber walls
without breaking the vacuum and the b. special automatic program
process parameters can be modified at 6. Fa s t e r d r y i n g t i m e s t h a n k s t o t h e
any time in order to reach the ideal drying combined rotations of the agitator,
process. In this way customers can choose which increases the product surface
the Italvacuum system that best meets exposed to evaporation
their needs. 7. Very high final vacuum levels
8. Easy cleaning of interior and exterior,
Turnkey Systems with practical access for inspection and
In addition to the dr yer, Italvacuum is swab testing
the only manufacturer in the world that 9. Simple agitator paddles dismantling
can design and produce internally all the and removal, without long machine
auxiliary units vacuum system included downtimes
ensuring that they are sized to meet any 10.Full system automation guarantees
processing requirements: batch-to-batch process
Saurus939 high vacuum pump
Vacuum condensation unit for drying
time reduction and extracted solvent
recovery
Exter nal cyclone filter, designed in
order to prevent pressure drop and
condensation, for full vacuum line
protection
H e a t i n g / c o o l i n g u n i t s fo r s y s t e m
temperature regulation
PLC control system with CFR 21
Par t 11 cer tified software, able to
guarantee reproducible dried batches
and interface with centralized control
systems.
Strengths
1. Energy consumption three times lower
than in conventional dryers
2. Threefold reduction in mechanical
and thermal stresses, to the benefit of
product purity
3. Eccentric agitator with ZeroFriction
planetary movement:
a. n o l o c a l i z e d f r i c t i o n o n t h e
product
b. p o s s i b i l i t y t o p r o c e s s v e r y
delicate temperature-sensitive
products
February 2016 53
CEW Products

NIR Moisture Sensor and Analyser Rack Monitor

Toshniwal mixer is a new generation
powder mixing equipment that helps
to meet the customers modern times
demand such as reduced source
and achieve excellency in quality
improvement; low power consumption
- higher yield and short time operation
with reduced maintenance cost.
OPW Engineered Systems offers
RM140W rack monitor to its complete
line of terminal solution offerings. Built
for truck or rail loading in petro-chemical
applications, the RM140W protects
against overfills and continuously
monitors the grounding connection,
increasing safety at the point of transfer.

These mixers are suited to handle solids, powders, flaky
materials, etc. It is widely used in food, animal feed,
construction, chemical, refractory industry, etc. Apart
from hematogenous mixing, it also helps in achieving the
desired technical performance in the final product and its
subsequent application.
In addition to being universally compatible, the RM140W
meets or exceeds the requirements of multiple organizations
as an explosion-proof device. This perfectly aligns with OPW
Engineered Systems belief of fostering a safe and productive
work environment. The RM140W rack monitor replaces the
Opti-Therm 8500 Series.

For details contact: For details contact:

Toshniwal Dover India Pvt Ltd PSG
267 Kilpauk Garden Road, Chennai 600 010 40 Poonamallee By-pass, Senneerkuppam
Tel: 044-26448983, 26448558 Chennai 600 056
Fax: 91-044-26441820 Tel: 044-26271020, 25271023
E-mail: sales@toshniwal.net E-mail: sales.psgindia@psgdover.com
or Circle Readers Service Card 1 or Circle Readers Service Card 2

Structural Analysis and Design

New version provides an organized, simple approach to structural analysis and design. Intergraph Process, Power & Marine (PP&M),
part of Hexagon offers Intergraph GT STRUDL 2016, the most advanced tool for structural engineers to quickly analyze designs
and deliver the most accurate structural analysis to build safe and cost-effective structures. GT STRUDL 2016 increases business
productivity, eliminates design errors and provides safe, dependable analytical results on which firms can stake their reputation.
GT STRUDL 2016 provides more efficient user experience with better organization of the structural engineers desktop into docked
dialogs and tabbed workspaces; creates more efficient workflow by decreasing the number of steps needed to execute a function
compared to the previous GT STRUDL version; allows for faster 3D modeling in an AutoCAD-based modeler with an increased display
speed; and expands the large library of compliance codes already within GT STRUDL so that work stays accurate, even in the face
of new rulings and editions.

Intergraph CADWorx & Analysis Solutions offerings allow design and engineering to share relevant information seamlessly, thereby
maintaining accuracy and improving efficiency. These include CADWorx Plant Design Suite, for AutoCAD-based intelligent plant
design modeling, process schematics and automatic production of plant design deliverables; CADWorx DraftPro, a free solution
for intelligent 2D design and layout; CAESAR II, the worlds most widely used pipe stress analysis software; PV Elite, for vessel
and exchanger design and analysis; TANK, for the design and analysis of oil storage tanks; GT STRUDL, one of the most trusted,
adaptable and fully-integrated structural analysis solutions in the world; and Visual Vessel Design, a comprehensive pressure vessel,
shell and tube exchanger, and boiler design and analysis solution.

For details contact:

Intergraph Corp
19 Interpro road
Madison, AL 35758, U.S.A
E-mail: jerry.felts@intergraph.com
or Circle Readers Service Card 3

54 February 2016 Chemical Engineering World

 Products CEW

AdvanceBio Columns Improve Laboratory Workflows

Agilent Technologies Incs new technology is designed to help
scientists achieve the reproducible results they need to develop
effective biopharmaceuticals. The new line of AdvanceBio SEC
columns represent a significant advance in size-exclusion
chromatography, a key technology used to quantify aggregation
in biotherapeutics such as monoclonal antibodies. Quantifying
aggregation is a vital factor in developing and producing safe,
effective biologics. AdvanceBio SEC columns deliver higher resolution for more accurate
quantitation as well as higher sensitivity to quantitate aggregates, even at low levels.

AdvanceBio SEC columns deliver reproducible resultscolumn to column, batch to batch and
lab to lab. Agilents new silica particle provides the resolution and stability to run shorter columns
at higher flow rates, giving laboratories the right result in a quarter of the time. This product
line will enable laboratories to control costs by eliminating sample rework, simplifying method
transfers and improving lab productivity.

For details contact:

Agilent Technologies India Pvt Ltd
CP-11 Sector 8, Technology Park, IMT Manesar, Haryana 122 051
Tel: 0124-4863000
E-mail: cag_india@agilent.com
or Circle Readers Service Card 4

Natural Gas-Operated Double-Diaphragm Pumps

Wilden, part of PSG, offers a new line of CSA-certified
natural gas-operated double-diaphragm pumps. These new
pumps have been certified by CSA International to be used
in applications where natural gas is the energy source to
drive the pump. Ideal for upstream and midstream oil and
gas applications, Wilden CSA-certified natural gas-operated
pumps are available in Wilden Original (clamped), Advanced
(bolted) and Advanced FIT Models, and come equipped with either the patent-pending
Wilden Pro-Flo SHIFT Air Distribution System (ADS), which is CSA-certified ANSI LC
6-2008, or the Wilden Pro-Flo X ADS, which is CSA-certified for the ANSI LC 6-2008
and TIL R-14. Wilden CSA-certified pumps are offered in 13 mm (1/2) clamped and
25 mm (1), 38 mm (1-1/2), 51 mm (2) and 76 mm (3) bolted configurations. Wilden
CSA-certified pumps also comply with all CE and ATEX requirements, and feature
extreme shear sensitivity, high-viscosity handling, dry-run capability, superior anti-
freezing and no deadhead damage. The max flow rate is 993 lpm (246 gpm) for the 76
mm (3) Model, and the max discharge pressure is 6.9 bar (100 psig) for all Models.
Wetted paths are aluminum or SS, and available diaphragm materials are Buna-N,
PTFE or Wil-Flex.

For details contact:

Dover India Pvt Ltd PSG
40 Poonamallee By-pass, Senneerkuppam, Chennai 600 056
Tel: 044-26271020, 25271023
E-mail: sales.psgindia@psgdover.com
or Circle Readers Service Card 5

Chemical Engineering World February 2016 55

CEW Products

Screw Pumps
Blackmer offers S Series screw pumps with or without external timing gears and bearings, are self-priming
double-ended positive displacement pumps. Blackmers twin and triple screw designs provide complete
axial balancing of the rotating screws and their timing technologies eliminate metal-to-metal contact with
the pump. S Series pumps are ATEX-certified for use in explosive or dangerous environments, and have
been designed to address the difficult pumping challenges found in the oil and gas, process and marine
industries. S Series pumps provide solutions that can meet the toughest application challenges regardless
of temperature, viscosity or pressure.

S Series pumps are offered in four distinct lines, each having multiple model configurations and sizes: S Series twin screw pumps
(WTG) are double-suction, self-priming twin screw pumps with external bearings and timing gear transmissions. They are suited for
the delivery of fluids free of solid substances and/or with little abrasives. S Series twin screw pumps with non-timing gear (NTG)
transmission feature a single-suction design for transferring lubricating fluids with higher viscosities, such as bitumen and residual
oil, at medium or high temperatures. S Series multi-phase twin screw pumps have been designed for medium- to low-pressure
applications and built to last within the water and oil and gas industries. Multi-phase pumps are commonly used in the oilfields that
have untreated streams and are ideal for higher differential and suction pressure applications. S Series triple screw pumps are
designed for handling clear, lubricating liquids without solid content in the most demanding applications.

For details contact:

Dover India Pvt Ltd PSG
40 Poonamallee By-pass, Senneerkuppam, Chennai 600 056
Tel: 044-26271020, 25271023
E-mail: sales.psgindia@psgdover.com
or Circle Readers Service Card 6

LPG Natural Gas Regulators

Mesura of France, a leading manufacturer of gas regulators, systems and services for regulating and measuring
of natural gas, and Nirmal Industrial Controls Pvt Ltd, Indias leader in the field of high pressure regulators,
slam shut valves and gas conditioning, pressure regulating and metering stations set up JV, Mesura Nirmal Gas
Controls Pvt Ltd, offers highly accurate, ruggedly constructed, attractively priced and ex-stock delivery of LPG
and natural gas regulators. Safety shut-off devices can be supplied in a gas train.

Regulators are well-protected against corrosion with consistent powder coating. It has extreme temperature-resistant
diaphragms, SS screws and bolts, and 1/4 connections for inlet pressure gauge of 1 to 17 Bar/outlet pressure gauge of 0.5 to 4 Bar,
100 Nm 3/hr of LPG flow, and 1 x 1 NPTF end-connection. It is also suitable for liquid LPG. Flows tested in accordance with UL144.
The Cavagna Groups top-line of LPG regulators for residential, commercial and industrial use is also offered by the JV.

It is the 1 st stage regulator for residential gas banks. Suitable for commercial use in hotels, malls, hospitals, IT parks, educational
institutes and ideal for use in industrial LOT/VOT for LPG bulk installation and bullets. It finds application in hot air generators,
furnaces, gas engines, burners and boilers, painting, powder coating, glass and ceramic, food, agriculture, automobile and foundry
industry.

For details contact:

Mesura Nirmal Gas Controls Pvt Ltd
Plot No: 39-40, Savli GIDC, Alindra
Vadodara, Gujarat 391 775
E-mail:tawde@nirmalindustries.com
vrushank.shukla@mesuranirmal.com
or Circle Readers Service Card 7

56 February 2016 Chemical Engineering World

 Products CEW

Energy-efficient Heat Transfer Solutions

HRS Process Systems Ltd (HRS PSL), part of HRS Group, UK,
offers wide range of innovative and energy efficient heat transfer
solutions widely used in process industries like chemicals,
pharmaceuticals, petrochemicals and many more.

Ecoflux corrugated tube heat exchangers (CTHE), HRS flagship

product is based on corrugated tube technology developed by
HRS for a range of processes like heating, cooling, condensation, chilling for various
products, utility, steam, oil, water and other heat transfer applications. HRS Funke plate
heat exchangers (PHE) are used for processes like water cooling, oxygen cooling and
heat recovery. These heat exchangers have also proven to give enhanced benefits in
terms of performance efficiency when integrated into heat exchanger based systems.
These systems (HES) are skids which ensure optimum utilization of energy with controlled
heating and cooling which avoids wastage in process, thus making it much more
environmentally efficient.

For details contact:

HRS Process Systems Ltd
201/202 Karan Selene, 851 Bhandarkar Institute Road
Pune, Maharashtra 411 004
Tel: 020-25663581, 66047894
E-mail: info@hrsasia.co.in
or Circle Readers Service Card 8

Scrapper Mechanism Filters

Scrapper mechanism self-cleaning filters are widely used for continuous
filtration requirement without any replacement of filter consumables
and without exposure of operators. Scrapper mechanism self-cleaning
filter is used wherein one cannot introduce any additional substance for
back washing.

Because of automatic continuous on-line filtration, the filtration process

becomes smooth. The gear motor runs against the spring actuated scraper
and the concentrated solids are drained off by the system, thereby keeping
the function of the cartridge well. PLC control function means differential pressure cleaning,
scheduling of cleaning process and manual cleaning. The differential-pressure is an important
parameter for operation and can be connected with the central control room. Validated by
practice, this filtration process is highly effective and using the wedge cartridge, it can be
easily cleaned with less abrasion. In many fields, this filter can replace the traditional filters
like sand filters, filter press, etc.

For details contact:

Filter Concept Pvt Ltd
302 Aalin, B/h Jet Airways Office, Ashram Road
Ahmedabad, Gujarat 380 014
Tel: 079-27541602 | Fax: 91-079-27540801
E-mail: info@filter-concept.com
or Circle Readers Service Card 9

Chemical Engineering World February 2016 57

CEW Products

High-specification Process O2 Analyser Flow Control Valves

The SERVOTOUGH OxyExact
high specification oxygen analyser
offers an unrivalled combination of
precision, flexibility and performance
for optimum process and safety
control. The OxyExact can be
configured with a safe or hazardous area control unit with
up to six transmitters. Zone 1 Certified to ATEX Cat 2, IECEx
and FM.CSA Class 1 Div 1. Three enclosure systems allow
sampling of any flammable gas up to 100 per cent O 2 and
pressures of up to 40 psi.
High temperature version eliminates the need to condense
hot sample prior to analysis.
Cipriani Harrisons flow control valves made
from forged SS-316L, are highly polished
and come standard with FDA EPDM seats
and seals. These valves have self-draining
machined bodies with a round shape that
allows for minimum resistance to flow.
The valve body, yoke and actuator are
assembled with clamps enabling quick and easy assembly and
disassembly. Available in sizes 1-2.5 with sanitary clamp and
butt-weld end connections as standard. The valve is operated
by means of a manual handle which moves a conical plug
gradually up or down. The plug has a calibrated profile that
allows for fine flow control. The plug can be fixed in the desired
portion with locking arrangement.

For details contact: For details contact:

Spectris Technologies Pvt Ltd Cipriani Harrison Valves Pvt Ltd
Plot No: A-168 MIDC 1901, GIDC, Phase IV, Vallabh Vidyanagar
Thane-Belapur Road Vitthal Udyognagar, Gujarat 388 121
Khairnae, Navi Mumbai 400 710 Tel: 02692-235082, 23512
Tel: 022-39342700 Fax: 91-02692-236385
E-mail: MEI_Sales@servomex.com E-mail: info@harisonengineers.com
or Circle Readers Service Card 10 or Circle Readers Service Card 11

Temperature Control Systems for Labs & Industrial Applications

JULABOs new PRESTO Models W50 and W50t provide a high dynamic temperature control system that can handle
temperature ranges of -50 0C to +250 0C for applications such as reactors, mini-plants, pilot plants, material testing
stands, micro-reactors, and material and component tests in the auto industry, for example. The new water-cooled
PRESTO Models are available in two versions: the W50 and the W50t with increased heating capacity. The PRESTO
W50 provides a heating capacity of 6-kW, while the W50t provides 12-kW. Both have a cooling capacity of up to 7.5-
kW. They are suited for compensating exothermic and endothermic reactions extremely quickly and have impressive,
very rapid heat-up and cool-down times.

High-performance pumps deliver up to 3.2 bar or 76 l/min. Both Models guarantee high flow rates at constant pressure and can
interactively compensate changes in the viscosity of the tempering medium. The integrated 5.7 industrial colour touchscreen
provides high functionality and intuitive user guidance. Extensive interfaces allow flexible usage, such as control and regulation
via USB interface, data logging via USB or SD Card, integration in process bus solutions (ie, Profibus), remote control via Ethernet
networks or wireless control through JULABOs WirelessTEMP application. Competent advising, a collaborative search process
for suitable solutions with the customer and many other customer services ensure that JULABO users find the ideal temperature
control solution.

For details contact:

JULABO GmbH
Eisenbahnstr 45, Seelbach
Baden Wrttemberg 77960 Deutschland, Germany
Tel: +49 (7823) 51-21 | Fax: +49 (7823) 2491
E-mail: m.ketterer@julabo.de
or Circle Readers Service Card 12

58 February 2016 Chemical Engineering World

 Oil & Gas World Expo 2016
Concurrent Events: SMP World Expo,
EnerTECH World Expo
Dates: 3 5 March 2016
Venue: BC&EC Mumbai, India
Details: Platform to showcase services,
technologies, innovations and current
& future trends of entire value chain of
hydrocarbon industry.
Contact: +91 22 40373636
Email: sales@jasubhai.com
Website: www.chemtech-online.com
India Chem 2016
Dates: 1 3 September, 2016
Venue: Bombay Exhibition Centre, Mumbai
Details: Event of chemicals and
petrochemicals industry in India in its 9th
edition
Organiser: FICCI
Contact: +91 22 2496 8000
Email: vishal.ganju@ficci.com
Website: www.indiachem.com
Chemspec 2016
Dates: 7 8 April, 2016
Venue: Bombay Exhibition Centre,
Mumbai
Details: Meeting and networking with
existing and potential partners and
business facilitators
Organiser: Quartz Businesss Media Ltd,
Contact: +91 22 240 44472
Email: rohit@chemicalweekly.com
Website: www.chemspecevents.com
Automation 2016
Dates: 22 25 August 2016
Venue: Bombay Exhibition Center,
Mumbai
Details: Automation 2016, a four day
automation event is set to introduce new
and upcoming technology this year
Organiser: IED Communications Ltd
Contact: 91 22 22079567
Email: jyothi@iedcommunications.com
Website: www.iedcommunications.com
Chemical Engineering World
ChemCon Europe 2016
Dates: 14 18 March 2016
Venue: Amsterdam, Netherlands
Details: Technical or commercial services
linked with the chemical industry.
Organiser: ARC Advisory Group
Contact: +31(0)88 348 88 88
Email: office@chemcon.net
Website: www.chemcon.net
Best Practices for Chemicals
Dates: 14 16 March 2016
Venue: Texas, USA
Details: The premier industry conference
for organizations using SAP.
Organisers: SAP, The Eventful Group and
ASUG
Contact: +1 877 411 4675
Email: sarah.carr@theeventfulgroup.com
Website: www.sapforindustries.com
ORPEC 2017
Dates: 13 15 May 2017
Venue: Muscat, Oman
Details: Designed to deliver key buyers to
Omans growing refining and petrochemical
industries creating a forum aligned with the
governments growth plans
Organiser: OMANEXPO LLC
Contact: Mr Ebrahim Taher
Email: info@omanexpo.com
Website: www.omanexpo.com
The 2016 Automation Summit
Dates: 27 30 June, 2016
Venue: Las Vegas, USA
Details: Siemens Automation Summit
A User Conference. All areas of industrial
automation will be covered including
factory, process, motion, and drives.
Organiser: Siemens Industry, Inc
Contact: +1 800 241 4453
Email: rich.chmielewski@siemens.com
Website: usa.siemens.com/summit
February 2016 59
CEW Project Update
New Contracts/Expansions/Revamps
The following list is a brief insight into the latest new projects by various companies in India.
CHEMICALS
Panoli Intermediates (India) proposes an expansion of its specialty
chemicals manufacturing unit and a new 10-MW coal-based captive
power project in Unit-III, GIDC Nandesari, district: Vadodara, Gujarat.
The estimated cost of the project is ` 100-million. The current status
of the project could not be ascertained. According to MoEF sources,
the total plot area is 15,480-sq m. The capacity of isomers and
DNCB such as 2:4 DCNB, 2:6 DCNB, 2:5 DCNB is to be augmented
from 200-TPM to 2,200-TPM, ortho anisidine/para anisidine from
100-TPM to 1,100-TPM, ortho nitro aniline/para nitro aniline from
300-TPM to 2,300-TPM, isomers of DCA from 80-TPM to 1,080-
TPM, isomers and DCNB such as 2:3 DCNB, 2:5 DCNB. isomers
of DCNB such as 2:3 DCNB, 2:5 DCNB, 3:4 DCNB from 200-TPM
to 2,200-TPM, H-acid from 50-TPM to 500-TPM and addition of a
new product namely, 1,500-TPM derivatives of nitro phenol and a
new 10-MW coal-based CPP. 10-MW power requirement is to be
met from MGVCL and 10-MW from the CPP. The effluent will be
treated in proposed effluent treatment plant.
Saras Plywood Products is planning a 60-TPM urea formaldehyde
resin manufacturing plant in New GIDC Gundlav, district: Valsad,
Gujarat. The existing land area is 1.5 acres. The estimated cost of the
project is ` 7.5-million. Kalyan Industries is the equipment supplier.
The project is waiting for environmental clearance. Civil work will
commence in 3 months. The project is planned for completion in
this year. According to SEIAA sources, the company has proposed
primary treatment plant followed by evaporator for treatment of
industrial effluent and has also proposed a multi-cyclone separator.
FMC India is planning an expansion of its chemical manufacturing
unit at IDA Patancheru, district: Medak, Telangana. The estimated
cost of the project is ` 17.5-million. As of September the project
was waiting for the environmental clearance. According to MoEF
sources, the plot area is 4.027 acres. The company proposes to
manufacture 50-TPM of products as part of the expansion. Green belt
on 33 per cent of the land area will be developed and maintained.
Power requirement will be made available through SPCPDCL. The
project will be completed within 2 years.
Globex Laboratories (R&D) proposes a pigments manufacturing
unit at village: Dabhasa, district: Vadodara, Gujarat. According to
MoEF sources, the project will come up in the existing land on
9,312-sq m. Kadam Environmental Consultants, Vadodara is the
environmental consultant. The project will entail manufacture of
40-TPM red pigments, 40-TPM yellow pigments and 450-TPM dilute
phosphoric acid. Environment clearance has been obtained for the
products red pigments and yellow pigments. Construction work
has begun, as EC and NOC have been received. Effluents generated
will be treated in effluent treatment plant having MEE. The company
60 February 2016
has applied for Amendment in Environmental Clearance dated 26th
September 2012 for change in fuel from LDO to agro waste briquettes
and addition of one raw material, ie, phosphoric acid and generation
of dilute phosphoric acid (25 per cent basis) as by-product.
Bohra Industries is implementing an expansion of its chemical and
fertilizer manufacturing unit at Umarda, district: Udaipur, Rajasthan
on 14,500-sq m of existing land. The project will entail expansion of
single super phosphate capacity from 400-TPD to 600-TPD, granulated
super phosphate from 200-TPD to 300-TPD and addition of new
products namely 150-TPD triple super phosphate, 550-TPD synthetic
gypsum, 30-TPD Di-calcium phosphate, 160-TPD phosphoric acid,
0.3-TPD potassium fluoride, 150-TPD H2SO4 and 0.3-TPD Sodium Tri
Polyphosphate (STPP). Machinery has been ordered from China. Civil
work is in progress. The project is scheduled for completion in 2018.
Ami Lifesciences proposes expansion of its synthetic organic
chemicals manufacturing unit (viz, pharmaceutical bulk drugs and
drug intermediates) from 65.70-TPM to 131.60-TPM in Padra, district:
Vadodara, Gujarat.The estimated cost of the project is ` 87.046-million.
Environmental Consultant to this project is Envisafe Environment
Consultants. According to MoEF sources, total plot area is 23,760-sq
m (existing 10,270-sq m and 13,490-sq m for expansion). The unit
currently manufactures 2-TPM 1-Acetyl Naphthalene, 1-TPM 2-Acetyl
Naphthalene, 6-TPM Itopide HCl, 1.20-TPM Loxapine Succinate, 0.30-
TPM Amoxapine, 6-TPM Venlafaxine, 6-TPM Progunil HCl, 6-TPM
CB-2-L-Valine, 0.60-TPM Nateglinide, 0.60-TPM Quetiapine, 24-TPM
Carbomazepin and 12-TPM Oxacarbomazepin. The expansion will
involve addition of new products. Water requirement from ground
water source will be increased from 34.53-cu m/day to 181-cu m/day
after expansion. Effluent generation will be increased from 9.35-cu
m/day to 79.5-cu m/day after expansion. Highly concentrated effluent
will be sent to captive incinerator for incineration. Remaining effluent
(70-m3/day) will be treated in the ETP comprising primary, secondary
and tertiary treatment. Treated effluent will be sent to CETP for further
treatment. ETP sludge, inorganic residue and incineration ash will be
sent to TSDF. Spent carbon, organic residue will be sent to incinerator.
Adi Finechem is planning a 40-TPA specialty products manufacturing
project on a 2-acre land at an estimated cost of ` 400-million in village:
Chekhala, district: Ahmedabad, Gujarat. The project is waiting for
environmental clearance.
RSPL is planning a 1,500-TPD soda ash plant and 40-MW captive
power project in village: Kuranga, district: Jamnagar, Gujarat. Land
acquisition is in progress. 85 per cent of land has been acquired. The
project is waiting for environmental clearance. The entire project is
planned for completion in 5 years from zero date.
Chemical Engineering World
 Project Update CEW
Superhouse is planning an expansion of its chemical mix-manufacturing project from 200-kg/
day to 500-kg/day in UPSIDC Industrial Area, district: Unnao, Uttar Pradesh. The product will
be used in leather tanneries. The project will involve installation of containers. The project is
in planning stage.

MINING
Metabluu Power, a sister concern of Minera Udyog India, is planning a 75,000-TPA iron ore
mining project in village: Devikonda, district: Karimnagar, Telangana. The project is awaiting
Government approval.

Aryan Ispat & Power is planning an expansion of its coal washery in village: Bamoloi,
district: Sambalpur, Odisha. The project will come up in the existing 204.65-acre integrated
steel plant premises. The capacity of the project is to be augmented from 0.70-MTPA to
5.70-MTPA. The cost of the project is ` 600.7 million. The project is awaiting environmental
clearance and planned for completion in 1-year from zero date. According to MoEF sources, the
expansion is based on heavy media cyclone (wet process) technology. The washery will produce
washed coal of an average ash around 34% (GCV 4,350-Kcal/kg), middling (ash content about
58%) of GCV around 2,350-Kcal per kg useable as fuel in FBC boilers. The proposed expansion
will be the state-of-the-art with close circuit water system, classifying cyclone, high frequency
screens, thickener and multi-roll belt press filters. Power requirement of 5-MVA will be sourced
from its own power plant connected with the Grid Corporation of Odisha.

NTPC is planning the Kudanali-Luburi coal mining project in district: Angul, Odisha. The company
has signed an agreement on June 15, 2015 with Jammu and Kashmir State Power Development
Corporation (JKSPDCL) for promoting a joint venture company with 67:33 equity participation It is time to Migrate to an advanced
Structural Analysis Software
for undertaking exploration, development and operation of jointly allocated Kudanali-Luburi Coal
Block at Odisha by the Ministry of Coal.
Easy User Interface
DSP Associates is planning a 15,17,600-TPA sand (minor mineral) mining project in the Conformancee to nuclear industry QA/QC - NRC
mines of Tikola-1 Sand Unit at village: Tikola, district: Gurgaon, Haryana. Mining lease area Integration with smartPlant 3D / Tekla / STAAD.Pro
is 42.50-hectare. The estimated cost of the project is ` 55-million. The project is waiting for
environmental clearance. Mining work is expected to commence soon. According to MoEF Validation & verication for more than
sources, out of the total area, 31.50-hectare area falls in the river bed and 11-hectare area falls 5000+test problems
in agricultural land (outside river bed). Method of mining will be opencast semi-mechanized
Base plate modeling & analysis
without drilling and blasting. The mine will be excavated out in layers up to a depth of 3-m in
riverbed and 9-m in agricultural field. Letter of Intent (LoI) for mining contract has been granted Linear and Non linear Static-Dynamic analysis
for a period of 9 years. Steel Frame & reinforced concreate design
CIS/2 analysis data interface
NON-CONVENTIONAL ENERGY
Hubli Electricity Supply Company is planning solar RTPV grid connected power plants in Comprehensive & detailed user documentation
district: Belagavi, Karnataka. E-tenders have been floated to design, manufacture, supply, Offshore structure analysis & deisgn
installation, testing and commissioning of solar RTPV grid connected power plants on roof-tops
of 31 HESCOM office buildings in Belagavi Zone Jurisdiction for total load of 136-KWp including
operation and maintenance for a period of five years. The approximate amount put to tender is
` 18.62-million.

Karnataka Renewable Energy Development is planning a 10-MW solar power project at an

estimated cost of ` 600-million (approximately) in village: Tingloor, taluka: Madhugiri, district: Tumkur,
Karnataka. Surana Telecom And Power has received Letter of Award (LoA) for development of
the project. Email: sales@iges.in

Maharashtra State Power Generation Company is planning a

50-MWp solar photo voltaic power project in Gangakhed, district: Parbhani, Maharashtra. The company www.iges.in
is scouting for land. Other details are yet to be finalized. TOLL FREE : 1800 102 4437

Chemical Engineering World February 2016 61

CEW Book Shelf

Chemical Process Safety: Fundamentals with

Applications (3 rd Edition)
Authors : Daniel A Crowl, Joseph F Louvar
Price : USD 372.09
Pages : 720 (Hardcover)
Publisher : Prentice Hall
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Process Safety, Third Edition, offers students and practitioners a
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vessel entry.
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Pages : 464 (Hardcover)
Chemical Engineering Design (2nd Edition) Publisher : McGraw-Hill Education
Author : Gavin Towler PhD, R K Sinnott
Price : USD 213.53 About the Book : Maximize plant
Pages : 1320 (Hardcover) profitability by minimizing operating
Publisher : Butterworth-Heinemann costs. Smart Process Plants addresses
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book available on the topic, reads Chemical Engineering Resources estimation, control, fault detection,
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Course, and also suitable for introduction to chemical engineering connects these activities to plant
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textbook that students will want to keep through their undergraduate education and on into their are included. The book discusses
professional lives. optimal instrumentation type, quality,
precision, and location along with
preventive maintenance techniques.
Production Systems Engineering: Cost and Performance
Practical examples throughout the book
Optimization (1st Edition)
demonstrate how to perform essential
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calculations.
Price : USD 30
Pages : 256 (Hardcover)
Publisher : McGraw-Hill Education Smart Process Plants covers:
Measurement instrument
About the Book : This pioneering work offers proven techniques, performance and measurement
partially created and developed at The Charles Stark Draper errors
Laboratory, for determining optimal resource allocation and Variable classification and canonical
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manufacturing environments. Production Systems Engineering Linear, nonlinear, and dynamic data
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resource establishes a new paradigm for the manufacturing world that can also be applied size elimination, and estimation
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manufacturing system design method, System design basics, time allocation, resources, Value of accuracy, control strategies,
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versus mostly manual systems, etc. Maintenance optimization

62 February 2016 Chemical Engineering World

 Ad Index CEW
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2 CRI Pumps Pvt Ltd 29 16 Suraj ltd 35

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7 ImageGrafix Engineering Services Pvt Ltd 55, 57, 59, 61 21 Chemtech World Expo 2017 Back Cover

8 Impart International Pvt Ltd/Munsch Chemie 7

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10 Kirloskar Brothers Ltd Inside Cover II

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12 Poonawalla Group 19

13 Rasaii Flow Lines Pvt Ltd 31

14 Rathi Transpower Pvt Ltd 37

Chemical Engineering World February 2016 63

CEW Interview

Turning India into a

Manufacturing Hub
by Rising above
Hurdles
I n d i a s g r o w t h d r i v e r w i l l b e i t s
population; states A M Tiwari, Managing
Director, Gujarat Alkalies
and Chemicals Limited
(GACL) in conversation with
Mittravinda Ranjan. He
comments on the chlor-
alkali market outlook in India
as compared to the Chinese
market which is slowing
down or the Middle Eastern
market which sees low
energy costs. He also speaks
about the competition in the
market, anti-dumping duties, potential
investments GACL may be making, etc.
Here are the excerpts.

64 February 2016 Chemical Engineering World


According to a recently released report,
the Chlor-Alkali market is estimated to
witness a CAGR of 6.0 per cent between
2014 and 2019 in terms of value and is
anticipated to generate a global market
value of USD 93936 million by 2019. How
do you see the market dynamics play up
in the years to come in India and globally?
The chlor-alkali industry is expected to remain
at a range CAGR from 6-7 per cent. It may
even improve as the GDP growth of India is
expected to be more than 7 per cent in coming
years as also growth in other user sectors like
Alumina is estimated at more than 10 per cent
and more than 8 per cent in the paper and
pulp sector. The most robust growth driving
factor for India would be its population which
is growing at 1.5 per cent.
Where does the Indian chlor-alkali industry
stand globally in comparison with China,
where the industry enjoys economies of
scale and with the Middle East where the
energy cost is very low?
Comparison with China
China is completely focused on design based
processing which cannot be easily done in
India due to a number of serious bureaucratic
hurdles. One way of improving processes and
technology is through research jointly done
by the academic institutions and industry.
Although India was a step ahead of China in
setting up institutes of CSIR, but China did a
better job when it set up these institutions. It
ensured every institute partnered with some
industry or the other and there was a lot of
research jointly done by the institutes and
the industry. Also, in China, the 1st stage of
development was export oriented and they
set up plants that were of global scale and
had to be super-efficient. The whole taxation
structure, financial institutions, logistics, et al
was driven with exports in mind.
In India, the basic chemical industry was
always focused on the domestic market and
as a result our industrial units were smaller
in size rather being able to serve the market
on a global scale. Between 1970s and 1990s,
the plants set up were small in size and now
the country faces a problem where majority
of our plants are not on par with the global
standards. If we take the example of caustic
soda, China buys salts from India but can still
manage to be competitive. Although the raw
Chemical Engineering World
material is available at an inexpensive price
in India, it is a challenge when it comes to the
actual production cost. India is bogged down
by many ideological issues and pressure
groups which is hurting our competitiveness.
However, making world scale plants with
captive downstream units to produce further
value added chemicals shall be the key
to success. Focus on various chlor-alkali
products like caustic soda (lye, flakes & prills),
chlorine, chloromethanes, hydrochloric acid
to African and European countries shall help
the Indian chlor-alkali industry to remain on
the growth track through economies of scale.
What are your thoughts on Comparison
with Middle East?
It is true that the cost of energy is very low
in the Middle East but that is mainly due to
the fact that Middle Eastern countries make
use of low priced natural gas for power
generation which is not the case in India.
On the other hand, the cost of salt in the
Middle East is ` 4000 per tonne or higher
but the same will cost not more than ` 800-
900 in India. Similarly, raw water is very
expensive there.
Middle East will have little chance of
competing with us if gas based value
addition is done there, the material is
brought here, then converted with some
value addition and exported to rest of the
world. Dahej in Gujarat is ideally suited for
value added export due to its proximity to
the Middle East and easy availability of key
domestic inputs. But India does not have the
port infrastructure to support such a move.
Also, the bureaucracy needs to be a little
more proactive to such suggestions from the
industry as various issues concerning Dahej
are already known but no concrete move to
address them is being taken up.
Please share your views on the impact of
low growth posted by China on the overall
market dynamics of chlor-alkali industry
and the impact on Indian industry? In
your view, how can our domestic industry
leverage on the opportunity?
Historically, many of products have been
dumped to India from China. High man
power cost, internal government policy,
low operation capacities are some of the
challenges that India needs to work on.
Even after the low growth posted by China
Interview CEW
in recent months it has not dumped caustic
soda into India because of the Tianjin port
closure due to NaCN blast. The electricity
cost in China is greater or at par with India.
Apart from this, India is geographically
better placed than China to cater to the
global market.
In another decade, the African market is
going to grow significantly and as of today
the countrys export to Africa is fairly good.
But India would require major capacity
expansions to meet the export requirements.
This is possible if India can explore having
tie-ups with companies like SABIC or Iranian
petrochemical manufacturers from where we
bring in investments and natural gas, carry
out cracking and conversion into ethylene and
propylene and sell it in market for further value
addition. This way, the foreign companies will
get access to the growing Indian market and
still be able to earn a reasonable profit. There
are two ways of doing this, either we go and
set up plants in countries like Iran or convince
them to jointly set up plants in India. Such an
arrangement will ensure better realisation in
export markets for Indian firms and assured
availability of critical inputs. Such steps
can work in favour of the country provided
decisions are taken quickly.
PCPIRs have been under the planning
stage for a very long time. How would
these reverse SEZs you speak of work?
PCPIR concept is on the verge of failure due to
the unreasonable attitude of so called Anchor
Units that are not willing to share the basic
building blocks with the downstream units and
by doing this, they will single-handedly kill this
good initiative. Lack of focus on infrastructure
like good port, efficient rail connectivity,
logistics handling agencies, reliable utility
suppliers, etc. are adding up huge capital
costs that are taking away the advantage of
port based locations of the PCPIRs. Iran is
the 2nd largest producer of natural gas and
when it comes to connectivity, Dahej is only
a day or twos journey from Iran. Crackers
can be set up in Dahej and ethane can be
transported across the Arabian Sea via ships.
If this is planned and executed well, it can be
a viable solution for huge downstream value
addition and export and the problem created
by Anchor Units can also be resolved.
February 2016 65
CEW Interview
What kind of competition across Indian chlor-alkali
manufacturing industry do you see? How does GACL maintain
its competitive edge? What are the various steps a company
has to take towards improving top and bottom line margins?
Chlor-alkali is nothing more than an ordinary commodity. This
industry does not have any competitive technology on which it can
can thrive. There is no differentiation factor for caustic soda as
every competitor will sell the same product and it is an everyday
struggle to market the product at a reasonable price.
In India, 200-300 tonne capacity caustic soda plants are set up
every 200-300 kilometres; be it in Odisha, Bihar, Andhra Pradesh,
Tamil Nadu, Gujarat, Punjab and Rajasthan. Gujarat has a higher
concentration of the industry as it has raw material available in
plenty. It is a wonder for us how in Europe or America a distance of
500-1000 kilometres is not much from the point of view of logistics.
Abroad, a company could make a product in one place and sell it as
far as 1400 kilometres with ease. In India, this does not turn out to
be a viable solution as someone has set up a small plant closer to
the customer and has the price advantage there. GACL has found
a solution to this issue by setting up a pipeline to the Dahej railway
station and leased rakes to transport the product from the West to
Nalco, etc. Ship was one of the options GACL tried to explore, but
there are complexities like the bunker fuel tax which make sending
the product through ship freight within India an expensive affair.
In comparison world over, ship transport is the cheapest option,
followed by rail and road. The situation is reverse in India due to
random policies. Road transport would mean sending 250 trucks
whereas the same amount can be sent at once through rail which
also saves on time.
Some of the measures GACL is considering to improve margins
are outsourcing value added products, compatible expansion plans,
improvement in the capacity of existing plants, broadening the base
of products baskets, optimisation of energy and operating costs,
focus on exports, penetrate eastern region market to balance over
supply in the western region market.
Does the Indian market provide level playing field for
competition between Indian and international players? What
is the structure of anti-dumping duty for various chlor-alkali
products to protect the domestic market?
Some products have the anti-dumping support. But it may be a
temporary call till the Indian industry can achieve the level playing
capabilities to compete with the global players, some of which are
deliberately hitting at small Indian producers and the industry must
be able to face the international imports/ dumping threats all the
time. We have started working on how we can live without anti-
dumping duty. Chemical sector cannot rely on anti-dumping duty
beyond 5-6 years. But the important question that remains is What
after that?
So far, major imports are from Iran wherein anti-dumping duty
is negligible. After lifting of sanctions, Iran will channelize their
products in nearby markets of European and Middle Eastern
countries and thus caustic soda export to India will reduce.
66 February 2016
GACL witnessed a jump in gross income during the period 2011-
12 from 2070 crores to 2432 crores and after which the growth has
plateaued till 2014. Can you please share some insights into the
companys performance during this period?
2011-12 was a remarkable year for the chemical industry and most of
the companies made a good profit. I was in GNFC in those days and
it made the 2nd highest profits in that year. We wrongly believed that it
was due to the efforts the team had put in but the year after we realised
that the same success story could not be repeated. 2011-12 was an
exceptional year for GACL as well and thereafter the prices kept on
declining. Market realisations were not in proportion with the costs due
to sluggish demand in the market for main products. But if you do a peer
group analysis, GACL performed much better during this period than
its peers. The vision at the time was to bring in internal efficiency rather
than taking up new projects. Also, at the time, plants were not being run
at full capacity because the natural gas and alternative energy costs
had gone up. This situation was stabilised at our Dahej complex in next
three years. GACL had to also tackle the problem of energy sourcing.
The R-LNG and APM natural gas run power plant in Dahej had to be shut
down due to a number of hurdles, such as increasing gas cost, policy
changes, etc. A number of crucial projects are in the pipeline but would
take some extensive planning and timely execution for them to be set
in motion.
According to GACLs annual report for the year 2013-14, high
crude oil and natural gas prices impacted top and bottom line
margins of the company. With the current fall in crude oil and
natural gas prices, what kind of improvement is anticipated for
the current financial year?
In 2013-14, GACL was adversely impacted by the depreciating rupee
as this badly affected our gas based power plant in Dahej. The company
retained its profitability with downstream products like hydrogen
peroxide, phosphoric acid and the plants were running at full capacity.
The idea was to bring down the energy cost and we expanded our wind
power program. Today, we have 156 MW wind power turbines with
plans of setting up more to ensure energy efficiency.
What are the future investment plans?
We have been working on debottlenecking of chloromethane which
would see an investment of ` 120 crores. The plants capacity would
be 170 tonnes per day (TPD) as compared to its previous capacity of
110 TPD. Basic engineering has been completed and civil work is to
start soon. GACL would be making an investment of ` 40 crores in
debottlenecking the caustic potash plant. Currently, the plant has a
capacity of 80 TPD which would increase to 140 TPD. Also, we would
be setting up a wind farm of 31 MW with an investment of about ` 190
crore. The total investment would be of about ` 350 crores.
In the next 2-3 years the company is planning numerous capacity
additions to the downstream products viz. chloromethanes, phosphoric
acid and hydrazine hydrate, etc. GACL would also be setting up a
joint venture with NALCO for an 800 TPD CS plant and a 100MW
imported coal based power plant for an estimated investment of about
` 1790 crores.
Chemical Engineering World
R.N.I. No. 11403/1966 Date of Publication: 29 th of every month. Postal Registration No: MCS/095/2015-17
Posted at Patrika Channel Sorting Ofce, Mumbai 400001, on 29th & 30th of every month. Total Pages No.:68