chemical world - april 2013

INDUSTRY WATCH - Chemical World April 2013

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EDITORIAL

5April 2013 | Chemical World

EditorialAdvisory Board

Pothen Paul Former Chairman,

Aker Powergas Pvt Ltd

D P Misra Director, TCE Consulting Engineers Ltd and Former

Director General, ICC

P D Samudra Executive Director (Sales) &

Member of the Board, Uhde India Pvt Ltd

Shale gas: The game changer?

Manas R [email protected]

Veerappa Moily, the Minister of Petroleum & Natural Gas, was spot on when

he recently stated that shale gas would be a game changer for India. Taking

the first step in this direction, the Union Government is currently in the

process of finalising the shale gas policy to tap this unconventional resource to

fuel the nation’s expanding economy and cut subsidies. So, why shale gas – a

natural gas trapped in sedimentary rocks (shale formations) below the earth’s surface – is

so important for India?

As existing conventional resources in India get either expensive or dry up, experts

believe that India could potentially have the fifth biggest shale gas reserve in the world with

recovery rate of up to 50 per cent – much higher than the 30 per cent in the conventional

oil and gas reserves. For an energy-starved country, this is a boon that needs to be

explored. But, the absence of a clear policy framework for shale gas exploration

has prevented such possibilities.

While now the process in on to frame new shale gas policy, it would be

imperative for the policy-makers to provide clarity on gas pricing and fiscal

incentives upfront as these could play dampener later. Further, the government

will have to offer a liberal fiscal regime to exploration companies, considering

the fact that shale gas industry is still in its infancy stage in India, and cost

of operations during the initial phase is expected to be higher than the

conventional oil and gas operations.

At present, many view shale gas as pure energy play. But,

going by the experience of the US, which has been witnessing

shale gas boom, a positive rub-off on the downstream industry

cannot be ruled out. According to the American Chemistry

Council, as a result of low-cost natural gas availability, in near

future, companies in the US plan to invest about $ 72 billion in

petrochemicals business – an industry that many believed, only

three years ago, was in long-term decline.

This may be far-fetched from India’s context, with energy and

fertiliser sectors being given priority for domestically produced gas.

Nevertheless, any affirmative action in these two sectors will positively

impact the chemical industry.

To begin with, India will have to put in place a favourable regulatory

regime, followed by strong service and infrastructure capabilities. While

many may argue that the Indian Government has belatedly woken up to the

potential of shale gas, it is never too late to realise its potential.


Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

Insight & Outlook: Alternative Energy/Fuels

Special Focus: IT for Chemical Process Industry

Virtualization .....................................................................

Automation vendors ..........................................................

Machine safety ....................................................................

Manufacturing Execution Systems ....................................

Automation in plant maintenance ......................................

Interface - Rajesh Rege, Director, Datacenter and Cloud Business, Cisco India and SAARC ................

Roundtable ..........................................................................

In Conversation With

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Amol S Sheth, Chairman, Anil Bioplus Ltd ......................................... 22

26Renewable energy ...............................................................

Biofuels ..............................................................................

Bio-based feedstock ............................................................

Interface - Andrew Soare, Analyst, Lux Research ...........

Roundtable ..........................................................................

Safety governance ...............................................................

Chemical processing ...........................................................

Ammonia market ................................................................

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Automation TrendsWirelessHART technology: Process and asset monitoring simplified ................................................

Energy ManagementISO 50001 certification: A structured approach to power conservation .........................................................

Policies & RegulationsGovernment incentives for alternative energy: Are the initiatives renewing interest in renewable energy? .............

StrategyBusiness plans for SMEs: Customised solutions with right pricing key to success ........................................

Tips & TricksRFID technology: Right tracking solutions for better resource utilisation ............................................

Cover illustration: Sachin Pandit

Regular SectionsEditorial ........................................................................ 5News, Views & Analysis .............................................. 10Technology & Innovation ............................................ 18Technology Transfer .................................................... 20Projects ........................................................................ 66Tenders ........................................................................ 68Event List .................................................................... 69Book Review ................................................................ 71Products ...................................................................... 72List of Products .......................................................... 82List of Advertisers ...................................................... 83

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Facility Visit: FLOSTEER Engineers Pvt LtdAdding quality value to valves with reliability .................... 38

Winning strategies for chemical manufacturers to ride out the global turbulence Details on page no. 69

42 44

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Business InsightsTechnologies

Opportunities

NEWS, VIEWS & ANALYSIS

Chemical World | April 201310

SPECIALTY CHEMICALS

BASF launches Master Builders Solutions in IndiaBASF has rolled out its Master

Builders Solutions brand in India,

as part of a phased launch process.

The portfolio of products and

services marketed under this brand

embraces chemical solutions for

new construction, maintenance,

repair & renovation of buildings and

infrastructure. These include concrete

admixtures, cement additives,

chemical solutions for mining and

tunneling, waterproofing, concrete

protection and repair products,

grouts and high-performance

flooring products.

Prasad Chandran, Chairman,

BASF Companies in India and

Head South Asia, said, “A powerful

brand builds trust and confidence.

The launch of Master Builders

Solutions is in line with BASF’s

new ‘We create chemistry’ strategy.

By bringing all the specialty brands

together, we are building up our

business spirit and investing for

future profitable growth. It will

facilitate better access to the market

and strengthen the awareness of the

construction industry on our existing

range of products and offerings.”

Diversified industrial manufacturer

Eaton has inaugurated its Filtration

Division’s first manufacturing, assembly

and distribution facility in India. The

newly built facility is located at Hinjewadi

in Pune. Richard Jacobs, President,

Eaton’s Filtration Division, said, “India

continues to be one of our focus markets.

This new facility will further energise

our efforts towards bringing Eaton’s

industry leading filtration solutions to

our customers in India.”

The new manufacturing facility

occupies an area of 6,500 sq ft. The

primary focus at this location is to

manufacture Eaton’s Internormen

filter elements with specification and

distribution that support local customer

requirements. The facility will currently

offer element and filter assembly services,

filter systems assembly, and customised

filter element design and manufacturing.

Nitin Chalke, Managing Director –

India, Eaton said, “Eaton is committed to

growing its diversified presence in India

and the new filtration facility is a step

forward in this direction.”

FILTRATION TECHNOLOGY

Eaton inaugurates filtration facility in India

LANXESS India achieved sales of about

` 1,672 crore in 2012, attributed to its

business out of its manufacturing unit in

Nagda, Madhya Pradesh. “The business

unit segment Advanced Intermediates

has shown a significant growth of 11 per

cent this year majorly coming from our

manufacturing facility at Nagda. This

has somewhat offset the drop in demand

from the automotive and tyre industries in

2012, on which our rubber businesses are

dependent. We have benefitted from the

increase in domestic demand in certain

segments such as paints and coatings,

pharmaceuticals and agrochemicals and

done well in businesses that are driven

by these segments,” said Venkatesh

Sankaran, Chief Financial Officer,

LANXESS India.

Dr Joerg Strassburger, Managing

Director and Country Representative,

LANXESS India, added, “Despite the

volatility in economic scenario and

fluctuations in exchange rates, LANXESS

has shown positive growth in terms of

sales in the Indian subcontinent. This

also implies that we are optimistic about

the Indian market in the long term, and

consider these uncertainties only a blip in

the potential growth.”

Globally, LANXESS is planning

capital expenditures of around Euro 650-

700 million for the current year. R&D

expenditures are expected to grow by about

10 per cent in 2013 from Euro 192 million

in the previous year. “The year 2012 was

the best year in our growth story so far.

Our business model proved itself once

again,” said Axel C Heitmann, Chairman

of the Board of Management, LANXESS.

Business development was driven notably

by the focus on emerging markets, solid

demand for agrochemicals, pleasing

contributions from acquisitions and the

price-before-volume strategy.

FINANCIAL REPORT

LANXESS India registers healthy growth in 2012

DIVESTMENT

Clariant India divests three divisions The Board of Directors of Clariant Chemicals India Ltd approved the proposal to

divest the business of textile chemicals, paper specialties and the emulsion products,

for a consideration of ` 209.15 crore. The divestment of the above businesses includes

a textile chemical plant situated at Roha. The Roha site has multi-business, multi-

product production facilities and the textile chemical plant occupies a minor proportion

in the overall site. “We are excited to continue crystallising our businesses and are

putting a strong emphasis on advancing our stakeholders’ interests,” said R A Shah,

Chairman - Board of Directors, Clariant Chemicals India Ltd.

“Repositioning the company’s portfolio is an essential part of Clariant’s 2015

profitable growth strategy. This move has been designed to focus on our key businesses

to ensure that Clariant in India provides maximum value to all our stakeholders,” added

Dr Deepak Parikh, Managing Director, Clariant Chemicals India Ltd.



MARKET FORECAST

Agrochemical research is on the rise, says a reportNew analysis from Frost & Sullivan,

‘Advances in Agrochemicals’, finds

that researchers have made significant

progress in producing broad-spectrum,

multi-purpose agrochemicals that

eliminate the need to apply different

chemicals for various purposes,

thereby reducing the exposure of crops

to chemicals. Also, seed treatment

technology, which involves coating

seeds with certain agrochemicals in

which the resulting seedlings and

plants acquire favourable properties,

is rapidly gaining popularity. “To

avoid the use of organohalides and

similar conventional agrochemicals

that harm the environment, ongoing

agrochemical research focuses on the

development of eco-friendly pesticides

and insecticides,” said a Frost &

Sullivan analyst.

The excessive use of conventional

agrochemicals over a long period

has led to the emergence of resistant

strains in moths, fruit flies and rats.

As such, this has created an urgent

demand for robust compounds capable

of fighting these strains. In addition,

biocompatible agrochemicals that

prevent the accumulation of harmful

chemicals in the food chain have

become a necessity.

R Mukundan, Managing Director,

Tata Chemicals, has been elected as

the Chairman of the Confederation

of Indian Industry (CII)

Western Region for

2013-14. He joined Tata

Administrative Service

(TAS) in 1990, after

completing his MBA from

FMS, Delhi University. He

is an Engineer from IIT,

Roorkee and an alumnus of

Harvard Business School.

During his 23-year career

with Tata Group, he has

held various responsibilities including

strategy & business development,

operations, corporate quality, corporate

planning, projects, etc across the

chemical, automotive and hospitality

sectors of the Tata Group. He has been

on the executive committees of various

industry forums including

Indian Chemical Council,

Automotive Component

Manufacturers Association,

Alkali Manufacturers’

Association of India, the

Council of EU Chambers

of Commerce in India. He

was Deputy Chairman of

CII Western Region

Council . Meanwhile,

Chetan M Tamboli,

Chairman and Managing Director,

Steelcast Ltd, has been elected as the

Deputy Chairman of the CII Western

Region for 2013-14.

National Chlorine Industries (NCI)

has awarded a contract to Uhde India

for expanding its caustic soda-chlorine

plant at its chemical facilities in Amman,

Jordan. The project, which is located

40 km south east of Amman city at

Al-Mowaqqer area, close to Sahab

Industrial Estate, proposes raising the

capacity of the electrolysers A & B from

20 tonne per day (tpd) to 54 tpd, with

the possibility of enhancing the capacity

to 100 tpd in future.

The expansion will be done by

replacing the generation II membrane

cell elements with the new generation V

membrane cell elements.

The scope of work includes basic

and detailed engineering services,

supply of cell elements and supervision

services during cell assembly, erection,

start-up and commissioning of the

plant. The project has a mechanical

completion date of 20 months from

the effective date of the contract. The

enhanced output from the current

project is intended for export, with

a small proportion intended to be

deployed for chlorinated paraffin wax.

Uhde India, who is among the

preferred single-stop partner for

membrane cell caustic soda plants,

offers ‘under one roof ’ solutions to the

caustic soda-chlorine industry globally.

Its association with NCI dates back to

the early nineties when the grassroots

plant was set up for the customer. NCI,

Jordan, is a publicly held company

formed in the early nineties and

engaged in the manufacture of caustic

soda, chlorine gas, hydrochloric acid,

sodium hypochlorite, hydrogen gas and

chlorinated paraffin.

APPOINTMENT

R Mukundan is the new Chairman of CII Western Region

EPC CONTRACT

Uhde India awarded contract for caustic soda plant in Jordan

PETROCHEMICALS

HPCL and Rajasthan sign MoU for refineryHindustan Petroleum Corp Ltd (HPCL) and Rajasthan Government have signed

a memorandum of understanding (MoU) envisioning a refinery and petrochemical

complex at Barmer, near oil fields producing and under development by Cairn India

Ltd. The project would be developed by state-owned HPCL, Rajasthan State Refinery

Ltd, and other equity partners. The Indian Ministry of Petroleum and Natural Gas

estimated the project cost at $ 6.85 billion and construction time at 4 years. It said the

complex would use crude oil produced locally and from elsewhere. The complex would

represent Rajasthan’s first refinery and India’s first petrochemical plant designed to

process indigenous crude oil.

Cairn India, in partnership with state-owned Oil & Natural Gas Corp, is producing

about 1,75,000 barrels per day (bpd) of waxy crude oil from a block near Barmer –

1,50,000 bpd from Mangala field and 20,000-25,000 bpd from Bhagyam field.

R Mukundan



WATER TREATMENT

Dow partners with Ahlstrom for drinking water solutionsDow Water & Process Solutions

(DW&PS), a business unit of The

Dow Chemical Company, has entered

into a collaboration agreement with

Ahlstrom, a global high-performance

fibre-based materials company, to use

Ahlstrom Disruptor technology for

drinking water applications. “This

technology can be applied to a number

of drinking water applications including

under-the-sink purification, post-

filtration for reverse osmosis, a counter

top or pitcher unit or a unit internal

to a refrigerator,” said Snehal Desai,

Global Business Director, DW&PS.

The agreement combines DW&PS

industry-leading market, R&D,

and manufacturing expertise with

Ahlstrom’s innovative non-woven fibre

technology to address an unmet need

in drinking water applications. “We

see a wealth of opportunities in our

collaboration with Dow for providing

pure water solutions through combining

our expertise with Dow’s industry-

leading product portfolio”, said Fulvio

Capussotti, Executive Vice President,

Advanced Filtration, Ahlstrom.

DW&PS will incorporate

Ahlstrom’s high-performance, break-

through filter medium into a new

set of drinking water purification

products that offer excellent pathogen

rejection while operating at high flow

and low pressure.

Cognex Corporation, the world’s leading

supplier of industrial ID systems, has

added two new models to the DataMan

50 (DM50) series of compact barcode

readers and a new DataMan 60 (DM60)

series with three models

that offer ethernet

connectivity. “Cognex

introduced the new series

of low-cost barcode

readers, DM50 & DM60

series, with an aim to

help improvise on the

performance of the readers

and target applications

typically handled by

single-line or raster laser

scanners. Cognex low-cost

barcode reader DM50 is

designed for those existing customers who

are not satisfied with the laser and RFID

bar code readers,” said Didier Lacroix,

Senior Vice President, International Sales

& Marketing, Cognex.

He added, “The laser & RFID

barcode readers can only capture single

scan line at a time, which means that their

ability of reading is limited, especially

while reading poorly printed or damaged

barcodes. However,

the Cognex DM50 is

structured to read where

continuous reading is a

major issue. The reader

can also achieve 99 per

cent of high read rates.”

In the chemical

industry, there exist

different sizes of packets

where labels are of

different sizes with

different size of bar codes.

“In such cases, laser &

RFID readers fail to achieve high read

rates, while Cognex low-cost barcode

readers DM50 and DM60 achieves it

efficiently,” claimed Lacroix.

Prasenjit Chakraborty

PRODUCT EXPANSION

Cognex expands its barcode readers range

NEW APPLICATION

Dow Corning launches silicone technologies for construction marketDow Corning, a global leader in silicones, silicon-based technology and innovation,

has launched a range of silicone-based technologies and solutions for the rapidly

growing Indian construction market. The newly launched solutions include sealants

for panel bonding, as well as fire-rated joint sealants and acrylic sealants designed

for internal perimeter of fire-rated doors & windows. Dow Corning introduced a

premium performance weatherproofing sealant, specifically designed for general glazing

and weather-sealing of curtain wall and building facades. One of the innovative

introductions is a Transparent Silicone Structural Adhesive (TSSA) - a new technology

that eliminates the need to drill holes in glass for bolt fixation in spider fitted hardware

in point fixed glazing systems. Another innovation is a high design strength system,

which can be used in high wind load environments.

GE displayed its advanced technologies,

products and services for water and

wastewater treatment at the recently

held Aquatech India in Greater Noida.

“India remains a water-stressed country,

and demand continues to outpace

supply, making water reuse imperative.

Our expanding installed base of more

than 70 projects in India demonstrates

our strong commitment to India. Local

engineering, project management and local

manufacturing help GE deliver the most

effective solutions to its Indian customers,”

said Hoshang Subawalla, Business Leader,

India - Water and Process Technologies,

GE Power & Water.

GE is a global leader in wastewater

reuse and has the broadest chemical and

equipment portfolio to address tough-to-

treat water and wastewater needs. GE’s

expertise on reusing sewage for industrial

and non-potable use is helping secure India’s

water resources. GE’s portfolio of advanced

technologies - membrane filtration systems,

next-generation membrane bioreactors,

zero liquid discharge systems and water/

wastewater/process chemicals - are

combined with leadership in process design

and engineering to address wide-ranging

customer problems.

EXHIBITION

GE showcases latest water treatment solutions at Aquatech



DISTRIBU TION STRATEGY

DKSH and Synthomer sign partnership deal in AsiaDKSH Business Unit Performance

Materials, a leading specialty chemicals

distributor and provider of market

expansion services for performance

materials, and Synthomer, one of the

world’s leading suppliers of emulsion

polymers for coatings, construction

chemicals, adhesives and technical

textiles, have entered into a regional

distribution partnership covering India,

the Philippines, Cambodia, Laos,

Vietnam, Myanmar and Thailand. The

partnership will cover Synthomer’s

business in the Construction & Coatings

and Functional Polymers businesses.

DKSH’s Performance Materials

Business Unit will distribute and

market Synthomer’s full range of

emulsion polymers in Asia for the

market segments coatings (excluding

Vietnam), construction, adhesives

(excluding Vietnam) and textiles

(excluding India). Synthomer offers a

particularly broad range of binders based

around acrylics, styrene-butadiene and

vinyl acetate chemistries for a wide

array of applications including weather-

resistant wood coatings, low-emission

interior wall paints, elastic coatings,

crack-bridging facade paints for cool

roofing applications and plaster, as well

as binders for PSA tapes, labels and

technical textiles.

Mike Turner, the newly appointed Director

- Agriculture Business of Vertellus

Specialties, is expected to give push to

the company’s agriculture business activity

in Asia. “Turner will spend a significant

amount of time in Asia servicing out

existing customer base and developing new

opportunities to further

grow and diversify our

business within the

agro-chemical markets.

He has more than 6

years of experience

managing and growing business in this

region,” said Bentley Park, President

- Agriculture and Nutrition Business,

Vertellus Specialties.

Turner will be responsible for

establishing the strategic direction

for the segment as well as its overall

business profitability globally at Vertellus

Specialties Inc, the world’s largest

producer of pyridine, picolines and

pyridine derivatives. Prior to joining

Vertellus, Turner was the Vice President

and General Manager for Universal

Fibers Asia. Located in Taicang, China,

he successfully established and grew

the business over the past several years.

Before this, Turner spent his career at

Honeywell International for more than

20 years, holding various positions within

technology, quality and operations. Most

notably, he managed a chemical additives

business located in

Eupen, Belgium, for

several years.

Park added,

“ A g r o c h e m i c a l s

business has been

growing globally at a rate of 3-4 per cent

and more specifically pyridine demand is

increasing 7-10 per cent annually driven by

high crop prices. Vertellus has benefitted

from satisfying this global demand for its

products and its ability to diversify and

enhance its product portfolio.”

With respect to Vertellus’ plans for

India, he said, “Vertellus offers its full

line of agricultural products in the Indian

market. Our growth within this market

will depend on the local demand and

growth rates.”

Rakesh Rao

NEW SELECTION

Appointment of Mike Turner to boost Vertellus growth plans in Asia

NEW PLANT

Micro Polypet offers PET plant contract to Uhde Inventa-Fischer Micro Polypet Pvt Ltd, an Indian joint venture comprising the chemical companies

RLG Group and Action Petrochem Pvt Ltd, has awarded Uhde Inventa-Fischer

a contract to build a plant for the production of high-quality PET for bottling

and packaging applications. The plant, which will be located in Panipat, will have a

production capacity of 2,16,000 tonne per annum (tpa). The feedstock, terephthalic

acid (TPA), will be supplied by IOCL following production at an adjacent plant.

Sumitomo Chemical has newly established

Sumitomo Chemical (Asia-Pacific) Pte

Ltd in Singapore as its Business Support

Regional Headquarters for the Southeast

Asia, India and Oceania region. The

new company has begun operation on

April 1, 2013. Sumitomo Chemical has

actively expanded its business activities in

the region over the years, most notably

through the petrochemical complex project

in Singapore that began commercial

operation in 1984 with Sumitomo

Chemical playing a core role while working

with other major international companies.

At present, 22 companies of Sumitomo

Chemical Group are operating in eight

countries in this region, and the region

is positioned as an important stronghold

for Sumitomo Chemical in advancing its

global business management.

This region, which includes Southeast

Asia with a population of over 600 million

and a gross domestic product (GDP) of

about $ 2 trillion, is expected to grow

further in the future, driven by continued

developments of various economic

initiatives and cooperation among

countries and areas in and outside the

region. Given the prospects, Sumitomo

Chemical has decided to establish

Regional Headquarters anew in Singapore

that will support the company’s business

development in this high-growth region

by securely capturing emerging business

opportunities and accelerating exploitation

of new business undertakings.

BUSINESS RESTRUCTURING

Sumitomo sets up regional headquarters for Southeast Asia, India and Oceania Region



BIOREACTOR TECHNOLOGY

Applikon acquires HaloteC’s biotech portfolioThe Netherlands-based Applikon

Biotechnology BV, a global leader

in bioreactor systems, has signed a

definitive agreement to acquire the

biotechnology portfolio of HaloteC

Instruments BV, a Dutch provider of

instruments and software solutions for

the biotech market. Arthur Oudshoorn,

CEO, Applikon Biotechnology,

commented, “We believe that the

acquisition of the biotech portfolio of

HaloteC Instruments will accelerate

our development of bioreactor software

solutions, allowing our customers

to greatly improve the efficiency

and performance of their R&D

departments. The instrumentation

for the food and biofuel industry

that HaloteC has developed extends

the products offering Applikon

Biotechnology for these industries.”

He added, “Companies are looking

for software solutions to allow parallel

processing of bioreactor systems and to

process the large amount of data generated

by these processes. The advanced

software solutions that HaloteC has

developed for these types of applications

allow the researcher to compare large

data sets and easily see relations between

various parameters. The software

and instrumentation excel in ease of

operation and robust design, and will

contribute to the increasing marketshare

of Applikon Biotechnology.”

As part of a strategy to strengthen its

product portfolio for biocides to serve

the megatrend urbanisation, LANXESS

has acquired Singapore-based PCTS

Specialty Chemicals Pte Ltd for an

undisclosed amount. Through the

acquisition, LANXESS is now one of the

leading suppliers of biocides for paints

and coatings in the rapidly-growing

Asia-Pacific region. LANXESS will gain

access to a complementary portfolio of

biocides and will benefit from PCTS’

highly-recognised product expertise

and know-how in paints and coatings.

“This transaction underlines LANXESS’

standing as a key supplier of high-tech

solutions for the megatrend urbanisation.

It also strengthens our company’s asset

base in the booming Asian market,” said

Rainier van Roessel, Member, LANXESS

Board of Management.

PCTS, owned by NIPSEA

Technologies Pte Ltd, specialises in

biocides for environment-friendly water-

based paints that meet stringent health

and safety, as well as environmental

standards. Biocides prevent the

deterioration and discolouring of the

paints caused by micro-organisms. PCTS

will be integrated into the LANXESS

business unit Material Protection Products

(MPP), which belongs to the company’s

performance chemicals segment. The

PCTS facility will also become the new

Asia-Pacific headquarters of MPP.

BUSINESS STRATEGY

LANXESS acquires Asian biocide specialist PCTS

BUSINESS REORGANISATION

BASF combines businesses for water, oilfield and mining solutions BASF has combined its global businesses of water solutions and oilfield & mining

solutions, effective April 2013, to increase efficiency and support its growth strategies.

The new global business unit will be located in Ludwigshafen, Germany. “By combining

the strengths of these businesses, sharpening our focussed market approach and, at the

same time, increasing operational and innovation excellence, we are in a good position

to advance innovative solutions to the water, oilfield and mining industries,” said Hans

W Reiners, President - Performance Chemicals, BASF.

BASF offers a wide range of products for key processes of industrial and municipal

water treatment, products for the drilling and completion of oil wells and mineral

processing reagents for the mining industry. All three businesses include parts of the

polyacrylamide (PAM) value chain.

Toyo Engineering Corporation has

been jointly awarded with ENPPI, an

engineering company under the Egyptian

Ministry of Petroleum, a contract to

build a 4,00,000 tonne per annum (tpa)

polyethylene plant as part of Ethydco’s

petrochemical complex to be established

in Alexandria, the Arab Republic of Egypt,

and owned by The Egyptian Ethylene and

Derivatives Company (ETHYDCO). This

will be the largest polyethylene plant in

Egypt. Toyo and ENPPI, based on the

most advanced polyethylene technology of

Univation Technologies of US, will execute

the EPC and commissioning under a

lump-sum turnkey contract.

Toyo will lead the entire project

execution, undertaking project management,

basic engineering, and procurement of

key equipment. ENPPI will be in charge

of joint project management, a part of

basic engineering, detailed engineering

and procurement of other equipment and

materials. Both companies will execute

the construction and commissioning

in collaboration with PETROJET, an

Egyptian construction company as a

subcontractor. The contract amount is

approximately $ 400 million, and the plant

is scheduled for start-up in early 2015.

EPC CONTRACT

Toyo awarded polyethylene plant contract in Egypt

L-R: Dr Torsten Derr, Global Head of Material Protection Products business unit, LANXESS,

and Shae Toh Hock, Senior VP - Corporate Planning & Development, Nipsea Group



PERFORMANCE MATERIALS

Momentive expands Korean technology centreMomentive Performance Materials Inc

(MPM), a global leader in silicones

and advanced materials, has announced

expansion of its current technology

centre in Seoul, Korea, creating a

global innovation centre focussed on

the electronics industry. The expanded

innovation centre will combine

existing technical labs with application

development, research and development

(R&D), testing and manufacturing

operations.The expanded Korea

Technology Centre (KTC) will be

devoted to developing materials and

solutions for display, light-emitting

diode (LED) and organic light-

emitting diode (OLED) applications.

The centre will strengthen MPM’s

existing presence in the region and is

expected to be complete in June 2013.

Based in the Gasan Digital Complex,

the centre will be over 1,500 sq m.

Jiangsu Sailboat Petrochemical Co Ltd

( JSPCL) has selected LyondellBasell’s

Lupotech T and Lupotech A process

technologies for a new plant scheduled to

be built in Lianyungang, China. JSPCL,

part of the Jiangsu Shenghong Group, said

that the plant will have a total capacity

of 300 kilo tonne (KT) per year for the

production of low density polyethylene

(LDPE) and ethyl vinyl acetate (EVA).

LDPE and EVA polymers are in

high demand driven by an increasing

need for consumer items ranging from

shoes to specialty films. Zheng Guo

Dong, General Manager, JSPCL,

commented, “We selected LyondellBasell’s

Lupotech platform based on the leading

manufacturing cost performance and the

capability to produce high-quality LDPE

and high EVA content LDPE.”

Key features of the Lupotech T tubular

technology and the Lupotech A autoclave

technology include low manufacturing

and investment costs, fast start-up and

grade changes, and high-quality LDPE

and copolymers with up to 40 per cent

EVA covering the entire range of melt

flows and densities. Proven single-line

capacities of up to 450 KT per year are

available with Lupotech T.

LyondellBasell is a leading licensor

of polypropylene and polyethylene

technologies. The more than 250

polyolefin process licenses granted by

LyondellBasell are twice that of any other

polyolefin technology licensor.

TECHNOLOGY TRANSFER

LyondellBasell licenses technologies for LDPE and EVA to Jiangsu Shenghong Asia

CHEMICAL DISTRIBUTION

Brenntag teams up with Bayer for sulfuric acid supplyBrenntag Schweizerhall AG, the Swiss subsidiary of the world market leader in

chemicals distribution, has announced a co-operation with Bayer CropScience and

Infrapark Baselland. Brenntag will invest in a new location with a sulfuric acid dilution

plant and relocate to the Infrapark industrial park. This plant and a newly installed

pipeline to Bayer CropScience, also with a location at Infrapark, will allow Brenntag to

supply diluted sulfuric acid to Bayer just in time.

“This system creates synergies for all participating companies. Bayer focusses

on its core area of expertise and we pool our outputs, while Infrapark Baselland

gains a new tenant,” remarked Wolfram Heymann, Managing Director, Brenntag

Schweizerhall AG.

Renaud Spitz, Head, Infrapark Baselland, added, “This settlement is a good example

of how our chemical industrial park supports the principal of networking. Synergies can

be used, and in this case, logistics costs decreased. Furthermore, the know-how and

experience of our employees can be cross-linked.”

MERGERS & ACQUISITIONS

Johnson Matthey completes Formox acquisitionJohnson Matthey recently completed the

purchase of Formox AB (Formox) for

SEK 1.05 billion (£ 107 million) in cash

from Perstorp Specialty Chemicals AB, a

company owned by PAI Partners.

Formox is a leading global provider

of catalysts, plant designs and licences

for the manufacture of formaldehyde,

an important chemical intermediate. It

has developed a market leading range

of novel metal oxide-based catalysts for

the production of formaldehyde from

methanol and is the leading provider of

process technology for metal oxide-based

formaldehyde production plants. Formox’s

technologies complement Johnson

Matthey’s existing strengths in process

catalysts and in plant design and licensing.

The acquisition enhances Johnson

Matthey’s position as a leading supplier of

technology for a range of syngas and other

chemical processes.

China has extended anti-dumping

measures on nonylphenol (NP)

imported from India and Taiwan for

another five years recently. NP, which

is used as a chemical intermediate,

is often a precursor to commercially

important detergents and is widely

used in the production of surfactant

and paint.

The Ministry of Commerce (MOC)

slapped five-year anti-dumping

duties ranging from 4.08 per cent to

20.38 per cent on NP imports from

India and Taiwan on March 28, 2007,

after finding that the imports had

hurt the interests of domestic

producers. At the request of domestic

producers, the Ministry launched

a review last year to evaluate the

possibility of dumping and damages

if the measures expired. The recent

announcement by MOC said it found

the damage is likely to recur if the

measures are lifted.

ANTI-DUMPING MEASURES

China extends anti-dumping duties on nonylphenol imports from India

TECHNOLOGY & INNOVATION


Honeywell announced the launch of

OneWireless Network Release 210, which

incorporates several new features that

make wireless technology easier to

deploy and operate, and result in lower

deployment and operational costs. New

features in Release 210 include over-

the-air field device provisioning and

a Gateway General Client Interface

(GCI) made possible by the ISA100

standard; and native integration

of OneWireless field networks into

Honeywell’s Experion® Process Knowledge

System (PKS). “Wireless technology is

transforming the industrial landscape

and we are trying to make it even easier

for end-users to deploy and use,” said Ray

Rogowski, Director, Global Marketing -

Wireless, Honeywell Process Solutions.

He added, “With OneWireless

Release 210, users can benefit from the

flexibility and scalability offered by the

ISA100 standard while maintaining

high performance and reliability.” With

the over-the-air provisioning feature,

field devices can now be configured

and commissioned without having to

invest in handheld devices or needing

to perform provisioning locally at the

device. The result is faster and less costly

deployment and improved worker safety.

The GCI feature, enabled by the

ISA100 standard, allows operations to

continue using legacy protocols and

proprietary applications while making

it easier to wirelessly expand those

applications throughout the plant.

The GCI also allows third party

client applications to communicate

natively using proprietary or common

field protocols with wireless field

instruments over the ISA100 network.

Enabling operations to continue using

existing applications or protocols

eliminates the need to reinvest in

additional equipment and new client

applications, re-train maintenance and

operations personnel.

Honeywell launches cost-effective wireless technology

Siemens launched new generation

controllers SIMATIC S7-1500. The

products are suitable for medium to

high-end machine and plant automation.

The new generation of controllers is

characterised by high performance &

efficiency and offers numerous benefits

such as integrated motion control, plant

security, and safety applications that are

easy to implement. Greater efficiency

is represented by the innovative design

that enables simple commissioning &

safe operation, by the configurable diagnostic functions that provide the plant

status and by the integration into the Totally Integrated Automation (TIA) Portal

for simple engineering and low project costs.

With regard to overall performance, the technology, security, safety and system

performance has been considerably improved. In order to increase efficiency, further

developments have been made specifically in the areas of design and handling,

system diagnosis and engineering with the TIA Portal. Commenting on the new

product, Bhaskar Mandal, Executive Vice-President, Industry Sector, South Asia,

Siemens Ltd, said, “Being in the Indian market for decades, Siemens has a thorough

understanding of the industry needs. It has continuously designed products &

solutions that help clients maximise productivity and increase efficiency. The new

SIMATIC S7-1500 controller sets new standards for maximised productivity. This

benefits small-series machines as well as complex installations that place high

demands on speed and deterministic communication. The SIMATIC S7-1500

is seamlessly integrated in the TIA Portal for maximum engineering efficiency.”

The Siemens Industry Sector’s Industry Automation division also announced

the enhancement of its TIA Portal engineering framework with numerous new

functions. Version 12 enables all Siemens drives of the Sinamics G converter series

to be parameterised via the TIA Portal, and additional diagnostic functions have

also been integrated. Among other things, the safety functionalities have been

extended for SIMATIC S7-1500 and the Profinet communication performance

has been expanded.

Mokon’s Iceman LT Series line of portable chillers is now available in air-cooled

and water-cooled models with up to 12 tonne nominal chilling capacities and

operating temperatures from -20 to +20°F (-29 to -7°C). They feature non-ferrous

components and a semi-hermetic discus compressor, providing superior energy

efficiency, robust operation and easy maintenance. Cylinder unloading, hot gas

bypass used for capacity control, increasing the longevity of the compressor, are

provided along with a microprocessor-based controller for extreme accuracy. The

Iceman LT chillers utilise R-507 refrigerant which provides customers with an

environment-friendly option to CFCs and HCFCs. Mokon’s low temperature

chillers are ideal for jacketed vessels, reactors, laboratory, sanitary and other

industrial applications.

Siemens SIMATIC S7-1500 enhances productivity

Mokon’s portable chillers provide superior energy efficiency

TECHNOLOGY & INNOVATION


Dow Water & Process Solutions

(DW&PS), a business unit of Dow

Chemical Company, launched Dow

FILMTEC Reverse Osmosis (RO) 75

and 100 gallon per day (GPD) home

drinking water membranes at the

Water Quality Association (WQA)

Aquatech USA 2013 conference and

exhibition recently. The FILMTEC

RO membranes are Dow’s latest

innovation to facilitate potable water

that tastes & smells better and has

fewer impurities to help bring clean

drinking water to homes in water-

stressed areas.

Dow FILMTEC elements help

remove contaminants that can lead

to health risks, and reduce impurities

such as calcium, magnesium, and iron.

With a stabilised salt rejection rate of

99 per cent at 75 GPD and 98 per cent

at 100 gallons per day, in standard sizes

(1812 configuration), Dow FILMTEC

BW-60-1812-75 and TW30-1812-

100HR home drinking water elements

offer premium water – faster. The new

75 GPD membrane uses new Dow

membrane chemistries, which have

been customised to maximise element

performance. The 75 and 100 GPD

elements offer a balance of flow and

high rejection, producing more water

with 20 per cent higher flow rates at

standard test conditions.

“Dow FILMTEC residential

elements are reliable, consistent and

high quality. Dow is committed

to helping OEMs and brand

owners meet the rising consumer

demand for better in-home water

treatment systems, and facilitate

cleaner, safer, better tasting water

to homes in water-stressed areas,”

said Chrys Fernandes, Manager,

Strategic Marketing, Residential and

Commercial, DW&PS.

Dow’s new FILMTEC RO helps remove contaminants and impurities in household water systems

Atlas Copco has come out with three ranges of nitrogen

and oxygen generators for on-site gas generation. With

these innovative gas generators, companies can expand

their existing compressed air installation to generate their

own nitrogen and oxygen. An independent supply of

on-site gas can realise significant economies of scale as

well as save on operational costs. Atlas Copco’s new

range of on-site gas generators are designed to meet the

highest purity standards and run economically for both

large and small applications. On-site gas generation is

more sustainable and cost-efficient than gas delivered

in cylinders or bulk liquid supply, as it eliminates

the operational and administrative costs of ordering, transporting, storing and

delivering the bottles or bulk liquid into cryogenic tanks. With an independent

supply of nitrogen and oxygen, companies’ gas demand is always met in time, at

the lowest cost.

Koen Lauwers, Vice-President, Marketing, Industrial Air Division, Atlas

Copco, said, “With these ranges of gas generators, our customers will dramatically

increase their productivity. We help them to discover untapped saving potential

through economy of scale, combining their compressed air systems with the

production of nitrogen or oxygen, serving their specific needs.”

Its membrane nitrogen generator (the NGM) is efficient, reliable and ideal for

applications such as fire prevention, tank and pipeline cleaning, and many other oil

& gas, mining and marine applications. The NGM uses membrane air separation

to produce nitrogen. A bundle of polymer fibre acts as a membrane that allows

nitrogen to pass and other gases (oxygen, water vapour and carbon dioxide) to

permeate. Compressed air goes in at the inlet and enriched nitrogen comes out

at the other end of nitrogen generator. Membrane technology generates nitrogen

with an adjustable purity and flows up to 500 m³/h. The OGP oxygen generator

also makes use of PSA technology, with zeolite pellets that act as adsorbent.

Conveying chains require continual lubrication to reduce high levels of friction that

can result in chain wear, high energy consumption and unplanned production stops.

Keeping this in mind, SKF has come out with a complete range of oil or grease

lubrication systems for conveyor chains, with or without air. These customised

systems are controlled and monitored by control units or special software. The

product has many advantages. These enable higher productivity by eliminating the

unplanned production downtime for lubrication tasks. Moreover, these increase

conveyor service life through reduction of chain wear and offer safety to operators.

Due to reduction in friction, energy is saved. The lubrication systems also find

application in the paintshops and drying kilns in the car industry. In most plants,

lubrication is applied manually – a task that requires the chains to continue running

while production is stopped. Downtime is costly, creates environmental problems

related to possible oil leakage, and can risk injury as operators lubricate while the

chain is moving. Inadequate lubrication and irregular lubrication cycles lead to

breaks in the chain or links, resulting in a need for frequent chain replacement.

Atlas Copco’s nitrogen and oxygen generators enable cost savings

SKF’s lubrication helps save energy and offers safety to workers

TECHNOLOGY TRANSFER


As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies.

We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.

TECHNOLOGY OFFERED

Activated carbon An Iranian firm is willing to offer

activated carbon from coconut shells.

Areas of application

Food processing, pharmaceuticals, etc

Forms of transfer

Technology licensing

Ethanol An Iranian company is offering ethanol

from molasses using the fermentation

of sacharomyces cerevisiae. Ethyl

alcohol is widely used for making many

organic chemicals.


Chemical and energy industries

Forms of transfer


Furfuryl alcohol technology An Indian firm offers technology

for producing furfuryl alcohol from

furfural by liquid hydrogenation as

well as vapour hydrogenation, with a

capacity of 6,000 tpa to 24,000 tpa.


Furan polymers, sealants & cements,

urea-formaldehyde, and phenolic resins

& foundry cores

Forms of transfer

Consultancy, technical services,

technology licensing

Precipitated calcium carbonate An Indian consulting company for the

chemicals, minerals & food processing

industries is offering precipitated

calcium carbonate and turnkey

projects for the same.


Plastics, paper, paints, rubber, inks

Forms of transfer

Consultancy, technical services

Phosphate estersAn Indian firm is offering technology

for manufacturing phosphate esters

like tributyl phosphate.


Specialty chemicals

Forms of transfer

Joint venture

Sodium hydrosulfite An Iranian company is willing to

manufacture sodium hydrosulfite using

chemical compounds. It is widely used

as a stripping agent in dyes and chemical

industries.


Chemical industry

Forms of transfer


Sodium silicate recovery from rice husk ashAn Indian firm is offering technology

to recover sodium silicate from rice

husk ash. The technology claims to

offer better ROI than other processing

methods.


Chemical industry

Forms of transfer

Consultancy, technical services,

turnkey, etc

Sodium sulfide An Iranian firm is willing to offer sodium

sulfide, which is used mainly in textile

industry, paper mill, artificial silk and

curriery.


Leather industry, textiles, curriery

industries, paper mills, etc

Forms of transfer

Turnkey

Synthesis routes for organic chemicals An Indian firm is offering consultancy

in design of synthesis routes for organic

chemicals.


Pharma industry, specialty chemicals,

plant protection chemicals, etc

Forms of transfer

Consultancy

Transformer oil unit An Indian company is willing to offer

consultancy for making a transformer

oil unit with domestic coal from

its waste.


Transformers

Forms of transfer

Consultancy, technical services

Zinc phosphatiser/rust converter (Ferphos)An Indian firm offers technology

to produce Ferphos – a unique

chemical formulation that acts as a

zinc phosphatiser cum rust converter.

Ferphos is an innovation and

improvement over existing phosphating

products/technologies practised around

the world. Ferphos solution does

not die, ie even after prolonged use,

and does not require daily addition

of chemicals and hence it results in

zero effluence. Ferphos solution also

acts as a rust converter when brushed

on rusted iron products. It is an ideal

substitute for sane/shot blasting.


All iron and steel products including

aluminium, SS, GI products

Forms of transfer


TECHNOLOGY TRANSFER


Share and Solicit TechnologyThe mission of Chemical World is to spread the technology culture. Here is an opportunity to be a part of this endeavour

by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information

about the particular technology offered or requested, its areas of application and forms of transfer. Contact us:

Chemical World, Network18 Media & Investments Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: [email protected]

Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacific Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacific (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi - 110 016, Tel: 011-3097 3758 (Direct), 3097 3710 (Board), Fax: 011-2685 6274, E-mail: [email protected], Web: www.apctt.org, For more information on technology

offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at

least two weeks for receiving a response from a prospective buyer/seeker through this website, before contacting APCTT for further assistance.

Activated carbon and sodium silicateA company from Thailand requires

technology for manufacturing activated

carbon and sodium silicate from rice

husk & rice husk ash.


Manufacturing and construction

industry

Forms of transfer

Others

Glyoxal An Indian company is looking to

switch the production technique for

manufacturing 40 per cent glyoxal from

its existing acetaldehyde-based method

to the MEG-based glyoxal production.


Pharma & textile

Forms of transfer

Others

Inorganic chemicalsAn Indian company is interested in

seeking the technology and process know-

how for production of potassium nitrate,

chromium acetate, and magnesium

hydroxide suspension. The company

already produces inorganic chemicals and

wants to add several other items.


Chemical industry

Forms of transfer

Others

LimeAn Indian company seeks to adopt

new cost-effective technologies, which

can reduce carbon emissions and earn

carbon credits, for manufacturing lime.


Quick lime and hydrated lime

Forms of transfer

Others

Phenolic and phenol formaldehyde resinAn Indian company needs the technical

know-how for producing phenolic and

phenol formaldehyde resins.


Foundry, rubber adhesives, rockwool,

abrasives, plywood, etc

Forms of transfer

Others

Quaternary ammonium chlorideAn Indonesia-based company is

planning to diversify into manufacturing

of quaternary ammonium chloride. It

is seeking technology along with the

supply of critical plant and machinery

for the manufacture of the chemical

3-chloro-2hydroxypropyl trimethyl

ammonium chloride that is produced

from epichhlorohydrin.


Chemical industry

Forms of transfer

Technical know-how, consultancy

Silica gelAn Indian firm is looking for new

technology for manufacturing silica gel

in which the wastewater discharge is

minimum.


For various industries and most

importantly breweries

Forms of transfer

Others

Small-scale environment-friendly chemical technologyAn Indian company is looking out

for an economically viable small-

scale environment-friendly chemical

technology useful in the textile sector as

well as in pharmaceutical sector.


Textile and pharmaceutical industry

Forms of transfer

Others

Solvent dyesAn Indian company has recently installed

a manufacturing capacity of 2,400 mtpa

and is looking to diversify its product range

by including various solvent dyes in its

product portfolio. The company is seeking

process consultancy for this project.


Plastics, petroleum, solvents, etc

Forms of transfer

Others

TECHNOLOGY REQUESTED

IN CONVERSATION WITH Amol S Sheth Amol S Sheth


The demand for The demand for bio-industrial bio-industrial

products is products is likely to get likely to get

strongerstronger

Pho

to: V

ijay

kum

ar S

onej

i

...says Amol S Sheth, Chairman, Anil Bioplus Ltd. In an interaction with Avani Jain, he underlines the fact that the demand for bio-industrial products is likely to get stronger. He also comments on the future trends for this segment and the company’s growth plans.


Amol S Sheth

How is the global demand for bio-chemicals and Active Pharmaceutical Ingredients (APIs)? Demand for bio-industrial products and APIs is strong. However, the market has gone down in the last few years due to recession in the US, European Union, Japan, and slowdown in China and India. However, the growth rate is still in early double digits. Also, it is believed that with recovery seen in the US and slowdown bottoming out in India and China, this figure is likely to go up by around 2-3 per cent by 2014-15.

How has been the shift from family business to a public-listed company?From the 90s, we started professionalising our whole business. That time, we thought that bringing in people into the system is the topmost thing. But gradually, we realised that it is not just that but several processes and systems had to be changed as although professionals were hired, the decisions were taken by the family. So, the need of the hour was to move out of that mould and let professionals do their job.

What prompted the company to invest in greenfield project near Vadodara to manufacture modern range of bio-chemicals?The company has already acquired land for this project and work has begun since November 2012. This project will enhance the capacities of the existing product line of Anil Bioplus and augment its products range with the addition of new enzymes and varieties of gluconates. By using the most sophisticated fermentation facilities with downstream processing, the company will be engaged in the production of APIs, specialty enzymes for pharmaceutical and other industries.

What are the challenges faced by the company in establishing this project?The challenges are similar to that of setting up any greenfield unit, ie the

time-bound implementation of the project. But the company is confident that it will be able to complete the project in time.

What are the recent R&D initiatives undertaken by the company?We are focussing on isolation of industrial strains to manufacture various bio-products including enzymes. Thus, we will be the first in India to manufacture some of the products at a cost-effective rate. For such products, we are at the advanced stage of development and trials are already in progress in the pilot plants. The initial results are encouraging. We have also developed four types of gluconates apart from calcium gluconate to cater to growing domestic as well as global needs. We are evaluating two new projects to convert process waste into a high value-added product, which has a good overseas market.

What would be the future trends?The demand for bio-industrial products is likely to get stronger. The reason for this growth is the fact that major contribution to bio-industrial products comes from the exports, which are likely to revive from FY13-14 due to recovery in developed markets and subsequent revival in their demand. The environmental norms and the massive environment-consciousness have also seen companies switch to bio-industrial products from conventional chemical ones.

What are the company’s growth plans?Environmental norms have actually triggered the shift from conventional chemical products to bio-industrial products. We have already started working in that direction to encash that trend. The company is optimistic about growth of bio-industrial products segment and aims at capitalising on this trend through its experience in related sectors. The current capacity expansion project will help the company touch ` 400 crore turnover on

completion. As and when the company completes this project, it will reassess the market situation and depending on the circumstances then, it may decide to further expand its capacity. The company is also looking for exports of these products to optimise margins and profitability.


Which was your toughest business decision?The toughest phase of my life was the period when we changed to a public-listed company. It was difficult for me to move out of the factory, be in the corporate office, and let the professionals run the factory.

What is it that you ensure before signing a deal?It is important to know whether the two companies are culturally aligned to each other or not, otherwise it would be like a marriage that fails in the long run.

How do you deal with a tough situation?In any difficult situation, it is important to analyse it without hitting the panic button and losing cool. Then you need to bring in the right set of people with whom you can discuss and work out a path. You also need to use your intelligence, and work accordingly as every problem has a solution. I also do the same.

What is the business etiquette you value the most?It is necessary to respect every individual. Right from the sweeper to the top professional, everyone commands respect. This is one thing that people forget and I hate it the most because everyone has an important role to play, which should be valued.

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SPECIAL FOCUS


IT FOR CHEMICAL IT FOR CHEMICAL PROCESS INDUSTRYPROCESS INDUSTRY

VIRTUALIZATION Serving IT optimisation on your fingertips ..............................................................................................26

AUTOMATION VENDORS Upgrading process control system with virtualised offerings ...................................................................28

MACHINE SAFETY From a discrete component to a discreet investment ...............................................................................30

MANUFACTURING EXECUTION SYSTEMSEnhancing production, maximising profitability ......................................................................................32Sunil Chaudhari, Country Manager - South Asia, AspenTech

AUTOMATION IN PLANT MAINTENANCE Securing all links to ensure safety .............................................................................................................34

INTERFACE - Rajesh Rege, Director, Datacenter and Cloud Business, Cisco India and SAARC “Virtualization is widely seen as a precursor for cloud adoption”.............................................................36

ROUNDTABLE Are Indian chemical companies leveraging on latest automation solutions? ...........................................37

SPECIAL FOCUS Virtualization


Rakesh Rao

In their quest to stay ahead of their

competitors, chemical companies

are adopting state-of-the-art

automation solutions to bring in

efficiency. While companies invest time

and money for upgrading their IT and

automation technologies, users may not be

able to take immediate advantage of the

upgraded software, thus resulting in lost

value for the organisation.

In order to address these challenges,

companies are increasingly using

virtualization technologies that allow

secure, one-time configuration and

enterprise-wide deployment in an

encapsulated or ‘virtualised’ environment,

which ensures shorter deployment times

and eliminates delays caused by end-user

software platform conflicts. Virtualization

allows one computer to replace multiple

computers and simplify software upgrades,

thus saving valuable time and allowing

automation users to concentrate on

improving production.

Barry Young, Principal Analyst, ARC

Advisory Group, observes, “Virtualization

reduces the amount of PC and server

hardware, and thus helps reduce hardware

costs. This is accomplished by taking a few

servers that may be only 10-15 per cent

utilised and combining the applications

onto one server that might be more than

50 per cent utilised. Also, the reduced server

hardware and data center footprint saves

energy in the form of electricity and cooling.

Because virtualization decouples hardware

from software, the operating system update

costs are also greatly reduced. A standardised

architecture allows for centralised

administration and maintenance. Users can

recognise these benefits immediately as well

as throughout the product lifecycle, thereby

reducing the Total Cost of Ownership

(TCO). Companies of all sizes can benefit

from virtualization.”

Chemical companies can extract

multiple benefits from virtualization,

which provides an efficient, cost-effective,

and secure solution for increasing

reliability for customers aiming to reduce

operating costs while ensuring the safety

and productivity of their plant.

Hardware refresh optimisationOne of the struggles industrial sites

consistently face is the disconnect

between the fast-paced, obsolescence-

driven world of computer hardware

and operating systems (OS) and that of

process control operations, which plant

managers want to remain static. But in an

industry where technology has to remain

current in order to be supported, plants

are struggling to keep up with the rate

of OS and computer hardware changes.

“Virtualization helps reduce the strain on

industrial facilities by allowing existing

hardware to be maintained for as long as

it is able to provide the minimum levels of

Illu

stra

tion

: Sac

hin

Pan

dit

Companies today look for technologies that can reduce costs, increase productivity, enhance security and fasten recovery process in case of disaster. Virtualization can prove to be panacea for these challenges by simplifying complex IT assets and creating a highly flexible information infrastructure. Against this backdrop, chemical companies are realising the virtues of virtual machines for keeping efficiency and productivity in control.

Serving IT optimisation on your fingertips


Virtualization

performance an application requires of a

virtual machine. By sticking with existing

hardware, plants can reduce the cost of

system upgrades. They can also stay on the

same operating system for a longer period

of time,” states Paul Hodge, Head Product

Marketing - Virtualization, Honeywell

Process Solutions.

Virtualization also minimises the

disruption to plant operations when

hardware changes are required. He adds,

“Thanks to more advanced virtualization

features, a computer’s operating system and

applications do not need to be shut down

during a hardware replacement. Operations

can continue without interruption while

this work is taking place.”

Higher availabilityVirtualization helps applications achieve

higher availability than they would be

able to natively support. This is performed

through the virtualization environment

monitoring the status of the virtual

machines and restarting a virtual machine

on another host if required. “Honeywell’s

new Premium Platform for Virtualization,

which leverages blade server technology,

provides the capability to ride through

a host upset without any impact on

operations,” says Hodge.

Another feature, snapshotting, allows

the current state of a virtual machine to

be captured like a picture. If a problem

is found, the virtual machine can be

instantly rolled back to a previous point

in time. He adds, “Honeywell Backup

Control Center solution enables industrial

facilities to simplify and automate the

key elements of disaster recovery: setting

up disaster recovery plans, testing those

plans, executing failover when a control

center disaster occurs or as the event

requires, and failing back to the primary

control room. This makes it possible to

provide faster, more reliable, and more

affordable disaster recovery protection

than previously possible.”

Facility and utility savingsDeploying virtualization allows multiple

virtual machines, each running their own

OS and application, to be operated at the

same time on a single physical machine.

Hodge elaborates, “Virtualization achieves

this while guaranteeing that a given

virtual machine gets exactly the amount

of resources required to do its job, and

ensuring any issues with one virtual

machine would not impact another. This

type of consolidation reduces the need for

multiple machines and maximises the use

of hardware resources.”

By improving hardware utilisation,

plants are able to cut down on the number

of physical computers they require, which

has a direct correlation with associated

running costs such as space, power,

cooling and maintenance. “Virtualization

also allows plants to undertake expansions

without adding new hardware. That is

because ‘platform virtualization’ is capable

of running many virtual machines on a

single piece of hardware. Machines can

continue to be added as long as there are

sufficient resources available to meet their

operational needs,” he explains.

Simplified system managementVirtualization supports a strategy of ‘build

once, deploy many’. It enables the hardware

configuration, OS and application to be

contained in a single ‘capsule’. Any new

instance of this capsule is exactly the

same, thus reducing configuration errors

and installation time, and ensuring a more

reliable and repeatable result.

Hodge opines, “With virtualization,

plants can undertake expansions or

upgrades without the need to add new

nodes to the control system, and without

having to perform fresh operating system

and application installations. Virtualization

also offers improved diagnostics, allowing

operators to monitor system performance

and access the desktop of any node. Health

and status information can be viewed from

a single, integrated user interface. Plus, it

simplifies remote management by allowing

remote access to the virtualization console.”

Improved console experienceVirtualization allows for the expanded use

of thin client technology within control

rooms. According to Hodge, through the

use of thin client technology, customers can:

Improve security through moving the

physical hardware that is required to

run the operator stations into a central

computer room

Reduce power, noise and heat in the

control room

Reduce Mean Time To Repair

(MTTR) from hours to minutes

Improve performance through the

use of common high performance

hardware for operator stations

India, rising fast In India, the market is heating up for

virtualization starting with business

process applications. The adoption rate

of virtualization in India are expected to

increase manifold as vendors are pitching

hard on several of their offerings as

hardware forms a key constituent in the

virtualization. Hodge sums up, “Usage of

virtualization is increasing in the private

sector in India; however adoption within

the public sector in India is still slow.

Skill shortages in various sectors are

driving some of this adoption along with

the increasing adoption of virtualization

within India’s IT industry.”


Virtualization reduces the amount of PC and server hardware, and thus helps reduce har dware cos ts .

Because virtualization decouples hardware from software, the operating system update costs are reduced.

Barry YoungPrincipal Analyst, ARC Advisory Group

With virtualization, plants can undertake expansions or upgrades without the need to add new nodes to the control system, and

without having to perform fresh operating system and application installations.

Paul HodgeHead Product Marketing - Virtualization, Honeywell Process Solutions

SPECIAL FOCUS Automation vendors


Rakesh Rao

All virtualization is abstraction

that uses software to create

an isolated, functioning

duplicate of a computer

system component. While virtualization

is not new, its application in the process

control systems has gained traction in

last few years, with leading automation

vendors offering virtualization technology.

Barry Young, Principal Analyst, ARC

Advisory Group, says, “Yes, all the major

automation suppliers now incorporate

virtualization to varying degrees within

their process control system architectures.

Initially, suppliers used virtualization in

the operator interface area in the form

of thin client HMIs being served by one

hardware server, rather than a separate

PC for each operator interface. Once

this application was field proven, other

applications were virtualised at the

operations management level. Today,

virtualization is used for engineering,

factory and software acceptance testing,

training, simulation, and advanced

process control. We are also beginning to

see virtualization used to emulate legacy

and proprietary control platforms.”

Expanding virtualised offeringsPractically any system component can

be – and has been – virtualised: disk

drives, servers, operating systems and

networks. Paul Hodge, Head Product

Marketing - Virtualization, Honeywell

Process Solutions, elaborates, “Because

of the many compelling benefits that

virtualization offers, its application

within the industrial control domain

is increasing rapidly. In a recent survey

of our large customers, 50 per cent of

these customers were virtualising their

advanced control networks today, and

the remaining 50 per cent had plans to

do so. Of these same customers, 80 per

cent have plans to virtualise their DCS

networks. In addition to the customer

demand, awareness is being driven by the

fact that most automation vendors now

have virtualization offerings.”

For virtualization to be successful

in the process automation industry,

customers need turnkey solutions.

These include supplying the processing,

networking and storage components along

with guidance and support to deliver a

complete solution from design through

implementation and management. Hence,

automation vendors such as Honeywell

Process Solutions, Emerson Process

Management, Rockwell Automation, etc

are expanding their range of products

with virtualization features.

Virtual portabilityThe application of virtualization in process

control environment is a challenging task

as it involves collaboration from multiple

disciplines. Young elaborates, “The use of

virtualization requires close co-operation

between a chemical company’s operations,

IT, and control engineering departments,

as well as with the automation supplier.

This has required some departments

that traditionally have had competing

agendas to now work together. Also, since

many applications are now virtualised

on ‘one box’, suppliers must address

user concerns over potential hardware

failures. Automation architectures for

high availability, and disaster recovery

and backup are available to address these

concerns.”

Realising these shortcomings,

automation vendors now offer solutions

that can solve challenges of people

training and design process skills.

“Customers face the challenge related to

training of their people, given that this

can be a new technology within their

organisation. For this, Honeywell has

training courses on virtualization that

can help customers learn how to apply

it in an industrial context. Another

challenge is the skills required in the

design process. We believe that building

a virtual environment for process control

is different from the approach that would

be taken in IT. Honeywell has taken its

process control expertise and designed

best practice virtualization reference

designs,” observes Hodge.

Though application of virtualization

in process control system is new

phenomenon, experts believe that in

next few years every aspect of chemical

industry right from plant and process

design to manufacturing operations will

run on virtual machines. Young agrees,

“Eventually, everything will be virtualised

in the process control architecture. The

use of virtualization will begin during

detailed design and then used throughout

the project lifecycle. Essentially,

applications are now ‘virtually’ portable

and hardware independent.”


UPGRADING PROCESS CONTROL SYSTEM WITH VIRTUALISED OFFERINGS

The use of virtualization in a control system is a recent phenomenon. However, chemical companies are showing increasing inclination to use virtual machine as it helps the plant operators to achieve the goal of maximising RoI by improving the utilisation of their control system server assets. In order to tap this trend, automation vendors are now offering a wide range of process control system architectures with virtualization feature.

SPECIAL FOCUS Machine safety



Machine safety is an

important factor

regardless of any

specific industr y.

For chemical industry, it holds more

importance as it handles hazardous

chemicals. Depending on the nature

of the chemical, its reaction with the

electrical sparks, spatters, current etc

should be taken into consideration while

deciding on the machine safety issue.

If the chemical under consideration

is inflammable, highly corrosive – the

vapours of which can cause health

hazards – these factors should also

be looked into seriously. “The

machines processing chemicals

for packing, conveying, etc,

should consider the health

hazard other than the regular

safety hazards. Earlier, there

was resistance from chemical

manufacturers towards adopting

safety concepts in machines. But,

slowly the Indian chemical industry

is realising the importance of machine

safety and its benefits,” says Suresh

Warade, Chairman, Warade Automation

Solutions Pvt Ltd.

Safety first Though initial cost of machines

incorporated with safety aspects may

seem little higher as compared to

traditional machines, payback is quite

fast. Safety is always important whether

it is machine or process safety, especially

for chemical companies that deal with

hazardous materials and expose plant,

people & environment to hazards.

As people work with machines, they

are exposed to personal injuries; and

injuries (which may be fatal in certain

circumstances) can lead to production

downtime; it will also dampen

employees’ morale and reduce the

efficiency of workers. “Machine safety

is important from the point of view

of the manufacturers because it lends

competitive advantage and enhances

public image of the company,” says

Abanibhusan Bera, ISA 84 SFS,

Industry Sales Manager - Oil & Gas,

Rockwell Automation India Pvt Ltd.

According to him, adoption of

machine safety in Indian chemical

industry is different from that in

developed countries. Law enforcement

in developed countries is stringent

because of which they adopt machine

safety to be cost-efficient rather than

bearing the penalty of non-compliance.

“However, in Indian chemical industry,

wherein the law enforcement is not as

stringent and monitored, the adoption

of machine safety (unlike process safety)

is likely to be not so proactive,” opines

Bera. Another reason for non-adoption

of machine safety is that end-users do

not consider the areas under machine

safety as critical to invest as in process

safety. However, nothing remains

constant forever, so is the chemical

industry.

Worldwide trends Globally, machinery directive 2006/42/

EC has been made compulsory. ISO

12100 provides overall framework

and guidance for designers

to enable them to produce

machines that are safe for

their intended use. Minimum

safety category expected is CAT3

globally. “Now, safety categories

are being changed to SIL2, SIL3,

and SIL4 standards. These are now

recognised as global safety standards

for machine safety,” says Warade.

According to Bera, the global trends

in safety are different with respect to

the twin safety domain – machine

safety and process safety. However,

the common characteristics of both

the domains are increased awareness

and adoption against the backdrop

of accidents still happening across

the globe. So far as machine safety

is concerned, emerging countries are

leaning towards adopting machine

safety due to growth in manufacturing

coupled with new safety requirements.

“However, the recent economic

downturn is forcing manufacturers to

prioritise their investment, which can

help reduce operation & maintenance

cost, and can yield immediate return on

investment. Areas of machine safety are

being looked upon as a non-critical area

From a discrete

component to a discreet investment

The concept of machine safety is evolving from being a discrete

component to an integrated system. It has been observed that an integrated system offers many

benefits when it comes to safety. As far as India is concerned, chemical

manufacturers should pay more attention to machine safety.


Machine safety

The recent economic downturn is forcing manufacturers to prioritise their investment, which can help reduce operation

& maintenance cost, and can yield immediate return on investment. Areas of machine safety are being looked upon as a non-critical area due to which the investment is either not made or delayed.

Abanibhusan BeraISA 84 SFS, Industry Sales Manager - Oil & Gas, Rockwell Automation India Pvt Ltd

due to which the investment is either

not made or delayed,” points out Bera.

The trend in developed countries is

somewhat different as those countries

are already having stringent safety

requirements. “The end-customers there

are concerned about people’s injury,

lost production, company reputation

and hence they prefer to use machine

safety devices for preventing injury, lost

production and avoiding government

law suit in case of accidents,” says Bera.

Changing phase of machine safetyLike in any other plant, chemical

plants also have several machineries

that include compressors, heat

exchangers, pumps, reactors etc. In

an increasingly competitive market,

owners are continuously challenged to

run the plant more profitably. “Since

any equipment failure can dramatically

affect throughput, we need to be able

to count on both the reliability and

availability of assets, especially pumps

and compressors. If a compressor or

turbine trips, whether due to excess

vibration, malfunctioning instruments

or surge, it can bring entire operation to

an abrupt halt and cause you to flare or

vent, creating environmental concerns,”

points out Dr A S Prasad, Director

- Solution Group, Emerson Process

Management (India) Pvt Ltd.

With the passing of time, the

concept of machine safety has also

evolved from being a discrete component

to an integrated system. The benefits

of integrated safety perhaps can best

be understood by first setting machine

safeguarding in historical perspective. “A

century ago, machine safety controls did

not exist. Accidents and injuries on the

shop floor were common. In an attempt

to reduce incidents, manufacturers began

to apply basic wiring techniques and

components – such as limit switches,

relays, and pushbuttons – to establish

early machine safety. The slow evolution

that started from relays, configurable

relays, stand-alone safety Programmable

Logic Controller (PLCs) is now in a

mature state with the ICSS that are

more efficient, flexible, and economical,”

opines Dr Prasad.

According to Warade, in earlier

days, machine safety meant having

limit switches for doors, some guards

and that was all about it. “It was

found that such systems were easy

to tamper with and most of the

time found to be completely bypassed.

Then came safety relays where one

has to put little more efforts to bypass

the safety. The process PLC used to

handshake with the safety components

in terms of digital signals. Safety

zones were controlled through locally

mounted safety components making

wiring too complex and cumbersome,”

he says. Now safety is evolved into an

integrated form with the process PLC.

Safety relays can now directly fit into

the integrated architecture of safety

process PLC. “It paved the way for the

quick installation, less wiring efforts

and debugging during maintenance,”

Warade points out.

Email: prasenjit.chakraborty@ network18publishing.com

FIVE PILLARS OF SAFETY

Globally, plant and people safety is given prime importance as it directly affects the

downtime (profitability) of the plant. In this context, the five pillars of safety drive

a strong safety eco-system.

Standards and legislations: These are considered as enablers for consistent

implementation of safety measures and are enforced through regulatory compliance.

Further, the standards, whether being implemented or complied are certified by

organisations such as DAR in Germany, UCAS in UK, BIS CCOE in India and

accrediting agencies such as TUV, Kema, SIRA, CASS etc.

Risk assessment: Every plant has different risk tolerance levels and it is important

to identify them and plan risk measures accordingly. This is also termed as risk

management, wherein probability of hazardous occurrences (low, medium, high) and

its corresponding consequential class (minor, medium and major) is determined. The

aim of risk management is to achieve controlled process of risk assessment, safety

requirement specifications, design implementation and operation of risk reduction

measures.

Integrated solutions: Plant automation systems are integrated with safety

systems (which were earlier standalone) that ensure accurate and quick safety

implementation measures to reduce downtime, plant hazards, and accidents; it also

offers comprehensive diagnostics, for eg line fault detections, F&G incidences.

Personal Protection Environment (PPE): Personal protection for people safety

is extremely important. All the plants have dedicated HSE departments that are

responsible for defining and implementing procedures, training, rules, programmes

and matrices (number of near miss incidences reporting etc). These actions are

converted into goals, objectives that become part of management behaviour and

are cascaded to the bottom level in organisations. Workplace environments are also

given equal importance.

Safety culture: Safety has now become an integral part of every organisational

culture that includes people, process and technology.

SPECIAL FOCUS Manufacturing Execution Systems


Sunil Chaudhari

De l iver ing products

that consistently meet

customer expectations

helps manufacturers

remain competitive and achieve higher

profitability. With a better understanding

on how their operations are performing in

real-time, companies can positively impact

the bottom line with timely, informed

decisions about production performance.

Transforming data into meaningful

business knowledge is vital to optimising

production and maximising commercial

potential. MES provides intelligence for

optimising operations with rapid, accurate

and transparent data in real-time. The first

milestone is MES 1.0, which integrates

the past to achieve more efficient data

management. MES 2.0 is called the era of

work process automation, which improves

production execution. Last but not the

least is MES 3.0, also called technology on

the move, which brings about enhanced

performance management.

MES 1.0: Integrating the pastMES first emerged in the process industries

over 30 years ago when minicomputers

had finally become affordable enough to

be successfully used in these industries.

The earliest applications were primarily

data historians in the large continuous

industries used for ‘historising’ time-

series data for trending and later analysis.

At first, manufacturers, who were

primarily batch-orientated, applied the

same data historians that had gained

acceptance in the continuous industries

to the problems that they were facing.

However, for those manufacturers

the majority of their production is

campaign-orientated with well-defined

start and stop times. While time-series

historians generally did provide some

value in analysing production runs, the

real analysis of production run campaigns

turned out to be a complicated, labour-

intensive process. It meant trying to track

different types of information, potentially

from different systems, which were all

related to the same batch, not just time-

series data, and then literally overlaying

them on top of one another in order to

provide the right context. Since this was

a fairly intense process, engineers rarely

performed this type of analysis, except

maybe when a customer complained

about the quality of a previous batch.

During the era of MES 1.0, other

new technologies, such as scheduling,

also emerged that further enhanced

manufacturing profitability. Scheduling

tools were developed that could provide

a fully integrated environment between

scheduling and plant operations,

supporting collaborative production

management. They were designed to

align with the key industry business

processes, providing manufacturers

with the capabilities to make real-time

decisions and synchronise the plant &

supply chain.

As MES software continued to evolve,

the foundations to greater manufacturing

profitability were being laid. During MES

1.0, an experienced engineer was usually

required to interface with an MES system.

Casual users either were intimidated or

the training requirements were too steep.

However, with the more recent advent

of new technologies, it is now possible

for casual users to take advantage of the

power of an MES system. Some MES

vendors are now providing ‘Google-like’

intelligent search to improve a user’s

ability to find information. Intelligent

search capability within a MES system

operates in a similar fashion as Google.

In short, it selects the best match similar

to the Google functionality.

Another recent innovation was the

increasing use of Business Intelligence

(BI), which changed the way

manufacturers managed their business.

Some years back, engineers manually

downloaded from the historian into

standard tools like Excel where they

could perform any type of analysis they

desired. Then improvements were made,

so that any report produced during this

process could be automatically distributed

throughout the enterprise via Microsoft

SharePoint. With more technological

advances, changes in historian data now

can automatically update spreadsheets,

which then are disseminated automatically

Today, a business needs to be more agile and responsive to fluctuations within the market. Effective performance management involves integrating planning, scheduling, production execution and ability to respond to change immediately. Here we take a look at how investment in Manufacturing Execution Systems (MES) software technology delivers more efficient data management, improved production execution and enhanced operational performance, enabling manufacturers to quickly turn data into profit.


Manufacturing Execution Systems

throughout the enterprise via SharePoint.

The net result of all these changes was

the increased ability to have information

at one’s fingertips without the need for

extensive and detailed training.

MES 2.0: The era of work process automationThroughout the 1990s and into the new

millennium, manufacturers recognised

the importance of automated processes

and workflow to allow for scalability and

meet the increasing needs of the business.

Simply relying on a data historian

alone was not enough. Fundamentally,

they needed the ability to manage all

the different aspects of the production

workflow and order management in a

manufacturing facility. This included

both the design and execution of

standard operating procedures, work

orders and production protocols

supporting procedural and regulatory

compliance. The design aspect would

consist of defining the recipe and

workflow to produce a given product.

On the other hand, the execution

aspect would dispatch the order to

the appropriate operator terminal at

execution time. The system would

need to deliver complete traceability,

an unalterable history, and automatic

generation of audit trails and reports.

In addition, during MES 2.0, vendors

started offering ‘production context’

technology that was more appropriately

aimed at solving problems associated with

production campaigns with a definitive

start/end time. Fundamentally, this

involved using any production marker,

such as a batch number, lot number, or

refinery blend type, and quickly gathering

all the relevant information that describes

a defined production period, regardless

of the data source. Production context

analysis, as it came to be known, allowed

a user to seamlessly overlay all relevant

data (eg historian data, ERP, lab, etc), so

that they can visually determine areas for

improvement or compare/contrast with

similar, previous production periods. The

data that provides contextualisation is all

the process and event data that is necessary

to understand that production period.

This technology allowed users to easily

visually compare and contrast previous,

similar production periods across units,

process cells, areas and even multiple

sites. In essence, the introduction of this

technology allowed batch manufacturers

to overcome the limitations that they had

encountered in MES 1.0.

MES today enables manufacturers to

quickly identify production performance

problems, assess root causes and take

corrective action. Production execution

software introduced during MES 2.0 is

now tightly integrated with data historian

software from MES 1.0 to improve

the manufacturing process, which

automatically reaps positive returns on

investment.

MES 3.0: Technology on the moveNew smart products developed during

the past decade have provided greater

communication and collaboration

functionalities, facilitating quicker decision

making while operating on the move.

Flexibility, ease of use and real-time data

visualisation are significant benefits to

users. This period of greater intelligence in

technology has opened up new possibilities.

The batch industry has a greater need

today to streamline processes to improve

operational performance and intelligently

manage the huge quantities of data that

process plants produce on an hour-by-hour

and minute-by-minute basis.

BI empowers employees to perform

with better flexibility as it helps improve

access to manufacturing data at all

organisational levels to drive quicker

decisions. Event notifications coupled

with mobile analysis tools enable faster

adjustments to minimise the impact of

production issues. This is vital in the

process industries because there are

many operations-based personnel who

are not desk-bound and can benefit from

access to real-time data, trends and alerts

anytime & anywhere.

The prevalence of mobile devices

is transforming the process industries.

Mobile solutions empower decision-

makers to have immediate access to

important data enabling them to make

informed and quick decisions to improve

profitability. Easy, digestible analysis

of plant information even in remote

locations helps industry leaders react to

adverse changes and keep the operation

performing to targets. The ability to

access and analyse real-time plant data

has enormous benefits. In the past, users

needed to be in the control room or in

front of a monitor to track and manage

manufacturing performance. Mobile BI

has proven to be more effective when

users are provided with visualisation

tools (eg charts, graphs, portals, etc).

Pillars of profitabilityOver the past 30 years, MES technology

has dramatically evolved to help

manufacturers survive in today’s highly

competitive markets. Real-time data and

decision support tools provide access to

plant information to allow quick and

timely responses to production issues

that negatively influence efficiency,

quality and regulatory compliance.

MES is essentially the nucleus of the

operation, which links all capabilities

of the business. It is an integrated set

of production activity and support

software designed to harmonise and

optimise the plant.

The bottom line is that effective

production drives operational excellence

enabling better and faster decisions.

Software technology helps the batch

industry achieve consistent performance

across all assets. It also defines the

importance of real-time business

performance management: plan,

execute, monitor and respond to change

immediately across all time horizons.

History has shown that MES has laid the

foundations to help batch manufacturers

across the globe strengthen their

competitiveness and build upon the

pillars of profitability.

Sunil Chaudhari is the

Country Manager - South

Asia at AspenTech. For

details, contact Minakshi Hase

on email: [email protected]

SPECIAL FOCUS Automation in plant maintenance



Before going into the intricate

details of automation

technologies, it is essential to

understand the importance

of safety and maintenance measures at a

chemical plant. The significance of safety

cannot be overemphasised ever, which has

been understood & realised with great

pain and loss 28 years back – Bhopal gas

tragedy at Union Carbide plant in 1984

is still in the memory of the entire world.

It had led to loss of lives of thousands of

innocent people and affected millions. “If

we add up the casualties of all the industrial

accidents of the entire world up-to-date, it

will not outnumber the casualties of the

Bhopal accident. The American Institute

of Chemical Engineers (AIChE) formed

the Centre for Chemical Process Safety

(CCPS) after Bhopal tragedy to take

proactive actions and measures in ensuring

plant safety,” says Abanibhusan Bera, ISA

84 SFS, Industry Sales Manager - Oil &

Gas, Rockwell Automation India Pvt Ltd.

As chemical manufacturers process

hazardous chemicals, it exposes people,

community and environment to danger;

and safety can never be undermined

and compromised in chemical plants.

It will be worth mentioning here that

Bhopal gas tragedy happened while the

plant was shut down for maintenance.

What is important here is that, unlike

today, technology was not so advanced

in those days due to which gas leakages

could not be detected. Hence, safety

and maintenance activities in chemical

plants are not isolated; but any flaw in

maintenance can jeopardise safety as well.

Role of automationHow important is automation for the safety

and maintenance of a chemical plant?

Automation is not a present-day affair in

any chemical plant or for that matter in any

manufacturing plant. Control and safety of

chemical plants are achieved through the

use of automation products and systems,

which nowadays are more IT-centric

and complex. Due to technological

advances, software-based systems have

helped in achieving productivity, and at

the same time, have also increased the

risk of improper operations as well as

maintenance. “The UK-based Health &

Safety Executive (HSE) had analysed 34

industrial accidents and found that all

accidents had been caused due to failure

of automation (mainly failure of control

and safety systems). It also found that all

these accidents could have been avoided,

if all the aspects of plant automation in

terms of specification, design, installation,

operation, maintenance, etc, would have

been flawless,” opines Bera. The picture

depicts the findings of HSE.

Where India stands?As the manufacturing sector in India

is gradually maturing, adoption of new

automation technology is becoming

increasingly important for running

a profitable and safe business or

plant. “This is even more important

today as the Indian manufacturing

sector is seeing significant rise in

labour costs, which means that

productivity must be improved in

order to maintain a competitive cost

Automation plays an important role in ensuring safe environment at a chemical plant. However, it was observed that several industrial accidents had occurred due to malfunctioning of automation system. Today, integrated safety and control system is in demand as it provides myriad benefits.

SECURING ALL LINKS TO ENSURE SAFETY

44%

15%6%15%

20%

Control system incidents

From ‘Out Of Control’ A compilation of incidents involving control and safety systems by the UK HSE

Functional safety standards address all these issues

Specification

Installation & commissioning

Operations & maintenance

Changes after commissioning

Design & implementation


Automation in plant maintenance

position. Indian chemical industry comprises several small

and medium-sized manufacturers who mostly require a

robust, reliable plant automation system to run their plants

safely,” points out Ritwij Kulkarni, Business Unit Head-

Field Products, Honeywell Process Solutions India.

Large chemical companies, however, are coming of age.

There is an increased awareness on how modern plant

automation can help them negotiate the uncertainties of

the market; improve bottom line by employing process

and business excellence initiatives; ensure plant safety by

deploying safer and more secure automation systems. “Safety

has to be the highest priority for all plant managers, be it

safety of the personnel or of assets. We have a wide variety of

offerings to help companies effectively manage both process

and personnel safety,” says Kulkarni.

Keeping safety and maintenance issues in mind,

automation providers have come out with new products

for different arenas. For example, Honeywell offers safety

system that includes assessment and documentation,

emergency services, shutdown optimisation services,

etc. For shutdown optimisation services, its expert review

of event log, including results of previous test findings,

is evaluated against initial testing recommendations.

“For example, our in-depth safety system health checks

enable plants to minimise the risk of equipment failure

and address a wide range of potential operational issues.

And our service staff responds 50 per cent faster than the

typical service organisation to expedite problem resolution.

With on-demand services, getting a safety system expert

to your facility can involve lengthy delays – potentially

impacting in-house productivity or even production by days,”

claims Kulkarni.

Safety trendsIncreasing awareness about safety systems coupled with

the need to improve safety standards and drive operational

excellence is encouraging both the process and discrete

industries to invest in safety systems. “Integration of control

and safety is important. This is an emerging trend in the

safety systems market for process industries. Integration

makes the entire system consistent and single-window

view of the process enhances operational excellence and

safety measures,” opines Arunkumar Janarthanan, Industry

Manager, Industrial Automation and Process Control

Practice, Frost & Sullivan.

Integration of safety and security is also equally important

in today’s context. “Earlier, an independent safety system

controlled all safety aspects related with process areas, whereas

a security system controlled plant access. However, nowadays

there is major concern with regard to cyber security. The

integrated system can simultaneously address process control,

safety and security,” points out Janarthanan.

Email: prasenjit.chakraborty@ network18publishing.com

SPECIAL FOCUS Interface - Rajesh Rege


What type of solutions do you offer in virtualization space? Considering the amount of scalability and

flexibility required, there is an increased

focus on IT spending, and Cisco offers

a huge portfolio of products that help

in increasing efficiency and productivity.

The Cisco Unified Data Center

consists of Unified Computing, Unified

Fabric and Unified Management. Cisco

takes a holistic fabric-based approach

to the data center, linking virtual and

physical resources.

Unified Computing is the innovative

fabric computing infrastructure that

simplifies operations, speeds deployment,

and runs applications faster in bare

metal, virtualised, and cloud computing

environments. Cisco Unified Fabric

provides the foundational connectivity.

By unifying storage, data networking,

and network services, Unified Fabric

delivers architectural flexibility and

consistent networking across physical,

virtual and cloud environments.

Unified Management features end-to-

end management software solutions.

These solutions provide an intelligent,

automated approach to IT management,

offering speed and enterprise-grade

reliability while simplifying deployment

and operation of physical and bare metal,

virtual, and cloud infrastructure.

What are the benefits of virtualization for chemical companies? The chemical industry faces a number

of important business imperatives that

can be addressed by cloud computing and

virtualization. These include operational

& cost productivity (globally scaling scarce

resources, while solving problems faster),

growth & innovation (bringing new ideas

to market faster than the competitors),

customer experience (providing new

services in support of customer service),

risk management protecting intellectual

property & mitigating global disruptions

to supply chains, and green initiatives

(ever-increasing demands to reduce

energy use and environmental impact).

What advice would you like to give to companies who are planning to go for virtualization?Virtualization does not necessarily entail

restructuring of the entire existing IT

system/structure. However, it is important

for the organisation to take a close look at

their existing IT infrastructure, practices

and processes, and get as much visibility

as possible before deploying it.

Can virtualization leverage on cloud computing for enhanced benefit? Virtualization is widely seen as a

precursor to cloud adoption; so the

adoption of virtualization is definitely

spawning greater adoption of cloud

computing as well. In India, the demand

for cloud computing is picking up –

as data center adoption is picking up.

Government support, a favourable

regulatory environment, and an effective

broadband/IT infrastructure are critical

factors for cloud development.

Is usage of virtualization increasing in India? Yes, some companies have made

significant strides towards virtualization

and others are just beginning their

journey. Though virtualization demands

a serious transformational process and

substantial investment in technology, the

benefits remain compelling.

Virtualization allows scaling of key

resources and skills. Specialised expertise

can be deployed anywhere in the world,

combating the loss of expertise due to

an aging professional workforce. Projects

can be staffed based on competency,

instead of physical location, improving

performance and outcome. People

can connect regardless of time, space,

or organisational boundaries. Asset

usage increases due to increased field

productivity. Virtualization allows

even smaller companies to establish an

effective global presence.

The dynamics of the chemical

industry are changing rapidly as old

business models quickly become

obsolete. Companies that cannot adapt

to the exigencies of ever-more-difficult

extraction/manufacturing of chemicals,

the pressure to operate globally, and

the increased scarcity of the industry’s

professional expertise will have a hard

time surviving. Companies need to map

how they will evolve to the next step,

using the network as a platform for

virtual, agile operations that respond

quickly to global changes.


Virtualization is widely seen as a precursor

for cloud adoption..says Rajesh Rege, Director, Datacenter and Cloud Business, Cisco India and SAARC. In conservation with Rakesh Rao, he offers insights into advantages of virtualization for chemical manufacturers.

SPECIAL FOCUSRoundtable


Are Indian chemical companies leveraging on latest automation solutions?

Chemical industry in India is more proactive in implementing IT& automation technologies when compared with other sectors. However, with regulatory norms becoming more stringent, there is more to be done. Through an interaction with industry experts, Prasenjit Chakraborty looks into the issue to gain more insights.

For the chemical industry, there is lot of scope to improve from what it is now. It is high time for chemical manufacturers to go for sophisticated IT & automation solutions. And as far as SMEs are concerned, they should not spend any more time sitting on fence.

EDITORIAL TAKE

Abanibhusan BeraISA 84 SFS, Industry Sales Manager - Oil &

Gas, Rockwell Automation India Pvt Ltd

Historically, chemical companies,

majority of which deal with

hazardous chemicals, not

only need to have complex

controls but also ensure safety

aspects. Consequently, chemical

industry is quite ahead of other

industries as far as the adoption

and implementation of modern

technologies such as IT, process

automation & advanced process

control are concerned.

While process automation

enhances product quality, improves

process safety & plant availability

and helps in the efficient use of

resources, IT helps to increase

productivity, efficiency and achieve

regulatory compliance. Let’s take

the example of pharmaceutical

industry – one of the sectors under

knowledge chemicals – wherein

IT solutions are being increasingly

implemented in order to achieve

regulatory compliance; keep pace

with technological advances; and

improve productivity.

Ritwij KulkarniBusiness Unit Head - Field Products,

Honeywell Process Solutions India

According to recent findings

of IMS Research, the global

industrial automation market is

likely to surpass $ 200 billion

by 2015. A lot of it, however,

will depend on the kind of

technologies and processes that

automation industry will adapt to,

going forward.

IT today has become the

backbone of process industries.

They have become technology-

friendly and are investing heavily

in technologies such as cyber

security, wireless and virtualization.

Automation solutions that

improve productivity are being

adopted by Indian companies, as

labour costs are rising in India.

These technologies give Indian

manufacturers the opportunity to

increase the level of automation in

a chemical plant to reduce labour

dependence. Repetitive tasks can

often be automated, freeing highly

skilled resources’ time to carry out

value-added tasks.

Arunkumar JanarthananIndustry Manager, Industrial Automation and

Process Control Practice, Frost & Sullivan

Chemical industry, being one

of the key users of various

automation solutions, is expected

to move beyond the conventional

use of automation. High global

standards, improved safety

& production rates, stringent

environmental norms and

high process complexity are

necessitating the optimisation of

assets and cost reduction through

increased automation adoption.

It is high time for the industry

to implement such technologies

to become globally competitive

and also ensure smooth process

operation. There is a greater need

to integrate the shop floor with top

floor by adopting Manufacturing

Execution System (MES), for

overall operational excellence.

Chemical industry is also expected

to focus on adopting solutions

enabling energy management and

green processes. All these will take

the chemical industry in India to

the next level.

FACILITY VISIT FLOSTEER Engineers Pvt Ltd


Avani Jain

The growth of chemical

industry has catapulted

the Indian industrial valves

market to new heights.

Future investments in chemical and

petrochemical projects are likely to

generate substantial revenues for the

industrial valves market, providing many

avenues for industry participants to

increase their marketshare. Leveraging on

the growth opportunities, FLOSTEER

Engineers Pvt Ltd manufactures various

types of valves including specialised

manual, automatic, pneumatic and

electrical actuated industrial valves.

The company, incorporated in 1995,

manufactures and exports wide range of

industrial valves. It has an area of around

703 sq m, with the modern manufacturing

facilities in Ahmedabad at GIDC, Vatva.

Sagar Patel, Director, FLOSTEER

Engineers Pvt Ltd, notes, “The chemical

industry is growing by leaps and bounds

in India, and this has generated demand

for industrial valves. Valves are at the heart

of any chemical plant and are important

for efficient production as well as safety.

Valves help in overcoming problems such

as leakage from pipe leading to fire and

other damage. For example, boiler blow

down valves help in releasing the extra

steam from the boiler, and thus blasts can

be averted. Valves are chosen according to

the application and chemical being used. ”

Manufacturing rangeThe company manufactures a variety

of valves that include gate valve, globe

valve, check valve (non-return valve),

ball valve, blow down valve, butterfly

valve, etc. Patel states, “At present, the

company manufactures nearly 12 varieties

of valves. The production capacity of the

plant is 1,000-1,200 valves. However, the

production capacity differs depending on

the size of the valve as it takes lesser time

to manufacture small-sized valves.”

The manufacturing facility is

divided into testing, assembly, painting

and machining areas. Patel notes, “The

manufacturing process involves casting

and machining. These two tasks are

performed in-house. After this, the

mechanical and chemical properties of

the parts are checked. Then the parts go

to the assembly area where the necessary

parts are assembled. Thereafter, testing is

done so as to ensure that the products are

up to the mark and conform to all the

With the Indian chemical industry making rapid growth strides, the demand for valves has increased manifold in the recent past. Identifying this market trend, FLOSTEER Engineers Pvt Ltd strives to offer the highest level of customer satisfaction through its quality and reliable products.

ADDING QUALITY VALUE TO VALVES WITH RELIABILITY

The manufacturing area


FLOSTEER Engineers Pvt Ltd

standards. Later, the products are painted

and dispatched.”

Material of construction is selected

based on pressure/temperature limits

and corrosion resistance. Manufacturer

and exporter, the company has advanced

engineering capabilities and innovation-

driven focus. The company mainly provides

services to power plants, pharmaceutical

plants, oil fields, petrochemical industry,

chemical plants, etc. The reliability of

FLOSTEER valves is reassured by the

fact that these are regularly procured by

all the users.

Ensuring the qualityThe company is stringent about the

quality of its products. The plant is ISO

9001:2000 accredited and American

Petroleum Institute (API) certified. The

company believes in providing third

party inspection also as per clients’ needs,

thereby striving to achieve growth and

leading position in the market. Patel

states, “The company has separate quality

control department. Every material is

thoroughly checked before it is used in the

plant. Only after conducting the required

tests, the materials are used for further

production. Inspection agencies are also

invited for the approval of the material.”

Through continuous efforts in

research and development, the company

has developed various types of valves

for high pressure, high temperature

and highly corrosive fluids. Import

substitution is another achievement of

the company. FLOSTEER valves have

been successfully substituted for valves

imported from technically advanced

countries and proved to be more efficient

for highly corrosive and critical service.

Patel notes, “We design the valves

according to the design approved by

our clients. Also, during innovating any

product, we never compromise on quality

and standards.”

The company has created a different

mark for itself in the market due to

various reasons. Patel notes, “What makes

us different from others is the fact that

we test our products two to three times

before dispatching to our customers.

For this purpose, we have improved

our testing bench and now, machining

of parts is also done in-house to ensure

maximum quality.”

Envisioning growth In future, the demand for automatic valves

will increase. Patel avers, “Standardisation

will become all the more important in

future as low-quality products can result

in plant shut down leading to huge losses.

However, there are many companies,

which are producing low-quality products.

Thus, if proper steps are taken to address

this problem, the demand for good quality

valves will increase in the future.”

He adds, “For tapping this growing

demand, we are setting up another unit

for manufacturing bigger valves. The total

area of this unit is 1,200 sq m and it will

mainly produce high-quality ball valve and

butterfly valve. The present plant will then

focus mainly on gate, globe & check valves

and few others.

Thus, the company strives to deliver

quality products to its customers. Patel

concludes, “We are not a profit-making

company and believe in manufacturing

quality products. This is our motto and

the principle for success.”

Photo: Nachiket Gujar


The company has separate quality control depar tment. Ever y material is thoroughly checked before it is

used in the plant. Only after conducting the required tests, the materials are used for further production.

Sagar PatelDirector

Finished valve ready for dispatch

Raw casting of valve body

INSIGHT & OUTLOOK


RENEWABLE ENERGYFuelling growth with specialty chemicals ..............................................................................................42

BIOFUELS A better alternative among renewable solutions! ...................................................................................44

BIO-BASED FEEDSTOCKLifting the load off fossil fuels...............................................................................................................46

INTERFACE - Andrew Soare, Analyst, Lux Research“Bioprocessing companies are uniquely positioned to succeed in the alternative fuel segment” ...........48

ROUNDTABLEAre Indian investments in renewables promising energy security? .......................................................49

SAFETY GOVERNANCENurturing the culture of ownership ......................................................................................................50K N K Murthy, Consultant

CHEMICAL PROCESSINGWhite biotechnology offering green solutions ......................................................................................52

AMMONIA MARKETStanding tall on a fertile ground ............................................................................................................54

ALTERNATIVE ENERGY/FUELS


Mahua Roy

The Indian Government has

quadrupled its renewable

energy targets as part

of its national plan to

reduce carbon intensity. It has aimed at

installing 74.4 GW of renewable energy

capacity by 2022 and reducing carbon

emissions intensity by 20-25 per cent of

2005 levels over the next decade.

As of today, India has a total installed

renewable energy capacity of 26,000

MW, and wind power comprises 18,275

MW. About 89 GW of wind power could

be installed in India by 2020. This would

attract around $ 16.5 billion of annual

investment to the sector. By 2030, the

installed capacity could reach as much

as 191 GW, as per report. The market

for wind power is about five times larger

than that for solar, as per Eric Peeters,

Vice President – Solar Solutions &

Wind Energy Solutions, Dow Corning.

“The main advantages of wind energy

are that it is utility scale, available 24

hours a day and relatively predictable,

especially for offshore. This has made it

attractive from an electricity generation

perspective, as wind turbine arrays can

be connected directly to the grid. The

other factor that makes wind attractive

is that this technology is relatively

mature,” he adds. Also, India expects

to achieve solar grid parity as early as

2017. The solar energy sector saw a 52

per cent increase in investments to reach

$ 147 billion in India.

These numbers translate to a

positive outlook for the wind and solar

power sector. Two special chemicals –

epoxy resins, EVA – and more recently,

silicones contribute heavily to these

sectors. In the wake of growth spurt in

these renewable sectors, the specialty

chemicals are consequently seeing huge

demand.

Epoxy resins fuelling wind turbinesThe global epoxy resins market is

projected to reach 3.03 million tonne

by 2017, according to a new report by

Global Industry Analysts, Inc. Known

for improving stiffness, stability, and

fatigue resistance of wind turbine blades,

epoxy resins found steady demand in

windmill turbine blade manufacturing.

Global major Dow Chemical’s Dow

Epoxy System (DES) established a

Epoxy resins, Ethylene Vinyl Acetate (EVA) and silicones are showing buoyant growth rates in recent times – the reason being their contribution as the backbone of the renewable energy industry. Research is being continuously directed towards their higher efficiency.

INSIGHT & OUTLOOK Renewable energy

with specialty chemicals


Renewable energy

manufacturing facility in China to

produce blends in a Dow Epoxy site

in South Korea. Dow expects demand

growth for epoxy resins in the wind

market at 20 per cent per year within the

next five years. Also, Hexion Specialty

Chemicals announced that it will build

a new specialty epoxy resin production

facility in Esslingen, Germany, for

use specifically in the production of

windmill blades.

Another major, BASF, launched

an expanded offering of epoxy resin

systems for fibre-reinforced composites

developed specially for the production

of wind turbine rotor blades. BASF’s

new offering includes two infusion

resin systems and one laminating resin

system designed for the production of

wind turbine rotor blades. Momentive

Specialty Chemicals recently introduced

a line of epoxy resins for longer and

lighter wind turbine rotor blades.

In India, at present, there are 16

wind turbine manufacturers with

a consolidated annual production

capacity of over 9,500 MW. Another

four companies are expected to enter

the sector over the next few years. By

2013-14, more than 20 wind turbine

manufacturers and suppliers would be

operating from India. Indian companies

are now exporting to Australia, Brazil,

Europe, USA and a few other countries.

Some of the international companies

with subsidiaries in India are sourcing

over 80 per cent of their components

from Indian component manufacturers.

As per estimates, India’s annual wind

turbine manufacturing capacity is likely

to cross 10,000 MW. A further backward

integration also brings out the growth in

demand for phenol and acetone. Around

40 per cent of phenol sold globally is

consumed in the production of bisphenol

A, an intermediate by-product, which

is in turn converted into two principal

materials – polycarbonate and epoxy

resins. Now typically, a standard

1.5 MW wind turbine has approximately

10 tonne of epoxy in its blades made

from 6.6 tonne of phenol and 2.2 tonne

of acetone.

Another opportunity exists in case

of dicyclopentadiene (DCPD). “One

specialty chemical that we believe

is of specific potential interest in the

Indian market is DCPD. It is made

as a by-product in the production of

ethylene, the major building block of the

petrochemicals industry. What makes

DCPD interesting in India is that it

can be refined to a 99.9 per cent pure

grade and then it can be polymerised

by reaction injection moulding using

a new generation of catalysts. Poly-

DCPD RIM provides a cost-effective

means of fabricating large strong

structures of wind turbine blades. With

some large steam cracking operations in

India, there is potentially a large supply

of DCPD available that could allow

for cost-effective domestic production

of large-scale wind turbines,” explains

Dr Mark Morgan, Global Managing

Director-Renewables, Business Advisory

Services, IHS.

EVA and silicones shine in solar sector“The energy policy for India is broad

and wide-reaching. In order to meet

the ambitious targets for renewable

energy, solar is likely to see the biggest

investment, especially if India builds its

own large-scale polysilicon production,”

adds Dr Morgan. Asia’s impressive

growth in the solar sector was largely

responsible for a predicted worldwide

EVA demand of 2,966,078 tonne by

2017. This contributed to EVA’s CAGR

of 4.4 per cent.

According to GBI Research, 9 per

cent of EVA manufactured globally is

used for photovoltaic panel production

as an effective encapsulant. “EVA is

used in the construction of solar voltaic

panels as an encapsulating material. It

prevents moisture from entering the

panels and shorting out the solar cells.

It also minimises glass shattering and

provides a buffer to prevent solar cells

from cracking. The growing solar power

industry is, therefore, predicted to play an

important role in the future production

of the co-polymer,” says Dr Morgan.

Encapsulants present an opportunity

to cut down on the cost of production

of solar energy. EVA has been used

as an encapsulant since the last 30

years to protect cells, as Peeters puts

forward. Encapsulants present an

opportunity to cut down on the costs.

“Silicones are ideal for solar panel

and photovoltaic applications. While

solar cells themselves are made of

silicon, silicones are used during

module assembly and installation

as encapsulants, coatings, potting

agents, adhesives and sealants. While

EVA performs well, it also has some

disadvantages. Thus, now several

companies are working on alternative

solutions like silicones. Silicone

encapsulation improves manufacturing

efficiency, durability and cell efficiency

through better UV transparency,”

elaborates Peeters.

Global silicone market is

forecast to reach $ 17.2 billion

by 2017, according to a report by Global

Industry Analysts, Inc. Also, since the

PV industry has been focussing most

of its innovation on cell efficiency,

concentrating on silicones is a big

investment. “In recent years, it has

become clear that large opportunities

for cost optimisation exist in the overall

system configuration and installation,”

adds Peeters. Dow Corning’s

Encapsulant series technology builds on

the UV stability of the silicone molecule

to enhance benefits for crystalline

modules by improving the durability

and efficiency.


Silicones are ideal for solar panel and photovoltaic applications. While solar cells themselves are made of silicon, silicones

are used during module assembly and installation as encapsulants, coatings, potting agents, adhesives and sealants.

Eric PeetersVice President – Solar Solutions & Wind Energy Solutions, Dow Corning

INSIGHT & OUTLOOK Biofuels

44

Mahua Roy

GIA’s annual report on

ethanol and biodiesel

markets states that the

global consumption

of ethanol and biodiesel is projected

to reach 135 billion gallons by 2018.

Biofuels are fast growing to become a

prominent alternative energy resource.

The Indian biofuels production industry

registered total revenue of $ 167.1

million in 2010, representing a CAGR

of 7.7 per cent for the period spanning

2006-2010. However, the performance

of the industry is forecast to decelerate,

with an anticipated CAGR of 5.7 per

cent for the five-year period 2010-

2015, which is expected to drive

the industry to a value of

$ 220.1 million by the end

of 2015.

However, the

good news is that

India is aggressively

moving towards

b e c o m i n g a

global clean tech

powerhouse and

currently ranks 4th

among the G20 nations

in terms of clean tech

investments. The goal

of India’s National

Policy on Biofuels is to ensure that a

minimum level of biofuels become

readily available in the market to meet

the demand at any given time. But is the

potential of this enormous plan being

realised truly?

Under-harnessed powerNational Policy on Biofuels was

approved by the Government of India

in 2009. The policy encouraged the

use of renewable energy resources

to supplement transport fuels.

Additionally, it proposed a target of 20

per cent biofuel blending by 2017. Then

came the ambitious National Bio-diesel

Mission, which identified jatropha

curcas as the most suitable source for

commercial bio-diesel production. The

Planning Commission had set target

to engage 13 million hectare of land

under jatropha cultivation by the end

of the 11th Five-Year Plan. However,

the biodiesel industry in India is still

in infancy stage, despite the fact that

demand for diesel is five times higher

than that for petrol. “Currently, jatropha

occupies only around 0.5 million

hectare of low-quality wastelands across

the country, of which 65-70 per cent

are new plantations of less than three

years. Only a few states have been able

to actively promote jatropha plantations

despite government incentives,”

says Prabhakar Nair, Executive VP -

Business Development Asia, Lanzatech.

Another major obstacle in

implementing the biodiesel

programme has been the difficulty

in initiating large-scale cultivation

of jatropha. “The jatropha production

programme was started without

any planned varietal improvement

programme, and use of low-yielding

cultivars made things even tougher.

The higher gestation period of

biodiesel crops (3-5 years) resulted in

a longer payback period. Besides, the

jatropha seed distribution channels are

currently underdeveloped,” explains

C S Jadhav, Director – Marketing,

Nandan Biomatrix.

India is still land of opportunitiesThe favourable subtropical climate,

huge stretches of culturable marginal

lands and the natural resource wealth

of the country stand testimonials to

the fact that the country has good


India currently imports 70 per cent of its total petroleum consumption. And in the

next two decades, this figure is expected to reach 94 per cent. However, the tables can turn if India

makes the most of its potential for biofuels. This will not only help in self-sustenance, but also heavily

aid the chemical manufacturing industry.

A strong National Energy Policy becomes the demand driver, which companies can use in their strategic plans to define

the tactics/investments to commercialise their new energy solutions. Effective energy solutions will be those that address energy needs at a local level.

Prabhakar NairExecutive VP - Business Development Asia, Lanzatech

A better alternative among renewable

solutions!


Biofuels

Source: Deloitte

scope for biofuel production. “India

has witnessed a steep rise in energy

consumption in the recent years and is

today the world’s sixth-largest energy

consumer, with the demand growing

at an annual rate of 4.8 per cent. The

demand for diesel is estimated to grow

at an annual rate of 5.8 per cent till

2030. India produces about 30 per cent

of its annual crude oil requirement of

approximately 105 million tonne. For

the balance, it relies wholly on imports,”

says Jadhav. According to experts, even

a 5 per cent blend of biodiesel could

generate anywhere between $ 400

million and $ 3 billion as additional

income for farmers, and save the

government around $ 420 million

to $ 1.5 billion on oil imports at

current prices.

The National Mission has given the

blending mandate of biodiesel with high

speed diesel. “To execute this mandate,

the biodiesel production by the end of

one year has to reach 13.38 million metric

tonne. This demands 11.19 million

hectare of land in the country to be

converted into biofuel plantations. These

numbers and statements provide scope

to the players in the industry to explore

the possibilities for commercialising the

biofuel production. Given the facts that

India spends more on the import of

crude oil and has got huge potential for

production of biofuels, this fuel has got

remarkable prospects as alternative fuel,”

says Jadhav.

The National Energy Policy is

an important driver to the growth of

alternative energy solutions. “These

policies serve to set the objectives for

the implementation of new energy

solutions by industry. A strong National

Energy Policy becomes the demand

driver, which companies can use in their

strategic plans to define the tactics/

investments to commercialise their

new energy solutions. Effective energy

solutions will be those that address

energy needs at a local level,” says Nair.

It will be a welcome move when the

industry and government, along with

the academia devise such responsible

solutions for tomorrow.

Aiding the chemical industryAn increasing interest has been seen in

the arena of bio-derived chemicals where

biofuels can play a huge role. The global

chemical industry can benefit hugely

from this development, if commercialised

effectively. “While bioderived chemicals

currently hold a small position, most

major chemical groups are now active

in the market, seeking to hedge

against rising petrochemical feedstock

prices, and anticipating potential

regulatory tightening along the lines

of the transport fuel sector,” adds

Nair. An analytics firm RNR Market

Research pegs the global bio-based

chemicals market to grow to $ 12.2

billion by 2021, accounting for 25.4

billion pounds of bio-based chemical

production at the end of the decade.

Steady sales for lactic acid and

biopolymers over the next decade will

act as stable drivers for the bio-based

chemicals market through 2021. The

overall growth of the market, however,

will greatly depend on the continued

adoption of biofuels to provide

steady glycerin production and the

market growth of new glycerin-based

intermediate chemicals.

India has taken serious cognisance

of the need to grow its chemical

industry as a whole and the Five-

Year Plan (2012-2017) is perfectly in

place for this industry. “This Plan will

enable the country to develop its entire

chemical sector including infrastructure,

IT, specialty chemicals manufacturing

and exports, thereby allowing India

to expand its current access to the

$ 4-trillion worth global chemicals

market. A part of this Plan will be used to

evaluate the use of renewable feedstocks

to produce chemicals. For example,

producing chemicals using precursors

such as ethanol that could be derived

from renewable sources,” adds Nair.


QUICK FACTSGlobally, India is in the fourth

position in generating power through biomass

The country is poised to become a world leader in the utilisation of biomass

Biomass power projects with an aggregate capacity of 1,083 MW through over 100 projects have been installed in the country

For the last 15 years, biomass power has attracted annual investments of over ` 1,000 billion, generating more than 9 billion unit of electricity per year

GREEN TRANSPORTBiofuels are transport fuels produced from biomass. Feedstock sources include food crops (sugars, starches and oil crops), fast growing energy crops (such as jatropha, miscanthus and algae), crop residues and waste products (such as used cooking oil).

They are broadly classified as:

First generation, which refers to crop-based ethanol and biodiesel

Second generation that includes ethanol and biodiesel from non-food crops and waste

Third generation constituting biofuels produced from algae

Fourth generation, which includes those with identical chemical structures to fossil fuels and other new products

India has witnessed a steep rise in energy consumption in recent years. Given the facts that India spends more on import of crude oil

and has got huge potential for production of biofuels, this fuel has got remarkable prospects as alternative fuel.

C S JadhavDirector – Marketing, Nandan Biomatrix

INSIGHT & OUTLOOK Bio-based feedstock


Avani Jain

The chemical industry uses

energy both to supply heat

and power for plant operation

and as a raw material for

the production of chemicals, plastics and

synthetic fibres. However, in the present

scenario, chemical manufacturers are

reeling under the pressures of energy crisis.

The reason for this being rising energy

prices; scarcity of conventional or fossil

fuel resources as these are

non-renewable and, at

the same time, polluting.

Therefore, such

resources need to be used

prudently. On the other

hand, alternative sources

of energy, ie renewable

resources, are indigenous,

non-polluting and

inexhaustible. This calls

for adoption of renewable

energy by chemical

companies to run their

plants, and subsequently,

become competitive in

the market.

T h e s e d a y s ,

companies have become

more conscious about

the strain (caused by human

activity) on the environment, and

many of them have started to change

their approach. In this scenario, bio-

based feedstock truly has the potential

to serve as an alternative to the

conventional resources and is the future

of chemical industry. Green or plant-

based chemistry principles can strongly

facilitate development of the industry.

Green chemistry is the key element

of sustainability. It is also important

to understand that it is not just about

bio-based feedstock, but mainly about

preserving the environment.

Advantage bio-based feedstockMost of the energy requirements in the

chemical plant are currently satisfied

using fossil fuels such as coal and

petroleum-based products. However,

domestic production of crude oil can

only fulfill 25-30 per cent of the national

consumption. This has inherently given

boost to bio-based feedstock. The biomass

resources are the biodegradable fraction

of products, wastes and residues from

agriculture, forestry and related industries

as well as the biodegradable fraction of

industrial and municipal wastes. It is

estimated that the existing biomass in the

form of agro/dairy/horticulture wastes and

municipal solid waste can meet our 40 per

cent energy demand through biogas. One

of the major advantages of using bio-based

feedstock is less pollution. Moreover, it

can result in energy efficiency as it can

generate more calorific value at lesser cost.

Thus, bio-based feedstock can make a

significant contribution to solving two of

the most urgent environmental problems,

ie climate change and depletion of fossil

fuels. In present times, non-renewable

energy use and greenhouse gas emissions

are reduced due to the current state-

of-the-art biotechnology, improved

fermentation and downstream processing.

Industrial biotechnology offers excellent

opportunities for mitigating greenhouse

gas emissions and decreasing dependence

on fossil energy sources, and

therefore, has the potential to

provide solutions to the chemical

industry. Research is on for

utilising bio-based feedstock in

the best possible manner, which

also will help in reducing the

operating cost. Although the use

of bio-based feedstock is limited,

it has a larger economic impact.

Overcoming bottlenecksThe use of renewable/bio-based

feedstock has gained importance

in last ten years due to high

prices of crude, and subsequent

uncertainty related to price and

availability of petro feedstock.

Mukul B Malvi, Partner,

TEXSPAN, notes, “As

seen in last five years,

weather has acted

as a damper, and

world over, bio-

based raw material’s

yield went down and prices skyrocketed.

Food security became a subject of

intense importance. Surplus stocks

of grains and other food items turned

in became deficit and food prices

doubled in a year’s time. Thus, bio-

based raw material has become unviable

in pricing and availability. However, if

proper steps are taken, then this issue

can be tackled.”

Rising energy prices are taking a toll on the chemical industry. Economic, environmental and energy security concerns resulting from excessive reliance on coal and crude oil are forcing companies to shift to alternatives such as bio-based feedstock for generating energy in their plants.


Bio-based feedstock

On the green path of progress Keeping all the facts in mind, it seems

that the use of biomass is likely to increase

manifold in the near future. It can provide

a replacement to the non-renewable

sources of energy being used in various

industries, if not completely, then at least

to an extent of 40-50 per cent. Narendra R

Mehta, Managing Director, Fibro Organic

(India) Pvt Ltd, observes, “In order to

increase the usage of renewable feedstock,

there has to be proper R&D and strategy

in place. Also, there needs to be proper

planning for collection, separation and

utilisation. Not only the industries but

also the government should take steps for

promoting the use of bio-based feedstock.

The government should come forward

and provide incentives to those who use

bio-based feedstock and put restrictions

on the companies using scarce fossil fuels.”

India’s crude oil and petroleum product

supplies are largely import-dependent.

With increase in oil import expenditure

by more than six times in the last 25

years due to escalation in global demand

and prices, alternative sources of energy

are likely to be pressed into services. The

alternative energy sources will be critical

in reducing the dependence on fossil fuels,

achieving higher energy security, and

reducing noxious emissions.

Thus, with the ever-increasing cost of

production and price of petro-products,

the Indian chemical industry is left with

no choice but to think about alternatives

to the existing feedstock. As a traditional

agro-based economy, the country needs to

look inward to work out its appropriate

development strategy for producing

chemical products from the agricultural

crops in a viable manner, which can

compete with the synthetic chemicals now

produced from petroleum-based feedstock.

But the challenge remains in exploiting

these appropriate and promising resources,

which can be achieved only by initiating and

implementing short-term and long-term

strategic plans with well-conceived R&D

programmes in a sustained manner.


As seen in last five years, weather has acted as a damper, and world over, bio-based raw material’s yield went down and prices

skyrocketed. Bio-based raw material has become unviable in pricing and availability. However, if proper steps are taken, then this issue can be tackled.

Mukul B MalviPartner, TEXSPAN

In order to increase the usage of renewable feedstock, there has to be proper R&D and strategy in place. Also, there

needs to be proper planning for collection, separation and utilisation.

Narendra R MehtaManaging Director, Fibro Organic (India) Pvt Ltd

INSIGHT & OUTLOOK Interface - Andrew Soare


What are the pros & cons of the various types of alternative fuels mentioned in your report?It is tough to generalise by each category,

since every company has its own unique

positives and negatives, but I can take

a more general look. Gasification and

pyrolysis are similar in that both can

process a range of low-cost feedstock

(such as MSW, agri-waste, wood, etc),

though typically these have high capital

cost. Crop modification companies

have a unique position at the top of

the value chain to create a lot of value,

but typically have long timelines to

reaching commercial scale.

Algae companies have high capital

and operating costs, and are unlikely

to be competitive with conventional

fuels. Bioprocessing companies have

flexibility to produce a range of end-

products (from fuels to chemicals), but

can be difficult to scale up economically

as novel organisms may scale irregularly,

need unique distillation infrastructure,

or require specific ambient conditions.

Catalysis companies are broad, and

tough to generalise, but the companies

focussing on biodiesel are hurt by high

vegetable oil prices, yet play into an

existing market today. Torrefaction

companies can tap into incentives for

renewable coal, but are typically more

expensive than conventional coal.

Does that mean algae-based fuel technology is witnessing lower investment?Yes, investment in algae has been

decreasing in the last few years. A few

companies are still raising investment, but

overall the investment has gone down.

How are bioprocessing companies placed? Bioprocessing companies are uniquely

positioned to succeed in this space

because many of these producers can

scale in the chemicals market, reach

critical mass where they improve

efficiencies, and then turn to the fuels

market when cost points are lower.

Will the shale gas boom in the US result in alternative fuel developers focussing more on developing markets? Shale gas is more a chemicals and energy

production play than a transportation

fuel play; so it has not decreased focus

on alternative fuels in regions with cheap

shale gas.

Will the rise in oil prices lead to increased investment in alternative fuels?Oil prices were certainly higher and

rising more quickly in the 2007-

2008 timeframe, and that is where a

lot of these plants were built. Today,

oil prices are likely to rise in certain

regions and there are a number of new

plants scaling up, but based on many

other reasons than just oil price – such

as high feedstock price, government

support, etc.

Are companies from India and China also investing in alternative fuels? Yes, these countries are investing in the

space, but less so in innovative companies

that we cover, and are more reliant on

conventional processing technology.

These countries will definitely

increase their investment in this

space as they require more and more

transportation fuel (and food) to supply

to their growing populations and must

look for alternatives.


Bioprocessing companies are

uniquely positioned to succeed in the alternative fuel segment

…says Andrew Soare, Analyst, Lux Research, and the lead author of the recently released report, ‘Leading alternative fuel developers race to real revenue in 2013’, which analyses companies in various categories of alternative fuels. During an interaction with Rakesh Rao, he provides insights into emerging opportunities for the alternative fuel technology developers.

INSIGHT & OUTLOOKRoundtable


Are Indian investments in renewables promising energy security?

The renewable energy sector has grown at an annual rate of 23 per cent to about 25,000 MW in 2012. But is this enough to meet the growing energy demand, in wake of rising crude oil prices? Mahua Roy speaks with experts in this sector to gauge the spate of investments.

Yes, investments are plenty. However, the growth rate at which investments were happening in the pre-recession era is yet to be achieved. The good news is that the government is already supporting clean energy as was seen in the announcement of 2013 Union Budget. As a result, we can expect more investments in this sector.

EDITORIAL TAKE

Gunderao Manurkar Business Manager – Energy Sector, Huntsman

Advanced Materials India Pvt Ltd

The energy sector in India is

growing at a tremendous pace

with energy generation capacity

reaching 1,80,000 MW, of which

renewable energy constitutes 8.5

per cent. Wind energy is the major

concentration area among the

renewable sector, with a 14,000

MW total installed capacity in

India. As per industry figures,

$ 9 billion would be invested in

India for wind power development

in next few years. Subsequently,

wind turbine generator capacity

addition in India has taken place

at a CAGR of 25 per cent over the

last 12 years. The government has

been supportive of this industry as

there is incentive based on power

generation. Wind power accounts

for 11 per cent of installed capacity

and 6 per cent of total generation

in India. The government targets

to increase the share of wind power

to 15 per cent by 2020. All these

will propel further investments in

this sector.

Dinesh Shahra Managing Director,

Ruchi Soya Industries Ltd

FDI worth about ` 4,900 crore

has been invested in India in the

renewable energy sector during the

last three years. When it comes

to generation of power through

biomass, India stands fourth

globally. Biomass power projects

with an aggregate capacity of 1,083

MW through over 100 projects

have been installed in the country.

Of the around 2,128 MW total

capacity registered, 50 per cent

is based on biomass and biofuel.

Further, 1,500 MW projects

are in pipeline. The country’s

energy demand is expected to

grow at an annual rate of 4.8-5

per cent over the next decade. In

last couple of years, the global

crude oil prices remained above

$ 100/barrel. This has inherently

given boost to biofuel production.

The industrial sector is positive

about the growth in the renewable

energy sector. Evidently, to meet

future demands, renewable energy

will pave the way.

David Anil KumarSenior Research Analyst - South Asia & ME,

Chemicals, Materials & Food, Frost & Sullivan

The Indian renewable energy sector is

experiencing a period of brisk activity.

Though the markets are not growing

at the 50 per cent rates as witnessed

before the recession, growth rates

greater than 20 per cent are expected.

In 2009, $ 2.3 billion was invested

in renewable energy in India. Then

the Jawaharlal Nehru National

Solar Mission was launched by the

government to promote solar energy

and install 20 GW solar capacity by

2022. As part of this, investments

to the tune of $ 19 billion are to be

pumped by the government with

support of the World Bank and

International Finance Corporation.

In India, investments related to

solar energy were witnessed across

various sections of the value chain.

Investment was also seen in solar

module and cell manufacturing as

a result of increased exports and

rising local demand. The government

mandate on domestic production of

panels and cells will further ensure

investments in the area.

INSIGHT & OUTLOOK Safety governance


K N K Murthy

Conceptually, safety has been

viewed as an ‘add on’ element

or necessity in whatever one

does. Accordingly, people

have been observed to be acting safe

whenever the compliance requirement is

preceded by an externally-driven attitude

change, behavioural correction (both

mostly accelerated through additional

motivation, encouragement, recognition

and enforcement) and supplemented by

compulsive enforcement through diktat,

mandate or statute.

Of late, this approach has turned out

to be a myth since the positive response

cannot be sustainable as it depends

greatly on the success rate of external

efforts, which can never be consistent

(as it may change from person to

person, establishment to establishment,

system to system etc). Accordingly, total

dependence on such initiatives has proved

to be nothing more than a ‘one and all’

exercise. This has been the case on a

larger scale even when people are wise,

duly educated, trained and experienced.

Besides any external appeal, demand

for safe behaviour encounters severe

resistance from most of the stakeholders.

The net effect is just lukewarm resulting

into the compliance becoming more of

an exception/reactive response than a

proactive strategy.

Few basic and conventional elements

aimed at enhancing safety compliance

include:

Company’s HSE policy

Organisational discipline or code

of conduct as part of personnel

establishment system

Establishment of training/awareness/

competency build-up covering

technical, systemic, administrative

and personnel (addressing attitudinal

problems and behavioural correction)

aspects

Campaigns and promotional activities

Statutory or legal requirements

Few indicative examples where the

compliance response has been limited/

inadequate/reactive in nature, especially

due to external impact and not because

of the inner instinct and belongingness

from stakeholders, are as follows:

(a) Adherence to just the bare minimum

safety practices as reflected in

standard operating procedures,

work instructions, log book entries

etc. At the most, these can provide

brief/detailed guidelines but always

have scope of further improvement,

finetuning based on the demand at job

location (especially in chemical plants

where varying process conditions/

situations may call for specific

deviations from set procedures/work

instructions etc)

(b) Reluctant enforcement of well-

established, proven, time-tested and

user-friendly permit-to-work or

similar job control system/procedures/

practices.

(c) Limiting safety compliance within

the ambit of statutory provisions. In

fact, statutes are quite generic being

applicable to a large cross-section

of industrial establishments in the

country and do not (cannot) provide

detailing of all safety aspects of

different types/nature/activities in the

establishments

(d) Acting just out of concern on

legal implications/prosecution/job

suspension/industry closure/public

pressure/social impact etc

(e) Negligence towards the use of

personal protective equipment even

while facing imminent injury risks

(ie, compliance is serious only while

being watched/reprimanded by

seniors; on certain occasions such

supervisory initiatives are also not

visible)

(f ) Providing special but temporary

makeover for safety/occupational

health/environment preservation,

which are restricted to campaigns,

seminars, conferences, week/

month-long celebrations, one-time

housekeeping drive etc

Moving forward All the well-intended systems/practices/

performance standards aimed at proactive

compliance and responsible care must

become instrumental in inculcating an

ownership- or belongingness-based

safety culture among all in the pyramidal

hierarchy of the organisation, society or

even family establishments. A beginning

can be made by weeding out the fallacies

of the long-time existent but inadequate

safety compliance responsibility matrix

By nature, everyone feels attached to what they possess, earn or achieve. This type of obsession has significant impact on one’s attitude towards observance of safety, in general, and industrial loss prevention, in particular. For reaping maximum benefits from such a natural instinct, it is imperative to adopt the right culture/methods for moving towards safety governance by all personnel, irrespective of the tasks being performed.

NurturingNurturing the culture of ownershipownership


Safety governance

in an organisation followed by periodical

reviews, revisions, amendments and

continual improvement as listed below.

Linking safety into the quality

assurance chain: Just like process control,

technical services, analytical laboratory,

utility, maintenance, supply chain and

marketing departments strive to ensure

the demand for highest quality standard

to the delight of customers, all aspects

of safety must be ensured when it comes

to the satisfaction of stakeholders (to be

precise ‘internal customers’ as per ISO

terminology), environment or society

at large. Once the awareness is created

about the hazards and consequential

risks associated with an activity, the

aspects of process technology, design,

detailed engineering, unit installation,

commissioning, sustained operation,

maintenance and/or other allied

functions must consider making safety

an inherent feature and not an ‘add on

liability, necessity or compulsion’. It is to

be considered as a value-added service

philosophy.

The selection and adoption of the

industrial activity: It must conform to

the latest safety standards and acceptable

risk level; wherever applicable, additional

inputs such as inventory control of

hazardous materials, installation of

machine/equipment with safer design

aspects, etc should be considered.

In a nutshell, a hazard identification/

risk assessment strategy should be

adopted, followed by finding ways and

means to bring down the projected risk

to the acceptable level.

The selection criteria of employees

(top to bottom): All the predetermined

factors being equal, preference must be

given to those having passion, obsession

and positive attitude to work safely.

Considering such persons for future career

growth (by evaluating their performance

with reference to safety along with other

factors) will motivate others to improve

upon. This can well be interlocked with

the performance appraisal/reward system

of the organisation.

The personnel/group training: This

need must be assessed, evaluated and then

implanted focussing on all areas having

general and specific safety concerns with

regard to their respective areas of work.

The responsibility matrix: It must

also clearly include the relevant safety

elements so that all individuals/groups

are motivated to consider the same as

part of the job requirement and not any

additional work load.

Company’s policy on delegation of

powers: This policy must consider vesting

adequate decision-making authority to

those concerned as part of their line

management functions (with reference to

general safety and concerns of imminent

danger).

Administrative convenience

and accountability: Mostly, certain

top authorities such as Occupier and

Factory Manager have been considered

responsible/accountable for statutory

compliance. However, it is prudent to

encourage the participation of other

senior officials down the line by assigning

the duties of planning, scheduling and

executing all relevant statutory functions

pertaining to their areas of work

(administrative, legal and technical) and

empowering them.

Safety, the ‘switch on’ agenda:

Safety aspects should be given priority

at regular production and quality-related

deliberations, periodical performance

review meetings etc. Maximum thrust

must be given to efficient execution of all

joint participative endeavours involving

workers and management. This will

create a true feeling of belongingness

among them.

The regular upkeep/maintenance of

equipment: Giving thrust to maintenance

of safety/fire service, health and

environment-related equipment, devices

and facilities around the installation must

become the onus of plant/field personnel

as they are in no way different to all other

process- and maintenance-related items,

which they own. However, with reference

to any specialised items, the guidance

of centralised Health, Safety and

Environment (HSE) professionals can be

sought in executing regular inspection/

rectification/refill/replacement as well as

improving the performance level besides

going for newly developed gadgets.

Facilitation efforts from HSE professionals This is the era of integrated HSE

management system in most of the

industrial establishments. Professionally

qualified safety, fire service, occupational

health and environmental scientists/

engineers are being deployed in most of

the units (especially those involved in

hazardous materials and manufacturing

processes). Managements must always

consider their observations, studies,

innovative ideas and suggestions in right

earnest, since they are required and do

carry out their duties independently

besides being directly responsible to the

chief executive. They play proactive and

liaison roles with regulatory authorities

and professional organisations. They

become catalytic in evolving systems/

procedures and practices besides getting

involved in sharing of case studies,

analyses of accidents/mishaps etc, all of

which add value to the ongoing safety

promotional initiatives in an organisation.

In short, whole-hearted efforts are

required from top management to ensure

that the culture of ‘true belongingness/

ownership’ is created, nurtured, and

promoted using proven and time-

tested behavioural improvement

techniques. Besides, such efforts must

be demonstrated, and the results must

be made visible to all stakeholders.

K N K Murthy has been

in the fertilisers and

petrochemicals industry for

38 years and retired as Senior

Manager (Safety) from

Indian Petrochemicals Corporation Ltd,

Vadodara. Currently, he works as a Safety

Consultant and is associated with Mahatma

Gandhi Labour Institute, Ahmedabad. He

has done pioneering works in various aspects

like hazard identification, safety audits/

inspections/surveys, training, emergency

preparedness planning, quality/environment

standards (ISO), etc. He can be contacted on

email: [email protected]

INSIGHT & OUTLOOK Chemical processing


Mahua Roy

Ten years ago, vitamin C

was produced industrially

using a complicated process

involving almost 13 steps,

and thus was extremely energy-intensive.

Today, using industrial biotechnology, the

high purity product can be obtained in

just one fermentation step. Other fine

chemicals like Polyhydroxyalkanoates

(PHA) are expected to show a double-

digit annual growth rate. Lactic acid is also

expected to show an above average rate of

growth, fuelled by the high potential seen

in Polylactic Acid (PLA) development,

one of the most promising biopolymers.

Glutamic acid is the largest-volume amino

acid produced in the world.

What is common to these fine

chemicals is their biotechnological method

of production. The misconception that

biotechnological methods are expensive is

fast diminishing. “It is more of a myth that

enzyme technology is always expensive.

Of course, in certain areas, specifically for

new applications, it might look as a costly

proposition vis-à-vis the corresponding

chemical process. But people have to

look at the overall advantages from the

environmental point of view, also,” echoes

G S Krishnan, Regional President - India,

Novozymes South Asia.

Biotechnological processing offers a

new possibility for the chemical industry

to improve environment-friendliness of

different processes. “Bioprocessing does

not require toxic catalysts and it also

aids in reducing fossil fuel consumption.

Bioprocessing is also interesting from the

economic point of view. Raw materials

are often plant-based wastes or industrial

side streams. The reaction conditions

are typically in low temperature, normal

pressure without the addition of expensive

additives,” says Jouni Ahtinen, Key Account

Manager - Industrial Biotechnology, VTT

Technical Research Centre, Finland.

Market scenarioThe global market for white biotechnology

is expected to generate about $ 182 billion

as per a recent report by McKinsey & Co.

White biotechnology essentially utilises

living cells such as moulds, yeasts or

bacteria, as well as enzymes, to produce

industrial chemicals. Few chemicals

currently produced by biotech means

include ethanol (bioethanol), acrylamide,

1,3-propandiol (for the production of

polytrimethylene terephthalate) and lactic

acid (for the production of polylactide).

Marketshare of chemicals produced

using fermentation techniques,

enzymatic conversion, or which use

bio-based feedstock, is expected to

increase to 10 per cent of the overall

white biotechnology market by 2013.

“Biotechnical production procedures are

primarily used in industrial processing

of renewable natural raw materials and

are increasingly replacing fossil raw

materials. This means they can also

make an important contribution to

sustainability, cutting material and energy

costs, and thereby reducing negative

impacts on the environment,” says

Dr Michael Nusser, Head - Department

of Emerging Technologies, Fraunhofer

Institute for Systems and Innovation

Research (ISI), Germany.

Rooting for the greener routeAs of today, the chemical industry is still

largely dependent on petrochemicals for

the raw materials. Over 90 per cent of

all industrially manufactured organic

bulk chemicals or base chemicals are

synthesised out of petroleum or natural

gas. A sophisticated and integrated

reaction system, in which by-products

from one synthesis can be used as

feedstocks for other synthesis can

permit highly efficient and economical

production of a wide range of chemicals.

The global market for white biotechnology will shoot up as crude oil costs surge worldwide, and parallelly as demand for green products put pressure on the chemical industry. Fine and specialty chemicals are increasingly adopting this biotechnological prowess to solve the problems of tomorrow, today. However, the first step right now is to bring down the cost of processing.

White biotechnologyWhite biotechnology offering green solutions


Chemical processing

One of the major goals of white

biotechnology has been the production of

biodegradable plastics. “Over the past two

decades, the efforts of R&D in this field

have concentrated mainly on polyesters

of 3-hydroxyacids (PHAs), which are

naturally synthesised by a wide range of

bacteria. These compounds have properties

similar to synthetic thermoplastics and

elastomers from propylene to rubber, but

are completely and rapidly degraded by

bacteria in soil or water. A major limitation

of the commercialisation of such bacterial

plastics has always been their cost, as

they are 5-10 times more expensive to

produce than petroleum-based polymers,”

adds Ahtinen. Thus, the major priority

currently is to bring down the cost via

process redesign.

Also, it is essential that the feasibility

and economic viability of the manufacturing

process is intact to make it commercially

successful. This is the biggest challenge

faced by the industry. “In pilot projects

the challenge is often the performance of

the engineered production process in real

process conditions. The yield must be high

also in less favourable conditions than in

the laboratory in order to reach economic

feasibility. Often nature’s biomasses and

industrial side streams contain inhibitory

compounds making biological processing

quite challenging,” voices Ahtinen.

Process redesigning, a challengeAnother challenge faced in the biotech

route is the stereochemical issues faced.

Two stereochemically opposite molecules

can have exactly opposite characters, and

this can create undesirable problems.

“If complex molecules have to be

manufactured or chiral substances to be

produced in an enantiomerically pure

form, petrochemical processes are generally

complicated and heavily expensive. For

such cases, white biotechnology has proven

to be enormously successful. For example,

proteins are solely accessible by biotech

routes. The more complex the chemistry

gets, the greater the opportunities pan

out for a biotech route of production,”

says Krishnan. For this reason, fine

and specialty chemicals are currently

white biotech’s biggest domains. “In a

broader perspective, enzymatic solutions

help specific industries manufacture

products with less toxic inputs, thereby

enabling environment protection. Often,

this reduced impact contributes to the

sustainable development of industries as

well as society as a whole,” adds Krishnan.

As per industry figures, world over,

almost two-third of all enantioselective

syntheses are currently performed using

enzymes as biocatalysts. Chemicals that

are metabolites of micro-organisms

are increasingly being synthesised

by fermentation as an alternative to

conventional, multistage chemical

production processes. “Industrial white

biotechnology includes the utilisation of

biotechnological processes in industrial

production and plays an important role

as a leading edge and cross-sectional

technology in several industries in the

innovation and growth process. Several

experts estimate that the realisation of

the economic potential of industrial

biotechnology is at the beginning of its

development,” adds Dr Nusser.

Encouraging developments“In the future, with more extensive

research and innovation project being

emphasised upon, biotechnological

processing will surely offer economical

and sustainable solutions for the

production of fuels, chemicals and other

materials,” adds Ahtinen. Many chemical

majors have started investing heavily

towards this, thus displaying a responsible

and forward thinking image.

LANXESS, one of the largest

producers of synthetic rubber globally,

has invested in US biofuel & biochemical

company Gevo, Inc as part of a proposed

co-operation to produce isobutene from

renewable resources. The companies aim

to find an alternative route to source

isobutene – a key raw material needed

in the manufacturing of butyl rubber.

Isobutene is conventionally produced

in steam crackers, which use petroleum

derivatives as a feedstock. Alternatively,

Gevo is developing a fermentation

process to produce the organic compound

isobutanol from the fermentable sugars in

biomass, starting with corn. Isobutanol is

a fundamental building block for making

biodiesel, bio jet fuel as well as plastics,

rubber and fibres. Also, LANXESS

is strengthening its commitment to

renewable raw materials as it aims to

produce phthalate-free plasticisers from

bio-based succinic acid.

DSM has invested in China-based

PHA developer Tianjin GreenBio

Materials to produce bio-based polymers

for applications in fibres, films and foams.

Wacker is developing innovative ways of

economically producing ethylene and

acetic acid from renewable raw materials.

It is already running a pilot plant for the

production of acetic acid produced via

biotechnology. Such laudable efforts by

chemical majors worldwide prove that

white biotechnology will be the next

big revolution for the industry. “The

only question that remains is, to what

extent and at what pace is the industry

going to adapt to biotechnology and

enzyme application in particular,”

concludes Krishnan.


In the future, with more extensive resear ch and innovation project being emphasised upon, biotechnological

processing will surely offer economical and sustainable solutions for the production of fuels, chemicals and other materials.

Jouni AhtinenKey Account Manager - Industrial Biotechnology, VTT Technical Research Centre, Finland

It is more of a myth that enzyme technology is always expensive. Of course, in certain areas, specifically for new

applications, it might look as a costly proposition vis-à-vis the corresponding chemical process.

G S KrishnanRegional President - India, Novozymes South Asia

INSIGHT & OUTLOOK Ammonia market


Rakesh Rao

Most of the commonly

used fertilisers such as

urea, ammonium nitrate,

Nitrogen Phosphorus and

Potassium (NPK), Diammonium Phosphate

(DAP)/Monoammonium Phosphate

(MAP) and calcium nitrate either directly

consume ammonia in their manufacturing

process or use a product (nitro phosphate)

that is derived from ammonia. There are

some other fertilisers that are not made

with the use of ammonia such as Muriate

of Potash (MOP), Sulfate of Potash (SOP),

Single Super Phosphate (SSP), and Triple

Super Phosphate (TSP). “But one look at

key fertiliser products by marketshare shows

that ammonia-based fertilisers dominate

the global fertiliser consumption,” observes

Brijesh Ramani, Analyst, GBI Research.

A similar trend prevails in Asia-Pacific

(China and India) and is expected to

continue in the near future. He explains,

“The main reason being the increase in

yield obtained by the use of nitrogen-rich

ammonia fertilisers, whereas the other

non-ammonia fertilisers do increase the

quality of crop. But, their contribution

in increasing the crop yield is still

limited. So, these countries, which have

huge population to feed, are using more

ammonia-based fertilisers.”

Rising fertiliser demand, aiding ammonia marketAs India and China lead a trend among

emerging countries seeking to become

self-sufficient in terms of food production

by using ammonia-based fertilisers, the

demand for ammonia is on the rise,

according to a new report by GBI Research.

These two countries have almost one-third

of the global population, which is also

increasing rapidly, generating increased

demand for food. The response to this

rise in food demand by their governments

has been the sustained use of agricultural

chemicals, particularly fertilisers. “The

response of these governments, which

are seeking to provide food security to

their nations, particularly because they

are still developing and have low per

unit area fertiliser utilisation, provides

substantial market potential for ammonia-

based fertilisers such as urea, ammonium

nitrate, sulphate and phosphate in terms

of increased consumption from these

countries,” says Ramani.

There is a high demand for

ammonia-based fertilisers such as urea,

ammonium nitrate, etc because they are

the major suppliers of nitrogen, which is

considered more important in increasing

the crop yield as compared to some other

phosphate- and sulphate-based fertilisers

that are necessary in increasing crop

quality. He adds, “Annual application is

not always needed, as the soil absorbs and

stores these two nutrients (phosphate and

sulphate) for a longer period compared

with nitrogen. So, ammonia-based

fertilisers must be applied every year to

maintain yield and biomass.”

Ammonia is the basis for all nitrogen

fertilisers and contains the highest

amount of nitrogen (82 per cent). “So,

these countries consume more ammonia-

based fertilisers because their main aim is

to increase crop yield, which is beneficial

in feeding their ever-increasing large

population. This does not mean that they

do not use other fertilisers, but ammonia-

based fertilisers have the predominant

share,” adds Ramani.

India and China, the growth drivers Agricultural fertilisers accounted for a

combined share of around 62 per cent of

ammonia demand in 2011. Asia-Pacific

accounted for a 58.7 per cent share of global

demand for ammonia in 2011, with China

and India accounting for the majority of

this. China and India’s large populations

As the consumption of fertilisers increases in India and China to augment agricultural production, the demand for ammonia – one of the key inputs for urea and other ammonia-based fertilisers – is all set to rise manifold in the region. In India, the new Urea Investment Policy is expected to give further boost to this market.

Standing tall on a fertile ground

Ammonia plant

Urea

Ammonium nitrate

Calcium nitrate

NPK fertilisers

DAP/MAP

TSP/SSP

Nitric acid plant

Nitrophosphate plant

Phosphoric acid plant

Sulphuric acid plant

Natural gas

Air

Air

Rock

Rock

CO2NH3

HNO3

H2SO4

H2PO4

Salts of K, Mg, S

Rock

Rock

Figure 1: Fertiliser production routes

Source: GBI Research; Yara Fertilizer Industry Handbook 2011-12


Ammonia market

and growing economies promise substantial

consumption potential, reflected in the

high growth of ammonia-based fertilisers.

As a result, the Asia-Pacific region will

continue to drive global ammonia market

in future. According to GBI Research,

global demand for ammonia increased

from 96.438 million tonne (MT) in 2000

to 120.780 MT in 2011, and is expected to

grow at a Compounded Annual Growth

Rate (CAGR) of 3.2 per cent to reach

160.094 MT in 2020.

To meet this rising demand, one

can expect to see more investment by

companies to increase ammonia capacity

in the region. “Definitely, we are expecting

more companies to invest in ammonia

capacity in India and China. For example,

China is expected to see the start-up of

around 8 new ammonia plants, whereas

India is expected to see the start-up of

3 new ammonia plants by 2018. As a

result, the Chinese ammonia capacity is

expected to increase from 66.73 MT in

2011 to 71.896 MT by 2018. Similarly,

India’s ammonia capacity is expected to

increase from 13.52 MT in 2011 to 16.36

MT in 2018. These capacity additions

are based on available announcements

and might see further increase in future,”

discloses Ramani.

Policy boost for ammonia While the demand for urea in India has

been growing at a rate of 3 per cent annually,

the sector has not seen any investments in

the last 15 years in the country because

of policy uncertainty till now. As a result,

India’s production has remained stagnant

at 21 million metric tonne per annum

(mmtpa), while its imports have increased

to 9 mmtpa now from nil in 2001.

In order to fill the widening gap

between domestic demand and supply of

urea, the Government of India announced

the new Urea Investment Policy 2012.

The new policy is expected to mobilise

dormant plans of fertiliser players in

the country bringing about a wave of

investments to the tune of ` 40,000 crore

in the next five years, which could enhance

domestic output by up to 10 million tonne.

According to a report of GlobalData, a

global research and consulting firm, urea

production capacity in India is expected

to increase at a CAGR of 5.2 per cent

during 2011-2016, showing substantial

improvement from the CAGR of

0.7 per cent during 2005-2011.

This will also result in more demand

for ammonia. “Yes, there is a definite

expected increase in ammonia demand

from around 16.1 MT in 2011 to around

21.2 MT in 2020. Currently, urea with

12.89 MT of demand is the largest end-

use for ammonia in India in 2011. And

now with the government announcing

urea policy to boost domestic capacity,

the consumption of ammonia is expected

to increase to 16.7 MT by 2020,” opines

Ramani. Though the domestic ammonia

capacity in India is expected to witness

rapid rise, the country will still have to

depend on imports to meet the demand.

“The increase in demand would definitely

see an increase in both production and

imports. But the growth of imports would

be more than the increase in production,

as only three new ammonia plants

are coming up in future. The percentage

of imports satisfying the demand is

expected to increase from around 14 per

cent in 2011 to 20 per cent by 2020,”

opines Ramani.

Reference: GBI Research report – ‘Ammonia

global market to 2020: Food security

concerns driving demand for ammonia-

based fertilisers’


AMMONIA, KEY NUTRIENT

Ammonia is one of the most highly produced inorganic chemicals because of its wide applications. Today, virtually all nitrogenous fertilisers are derived from synthetic ammonia. The main fertilisers such as urea, ammonium nitrate, ammonium phosphate are produced directly from ammonia. Other fertilisers such as ammonium sulphate and ammonium chloride are mainly obtained as co-product or by-product of the production of caprolactam or soda ash, also using ammonia as a raw material.

China (with about 32 per cent of the worldwide production) is the leading producer of ammonia in the world, followed by India, Russia and the US. More than 80 per cent of the ammonia produced is used for agricultural needs. Ammonia is also used for the production of plastics, fibres, explosives, and intermediates for dyes and pharmaceuticals.

Today, most ammonia is produced on a large scale by the Haber-Bosch process with capacities of up to 3,300 metric tonne per day.

25

20

15

10

5

0

25%

20%

15%

10%

5%

0%

2000 2005

Vol

ume

(mil

lion

ton

ne)

2011 2020

Demand Imports Imports/Demand (%)

Figure 2: India’s ammonia demand and import dependency, 2000- 2020

Source: GBI Research

AUTOMATION TRENDS WirelessHART technology


Pho

to c

ourt

esy:

Em

erso

n P

roce

ss M

anag

emen

t

Jonas Berge

Industrial wireless sensor networks

have existed for more than ten

years. However, the first generation

of wireless sensors was impractical

because every manufacturer had a different

proprietary protocol. Products from

different suppliers did not work together.

Multiple gateways and configuration

software were required to use different

kinds of sensors. This mirrors the early

days of ‘smart’ protocols for 4-20 mA

transmitters. DCS manufacturers used

different protocol that only supported

their own devices. Multiple handheld

terminals were required. Eventually, the

HART protocol prevailed, and thanks to

4-20 mA/HART, most DCS can now

communicate with any 4-20 mA device,

and only a single field communicator is

required. WirelessHART is doing the

same for wireless.

IEC 62591 is the only international

standard for wireless in process

applications. It was originally developed

by the HART Communication

Foundation (HCF), released in 2007, and

subsequently approved as an international

standard in April 2010.

Standard WirelessHART products

are available, thus there is no need to buy

proprietary or ‘standards-ready’ wireless

products now, and later worry about how

to upgrade. The same common handheld

field communicators and laptop software

that plants already have for configuring

4-20 mA/HART devices can also be used

to securely commission WirelessHART

devices, regardless of manufacturer

or type before it joins the

WirelessHART network.

WirelessHART security measures

include encryption, authentication,

verification, key rotation, sequence

number etc, but if not enabled it

would be useless. For this reason,

WirelessHART security cannot be turned

off, ensuring these security measures are

constantly active.

Meeting process users’ needsWirelessHART was developed to meet

the requirements of process industry

users. In the early phase of development,

the HCF collected wireless requirements

from end-users in the process industries.

Users demanded coexistence, reliability,

long battery life, security, multi-vendor

interoperability – all that plants need to

solve process problems – and end-users

are experts on their process. However,

end-users are not necessarily experts

on Radio Frequency (RF) design or

communication protocol stacks, so HCF

member companies sent their experts on

RF and digital communication to design

the WirelessHART technology to meet

these process requirements.

Wireless plant networkWirelessHART is a wireless level

1 network for sensors and actuators

that complements the existing level 2

industrial protocols that may use Wi-Fi

(wireless Ethernet) such as Modbus/

TCP, EtherNet/IP, FOUNDATION

fieldbus HSE, and PROFINET, etc, as

well as level 3 and 4 standard protocols

for web browsing, email, file transfer,

voice, video, etc. It is not a good idea

to put all eggs in one basket, so a single

wireless network covering the entire plant

may not be ideal. A practical solution

would be having one network per plant

area, just like plants have one DCS

controller per plant area. It fits in with

the DCS architecture in most plants and

the division of job responsibilities within

the plant. WirelessHART supports this

architecture. It is even possible for the

same area to have different gateways for

process automation and asset optimisation

if preferred, but usually a single gateway

is used. Data from gateways in different

plant areas is backhauled over Ethernet

or Wi-Fi using the HART-IP protocol,

Modbus, etc.

WirelessHART fits well with

existing plant philosophies. Because

WirelessHART requirements were

collected from end-users only in the

process industries, not from factory

automation, building automation, or

Process and asset monitoring simplified

Over the past few years, WirelessHART transmitters have been used in process and asset monitoring tasks that previously were too risky or impractical to automate by laying cables in an operating plant. But what important characteristics of the WirelessHART technology make it so uniquely adept for process applications? Read on…


WirelessHART technology

power grid, the protocol is optimised

for process application. An advantage

of this application optimisation is that

a multitude of communication options

need not be set at commissioning. This

prevents errors and reduces delays.

A true standardOver the past few years, WirelessHART

devices have made their way into all kinds

of plants in every industry around the

world. A vast majority of these devices

in operation are so called native devices

meaning the radio, antenna, and power

module (battery pack) are built into the

device as a single integrated unit such

as a pressure or temperature transmitter.

The other solution is wireless adapters

that are mounted on conventional

4-20 mA/HART devices and tap into

the digital HART communication,

tunneling the device set-up information

and diagnostics to intelligent device

management software. Such tunneling is

only required for the HART protocol,

and it is useful because more than 90

per cent of the 4-20 mA/HART devices

installed are not digitally integrated;

they use 4-20 mA to the DCS. The

HART communication is only used

with a handheld field communicator

at commissioning. A WirelessHART

adapter is an easy way to add HART

capability to an old DCS. However,

FOUNDATION fieldbus, PROFIBUS,

and Modbus, etc, have no 4-20 mA,

they are all purely digital, and therefore,

already digitally integrated with the DCS.

Therefore, there is no need for wireless

adapter or tunneling for those protocols;

tunneling HART is sufficient.

By using a single standard protocol,

WirelessHART avoids the problem

of multiple protocols such as multiple

gateways, numerous drivers, and

different ways of mapping the process

variable (PV) to the system database.

A single protocol avoids multiple ways

to configure, calibrate, and diagnose/

troubleshoot device problems. The

WirelessHART approach is to use a

single common protocol for all wireless

devices regardless of manufacturer and

type. Moreover, native integration of the

DCS with the gateway or wireless I/O

card is possible without drivers and data

mapping. A single common protocol is

the only way to true interoperability.

Technology ready for control when you areWirelessHART operates in the same

license-free 2.4 GHz ISM-band as

Wi-Fi and other wireless technologies,

but since it uses channel hopping and

channel black listing, WirelessHART is

able to coexist with these technologies.

WirelessHART transmitters are

predominantly used for process and asset

monitoring. However, the technology

is ready for control when you are. The

technology is time synchronised and

scheduled with a precisely periodic

macrocycle (called superframe), and

makes use of publisher/subscriber (called

burst mode and catch) communication

similar to FOUNDATION fieldbus. The

result is deterministic communication.

Full mesh topologyAlthough opinions of wireless experts

differ on many points, there is consensus

on at least one point: that self-organising

mesh topology is the most robust. This is

because devices establish multiple paths

among themselves, routing messages at

device level, in a mesh. If one of the paths

is disrupted, the network automatically

switches to another path, thus maintaining

a reliable connection. That is, redundant

data pathways eliminate single points of

failure. Actual installations consistently

demonstrate more than 99 per cent data

reliability. Mesh topology is therefore the

best practice. Star topology is typically

not used although supported by the

technology.

WirelessHART uses a unique full

mesh topology as many as seven hops

deep, providing an important advantage:

It does not need a costly infrastructure of

multiple backbone routers to be installed

throughout the plant within range of

every wireless device. Running costly

hazardous area power supply to backbone

routers is therefore not required. Mesh

topology is truly wireless and with low

risk. The ability to self-organise is critical

in a plant environment with intermittent

sources of noise and temporary

obstructions. With sources of noise

ranging from motors and pumps starting

and stopping to walkie-talkies, the RFI

environment is constantly changing. But

a self-organising network can easily adapt

and maintain high data reliability. It also

makes adding and removing devices easy

as manual configuration is not required.

Deploying wirelessAfter thousands of installations in

industries globally, users have found that

choosing their wireless network can be

simple with a few thumb rules to follow.

Choose a wireless technology, which is

an international standard supported by

one’s preferred transmitter suppliers, and

has all the device types required for one’s

current and future applications. Narrow

it down to a single protocol that ensures

ease of deployment and long-term device

maintenance, and which makes use of

your existing commissioning tools and

requires less training. Make sure to

use a self-organising mesh topology

for maximum robustness and ease of

management. One common protocol

customised for process automation users

eliminates the need for superfluous

configuration. Last but not the least,

security that cannot be turned off greatly

reduces cyber security risks. Many believe

that the question is not if they will use

wireless, it is merely a question of when.

By choosing the wireless network wisely,

the investment will be repaid not only

on the first application, but for every

additional application that is added to

the same network in the future.

Jonas Berge is Director

of Applied Technology at

Emerson Process Management.

He has more than twenty five

years of experience in the field

of instrumentation and controls. Berge is a

subject matter expert in the field of fieldbus,

wireless, and intelligent device management.


ENERGY MANAGEMENT ISO 50001 certification


Avani Jain

The chemical industry is

currently facing a difficult

energy scenario. This is

because energy prices are

steadily going up, thereby upsetting the

economics of operations. In addition,

procuring energy sources such as coal

and natural gas is posing problems due to

shortage conditions. In fact, besides raw

materials, the energy cost is considered to

be the second-largest operating expense

in a chemical manufacturing plant.

Thus, ensuring energy efficiency

at the chemical plant becomes

imperative.

Manish Trivedi, Head,

Det Norske Veritas AS

- Gujarat & South

Africa Operations,

states, “Energy

efficiency results

in reduction of

energy usage by

cutting down

the amount

required for a

given output.

It is achieved

through process

i m p r o v e m e n t ,

t e c h n o l o g i c a l

progress and proper

repair & maintenance.

Energy conservation

also helps in cutting down

consumption. Further, chemical

industry is polluting by nature.

Hence, effective energy management,

which can reduce wastage and pollution, is

important from energy and environment

point of view.”

Energy management system enables

an organisation to achieve continual

improvement in energy performance,

efficiency and conservation. He adds,

“It provides a formalised structure and

a systematic approach for ensuring that

energy issues are addressed and works

to control significantly a company’s

energy use as well as achieve regulatory

compliance.”

Awareness about ISO 50001:2011 The ISO 50001:2011 was formally

released on June 15, 2011, for

certification. Trivedi notes, “Within

less than two years, several hundred

companies have been certified globally.

In light of the success stories of these

leading companies, increasing number of

organisations are showing interest for the

certification.”

According to him, there is no big

difficulty for chemical organisations to

achieve ISO 50001 certification. In the

wake of energy crisis, most chemical

manufacturers have already implemented

energy conservation schemes. “In all,

ISO 50001 energy management system

offers a comprehensive and structured

approach for management of energy in

the entire supply chain management

from purchase to utilisation through

sustained management attention to

achieve energy-efficiency improvement.

Underpinning success factors are

management commitment,

provision of resources,

collection and monitoring

of energy data and

training, among other

key issues,” Trivedi

opines.

Need for international standardsNew pressures

and threats

to business

can influence

the decision

to implement

a n e n e r g y

m a n a g e m e n t

system. These threats

include global warming,

new legislation (PAT for

major consumers & Bureau

of Energy Efficiency), public

concern, media attention, customer

requirements & marketing benefits,

internationalisation, new knowledge &

technology and stronger enforcement.

An energy management programme

can help overcome these pressures

and also demonstrate corporate social

responsibility.

Trivedi notes, “According to a

recent global survey, controlling

costs, protecting global climate and

maintaining a good corporate image

among customers are the top three

reasons for an organisation’s interest

in energy efficiency. Further, energy

As feedstock and energy prices continue to rise with each

passing day, it has become imperative for the chemical and process industries to adopt energy conservation measures like the energy management

system to optimise plant’s overall efficiency. Adopting ISO 50001 can offer

numerous benefits to chemical manufacturers when it comes

to saving energy.

A STRUCTUR

ED AP

PROACH TO POWER CONSERVATION


ISO 50001 certification

is the major cost in any chemical process plant. Thus, with

the help of ISO 50001:2011, energy cost can be reduced

substantially by systematic energy review.”

ISO 50001:2011 provides a framework for

implementing an energy management system, which

meets an organisation’s stakeholder interests. “It can

minimise waste & energy bills; reduce greenhouse emission

and carbon footprint; increase awareness about energy

among staff members; facilitate better business processes;

enhance company reputation; improve compliance; meet

concerns of interested parties; gain international recognition;

improve marketing potential; and reduce liabilities & risks,”

he states.

Future trendsSustainability is a critical global issue, and without energy

security it cannot be achieved. Trivedi concludes, “Therefore,

every energy-intensive industry including chemical will have

to improve energy performance. Many countries have already

set energy performance targets for energy-intensive industries.

Other countries will need to follow similar regulations.

Therefore, the world will witness significant growth in energy

management system certification in coming years.”


REQUIREMENTS FOR COMPLIANCE

There are numerous steps that need to be taken in order to fulfil the requirements of ISO 50001:2011 certification. According to Trivedi, companies have to adhere to the following ten-point rule:

Identify activities in the organisation where energy is used

Carry out energy review based on past energy consumption data v/s output

Fix-up energy baseline and predict energy consumption to calculate energy saving

Provide meters and metering plan

Identify significant energy use

Get energy performance objectives & goals and monitor energy consumption data for significant energy uses

Train employees for operation control for managing energy uses

Identify opportunities for energy performance improvement by reducing energy wastage, improving equipment efficiency and procuring energy-efficient equipment, optimising process, etc

Take corrective actions when deviations are observed

Conduct management reviews at intervals to ensure continual improvement

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POLICIES & REGULATIONS Government incentives for alternative energy


Mahua Roy

About 25 per cent of our

country’s population, or 288.8

million people, have no access

to electricity, according to

the International Energy Agency. Union

Finance Minister P Chidambaram has

thus termed renewable energy sector as

a priority. The Climate Policy Initiative

(CPI) and the Centre for Emerging

Markets Solutions (CEMS) at the Indian

School of Business (ISB) have found that

high interest rates and relatively short-

term loans for renewable energy projects

in India add 24-32 per cent to the cost

of renewable energy in India compared

to similar projects in the US and Europe.

The government has set a goal to reach

4,000-10,000 MW of renewable energy

by 2017 and 20,000 MW by 2022.

Recently, a scheme was announced

for making renewable energy cheaper by

providing for low interest bearing funds,

besides offering incentives for wind power

generation and waste-to-energy plants.

Such incentives are expected to rekindle

growth in India’s renewable energy

sector, which is currently suffering from a

noticeable downturn.

The Government of India has steadily

been promoting an inclusive growth,

while renewable energy supports this

ambitious objective. The renewable energy

sector has grown at an annual rate of

23 per cent to reach about 25,000 MW

in March 2012. The renewable power

installed capacity forms 6.5 per cent in

the total electricity mix and 12.5 per

cent of total installed capacity in 2011-

2012. Wind energy accounts for 70 per

cent of installed capacity. Also, as per

proposed investments, capacity addition

of around 30,000 MW is planned from

various renewable energy technologies in

the next five years. Taking into account

all the renewable energy categories, India

currently ranks fifth in the world with

15,691.4 MW grid-connected and 367.9

MW off-grid renewable energy based

power capacity, as per an Ernst & Young

report. Also, India is among the top five

destinations worldwide for solar energy

development, according to Ernst & Young’s

renewable energy attractiveness index. So,

the potential exists tremendously; what

is needed is the big support by way of

government measures.

“India has significantly increased

its renewable energy investment with

tax benefit for wind power projects and

funding support for solar power. Reasons

for India’s impressive 25 per cent growth

shows that investment was supported by

a number of factors, including a race to

exploit the accelerated depreciation tax

Are the initiatives renewing

interest in renewable

energy?That India is right on track to achieve the proposed ambitious target of reaching 30,000 MW installed

renewable energy capacity by 2017 is indeed electrifying news. It currently has an installed capacity of 26,920 MW. But the past two years have seen a slowdown in

investments in this sector. Is the government taking enough measures to set the record straight?

The growth in installed capacity for solar power generation is expected to be the highest among the renewable sources

because of the government’s target of 20 GW by 2022 (under the Jawaharlal Nehru National Solar Mission).

Kalpana JainSenior Director, Deloitte India


Government incentives for alternative energy

Source: KPMG

break for wind projects before reforming

in 2012; the government’s new Solar

Mission to develop 1 GW of grid-

connected capacity by 2013; and the

launch of Renewable Energy Certificate

and Renewable Purchase Obligation

schemes,” explains Kalpana Jain, Senior

Director, Deloitte India.

Winding up the bad times?The wind energy sector has remained

the most favoured among all renewable

energy technologies in India for the

last several years. “This was due to the

announcement of two crucial incentives

for the wind energy sector – Generation-

based Incentive (GBI) and accelerated

depreciation. Surprisingly, both were

repealed in April 2012. As a direct

consequence, the capacity addition in this

sector fell significantly,” says Jain

However, P Chidambaram

recognised that the wind energy sector

deserves incentives, and hence proposed

to reintroduce GBI for wind energy

projects and provide ` 800 crore to the

Ministry of New and Renewable Energy

for the purpose, as per Union Budget

2013 announcement. This is expected

to increase activity in this sector again.

Wind energy is the most promising of

renewable energy sources in India.

Waste-to-energy gains recognitionIncentives have also been announced for

waste-to-energy projects in cities across

the country. The technology remains

in a nascent stage with less than 100

MW capacity installed by January 2013.

“The Ministry of New and Renewable

Energy had set a target to install 20 MW

of waste-to-power projects in urban and

industrial sectors in 2012-13, but only

6.4 MW capacity had been added by

January 2013. The government has

announced that it will provide financial

support to city authorities that intend

to set up such projects,” says Dr Suneel

Pandey, Fellow, Centre for Environmental

Studies, The Energy and Resources

Institute (TERI).

It is in this context, the role of

renewable energy is no longer seen as

alternative energy, but is increasingly

becoming a vital part of the solution to

the nation’s energy shortfall. “India has

an estimated potential of over 30,000

MW of power from biomass, but around

3,000 MW has been exploited. Thus,

over 90 per cent of potential capacity lies

untapped,” adds Dr Pandey.

The overall demand-supply gap in

the energy sector is expanding due to an

increase in the standard of living of the

growing population. The demand-supply

gap in power is currently at 10.3 per cent

and is one of the key drivers of renewable

energy, states an Ernst & Young report.

Sunny side up, yet?“The growth in installed capacity for

solar power generation is expected to be

the highest among the renewable sources

because of the government’s target of

20 GW by 2022 (under the Jawaharlal

Nehru National Solar Mission). Also,

there has been substantial reduction in

PV prices, which is expected to drop

further. Friendly policies have helped in

the development of technology, which

is expected to reduce unit cost of power

generation,” summarises Jain.

Over the past few years, the

government has announced incentives

such as reduction of duties on imported

solar modules or equipment used for

setting up solar thermal power plants, or

other financial incentives for off-grid solar

power solutions. Almost certainly, the

cheaper loans and the generation-based

incentives would attract investors and

project developers to set up more projects.

With all the attractive characteristics

and potential stated above, India presents

a significant market opportunity for

renewable energy firms worldwide.

However, the government needs to

provide extensive guidance and assistance

on several strategic and operational

aspects before this sector is in a position

to effectively tap into this opportunity.


POLICY INITIATIVES Support schemes for renewable energy generation in India include:

Foreign Direct Investment (FDI): India permits FDI up to 100 per cent in the sector under the automatic route in Renewable Energy Generation and Distribution projects.

Tax holiday: Undertakings engaged in generation or generation and distribution of power have been offered a 10-year tax holiday for renewable energy plants, if they began power generation before March 31, 2013. However, they have to pay a minimum alternate tax at the rate of approximately 20 per cent, which can be offset in future years.

Financing: The Indian Renewable Energy Development Agency has been set up under Ministry for Non-Conventional Energy Sources and is a specialised financing agency to promote and finance renewable energy projects.

Generation-based incentives: Wind power @ ` 0.50 per MW, Solar Power @ ` 12.41 per KW

Accelerated depreciation: Renewable companies (solar as well as wind power) were provided with accelerated depreciation at 80 per cent. However, recently, the government has restricted the accelerated depreciation of 80 per cent to windmills installed on or before March 31, 2012. Windmills installed after March 31, 2012, will be eligible for depreciation of 15 per cent instead. But, 80 per cent depreciation is still available for solar power projects.

India has an estimated potential of over 30,000 MW of power from biomass, but around 3,000 MW has been

exploited. Thus, over 90 per cent of potential capacity lies untapped.

Dr Suneel PandeyFellow, Centre for Environmental Studies, TERI

STRATEGY Business plans for SMEs



With Asia’s growing

contribution to the

global chemical

industry, India has

emerged as one of the key destinations

for specialty chemicals. The specialty

chemicals industry provides colossal

growth opportunities for SMEs as well

as big players, thanks to the increasing

demand for chemical products within the

country and emerging markets.

Green is the futureIt is a fact that global companies are today

eyeing India for future business relations

as it offers quality products and services

for the high-value and low-volume

chemicals, which are known for their

end-use applications and performance

enhancing properties. Hence, there is

vast potential for chemical industry to

explore opportunities within the country

and become a dependable supplier of

quality chemicals to the world. According

to Omkar P Herlekar, Whole-Time

Director, Omkar Speciality Chemicals

Ltd (OSCL), Indian specialty chemicals

market size is pegged at $ 24.3 billion,

witnessing a steady growth at 14 per cent

per annum. “As one of the dominant

players in the specialty chemicals space,

we are of the opinion that the Indian

specialty chemical industry is at an

inflection point and is expected to emerge

as a major contributor to the country’s

growth in the coming years,” he adds.

However, the critical success

factors for most of the SMEs in

specialty chemicals segment hinge on

understanding customer needs and

products, application development to

meet the demand at a competitive

price-performance ratio. Going ahead,

innovation and sustainability initiatives

will be the major game changers for

the sector, including development of

processes, products through green

chemistry route. “Specialty chemicals

have witnessed a high growth rate in

the past and have grown at about 11.5

per cent per annum since FY07 while

the market size was about $ 13.5 billion.

Going ahead, the growth potential of the

specialty chemicals consumption in India

is poised to remain irrepressible and is

expected to reach about $ 45 billion by

FY17,” says Herlekar.

India gaining competitive edgeCompared to the developed world – the

US, Europe – the current penetration of

specialty chemicals within India’s end-

markets is low. With an increased focus on

improving products, the usage intensity

of specialty chemicals within the end-

markets will rise in India in couple of

years. Further, increasing global demand

is most likely to result in improved

production by low-cost manufacturing

locations of Asia-Pacific. Currently,

India exports to most of the Asia-Pacific

countries and other developed countries

of Europe, and the US. Going ahead,

India’s exports are likely to proliferate

further as many of the neighbouring

countries lag in competitive capacities.

India is potentially seen as a preferred

sourcing hub over China. “It is also

because India has a balanced IPR regime

with decent talent pool, pro-industry

labour laws, and low R&D cost. All these

make India a preferred destination to set

up manufacturing units,” says Herlekar.

Challenges for SMEsThe chemical industry, to a certain

degree, lags behind in focussed growth

and planning, which hampers global

competitiveness. It needs to increase

domestic value-addition and technological

depth to promote sustained growth. The

industry requires substantial investments

for capacity creation, technology

development, access to feedstock and a

larger pool of skilled human resources.

“To make it happen, the sector requires

investments to the tune of $ 200 billion.

Pro-active action by the government and

nodal agencies of Petroleum, Chemicals &

Petrochemicals Investment Region zones

by way of encouraging anchor tenants

to establish facilities, making feedstock

available for downstream plants and

creating a favourable ecosystem in terms

of infrastructure and other facilities will

help the sector evolve strong chemical

manufacturing competence centres, thereby

sending a positive message to the global

investing community,” points out Herlekar.

The R&D spend of the chemical

industry needs to go up substantially –

from the current level of 0.5 per cent of

sales to the global benchmarks of four per

cent of sales. It will also enhance India’s

global competitiveness in the chemical

sector. “With current initiatives of industry

and government, the Indian chemical

industry has the potential to grow at 11

per cent to reach the size of $ 224 billion

by 2017,” concludes Herlekar.


For SMEs aiming to gain foothold in the market, it is imperative to understand the exact needs of customers and deliver the products at competitive rates. In the present context, developing products by adopting green route is also essential for success.

Customised solutions with right pricing key to success

TIPS & TRICKSRFID technology


Work In Progress

( WIP): In the

chemical industry,

there exist many

WIP applications.

One example is that of chemical vats,

which have undergone different

treatments, but may look similar to

the eyes. By tagging the vats, right

vats can be used for the next process

step. Another WIP application may

include chemical labelling. RFID

labels are integrated into the chemicals

used in manufacturing and the

manufacturing process is updated to be

able to automatically identify and request

required chemicals.

Returnable assets:

There are many

assets in the chemical

industry, which move

through the supply and

manufacturing chain and are returned to

the supplier. Assets such as drums, totes

as well as many others can be tracked in

order to facilitate finding them as well as

their return.

Access control: In

chemical facility, there

are many sensitive

areas where only

authorised personnel

can enter. The movement of people

to such sites can be controlled and

monitored by using RFID access cards

at the gates and doors. Access control,

when coupled with tagged equipment,

can be used to prevent theft of high

value or strategic equipment.

Asset tracking and

management: RFID

can be used for tagging

and tracking expensive

tools, materials and

equipment to enable a more optimal

utilisation. The usage of tagged assets can

be tracked, and schedules for the asset can

be more easily and accurately planned.

Some assets are especially hard to track

due to environmental or geographical

conditions. In such cases, active RFID

tags can be used to automate accurate

tracking information.

Safety tool: RFID

can be an important

safety technology for

workers in the chemical

industry. Companies

can use RFID to protect workers who

have access to areas in which they may

be exposed to harmful radiation. With

RFID, managers can calculate how much

time a worker has spent in a given area

and call him out if he risks overexposure.

Warehousing: Efficient

warehous ing o r

distribution centres

(DC) can be enabled

with RFID, thus

resulting in useful savings. Some potential

applications where RFID can be useful

include pallet, case and item tracking

(especially, if pallets continue to be reused

within the warehousing system); forklift

localisation, asset management allowing

optimal usage of all assets in the warehouse

or DC; monitoring of tagged goods to

prevent unauthorised removal etc.

Inventory management:

Reduced inventory

levels and the

traceability of material

usage are possible

with RFID. Inventory levels can be

dynamically set based on production

plans and inventory can be automatically

reordered once a threshold is passed.

Production slowdowns due to lack of

inventory can be reduced, which bring

down inventory expenses.

Supply chain visibility:

RFID systems can

foster better and more

accurate information

shar ing between

chemical company and suppliers. This

leads to more accurate and timely

delivery of supplies making sure the

company has the right supplies in the

right place at the right time and in the

right sequence.

Traceability: It is

increasingly gaining

importance in many

industries where the

genealogy of a part

or a product at every

point in its lifecycle is required. RFID

has memory on the tag that can be

updated at any point. The data can be

stored both locally and externally in a

database creating a redundancy. Recalling

and service of the product becomes

much easier and fake items can be

identified quickly.

Courtesy: Total RFID Solutions Inc


RIGHT TRACKING SOLUTIONS FOR BETTER RESOURCE UTILISATION

Chemical industry comprises complex manufacturing processes and supply chain network. To ensure safety during manufacturing and transport, the industry has to comply with international standards and regulations. Chemical companies can use RFID technology to track hazardous goods shipments and to monitor temperature, pressure & the general condition of individual containers. They stand to benefit from RFID implementation in order to lower operating costs. Given below are different areas within this industry, which might benefit from RFID application.

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PROJECTS


Benificiated rock phosphateInternational Speciality Chemicals LtdProject type New facilityProject news ISC Speciality Chemicals Pvt Ltd is planning to set up a new chemical plant at Bharuch in Gujarat to manufacture non-ferric alum. Project location Bharuch, GujaratProject cost Not knownImplementation stagePlanning

Contact details:International Speciality Chemicals Ltd101, Atlanta, 209, Nariman Point Mumbai 400021, Maharashtra Email: Technical@isc-chemicals.com----------------------------------------Carbon blackKarthik Alloys LtdProject type New facilityProject news Karthik Alloys Ltd is planning to set up a new chemical project in Goa. The plant will involve in manufacturing of carbon black. Project location South Goa, GoaProject cost Not knownImplementation stage Planning

Contact details:Karthik Alloys LtdL6 & L7, Industrial Estate Cuncolim, Salcete Tq South Goa, Goa 403703Tel: 0832-2763402/539 Email: bsrinivasa@karthikgroup.com----------------------------------------Carbon disulphideIndo Baijin Chemicals Pvt LtdProject typeNew facilityProject news Indo Baijin Chemicals Pvt Ltd is planning to set up a new chemical

project at Bharuch in Gujarat. The project will involve in manufacturing of carbon disulphide. Project location Bharuch, GujaratProject cost Not knownImplementation stage Planning

Contact details Indo Baijin Chemicals Pvt LtdC/o Indofil Industries LtdPlot no Z/7/1, Dahej SEZ Part - ITal: Vagra, Dist Bharuch 392130Gujarat Tel: 02641-304100/101Email: rmishra-icc@modi.com----------------------------------------ChemicalsKhushi Chemicals Pvt LtdProject typeNew facilityProject newsKhushi Chemicals is planning to set up a chemical unit at Mahesana in Gujarat. An MoU has been signed with the State Government of Gujarat.Project locationMahesana, GujaratProject costNot known Implementation stagePlanning

Contact details:Khushi Chemicals Pvt LtdPlot no 3548, Phase-4GIDC Chhatral, Kalol TalukaGandhinagar 382729, GujaratTel: 02764-326551Email: khushichemical@yahoo.com----------------------------------------Essential oils & resinoidsSynthite Industries LtdProject typeNew facilityProject newsSynthite Industries Ltd is setting up an essential oils and resinoids unit (phase1) with a capacity of 13,200 tpa at Prakasam in Andhra Pradesh. Project locationPrakasam, Andhra Pradesh

Project costNot knownImplementation stageWork ongoing

Contact details:Synthite Industries LtdAjay Vihar, MG RoadKochi, KanayannurErnakulam 682016, KeralaTel: 0484-3051200Email: info@synthite.com----------------------------------------HCFC-chloro difluoro methaneGujarat Fluorochemicals LtdProject type New facilityProject news Gujarat Fluorochemicals Ltd is planning to set up a new chemical plant at Panchamahals in Gujarat. The project involves manufacturing of HCFC-Chloro Difluoro Methane(R-22). Project location Panchamahals, Gujarat Project cost Not knownImplementation stagePlanning

Contact details:Gujarat Fluorochemicals LtdINOX Towers, Plot no 17 Sector-16 A , Noida 201301Gautam Budh NagarUttar Pradesh Tel: 0120-6149600Email: [email protected] ----------------------------------------Liquid choline chlorideJubilant Life Sciences LtdProject type New facilityProject news Jubilant Life Sciences Ltd is planning to set up a new chemicals project at Vadodara in Gujarat for manufacturing of liquid choline chloride.Project locationVadodara, GujaratProject cost Not knownImplementation stage Planning

PROJECTS


Information courtesy: Tendersinfo.com

1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

Tel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]

Contact details:Jubilant Life Sciences Ltd1A, Sector 16A, Noida 201301Uttar Pradesh Tel: 0120-4361000 Email: [email protected] ----------------------------------------NPK fertilisersGujarat State Fertilisers & Chemicals LtdProject typeNew facilityProject newsGujarat State Fertilisers & Chemicals plans to set up a D Train DAP/NPK fertilisers unit with a capacity of 1,650 tpd at existing complex of GSFC in Sikka.Project locationSikka, GujaratProject costNot knownImplementation stage Planning

Contact details:Gujarat State Fertilisers & Chemicals LtdPO: Fertilisers NagarVadodara 391750, GujaratTel: 0265-2242651/751Email: info@gsfcltd.com----------------------------------------PerfumesOriental AromaticsProject typeNew facilityProject newsOriental Aromatics is planning to set up a perfume manufacturing unit at Ambarnath in Thane district of Maharashtra.Project locationThane, MaharashtraProject costNot knownImplementation stageWork ongoing

Contact details:Oriental Aromatics

Jehangir Building2nd Floor, 133 MG RoadMumbai 400001, MaharashtraTel: 022-66556000Email: sales@orientalaromatics.com----------------------------------------Pinaverium bromideJubilant Life Sciences LtdProject type New facilityProject news Jubilant Life Sciences Ltd is planning to set up a new chemical plant in Karnataka for manufacturing of pinaverium bromide. Project location Mysore, KarnatakaProject costNot knownImplementation stage Planning

Contact details:Jubilant Life Sciences Ltd 1A, Sector 16A, Noida 201301Uttar PradeshTel: 0120-4361000 Email: [email protected] gas Monnet Ispat and Energy Ltd Project type New facilityProject news Monnet Ispat and Energy Ltd is planning to set up a new chemicals project in Chhattisgarh to manufacture producer gas.Project location Raigarh, Chhattisgarh Project cost Not knownImplementation stage Planning

Contact details:Monnet Ispat and Energy LtdMonnet House 11, Masjid MothGreater Kailash Part – IINew Delhi 110048

Tel : 011-29218542/46 Email: monnet@monnetgroup.com----------------------------------------Single super phosphateKhaitan Chemicals & Fertilizers LtdProject type New facilityProject news Khaitan Chemicals & Fertilizers Ltd is planning to set up a new chemicals project in Uttar Pradesh for manufacturing of single super phosphate.Project locationFatehpur, Uttar PradeshProject cost Not knownImplementation stage Planning

Contact details:Khaitan Chemicals & Fertilizers Ltd301-308, Apollo Arcade 1/2, Old Palasia Indore 452001Madhya PradeshTel: 0731-2564936/937, 2565663 Email: [email protected] ----------------------------------------Quinine sulphate Surya Pharmaceutical LtdProject type New facilityProject news Surya Pharmaceutical Ltd is planning to set up a new chemical plant at Patiala in Punjab. The project involves manufacturing of quinine sulphate.Project location Patiala, Punjab Project cost Not knownImplementation stage Planning

Contact details:Surya Pharmaceutical LtdSco-164-165, Sector-9Chandigarh 160017Tel: 0172-5005000 Email: [email protected]

TENDERS


Latest Popular Tenders brought to you by www.tendersinfo.com

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type

Information courtesy: Tendersinfo.com

1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

Tel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]

Ammonia detection systemOrg : Department of Atomic EnergyTRN : 15477503Desc : Supply, erection and commissioning of fixed type gaseous ammonia detection systemBOD : April 22, 2013Loc : Hyderabad, Andhra PradeshBT : Domestic_______________________________________________

Dissolved oxygen monitorOrg : Petrochemical Kala CompanyTRN : 15343628Desc : Purchase of parts for dissolved oxygen monitorBOD : April 22, 2013Loc : TehranBT : ICB_______________________________________________

Mobile oil spill recovery unitORG : Indian Oil Corporation Ltd (IOCL)TRN : 15462632Desc : Supply of mobile oil spill recovery unit gully suckerBOD : April 22, 2013Loc : Panipat, HaryanaBT : Domestic_______________________________________________

Hydrocarbon gas detection and monitoring systemOrg : Numaligarh Refinery LtdTRN : 15451865Desc : Design & engineering, supply, installation & commissioning and post-commissioning maintenance of safety PLC-based hydrocarbon gas detection and monitoring systemBOD : April 24, 2013Loc : Golaghat, AssamBT : Domestic_______________________________________________

Gas analyserOrg : Mangalore Refinery and Petrochemicals Ltd TRN : 15345910

Desc : Supply of completely assembled dilution type SO

2/NO

x/CO analyser

BOD : April 25, 2013Loc : Mangalore, KarnatakaBT : Domestic_______________________________________________

Dew point analyser for hydrogen gasOrg : Punjab State Power Corporation Ltd (PSPCL)TRN : 14886150Desc : Supply of dew point analyser for hydrogen gas, Qty-02BOD : April 26, 2013Loc : Roopnagar, Punjab BT : Domestic_______________________________________________

Gas analyserOrg : La Société Des Ciments De Zahana S.Ci.ZTRN : 15459609Desc : Supply, installation and commissioning of a gas analyser for four coino/02 the dry cement BOD : May 08, 2013Loc : Zahana, Algeria BT : ICB_______________________________________________

Toximeter, methanometer, multigas detector, oxymeterOrg : Eastern Coalfields LtdTRN : 15375654Desc : Supply of Toximeter - 50 nos, methanometer - 17 nos, multigas detector - 01 nos and oxymeter- 03 nosBOD : May 09, 2013Loc : Burdwan, West BengalBT : Domestic_______________________________________________

Dissolved oxygen removal systemOrg : Department of Atomic EnergyTRN : 15398146Desc : Design, fabrication, supply, installation, commissioning & guarantee of membrane-based dissolved oxygen removal systemBOD : May 16, 2013Loc : Mumbai, MaharashtraBT : Domestic

EVENT LIST


NATIONAL

Poly IndiaA trade show for plastics and

petrochemicals industries; April 25-27,

2013; at Chennai Trade Centre, Chennai

For details contact:

Federation of Indian Chambers of Commerce

& Industry

Federation House

1 Tansen Marg, New Delhi

Tel: 011-23738760/8770

Fax: 011-23320714

Email: f [email protected]

CopexpoA trade show for industrial paint and

coating industry, which will be attended

by industrialists, policy makers, dealers,

researchers; June 07-09, 2013; at Chennai

Trade Centre, Chennai


Smart Expos

New No 116

Old No 81 Mount Road, Guindy

Chennai, Tamil Nadu

Tel: 044-22501986, 22501987

Fax: 044-28604261

Email: off [email protected]

PetroWorld IndiaAn event showcasing novel technologies

in oil & gas sector; August 22-24, 2013;

Bombay Exhibition Centre, Mumbai


Siddharth Chibba

Inter Ads Exhibitions Pvt Ltd

Plot No 859, Phase-V, Udyog Vihar,

Gurgaon 122016, Haryana

Tel: 0124-4524200/4201

Fax: 0124-4381162


Process Engineering ExpoAn international exhibition and

conference on process technology;

September 04-06, 2014; at Hyderabad

International Trade Exposition Centre

(HITEX), Hyderabad


HITEX

First Floor, Trade Fair Office Building

Hitex Exhibition Centre

Izzat Nagar, Hyderabad

Andhra Pradesh

Tel: 040-23112121/2122

Fax: 040-23112124

Email:[email protected]

India Chem GujaratThe exhibition will showcase the

latest products, machinery, equipment

and developments in the chemical

industry; October 24-26, 2013; at

Gandhinagar, Gujarat



& Industry

Federation House

1, Tansen Marg, New Delhi

Tel: 011-23738760/8770


analytica Anacon India 2013International trade fair for

laboratory technology, analysis,

biotechnology and diagnostics; November

12-14, 2013; at Bombay Exhibition

Centre, Mumbai


Avisha Desai

Project Manager

MMI India Pvt Ltd

Lalani Aura, 3rd Floor,

34th Road, Khar (West)

Mumbai 400 052

Tel: 022-42554710


Chemical Expo

A trade show for chemical equipment,

environment & safety, plastic &

packaging, electric & electronic,

petroleum & gas, engineering and

equipment; December 07-10, 2013,

AIDS Ananpura, Ankleshwar, Gujarat


Better Deal

204, Concord Complex

R C Dutt Road

Alkapuri, Vadodara 390007

Tel: 09979871798


India Chem 2014An international exhibition on chemicals,

petrochemicals, pharmaceuticals,

technologies, process plant machinery and

control & automation systems; October

9-11, 2014; at Bombay Exhibition Centre

(BEC), Mumbai



& Industry

Federation House

1, Tansen Marg, New Delhi

Tel: 011-23738760/8770


For details

Network18 Media & Investments LtdRuby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028.

• Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: [email protected]

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation,

Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

HYDERABADAndhra Pradesh,

May 31-June 3, 2013

The trade exposition on chemical plant, equipment

and process industry; February 2014; at Surat International Exhibition & Convention

Centre, Surat, Gujarat

For details contact: Network 18 PublishingRuby House, A-Wing, 1st Floor, J K Sawant Marg,

Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499


EVENT LIST


Kuwait Oil and Gas Summit & ExhibitionAn exhibition & conference focussing

on the development, diversification and

growth of the oil & gas industry of

Kuwait; April 28-30, 2013; at Kuwait

Regency Palace Hotel, Kuwait City


The CWC Group Ltd

Regent House, Oyster Wharf 16-18

Lombard Road

London, The UK

Tel: +(44)-(20)-79780000

Fax: +(44)-(20)-79780099


Israchem ExpoAn exhibition focussing on metal

coating and automation accessories for

the process industries such as chemicals,

gas, etc; April 30-May 02, 2013; at Israel

Trade Fairs and Convention Center,

Tel Aviv, Israel


Stier Group Ltd

Stier Group Building

12 Tversky

Tel Aviv, Israel

Tel: +(972)-(3)-5626090

Fax: +(972)-(3)-5615463


Petrochem ArabiaAn event dedicated to the technological

improvements and sustainability of the

downstream and petrochemical industries;

May 12-14, 2013; Dhahran International

Exhibition Center, Dammam,

Saudi Arabia


Bme Global Ltd

Waterfront Studios

1 Dock Road, London

E16 1 Ag

London, The UK

Tel: +(44)-(207)-5119582

Fax: +(44)- 207 022 1722


IE Expo - IE WaterAn exhibition focussing on water supply,

drainage & water treatment (CWS);

May 13-15, 2013; at Shanghai New

International Expo Centre (SNIEC),

Shanghai, China


Shanghai Zhongmao Exhibition Service

A/10, Huading Tower, 2368

Zhongshan West

Shanghai

China (Macau SAR)

Tel: +(853)-(21)-54592323

Fax: +(853)-(21)-54253480


Asia Coatings CongressAn event focussing on the latest

developments of the coatings sector; May

14-15, 2013; at Windsor Plaza Hotel,

Ho Chi Minh City, Vietnam


Quartz Business Media Ltd

Quartz House

20 Clarendon Road, Surrey

Redhill, England

The UK

Tel: +(44)-(1737)-855000


Petro.t.ex AfricaFocussed event on refineries & oil and

related technology; May 14-16, 2013; at

Gallagher Convention Centre, Midrand,

South Africa


Exhibition Management Services

PO Box 650302

Benmore, Johannesburg

South Africa

Tel: +(27)-(11)-7837250

Fax: +(27)-(11)-7837269


Oil And Gas Asia 2013An exhibition showcasing the latest

technology, equipment and machinery in

the fields of oil, gas and petrochemical

engineering; June 05-07, 2013; Kuala

Lumpur Convention Centre (KLCC),

Kuala Lumpur


Allworld Exhibitions

12th Floor, Westminster Tower

3 Albert Embankment

London, The UK

Tel: +44 (0)20 7840 2100

Fax: +44 (0)20 7840 2111


Dye+Chem Bangladesh 2013An international exhibition on all

kinds of dyes and fine & specialty

chemicals; September 05-08, 2013; at

Bangabandhu International Conference

Centre, Dhaka, Bangladesh


CEMS-Global Asia Pacif ic Pte Ltd

8 Temasek Boulevard, # 42-00

Suntec Tower Three

Singapore 038988

Tel: + (65) - 6829 - 2144

Fax: + (65) - 6829 - 2145


China AdhesiveAn exhibition focussing on latest

development on adhesive and

sealant products, chemicals and raw

materials for adhesives & sealants;

September 25-27, 2013; at Shanghai

Everbright Convention & Exhibition

Center, Shanghai


CCPIT Sub-Council of Chemical Industry

Building 16, Block 7, Hepingli

Dongcheng District

Beijing, China

Tel: +(86)-(10)-64275419


The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Chemical World

BOOK REVIEW


This book will enable engineers and research scientists to design and analyse

complex flow and reaction systems, thereby helping to take commercialised

reactions from the lab to the manufacturing area. Specifically dealing with

mixing effects important to the design of chemical reactors, it uses systems

models, typical of any large chemical plant or oil refinery, to examine temporal

mixing, or the mixing among particles or any conserved entities that have

remained in the system for different lengths of time. In addition, it views

mixing from a spatial perspective, treating it as a process that brings system

components into closer physical proximity. In addition, it reports the first

step towards unification of the temporal and spatial viewpoints of mixing. It

includes the basics of scaleup and mathematical modelling. It also explains

how to select reactors and study flow pattern. There are special sections on

fluidised beds and laminar flow processes. Stagewise and continuous mass

transfer processes are detailed in the book. The final section deals with gaining

experience through pilot plants and demonstration units.

An ideal text for graduate students with a working knowledge of physical

chemistry, classical gas absorption and mass transfer processes, it constitutes

an exhaustive treatment of four important areas: industrial exposure, theory,

applications, and practical problems along with their remediation.

Scaleup of chemical processes

Authors: Attilio Bisio and Robert L Kabel

Price: ` 3,495

Industrial distillation happens to be the most common separation technique

used in the chemical and petroleum industries. All distillation columns need

to be carefully controlled in order to meet specified production and quality

levels. This book enables readers to analyse, and troubleshoot all aspects

of column controls. It includes special chapters on underlying principles of

distillation, including separation processes, reflux and boil-up ratios, and

composition dynamics. The book also emphasises on important aspects such

as composition control, pressure control and condensers, reboilers and feed

preheaters, application of feed-forward, unit optimisation and complex towers.

The book is a complete guide with clear diagrams and illustrations that

clarify complex concepts and guide readers through multi-step procedures. It

will guide engineers as well as professionals working in process facilities, which

use distillation to separate materials, to implement the latest tested and proven

distillation control methods to meet their specific processing needs.

Reviewer: Tejas Padte, Lecturer, Ramnarain Ruia College

Distillation control: An engineering perspective

Author: Cecil Smith

Price: ` 5,100

Available at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001Tel: 022-2207 4484/6631 8958, Telefax: 022-2203 4058, Email: [email protected]

PRODUCTS


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

Looking For A Specific Product?Searching and sourcing products were never so easy.

Just type CW (space) Product Name

and send it to 51818eg. CW Pump and send it to 51818

One must invest wisely. Choose a product which

cuts down the operational cost without affecting

optimisation and efficiency.

Navneet Punj (Head – Business Operations)Wide Bridge Consulting

BPT tubing

BPT tubing formulation is ideal tubing

for use in cell culture, tissue culture work,

medical diagnostic product manufacturing,

fermentation systems and purification

applications. It is manufactured according

to GMP; is FDA-compliant (21 CFR

177.2600); and meets USP Class VI, European

pharmacopoeia and NSF (Standard 51) requirements. It can be used in

clean-in-place (CIP) and steam-in-place (SIP) cleaning systems and

can be sterilised by autoclave, ethylene oxide or gamma irradiation. This

tubing is non-toxic, non-hemolytic with extremely low permeability. It

resists acids, alkalies, oxidising agents and animal & vegetable oils.

PharMed BPT is heat-resealable, bondable and formable, making it

ideal choice in bioreactors and single use applications. It is useful in

applications involving light-sensitive samples. It operates optimally in

temperatures between -59°C to 135°C.

Cole-Parmer India Pvt Ltd

Mumbai - Maharashtra

Tel: 022-67162209/2222, Fax: 022-67162211


Website: www.coleparmer.in

Booster system

The hydro-pneumatic pressure booster system

consists of an automatic pressure controlled

pump and a pressure tank, along with an air-

filled Poly-Ether-Urethane (PEU) bladder.

Water pumped into this tank is compressed and

generates pressure on the bladder. This in turn maintains a desired pressure

within the whole water system. The automatic system requires no manual

intervention and is built for flow maintenance.

Jay Water Ltd

Ahmedabad - Gujarat

Tel: 079-2685 0026


Website: www.jaywater.com

Air operated double diaphragm pump

Lutz air operated double diaphragm pump is simple,

versatile, easy to use and maintain. The pump

sizes range from 1/4” to 3”size. Pump housings are

available in polypropylene, PVDF, nylon, aluminium

and stainless steel. Internals are available in teflon, EPDM, nitrile rubber

or viton. The pump runs on dry, non-lubricated, clean air. It is lube-free,

non-stalling operation, corrosion-free, weight reduction, air valve body

available in corrosion-free engineered plastics, commonality of spares

across models and sizes. The double diaphragm pump come in bolted

construction and are designed for a variety of industrial applications. It

is self-priming and can carry solid particles/slurries without any damage.

Typical pumping applications include industries such as pharmaceuticals,

glass and fibreglass, oil and gas, marine/shipbuilding, metal and steel,

effluent treatment, paint, aircraft, electroplating/surface treatment, food

and beverage, automotive, chemical, clay and ceramics etc.

Shanbhag & Associates

Mumbai – Maharashtra

Tel: 022-28346604/28340071


Website: www.shanbhags.com

Air operated pump

The air operated pump is used for handling viscous

liquids (solvents, toxic fluids, oil, grease, etc). It provides

hydro-static pressure testing with high pressure up to

500 bars. This is used for high pressure greasing. This

does not need electricity as it runs on compressed air.

Din-Tech Control Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-22820008, 22821417

Email: [email protected], Website: www.dtcpl.in

PRODUCTS


Internal gear pump

Internal gear pump is positive

displacement pump with linear

flows and is widely used in the

chemical industry. It is ideal for

transfer of thin, viscous liquids

and slurries. The pump is self-

priming with dry suction lift

of 0.5 bar and wet lift of 0.8 bar. It is available with integral single

and double precision relief valves and in CI, carbon steel, SS and other

materials of construction. Soft packing or mechanical sealed versions can

be offered based on liquids being handled. Magnetic gear pump is ideal

for hazardous and corrosive liquids, handling them in a leak-free manner

and is cost-effective when compared to pumps requiring specialised

sealing options. The flow rates vary from 0.5 m3/hr to 340 m3/hr with

pressures of up to 14 bar. The pump can handle up to 3,80,000 cSt liquid

viscosities and can work with operating temperatures of 370oC. Various

suction or discharge configurations can be offered based on liquids and

site conditions.

Shanbhag & Associates


Tel: 022-28346604/28340071


Website: www.shanbhags.com

Automatic amino acid analyser

The innovative automatic amino acid

analyser AT 2433 combines the advantages

of the classical ion exchange separation

method with the modern technique of

high performance liquid chromatography.

The complete package of sophisticated

instrumentation, a wide variety of

prepacked and tested separation columns,

combined with optimised ready-to-use buffer solutions and chemicals,

creates the right answer for any routine or research problem in amino

acid determination. With old fashioned step-elution systems, four and/

or five buffer solutions were needed. Now, due to the optimised buffer

system, only two buffers for hydrolysates and three for the physiological

sample are necessary. The buffer can be adjusted individually to the

samples by varying the mixture of the buffer. The flexible design of each

instrument allows the user to change all important parameters to fit the

desired application from protein hydrolysates, physiological fluids to

sugar analysis and biogene amines.

Analytical Technologies Ltd

Vadodara – Gujarat

Tel: 0265 – 2253620

Email: [email protected], [email protected]

Website: www.analyticalgroup.com, www.hpcltechnologies.com

PRODUCTS


One should scan the market for relevant products

which suit the company’s requirements.

Amarpreet Singh (Sr. Manager – Services)Geo Informatics Consultants Pvt Ltd

Test tool

The Fluke Color ScopeMeter test tool comes with

automated test capability for Fieldbus, Profi Bus

and other industrial communication protocols. Fluke

225C and 215C ScopeMeter test tools are designed

for maintenance specialists who keep automation and

process plant equipment operational. These instruments

feature easy signal validation of all the critical signal parameters, such as

amplitude & noise and have floating and fully isolated inputs for true

differential signal measurements on two-wire differential bus systems.

TTL Technologies Pvt Ltd

Bengaluru - Karnataka

Tel: 080-25251859


Digital test gauge

Digital test gauge for pressure measurement

and calibration in process monitoring and

control application is ideal for calibrating

pressure transmitters, switches and gauges.

It offers outstanding accuracy, resolution

and stability for pressure measurement

and calibration requirements. Accu-

Cal Plus is ideal for calibrating pressure

transmitters, switches and gauges. It is

housed in waterproof casing of polished stainless steel and rated IP65/

NEMA4. Accurate stainless steel pressure sensors offer models to cover

from vacuum up to 10,000 psig with accuracy up to 0.05% of full scale.

It provides numerous user-configurable features including adjustable

sample rates, dampening, tare, custom engineering units, min/max

and password-protected field calibration. A five digit rotating backlit

display with oversized digits, 20 segment bar graph and high contrast

provides superior resolution and excellent readability in poor light

conditions or bad viewing angles. Temperature compensation circuitry

and multi-temperature calibration provides outstanding accuracy over a

temperature range of 0° to 50° C.

Cole-Parmer India Pvt Ltd


Tel: 022-67162209 / 2222, Fax: 022-67162211

Email: [email protected], Website: www.coleparmer.in

Hollow fibre ultrafiltration module

Q-SEP hollow fibre Ultrafiltration (UF) modules

contain UF membranes manufactured with an innovative

cloud point precipitation method. This process ensures

a high pore density along the length of the fibre and

uniform pore size distribution in the membrane. Q-SEP

modules deliver superior performance characteristics

and product water quality that surpasses the quality from conventional

UF modules, with low silt density index (SDI) and excellent rejection of

bacteria and viruses. Q-SEP UF modules are made from a hydrophilic

polyethersulfone material that provides high fibre strength and excellent

low fouling characteristics, resulting in higher productivity. These hollow

fibre membranes operate under low transmembrane pressure in an inside-

out flow configuration for superior performance.

Aquatech Systems Asia Pvt Ltd

Pune - Maharashtra

Tel: 020 – 66547000/7269, Mob: 09890343114


Website: www.aquatech.com

PVDF pipe

PVDF pipe has the characteristic

stability of fluoro-polymers when

exposed to harsh thermal, chemical

and ultraviolet environments

while retaining the properties

of a conventional thermoplastic

material. Its features are high chemical resistance, low temp resistance,

mechanical strength and toughness, abrasion resistance, thermal

stability and low permeability to gases and liquids.

Sangir Plastics Pvt Ltd


Tel: 022-28726120


Website: www.sangirplastics.com

` `` `

You Pay ` 899/-

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Get 25% off on cover Price ` 1200/-Get 39% off on cover Price ` 3600/-

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PRODUCTS


Digital magnahelic gauge

This digital magnahelic gauge is used for

pressure/vacuum measurement in the

magnahelic pressure range. The instrument

is capable of measuring differential pressure

(two ports), gauge and vacuum measurement

for all ranges. Also available is the standard pressure measuring range

of 0 to 1, 2, 4, 5, 10, 40, 100, 400, 700 bar gauge pressure indicator and

0.0 to -760.0 mm hg vacuum range indicator. It finds applications in

cleanroom pressure measurement, HVAC equipment, Hepa filters, boiler

equipment, air handling units, etc.

Ace Instruments

Hyderabad - Andhra Pradesh

Tel: 040-23078848, Mob: 09394030848


Wastewater treatment system

This wastewater treatment system employs pulsed

electric field processing. The operations of a pulsed

electric field (PEF) wastewater treatment system

are based on the process of electroporation in cells

to accelerate pre-digestion. This results in up to 80

per cent less solid waste output. The wastewater

treatment PEF system destroys cell membranes by applying 1-20

microsecond, 35-50 kV/cm high voltage pulses at a frequency of up to

2 kHz to the wastewater stream. This system facilitates the anaerobic

digestion process of cells and is available in sizes beginning from 10,000

lph and reduces the solid waste by up to 80 per cent.

Diversif ied Technologies Inc

Massachusetts - USA

Tel: +1-781-2759444


Facemask respirator

The facemask respirator is used for dust filtration. It

is convenient to carry in the pocket. The facemask

respirator has a durable elastic band, which is soft and

safe when it comes in contact with the skin. This mask is

easy to wear, comfortable while talking and has breathing

resistance. The product finds applications in various

industries, such as cable, battery, PVC processing, heavy electrical, power

and cement plants, ceramic, silica and glass. It is also used while laying

cables, spraying paints, grinding, dusting, soldering and electroplating.

Empire Trades

Coimbatore - Tamil Nadu

Tel: 0422-5377228, Mob: 09894232828


PRODUCTS


Pipe bevelling tools

Pipe bevelling tools are fully portable for

offshore pipelines and onsite use and can bevel

at any degree of angle including precision ‘J

preps’ for automatic welding. It is designed

for long life and ease of use and requires no

special operator training, all clamp to the pipe

I.D., employ direct-drive bearing supported

gears and use the EscoLock blade lock system

with interchangeable cutter blades to bevel, face and bore simultaneously.

A broad line of portable welding end prep tools for bevelling pipe

ranging from 38 mm I.D. to 914 mm O.D. made of hard super alloys,

offshore and in fabrication shops, is available with pneumatic, hydraulic

and electric motors, depending upon model. They are suitable for

bevelling stainless steel, super duplex and P-91 alloys.

ESCO Tool

Massachusetts - USA

Tel: (508) 429-4441


Website: www.escotool.com

Centrifugal PP monoblock pump

The PCX M series Polypropylene (PP)

monoblock pump is used for handling

chemicals, loading and unloading tankers,

acid pickling, etc. The casing, impeller and

back plate are made of virgin moulded PP.

The shaft is covered with high alumina

ceramic sleeve and mechanical seal of teflon bellow type with GFT v/s

ceramic seal faces. The pump eliminates the problem of pump and

motor alignment generally faced in coupled type pumps. It also

reduces chances of seal failure and provides long operating life. The

pump comes with std. 415 V, 2900 RPM TEFC NFLP motor. The

PCX M series pump is available in 1, 2, 3 and 5 HP models with

capacity up to 40 m3/hr and maximum head up to 32 m.

Taha Pumps & Valves

Surendranagar – Gujarat

Tel: 02752 – 240233

Mob: 09825599415, 09825829875

Email: [email protected], [email protected]

Website: www.tahapumps.com

Industrial plastic components

A wide range of industrial plastic

components is available in ABS,

polycarbonate, EVA, polyacetal,

nylon, HDPE, PP, HIPS, PVC

and PET. Also offered are rings,

closures, spacers, bushings, gears, lids, clamps, housings,

handles, brackets, caps, connector brackets, electrical switch

boxes, pumps and valve components, etc.

A S Engineering Works


Tel: 022-65277554, Mob: 09833617762


Website: www.asengineeringworks.com

Cooling tower

The evaporative Fibreglass Reinforced Plastic

(FRP) cooling tower has a vertical induced

draft counter flow design with uniform water

distribution and optimal heat transfer. The tower

casing is made of tough FRP and has sufficient

structural strength to withstand high wind

velocities and vibrations. The fill splits the air and water into several

streams, increasing the time of contact. Automatic rotary sprinkler system

is made of nylon 66 material, rotary head and sprinkler pipe distribute

the hot water over the entire space of the filler. Sprinkler pipes are non-

clogging, require low pressure to operate and assure uniform water flow

with minimal operating pump head. The performance of cooling tower

depends upon the water distribution over the fills. The water is distributed

evenly through a wide spray angle without any dry pockets.

Gem Equipments Ltd

Coimbatore - Tamil Nadu

Tel: 0422-2363800, Mob: 09366631697


Website: www.gemindia.com

Hydrogen gas detection system

The hydrogen gas detection

system is used for detection of

hydrogen gas. It uses a 3-status

technology, which displays in

terms of low/medium/high

concentration. It has selectable

slide switch for audio and visual

built-in solid state buzzer. The system has the facility to function five

gas detectors with independent alarm latching facility, potential free

N.O/N.C contact and recorder output. The system is equipped with

4-wire technology and maturity timer.

Subtronics (India) Pvt Ltd


Tel: 022-24224461


Website: www.subtronicsindia.com

PRODUCTS


Hybrid stepping motor

The PJPL series linear-type hybrid stepping

motors enable linear motion of motor shaft with a

combination of threaded shaft and inner threaded

rotor. The motors do not require any outside

mechanical parts, such as lead screw, wire or belt for linear motion. These

motors are available in two sizes: 28 mm² and 42 mm².

Nippon Pulse Motor Co Ltd

Tokyo - Japan

Tel: +81-3-38138841


Reverse osmosis desalination system

The PW series reverse osmosis desalination

system is provided with the Aqua Pro 3

or 5-plunger high-pressure pump, titanium

head for maximum corrosion resistance,

balanced drive for lowest noise and pulsation,

PVC cable tray

The rigid PVC perforated cable tray is

an ideal replacement to MS tray. This

PVC tray is not affected by any corrosive

chemicals and is waterproof. It is used

outside for prolonged periods as it is

UV stabilised to resist ultraviolet rays of sun. It is available in width

ranging from 50 mm to 300 mm, flange heights of 25 m and 50 mm

and with a standard length of 2.9 m. The cable tray is lightweight

and maintenance-free. It is joined by socketed jointing system, which

means no coupler plate is required.

Supreme Electroplast Industries


Tel: 022-28873428, Mob: 09820306252


Website: www.supshitl.com

ceramic plungers and nylon valves. The boost pump provides up to 50 psi

of boost pressure to the filtration system. The system is equipped with

easy-to-operate SS-316 high-pressure bypass valve, which controls the

operating mode from cleaning/rinsing to water production and allows

high pressure bypass for start-up and low pressure flushing without

readjustment of regulating valve.

Parker Hannif in India Pvt Ltd

Navi Mumbai – Maharashtra

Tel: 022-65137081


PRODUCTS


Air classifier

This is a screenless machine for grading offline powder

into distinct coarse and fine grades from 60 mesh down

to 40 microns. The conventional vibrating screens have

choking problems along with low capacity when used

for fine powder separation. Also separation efficiency is

reduced. The air classifier can be operated in closed circuit.

Premium Vijimech Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-40083450

Mob: 09712987467


Cage mill flash dryer

This system has capacity that ranges from 10

kg/hr to 5,000 kg/hr. Due to low residence time

in the range of 0.5 to 2 seconds in the flash

dryers, heat-sensitive products can be easily dried

without degradation. The cage mill flash dryers

are compact, requiring less maintenance and user-friendly.

Raj Process Equipments & Systems (P) Ltd

Pune - Maharashtra

Tel: 020-4071001, Mob: 09766441144


Dust filtration system

The Dustkiller DK 500 captures fine particulates

before they settle down on precision equipment.

Dust is sucked by the centrifugal blower

through the inlets on the top. Capacity is

500 cm³/hr, input voltage is 230 V ±10 per cent, with

low noise and wall mounting with fixtures.

Powertech Pollution Controls Pvt Ltd


Tel: 080-23452156


Silicone grease

Silicone grease is a single component modified silicone

system. It does not harden, dry out or melt even after

1000 hours at 200°C, showing good di-electric and

lubricating properties. It wets and adheres to dry

surfaces of metals, ceramics, plastics etc, providing

high surface resistivity under moisture condensing conditions.

Anabond Ltd

Chennai - Tamil Nadu

Tel: 044-24402311/13, Mob: 09825688244


Website: www.anabond.com

Filter press

The sparkler-type filter press (model BPSF–8) consists

of stainless steel shell and top cover, which use bolts

to give pressure-tight enclosure. The filter cartridge

assembly inside the shell consists of several horizontally

arranged disc-type filter plates with perforated

supporting screens, filter media and interlocking cups.

Bombay Pharma Equipments Pvt Ltd


Tel: 022-28594877


Website: www.bombaypharma.com

Wear plate and wear pad

The wear plate and wear pad overcome the problems of wear in critical

sliding surfaces of machinery. It is used in sugar mills, cement plants and

other engineering applications. It is a modified bronze-sintered PFE

material with inherent characteristics of self-lubrication, low friction and

high load-bearing capacity. It can withstand high working pressure of 115

kg/cm² and temperature of –218°C to +260°C. It is fungus-resistant and

not affected by weather/moisture and most chemicals.

Rollon Bearings Pvt Ltd


Tel: 080-22266928


Website: www.rollonbearings.com

Simulator

The simulator is an apparatus that provides

(for testing purpose) conditions like those

which are encountered in real operation or

replica of real plant with real-time data. Real-

time simulators are offered for refinery: VDU,

CDU, FCCU with emulated TDC-3000 console, fertiliser: ammonia

and urea plant simulation with emulated Yokogawa DCS console, power

plant 210 MW on KWU and LMZ turbines.

Triangle Simulation Pvt Ltd


Tel: 022-24095682, Mob: 09969074960


Website: www.trianglesimulation.com

PRODUCTS


The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any

case, it does not represent the views of Chemical World

Diesel and gasoline nozzles

The diesel and gasoline nozzles are designed

for use on farm and consumer pumps. The

lightweight tensalloy aluminium diesel nozzle

provides high flow capacity required by

truck stops and terminal operations. Micro-

touch valve provides smooth operation and

exceptional flow control. Super tough nylon

hose guard and hold-open clip and easy-to-change lockout style

spout assembly are other important features. The lightweight

diesel nozzle offers efficient refuelling.

Dixon Asia Pacif ic Pvt Ltd


Tel: 022-40931555


Website: www.dixonvalve.com.au

Energy saver

Sensor-based energy saver automatically switches the

air-conditioners On and Off when the temperature in

the room is achieved. There is a 3-minute compressor

protection time interlock between each On/Off operation.

The existing air-conditioner has a crude non-sensitive thermostatic control,

which senses the grill temperature to switch the air-conditioner On/Off,

whereas the energy saver has a precision sensor, which can be placed, in any

part of the room to switch the air-conditioner On and Off. This helps in

maintaining the comfort temperature in most used part of the room.

Gautam Enterprises


Tel: 022-28750421


Website: www.gautament.com

Laser particle size and shape analyser

The laser particle size and shape analyser is

available in wet and dry mode feeding. Low-

cost particle sizers for small-scale industry

and colleges, mid-range models for quality

control, and top-of-the-line models for large-scale industry and

research institutes are available. These analysers find applications

in pharmaceuticals, cement, pesticides, battery material, graphite,

petrochemicals, metallic powders, catalysts, etc.

MeasureTest Corporation


Tel: 022-22027982, Mob: 09869012701


Website: www.measuretest.com

Multi-titration system

The automated multi-titration system is equipped with a

comprehensive Windows-based titration operating system, and is

capable of multiplexing. With a PC and user-friendly software, the

system controls every aspect of titration analysis, from real-time

runs to calculated results. The system performs a variety of specific

titrations, such as pH, thermo titration, optical, conductometric and

on-line titrations. It also includes four titration endpoint-sensing

methods available with rapid multiplexing between thermometric,

potentiometric, conductometric and chemiluminescence.

Multiflo Instruments Pvt Ltd

Navi Mumbai - Maharashtra

Tel: 022-27780880


Website: www.multifloinstruments.com

Electronic dosing pump

The electronic dosing pump is available from 0-20

lph. It is compact in size and lightweight. The

pump is diaphragm-type solenoid-operated pumps.

The diaphragm is made of PTFE and backed by

hyphalon. It can also be provided with automatic

flow switches and level controllers. The pump is suitable for applications

in water and wastewater treatment, fuel metering and other chemicals

dosing in many process industries.

Positive Metering Pumps (I) Pvt Ltd

Nashik - Maharashtra

Tel: 0253-2381993, Mob: 09326781757


Website: www.positivemetering.com

Rotary dryer

Rotary dryer is used for drying wet powders

and cakes. It consists of a rotating drum with

angle lifting blades, which lift the feed as the

drum rotates and showers in the stream of hot

air flowing through the drum. The capacity

ranges from 100 kg/hr to 50,000 kg/hr and

operating temperatures go up to 600°C.

Raj Process Equipments And Systems Pvt Ltd

Pune - Maharashtra

Tel: 020-4071001, Mob: 09766441144


Website: www.rajprocessequipment.com

LIST OF PRODUCTS


Sl. No. Product Pg. No. Sl. No. Product Pg. No. Sl. No. Product Pg. No.

Acoustic enclosure ................................ BC

Air classifier................................................. 80

Air operated double diaphragm pump ........ 72

Air operated pump ...................................... 72

Aluma coat .................................................. 29

Amino acid analyser .................................... 84

Atomic absorption spectrophotometer ........ 84

Automatic amino acid analyser ................... 73

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

Ball check valve ........................................3

Ball valve ............................................... 13, 79

Ball valve - teflon lined ................................. 4

Bellow and dip-pipe ...................................... 4

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

Booster system ............................................ 72

BPT tubing ................................................. 72

Butterfly valve ....................................... 13, 79

Butterfly valves - teflon lined ........................ 4

Cage mill flash dryer ............................... 80

Cake pressing .............................................. 35

Centrifugal PP monoblock pump ............... 78

Check valve ................................................. 13

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

Chemical and pharmaceutical ..................... 77

Chemical pump ........................................... 73

COD analyser ............................................. 59

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

Cooling tower ............................................. 78

Diaphragm valve ..................................... 79

Diesel and gasoline nozzle .......................... 81

Digital magnahelic gauge ............................ 77

Digital test gauge ........................................ 74

Dry van pump ............................................BC

Dryer ........................................................ BIC

Dust filtration system .................................. 80

E/P positioner ........................................ 73

Electronic dosing pump .............................. 81

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

Energy saver ................................................ 81

Evaporator ................................................ BIC

Exhibition - Plastivision 2013 ...................... 8

Expansion bellow .......................................... 3

Facemask respirator ................................ 77

Filter cock ................................................... 79

Filter press ................................................... 80

Flash dryer ................................................ BIC

Flow indicator ............................................. 79

Foged steel valve ......................................... 13

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

Gas chromatograph ................................. 84

Gate valve .................................................... 13

Globe valve .................................................. 13

Hastelloy ................................................ 13

Hollow fibre ultrafiltration module ............ 74

Hybrid stepping motor ............................... 79

Hydrogen gas detection system .................. 78

Impeller .................................................. 79

Industrial machinery plant and equipment ..... 77

Industrial plastic component ....................... 78

Internal gear pump ...................................... 73

Large diameter welded pipe ..................... 77

Laser particle size analyser .......................... 84

Laser particle size and shape analyser ......... 81

Limit switch ................................................ 73

Lined ball valve ............................................. 3

Lined valve .................................................. 13

Lined valve and pipe fitting .......................... 4

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

Modular system pump ............................. 47

Monel .......................................................... 13

Monoblock pump ........................................ 73

Multi-stage cake washing ........................... 35

Multi-titration system ................................. 81

Nickel aluminium bronze ........................ 13

Non-metallic pump ..................................... 73

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

P/P positioner ........................................ 73

PFA lined ball valve ...................................... 3

PFA lined plug valve..................................... 3

PFA lined product ........................................ 3

Pipe bevelling tool ....................................... 78

Piping system from polypropylene ................ 6

Plug valve .................................................... 13

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

Polypropylene process pump ....................... 73

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

Production HPCl ........................................ 84

PTFE lined ball check valve ......................... 3

PTFE lined fitting ........................................ 3

PTFE lined pipe ........................................... 3

PTFE lined product ...................................... 3

PTFE lined spool pipe .................................. 3

PTFE lined valve and pipe fitting ................ 4

Pump ....................................................73, BC

Pump for chemical equipment .................... 11

PVC cable tray ............................................ 79

PVDF pipe .................................................. 74

PVDF pump ............................................... 73

Reducer .................................................. 79

Reverse osmosis desalination system ........... 79

Roots blower ..............................................BC

Rotary atomiser ........................................ BIC

Rotary dryer ................................................ 81

Rotary gear pump........................................ 73

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

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

Seamless pipe .............................................. 77

Self priming mud pump .............................. 73

Self-priming sewage pump ......................... 73

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

Silicone grease ............................................. 80

Simulator ..................................................... 80

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

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

Spin flash dryer ........................................ BIC

Spool pipe ..................................................... 3

Spray dryer ............................................... BIC

Stainless steel pipe....................................... 77

Strainer .......................................................... 4

Super duplex ................................................ 13

Tee ....................................................... 79

Teflon lined valve and pipe fitting ............... 4

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

Test tool ...................................................... 74

Thermoplastic valve ...................................... 6

Titanium ..................................................... 13

Trade show .................................................. 60

Tube ............................................................ 77

‘U’ tube ................................................... 77

Vacuum booster pump .......................... BC

Vacuum or hot gas drying........................... 35

Vacuum system ..........................................BC

Valve ........................................................ 3, 79

Valve positioner ........................................... 73

Vertical glandless pump .............................. 73

Washer ................................................... 79

Wastewater treatment system ..................... 77

Wear plate and wear pad ............................ 80

Welded pipe ................................................ 77

Wind turbine .............................................FIC

‘Y’ type strainer ....................................... 79

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

Looking For A Specific Product?Searching and sourcing products were never so easy.

Just type CW (space) Product Name and send it to 51818eg. CW Pump and send it to 51818

al

LIST OF ADVERTISERS

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No


BC - Back Cover, BIC - Back Inside Cover, FIC - Front Inside CoverOur consistent advertisersNot applicable

All India Plastics Mfrs Association 8

T: +91-22-28217324

E: [email protected]

W: www.plastivision.org

Analytical Technologies Limited 84

T: +91-265-2253620


W: www.ais-india.com

Anup Engineering 77

T: +91-2646-250025


W: www.megamachineryindia.com

BASF India Ltd FIC

T: +91-22-66618000


W: www.basf.com

BHS-Sonthofen (India) Pvt Ltd 35

T: +91-40-23315341/45


W: www.bhs-sonthofen.in

Chemical & Process World 60

T: +91-22-30034650


Dev Engineers 73

T: +91-79-26403839


W: www.devpumps.com

Dip-Flon Engineering Co. 3

T: +91-79-25624003


W: www.dipflon.com

Everest Blower Systems BC

T: +91-11-45457777


W: www.everestblowers.com

Flucon Automation 73

T: +91-79-65722609


W: www.fluconautomationinc.com

G M Engineering 13

T: +91-2827-287658


W: www.gmengg.com

Hi-Tech Applicator 4

T: +91-79-25833040


W: www.ptfeindia.com

Jyoti Ceramic Industries Pvt Ltd 29

T: +91-253-2350120


W: www.jyoticeramics.com

LAN Marketing Pvt Ltd 47

T: +91-09920780721


W: www.maag.com

Parth Poly Valve Pvt Ltd 79

T: +91-79-22200198


W: www.parthvalves.com

Pentair Water India Pvt Ltd 11

T: +91-120-4199444


W: www.pentair.com

Shachi Engg Pvt Ltd BIC

T: +91-20-66546900


W: www.shachiengg.com

Suraj Limited 77

T: +91-79-27540720


W: www.surajgroup.com

Uniphos Envirotronic Pvt Ltd 59

T: +91-22-6123500


W: www.uniphos-she.com

UNP Polyvalves India Pvt Ltd 6

T: +91-265-2649248


W: www.polyvalve.com

chemical world - april 2013

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