INDUSTRY WATCH - Chemical World December 2012
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EDITORIAL
5December 2012 | Chemical World
EditorialAdvisory Board
Pothen P aul 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
A seamless blending
Manas R [email protected]
To predict the prices of oil (even on a short- to medium-term basis) is certainly
becoming more uncertain these days! Thanks to numerous global geo-political
factors apart from the fundamental demand-supply trade-offs, the science of
forecasting oil price is getting increasingly complicated with a higher probability
of missing out the real numbers. The bad news is this editorial piece is not going to inform
you either about a magic formula to get it right!
However, one thing is certain. The pulsating oil prices along with global warming are
driving the industry and users alike to actively explore non-conventional fuels as viable
alternatives, sooner than later. Although various alternatives such as ethanol, biodiesel, fuel
cells, biomass, photovoltaic etc are currently available in the market, several critical questions
related to their development, supply and price remain convincingly unanswered today.
While there is no denying that the need of the hour is to migrate fast to eco-friendly
fuels, the real challenge facing the policy makers and technocrats today is how
to make this transition seamless and comprehensive.
In this backdrop, the government’s recent decision to have mandatory
5 per cent ethanol blended in petrol before being sold across India, can
escalate the prices of this basic raw material of the chemical industry (among
other industries such as agrochemicals, dyes, pigments, paints, additives
and pharmaceuticals) to new heights. The reason being current yearly
availability of ethanol is rather limited in the country and is insufficient
to meet the requirements of different user-industries.
Here’s a sneak peek into some statistics on the Ethanol Blended
Petrol (EBP) programme and its progress card. The EBP programme,
introduced in 2006, has included 13 States with reportedly moderate
success so far. As a matter of fact, oil companies used 44 crore litre
of ethanol for blending in FY12.
With India’s ethanol production in FY13 expected to drop down
to 200-220 crore litre from its previous year’s figure of about 230 crore
litre and given the rising demand, it may be required to be imported
for meeting petrol blending requirements. Worse, it may even result in
increased price of molasses, as almost the entire ethanol production in
India comes from sugarcane molasses.
While it may not be that difficult for the potable alcohol industry to
pass on this rise in input cost to the consumer, the chemical industry will
find it hard to do so. As further clarity on implementation of this policy
is awaited, hopefully these concerns will be addressed well in time so that
the fundamental objectives of providing greener fuel and reducing India’s
ever-rising oil import bill are not overlooked.
7December 2012 | Chemical World
Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise
Insight & Outlook: Asset Optimisation
Special Focus: Filtration & Separation
Ultrafiltration technology ...................................................
Centrifugal method ............................................................
Membrane separation .........................................................
Pleated bag filters ...............................................................
Filter media .........................................................................
In Conversation With
24
26
28
30
32
Chaitanya Koranne, Chief Executive Officer, CRI Pumps Pvt Ltd .................................. 20
38
Asset optimisation .............................................................
Asset management .............................................................
Roundtable ..........................................................................
Accident reduction ..............................................................
Oil price volatility ...............................................................
38
40
42
Automation TrendsWireless technology: Redefining asset management process ...........................................................
Energy ManagementCold pilger process: A cool solution to tube forming .......
Policies & RegulationsREACH impact: Cascading effect on the global regulatory framework ..........................................................
StrategyTapping human resources: Capitalising on intelligent quotient ...........................................................
Tips & TricksControl system migration: Effective ways to upgrade automation capabilities .........................................
Event Preview�� Engineering Expo Ludhiana 2012: Making
manufacturing-friendly North accessible .....................
�� Engineering Expo Indore 2013: Tapping India’s central vantage point .........................................
Event Report�� Engineering Expo Pune 2012: Generating high
volume of opportunities ..............................................
�� Engineering Expo Chennai 2012: Showcasing Southern manufacturing strengths ..............................
Cover visual: Mahendra Varpe
Regular SectionsEditorial ........................................................................ 5
News, Views & Analysis .............................................. 10
Technology & Innovation ............................................ 17
Technology Transfer .................................................... 18
Projects ........................................................................ 58
Tenders ........................................................................ 63
Event List .................................................................... 64
Book Review ................................................................ 74
Products ...................................................................... 76
List of Products .......................................................... 86
List of Advertisers ...................................................... 87
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52
54
56
66
68
70
72
44
Facility Visit: Dow Corning India Pvt Ltd
‘Lean’ing on efficiency for better productivity ................. 34
46
Highlights of Next EditionSpecial Focus: Wastewater & Effl uent Treatment
Insight & Outlook: Industrial Gases Details on page no. 59-62, 64
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9December 2012 | Chemical World
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Business InsightsTechnologies
Opportunities
NEWS, VIEWS & ANALYSIS
Chemical World | December 201210
Dow Wolff Cellulosics (DWC), a business
unit of The Dow Chemical Company, is
eyeing to tap the burgeoning pharmaceutical
market to boost its business in India.
“Healthcare is one of the mega trends
the company is focussing on globally, and
India, of course, is one of the most strategic
regions for pharmaceuticals. That is why
we have established a scientifically-advanced Customer Application
Development Centre at Mumbai in 2011. The centre provides all
technical support and expert guidance to customer needs in the
areas of hot melt extrusion technology, extrusion-spheronisation,
enhanced granulation & particle coating, high performance tablet
coating and tablet compression with CFC system,” said Dago
Caceres, Global Pharmaceutical Marketing Leader, The Dow
Chemical Company. As a part of its growth strategy, DWC recently
launched a new product in India, especially designed to meet one
of the most pressing needs of the pharmaceutical industry, the
solubilisation of active pharmaceutical ingredients.
Rakesh Rao
LANXESS, a global leader in specialty
chemicals, has inaugurated a new
wastewater post-treatment plant at its
manufacturing site in Nagda, Madhya
Pradesh. With an investment of nearly
` 35 crore in this project, this plant aims
at making the site virtually free from any
effluents and also recovering water for
reuse in its production processes.
The inauguration event was
graced by the presence of senior
government officials, representatives
from the local administration and
LANXESS employees among other
dignitaries. Present on this occasion
were Michael Siebert, Consul General,
Federal Republic of Germany; Kailash
Vijayvargiya, Minister of Industries and
Employment, Government of Madhya
Pradesh; Dr Hubert Fink, Head,
Business Unit Advanced Industrial
Intermediates (AII), LANXESS AG;
Dr Joerg Strassburger, Managing
Director and Country Representative,
LANXESS India; Neelanjan Banerjee,
Head, Business Unit AII India, and
Senior Executive Director, LANXESS
India; and Bappa Bandyopadhyay, Vice
President – Manufacturing, Nagda site.
In his address, Siebert highlighted
the long-term investment approach
and sustainable development of the
eco-system by German companies.
Vijayvargiya while welcoming this
investment in Madhya Pradesh
appreciated LANXESS’ achievement in
this project, especially as it can bridge
the gap in availability of water, given its
scarcity during the summer months in
this central part of India.
Explaining the significance of this
plant, Dr Fink said, “We are not only
producing world-class products at this
plant in Nagda but are also reaching
new levels of sustainable development.”
Dr Strassburger informed the audience
of his organisation’s commitment to
continue to invest in further improving
the levels of safety and sustainability at
LANXESS’ manufacturing facilities in
India. In the words of Banerjee, “We
have used some of the best technologies
available in the world and have partnered
with some of the best-known suppliers
in the industry for this plant.”
LANXESS’ Nagda site has a full-
fledged effluent treatment plant and a
state-of-the-art sewage treatment plant,
which treats sewage water from the
nearby colonies and renders it fit for
use in the production processes. The
company has zeroed in on a concept for
wastewater post-treatment that involves
a reverse osmosis process followed by an
evaporation step. LANXESS is a member
of the leading sustainable indices Dow
Jones Sustainability Index (DJSI) World
and FTSE4Good.
Manas R Bastia
DRUG FORMULATION
Dow eyes major gains in India’s pharma sector
SUSTAINABLE DEVELOPMENT
LANXESS creates new benchmark at Nagda
PERIPHERAL PRODUCTS
Home and personal care industry witnessing robust demand Peripheral product categories are seeing an unsurpassed rise in
the Home & Personal Care (HPC) industry, as per research by
Tata Strategic Management Group (TSMG). Peripheral categories
comprise those products that are specific to certain functionality.
“Handwash and facewash product categories, for eg, fall under
peripheral categories as they are replacing the functionality of a bar
soap. These are the days of specificity and customisation. This is a
mega trend and we see it percolating down the society,” said Rajiv
Subramaniam, Principal – Consumer & Retail, TSMG. This spells
huge opportunities for the specialty chemicals industry to offer
functional solutions to the HPC industry.
Another macro trend is that of premiumisation. This has thus
seen the rise of niche products in the fabric care segment, such
as after wash, fabric softener/conditioner, stain remover. “This is
a significant opportunity for suppliers to cash upon. HPC sector
is poised to grow as seen by the market trends. Individualism
is an observation, which is seen in this industry, ie designing
products catering to different people,” added Subramaniam.
Mahua Roy
Dago Caceres
Inauguration of the new wastewater post-treatment plant
NEWS, VIEWS & ANALYSIS
Chemical World | December 201212
RARE METALS
Bulk gallium nitride price to witness steep fall by 2020Gallium nitride (GaN), used for its
energy saving properties in electronics
industry, will become more competitive
compared to traditional silicon by 2020
due to drop in prices, according to a Lux
Research report. Bulk GaN is expensive
today, costing about $ 1,900 or more for
a two-inch substrate, compared with
$ 25-50 for a larger six-inch silicon
substrate. But GaN materials offer
higher efficiencies than silicon, leading
to better energy savings in devices such
as power electronics, laser diodes, and
light-emitting diodes (LEDs). These
gains can offset cost disadvantages –
the price-to-performance ratio is the
key to adoption.
“The future of bulk GaN is going to
come down to how it faces off against
silicon substrates. Bulk GaN wins in
laser diodes and it can become relevant in
LEDs and power electronics by boosting
yield and performance,” said Pallavi
Madakasira, Lux Research Analyst,
and the lead author of the report titled,
‘Price or performance: Bulk GaN vies
with silicon for value in LEDs, power
electronics and laser diodes’. The report
added that bulk GaN can overcome
high cost by boosting performance in
terms of lumen (lm) output in LEDs
or volt-amp (V-A) capacity in power
electronics.
CRI Pumps, one of the leading
manufacturers and exporters of
pumps from India, is setting up a new
manufacturing unit in Coimbatore.
This announcement comes soon after
the business transfer agreement with
UK-based Pumps and Process Systems
Ltd (PPSL). The entire manufacturing of
pumps from the PPSL product portfolio
has now been transferred to India, post the
non-competitive agreement with PPSL
that has been in operations for more than
20 years now and has well-established
global clients.
The new facility is 45,000 sq ft with a
test bed. The greenfield unit is slated for
completion in the first quarter of 2013.
“The arena of slurry pumps is relatively
new, which we identified as an opportunity
area. We will have two portfolios in India
– the hard line, which is the metal line, and
the rubber line, thus enabling the process
industries to handle different degrees of
corrosiveness,” said Chaitanya Korrane,
Chief Executive Officer, CRI Pumps.
Mahua Roy
NEW FACILIT Y
CRI Pumps setting up new manufacturing unit at Coimbatore
Moody’s Investors Service, one of
the leading providers of credit ratings,
research, and risk analysis affirmed Tata
Chemicals Ltd’s (TCL) Ba2 corporate
family rating and maintains the stable
outlook. Moody’s acknowledged that
TCL’s performance in recent years has
benefited from steady growth derived
from both acquisitions and organic
expansion while maintaining an adjusted
EBITDA margin of more than 17
per cent. While this level of margin
is strong for its rating category, its
balance sheet and liquidity profile are
commensurate with a Ba range rating.
P K Ghose, Executive Director &
Chief Financial Officer, Tata Chemicals
Ltd, said, “We respect Moody’s rating of
our company and are happy that it has
been recognised despite adverse market
conditions. Going forward too, we expect
the Indian market to continue the growth
momentum. We are also positive that our
diversity in product portfolio will help
reduce volatility and balance our earnings
in the future.”
TCL has considered large-scale
expansion of its existing urea plant in
India, which would help to reduce the
country’s imports of the fertiliser, but the
supply of natural gas has been a stumbling
block. Moody’s expects TCL to continue
at its current brisk rate of growth with
further small investments to bolster
existing activities and continuing cost
reduction and productivity improvements.
CREDIT RATING
Moody’s affirms stable outlook for Tata Chemicals
PLANT SAFETY
Dow Corning’s Pune site wins DCCIA Award for best practices in safetyDow Corning’s Ranjangaon site
has been recognised by the Deccan
Chamber of Commerce Industries
and Agriculture (DCCIA) Pune for
best practices in safety under the
chemicals category. David Longo,
Manager, Pune site, Dow Corning,
said, “Safety is one of our seven core
values at Dow Corning and our team
is committed to an injury-free work
environment. While this is an important recognition for all our employees’ efforts,
we should continue our journey into safety.” Suneel Joshi, Dow Corning’s Employee
Safety and Security Manager, Pune site, stated, “The safety award from DCCIA is a
significant acknowledgement and a strategic step forward to showcase our commitment
to safety and safe practices to the external world.”
Chaitanya Korrane
NEWS, VIEWS & ANALYSIS
Chemical World | December 201214
NEW PRODUCT
INPEX Corporation to use SCADA and PKS from HoneywellJapan’s INPEX Corporation will
implement Honeywell’s Experion
Supervisory Control and Data
Acquisition (SCADA) and Experion
Process Knowledge System (PKS) in its
new pipeline control centre, which will
process natural gas from domestic and
overseas sources for local distribution
and consumption. Experion SCADA
will be used to integrate and manage data
coming from more than 160 monitoring
and control stations along a 1,400 km
gas distribution network, spanning nine
prefectures, and also manage the delivery
of gas to homes and businesses in the
Tokyo metropolitan area. The software’s
ability to handle multiple servers and
switch over to a standby server in
case of failures will enable INPEX to
continue operations safely and without
disruption in the event of equipment
or system failures. INPEX manages the
production of natural gas from Minami-
Nagaoka, the field which accounts for
about 40 per cent of Japan’s total natural
gas production.
With the growing demand for
natural gas in Japan ranging between
2.5 and 3 billion cubic meters annually,
INPEX plans to tap gas from overseas
to supplement the domestic demand.
The company’s new liquefied natural
gas terminal and Pipeline Control
Centre in Joetsu City, Niigata Prefecture
will support this plan and become
operational in 2014.
Balaji Amines Ltd has been awarded
for the category of ‘Best Manufacturer
– Exporter (Medium)’ at the Indian
Exporter Excellence Awards 2012
instituted by the Export Credit Guarantee
Corporation of India Ltd (ECGC), in
association with Dun and Bradstreet
(D&B), which seeks to recognise leading
exporters for their excellence in their
respective fields.
A Prathap Reddy, Chairman &
Managing Director, Balaji Amines Ltd,
appreciated and congratulated the efforts
of his team members in achieving this
Award. He stated, “Recognition on such
a huge platform will encourage and boost
them for further achievements.”
Most of the products of Balaji
Amines Ltd are developed via in-house
R&D for which the Ministry of Science
& Technology, Government of India,
has given ‘In-house R&D Recognition’.
Also, its recent facility for manufacturing
PVPK-30 at Chincholi MIDC area,
Maharashtra, was awarded Certificate
of Suitability (COS) from European
Directorate for the Quality Medicines
& Healthcare (EDQM), in addition to
WHO-GMP certification.
RECOGNITION
Balaji Amines bags ECGC’s export award
Waters Corporation recently announced
that its ACQUITY UPLC System is
now available with online solid phase
extraction (SPE) technology from
Spark Holland BV. The technology is
now available as an integrated Waters
UPLC/MS system or as an upgrade to
installed ACQUITY UPLC Systems.
High-throughput analytical laboratories
can now streamline sample preparation
and analysis time, and generate test
results faster than before.
“Combining our UPLC technology
with Spark Holland’s online SPE
technology offers benefits to high-
throughput laboratories intent on
producing the highest-quality test
results, quickly and reproducibly for
UPLC/MS analyses. Automating the
process of sample preparation can help
laboratories improve turnaround times,
reduce errors and control costs,” said
Ian King, Vice President, Separations
Technologies, Waters Division.
ANALYTICAL INSTRUMENTATION
Waters offers automated online sample preparation in UPLC platform
SPECIALTY CHEMICALS
AkzoNobel honours Ashland Specialty Ingredients with Best Service Award Ashland Specialty Ingredients, a commercial unit of Ashland Inc, recently received the
2012 Best Service Award from AkzoNobel, one of the largest coatings manufacturers
in the world. The award recognised Ashland’s outstanding achievements as a top
global supplier in delivering high-quality coating additives solutions while fulfilling
application requirements.
The Best Service honour is awarded annually to suppliers in recognition of world-
class performance in the areas of product quality, technical service and supply reliability.
Ashland is among the top seven winners this year.
“We are proud to receive AkzoNobel’s highest award for suppliers, as it drives us
to continue contributing towards their growth and success. Our effective collaboration
makes it possible to bring innovative products and solutions more rapidly to the global
market,” said William Zhao, Sales Director, Ashland Specialty Ingredients China. In
addition to supplying rheology products, Ashland works with AkzoNobel to develop
new generation of products catering to the local market. “Our coating sales team
also scored high on our expertise and outstanding service,” says James Huang, Sales
Manager, Coating Specialty, Ashland Specialty Ingredient China.
A Prathap Reddy receiving the award from M S Rao, Secretary, Commerce and
Industry, Government of India, during the function
NEWS, VIEWS & ANALYSIS
Chemical World | December 201216
NEW LAUNCH
Dow Epoxy and Dow Polyurethanes launch products Dow Epoxy, a business unit of The Dow
Chemical Company, has introduced a
broad portfolio of epoxy products
designed for civil engineering, general
coating, adhesive and composite,
featuring new high-performance
D.E.H. curing agents and FORTEGRA
series. The expanded portfolio includes
epoxy components, specialty resins,
curing agents, as well as resin blends
and hardener solutions. Dow introduces
specialty offerings in the expanded epoxy
portfolio that include low temperature
cure, low-emission and waterborne
curing agents as well as toughing agents,
such as FORTEGRA series.
Another business unit of The
Dow Chemical Company, Dow
Polyurethanes in co-operation with
Cannon SpA, announced that
PASCAL polyurethane insulation
technology for household refrigerators
and freezers is now available to retrofit
to existing production lines. “With the
ability to retrofit PASCAL to existing
production systems, manufacturers
benefit from increased production
efficiency and consumers benefit
from refrigerators with higher energy
efficiency,” said Mark Bassett, Global
Vice President, Dow Polyurethanes.
PASCAL is a polyurethane foam
insulation technology that improves
energy efficiency in refrigerators and
freezers by up to 10 per cent.
Specialty chemicals group LANXESS
has invested Euro 5 million in its
phosphorus chemicals production
network in Leverkusen. One of the
largest of its kind in the world, this
network is the foundation for efficient
production, global availability and high
supply reliability. The newly implemented
measures will result in a capacity increase
of ten per cent for phosphorus chlorides.
“In addition to debottlenecking
the production unit, we improved the
logistics concepts for our drum- and tank
car-filling facilities. That gives us even
more flexibility. We are well-equipped
now to meet the increased demand on
the global market,” said Jorge Nogueira,
Head, Functional Chemicals (FCC)
Business Unit, LANXESS.
LANXESS is a leading supplier
of phosphorus chemicals. Excellent
backward integration, decades of
experience and modern plants provide
the foundation required for economical
production and top-level quality. Starting
with elemental phosphorus, it produces
a variety of derivatives, which can be
used in numerous fields of application.
Phosphorus chlorides are starting
materials for the chemical synthesis
of flame retardants, water treatment
chemicals, lubricant additives, crop
protection active ingredients and active
pharmaceutical ingredients.
INVESTMENT
LANXESS invests Euro 5 million in phosphorus chemicals production
Malvern Instruments’ dynamic light scattering system, Zetasizer
Nano ZSP, has got its first customer - Dr Kikuo Okuyama of
the Department of Chemical Engineering at the Graduate School
of Engineering, Hiroshima University in Japan. In Dr Okuyama’s
work, the objective is to find alternative materials for rare earths and
to develop rare earth-free functional materials. This involves research
into the composition and structure of functional fine particles and
will use the Zetasizer Nano ZSP in the evaluation of nano particle
size, dispersion and surface chemistry.
ANALYTICAL INSTRUMENTATION
Hiroshima University installs Malvern’s new Zetasizer Nano ZSP
NEW TECHNICAL CENTRE
WACKER opens technical centre in DubaiThe Munich-based WACKER has
expanded the service portfolio at its
technical centre in Dubai. The centre
of excellence located at the Dubai
Silicon Oasis (DSO) technology park
now includes a dedicated laboratory for
interior and exterior paints and coatings
applications. The new lab comprises
applications technology and test equipment
for polymer dispersions needed as binders for interior architectural paints. A further focus is
on silicone additives and binders for interior and exterior paints & coatings.
The expansion not only enables WACKER to help its local customers develop new
and tailor-made products for the growing market for high-quality coatings but also
encourages the exchange of know-how and promotes internationally recognised quality
standards in the region. The expansion was made necessary by the region’s strong economic
growth, particularly with regard to sophisticated paints and coatings applications. This
measure will help WACKER to further bolster its position as a leading producer for vinyl
acetate-ethylene copolymer (VAE) dispersions and silicone additives & binders.
ECO-FRIENDLY MEASURES
SABIC releases first Sustainability ReportSABIC released its first Sustainability Report, entitled
‘Sustainability+Performance’. The report, covering
sustainability performance in 2011, will be published
annually and serve as a valuable tool for customers,
investors and stakeholders to evaluate SABIC’s commitment
and performance towards sustainable business practices.
Mohamed Al-Mady, Vice Chairman and CEO, SABIC, said,
“Sustainability for SABIC means we have strategies, goals
and actions in place to address stakeholder expectations of
our responsibility as a corporation.”
TECHNOLOGY & INNOVATION
17December 2012 | Chemical World
Honeywell has launched its new
thyristor line of products designed to
regulate accurate power to electrically
heated industrial devices and provide
protection from transient overvoltage
conditions. The product line is ideal
for industrial applications involving
electrically heated equipment in
electric furnaces, automotive painting
booths, textile machinery, drying
ovens, petrochemicals, metals (ferrous
and non-ferrous), glass, plastics and
semiconductor machines. The new
thyristors use the latest microprocessor-
based design to accurately control a wide
spectrum of electrical loads, ranging
from simple constant resistances to
highly complex variable resistances and
transformer coupled loads.
They are modular, scalable
and offer a wide range of product
configurations available. The complete
product line can switch loads from 30
amperes (amps) to 2,700 amps and
provide good performance even in the
most demanding applications. The
solid state design removes the need
for periodic preventive maintenance
and reduces premature element
ageing with optimised heater power
requirements. For companies in
the process industry, this results in
reduced costs and improved quality
of heat treated material, eliminating
the shortcomings of the traditional
electromechanical contactors used in
electric furnace control applications.
“Downtime in the system due to
unscheduled outages and ageing of
electrical heating devices often result in
costly project delays and repeated loss
of production. Capable of functioning
in varied application environments,
Honeywell’s Thyristors deliver precise
power, enhance efficiency and ensure
maximum equipment life,” said
Amitava Biswas, Country Head, India,
Honeywell Process Solutions.
Honeywell’s thyristors reduce downtime and enhance productivity
Mettler Toledo’s new InPro 5000i is a fully sterilisable in-place and
autoclavable in-line carbon dioxide (CO2) sensor. It features a class
N5 surface and EHEDG certification for compliance with hygienic
requirements. The sensor’s membrane provides an excellent barrier
against volatile organic acids, ensuring errorless measurement.
InPro 5000i is the latest member of Mettler Toledo’s Intelligent
Sensor Management (ISM) family of sensors and transmitters.
This dissolved carbon dioxide sensor is fully sterilisable in place
(SIP) or in an autoclave. Optimum yield in bacteria fermentation
is strongly related to the proper control of CO2 partial pressure.
In cell culture applications, mammalian cells depend on a set of
specific environmental conditions within a narrow definition in
order to survive and ensure optimal growth.
InPro 5000i’s modular design helps simplify maintenance and
spare-part replacement. Suitable housing for the sensor is the
retractable InTrac 797. Its integrated flushing chamber allows
easy sensor calibration and cleaning, even during a running
fermentation. The interior body, a high performance pH electrode,
can easily be replaced at the customer site. The robust and fully
sterilisable sensor design meets all requirements for hygienic processes. ISM
technology provides all sensor relevant information for maintenance planning,
and pre-batch or real-time diagnostics. For full traceability, all pertinent data
such as calibration details and number of SIP or autoclavings are stored inside
the sensor.
Yokogawa Electric Corporation has come out with RotaMASS LR, the world’s
smallest dual bent tube Coriolis mass flow meter. The new RotaMASS LR employs
a proven dual bent tube design and represents a significant advance to Yokogawa’s
RotaMASS low flow line product family for gas and liquid flow measurement.
Designed to be self-draining and to measure both liquids and gases, the mass
flow measurement spans from 0-40 kg/h. The accuracy is +/- 0.15 per cent for
liquids and +/- 0.5 per cent for gasses. RotaMASS LR meets the market’s demand
for accurate and stable measurement of fluids at low flow rates. Yokogawa has
developed the low flow Coriolis meter based on its proven dual bent tube design
to overcome the current shortcomings of single tube low flow meters. These
shortcomings include susceptibility to external vibrations and changes in ambient
or process fluid temperatures, which lead to less accurate and stable measurements
in real-world conditions.
RotaMASS LR employs a dual bent tube design that optimally
decouples the core measuring element from process vibration that can cause
fluctuating zero stability and decrease measurement accuracy. When fluid
density changes, a single tube Coriolis flow meter can become imbalanced.
RotaMASS LR remains balanced due to the equal mass change in both tubes
and the absence of interference from the process piping. The two tubes are
made from C-22 alloy, which is less susceptible to thermal expansion than
conventional stainless steel.
Mettler Toledo’s sensor helps simplify maintenance
Yokogawa’s new flow meter provides accurate and stable measurement
TECHNOLOGY TRANSFER
Chemical World | December 201218
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.
Areas of application
Chemical and energy industries
Forms of transfer
Technology licensing
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.
Areas of application
Furan polymers, sealants & cements,
urea-formaldehyde, and phenolic resins
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.
Areas of application
Plastics, paper, paints, rubber, inks
Forms of transfer
Consultancy, technical services
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]
Activated carbon and sodium silicateA company from Thailand requires technology for manufacturing activated carbon and sodium silicate from rice husk & rice husk ash.Areas of application
Manufacturing and construction industryForms of transfer
Others
Glyoxal An Indian company is looking to
switch the production technique for
manufacturing 40 per cent glyoxal from
its existing acetaldehyde-based method
to the MEG-based glyoxal production.
Areas of application
Pharma & textile
Forms of transfer
Others
Inorganic chemicalsAn Indian company is interested
in seeking the technology and
process know-how for production of
potassium nitrate, chromium acetate,
and magnesium hydroxide suspension.
Areas of application
Chemical industry
Forms of transfer
Others
LimeAn Indian company seeks new cost-
effective technologies that can reduce
carbon emissions for lime manufacturing.
Areas of application
Quick lime and hydrated lime
Forms of transfer
Others
Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacific Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacific (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi - 110 016, Tel: 011-3097 3758 (Direct), 3097 3710 (Board), Fax: 011-2685 6274, E-mail: [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.
TECHNOLOGY REQUESTED
IN CONVERSATION WITH Chaitanya Koranne
Chemical World | December 201220
IN CONVERSATION WITH
There is dearth
of people with extensive knowledge of
hydraulics and pneumatics
Ph
oto:
Jos
hu
a N
av
alk
ar
…says Chaitanya Koranne, Chief Executive Officer, CRI Pumps Pvt Ltd. In this exclusive interaction with Mahua Roy, he talks about the dynamics of the pumps & valves industry and what makes CRI Pumps India’s largest manufacturer and exporter of pumps.
21December 2012 | Chemical World
Chaitanya Koranne
How has the company grown over the years?CRI Pumps has a cherished history
of more than 50 years. It started out
typically as a small non-ferrous foundry.
Then it started manufacturing foot valves
and pumps for agricultural use. In the
80s, this company was the first to start
a new range of pumps with diversified
application areas. Since then new
products have been introduced regularly.
These products have been ahead of time,
better than what the current market
conditions commanded or demanded.
That is how we grew from strength to
strength. As of 2000, this company was
the first one to commence exports of
its product portfolio. Today, we are the
largest exporter of pumps from India.
What was the rationale behind acquiring a UK-based pumps major?We recently signed a business transfer
agreement with UK-based Pumps and
Process Systems Ltd (PPSL). The
agreement will enable CRI to reach new
heights in embracing new innovative
technologies for delivering industrial
pumping solutions such as pulp handling,
slurry handling and chemical handling
for a variety of industries that include
paper mills, metal and mining, power,
coal, chemicals and petrochemicals,
food & beverages among others. PPSL
has been in operations for more than
20 years now and has well-established
global clients. This association will
help us gain access to that client base.
The entire manufacturing has been
transferred to India, post the non-
competitive agreement with PPSL. A
new manufacturing unit in Coimbatore
is also underway.
How mature is the Indian process industry in the adoption of pump technology? The Indian process industry today
is comparable to the global one. The
expectations are similar in nature. The
companies are open to try out new
technologies and spend accordingly to
meet the market demands. Yes, the extent
of competition in the space of pumps
& valves has definitely made a huge
difference to the business dynamics. Thus,
the industry is willing to absorb new
technologies readily. However, occasionally,
initial price and capital investment does
become a hurdle, especially when dealing
with SMEs.
How is the demand dynamics in the SME sector?The economic scenario in India is growing
rapidly. This is propelling investments in
the process industry largely. Thus, we
see a rising demand for pumps & valves
in India. Interestingly, SMEs are an
integral part contributing to the growth
story. SMEs in India are expanding,
adding capacities; new companies are
entering the market and new products
are being introduced subsequently. This
trend is seen in almost every sector.
Correspondingly, the pumps & valves
industry is growing at an exponential
rate. To succeed in the highly active SME
sector, the communication should be 100
per cent convincing and appropriate.
What are the challenges faced by the pumps industry?There is dearth of people with extensive
knowledge of hydraulics & pneumatics.
This market thus completely depends
on the pitch made to customers. Also,
there needs to be more development
in research and technology for pumps,
especially hydraulics. Besides, research for
developing new materials is also needed.
The industry needs to be educated about
right selection of pumps. Pump failure
is caused due to faulty selection of a
pump for a certain application. Another
challenge is the shortage of foundry
capacity in India. As valves come under
capital-intensive projects, lead time gets
affected due to this shortfall.
What are the features that need to be considered while selecting a pump?The top criteria include paying utmost
attention to materials of construction
of pump, and investing time in
understanding the intricacies of the
pump design. The company needs to
understand the chemicals it is dealing
with and then decide the technology.
For specialty chemical sector, high
purity and hygiene are demanded; for
bulk, hazardous chemicals, the nature is
corrosive and abrasive. Thus, accordingly
the material selection has to be made. In
general, one should consider the energy
efficiency offered by the pump selected.
Also, it should be able to deliver a longer
service life before periodic maintenance.
What are the future strategies of CRI Pumps?We will be introducing new range of
products in the market in the coming five
to six months. We are also planning launch
of specific products for applications in
the highly emerging water management
industry. Additionally, we are also looking
at investing in new facilities. For exports,
we are focussing hugely on Africa as it
has high potential for agricultural as well
as industrial pumps. Also, there are huge
opportunities in South America and the
Middle East.
Email: [email protected]
Latest book you read…I re-read Marketing Warfare. Last, I had read it during my MBA days. This acted as a refresher.
One business etiquette you always follow…I honour time & commitment of others and thus I am always punctual.
A motivating factor… The fire of creating something completely new for my company highly motivates me every single day.
SPECIAL FOCUS
23December 2012 | Chemical World
ULTRAFILTRATION TECHNOLOGYA smart solution for better separation ......................................................................................................24
CENTRIFUGAL METHOD Separation process simplified! ..................................................................................................................26
MEMBRANE SEPARATIONLimitless possibilities with novelty ...........................................................................................................28
PLEATED BAG FILTERSA clean route to control air pollution .......................................................................................................30
FILTER MEDIAOn a swift rise ...........................................................................................................................................32
FILTRATION & SEPARATION
SPECIAL FOCUS Ultrafiltration technology
Chemical World | December 201224
Prasenjit Chakraborty
Recent technologica l
innovations in the area of
filtration and separation
have been enabling
chemical companies meet the present
quality standards. One such innovation
is the ultrafiltration technology with
which separation processes can be carried
out efficiently as well as economically
as compared to other conventional
separation processes. The prime reason
for its popularity is that it does not
require any chemical inputs. Easier
retrofitting of any traditional technology
also gives priority to ultrafiltration as
many chemical companies would like to
upgrade their process economically.
In a new perspective, ultrafiltration-
based separation process supports
chemical companies in their green
initiatives. “At the heart of ultrafiltration
process is membrane, and hence various
efforts are being taken to fabricate
biodegradable membrane. Moreover,
the entire ultrafiltration process offers
green solution for the reasons such as
it consumes lesser energy and leads to
lesser footprint. In the present decade,
many chemical companies have become
environment-conscious and hence
follow various regulations implemented
by the pollution control board,” states
Dr G Arthanareeswaran, Associate
Professor, Department of Chemical
Engineering, National Institute of
Technology, Tiruchirappalli. This drives
the chemical industry to carry out
economic analysis and environmental
impact assessment for any treatment
technology that is adopted.
Ultrafiltration will surely be the
smartest separation technology as it
helps in effluent reuse and chemical
recovery that subsequently leads to zero
discharge of pollutants. “Ultrafiltration
is being used for reducing/substituting
the use of chemicals for wastewater
treatment. For example, refineries use
ultrafiltration membranes in combination
with reverse osmosis for clean water
recovery from wastewater. Ultrafiltration
is also used extensively where there is a
need for dewatering/removal of water
in the manufacturing processes. This
brings down the energy requirements
compared to traditional drying processes,
increases plant efficiencies and, reduces
spent material costs (of disposal),” points
out P S Easwaran, Senior Director,
Deloitte, India.
Supporting green initiativesAccording to Jayateerth Nadgir,
Business Development Manager – India
(Engineering & Projects Group ), Nalco
Water India Ltd, ultrafiltration helps the
chemical industry to concentrate the fine
solids present in wastewater generated
in the process, which enables to recover
the product (reduce waste). “By reducing
the waste in wastewater generated from
process, ultrafiltration helps in bringing
down the load of Effluent Treatment
Plant (ETP), which in turn reduces
operating cost of treating wastewater in
the form of less downtime and power
consumption for treating the water
to finally meet the pollution control
norms, recycle the water back to cooling
towers or in some cases process
depending upon the criticality and
quality of wastewater produced &
treated water required,” he says.
Today, the manufacturing companies
around the world have realised the
importance of carefully treating waste
and residue before discharging it
from their facilities. “Not only does
this practice protect the environment,
but it also helps in extracting many
by-products for use in several
industries. Manufacturers in the fields
of petrochemicals, pharmaceuticals,
textiles, paints & dyes and detergents
are becoming more aware about using
ADVANTAGE ULTRAFILTRATION
� This process consumes lesser energy
� The method helps in effluent reuse and chemical recovery that subsequently leads to zero-discharge of pollutants
� Ultrafiltration membranes are one of the key technologies widely used globally for wastewater treatment
� Use of ultrafiltration technology is more in sugar, beverage and pharmaceutical industries in India
� Regulatory pressure over effluent disposal is paving the way for extensive use of ultrafiltration method
� Besides protecting environment, it also helps in extracting many by-products, which can be used in several industries
Though adoption of ultrafiltration technology in India is still low, its demand is gradually picking up among the chemical manufacturers. Rapid innovations in this technology make the entire separation process easy and economically viable. Moreover, it also helps promote green initiatives undertaken by several chemical companies.
25December 2012 | Chemical World
Ultrafiltration technology
ways to reduce the impact of effluents in
the environment and also use waste as
an energy- and cost-saving tool. One
of the key technologies widely used
globally for wastewater treatment is
ultrafiltration membranes,” says Sharad
Gollerkeri, Regional Commercial
Manager, Dow India.
Since ultrafiltration technology
is in demand and it helps promote
green initiatives, several companies are
coming out with innovative offerings.
For instance, Nalco offers detailed plant
audit to understand the customers’
processes and criticality of water in the
client premises, using the best industry
practice and in-house knowledge of
industry experts. “We help in reducing
water and carbon footprint, which is the
ultimate goal for any industry towards
making the world greener. Nalco has
always believed in providing solutions
rather than advocating products for
client problems, we always follow
the CASE (chemicals, automation,
services and equipment) approach.
Generally, products such as pressurised
ultrafiltration, submerged ultrafiltration
and tubular membrane systems can be
used for separation-related applications
and, of late, ceramic membranes are also
being offered for these purposes,” points
out Nadgir.
Technological advancementsUltrafiltration was earlier used in food,
dairy and pharmaceutical industries
for carrying out the process as it is
capable of separating high molecular
weight substances such as colloids,
proteins and so on. But in recent times,
ultrafiltration is finding applications
in wastewater treatment plants in
chemical industry. The competitive
performance of ultrafiltration over other
conventional means has been proven
in many industries. It could be either
employed in pre-treatment for reverse
osmosis plants or can be integrated
with any primary treatment method.
“The recent increase in the use of
ultrafiltration in wastewater treatment
application is attributed to increased
regulatory pressure over effluent
disposal. The commercialisation of
membrane technology also has paved
way for the adoption of ultrafiltration
in many chemical companies for various
processes as well as effluent treatment,”
observes Dr Arthanareeswaran.
In India, as far as ultrafiltration is
concerned, it is attaining greater heights
for sugar, beverage and pharmaceutical
industries. In order to improve the final
quality of products and reduce energy
and space requirements, ultrafiltration
has now turned from laboratory
scale to industry scale in India. Such
developments are instrumental in
bringing many new technologies in the
market. Nadgir says, “Ultrafiltration
in ceramic as material of construction
(MoC) and SS with titanium coated
is among the latest technologies. And
both these membranes operate in cross-
flow filtration. These membranes can
withstand pH variation and temperature
variation in process as well as during
clean-in-place (CIP) procedure.”
When it comes to adoption of such
technologies in India, it is quite low. “At
the moment, the adoption is low since
not much of references are available and
also the ability to take risk by changing
the existing or old technology adopted
in process and wastewater systems is
lacking. This needs intensive piloting
with detailed data collection and Nalco’s
CASE approach will help in addressing
this apprehension,” he adds.
Similarly, Dow has also come out
with few solutions in this direction.
The Dow ultrafiltration double-walled
hollow fibre membrane is formed from
high-grade polymeric chemicals viz
hydrophilic polyvinylidene difluoride
(PVDF). “The virtually defect-free,
double-walled fibre membrane is much
more robust and less prone to breakage
than single-wall hollow fibres and due
to the high pore distribution, does
not comprise flux. The uniformity of
pore size and outside in-flow ensures
that the Dow ultrafiltration membrane
creates a perfect barrier without
sacrificing performance,” says Tanmeet
Gulati, Regional Marketing Manager,
Dow Water & Process Solutions,
Dow India. Dow also provides ready-
to-assemble Dow IntegraPac skids,
which are pre-engineered – direct-
connect ultrafiltration modules – that
reduce material costs, freight costs, and
enable faster assembly. “This
revolutionary ultrafiltration solution
dramatically simplifies the process
of incorporating Dow ultrafiltration
technology into water treatment
systems,” claims Gulati.
Email: prasenjit.chakraborty@ network18publishing.com
Not only does this practice (treating wastewater) protect the environment, but it also makes available many
by-products for use in several other industries. One of the key technologies widely used globally for wastewater treatment is ultrafiltration membranes.
Sharad GollerkeriRegional Commercial Manager, Dow India
By reducing the waste in wastewater generated from process, ultrafiltration helps in bringing down the load
of ETP, which in turn reduces operating cost of treating wastewater.
Jayateerth NadgirBusiness Development Manager – India (Engineering & Projects Group ), Nalco Water India Ltd
At the heart of ultrafiltration process is membrane. The entire ultrafiltration process offers green solution for
the reasons such as it consumes lesser energy and leads to lesser footprint.
Dr G ArthanareeswaranAssociate Professor, Department of Chemical Engineering, National Institute of Technology, Tiruchirappalli
SPECIAL FOCUS Centrifugal method
Chemical World | December 201226
Prasenjit Chakraborty
Centrifugal filtration and
separation is widely applied
in wastewater treatment
plants as it can reduce
wastage up to 85 per cent. It is used
in the primary treatment stage of any
industry because solid or sludge content
will be relatively high during the initial
stages of wastewater treatment. Most
of the treatment method operates
biologically with the help of microbes to
reduce organic content of the waste. The
continuous biological operation leaves
behind huge mass of sludge in terms of
biological colonies and mass that need to
be simultaneously purged. “Centrifugal
filtration helps in thickening of sludge,
thus making the solid disposal easy to
handle before the slurry is taken to the
next treatment stage. Centrifugation
operates in either thickening or
dewatering step of any treatment plant.
By carrying out these steps, operating
difficulty is minimised and further
processes were made easier. Centrifugal
filtration combats the needs of the
industry by recovering higher density
liquids and solids,” points out Dr G
Arthanareeswaran, Associate Professor,
Department of Chemical Engineering,
National Institute of Technology,
Tiruchirappalli. So, the separated waste
products can either be reused or properly
disposed of by companies.
Case in pointIn municipal wastewater treatment,
centrifugal separation plays a pivotal
role. The volume of solids is always high
in municipal wastewater and centrifugal
means of separation helps in optimum
thickening with a simultaneous reduction
in energy and costs. “Centrifugal
decanters and separators assure
maximum dewatering of sewage sludge
and separation of solids. Centrifugal
separation and cleaning is needed for the
cleaning of oils in diesel engine. This is
one of the ingenious solutions for many
industries handling oil. Rather than
any other technology, centrifugation
proves efficient for high solid content.
In India, most of the process industries
rely on centrifugal filtration,” opines
Dr Arthanareeswaran.
Due to higher level of
commercialisation in the separator
industry, centrifugation is followed
in many chemical companies. Food
processing industry is using centrifugal
technology for thickening the final
concentrate. However, there are new
avenues in centrifugation technology
coming up and those should also be
practised by companies in India.
For instance, Dow Water and
Process Solutions (DW&PS) recently
introduced Tequatic Plus Fine Particle
Filter. Tanmeet Gulati, Regional
Marketing Manager, DW&PS, Dow
India, claims, “Tequatic Plus filter
enables continuous cleaning, cross-flow
filtration with centrifugal separation,
providing over 99 per cent uptime. It
helps enhance safety and sustainability
by reducing handling pressures and
waste. The product can be used as
an alternative or as a complement to
traditional filtration technologies.”
Latest filtration technologies No doubt filtration and separation
segment has seen many changes in
terms of new technologies. According
to Dr Arthanareeswaran, chemical
manufacturers in India are adopting
new technology in the arena of filtration
and separation. He says, “Indian
chemical manufacturers are helping to
implement the laboratory innovations
on an industrial scale. As a result of
their interest in new technologies, recent
filtration methods such as membrane
filtration, hybrid centrifugation were
commercialised. Easy automation and
upgradation is paving the way for new
filtration technologies in the Indian
chemical industry.”
Over the past decade, Indian
chemical companies do not stop
just at production but also involve in
innovations. It extends huge investments
in R&D sector to ensure significant
growth competence in the world market.
Environmental awareness also remains a
reason behind the technology adoption
by companies. Zero-discharge and other
effluent disposal norms are forcing
companies to innovate and organise
efficient treatment methods. “Though
initiatives are being taken, the Indian
chemical industry lags behind several
developed countries in many areas.
Companies allocate below 1 per cent of
sales as the expenditure for R&D whereas
developed countries spend 4-5 per cent
of sales for R&D expenditure. At this
point, Indian chemical manufacturers
also need to think more about R&D
to modernise the industry with the
help of new technologies,” exhorts
Dr Arthanareeswaran.
Email: prasenjit.chakraborty@ network18publishing.com
The chemical industry is witnessing a rise in filtration and separation through centrifugal method, especially in the area of wastewater treatment, as it eases operational difficulties. With more futuristic advancements, the process is all set to establish a toe-hold in the market.
SPECIAL FOCUS Membrane separation
Chemical World | December 201228
Prasenjit Chakraborty
Membrane separation
remains a viable
option for any
industry facing
concerns related to effluent treatment.
Almost all the industries look
towards upgrading and expanding the
conventional effluent treatment plant.
This key feature gives priority to the
membrane separation process in many
sectors. “Its exceptional separation
performance makes it popular and, hence
membrane-based treatment is preferred
in one or the other stages of effluent
treatment. The secondary and tertiary
stage at any treatment plant would
necessarily employ membrane
separation because it can
be processed in any typical
microfiltration, ultrafiltration,
nanofiltration and reverse
osmosis stages of effluent
treatment,” points out
Dr G Arthanareeswaran,
Assoc ia te Pro fe s sor,
Department of Chemical
Engineering, National Institute of
Technology, Tiruchirappalli.
Since membrane separation is
mandatory to meet effluent standards,
it remains popular among industries for
treating effluents. Now, use of membrane
bioreactor is on the rise in treating
effluents as it avoids the separate step for
nutrient removal. This technology results
in reduced footprint of about 25-30
per cent as compared to conventional
treatment methods. Higher stability to
organic loading and easy automation
makes this popular in industrial effluent
treatment. “There has been a wide range
of innovations in the membrane separation
process, especially in the area of treating
industrial effluents. As government
regulation on discharging effluents is
getting more stringent, the most cost-
effective and environment-friendly
solution cited by industry experts is the
membrane separation process,” opines
Sharad Gollerkeri, Regional Commercial
Manager, Dow India.
Advantages of membrane separationMembrane separation process offers
numerous advantages such as lesser thermal
and chemical inputs, lower cost in terms
of installation as well as lifecycle cost, easy
cleaning and replacement of membranes.
The compact design of membrane
treatment technology results in lesser space
consumption and thus any industry can
adopt it for limited expansion.
Many filtration systems for settling,
sedimentation, clarification were
conventionally used by industries. However,
when it comes to the high loading of total
dissolved solids, membrane separation
is preferred in terms of reverse osmosis
plants. The easier regeneration of chemicals
utilised by industries is also possible by the
membrane separation process. Thus,
it gives several advantages with low
cost, space and energy requirements.
Apart from the multiple innovative
options available, there are numerous
advantages of membrane separation
in the treatment of industrial effluents
too. Some of these include appreciable
energy savings, clean technology with
operational ease. In addition, it replaces
the conventional processes such as
filtration, distillation, ion-exchange and
chemical treatment systems; produces
high and quality output; greater flexibility
in designing systems, and enables water
recycling and reuse.
According to Sasidhar Chidanamarri,
Industry Manager, Environment &
Building Technologies Practice, Frost
& Sullivan, the usage of membranes for
recycle and reuse of industrial effluents is
limited today. “The most common method
adopted in India for effluent treatment is
activated sludge process (ASP), which is a
conventional technology. The recycle and
reuse of industrial effluent market
is at a developmental stage in
India. The market was worth
` 6,000 million approximately
in 2010 with an anticipated
annual growth of 15-17 per
cent till 2015. Of the total
industrial effluents generated in
India, 60 per cent is treated while
the remaining 40 per cent, which is 6.2
billion litre, is untreated and dumped into
fresh water reserves. Currently refineries,
municipal, residential, chemical and
pharmaceutical industries adopt recycling
and reuse of wastewater,” he points out.
The usage of membranes in the
treatment of industrial effluents would
increase the practice of recycle and reuse.
Hence, dependence on fresh water reserves
for applications such as agriculture and
landscape irrigation, industrial process
water, toilet flushing, etc, would be reduced.
This in turn would help reduce water stress
that is growing at a fast rate in India.
Solutions offeredRise in demand for membrane separation
process is prompting technology providers
Membrane separation process offers a plethora of advantages
right from lesser thermal and chemical inputs to lower cost in
terms of installation. The compact design of membrane treatment
technology leads to lesser space consumption and thus any industry can adopt it for limited expansion.
Courtesy: Koch Membrane
Limitless possibilities with novelty
29December 2012 | Chemical World
Membrane separation
to offer innovative solutions. For example,
Dow Water and Process Solutions’
(DW&PS), with its vast experience in
technologies such as reverse osmosis (RO),
ultrafiltration (UF), nanofiltration and ion-
exchange resins, provides cost-effective
solutions that treat effluents and purify
water. “Focussed on advanced separation
technologies for wastewater treatment,
Dow is committed to maximising the vast
potential in the world’s reusable water –
working with industries and communities
to recover water, energy, nutrients and
other valuable components of wastewater
streams,” says Tanmeet Gulati, Regional
Marketing Manager, DW&PS, Dow India.
Similarly, Nalco offers complete
solutions in the form of water audit,
design, engineering, supply and erection
commissioning of wastewater and recycle
including ZLD systems.
Adopting membrane separationOver the last decade, Indian industries
were mostly using indigenous
technologies for effluent treatment.
Now, microfiltration and ultrafiltration
technologies have been applied in most
of the effluent treatment plants. To
meet the stringent pollution control
norms, organised industries such as
steel, refineries, etc now adopt reverse
osmosis plants for tertiary treatment of
effluents. Some of them have installed
membrane treatment technology but
not yet commissioned. In a wider sense,
effluent treatment plants in paper mill,
fertiliser, sugar industries and distilleries
have initiated the membrane process as
the primary and secondary treatment
technology. Typical reverse osmosis
plants are not popularly adopted in
Indian industries and it has just surfaced
among some highly organised sectors.
Membrane treatment was previously
used for drinking water treatment and
also in desalination of saline and brackish
water. But, due to the advancements in
overcoming the limitations of membrane
separation, it is now capable of operating
in industrial effluent treatment plants.
“The market of membrane separation is
estimated to be growing at a rate of 10-12
per cent every year. With increasing
demand for water, this rise could also be
made twice or thrice in Indian chemical
industry by employing effluent treatment
plants,” says Dr Arthanareeswaran.
In the words of Jayateerth Nadgir,
Business Development Manager – India
(Engineering & Projects Group ), Nalco
Water India Ltd, “The use of membrane
technology is seeing a rise with respect
to UF & RO membranes in recycling
system, but membrane bioreactor in
industrial effluent is not that popular as
compared to domestic sewage because
of the wide variation in the inlet quality.
Microfiltration system is slowly gaining
popularity as pretreatment for RO system
and for special applications such as oil
concentration in automotive industry,
lime soda softening in case of wastewater,
cooling tower blowdown, etc.”
Email: prasenjit.chakraborty@ network18publishing.com
SPECIAL FOCUS Pleated bag filters
Chemical World | December 201230
Rakesh Rao
Baghouse, an air pollution
control (APC) device, removes
particulates out of air or
gas released from industrial
processes. Industries such as chemicals,
power, steel, pharmaceutical, food &
beverages, etc often use baghouses to
control emission of air pollutants. Because
of the wide range of available fabric filter
media, baghouse has proven that it will
remain a prime player in the worldwide
quest for clean air. In order to improve
the efficiency of baghouses, many
manufacturers now use pleated cartridge
filter as it increases durability, saves energy
and is easy to install compared to other
conventional bag filters.
Pleated bag filtersIn order to save space and reduce
operating cost & downtime, there has
been rise in demand to upgrade existing
baghouses, especially in chemical
industry, by incorporating pleated filter
bag to increase throughput.
“With more than 20 years of experience
within dust filtration, we draw upon our
extensive know-how to help our customers
select the optimum filter media solution
for their specific applications and site-
specific issues. Our cartridge filters and
pleated bags are amply used within the
chemical industry where we handle dust
from glass production, titanium dioxide,
acids and more. It is our experience that
certain chemical applications require special
flanges and straps, which do not contain
glue. We eliminate the use of glue by using
our ultrasonic welded Weldtech straps and
flanges with metal, polyurethane (PU) or
polyamide finish,” says Steffen Møller,
Product Manager - Pleated Bags, Nordic
Air Filtration – which offers a wide range
of filter media for pleated cartridges.
Environment norms driving demandCountries across the world have already
instituted stringent emission norms to
reduce air pollution. Hence, manufacturers
are searching for an economical way to
meet the new regulatory requirements.
Pleated filter can provide economical
alternative to these manufacturers since
it can significantly improve air filtration
efficiency compared to conventional bag
filters. This is one of the factors driving
the demand for pleated filters. Møller says,
“The growth of the market for pleated
bags is a natural consequence of the
rigorous emission regulations. Traditional
filter bags often do not offer sufficient
filtration efficiency because of their depth
filtration technology. The spunbond media
used in pleated bags, on the other hand, is
a more efficient surface filtration media,
which helps filtering even the smallest
particles, and thereby meets the stricter
emissions requirements.”
BAG FILTERS VS PLEATED BAGS
Benefits of using pleated filter bag include: � It has 2-3 times larger filter surface area compared to conventional bag filter
� It has longer lifecycle compared to bag filter
� It is easy to install and maintain
� It consumes less power (in some cases 50 per cent lower) than bag filter
� It requires less air for cleaning compared to bag filter
� It minimises compressed air usage
� It has better resistance to inlet abrasion
� Its short filters minimise need for investing in large bag collectors and require less air for pulse cleaning
Courtesy: Nordic Air Filtration and The Cary Company
Pleated bag filters, which meet the process needs and throughput requirements of the process industry, may be used to filter liquids
or gases with high efficiency, low pressure drop, robust dirt holding capacity and long life. Implementation of stringent environmental
norms will give further boost to demand for pleated filters.
A clean route to control air pollution
31December 2012 | Chemical World
Pleated bag filters
He adds, “In addition to the higher efficiency offered by
the pleated bag with spunbond media, pulse cleaning is easier
(fewer pulses needed), air permeability is better (usage of main
fan is reduced) and the filter lifecycle can be significantly
prolonged when upgrading from a traditional filter bag to a
spunbond pleated bag.”
Make a right choice Chemical manufacturers have to select right filtration media,
which can withstand harsh conditions such as corrosive
chemicals, high temperatures, etc. The number of pleats,
depth of pleats, selection of media, number and type of bands,
core velocities and cleaning system must all be taken into
consideration when selecting the right pleated bags.
Choosing the right filter media is crucial for both long-
term performance and lifecycle of the filter. One has to consider
various parameters while selecting filters for a given application.
Some of the most important ones are type of dust, air flow,
grain load, temperature, previous experience with filtration
media, etc.
Møller explains, “We often come across customers who
tend to go with the cheapest solution without taking into
consideration particle size, grain load, temperature and air flow.
No doubt, the actual filters are cheaper, but the short filter
lifecycle, more frequent pulsing leading to increased energy cost,
higher maintenance costs and sometimes even unscheduled
plant shutdowns often make the ‘cheap choice’ end up incurring
a somewhat higher Total Cost of Ownership (TOC) for the
customer. Having seen too many of these cases, Nordic Air
Filtration has developed a valuable tool enabling us to create an
accurate TOC Savings Report, which gives our customers full
overview of the long-term economical consequence of acquiring
a cheaper filter bag solution as opposed to a pleated bag solution.”
On domestic front In a study released earlier this year, India ranked last out of
132 countries surveyed by environmental research centres at
Yale and Columbia universities in terms of air quality and
effects on human health. While India has taken many steps
to reduce emissions from industries, going forward, experts
believe that norms will become more stringent. As a result,
demand for pleated filters is likely to increase in the country.
Møller says, “In India, there is growing demand for filters,
especially pleated bag filters that can improve dust collector/
baghouse performance through increased air volume and lower
emission output without having to rebuild or renovate the
collector or baghouse.”
To tap this emerging demand, manufacturers of pleated
filters are planning to expand capacity and distribution reach
in India. Møller rightly sums up, “Our potential in India is
significant and we are working on expanding the co-operation
with our loyal resellers in India.”
Email: [email protected]
SPECIAL FOCUS Filter media
Chemical World | December 201232
Rakesh Rao
The global filtration market
is estimated to grow at
a compounded annual
growth rate (CAGR) of
approximately 5.2 per cent during the
period 2008-14. In next two to three years,
the filtration industry is expected to reach
$ 77 billion market size. Water and process
filtration make up 65 per cent of the
end-user market. Liquid filtration
– which includes water, oil, fuels,
gas and other liquid synthetics –
makes up the bulk of the global
filtration market. “Filters find
applications in air/gas filtration,
environmental monitoring, etc
and are used for the removal
of impurities, classifying
and cleaning of mixtures
& solutions,” says Kashmira
Nadkarni, Product Manager, Cole-
Parmer India.
Though North America accounts
for a lion’s share of the global filtration
industry, Asia – which currently represents
a small share – is expected to grow the
fastest on the back of industrial expansion
and environmental needs in countries
such as China and India. According to a
study titled ‘India: Non-woven and woven
fabrics for filtration’, published jointly by
Filter Media Consulting and Business
Co-ordination House, India’s filter media
market amounted to $ 108.2 million (about
` 541 crore) in 2009 and is growing at
a healthy rate of 17-18 per cent. India
is considered to be the fast growing
filtration market, although the current
technology is not totally at the same level
as compared to other developed markets.
Nadkarni says, “India is well-known for
generic chemical production capabilities.
Filters are mainly used in separation and
purification techniques in the chemical
and process industries. They separate the
components of a mixture and can also
purify it by removing the impurities. They
find presence in almost every important
application whether it is in the lab or in the
process. Hence, we find a high demand for
filters and associated products.”
Burgeoning domestic market Recognising considerable opportunities in
the filtration market, many global players
are planning to increase their presence
in India. In order to tap the non-woven
filters market, Hollingsworth & Vose, a
global manufacturer of advanced materials
used in filtration, is currently developing
an operating capability in India that will
begin with the production of engine
filter media. In March 2012, the
Germany-based Freudenberg Filtration
Technologies acquired Pyramid Filters
Pvt Ltd, which develops air filter elements
and systems for clean room applications
in the pharmaceutical, medical, food and
chemical industries.
Similarly, Cole-Parmer has acquired
authorised distribution rights in India
to Advantec’s wide range of filtration
solutions for laboratory, research and
process applications. Nadkarni elaborates,
“Advantec products are used in a wide variety
of scientific capacities and applications such
as microbiological analysis, air/gas filtration,
and environmental monitoring. It offers our
customers an additional and valuable range
of unique quality products that enhance
their process and increase productivity.”
The options for filters are virtually
limitless ranging from mesh screens
to depth style media such as threads
or chopped paper to 100 per
cent natural cellulose and 100
per cent man-made microfibres
to almost any conceivable
combination in between.
Nadkarni says, “Filtration
is essential to many
modern products
and processes, and
it becomes even
more critical as
quality expectations and
technology requirements for
finer and more consistent results develop
and increase. Uniform membrane materials
and superior separation technology
enhance and safeguard customers’ processes,
products, instruments & services, and
provides consistent results. Where filtration
is necessary for a process, it needs to be
consistent and reliable throughout the life
of the filter and from filter to filter. Filter
performance variability can be serious,
leading to inconsistent product quality,
additional costs from rework, rejections,
product recalls, disposal costs and
business risks.”
Despite the much publicised slowdown
of the Indian economy, experts believe
that the filtration market in India will
continue to grow at a faster rate compared
to the general economy. Although, it
is still a price-sensitive market with less
sophisticated filter system designs than in
the developed markets, the demand for
performance-based products is expected to
rise in India in near future.
Email: [email protected]
As the Indian economy advances, driving need for better
environmental norms, demand for high-quality filters is expected to
increase in next two to three years. No wonder, the global players are planning expansion in India to tap
this burgeoning market.
Filters find presence in almost every important application whether it is in the lab or in the process. Hence,
we find a high demand for filters and associated products.
Kashmira NadkarniProduct Manager, Cole-Parmer India
FACILITY VISIT Dow Corning India Pvt Ltd
Chemical World | December 201234
Rakesh Rao
Take a look at materials
used to make innovative
products in areas such as
photonics, nanotechnology,
plasma, building materials, alternative
energy, etc, and one can realise how
important is the role of silicones in their
existence. In addition, the contribution of
silicone in improving quality of life and
sustainability is immense. Unleashing
this power of silicon for applications in
various industries is Dow Corning, one
of the leading companies in silicones and
high-purity silicon – which is derived
from sand (quartz). David Longo, Site
Manager – Pune Manufacturing Facility,
Dow Corning India Pvt Ltd, says, “Dow
Corning was established specifically
to explore the innovative potential of
silicones. Our expertise in silicon science
is helping address challenges relating to
efficiency, sustainability and innovation.
About 4-5 per cent of our sales are
invested in R&D and we have about
4,552 patents worldwide.”
The journey to Pune Dow Corning started manufacturing
operations in India, with Universal
Silicones, in 1999 at Tarapur, Mumbai.
To meet the rising demand for silicone
products, the company moved its
production activities to Ranjangaon
near Pune by end of 2005. “Prior to
Ranjangaon plant, we did have a facility
at Tarapur, but given the rapid pace of
expansion that we required, we decided
to establish an enhanced facility that
would enable us to serve our customers
more effectively and efficiently. We
decided on Ranjangaon because of the
easy availability of qualified personnel
in Pune, as well as the high quality of
infrastructure and ease of set-up,” says
Longo, who moved to Pune in 2010
from Europe. The fact that Ranjangaon
is rated as a five-star MIDC, and has
many OEMs made the decision to shift
much easier to implement.
Quality par excellence The facility now houses laboratories
for quality assurance and application
engineering, as well as an area for current
Good Manufacturing Practices (cGMP),
where it manufactures materials for
personal care applications. “As of now,
we have about a 100 people working
at our site in various positions, such as
manufacturing, science and technology,
quality assurance, etc,” says Longo.
Currently, Dow Corning manufactures
emulsions and amino polymers, cosmetic
grade emulsions, custom blends, greases
and dispersions, and also performance
sealants. These products go into a lot of key
industries such as construction, personal care,
automotive, textiles, pulp & paper, paints &
FACTSHEET
� Adopted American Chemistry Council’s Responsible Care Program
� Periodic Responsible Care audits and Operational Excellence Management
System audits to ensure long-term safe operations
� No Lost Time Injury (LTI) since more than five years
� Global Incident Management System (GIMS) and Global Shared Learning
(GSL) tools in place
� Balance of Consequences Tool in place
� cGMP and 5S activities implemented
� 6 Sigma Methodology driving continuous improvement project portfolio
Ranjangaon facility in Pune of Dow Corning, the global leader in silicones, has been catering to the demand in India with quality and innovative products. In order to improve the efficiency of the plant, it has taken a number of steps
such as lean manufacturing, good manufacturing practices, quality management system, etc.
‘Lean’ing on effi ciency for better productivity
35December 2012 | Chemical World
Dow Corning India Pvt Ltd
inks, electronics, industrial lubrication, etc.
“In addition, the Application Engineering
Technical Services laboratory housed in the
manufacturing facility provides us with the
opportunity to work closely with our Indian
customers; allowing us to develop materials
and solutions for India,” says Diane Kelly,
India President, Dow Corning.
Lean manufacturing Dow Corning has adopted the concept of
lean manufacturing, which is based on the
Six Sigma methodology, and is used as a
consistent way to discover and eliminate
unnecessary steps or defects in its activities;
this enables us to increase the value Dow
Corning delivers to customers. As per lean
manufacturing, any product or operation
has to move in one direction. Hence, raw
materials enter the facility from one end,
undergoes processing and the end-products
(packaged and sealed) leave the facility
from different end. This facilitates seamless
movements of the products.
Improvements can be identified in
terms of safety, quality, delivery cost,
speed, flexibility and internal & external
customer satisfaction. “Our focus is on
the three types of waste reduction called
Muda (waste), Mura (abnormality or
unevenness) and Muri (strain or stress),”
adds Yogesh K Khaladkar, Production
Manager, Dow Corning India Pvt Ltd.
Last year, the company implemented
a lean suggestion scheme process
allowing all site employees and operators
to contribute their ideas and suggestions.
Khaladkar opines, “All ideas are
screened based on their potential and
implementation requirements. A monthly
reward process for the best implemented
ideas is also in place to encourage
participation and idea submission. In
2012, this process allowed us to make
improvements at the plant by reducing
waste or increasing our energy efficiency,
all of which are part of our site objectives.”
The 5S initiative (Sorting, Sweeping/
Straighten, Shine, Standardisation and
Sustain) is used as a path for continuous
improvement and lean manufacturing. “It
is a philosophy of housekeeping that arose
in Japan aiming to improve workplace
efficiency and enhancing the appearance
of the workplace,” says Khaladkar.
Area 5S owners are identified and a
quarterly audit process is put in place
to assess performance vs requirements
while building recommendations for
improvements.
Quality with responsibility Dow Corning has developed a web-
based global Operational Excellence
Management System (OEMS) manual,
which links to all local manuals and is
also in compliance with the requirements
of Quality Management System ISO
9001:2008. The Pune site is part of
Dow Corning global ISO 9001:2008
Certification by BSI (Certificate:
FM10734). “We are also following
cGMP guidelines for manufacturing
of products associated to specific
applications,” adds Longo.
Dow Corning follows American
Chemistry Council’s Responsible
Care Program to ensure that good
environmental, health and safety practices
are well-established across the company,
including its site in Ranjangaon. Longo
says, “Our OEMS manual supports
Environment, Health, Safety, and
Security (EHSS) and Responsible
Care commitment in compliance with
ISO14001 and RC14001.”
Meeting the growing needsThe company has been built on a culture
of innovation, and new products are being
rolled out constantly. “Over the years,
we have installed new manufacturing
equipment on the shop floor and in the
labs, as well as scaled up manufacturing
capacities to keep pace with customer
requirements. Expansion of our facility
would depend on customer demand,
and our ability to effectively fulfill these
demands. While we have acquired more
than 90,000 sq m of land, the built-up
area is about half of that, so we do have
space for expansion as and when we need
it,” states Longo.
Explaining the significance of
the plant, Kelly says, “Dow Corning’s
Ranjangaon facility was established to
help us better serve our customers in
this region, and is a key element of the
company’s India growth strategy. Dow
Corning offers two brands – the Dow
Corning brand that provides innovative
specialty products and solutions, and
the online XIAMETER business model
that offers customers the convenient
option of purchasing standard silicone
materials online at market-based prices.
The Ranjangaon plant supports both
these business models, thus enabling us
to effectively meet the business needs of
both sets of customers.”
Photo: Prasad Krishnapurkar for Dow Corning
Email: [email protected]
T h e A p p l i c a t i o n Engineering Technical Services laboratory housed in the manufacturing facility provides us with the
opportunity to work closely with our Indian customers; allowing us to develop materials and solutions for India.
Diane KellyIndia President
Expansion of our facility would depend on customer demand, and our ability to effectively fulfill these demands.
We do have space for expansion as and when we need it.
David LongoSite Manager – Pune Manufacturing Facility
cGMP area in the plant
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INSIGHT & OUTLOOK
37December 2012 | Chemical World
ASSET OPTIMISATION Predicting risks, driving profitability ......................................................................................................38
ASSET MANAGEMENT The CEO’s perspective .........................................................................................................................40
ROUNDTABLEAre companies taking enough steps to sensitise employees about asset optimisation? .........................42
ACCIDENT REDUCTION Safety ensured, rest assured ....................................................................................................................44
OIL PRICE VOLATILITYThe new economic reality ......................................................................................................................46
ASSET OPTIMISATION
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INSIGHT & OUTLOOK Asset optimisation
Chemical World | December 201238
Mahua Roy
F or optimising asset (ie
chemical plant) maintenance
is inevitable for the process
industry. Equally important is
strategising the maintenance procedure.
Forward thinking lies in the adoption
of predictive maintenance technique.
But how much has the industry come
forward and accepted this?
“Predictive maintenance strategies
offer an impressive return on investment
(RoI). Equipment failure can be
expensive and potentially catastrophic.
Unplanned production downtime,
missed contract deadlines, costly
machinery replacements, as well as safety
problems, environmental concerns, and
regulatory violations are all potential
consequences of a maintenance
programme that fails to predict and
monitor equipment problems,” says
Pradeep Kumar Gupta, Practice Head-
Manufacturing, IFS India.
Maintenance strategyA study by research firm ARC
indicates that maintenance accounts for
40 per cent of the manufacturing cost.
Related research has shown that on an
average, a facility spends around 10 per
cent of its overall maintenance budget
on the automation and control system.
If strategised optimally, and this expense
reduced, just imagine its direct impact
on productivity! ARC also pointed out
that 50 per cent of maintenance is still
done by the reactive methodology, ie
unplanned maintenance. The maths
is easy to deduce the shortfall of this
technique, it being more expensive and
unpredictable, which is both, dangerous
and unprofitable.
Another strategy is that of
preventative maintenance, which ARC
reports say, is done only 25 per cent
of the time. “Preventative maintenance
seeks to intervene procedures prior
to the expected failure date of the
equipment. In addition, vendors
add a small margin of error to their
estimates. However, the real difficulty
with preventative maintenance is that
it is time-based instead of based on the
actual condition of the equipment,” says
Bharat Gala, President, SNC Lavalin
Engineering – India.
ARC notes that typically,
60 per cent of preventative maintenance
is usually unnecessary. Because of this
level of unnecessary work, preventative
maintenance is five times more costly
than predictive maintenance, which is
based on the actual condition of the
equipment. However, to determine
the actual equipment status requires
investment in diagnostic tools and
software.
Typically, plants that have developed
effective predictive maintenance
programmes discover that the
monitored assets rarely cause unplanned
problems or downtime. “This freedom
from emergencies allows maintenance
departments to address issues that can
improve the overall condition of the
operating assets even further. Smooth
operation also improves the morale of
maintenance technicians,” opines Gala.
Predicting profitabilityPredictive maintenance programmes
are based upon the actual condition
of the equipment. This, coupled with
a determination of when maintenance
should be performed, adds to cost savings
substantially. New techniques such
as ultrasound, infrared and vibration
testing make predictive maintenance a
practical alternative. Many plants have
incorporated smart instrumentation
and predictive maintenance strategies
to streamline maintenance operations,
reduce overtime and optimise
subsequent turnaround activities.
“Changing the daily work routines
When everything is going right for a company, an unplanned shutdown could translate into a dangerous proposition, threatening profitability and plant safety. Choosing an effective maintenance strategy goes a long way in pre-empting catastrophe and prolonging the life of the chemical plant.
Disclaim
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39December 2012 | Chemical World
Asset optimisation
of instrument technicians, control
engineers and other maintenance
staff based on new technologies can
greatly reduce unplanned shutdowns,
overtime call-outs and consequently,
the overall maintenance cost.
Linking asset optimisation systems
with turnaround planning reduces
unnecessary maintenance and allows
more efficient use of maintenance
resources on the highest-priority items,”
summarises Gupta.
Decoding the strategiesPredictive technologies are plant and
process optimisation tools. Plants are
turning to predictive maintenance
strategies increasingly. Some are
implementing predictive tools in-house,
while others outsource it to software
companies or original equipment
manufacturers (OEMs). “Predictive
maintenance includes a number of
analytical tools, including vibration
monitoring, oil analysis, temperature
monitoring and infrared imaging. They
share one thing in common, collecting
data on plant equipment and analysing
that to see if and when things are out
of order,” says Gupta.
New developmentsIn the chemical process industry where
hazardous chemicals are handled,
there is strong emphasis on limiting
the number of staff working in risky
environments as far as possible, without
impacting on reliability or availability of
production. By monitoring equipment
performance remotely, it is possible to
identify problems that could otherwise
result in a plant shutdown.
New introductions and ongoing
research in IT and engineering have
helped develop tools to counter
unplanned breakdowns. The ideology
and methodology followed is that of
predictive maintenance principles.
Using various conditions and readings
from integral installations, an informed
decision about maintenance can thus
be taken by the engineers. Technologies
providing such data analysis are seeing
huge demand in the industry.
Advances in predictive maintenance
technologies are being driven by
commercial demands for improvement
in productivity, quality, inventory
control and expenditure on plant
& machinery. Recent technological
developments include improved
knowledge of material failure
mechanisms; advancements in failure
forecasting techniques, monitoring &
sensor devices, diagnostic & prognostic
software; acceptance of communication
protocols, developments in maintenance
software applications and computer
networking technologies, to name
a few. What the customers for such
technologies are looking for are
essentially speed, versatility, flexibility,
ease-of-operation and of course,
cost-effectiveness.
“Advances in the adoption of
maintenance technologies that include
digital instruments supported by both
data management and spectral analysis
software enable us with the capability
of performing route-based inspections,
data management, trending and even
sound analysis. Ultrasound technology
is an extremely versatile technique,
and therefore, fits seamlessly into any
maintenance programme whether the
emphasis is on mechanical, electrical or
even fluid systems. Such developments
create many opportunities for users
to expand the realm of traditional
condition monitoring of mechanical
operations to electrical equipment
and even fluid systems such as valves,”
says Gupta.
Smart control valves are finding
increased adoption. As per a research
by Freedonia Group, it is expected
that the global market for automatic
valves will outpace that for
conventional valves due to the
continuing efforts of process industry
to enhance operational efficiencies.
The advancements in valve technology
can potentially save facilities millions
of dollars a year by providing a
window into critical processes,
allowing customers to reduce operating
costs through integrated control
and unpara l le led diagnost ic
capabilities. Smart valves enable an
efficient and dependable two-way
communication and provide remote
calibration capabilities. This provides
convenience and can actually bring the
shop floor easily into the boardroom.
One of the unique capabilities of these
intelligent valves is the ability to store
information from the entire life of the
valve in its memory.
“Advanced process control systems
that have greater visibility and
control on equipment more prone to
vulnerability have become a necessity.
This is highly aiding predictive
maintenance. Agile eco-friendly
ERP applications having integrated
asset optimisation tools, coupled
with techniques to achieve increased
overall equipment efficiency, are
witnessing high demand. It assists in
integrating multiple technologies and
provides a deeper insight into asset
management data and is also helpful in
reducing asset management cost while
keeping them environment-friendly,”
says Gupta.
Email: [email protected]
Linking asset optimisation systems with turnaround p l a n n i n g r e d u c e s unnecessary maintenance and allows more efficient
use of maintenance resources on the highest-priority items.
Pradeep Kumar GuptaPractice Head-Manufacturing, IFS India
Freedom from emergencies allows maintenance departments to address issues that can improve the overall condition of
the operating assets even further. Smooth operation also improves the morale of maintenance technicians.
Bharat GalaPresident, SNC Lavalin Engineering – India
INSIGHT & OUTLOOK Asset management
Chemical World | December 201240
Mahua Roy
So what is the new to-do item
in the strategy list of senior
management, apart from
managing sales, promotional
strategies, new facilities, etc? The new
generation of senior management
is investing heavily and holding
brainstorming sessions to promote
the attitude of asset optimisation
among its employees. Companies have
always been managing their assets for
years, but only recently it has become
a corporate priority. Nowadays,
maintenance and equipment auditing
followed by necessary corrective
measures have become a trend, which is
here to stay. Over the past few years, the
role of maintenance has grown in
plant operations.
Shutdowns, downtime and
consequent business risks, such as safety
hazards, loss in productivity have been a
severe production engineering problem.
However, by managing maintenance
schedules and cycles, this issue has always
been taken care of at the facility or site
level. Many companies have recently
implemented reliability initiatives geared
towards optimising the maintenance
function at their plants, backed by
the support of enthusiastic senior
management.
Now a boardroom issueForward thinking corporations of today
are starting to look at the issue of asset
management in a different way. They are
now focussing on how adoption of lean
maintenance strategies can actually help
their business grow. This way, the senior
management is relocating the discussions
on maintenance from the facility into the
boardroom. Most members of the senior
management now view maintenance
efficiency as a factor that can affect
all the business indicators such as
environmental integrity, energy efficiency,
product quality and customer service, and
not limited to just cost.
Implementing an asset management
programme can be tough in today’s
world of corporate business thinking. In
order to pursue an effective programme,
one needs to have a basic plan with
practical goals and objectives. “Modern
industry is at crossroads in today’s world.
The management is driven to reduce
costs and provide higher productivity
at the same time,” says Anthony Wong,
Managing Director, Jotun India. Yet, the
management in many cases may not have
the exact technical information required
to make long-term, cost-effective
decisions with regard to the maintenance
of facilities, buildings, infrastructure,
utilities, and assets that produce parts that
make up the final product. What they
may have is a summary and deductions
made from available data.
For some companies, predictive
maintenance has become a boardroom
issue. There are companies that
consider their maintenance principles
a strategic advantage. “The global
financial crisis has encouraged the
use of predictive maintenance tools.
The tools are becoming more popular
as plants struggle to extend the life
of their equipment and optimise
equipment operation in the midst of
a severe downturn. Plants can no
longer afford scheduled maintenance,
which often means replacing something
that is not broken or expensive
breakdown maintenance strategies,”
adds Mukul Gupta, Managing Director,
Chemtreat India.
Success is typically measured by the
improvement to the company’s bottom
line. To achieve the financial success of
any project, the key cost drivers addressed
by the project have to be understood.
Another perspective of looking at
maintenance strategies is not only to
maintain the assets but also to enhance
the process or the plant operation system
as a result of turnaround planning. “Thus,
rather than restoring the equipment to
its original performance, planning a
turnaround could better still be aimed at
Rather than restoring the equipment to its original performance, planning a turnaround could better still be
aimed at enhancing the process and performance of a plant, equipment or any system.
Mukul GuptaManaging Director, Chemtreat India
The CEO’s perspective Asset management encompasses safety, profitability, brand image,
cost efficiency, energy management, and several other factors. It means different things to different people. What does the head honcho
of an organisation view it as? Read on…
41December 2012 | Chemical World
Asset management
enhancing the process and performance
of a plant, equipment or any system,”
adds Gupta.
Orienting the workforce“The best process and technology
platform will be successful only with
the presence of trained and motivated
employees. An ideal maintenance
management programme will require
the combined skillsets of engineers,
operators, analysts as well as technology
professionals,” opines Wong. Ultimately,
tackling maintenance issues is identical
to solving a business problem.
“Effective maintenance is no longer
viewed as a cost centre, as was the case
traditionally. It can be transformed into a
profit centre, if strategised optimally,” says
Wong. That is where the involvement of
senior management is imperative. The
responsible and authoritative stamp
of the senior management proves the
seriousness they put into this issue.
Turning an unmanaged cost into a
managed asset and thereby converting it
into a profit centre is the hallmark ‘KRA’
of senior management today.
Adapting to a cultureNo programme can succeed completely
if it is not well-conceived by the entire
workforce. If implemented optimally, a
maintenance programme alone has the
ability to change the culture, philosophy
and workflow of the production
department. “It is not just the addition
of a new technology or tool, but a
different approach and strategy towards
maintaining one’s assets. This approach is
being undertaken in order to gain specific
benefits that can and should be measured.
These benefits include increased uptime,
reduced failures, shorter planned outages,
fewer preventive maintenance actions
and, ultimately, a more efficient facility,”
summarises U Shekhar, Managing
Director, Galaxy Surfactants.
The senior management has the
onus of streamlining the said strategies.
Failure to adapt the culture to this new
philosophy, and effectively benchmarking
the gains, will eventually lead to the
programme’s dissolution. Adopting
new technologies without changing
maintenance strategies will not produce
the desired benefits. Ongoing training is
an important ingredient of a successful
programme. However, it needs to be the
correct type of training, a combination
of complementary technology and
managerial expertise.
Email: [email protected]
It is not just the addition of a new technology or tool, but a different approach and strategy towards maintaining one’s assets.
This approach is being undertaken in order to gain specific benefits that can and should be measured.
U ShekharManaging Director, Galaxy Surfactants
INSIGHT & OUTLOOK Roundtable
Chemical World | December 201242
Are companies taking enough steps to sensitise employees about asset optimisation?
As companies explore avenues to increase their profitability, optimising their existing assets acquires extreme importance in determining further growth plans. The onus of optimising the assets does not lie on the shoulders of the maintenance department anymore, and companies are focussing on sensitising every employee about this aspect. Mahua Roy talks to experts on this to know more.
Managing the assets optimally is a constructive strategy that can help boost productivity of a manufacturing plant. And asset optimisation
is not just limited to machinery and utilities such as water and energy but also people. Companies are actively co-developing strategies with
employees to promote asset optimisation and investing heavily in their delivery.
EDITORIAL TAKE
Anthony WongManaging Director, Jotun India
Asset management and optimisation
is key to turning businesses
profitable. Making the workforce
realise the importance of assets,
as basic as electricity and water as
well as equipment and machinery,
is imperative for attaining success in
business. We fuel innovation among
our employees and promote asset
optimisation. Collaboration among
them and application of their unique
skill-sets result in innovation. They
can be led to devise for themselves
a carefully orchestrated combination
of business, technical and scientific
skills to help set company strategy
towards asset optimisation. We
encourage the team to come up
with pathways and results. This
way every employee gets a three-
dimensional expertise. Employees
need to appreciate vertical industry
trends and end-user needs as well
as global economics, finance and
advances in science and technology
that affect various industries.
Farooq MerchantManaging Director, Messung Systems Pvt Ltd
Manufacturing and production
enterprises are under intense pressure
to deliver maximum efficiency,
under various operating conditions.
The ultimate winners will be those
who use their people and equipment
assets most effectively. The objective
is to completely optimise the
utilisation of all plant assets, from
entire process lines to individual
pressure vessels, piping, process
machinery, and other vital machine
components. Continuous training
to personnel is the most effective
method to sensitise the employees
about asset management. This can
also be coupled with imparting of
safety training. Understanding the
safety issues related to installation,
operations, and maintenance of the
equipment assets and production
processes is also crucial. Safety
concerns affect decisions on when
to perform certain high-risk repairs
and how long to operate an asset,
which is in critical need of repair.
Bharat GalaPresident, SNC Lavalin Engineering India
Most of the critical process-
driven industries are growing.
Such industries are investing more
on engineering, project and asset
management tools to optimise the
use of existing assets. This provides
an additional boost to plant safety.
Initially, asset management was
never looked upon as a tool by the
industry. It was considered more of
a luxury. But today, as the industry
globalises, with technology providers
customising solutions, plant
maintenance and asset management
are being readily accepted and
incorporated in production
departments. Ability to integrate
technologies – from inventory
management to supply chain
dynamics and real-time management
of assets – is equipping the industry
personnel in planning future projects.
Orienting the employees about such
technologies is a must. Investing in
employees is a big investment too.
They are the biggest assets.
INSIGHT & OUTLOOK Accident reduction
Chemical World | December 201244
Workplace accidents and other untoward incidents add to the cost pressures of any company. However, if
efforts are taken to analyse and compute different types and quantum of expenditure incurred in controlling/combating/compensating/mitigating
accidents, a bigger picture can unfold. Here is an attempt to revisit different ways and means of costing the undesirable incidents and saving every rupee through assurance of safety.
Safety ensured, rest assured
KNK Murthy
A lot of money is saved while
working safe; however
huge amounts also get
squandered in an accident.
Knowingly or unknowingly the costing
part of safety governance is not seriously
taken up and people get carried away
or contended by the so-called overhead
terminology and tend to write off the
expenditure considering accidents as
just one of or rare occurrences. Reliable
cost information is one basis for making
decisions upon which efficiency and profit
of the organisation depend. Even in so
obviously desirable an activity as incident
prevention, some proposed measures or
alternatives must be evaluated on the
merit of their potential effect on profits.
This may serve as a panacea to prevent
untoward incidents.
Although most company executives
want to make their organisation a safe
place to work, they have to do some
balancing act while delivering the
assigned and primary task of running the
business profitably. Consequently, they
may tend to spend less on safety and
accident prevention goals, unless there
is convincing argument on the scope of
saving at least what has
been spent. It is exactly here
that the accident costing becomes helpful
in projecting the lower rate of capital
investment on safety and higher rate of
recurring post-incident expenditure.
People at the managerial and
topmost executive levels get more
attracted towards cost reduction figures
as compared to accident reduction
figures (the latter being preferred by
and large among safety professionals).
Table 1: Direct costs
Attribute Information access
Payment of wages to injured during his leave of absence
Pay slips (in certain organisations they specifically mention this as accident leave along with the break-up data)
Reimbursable medical expenditure Medical, personnel or accounts department
Insurance premium being paid (for personnel and assets including public liability)
Personnel/accounts department
Compensation paid against any type of disability (temporary, permanent, partial or total)
Personnel/welfare/accounts department
Additional wages paid to the employee who work as substitute
Accounts department
Repair/replacement expenditure on equipment damaged due to the accident
Unit in-charge in whose area the accident took place
Cost of fire extinguishing materials Fire service department
Cost of other mitigation expenditure (hiring expenditure of cranes, transport vehicles, purchase of contingency materials such as cement bags, excavation tools, temporary shelter erection etc, to name just a few)
Materials, engineering services, transport (administration), departments
Supply of beverages and food for rescue personnel, medical staff etc
Canteen or hotel bills
Legal expenditure (court cases), investigation fees (especially when the function is outsourced)
Legal or secretariat department, contract cell etc
45December 2012 | Chemical World
Accident reduction
In addition, presenting the trend of cost
reduction vis-à-vis incident occurrences
will motivate shop-level supervisors to
ensure improved compliance of safety
systems, procedures and practices.
National Safety Council (USA),
a premier organisation devoted to
nurturing, promotion and development
of safety, brings out an annual
publication called Injury Facts. One
simple illustration appearing in its 2009
edition says it all while notifying that
the actual cost of accidents incurred
by the US in just one year touched a
whopping $ 693.5 billion. Though
highly unimaginable or prohibitive, the
revelation is factual.
How the costing could have been made?Elephants have two types of teeth –
outer (tusks) for displaying and inner
for chewing (which is a more serious
activity). Similarly, in most of the
accident reports, one can come across the
immediately visible (outer) expenditure
(also known as direct) which gets
more coverage, leaving less scope for
the indirect. In fact, in majority of the
cases, the indirect costs turn out to be
many times higher – including difficult
to measure or abstract data. First let
us start listing the direct costs (easily
available and duly measurable) including
the source of information access in any
type of organisation. Thereafter, the
attention could be on indirect costs
(Refer Tables 1 and 2).
Above all, there are few hidden but
significant costs in terms of company’s
image, prestige and reputation among
all stakeholders, society, and the nation,
which may not have a price tag but
affecting overall productivity and
entrepreneurship of the organisation.
Prevention is bestAll types of establishments are nowadays
being confronted with challenges
concerning profitability from different
angles. In this context, it would be
wiser for unit heads and senior- level
executives to integrate safety and loss
prevention along with other elements
in the productivity while looking for
saving and cost reduction. There cannot
be a better indicator than accurate
figures with respect to proactive (safety
assurance) and reactive (post-accident)
costing. Safety personnel must take lead
in this aspect considering their expertise
in convincing and communicating
(which is their basic professional asset).
They must directly take up the issue
with the agencies as mentioned in the
tables (who can facilitate the initiation
process by sharing the data as required
for the costing exercise).
Armed with the right/accurate
information, the safety executives
are required to attend the regular
managerial meetings in the organisation
and take up the issue of the lessons
to be learnt from all consequences in
general and financial implications in
specific with reference to the types of
accidents. Thereafter, they will be in an
unassailable position to advocate the
need for investing as much required for
safety improvement so as to save more
and avoid painful expenditure after an
undesirable occurrence.
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]
Table 2: Indirect costs (At times abstract or non-quantifiable)
Attributes Information access
Unclaimable amount from insurance companies (fixation of minimum payable value, loss not duly covered/specified in the listed items, lack of evidence, overshooting warranty/disclaimer clauses etc)
Special and one-time approvals for waiver/ write off by top management
Demurrages/compensation against stoppage, delay of delivery to customers, service providers or other stakeholders
Marketing/materials/contract departments
Loss due to process interruption, suspension or long spells of shutdown due to accident
Production department
Payment to injured against restricted activity (eg, allotting light duty)
Departmental heads/personnel etc
Expenditure incurred in helping out family members of accident victim to reach hospital and staying as attendants
Personnel department
Cost of man-days spent for training a substitute to takeover victim’s workload
Departmental heads/personnel department
Cost of man-days spent on personnel attending to the victim (peers and supervisors)
Departmental heads/personnel department
Cost of materials/equipment, which got either spoiled or damaged beyond salvation
Operations and maintenance department
Additional cost of cleaning up operation Production department
Increase of production cost while trying to get additional material or equipment (urgent supply) through traders and dealers after the accident (inflationary rates)
Production and planning department
INSIGHT & OUTLOOK Oil price volatility
Chemical World | December 201246
Dr Mosongo Moukwa
The oil markets for the
remainder of 2012 will
be driven mainly by
fundamentals and, in
particular, by the supply side: very
tight crude oil stocks, low spare
capacity from the Organisation of
the Petroleum Exporting Countries
(OPEC), and significant non-OPEC
supply disruptions. In addition, both
actual and potential supply disruptions
from Iran will be an important factor for
the markets.
Extreme volatility in oil prices is
here to stay. It will affect every sector
of the economy, including the chemical
industry and allied sectors such as the
paints and coatings industry. Indeed,
most raw materials used in the paints
and coatings are hydrocarbon-based,
and their price is directly affected by
both the oil and gas prices. This has
important implications for executives,
who are challenged to know where to
put their bets.
Demand for oil There are many doubts regarding
the demand for oil. OPEC and the
International Energy Agency (IEA)
had revised their forecast for oil
demand growth in 2012 based on
worries about the weak global economy,
and in particular, the Euro zone crisis.
Steeper declines are observed in the
US and the OECD-Europe due to a
combination of economic stagnation
and gradual gains in efficiency. Demand
in Europe is down by 8,00,000 barrels
per day in just two years, primarily
because of the concerns about the debt
crisis in Europe. Demand growth has
been concentrated in developing world,
with China using more than 10 million
barrels per day.
Tightness of the supplyThe tightness of the supply is mostly
a result of supply side issues. Barclays
Capital estimates that the problems in
Sudan, Yemen and Syria alone could
together curtail over one million barrels
a day output – more than one per cent of
global supply. That is now compounded by
the European ban on Iranian imports that
took effect on July 1. This will deprive the
European Union of up to 6,00,000 barrels
a day of crude. If this happens, India and
Japan will lose tens of thousands of barrels
of daily supply and the world will be short
of 1.6 million barrels a day.
The aftermath of the Arab Spring
has obliged Middle Eastern governments
to boost social expenditures across the
region. It is estimated that in order to
meet these obligations, expenditures for
the increased production of oil (upstream
allocations) will require almost $ 4 trillion
between now and 2035 – on a sliding
scale starting at $ 100 billion annually.
OPEC, which accounts for 30 million
of the 80 million barrels released to the
market every day, will need an average
crude price of $ 80 a barrel now and
more than $ 120 within a few years. This
is due to increasing capital outlays to
maintain the flow of oil. It can choose to
reduce output as a means to push prices
higher and can increase it to meet greater
demand. Oil is also priced in dollars.
Thus, movements in the exchange rate
have impacts on crude. The weaker
the dollar, the higher the dollar price
of oil because it takes more dollars to
buy a barrel.
Impact of oil price on the chemical industryThe impact of oil prices on the price
of chemicals has become more difficult
to predict. Applying historical product-
to-feedstock price spreads to outlooks
based on a given margin and return is no
longer valid. This was possible years ago
when past and future plants relied on the
Higher oil prices and associated volatility have significantly changed the relative profitability and competitiveness of chemical sector, although the relationship between various chemical groups and supply chains are impacted differently. Companies will need to revisit the basics of supply and demand, taking into account production costs, substitution, alternative production routes, as well as trade and logistical linkages among various regions.
THE NEW ECONOMIC REALITY
43210
-1-2-3-4
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
2009
Sources: IEA, OPEC, news reports
2012 world oil demand growth
9,40,000 bpd (revised from 1.06 mn bpd)
World oil demand 86.94 mn bpd 87.82 88.76
2010 2011 2012
Non-OECDOECDWorld
World oil demand growthBy quarter, in million barrels per day (bpd)
47December 2012 | Chemical World
Oil price volatility
Sustained higher oil prices and volatility have not only
changed the price relationships among petrochemicals
producers but also call for the adoption of non-hydrocarbon-
based feedstock.
same basic technology, built in the same
region, and all players had similar capital
investment expectations.
Sustained high oil prices have had
significant effects on the entire chemical
industry. Generally, higher feedstock
costs increase the manufacturing cost of
most petrochemicals; this has impacted
the profitability of many companies. As
high oil prices alter the price of some
chemicals more than others, the relative
profitability of some products are affected
more than others. This is already affecting
the chemical industry.
Take propylene, for example.
Propylene price has been traditionally
linked to its alkylation value. With rising
oil prices around 2005, the alkylation value
was pushed higher, and propylene price
detached from this pricing mechanism.
The marginal use of propylene instead
became polypropylene (PP) substituting
for high density polyethylene (HDPE),
and a new pricing level was established. By
2010, the US propylene market became
tight as propylene demand continued to
grow faster than supply. In the new tight
market, propylene then moved up the
value ladder to a point where its price
is being set by PP competing in some
applications with polystyrene (PS).
Geographical differential prices have
also been altered. The world is more
globalised, where the long-term price
setter may be situated in a different region
with a different cost structure. Chemical
flows, traditionally coming from North
America and Western Europe, are more
complex today and affect the price
differential across the various regions of
the world. The emergence of powerful
new producers with different cost
positions and decision mindsets in regions
such as the Middle East and China has
changed the landscape altogether.
Discontinuities are also emerging
along the hydrocarbon and petrochemical
chains. The discovery of abundant ethane
containing shale gas has added new
supplies of ethylene. These new sources,
however, will only partly cover the global
demand for ethylene, estimated to reach
160 million metric tonne per year by
2020. New naphtha crackers will still be
required in order to meet the demand
requirements. The price of naphtha,
gas and other light distillate oil-based
products are related to the price of oil;
thus they are also affected by the macro-
economy and geopolitical uncertainty.
Naphtha-based ethylene crackers generate
substantial quantities of by-products such
as propylene and butadiene, and the price
of ethylene depends upon the price the
producers receive for those by-products.
Sustained higher oil prices and
volatility have not only changed the price
relationships among petrochemicals
producers but also call for the adoption
of non-hydrocarbon-based feedstock.
It is also forcing companies and
technologists to look for inter-polymer
substitution among the commodity
polymers. For example, capital-intensive
manufacturing processes may fare
much better than feedstock-intensive
processes; energy-intensive processing
will suffer and non-petroleum-based
products will be preferred.
Turbulence has increased. It is
neither uniform across the hydrocarbon
and the petrochemical chains, nor across
countries, nor steady over time. The
current economic crisis is not the cause
of the market turbulence. It is simply the
latest symptoms of the volatility inherent
in global markets and the various
discontinuities that have emerged over
the last ten years.
Welcome to the new oil economyThere will be a rise and fall in oil
prices moving forward. Nonetheless, the
overall trajectory will continue upward.
With less supply and constant demand
– at a minimum – oil prices can only go
higher. Higher oil prices and associated
volatility have become the new
economic realities. It has changed the
business dynamics and competitiveness
of chemical sector. Companies will need
to go back to the basics of supply and
demand, taking into account various
factors that include production costs,
substitution, and alternative production
routes, among others.
An increase in the prices of gas and
crude oil is significant for the paints and
coatings industry. It represents a source of
major concern for manufacturers of paints
and coatings, as 60-70 per cent of the raw
materials are based on petrochemicals
derivatives. The situation in India is such
that out of the 300 raw materials used in
paints and coatings, about half of them
are imported. Paints and coatings consist
of three major components.
Even in the most volatile environment,
opportunities can be found. Periodic golden
opportunities are interspersed among many
smaller chances. The trick is to keep in the
information flow, talk through alternative
scenarios, and keep discussing possible
opportunities for the management team to
identify the most attractive.
The flow of information must be in
real-time to keep abreast of the fluid state
of affairs to spot emerging opportunities
and threats early enough to act on them.
Executives must work through possible
scenarios to assess how the process might
evolve and what it might mean for the
industry or for their particular business.
They must also study what is happening
in other countries to apply some lessons.
Dr Mosongo Moukwa is Vice
President (Technology), Asian
Paints Ltd, Mumbai. He
was Vice President (Global
Technology), Reichhold,
North Carolina. He is a member of the
American Chemical Society, the Commercial
Development and Management Association
and the Licensing Executive Society.
Email: [email protected]
AUTOMATION TRENDS Wireless technology
Chemical World | December 201248
Mahua Roy
The worldwide market for
wireless technology for
plant maintenance and
asset management will
grow 26 per cent annually over the next
few years, as per a forecast by the ARC
Advisory Group. Driving that demand
is a strong realisation regarding not only
the forseeable cost savings that accrue
from doing away with wires but also
the ability of wireless applications to
enable new and better ways of operating
in the process industry. Wireless
communications have traditionally been
serving remote monitoring applications
in oil & gas production and water &
power utilities. However, the potential
for wireless technologies to link
field devices and control systems in the
plant is creating a huge flutter in the
chemical industry.
Intelligence, modularity and remote
diagnostics are the trends of the future.
Decentralised automation allows
distribution of intelligent automation
components across the plant. New
biotechnological processes represent
new challenges for automation,
particularly in the production of
pharmaceuticals and biotech-based
fine chemicals. “In the past one decade,
automation and instrumentation
have changed because supporting
technologies – especially software
and surface-mounted devices – have
developed significantly. Today, web-
based management technologies such
as remote viewing, Wireless-HART
technologies, radio communications
and RFID technologies are evolving
and influencing the automation arena.
Developments have been such that it
is even possible to receive an alert on
a mobile phone or laptop regarding
the process of the plant,” states Sunil
Khanna, Managing Director, Emerson
Network Power India.
Live wirefreeWireless technologies offer an array
of benefits, even economically. “It can
typically bring down the capital cost
of a project by almost 50-80 per cent,”
adds Khanna.
How does one summarise the
futuristic wireless technologies adopted
in plants? What is their value-addition
to currently installed assets? It cannot
be ignored that wiring incurs high
expenses, coupled with its maintenance.
Adopting a wireless environment will
essentially lead to cost savings for the
company. “Few pieces of equipment
that must be monitored have wired
instrumentation because the cost of
wiring back to the control room is
prohibitively expensive. As a result,
a plant needs to shift focus towards
wireless technologies. One can continue
to have wired protection systems only for
high-value assets such as large turbines,
which generally represent less than 10
per cent of rotating equipment,” says
Farooq Merchant, Managing Director,
Messung Systems Pvt Ltd.
Wireless technology offers the
process industry the functionalities
it might lack. “For instance, a new
category of low-cost field devices can
gather additional indication – only
data – that will help operators run
units smoothly. These devices do not
aim to replace wired instruments in
controlling the process but rather will
provide extra data points to improve
optimisation. In turn, safety of assets
and employees will also be guaranteed.
In a wireless environment though, being
We are not very far from the idea of a wireless plant. The rapid development and sophistication in technologies have led to the adoption of wireless technology by the process industry.
asset management process
In the wireless plant of the future, daily rounds will become less frequent
because wireless instrumentation will be able to capture live and then immediately send
relevant data back to the control system.
49December 2012 | Chemical World
Wireless technology
able to implement a basic device such as
an incremental temperature transmitter
can make a significant difference,”
adds Merchant.
In the wireless plant of the
future, daily rounds will become
less frequent because wireless
instrumentation will be able to capture
live and then immediately send relevant
data back to the control system. Thus, a
lot of saving on manual labour can be
avoided, preventing errors. Besides, it
will be possible to get high-quality data
several times a day from assets.
Live streamingAnother area expected to grow over the
next few years is streaming audio and
video over the wireless network. “For
instance, maintenance personnel may
wish to observe only a specific integral
pump. If it begins to fail, staff can view
the video to see if anything is physically
wrong with the unit without having to
drive to the location. Likewise, wireless
video can ensure that contractors are
performing work in a safe and acceptable
manner,” says Merchant.
And of course, remote access
is the biggest advantage provided.
“Maintenance engineers carrying wireless
video cameras on rounds will be able
to show a remote expert, thus speeding
up a troubleshooting or repair process,”
he adds.
RFID boomEmerging deve lopments in
wireless technology promote employee
safety and physical asset tracking in a
big way. “In future, I see wearable RFID
tags to become common, enabling
plants to readily locate workers.
This will prove an important strategy in
case of plant emergencies. Many R&D
houses are working on this technology.
Besides, RFID tags also will allow
keeping track of high-value assets
vulnerable to theft or misplacement,”
says Merchant.
Go wireless, save time This pool of information provided by data
will lead to availability of much greater
time for in-depth analysis. This will result
in less downtime, decreased maintenance
costs and increased production. “Research
shows that using wireless instrumentation
to monitor assets more frequently
sometimes can cut maintenance costs
in half. Workers in the plant will spend
their days quite differently. With live data
on their fingertips, they will be able to
operate more effectively,” notes Khanna.
As per feedback from expert vendors
in the industry, many chemical majors
and process industries are steadily
reformulating their wireless strategies.
By carefully choosing wireless projects,
working with experienced vendors and
selecting wireless equipment that can
handle today’s needs and provide the
scalability to support future requirements,
some sites already are well on their way to
becoming futuristic.
Email: [email protected]
ENERGY MANAGEMENT Cold pilger process
Chemical World | December 201250
Rakesh Rao
Cold pilgering is a rolling
process for metal tubes
in which diameter and
wall thickness are reduced
in a number of forming steps. This
technology can be used to manufacture
tubes or pipes, which are used in
chemical industry applications. “Yes, they
can be also used in the chemical industry.
The application is difficult to specify as
high-quality stainless tubes can be used
everywhere,” observes Tobias Korz, Sales
Manager - Cold Pilger Equipment,
SMS Meer GmbH – which offers cold
pilger mills.
Cold pilger mill machines perform
work on pre-existing tubes produced by
means of cast, welding or extrusion.
Pilgered tube metal alloys include
aluminium, copper, gold, silver,
stainless steel, titanium, zirconium
and a host of many other special
materials that are derived from
various metal alloys.
Pilgering is a fast process. The
saddle holds the top & bottom
dies and forces the two dies over
the tube material outside diameter.
The mandrel is stationary but does
rotate at a specific time in the process.
The mandrel is tapered and maintains
the tube inside diameter while the dies
reduce the outside diameter. At a specific
time in the cycling process, the incoming
tube is fed into the dies and over the
mandrel. As the tube is reduced from a
larger diameter to a smaller one, the tube
is elongated and, therefore, the finished
tube becomes considerably longer.
Advantage cold pilgerThis special forming process is
indispensable for numerous applications,
and economical for many others. Large
cross-section reductions (diameter and
wall thickness) are possible, thanks to a
forming process involving the application
of pressure from all sides, enabling
substantial reduction of eccentricity
due to a homogenising material flow in
circumferential direction, achievement
of special material microstructures and
manufacture of large tube lengths. With
cold pilgering, one can avoid additional
operations and processes such as cleaning,
annealing, pickling, cutting, handling,
straightening, etc. Other advantages
include:
� The large number of forming
steps improve roundness, stress
homogeneity and surface roughness
� Free sinking with its negative effects
is completely avoided
� Achievement of closest tolerances in
diameter and wall thickness
� No process-related material losses
� Suitable for forming difficult
materials, which are beyond the
capabilities of other processes, eg
drawing
� High cost-efficiency due to large
shell weights & shell lengths, and the
production of various tube sizes from
one shell size
No other cold forming process for
tubes is able to offer so many positive
benefits. Furthermore, the cold pilger
rolling process is not limited just to the
production of cylindrical tubes.
Saving power There is another major metal
working process, cold draw, used
to reduce the same types of tubing
and alloys. However, it has been
observed that when producing large
quantities of tubing, cold drawing is
considered to be slow, compared to
the pilgering process. For example,
a cold drawn tube may have to be
drawn 3-4 times to equal the same
amount of work of a pilger mill.
Each time a tube is cold drawn, the tube
must be cleaned and annealed (softened)
before drawing again. Hence, it is believed
that cold pilgering technology is energy-
efficient compared to other technologies
used to manufacture tubes or pipes. Korz
A COOL SOLUTION TO TUBE FORMINGRise in demand for specialised tubes from process industry is leading to increased adoption of cold pilger technology. While it offers advantages such as better finish, avoidance of additional operations & processes, suitability for forming difficult materials, etc, low energy consumption gives this technology an edge over other methods.
Cou
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51December 2012 | Chemical World
Cold pilger process
Source: SMS Meer GmbH
says, “Yes, cold pilgering technology is
energy-efficient as it can reduce large
cross-sections, which saves additional
forming steps. Compared to, for example
drawing processes, the pilgering does not
result in waste of crimped ends.”
Explaining the advantages of
using cold pilger mill technology to
manufacture tubes or pipes, Sanjay
Waghulade, Whole-time Director,
Innoventive Industries Ltd, says, “Using
this process, there is a significant
reduction in energy, labour and material
costs in comparison to the draw bench
method. Also, products manufactured by
this process have unmatched quality, with
superior surface finish, higher tensile
strength while remaining competitively
priced because of these savings.”
Cold pilgering technology helps
achieve higher cross-section reductions
whereas in draw bench cross-section
reductions are limited. Waghulade says,
“So cold pilgering technology significantly
reduces the number of passes required to
achieve the desired specification to the
conventional draw bench technology that
requires many more passes to achieve
the same specification. The savings are
magnified in the case of tubes with a
smaller diameter. The large cross-section
reductions help to limit process-related
conversion costs, because cold pilgering
reduces number of additional processes
such as end pointing, pickling, cutting,
handling, and straightening between
drawing operations. All these help to
lower the energy consumption.”
India taking the leadIn July 2012, Innoventive Industries Ltd
was granted a patent for a cold pilgering
technology, which the company claims
can help to manufacture quality tubes
with enhanced characteristics in a most
energy-efficient and cost-effective
manner. “The cold pilgering for welded
tubes technology is a proprietary
technology developed by Innoventive
Industries to manufacture Cold
Drawn Electric Welded (CEW) tubes
from Electric Welded (ERW) tubes
without the use of draw bench. This
process results in energy, labour and
process-related conversion cost saving
and provides tubes with enhanced
mechanical properties such as better
surface finish, dimensional accuracy
and strength, compared to typical
CEW tubes,” states Waghulade.
As per the study conducted by
the Indian Institute of Technology,
Mumbai, the process saves up to 80 per
cent energy costs and also has significant
environmental advantages. “The usage
of chemicals is significantly minimised
and the wastage of steel is reduced by
7 per cent without compromising
on the quality of the product,”
claims Waghulade.
Clamouring for demand With the demand for tubes rising,
cold pilgering technology is gaining
traction. Korz says, “Yes, there is for
sure a big rise in usage of cold pilgering
technology as there is a big market for
high-quality tubes made from stainless
steel, brass alloys, copper, zirconium
and nickel-chromium-based alloys. The
future is good for the cold pilgering
technology, especially for high-quality
machines from SMS Meer, which have
higher output and quality of tubes
compared to the competitors. Modern
production facilities trust the machines
of SMS Meer. There is a growing
market for very special tubes.”
Adds Waghulade, “We are seeing
greater understanding and acceptance
of this process by our clients as they
realise the value they can derive.”
The growth prospect of cold
pilgering is promising as tubes
manufactured by this process
are competitively priced without
compromising on the quality. Its
low energy consumption is an added
advantage. Hence, companies offering
services and technology for cold
pilgering are also upbeat about the
future. Waghulade concludes, “While
our technology is currently focussed on
the process of conversion of ERW tubes
into CEW tubes, we are evaluating
multiple products across industries
where the efficiency of this process can
be leveraged to create value. We see
increased preference for this process in
the future.”
Email: [email protected]
Table 1: Materials that can be cold pilgered
Materials Applications
Stainless steel Chemical industry, medicine, food, and pure gas applications
Antifriction steel bearings Antifriction bearings
Ferritic steels Boiler construction and chemical engineering
Low-alloy steels Boiler construction, drilling & boring, high pressure tubes, and automotive engineering
Inconel, Incoloy, nickel alloys Heat exchangers for power plant, and chemical engineering
Copper Plumbing tubes, air-conditioning systems, refrigerators and heat exchangers
Copper-nickel, brass Seawater desalination plant, and marine engineering
Titanium alloys Aeronautical engineering and medicine
Zircaloy Nuclear power plants
Cold pilgering technology signif icantly reduces the number of passes required to achieve the desired specification to
the conventional draw bench technology that requires many more passes to achieve the same specification. The savings are magnified in the case of tubes with a smaller diameter.
Sanjay WaghuladeWhole-time Director, Innoventive Industries Ltd
POLICIES & REGULATIONS REACH impact
Chemical World | December 201252
Stephen Van Heerden
The EU REACH regulation
has taken centre stage
for companies exporting
products to Europe since
its inception. As per statistics from
European Chemical Agency (ECHA),
first registration deadline (November 30,
2010) for substances exported more than
1,000 tonne per annum (tpa) resulted
in submission of 25,000+ registrations
for approximately 4,300 substances to
agency. Registrations with intermediate
use comprised approximately 25 per cent,
and of the total registrations 19 per cent
were submitted by ‘only representatives’.
Majority of registrations (above
94 per cent) for 2010 deadline were
done as joint submission, where
a company takes the role of lead
registrant and submits all data required
as per tonnage band with rest of
companies, who become member
registrants, submitting the dossiers
referring to this data by paying data
cost (Letter of Access – LoA) except
company-specific information. Besides
the registration, companies submitted
more than Classification, Labelling
and Packaging (CLP) notifications to
the agency.
With successful completion of
two deadlines, the present focus of
companies is registration deadline due
next year for tonnage band from 100 to
1,000 tpa. ECHA has released tentative
timelines for 2013 registrations, which
show that lead registrant has to submit
the dossier at least three months before
the deadline.
Global chemical regulationsThe REACH regulation has played an
inspirational catalytic role in drafting
and implementation of chemical
regulation across the globe. Countries
such as China, Turkey, Japan, Taiwan,
etc, have recently adopted regulations
on similar pattern and in some countries
the regulations are in draft stages such
as South Korea, Malaysia, the US and
India. Chemical regulations of few
countries have been mentioned below.
China: Chemical management
in China is regulated by Measures on
Environmental Management of New
Chemical Substances (China REACH,
2010), which is being looked after by the
Ministry of Environmental Protection
(MEP). The law came into force in
October 2010 and requires notification
of ‘new’ chemical substances not listed
in the Inventory of Existing Chemical
Substances in China (IECSC). The
inventory has 45,602 substances, of which
3,166 substances have been claimed
confidential and 8,175 substances are
without Chemical Abstracts Service
(CAS) number.
China has also implemented
Regulations on Safe Management of
Hazardous Chemicals (China GHS,
2011) which require companies to
update the Safety Data Sheets (SDS).
The regulation is in force since
December 2011. In past few months,
a Chinese authority in Shanghai has
seized shipments of more than 1.55
million tonne of hazardous chemicals
worth $ 45 million, which were not in
compliance as per China’s regulatory
requirements such as faulty labels.
Japan: Chemical Substances
Control Law (CSCL) is in force
The REACH regulation has played an inspirational
catalytic role in drafting and implementation of
chemical regulation across the globe. Countries
such as China, Turkey, Japan, Taiwan, etc, have
recently adopted regulations on similar pattern.
Since Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) regulation came into force in the European Union (EU) on June 1, 2007, other countries have taken steps to implement stringent norms to monitor safe usage
of chemicals. Read on to learn about some of the new global regulatory frameworks in the chemical industry.
Cascading effect on the global regulatory framework
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53December 2012 | Chemical World
REACH impact
since 1973 and amended in 2009. It
requires manufacturers and importers
to submit the notification to concerned
agency. The law applies to both
new as well as existing substances
(already manufactured/imported
at the time of the promulgation of
the CSCL). Chemical inventory
is named Japanese Existing and
New Chemical Substances Inventory
(ENCS) which has approximately
20,600 existing substances. The type of
registration depends on the nature of
substance and tonnage.
Turkey: The chemical regulation
is inventory and control of chemicals
nicknamed ‘Turkey REACH’ in force
since March 2011. The law requires
manufacturers and importers to submit
the notification to authority in Turkish
language for more than 1,000 tpa and
1-1,000 tpa band. The law is governed
by the Ministry of Environment
and Urbanisation. There is also
requirement for SDS in Turkish
language to be prepared by person
certified by Turkish authority.
Korea: Korea has Toxic Chemicals
Control Act (TCCA) in force and
‘Korea REACH’ in draft stages. The
Ministry of Environment is the authority
responsible for the law. The proposed
modification involves (pre-) registration
of new and existing chemicals.
A non-Korean manufacturer can appoint
only representative in same way as in
EU REACH.
On the road to complianceWith REACH deadline of May 2013,
many companies are not finding time as
well as are short of resources to look at
the upcoming REACH-like regulations
across the world. Due to language issues
most of the guidance and regulatory
documents are difficult to understand
for planning necessary compliance
measures. Hence, the industry players,
who are exporting globally, must start
checking their regulatory compliance
status for China, Turkey, Japan and
Taiwan without delay as these countries
have adopted and implemented
REACH-type regulations and for
most of them the deadline has already
passed. In addition to inventory listing/
notification/registration requirements,
it is equally important to keep one’s
Material Safety Data Sheets (MSDS)
in line with the regulatory compliance
for each country. Just preparing a
16-point SDS does not mean fulfillment
of SDS requirements, as each country
has altered the format while
implementing UN GHS or EU
453/2010. So, there is no master SDS,
which can be used for all countries and
the present SDS may require significant
improvement.
Stephen Van Heerden is the Sales Director at
REACHLaw Ltd, Finland. REACHLaw is one
of the leading service providers for REACH,
CLP and global regulatory compliance.
Email: [email protected]
STRATEGY Tapping human resources
Chemical World | December 201254
Avani Jain
Skills and knowledge are the
driving forces of economic
growth and social development
for any country. Countries with
higher and better levels of skillsets are able
to effectively overcome the challenges faced
by various industries as well as leverage
on the emerging opportunities. As India
moves progressively towards becoming
a ‘knowledge economy’, it becomes
increasingly important that the country
focusses on betterment of skills and human
intelligence for the advancement of all
industries including the chemical. Thus,
developing intangible assets such as human
intelligence assumes high importance.
Need for talent development infrastructure The chemical industry has not been
able to attract top-class talent, which
has created a severe shortage of skilled
manpower, seriously impacting its
productivity and growth. It is estimated
that India will need over 14,000 highly
skilled, chemical engineers within the
next decade to join the specialty chemical
industry alone. However, the industry as a
whole is already facing scarcity of skilled
and trained manpower. A potential
shortfall of 8,000-10,000 chemical
engineers is indicated, driven by limited
talent from Tier-1 universities and lack
of attractiveness of the chemical sector
for employment. Thus, the industry as
well as the government need to take steps
to channelise these intangible assets into
profitable ideas.
Dr Kirti Chandra Sahu, Assistant
Professor-Department of Chemical
Engineering, Indian Institute of
Technology (Hyderabad), notes, “At
present, in India, the technology and
process required for performing research
is traditional and outdated. Further,
India is lagging behind in fundamental
research activities. Companies directly
want to undertake applied research but
this is not possible until and unless there
is strong fundamental/basic research to
support it. In order to carry out this
fundamental research, companies have to
involve professionals from the institutes
who have the required knowledge and
skills. The professionals from research
institutes have good theoretical and
fundamental knowledge, which they
can apply effectively so as to provide
innovative solutions to the industry and
answer all their problems.”
To resolve the manpower shortfall and
develop human intelligence, the industry
must improve the value proposition for
chemical engineers. It should also form
a close collaboration with academia
through joint projects to source talent
and participate in curriculum formation.
In the chemical industry, it is generally
seen that all production processes
require skilled engineers. Also, high-
grade machines require skilled operators.
Companies need efficient workforce
for marketing. Thus, through industry-
academia collaboration, the industry can
actually train the students to meet the
above-mentioned requirements.
“Moreover, industry generally faces
substantial shortage of research talent
with the requisite skillset and experience
in advanced analytical researches, but
industry-academia collaboration can help
the industry in this aspect,” adds Dr Sahu.
Role of the governmentThe government can work in
collaboration with industries to upgrade
the current chemical departments in
Tier-2 universities to become state-
of-the-art departments (in terms of
infrastructure, faculty qualifications,
industry interaction and administration).
Also, to meet the future demand, 1,000
new ITIs, vocational training institutes
and diploma institutes could be set up.
Besides, the government can establish
specialised universities, vocational
training institutes and develop a skill
base. Institutes could be set up closer to
clusters and government could provide
rebate on training & development as
given for R&D. Corporates could be
incentivised to engage trainees/students
from these institutes on projects to
provide industry exposure. This could
lead to a closer bonding between industry
and academia, which can lead to the
development of indigenous technology
and intellectual property.
Gauging the futureThe future of the chemical industry
in India appears bright. However, the
industry will require additional 4.5 to 5
million skilled workers by FY17. Thus,
adequate steps including educational
infrastructure would be required to
impart vocational training for developing
the required manpower.
To meet the future demand, several
new ITIs, vocational training and
diploma institutes would be required.
This will help in creating skilled &
knowledgeable technical manpower
to achieve the projected growth of the
chemical industry and generate profitable
ideas for the success of companies.
Email: [email protected]
With the chemical industry expanding its horizon in the country, there arises the need to develop and sustain intangible assets such as human intelligence so as to generate more business and provide a boost to the industry. Chemical
companies, government and the industry bodies should take the onus to channelise this intangible asset for generating profitable ideas.
TIPS & TRICKS Control system migration
Chemical World | December 201256
Assess your
current system: A
system assessment
is essential for determining installed assets,
as well as identifying current maintenance
costs. The assessment outlines areas for
improvement and the anticipated value
of those activities, and specifies actions
that will achieve improvements. The
system assessment typically includes
audit of the current system and process;
recommendations for Human Machine
Interface (HMI) migration and effective
operator displays; suggestions for
base regulatory and advanced control
improvements; recommendations
for overall system improvements in
maintenance and performance; strategies
for migrating hardware and software as
well as protecting current installation
investments; plans for personnel training
& implementation, and recommendations
for optimisation and integration.
Ensuring operator
a c c e p t a n c e :
O p e r a t o r
acceptance is key and can determine
migration project success. Because
the control system is a direct operator
interaction device, even if the new
technology outperforms the legacy system,
a lack of consideration for operational
improvement or needs can lead to failure.
R e p l a c i n g
HMI : T h e
HMI included
in a DCS can be most vulnerable
to support issues. At many plants,
multiple types of HMIs are installed.
At some point, the HMI hardware
will exceed its life expectancy or the
cost of finding replacement parts will
become prohibitive. End-users need a
solution that allows the new HMI to
communicate with existing controllers
on a continuous basis.
Creating third-
party interfaces:
Communication
and interfaces with third-party devices
can be a major stumbling block to
automation system upgrades. Control
systems frequently communicate with
legacy systems, such as Programmable
Logic Controllers (PLCs), safety systems
and advanced applications. Many modern
systems can take advantage of new
technologies that enable a richer interface
resulting in tighter communications.
Identifying these systems and determining
a detailed interface plan is essential for an
effective migration.
S c h e d u l i n g
migration work:
When it comes
to a control system migration strategy,
careful lifecycle planning can reduce
or eliminate risks. First and foremost,
end-users should give thoughtful
consideration to the scheduling of
any migration. Long-term multi-year
planning for multiple migration stages
will help to ensure maximum ROI and
minimal disruption.
Preparing for
system cutover:
System cutover
requires careful planning to minimise risk.
A comprehensive cutover plan is a critical
requirement for seamless transition to
a new control platform. Without proper
preparation, migration projects can be
affected by cutover delays and other
unexpected issues that may cause downtime.
Reference: � Honeywell Process Solutions
Email: [email protected]
Improving the performance and business results of plants through control system migration has become an important strategic
initiative. The typical drivers for migration projects include the impact of downtime of existing control platforms, the ever-increasing cost of maintaining obsolete equipment, and the need to acquire or supervise global business data. The need to upgrade to new automation capabilities means that industrial operations must select the best migration strategy and technology solutions based on various critical factors, including control reliability, data configurability, plant-wide architecture support and standardisation & Safety-Instrumented Systems (SIS) integration. Here are some tips on how to go about managing migration from an existing DCS to a new automation system.
Effective ways to upgrade automation capabilities
Today’s competitive environment demands automation solutions that increase plant efficiency and profitability. Control system performance can significantly impact a manufacturer’s bottom line. Leveraging automation capabilities through simplified, cost-effective migration to a new technology, while optimising
current investments, is key to success. Here are some tips to manage migration from an existing distributed control system (DCS) to a new automation system.
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PROJECTS
Chemical World | December 201258
Dyes & chemicals
Spectrum Dyes and Chemicals Pvt Ltd Project type
Capacity expansion
Project news
Spectrum Dyes and Chemicals Pvt Ltd
has proposed expansion of dyes and
dyes intermediates manufacturing from
650 MTPM to 3,500 MTPM at
Palsana, Gujarat.
Project location
Surat, Gujarat
Project cost
` 37,450 million
Implementation stage
Planning
Contact details
Spectrum Dyes & Chemicals Pvt Ltd
B-484, 502, 503 & 504 NH
PO Palsana, Taluka: No-8
Palsana, Surat 394315, Gujarat
Fax: 02622-264615
Email: [email protected]
----------------------------------------
Methyl tertiary butyl ether
Vinati Organics Ltd Project type
New facility
Project news
Vinati Organics Ltd is planning to
set up a new facility at Ratnagiri in
Maharashtra to manufacture high purity
methyl tertiary butyl ether.
Project location
Ratnagiri, Maharashtra
Project cost
Not known
Implementation stage
Planning
Contact details
Vinati Organics Ltd
Shiv Ashish, 2nd Floor
Andheri Kurla Road
Sakinaka, Mumbai 400072
Maharashtra
Tel: 022-42014428
Email: [email protected]
----------------------------------------
Pesticide
S C Enviro Agro India Pvt Ltd Project type
Capacity expansion
Project news
S C Enviro Agro India Pvt Ltd has
proposed for expansion of pesticide
manufacturing from 209 MTPM to 344
MTPM at Tarapur MIDC area, Thane,
Maharashtra.
Project location
Thane, Maharashtra
Project cost
Not known
Implementation stage
Planning
Contact details
SC Enviro Agro India Pvt Ltd
T-137,138,113,251, MIDC Tarapur
Boisar, Thane, Maharashtra
Tel: 02525-70322/72125
Email: [email protected]
----------------------------------------
Resins
Micro Resins Pvt Ltd Project type
Capacity expansion
Project news
Micro Resins Pvt Ltd has proposed
capacity expansion of its resin
manufacturing from 350 TPM to 860
TPM. The manufacturing unit is located
at Vapi, Gujarat.
Project location
Valsad, Gujarat
Project cost
` 335 lakh
Implementation stage
Planning
Contact details
Micro Resins Pvt Ltd
11, Peninsula Centre, S S Rao Road
Parel, Mumbai 400 012
Maharashtra
Tel: 022-40586777
Email: [email protected]
----------------------------------------
Resin
Almega Paints Pvt Ltd Project type
New facility
Project news
Almega Paints Pvt Ltd has proposed to
manufacture resins with a capacity of
5,520 TPA. The project is to come up at
Tulsiberia village, Howrah, West Bengal.
Project location
Howrah, West Bengal
Project cost
Not known
Implementation stage
Planning
Contact details
Almega Paints Pvt Ltd
63-A, Vidyavilla, Paddapukur Road
Bhawanipur, Kolkata 700020
Fax: 022-25942446
Email: [email protected]
----------------------------------------
Resin
Taurus Timber Pvt Ltd Project type
New facility
Project news
Taurus Timber Pvt Ltd has proposed to
set up a new resin manufacturing plant
at Kutch district, Gujarat.
Project location
Kutch, Gujarat
Project cost
` 4.128 million
Implementation stage
Planning
Contact details
Taurus Timber Pvt Ltd
Plot No 326, Tehsil Gandhidham
No1-A, 1st Floor, District Kutch, Gujarat
Tel: 02836-229821
Email: [email protected]
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the chemical and allied industries.
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]
Invites You ToIndia’s Largest
SME Gathering
CUT
HER
E
Auto & Auto Components | Chemicals & Allied Products | Testing & Measuring Instruments Electrical & Electronics | Hydraulics & Pneumatics | IT Products & Services | Automation | Instrumentation Material Handling Equipment | Packaging Machinery | Wires & Cables Machine Tools & Accessories | Pipes & Fitting | Plastics & Polymers
Safety & Security | Process Machinery & EquipmentLight & Medium Engineering
250+ participants | 20,000+ business visitors expected | 15,000+ products on display | Business transactions worth ` 48 crore expected Spread over 4200 sq mtr | Showcasing more than 30 diverse industry
categories.
21 - 24 December 2012GLADA Grounds, Chandigarh Rd | 10 am - 7 pm
Exhibitor Profile
CUT
HER
E
L U D H I A N A
Concurrent Event
Invites You ToIndia’s Largest
SME Gathering
CUT
HER
E
Auto & Auto Components | Chemicals & Allied Products | Testing & Measuring Instruments Electrical & Electronics | Hydraulics & Pneumatics | IT Products & Services | Automation Instrumentation | Material Handling Equipment | Packaging Machinery | Wires & Cables Machine Tools & Accessories | Pipes & Fitting | Plastics & Polymers | Safety & Security
Process Machinery & Equipment | Light & Medium Engineering
225+ participants | 12,000+ business visitors expected | 7,000+ products on display Business transactions worth ` 55 crore expected | Spread over 5500 sq mtr
Showcasing more than 28 diverse industry categories.
11 - 14 January 2013Labhganga Convention Center
10 am - 7 pm
INDORE
Exhibitor Profile
CUT
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Supported by Online partnersBrought to you In association with Pre-event partner Supporting partner Travel partner Hospitality partner Ratings partner
TENDERS
63December 2012 | Chemical World
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
Chloronome plantsOrg : Military Engineer ServicesTRN : 13414829 Desc : Repair, maintenance of chloronome plants BOD : December 20, 2012Loc : Meerut, Uttar Pradesh BT : Domestic _______________________________________________
Biogas plantOrg : Hubli Dharwad Municipal Corporation TRN : 13541074 Desc : Supply and installation of biogas plant of 2 TPD capacity BOD : December 24, 2012Loc : Hubli, KarnatakaBT : Domestic_______________________________________________
Fourier transform infrared exhaust gas analysis systemOrg : Automotive Research Association of India TRN : 13569624 Desc : Provision of fourier transform infrared exhaust gas analysis system BOD : December 24, 2012Loc : Pune, Maharashtra BT : Domestic _______________________________________________
Nitrogen generating systemOrg : Kuwait Oil Company TRN : 13501507 Desc : Pilot trial of self-contained mobile nitrogen generating systemBOD : December 25, 2012Loc : Ahmadi BT : ICB_______________________________________________
Fuel oil tank Org : Saline Water Conversion Corporation (SWCC) TRN : 13145604 Desc : Replacement of main fuel oil tank BOD : December 25, 2012Loc : Jubail, Saudi Arabia BT : ICB
Electronic chlorinating plantsOrg : Northern Railway (NR) TRN : 13564460 Desc : Installation of electronic chlorinating plants at piped water supply station and treatment of drinking waterBOD : December 27, 2012Loc : Moradabad, Uttar Pradesh BT : Domestic _______________________________________________
Water chloronome plantsOrg : Military Engineer ServicesTRN : 13554724 Desc : Provision of water chloronome plantsBOD : December 28, 2012Loc : Visakhapatnam, Andhra Pradesh BT : Domestic _______________________________________________
Chemical dosing systemOrg : Water Supply & Sanitation Department TRN : 13482741 Desc : Provision of pumping machinery, CI pipes, chemical dosing system, etcBOD : December 28, 2012Loc : Patiala, PunjabBT : Domestic _______________________________________________
Heat exchangerOrg : Oil and Natural Gas Corporation Ltd TRN : 11550855Desc : Fabrication and supply of floats for heat exchangers BOD : December 31, 2012Loc : Mumbai, MaharashtraBT : ICB_______________________________________________
Automatic phosphating plantOrg : Ordnance Factory Board TRN : 13092197 Desc : Supply of automatic phosphating plantBOD : January 3, 2013Loc : Thane, MaharashtraBT : Domestic
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]
EVENT LIST
Chemical World | December 201264
NATIONAL
INNOVASIA 2013Concurrent with Vibrant Gujarat, this event
will showcase investment opportunities
and technology collaborations in the state;
January 08-10, 2013; at Mahatma Mandir,
Gandhinagar, Gujarat
For details contact:
Sunil Shah, Global Innovation Centre
All Gujarat Innovation Society
402, Sheel Building, 4 Mayur Colony
Mithakhali, Navrangpura, Ahmedabad 380009
Tel: 09978904476
Email: [email protected]
EverythingAboutWater Expo 2013An international exhibition and
conference on water & wastewater
management; February 28-March
2, 2013; at Chennai Trade Centre,
Nandambakkam, Chennai
For details contact:
EA Water Pvt Ltd, A1/152, Neb Sarai
IGNOU Road, New Delhi 110 068
Tel: 011-4310 0568, Fax: 011-4310 0599
Email: [email protected]
ChemProTech 2013An international event on chemical
processing technology and equipment
to be held concurrently with fine and
specialty chemicals trade fair, Chemspec;
April 11-12, 2013; at Bombay Exhibition
Centre, Mumbai
For details contact:
Krunal Goda
Koelnmesse YA Tradefair Pvt Ltd
1102, 11th Floor, DLH Park
S V Road, Near MTNL Office
Goregoan(W), Mumbai 400062
Tel: 022-2871 5207, Fax: 022-2871 5222
Email: [email protected]
Poly IndiaA trade show for plastics and
petrochemicals industries; April 25-27,
2013; at Chennai Trade Centre, Chennai
For details contact:
FICCI, Federation House, 1
Tansen Marg, New Delhi
Tel: 011-2373 8760/2373 8770
Fax: 011-2332 0714
Email: f [email protected]
PetroWorld IndiaAn event showcasing novel technologies
in oil & gas sector; August 22-24, 2013;
Bombay Exhibition Centre, Mumbai
For details contact:
Siddharth Chibba
Inter Ads Exhibitions Pvt Ltd
Plot No 859, Phase-V, Udyog Vihar,
Gurgaon 122016, Haryana
Tel: 0124-4524200, Fax: 0124-4381162
Email: [email protected]
Petrochem ArabiaAn exhibition and conference focussed
on technological improvements and
sustainability of the downstream and
petrochemical industries; January 20-22,
2013; at Dhahran International Exhibition
Center, Dammam, Saudi Arabia
For details contact:
Bme Global Ltd
Waterfront Studios,
1 Dock Road, London, E16 1 Ag
London, England, United Kingdom
Tel: +(44)-(207)-5119582
Email:[email protected]
Gas Tech CairoFocussed event showcasing latest
innovation, technologies and
developments across the gas value chain;
February 04-05, 2013; at Sonesta Hotel,
Tower & Casino Cairo, Egypt
For details contact:
World Promotion Centre
35 Abd Elhamed Awad St.
4th Floor, nasr City, Cairo
Al Qahirah, Egypt
Tel: + (20)-(2)-2273 8278 / 2273 8279
Fax: + (20)-(2)-2273 8303/2273 8304
Email: [email protected]
InformexUSA 2013Exhibition and conference bringing
together buyers and sellers of chemicals,
chemical technologies and related
services; February 19-22, 2013; at
Anaheim Convention Centre, Anaheim,
California, USA
For details contact:
Informex Holdings, LLC
300 American Metro Blvd
Suite 125, Hamilton
NJ 08619, USA
Tel: +1 609 759-4700
Email: [email protected]
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
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.
LUDHIANAPunjab,
Dec 21-24, 2012
INDOREMadhya Pradesh, Jan 11-14, 2013
HYDERABADAndhra Pradesh,
May 31- June 3, 2013
AURANGABADMaharashtra, Feb 1-4, 2013
RUDRAPURUttarakhand,
Feb 23-26, 2013
INTERNATIONAL
EVENT PREVIEW Engineering Expo Ludhiana 2012
Chemical World | December 201266
Anwesh Koley
The emerging markets in
the North have become
an attractive investment
haven and Ludhiana is one
such prospective destination where the
manufacturing sector is growing at a rapid
pace. In a bid to provide ample growth
opportunities to the manufacturing
fraternity, Engineering Expo Ludhiana,
slated to be held during December
21–24, 2012, is expected to generate
high levels of enthusiasm among the
manufacturers in Punjab.
Engineering Expo has been
instrumental in providing a fruitful
business platform to manufacturers
across the country, with key industry
players participating in the event. It has
been synonymous with enabling healthy
business interactions, thus helping
generate business leads and playing
the role of a catalyst in the Indian
growth story.
Northern prospectsElaborating on the changing scenario
in the manufacturing arena in Punjab,
Robin Basant, Managing Partner,
Basant Mechanical Works, says, “The
industry in Punjab is now embracing
global manufacturing technologies on
the shop floor; the mindset of people
is changing as well. Everybody is now
concentrating on quality and quantity.
Punjab is known globally for woollen
clothes, hosiery, machine tools, auto/car
parts, cycle manufacturing, etc. People
are travelling places to learn the new
technical skills being used by bigger units
in the international market.”
Commenting on the growth potential
of Punjab as an industrial area, Didarjit
Singh, Proprietor, Karam Chucks, states,
“Manufacturing in Punjab has undergone
various phases of development over the
last 10 years. It has grown at a robust
rate during this period and has been one
of the best performing manufacturing
economies. The manufacturing sector
contributes about 15 per cent to Punjab’s
GDP and 50 per cent to the country’s
exports. It employed 58 million people
(about 12 per cent of the workforce) in
2008. By 2012, it is estimated, based on
the current economic projections, that
this sector will employ a further 12–13
million out of the nearly 89 million
additional people who will enter the
workforce.” The key markets in Punjab
include Ludhiana, Hoshiarpur, Samana,
Jalandhar and Amritsar.
Ludhiana: Potential waiting to be tappedThe growth potential of the city
has brought it on the radar of large
manufacturing houses. Singh elaborates,
“People of Ludhiana are skilled and
high spirited. In addition to theoretical
knowledge, they have technical
skills imbibed through their family
lineage. Besides, they are regularly
upgrading themselves as per the needs
of the time. So, many international
machines/technologies are being used
by manufacturers to stay abreast with
competition. All the big industries are
eyeing Ludhiana for sourcing materials
and selling products to end-users.”
Sharing similar sentiments, Manjit
Singh Matharoo, General Manager,
Consortium of Ludhiana Machine
Tools Manufacturers (CLMTM),
observes, “Ludhiana has a large
base of manufacturing companies,
with a wide network of possibilities.
It is capable of delivering quality, and
since the last six years, the area has seen
rapid development of internal support
units. It has the perfect model for
cost-effective business.”
Making manufacturing-friendly
North accessibleLed by manufacturing biggies, Ludhiana is fast emerging as a leading investment destination in the northern belt of India. In this backdrop, the upcoming Ludhiana edition of Engineering Expo, being organised by Network 18 Publishing during December 21–24, 2012, will bring into the limelight the potential that northern region offers manufacturers by showing investors how to gain easy access into this manufacturing-friendly zone.
LUDHIANADecember 21-24, 2012
GLADA Ground
Highlights of this edition250+ expected exhibitors
20,000+ business visitors expected
Business transactions worth
` 150 crore expected
20,000+ products on display
Spread over an area of more than
1,50,000 sq ftShowcasing more than 30 diverse
industry categories
67December 2012 | Chemical World
Engineering Expo Ludhiana 2012
Ludhiana is also emerging as a
major automotive hub in northern
India. “Ludhiana is the most appropriate
destination for investment. The latest
study by World Bank has adjudged
Ludhiana as the best place for doing
business in India. Though not a major
tourist destination, the city has come up
as a major medical tourism destination
and also a budding commercial centre.
The city is not far from the National
Capital and hence, is easily accessible,”
adds Basant.
Sajni Khanna, Consultant, AMC Pvt
Ltd, states, “The area has been emerging
due to its proximity to the National Capital
and provides immense opportunities to
domestic and international investors.”
Exhilarating Engineering Expo There is general consensus that
Engineering Expo is getting better
with each passing year, and coming up
with novel initiatives keeping in mind
SMEs in the region. Its association with
leading organisations such as National
Small Industries Corporation (NSIC);
United Nations Industrial Development
Organisation – International Centre
for Advancement of Manufacturing
Technology (UNIDO-ICAMT) and
CLMTM will take Engineering Expo
Ludhiana to new heights.
Commenting on the Expo, Sandeep
Khosla, Chief Executive Officer,
Network 18 Publishing, says, “After
10 successful years of service to the
industry, Engineering Expo today has
established itself as India’s largest multi-
location trade show on manufacturing.
The Expo is a preferred destination
for small and medium enterprises as
well as manufacturing & engineering
organisations to further their growth and
that of the industry at large. For the 2012–
13 season, we have eight editions spread
across an equal number of locations of
a rising India. Keeping our esteemed
exhibitors and valued customers in mind,
we have made elaborate provisions to
offer a never before experience. These,
we reckon, will add substantial traction
to the industrial growth of the nation.”
Expressing his views on the event,
Basant opines, “Today, Engineering
Expo attracts more business visitors
than some of the other large events
organised to facilitate business. More
than one lakh industrial buyers benefit
from Engineering Expo every year. Over
the years, it has become one of the most
lucrative platforms for business growth.
In fact, they help us interact with national
as well as international visitors including
manufacturers, investors, diplomats,
government officials and industry
stalwarts. And as a multi-location
tradeshow, Engineering Expo reaches
out to prospective clients, in their
respective cities.”
With more than a decade of experience
in organising exhibitions, Network 18 has
been successful in understanding and
meeting the expectations of exhibitors,
which in turn has resulted in unconditional
trust in the Expo. Singh observes, “In
today’s world, displaying your strength,
product range and skills on a common
platform is important. People who do not
know you directly can gain full knowledge
about your product range at such
types of platforms. This Expo provides
a one-to-one meeting opportunity and a
platform to share vital prospects to grow
one’s business. Besides, having an organiser
like Network 18 is again a value addition.”
Echoing similar sentiments, Ashok
Kumar Gupta, Managing Director, Crane
Bel International Pvt Ltd, says, “We have
been associated with Engineering Expo
for a long time, and since Network 18 is
the organiser, we are keen to extend our
relationship further. We keep introducing
innovative concepts every year at the
Expo, and this year will be no different.”
Business opportunities galoreThe Expo plays a crucial role not only
in business development, but also in
increasing profitability. Over the years,
it has evolved as an ideal launchpad for
exhibitors. Basant asserts, “Engineering
Expo is considered to be an ideal
platform for companies to foster growth
through reach and awareness to their
right target audience. It proves to be
a perfect combination of a vast range
of exhibitors, spacious venue, state-of-
the-art amenities and humungous visitor
turnout, which constitute the most
crucial factors for any exhibitor.” Talking
about his expectations from the Expo,
Singh says, “Personally, my expectations
from Engineering Expo Ludhiana
are high. Looking at the potential,
knowledge and management of the
organiser, we expect a huge turnout of
quality-oriented customers at the show.”
Engineering Expo is considered an
ideal platform to showcase the industrial
talent residing in smaller towns and
cities of India. Matharoo feels, “A place
like Ludhiana has the skills to attract
international manufacturers to India, and
such events do a commendable job in
materialising this goal.” With enthusiasm
and optimism regarding the event riding
high among participants, the Engineering
Expo Ludhiana is poised to provide an
important ground for nurturing business
opportunities in the State of Punjab and
explore untapped markets, which can
emerge as lucrative business sites.
Email: [email protected]
�� Panel discussion aims at providing a roadmap to infuse growth in the region
� Institutional Buyer Involvement Plan to attract delegations from large corporate and major institutions
� Improvised visitor profi ling - profi le, scan, fi lter and bring in visitors as per exhibitors’ requirements
� Providing business networking support to exhibitors by leveraging Network 18 Publishing’s industry connect
� Credit rating facilities for the benefi t of exhibitors
� Providing complete travel solutions for exhibitors
� Off ering logistics services to ensure smooth cargo handling, custom clearing, transport compliance, etc.
New attractions in this edition
EVENT PREVIEW Engineering Expo Indore 2013
Chemical World | December 201268
Sweta M Nair
One of Madhya Pradesh’s
largest cities known for
its palatial splendour, in
the recent decade has
come of its industrial age. The city of
Indore, amid its royal structures, today
voices its determination in shaping its
future towards industrial excellence.
According to a recent study published
by Cushman & Wakefield, Indore is one
of the top ten emerging cities of India -
ideal for long-term business investments
across industries. The city’s geographic
positioning, population demographics,
development in infrastructure, current
economic growth and governmental
support, contribute towards its resolute
positive outlook.
Industrial tranquilityIndore has undergone rapid transition
and vast development in almost every
sector of business. As per published
reports, in recent times, the per capita
income of Madhya Pradesh has
doubled. According to Manoj Pugalia,
Proprietor, Oswal Rubber Industries,
“Owing to the city’s systematic and
organised planning, many companies
find it fairly convenient to set up base
here. Additionally, industries here are
not vexed by the otherwise rampant
problems of labour and power.” Ranging
from the automobile to pharmaceuticals
and from software to retail, the
burgeoning city, on an average, receives
a bulk of its trade from small, medium
and large-scale manufacturing & service
industries. Indore’s major surrounding
industrial belts are present at Pithampur,
Sanwer, and Dewas.
The city’s automobile hub is
situated in Pithampur, which is a well-
developed industrial area. Companies
such as Eicher Motors Ltd, Cummins
India Ltd, Mahle Engine Components
(I) Pvt Ltd, Mahindra Two Wheelers
Ltd and Bridgestone Tyre Ltd, among
others, have set up plants in this area.
Additionally, Cipla Ltd, Indorama
Synthetics (I) Ltd, Piramal Healthcare
and Glenmark, among others, are also
present in Pithampur.
Home to industries such as textiles,
chemical processing, food processing
and distilleries, the industrial belt
includes an industrial Special Economic
Zone (SEZ) as well. Other upcoming
sprawling industrial belts include
Govindpura, Manideep and Pologround.
Elaborating further, Kishore Bundela,
Director, Protec Aqua Solution Pvt
Ltd, states, “Formerly, the region was
famous for its auto cluster. But now,
pharmaceuticals and IT companies are
also commencing operations in Indore.
One major advantage of being situated
here is that all major Indian cities are
equidistant from Indore.”
Attracting investor interestOwing to its sheer industrial potential,
Indore, in October, played host to
the Global Investors Summit 2012.
In the state’s bid to augment overall
development, a series of meets were
facilitated so as to attract investor
interest. With the underlined support
of better infrastructure and strong
government backing, many international
investors are gradually entering the city.
In relation to this event, Omprakash
Gupta, President, Madhya Pradesh
Electric Merchants and Contractors
Association (MPEMCA), says, “Indore
is the business capital of Madhya
Pradesh. It can be noted that nearly 80
per cent of electrical business of Madhya
Pradesh is concentrated in Indore. After
the summit, the central state of India is
looking for major investments.”
Tapping India’s central vantage pointStaying true to its core competence as one of India’s leading auto clusters, Indore spruces up its industrial portfolio as a spree of investments from the IT and pharmaceuticals industries come trickling in. Mirroring the growth of this centrally positioned city will be the fifth edition of Engineering Expo Indore, organised by Network 18 Publishing. Setting the tone for acquiring business prospects, the Expo will bring together exhibitors who will showcase their latest products and services. Scheduled to be held during January 11–14, 2013, Engineering Expo Indore aspires to play the role of a catalyst in the city’s fledgling growth.
INDOREJanuary 11-14, 2013
Labhganga Convention Center
Highlights of this edition
225+ participants
12,000+ business visitors expected
Business transactions worth
` 55 crore expected
7,000+ products on display
Spread over an area of more than
5,500 sq mShowcasing more than 28 diverse
industry categories
69December 2012 | Chemical World
Engineering Expo Indore 2013
“By providing a platform for
investments from major players in India
and abroad, I believe that Engineering
Expo will be the next step for this
revolution. MPEMCA would like
all major companies in electrical and
electronics to showcase their products
and technology in the Expo. With
Network 18 Publishing’s experienced
organisational skills, we are looking
forward to the integration of new
styles and services in this show. Nearly
60 members along with their parent
companies will participate in the Expo,”
Gupta adds.
In the MPEMCA pavilion, products
related to industrial & domestic
electricals, electronics, industrial
automation, specialised automation
products, auto industries products,
panel accessories, submersible and
mono block pumps, wires & cables, HT
line material & switchgears will be put
on display.
In store for 2013Coined as the ‘State of Opportunities’,
Madhya Pradesh’s investor-friendly
ambience and presence of big industries
catering to different needs are shaping
a positive future. Commenting on the
same, Rajesh Godse, Proprietor, Reliable
Terrestrials, avers, “Availability of land
& labour and a stable government are
some of the factors that are contributing
towards Indore’s success as an ideal
investment destination. Moreover,
NTPC-run Vindhyachal project in
Madhya Pradesh is expected to increase
its capacity by 2013, which will further
foster industrial development.”
The Expo’s rich legacy in helping
businesses connect has, so far, conveyed
the exhibition to many Indian cities.
Sharing his views on the continued
success of Engineering Expo, Sandeep
Khosla, CEO, Network 18 Publishing,
says, “After 10 successful years of service
to the industry, Engineering Expo
today has established itself as India’s
largest multi-location trade show on
manufacturing. The Expo is a preferred
destination for small and medium
enterprises as well as manufacturing
& engineering organisations to further
their growth and that of the industry
at large. For the 2012–13 season, we
have eight editions spread across an
equal number of locations of a rising
India. Keeping our esteemed exhibitors
and valued customers in mind, we have
made elaborate provisions to offer
a never before experience. These, we
reckon, will add substantial traction to
the industrial growth of the nation.”
The exhibitors’ category at the Expo
will consist of companies representing
machine tools & accessories, hydraulics
and pneumatics, light & medium
industries, electrical and electronics,
material handling equipment, etc.
Expounding further, Yogesh Mantri,
Proprietor, Automation & General
Electric Co, states, “This is the
second time that our company will
be participating in Engineering Expo.
Exhibiting here allows us to gauge
market demands and customer needs.
Moreover, it is a good internal exercise
for the industry as well. The platform, in
a way, facilitates business for customers,
as exhibitors belonging to different
segments showcase products under
one roof. For the Indore edition, our
exhibits would mainly consist of LED
lighting systems, special cables for solar
generation, CNC machine retro-fittings,
adjusting cable range, switchgear,
Schneider universal enclosure, etc.”
For many exhibitors, Engineering
Expo is an energising outlet for gaining
new customers as it is an ideal platform
that helps them grasp market trends and
innovations. Sharing similar sentiments,
Bundela states, “The Expo’s byproducts
revolve around creating awareness,
brand building and generating a good
response.” Having participated in
the previous editions of Engineering
Expo, Godse exclaims, “We have been
associated with Engineering Expo
since its first edition in Indore. Since
Network 18 Publishing announces the
dates well in advance, we have ample
time to decide our exhibiting range.
Moreover, for business, the January
2013 timeframe will be good as it does
not clash with any festivals.”
The upcoming Engineering
Expo Indore 2013 promises to
leverage its geo-strategic positioning
to the fullest by inviting an array of
stakeholders to witness industrial
excellence of all sorts.
Email: [email protected]
�� Panel discussion aims at providing a roadmap to infuse growth in the region
� Institutional Buyer Involvement Plan to attract delegations from large corporate and major institutions
� Improvised visitor profi ling - profi le, scan, fi lter and bring in visitors as per exhibitors’ requirements
� Providing business networking support to exhibitors by leveraging Network 18 Publishing’s industry connect
� Credit rating facilities for the benefi t of exhibitors
� Providing complete travel solutions for exhibitors
� Off ering logistics services to ensure smooth cargo handling, custom clearing, transport compliance, etc.
New attractions in this edition
203+ exhibitors
9,829+ visitors
5,000+ products displayed
` 45 crore business generated
4,800 sq m exhibition area
1,10,000 kg machinery moved
45+ delegations from diff erent
companies attended the Expo
Glimpses of previous edition
EVENT REPORT Engineering Expo Pune 2012
Chemical World | December 201270
Mahua Roy
Over the past few decades,
the concent ra t ion
of industrial units
has transformed the
city of Pune into one of the major
manufacturing hubs in the country.
While proximity to the commercial
capital Mumbai has certainly
played a role in it achieving this
grand status, other important factors
contributing to its prominence include
availability of skilled manpower,
conducive climate and intellectual
r ichness. Also, the industrial
infrastructure in the area has kept pace
with the real estate development.
Providing a boost to the attractive
investment destination, Engineering
Expo Pune saw impressive activity.
Organised by Network 18 Publishing,
it was held at Auto Cluster Exhibition
Centre, Chinchwad, in November,
an extremely strategic time for
business generation. Engineering
Expo Pune has turned into a
favourite destination for generation of
high-volume business leads. Bringing
together high-profile visitors, decision
makers and a multitude of exhibitors
all across the country, Engineering
Expo Pune truly emerged as the largest
SME gathering.
The 7th successful edition of
Engineering Expo Pune was inaugurated
in the presence of eminent dignitaries
Anant Sardeshmukh, Director General
– Mahratta Chamber of Commerce,
Industries & Agriculture; Nitin Chalke,
General Manager – India & South East
Asia, Eaton Fluid Power Ltd; Sanjay
Marathe, Head – Strategic Services Unit
and CTO, Zensar Technologies; Sandeep
Khosla, Chief Executivie Officer,
Network 18 Publishing; Sudhanva
Jategaonkar, Associate Vice President,
Network 18 Publishing; and Manas
R Bastia, Senior Editor, Network 18
Publishing. The traditional lamp lighting
ceremony was followed by the unveiling
of the official exhibitor directory, which
comprised all important details in a
consolidated manner.
Pune as an ideal investment destinationExperts have been noting the rise
in technology adoption of SMEs.
Expositions such as Engineering Expo
have been promoting an atmosphere
of high-end technology. According
to Marathe, “SMEs have been showing
an encouraging response to the adoption
of advanced technologies such as
cloud computing.”
Pune, being an industrial hub,
has benefitted greatly through the
Expo because of the variety and wide
range of technologies and solutions
on display. Commenting on the
same, Chalke observed, “The area chosen
for the Expo, Auto Cluster, is strategic
and ensures quality turnout of visitors.
Pune, being a hub for auto industry
and ancillary units, has seen real-time
advantages due to Engineering Expo.”
Housing varied manufacturing industries as well as services sector, etc, Pune has witnessed immense development in the past few years. Engineering Expo Pune has proven to be a catalyst by accelerating business transactions, especially for SMEs in the manufacturing industry. The four-day event, held between November 2 and 5, 2012, saw some serious business opportunities and leads transforming into profits. Many exhibitors confirmed participation, and most visitors plan to exhibit in the next edition!
PUNENovember 2-5, 2012
Auto Cluster Exhibition Centre, Chinchwad
Generating high volume of opportunities
Dignitaries unveil the exhibitor directory at the 7th edition of Engineering Expo Pune
71December 2012 | Chemical World
Engineering Expo Pune 2012
Promoting collaborationIn recent times, the SME sector
is witnessing extensive growth in
Pune. New projects and capacity
expansions are a visible result. In
this backdrop, Engineering Expo
brings in its expertise of uniting the
SME sector with prospective clients,
thus providing a holistic business
generation experience.
One of the biggest takeaways from
trade shows has been the creation of
a collaborative atmosphere among the
companies. SMEs benefit hugely from
this experience, which helps them
develop products and technologies of
a higher quality, thus making them
globally competitive.
Elaborating further, Marathe
opined, “Innovation is a differentiator
when it comes to SMEs. Trade
shows such as Engineering Expo
nurture the collaboration in a
competitive environment, something
which is difficult to achieve
otherwise. Both exhibitors and visitors
utilise this opportunity to make
the most out of this experience and
improve the quality of their products
and services.”
Being the largest SME gathering
for the manufacturing industry, this
platform has helped them immensely.
“Manufacturing is one of the most
important revenue-generating sectors
for Pune. A tradeshow of this scale
has added greatly to the growth of the
manufacturing segment as it majorly
focusses on SMEs in the segment.
The event is an excellent platform
for promoting businesses, branding
and networking. It is an extremely
relevant concept, which is benefitting
the nearby SME clusters year on
year. They get to learn and update
themselves on the new technologies,”
said Sardeshmukh.
Wide array of technology on displayThe exhibition halls were buzzing
with activity on all the days.
Most exhibitors were buoyant about
the sales and leads generated in huge
numbers. Emphasising on his association
with Engineering Expo, Snehal
Mehta, Director – Marketing, Energy
Mission Machineries (India) Pvt Ltd,
said, “We have been participating in
Engineering Expo since a long time.
The event has helped us build our
brand name and enhance the image
of our organisation. It has helped us
gain industry exposure and has enabled
us to generate business leads. The show
has provided us an ideal platform to
display and demonstrate our products
and meet potential buyers.”
“We are machinery manufacturers
and so, we aim at building long-term
associations with the industry. In such
a case, the Expo helps us introduce our
products to new buyers and gradually
get the enquiries converted into
business leads,” Mehta added.
The exhibitors were able to interact
with a large number of serious business
visitors. To this, Sridhar Nalluri,
Country Manager, CST Sensors India
Pvt Ltd, added, “We are expecting to
increase our brand value and reach
more customers in the Maharashtra
industrial sector through this trade
show. We are looking to tap the
machine tools, SPM & automation
segments through Engineering Expo.”
With a large range of technologies
on display, visitors benefitted greatly
from the exhibition. “This is an
effective platform for generating
business opportunities. I came to
scout for suppliers for my venture.
There is wide range of products and
services for hydraulics & pneumatics,
material handling etc,” said, Chintan
Shah, Proprietor, Mech Tech Engineers,
a visitor.
“This is a one-stop solution for all
my business needs as I found relevant
products on display. There are exhibitors
from various parts of the country,
which makes this a holistic exhibition,”
Shah added.
“It is an all-in-one Expo on a large
scale, with technologies ranging from
automation & cooling solutions to
IT. It includes a mix of big names
as well as SMEs. Branding is more
visible. I could generate many leads
relevant to my business,” commented
Nitin Penpatil, Director, FS Engineers,
another visitor.
Gearing up for the next edition of Engineering Expo!With a splendid response received
in this edition, most exhibitors have
already booked slots for Season 2013
of Engineering Expo. Some have
even confirmed participation at more
than one edition. An interesting
observation was that most visitors
are planning to turn exhibitors in the
next season.
“It was a great experience for us.
The new technologies on display served
as an eye-opener. We look forward to
leverage our experience at Engineering
Expo to better our products and
solutions. We were actually looking
for MNCs and have got many leads.
We plan to be an exhibitor in the
next edition,” said Sherman Britto,
Executive – Business Development,
Vinsys IT Services India Pvt Ltd, a
visitor at the event.
Email: [email protected]
Highlights of this edition
200 exhibitors from across India
Spread over more than
3,500 sq m16,000 business visitors
Business transacted worth
` 68.03 crore7,860 business leads
generated
15,000+ products displayed
More than 1,10,000 kg machinery moved in for display
EVENT REPORT Engineering Expo Chennai 2012
Chemical World | December 201272
Suprita Anupam
In the recent years, along with
IT investments of repute,
Chennai has bagged huge deals
in the auto, OEM and ancillary
industries. The city has, over the years,
transformed itself into a bustling
investment destination with major
auto companies such as Daimler, Ford,
Ashok Leyland, Mahindra, NISSAN,
Renault, BMW and TAFE Tractors
offering a boost to the ancillary units
in the industrial clusters of Ambattur,
Sriperumbudur and Padi. According to
P Shanmugasundaram, Chief GM –
Projects, TIDCO (OD) & MD, TICEL
Bio Park Ltd, “Unlike China, Chennai’s
development is not an integrated one
but has its own reasons for housing
34,500 companies and 35,000 expats.
The Tamil Nadu Government also
facilitates the process of clearances
to set up companies.” Leveraging on
the Chennai advantage is Engineering
Expo Chennai, which brings in its
expertise of uniting the buyers and sellers
of the engineering and manufacturing
sectors, thereby providing a holistic
business ecosystem.
Launched in Ahmedabad in 2002,
Engineering Expo has come a long
way today by becoming one of India’s
largest multi-location SME meeting
points. Elaborating on the legacy of
Engineering Expo, Sandeep Khosla,
CEO, Network 18 Publishing, said,
“After 10 successful years of service to
the industry, Engineering Expo today has
established itself as India’s largest multi-
location trade show on manufacturing.
The Expo is a preferred destination
for small and medium enterprises as
well as manufacturing & engineering
organisations to further their growth
and that of the industry at large. For
the 2012–13 season, we have eight
editions spread across an equal number
of locations of a rising India (including
Ahmedabad, Pune, Chennai, Ludhiana,
Indore, Aurangabad, Rudrapur and
Hyderabad). Keeping our esteemed
exhibitors and valued customers in mind,
we have made elaborate provisions to
offer a never before experience. These,
we reckon, will add substantial traction
to the industrial growth of the nation.”
The inauguration… The 5th edition of Engineering Expo
Chennai 2012, one of the largest trade
fairs in the city, was inaugurated in
the gracious presence of Ramesh P S,
President, Ambattur Industrial Estate
Manufacturers’ Association (AIEMA),
& MD, Airflow Engineering; Ameer
Munaff, CEO, Fein Power Tools;
Shanmugasundaram; Sandeep Khosla;
and Manas R Bastia, Senior Editor,
Network 18 Publishing. “Engineering
Expo provides a single window shopping
solution for SMEs as they usually sell
their products to a variety of clients such
Chennai’s favourable business climate has helped the city bag several envious deals over the years. With an aim to help manufacturers across the country encash on the Chennai advantage, Network 18 Publishing held the 5th edition of Engineering Expo Chennai 2012, at Chennai Trade Centre, Nandambakkam, Chennai, from November 22-25, 2012. Offering both exhibitors and visitors a platform to interact and witness engineering marvels, the Expo proved to be a one-stop shop for one and all. A report…
CHENNAINovember 22-25, 2012
Chennai Trade Centre, Nandambakkam
Showcasing Southern manufacturing strengths
(L-R): Nitin Kunjir, Deputy Manager – Sales, Network 18 Publishing; Manas R Bastia; Ramesh P S; P Shanmugasundaram; Sandeep Khosla; Ameer Munaff; and Hari Hara
Subramaniam, Manager – Sales, Network 18 Publishing at Engineering Expo Chennai 2012
73December 2012 | Chemical World
Engineering Expo Chennai 2012
as automobile, machine tools, material
handling and so on. Additionally, a visitor
can meet all his demands in one day,”
highlighted Ramesh while commenting
at the occasion.
Elaborating further, Munaff averred,
“Engineering Expo is one of the
best platforms for us to reach the end
customer. This is also an opportunity for
us to let our customers have a feel of
our product operations and train them
about the right working procedures. This
is one of the major reasons why we are
launching our new handheld core drilling
machine - the first-of-its-kind in terms
of technology, quality and cost in the
whole world.”
Cutting-edge technologiesOver the years, Engineering Expo
Chennai has been providing opportunities
for SMEs, which are critical for the
growth of emerging markets such as
India, to display their products as well as
witness some of the latest technologies
that could help develop their business.
The 2012 edition offered similar growth
avenues. The Expo served as a platform
for Indian & overseas companies to
exhibit their products & services,
interact with potential buyers & sellers,
generate new incremental business and
forge new partnerships. Showcasing
cutting-edge technologies, this year’s
edition also unveiled the latest in
products, machinery and equipment from
manufacturing & related industries. This
edition of Engineering Expo Chennai,
which spanned over a period of four
days, generated revenue in excess of
` 62.47 crore.
Exhibitors speak The Expo showcased over 30 diverse
segments of industries and gave visitors
an opportunity to witness the latest
technologies and products. Some of the
leading companies who participated
in this edition included National
Instruments, Durga Bearings, Dirak
India, Fein Power Tools India Pvt Ltd,
Gandhi Automation Pvt Ltd, Hitachi
Koki India Ltd, Larsen & Toubro Ltd,
Macht Exim Llp, Malwa Machine Tools,
MGM-Varvel Power Transmission Pvt
Ltd, Shuter Enterprises India Pvt Ltd,
Testo India Pvt Ltd and Tussor Machine
Tools India Pvt Ltd among others.
Among the exhibitors, Sonal Sulania,
Director, Durga Bearings Pvt Ltd, stated,
“We decided to participate in this event
due to the direct involvement of Network
18. Earlier, we used to participate in
events, which were focussing on a specific
sector. The focus of Engineering Expo is
diversified and you can avail the benefit
of a single platform to reach all the
sectors. The Expo provided a brilliant
platform for all sectors to interact. To
gain more prominence, perhaps, more
well-established companies could
also showcase their products along with
other SMEs.”
Vishak Mani, Director, Clasys,
another visitor, stated, “This is the
fourth time that we are participating
in Engineering Expo and second time
that we are participating in Chennai;
the previous three editions were quite
successful for us. Exhibitions like these
help us get new customers as well as
enhance the know-how of the market.”
Visitors’ verdict A variety of visitor groups were seen at
the Expo, which included engineering
students, universities’ R&D professors,
SME proprietors and tier I companies
representatives. Dr P Meganathan,
Consultant, Sinto India Ltd, who visited
the event the very first day, exclaimed,
“We are in the process of setting up a
new manufacturing plant here and I
was looking for prospective suppliers at
the Expo. It was my first visit to such
a diversified exhibition, and I have
interacted with a couple of fabrication,
rubber and tool making companies.
So far, I have had a positive response in
this regard.”
Another visitor, Karthik Chandra
Shetty, Director, Lumens Group of
Company, said, “I have been regularly
visiting Engineering Expo since the last
2–3 years in Pune and Ahmedabad, and
it is good to see that it has prospered
over the years. Engineering Expo covers
almost all the segments of engineering
goods. I always get to learn new things
at the Expo.”
Expanding business horizon Since the Expo is expected to generate
business leads worth more than
` 1,000 crore all over India, it offered
an apt platform for exhibitors to directly
interact with end-customers. Besides,
it served as a launchpad for SMEs and
facilitated interaction between end-
customers and suppliers. The 2011
edition of Chennai Engineering Expo
recorded business transactions worth
` 41.98 crore, with more than 12,692
business leads being generated; this year
the transaction exceeded to ` 62.47 crore
as per the feedback received from
exhibitors. Over 8,000 products from
various industries were on display in an
area spanning 4,500 sq m.
The next edition of Engineering
Expo will be held in Ludhiana from
December 21–24, 2012. Be there to catch
the action!
Email: [email protected]
Highlights of this edition
200 exhibitors from across India
Spread over more than
4,500 sq m
12,072 business visitors
from across India
Business transacted worth
` 62.47 crore8,893 business leads
generated
8,000+ products displayed
from diff erent industries
More than 80,000 kg machinery moved in for display
BOOK REVIEW
Chemical World | December 201274
This is one of the most exhaustive books for the process industry, which
outlines the intricacies and technologies for drying. In all process facilities
where drying plays an important role, such as chemical, pharmaceutical,
plastics, and food industries, the purchase of improper industrial drying
equipment can significantly affect a manufacturer’s bottom line. With the
guidance offered in this book, engineers will be able to confidently choose
industrial drying equipment that increases profits, runs efficiently, and
optimally suits their needs.
A detailed reference of interest for engineers and energy specialists working
in the process industry field, the book investigates the current state of industrial
drying practices. It deeply examines the factors influencing drying’s high costs
in both equipment and energy consumption, and summarises key elements for
keeping drying operations under budget and performing at peak capacity safely
while respecting the environment. Extensive coverage of dryer basics as well as
essential procedures revolving around the selection of industrial dryers help to
inform readers on the various criteria for generating scalable specifications that
greatly assist buying decisions.
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]
Drying in the process industry
Author: C M van ‘t Land
Price: ` 6,500
This book introduces chemistry students to the applications in the field of
engineering design and function across a wide range of subjects, from fuels and
polymers to electrochemistry and water treatment. Each chapter concludes with
a reading list of relevant books and articles as well as a set of exercises, which
includes problems that extend the topics beyond the text. Other supplements
to the text include a laboratory section with step-by-step experiments and a
solutions manual for instructors.
The USP of this book is that it outlines new chapters on semiconductors
and nanotechnology. It includes a broad coverage of relevant research in the
chemical industry. This book should be used by both researchers and chemists
working in the field of applied chemistry. Besides, industry personnel can also
gain enough expertise with this book.
Reviewer: Nita Mehta, Associate Professor, Chemical Engg Dept, Thadomal Shahani Engg College
Applied chemistry: A textbook for engineers and
technologists
Authors: O V Roussak and H D Gesser
Price: ` 5,450
PRODUCTS
Chemical World | December 201276
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
al W
Hot and cold zinc phosphating chemical
The zinphophos – hzp is designed to
provide heavy zinc phosphate coating with
thickness of 300 mg/sq ft within 15 to 20
minutes on iron and mild steel components
by simple immersion method. A dense,
heavy adherent coating is obtained by
this method and prevents excessive wear and tear of moving parts of
machinery. This coating serves as base for paints as well as for rust
preventive oil coating. It is operated at a temperature of 85o to 95oC. It
is available in packages weighing between 5 and 40 kg.
Priyadharishini Chemicals
Coimbatore, Tamil Nadu
Tel: 0422-2567040/2567114
Mob: 09443022310/09865222310
Email: [email protected], [email protected]
Website: www.prichem.in
Chemical transfer pump
CFP series pump in SS 316 material
is used for handling mild corrosive
chemicals and various other liquids in
different industries such as chemical,
petrochemical, steel plants, printing
houses, pharmaceuticals and food
processing etc. The main features of the pump are high efficiency,
good performance and reliability. The pump is available from 0.25 HP
to 10 HP in different capacities in monoblock and bare pump design.
All the wetted parts are made of graded SS 316 material. The sealing
is by mechanical seal of different face combination of carbon, ceramic,
GFT, silicon, tungsten etc. The pump can be used for high temperature
application of up to 250oC. Special pumps are also available with casing
steam jacketing and with flameproof motors.
Taha Pumps & Valves
Surendranagar – Gujarat
Tel: 02752 – 240233
Mob: 09825599415/09825829875
Email: [email protected], [email protected]
Website: www.tahapumps.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
Email: [email protected]
Website: www.shanbhags.com
One must consider the cost of the product before
purchasing so as to secure defi nite and assured
returns over the period of time.
Manisha Kadam (Assistant Manager) Ashok Industry
PRODUCTS
77December 2012 | Chemical World
To make the product of superior quality, it must
adhere to safety and contamination-free norms. This
makes the end-product well accepted in the market,
thus reducing its rejection rates.
Agnish Roy (Manager - Business Development)
Marsap Services Pvt Ltd
Fume extraction and scrubbing systems
The packed tower absorption system removes gaseous
pollutants such as HCl, Cl2, ClO2, SO2, NH3, NOx,
HCN, H2S, mercaptans and amines. The typical
absorption unit consists of a packed absorption tower,
recycle tank, heat exchanger, recirculation pumps and
ID/FD fan. The gaseous stream flows upward through a packed bed tower
while the scrubbing liquid flows downward by gravity over the packing. The
incoming liquid is distributed over the tower cross-section using a liquid
distributor. Gases leaving the packed sections are passed through a mist
eliminator to remove the moisture entrainment before discharging to the
outlet gas connection at the top of the tower. The scrubbing liquid is stored
in recycle tank and circulated using recirculation pumps. As most of the
absorption processes are exothermic, a heat exchanger is necessary to remove
the heat of absorption. The fume extraction and scrubbing system can be
used in the agrochemical plants, plastics, paint and varnish plants, soap and
detergent plants, sulphuric acid plants, fertiliser manufacture, nitric acid and
ammonia plants, acid pickling plants, welding electrode plants, foundry,
boilers, process heaters, catalyst regenerators, flares, reactors, storage tanks.
Trans Tech Projects Pvt Ltd
Pune – Maharashtra
Tel: 020-65002534/65008534
Email: [email protected]
Website: www.transtechprojects.com
PRODUCTS
Chemical World | December 201278
In-line homogeniser system
In-line homogeniser system allows smooth
changeover from laboratory to production
plant. The homogeniser allows the user to select
from seven different mixing technologies using
a variety of available mixing heads, all with
programmable speed control to determine the best mixing function for
the process. It offers a great variety of applications for many different
mixing and particle size reduction processes. It also eliminates the need
to purchase separate mixers – operates as both a batch mixer and in-line
mixer. The compact, tabletop design minimises space requirements. This
dispersing and mixing system was developed to meet the needs of research
scientists and mixing specialists within the pharmaceutical, cosmetics,
chemical, and food industries who need to use the same methods from
initial formulation to mass production.
Cole-Parmer India Pvt Ltd
Mumbai - Maharashtra
Tel: 022-67162224/2222, Fax: 022-67162211
Email: [email protected]
Website: www.coleparmer.in
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
Email: [email protected]
Chemical compound for cleaning and finishing machines
A wide range of cleaning chemicals is used in various machines and
equipment such as vibratory finishing machines, tumbling barrels,
ultrasonic equipment, washing machines, spray cleaning equipment,
etc. These chemicals are used for various functions such as cleaning,
degreasing, descaling, deburring, brightening, etc.
Ashok Industry
Mumbai – Maharashtra
Tel: 022–26232133, Mob: 9892848669
Email:[email protected]
Website: www.ashokindustry.com
PRODUCTS
81December 2012 | Chemical World
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
Mumbai – Maharashtra
Tel: 022-28346604/28340071
Email: [email protected]
Website: www.shanbhags.com
Flameproof magnetic drive chemical pump
PMD/SMD series seal-less magnetic drive
pump with flameproof electric motors
is suitable to use in hazardous industrial
environment in different industries
for handling toxic and fuming liquids/
chemicals. Due to the use of high power rare
earth magnets, these pumps are made seal-
less in design and give zero leakage during
operation. Since there is no shaft seal, there is no leakage or breakdown. Also, the
seal-less feature ensures handling of wide variety of liquids, which conventional
seal type pump cannot handle. The pumps is ideal to handle corrosive chemicals,
acids, dyes, solvents, petrol, kerosene, etc. The motors comply with Indian Standard
specification IS 2148 for Gas groups I, IIA, IIB, II C. Typical applications are
in industries such as chemical, pharmaceuticals, petroleum, dyeing and printing,
electroplating, photo processing, solvent extractions, etc. The pump is available
in capacity of 50 LPM up to 2,000 LPM having maximum head of 60 m. Special
application pumps can also be designed as per customer requirement and import
substitute.
Taha Pumps & Valves
Surendranagar – Gujarat
Tel: 02752 – 240233
Mob: 09825599415/09825829875
Email: [email protected]; [email protected]
Website: www.tahapumps.com
PRODUCTS
Chemical World | December 201282
Vapour phase corrosion inhibitor
Corobit-VP is a vapour phase corrosion inhibitor
used for prevention of rust and corrosion of
ferrous and non-ferrous metals. It is available in
powder form and when sprinkled in enclosed
systems, it emits vapours that form invisible
protective film on surrounding metallic surfaces,
thus preventing corrosion.
Ashok Industry
Mumbai – Maharashtra
Tel: 022 – 26232133, Mob: 09892848669
Email:[email protected]
Website: www.ashokindustry.com
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
Email: [email protected]
Website: www.jaywater.com
Drum dryer
A range of drum dryers is available
with quality standards and optimum
effectiveness. This range is broadly
accepted by prospective clients due
to the fine efficient performance,
robust construction and longer
service life. The dryer is available
as per customised specification and also at industry leading prices.
Moreover, the range of dryers is manufactured using finest quality raw
material sourced from reliable vendors after an appropriate inspection
process. The range is manufactured using superior quality raw material
and is used to convert liquid material into dry flakes.
Tridev Industries
Ahmedabad - Gujarat
Tel: 079-25895865, Mob: 09978917299
Email: [email protected]
PRODUCTS
83December 2012 | Chemical World
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
Degreaser
A wide range of alkaline, solvent-based and water-based degreasers
is available, which feature metal-safe and fire-boil safe range and
cleans, emulsifies, degreases the toughest of thick burnt greases. It
has minimum odour; is reusable, biodegradable and economical on
dilution. The degreaser is an excellent substitute for caustic soda,
kerosene, diesel, CTC etc. The degreaser range includes Magna
100 hard surface cleaner, which is an alkaline-type detergent that
emulsifies, absorbs and floats away the toughest of greases and oils.
The Magna 106 alkaline degreaser is a powerful liquid degreaser
that avoids most of the risks common to powerful cleaners and with
anticorrosion properties. The Magna big blue, high power, emulsifiable
solvent degreaser is used to clean heavy engine parts, blocks and
related components in shipyards, oilrigs, etc. The Magna Husky is an
ideal cleaning compound formulated to clean all types of filtering
equipment, deep fat fryers, ovens, greasy vents, etc.
Ecochem Innovative Solutions & Services
Mumbai – Maharashtra
Tel: 022-23880007, Mob: 09322294436
Email: [email protected]
pH Meter
Oakton pH 2700 is a GLP-compliant meter
with pH measurement capability along with
temperature. The pH range varies from
-2.000 to 20.000 pH with accuracy of ±0.002
pH. The meter offers a new compact design
that is over 40 per cent smaller than other
benchtop meters. The large display is easy
to read even at a distance and features stability indication. All
measurements include temperature display. The meter includes auto-
buffer recognition for both USA and NIST pH buffer sets with up to
5 points calibration. A calibration due alarm function means no more
outdated calibrations. Multiple pH slopes and offset display enables
quick, easy electrode diagnosis. The convenient pull-out, quick-
reference card keeps keypad functions at your fingertips. By utilising
the RS-232 output, you can print required data or a calibration report
with a click of a button in the desired viewable format. Calibration
report provides detailed information on the most recent calibration.
It includes date and time, calibration standard(s), offset, temperature,
number of days calibration is over-due, slope information, etc.
Cole-Parmer India Pvt Ltd
Mumbai - Maharashtra
Tel: 022-67162224/2222
Email: [email protected]
Website: www.coleparmer.in
LIST OF PRODUCTS
Chemical World | December 201286
Sl. No. Product Pg. No. Sl. No. Product Pg. No. Sl. No. Product Pg. No.
Accelerated aging test ............................. 33Acoustic enclosure .....................................FICAgitator .............................................. 19, BICAir operated double diaphragm pump ........ 76Aluminium extrusion .................................. 77Amino acid analyser .................................... 88Analytical instrumentation .........................BCAtomic absorption spectrophotometer ........ 88Automatic and contained discharge ............ 31Ball check valve ...................................... 49Ball valve ............................................... 13, 49Basket centrifuge ......................................... 41Batch disperser ............................................ 19Bellow & dip-pipe ........................................ 4BioSpec-nano .............................................. 75Booster system ............................................ 82Bush ............................................................ 49Butterfly valve ....................................... 13, 49Buying & selling used industrial machinery plant & equipment .................... 83Cake pressing ......................................... 31Calorimeter ................................................. 19Check valve ................................................. 13Chemical & pharmaceutical ........................ 83Chemical compound for cleaning and finishing machines ...................................... 78Chemical tank ............................................. 78Chemical transfer pump .............................. 76Chill vector system ...................................... 65Chromatography data software ..................BCColumn & chemistries ...............................BCCompositional & trace metal analysis ........ 33Continuous or batch filtration .................... 31Decanter ................................................. 41Degreaser ..................................................... 83Diaphragm valve ......................................... 49Diesel........................................................... 33Disc-bowl type centrifuge separator ........... 41Disperser ..................................................... 19Drawer magnet ............................................ 78Drum dryer ................................................. 82Drum type magnetic separator .................... 78Dry van pump ...........................................FICDryer ........................................................... 22Evaporator ..................................... 22, BICExhibition - Engineering Expo ............ 59, 61Failure analysis ....................................... 33Feed water heater ........................................ 65FEP/PFA/PVDF material .......................... 49Ferrous/non-ferrous casting ........................ 77Filler compositional analysis ....................... 33Finishing machine ....................................... 78Fittings ........................................................ 49Flameproof magnetic drive chemical pump 81Flash dryer ................................................... 22Flexible hose ................................................ 82Forged component ...................................... 77Forged steel valve ........................................ 13FRP battery stand ....................................... 29FRP cable tray ............................................. 29
FRP canopy ................................................. 29FRP grating ................................................. 29FRP handrail & fencing ............................. 29FRP ladder .................................................. 29FRP luminaries ........................................... 29FRP piping .................................................. 57FRP pole & mast ........................................ 29FRP storage tank ........................................ 29FRP structural profiles ................................ 29Fuel storage ................................................. 27Fume extraction and scrubbing system ....... 77Gas chromatography ............................... 88Gasket ......................................................... 49Gate valve, globe valve ................................ 13Gear oil ....................................................... 33Hastelloy ................................................ 13Heat exchanger .................................... 8, BICHeating bath ............................................... 19High intensity roller type magnetic separator .....78High pressure homogeniser ........................ 19Hose ............................................................ 82Hot and cold zinc phosphating chemical ... 76Hot plate ..................................................... 19Hotshot mechanical automatic pump ......... 65HPLC ........................................................BCIndustrial valve ....................................... 77Informatics .................................................BCInline disperser ............................................ 19In-line homogeniser system ........................ 78Inline magnetic separator ............................ 78Inorganic ceramic adhesive ........................... 3Internal gear pump ...................................... 81Kneading machine .................................. 19Laboratory reactor .................................. 19Laboratory software..................................... 19Large diameter welded pipe ........................ 83Laser particle size analyser .......................... 88Lighting system ........................................... 27Lined valve .................................................. 13Lined valve & pipe fitting ............................ 4Liquid jet ejector ......................................... 65Lubes - engine oil ....................................... 33Machined components ............................ 77Magnetic drum pulley ................................. 78Magnetic stirrer ........................................... 19Material identification ................................. 33Mechanical vibratory feeder ........................ 78Metallography ............................................. 33Mills ............................................................ 19Modular system pump ................................ 53Monel .......................................................... 13Multi-stage cake washing ........................... 31Nickel aluminium bronze ........................ 13Non-return valve ........................................... 4Oil meter ................................................ 81Over band type magnetic separator ............ 78Overhead stirrer .......................................... 19Peristaltic pump ...................................... 55Petrol ........................................................... 33pH Meter .................................................... 83
Pilot plant .................................................... 19Pipe ............................................................ 49Piping system from polypropylene ................ 6Plug valve .............................................. 13, 49Pollution control equipment .................... BICPolymer characterisation ............................. 33Power distribution, power rental ................ 27Pressure and vacuum filtration .................... 31Product assemblies ...................................... 77Production HPCL ...................................... 88PTFE .......................................................... 49PTFE lined valve & pipe fitting ................... 4Pump .................................................. 82, FICPump for chemical equipment .................... 11Pumping solution ........................................ 85Rod ....................................................... 49Roots blower ...................................... 82, FICRotary atomiser ........................................... 22Rotary evaporator ........................................ 19Seamless pipe.......................................... 83Sheet ............................................................ 49Single gas monitor ...................................... 81Spin flash dryer ........................................... 22Spray dryer ......................................... 22, BICStainless steel pipe....................................... 83Steam jet air ejector system......................... 65Steam jet booster and ejector ...................... 65Strainer .......................................................... 4Super centrifuge .......................................... 41Super duplex ................................................ 13Surface condenser ........................................ 65Suspension magnet ...................................... 78Swing check valve ....................................... 49Teflon-lined ball valve, butterfly valve ......4Teflon-lined check valve, sampling valve ..... 4Teflon-lined valve & pipe fitting .................. 4Tefzel HHS isotactic PP material ................ 6Test tool ...................................................... 78Testing ........................................................ 33Thermocompressor ...................................... 65Thermoplastic valve ...................................... 6Titanium ..................................................... 13Transmission fluid ....................................... 33Transmitter.................................................. 15Trap magnet ................................................ 78Tube ...................................................... 49, 83Turbine vacuum system .............................. 65Turned components .................................... 77Twin lobe roots blower ............................... 82Two-stage vacuum pump ............................ 82‘U’ tube ................................................... 83UPLC .........................................................BCVacuum booster pump ......................... FICVacuum or hot gas drying........................... 31Vacuum system .........................................FICValve ............................................................ 49Vapour phase corrosion inhibitor ............... 82Water-based paint .................................. 43Water ring vacuum pump ........................... 82Welded pipe ................................................ 83
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