Chemical Engineering World July 2013

VOL.48

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VOL. 48 NO. 7 July 2013 US $ 10 ` 150

ChemTECH South 201310-12 October 2013, Chennai, India

FILTRATION AND SEPARATION

July 2013 • 1Chemical Engineering World


40

Road,

4 • July 2013 Chemical Engineering World

ContentsCEW

Vol. 48 | No. 7 | JULY 2013 | Mumbai | ` 150

NEWS ►Industry News / 06

Technology News / 12

NEWS FEATURES ►14 Coal Blocks Allocated to PSUs / 14

Centre to Announce Revised Chemical Policy / 16

FEATURES ►

Combustion Ion Chromatography /18

– Deepak Parab, Sankar Babu – Metrohm India Ltd

In Situ Particle Characterisation / 26

– Benjamin Smith – Mettler-Toledo AutoChem, Inc

Plastic Recycling / 32

– Next Generation Recyclingmaschinen GmbH

Coalescing Technology: An Overview / 38

– Nitin Nageshwar – YoKu Consultants

Case Study: Water Treatment in Modern Times / 46

– Dr Jens Lipnizki, Beryn Adams, Kedar Oke – Lanxess India Pvt Ltd

Synthesis of APIs/HAPIs / 52

– Lars Voges – De Dietrich Process System AG

Liquid-Liquid Extraction Systems / 56

– Sunil Bhosale – Hitek Engineers Pvt Ltd

MARKET INSIGHTS ►All Women Affair / 60

PRODUCTS ► / 62

EVENTS ► / 69

PROJECT UPDATE ► / 70

BACK OF BOOK ►

Ad Index / 72

Book Shelf / 73

Interview / 74

All’s Well That Ends Well

– P N Prasad, Managing Director, Brahmputra Cracker & Polymers Ltd (BCPL)

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Industry NewsCEW


New Delhi, India: Mangalore Refinery and Petrochemicals Limited (MRPL) is all set to resume oil imports from Iran, after stopping in April, having secured local reinsurance for claims of up to ` 5 billion (USD 84.14 million). MRPL, which was IranÊs top Indian client, halted imports because local insurers said they could no longer cover plants that process Iranian crude.

P P Upadhya, Managing Director, MRPL, said that MRPL would take all necessary steps for recommencement of import/processing of Iranian crude oil in its refinery, in a letter to Oil Secretary Vivek Rae.

He noted that MRPL has held meetings with officials from the Indian Oil Ministry as well as local reinsurer General Insurance Corp (GIC) in order to resume crude oil imports from Iran.

BPCL-Kochi Refinery Expansion Site Declares ÂStrike Free ZoneÊ

Essar Projects Bags IOC Contract

Kochi, India: The ` 20,000 crore BPCL-Kochi Ref inery expansion project site at Ambalamugal has been declared a Âstrike-free zoneÊ with a view to completing the project within the scheduled 42 months.

A decision to this effect was taken at a conciliatory meeting of stakeholders of the project, including prominent trade unions, company management, contractors association convened by the Centre and state government.

The Integrated Refinery Expansion Project (IREP) envisages enhancement of refining capacity of BPCL-KOCHI Refinery from existing 9.5 million tones per annum to 15.5 MMTPA. Besides IREP with a total outlay of ` 14,225 crore, BPCL has proposed to venture into petrochemical at a cost of ` 6000 crore for production of petrochemicals from propylene supplied by the refinery.

Mumbai, India: Dubai-based engineering firm Essar Projects has bagged a contract from Indian Oil Corporation (IOC) to implement process safety related improvements at its terminals and depots across the country. The assignment involves basic and detailed design and project management relating to implementation of various HSE requirements in 109 POL terminals/depots across the country. The project is expected to be completed within 24 months. lwyn Bowden, CEO, Essar Project, said that Essar will be executing this project on a fast track mode and is delighted to secure such a prestigious project from IOCL in which EPL can show-case its engineering and project management capabilities.

MRPL to Resume Iran Oil Import Mumbai, India: KSB Pumps Sinnar Division has won 2nd prize in large scale industries group the pres t ig ious ÂVasundhara Award 2013Ê for its goal towards protect ion of envi ronment in t h e S t a t e o f M a h a r a s h t r a . The award was presented by Pruthviraj Chavan and Ajit Pawar, Honourable Chief Minister, Dy Chief Minister of Maharashtra,

respectively, in a special function organised in Mumbai. Sunil Bapat, DGM (Operations), Shreepad Khare, GM (Integrated Management Systems), A Bhilare, Manager (HR & Admin), R B Gote, Manager ( Integrated Management Systems) and M M Wani, Manager (Maintenance), KBR Pumps were attended the said function.

New Delhi, India: With just less than half the ethanol procured so far for doping with petrol, Petroleum Minister M Veerappa Moily has asked oil firms to float tenders for remaining quantities this month and tie-up supplies at the earliest. Oil firms need 100 crore litre of ethanol to implement the 5 per cent mandatory doping in petrol but so far only 40 crore litres has been procured in tenders floated previously. Moily directed fuel retailers to expedite delivery of already procured ethanol and buy additional quantity through fresh tenders to meet 5 per cent mandatory requirement under Ethanol-Blended Programme (EBP). He also asked them to expeditiously procure additional quantity of ethanol through fresh tenders to meet the EBP requirement.

KSB Pumps Wins ÂVasundhara Award 2013Ê

Oil Firms to Float Tenders for Ethanol

Pruthviraj Chavan, Honourable Chief Minister, and Ajit Pawar, Dy Chief Minister of Maharashtra Present the Award to KBR Pumps.

Tata Chemicals Bags UnileverÊs ÂPartner to WinÊ Award

Mumbai, India: Recognising Tata Chemicals ef for t in aiding Unilever to significantly reduce the environmental impact of laundry powders and their business association to create traceability for mined chemicals; the company has felicitated with the prestigious UnileverÊs ÂPartner to WinÊ Award for Winning Sustainability. The award was hosted at UnileverÊs largest Supplier Summit in Singapore recognising supplier contr ibutions in the areas of innovation, sustainability, joint value creation among others. The award is a testimony to the synergistic relationship between Tata Chemicals and Unilever which dr ives consistent sustainable growth and responsible care.

On this occasion, R Mukundan, Managing Director, Tata Chemicals, stated that Tata ChemicalsÊ corporate philosophy is deeply rooted in the principles of sustainability which implies a commitment to environmental stewardship while adding economic value. The company par tnership with Unilever fur ther endorses this and to get an award for the same is gratifying and enabling. We thank the team at Unilever for encouraging best practice init iat ives across var ious f ie lds o f bus iness and look fo rward to our continued association.


Industry NewsCEW


Talcher, India: State-owned gas utility GAIL India is in process to acquire 5 to 10 per cent stake in Rashtriya Chemicals and Fertilizer LtdÊs (RCF) urea and ammonium nitrate plant at Talcher in Odisha. RCF, GAIL and Coal India came together for a ` 10,000-crore project to convert coal in Talcher mines into gas and then use it as feedstock for manufacturing urea and power. Gail wants to take a minimum 50 per cent stake in the ` 3,000-crore upstream coal-gasification project that will produce enough natural gas to not just fire the fertiliser plant but also a captive power plant. Also, the captive power plant would generate surplus electricity that would be sold to the grid.

Mumbai, India: L&T Hydrocarbon has secured an order of over Rs 1000 crore to construct a paraxylene plant for a leading ref inery in India. The company signed a memorandum of understanding to execute composite construction works, including civil, mechanical and erection and installation, for the project.

L&T will mobilise about 25,000 workmen and 600 staff for the project which will be executed over a period of 30 months. L&T Hydrocarbon provides complete design-to-build engineering and construction solutions for the oil & gas sector. In-house expertise, extensive experience and collaborations with strategic business partners enable it to deliver end-to-end solutions for every phase of project from front-end design engineering through fabrication, project management, procurement, construction and installation right up to commissioning.

GAIL to Acquire Stake in RCFL&T Hydrocarbon to Build Paraxylene Plant

New Delhi, India: In a bid to set up a petroleum storage facility in Mauritius, India will push for renewing the petroleum product exports contract with the country, with as part of its efforts to diversify and expand commercial exchanges with Mauritius. In a 3-year agreement, worth USD 2 billion, with the State Trading Corporation (STC) of Mauritius, Mangalore Refinery & Petrochemicals Ltd (MRPL) has been supplying 1.1 million tonnes of auto fuels, jet fuel and furnace oil annually for three years to the country and India will try to keep the contract intact. Petroleum products account for more than 80 per cent of IndiaÊs exports to Mauritius.

Mumbai, India: Honeywell Automation India Limited (HAIL) has awarded two Indo-American Corporate Excellence awards at a felicitation ceremony organised by the Indo American Chamber of Commerce (IACC). Anant Maheshwari, Managing Director, HAIL, received the awards from Prithviraj Chavan, Honorable Chief Minister of Maharashtra, as a part of the pre-American Independence Day celebrations.Honeywell received the Corporate Excellence Award for Technology and Communications for driving a successful technology enterprise and its contributions to the Indo-US technology sector. The Corporate Excellence Award in Manufacturing recognises the company for its innovative manufacturing principles using lean manufacturing, Kaizen, and Six Sigma processes, to deliver high quality products to its customers.

Mumbai, India: Bharat Petroleum Corporation will invest ` 900 crore to set up a new LPG pipeline from its Kochi refinery to Coimbatore and to enhance the storage capacity at its Irumpanam installation. The 229-km pipeline, at an investment of ` 600 crore, will not only minimise transportation of gas through road but also connect the companyÊs bottling plants in Palakkad and Coimbatore, thereby improving the distribution network. The company would invest another ` 300 crore at its Irumpanam unit near Kochi Refinery to increase the storage capacity by four million tonnes.

The storage capacity will be increased to 8 million tonnes with the completion of Integrated Refinery Expansion Project (IREP). The funds for both these projects wil l be in addition to the ` 14,225-crore investments set apart by the company for IREP, which envisages increasing the refining capacity to 15.5 mmtpa from 9.5 mmtpa. The company intends to launch both these projects simultaneously with the IREP project scheduled to be commissioned by September 2015.

New Delhi, India: IndiaÊs Organic Chemicals imports in June-2013 has fallen to USD 1427.5 million, a decrease of 18.75 per cent compared to May 2013, the report is based on India Organic Chemicals import database of InfodriveIndia, IndiaÊs premier export import market research company, and is based on shipping documents filed at Indian customs. This finding is based on India Organic Chemicals import data of InfodriveIndia.com and is compiled from shipping documents filed at Indian customs through June-2013 at more than 110 ports in India like JNPT, Bombay Air and Sea , Chennai Air & Sea , Delhi IGI Air, Delhi Tughlakhabad ICD, Delhi Patparganj, Kolkata Air and Sea, Bangalore Air and many more.

New Delhi, India: In a new turn of events, the planning commission has recommended priority allocation of natural gas for fertiliser sector, leaving power sector for gas pooling along with other industry sectors. Earlier it had recommended natural gas to be provided at subsidised price out of the general pool for sectors like fertiliser and power both. However power ministry has refused to go for general pool as companies generating electricity have already entered into long term contracts with gas producers at old rate. These rates cannot be revised as per the terms of the contract, said official sources close to the development. Currently, the fertiliser and power sectors get 29.4 and 17.5 million metric standard cubic meter per day of gas, respectively.

Govt Seeks Renewal of MRPL-Mauritius Contract

Honeywell Receives Indo-American Corporate Excellence Awards

BPCL to Invest in LPG Pipeline Infrastructure

IndiaÊs Organic Chemicals Imports Decrease

Priority Allocation of Natural Gas to Fertiliser Sector: Plan Panel


Industry NewsCEW


Texas, US: Low viscosity polyalphaolefins producer Ineos Oligomers is planning to construct a new linear alpha-olefin (LAO) facility on the Gulf Coast of the US. The proposed new LAO plant forms part of the companyÊs growth plans for its LAO and polyalphaolefin (PAO) product lines. The project is scheduled to be completed by the end of 2016.The new plant is expected to add to companyÊs current LAO capacity, which will also provide additional feedstock supply to support the expected growth of its PAO business.

Ineos Oligomers CEO Bob Learman said that the unit will have an initial capacity of 350,000 metric tonnes per annum (mtpa), and is built to expand capacity by 50 per cent to 500,000 mtpa. „So ultimately the capacity could reach over 500 thousand metric tonnes,‰ Learman added.

Solvay Aroma to Construct Chinese Vani l l in Manufacturing Facility

Zhenjiang, China: Solvay Aroma Performance is planning to construct a new vanillin production facility in Zhenjiang, Jiangsu Province, China. The plant is expected to increase SolvayÊs manufacturing capacities by 40 per cent and help the group to meet the growing demand for vanillin and ethyl-vanillin, especially in the Asian market. The new Zhenjiang plant, which will be fully compliant with both international and local stringent regulations, is scheduled to go on stream by the end of 2014.

Dominique Rage, President, Solvay, said the addit ion of the manufactur ing faci l i ty in China makes the group a uniquely positioned, highly reliable par tner for its worldwide customers, especially those in the highly regulated food industry. He added that it is an important step for SolvayÊs strategy to continue strengthening the market position, by offering a truly global production footprint that ensures full traceability for food safety and to consolidate Solvay as the global reference for food-safe vanillin.

Ineos to Set up Alpha-Olefin Facility in US

Newport, UK: US-based Eastman Chemical Company has broken ground on a new manufacturing facility in Newport, Wales, UK, to expand its Therminol heat transfer fluids production. Scheduled to be operational in the second half of 2014, the faci l i ty wil l produce Therminol 66 and other biphenyl based co-products. The manufactur ing facil i ty is expected to increase EastmanÊs total capacity for Therminol 66 by more than 50 per cent.

Eastman Specialty Fluids and Intermediates segment specialty fluids business global business director Ravi Prakash said the company aims to help customers meet demand by providing a reliable supply of Therminol 66, while meeting its vision of providing high temperature heat transfer fluids.

„This expansion positions Eastman to meet the needs of heat transfer fluid customers with our flagship Therminol 66 product,‰ Prakash added.

Campo Quijano, Argentina: Australia-based mineral resource company Orocobre is planning to relocate its borax chemical fac i l i t y f rom i t s cu r ren t loca t ion in Campo Qu i jano to the Tincalayu mine site in Argentina. The Borax Argentina chemical p lant manufactures borax decahydrate, borax pentahydrate and anhydrous borax.

The re locat ion is expected help the company min imise the opera t ing un i t cos ts and improve overa l l m inera l recover y from the mine.

Currently, run-of-mine ore at 17 per cent B2O3 is concentrated at

Tincalayu using dry magnetic separation to manufacture a 21 per cent grade, which is then transported 350 km from Tincalayu to Campo Quijano for production of borax chemicals. Recovery through the dry magnetic separation plant is only approximately 60 per cent, according to Orocobre.

On relocation, the borax plant will treat run-of-mine ore without using the magnetic separation facility, resulting in improved mineral content and freight cost profile.

Iowa, US: US-based Harr is and FordÊs newly formed aff i l iate HF Chlor-Alkali will construct a salt conversion facility adjacent to Cargill Ês corn mill ing facility in Eddyville, Iowa, marking the companyÊs entry into manufacturing. Construction work on the facility is expected to begin this summer with the first product scheduled to roll off the lines in early 2015.

Built on 29 acres at the Cargill Eddyville complex, also known as the Iowa Bioprocessing Center, US, the facility will manufacture a minimum of 100,000 dry short tonnes of caustic soda and 250,000 short tonnes of muriatic acid per annum.

The plant, which is supported by the Iowa Economic Development Authority, will also manufacture bleach and is expected to serve all of CargillÊs US facilities.

Eastman Expands Footprint in UK

OrocobreÊs Argentina Chemical Plant to Relocate

HF Chlor-Alkali to Construct Salt Conversion Facility in US

Dar es Salaam, Tanzania: Tanzanian companies - Gro Energy and Infotech Investments Group - have signed a memorandum of understanding (MoU) with the Malaysian company Huchems Fine Chemical for the construction of east AfricaÊs first ammonia-based chemical manufacturing plant in the country. The USD 800 million agreement with Huchems follows discovery of natural gas resources in the east African nation.

The plant will be located in Tanzania and will utilise the countryÊs abundant natural gas resources. The parties expect to conclude a final agreement before the end of 2013.

Ammonia Plant Comes up in Tanzania


Technology NewsCEW


Technology in Producing Acrylic Acid

Ludwigshafen, Germany: BASF, Cargill and Novozymes report the achievement of an important milestone in their joint development of technologies to produce acrylic acid from renewable raw materials by successfully demonstrating the production of 3-hydroxypropionic acid (3-HP) in pilot scale.

3-HP is a renewable-based building block and one possible chemical precursor to acrylic acid. The companies also have successfully established several technologies to dehydrate 3-HP to acrylic acid at lab scale. This step in the process is critical since it is the foundation for production of acrylic acid. In August 2012, BASF, Cargill and Novozymes announced their joint agreement to develop a process for the conversion of renewable raw materials into a 100 per cent bio-based acrylic acid.

UKÊs Bioethanol Plant Uses Praj Technology

BPÊs Chinese PTA Plant Gets Approval

Pune, India: Vivergo Fuels Ltd has officially opened the UKÊs largest bioethanol plant based on Pune-based Praj technology and design. Praj is a global process engineering and solutions provider for bioethanol, alcohol & brewery, water & wastewater and process equipment.

This greenfield biorefinery operating on UK feed wheat is highly energy eff ic ient with dist i l lat ion, dehydrat ion and evaporation integrated uniquely reducing energy consumption. The plant adheres to EU sustainability criteria for Greenhouse Gas (GHG) savings.

Praj provided the licence for the technology, basic engineering as well as certain equipment for the core process block which includes liquefaction, fermentation, distillation, multi effect evaporation and molecular sieve dehydration. The plant is designed to use 1.1 million tonnes of feed-grade wheat to produce 420 million litres of bioethanol and 500,000 tonnes of protein rich animal feed per year.

Zhuhai, China: BP and its par tner, Zhuhai Por t Co, have received the final approvals from the Chinese Government for the construction of a third purified terephthalic acid (PTA) plant, at Zhuhai, Guangdong.

The ÂZhuhai 3Ê plant will have a capacity of 1.25 million tonnes per year and is expected to start up in late 2014. PTA is the preferred raw material used to manufacture polyethylene terephthalate (PET), a widely used polyester polymer for the production of textiles, bottles, packaging and film products. In China, 90% of PTA production is used in the textile industry.

Clariant Opens Leather Excellence Centre

Chennai, India: Swiss specialty chemicals company Clariant has opened a new Leather Excellence Center in Ranipet, Chennai, India. The centre, which marks a major investment by the company in its leather business, is expected to help the company meet anticipated growth in the Indian leather production segment. The USD 1 million excellence center is expected to help the company to provide a central application laboratory and technical services for the entire country, as well as for all the key accounts across southern India. Clar iant Chemicals (India) Leather Services Business Unit India head Kumaresan said the laboratory includes a new testing facility for water-repellent leathers and will enhance the business units ability to offer tailor-made solutions for leather ar ticles development.

„The new laboratory will be instrumental in bringing ClariantÊs latest technologies and systems to our customers at an even faster pace than before,‰ Kumaresan added. „It shows our commitment to the specialty chemicals business in offering innovative and personalised solutions for our customers.‰ The chemicals company already runs production facilities in Kanchipuram, Tamil Nadu, and in Roha, Maharashtra, India.

Al-Jubail, Saudi Arabia: Saudi Organometallic Chemicals (SOCC), a 50-50 joint venture (JV) company owned by Albemarle Netherlands and Saudi Basic Industries (Sabic) affiliate Speciality Chem, has initiated start-up operations of its aluminum alkyls facility in Al-Jubail, Saudi Arabia.

The facility will manufacture 6,000 mt annually of tri-ethyl aluminum (TEA), a Ziegler Natta co-catalyst used in the plastics industry, and an ultra-low hydride grade of TEA (TEA-ULH). The facility produced first batch of TEA in mid April and met or exceeded all commercial specif ications while full commercial production is expected to star t once in the third quar ter of 2013 following completion of customer qualifications.

Kolkata, India: In a path-breaking discovery, scientists of the Council of Scientific and Industrial Research (CSIR) and Indian Institute of Chemical Biology (IICB) have created an artificial peptide (a smaller version of proteins which are coded by DNA), which successfully curbed melanoma (skin cancer) in rats. „The cancerous cell was induced from humans. However, we have not yet conducted clinical trials on humans with the peptide,‰ said Prof Siddhartha Roy, Director of IICB, Kolkata.

SOCC Starts Saudi Tri-ethyl Aluminum Facility

Scientists Develop Synthetic Peptide Lyondell Technology for Chinese PP Facility

Beijing, China: CNOOC Oil and Petrochemicals, a wholly-owned subsidiary of CNOOC, has licensed LyondellBasell Spherizone technology for its new polypropylene (PP) facility in the Republic of China.Spherizone is a multizone circulating reactor process, which is believed to offer a cost-efficient method of producing a range of high-quality PP and polyolefins resins on a single-line, with manufacturing capacities of around 500 ktpa. LyondellBasell said it has licensed the Spherizone process to more than 3.5 million tonnes of capacities since the launch of the technology in 2004.


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News FeaturesCEW

14 Coal Blocks Allocated to PSUsMinistry of Coal has allocated 14 coal blocks for power sector located in six host states on the recommendation of the Inter Ministerial Committee (IMC) after due deliberations at every stage with applicant State Government, host states, where the coal blocks are located and the concerned administrative Ministry i.e., Ministry of Power and Central Electricity Authority. Around 15 states and 6 Central PSUs have been allocated coal blocks. Some of the coal blocks, because of their size had to be given to more than one state. Namely, Deocha-Pachami block in West Bengal having a reserve of 2102 MT has been given to six different state power PSUs.

Odisha

West Bengal

Jharkhand

Chha

ttisg

arh

Maharashtra

Madhya Pradesh

Coal Block / Capacity/ Host State

Proposed Govt. Co., - Allocated Coal Reserves (MT)

Tentuloi/1234 MT OTPCL - 1234.00

Chandrabila/550 MT NTPC Ltd - 550.00

Kudanali-Luburi/396 MT NTPC Ltd - 266.00 + JKSPDCL - 130.00

Sarapal-Nuapara/701 MT APGENCO - 701.00



Bhalumuda/550 MT NTPC Ltd - 550.00

Banai/629 MT NTPC Ltd - 629.00

Baisi/150 MT CSPGCL - 150.00

Jilga-Barpali/546 MT NLC / Sirkali (Tamil Nadu) - 396.00 + CSPGCL - 150.00

KenteExtn./200 MT RVUNL - 200.00



Pachwara-South/279 MT NUPPL - 279.00

Kalyanpur-Badalpara/102 MT UPRVUNL - 51.00 + HPGCL - 51.00



Mahajanvadi/340 MT MAHAGENCO - 170.00 + GSECL - 170.00



GondbaheraUjheni/532 MT MPPGCL - 532.00



Deocha-Pachami/2102 MT KPCL - 382.00 + WBPDCL - 584.00 + BSPGCL & SJVN Ltd - 486.00 + PSPCL - 229.00 + TANGNDCO - 171.00 + UPRVUNL - 250.00

Abbreviations • OTPCL: Odisha Thermal Power Corporation Ltd• JKSPDCL: Jammu & Kashmir State Power Dev Corp Ltd • CSPGCL: Chhattisgarh State Power Gen Co Ltd • NUPPL: Neyveli Uttar Pradesh Power Ltd• APGENCO: Andhra Pradesh Power Generation Corporation Ltd• RVUNL: Rajasthan Vidyut Utpadan Nigam • KPCL: Karnataka Power Corp Ltd

• WBPDCL: The West Bengal Power Dev Corp • PSPCL: Punjab State Power Corp Ltd• TANGNDCO : Tamil Nadu Generation & Dist Corp Ltd• UPRVUNL: Uttar Pradesh Rajya Vidyut Utpadan Nigam Limited• MAHAGENCO: Maharashtra State Power Generation Co Ltd• GSECL: Gujarat State Electricity Corporation Limited• MPPGCL: Madhya Pradesh Power Generation Company Limited


Steam Tube Bundle Rotary Dryer


News FeaturesCEW

Centre to Announce Revised Chemical Policy

During a recent chemical industry conclave, Ajay Vara Prasad, Joint Secretary Department of Chemicals

& Petrochemicals, Ministry of Chemicals & Fertilizers, Govt. of India, informed that the Centre is revising current policy and will shortly announce the same which would address the key aspects viz. imports, exports, patents, research & development.

The Government has underscored the importance of the chemical industry during the 12th Five Year Plan and come up with the National Chemical Policy which aims at increasing the chemical industry from its current size of USD 108 billion to USD 224 billion by 2017 and increase its share in countryÊs manufacturing pie from current 16 per cent to 25 per cent. Presently, there are around 70,000 chemical units, 80 per cent of which are small scale and provide employment to approximately 3.3 million.

Prasad also stated that share of chemical industry in countryÊs GDP has dropped to 1.9 per cent from highs of 2-3 per cent, and he expects the industry to still grow at 11 per cent after touching the peak growth levels of 15 per cent during the recent past. However, the biggest issue would be taking production levels to the order of Rs 3 lakh crore, he added.

Lack of conducive policies and infrastructure are major barriers in the

growth of chemical industry. He is extremely optimistic about the amendments that are being made to the National Chemical Policy and said that once approved by the Government, the policy will open multitude of avenues for growth of Indian chemical industry and the new set of reforms would catapult the growth of Indian chemical industry.

Vipul Shah, President, CEO & Chairman, Dow India, states, „I firmly believe that if we tread the right path, the Indian chemical industry has a potential to grow at 11 per cent annually, even in this challenging economic environment. Being 3 per cent of the global chemicals business, it can clock an estimated turnover of USD 224 bill ion by 2017.‰ He said, „My key expectations from the forthcoming chemical policy is the right push to reform the agenda in the sector and fast track setting up of chemical parks to attract investments.‰

Shah emphasises, „This would help efficiently meet the demand, rapidly grow the domestic market and generate significant employment.‰ This, coupled with Âzero dutyÊ on the import of chemicals to facilitate easy availability at competitive cost; roll out of GST and a complete waiver of Special Additional Duty (SAD) would provide the much needed fillip to the chemical sector, he adds.

Shah stresses on the urgent need to provide for steps to boost R&D by formation of sophisticated R&D facilities with internationally recognized accreditation. Further, extension of income tax exemption under Section 35 of Income Tax Act on the initial investment for setting up of R&D facilities and extension of customs duty exemption on import of R&D equipment for the chemical sector could be some initial welcome steps in these difficult times, Shah adds.

Emphasising on the need of new reforms to boost the growth of chemical industry, R Mukundan, Managing Director, Tata Chemicals, says, „The chemical sectorÊs GDP contribution has reduced from

present 2-3 per cent to 1.9 per cent and needs urgent policy push for growth. The required new policy should leverage the countryÊs existing infrastructure and competencies, ensure availability of feedstock, foster a strong R&D base, and recognise incorporation of Indian IPR in global standards while promoting entrepreneurship, innovation and special focus on exports. It should be focused on Âgreen technologyÊ to combat the negative connotations attached with the industry.‰

Zero duty on chemical imports Roll out GST Fast track setting up of chemical

parks Complete waiver of SAD Extension of IT exemption under

Section 35 of Income Tax Act Leverage existing infrastructure

and competencies Ensure feedstock availability Foster stronger R&D base Recognise incorporation of Indian

IPR in global standards Promote entrepreneurship

Industry Expectations from Revised Policy

My key expectations from the forthcoming chemical policy is the right push to reform the agenda in the sector and fast track setting up of chemical parks to attract investments.- Vipul Shah

The chemica l sec to r ’s GDP contribution has reduced from present 2-3 per cent to 1.9 per cent and needs urgent policy push for growth. - R Mukundan



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Chromatography has emerged as the key analytical technique in characterising the petroleum

products based on its physical and chemical properties. Chromatography is a physicochemical method for separating mixtures of substances. The separation effect is based on repeated distribution between two phases; one is stationary phase while the second, mobile phase moves in a particular direction. A further differentiation of chromatography methods can be made according to the basic processes. Gas and liquid chromatography techniques are equally important in the industry in controlling and assuring the quality of products.

High Performance Liquid Chromatography (HPLC) can be differentiated according to the different physicochemical interactions between the substances in a sample and the stationary phase. Although in reality, there are usually several different mechanisms responsible for a successful separation, a broad classification according to separation mechanisms viz., adsorption, distribution, size exclusion, affinity, ion exchange, ion pair formation, ion exclusion, is possible. Ion chromatography technique provides solution for lot of analytical challenges in the industries.

Combustion Ion Chromatography

Petroleum products are h ighly c o m p l e x c h e m i c a l s , a n d considerable effort is required to characterise their chemical and physical properties with a high degree of precision and accuracy. Indeed, the analysis of petroleum products is necessary to determine the properties that can assist in resolving a process problem as well as the properties that indicate the function and performance of the product in service.

The term Âion chromatographyÊ was coined in 1975 with the introduction of detection by conductivity combined with a chemical reduction in conductivity by Small, Stevens and Baumann; it was subsequently used as a trade name for marketing purposes for a long time. In the meantime the abbreviated term Âion chromatographyÊ (IC) has become established as the super ordinate term for the ion exchange, ion exclusion and ion pair chromatography methods included under HPLC. IC, today, is dominant in the determination of anions while the atomic spectrometry methods, commonly used for the determination of cations, are hardly useful for determining the electronegative anion formers of the fifth to seventh main groups of the periodic system.

According to the International Union of Pure and Applied Chemistry (IUPAC) ion exchange chromatography is defined as, „In ion exchange chromatography separation is based on differences in the ion exchange affinities of the individual analytes. If inorganic ions are separated and can be detected by conductivity detectors or by indirect UV detection then this is also called ion chromatography‰. An older, more general definition is more suitable for defining ion chromatography. „Ion chromatography includes all rapid liquid Figure 1: Cation Exchanger and Anion Exchanger

chromatography separations of ions in columns coupled online with detection and quantification in a flow-through detector.‰

Ion exchange chromatography (IC) is based on a stoichiometric chemical reaction between ions in a solution and a normally solid substance carrying functional groups which can fix ions as a result of electrostatic forces. In cation chromatography these are sulfonic acid groups, in anion chromatography quaternary ammonium groups. (Figure 1)

Solid/Liquid Separation and Drying

• Process Tests incl. Scale-up

• Planning, Integration and Qualification of our Plants acc. to cGMP and FDA Guidelines

• Complete Systems: Design and Integration of peripheral Equipment to our Plants

• Design of CIP/SIP Procedures

Contained Filtration, Drying and Powder Handling of HAPI under sterile Conditions


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In theory ions with the same charge can be exchanged completely reversibly between the two phases. The process of ion exchange leads to a condition of equilibrium. The side towards which the equilibrium lies depends on the affinity of the participating ions to the functional groups of the stationary phase. Figure 5 (on next page) is a schematic diagram showing the exchange processes for cations and anions. The analyte ions are marked A, the eluent ions competing with them for the exchange positions with E.

Ion chromatography technique with wide range of detection technique viz., Conductivity, UV-Visible, Electrochemical detections provides unrivalled option for the analytical chemist to solve the challenging analytical problems. It offers solution for many analytes of categories anions, cations, organic acids, amines, quaternary ammonium compounds, amino acids, carbohydrates, cyanide, sulphide, rare earth metals, transition metals, phenols, sugar alcohols and amines, etc.

In petroleum industry, fluorine, chlorine, bromine, and sulfur can cause corrosion in many industrial processes, decrease the lifetime of many catalysts, and cause environmental pollution. Sulfur in petroleum products causes corrosion in pipelines, poisons catalysts, affects stability during storage, and can decrease product performance. Chlorine

Figure 2 B : Separation of anions; Eluent: Bicarbonate; Analyte: Chloride ion

corrodes equipment, clogs pipelines, and increases catalyst consumption during manufacturing and adversely affects product quality. Hence, there is a requirement in estimating the specified analytes in single go.

Petrochemicals, gaseous samples, solid samples, and complex chemicals are very difficult to analyse with conventional IC. Sample preparation is required to extract analytes or remove interfering matrices, but these techniques can be costly and labor intensive. Automated combustion IC reduces the time and labor for determination of corrosive halogens and sulfur in difficult samples. There is a published standard method ASTM D7359 to carry

out the analysis. This test method can be adopted to estimate total sulfur and halogens in aromatic hydrocarbon matrices, in finished products and can be used for compliance determinations when acceptable to a regulatory authority using performance based criteria.

Petrochemical and chemical industry together requires about 52 per cent Combustion Technique in different analysis processes. Further, it is used by different other industries and sector including nuclear power plant (9%), university and government (6%), food industry, mining and minerals, recycling industry, semiconductor (2% each), electronic (7%), labs and other R&D work (11%).

Petrochemical is one of the industries, where the Combustion Ion Chromatography (CIC) technique is more useful and suitable so lut ion prov ider for the ex is t ing analytical challenges. CIC is an extended option to handle the samples of nature such as petrochemicals, viscous or non-aqueous industrial chemicals, and solid samples.

The combustion IC system developed by Metrohm & Mitsubishi (Japan) can be used for automated qualitative and quantitative analysis of halogens and sulfur in petrochemicals, coal-based chemicals, and construction materials, chemicals, and polymers. (See figure 3)Samples are introduced into the AQF-100 using the ABC-100 Automatic Boat Controller. Pyrolysis occurs at 800 1100

Figure 3: Combustion IC set up

Samplesulfur compounds

halogen compounds

combustionsox

Hx,x2

so42

X

Abosorbent Analysis

ion chromatography

Liquids

or

gas inlet

sample introduction absorption absorption analysis by IC

solids

Figure 2 A : Separation of cations; Eluent: Nitric acid; Analyte: Sodium ion



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AuthorsÊ Details Deepak Parab

Chief Executive OfficerMetrohm India Limited

Email: [email protected]

Sankar BabuLab Manager

Metrohm India Limited [email protected]

■C. The samples containing halogen and sulfur are oxidized by O2 and absorbed in the absorbing solution. The samples in the absorbing solution are transferred to the IC system for analysis. Phosphate is added into the absorbing solution as an internal standard to calibrate the analytical results. H2O2 is added into the absorbing solution to oxidize SO2, which is produced from the incomplete oxidisation of S, to SO3, so it can be analyzed in the form of SO4

2-.

CIC system will be the solution for the analysis of ionic contaminants estimation in hard-to-analyse samples such as petrochemicals, viscous or non-aqueous industrial chemicals, and solid samples. This automated system not only saves time and labor, but also produces less hazardous waste than costly, solvent-intensive, and environmentally unfriendly extractions. Major applications for CIC include analysis of sulfur and halogens in plastics, polymers, epoxies, lumber, petrochemicals, coal, inks, aluminum powder, polishing agents, lubricating oil, and electronic components.

Also, the combustion IC system is ideal for manufacturers that must monitor contamination of chemicals, raw materials, in-process samples, finished products, or waste streams for quality control or environmental regulation compliance. Appl icat ion f ie lds include the petroleum, coal, plast ic,

Figure 4: Analysis of 1-Benzyl-3-(4-Chloro-2-(Trifl uoromethyl)-Phenyl)-2-Thiourea in Ethanol usign Metrohm Combustion IC for halogens estimation. Column : Metrosep A Supp 5 150/4.0; Eluent : Default condition.

Figure 6: Ion chromatogram using conductivity detection after Pyrolysis of S-Benzyl thiouronium chloride

Figure 5: Sulfur analysis in biodiesel: At present a maximum sulfur content of 10 ppm applied to biodiesel (EN 14214)

semi-conductor and power generation industries, which are obliged to monitor banned toxic compounds as they are sources of corrosion or poison.

References: • Metrohm IC monograph • Handbook of petroleum product analysis, James G Speight. • ASTM Method D7359 - Standard Test Method for Total Fluorine, Chlorine

and Sulfur in Aromatic Hydrocarbons and Their mixtures by Oxidative Pyrohydrolytic Combustion followed by Ion Chromatography Detection (Combustion Ion Chromatography-CIC)

• Technical poster, Determinat ion of halogens by combustion ion chromatography by C. Emmenegger, Y Zhen, J-R Kim and A Wille.

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Separation of fine solids from a water stream presents significant challenges in the mining, oil sands,

pulp/paper, and biotech industries. And though processes may differ, flocculation is a separation improvement technique that is used to improve water recycle and control fines accumulation.

In flocculation, the density of dispersed particles is increased to form sediments. Current treatments involve adding highly-engineered polymers and chemicals to modify rheology for the specific slurry being processed. By inducing flocculation, scientists and engineers adjust particle size distribution to maximise solid-liquid separation and downstream throughput. This so-called dewatering efficiency is directly proportional to incoming particle size distribution/population, polymer type/dosage, shear, and the flocculated particle strength, porosity, and aggregate size.

Monitoring a Non-linear ProcessHowever, while flocculation sounds straightforward enough, it isnÊt linear. For example, after shear is introduced to improve polymer dispersion, initial

InSitu Particle Characterisation

Separating water from fine tailing in the minera ls and petro leum industries is a longstanding and w e l l - d o c u m e n t e d c h a l l e n g e . E s t a b l i s h e d i n s i t u p a r t i c l e characterisation technology allows real-time monitoring of particle phase behav ior as eng ineered p o l y m e r s a n d c h e m i c a l s a r e introduced. This enables additive, dosage and shear optimisation for enhanced downstream throughput and improved productivity.

aggregate size distribution often increases; however, flocculant strength and shear intensity can result in a breakup of solids over time, causing an undesirable shift to smaller particle counts. These fine, dispersed particles have a negative impact on dewatering.

Essentially, because flocculation is a dynamic process with changing particle size and concentration, representative sampling and offline analysis are often not enough to make optimal control decisions. Additionally, because offline samples are typically manipulated through dilution or dispersion prior to measurement, fragile particle structures are often altered or destroyed, reducing the accuracy of measurements and the conclusions that are drawn from them. Established in situ particle characterisation technology, on the other hand, can help scientists and engineers quickly measure particle phase behavior without the added time and procedural burden of pulling samples. This allows real-time optimisation decisions for improved solid-liquidseparation and better downstream throughput. Predictive data can also be

used to select appropriate polymers and other chemicals for optimised processing.

Real-time Statistics and VisualsTypes of in-process particle monitoring tools used to provide this real-time predictive measuring and feedback include ParticleTrack™ with Focused Beam Reflectance Measurement (FBRM®) and Particle Vision and Measurement (PVM®).FBRM technology tracks the rate and degree of change to particles and particle systems as they exist in process in real time. PVM technology is a probe-based video-capture tool that provides high-resolution images of particles and droplets as they exist in process, adding a real-time visual element to help monitor and manage particle system changes in a particular process or slurry.

Tracking Changes to Size and NumberBy implementing in-process particle measurement technologies such as FBRM and PVM, real-time flocculation performance is measured at full process concentration, allowing dewatering optimisation at the bench or in the field. Figure 1 (on next page) depicts how these in-process measurements allow users to measure changes to particle



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size and number as polymer dosage increases. However, the addition of shear to improve polymer dispersion can cause a diffusion and breakup of solids over time.

Preventing this type of action · which, as noted, can reduce dewatering effectiveness · is a primary benefit of implementing inline particle characterisation technology. In the following example, when ParticleTrack statistics and PVM images are combined to track a batch flocculation process, they identify four stages of an MFT shear progression curve (Figure 2). These are:A. Incoming steady-state MFT dispersion

and poor water release;B. Polymer dosage followed by flocculation;C. Floc breakdown and maximum dewatering;

and D. Floc shear and dispersion reverting to

MFT and less water release. Adjustment of dosage and shear in this instance, using the kind of robust data gained via in situ monitoring, can provide the critical data necessary to enhance dewatering performance. The following real-world examples show how important inline monitoring is to optimise flocculation and dewatering.

Choosing Polymer and DosageCSIRO and Suncor Energy researchers showed that particle size distribution can help determine correct polymers for the nature of incoming tailings to maximise

dewatering. They also determined that ideal dosage levels correspond with incoming solid content, and that correct shear allows particle size distribution to be optimised to further maximise dewatering and water recycle. However, their research also showed that variability in particle-to-polymer ratio can result in under- or overdosing the tailing system, resulting in high retention of fine solids or low-porosity flocculated solids. Likewise, insufficient or excessive shear produces a particle size distribution with reduced permeability, resulting in less-than-ideal dewatering. Data gained from in-process particle size characterisation enabled the tracking of entire dynamic particle systems. Appropriate decisions can

then be made to avoid these undesirable states in the future.

Predictive Data-based on HydrodynamicsIn the second example, researchers at CSIRO Australia proved that using FBRM technology to follow flocculation in turbulent pipe flow (quantifying aggregate growth kinetics and breakage) helped determine average chord length measurement over time. In turn, this average chord length was used to describe the inline particle size distribution based on aggregation efficiency and breakage rates. Dewatering performance, therefore, can be predicted based on corresponding particle size, flow rate,and hydrodynamics. CSIRO showed that varying the slurry flow rate for a fixed polymer dosage greatly affects the extent of aggregation and degree of breakage over longer times. By measuring the real-time particle dimension over a range of conditions, a population balance model can be applied using hydrodynamic modeling output. This type of modeling would allow optimisation of operating conditions in pipes, channels, or thickener feed wells. Corresponding settling rates were found to diminish at longer reaction times (Figure 3), which is attributed to flocculate deactivation preventing additional growth at longer reaction times, and a corresponding reduction in dewatering performance.

CSIRO also showed that a complex mechanism between solids concentration and flocculation efficiency exists. Therefore, for a fixed dosage, a maximum relationship exists between flocculant particle size and solids concentration. CSIRO also used in-process particle characterisation tools to

Time (min)

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Figure 1: Inline ParticleTrack distributions measuring flocculation over time

Figure 2: PVM images and ParticleTrack trends measuing four stages of flocculation and dispersion



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show that measuring particle size, shape, surface area and surface chemistry can accelerate or slow growth kinetics and reduce the strength of the aggregated structure.

Enhancing Separations PerformanceWithout inline particle measurement, conclusions such as the ones described above could not be drawn effectively. However, these conclusions have been shown to significantly enhance separations performance, process throughput, and process stability, making investment in appropriate inline monitoring technology not only worthwhile, but likely able to pay for itself in enhanced productivity, better safety, and less unnecessary dosage in very little time, depending on processing volume. Using in situ monitoring, hydrometallurgical processing gravity thickeners or oil sands MFT streams can be measured at standard operating concentrations, temperatures and pressures without sampling or sample dilution in the field. As the incoming stream varies in both concentration and mineral makeup, real time particle size, shape, and count measurements enable a controlled response on the part of engineers and scientists seeking to understand how the particle system responds to changing process parameters.

Ongoing OptimisationThis real-time feedback on particle size distribution behavior allows engineers and scientists to track the rate and degree of change to particles and particle structures as they actually exist in process. Statistics such as mean or number of particles measured in a specific size class are trended over time, allowing troubleshooting of unexpected process changes and incoming slurry variability. The real-time optimisation of polymer additive type, dosage, and shear that this feedback enables allows scientists and engineers to ensure consistency in solid-liquid separations relative to the target distribution on an ongoing basis.

Mea

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øm, s

q W

t)

Setti

ng R

ate

(m h

-1)

Reaction Time (s)

AuthorÊs Details Benjamin Smith Market Manager

METTLER TOLEDOEmail: [email protected]

Figure 3: ParticleTrack is applied to predict conditions for the optimum setting rates and reaction time after flocculant additions

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Figure 1. Abb.: 4,Foto NR. : 1301A00034 , 129: 1

Defects in shrink- and stretch films lead to optical impairments of the products, and minimise the

mechanical characteristics or even cause the film to fail. The defects influence the manufacturing process of fi lms negatively. These defects are often caused by impurities in the polymer. In connection with said defects, the developments to even reduce the film-thickness further, puts even higher requirements on the purity of the polymers.

Besides the polymer-defects, which may be found in virgin-material, there are a number of impurities, which depending on size, form and frequency also affect the manufacturing process and the film-quality in a negative manner.

Generally one can state that the more often the resin or fi lm is manipulated within the chain of virgin-material-supply to material-recycling, the higher the impurities within the polymer gets.

Virgin Material Not Entirely Without DefectsDuring the manufacturing of virgin material, the plastic-material is screened inline. At this screening, a plastic film is being produced and a camera

Plastic Recycling

The following article on “Plastic-R e c y c l i n g - M a c h i n e s f o r t h e Pelletising of Post Industrial Waste out of Shrink- and Stretch Film Manufacturing with focus on gel-development,” deals with the causes of impurities in the polymer-matrix and shows the measures modern plastic recycling equipment provide to limit further gel development.

detects impurities, a computer does the counting and measures the size ofthe defects.

Gels are classified as per the size and frequency of appearance, then batches of virgin material is sorted according to the findings but eventually not all impurities can be eliminated. At this very point gels are typically found, which are displayed in figure 1. A high-molecular-polymer-matrix out of PE, with MFI of 8 embeds a gel with a very much lower MFI.

The following image shows a polymer-defect, which was within virgin-material and found its way to the outer layer of a multilayer-film.

Figure 2. Abb.:6, Foto Nr.: 1203A00019 , 207 :1

Fai lure in F i lms Smal l Cause, Big DamageHow dramatic the influence of impurities within the polymer-matrix - during the manufacturing-process - may get, is displayed in the figures 3 and 4 on next page. Figure 3 shows a torn hole, whereas figure 4 shows the cause for the high tension within the film, which is leading to the damage (figure 4 is displaying a larger section of figure 3). Here, a small particle of not properly dissolved plastic-additive rips the film into pieces. Starting point is a pinpoint-sized (approx. 100um) small silicate-grain, originating from poorly homogenised molten mass small cause, big damage. Improper dissolving of additives is usually being caused

NGR recycling machine S: GRAN

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polymer. Black spots appear in plastic-converting due to „dead space‰ in the flow of the molten plastic mass. Plastic accumulates in the dead space area, is further being heated and begins to thermally disintegrate, while the mass of plastic flows by and transports small parts of the destroyed material into the finished film. To overcome such situations, the plastic processing equipment, as well as any recycling-equipment, is to be designed, avoiding dead spaces.

Figure 9 displays a cellulose-fibre, embedded in a polymer-matrix. These particles are usually brought into the polymer-stream by using improper machine-cleaning clothe and due to improper maintenance designof machines.

Summary „Voids in Polymers„ • Voids in polymers may be limited, but

cannot be fully excluded even in virgin-material small defects are contained.

• During film-manufacturing, even small impurities may lead to film failure. The thinner the single layers get, the more problems are caused.

amongst others - by either too low melt-temperature, weak homogenising or poor additive-quality. Figure 5 shows a LLDPE-film at the edge of a hole, which has been created by a grain of starch. The starch-grain was introduced into the polymer-stream by a contaminated silo-transporter.

Film Failures Typical and UntypicalIf an accidental mixing between polymers of different melting points happens, then it is likely to result in a gel, as displayed in figures 6 and 7. Figure 6 shows a gel from the outside of the film, image 7 provides the cross-section-view. The gel consists of HDPE, which is included in a PP-matrix. The mixing of polymers of different types usually happens in an environment of poorly developed waste-management abilities.

Figure 8 shows a classic „Black Spot„, which is thermally damaged, cracked

Figure 3. Abb.: Foto Nr. : 1211A00077 , 27.4 : 1 Figure 6 . Abb.: 1, FotoNo.: 1202A00359 , 104:1

Figure 7. Abb.: 2, Foto Nr.: 1202A00360, 207:1Figure 4. Abb.: 25 FotoNr.: 1211A00078 , 69.3: 1

Figure 5 abb.: Foto Nr.: 1207A00650 , 41.5:1 1mm

• Each s tep in the handl ing-chain of po lymers ( f rom t ranspor t , s tock ing t o i n t e r n a l d i s t r i b u t i o n a t t h e conver te r ) i nco r pora tes some r i sk of contamination.

• Dead spaces in the polymer-melt-stream lead to Black Spots and reduce the quality of the finished product.

• Rema ins o f c lean ing-c lo the in the polymer call for the use of proper tissue

but also for a proper maintenance design of the processing-equipment and the l imitat ion of machine-par ts, w h i c h a r e i n d i r e c t c o n t a c t w i t h the polymer.

High Quality Resin from Production-WasteThe goal of pelletising polyolefin industrial waste-material is to provide plastic-resin, which characteristics are equivalent to virgin-material, and can therefore be applied in the primary process of manufacturing high quality products. Industrial waste-materials range from lumps to cut-offs, but also to normal film-refuse. Here it is important to prevent the material from being further contaminated and to preserve the mechanical properties of the polymer as far as possible.

Figure 8. Abb.:1,FotoNr.: 1301A00031 , 207:1

Figure 9. Abb.: 9 FotoNr.: 1301a00037 , 207: 1 200 μm 200 μm500 μm

1mm 500 μm 200 μm

Undisputed is the fact that the lengths of the polymeric moleculechains have the biggest influence on the mechanical properties –highest attention therefore has to be directed towards treating thematerial with most caution.



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Figure 10 Basic design of a modern shredder-feeder-extruder-combination for the pelletising of Stretch- and Shrink Films Figure 11: Construction of filler media in the screen cavity

CourtesyNext Generation Recyclingmaschinen GmbHEmail: [email protected]

Gentle Processing All to Ensure Long Molecule ChainsUndisputed is the fact that the lengths of the polymeric molecule chains have the biggest influence on the mechanical properties

highest attention therefore has to be directed towards treating the material with most caution. Recycling-systems, which keep the thermal exposure (slow and uniform heating and stringent temperature control) and the mechanical, stress due to shear, at the lowest possible level, are consequently the preferred choice.

The shredding of the plastic waste should be done with slow rotating knives, so to avoid any partial overheating of the material. The designs of shredders in a drum-like manner have been proven appropriate. The feeding of the shredded material to the extruder should provide for pressure-build-up, but should not thermally stress the material. The feeding itself should be quick enough, as freshly cut plastics tend to oxidise and change color (which is the indicators of possible material-degradation). The transfer of heat into the material takes place in thetemperature-controlled extruder by applying as little shear as possible. Melt-temperature as well as melt-pressure is to be maintained at the lowest possible level.

Besides keeping temperature and pressure-settings well under control, there are several more design-aspects to be considered, such as:

• Avoidance of dead space, in which the molten plastic mass could accumulate but also in the area of shredding, no material is to remain outside the material-stream.

• Easy accessibility to the cleaning and maintenance of any machine-part, which is in connection with the plastic-material.

• In order to minimise the shear applied to the mater ial, i t is recommended to not employ directional changes to themolten mass.

Filtration of the Molten Mass The filtration-performance of the filtration-systems depends on the required cleaning-performance. In other words the filtration-

performance is equivalent to the level of contamination of the waste material versus the desired purity of the recycled pellets. In all plastic-filtration-processes, a mesh gathers the impurities and separates the same from the molten mass. Depending on the specific demands, combinations of various different meshes are arranged to provide the desired filtration-performance.

In the area of plastic-recycling continuous filter-systems with back flushing provide excellent results. The choice of the best fit system takes the filtration-performance, but also desired level of automation into account.



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Figure 1. Coalescing steps

Coalescence is the process by which two or more small droplets come together to form larger

droplets. It works by attracting miniscule droplets of water or other liquid, possibly even as small as a single molecule. The droplets come together by the force of molecular attraction and surface tension. When they reach a sufficient size, they can be removed from the system by suitable means.

When two liquids are immiscible, or non-soluble in one another, they can form either an emulsion or a colloidal suspension. In either of these mixtures, the dispersed liquid forms droplets in the continuous phase. Traditionally, gravity separators were used to handle emulsions before the use of coalescer became common. In this equipment, differences in densities of the two liquids cause droplets to rise or fall by their buoyancy. The greater the difference in densities, the easier the separation becomes. Rising or falling droplets are slowed by frictional forces from viscous effects of the opposing liquid. This mechanism of separating liquids by gravity is called Stokes Settling. The various steps of coalescing are:

• Collection of droplets • Small droplets coming together to form

larger ones • Rise or fall of the enlarged droplets

It is very important to understand the characteristics of the emulsion that has to be treated. The finer the droplets dispersed in an emulsion, the more stable it is, because the buoyancy force diminishes in magnitude as the diameter decreases. The manner in which the mixture is created

Coalescing Technology: An Overview

Coalescing is one of the separation technique used worldwide by the process industry for liquid-liquid and liquid-gas separation. This technique involves coalescing of small particles or droplets into larger ones by means of barrier or electrical energy. It is one of the most cost effective methods used today as compared to salt driers, settlers or thermal / vacuum separators. Nowadays, coalescers are often considered preferable to conventional gravity separators. It requires less capital, low operating cost, minimal maintenance and requires less floor space.

effects the droplet size distribution. It is also important to know how much time has elapsed since the mixing/shearing occurred. This is because as time goes on, smaller droplets aggregate or coalesce and larger droplets are more likely to have joined a separate layer so that they are no longer considered to be entrained. An important tool to quantify an emulsion is the Droplet Size Distribution Curve generated by plotting the droplet diameters against the volume. A coalescer is often needed for mature emulsion.

Mixtures of immiscible liquids can generally be separated by a process of settling as a result of the density difference between the two phases. However gravitational settling becomes increasingly difficult as the droplet size of the dispersed phase decreases. Coalescers uses mats, beds or layers of porous or fibrous material whose properties are especially suited for coalescing purpose. The settling process

can be enhanced considerably by passing the dispersion through a suitable coalescer pack or providing electrical energy. There are two types of coalescer generally available in the market i.e. Electrostatic and Mechanical Coalescers.

Electrostatic CoalescerAn electrostatic coalescer uses weak electric charges to attract molecules of water to the surface where they undergo collection. Here a weak electric charge is passed through a collection device which imparts a tiny charge that attracts molecules of water or other matter designated for removal.

Here, electrostatic force is used to break oil-water emulsions and subsequently increase in water droplet size. This technology is quite common in offshore production facilities to ensure the maximum allowable water content in oil is less than one percent. A coalescer forces small

Submicron droplets flow around target

Several captured dropletscoalesce, forming largerdrops

Droplet strike target and adhere

Trickle down and fall, becoming seperated

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Figure 2: Small liquid droplets coalesce to form large drops

on the physical properties of the two liquid phases. In liquid-liquid phase, the coalescing phenomenon is dependent upon coalescing media, specific gravity, viscosity and interfacial tension of the two liquid phases. They help in determining how easily two fluids can be separated.

Liquid-liquid coalescers can be used to separate hydrocarbons from water phases such as oil removal from produced water. They are also used for removing quench water in ethylene plants, last traces of contaminants like amine or caustic from intermediate products in oil refineries, last stage dewatering of final products like kerosene or jet fuel, LPG, gasoline and diesel. Typically, a liquid-liquid coalescer can be designed for a process inlet discontinuous phase concentrations up to 10 per cent and reduce them to ppm levels in the outlet for interfacial tensions as low as 0.5 dyne/cm. Coalescers typically will have a service life of 1 to 2 years when protected adequately by prefiltration.

Liquid-gas coalescers are widely used in oil and gas Industry to remove water and hydrocarbon liquids to <0.01 parts per million by weight and particulate matter less than 0.3 um in size from natural gas to ensure natural gas quality and protect downstream equipment such as compressors, gas turbines, amine or glycol absorbers, molecular sieves, metering

water droplets to merge and form larger and thus faster separation. Therefore, the settling velocity of water droplets in oil not only depends on viscosity and density, but also on the droplet radius.

The main feature of electrostatic coalescers is the effect its electrostatic field strength has on the conductive droplets such as water in an insulating medium such as oil. In the presence of an electric field, the water droplets become dipoles whose electric charges can overcome the repulsive surface-surface interactions, resulting in oil fi lm drainage and consecutive coalescence. The coalescing of droplets is mainly dependent on electrostatic induced forces, fi lm rheology, collision frequency depending on laminar or turbulence level and concentration. Mechanical CoalescerMechanical coalescer uses a series of filters or dividers, known as baffles, to induce small drops to move from a mixture and to collect together. A mechanical coalescer relies on a series of barriers, known as baffles or filters, made of very fine mesh, knitted polymer, corrugated sheet or fiberglass fibers, etc. The vapor or liquid passes through the filter, and is attracted to the filter material or the surface of the baffle.

The principle by which this is done is to pass the water-contaminated oil through a thick inorganic fibre bed or filter mat. Water droplets are intercepted by the fibres. The oil on the fibres is thinned by displacement and the effect of viscous drag, until ultimately the oil fi lm ruptures and allows the water droplets to attach themselves completely to the fibre, with the oil fi lm dispersed and passed on through the mat. Other water droplets are now collected by the fibres in a similar manner, and these will join with others, forming streams along the fibres. The droplets continue to grow in size until drag and gravity forces break them away from the fibre, and they drop off from the filter mat.

Mechanical coalescer is used for liquid-liquid or liquid-gas separation. Separating liquid liquid dispersions can be difficult and costly, depending

stations, mercury guard beds, gas fired heaters or furnaces, heat exchangers or gas-gas purification membranes. Liquids from upstream of the compressor, which may include aerosol particles, entrained liquids or large volumes of liquids called „slugs‰ and which may be water or a combination of hydrocarbon liquids should be removed by a coalescer located upstream of the compressor. The typical service life for liquid-gas coalescer element is 1 2 years. They are generally sized for a clean differential pressure of 2 5 psi, and are replaced with a new element after 15 psi.

Points to Be ConsideredIt is very important to understand the mature emulsion formation process, the droplet diameter size distribution, selecting right media for the given fluid based on its physical and chemical properties, coalescer media depth, coalescer media placement, coalescer vessel configuration while selecting the coalescer.

Coalescing MediaSelecting the right coalescing media for the duty depends on many factors with initial consideration given to the droplet size range in the dispersion and the target separation performance. Some of the coalescing media used are: polymer, polyester, nylon, fluoropolymer, fiber glass, polytetrafluoroethylene fibres, polyurethane foam, fired boards of

Media



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AuthorÊs Details Nitin Nageshwar

CEO -YoKu Consultants & YoKu FiltersEmail: [email protected]

saffil fibers, polyamide fibers, matrix of stainless steel wool, multistage filter with cotton polyester and aspen wood fibers, aluminum or steel fibers coated with vinyl acrylic, polyethylene, or PVC, copolymer of acrylonitrile and methyl acrylate matrix, oleophobic/hydrophobic treated media, etc.

There are two types of media i.e. hydrophobic and oleophobic. A hydrophobic media is to separate water droplets and oleophobic media to separate oil and hydrocarbon droplets. Apart from this, there is surface treated coalescer elements used to enhance coalescing property, extend life, reduce fouling and lower saturated pressure drop.

Benefits • Low Capital Cost • Low Operational Cost • Minimal Maintenance • Low Energy Consumption • Compact and less floor Space

Limitations When coalescers used for separating fluids with a very high viscosity and a high solids loading, the highly viscous fluids will plug the coalescer media, reducing its efficiency. Increasing the operating temperature to reduce viscosity can help in overcoming this limitation. Apart from this, solids at high concentration can be problematic. Due to the fine pore structure of the coalescer medium, the solid particles block the pore thereby reducing the coalescing efficiency. It is recommended to install prefilter at the upstream of the coalescer assembly. Sometimes prefilter element and coalescing element comes in the single housing.

Typical Industrial ApplicationsLiquid-Liquid Coalescer:

• Pipeline Condensate in Gas Production • Produced Water • Petrochemical Final Products • Caustic Treating

Droplet Diameter Range

CoalescingMedia

Type

40 to 1000 micron

Corrugated Sheet and proprietary packing

20 to 350 micron

Wire Wool and proprietary packing

10 to 250 micron

Knits of Wire and Polymer

1 to 30 micron

Knits of Fiber Glass and other material

• Recover Liquid Catalysts • Removing water f rom Lubr icat ing /

Hydraulic Oil • Fuel / Diesel Purification • Solvents removal from effluents • Solvent extraction • Separation of dispersions formed by

azeotropic distillation • Vegetable Oil

Liquid-Gas Coalescer: • Compressor Protection • Amine/Glycol Contactor Protection • Well Head Hydrate Inhibition • Molecular Sieve Protection • Low and Ultra Low NOx Burner Protection

References • F i l t e r s a n d F i l t r a t i o n H a n d b o o k , 5 t h

Edition, 2008 • Handbook of Filter Media, 2nd Edition, 2002 • Handbook of Natural Gas Transmission and

Processing, 2006 • Per ry ’s Chemica l Eng ineer ’ Handbook,

International Edition, 1984 • Coalescer, Wikipedia • ACS Separations & Mass-Transfer Products,

Liquid-Liquid Coalescer Design Manual

Figure 3. Selecting the right coalescing media for the duty depends on many factors



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Water treatment in todayÊs modern world requires highly technical, high performance separation products

to achieve increasingly str ingent treated water qualit ies, or to provide the lowest cost of water production. However, more than one separation technology is often applied to achieve the demanded quality. This development was a main consideration for Lanxess to start production of Lewabrane reverse osmos is (RO) membrane and e lements a t a new produc t ion s i te in Bitterfeld, Germany.

The dominant reverse osmosis membrane structure is based on a thin film composite membrane. The barrier (or rejection) layer is a 0.1øm thick polyamide layer which is supported by a polysulfone substructure. The polyamide layer is formed by a polymerisation process. (See Figure 1)

Although thin film composite membranes based on this process have been used for more than th i r ty years, the newest technology now offers the possibi l i ty to

Water Treatment in Modern Times

This case s tudy presents how c o m b i n i n g r e v e r s e o s m o s i s and ion exchange t echno logy addresses water treatment issues with significant lower costs and improved reliability.

Case Study

The ion exchange resin manufacturing plant at Bitterfeld, Germany

control the polymerisation process more precisely. Accordingly, a strong focus of our membrane development was the enhanced polymerisation degree of the polyamide layer. A higher polymerisation degree improves the mechanical and chemical stability of the thin barrier layer offering greater durability. Additionally, the negative charge on the membrane surface is reduced which leads

to a lower cationic adsorption (fouling) on the membrane surface. Due to i ts chemist r y, the sur face of a polyamide membrane is usually negatively charged, and often results in cationic fouling that is extremely difficult to remove. A typical example for cationic fouling is the fouling with iron. Iron chloride (FeCl3) is a very common

Figure 1: Structure of a thin film composite membrane

Chemistry of RO Membrane Functionality of RO Membrane Structure PS Layer Membrance Preformance

Pure Water

PA Layer

PS Layer

Pon Woven



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flocculation chemical used in pretreatment systems. If the dosing is too high, even just for a short period, the cationic fouling can irreversibly foul the RO membrane surface. Apar t from a well-adjusted iron chlor ide dosing system, a lower negative surface charge is the best option to reduce the fouling potential of this event.

The membrane separation composite layer is the most essential part of the RO separation process. Before use, this critical component is assembled into a device, called an RO element. The winding process for spiral wound RO elements involves many steps all of which need to be carefully controlled. T h e L a n xe s s m a nu fa c t u r i n g p r o c e s s involves state-of-the-art robotic equipment to careful ly prepare the RO element to exacting mechanical specifications. Much of this development was conducted with the assistance of outside Institutes who appl ied modern computer aided design capabilities to confirm mechanical strength and optimise hydrodynamic design (see Figure 2). This kind of critical development process was necessary to assemble the improved membrane chemistry into a modern RO element.

The first field tests of the new Lewabrane RO B400HR elements star ted in January 2012. The elements were placed in an existing RO plant, which is treating 40m3/hr of Rhine river water after an Ultrafiltration sys tem. A to ta l o f s i x e lements were instal led in a pressure vessel. The RO system also contained several pressure vessels with RO elements from another supplier. These elements were instal led approx one year prior, and were operated in parallel to the Lewabrane pressure vessel. The entire RO system was operated in a two stage system with a 6:3 array using six element pressure vessels.

Figure 2: Stress test on the Anti-telescoping device (ATD) and permeate tube

In comparison with the installed elements from another supplier, it could be shown that the Lewabrane elements provided a flux value in the same order of magnitude. The Total Organic Carbon (TOC) and silica re jec t i on were measured pe r iod i ca l l y during the field testing. The TOC rejection was measured at approx 95-96 per cent, and the rejection of the total si l ica was measured a t approx 99.3 per cent . In conclusion, it was demonstrated that the new Lewabrane RO membrane element performs in a similar manner under the same operating conditions.

The reason that Lanxess undertook the big step in adding RO membrane technology to i t s separa t ion products por t fo l io i s that reverse osmosis is a complementary technology to the ion exchange (IX) resins. The LANXESS ion exchange resins have been produced for more than 70 years under the brand name Lewatit ®. As a general rule, reverse osmosis can efficiently desalinate water with a high salinity, but ion exchange can selectively remove cer tain ions from the water. Table 1 shows that depending on the requested permeate quality, which separation technique could be used.

In modern separation applications, combined RO and IX processes are not only used in applications like the desalination of boiler feed water, but in other process applications like the removal of Boron from sea water,

Process Demineralisation Desalination

Limits Conductivity < 2 øS/cmTOC < 500 ppbSiO2 < 50 ppb

Conductivity < 0.055 øS/cmTOC < 100 ppbSiO2 < 10 ppb

Technology Ion ExchangeReverse OsmosisElectrodialysis

Ion Exchange (mixed bed)Electrodeionisation (EDI)

Table 1: Selection of separation technique depending on required permeate quality.

or the treatment of produced water from unconven t iona l gas resources. These appl icat ions have recent ly been under much discussion because of increasing pub l i c conce r n fo r wa te r qua l i t y and environmental considerations.

The production of gas from unconventional sources is growing rapidly worldwide. Water that comes up along with the gas is not only challenging to treat, but must often meet strict regulatory standards prior to release into the environment. Such regulat ions pose challenges to water treatment system des igners. Whi le var y ing s ign i f icant ly, typical waters may have a TDS range of 2,500 10,000 mg/ l , total a lkal in i ty of 1,000 3,000 ppm as CaCO3, and a pH in the order of 8-9. Since most inland areas are sensit ive to the discharge of salts, the concentrate from a water treatment process will require specialised disposal. Therefore, minimizing the volume of waste concentrate is paramount to the success of the application. RO processes with a high recovery rate and low usage of chemicals are one solution. To achieve this goal, softening with IX as pretreatment and inter-stage treatment for a three stage, single pass RO unit is one option.

I n o rde r t o ach ieve a h i gh r ecove r y, softening down to ppb levels of hardness i s r e q u i r e d . To a c h i eve t h i s r e l i a b l y, pa r t i cu la r l y fo r h igh sa l i n i t y wa te r, a selective IX process is used. One example of this is the weak acid cation resin type (for example, Lewati t CNP80), which is typically used prior to the RO treatment fo r b rack ish waters. Another example is che la t ing res ins, wh ich are able to effectively soften to ppb levels, even from saturated br ine solut ions. This type is typically used to soften the concentrate from an RO plant, ahead of fur ther RO treatment. An iminodiacetic acid chelating res in ( fo r example, Lewat i t MonoPlus TP208) is typically selected when strontium



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and barium removal is important; otherwise a n a m i n o p h o s p h o n i c a c i d r e s i n ( fo r example, Lewat i t MonoPlus TP260) is preferentially used.

In most applications a chemical treatment w i t h ac i ds o r an t i s ca l an t i s used as p re t rea tment fo r an RO process. The softening process with IX has advantages if, like in the example above, the discharge of sa l ts is d i f f icu l t , or i f the so lub i l i ty products (Ksp) of the salts are far above the saturation limit so that an antiscalant cannot be used for the application. (Table 2)

In contrast to the produced water treatment example above IX is used as a post-treatment for Boron removal. Boron removal with RO alone is done at pH 9. At this pH, the Boron is partially negatively charged and the rejection can be up to 90 per cent with Seawater RO, and 75 per cent with Brackish water RO elements. To achieve a limit of below 0.5 mg/l Boron in the permeate, an additional RO treatment of the first permeate is necessary (via 2 pass, or partial two pass system). The pH adjustment is done in front of the second pass in such a case.

An alternative for this process is a post t reatment wi th IX. Al though only a few plants are installed with this technique, this process has some clear advantages i f the cus tomer requests a low Boron concentrat ion (0.3 mg/ l i ter) . In a pi lot test of a seawater desalination plant the boron level could be reduced from 0.7 mg/l (after RO) to 0.2 mg/l (operating capacity of 2.6 g/l). Since IX is a separation process with a high select iv i ty, mainly Boron is removed and the capaci ty of the resin is not exhausted by other ions. Similar processes can be used to remove other cr i t ical compounds select ively af ter an RO process, like arsenic or heavy metals.

Most engineers use customised software from product manufacturers to design ion

exchange or reverse osmosis systems. Since July, a new comprehensive software, designated LewaPlus, is avai lable from LANXESS. This sof tware can calculate r ev e r s e o s m o s i s a n d i o n ex c h a n g e arrays ins ide the same sof tware. As a consequence, water treatment plants with a two pass system or hybr id processes using RO followed by IX can be compared, allowing the designer to quickly optimise the water t reatment plant. Addit ional ly, t he e f fec ts o f p rocess va r iab les , l i ke t e m p e r a t u r e , c a n b e c a l c u l a t e d a n d assessed for a whole system.

When designing an RO plant, the software offers the possibility to get a recommended ar ray based on the in for mat ion wh ich has been entered. Fur ther updates are planned this year, for example the option for post-treatment with IX, and a detailed c o s t a n d e n e r g y c a l c u l a t i o n fo r t h e RO design.

In making an economic validation of RO and IX processes, the cost of discharging the concentrate is often important. However the salt concentration of the feed is usually o f pr imar y in terest . Whi le the spec i f ic costs for demineralisation water using IX is dependant on the salt concentration of the feed water, the specif ic cost for an RO plant is constant for a broad range of salt concentrations. On the other hand the specific costs of the RO treated water are star ting at a higher level so that the breakeven point (intersection) shows the designer where the salinity values of IX and RO have the same costs. Apar t from the economic val idat ion other reasons may appear why a RO or IX is selected for a process. In general, RO process is preferred if an easy handling is a critical selection issue while IX is preferred if a high selectivity is beneficial.

Both IX and RO technologies will continue t o s t r o n g l y g r ow i n t h e n e a r f u t u r e .

Seawater desalination is rapidly growing with an expected growth rate of 12 per cent; brackish water at a sl ight ly lower growth rate. The RO membrane process clearly has a bright future. And, with water treatment processes, demanding greater efficiency and selectively, IX also has a br ight future. The modern technology of water treatment requires the combination o f severa l techno log ies, fo r example, the in tegra t ion o f d i f fe ren t membrane p rocesses (e .g U l t ra f i l t ra t ion and RO membrane separation) or the combination of severa l techniques l ike RO and IX, or RO and EDI.

Lanxess now offers two state-of-the-ar t process solut ions (RO and IX) to al low the process des igned to op t im ise the water treatment process with the goal of a lower cost and higher reliability of water treatment for the user.

Table 2: Saturation level of salts where antiscalant cannot be used

Scale Forming compound Conservative Saturation Level

CaSO4 230 per cent

BaSO4 6,000 per cent

SrSO4 800 per cent

SiO2 150 per cent (or 200ppm)

CaCO3 LSI > 1.8, SDSI >1.0

Beryn AdamsHead of Technical Marketing APACIon Exchange Resins Business Unit

LANXESS Pvt Ltd

Kedar OkeSenior Manager - Technical

MarketingLANXESS India Pvt Ltd

AuthorsÊ Details Dr Jens Lipnizki

Membrane Applications Manager LANXESS Deutschland GmbH




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Figure 1: Filter/Dryer for sterile API Figure 2: Filter/Dryer with preparation for later fi tting of glove box

Synthesis of APIs/HAPIs requires mostly several steps which are either in liquid or in solid phases. One step

is the exact interface between both phases: the solid-liquid separation. This is a very critical step during the process where the total batch time can be drastically reduced or increased, and where the quality of the product can be strongly influenced. Most of the time, at step, the product has already a high added value and therefore high costs- especially for final steps.

One piece of equipment which is used more and more to realise this critical process is the filter/dryer. This equipment provides the advantages of combining the mechanical solid-liquid separation phase as well as the thermal drying phase. These two steps are processed in a fully contained way, giving reproducible results and in a fully safe way for both the environment and the product.

Planning, Designing and Integrating Complete Engineered Systems Under cGMP and FDA Guidelines

With experience in the field of API, knowledge of trials and with understanding

of the product, it is possible optimise the design of the filter/dryer. Additional items of interest are: (See figure 3 above)

• All direct ancillary equipment (heating/cooling skid, vacuum units, filling stations)

• Containment devices (isolators, filling liners, soft bag containment)

• Post system filter/dryer for powder API (mill, powder transfer device, blender, packing station)

• The con t ro l sys tem fo r the a l l the aforesaid installation and ancillaries

Agitator and Drive UnitThis is the heart of the equipment. The „S blade‰ Rosenmund agitator ensures not only a perfect mixing of the powder, even by very low filing rates but also aids with optimal heat transfer. This is possible due to the specially machined grooves for heating/cooling media along the shaft and the agitator. The heat transfer is not only a matter of high exchange surfaces, but also, and moreover, a matter of the kind of flow for the circulation of the thermal fluid. The

Synthesis of APIs/HAPIs

This article explains “Synthesis o f A P I s / H A P I s u n d e r s t e r i l e c o n d i t i o n s a n d / o r w i t h h i g h containment requirement,” and highlights different steps involved in the process a long wi th the characteristics of the equipment, its design and functionality.

Figure 3: 3D drawing of the CIP system on Filter/Dryer


When The Others Are Stopped… SAURUS Vacuum Pump Continues!Main features

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combined actions of mixing of the powder with a constant turbulent flow for the thermal fluid allow shortest drying time and very low residual humidity.

Vacuum Dust FilterThe use of a vacuum pump is mandatory for a contact drying process. Because this kind of pump needs to be protected from solid particles, Rosenmund integrates dust filters directly on the top of the filter/dryer. These are designed big enough to allow an optimised use of the vacuum pump capacity, and compact enough so that there is no compromise of the nozzles on top of the filter/dryer is required. The uses of filter cartridges (synthetic or metallic) as well as integrated automated choking by N2 and CIP are realised in most of the cases.

Side Discharge ValveFrom a process point of view, the side discharge valve should be able to discharge the all amount of powder without blocking the falling tube. This must be done carefully without losing the tightness of the discharge valve. This is solved by Rosenmund® by using very special metallic sealing seats.

From a safety point of view - and since the plug of this side discharge valve needs to withstand the process pressure - any kind of risk of „bang opening‰ or deformation of the drive of the plug must be avoided. Safety is constantly on the top of RosenmundÊs list and these points are the main focus of the design of our comapanyÊs side discharge valve.

INNOVATION TO SERVE OUR CUSTOMERSGas KnifeThe safety space between the agitator and the filter media is required to protect the filtration media (synthetic and metallic) from mechanical damages. The main drawback of this is the product remaining which is impossible to discharge in a traditional

mechanical way. To address this issue, the company has developed the „Gas Knife. „Gas Knife is a system which allows nitrogen through the shaft up to nozzles welded on one blade of the agitator. With this device you are able to mechanically blow the residual product heel up to the side discharge valve. Achievement and efficiency is product depending, but out of the numerous systems already installed, some achieve removal of more than 90 per cent of the heel. There is no need to open the machine for these steps, so that the containment does not break. Also for sterile application, this system has been validated by FDA in the few cases where it has been required.

Easy Clean When it comes to sticky powder, metallic seats of the side discharge valve might lose their tightness over time and the „open/close‰ sequences. In order to avoid a delicate opening of the side discharge valve housing (including loss of containment, loss of time, risk of product contamination, and risk for the operator), Rosenmund developed „Easy Clean‰. „Easy Clean‰ is a special side discharge valve including two gloves and additional sight glass. The operator can easily put his hand into the glove (hand hole fitted with a safety switch) and manually clean the dirty metallic seat by checking visually the all operation.

HANDLING HAZARDOUS PRODUCTSEven if the filter/dryer provides 100 per cent containment for the mechanical separation and thermal drying steps, Active Pharmaceutical Ingredients (APIs) are mostly still very active and/or very toxic in their dried form. Therefore, the requirement for a high level of containment is still there for the discharge steps of the API powder out of the Agitated Nutsche Filter Dryer (ANFD) and the following processes - milling, blending, filling and packing.

Depending on the Operator Exposure Level (OEL) value that is given by the user, there are different solutions which might be applicable to reach the requirements. This field of solutions is going from a very simple filling directly in container (via double butterfly valve or liner) up to a more sophisticated glove-box or flexible glove-bag. Rosenmund help in defining the best suitable solution for

AuthorÊs Details Lars Voges

Sales Director RosenmundDe Dietrich Process Systems AG


Figure 4: Detail of the very high performance S blade agitator of Rosenmund®: improved mixing, heat t ransfer and torque transmission

applications and designing it as per cGMP and FDA guidelines.

These containment solutions can be developed and integrated directly by Rosenmund including mechanical tests during Factory Acceptance Test (FAT) for the following process steps:

• Product filling in the filter/dryer • Product discharge • Product sampling • Safe change of items on the filter/dryer

(dust filter cartridges, and filter media)

CONCLUSIONManufacturing sterile APIs and/or drugs according to cGMP and FDA guidelines for the export to regulated markets is always a challenge especially when to high investments for which the Return of Investment (ROI) must be as short as possible. Time to market of the drug is crucial.

One process step where days and weeks can be easily won or lost are the mechanical separation and drying steps. A few points are here which can influence this timing and at the end the ROI:

• R e d u c i n g t h e i n t e r f a c e s d u r i n g the project: This is the key to avoid heavy and time consuming discussions by coordinat ing di f ferent equipment suppliers. The supplier of one stream like mechanical separation and drying should have the proper engineering capacities and know how to manage all interfaces

• Reducing batch time: This is a key parameter to be retained for the choice of the r ight par tner. A proper heat transfer, mixing, heel removal and CIP are essential there.

• Reactivity for service during and after the project: Skilled people should be available within few hours or days. This can be easily achieved with a local setup.

• Profess ional documentat ion and traceability: this is mandatory when it comes to regulated markets. Experts in the field of processes are required when it comes to equipment optimisation, start up andtrouble shooting.


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Extraction systems are very useful to separate substances whose vapour pressures are nearly the same.

It requires a lot of understanding and experience apart from empirical studies of substances and separation dynamics to choose the optimal process distillation or extraction or a combination of both. Liquid-liquid extraction is a mass transfer operation in which a liquid solution (the feed) is contacted with an immiscible or nearly immiscible liquid (solvent) that exhibits preferential affinity or selectivity towards one or more of the components in the feed. Two streams result from this contact, the extract, which is the solvent rich solution containing the desired extracted solute, and the raffinate, the residual feed solution containing little solute. The Decisive Edge

• Proven and time tested technology for problems involving marginal differences in specific gravities

• Guaranteed recovery of product from mother liquor, without using any moving components inside the column

• Enables shi f t ing from batch type to continuous type

• Designed for low-flow resistance • Very durable • Low maintenance

DescriptionVarious components comprise the Liquid-liquid extraction such as extraction column, separators and distributors. The extraction column is packed with specially developed Hitek Structured Packings. Mother liquor containing product is pumped through the distributor, into the extraction column. The solvent for extracting the product from the mother liquor is pumped

Liquid-Liquid Extraction Systems

Liquid-liquid extraction, also called solvent extraction, is used over the years for separating successfully a number of substances, which are chemically different or which undergo thermal decomposit ion,at higher temperatures. This article describes important parameters that should be considered when optimising extraction systems.

through the opposite end of the column. The light density material is pumped from the bottom of the column and the heavy density material is pumped from the top of the column.

The process form two phases (a) Continuous Phase (preferred low viscosity phase) and (b) Dispersed Phase.

Light density material travels from the bottom of the column to the top of the column where it gets separated at the top separator forming an interface (for light phase as dispersed phase, interface shall be at the bottom and vice versa) and overflows out from the top nozzle. The heavy density liquid enters from the top of the column through the distributor and travels towards the bottom separator.

Due to the geometry of the structured packings, a highly efficient mass transfer is achieved. This column has two feeds and two outlets and run continuously in the counter current mode with the densities difference as driving force.

Advantages of counter-current system is rich mother liquor that comes into contact with product saturated solvent, hence making solvent fully saturated. As well as lean mother liquor that comes into contact with fresh solvent to extract maximum possible product from outgoing stream. This makes the system highly efficient. Another advantage of this system is that there are no moving parts and operation is continuous. Hence no maintenance or supervision is required till the column is disturbed.

This system is suitable for low to moderate properties of the liquids i.e. viscosity, surface tension, density etc. Space required

for this system is very low compared to other systems.

Parameters to be Considered for Designing the Extraction SystemLiquid-liquid extraction systems are not very commonly used processes as these are not well defined in the literature or difficult to design. This process can give significant savings in operating costs which can be achieved by fine-tuning extraction systems.

The following are the important parameters need to be carefully evaluated when optimising the design and operation of the extraction processes.

• Solvent selection • Operating Conditions • Design Criteria


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FeaturesCEW

Solvent SelectionSolvents differ in their extraction capabilities depending on their own and the soluteÊs chemical structure. The distribution coefficient and selectivity are the most important parameters that govern solvent selection. The distribution coefficient or partition coefficient for a component A is defined as the ratio of concentration of a A in extract phase to that in raffinate phase. Selectivity can be defined as the ability of the solvent to pick up the desired component in the feed as compared to other components. The desired properties of solvents are a high distribution coefficient, good selectivity towards solute and little or no miscibility with feed solution. Also, the solvent should be easily recoverable for recycle. Designing an extraction system is usually a fine balance between capital and operating costs.

Selection of Extraction ConditionsDepending on the nature of the extraction process, the temperature, pH and residence time could have an effect on the yield and selectivity. Operating pressure has a negligible effect on extraction performance and therefore most extractions take place at atmospheric pressure unless governed by vapourpressure considerations.

Temperature can also be used as a variable to alter selectivity. Elevated temperatures are sometimes used in order to keep viscosity low and thereby minimisingmass-transfer resistance. Other parameters to be considered are selectivity, mutual solubility, and precipitation of solids andvapour pressure.

Design CriteriaThe basic function of extraction equipment is to mix two phases, form and maintain droplets of dispersed phase and subsequently separate the phases. Following factors need to be considered while designing and optimising extraction equipment.Mixing: The amount of mixing required is determined by physical properties such as viscosity, interfacial tension and density differences between the two phases. It is important to provide just the right amount of mixing. Less mixing causes the formation of large droplets and decreases interfacial area (interfacial area varies with the square of the droplet diameter). This reduces mass transfer and decreases stage efficiency. Higher agitation (more mixing) minimises mass transfer resistance during reactions and extraction but contributes to the formation of small and difficult-to-settle droplets or emulsions. Settling: The settling characteristics depend on the fluid properties viz. density difference, interfacial tension, and continuous phase viscosity, and the amount of mixing. In continuous columns, a settling section is provided either as a part of the extraction system or as a separate piece of equipment downstream of the extraction system. Emulsions are usually formed due to over agitation and in such cases, settling needs to be carried out over an extended period. Emulsions can also form due to the inherent nature of the chemical compounds involved or due to contaminants that substantially lower the interfacial tension. Sometimes coagulants are added to prevent or minimise emulsification. Passing the emulsion layer through a coalescer

can break some of these emulsions. In continuous extractors, the creation of emulsions is less severe as good droplet size distribution can be attained at lower agitation speeds in a lesser diameter column. Selection of continuous and dispersed phases can have an effect on formation of emulsion and rag layer. Reversing continuous and dispersed phases sometimes drastically reduces or eliminates emulsion formation. Changing extraction temperature could also help in reducing emulsionand rag layer. Selection of Continuous and Dispersed Phase: In column extractors, the phase with the lower viscosity (lower flow resistance) is generally chosen as the continuous phase. Also note that the phase with the higher flow rate can be dispersed to create more interfacial area and turbulence. This is accomplished by selecting an appropriate material of construction with the desired wetting characteristics. In general, aqueous phases wet metal surfaces and organic phases wet non-metallic surfaces. Change in flows and physical properties along the length of extractor should also be considered. Choosing a continuous phase is generally not available in batch processes, as the larger liquid phase usually becomes the continuous phase.

ConclusionAs we have seen above, there are a number of factors affecting extraction performance. Pilot plant testing using actual feed and solvent is a great help in achieving the optimisation.

References:1. Robbins, Chem. Eng. Prog., 76(10), 58-61 (1980). 2. Cusack, R.W., & Glatz, D., et al, “A Fresh Look at Liquid-Liquid

Extraction”, Chemical Engineering, February, March & April 1991. 3. Madhavan, Optimize Liquid-liquid Extraction, Chemical and Process

engineering Resources

AuthorÊs Details Sunil Bhosale

B.Tech. (Chemical engineering), IIT MumbaiCEO, Hitek Engineers



Market InsightsCEW


Productivity at our all women manufacturing facility has tripled in a short span of time, says elated Dr R V Rajkumar, Divisional Head, Coimbotore Plant, KBL, which is engaged in

manufacturing of industrial pumps, after receiving the ASSOCHAM award for Women Empowerment. „It is indeed a matter of pride for us,‰ Rajkumar adds. Sanjay Kirloskar, Chairman & Managing Director, KBL, envisaged Coimbatore industrial pumps project as an initiative towards self-sustenance for women and improving their standards of living.

Although the women force has increased in the corporate houses, the manufacturing sectors still prefers having male employees. Rajkumar notes, „In India, mere 30 per cent of women have white collar jobs based on their educational qualification and rest 70 per cent are either undereducated or uneducated to work in the corporate environment.‰ He expresses that there is a huge potential in the industry to offer employment to women from rural areas that is fairly untapped.

KBL envisaged this project as an initiative towards women empowerment by offering employment to the women from the rural areas near Coimbatore. Though the culture of women working in a production facility has still not seeped into the rural areas and people are still apprehensive towards sending the girls to work in the factories, KBL has very successfully crossed this barrier. The facility employs 70 women between the age group of 19 30 years on the shop floor.

KBL has gone extra mile to impart intense industrial training course for all the employees at this facility during induction, which included 16 hours training during the course of employment and 6 days of mandatory training for each operation. In addition, KBL has also tied up with the Government ITI to train personnel under MES Central Government Scheme and receive NCVT certification.

Rajkumar appreciates the approach of women towards handling the responsibilities which are far better than their male counterparts as women are naturals when it comes to multi-tasking. He considers this as a reason for the inclination of large corporates towards hiring women professionals for creating balanced work environment.

„In fact, when we started the facility, our productivity was 60 seconds per pump which has increased to 20 seconds per pump,‰ Rajkumar reveals. He further adds that with all-women facility, KBL has busted the myth about inability of women to run the shop floor efficiently as compared to men.‰ However, Rajkumar feels,

An All Women Affair

retention of associates and frequent absenteeism from work as the biggest challenges and KBL has introduced the sabbatical leave policy for the employees to address these issues.

„It feels very safe being surrounded by women , which makes it easier to work in perfect harmony,‰ says L Bhuvana who works as the production supervisor at the facility. another senior employee, N Eswari adds that working in an all women environment not only makes them feel much safer but also excel in thier work. „We feel like one huge family where we share compassions for our colleagues which is not the case while working with the male colleagues,‰ shares C K Selvi, Assistant Manager Materials.

The women are much more confident now working in the facility and increase in productivity has been extremely encouraging for the entire team at the facility. Eswari laments about the long commuting time but feels very proud to be independent and having been able to contribute to the family income. Bhuvana rues that females are underestimated in the industry, but she feels extremely proud that KBLÊs initiative that will now change this perception in the society.

The team appreciates on the job training offered by the employers which has enabled them understand the technical aspects of the pumps and work efficiently. According to Selvi, it is the disciplined approach of KBL that has helped employees give thier best.

Mahila Mission 20 has been a great achievement for KBLÊs female associates and worked very well. Rajkumar hopes that this novel step would be a milestone for the manufacturing industry and encourage more women professionals to seek job opportunities on the shop floors and reduce the existing gender disparity in the production facilities.

Productivity at KBL’s Coimbatore facility, which employs all women, has tripled since inception thus breaking the myth of men’s superiority on the shop floor.


ProductsCEW


Sharplex offers tubular centrifuge high speed separation and clarification The tubular centrifuge ensures high speed separation and clarification. It is a solid bowl type machine used for continuous separation of two immiscible liquids w i th dens i ty d i f fe rence. I t i s a lso applicable for separating small quantity of impurities from liquids.

This tubular centrifuge is applicable in pharma, chemical, food industries, edible

oil industries, printing Ink, paint industries, gum clarification and biodiesel plants. The tubular centrifuges are available in two different models; SA 16 and SA 26.

For details contact:Sharplex Filters (India) Pvt LtdR-664, Rabale, MIDC TTC Industrial AreaThane Belapur Road Navi Mumbai 400 701Tel: 022-27696322, 27696339, 27696331Fax: 91-022-27696325E-mail: [email protected]

or Circle ReadersÊ Service Card 1

Sharplex has launched self cleaning filter Disc Type specially designed for applications in food, pharmaceutical, chemical, edible oil, fertiliser, petroleum and mining industries.

The SFC Series auto-clean liquid filters are designed to remove suspended solids of 10 microns and larger from all types of liquids like oils, resins, paints, coatings, adhesives, pigments and crude vegetable oils.The SFC filter system incorporates a stainless steel/carbon steel housing which contains tubular wedge wire filter element screen in stainless steel construction. The screen used is 50 to 80 microns. The SFC series auto-clean liquid filters are available in three different models; SFC-400 (capacity up to 7 m3/hr), SFC-800 (capacity up to 14 m3/hr), SFC-1600 (capacity up to 25 m3/hr). These models are available with contact parts in SS 304, SS 316l or carbon steel. The widge wire element is SS 304 or SS 316L.

For details contact:Sharplex Filters (India) Pvt LtdR-664, Rabale, MIDC, TTC Industrial Area Thane Belapur Road, Navi Mumbai 400 701Tel: 022-27696322, 27696339, 27696331 Fax: 91-022-27696325E-mail: [email protected]

Self Cleaning Filter Disc Type

Tubular Centrifuge High Speed Separation and Clarification

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M a l ve r n I n s t r u m e n t s o f fe r s n ew s o f t wa r e fo r t h e M o r p h o l o g i G 3 pa r t i c le charac te r i za t ion sys tem, extending the instrumentÊs capabilities to include the detailed measurement

of fibers. The Morphologi G3 measures the size and shape o f par t i c les by image ana lys is and the new sof tware function delivers accurate measurement of f iber-specific parameters, including fiber total length, fiber width, fiber straightness and fiber elongation. When measuring curved or branched fibers by image analysis, traditional caliper-based measurements of par ticle length and width often fail to deliver all the information needed to fully determine the fiber par ticle proper ties. Fiber total length and fiber width measurements, now available with the Morphologi G3 often prove to be more valuable parameters. The system also calculates fiber straightness and fiber elongation, adding fur ther detail into understanding a fiberÊs characteristics.

For details contact:Malvern Aimil Instruments Pvt LtdNaimex House, BSEL Tech Park B Wing 906 Sector 30A, Vashi, Navi Mumbai 400 705Tel: 022-39183596, Fax: 91-022-39183562 E-mail: Stuar [email protected]

Fiber Analysis Capabilities for Morphologi G3 System


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August 2013Pumps & Valves Special

Jasubhai Media Pvt. Ltd.rd210, 3 Floor, Taj Building, Dr. D. N. Road,

Fort, Mumbai 400 001, INDIA. Tel.: 022-4037 3636, Fax: 022-4037 3635 E-mail: [email protected] AN ISO 9001:2008 CERTIFIED COMPANY

CHEMICAL ENGINEERING WORLD

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According to reports, due to ongoing infrastructure projects in the power generation, building services, metals, cement, water and wastewater, oil and gas, amongst others, the total Indian market for pumps and valves is expected to grow at a much faster pace than that of the rest of the world.

will contain technical articles on the specific usage of pumps and valves in process industry. The issue will highlight latest trends and technologies being accepted around the globe.

August 2013 Issue of Chemical Engineering World (CEW)

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ProductsCEW


SensoTech offers the inline analyzer LiquiSonic. The measuring system continuously analyzes the Plato, Brix or dry matter content. So not only the product quality is monitored in running the production process, but also the process can be resource-efficiently controlled. Based on the sonic velocity measurement, the LiquiSonic sensors determine the concentration in liquids and provides highly accurate, stable and in seconds updated measuring values.

The sensors are completely made of SS DIN 1.4571 and some sensor types are even available with 3-A-certification. As process connections various options are available, in which Varivent, Clamp or dairy flange are preferred in the food industry.

For details contact:SensoTech GmbHSteinfeldstr 1, D-39179 Magdeburg Barleben, GermanyTel: +49 39203 514100, Fax: +49 39203 514109E-mail: [email protected]

Inline Analysis of Ingredients



Particle Analysing System

The PAMAS SBSS particle analysing system is a tried and trusted consistent measuring instrument for laboratory particle counting. Using measuring data provided by fluid samples with known particulate contaminant, PAMAS has proved the repeatability of its particle counting systems.

The evaluations of these measurements clearly show that the results of different measurements of the same fluid sample scarcely deviate from one to the next.

Many renowned laborator ies appreciate the extremely high measur ing accuracy of PAMAS par ticle counters and in turn, manufacturers of conventional par t icle counters use the PAMAS SBSS par ticle analysing system as a reference for their calibration.

For details contact:PAMAS No: 203, I Floor, Oxford House#15 Rustam Bagh Main Road(Off HAL Old Airport Road)BengaluruKarnataka 560 017Tel: 080-41 15 00 39Fax: 91-080-41 48 01 71E-mail: [email protected] / [email protected]

Intellitect Water offers V2 Intellisonde (IV2) in-pipe water quality monitor, which offered new advantages; retained calibration data and improved chlorine measurement. Intellisondes feature a unique electrochemical configuration that eliminates the issues experienced by traditional sensors. In contrast, the Intellisonde chlorine sensor efficiently reaches equilibrium and operates over an extended lifetime compared with other equipment. The head of an Intellisonde is a mere 3.6 cm in dia, but fully populated can provide continuous water quality data for up to 12 parameters. Measurement options include free chlorine, mono-chloramine, dissolved oxygen, conductivity, pH, ORP/Redox, flow, pressure, temp, turbidity and colour. An ISE channel is also available for fluoride, nitrate or ammonium. No chemicals or membranes are necessary to operate or calibrate the Intellisonde sensors, and they are quickly and easily replaced at the end of their service lives. The reference electrode, chlorine and dissolved oxygen sensors are replaced after 6 months; pH/ORP and ISE after 1 year ; and conduct iv i ty sensor after 2 years.

For details contact:Intellitect Water LtdUnit 4, The QuadrangleAbbeyPark Indl EstateRomsey, Hants, SO51 9DL, UKTel: +44 (0)1794 834280

Chlorine Monitoring in Water with High Mn/Fe Salts



ProductsCEW


O v e n I n d u s t r i e s Ê 5 R 7 - 0 0 1 temperature controller creates a seamless transition between heating and cooling devices, as it serves as the commander of thermoelectric modules. With a bi-directional or unidirectional H - b r i d g e c o n f i g u r a t i o n , t h e temperature controller has many

benefits. The software also enables the temperature controller to operate as a stand-alone unit. A computer can also be connected to the device, for retrieving data. The 5R7-001 offers temperature setting and control through the remote potentiometer and the optional display. Delivering a load current of .1 to 25 Amps, the controller has several other features that make i t appeal ing, including being RoHS compliant, allowing for a set temperature range of -40 to 250 degrees Celsius, having a large program memory space for customization, being PC programmable and having 0-36 VDC output using a split power supply system.

For details contact:Oven Industries, Inc 5060 Ritter Rd, Bldg C, Suite 8Mechanicsburg, PA 17055, U.S.A.Tel: (717) 766-0721, Fax: (717) 766-4786 E-mail: [email protected] / [email protected]


Oven Industries, Inc offers wide variety of temperature sensor probes, from thermistors and thermocouples, to resistance thermometers.

From ensuring accuracy and ensuring that the high-quality sensor probes are easily integrated with other PID temperature controller systems, Oven Industries, Inc. is leading the way with temperature sensors. Sensors from Oven Industries, Inc have a tolerance of up to μ0.1 C. As a full-service temperature control solution provider, the company also has a complete selection of other temperature control products. Capable of meeting every industry requirement, each sensor available can be customized.

For details contact:Oven Industries, Inc 5060 Ritter Rd, Bldg C, Suite 8Mechanicsburg, PA 17055, U.S.A.Tel: (717) 766-0721Fax: (717) 766-4786 E-mail: [email protected] / [email protected]

Temperature Sensors

Temp Controller for Embedded Applications

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The new FHM 1000 Series, Bosch Packaging Technology offer semi-automated, modular laboratory devices for liquid pharma filling operations. The laboratory device ser ies currently consist of four

different modules, the Human Machine Interface (HMI), the filling module, the weighing module and the needle movement. All automation processes are operated from the HMI. The filling process with its filling needle movement and in-process control weighing are parameter sized via the HMI, whereas input and output of the containers is done manually.

The prototype operates with a peristaltic pump. Further filling modules are planned, for instance with a rotary slide piston pump. According to demand, the different fi l l ing systems can then be flexibly exchanged. The integration of a closing module is also planned, enabling containers to be equipped with different types of stoppers. A protective housing for both the fil l ing module and the needle movement ensure product and operator safety. All modules conform to the EU Machinery Directive 2006/42/EG.

For details contact:Robert Bosch GmbHPostfach 106050, D-70049 Stuttgar t, GermanyTel: + 49 711 811-58502, Fax: +49 711 811-58509

Automated Modular Laboratory Devices


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Events CEW


INTERNATIONALPetroWorld IndiaDates : 22 24 August 2013Venue : Bombay Exhibition Center (BEC), Mumbai, IndiaEvent : PetroWorld India is one of the biggest shows of its kind which will have participations from large number of exhibitors from different parts of the world from the petroleum sector. This event will help the exhibitors to do good deal of networking with the fellow exhibitors and it is expected that the participating companies will sign new trade agreements for better market access. As a part of this show, the exhibitors will also understand the local market well and according to the market trends, the exhibitors will be able to discover products and services.

For details contact:Inter Ads Exhibitions Pvt LtdPlot No.859, Phase-V, Udyog Vihar, Gurgaon-122 016, Haryana, IndiaTel: +91 124 452 4200/452 4201; Fax: +91 124 438 1162Email: [email protected], [email protected]: www.petroworldindia.com

ChemTECH South 2013

Dates : 10 12 October 2013Venue : Chennai Trade Centre, Guindy, ChennaiEvent : ChemTECH South 2013 w i l l be o rgan i sed from 10th to 12th October 2013 in Chennai Trade Centre, Guindy, India. The international exhibition will have display of state-of-the-art technologies, equipment, accessories and services from national and international players for various sectors. Concurrent International conferences - EPC Sourth, ChemPetro South, Industry Automation & Process Control South and WaterEX South will have deliberations on topical issues by industry leaders, experts and influencers, and offer high level networking opportunities to take the businesses to newer heights.

For details contact:Chemtech Secretariat26, Maker Chambers VI, Nariman Point, Mumbai 400 021Tel: + 91 22 40373737; Fax: +91 22 22870502Email: [email protected]; [email protected]

India Chem GujaratDates : 24 - 26 October 2013Venue : Mahatma Mandir Exhibition Centre, Gandhinagar, IndiaEvent : India Chem Gujarat will be held for three consecutive days in Gandhinagar. The attendees of this show will discuss about the reforms and regulatory mechanisms, research and development and export potential associated with chemical industry of India. This event will provide opportunity to the participants to establish new business collaborations and tie ups with potential clients. Conference, networking opportunities, product launches and one to one meeting with clients will be some of the highlights of this show. Dye chemicals, pesticides, paint and varnishes, construction chemicals, bio chemicals, reagent and colorants and fine ceramics are some of the important products which will be at displayed in this show. This event will provide an ideal platform for the participants to meet and interact with industrial leaders and key market players from chemical industry.

For details contact: Federation of Indian Chambers of Commerce & IndustryFederation House, 1, Tansen MargNew Delhi, Delhi, IndiaTel: +91 11 23738760/70; Fax: +91 11 23320714Website: www.indiachemgujarat.com

China International Chemical Industry Fair - 2013 Date: 04 - 06 September 2013Venue: Shanghai World Expo Exhibit ion and Convention Center, Shanghai, ChinaEvent: The sponsor of ICIF China is China Petroleum and Chemical Industry Federation (CPCIF), the former Ministry of Chemical Industry, and the former State Administration of Petroleum and Chemical Industry. The petroleum and chemical industry is essential for the development of national economy. CPCIF, as the only comprehensive association of this pillar industry, has committed itself to the mission of uniting ChinaÊs petroleum and chemical industry and facilitating its development. ICIF China is one of its major activities to encourage international exchange and cooperation.

For details contact:Canton Trade FairCCPIT Sub-Counci l of Chemical IndustryRoom - 456, Bldg. - 16, Block - 7, Hepingli, Beijing, 100013Tel: +86 10 64222898, 64272119, 84292988Fax: +86 10 84292180E-mai l : l [email protected]: www.ic i f.org.cn

Speciality & Agro Chemicals AmericaDate: 09 - 11 September 2013Venue: Hil ton Wilmington Riverside, Wilmington, USAEvent: Speciality and Agro Chemicals America will be held for a period of three days in Wilmington, United States Of America. This international trade show will make the leading experts related to animation, toys and games industry as well as the enthusiasts and collectors of the contemporary times aware of the modern techniques which will help in the improvement of this sector. Developmental changes which are taking place in this sector will also be highlighted in this event and will make this event more advanced.

For details contact:American Chemical Marketing809 Nor th Fairway Road, Glenside, PA19038Glenside, United States Of Amer icaTel: +1 215 882 9100Fax: +1 215 695 5520Email : [email protected]: www.chemicalsamer ica.com


Project UpdateCEW

New Contracts/Expansions/RevampsThe following list is a brief insight into the latest new projects by various companies in India.

CHEMICALS Macro Polymers Private Limited is planning to set up a 15,000 TPM synthetic resin manufacturing project at a cost of ` 250 million in village Chacharwadi, district Ahmedabad, Gujarat. Land acquisition is in progress. The project is waiting for clearances and is planned for completion on 1st April, 2014.

Sika India Private Limited is implementing a construction chemicals manufacturing project (water-proofing products) in Jhagadia GIDC, district Bharuch, Gujarat. As of June 2013, civil work is in progress and the project is scheduled for completion in September 2013.

Hindusthan Chemicals Company, formerly known as Cyanides & Chemicals Company, is planning an expansion of its sodium cyanide manufacturing project from 5,400 TPA to 12, 000 TPA in Olpad, district Surat, Gujarat. As of May 2013, the project is waiting for environmental clearance. Work on the project will commence in 2014 and is planned for completion in 2016.

Ardex Endura (India) Private Limited belonging to the Ardex Group, is planning a tile-fixing adhesive, flooring, water-proofing and allied products manufacturing project at a cost of ` 100 million in Aerotropolis, Asansol, distr ict Bardhaman, West Bengal. As of March 2013, the project is in planning stage and planned for completion in Q4 of 2014. The estimated land area is 3 acres.

Ricela Health Foods is planning a nutraceutical plant (oryzanol concentrate) in district Sangrur, Punjab. As of January 2013, the project is in planning stage. Work on the project is expected to commence in 2014.

KPR Fertilisers, belonging to the KPR Group, plans to manufacture dimethyl sulphate (50 TPD), linear alkyl benzene sulphonic acid (40 TPD), alum (ferric/non-ferric) (50 TPD) and chlorosulphonic acid (50 TPD) at a cost of ̀ 200 million in village Biccavolu, district East Godavari, Andhra Pradesh. Work on the project commenced in January 2013 and is planned for completion in December 2013. The unit currently manufactures 500 TPD single super phosphate, 800 TPD NPK mixtures, 30 TPD di-calcium phosphate and 300 TPD sulphuric acid and has a 3 MW co-generation power project.

Mohit Petrochemicals is implementing an ethyl acetate manufacturing project (50 TPD) in Nagina Road, district Bijnor, Uttar Pradesh. As of September 2012, civil work is in progress and the project is scheduled for completion in 2013.

JBF Industries is planning a 1.25 MTPA purified terephthalic acid manufacturing project in Mangalore, district Dakshina Kannada, Karnataka. As of August 2012, the land for the project acquired. The project will spread over 104 acres of land and is planned for completion in 2014.

MININGSri Venkatesh Granites is planning a colour granite mining project in district Karimnagar, Andhra Pradesh. As of December 2012, environmental clearance has been received. The project will come up on 4.56 hectares of leased area. Global Enviro Labs is the environmental consultant.

Western Coalfields is planning the Penganga open cast coal mining project (3 MTPA and peak capacity is 4.5 MTPA) on 781 hectares land in village Wirur, district Chandrapur, Maharashtra. As of November 2012, the project has been submitted in the 59th EAC (Thermal & Coal Mining Projects) meeting held on 6th November, 2012.

Central Coal Fields is planning the 0.3 MTPA Ray Bachra underground coal mining project in district Ramgarh, Jharkhand on 1,215.45 hectare land. As of September 2012, the project has been submitted in the 57th EAC (Thermal & Coal Mining Projects) meeting held on 17th September, 2012.

Rajasthan Rajya Vidyut Utpadan Nigam is planning the open cast Parsa East & Kanta Basan coal mining project (10 MTPA) and a coal washery (10 MPTA) in Udaipur, district Surguja, Chhattisgarh. As of August 2012, the project has been submitted in the 55th meeting of the EAC (Thermal & Coal Mining Projects) held on 28th August 2012.

Odisha Power Generation Corporation is planning the Manohar pur open cas t coa l m in ing p ro jec t in d is t r i c t Sundergarh, Odisha. As of July 2012, the company is wait ing for environmental clearance.

Chhattisgarh Mineral Development Corporation is planning ÂSondihaÊ open cast and underground coal mining project in distr ict Surguja Chhatt isgarh. As of July 2012, the company is wait ing for environmental and forest clearance.

Central Coalfields Limited plans expansion of its Churi Benti UGP coal mining capacity from 0.16 MTPA to 0.81 MTPA in district Chatra, Jharkhand. As of June 2012, MoEF clearance has been received and the project is planned for completion in 2 years from zero date.

Zain Coke & Energy India is planning a 150,000 TPA metallurgical coke manufacturing project at a cost of `450to ̀ 500 million in Chickanthapura, district Bellary, Karnataka. As of May 2012, The project is waiting for revenue and statutory clearance and is planned for completion in 10 months from zero date.

Calcom Cement India, belonging to the BK Group, is implementing the New Umrangshu l imestone mining project in vi l lage New Umrangshu, distr ict Dima Hasao, Assam. As of Apr i l 2012, the mining work wil l commence in 2013.


CEWProject Update

Stork Ferro & Mineral Industries, belonging to the Stork Group, is planning a 100 MW captive power project in India. As of December 2012, the project is in a conceptual stage.

Maharashtra State Power Generation Company is planning a 2 660 MW coal-based thermal power project near Manora, at Tiroda, district Gondia, Maharashtra. As of September 2012, preliminary activity for land acquisition is in progress.

SKS Power Generation (Madhya Pradesh), group company of SKS Ispat & Power, is planning a 2 660 MW super critical coal-based TPP in village Rahiwada and Amarwada, district Chhindwara, Madhya Pradesh. As of August 2012, the project is waiting for environmental clearance and is planned for completion in 1 year from zero date.

Jharkhand Sales Agencies is planning a waste heat recovery based thermal power project in village Marhand, district Hazaribagh, Jharkhand. As of April 2012, the project is in planning stage.

POWER GENERATIONSintex Power, belonging to the Sintex Group, is planning a 1,720 MW (1 400 MW gas-based and 2 660 MW coal-based) thermal power project in village Lunsapur, district Amreli, Gujarat. As of June 2013, the project is waiting for the Government approval and is planned for completion in 1 year from zero date. The estimated land area is 600 acres. The main plant will come up on 350 acres, 175 acres land will be for ash pond and 65 acres land will be for onsite utilities. 10 acres land will be required for staff colony. Another 50 acres of land will be required for laying 16 km long water pipeline corridor. The coal required for the plant will be 5.6 MTPA and will be imported from Indonesia and South Africa. 1.65 MMSCD natural gas will be supplied by GSPCL.

Manchukonda Agrotech is implementing a 5 MW biomass-based captive power project in district Raichur, Karnataka. As of April 2013, equipment suppliers are yet to be appointed. Civil work is in progress and the project is scheduled for completion in March 2014.

Heidelberg Cement India Limited is planning a 12.15 MW waste heat recovery-based power project at a cost of ` 1,450-1,500 million in Narsingarh, district Damoh, Madhya Pradesh. As of February 2013, the project is in planning stage and planned for completion in January 2015. The project has been approved by the Board. The plant will produce approximately 12.15 MW of power from available waste heat of pyro-processing system of all three clinkerisation lines at Narsingarh.

BGR Energy Systems is planning a supercritical boilers, turbines and generators manufacturing project in Madurantakam, district Kanchipuram, Tamil Nadu. As of November 2012, MoU has been signed with the Government of Tamil Nadu. The project will be executed in technical collaboration with Hitachi Japan and Hitachi Europe.

Jaiprakash Associates is planning limestone mining project in, village Kothar, district Satna, Madhya Pradesh. As of March 2012, the project is waiting for environmental clearance and the project completion date is yet to be finalized.

NON-CONVENTIONAL ENERGYFavorich Sugars, belonging to the Favorich Group, is planning a 15 MW bagasse-based co-gen power project in Krishnarajpet, district Mandya, Karnataka. As of January 2013, the company is waiting for land approval from Karnataka Industrial Areas Development Board. The project is waiting for financial closure and is planned for completion in 18 months from zero date. The state government had allotted 250 acres of land for the sugar project, distillery and mega food park.

Vishwanath Sugar & Steel Industries is planning to expand its bagasse-based co-gen power project from 39 MW to 64 MW in Bellad Bagewadi, district Belgaum, Karnataka. As of October 2012, environmental clearance has been received and the project is planned for completion in 18 months from zero date. The project is coming up in the existing plant premises.

Green Planet Energy Private Limited is planning a 11 MW biomass-based IPP in village Bir Pind, district Jalandhar, Punjab. As of July 2012, 30 acres of land for the project has been acquired. The project is awarded by Punjab Energy Development Agency on BOO basis. PPA has been signed with the Punjab State Electricity Board. Work on the project commenced in October 2012 and is planned for completion in the first quarter of 2014.

NON-CONVENTIONAL POWERIPL Sugars & Allied Industries, a group company of Indian Potash, is planning a 20 MW bagasse and rice husk-based IPP spread over 250 acres of land in village Motipur, district Muzaffarpur, Bihar. As of March 2012, the existing plant will be demolished and the new plant will be constructed. The project is planned for completion in 1 year from zero date.

Tathagata Bio Energy Private Limited plans to set up 12 MW biomass power plant in Gaya, Bihar. As of May 2011, work on the project is under planning stage.

THERMAL POWERJayaswal Neco Industries Limited is planning a 50 MW waste heat recovery-based independent power project in villages Dagori, Ameri Akberi and Udgaon, district Bilaspur, Chhattisgarh. As of February 2013, public hearing for the project is over. MoU is yet to be signed with the State Government. The project is waiting for environmental clearance and is planned for completion in 20 months from zero date.

Universal Crescent Power, belonging to the USE Group, is planning the 3-phase Saurashtra Super Thermal Power project in village Bhatvadia, district Jamnagar, Gujarat.

CEW Ad Index


1 A t o m i c Va c u u m C o m p a n y ( E x p o r t s )

Inside Cover I

2 Boerger Pumps Asia Pte Ltd 35

3 Chempro Technovation Pvt Ltd 76

4 Chemtech South 2013 47

5 Chemtech World Expo 2015 65

6 Cole-Parmer 55

7 D Parikh Engineering Works 27

8 De Dietrich Process Systems India Pvt Ltd 19

9 Dip-Flon Engineering & Co 7

10 Emjay Engineers 53

11 Everest Blowers 43

12 Evergreen Technolgies Pvt Ltd 13

13 Fenix Process Technologies Pvt Ltd 37

14 Filterfab 57

15 Gopani Products Systems 55

16 Grundfos Pumps 17

17 Heidelberg ProMinent Fluid 59

18 Hitech Applicator 9

19 HRS Process Systems Ltd 5

20 Kevin Enterprises Pvt Ltd 23

21 Khosla Profil Pvt Ltd 53

22 Kirloskar Brothers Ltd Inside Cover II

23 Kwality Process Equipments 3

24 Mazda Ltd 61

25 Mist Resonance Engg Pvt Ltd 31

26 PSA Nitrogen Back Cover

27 Pumps, Valves & Fittings South 2013 49

28 Raj Process Equipments & Systems Pvt Ltd 15

29 RG TexIn Manufacturing Company Pvt Ltd 59

30 Sachin Industries 29

31 Samarth Engineers 63

32 Scaleban Equipments Pvt Ltd 33

33 Seal Excel (India) Pvt Ltd 57

34 Sharplex Filters (India) Pvt Ltd 25

35 Shree Ganesh Process Equipments Pvt Ltd 11

36 Suraj Ltd 59

37 Transflow Asia 57

38 Uni Klinger Ltd 45

39 USP Trading & Manufacturing Pvt Ltd 39

Sr No Client’s Name Page No Sr No Client’s Name Page No


CEWBook Shelf

Solid/ Liquid Separation: Principles of Industrial Filtration

Authors : J D Seader, Ernest J Henley, D Keith RoperPrice : USD 173.18Pages : 848 [Paperback] Publisher : Wiley

Separation Process Principles

Authors : Stephen Tarleton, Richard Wakeman

Price : USD 313.50Pages : 340 [Hardcover] Publisher : Elsevier Science

About the Book : Solid/Fluid separation is a major element in the processes performed in pharmaceutical, food, beverage, water, and pulp & paper industries. Several books now exist on the more esoteric aspects of the techniques, but accounts of the fundamental principles involved are few. Written by two well-known chemical engineers, this book reviews the scientific and engineering bases for solid/fluid separation processes in an approachable style. Coverage focuses on fluid dynamics, gravity, centrifugal & membrane separations, filter cake formation, de-liquoring and washing.

Complete with an extensive bibliography to allow readers to pursue topics in greater depth. This book will Help readers to understand how filtration processes work, Facilitate the application of knowledge to start-up and existing processes, helping readers to improve process performance, and Help ensure your equipment is appropriate for its purpose and is working optimally, saving time and money.

Another volume currently available from the set is Wakeman & Tarleton: Solid/Fluid Separation Processes: Equipment Scale-up for Liquid Filtration ISBN: 185617 4204.

Separation and Purification Technologies in Biorefineries

Treatment of Tannery Effluents by Membrane Separation Technology

Authors : Sirshendu De, Chandan Das, Sunando DasguptaPrice : USD 89.00Pages : 156 [Hardcover]Publisher : Nova Science Pub Inc

About the Book : Tannery is one of the most polluting industries. In order to recover the process water and costly chemicals, membrane based processes can be effectively used to treat the effluent emerging from each of the tannery units. This book presents a systematic and comprehensive study to develop a greener route to treat such effluents. It is to be emphasised that no such book dealing with application of membrane filtration in tannery waste exists currently. Therefore, this book obviously has significant advancement compared to existing books on membrane technology. This book will have two fold impacts. Firstly, its academic value is quite high; secondly, it will have remarkable impact of scaling up such system in actual industrial scale from pilot plant data in an emerging area.

Editors : Shri Ramaswamy, Huajiang Huang, Bandrau RamaraoPrice : USD 160.93Pages : 608 [Hardcover]Publisher : Wiley

About the Book : Completely rewritten to enhance clarity, this third edition provides engineers with a strong understanding of the field. With the help of an additional co-author, the text

presents new information on bioseparations throughout the chapters. A new chapter on mechanical separations covers settling, filtration, and centrifugation, including mechanical separations in biotechnology and cell lysis is also incorporated. Boxes help highlight fundamental equations. Numerous new examples and exercises are integrated throughout as well. In addition, frequent references are made to the software products and simulators.

About the Book : Separation and purification processes play a critical role in biorefineries and their optimal selection, design and operation to maximise product yields and improve overall

process efficiency. Separations and purifications are necessary for upstream processes as well as in maximising and improving product recovery in downstream processes. These processes account for a significant fraction of the total capital and operating costs and also are highly energy intensive. Consequently, a better understanding of separation and purification processes, current and possible alternative and novel advanced methods is essential for achieving the overall techno-economic feasibility and commercial success of sustainable biorefineries.


InterviewCEW

All’s Well That Ends Well

Talking exclusively to CEW, P N Prasad, Managing Director, Brahmaputra Cracker & Polymers Ltd (BCPL), informs that the project has already achieved 93 per cent of physical progress. He shares insights into the project and how commissioning of the cracker will transform the socio-economic conditions of the North Eastern region of country making it a much sought-after destination for the plastic processing industry.

Please apprise us of the current status of the gas cracker project? As on 15th of July the gas cracker project has already achieved overall physical progress of around 93 per cent against the cumulative target schedule of 99.8 per cent. Approximately 99.2 per cent of manufacturing and delivery has been completed. We have achieved 100 per cent completion of site development jobs and infrastructure development and major parts of civil and structural works for complex are nearing the completion stage. Mechanical works are going on in full swing and we have already erected 857 out of total 1091 number of equipment for the cracker project.

As approved by CCEA, the project will attain mechanical completion by July 2013

and the commissioning by December this year. We have already started pre-commissioning and commissioning activities for gas dehydration unit at Duliajan plant, 48 KMs (18‰) Duliajan-Lepetkata gas pipeline, utilities and offsites, 56 MW Captive Power Plant and Gas Sweetening/C2+ recovery unit at Lepetkata.

Has BCPL evaluated the cost escalation factors and its impact on overall project economics? How are you raising the extra funds required for project completion?Detailed Feasibility Report (DFR) of BCPL was prepared in 2005 based on the costs prevailing in the same year and in-house data available with Engineers India Ltd (EIL); however, based on the project, the requirements were made

in the year 2008. Time escalation, technology and design changes, and increase in power requirement, statutory variation in Wholesale Price Index (WPI) and taxes are the major factors that have contributed to escalation of project cost.

There is no cost overrun on the revised project cost and BCPL has evaluated the cost escalation factor in consultation with EIL. And after considering the escalation, extra work and forex fluctuation etc. till scheduled project commissioning, the project is expected to be within approved revised cost of the project.

The funds required for the project on the basis of revised cost have been arranged through equity,


CEWInterview

capital subsidy and debt as per approved means of finance. The debt component of the project cost has been arranged in a mix of term loan from banks by open competitive bidding and Oil Industries Development Board (OIDB) and one ofthe promoters.

May we have your comments on the factors that have affected timely completion of the project, especially the shortage of manpower? The cracker involves modern engineering and latest state-of-the-art technologies that require highly skilled manpower for construction. Moreover, being a socio- economically under developed part of the country, there is always a shortage of required quality as well as quantity of manpower which is one of the prime reasons for the delay. But the backlog in the construction progress is not only because of lower output by contractors and contract labour engaged for the project but also due to various other reasons. Adverse weather conditions, frequent bandhs, strikes and festival holidays added to slowdown in pace of project execution. As on 30th June 2013, the project has lost 288 days due tothese reasons.

How has the delay in project impacted the subsidies and the tax exemption offered for Government project? Both the economic parameters, the Investment Return Ratio (IRR) and Debt Service Coverage Ratio (DSCR) can be maintained mainly in view of subsidies and tax exemptions offered by the Government and there are no changes because of the delay in project execution. Being a public sector company, we are committed to follow all the tendering and procurement guidelines as mandated by the Indian Government. However, the performance of various contractors appointed by BCPL was not up to the mark.

How did BCPL manage the Over Dimensioned Consignments (ODC)? Beforehand action in terms of extensive route survey, selection of route and adequate logistics planning helped overcoming the hurdles and all ODC assignments for the project have safely landed at the project site. Only surface transport for ODCs was undertaken for the project.

Which products will be manufactured at the facility once the production is on-stream? Once commissioned, how will the project change the market dynamics? Are there plans to export a part of production? BCPL will produce 2,26,000 TPA of Linear Low Density Polyethylene (LLDPE) and High Density Polyethylene (HDPE); and 60,000 TPA of Polypropylene (PP). Availability of polymer will induce growth of new downstream plastic processing industries in the region and generate employment avenues, trade and commerce in the region, thus increasing economic activities in the region. The polymer can be further used by the downstream plastics processing units to manufacture various products such as films, raffia bags, household items, plastic furniture, blow moulded containers etc. GAIL owns the rights for selling the products and is expected to sell the polymer in the North Eastern region itself. However, GAIL intends to supply 10 per cent of production to neighbouring countries subject to the demand.

What value will the project add to the North-East region in terms of employment potential and economic development? The main spirit behind setting up of this gas cracker project in Assam is to improve socio-economic conditions of North East Region. Presently, consumption of plastic in Assam is 1-2 Kg per capita which is far less than the national average of 7 Kg per capita. As plastic market is supply driven, it is expected that consumption of plastic products will increase many folds with commissioning of this project. The project will supply feedstock to the downstream plastic processing industries, and availability of raw material will encourage setting up of many downstream industries thus resulting in creation of ample job opportunities in plastic industries in the region. Assam Government has also taken initiative to set up plastic park at Gelapukhuri, Tinsukia with a view to provide all necessary assistance to set up industrial ventures.

Currently, BCPL has 273 employees on BCPLÊs pay roll and on the average, around 500 labourers are deployed daily by various contractors at the project site at Lepetkata. 90 per cent of these daily wagers are from the local region. BCPL will offer direct employment to around 630 and many

more through outsourced jobs in various areas such as housekeeping of township, bachelorÊs hostel, guest houses, canteen, transportation, loading and unloading, maintenance of civil and electrical works etc. It may be difficult to give any exact numbers for the employment potential. Apart from employment generation, the commissioning of project envisages enhancing commercial activities in the adjoining areas thus contributing towards the economic development of local populace and accelerating the growth of the region.

What are your future plans if BCPL intends setting up further downstream processing units? As of now we do not have any plans to expand downstream into plastic processing. However, it has been estimated that up to 500 plastic processing units can come up in the North Eastern region once the cracker goes on stream. And the project is expected to give rise to direct/indirect employment generation as a result of investment in downstream plastic processing industries and allied activities.

May we have your comments on the role of BCPL in the planned plastic parks?Assam Industrial Development Corporation (AIDC) is setting up the plastic park and requested BCPL for equity contribution of ̀ 25 crore for the planned project in Tinsukia district of state. However, the decision is pending as the BCPL board is mulling over this and will take the call only after a detailed analysis.

What are the various CSR activities undertaken by BCPL?Currently, BCPL is at the stage of project implementation and not making any profits. Notwithstanding this, we have continued our CSR initiatives aimed at developing the nearby areas. BCPL formulated its CSR policy in the year 2010 and has been implementing various schemes from the same year in Dibrugarh district in the fields of infrastructure, community development, education and literacy enhancement; healthcare, medical and sanitation etc. The CSR projects undertaken so far include building classrooms at Moran Blind School and rooms at urban dispensary, construction of roads, installation of transformers and augmentation of power supply and Sulabh toilet complex.



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Chemical Engineering World July 2013