Chemical & Process World July 2013

ChemiCal & ProCess World July 2013

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Editorial

July 2013 | ChemiCal & ProCess World | 7

indian chemicals and petrochemicals industry has been one of the prime contributors to the national economy since decades. With an annual turnover exceeding $ 100 billion and nearly 70,000 units in the country, this sector is estimated to account for nearly one-eighth of India’s industrial production and one-sixth of the country’s manufactured goods export.

Of late, some of the megatrends visible in this industry include the following. While the domestic market still has several high-growth opportunities in store, there has been a surge in the intensity of competitive headwinds both from imports as well as global majors foraying into India by having their manufacturing footprint here. These are accompanied by an incessant focus on lowering costs and increasing throughput by deploying various means & measures.

Amid this fast-emerging global paradigm, the Indian chemical sector seems to be losing steam and descending from its earlier peaks as far as growth is concerned. The present level of growth witnessed over the recent times is nowhere close to the earlier highs of 15 per cent per annum (pa). Not surprisingly, the sector’s contribution to GDP has come down to 1.9 per cent from 2-3 per cent earlier.

The big question facing the industry today is how it can steer clear of this rising storm and

head into clear horizons of profitable prospects. While the answer would entail successfully leveraging the high-growth domestic market in an increasingly competitive scenario, the time has come for Indian chemical companies to put in practice indigenous strategies befitting their growth objectives and areas of operation(s).

In these circumstances, the government’s plan to introduce a new chemical policy soon is a welcome step. According to top official sources in the Department of Chemicals and

Petrochemicals, the policy is intended to provide a push to the chemical sector. It is reported to cover all aspects of the industry including imports, exports, patents, R&D, innovations as well as basic and specialty chemicals,

knowledge-intensive technologies, etc. Hopefully, this new policy will act as

a catalyst to drive the growth of Indian chemical industry at 11 per cent pa as against the current rate of about 5 per cent. In this process, one can be optimistic of seeing the country’s production levels return to the order of above ` 3 lakh crore.

Suffice to say, this should give rise to new entrepreneurs in this space as well as formulate a comprehensive roadmap for the country with short-term and long-term strategic perspectives in tow.

editorial advisory Boarddr Kishore shah Chairman and Managing Director, Sauradip Chemical Industries Pvt Ltd

dr P d samudra Executive Director - Sales and Member of the Board, Uhde India Pvt Ltd

Pratik Kadakia Principal, Roland Berger Strategy Consultants Pvt Ltd

ravi Kapoor Managing Director, Heubach Colour Pvt Ltd, and Chairman – Gujarat Chapter, Indian Chemical Council

sunil Chaudhari Country Manager - South Asia, AspenTech India

Manas R [email protected]

The time has come for Indian chemical companies

to put in practice indigenous strategies befitting their growth objectives and areas of operation(s)

Policy imperative for propelling growth

8 | ChemiCal & ProCess World | July 2013

Cover story .......................................................................................................22

editorial ......................................................7Policy imperative for propelling growth

News, Views & analysis................................ 12Technology & innovation ............................... 16Technology Transfer............................... 18Projects ................................................... 64

Tenders .................................................... 65event list ................................................. 66Book review .............................................. 71

Products............................................. 72

list of Products .................................... 82list of advertisers ................................. 83

Cover photo: Joshua Navalkar; Location courtesy: MicroChem Silliker Pvt Ltd, Mahape (Navi Mumbai)

Recent investments in applications and research labs by both domestic and overseas specialty chemicals companies in India clearly indicate the enormous potential the Indian market offers to this sector. It is time to take the plunge to make the most out of the emerging opportunities.

in Conversation With“We need to prove that we are

responsible stakeholders”

20

Shrikant KulkarniCountry Manager - Specialty Chemicals,

Akzo Nobel India

r&d in specialty chemicals: evaluating the promising prospects

User-industry monitor .................................. 50Textile industry: adding new colours to dyes and pigments sector

automation Trends ...................................... 52iT in logistics: Facilitating smooth and seamless transportation

sustainability mantras ................................. 54Bio-refining: Combining profitability with environmental benefits

Policies & regulations ................................. 56Chemical clusters: Yet to make a difference!

strategy ................................................... 58management degree: is it a necessity in chemical sector?

Tips & Tricks ............................................. 60Personal protective equipment: Practical guidelines for right selection

l engineering expo hyderabad 2013: invoking the ‘andhrapreneurial spirit’ for industrial leap ..............68l engineering expo hyderabad 2013 - Panel discussion: is hyderabad ready for the industrial leap? ..............70

eVeNT rePorT

CoNTeNTs


Facility Visit ......................................................................................................36

CoNTeNTs

61

details on : page no. 62-63, 66

Kirloskar Brothers ltd: Pumping in process efficiency for high productivity

SpecIal FocuSsupply Chain management for Chemicals

Chemical sCm ...................................28Global megatrends bolstering logistics strategies

reducing carbon footprint ....................30leaving a green mark on supply chain

Chemical manufacturers .......................32Strategic moves to attain supply chain efficiency

supply chain dynamics .........................33on the transformation mode

roundtable........................................34How important is logistics efficiency to the Indian chemical industry?

InSIGHt & outlookPetrochemicals

Petrochemicals ..................................40plastics fuelling high demand

Petrochemical processing .....................42Inherent safety approach for a safer tomorrowP Vijayaraghavan, former Site President in the Dahej (Bharuch) and Baroda units, Reliance Industries Ltd

detergent market ................................44Surfactants adding to the bubbly prospectsPiyush Agrawal, former VP (Corporate Affairs), Advance Surfactant India Ltd

Gas analysers ....................................46effective tool to monitor air quality

r&d ................................................48triggering innovation for better returnsDr Mosongo Moukwa, Vice President - Technology, Asian Paints Ltd

Special Focus: Safety, Health & Environment Insight & Outlook: Bulk/Base Chemicals

highlights of Next edition

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

SUPPLY CHAINMANAGEMENT

FOR CHEMICALS

Trade exposition on chemical & process

industry

27 39


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News, Views & Analysis


Sachin Industries inaugurates its second unit

The Ahmedabad-based Sachin Industries Ltd, manufacturer of filtration equipment, has inaugurated its second unit in Mehsana district of Gujarat. The new plant will manufacture glass-lined reactors under the brand name SILGLAS. The facility is spread over one lakh square metre and the production capacity, at present, is 60 reactors per month.

Speaking about the new venture, Sachin K Patel, Managing Director, Sachin Industries Ltd, said, “After rigorous R&D, we decided to enter into the field of glass-lined reactors. The main reason for entering into this segment was to fulfil the demand-supply gap as there are only few companies manufacturing this product.

This had been leading to other problems such as late deliveries. Thus, through this initiative, we would be able to help our customers in terms of timely deliveries.

The facility was inaugurated by Shankerbhai R Patel, Senior Vice-President, Gujarat Chamber of Commerce & Industries, who was the Chief Guest for the event. The Guests of Honour included Satish Wagh, Chairman, CHEMEXIL and Umakant Bijapur, General Manager-North Gujarat Zone, Bank of Baroda.

Avani Jain

ProCess equiPment

sachin industries inaugurates manufacturing unit for glass-lined reactors

Clariant, a world leader in specialty chemicals, has opened a Leather Excellence Centre in Ranipet, Chennai. It is a major investment by the company in its leather business, and a strong indication that the company’s Leather Business Unit sees huge opportunities for continued growth in the Indian leather manufacturing sector. “We are committed to the long-term development of our products and services for India’s leather sector. We see the country’s leather-related businesses growing, and we expect an above average growth for our products and services. We are looking for double-digit growth of the business in India,” stated Oliver Kinkel, Head-Global Leather Business Unit, Clariant.

Clariant already has major production sites at Kanchipuram, Tamil Nadu, and at Roha, Maharashtra. Ranipet was chosen for the development of the new Leather Excellence Centre as it is perfectly positioned to enable Clariant to provide the central application laboratory and technical services for the whole country and especially across southern India. Dr Deepak Parikh, Vice Chairman & Managing Director, Clariant Chemicals (India) Ltd, said, “As one of India’s leading specialty chemicals business, we are committed to sustainable and innovative growth in India.”

leather Centre

Clariant opens new leather excellence Centre in Chennai

In a strategic move, Oil India Ltd (OIL) is set to acquire 49 per cent equity in Assam Petrochemicals Ltd (APL), credited to be the first company in India to manufacture petrochemicals using natural gas as feedstock. A deal with the Assam Government, which holds majority stake in the company through Assam Industrial Development Corporation Ltd (AIDC), is likely by October 2013.

The Assam Government currently holds 88.2 per cent stake in the AIDC, while

domestic institutions and others hold the remaining stake. The Union Government-controlled OIL would bring in the much-needed equity infusion of about ` 230 crore in the company. It will also partly fund ` 1,030-crore investment in building a new petrochemical plant at Namrup in Assam. OIL already has stakes in Brahmaputra Cracker and Petrochemicals Ltd (BCPL), a joint venture with GAIL India, the Assam Government, and Numaligarh Refinery Ltd.

mergers & aCquisitions

oil india ltd to acquire 49 per cent equity in assam Petrochemicals ltd

uhde india certified Bs ohsas 18001 and iso 14001Uhde India has been certified under BS OHSAS 18001:2007 and ISO 14001:2004. The certifications – which were carried out by TUV India, the certification agency functioning aegis of TUV Nord of Germany – are valid up to June 2016. The BS OHSAS 18001 certification certifies that Uhde India has in place an Occupational Health & Safety System. The ISO 14001 certification certifies Uhde India‘s Environmental Management System.

technip awarded services contract for a new petrochemical plant in ChinaTechnip was awarded a services contract by BP Zhuhai Chemical Company Ltd, a joint venture between BP and Zhuhai Port Co Ltd, for the execution of a new world-scale Purified Terephthalic Acid (PTA) plant at their Zhuhai site in the Guangdong Province, China.

lux research predicts key semiconductors for solar inverters Lux Research has predicted that wide bandgap semiconductors – specifically, silicon carbide (SiC) and gallium nitride (GaN) – will lead the charge as the market for solar inverter discrete devices grows to $1.4 billion in 2020, driven by the downstream demand for solar modules.



Tata Chemicals team felicitated with Unilever’s ‘Partner to Win’ Award for Winning Sustainability

Recognising Tata Chemicals’ effort in aiding Unilever to significantly reduce the environmental impact of laundry powders and their business association to create traceability for mined chemicals, the company was conferred with the prestigious Unilever’s ‘Partner to Win’ Award for Winning Sustainability.

The award is a testimony to the synergistic relationship between Tata Chemicals and Unilever, which drives consistent sustainable growth and responsible care. R Mukundan, Managing Director, Tata Chemicals, stated, “At Tata Chemicals, our corporate philosophy is deeply rooted in the principles of sustainability, which implies a commitment to environmental stewardship while adding economic value. Our partnership with Unilever further endorses this and to get an award for the same is gratifying and enabling. We thank the team at Unilever for encouraging best practice initiatives across various fields of business and look forward to our continued association.”

reCognition

tata Chemicals bags unilever’s sustainability award

Honeywell recently released its new range of refrigerants in air-conditioning applications. The Indian modern retail industry will hugely benefit from this launch. “For modern retail industry, Honeywell has commercialised and successfully launched Performax LT, which can replace R404A and R22 in modern supermarkets for commercial refrigeration applications. Honeywell has worked with leading supermarkets in Europe and USA to replace R404 and R22 with Honeywell Performax LT and these supermarkets have benefitted from lower carbon footprint (in terms of lower Global Warming Potential of the refrigerant) and also increased energy savings, as Honeywell Performax LT has demonstrated lower energy consumption Vs R404A that is currently used,” said Paul Sanders, Managing Director, Honeywell Fluorine Products in Europe, Middle East, Africa and India.

Mahua Roy

reFrigerants

honeywell develops solutions to aid modern retail industry

Libra Techcon Ltd (LTL), the Mumbai-based EPC company, announced that it was recently selected by Godavari Biorefineries and Gulf Stabilizers Industries (GSI) as its Detailed Engineering consultants for their upcoming projects. The projects were awarded in June 2013 and are likely to be completed by early next year. GSI, a joint venture company between Zamil Group Holding Company, Middle East’s

leading manufacturing company, and Chemtura Corporation, has entrusted LTL with the task of providing Detailed Engineering for their upcoming chemical expansion project. Besides, LTL has been selected as an EPCM consultant for the project of Godavari Biorefineries Siddharth Wazir, Director, Libra Techcon Ltd, said, “These orders will help us to further establish our footprint in the Indian and global market.”

ePC ContraCt

libra techcon ltd receives contracts from india and saudi arabia

invensys acquires SmartGlance softwareInvensys, a focussed supplier of industrial software, systems and control equipment to the world’s major industries, has acquired the SmartGlance mobile reporting product of Sarla Analytics, LLC, a part of the Sarla Group of software companies, headquartered in Barrington. Sarla Analytics’ mission is to leverage the power of enterprise mobility to increase productivity, reduce costs and streamline operations.

Clariant invests in indiaClariant Chemicals (India) Ltd (CCIL) recently announced an investment of ` 38 crore in its pigments business at its Roha site, Maharashtra. The investments also include the construction of a new pigment plant at Roha that will double the plant’s capacity.

atlas Copco introduces 3 ranges of nitrogen and oxygen generatorsRecently, Atlas Copco introduced three ranges of nitrogen and oxygen generators for on-site gas generation. With these innovative gas generators, companies can expand their existing compressed air installation to generate their own nitrogen and oxygen. An independent supply of on-site gas can realise significant economies of scale as well as save on operational costs. The new range of on-site gas generators are designed to meet the highest purity standards and run economically for both large and small applications.

Considerably reshaped by pending regulations, and despite persistent Eurozone economic uncertainty, the specialty biocides market in Europe is expected to grow by 2.1 per cent over the next five years, according to Kline’s recently published report ‘Specialty Biocides: Regional Market Analysis’. While several segments in the US specialty biocides market are likely to see over 6 per cent volume CAGR, China and India, albeit growing from smaller bases, hold even greater promise. The European specialty biocides market in applications covered by Kline’s report generated an estimated Euro 569 million in revenues through 2012, with market volumes of approximately 1,12,000 tonne.

market ForeCast

kline publishes its new report ‘specialty Biocides: regional market analysis’



The 63rd Annual General Meeting of the Dyestuffs Manufacturers’ Association of India (DMAI) and the awards presentation function were recently held in Mumbai. Dr Anil Kakodkar, Ex- Chairman Atomic Energy Commission of India was the Chief Guest. Indrajit Pal, Secretary, Department of Chemicals & Petrochemicals,

Ministry of Chemicals & Fertilisers, Government of India, was the Guest of Honour. More than 100 members of the Association, special invitees, and other dignitaries attended the meeting.

Janak Mehta, President, DMAI, welcomed the members, while presenting the Annual Report for the 2012-

2013. Jitendra Patel, Hon Secretary, DMAI, highlighted the various activities of the association. Mehta, in his address, highlighted the problems faced by the colourant industry.

Pal said that the colourant industry is instrumental in adding value to the final products in industries such as textile, leather etc.

annual general meeting

63rd agm for dmai held in mumbai

BASF, Cargill and Novozymes announced 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) on pilot scale. The 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. “3-HP is a potential key raw material for the production of bio-based acrylic acid, which is a precursor of superabsorbent polymers. We still have a fair amount of work to do before the process is commercially ready, but this is a significant milestone, and we are confident that we can continue to the next level of scale-up for the entire process in 2014,” said Teressa Szelest, Senior Vice President, Global Hygiene Business, BASF.

Acrylic acid is a high-volume chemical that feeds into a broad range of products. BASF is the world’s largest producer of acrylic acid and has substantial capabilities in its production and downstream processing.

neW milestone

BasF, Cargill and novozymes achieve milestone in bio-based acrylic acid process

arC releases process automation study A new ARC global market research study reveals that the market for process Input-Output (I/O) module sales showed growth in 2012, though at slower pace than in the previous two years. In 2013, ARC expects the growth to stay at a low level, but will pick up pace in 2014 and beyond. The market for process I/O modules is mainly driven by two forces: an increasing need for intrinsically safe I/O modules and the increasing demand from the Middle East and the BRIC countries.

linde to invest $ 200 million for asu in texas facilityThe Linde Group will invest more than $ 200 million to build a state-of-the-art Air Separation Unit (ASU), a new gasification train and supporting equipment and facilities in La Porte, Texas. The project is scheduled to come onstream in 2015. The ASU will be the largest unit operated by Linde in the US.

WaCker appoints new distributor in Poland WACKER, the Munich-based chemical company, has reorganised its distribution network for its BELSIL brand silicone products for personal care applications in Poland. Effective July 1, 2013, the Dutch IMCD-Group-affiliated chemical distributor IMCD Polska has replaced the previous distribution partner Brenntag Polska.

Praj, a global process engineering solutions provider, offers innovative solutions to significantly add value in water and wastewater treatment plants, bio-ethanol and brewery plants, critical process equipment & systems.The company has received its second repeat

order for Zero Liquid Discharge (ZLD) application from the Common Effluent Treatment Plants (CETPs) based in Tirupur textile belt. The first two orders were from Veerapandi Textile CETP and the third one from Sirupooluvapatti CETP, Tirupur, Tamil Nadu.

Successful operation of first ZLD system at Veerapandi CETP, Tirupur, led to the repeat order. Praj successfully commissioned a 100 kilolitre per day ZLD system based on multieffect evaporation technology at Veerapandi, Tirupur. The entire plant was designed, engineered, fabricated and erected by Praj on turnkey basis.

rePeat order

Praj receives repeat order for zero liquid discharge solutions



Kemira has signed an agreement to acquire 3F Chimica SpA (3F), a privately owned company, headquartered in Sandrigo, Italy, excluding certain part of their assets in the US, for Euro 85 million. The acquisition is subject to fulfillment of certain conditions, and closing of the transaction is expected in the fourth quarter of 2013.

3F produces dry and emulsion polyacrylamide polymers and related process chemicals. Their polymer production is supported by

backward integrated key intermediates, such as bio-acrylamide and cationic monomers. The acquisition includes two manufacturing sites in Italy (San Giorgio and Sandrigo) and one manufacturing site in USA (Aberdeen, Mississippi).

“The acquisition of 3F accelerates our strategic plan and secures our position as a leading global polymer producer. It also supports Kemira’s future growth by providing additional polymer capacity and by enabling

us to close technology gaps in monomer and polymer production in Europe and the US,” said Randy Owens, President-Oil & Mining and Region Head (North America), Kemira.

Polymers are forecast to grow above-the-market and are highly synergistic with Kemira’s other differentiated process chemicals. Besides the strong strategic fit, the transaction is expected to result in substantial synergies through raw material, logistics and fixed cost savings.

Water ChemiCals

kemira oyj to acquire 3F Chimica spa, italy

Aker Solutions has delivered the steel frame for the world’s first subsea gas compression facility to be installed at the Statoil-operated Åsgard field. The installation, set to come onstream in 2015, will enable the recovery of an additional 280 million barrels of oil equivalents.

The 1,800-tonne steel frame will be installed on the Åsgard field seabed to form the base of the

world’s first subsea gas compression facility. It is the largest template manufactured by Aker Solutions, measuring 74 metre in length, 45 metre in width, and 26 metre in height.

“The Åsgard project is a game changer for the entire industry. The technology has the potential to change offshore gas field developments worldwide and I am pleased that we have delivered this part of the project on schedule,” said Per HaraldKongelf, Regional President, Aker Solutions, Norway.

Reservoir pressure at gas-producing fields drops over time, reducing output. Gas compressors are used to raise the pressure and extend the life of a field. Such compressors have typically been installed on platforms over sea level.

ePC ContraCt

aker solutions delivers Åsgard template to statoil

Honeywell has concluded a three-day Asia-Pacific Channel Conference to recognise the contribution of its partners to its regional process solutions business. More than 100 business partners from India, China, Korea and Southeast Asia attended the annual conference, which focussed on the importance of mutual growth and success for Honeywell and its partner community.

The conference featured sessions on new initiatives, best practices and channel

management programmes for 2013. Awards were presented in four categories: Regional Partner of the Year 2012, APAC Line-of-Business (LOB) Partner of the Year 2012, APAC Emerging Partner of the Year 2012 and APAC Channel of the Year 2012. The winners were chosen on the basis of their overall business achievement in 2012, customer service track-record and compliance with various commercial, legal and contractual commitments while dealing with Honeywell.

ConFerenCe

honeywell recognises performance achievements of asia-Pacific Channel Partners

thyssenkrupp uhde and Bayer launch new technologyA new technology from ThyssenKrupp and Bayer, which was commercially launched worldwide, enables the production of chlorine with significantly less electricity. Its widespread use would enable economically significant savings of energy. The new Oxygen Depolarised Cathode (ODC) technology is used for the electrolysis of table salt, by which means 95 per cent of all chlorine is produced.

Clariant launches ingredients for homecare productsClariant, one of the global leaders in specialty chemicals, launched TexCare SRA 300 F – an innovative soil release polymer for powder detergents that removes stains and helps keep fabrics clean and white. According to the company, the product matches consumers’ preference for convenience from their laundry experience.

technip awarded contract for a new calcination unit in abu dhabiTechnip has been awarded a significant contract comprising technology, engineering services and supply of core equipment for Abu Dhabi Oil Refining Company – Takreer’s new coke calcination unit. This new unit is part of the Carbon Black & Delayed Coker project being implemented adjacent to Takreer’s existing Ruwais refinery located in the UAE.

Technology & Innovation


ameTeK Process Instruments, a leader in online analytical instrumentation, has introduced the next-generation in close-coupled extractive combustion analysers with the launch of the Thermox WDG-V combustion analyser for measuring oxygen, combustibles and methane levels in hot, wet flue gas.

The WDG-V analyser provides a reliable and cost-effective solution for monitoring combustion, reducing excess oxygen, lowering emissions of NOx, CO and CO2 and improving operating

efficiency. The reliable detection of low-combustion oxygen or high or low combustibles (CO) in a fired heater or boiler is critical to the effectiveness of burner management systems.

“We believe the WDG-V is the combustion analyser of the future. The role of combustion analysers in control and safety functions is evolving rapidly. Maximising fuel efficiency, while reducing emissions from combustion processes, requires utilising aggressive operating set points that dictate the need for additional layers of safety for risk reduction,” said Mike Fuller, Vice President-Marketing and Business Development, AMETEK Process Instruments & Analytical Instruments.

WDG-V combustion analyser provides a layer of control and safety to a basic process control system, while significantly reducing the risk of an uncontrolled combustion event.

oven Industries, Inc, offers a wide variety of temperature sensor probes, right from thermistors and thermocouples, to resistance thermometers. By providing 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.

Oven Industries website provides a useful ‘Temperature Sensor Selection Guide’, which can help with selection of the correct sensor probe for the right project. The guide shows the tolerance level, model number, temperature range and key details about the five sensors that the company offers. With a wide range of applications and versatility for temperature sensors, the company stands ahead of the competition. These sensors have a tolerance of up to ±0.1°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 customised. Highly skilled experts at Oven Industries offer help to business owners for building the optimum electronic control solution device for a wide range of needs and purposes.

New enzyme technology increases ethanol yield from cornnovozymes has launched a new enzyme technology that can increase ethanol yield from corn by up to 5 per cent. The technology also increases corn oil extraction by 13 per cent, while saving 8 per cent energy. The efficiency improvements can be achieved when two new enzymes, Spirizyme Achieve and Olexa, are used together with another Novozymes enzyme, Avantec. “These new enzyme innovations offer strong benefits to ethanol producers. It allows our customers to make more from less and substantially improve their profit margins,” said Andrew Fordyce, Executive Vice President-Business Operations, Novozymes. A typical US ethanol plant uses around 36 million bushels (9,00,000 tonne) of feed-grade corn per year to produce 100 million gallons of fuel ethanol; 3,00,000 tonne of animal feed (DDGS); and 8,500 tonne of corn oil.

By using Avantec, Olexa and Spirizyme Achieve, such a plant can save up to 1.8 million bushels (45,000 tonne) of corn while maintaining the same ethanol output, increasing corn oil extraction, and generating up to $ 5 million in additional profit. Corn is the key raw material in biofuel production in the US, and by far, the biggest cost component for an ethanol plant. After the corn is harvested, the kernels are ground into corn meal and water added to make a mash. Enzymes convert the starch in the mash to sugar, which can then be fermented to ethanol.

AMETEK’s next-gen combustion analyser improves process and safety functions

New varieties of temperature

sensors from Oven Industries

ensure accuracy

Technology Transfer


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

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

TeChnology offered

aCTivaTed Carbon An Iranian firm is willing to offer activated carbon from coconut shells. areas of application

Food processing, pharmaceuticals, etcforms of transfer

Technology licensing

eThanol An Iranian company is offering ethanol from molasses using the fermentation of sacharomyces cerevisiae. areas of application

Chemical and energy industries forms of transfer


furfuryl alCohol TeChnology An Indian firm offers technology for producing furfuryl alcohol from furfural by liquid hydrogenation as well as vapour hydrogenation, with a capacity of 6,000 tpa to 24,000 tpa. areas of application

Furan polymers, sealants & cements, urea-formaldehyde, and phenolic resins & foundry cores forms of transfer

Consultancy, technical services, technology licensing

PreCiPiTaTed CalCium CarbonaTe An Indian consulting company for the chemicals, minerals & food processing industries is offering precipitated calcium carbonate and turnkey projects for the same. areas of application

Plastics, paper, paints, rubber, inksforms of transfer

Consultancy, technical services

PhosPhaTe esTersAn Indian firm is offering technology for manufacturing phosphate esters like tributyl phosphate.areas of application

Specialty chemicalsforms of transfer

Joint venture

sodium hydrosulfiTe An Iranian company is willing to manufacture sodium hydrosulfite using chemical compounds. It is widely used as a stripping agent in dyes and chemical industries.areas of application

Chemical industry forms of transfer


sodium siliCaTe reCovery from riCe husk ashAn Indian firm is offering technology to recover sodium silicate from rice husk ash. The technology claims to offer better ROI than other processing methods.areas of application

Chemical industry forms of transfer

Consultancy, technical services, turnkey, etc

sodium sulfide An Iranian firm is willing to offer sodium sulfide, which is used mainly in textile industry, paper mill, artificial silk and curriery.areas of application

Leather industry, textiles, curriery industries, paper mills, etc forms of transfer

Turnkey

synThesis rouTes for organiC ChemiCals An Indian firm is offering consultancy in design of synthesis routes for organic chemicals.areas of application

Pharma industry, specialty chemicals, plant protection chemicals, etc forms of transfer

Consultancy

Transformer oil uniT An Indian company is willing to offer consultancy for making a transformer oil unit with domestic coal from its waste.areas of application

Transformersforms of transfer

Consultancy, technical services

ZinC PhosPhaTiser/rusT ConverTer (ferPhos)An Indian firm offers technology to produce Ferphos – a unique chemical formulation that acts as a zinc phosphatiser cum rust converter. Ferphos is an innovation and improvement over existing phosphating products/technologies practised around the world. Ferphos solution does not die, ie even after prolonged use, and does not require daily addition of chemicals and hence it results in zero effluence. Ferphos solution also acts as a rust converter when brushed on rusted iron products. It is an ideal substitute for sane/shot blasting.areas of application

All iron and steel products including aluminium, SS, GI productsforms of transfer


Technology Transfer


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

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

information about the particular technology offered or requested, its areas of application and forms of transfer. Contact us: Chemical & Process World, Network18 Media & Investments Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028

Tel: 022-3024 5000, 3003 4672, Fax: 022-3003 4499, Email: [email protected]

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

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

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

TeChnology requesTed

aCTivaTed Carbon and sodium siliCaTeA company from Thailand requires technology for manufacturing activated carbon and sodium silicate from rice husk & rice husk ash.areas of application

Manufacturing and construction industryforms of transfer

Others

glyoxal An Indian company is looking to switch the production technique for manufacturing 40 per cent glyoxal from its existing acetaldehyde-based method to the MEG-based glyoxal production.areas of application

Pharma & textileforms of transfer

Others

inorganiC ChemiCalsAn Indian company is interested in seeking the technology and process know-how for production of potassium nitrate, chromium acetate, and magnesium hydroxide suspension. The company already produces inorganic chemicals and wants to add several other items.areas of application

Chemical industryforms of transfer

Others

limeAn Indian company seeks to adopt new cost-effective technologies, which can reduce carbon emissions and earn carbon credits, for manufacturing lime.areas of application

Quick lime and hydrated limeforms of transfer

Others

PhenoliC and Phenol formaldehyde resinAn Indian company needs the technical know-how for producing phenolic and phenol formaldehyde resins.areas of application

Foundry, rubber adhesives, rockwool, abrasives, plywood, etcforms of transfer

Others

quaTernary ammonium ChlorideAn Indonesia-based company is planning to diversify into manufacturing of quaternary ammonium chloride. It is seeking technology along with the supply of critical plant and machinery for the manufacture of the chemical 3-chloro-2hydroxypropyl trimethyl ammonium chloride that is produced from epichhlorohydrin.areas of application

Chemical industryforms of transfer

Technical know-how, consultancy

siliCa gelAn Indian firm is looking for new technology for manufacturing silica gel in which the wastewater discharge is minimum.areas of application

For various industries and most importantly breweriesforms of transfer

Others

small-sCale environmenT-friendly ChemiCal TeChnologyAn Indian company is looking out for an economically viable small-scale environment-friendly chemical technology useful in the textile sector as well as in pharmaceutical sector.areas of application

Textile and pharmaceutical industryforms of transfer

Others

solvenT dyesAn Indian company has recently installed a manufacturing capacity of 2,400 mtpa and is looking to diversify its product range by including various solvent dyes in its product portfolio. The company is seeking process consultancy for this project.areas of application

Plastics, petroleum, solvents, etcforms of transfer

Others

In Conversation With | Shrikant Kulkarni


Phot

o cou

rtesy

: Akz

o Nob

el In

dia

…says Shrikant Kulkarni, Country Manager - Specialty Chemicals, Akzo Nobel India. In an interaction with Mahua Roy, he outlines the role of the chemical industry in promoting a responsible image and discusses the megatrends affecting this sector.

We need to prove that we are responsible stakeholders

What are your top priorities for the business of akzoNobel in india?At AkzoNobel, we continue to be a reliable and preferred partner for our customers, working with them on value-additions and providing technical solutions wherever possible. In addition, safety and sustainability are important pillars of our strategy and we have adopted these as

part of our key best practices. Globally, AkzoNobel is a leader in sustainability, having been ranked first within the chemicals super-sector on the prestigious Dow Jones Sustainability Index (DJSI) 2012. We focus on the following areas of sustainability: Environmental impact by way of reduction in CO2; reduction in fresh H2O consumption; and community welfare. All our efforts are focussed on

creating value for customers, employees, shareholders and other stakeholders.

Can sustainability and productivity go hand in hand?Sustainability and high performance is the combination that ideally serves today’s consumer demands, and the one that the chemical industry is actively seeking to achieve. Traditionally, however,


Shrikant Kulkarni

the two have been thought of as mutually exclusive. Latest developments show that being green and providing superior performance are not mutually exclusive. Intelligently designed and innovative products based on renewable resources can match, and in many cases, exceed the performance of the current market standards, resulting in attractive offerings.

Within the broad framework of sustainable development, the government, academia and industry strive to maximise resource efficiency via conservation of energy and non-renewable resources, risk minimisation, pollution prevention, reduction of waste at all stages of the product lifecycle, and the development of products that are durable, reusable as well as recyclable. Therefore, given that sustainable chemistry involves the design, manufacture and use of efficient, effective, safe and environmentally sound chemical products & processes, it will be apt to say that all sustainability-related research in this industry is about sustainable chemistry.

Which are the consumer trends you plan to tap?The Indian chemical industry has emerged as one of the fastest growing industries in the country. This is mostly due to the increase in consumption of value-added products that use specialty chemicals. We see an all-round growth in the construction, retail and packaging segments that will boost the demand for specialty plastics. This is good news for many of our businesses like polymer and performance additives, organic peroxides, etc. Lifestyle products are becoming more popular and our range of ingredients for personal care products will benefit from this trend. Agro industry too is increasingly adopting best practices to improve yields. Many of our businesses such as ethylene amines, sulphur derivatives, surfactants, chelates and micronutrients find an important role in this segment. The quality standards across sectors have enhanced manifold and customers are looking to

work with reputed companies, which can offer complete solutions along with wide and high-performance product portfolio, superior technical service and safety support.

Which are your star products in the indian market? We have a leading position in many product segments namely, organic peroxides, metal alkyls, performance additives, personal care ingredients, asphalt emulsions, paper chemicals, etc. Our R&D supports the introduction of new products that offer technical superiority in respective product applications.

What are your views on the outlook for the specialty chemicals industry in india?The chemical industry forms as essential part of the economic development of the country, contributing to the growth of the manufacturing and agriculture sectors. With a shift in demand for chemicals across sectors, India is expected to emerge as a key sourcing market for chemical companies the world over. The chemical industry is gearing up to build an economy of scale that would cater to

both, the domestic demand as well as export opportunities. Along with that, several government initiatives to promote Special Economic Zones (SEZs) and Petroleum, Chemicals & Petrochemicals Investment Regions (PCPIRs) will boost investments by both local companies and MNCs looking to expand their presence in India. Emerging technologies and a breakthrough in untapped sectors such as fertilisers and pesticides would also prove to be a game-changer in the chemical sector.

What do you think about the challenges faced by the industry?The main challenge that the Indian chemical industry faces as of now is the need to address the issue of ‘Return on Investment’ as this industry is highly capital-intensive and needs to ensure sustainable profitability as well. The chemical sector has to make an extra effort to convince the society and address environmental concerns. We need to prove that we are responsible stakeholders. Another challenge is to continuously invest in R&D to upgrade technology, drive product introduction and stay ahead.

Email: [email protected]

Up close and personal last motivational book you read...I enjoy reading books on business management and spirituality. I am currently reading ‘Who Am I’ by Ramana Maharishi. The book helps me find purpose and internal peace.

Your all-time favourite movie...‘Lagaan’ – for its emphasis on qualities of focus, determination, teamwork and leadership.

Your inspiration, every single day...Variety and challenges of life.

one business etiquette you always follow...Punctuality – an individual must always be prepared to add value in any given situation.

The biggest strength, according to you, of the indian chemical industry...Huge domestic demand and availability of skilled talent in the industry.

Cover Story | R&D in specialty chemicals


Photo: Joshua Navalkar; Location courtesy: MicroChem Silliker Pvt Ltd, Mahape (Navi Mumbai)

Prasenjit Chakraborty

Recent investments in applications and research labs by both domestic and overseas specialty chemicals companies in India clearly indicate the enormous potential the Indian market offers to this sector. It is time to take the plunge to make the most out of the emerging opportunities.

in spite of strong global headwinds, the demand for specialty chemicals has continued to surge upwards. Evolving megatrends are driving growth in this dynamic sector, which produces a multitude of products used to enhance performance across wide-ranging industries globally. According to Pravin S Herlekar, Chairman & Managing Director, Omkar Speciality Chemicals Ltd (OSCL), the specialty chemicals titans of the West have set their eyes on the Indian specialty chemicals industry for its colossal growth potential.

He strongly believes that the sector is expected to grow at a CAGR of 15 per cent – almost twofold growth of the global industry. “Similarly, exports are also poised to grow from $ 4 billion in 2007 to $ 13.5 billion by 2014, representing a

CAGR of over 22 per cent. This clearly indicates that India is the flavour of the season,” he says. Although the major geographies accounting for specialty chemicals continue to be Europe and the US, Asia is the only region where sales grew 10 per cent, while the EU region and the US slipped by 12.5 per cent and 6 per cent, respectively during 2010-11. “Earlier, China was ahead of India. Now, India has surged ahead with its growth in the specialty chemicals sector,” points out Herlekar.

India has slowly become a significant player in the international chemical market, with many companies intent on sourcing from here, which is amplified by another emerging trend – growing equity participation by multinationals in their Indian arms. As India’s edge in specialty chemicals is more visible, mergers and acquisitions (M&A) activity is likely to grow. And it is not just multinationals who are ramping up their sourcing plans from India, even home-grown firms are creating new capacity, increasing productivity and going in for acquisitions.

Success in the niche specialty chemicals segment, unlike commodity chemicals, is governed by the ability to invent new, value-added molecules and invest in research and development (R&D) of new products. Also, with the erosion of margins and the shrinkage of markets for many of the niche chemicals, largely because of increased environmental awareness, the companies are solely banking on innovation as a vital tool to stay ahead of the curve.

investment in r&dCompetition in the specialty segment is not on price or raw materials front but on product technology and innovation fronts. Many companies in the Indian specialty chemicals industry have decided to leverage the lower R&D costs in India, as compared to Europe and the US, to undertake intensive research for developing value-added products.

We keep getting enquiries for the development of next-generation drugs and their intermediates on a regular basis. The R&D facility mainly caters to these requirements.

Pravin s herlekarChairman & Managing Director, Omkar Speciality Chemicals Ltd


R&D in specialty chemicals

According to The Indian Chemical Council (ICC), the specialty chemicals segment is expected to grow at a rate of 11-12 per cent in 2013. The growth rate will be maintained over the next 3-4 years. Also, the demand for specialty chemicals is strongly hinged on the demand from the end-use industries. As they grow, the demand for specialty chemicals will also rise. “I see growth opportunities in almost every end-use sector as MNCs plan to expand their manufacturing base in India,” observes Herlekar.

Growth driversThere are several factors contributing to the growth of the specialty chemicals industry in India, and the country is the third-largest market for specialty chemicals in Asia. The growth in India’s specialty chemicals industry will be driven not only by underlying end-market growth but also by increased usage intensity and new product specifications & standards. The intensity of usage of specialty chemicals in India is at a much earlier stage of development than in Western markets and China, creating significant scope for growth.

In order to consolidate its position in the market, OSCL has invested about ` 3 crore in setting up a state-of-the-art R&D centre at Unit III–B-34, MIDC, Badlapur (near Mumbai) which is recognised by the Department of Scientific and Industrial Research (DSIR), under the Ministry of Science and Technology, Government of India. The R&D centre is equipped to carry out an array of reactions with various unit operations and processes. The R&D activities contribute towards: Increase in sales of newly developed

molecules Development of intellectual properties Cost reduction Quality enhancement Trouble shooting

OSCL’s client base includes all major domestic and global pharma MNCs. “We keep getting enquiries for the development of next-generation drugs and their intermediates on a regular basis. The R&D facility mainly caters to these requirements,” says Herlekar. Additionally, OSCL has targeted specific areas for development of new technologies for certain specialty chemicals. Apart from this, it develops products through innovative green routes of synthesis, which are eco-friendly.

Similarly, Merck KGaA made its Indian Application and Technology Centre lab a part of its global network. “We have eight application labs worldwide. Our aim is to facilitate useful exchange among the network in order to gain synergies and promote faster benefits of products to customers,” says Dr Matthias Lergenmüller, Senior Director - Business Field Cosmetics, Merck KGaA. Besides India, Merck has application and technology centre in China, Thailand, and Japan in Asia. The Indian centre, which is located at Nerul (Navi Mumbai), enables Merck to offer customised application and technology solutions to its customers in fields ranging from drug discovery to automobile and decorative paints. The lab is focussing on India-specific projects and also undertakes projects from other countries as well.

According to Dr Lergenmüller, Merck is the market leader in pearl lustre effect pigments with about 55 per cent marketshare globally. Pearl effect pigments market is estimated to be about Euro 600-650 million globally, while in

India it is about ` 120-125 crore. The need for differentiated products is boosting demand for pearl lustre effect pigments.

Another specialty chemicals & materials company, Momentive Performance Materials Holdings LLC (Momentive) , recent l y opened Global Research and Development Centre and

business headquarters in Bengaluru through its subsidiaries, Momentive Performance Materials Inc and Momentive Speciality Chemicals Inc. The Global Research and Development Centre is catering to the needs of India, Middle East and Africa (IMEA) region. The new facility is located on a two-acre plot in Bengaluru and will initially house around 100 associates.

Research scientists based at the facility will work on new global technology platforms and product development for new and existing applications in diverse industry segments, including personal care, energy, healthcare, electronics, automotive and construction. In addition, as Momentive’s regional headquarters, the facility will house its commercial, business support, business process and information technology functions. The Bengaluru facility will be a key addition to Momentive’s global network of research and development centres located in strategic regions to drive innovation for customers. “This new Global Research Centre and regional headquarters represent an important step in our continuing investment in India and demonstrates our commitment to customers in the region and all over the world,” says John Dandolph, President, Silicones and Quartz Division, Momentive Performance Materials Inc.

He adds, “India’s world-class technical talent, growing demand for new applications enabled by our products, and strong growth opportunities combine to make this an excellent location to fuel and support our growth plans.” All these clearly indicate the importance of India.

The Indian market is important to us, as is the broader Asia-Pacific, which is one of the fast-growing regions in the world. Our R&D expenditures reached $ 44 million in 2012.

Craig a rogersonChairman, President & CEO, Chemtura Corporation


R&D in specialty chemicals

significance of indian marketAs India emerges as potential market for specialty chemicals, MNCs have started focussing on its potential. Take the example of Chemtura, which is optimistic about the Indian market. Craig A Rogerson, Chairman, President & CEO, Chemtura Corporation, says, “The Indian market is important to us, as is the broader Asia-Pacific, which is one of the fast-growing regions in the world. Chemtura recently acquired the bromine assets in India of Solaris ChemTech, which provides our Great Lakes Solutions business with a cost-competitive bromine source closest to our growing customer base.” For Chemtura as a whole, this acquisition represents increased presence in this fast-growing region and growth in our target industry segments of electronics, energy and agriculture.

According to Dr Joerg Strassburger, Country Representative & Managing Director, LANXESS India Pvt Ltd, innovation will demarcate the long-term players from the small businesses and will also determine the growth of the industry. “As a reaction to economic slowdown, companies would usually cut costs; but the more effective way of looking at it would be to improve operational and process-related efficiencies in an organisation,” he says. It is also important to understand the future needs of the customer and tap the right products for the right market – this could be achieved by application-oriented innovation.

High innovative capability is vital for OSCL as a leader in niche specialty chemicals industry. “We have combined different concepts for innovation, including ongoing development of products, processes and applications. We constantly evaluate long-term market trends to help derive new areas of growth for OSCL. Our R&D experts work closely with the marketing and the sales team. Therefore, our innovations

are closely aligned to the needs of our customers, enabling us to enhance our competitiveness through new and improved products & applications,” points out Herlekar.

innovation is key In a typical industry environment, innovation is the key for healthy growth. However, global recession forced most of the companies to embrace aggressive innovation to survive and to charter a growth strategy for sustainability. “While there is a tendency to reduce R&D spending during recession, some companies have focussed on driving innovation to find solutions. Companies have innovated not only in product development, but also in terms of strategy and approach,” observes Chemicals, Materials & Foods Practice team, Frost & Sullivan.

Take the example of Chemtura Corporation – the company significantly increased its spending on R&D. “Our R&D expenditures reached $ 44 million in 2012; an increase of 16 per cent when compared with 2011,” reveals Rogerson.

No wonder, BASF is implementing its global ‘We create chemistry’ strategy in Asia-Pacific with a set of ambitious targets and a focus on sustainability. Around 25 per cent of BASF’s global R&D will be conducted in Asia-Pacific by 2020, to develop innovative solutions that address the region’s challenges of resource efficiency, food and nutrition, and quality of life. “In the next decade, Asia-Pacific will face huge challenges while remaining the fastest growing market for the chemical industry. With

our Asia-Pacific strategy, we are positioning BASF as the leading provider of sustainable solutions for the Asia-Pacific region,” says Dr Martin Brudermüller, Vice Chairman - Board of Executive Directors, BASF SE, responsible for Asia-Pacific.

looking ahead into the futureDue to recession, some of the

major companies, especially in North America and EU, started carving themselves out from commodities to specialties. The companies started positioning themselves from scale and commodity operators to specialty and services operators. This kind of paradigm shift was essential for survival as most of the commodity companies have shifted their production base to low-cost regions such as East and Middle East Asia. India is certainly going to benefit from this as it offers volume in every segment. However, the prospects of Indian chemical industry, to a large extent, depend on the government policies.

“Government has a substantial role to play in facilitating the growth of the Indian chemical industry. The long-term growth will depend on the effectiveness of government policies. Unfortunately, the present policies and regulations are not investor-friendly, when it comes to both local and foreign companies. Increasing burden in terms of taxes, rise in gas prices, high logistics and infrastructure costs and non-uniform compliance to environmental regulations are some factors, which are making India unattractive for investments,” observes Strassburger.

Infrastructure development for chemicals parks, PCPIRs have a long way to go, which means that the companies have to invest more with regard to compliance and sustainability requirements. Government support is quintessential on all these fronts; else the economic crisis may turn out to be a long haul for the industry.


As a reaction to economic slowdown, companies would usually cut costs; but the more effective way of looking at it would be to improve operational and process-related efficiencies.

Dr joerg strassburgerCountry Representative & Managing Director, LANXESS India Pvt Ltd

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Special Focus


SUPPLY CHAINMANAGEMENT

FOR CHEMICALSSupply Chain Management

for Chemicals With growing demand for chemicals worldwide, logistics form a key aspect of the chemical industry as production and consumption locations are mostly separated by hundreds of miles. This calls for efficient, competitive and sustainable logistics for the future development of industry. Taking cue from the latest trends in the logistics arena globally, chemical companies are experimenting with various strategies to synchronise their transportation assets, and exploring avenues for implementation of IT in logistics. Moreover, the Indian chemical industry is focussing more on innovations to produce environment-friendly technologies and products. All these will go a long way in aiding the chemical logistics segment to take the green route and reduce its carbon footprint.

Special Focus | Chemical SCM


in a product as simple as your shampoo, you will see a host of ingredients. The sodium lauryl sulfate may have been produced in Taloja, Mumbai; while the glycol distearate may have come from Gujarat. The dimethicone and panthenol in your conditioner might have been sourced all the way from Singapore; while the cetyl alcohol would have come from Europe. All these get processed at an FMCG unit in India and then

distributed to the remotest of locations in the country. The factor connecting the seamless execution of production is logistics. While productivity and, thereby, bottom lines are majorly getting enhanced, logistics is an area that is facing a huge impact.

megatrends affecting logisticsThe chemical industry is witnessing the following megatrends globally, and

companies are thus adapting logistics strategies subsequently.

Elongation of supply chain: Global sourcing has become a key strategy adopted by most chemical companies to ensure high-quality assurance and product integrity. This has led to longer and more complex supply chains. As a result, one faces higher logistics costs and constant pressure on transport capacity. “Increasing congestion, more restrictions and continued lack of investment in logistics infrastructure have led to more congestion and reduced supply chain reliability. Increased competitive pressures for constrained logistics capacities, coupled with a broader geographic scope and increased need for risk management, are leading to challenges,” adds Ramanand Gupta, Managing Director, Revex Plasticisers Pvt Ltd.

Clustering: Another important trend is the development of chemical industrial clusters in many parts of the world. This trend brings out positive infrastructural capabilities in the manufacturing zones;

however, the consumer cluster is situated quite farther from the production area. This in turn strains the logistics even more.

Tapping new markets: As a result of slowdown globally, emerging markets have suddenly captured worldwide attention. “Chemical majors are heavily concentrating on tapping the opportunities in these regions, starting from the logistics strategies from scratch. This again opens up whole new plans of

Global megatrends bolstering logistics strategies

Mahua Roy

Globalisation and consolidation in the chemical industry are leading to magnification of megatrends. Logistics is a key area, which is directly impacting margins. So how is the chemical industry managing this situation? What are the top strategies being devised globally?


Chemical SCM

action for making the most in these key geographies,” explains Siddharth Paradkar, Principal – Logistics & SCM, TSMG.

S u s t a i n a b i l i t y a n d safety: “Apart from delivering on-schedule and promising efficiency, another key responsibility for the logistics sector is concentrating on safety, security and sustainability of the transit operations. In fact, it is the most important consideration today when going green is the buzzword across the industry. This megatrend is expected to transform the way one looks at logistics strategies,” observes Paradkar.

Unusual demand-supply scenario in the industryAs an outcome of the trends enumerated above, most chemical companies are complaining that their logistics costs are outweighing the manufacturing costs at times. One of the most unusual observations is that 2009 was an incredibly bad year, and the volumes for chemicals went down globally. Subsequently in 2010, volumes came back suddenly due to inventory rebalancing, but availability of logistics to support the skyrocketing demand was not there. The industry quickly faced a capacity issue and pricing soared. As there was no forecasting, shippers were not ready for the demand.

Chemical transportation companies are not sure what approach to take. Should they keep hiring drivers and adding assets to their fleets to keep up with current demand? Or should they be cautious in case the economy sinks once more, dragging chemical shipments downhill yet again? However, production trends are improving globally with most companies announcing greenfield and brownfield expansion projects, thereby spelling good news for logistics providers. Optimistic growth has been forecast in the sectors such as plastic resins, synthetic rubber, man-made fibres, industrial gases, pharmaceuticals, consumer products and adhesives & other specialties. This is

expected to offer some relief to the logistics costs worldwide. Apart from this, the logistics industry faces inherent problems of its own. “Among the various factors that affect the transport costs in the chemicals sector are fluctuation in fuel rates, poor quality of roads, inadequate training of transport personnel, poor maintenance of vehicles, multi-level local taxes and check posts, which hamper seamless delivery of products to the factory and economical delivery of products to the customers,” states Suyog Seth, Production Head – Mahad, Specialty Chemicals, Akzo Nobel India.

managing the cost factorEnsuring prompt and economical delivery of chemical products is a challenge in India. Unlike European or other Asian countries, India has limited number of cost-effective and quick alternatives. The logistics industry is still dependent on surface transportation. Road transport accounts for 70-85 per cent of domestic supply chain. Coastal waterway systems are still in a primitive stage, whereas their operational cost is 50-60 per cent lesser than road transportation. The wide Indian rail network is still unable to provide effective service to the industry. Such underdevelopment adds up to the cost in a big way. However, the government’s initiative to invest in the development of arterial roads connecting major parts of the country has resulted in strengthening of the road network each passing year, and so things are improving, although they are still far from optimal.

“Logistics is a key component of the chemical industry. Often, reducing

the transport cost is a big challenge. However, effective and sustainable management of logistics not only provides enormous opportunities for future development of products, but also helps in keeping a tab on the cost involved,” says Seth.

Best practices across the industry concentrate on realigning the strategies to

manage skyrocketing logistics costs. One of the key actions that help control the logistics cost includes setting up of warehouses closer to the customer base. Seth adds, “This in turn offers a synergy between cost optimisation and maximum capacity utilisation of the transport. Monitoring the last mile delivery of our products to the customer also helps in time and resource management.”

Better management of warehousesAnother big trend in the industry globally is pertaining to the management of warehouses. All chemical companies, whether or not they outsource logistics services, are gradually streamlining operations. “Chemical manufacturers face a lot of issues unique to their business. Managing a large product catalogue with descriptive features and disparate production sites, while at the same time trying to improve production efficiency and respond to market demand, form a set of problems that we have to face simultaneously,” says Gupta.

Companies are experimenting with various strategies to synchronise their transportation assets. Rather than investing in a big warehouse, they are going directly from the production line to the rail car or tanker truck, skipping the intermediate storage area. As Seth agrees, “Transporting chemicals directly to the customer is always advisable on account of safety. The railway system in the country is not geared to provide the effectiveness and safety required to deliver chemical products of volatile nature.”


Increasing congestion, more restrictions and continued lack of investment in logistics infrastructure have led to more congestion and reduced supply chain reliability.

Ramanand GuptaManaging Director, Revex Plasticisers Pvt Ltd

Special Focus | Reducing carbon footprint


Leaving a green mark on supply chain

Rakesh Rao

To make their business sustainable, chemical manufacturers are taking several steps to reduce carbon footprint in the supply chain. While companies are banking on technologies to make their supply chain clean, they are also offering training programmes to their suppliers to make them partners in this green journey.

The carbon emissions in supply chain are not only costs but also future liabilities for the sustainability of any business. In the chemical industry, sustainability is often viewed as within the fence issue of the manufacturer; it is also a critical differentiator for supply chain. Sanjay Choudhary, Chief Technology and Sustainability Officer, Tata Chemicals Ltd, says, “In the chemical supply chain, the largest environmental impact is, without a doubt, from transportation. The reduction of carbon emissions will get to top of the agenda for distribution in view of the cost and consequences of disruptions due to environmental impacts related to climate change.”

Supply chain and logistics affect the success of chemical industry because they have a high share of cost in the bottom line and are critical for service level and top-line; and the cost represents about 10 per cent of revenues, which is material to profitability. Rajendra Jog, Associate Director - Supply Chain, Dow Chemical International Pvt Ltd, says, “Nowadays, the scale of operations in chemical plants is becoming bigger. This means that globally the demand is met from fewer plants around the world. This has obviously led to rapid increase in the amount of material flow worldwide and therefore, the volume of traffic as well.”

Currently, the volume of traffic is one of the key factors causing the highest amount of greenhouse gas (GHG) emissions. Jog says, “A big challenge for the industry is to

handle the increasing amount of material flow and reduce the GHG emissions and consumption of resources at

the same time. The regulations around emissions are becoming stringent day by day; and it has

become important for companies to find new ways to remain compliant and cost-effective in order to make their business more sustainable.”

simplifying complexitySupply chain in the chemical industry is often complex, and hence adequate steps need to be taken to reduce carbon footprint during the transit of chemicals. Complexity of chemical logistics is increasing with geo-shifts of production due to

globalisation, leading to significant increase in global trade; and different models are evolving over the time

to meet the market needs with collaboration across the supply chain.

The chemical industry is highly regulated and fragmented in a country like India, plus the transportation mix is different than most other industries, with higher percentage of rail and ocean shipments due to increasing global trade in chemicals. “Real-time

tracking & tracing, multi-echelon planning tools, cloud computing, etc are providing some answers. Chemical industry needs to use the integrated planning to improve logistics productivity and reliability, which will help in reducing carbon footprint significantly. It is driven by economies of scale, making logistics an essential part of the industry,” opines Choudhary.

The reduction of carbon emissions will get to top of the agenda for distribution in view of the cost and consequences of disruptions due to environmental impacts related to climate change.

sanjay ChoudharyChief Technology and Sustainability Officer, Tata Chemicals Ltd


Reducing carbon footprint

CaRbon ReduCtion avenues

Jog believes that in order to reduce carbon footprint, one must first identify the various carbon reduction opportunities that are available. the industry, according to him, can look at the following steps: as much as possible, move the product

in bulk rather than smaller quantities Move the product in a concentrated

form, as a diluted product will have more volume

Move the product through pipeline for short distances wherever possible

use of efficient vehicles with higher carrying capacity

Multiple deliveries during a single shipment rather than multiple shipments

For the chemical industry, rail transportation is a low carbon option compared to road transportation, especially within the country. However, the limited number of rail carriers in any particular geographic area has distorted rail market. Choudhary says, “Transportation by rail is often constrained and delayed because of priority to moving food and other more important resources as the rail is dominated by sole national rail ownership. The situation becomes more complex as chemical plants are often located in remote places close to raw material sources without rail connectivity.”

supplier, the critical linkGlobal chemical manufacturers need to work closely with their suppliers (who are spread across the world). Given this background, ‘supplier training’ programme is gaining importance in the chemical industry for green supply chain. Jog avers, “It is important to educate our suppliers to follow green supply chain. Suppliers should be aware of the impact from the initial stage of designing the product, manufacturing process, material purchase,

packaging, storage in warehouse and transportation to reverse logistics. At every stage, there is scope to reduce the GHG emission.”

The value chain sustainability strategy is a significant undertaking that can generate savings and stakeholder confidence across the chain. For all the partners in the chemical supply chain, it has become increasingly important, from the business and branding perspective, to operate in a sustainable way. There is growing engagement with Responsible Care, which is a voluntary initiative of the global chemical industry for addressing the safety and environmental impact in the supply chain, with a focus on product stewardship.

Communication of sustainability strategies is often overlooked and the supply chain partners training programme on green supply chain will be of great value. Each of the partners needs to provide a vital link for a sustainable value chain and share the information up and down the supply chain for sustainability management. Choudhary elaborates, “This is central to the new global product strategy announced under Responsible Care, which redefines the relationship producers have with distribution and the supply chain. This has broadened the product stewardship espoused under Responsible Care earlier, which focussed on risk management to include risk reduction with the emphasis on finding safer and greener options. This is where distribution and logistics companies play an important role. Reducing the distances shipments travel, the amount of handling that occurs, and the number of people and steps involved

in chemical logistics reduces both risks and costs.”

Tracking the right pathGrowing complexity has led to the development of many tracking and tracing technologies, which play important role in making supply chain greener and cleaner. Jog says, “Tracking of performance will bring the best out of any system and

supply chain is no exception. Unnecessary waste of energy can be avoided, if we track and control such wastes. Currently, Dow Chemical International Pvt Ltd (DCIPL) has an internal tool, which allows GHG emission to be monitored.”

Chemical companies, whether or not they outsource logistics, need to streamline and integrate their operations and logistics assets. Some of the choices to be made are either to focus on warehousing or go directly from the production line to the rail car or tanker truck. “For effective co-ordination for loading, unloading, and other associate operations, chemical companies are turning to Transportation Management Systems (TMS) for optimum transportation networks. TMS automate key elements of logistics infrastructure from strategic and operational perspectives, network layout design, execution and monitoring, invoicing, billing, and settlement etc,” observes Choudhary.

Chemical companies also use technologies such as RFID and GPS for ensuring efficient shipping and on-time delivery as well as cutting costs. Choudhary says, “These technologies give real-time visibility and help to comply with government regulations related to safety and security concerns, and provide support for insurance settlements. Other key benefits include improved asset management, achievement of the best overall transportation cost, and quick response to changes with agility to stay cost-competitive in view of the global overcapacity.”


Tracking of performance will bring the best out of any system and supply chain is no exception. Unnecessary waste of energy can be avoided, if we track and control such wastes.

Rajendra JogAssociate Director - Supply Chain, Dow Chemical International Pvt Ltd

Special Focus | Chemical manufacturers


TaTa Chemicals Ltd, one of the leading chemical companies in India, has redefined the product portfolio and LIFE (Living, Industry and Farm Essentials) chemicals, and is internalising sustainability in the strategic planning. As part of the carbon strategy, the company has set the goal of 20 per cent reduction in the carbon intensity of the products by 2020 over the 2008 baseline.

“The carbon intensity also includes the carbon footprint associated with the logistics. The logistics process is carbon-conscious and the company is considering the low energy and low carbon options such as the mix of rail, road and shipping as part of planning for primary and secondary transport of the products. Some of the measures such as returnable jumbo packing and bulk transport of the products are towards carbon reduction,” says Sanjay Choudhary, Chief Technology and Sustainability Officer, Tata Chemicals Ltd.

Tata Chemicals has, over the years, done strategic acquisitions of soda ash production facility across the globe, which gives it

the distinct competitive advantage of having presence in the global trade flows resulting in lower transport costs and logistic carbon emissions. Choudhary explains, “This is aligned to the imperative of a cohesive and consistent approach to sustainability stated by the Chairman of Tata Group in his message: As we look to grow in the next decade, it is important to reiterate that continuing responsible growth can only be achieved through a ‘Sustainable Tata Way’. We take a long-term approach in our strategy, and as an empowered part of society, we take our roles and responsibilities seriously while working towards shaping our shared future.”

multi-pronged approachSimilarly, other companies are adopting multiple ways to reduce carbon footprint in their supply chain. Rajendra Jog, Associate Director - Supply Chain, Dow Chemical International Pvt Ltd (DCIPL) emphasises, “At DCIPL, we are serious about reducing our carbon footprint.” In keeping with Dow’s 2015 sustainability goals, some of the measures taken by the company are as follows: Multimodal operations: Here, more than one mode of

transportation is used. In our case, we use road-rail-road where the first and the last link in the supply chain is road and majority of the movement happens through rail. This leads to lesser Greenhouse Gas (GHG) emissions as compared to direct road movements.

Bigger capacity vehicles: With infrastructure development and widened roads, many service providers have started providing higher capacity vehicles and this helps in reducing the number of deliveries. Earlier, the deliveries used to happen in 9 MT truck load for packed cargo and, nowadays, the capacity has increased to 16 MT and, in the near future, this will increase to 21 MT. For bulk shipments, the industry has moved from 10 MT to 16 MT and, currently, 32 MT capacity vehicles are deployed

Bulk storage of products Converting drum customers to bulk customers to help reduce

the number of deliveries Sharing best practices among business partners (transporters,

warehouse service providers, etc) to minimise GHG emissions In addition, the company has initiated The Dow S4TAR Programme – a mutually beneficial initiative from the Dow Business Services Group in India to promote business growth for both DCIPL and its supply chain partners, in a sustainable manner. “The S4TAR Programme is designed to encourage sustainability excellence in DCIPL’s supply chain partners. It provides a specific framework to recognise our partners who exhibit exceptional performance. Each year, through fair and transparent quarterly and yearly evaluations (which are based on pre-set measurements that are communicated to our partners), the S4TAR awards are presented to the best carrier, best warehouse, and best freight forwarding service,” says Jog.


Strategic moves to attain supply chain efficiency

Rakesh Rao

In order to achieve their sustainability goals, chemical manufacturers are leaving no stone unturned. Here are a few examples of how companies are achieving their green objectives.

Supply chain dynamics | Special Focus


as the Indian chemical industry taps opportunities in emerging markets, both domestically and internationally, and maintains a strategic sourcing plan, the logistics is getting more and more complex. In transit, chemical products are subjected to varying degrees of impact, vibration, compression and other adverse effects as well as exposure to the harmful external environment. Other crucial factors such as improper packing of the contents or poor storage may also lead to release of chemicals to the environment resulting in emergencies such as fire, explosion or even toxic release. Hence, sustainability of the desired supply chain strategy needs to be taken into account to avoid unwanted exposure to a maligned brand value.

Also, logistics brings with it high levels of fuel consumption, which strains the economy to a large extent. While rising oil and natural gas prices increase fuel surcharges for shippers, the upward energy spiral presents a double shock to chemical manufacturers. That is because chemical companies need to pay for crude oil as a key ingredient in a wide range of products, as well as for use in the vehicles that transport their raw materials and finished products.

mirroring global best practicesAs per a recent global survey by TUV SUD, it was concluded that 84 per cent of consumers was prepared to pay an average 27 per cent premium for green products and services. Consumer demand and awareness appear to be contributing

to some of the gains in eco-friendly and sustainability-focussed progress that is being made in the global marketplace. Now when carbon footprint indices are available for calculation, it is only a matter of time when the trend will catch up on a global scale and become an important attribute towards purchasing decisions, especially while choosing logistics vendors in the highly competitive B2B marketplace. Since logistics is still viewed as a cost centre by most organisations, any player that commits to reducing this head, but with efficient performance, will eventually prove to be the winner. Besides, international regulations and trends will make sure that the industry is in a position to adapt to the changing marketplace. “Responsible

Care and REACH regulations promote discipline as exporters need extensive documentation. This will make sure that sustainability is promoted in the logistics industry,” adds Siddharth Paradkar, Principal – Logistics and SCM, TSMG.

regulation and educationThere are regulations in place that are gradually warming up this sector and sensitising it towards the harmful environmental impact, thereby heavily promoting green logistics in India. “Because of these regulations, logistics service providers have taken brilliant initiatives in this regard, though currently it is at a nascent stage. But the change is a welcome one, where the logistics service providers have at least started to use terms like ‘reducing carbon footprint’,

or ‘streamlining logistics strategies’. These concepts are slowly catching up,” says Paradkar.

To effectively promote green logistics in India, the service providers must be able to communicate the value proposition that the client will derive from implementing green logistics. A detailed cost-benefit analysis can prove to be an effective tool for promoting green logistics. Today, the Indian chemical industry is focussing more on increasing innovations to produce environment-friendly technologies and products.

Not just depending on stringent regulations, there is also a huge need to educate all the stakeholders associated with the chemical and allied industries. “People associated with the industry have

to understand the dynamics of supply chain, only then the objectives of such regulations will be materialised. Since the majority of chemical manufacturers in India fall under the SME category, we do not expect them to change their attitude towards transportation overnight. They need to understand the impact that can be created by going green when it comes to logistics,” explains Paradkar.

And this change will come soon. The global majors, who set an example about best practices, will play an influential role in trickling down the strategies in the entire industry. The transformation will be gradual, but profound. Looking at the growth of the chemical industry, the implementation process of such regulations has to be expedited.


On the transformation mode Mahua Roy

Logistics accounts for nearly 40 per cent of the costs in the Indian chemical industry today. Given that the technology adoption towards sustainable and efficient operations has not penetrated enough, what will be the future of chemical logistics in the country? What efforts can be taken to make this a cost-efficient proposition?

Special Focus | Roundtable


With the Indian chemical industry actively setting up manufacturing bases in various locations, logistics is the biggest point of consideration. Mahua Roy interacts with key players in the industry to gauge the importance attributed to logistics.

How important is logistics efficiency to the Indian chemical industry?

siddharth ParadkarPrincipal (Logistics & SCM),

Tata Strategic Management Group

Logistics cost in India is estimated at about 14 per cent of GDP, which is high as compared to developed countries. With the exposure to global best practices in the country, there has been a definite push towards benchmarking offerings against world-class standards and integrating the complete supply chain resulting in increased demand for third party logistics services and fuelling the growth of the industry. The logistics industry in India lags behind other countries when it comes to technology adoption and investments. However, as more international players enter into this industry in India, we may see a change in the adoption of best practices.

suyog sethProduction Head – Mahad, Specialty Chemicals,

Akzo Nobel India

Often, reducing the transport cost is a challenge across all industries. However, effective and sustainable management of logistics not only provides good opportunities for future development of products, but also helps keep a tab on the cost involved. We have ‘Distribution risk assessment’ procedure that is implemented to ensure safety and security during handling and distribution of chemical products. We review this procedure frequently and extract an improvement plan each time. The offsite mock drills also help increase our preparedness of handling emergencies during transit, if they arise. However, there is a definite need to bring more awareness among the highway handling crew as well as highway users.

dr swapan Kumar GhoshDirector,

Nova Surface-Care Centre Pvt Ltd

Logistics, as a business tool, is often underrated when it comes to strategies for regions and markets. The question in the past was: How to be part of the growth story of emerging markets. And now that this has been established by most companies, today’s big question is how to organise production and distribution. Optimum logistics management is a key strategy. With harmonised production cycles, transparent order processing and integrated logistics, one can achieve business objectives. Safety and sustainability continue to be high up on the agenda. Chemical companies need to actively assess their transport operation risks. The winners in this industry will be those that manage the increasing complexity through better process and system integration, effective partnering along the supply chain and advanced technology deployment.

Logistics is still considered to be a cost centre by the chemical industry. It has still not opened up to adopting sophisticated technologies for improving safety aspect and efficiency of transportation. However, as this industry expands, there will be more penetration of advanced technologies.

Facility Visit | Kirloskar Brothers Ltd


The facility of KBL is located at Kirloskarvadi in Sangli district, Maharashtra. With its expertise, KBL has emerged as a pioneer in pump and pumping systems. It manufactures a wide range of pumps for a variety

of applications required in chemical process industry. Process industry is driven by certain standards for compliance. “KBL process pumps comply with all major standards required for this industry, eg DIN 24256, ISO 2858, API 610 (different editions) and ISO 5199. Apart from compliance to these standards, major strength lies in unique hydraulics, which takes care of low-end, medium-end and high-end process segments,” says Dattatray Vetal, Senior Vice President and Head-Corporate Manufacturing, KBL.

Thus, KBL offers highly efficient pumps catering to all chemical segments

with different requirements. There are four manufacturing units located in Kirloskarvadi; and one of the units involved in pump manufacturing mainly for the chemical industry is known as KPD unit.

Changes initiatedIn its endeavour to bring in more efficiency, KBL, of late, has brought in changes in the manufacturing set-up. Its manufacturing set-up is broadly categorised by the type of manufacturing processes being followed. Some examples are as follows: Foundry: Pouring of castings Machine shop: Machining of critical

components Assembly: Assembly of various types

of pumps Testing: Performance testing of

pumps

KBL has brought in major changes in the areas of machining and testing. “We have changed in the entire layout to have uni-directional material flow and optimum space utilisation. While achieving this, we wanted to create

world-class manufacturing facility in the pump industry,” says Vetal. While redesigning the manufacturing processes, the focus was on simplifying the processes; eliminating non-value adding activities and movements; eliminating the fatigue of the operator; switching over and accommodating the operations being performed on conventional machines to existing CNC machines and removing old conventional machines; and reducing the number of set-ups. Vetal adds, “To improve the reliability of components for leakage testing, we have introduced hydro testing of bare casing to the higher pressures.”

Pumping in process efficiency for high productivity


Kirloskar Brothers Ltd (KBL), a market leader in pump and pumping systems, has brought in certain changes to make its manufacturing process lean and productive. Besides, it has introduced innovative manpower training that helps the company significantly attain its productivity goals.

View of KPD unit View of split case type pump shop – machine shop, assembly & testing


Kirloskar Brothers Ltd

The other areas of focus included: Innovating and designing

composite tools on CNC machines to achieve closer geometric accuracies and multifold productivity.

Implementing the concept of Single Minute Exchange of Dyes (SMED) to its true meaning, resulting in easy changeovers and reduced inventories. This has also resulted in reduction in throughput time to facilitate faster deliveries.

Multi-tasking for the operators to operate 2/3 work stations simultaneously based on Standard Work Combination Chart (SWCC).

Uniqueness of KPd unitKBL, as an organisation, has established competency in designing and producing world-class hydraulic solutions for the chemical industry and other sectors. “While developing new product or upgrading existing products, we systematically follow the process of understanding the needs and expectations of customers. And then conceptualise the right product for their application. The process also involves design, development and testing of the same to fulfil the application requirements,” says Vetal.

KBL is equipped with its own captive foundry for various special ferrous and non-ferrous materials,

which facilitates the company to take control on all manufacturing processes in foundry, machine shop, assembly, performance testing and coupling with the prime mover. “In machine shop, we have installed different types of CNC machines from renowned manufacturers, which are capable of delivering geometric accuracies to the tune of microns. We follow Kirloskar Production Systems (KPS) meticulously in all our manufacturing plants, thereby exhibiting lean manufacturing,” says Vetal.

KBL is also equipped with various test facilities for non-destructive testing of the components and test beds for performance testing of pumps.

machines installed in KPdKBL’s approach is to make optimal use of CNC machines or semi-automatic machines, wherein the manual work contents are very less. “This not only reduces the fatigue to the operator but also eliminates the subjectivity in the quality of components produced on it,” points out Vetal.

manpower trainingIn any organisation, providing training to the people plays a vital role in ensuring radical growth. KBL offers training to its employees – both staff as well as workmen category. It includes technical that is knowledge-based, and behavioural, which is personality-based. Most of the time, external faculties are hired, who are well-known in

their field. Volunteer trainers are also developed within the organisation.

“We have pioneered a kind of training programme, which we have named as Out Bond Training (OBT). This is one-of-its-kind programme and no one other than Kirloskars has tried it,” says Vetal. Started way back in 2000, this training has been imparted to the entire group of employees, who are working in a team on common objectives/tasks. This unique programme has transformed their overall behaviour and thought process inside and outside of the organisation. OBT is a Self Soul Seeking Programme, in which the participants are isolated from their workplace and home. OBT programmes are designed to include the classroom sessions as well as some games and role plays.

Getting to the coreKBL is aggressively marketing its process pumps in chemical industry for core applications. There is a separate segment, which specifically focusses on chemical process industry. Its wide network of dealers, distributors and regional & zonal offices addresses the needs of the chemical industry. “Today, the marketshare of KBL process pump is 20 per cent. Of this, core chemical process pump constitutes 7.5 per cent. This year, 15 per cent growth is expected in core chemical process pump segment by way of innovative product range added in the recent past,” asserts Vetal.

Photo: Joshua Navalkar


Machines used in KPD shop of KBLMachines Quantity Used for

Heller make horizontal machining centre 1 CasingsDoosan make horizontal machining centre 1 CasingsHydro testing rig 1 CasingsKWS make C500 turning centre 3 Impellers

HMT make turning centre 2 ImpellersHorizontal broaching machine 1 ImpellersDynamic balancing machine 1 ImpellersComponent washing machine 1 Casings and impellers

While developing new product, we systematically follow the process of understanding customer needs. And then conceptualise the right product for their application.

Dattatray VetalSenior Vice President and Head-Corporate Manufacturing

Insight & Outlook


Petrochemicals The petrochemicals industry in India is one of the fastest growing verticals with growth rates of approximately 10 per cent being witnessed since 2010, which is expected to sustain till 2015. However, for this industry, the main areas that demand attention revolve around overcoming economic difficulties and energy concerns. But the good news is that the rising demand for plastics is facilitating the growth of the petrochemicals industry in India. India has inherent competitive advantage in the downstream petroleum product manufacturing. These factors indicate a bright future for the petrochemicals sector in the times to come.

Insight & Outlook | Petrochemicals


The Indian chemical industry ranks 12th in the world in terms of production volume, generating an annual revenue of over $ 30 billion. The petrochemicals industry in India is one of the fastest growing verticals with growth rates of approximately 10 per cent being witnessed since 2010, which is expected to sustain till 2015.

Plastics-infused growthApart from basic chemicals and intermediates, petrochemicals include polymers such as Polypropylene (PP), High Density Polyethylene (HDPE), etc. According to Chemicals, Materials & Foods Practice team, Frost & Sullivan, India currently produces approximately 7.5 million metric tonne of polymer products per annum and this is estimated to increase at a CAGR of 9 per cent till 2016.

While India exports polymers, it also imports a sizeable amount of polymers for domestic use. Furthermore, it is estimated that for key polymers such as HDPE, Linear Low Density Polyethylene (LLDPE) and Polyvinylchloride (PVC), demand is expected to outstrip supply by 2016. Demand for these polymer products is expected to be driven by industrial segments such as automotive, construction, white goods, packaging, etc. “As of 2012, India’s per capita consumption of plastics is a mere 7

kg against China’s 46 kg and a global average of 28.9 kg, highlighting the immense potential for growth. Owing to this, many Indian companies such as GAIL, IOCL, MRPL, have started investing in petrochemical projects,” says the Frost & Sullivan team.

According to Biswanath Bhattacharya, Director, KPMG in India, growth in petrochemical industry is driven by higher consumption of plastic products across various end-users. “Indian consumption of plastics is estimated to be 12.5 million tonne in 2013 and is expected to double in the next 12-15 years. GDP growth, higher disposable income, urbanisation have created high demand for plastic products in industrial goods segments like consumer durables and automobiles; consumer goods & services such as packaging, retail, technical textiles and healthcare. Higher demand for food production necessitates more use of plastics in agriculture,” says Bhattacharya. In spite of the high growth observed in consumption of plastics in India, the per capita annual consumption is still 8-10 kg per annum, which is much lower than

the global average consumption. “This provides a significant opportunity for growth in plastics and petrochemicals industries,” he adds.

I n d i a n p o l y m e r consumption pattern has shown a northward trend for several years. Major drivers for polymer use have been packaging, automotive and electronic

Prasenjit ChakrabortyThe rising demand for plastics is facilitating the growth of the petrochemicals industry in India. Currently, the per capita consumption of plastics is quite low when compared with that of China. This also provides further scope for the petrochemicals industry to leverage the potential. The investment by reputed companies in this sector is an indication in this direction.

Courtesy: CN Moulding

Indian consumption of plastics is estimated to be 12.5 million tonne in 2013 and is expected to double in the next 12-15 years.

biswanath bhattacharyaDirector, KPMG in India


Petrochemicals

appliances. “Healthcare-hygiene, agriculture, infrastructure and construction sectors have also contributed to the increasing demand. With rise in disposable income, consumption of commodity plastics such as polythene bags, food packaging etc is rising significantly. Engineering plastics like poly-carbonate, poly-amide etc is posting strong growth due to technology advancement and substituting wood and metal in many cases,” says Savan Godiawala, Senior Director, Deloitte Touche Tohmatsu India Pvt Ltd. With economic development, consumption pattern would continue to grow with per capita consumption of plastics in India being lower than in China or the global average.

downstream plastic processingAs downstream plastic processing industry in India is fragmented in nature, majority of units are small-scale in nature; hence they account for a

relatively smaller share of total polymer consumption. “Depending on the application, plastics can be made either by injection moulding, blow moulding or extrusion. Extrusion accounts for majority of the total capacity, injection moulding is second in volume in terms of route of processing while the rest come under blow moulding type. The share of injection moulding has increased over the years at the cost of extrusion capacity,” says Bhattacharya.

In the recent years, most capacity addition has been seen in the commodity plastics segment following the domestic market trend. Low level of technology in the small-scale sector is being overcome with investment attracted through MSME Act 2006, which has improved the average capacity per machine, leading to increase in productivity, higher energy efficiency and competitiveness. As far as changes in downstream plastic processing are concerned, Godiawala feels that polymers have been a subject matter of innovation for long time. “Through R&D efforts and processing techniques, eco-friendly polymers have been developed, which support the overall systems of environment in a balanced way. Plasticulture, term used for plastic use in agriculture application, has witnessed important technology developments in downstream plastic products such as soil fumigation films, polytunnels, greenhouses, drip tubing etc,” he says.

an export hub for petrochemicalsOver the years, India has witnessed significant developments in the

pe t roc hemic a l s e c to r, especially in terms of new processing facilities and domestic gas production. Domestic opportunities and infrastructure development in the sector are attracting investments from Indian companies as well as global players. A major initiative, inter alia, taken by Government of

India to give boost to petrochemical sector is promotion of Petroleum, Chemicals and Petrochemicals Investment Regions (PCPIRs) for planned establishment of manufacturing facility for domestic and export-led production. Several billion dollars is proposed to be invested through PCPIR route to increase petrochemical production capacities leading to improved trading of feedstock, intermediates and final products.

“Public sector companies such as IOCL, GAIL, MRPL and private sector companies like Reliance Industries, GSPC etc are investing in PCPIR. MNCs such as ExxonMobil, Itochu, Shell, etc have their plans to participate in the region. Clustering of process units would also result in reduction of operational costs and risks associated with transportation of raw material, giving competitive edge to the industry,” points out Godiawala.

Additionally, factors such as increased domestic gas production due to gas found in KG Basin; talent pool available in India for developing R&D; use of advanced technology by the players; and large-scale production could be instrumental in leading India as emerging export hub for petrochemicals. “Integrated PCPIRs have been proposed to reap the benefits of networking and efficiency through use of common infrastructure and support services. Master plan for PCPIRs in Kerala, Andhra Pradesh, Orissa, Gujarat, Tamil Nadu is underway,” concludes Bhattacharya.


AdvAntAge IndIA India has inherent competitive advantage

in the downstream petroleum product manufacturing

the country has low unit labour costs and the demographic potential for a large and capable skilled/managerial workforce

geographically, India’s West Coast is strategically located directly facing the Persian gulf across the Arabian Sea, from where over 40 per cent of the world’s sea-borne crude oil originates

In addition, the Middle east’s refined product demand is growing rapidly

India is also strategically placed between key global crude producers in the Middle east and the growing consumption centres of east and Southeast Asia.

there have been policy support recently to make India a petrochemicals manufacturing hub, including an intent to achieve significant exports

Through R&D efforts and processing techniques, eco-friendly polymers have been developed, which support the overall systems of environment in a balanced way.

savan GodiawalaSenior Director, Deloitte Touche Tohmatsu India Pvt Ltd

Insight & Outlook | Petrochemical processing


“The concern for man himself and his safety must always form the chief interest of all technical endeavours. Never forget this in the midst of your diagrams and equations.” This statement by Albert Einstein is more relevant in the aftermath of what went wrong at the Union Carbide’s Pesticides Unit (UCIL) at Bhopal about three decades ago whenever any talk of development and progress centres around business growth through industrialisation.

Scientific discoveries and technological innovation have always been instrumental in many ways for prosperity and enhancement of quality of life. However, with each innovation, there comes a heavy price tag of safety concern. It is never too early to integrate productivity with process safety and be prepared to bring out changes and value-additions with respect to hazard identification and risk assessment, which can act as an effective means towards accident and loss prevention.

The Bhopal disaster that occurred in December 1984 at UCIL plant is one of the world’s worst industrial catastrophes. Water ingress into the storage tank caused a massive chemical runaway reaction and consequent over-pressurisation/release of methyl isocyanate vapour, heavily polluting air, water and land with casualties of over 5,000 in the vicinity, led to serious domino effects. This raises an important question as to ‘have we learnt our lesson from Bhopal?’

Are we confident that such incidents

will never ever happen? The answer could be yes and no.

existing safety governance attributes in india Safety management has always been highly dynamic, and therefore, requires continual improvement through review/revision/amendment on sustainable basis besides introduction of emerging ideas with reference to Process Safety Management (PSM).

statutory provisionsBasically, all industrial establishments are covered under various statutory provisions pertaining to labour safety/welfare and health surveillance besides technical safety concerns involving hydrocarbons, pressure vessels (static/mobile), boilers, prime movers, gas cylinders, explosive materials, hazardous wastes and a host of other activities affecting environmental quality. An effective compliance of all the above statutes can accelerate the process of safety governance.

Till recent times in most organisations, safety was handled by a welfare officer along with a safety person, probably with an industrial safety diploma, an industrial hygienist and/or a joint participative safety committee. They used to concentrate mainly on prevention/reduction/control of shop injuries, which are frequent but of low severity or lesser consequential impact. The response was also limited to

shop floor worker amenities and use of Personal Protective Equipment (PPE). This was definitely a good foundation of workplace safety and a system for process safety can be built on top of that. This makes line management more responsible with better focus on behavioural issues along with systems and procedures looking beyond regulations.

As the name indicates, petrochemicals include both hydrocarbons and allied chemical units. Basically, they are the downstream of the oil and gas industry – an industry whose products are a part of our daily lives commencing with milk pouches, bottles, carpets, synthetic clothing, fertilisers, tyres, paints, pharmaceuticals, cosmetics and many other applications. This unit generally comprises different areas – processing, purification, blending, packaging, storage, transfer, loading/unloading, transportation etc, involving hazardous chemicals. The Chemical Process Safety Management (CPSM) system starts with documenting the physical and chemical properties of these chemicals and ensures that all stakeholders are aware of its properties/hazards before use.

Chemical hazards and risk assessmentAll activities involve hazards, and risk is a likelihood of the damage by an incident that escalated from the hazard during the activity. It is beyond human control to eliminate them but

Inherent approach forP VijayaraghaVan

The process safety culture of an organisation determines how process risk control issues are handled. In the long-term, processes will be made inherently safer through the elimination of hazards rather than their control. As a result, the use of inherently safer process and techniques is the best approach to ensure safe operations in petrochemical industry.

a safer tomorrow


Petrochemical processing

effective CPSM guides that the risk can be controlled and the hazard can be managed to avoid any catastrophe. So, hazards involved in these different activities are identified and the risks are assessed. Consequently, elaborate systems and procedures are built to contain these risks within acceptable levels. This exercise is done methodically covering all areas of manufacturing such as raw material receipt and storage; process units where these chemicals undergo different unit processes & unit operations at different temperature and pressure conditions; product storage and loading; waste disposal/effluent treatment units, etc. The chemical reactions may be exothermic in nature, which can result in any unfavourable consequences, if not controlled, for which such exercise becomes immensely beneficial. Thus, it helps to first recognise and subsequently manage the risks involved in each step of a manufacturing cycle.

The hazards associated with any process typically result from either the fundamental chemical characteristics of the process materials (eg, toxicity, flammability, reactivity, exclusivity), the physical conditions under which the materials are handled (eg, temperature and pressure), the characteristics of the process equipment, or a combination of these factors.

Risk is calculated by identifying probable consequences and their frequency of occurrence and multiplying these two to get a risk score. Both routine and non-routine activities are subjected to hazard identification and risk assessment and high score activities are reviewed further for incorporating measures to reduce the risk. This forms the backbone of a good CPSM system. The Centre for Chemical Process Safety (AIChE) describes various elements and principles as follows. Commitment to process safety (PS) Using PS as a core value; strong

leadership; high-performance standards Developing process safety culture Zero tolerance for willful violations;

reward PS performance Compliance against process safety

standards Standard owners Process safety competency Improving knowledge updates on

PSI; apply the learning Workforce competency Confident, disciplined and

enlightened shop floor workforce Understanding hazards and risks Identify process risks and risk control

measures Process knowledge and management Catalog, protect, update and use

process knowledge Risk management Improved procedure related and

administrative controls Operating procedures Identify procedures required; develop,

use and maintain procedures Safe work practices Control non-routine jobs Asset integrity and reliability Identify in-scope equipment;

maintain knowledge, skills, procedure and tools; ensure continued fitness for purpose; address failure; analyse data

Management of outsourced activities

Conduct work activities; monitor contractor management system

Training Identify training needs; provide

effective training; monitor performance

Management of change

Identify potential change; evaluate risk to allow the change

developing process safety cultureThe process safety culture of an organisation is a significant determinant of how we approach process risk control issues and how we behave when no one is watching. Incidents are system failures that can often be linked to such cultural deficiencies. It has strong systems such as Permit to Work (PTW). No job can be performed without it coupled with strong management Technical Authority Limits (TAL), etc, and provides a CARE culture – Counsel, Appreciate, Reprimand and Enforce.

In the long-term, the focus will be on inherent safety by way of hazard elimination rather than its control. This approach relies upon the intrinsic safety characteristics of the people, process and equipment to prevent injuries, environmental damage, and property damage rather than on control systems, interlocks, or procedures that prevent, stop or mitigate incidents. It is essential for industry practitioners, research professionals and academicians to fulfil their responsibility by learning and propagating PSM. This change is probably little slow for altering the course of occasional incidents and a lot more needs to be done. It is a huge effort; and the best part is that it is happening.

P Vijayaraghavan, a Chemical Engineer, has total 42 years of experience in petrochemical sector. He retired as Site President and Factory Manager at the Baroda Unit of Reliance Industries Ltd (erstwhile Indian Petrochemicals Corporation Ltd). Email: [email protected]

Major incidents in chemical industry in different parts of IndiaLocation Year Origin of

incidentChemical involved Number of

Deaths Injured EvacuatedNew Delhi 1985 Release Sulphuric acid 1 340 >10Mumbai 1988 Fire in refinery Oil 35 16 -Nagothane 1990 Leakage Ethane and propane 32 22 -Visakhapatnam 1997 Refinery fire LPG 60 31 15000Vellore 2003 Explosion Explosives 25 3 -Jaipur 2010 Fire Motor spirit 13 150 -Hazira (Surat) 2013 Fire Motor spirit 5 None Not warranted

Insight & Outlook | Detergent market


detergents are classified under two broad categories – oil-based laundry soaps, and synthetic detergents, including bars, powder and liquids. The detergent market is mainly concentrated in urban areas, but gradually penetration in the rural areas, over the last few years, has been good.

The Indian detergent market is expected to grow at 7-9 per cent pa in volume terms. HLL, Nirma and P&G are the major players in the market with 82 per cent of the marketshare; HLL dominates the premium segment and Nirma is the leader in the popular segment.

The demand for detergents has been growing at an annual growth rate of 10-11 per cent during the past five years. Where an urban consumer prefers washing powder and detergents, a rural consumer is more inclined towards washing cakes and bars. But, over the

last few years, rural consumers are gradually shifting from detergent bars to detergent powders.

Rural India is rapidly becoming target market for most of the brands in the country. The contribution of rural markets in the FMCG sector is growing faster than urban markets. Rural consumers are upgrading their lifestyle with shifting preferences from non-branded and local products to the branded ones.

surfactants, the major constituent of detergents Linear Alkylbenzene Sulfonate (LAS) is the world’s largest-volume synthetic surfactant and is widely used in household detergents as well as in numerous industrial applications. About 82-87 per cent of LAS is used in household detergents, including laundry powders, dishwashing liquids and other household cleaners in varying proportion based on

cost factor. The percentage of LAS in liquid form varies depending upon the cost of bars and powder detergents. Industrial, institutional and commercial cleaners account for most of the other applications, but LAS is also used as an emulsifier (eg, for agricultural herbicides and in emulsion polymerisation) and as a wetting agent.

LAS competes with several other major surfactants for use in household detergents. Some of the competitive surfactants have higher hard-water tolerance and better compatibility with enzymes and are milder than LAS. Historically, however, LAS has most often been lower in cost and has had other favourable properties compared with competing surfactants. Although consumption of LAS is likely to stabilise

or decline slightly in the highly developed regions, it will increase by 2-4 per cent in the less developed regions, such as the Middle East, Africa, India and China, as well as Southeast Asia. As a result of the rapid growth in demand for LAS in the Asia-Pacific region, it is expected that by 2016, the region will account for more than 50 per cent of global demand. Worldwide, growth in demand for LAS is expected to average about 2 per cent per year during 2011-2016. It will be negatively impacted by the efforts of the detergent manufacturers to reduce the active content in their surfactant formulations.

LAS is the most cost-effective surfactant as compared to other products. It can be manufactured cost-effectively, if large-scale super phosphate manufacturers starts making LAS by wet route. Spent sulphuric acid, a by-product of LAS plant, can be used in super phosphate

Surfactants adding to the bubbly

prospects

Piyush AgrAwAlThe detergent market is one of the segments in the FMCG market in India that has high growth potential. However, the type of detergent preferred by rural and urban consumers varies. And surfactants form a major constituent in detergents, which play a vital role when it comes to applications of detergents in various areas.


Detergent market

manufacture as raw material.This will give cost benefit for the product as well as avoid transportation of hazardous chemicals.

liquid detergentsThe liquid detergent is as effective as the powder detergent. What makes liquid popular is the ease of operation and improvement in productivity with the automated dosing system. Powder is manually dosed and is susceptible to error, leading to inconsistent results whereas liquid is automated and more reliable. Solid detergents contain solid fillers to reduce the cost, which ultimately get either deposited on cloth or add up TDS loading on wastewater. The dosages of the liquid detergents are controlled and are not subject to human intervention. This brings in consistent cleaning performance to the linen day in and out.

In fact, the cost of liquid detergent is higher compared to powder. But, when it comes to the productivity and consistent wash results, the liquid detergent is cost-effective. In case of India, with the awareness about the liquid system increasing, several customers are shifting to liquid laundries.

Detergents primarily have three roles – to improve wetting ability of water; to loosen & remove soils; and to emulsify, suspend or eliminate soils in the washing solution. It is basically the customer’s choice between liquid and powder detergents, as both have their own features and limitations. As far as product stability is concerned, powder detergent may become lumps or cakey when stored in high humid area due to its hygroscopic nature and get wet during rainy season. Liquid detergents may solidify or separate out as they are temperature-sensitive.

Actually, both powder and liquid detergents contain several ingredients such as builder, anti-re-deposition agent, water conditioning agent, corrosion inhibitor, opacifiers, fabric softening agent, fragrance, digester and

enzymes. Liquid detergents are not necessarily effective in all cases, but they work better on typical stains and do not harshly affect the fabric if designed with balanced surfactants. These detergents are better options from the environment point of view and hence gaining momentum in India due to ease of handling for working class.

advantages of liquid detergentsThe packaging material cost (such as HDPE jar) and the high price of surfactants also influence the overall cost of liquid detergents. But, product wastage is minimal with liquid detergent applications and it is a value-addition to the fabric. Good liquid detergents are phosphate free and do not contain major inorganic constituents. With better foam and better results, it is recommended for soft & premium fabrics and for those that are not colour fast.

Sometimes powder detergents may leave residue on the clothes, which can be avoided using liquid detergents with a proper dosing system. The newly developed professional laundry machines have inbuilt design of dosing system, which makes things easier. Dosage depends on laundry cycle, usage of additional booster, softeners, biocides, whitener, bleaches and neutralisers.

Indian customers demand result-oriented products at minimum cost. Liquid detergents will take time to become popular considering the Indian environment, available water quality and product cost. These are available in various scents and colours, whereas powdered detergents may not be as versatile.

Liquid detergents are becoming popular around the world due to its convenience in dispensing, easy dispersion and dissolution in the wash water. These are most common in bigger laundries where they have auto-dosing system. Further mixing of chemicals with liquid detergent becomes much easier as it is aqueous-based.

other surfactantsThere are other categories of surfactants as well. Sugar-based surfactant development is currently gaining ground. Growing demand for Alkyl Polyglucoside (APG) – a non-ionic surfactant made from vegetable oils and starch – is driving new developments and increasing marketing for other sugar-based surfactants. These products could replace traditional petroleum and even other natural oil-based surfactants.

Methyl Ester Sulfonate (MES) is not ideal for liquid products, due to the stability at low temperature. Unlike LAS acid, MES is not as flexible and easy to adopt into the final detergent product. It has high detergency at low surfactant concentration or low detergent dosage, even in high calcium-contained washing water. In this respect, it is rather easy to make concentrated powder detergents with MES.

research and technology advancementsAlthough technological developments and growing understanding of chemical processes had improved the industry’s ability to restore soiled garments and other objects to their presoiled condition, available soaps and detergents still failed to achieve perfect results. Chemical scientists, therefore, continue to work on developing innovative laundry additives such as new enzymes and oxygen bleaches. Zeolite, sodium citrate, sodium carbonate, and sodium nitrilotriacetate were under investigation as possible builders to replace phosphates. Other questions being addressed include product safety, water quality, chemical disposal, the ability to wash in unheated water, and indoor air quality.

Piyush Agrawal has 35 years experience in operation management in fertilisers and petrochemical industries. He retired as Vice President (Corporate Affairs) from Advance Surfactant India Ltd. Email: [email protected]

Insight & Outlook | Gas analysers


air analysers indicate the level of pollutants in the atmosphere. These pollutants have varying levels of impact on human beings, plant and animal life. The pollutants are emitted by process plants by wind effect and dispersion move and hence, have detrimental effect in the vicinity of the plants and beyond. In order to control the pollutants, estimation becomes essential and here is where analysers (as sensors) provide a valuable help in the design of pollution control equipment.

According to Craig Marvin, Solution Business Manager (GAS Phase Division), Agilent Technologies, several chemical manufacturers monitor production of gases to verify process efficiency by employing various technologies. “These systems are not routinely used to monitor air quality within the plant. Monitoring the quality of air in and around the plant usually requires a system that measures volatile organic components. Depending on the required reporting limit, such systems may or may not use pre-concentrators to concentrate volatiles prior to sample injection and analysis,” says Marvin.

The number of sampling systems tied to the analyser will depend on the required frequency of sampling and reporting. Plants monitor Benzene, Toluene, Ethylbenzene and Xylenes (BTEX) and other volatiles

to protect workers from chemicals that pose threat to their health. Air analysis also alerts the plant’s control centre about the build-up of gases that can create a potentially dangerous and explosive environment. Fence line monitoring of production facilities helps to protect the local community from the release of, or build-up of, potentially toxic chemicals into the atmosphere. “As concerns about global warming increase, environmental regulators may require that industrial gas producers monitor the release of greenhouse gases into the atmosphere. This analysis will involve measurement and reporting of CO2, CO and NO2 and other gases in stack and other plant emissions,” says Marvin.

level of adoption Process efficiency and product quality drive profitability for companies in the chemical industry. Ensuring that raw materials meet purity requirements prior to introduction

to the process ensures maximum output and product quality. Protecting expensive catalyst beds from contaminants also help producers avoid undue production expenses. “Producers have incorporated solutions from Agilent Technologies and its channel partners to monitor production processes through at-line and in lab analysis. The global reach of the chemical industry and its impact on consumers necessitates standardisation of material specifications and compliance methods to ensure consistent product quality as well as facilitate contract negotiation between parties within the industry,” states Marvin.

As a technology leader, Agilent Technologies has a 40-year history of collaboration with American Society for Testing and Materials (ASTM) International for industry standards and methods development. Scientists from Agilent actively monitor emerging requirements and trends to increase visibility of industry requirements

to ASTM. Through these efforts, Agilent brings ASTM solutions and experience for the benefit of its customers worldwide. It offers analytical instrumentation that provides producers with tools to monitor process efficiency; evaluate product quality; and protect expensive process components through the

Effective tool to monitor air quality

Prasenjit ChakrabortyGas analysers play an important role in addressing environmental issues. Besides, these, to some extent, help in promoting workplace safety in chemical plants. Such analysers also caution the plant’s control centre about the build-up of gases that can create a potentially dangerous and explosive environment.

As concerns about global warming increase, environmental regulators may require that industrial gas producers monitor the release of greenhouse gases.

Craig MarvinSolution Business Manager (GAS Phase Division), Agilent Technologies


Gas analysers

determination of trace level contaminants in difficult matrices.

“Analytical solutions built around laboratory GC for low level lab or at-line analysis and Micro GC rapid analysis facilitate process monitoring and product quality evaluation. Recent developments with the Agilent portfolio include solutions for analysing natural gas, refinery gas, and trace contaminants in high purity gases,” says Marvin.

Giving an Indian perspective, Dr N Anantharaman, Professor, Chemical Engineering Department, NIT, Trichy, says that in the past two decades, due to legislation brought in by Indian government, there is a significant improvement in the level of awareness. “Today, the companies aspire to get EMS certification, and for this they need to adhere to the specified norms. This has really made companies to think about the use of devices to estimate and control the pollutants,” he observes.

Gas analysisChemical producers interested in monitoring process efficiency through gas analysis should consider the following points: Representative sampling: Getting a

sample that accurately represents the process to the analyser can present a challenge to chemical producers. Planning sampling and analysis schemes should take into account the stability of the sample, ease with which samples can be collected, transport to the analyser, and injection into the analytical system.

At-line versus laboratory-based analysis: Some processes and matrices are not conducive to transportation of samples to the analyser due to analyte stability, or other factors. Such processes may require at-line analysis. Processes for which sampling and transport of samples do not present a problem allow for laboratory analysis.

Controlled or non-controlled locations: Within the chemical industry, plant safety represents a significant concern. Analysis of processes in controlled environments will require ATEX or Div 1, Class II certified enclosures for the analyser. Laboratories or monitoring stations operated in non-controlled environments allow use of conventional bench top or at-line equipment.

Dr Anantharaman strongly feels that the government should make the companies take ISO certification on EMS. “Also, people should look at eco-labelling and purchase items. Once awareness is created among the public automatically, companies will come forward for maintaining a clean environment and also adhere to the norms prescribed by pollution control authorities,” he concludes.


Insight & Outlook | R&D


major US chemical producers are likely to increase their spending in R&D this year. While the increase may be smaller than in earlier years, it could still have an impact on broader industries. R&D spending by chemical companies is expected to create a ripple effect that generates more innovation, and results in expansion in the downstream sectors, such as paints and coatings industries.

One-tenth of all patents filed in the US are from the US chemicals and advanced materials sectors.

Spending more in R&D does not necessarily create innovation. Data suggests that there is no direct relationship between R&D spending and common measures of corporate success such as growth, profitability and shareholder returns. Profitable

innovation, in other words, cannot be bought. It can lead to a waste of resources on increasingly marginal products. The solution to innovation anaemia is in reassessing the effectiveness of base line spending and increasing the return on innovation investment (ROII). The company’s ROII must be lifted.

The innovation effectiveness curveIt is important to understand the innovation curve of any company and its economics. Innovation is embodied by a product or service offering that contains significant element of newness. ‘New’ may not mean entirely new to the world, of course, since line extensions of existing brands are frequently a profitable form of innovation. True innovation can take the form of a new product, technology process, content, or even the presentation and marketing of existing products or services.

Incremental innovations are subject to diminishing returns. Each additional dollar spent on new product development ultimately yields a lower return. This makes sense. Spending beyond a certain point on any development portfolio results in lower returns, since a company will naturally invest in the best projects first, the next best after that, and so on, until it is tossing good money

Triggering innovation for better returns

Dr Mosongo MoukwaThe pace of corporate R&D spending, especially in chemical companies, is expected to accelerate as they believe that enhanced innovation is required to fuel future growth. However, R&D cannot be seen as a separate function in the innovation chain; it merely acts as a catalyst to stimulate innovative ideas.


R&D

away on more and more dubious projects.

This is perhaps best illustrated in Figure 1 where two companies A and B and their marginal ROII are shown. The area under the curve gives a sense of the effectiveness of innovation. The larger the area under the curve, the better is the company’s innovation effectiveness. Each company has an intrinsic innovation effectiveness curve, which can be drawn easily by plotting the ROII of each project in the development pipeline and the cumulative innovation investment. The curve predicts the company’s future revenue, profit and growth derived from new products. The company’s innovation effectiveness is surprisingly stable, even when projects within the portfolio change. The intrinsic curve limits the return it achieves from marginal investment in innovation.

The law of diminishing return in innovation effectiveness explains the numerous cases in which increase in R&D spending does not significantly improve sales or growth. These companies are not raising the curve, but rather riding the curve. They are probably spending on idea generation and new product development, without altering the processes, systems and structures, or capabilities that really determine their ROII.

The results of raising innovation effectiveness can be profound. Companies increase the return on their base innovation spending (more high-quality, new product at faster rate and lower cost) and get an option to invest more while maintaining a high level of return. The height of the curve defines the company’s overall innovation effectiveness. Companies within the same industry can differ widely in their innovation effectiveness; it is clear that firms must raise the innovation return curve.

addressing the entire innovation value chainRaising the inherent innovation effectiveness curve requires senior management to understand that innovation is not a discrete activity, but a multifunctional capability that requires several types of competencies. Innovation must be seen as an expression of a well-organised value chain, with four set of capabilities: ideation, project selection, development and commercialisation. The innovation effectiveness curve cannot be raised unless all four elements are mastered; a chain is only as strong as its weakest link.

It has been noticed that the silo-ization of ventures is a challenge in project selection. Often, investment decisions are made individually. The best approach is to assess projects within the context of the whole portfolio, since all new product candidates are competing for the same pool of resources (both people and money). Net Present Value (NPV) cannot be the sole criteria for ranking projects. Instead, companies with the highest ROII incorporate a number of relevant metrics such as strategic fit, risk adjusted NPV, new product portfolio balance and prioritisation, and current & near future resource availability by geography, skills or functional area.

Some projects need to be put through their pace quickly, which allow companies

more flexibility in selecting a launch date and more time to devise & execute the commercialisation plan. It also keeps the spending down. Time to market is critical for some projects than others. Delays in new product introduction directly affect development costs and returns.

on the innovative path Efficient project management is another requirement. It eliminates waste and duplication. Most efficient organisations are lean with strong cross-functional teams

including manufacturing and R&D, and able to run processes in parallel. Commercialisation capability must be core, coupled with a strong sales forecast capability. Current incentive structures often encourage marketing and sales personnel to be too optimistic in their projects, and this must change.

The key question to address is the overall culture of the organisation. The first step is to change the innovation culture. This is where the top management comes in. They need to lead the shift in mindset so that innovation is the centre of everything in that company. For many companies, this is not easy. It will require a phase change to the creative economy. It also means specific management changes and focus on innovation to add value for the customers. Management has become the art and science of generating continuous supply of additional value. R&D cannot be seen as a separate function in the innovation chain. It is merely an input to innovation.

Dr Mosongo Moukwa is Vice President (Technology), Asian Paints Ltd, Mumbai. He was Vice President (Global Technology), Reichhold, North Carolina. He

is a member of the American Chemical Society, the Commercial Development and Management Association and the Licensing Executive Society. Email: [email protected]

Innovation Investment

Total InnovationInvestment by A

Total InnovationInvestment by B

Cost of capital

Source: Booz Allen Hamilton

Mar

gina

l Ret

urn

on In

nova

tion

Inve

stm

ent

Company ALarge projects, poor projectdepth (too few viable projects)

Company BSmall projects, good project depth (many projects generate acceptable returns)

Figure 1: The Innovation Effectiveness Curve

User-industry Monitor | Textile industry


Colouring matters, which may be classified as dyes and pigments, have been exploited by man for their aesthetic values and used to embellish various articles including clothes. Starting with Indigo, the oldest known dye, originating from India; the royal Phoenician’s dye, Tyrian purple (or Royal Purple) of the ancient city of Tyre; Alizarin, among the Turkey people; to Cochineal of the European and Mexican dyers, indigenous dye-yielding plants have been discovered in almost every region of the world.

Dyes are soluble substances used to pass colour to the substrate and find applications primarily in textile industry. There are several types of dyes; however, in India, disperse, reactive and direct dyes are most commonly used. Pigments are insoluble substances and could either be in powdered or granular form. They impart colour by reflecting only certain light rays. Pigments can be broadly classified as organic and inorganic.

global scenarioThe global market for dyes and pigments is forecast to reach 9.9 million tonne by 2017 and touch $ 26.53 billion, driven by the growth in key end-user industries. Additionally, market demand is rising from stringent and increasingly rigorous quality, performance and environmental standards. Increasing consumer preference for environment-friendly products, which in turn is driving the consumption of high-performance dyes and organic pigments, is expected to provide stimulus to the pigments and dyes market globally.

india storyTraditionally, India has been a major manufacturer of textile dyes, tracing its history to the rise of textile industry in the early 1900s. If we look at the more recent facts, following the decline of the traditional producers in the developed world, particularly in Europe, the simultaneous ascent of new ones in Asia,

particularly India and China, is arguably one of the most significant changes ever seen in this industry. The shift has been quite swift and followed the migration of end-user industries, notably textiles and leather, to low-cost economies of Asia such as India. Thus, currently, the Indian dye and pigment industry is a major player in the global supply chain for textiles.

Manish Kiri, Managing Director, Kiri Industries Ltd, notes, “The dyes and pigments industry is mainly dependent on the consumption levels in the textile industry. Since the textile industry is rising in India, the demand for dyes and pigments is increasing as well. Further, the industry in India is mainly export dependent. Around 70 per cent of the products are exported.”

The dyes and pigments industry constitutes nearly 950 small-scale units and 50 large units manufacturing dyes, dyestuffs and pigments, with a total capacity of 1,60,000 tonne. Of this, the production capacity of pigments is estimated at 40,000 tonne per annum (tpa), half of which is in the small-scale sector. Two states – Maharashtra and Gujarat – account for around 90 per cent of the total dyestuff production in the country. The dyestuff industry has forward and backward linkages with many sectors but the major being textiles. In fact, the textile sector consumes around 80 per cent of the total production due to high demand for polyester and cotton, globally.

Adding new colours to dyes and pigments sector

AvAni JAin

Being a leading player in textiles, India has created a major demand for colourants, including dyes and pigments, which find wide applications in textile industry. Hence, dyes and pigments constitute one of the core areas of Indian chemical industry coupled with high export potential.


Textile industry

Textile industry: Boosting demandDyes currently used in the textile industry are mostly synthetic. They are derived from two sources – coal tar and petroleum-based intermediates. These dyes are marketed as powders, granules, pastes or liquid dispersions. The concentration of active ingredients typically ranges from 20-80 per cent. The textile dye segment is characterised by new dyes regularly developed for meeting the demands of new technologies, latest fabrics, detergents, advancements in dyeing machineries, along with overcoming the serious environmental concerns posed by some existing dyes.

With the fast changing product profile of the textile industry, from high-cost cotton textiles to the durable and versatile synthetic fibres, the pattern of consumption of these dyes is also going

through rapid changes. Nowadays, polyesters account for a major part of dye consumption. Due to wide use of polyester and cotton-based fabrics, there has been a shift towards reactive dyes, used in cotton-based fabrics, and disperse dyes, used in polyester. The demand for reactive and disperse dyes is expected to grow fast due to this trend. The textile industry will remain the largest consumer of dyestuffs. However, growth will be driven by markets such as printing inks, paints and plastics. These segments will also increase

the consumption of high-performance pigments, thus improving profitability.

growth driversThe demand for dyes and organic pigments is expected to grow at 11 per cent per annum till 2020 to reach $ 10 billion. However, the industry can aim to grow faster at 15 per cent to

reach $ 14.5 billion. To achieve its aspirations, the

industry needs to take efforts in critical areas and focus on innovations, with emphasis on R&D; optimise the product portfolio; and build better quality & high performance colourants. Further, improving environment-friendliness of products & services, and ensuring compliance to international regulations to continue access to the exports markets will help provide a boost to the industry.


Since the textile industry is rising in India, the demand for dyes and pigments is increasing as well. Further, the industry in India is mainly export dependent.

Manish KiriManaging Director, Kiri Industries Ltd

Automation Trends | IT in logistics


The chemical industry is one of the top five revenue generators for the logistics sector in India. This industry today has a global supply chain, which brings along a new set of challenges, particularly in India. For example, on a daily basis, a chemical company has to deal with volatile fuel prices, increasing raw material costs and mounting price margin pressure, besides ensuring that materials are delivered to the factory for production, and then products are sent to the customers or warehouses on time. A mammoth task before the industry is making certain that all these processes take place seamlessly.

adopting iT as a forward mindsetThe chemical industry worldwide is characterised by clustered production capacity and distributed consumption points. “Efficiency, competitiveness, agility, and sustainable logistics are thus important success drivers in this industry. Dependence on specialised service providers who can customise and deliver improved logistics services at reduced costs is on the rise,” says Asim Behera, General Manager – India, Swisslog. In this backdrop, IT is emerging as a key enabler of innovation, strategic transformation and operational excellence. Network expansion, process integration and risk reduction are three areas where IT can play the role of an enabler as well as accelerator. “Chemical manufacturers face several issues unique to their businesses.

Managing a large and complex supply chain with descriptive features and disparate production sites, while at the same time trying to improve production efficiency and respond to market demands, constitute a set of problems that we have to face simultaneously. One needs to learn to live with these issues, and also to cope up with the resources that are required to deal with these. IT, today, plays an integral role and if right IT solutions are implemented in the key area of logistics, chemical manufacturers can boost profits, grow their customer base and reduce wasteful practices,” says Ramanand Gupta, Managing Director, Revex Plasticisers Pvt Ltd.

delivering safety and securityThe chemical industry has a high intensity

of risks inherently attached to it because of the volatile and hazardous nature of products. This directly has an impact on the supply chain mechanism. Safety is an important aspect to consider during the strategic planning of transit. Along with safety, comes security. For example, the sea route to Africa is plagued with sea pirates. Ensuring safety of products and personnel thus comes with a cost, which is heavily justified. Here is where adoption of sophisticated IT software comes into play. The industry needs to understand the cost-benefit analysis of ensuring a safe and secure transit operation.

“The use of new generation technology will give Logistics Service Providers (LSP) a lead over their competitors. This will also be essential in attracting higher outsourcing from overseas players. Usage of technology tools such as Global Positioning System (GPS), Radiofrequency Identification (RFID) will definitely help companies and markets to grow, but the stakeholders need to be made aware of the value-addition done by technology adoption,” adds Behera.

seamless integration “Creating chemicals is a complex process. Sequence-dependent production means there are numerous steps required to go from raw materials to a compound ready for sale, and then comes its distribution. When this is spread over several geographical locations, the chances of

Facilitating smooth and seamless transportation

Mahua Roy

As India starts featuring on the global strategic map of MNCs, we see a lot of transformation in the outlook of the chemical industry. There is more adoption of automation and sophistication of technology. One of the crucial pillars holding this industry together is the logistics sector. Has it opened up to the opportunities IT can provide?


IT in logistics

this process going wrong become much higher. All the work needs to be balanced in a hierarchical order too. Doing tasks like these manually is difficult and is much prone to mistakes. For example, if a specialised storage vessel is double-booked, it could result in delay of a customer order,” explains Gupta.

For chemical shippers, technology is the key to reducing transportation and logistics costs. Transportation Management Systems (TMS), in particular, can provide chemical companies the visibility they need to manage logistics with an eye for efficiency and cost-effectiveness. TMS provides the granular detail that helps chemical shippers make decisions on how to manage the supply chain in the face of rising costs. To better coordinate loading, unloading and other operations, most companies are now turning to TMS to optimise their transportation networks. TMS products automate key elements of a company’s shipping infrastructure, including strategic and operational planning, network design, transportation execution and monitoring, invoicing, billing and settlements. Gupta further elaborates that without in-depth demand visibility, backed by a complete overview of the status of all the equipment needed to produce a particular chemical, the sales team simply cannot provide an accurate forecast of when customers can expect to receive their orders. This could result in customers choosing another manufacturer who can guarantee when the products they want will be delivered. And, this might severely hit production and revenues. “While many manufacturers might feel that they are working effectively without a specialised system, the initial investment will be repaid many times by the increases in efficiency delivered. So to ensure that you excel in the future, it is important that you invest in the right technology and foresee its benefits,” adds Gupta.

ensuring productivityBesides, IT can significantly hasten the process of scaling the intermodal networks – for example, efficiency and risk-based network design. It also helps in accelerating the operationalisation of warehouses, integrating processes for execution and co-ordination, enabling higher productivity and throughput, lowering unit cost by optimising asset utilisation and cargo planning, enhancing operational control by generating continual visibility to consignments and their status. “We can expect to see the Indian chemical industry pushing for more global products to reduce portfolio complexity, and customers from emerging markets will expect Western standards of product quality and sophistication. Successful logistics providers will have to provide advanced storage, product handling and transport equipment. They will also have to supply cleaning facilities in line with producers’ global SHE policies to support local production and imported flows of product. This can be ensured with deeper penetration of IT solutions,” concludes Behera.


Sustainability Mantras | Bio-refining


The bio-fuels are gaining momentum the world over, including India, mainly due to depletion of oil resources and increased oil prices; mitigation of CO2 emissions & climate change; and reduction of dependence on imported oil & petroleum products. Currently, the biggest demand is for advanced biorefining, ie production of biofuels and chemicals from cellulosic biomasses. There are significant technological and cost differences between the biofuel generation technologies. “Currently, commercial bioethanol is produced by first generation (1G) technology from food crops. The second and third generation (2G and 3G) technologies use non-food, lingo-cellulosic biomasses and are on the threshold of commercialisation. The unique advantage of Chempolis’ 3G technology is the selective fractionation of biomass resulting in reduced requirement for costly enzymes and high purity of products,” says Pasi Rousu, President, Asia & Pacific, Chempolis.

It is important that biomass is put into sustainable use, such as biorefineries, as this will be highly beneficial to the society. For 1G ethanol producers, the use of non-food biomasses along with the existing capacity would give both profitability as well as creditability with respect to environmental and social sustainability. In India, the 3G technology

would provide approximately three-fold revenues from the use of bagasse when compared to current use in co-generation at sugar mills.

Technology edgeIn general, cellulose, hemicelluloses and lignin are the main components of all cellulosic biomasses. The 2G biorefining technologies typically aim at converting

both cellulose and hemicelluloses into cellulosic ethanol while the remaining biomass fractions are utilised for lower value-added products. Principally, the bulk of lignin-rich slurry containing significant amount of water is intended for production of energy. So far, high enzyme costs and complicated fermentation have stressed the profitability of these technologies in which both cellulose

and hemicelluloses are simultaneously enzymatically hydrolysed and further fermented in the presence of lignin. “However, the enzyme costs can be significantly reduced when biomass fractionation is carried out selectively and one gets to feed a pure cellulose fibre into enzymatic hydrolysis. Further benefits are gained when the resulting pure glucose can be conventionally fermented to

ethanol,” points out Rousu. When compared to 2G

biorefining technologies, the main advantage of the 3G technology is the selective fractionation of cellulosic biomass and the possibility to produce pure cellulose, hemicellulose and lignin fractions. The fractionation enables co-production of multiple value-added products without generation of waste, reduced operating costs (especially enzyme cost), higher revenues and a full recovery of chemicals and water. “Moreover, high pressures and temperatures, characteristics for

2G technologies, are not needed due to the innovative and fully recyclable bio-solvent,” he says.

Cellulosic biomass as a raw material Biorefining – converting of biomass into fuels, chemicals, and other value-added products – is already a major, established industry. Citing an example, Rousu explains, global annual production of 1G

Combining profitability with environmental benefits


It is high time for India to provide a major thrust to the usage of bio-fuels for effectively combatting energy crisis. India can make a significant progress in this arena as it has plenty of residual biomasses such as straw and bagasse. Adoption of right technology and necessary government support could make the segment a vibrant one.

July 2013| ChemiCal & ProCess World | 55

Bio-refining

biofuels for transportation is around 100 million tonne, and production of pulp for papermaking is almost 200 million tonne. In addition, recently, governments around the world (including India) have made strong mandates for increasing the consumption of biofuels. Such mandates and related incentives are promoting the expansion of biorefining. However, the role of advanced biofuels using cellulosic biomasses as raw material is still expected to grow. Currently, first such kind of production facilities are being built and brought on-line in the US and EU; but the progress has been slower than expected few years ago. “Governments have created certain incentives for the production, but the support should be clearly stronger to enable advanced biorefining as an essential tool for sustainable development,” says Rousu.

Where india standsIndia is facing energy crisis due to increasing population and hence, the

dependence on imported foreign fossil energy sources is also increasing. New renewable energy, fuels and non-fossil-based chemicals are needed to meet the economic growth. The current situation consuming a significant share of the Gross National Product (GNP) for the import of oil is not sustainable in any way. “India is a rich country when it comes to the availability of residual biomasses, such as straw and bagasse. These biomasses are generated annually over 400 million tonne in India. Using 30 per cent of these available residues in 3G biorefining would enable bioethanol production of 20 million tonne per annum,” notes Rousu.

The possibilities to choose environmentally benign alternatives must be made easy and attractive. This can be enabled by governmental policies, such as feed tariffs, subsidies, grants and tax incentives. Educating people about clean energy benefits in day-to-day life is important. “We expect a tremendous

change in advanced biofuel business to take place in near future. 1G ethanol has to give place for non-food solutions, and usage of molasses just cannot fulfil the targets. We offer a 3G non-food, biorefining platform, which produces pure cellulosic sugars, biochemicals and solid biocoal,” he points out.

Biomass is selectively fractionated with a recyclable biosolvent while all the biomass components are processed into valuable products. When it comes to India, the main challenge for advanced biorefining is to establish first reference projects of commercial production. “India has several advantages and it certainly can be at the forefront of biorefining, because Indian companies already have a tradition to utilise residual biomass from agriculture, especially combustion of sugarcane bagasse and production of electricity. The country also has existing production of ethanol and related infrastructure,” points out Rousu.


Policies & Regulations | Chemical clusters


Today, there is an urgent need to build better infrastructure and provide adequate resources such as power, water etc, to support industrial growth. The chemical industry faces various challenges related to safe transportation of products, proper storage facilities etc. Infrastructure is also inadequate for facilitating seamless exports. Investments are needed to develop roads, railways, waterways, ports, and warehouses, among other requirements, to support the overall industrial growth. Further, chemical units are dispersed throughout the country due to incentives offered by different State Governments. Thus, there is a need to form clusters, with provision of common infrastructure facilities, to address the constraints of

common effluent treatment, transport linkages, including roads, power supply, water facilities, etc.

Jaimin Vasa, President, Gujarat Chemical Association, and Managing Director, Vasa Pharmachem Pvt Ltd, says, “A cluster-based approach will help the industry to grow and the government will also be able to provide basic amenities to all the companies in a particular area. This will encourage planned development in the state, besides giving a boost to the chemical industry there.”

Cluster development Industry clusters are establishments where several players set up plants around an area to reap the benefits of co-location. Some of the major benefits of chemical clusters include sharing of resources to

reduce costs, proximity of suppliers/buyers, thereby improving co-ordination across players and availability of trained & industry-specific skilled manpower.

There are various other benefits offered by chemical cluster, the major being that it will provide a boost to SMEs in the sector, which lack adequate funds, infrastructure and technology. Further, clusters can work to obtain clearance from regulatory agencies in export markets. Companies can get easy access to common services such as power, transportation infrastructure, legal services for patent and intellectual property rights-related queries, and a well-equipped laboratory for quality checks as well as compliance-related

issues. This will also save transportation costs of companies by easily connecting them with the key raw material suppliers, giving them tremendous logistics benefits and operational flexibility. The clusters can set up their own common waste disposal plants like the effluent treatment plants. However, in reality, the success of the cluster development policy is often debated as the industry experts believe that they have not contributed much in driving the growth of the chemical industry.

Case study: PCPirThe presence of chemical manufacturing mega-estates at several industrial clusters in Gujarat has promoted the growth and expansion of the industry by providing an appropriate business ecosystem. Chemical

clusters, especially at Ankleshwar, Panola, Vapi, Vatva, Jhagadia, Dahej etc, have facilitated rapid development. At present, Vapi is one of the country’s largest chemical clusters. It mainly comprises small and medium players. It consists of about 1,300 industrial units, of which about 1,900 are involved in chemical and pharmaceutical processing.

Further, Petroleum, Chemicals and Petrochemical Investment Region (PCPIR) – a specially delineated investment region planned for the establishment of manufacturing facilities for domestic and export-driven production of chemicals and petrochemicals – at Dahej is spread over 453 sq km of brownfield area in the coastal belt of

the Gulf of Khambhat. With a capacity of 22 million metric tonne per annum (MTPA), it is in the vicinity of the Dahej port. The PCPIR offers scope for future expansion possibilities to augment capacities to 30 MTPA for catering to LNG, dry bulk and liquid chemicals.

issues to be addressedWhile everything seems positive about the pace at which the PCPIR is being developed in the state, there are few points, which the government needs to keep in mind. Vasa observes, “It is necessary to landfill the area in order to increase its height by 1.5-3 metre. This is due to the reason that a large portion of area where the proposed PCPIR has to be built turn into a wetland during monsoon season. Government also needs to ensure

AvAni JAin

The chemical industry in India is growing at a rapid pace. In order to add impetus to this growth, and provide a boost to the Small and Medium Enterprises (SMEs) in the sector, chemical clusters have been created. However, the extent of the impact of cluster development policy on the chemical industry is often debated.

Yet to make a difference!


Chemical clusters

effective effluent disposal scheme in the proposed PCPIR. Considering the scenario, the treated effluent will have to be discharged in the deep sea, which will attract a sizable capital and recurring cost that an individual or an association cannot meet alone. Thus, the government has to provide support in this area also. These steps will pave the path for a clean environment in the chemical zone.”

The proposed industrial Special Economic Zone (SEZ) in this PCPIR will include petrochemicals and downstream petrochemical, synthetic organic chemicals, industrial gas producing and other small industries. “Since there will be many major industries in that area, there needs to be a specific zone-based incentive scheme and soft loan from financial institution for chemical-based SMEs,” says Vasa.

He adds, “The government needs to ensure that everyone gets access to the common amenities like basic infrastructure. Moreover, it has to look at assured water and power supply for

all. Efforts should be taken to shift the existing chemical companies to this area as this will help them to better utilise the facilities that are meant for them.” Thus, in simple words, the cluster development policy has yet to prove its worth for the industry.

As a result, the Government of India has developed ‘Industrial Cluster Upgradation Scheme’ to facilitate the growth of all industries including the chemical. The proposed scheme primarily focusses on developing and upgrading industrial infrastructure at existing clusters. The overall objective of the scheme is to influence efficiency and enhance competitiveness of companies located in such clusters. The scheme covers areas such as infrastructure support, market intelligence, technology transfer, human resource development etc.

Gauging the futureThe chemical industry in India is well-established and has recorded a steady

growth over the years. It offers a wide scope for development that contributes positively to economic growth and regional development. The outlook for the industry is bright with positive developments expected in various chemical sub-sectors. In order to promote investment in this sector and make the country an important hub for both domestic and international markets, the government has decided to set up chemical clusters so as to attract major investments, both domestic and foreign.

However, the chemical clusters need to leverage individual capabilities and unique selling points to attract businesses. Clusters need to be projected as a single destination for potential buyers of chemicals catering to the needs of all buyers. Thus, it can be said that the chemical cluster can aid the growth of chemical industry and can be a viable option for the industry, if the concerns are addressed as soon as possible.


Strategy | Management degree


JosePh Wharton founded America’s first business school at the University of Pennsylvania in 1881. Few decades later, in 1964, the UK government set up the London Business School and Manchester Business School. Since then, the MBA degree has become the most sought-after degree worldwide. But is this degree over-rated? Does the industry prefer the degree more than technical expertise? What relevance does this qualification have in the hardcore sector of chemicals?

The crucial decision after engineeringThe dilemma faced by an engineer on completion of the engineering degree is whether to seek an advanced engineering degree or an MBA. “Technical professionals who opt for an MBA believe it would give them the potential to achieve higher pay, allow them to move

more easily into management arena within the technology department, obtain employment at a preferred company or land; and work in a new, business-oriented technical role,” says Dr Pranabesh Ray, Dean – Academics, Xavier Labour Research Institute, Jamshedpur (XLRI).

examining the mBa degreeGlobal recruitment firm Randstad went deep into the CVs of CEOs in India to compile a report conducted among the BSE 100 firms. It found that 45 per cent of them were equipped with engineering degrees at the undergraduate level. Of this, 78 per cent had gone on and completed post-graduation as well. What is

significant, though, is that 64 per cent of those who pursued a post-graduate degree went for an MBA.

Additionally, 42 per cent of the CEOs finished their MBA from top management schools such as the IIMs,

XLRI, Harvard, Stanford and Wharton. Within this universe, 70 per cent of CEOs

had post-graduation degrees while only 30 per cent

were undergraduates. An analysis of the undergraduate

degrees of all the CEOs showed that 45 per cent of CEOs had pursued engineering.

“Many employers will take an MBA degree in lieu of experience and this can help one to promote more quickly in a different field. If one prefers to work as a consultant in his/her area of expertise instead of doing hands-on work, an MBA degree can give him/her the required credibility. For instance, some technical experts like to become consultants for businesses, explaining to clients how to change or improve their technology. An MBA degree would help these consultants in their role because it would teach

them how to understand the entire business picture. People would also take the consultants more seriously with an MBA degree along with their technical certification,” adds Satindra Sen, Co-Founder and Director, Exper Executive Education Pvt Ltd. As is the general consensus, if one does not have a lot of work experience, but wants to promote

Mahua Roy

A long-standing debate deliberates what relevance does an MBA degree has to the highly technical skills of a professional engineer; and is there a real need for engineers to pursue MBA?

Is it a necessity in chemical sector?

An engineer will need to know how to look at his/her technical skills from a business perspective, and how to channelise the knowledge into profitability and productivity.

Dr Pranabesh RayDean – Academics, XLRI


Management degree

out of the current work position, one may want to consider an MBA degree.

Having already obtained a technical degree, an MBA completes one’s education in the wider areas of management that usually includes subjects such as finance, marketing, human resource management, organisational behaviour and management strategy. This is also important because the role of the engineer is changing; within an industry, an engineer is likely to be a manager who has to implement new practices and technologies, or manage a set of people in the field, be it sales or even manufacturing. Thus, the engineer often becomes the primary manager of change within the modern organisation, which again requires specific skills and learning.

seek your future goalThe answer to the crucial question of choosing between an engineering and

management degree lies solely with a person’s future goals. If one plans a start-up of consulting or manufacturing, an MBA degree could be a valuable asset. An engineer will now need to understand more than just technical architecture. “He/she will need to know how to look at his/her technical skills from a business perspective, and how to channelise the knowledge into profitability and productivity. An engineer will learn how to market his/her skills to prospective customers and how to manage finances when he/she is on a job. These skills

are honed in an MBA degree programme,” says Dr Ray.

Taking the decision of whether to get an advanced engineering degree or an MBA will mean taking a hard look at personal goals. An MBA complements most other degrees. However, the reality is that most individuals feel like they are time or resource constrained and can only afford one advanced degree.

In that situation, the answer to the question regarding whether engineers should obtain an MBA versus an advanced engineering degree is completely dependent on future aspirations. Sen concludes, “The strong analytical capability that engineers possess is highly valued in the business world; but it is imperative that they also understand the other, more qualitative aspects. These qualitative skills are what engineers stereotypically lack; we like black and white answers, but in the business world, it is not typically that simple.”


The strong analytical capability that engineers possess is highly valued in the business world; but it is imperative that they also understand the other, more qualitative aspects.

Satindra SenCo-Founder and Director, Exper Executive Education Pvt Ltd

Tips & Tricks | Personal protective equipment


Various nuances with PPE commence with management policy on PPE, need-based identification, budget allocation,

selection, procurement of user-friendly/standard appliances, proper distribution, inventory management, upkeep/maintenance, various procedural aspects on training, participative techniques, motivation, control system, and the best suited/appropriate enforcement strategy.

Bureau of Indian Standards (BIS) or equivalent overseas standards/guidelines from developed countries offer

detailed specifications on PPE with respect to hazard resistance properties/characteristics, user comfort, design, size, strength and durability.

At tent ion should be paid to the

variety of PPE, which can be used. Some of the examples include helmets, regular footwear (safety shoes), goggles, gloves, aprons, coats, respiratory masks (other than dust/mist filters), breathing apparatus, and fall protection devices (safety belt lifelines/harness/fall arrestor units).

One should take into account the nature of job while deciding on the PPE. Different types of equipment

are used in various work situations, ie manufacturing/operation/maintenance activities, material handling, etc. There are different materials, which are used for making varied types of PPEs. Depending on the nature of work, the material for PPE should be carefully selected. Periodicity of jobs – continuous, occasional, intermittent or emergency – also helps in choosing the right PPE.

For selecting the headgear – the most primary PPE – one should ensure the basic point that it is dome-shaped

without any metallic component attached or lined below or insulated above (for reinforcement). The surface of the helmet should have a smooth finish and should be free from burrs, sharp edges, etc, along with an aesthetic look.

When it comes to protective gears for arms, for instance, gloves, canvas-cum-leather (leather for the palm section and

canvas for the outer) should be selected for valve operations, material handling, etc. Full leather

gloves can be used for gas cutting. There are other materials, eg, wool-lined aluminium

foil fabric, which are also available to suit the needs of various applications.

P r o t e c t i v e gears for ears assume high

importance and are among the most primary PPEs. The various types of

hearing protection devices include enclosure (helmets designed to fully

cover both head and ears), aural (ear insert similar to the cotton buds being

worn by air passengers also known as ear plugs), and ear muffs.

The maintenance/upkeep of PPE is especially critical and those meant for common use (such as breathing

apparatus, safety harness) must get top priority. The engineering/design aspect and costs of all types of PPE should be thoroughly explained, so that employees are well aware and also use these types of equipment voluntarily.


Personal Protective Equipment (PPE) assumes high importance in various industries, especially chemical, as often the raw materials and processes involved are highly hazardous. Appropriately designed PPE plays a vital role in preventing/reducing/controlling injuries/disabilities in the chemical industry. However, proper selection of PPE, depending on the nature of work, is essential; and here are some tips for getting it right.

Practical guidelines for right selection

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As told to Mahua Roy


Projects


ammoniarashtriya ChemiCals & Fertilisers ltdProject type New facilityProject newsRashtriya Chemicals & Fertilisers Ltd is planning to set up a 2,700 MTPD capacity ammonia plant inOdisha.Project locationTalcher, OdishaProject cost Not knownimplementation stagePlanning

Contact details: Rashtriya Chemicals & Fertilisers LtdPriyadarshini, 10th Floor Eastern Express Highway Sion, Mumbai-400022 Maharashtra Tel: 022-25523057 Fax: 022-24045197 Email: mthyagarajan@rcfltd.com................................................................KetosulfonePunjab ChemiCals & CroP ProteCtion ltdProject type New facilityProject news Punjab Chemicals & Crop Protection Ltd is planning to set up a new chemicals plant to manufacture ketosulfone in Punjab. Project location Ropar, PunjabProject cost Not knownimplementation stage Planning

Contact details: Punjab Chemicals & Crop Protection LtdOberoi Chambers II 5th Floor, 645/646 New Link Road

Andheri (W), Mumbai-400053 MaharashtraTel: 022-26747900 Fax: 022-26736193/78 Email: enquiry@punjabchemicals.com................................................................Phosphatebhilai engineering CorPoration ltdProject type New facilityProject news BEC Fertilizers (Unit of Bhilai Engineering Corporation Ltd) is planning to set up a new chemical plant in Chhattisgarh. The project involves manufacturing of boronated single super phosphate. Project location Bilaspur, ChhattisgarhProject cost Not knownimplementation stage Planning

Contact details: Bhilai Engineering Corporation LtdHathkhoj Village, Industrial Area Bhilai-490026, Chhattisgarh Tel: 0788-4088100 Fax: 0788-2285499 Email: [email protected] ................................................................sodium cyanide hindusthan ChemiCals ComPanyProject type Capacity expansionProject news Hindustan Chemicals Company, (formerly known as Cyanides & Chemicals Company) is planning to expand its sodium cyanide manufacturing capacity from 5,400 TPA to 12,000 TPA in Gujarat. Work on the project will commence in 2014 and is planned for completion in 2016. Project location Surat, Gujarat

Project cost Not knownimplementation stage Planning

Contact details: Hindustan Chemicals Company65, Free Press House 215, Free Press Journal Road Nariman Point Mumbai - 400021 MaharashtraTel: 022-22853669 Fax: 022-22029430/61510900Email: [email protected] ................................................................refinery & Petrochemical hindustan Petroleum CorPoration ltdProject type New facilityProject newsHindustan Petroleum Corporation Ltd (HPCL) plans to set up a refinery-cum-petrochemical complex at Pachparda in Rajasthan. The proposed refinery project will come up on around 3,700 acre of land. HPCL, through joint venture between its subsidiary MRPL and Cairn Energy, UK, plans to set up a nine million tpa petroleum refinery and petrochemical complex in Rajasthan.Project location Barmer, RajasthanProject cost ` 37,229 crore implementation stage Planning

Contact details:Hindustan Petroleum Corporation LtdPetroleum House 17, Jamshedji Tata Road Mumbai-400020Maharashtra Tel: 022-22863900 Fax: 022-22872992Email: [email protected]

information courtesy: tendersinfo.com1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

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

Tenders


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

org: Organisation’s name, TrN: Tendersinfo Ref No, desC: Description, Bod: Bid Opening Date, loC: Location, BT: Bidding Type

information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

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

oxygeN aNalyserOrg : Bharat Petroleum Corporation LtdTrN : 16820976Desc : Supply of Ametek oxygen analyserBOD : July 22, 2013LOc : Mumbai, MaharashtraBT : Domestic

NiTrogeN PlaNTOrg : Heavy Alloy Penetrator ProjectTrN : 16279396Desc : Designing, manufacturing, supply, installation & commissioning of nitrogen plantBOD : July 25, 2013LOc : Tiruchirappalli, Tamil NaduBT : Domestic (NCB)

diaPhragm PumPOrg : Bharat Petroleum Corporation LtdTrN : 16820972Desc : Supply of diaphragm pump BOD : July 22, 2013LOc : Ernakulam, KeralaBT : Domestic (NCB)

mulTiPle Parallel auToClave sysTem

Org : Indian Oil Corporation Ltd TrN : 16744327Desc : Supply of multiple parallel autoclave system BOD : July 26, 2013LOc : Faridabad, HaryanaBT : Domestic

hydrogeN PlaNTOrg : Heavy Alloy Penetrator Project TrN : 16279629Desc : Designing, manufacturing, supply, installation & commissioning of hydrogen plant BOD : July 25, 2013LOc : Tiruchirappalli, Tamil NaduBT : Domestic

reCiProCaTiNg PisToN PumPOrg : Pakistan National Shipping Corporation TrN : 16794233Desc : Supply of reciprocating piston pump BOD : July 26, 2013LOc : Karachi, PakistanBT : ICB

Fluid exTraCTioN uNiT Org : Centre for Aromatic PlantsTrN : 16803365Desc : Supply and installation/ commissioning of super critical fluid extraction unit BOD : July 25, 2013LOc : Dehradun, UttarakhandBT : ICB

PlaNeTary Ball millOrg : Indian Institute of Technology BhubaneswarTrN : 16763884Desc : Procurement of planetary ball mill BOD : July 26, 2013LOc : Bhubaneswar, Odisha BT : Domestic

NiTrogeN PlaNTOrg : Ordnance Factory BoardTrN : 16428815Desc : Designing, manufacturing, supply, testing and commissioning of nitrogen plant BOD : July 30, 2013LOc : Tiruchirapalli, Tamil Nadu BT : Domestic

Event List


NatioNal

PetroWorld indiaWhat : an event showcasing novel technologies in oil & gas sectorWhen : august 22-24, 2013Where : Bombay Exhibition Centre, Mumbai

For details contact:inter ads exhibitions Pvt ltdtel: 0124-4524200/4201Email: [email protected]...........................................................................

india oil and Gas reVieW sUmmit and international eXhiBition What : an event that will highlight the latest developments in anti-corrosion & corrosion control systems, compressors, exploration and production technology, environmental engineering, systems & equipment, fire prevention, gas processing equipment etcWhen : September 03-04, 2013Where : taj lands End, Mumbai

For details contact:oil asia Publications Pvt ltdtel: 022-66814900Email: [email protected]

india Chem GUjaratWhat : the exhibition will showcase the latest products, machinery, equipment and developments in the chemical industryWhen : october 24-26, 2013Where : Gandhinagar, Gujarat

For details contact:Federation of indian Chambers of Commerce & industrytel: 011-23738760/8770Email: [email protected]...........................................................................

analytiCa anaCon india 2013What : international trade fair for laboratory technology, biotechnology & diagnosticsWhen : November 12-14, 2013Where : Bombay Exhibition Centre, Mumbai

For details contact:mmi india Pvt ltdtel: 022-42554710Email: [email protected]...........................................................................

ChemiCal eXPoWhat : an event for chemical equipment, environment & safety, plastics & packaging, electric & electronics, petroleum & gas, etc

When : December 07-10, 2013Where : aiDS ananpura, ankleshwar, Gujarat

For details contact:Better dealtel: 09979871798Email: [email protected]...........................................................................

PetroteChWhat : the event will showcase power generation tools, oil and gas machinery, engineering equipment and pollution control tools etcWhen : January 12-15, 2014Where : india Expo Centre and Mart, Greater Noida

For details contact:Petrotech societytel: 011-23355072Email: [email protected]...........................................................................

ProCess enGineerinG eXPoWhat : an international exhibition and conference on process technologiesWhen : September 04-06, 2014Where : Hyderabad international trade Exposition Centre (HitEX), Hyderabad

For details contact:hiteXtel: 040-23112121/2122Email: [email protected]...........................................................................

india Chem 2014What : an international exhibition on chemicals, petrochemicals, pharmaceuticals, technologies, process plant machinery and control & automation systemsWhen : october 09-11, 2014Where : Bombay Exhibition Centre, Mumbai

For details contact:Federation of indian Chambers of Commerce & industrytel: 011-23738760/8770Email: [email protected]

The trade exposition on chemical plant, equipment and process industry;

February 2014; at Surat International Exhibition & Convention Centre, Surat, Gujarat

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

Dadar (W), Mumbai-400028 Tel: 022-30034651 • Fax: 022-30034499


For detailsNetwork18 Media & Investments Ltd

Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. • Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: [email protected]

India’s premier industrial trade fair on products and

technologies related to Machine Tools, Hydraulics

& Pneumatics, Process Machinery & Equipment,

Automation Instrumentation, Packaging & Auxiliaries,

IT Products, Electrical & Electronics, Material

Handling and Safety Equipment.

AhMedAbAdGujarat

March 7-10, 2014

LudhIANAPunjab

December 20-23, 2013

AurANgAbAdMaharashtra

January 10-13, 2014

INdoreMadhya Pradesh

Jan 31-Feb 03, 2014

KoLKAtAWest Bengal

February 21-24, 2014

PuNeMaharashtra

October 18-21, 2013

CheNNAI Tamil Nadu

November 14-17, 2013

JAIPur Rajasthan

Nov 29 - Dec 02, 2013

Event List


iNtErNatioNal

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

China (GUanGZhoU) international eleCtroniC ChemiCals eXhiBitionWhat : Focussed event on cathode and anode material, electrolyte battery additives, intermediates, etc When : august 15-17, 2013Where : Canton Fair Pazhou Complex area B, Guangzhou, China

For details contact:Guangzhou Zhenwei international exhibition Co ltdtel: + (86)-(20)-84120362Email: [email protected]...........................................................................

saraWaK oil & Gas eXPoWhat : Focussed event on oil & gas technology and conference where prominent speakers will highlight the latest developments in the sector When : august 20-22, 2013Where : Miri indoor Stadium, Miri, Malaysia

For details contact:Fireworks event m sdn Bhdtel: +(6)-(3)-79830680Email: [email protected]...........................................................................

VehiGasWhat : a specialised international event on natural gas and liquid petroleum gas organised every two years When : august 21-23, 2013Where : Jockey Plaza Convention Center, lima, Peru

For details contact:thais Corporation s. a. Ctel: +(51)-(13)-4443860Email: [email protected]...........................................................................

dye+Chem BanGladesh 2013What : international exhibition on dyes and fine & specialty chemicals

When : September 05-08, 2013Where : Bangabandhu international Conference Centre, Dhaka, Bangladesh

For details contact:Cems-Global asia Pacific Pte ltd tel: + (65) - 6829 - 2144Email: [email protected]...........................................................................

sPeCiality & aGro ChemiCals ameriCaWhat : the event will showcase the latest and advanced products and services including adhesives, sealants, resins, agriculture, crop protection, biofuels, biodiesel, coatings, paints etcWhen : September 09-11, 2013Where : Hilton Wilmington riverside, Wilmington, USa

For details contact:american Chemical marketingtel: 1-215-8829100Email: [email protected]...........................................................................

neFteGas eXPoWhat : an international event for process industries that will showcase the latest trends and developments in the sector When : September 10-13, 2013Where : lenexpo Exhibition Centre, St.Petersburg, russia

For details contact:restec exhibition Companytel: +(7)-(812)-3206363Email: [email protected]...........................................................................

asia PaCiFiC CoatinGs shoWWhat : leading coating show of Southeast asia and will focus on raw material supply for plastics, inks and adhesive manufacturersWhen : September 12-13, 2013

Where : Bangkok international trade & Exhibition Centre (BitEC), Bangkok,thailand

For details contact:Quartz Business media ltedtel: +(44)-(1737)-855000Email: [email protected]...........................................................................

China adhesiVeWhat : Exhibition focussing on adhesive and sealant products When : September 25-27, 2013Where : Shanghai Everbright Convention & Exhibition Center, Shanghai

For details contact:CCPit sub-Council of Chemical industrytel: +(86)-(10)-64275419Email: [email protected]...........................................................................

GassUF 2013What : Focussed event on gas and gas filling technology When : october 15-17, 2013Where : VVC Exhibition Centre, Pavilion no 75, Moscow

For details contact:mVK internationaltel: + (7) (495) 9358100Email: [email protected]...........................................................................

Chem shoWWhat : an exhibition that will showcase process plant & technology for chemical industry, process control instrumentation, pumps etcWhen : December 10-12, 2013Where : Jacob K. Javits Convention Center, New York, USa

For details contact:international exposition Companytel: +(1)-(203)-2219232Email: [email protected]

Event Report | Engineering Expo Hyderabad 2013


While the industrial climate is conducive for growth and opportunities are rife in India, Andhra Pradesh, in general, and Hyderabad, in particular, are brimming with potential and possibilities. Andhra Pradesh’s manufacturing might has helped it emerge as a key state for the knowledge-based industry. And the mushrooming of MNCs is a clear reflector of the healthy FDI inflows that the state has attracted over the years. Among the other regions in the state, Hyderabad exudes tremendous potential owing to its strategic geographic

positioning, availability of low-cost, highly skilled labour and the presence of a strong SME circuit.

Acting as a catalyst to help the engineering and manufacturing fraternity leverage on the Hyderabad advantage, Network 18 Publishing organised the maiden edition of Engineering Expo Hyderabad at HITEX Exhibition Centre from May 31 to June 3, 2013. The four-day Expo portrayed the best of Hyderabad’s industrial assimilation and perfected a platform for the industry to showcase

the city’s calibre in terms of innovations, products & technologies, diverse industry verticals and customised manufacturing.

The event was hosted with value adding partnerships from FAPCCI (Federation of Andhra Pradesh Chambers of Commerce and Industry) and with co-operation from UNIDO-ICAMT (United Nations Industrial Development Organization - International Centre for Advancement of Manufacturing Technology); FIEO (Federation of Indian Export Organizations) and NSIC (National Small Industries Corporation); MSME (Micro, Small & Medium Enterprises) and was supported by Andhra Bank.

setting the stageEngineering Expo Hyderabad was inaugurated in the presence of esteemed dignitaries including Devendra Surana, President, FAPCCI; Ganesh Parthasarathy, CEO, Tussor Machine Tools India Pvt Ltd; and Ravi Ramana, Assistant GM, Andhra Bank. The most striking feature of the trade show was that over 60 per cent of the 130+ exhibitors were from across the country. It also witnessed delegations from Bharat Heavy Electricals Ltd (BHEL); Tata Projects; Defence Research and Development Organisation (DRDO); NSL Renewable Power; Vasantha Group and Amara Raja,

Invoking the ‘Andhrapreneurial spirit’ for Industrial Leap

Debarati basu Das

Post the IT revolution, Hyderabad has undergone a metamorphosis. Over the last few years, the city has been trying to give its manufacturing mettle a new global identity. Rising as a favourable destination for businesses in the south, the city already has global heads making a beeline for investments in the region. Giving impetus to this growth story, Engineering Expo made its debut in Hyderabad. A report…

hyderabadMay 31-June 3, 2013

hITeX exhibition Centre

Lighting the lamp (L-R): Ravi Ramana; Devendra Surana; Archana Tiwari-Nayudu, Editor, Network 18 Publishing; Ganesh Parthasarathy; and Nitin Kunjir, Deputy Manager – Marketing, Network 18 Publishing


Engineering Expo Hyderabad 2013

among others. This unique blend of local and national participation gave a special boost to the business dynamics that the Expo offers.

Commemorating this fact, Surana said, “Such exhibitions ensure that we remain updated about the latest happenings in the domestic industry.” Parthasarathy, a regular participant at Engineering Expo, highlighted, “There are many flagship expos but most expos in India are not as well-organised as Engineering Expo. Today, Engineering Expo has become one of the most important exhibitions in the country.”

Engineering Expo is India’s largest SME gathering on engineering and manufacturing. The trade show has always sought to provide SMEs – the small wonders that play a pivotal role in helping the country progress economically – a stepping stone to success. Apart from finding the right contacts, SMEs need finances to thrive in this competitive era. Commenting on the need to finance SMEs, Ramana, at the inaugural function, explained, “We feel that every bank should understand SMEs’ potential and encourage them financially.”

opportunities for exhibitors Engineering Expo Hyderabad received an enthusiastic response from exhibitors. Elaborating on how the trade show has been a boon for participants, Ilesh Pancha, MD, iPan Engifab, a Gujarat-based fabrication firm, stated, “We have been dealing with customers in Hyderabad but did not have a proper avenue to exhibit ourselves in this city. In this backdrop, Engineering Expo was the best medium for us to connect to a larger audience in Hyderabad.”

Similarly, Srinivas Kumar Twarakavi, Founder & CEO, G4 Solutions & Applications Pvt Ltd, a Hyderabad-based company, averred, “This is a good platform to connect with a national audience. We are confident of taking our product to a bigger platform at this Expo.”

There were other exhibitors who reiterated the fact that Engineering Expo Hyderabad gave them an opportunity to explore the region. Affirming the same, B Mukherjee, Product Manager, Juaristi Oriental Engineering Services, a Mumbai-based company, expressed, “Hyderabad is one of the new areas that our company wants to explore.” Engineering Expo Hyderabad had something for everyone; it helped participants successfully generate more than 50 business leads per day.

Visitors optimise@expoEngineering Expo was visited by more than 10,600 people. The four-day event

received an overwhelming response from the Hyderabad crowd who optimised their visit. It had everyone, right from entrepreneurs who wanted to strike deals and youth who wanted to learn about the various technologies available in the country to new entrepreneurs who wanted to build contacts for their future endeavours.

Commenting from a visitor’s perspective, Suresh S, CEO, Excell Industries, stated, “I make it a point to visit expos across the country to know about the latest technologies that are coming up in the industry. However, Hyderabad does not have many expos and, even if

there are any such expos, the level of participation is low. Interestingly, even on Day 1 of Engineering Expo Hyderabad, the participation of exhibitors and visitors was encouraging, which is a rare sight.”

Engineering Expo Hyderabad has become a ‘myth breaker’ in the region. According to Rajshekhara T, Manager- Sales, Sai Engineering, a visitor, “Hyderabad is a pharma-dominated industry. You do not find many exhibitions that cater to automotive and machining industries. Engineering Expo will break this myth; if it is organised on a regular basis, we will have a good expo to look forward to. More so, there are so many companies from Gujarat,

Maharashtra and other states. This gives us a holistic vision on all that is happening in the industry across the country. This will also help us to understand the things that we need to do to meet the demands of the industry outside Hyderabad.”

The event also had visitors who hoped to make the Expo a base for their entrepreneurial venture. Manohar M, a retired industry personnel from the plastics industry, was one such visitor. He commented, “I have retired from my services, but I am looking for options to start my own business in the plastics industry. I am basically here to look for the kind of products on display to get a feel of the

industry’s need. This Expo is certainly worth an experience as there are a few good companies that have displayed some good products in the plastics sector. This will help me build contacts for the small-scale enterprise that I intend to start.”

a grand success… This maiden edition of Engineering Expo Hyderabad proved to be a boon for the Hyderabad industry. It not only helped the country understand and see the capabilities that Hyderabad has but also took Andhra Pradesh’s entrepreneurial spirit one notch higher.


Highlights of this edition Pan India participation from 139 exhibitors Spread over more than 50,000 sq ft 10,638 business visitors across India Business transacted worth ` 70.85 crore* 7,457 business leads generated* 4,500+ products displayed from different industries More than 78,000 kg machinery moved in for display 78% exhibitors are satisfied with the visitors 80% exhibitors intend to participate next year 85% exhibitors recommended Engineering Expo to others 82% exhibitors prefer Engineering Expo over other

industry exhibitions* Feedback received from exhibitors

Event Report | Engineering Expo Hyderabad 2013 - Panel Discussion


hyderabad is now going through its next phase of evolution by taking its potential to the world. Providing the platform for the right growth trajectory and understanding the need gaps, Network 18 Publishing organised a panel discussion on the sidelines of Engineering Expo Hyderabad 2013 at Aditya Sarovar Premiere, Hyderabad. The online partner of the event was Apex Auction. The panel discussion was conducted on the theme ‘Is Hyderabad ready for the industrial leap?’ This discussion was truly insightful and acted as food for thought for the more than 200 industry professionals gathered at the venue.

at the discussion… The discussion comprised an eclectic mix of experts including Sreeram MM, MD, Scarlet Industries Pvt Ltd; M Sreenivasulu, Dy Director (IMT), MSME - Development Institute; Devendra Surana, President, FAPCCI; and Y Sreenivas Rao, Project Director, DRDO. The panel discussion was

moderated by Archana Tiwari-Nayudu, Editor, Network 18 Publishing.

Each speaker had a unique growth story for Hyderabad; however, they all agreed on one aspect – Hyderabad is destined to become an investment hub. Hyderabad not only manufactures world-class aerospace and defence products, the country’s demand for tooling accessories is also met by the city. All these are coupled with the advantage that the city gets from strong clusters of SMEs that are in every way capable of manufacturing world-class products. However, the speakers opined that even though the city has every possible advantage to grow, the opportunities are not being utilised optimally. Issues such as power outage and political uncertainty have handicapped the manufacturing sector.

What’s the solution? The discussion not just highlighted the problems but also gave solutions for the same. Every speaker expressed measures that need to be taken to regain growth. For instance,

Surana pointed out, “Hyderabad already has a fantastic availability of manpower and entrepreneurial spirit. If these two problems are addressed, the city will grow at the rate of 15–20 per cent.”

Rao opined, “We have to decongest Hyderabad. We need to have 7–8 clusters each with a nodal centre, which will have the technology. Each cluster should have proper infrastructure, export and marketing requirements and focus on a particular skill. This will enhance the manufacturing set- up. We need to foresee 10 years ahead and project growth prospects,” he expressed.

Sreenivasulu, on the other hand, talked about the various government schemes available for the growth of SMEs. He argued that human resource development and finance are the areas that need to be strengthened. Sreeram wrapped up the session by emphasising on the need for multiple financial cities in the country. “Hyderabad has the prerequisite infrastructure and knowledge base; it must be identified as a financial hub for national growth. SMEs have grown over the last 40–50 years and contribute 70 per cent to the state’s GDP. If we address these problems, Hyderabad will carve a place for itself on the global map,” Sreeram concluded.

Way to go… Every city has its roadblocks to opportunities. But for Hyderabad, what lies ahead are opportunities abound. The industry and government need to take collective steps to overcome the hurdles and carve the roadmap to global opportunities for Hyderabad.


Is Hyderabad ready for the industrial leap?Debarati basu Das

Hyderabad is renowned for being the IT hub. But, over the years, the city has expanded its horizons to harness its manufacturing potential. However, it needs to make its mark on the global domain. In an attempt to help the region gain 3600 visibility, a panel discussion on the topic ‘Is Hyderabad ready for the industrial leap?’ was organised on the sidelines of Engineering Expo Hyderabad 2013, on May 31, 2013. A report…

The discussion comprised an eclectic mix of experts (L-R) Devendra Surana, Y Sreenivas Rao, Archana Tiwari-Nayudu (moderator of the panel discussion), M Sreenivasulu and Sreeram M M

Book Review


organometalliC compounds play an integral role in industrial chemical synthesis. More and more industrial processes rely on organometallic chemistry. As a result, readers will find the step-by-step instructions provided in this book essential in fields such as natural product synthesis, pharmaceuticals, fine chemicals, biotechnology, polymers and materials science.

The book enables readers to conduct seamless synthetic reactions involving key organometallics. The interesting aspect of the book is that each reaction is presented in a lucid format so that readers can easily replicate the results. Each section offers hands-

on guidance and practical examples illustrating the preparation of organometallics and their applications in organic synthesis.

Salient topics covered in this book include organoalkali chemistry; organomagnesium and organozinc chemistry; organosilicon and

related organotin chemistry; organoiron chemistry; and organopalladium chemistry.Readers are provided with detailed background information to learn more

about the class of organometallics as well as mechanistic considerations. In addition to current applications, the book explores future research opportunities for

each organometallic class.

Organometallics in Synthesis Edited by: Manfred Schlosser

Price: ` 7,550

the book is the ultimate reference work for scientists and professionals looking for reliable information on chemicals, drugs and biologicals. The 15th edition contains up-to-date information about newest additions to the index. It enlists over 10,000 monographs with information related to compounds of significance in research, commerce and environmental impact. Over 35 per cent of the existing entries are updated. Along with this, more than 18,000 compounds with 50,000 synonyms are incorporated. The molecular weights are recalculated with the latest IUPAC standards. There is an inclusion of a new table showing non-proprietary name stems. There is a section for revised periodic table and atomic weight tables.

The book serves as an essential reference for all scholarly and professional chemists, biochemists, pharmacists and toxicologists and is of interest to students, teachers, academic libraries, academic researchers, information professionals, solicitors, journalists and government agencies.

Reviewer: Tejas Padte, Lecturer, Department of Chemistry, Ramnarain Ruia College, Mumbai

The Merck Index: 15th editionPublished by: RSC Publishing

Price: ` 8,800

Available at: Wisdom Book Distributors, Hornby

Building, 1st floor, 174, D N Road, Mumbai – 400001 Tel: 022-22074484/66318958, Telefax: 022-22034058


Available at: Sci-tech Books & Periodicals,

414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai – 400053 Tel: 22-26735260/66970507

Email: [email protected]@scitechbooks.co.in


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FloWmeterCorrelated flowmeter is ideal for process plant applications and provides precise readings even in aggressive plant environment. Its correlated variable area is available in 65 mm or 150 mm scales. Common applications for these low-cost variable area flowmeter include air sampling equipment, chemical processing, metering of gases in chromatography systems, desalinisation equipment, gas analysers and water treatment systems. It can be used with gas or liquids and it is also available in a choice of materials, with or without control valves and range of flow tube sizes. It is available in aluminum body, brass body, 316 stainless steel body, high-precision valve flowmeter. This flowmeter uses a universal millimeter scale to allow the flowmeter to be used with a number of different fluids, at changeable pressure and temperature conditions, by cross-referencing the scale against a correlation data sheet. These flowmeters can measure liquids flow from 0.0002 ml/min to over 400 LPM and for gases from 0.02 ml/min to 700 m3/hour.

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methyl methaCrylate adhesivePARTITE Methyl Methacrylate Adhesives (MMA) fills in the gap where two-part epoxy adhesives and two-part polyurethane adhesives lack the performance required by the assembly industry. It provides cure-on-demand, excellent balance of adhesion and toughness, chemical resistance, long-term durability and requires minimal surface preparation. PARTITE 7300 is useful in fast assembly. It gives almost a full cure within 10 to 15 minutes after application. PARTITE 7390 is useful to bond larger parts. It gives a full, strong cure in 150 minutes. Unlike epoxies and polyurethanes, PARTITE MMAs are most suitable for bonding dissimilar substrates: metal-to-plastic, composites to plastic, etc. It helps industrial assembly-lines save lot of time, labour and capital cost by eliminating long fixture and surface preparation time while providing better performance to the finished products. The company offers 1:1 and 10:1 PARTITE Methacrylate Adhesives (MMA) as well as tailored solutions.

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Boron CarBide aBrasive grainsThese have high strength-to-weight ratio and low thermal conductivity and it is ideal for a wide variety of applications. Thermal neutron capture cross-section is 600 bam. Grit sizes of available grains are # 80, 120, 150, 180, 220, 240, 280, 320, 360, 400, 500, 600, 800, 1,000 and 1,200.

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Boron CarBide PasteTurbolap boron carbide paste finds applications in lapping and polishing of various components in the following industries – automobiles, compressors, ceramics, pumps and valves, tools & gauges and dies & moulds. It can cut three times faster than silicon carbide on hard metal

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WaterProoF multiParameter meterIt is a waterproof multiparameter meter of the Testr 35-series from Oakton. A pocket-sized meter that measures pH, conductivity, TDS, salinity and temperature, it is perfect for water, wastewater, laboratory and plant-use. This pocket-sized meter has long-life pH electrodes and stainless steel conductivity sensors for a wider range of sample

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airless Paint sPraying PumPThis pump is suitable where better paint finish, gloss of paint and aesthetic results of the machine are prime requirements. It gives high output of paint and thus save time, manpower, paint & cost by giving high efficiency. It is also possible to spray high build paints for anti-

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digital FloW meterThe paddle wheel insertion-type digital flow meter is a unique 2-in-1 combination, wherein the rotameter measures flow rate vertically. The water meter counts total horizontally and measures both the aspects.

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total Water hardness test striPWater hardness test strip is used for quick and easy determination of water hardness. The convenient dip and read procedure and the clear colour changing from green to red ensures reliable results within seconds. The water hardness depends mainly on the amount of calcium and magnesium salts within the water. The total sum of these salts determines the actual water hardness. The strips are used in a wide variety of industries and applications. Hard water may cause calcification and can thus damage machinery, appliances, pipes or heating units. In many industries, water hardness is an important parameter in process control and has to be monitored constantly. Some examples of industries include the textile industry, dyeing factories, large-scale laundries, water works, fish-farming and aquaculture. The water hardness test strips come in a wide variety of different gradations and packaging options catering to very specific or unique requests. These are the ideal choice to quickly, easily and reliably determine water hardness.

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tuBe exPanderTube expander forms a perfect mechanical seal between the tube and the tube sheet. The tube expander produces a smooth, unrigged surface in heat exchangers and condenser, oil and air cooler, pre-heaters, super heaters, radiators, boilers, economisers, juice heaters, evaporators, etc. It is designed for long service, and features an adjustable ball bearing thrust collar to eliminate frictional heat. Rolls have gradually tapered noses to eliminate sharp offsets in the rolled tubes and ensure uniform tube tightness throughout the thickness of the tube sheet. Adjustable tube expanders are available with 6.3-102 mm OD tubes of various sheet thickness and fixed roller length tube expanders with 20-102 mm OD tubes and 26-95 effective expansion. The device can be used manually, with electric or with a hydraulic tube expansion equipment.

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viBro shiFterVibro shifter is known for its sturdy construction, corrosion resistant and durable features. It is highly result-oriented and offers best results in the usage. It is energy-efficient, has a long functional life and excellent performance. The vibro shifter is used for sieving and screening of chemicals, cosmetics and pharmaceuticals.

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Water saver nozzleThe cleaning gun/water saver nozzle is suitable for hot or cold water cip and cleaning jobs with options of two spray actions-cone and jet spray. A hose suitable for working temperature of 164oC and working pressure of 20 bar for the nozzle is available. Hose length of up to 40 mtr can be fitted with the nozzle and is supplied

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aas and iCP standard solution The new line of certified standards is dedicated to ICP and AAS. This inorganic ICP standard features extended expiration dates and is a reasonably priced alternative to others available today. Specific element

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PneumatiC ConveyorThe MiniVac pneumatic conveyor comes with a complete integral blower, which eliminates the need for an expensive plant air or a separate compressor. The regenerative blower increases operating efficiency. It lengthens filter life and maximises performance with a standard reverse pulse jet filter cleaning system that keeps the filter clean and at optimum operating efficiency. The standard size access doors allows for easy filter replacement in less than five minutes without the use of any tool. The compact and integral blower eliminates the need for air piping and makes installation easier.

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3/8" inCh simPlex sProCketsRoller chain drives require correctly designed and accurately cut sprocket teeth in order to give satsfactory service and quiet operation. Sprocket wheels are manufactured from

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motor ProteCtion relayThis instrument displays various parameters, trip count and trip data on 8-digit alphanumeric display, and has separate LEDs for individual fault indication. This is four-user programmable output relay, it is built in self-supervision, and self-testing feature helps maintenance. It provides easy operation by 5 push buttons. It also has RS485 port for serial communication with ‘MSCOM’ user-friendly software.

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eleCtroniC humidistat and ControllerMeasuring range is from 30°C up to +80°C. Accuracy is <±2 per cent RH and <±0.5°C in the full measuring range. Each sensor comes with a calibration protocol for 0 per cent RH and 75.3 per cent RH. The sensor can easily be changed and after setting the calibration parameters on the display the

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high Pressure triPlex Plunger PumPThe high-pressure triplex plunger pump series 4500 with unloader and safety valve has an electric motor or diesel engine assembled with a centrifugal pump. It supplies pressurised clean water at pump inlet. The water inlet temperature is 50 0C, plunger diameter is 22 mm and holds

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in-situ FermentorIt offers computer compatible control system on request and has temperature, pH, O2 and pCO2, pressure and level as an option. Jacketed pressure vessel is made of stainless steel with standard ports. Audio visual annunciation system is provided to track parameter set point failures. It has double mechanical shaft seal with steam condensate and circulation ensureinglong life. It provides detachable modular 19" standard control rack and provides accurate controls with digital readout for aeration.

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level leaF FilterSharplex level leaf filters are used for polishing filtration in post filtration stage to trap the fine particles from the filtrate of main filter. The filter elements have filter surface at both the sides, and hence the filters become compact even at higher filtration areas. The filter medium can be cloth or paper. The filters are available from 2m2 upto 15m2.

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PortaBle shot Blasting maChines S7-150 is recommended for light job and intermittent requirement of blasting. An economical model, light weight and mobile, it can be operated by one operator.S7-300R is recommended for medium production work and has all the features of production machines. For automatic start/stop, the machine can be provided with remote control unit.

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Products


air monitorThe air monitor developed by UEPL is a microprocessor-based, non-dispersive spec t rophotometer tailor-made for the analysis of the five pollutants SO2, NO2, NH3, Cl2, O3 at parts

per billion levels. The instrument is light-weight and moderately priced. Ambient air is sampled for the required time duration, eg 4, 8 or 24 hours. The Uniphos air sampler can sample three different gases simultaneously using three impingers filled with recommended gas absorbing solvents. The solutions from the impingers are further treated with other reagents to form coloured dyes. The measurement of absorbance on this coloured dye is made on the Envirotrack. The analysis is simple and all the calculations are done by the microprocessor with results displayed on the instrument. The results can also be transferred to a computer or laptop with date, time, location and other identification using GUI software, which can be separately bought with the instrument.

Uniphos Envirotronic Pvt LtdValsad – GujaratTel: 260-2730156/158 Email: [email protected]: www.uniphos.com

reaCtion vesselsThese industrial reactors are fabricated to accuracy using qualitative material and are constructed either in MS or SS. These vertical reactors are provided with different capacities ranging up to 25 KL and comprise

the following construction elements: sturdy construction, leak proof and durable and finds application in various industries such as pharmaceutical, fertilisers, food and dairy, petrochemical, pharmaceutical, pulp and paper, dyestuff and chemical engineering. The various types of vessels available are jacketted reactor, limpet coiled reactor and internal coil reactor.

Aries EngineersThane – MaharashtraTel: 022 – 28555751Mob: 09323649078, 09930992671Email: [email protected], [email protected]: www.ariesengineer.com

Products


rotor unitsThe high-quality stainless steel desiccant rotor cassettes provide greater flexibility to AHU manufacturers. Applications requiring air to be supplied at lower dewpoints can be effectively and efficiently achieved using cooling coils.Specifically designed for use in customised air handling units, all cassettes include the SSCR silica

gel rotor, geared drive motor, rotor drive system, radial and peripheral seals. Its dehumidifying capacity is at 20°C/60 per cent RH.

Jay Jagannath Air EquipmentsVadodara - GujaratTel: 0265-3913451, Mob: 09925003183Email: [email protected]: www.jjgroup.com

saFety sWitChgearThe PSR is a comprehensive range of safety switchgear. In addition to the basic approvals for mechanical and plant engineering, the modules are also approved for process engineering, furnaces and shipbuilding.

It offers high standard for monitoring safety relevant signals. All connections are pluggable, coded, and designed as both screw or twin spring-cage connection. With compact and space-saving design, the PSR modules offer increased isolation between input/output and enabling/signaling current circuits. It is controlled via one/two channels with or without cross-circuiting detection.

Phoenix Contact (I) Pvt LtdNew DelhiTel: 011-3026 2800 Email: [email protected] Website: www.phoenixcontact.co.in

tWo Wire temPerature transmitters These transmitters LTX-3000-H-2 accepts (Pt-100) or thermocouple or variable resistance signal as the input and provides DC current output of (4-20) mA proportional to mV or resistance values. The transmitter is linearly calibrated to the signal produced by a thermocouple or RTD sensors and is not to the actual temperature.

Libratherm Instruments Pvt LtdMumbai - MaharashtraTel: 022-28963823Mob: 09821136685 Email: [email protected]: www.libratherm.com

vertiCal Pressure leaF FilterVertical pressure leaf filter is used for filtration of liquids with suspended solid contents up to 7 per cent. No filter cloth is required. It provides automatic dislodging of filtered cake by pneumatic vibrator or oscillating sluice header. Dry or wet cake discharge is possible. Filtration area is up to 120m2. The various application areas are resins, bleaching earth/activated carbon, crude oil, sulphur, ni-catalyst, glucose, fatty acid, brine, winterisation, electrolyte and beverage industry. Material of construction is CS, SS, SS904L, titanium, hastelloy, monel, polypropylene/teflon coated.

Sharplex Filters (India) Pvt LtdNavi Mumbai - MaharashtraTel: 022-27696322/6339Email: [email protected]: www.sharplex.com

Fuel PumPFuel pump has 600 models of fuel units to choose from. Small capacity burners are available from 10 to 1,000 kw for light oil, kerosene applications, pumps with or without solenoid valve. Single-

step or two-step operation models available are AN, AL, AS, AT, A2L. Medium capacity burner are from 400 to 3,000 kw for light oil

or heavy oil applications. Pumps with or without hydraulic cut-off model are D, AJ, E, J. High capacity burner are from 3000 to 30,000 kw. Pumps with electric preheater facility for heavy oil applications models are T, TA etc.

Classic EnterprisesMumbai - MaharashtraTel: 022-22034496Email: [email protected]: www.classic-combustion.com

Products


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

case, it does not represent the views of Chemical & Process World

riBBon BlenderThe ribbon blender is an efficient and versatile blending machine for mixing of dry granules and powders homogeneously. Approximately, two-third of the volume of the container of ribbon blender is filled to ensure

proper mixing. The ribbon blender gives best result for mixing of dry powder and granules due to the design and shape of the mixing ribbon and product container. These are manufactured in a range of 25 kg to 5,000 kg batch capacity in mild steel and stainless steel. It features less working time, no dust formation, less maintenance cost, less service after sales. Application areas include food processing, pharmaceutical, chemical pesticides, fertilisers and cosmetic industries.

Aries EngineersThane – MaharashtraTel: 022 – 28555751Mob: 09323649078, 09930992671Email: [email protected], [email protected]: www.ariesengineer.com

siliCone transParent tuBingThese transparent tubings are made from 100 per cent pure silicone rubber by using fully automatic state-of-the-art machineries and technologies. Silicone transparent tubings are manufactured under stringent

quality control and having the following distinguished features: it is made from medical grade silicone rubber, which complies with USP Class VI requirement & FDA 21 CFR 177.2600, temperature resistant from -80°C to 250°C (-110°F to 480°F), non-reactive to body tissue and fluid, non-adherence to tissue. It remains unaffected by most water soluble materials and is sterilisable by steam, dry heat, ethylene oxide (ET) and gamma radiation, which resists oxidation, ozone and radiation. It has an indefinite shelf-life. Silicone sleeves are also manufactured. It finds application in food, pharma, chemical, medical, heavy engineering, thermal power stations and PSUs.

AMI Polymers Pvt LtdThane - MaharashtraTel: 022-28555107/631Mob: 09223290931Email:[email protected]: www. amipolymer.com

List of Products


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

3/8” inch simplex sprocket ................................ 77AAs and ICP standard solution ........................ 77Acoustic enclosure ...........................................25, BCAir cooled heat exchanger ...................................FICAir monitor ............................................................79Air-cooled steam condenser ................................FICAirless paint spraying pump ...................................74Alarm management device .....................................78Aluma coat ...............................................................3Automatic filter press .............................................84Bag filter .......................................................... 57Ball check valve ......................................................59Ball valve .......................................................... 17, 59Ball valve - screwed end ..........................................79Ball valve - three piece design .................................79Ball valve - teflon lined .............................................6Basket filter.............................................................57Bellow and dip-pipe .................................................6Blender ...................................................................51Boron carbide abrasive grain ...................................72Boron carbide paste ................................................73Bush ......................................................................59Butterfly valve ................................................... 17, 59Butterfly valves - teflon lined ....................................6Cable management system ................................ 47Cartridge filter ........................................................57Ceramic coating .......................................................3Check valve ............................................................17Check valve - teflon lined .........................................6Chemical process equipment ..................................53Chemical pump ......................................................73Condenser ..............................................................51Continuous nitration system ..................................53Cooling tower ......................................................FICCooling tower solution ...........................................47Diaphragm valve .............................................. 59Digital flow meter ..................................................74Dry van pump .................................................25, BCE/P positioner ................................................. 73Elbow - butweld type .............................................79Electronic humidistat and controller ......................78End cap ..................................................................79Exhibition - Plastivision 2013 ................................38FEP/PFA/PvDF material ............................... 59Filter plate ..............................................................84Filter press ..............................................................84Filter press terminology ..........................................84Fitting.....................................................................59Flow verturi tube ....................................................51Flowmeter ..............................................................72Forged steel valve ....................................................17Food emulsifier .......................................................72Foot valve - non-return valve ..................................79FRP cross arm ........................................................47FRP epoxy pultruded profile ..................................47FRP/GRP handrail and fencing .............................47

FRP/GRP ladder ....................................................47FRP/GRP moulded grating ...................................47FRP/GRP profile ...................................................47FRP/GRP pultruded grating ..................................47FRP/GRP step tread ..............................................47Fuel pump ..............................................................80Fully automatic robotic cloth washing system ........84Gasket ............................................................. 59Gate valve ...............................................................17Globe valve .............................................................17GMP and non-GMP .............................................53Hastalloy ......................................................... 17Heat exchanger ................................................. 51, 53High heat transfer coefficient rate ..........................10High pressure triplex plunger pump .......................78High speed mixer ...................................................53Hope ball valve - flange end ...................................79Hydraulic filter press...............................................84In-situ fermentor ............................................. 78Large diameter welded pipe .............................. 79Level leaf filter ........................................................78Light poles and utility poles ...................................47Limit switch ...........................................................73Lined valve .............................................................17Lined valve and pipe fitting ......................................6Logistics solution ................................................BICLong neck pipe end ................................................79Low maintenance ...................................................10Manual filter press ........................................... 84Membrane holder ...................................................57Methyl methacrylate adhesive ................................72Monel .....................................................................17Monoblock pump ...................................................73Motor protection relay ............................................77Nickel aluminium bronze ................................. 17Nitrogen plant manufacturer ..................................35Non metallic pump .................................................73Non return valve .......................................................6Nut shell filter.........................................................57P/P positioner .................................................. 73Pipe ......................................................................59Piping system from polypropylene ...........................4Plate & membrane type filter press ........................84Plug valve ......................................................... 17, 59Pneumatic conveyor ................................................77Polypropylene process pump ..................................73Portable shot blasting machine ...............................78PP butterlly valve - flange end ................................79PP diaphragm valve flange end and screwed end ...79Pressure vessel ................................................... 51, 53PTFE .....................................................................59PTFE lined valve and pipe fitting ............................6Pump .........................................................25, 73, BCPump for chemical equipment .................................5PVDF pump ...........................................................73Reaction vessel ................................................. 79

Reactor ...................................................................53Ribbon blender .......................................................81Rod ......................................................................59Root blower .....................................................25, BCRotary gear pump ............................................. 55, 73Rotary jocketed pump ............................................55Rotary main oil pump ............................................55Rotary monoblock pump ........................................55Rotary tracodial pump ............................................55Rotary twin gear pump ...........................................55Rotor unit ...............................................................80safety switchgear.............................................. 80Sampling valve - teflon lined ....................................6Seamless pipe..........................................................79Self priming mud pump .........................................73Self priming sewage pump .....................................73Sheet ......................................................................59Silicone FBD gasket ...............................................81Silicone rubber braided hose...................................81Silicone rubber compound ......................................81Silicone rubber corona teater sleeve ........................81Silicone rubber extruded gasket and profile ............81Silicone rubber moulding .......................................81Silicone rubber sheet ..............................................81Silicone rubber sponge ...........................................81Silicone rubber tubing ............................................81Silicone transparent tubing .....................................81Sintered filter ..........................................................57Socket .....................................................................79Stainless steel pipe ..................................................79Sterility test kit .......................................................57Storage tank...................................................... 51, 53Strainer .....................................................................6Super duplex ...........................................................17Swing check valve ...................................................59Teflon lined valve and pipe fitting ....................... 6Tefzel HHS isotactic PP material ............................4Thermoplastic valve ..................................................4Titanium ................................................................17Total water hardness test strip ................................74Trade show .............................................................62Tube ................................................................ 59, 79Tube expander ........................................................74Two wire temperature transmitter ..........................80‘U’ tube ............................................................ 79vacuum booster pump ................................25, BCVacuum system ................................................25, BCValve ......................................................................59Valve positioner ......................................................73Vent filter ................................................................57Vertical glandless pump ..........................................73Vertical pressure leaf filter .......................................80Vibro shifter ...........................................................74Water saver nozzle............................................ 77Waterproof multiparameter meter ..........................73Welded pipe............................................................79

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Chemical & Process World July 2013