Chemical World - March 2013

Industry Watch - chemical World March 2013

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5March 2013 | Chemical World

EditorialAdvisory Board

Pothen Paul Former Chairman,

Aker Powergas Pvt Ltd

D P Misra Director, TCE Consulting Engineers Ltd and Former

Director General, ICC

P D Samudra Executive Director (Sales) &

Member of the Board, Uhde India Pvt Ltd

Budget 2013-14: Pragmatic, yet lacking the push?

Manas R [email protected]

A t first glance, the Union Budget 2013-14 seems to have taken a fairly cautious step with a clear focus on getting a good grip on fiscal fitness. To begin with, it has emphasised on two specific areas – infrastructure development and Micro, Small and Medium Enterprises (MSMEs) – the key to fuel the growth of Indian economy.

Although full-fledged implementation of Goods and Services Tax (GST) is still months (hopefully not years!) away, the Finance Minister’s proposal for payment of ` 9,000 crore as the first installment of balance of Central Sales Tax (CST) compensation is a good step in the right direction. Among other highlights, the Budget recommendation to extend MSME benefits for a period of three years after moving to a higher category is well timed and the need of the hour. It should motivate the home-grown emerging enterprises to take the next big leap in their growth trajectory. The exemption of 15 per cent in investments of more than ` 100 crore to set up plant and machinery should further galvanise industrial activity in the country. Also, the commitment to increase availability of low-cost funds to the infrastructure sector augurs well for higher investments.

Last but not the least is the spotlight on national skill development programme as well as the additional ` 200-crore outlay to fund ‘technology for common man’, which is the need of the hour to broadbase the country’s growth keeping in mind the abundance of educated youth as well as their aspirations. Other noteworthy initiatives in this Budget include measures to strengthen the investment climate in manufacturing and infrastructure, MSME growth and capital market development. These should benefit the chemical industry directly and indirectly.

To sum up, although this Budget lacks the fireworks of its previous editions, this can be considered as the best possible foot forward by the government in the current complex geo-political climate. A contrary viewpoint suggests that the government missed an opportunity to give a greater thrust to various government policies, especially when the whole world is looking at emerging nations like India to accelerate the global growth engine. For more insights into the Budget, especially for the chemical sector, turn to the special section Post Budget Analysis.

All said and done, the Budget is a statement of the government’s action plan for the next fiscal. The real result will accrue from its effective implementation. While it is imperative for the government to ensure that all these policy announcements stay on track, the industry needs to leverage the advantages offered in this Budget to take the India success story a notch higher.


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

Insight & Outlook: Fine Chemicals

Special Focus: Safety & Maintenance

Post Budget Analysis

Plant maintenance ..............................................................

Welding process ..................................................................

Maintenance services outsourcing .....................................

Interface - Mike Baldi, Chief Cyber Security Architect, Honeywell Process Solutions ..............................................

Budget Analysis: Chemical industry ..................................

Budget Impact: Oil & gas ..................................................

Budget Views ....................................................................

In Conversation With

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Pravin S Herlekar, Chairman and Managing Director, Omkar Speciality Chemicals Ltd ............ 20

30Fine chemicals ....................................................................

Personal care ingredients ....................................................

Agrochemicals.....................................................................

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

Market slowdown ..............................................................

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Automation TrendsCase Study - Qatar Fertiliser Company: Troubleshooting instrumentation issues for smooth project completion ......

Energy ManagementPumping systems: Driving energy savings through right selection ......................................................................

Policies & RegulationsResponsible Care: Incentivising HSE performance for better compliance .........................................................

StrategyTalent development: Empowering people, retaining growth .................................................................

Tips & TricksFire prevention: Handy tips for safe handling of f lammable materials .......................................................

Event Reporto Engineering Expo Aurangabad 2013: Exhibiting

Aurangabad’s unparalleled potential ............................

o Engineering Expo Aurangabad 2013 - Panel Discussion: Gauging Aurangabad on the critical parameters .........

Cover illustration: Sachin Pandit

Regular SectionsEditorial ........................................................................ 5News, Views & Analysis .............................................. 10Technology & Innovation ............................................ 16Technology Transfer .................................................... 18Projects ........................................................................ 67Tenders ........................................................................ 68Event List .................................................................... 69Book Review ................................................................ 73Products ...................................................................... 74List of Products .......................................................... 82List of Advertisers ...................................................... 83

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Facility Visit: Rama Phosphates Ltd

Banking on process innovations for fruitful gains .............. 38

Highlights of Next EditionSpecial Focus: IT for Chemical Process Industry

Insight & Outlook: Alternative Energy/Fuels Details on page no. 69

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Business InsightsTechnologies

Opportunities

News, Views & ANAlysis

Chemical world | March 201310

Market forecastIndian specialty chemicals market to reach $ 50 billion by 2018According to a Research and Markets report, ‘India specialty chemicals market outlook 2018’, the market for specialty chemicals in India is expected to reach $ 50 billion by the end 2018. Driven by the boom in end-user industries, the domestic market for specialty chemicals is expected to grow strongly, buoyed also by the increased adoption of specialty chemicals and their increased usage in different product categories. Paints, coatings and construction chemicals, colorants, Active Pharmaceutical Ingredients (APIs), personal care chemicals and flavours & fragrances are the specific segments that are expected to do well in the Indian market.

Satish Wagh, Chairman, Chemexcil, commented, “Growth in the Indian specialty chemicals industry is driven largely by robust domestic demand with exports based growth in select segments. Local demand for specialty chemicals in India will continue to grow, driven by factors such as demand from key consumer industries; emerging customer needs calling for high-quality products.”

Avani Jain

Reliance Sibur Elastomers Pvt Ltd (RSEPL), a joint venture between Reliance Industries Ltd (RIL) and SIBUR, has begun construction of its butyl rubber plant, in Jamnagar. When commissioned in 2015, the new plant will be India’s only manufacturer of butyl rubber and the JV will be among the world’s top five manufacturers of

butyl rubber. RIL and SIBUR signed a technology licence agreement facilitating use of SIBUR’s proprietary butyl rubber production technology at the new facility. The licensing package includes development of a Basic Engineering Package (BEP) and full-time provision of highly experienced technical personnel on both project and operational stages.

GreenfIeld projectreliance sibur begins construction of butyl rubber plant

HRS Process Systems Ltd (HRS PSL), a part of the UK-based HRS Group, shipped its first FP 160, the company’s largest Plate Heat Exchanger (PHE), to an Indonesian company in Malaysia. The PHE will be utilised for cooling condensate water in ammonia plant. With a height of 3 metre and requiring floor space of around 1.2 m x 4 m, this PHE has 483 plates, amounting to a heat transfer area of 769.6 sq m. The PHE weighs more than

10 tonne while in operation and approximately 7.9 tonne when empty. V Gokul Das, Managing Director, HRS PSL, said, “The development of this PHE is a remarkable accomplishment that has propelled us in the league of top players in the industry. HRS is known for innovation and our strong focus on applied engineering. This PHE is yet another product that demonstrates these strengths.”

Heat excHanGerHrs supplies its largest plate heat exchanger

specIalt y polyMershale gas and personal care markets driving solvay’s guar solutions business

The growing oil & gas and personal care markets are offering major growth prospects for the guar solutions business of Solvay, which recently announced plans to increase its global derivatised guar production by 40 per cent with the recent expansions in the US and China. “We see this year’s demand for guar as similar to last year’s and feel new crop yields will meet that level of demand. Further, near-term pricing should reflect the balanced situation with supply covering demand in 2013 and everything we have seen so far suggests a balanced guar market in 2013.

The North America shale gas boom has been a primary driver in the growth of demand for guar. But, we are also seeing a growing demand for our guar solutions in personal care applications, especially hair conditioning, and in agrochemicals with our Starguar anti-drift fertiliser tank mix solutions,” said Emmanuel Butstraen, President, Solvay Novecare.

Solvay, which sources its raw material from India through its joint venture with HiChem (one of the leading suppliers of guar gum and guar extracts), is also eyeing to tap the Indian market. He added, “As India’s middle class continues to grow, we see potential as a growth market for derivatised guar. In addition, there have been some very preliminary, exploratory analyses regarding potential shale gas fields. But again this remains very much in the discovery phase.”

Rakesh Rao

epc contract technip awarded contract by jBf petrochemicals in IndiaTechnip was awarded by JBF Petrochemicals, a wholly–owned subsidiary of JBF Industries Ltd, an important contract for a 1.25 million tonne per year latest-generation Purified Terephthalic Acid (PTA) unit, to be located in the Special Economic Zone in Mangalore. The contract covers the basic engineering, front-end engineering design, detailed engineering and procurement services for the Inside Battery Limit (ISBL) and the Outside Battery Limit (OSBL) of the unit.

emmanuel Butstraen



HoMe & personal careclariant showcases solutions developed for Indian needsClariant’s BU Industrial & Consumer Specialties (ICS) recently launched a range of unique personal & home care products specially catering to Indian needs. The range included mild surfactants, performance and optical effect boosters. Dr Alexander Snell, Head - ICS Business India, Clariant, explained, “India - an important market in Asia - is one of the first markets where we tailored our products specifically for the local market needs. In recent years, Clariant has stepped up its efforts in localising its products and dedicated to the growing domestic market in India.”

One of its products Diamonds & Pearls Aristoflex TAC is an effective suspending agent for surfactant systems. It stabilises wax pearls and bubbles in liquids thus offering product differentiation in the competitive category of face washes and shower gels.

Mahua Roy

Harsh Vardhan Pande and Aditya Yadav from SRM Unniversity were selected to represent India in the finals of Henkel Innovation Challenge, Henkel’s international innovation

competition for students. Convening international students from 27 countries for the 6th time, this year’s global finals will take place in Shanghai, China from March 18-20, 2013. The winning concept of Pande and Yadav was based on the adhesives industry. The students calling themselves ‘Radicals’ invented an illuminating adhesive. They presented a sample of their proposed product giving a practical feel. The national finals held in Mumbai saw an enthusiastic display of ideas and innovations from the students of IIM, IIT, and other renowned institutes.

Maharashtra Industrial and Economic Development Association (MIEDA) and SME Chamber of India recently organised ‘Maharashtra Industry Summit’ at Hotel Sofitel in Mumbai. The event, with the theme ‘Sustainable Industrial Growth Opportunities and Challenges’, was supported by the Government of Maharashtra.

Prithviraj Chavan, Chief Minister, Maharashtra inaugurated the Summit. During his inaugural speech, he observed, “Maharashtra despite the competition from

other states is still the leading industrial State and receives the highest FDI (33 per cent) of the total FDI in India.” Speaking about the State’s taxation policy, he assured that the government aims to completely abolish octroi tax very soon to encourage the investment climate in Maharashtra. While emphasising on the importance of developing adequate industrial infrastructure, he added that the government has started focussing on development of private ports. On the New Industrial Policy, Chavan mentioned that the policy would focus on overall development of backward regions of the State, attract more investments from the private sector and generate 20 million jobs.

Chandrakant Salunkhe, Founder & President, MIEDA, in his welcome address commented on the industrial and economical development of Maharashtra

and highlighted the key areas that the State Government needs to address in order to build sustainable economy of the State and compete successfully with Gujarat, Madhya Pradesh and Karnataka. He recommended the government to take various initiatives to truly make Maharashtra a highly industrialised and economically advanced State.

The Summit also featured the launch of ‘Activity Report of MIEDA – 2012’, ‘NRI Business Support Centre’ and ‘www.doingbusinessinmaharashtra.org – portal’. The event was well attended by several dignitaries from the government and industry as well as consulates of various countries and over 350 Indian delegates. A special interactive session was organised where the participants got an opportunity to interact with the Chief Minister.

coMpetItIonHenkel selects finalists from India for its global innovation challenge

sustaInaBle developMent Maharashtra Industry summit calls for sustainable industrial development

pHarMaceu tIcal InGredIentsIMcd plans expansion post acquisition of Indchem business IMCD Group, which recently acquired the business of Indchem International (an established player in the pharmaceutical ingredients market in India), is planning to bring innovative products in the country to further expand its business in India. “Acquisition of Indchem adds to our profile and presence in India and provides a strong foundation to taking a leading position in the market over the coming years. Post acquisition, IMCD will look to expand across the regions and drive to bring an extensive product portfolio to the market,” said an IMCD spokesperson.

Rakesh Rao

jeremy Hunter, country president, Henkel India, (second from left) and ranjan das,

Hr director, Henkel India, (first from right) with the winners

Inaugural address by the chief Minister of Maharashtra



sIlIcone cHeMIstry XIAMETER addresses critical areas of a carSilicones play an important role in safety, performance and fuel efficiency-related issues of a car. To consolidate its position in the market, Dow Corning collaborates with vehicle OEMs and tyre suppliers to find cost-effective solutions for system design challenges. Its XIAMETER brand offers a range of fluorosilicone rubbers for automotive applications and silicone emulsions for auto appearance. Ivan Mini, Global Marketing Manager - XIAMETER brand, Dow Corning, said, “Vehicle designers and engineers rely on silicones for their excellent thermal stability, mechanical and corrosive resistance, as well as their compatibility with metals, plastics and other materials.”

Honeywell announced that it has been selected by OOO Kirishinefteorgsintez, part of OAO Surgutneftegaz holding, to supply its Experion Process Knowledge System (PKS) and Advanced Alarm Manager system at the company’s refinery in Kirishi, in the Leningrad region of Russia. OOO Kirishinefteorgsintez chose to install Experion PKS as part of the upgrade process to its gas fractionating unit’s compressor block and the crude

distillation unit. Experion PKS will help to optimise production processes by providing the tight integration of production subsystems as well as safety, industrial security and advanced control systems, enabling plant operators to work more effectively and make more informed decisions.

Honeywell will also deploy its suite of Advanced Alarm Management products to improve plant uptime and safety by reducing losses through a more effective warning and alarm system, helping to prevent accidents at the plant, which could lead to financial or environmental losses. “Honeywell’s Experion PKS solution enabled us to rise to the challenge of automating our process units,” said Vadim Somov, General Director, OOO Kirishinefteorgsintez.

au toMatIon tecHnoloGykirishi inducts Honeywell’s Experion PKS in its plant

processInG tecHnoloGy Mettler toledo releases white paper for gas scrubber efficiency

In chemical plants, oil refineries and steel mills, wet gas scrubbers play a significant role in preventing pollutants to the atmosphere. However, use of inappropriate analytical sensors compromises their efficiency potentially leading to breaches in regulations and damage to the environment. Keeping this in mind, in a new white paper titled ‘You’re scrubbing, but are you clean?’, Mettler Toledo explains the importance of choosing the correct sensors in scrubber applications. The white paper discusses the challenges related to environment and outlines analytical sensor technology called Intelligent Sensor Management which, as a feature of Mettler Toledo’s highly resilient analytical sensors, results in increased scrubber efficiency and reduced scrubber operating costs.

Many chemical and petrochemical processes produce gaseous emissions that contain polluting substances such as sulfur dioxide and hydrogen chloride. If released into the atmosphere, these compounds would violate regulations and cause serious environmental damage as both are components of acid rain. Therefore, units called wet gas scrubbers are used to remove them.

cHlor-alkalI conference vinyl India 2013 to be held in Mumbai To provide growth impetus to the vinyl and chlor-alkali industry, Vinyl India 2013, which is the third international PVC & chlor-alkali conference, will be organised by ElitePlus Business Services Pvt Ltd (EPBS) along with Chemicals & Petrochemicals Manufacturers’ Association (CPMA), All India Plastics Manufacturers’ Association (AIPMA) and Plast India Foundation. About 600 industry experts and players (Indian and overseas) are expected to participate in the event, which will be held from April 11-12, 2013, at Hotel Grand Hyatt in Mumbai.

epc kpr Industries awards uhde India caustic soda plant contractKPR Industries India Ltd has awarded Uhde India a contract to set up a grassroots 200 tonne per day (TPD) caustic soda-chlorine plant at Balabhadrapuram in Andhra Pradesh. The scope of services includes basic & detailed engineering, project management services, technical procurement, supply of imported cell elements, supervision services during civil & erection and assistance during commissioning and guarantee test runs.The project has a completion period of 22 months.

Kemira Oyj and Rockwood Holdings Inc have signed an agreement, according to which Rockwood bought Kemira’s share (39 per cent) of the titanium dioxide joint venture Sachtleben GmbH. The transaction price of the deal is Euro 97.5 million and will impact Kemira’s cash flow positively in the first quarter of 2013. This strengthens Kemira’s focus on water technologies. “Ever since establishing the JV, we have clearly communicated that this is a non-core asset for Kemira. We are now able to finalise the exit of the business in a manner that is a good fit for both parties. This divestment is again another milestone in implementing our water strategy,” said Wolfgang Büchele, President and CEO, Kemira.

Buyou tkemira to reinforce focus on water technologies



fInancIal resultdamco’s net profit rises by 7 per cent Damco, one of the world’s leading freight forwarding and logistics service providers, reported a 19 per cent increase in net revenue compared to 2011. Net revenue in 2012 increased to $ 3,272 million, from $ 2,752 million in 2011. Gross profit saw a rise of 7 per cent to $ 807 million in 2012. “I am satisfied about our solid results for 2012. We have taken full advantage of our acquisition of NTS (a China-based freight forwarder), and that all of our products continue to grow organically faster than the market,” said Rolf Habben-Jansen, CEO, Damco.

Dr Deepak Parikh has been appointed as the Managing Director of Clariant Chemicals (India) Ltd. He will also take over as Vice Chairman of the Board effective from April 2013. Dr Parikh joins Clariant Chemicals (India) Ltd from Lion Copolymer (USA), where he held dual roles as the Chief Vice President of Asia-Pacific Business and Chief Technology Officer. Prior to joining Lion Copolymer, he

worked with Dow Chemical and DuPont in USA and Asia for almost 20 years

where he held various global and regional leadership roles in commercial, R&D and business development functions.

Peter Palm has resigned as the Vice Chairman and Managing Director of the company and will continue as

the Executive Director and Vice Chairman till his retirement effective April 2013.

appoIntMentdr deepak parikh is the new Md of clariant in India

Warren Rupp Inc, a leading manufacturer of air operated double diaphragm (AODD) pumps, has been selected as one of IndustryWeek’s Best Plants for 2012. It is one of 8 award winners based in North America for 2012, and the only AODD pump manufacturer to win this award in the 23 year history. The award criteria cover three years of historical data and results focussed on quality, productivity, on-time

delivery, service and safety. “On a daily basis, the Warren Rupp team focusses on continuous improvement in manufacturing quality products, exceptional on-time delivery and the highest level of customer service. This award recognises the hard work and dedication of the entire team. We are thrilled to be recognised with the Best Plants award,” said John Carter, President, Warren Rupp.

recoGnItIon Warren rupp named IndustryWeek’s Best plant

productIon strateGyWacker stops short-time work at Burghausen’s polysilicon facilityWacker Chemie AG has stopped the short-time work schedule introduced at Burghausen’s polysilicon facilities back in early October 2012. The Munich-based chemical company took this decision amid growing demand from its solar sector customers. The company is ramping up its current capacities, which are currently curbed to two-thirds of full utilisation, and is, thus, ending short-time work at Wacker Polysilicon. “We sold more polysilicon than expected in January. Our order intake has increased so much over the last few weeks that plant utilisation levels are currently insufficient to produce the quantities ordered. Thanks to its modern and flexible technologies, Wacker could align capacities to customer needs at short notice. Hence, the company could react to current and future market trends promptly,” said Ewald Schindlbeck, President, Wacker Polysilicon.

BusIness restructurInG solvay reshapes its operating structureSolvay has announced a new business structure, which reflects the Brussels-based group’s integration of Rhodia, the French materials group it acquired in 2011. Rhodia’s polyamides business has been placed into an operating segment called Functional Polymers along with Solvay’s chloro-vinyls business. This segment mainly supplies to the construction and infrastructure, automotive and electrical/electronics industries. Specialty polymers are part of an operating segment called Advanced Materials, which also includes silica, rare earths and special chemicals. End-markets for these materials are advanced transportation, healthcare, energy-efficient tyres, automotive emission control, smart devices and hybrid vehicles batteries. The other operating segments are Consumer Chemicals, Performance Chemicals and Corporate Business & Services.

appoIntMentkoch names Matias amor as regional sales Manager for spain & portugalKoch Membrane Systems (KMS), a Koch Chemical Technology Group Ltd company, has announced that Matias Amor has joined the company as Regional Sales Manager, Water and Wastewater, for Spain and Portugal. He will be responsible for increasing KMS’ commercial growth in this region and developing strong relationships with major multinational contractors and engineers working abroad.

autoMatIon tecHnoloGyaspentech’s new software enables more profitable decisions Aspen Technology, Inc, one of the leading providers of software & services to the process industries, announced the latest enhancements to the aspenONE process optimisation software suite. The V8.1 release features the new Aspen IMOS (Aspen Inventory Management and Operations Scheduling), significant enhancements for assay management within Aspen PIMS, the first ever Aspen Deployment Assistant, and new Aspen HYSYS Teaching Modules. The new Aspen IMOS is a web-based software solution that enables companies to optimise petroleum supply chain operations.

deepak parikh

Technology & InnovaTIon

chemical World | March 201316

Invensys Operations Management, a global provider of technology systems, software solutions and consulting services to the manufacturing and infrastructure operations industries, has enhanced its Triconex critical control and safety offerings for industrial operations. The new Triconex safety view solution is the world’s first software for effective alarm and bypass management certified by TÜV Rheinland to IEC61508 Systematic Capability 3 for use in applications up to Safety Integrity Level 3. Additionally, the company’s market-leading Triconex Trident and Triconex general purpose safety instrumented systems now support OPC Universal Architecture for greater communications connectivity. “Changing market dynamics and emerging technologies require a fundamental rethinking of how companies will manage their operations today and in the future,” said Gary Freburger, President, Systems Business, Invensys Operations Management.

He further added, “To address these new and ever-more complicated challenges, companies need to become more agile without jeopardising plant safety. Our new Triconex products provide this agility by reducing risks when bypassing safety systems during startup and shutdown, as well as the risks associated with integrating safety systems across different vendor platforms. In addition, they provide a pathway for modernising existing plant operations, one that links business processes with production processes; removes traditional barriers to collaboration; and empowers our customers’ most valuable resource – their people.” Triconex safety view provides the highest levels of safety integrity for critical alarm management applications.

Invensys enhances Triconex safety offerings

Brooks Instrument, a leading provider of advanced flow, pressure, vacuum, level and vapour delivery solutions, has come out with GF 80 mass flow controller which is part of its expanded GF 40/80 Series portfolio. It now features an increased flow rate up to 50 slpm. The GF 40 is now equipped with a ‘normally open’ valve typically used to maintain purge gas flow in the event of a power interruption. The GF 80 now features a teflon valve seat, allowing it to be used on all gases, including corrosive and reactive gases. Additionally, the GF 40/80 Series has expanded RS485 communication protocols. The GF 40/80 Series leads the market in long-term zero stability at less than 0.5 per cent per year. This specification means the device will return more reliable accuracy data for a longer period of time than competitive devices. It gives the user greater confidence in the numbers reported, and reduces the time and cost associated with recalibrations. The GF 40/80 Series is also available with Brooks’ patented MultiFlo, a powerful technology that enables users to re-programme the gas or range of the device in minutes without the trouble and cost of removing the mass flow controller from service. Brooks will display the product at Pittcon 2013, slated to be held from March 17-21, in Philadelphia.

Rockwell Automation has come out with compact Allen-Bradley PowerFlex 525 AC drive to help machine builders and end users simplify equipment design and operation, and speed installation and configuration. To help simplify and streamline set-up, users can configure the PowerFlex 525 AC drive through its human interface module (HIM), Rockwell Automation Connected Components Workbench software or Rockwell Software Studio 5000 Logix Designer. The PowerFlex 525 AC drive offers time-saving application sets, which are groups of pre-defined parameters for common drive applications that users can apply as it is or customise for a machine. Using a standard USB connection, machine builders can easily download the completed configurations and share with multiple drives, which speeds up

commissioning time. The product is suitable for a wide range of applications, including conveyors, material handling, compressors, fans and pumps. The PowerFlex 525 AC drive provides a variety of motor control options to accommodate open- and closed-loop applications. Representing the first in the company’s next generation of compact drives, it features a modular design in power ranges from 0.5 to 30 horsepower or 0.4 to 22 kilowatt at 100 to 600 volt input. Its embedded EtherNet/IP, safety, USB programming, energy savings and a variety of motor control options are ideally suited for machine-level and stand-alone applications or simple system integration.

Mass flow controller from Brooks reduces cost on recalibrations

Allen-Bradley PowerFlex 525 AC drive simplifies equipment design and operation

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. Ethyl alcohol is widely used for making many organic chemicals.

Areas of application Chemical and energy industries

Forms of transfer Technology licensing

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

Furan polymers, sealants & cements, urea-formaldehyde, and phenolic resins

Forms of transfer Consultancy, technical services,

technology licensing

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

Plastics, paper, paints, rubber, inksForms of transfer

Consultancy, technical services

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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. Areas of application

Chemical industryForms of transfer

Others

LimeAn Indian company seeks new cost-effective technologies that can reduce carbon emissions for lime manufacturing.Areas of application

Quick lime and hydrated limeForms of transfer

Others

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Technology requeSTed

In ConversatIon WIth Pravin s herlekar

Chemical World | March 201320

In ConversatIon WIth

Specialty chemical industry is an important growth

driver for our economy

Phot

o: Jo

shua

Nav

alka

r

…says Pravin S Herlekar, Chairman and Managing Director, Omkar Speciality Chemicals Ltd (OSCL). In an interaction with Prasenjit Chakraborty, he highlights on the impact of emerging global trends on the pharma industry, prospects in African markets for specialty chemicals, opportunity for chemical industry against the backdrop of current uncertainty in Europe and other developed countries, etc.

With many blockbuster drugs coming off patent by 2015, how will companies such as OSCL benefit?With availability of a wide range of products and raw materials, several multinational pharma companies are eyeing Indian specialty chemical companies such as OSCL in a big way. Hence, specialty or fine chemicals segment catering to the pharma industry has humungous growth

potential, which is poised on the cusp of an exciting period of growth, driven by a colossal demand post-global drug off-patent regime (by 2015). The demand for specialty chemicals is linked to the growth from the end-user industries, such as agrochemicals, dyes and flavours & fragrances, each representing about 8-10 per cent of the overall market. The pharma industry, however, remains the largest consumer of specialty chemicals for a long

time now. Roughly 15 years ago, the pharma industry consumed barely about half of the specialty chemicals marketshare. However, pharmaceuticals enjoyed significantly higher annual growth rates than other consumers of specialty chemicals over several years, and its share of the overall intake touched approximately 65 per cent during 2010-2011. It is imperative to note that substantial marketshare of pharmaceuticals indicates that trends


Pravin s herlekar

and developments in the pharma market largely determine what is happening in the specialty chemicals industry. Therefore, continuing growth in the pharma market will provide further growth impetus for the specialty chemicals industry.

How important is the African market for specialty chemicals manufacturers in India? A handful of countries, particularly South Africa, have indigenous companies developing medicines and manufacturing generics & patented drugs under licence. For Indian manufacturers, Africa has all the necessary ingredients for setting up industry, despite the fact that it faces challenges, such as infrastructure gap and shortage of skilled labour. Merely manufacturing pharmaceutical products would not create an industry in Africa nor will manufacturing in Africa make medicines cheaper as it needs to be supported with distribution and supply chains, followed by competent wholesale dealers and licensed retailers. As generic drug producers are globalising, Africa is one of the focus areas. Once they manufacture in volume, the pharma players will capitalise on reduced transport, customs costs and other expenses to tap Africa.

What are the growth drivers for chemical industry? The specialty chemicals industry is an indispensable and integral constituent in the Indian subcontinent. It occupies a pivotal position in meeting basic needs and improving quality of life, besides being one of the most diversified sectors covering thousands of commercial products. It is also the mainstay of the industrial and agricultural development of the country and provides building blocks for several downstream industries, such as textile, paper, paint, soap, detergent, pharmaceutical, varnish, etc. Global specialty chemicals industry is estimated to be about $ 740 billion accounting for about 22 per cent of the global chemical industry.

Indian specialty chemical industry, excluding agrochemicals and dyes & pigments, is currently pegged at $ 17.7

billion and is an important growth driver for our economy. The segment has the potential to reach $ 38 billion by the end of 2017 with a growth rate of 13-14 per cent every year.

Do you think the current global uncertainty will work in India’s favour with more investments coming into the country?India’s pharma industry has been growing at record levels in recent years. It now has unprecedented opportunities to expand in a number of fields. The domestic industry’s long established position as a world leader in the production of high-quality generic medicines is set to reap significant new benefits as the patents on a number of blockbuster drugs are scheduled to expire over the next few years. In addition, more and more governments worldwide are seeking to curb their soaring prescription drug costs through greater use of generics. These opportunities are presenting themselves not only in traditional wealthy markets such as the US and European Union nations but also in emerging economies with vast population such as Africa, South America, Asia, and Eastern & Central Europe.

In addition, India is a preferred manufacturing location for multinational drug manufacturers and this is quickly spreading into other areas of outsourcing activities. Soaring costs of R&D and administration are persuading drug manufacturers to move more of their discovery research and clinical trial activities to the Indian subcontinent or to establish administrative centres there, capitalising on India’s high levels of scientific expertise as well as low wages. Both multinational and local drug manufacturers could eventually benefit from the market potential of India’s population of over one billion. A large market is likely to open up as the result of a projected boom in health insurance, an area in which the country is currently woefully underdeveloped.

What strategy did you adopt to ward off competition from Chinese manufacturers?Specialty chemicals industry has diverse categories, such as commodity and niche

chemicals. Niche products have higher and more stable margins & create less susceptibility from any competitors. However, commodity products are vulnerable to global competition. OSCL predominantly produces niche high value-added organic and inorganic molecules, which emancipates us from every Chinese competition. China perennially specialises in commodity-based chemicals as it does not have the core competence to produce niche specialty chemicals, which we are capable of. It is this inherent business module of ours that has created an edge over our Chinese competitors. It is also because R&D and innovation are our hallmark and our niche product portfolio remains our biggest growth driver.

What are your future plans?We export specialised product range to about 21 countries, including regulated markets such as Europe, Canada, Asia and South America. OSCL’s export revenues in H1FY13 stood at ` 34.19 crore (about 35 per cent of the total revenues) as against ` 26 crore in FY12, which is reasonably significant. OSCL is currently targeting exports worth ` 60 crore in FY13.

Email: [email protected]

What motivates you most in life?Creativity has been pivotal to the survival of my business as it motivates me to find ways to stay nimble, adaptive and innovative.

What was the toughest decision ever made by you?There are some life altering decisions that we have to take from time to time to get to the next level. I did the same by quitting a stable job to start my own venture.

Which is your favourite book?I am an indefatigable reader of biographies and autobiographies of personalities who have contributed in various fields in societal development – the true leaders who lead by their examples.

Post Budget AnAlysis


Budget AnAlysisChemical industry: Fiscal prudence for growth sustenance .....................................................................24Aashish Kasad, Partner & Tax Leader – Chemicals Practice, Ernst & Young Pvt Ltd

Budget impAct Oil & gas: Clarity on policy and pricing, the missing link ......................................................................25L K Gupta, Managing Director & CEO, Essar Oil Ltd

Budget Views On par with industry expectations? ..........................................................................................................26

Budget AnAlysis Chemical industry


Aashish Kasad

T he Finance Minister had macro challenges to address such as fiscal deficit, increasing inflation and

working towards attaining the estimated growth rate of 6.1-6.7 per cent ahead of the Budget 2013. Therefore, quite expected there has been number of proposals addressing issues surrounding agriculture, infrastructure, employment and savings. While there were no big ticket reforms, the Budget has tried to address other critical areas of economy, ie rural development, capital market, financial sector, education, banking, insurance, etc.

The proposals for encouraging investment and infrastructure such as

setting up of Cabinet Committee on Investment to monitor the investment proposals as well as projects under implementation and also quickening the pace of implementation; investment allowance to manufacturing companies making investment of over ` 100 crore in plant and machinery; forming of regulatory authority for road constructions; encouraging infrastructure debt funds, etc are welcome signs for bringing on track the overall investment sentiments and infrastructure of India.

The Finance Minister has attempted to not propose any significant changes in direct tax rates and indirect tax rates, in the backdrop of the Direct Tax Code (DTC) Bill being introduced in the Parliament in

the Budget session. As regard to the tax reforms such as General Anti Avoidance Rule (GAAR), DTC and GST, the Finance Minister has proposed that the provisions of GAAR would be effective from April 1, 2016. However, one needs to wait and watch as to when DTC and GST would be made effective. Overall, considering the fact that the Finance Minister had macro-economic issues on priorities, the Budget 2013 is on the right trajectory to increase India’s growth rate and, to an extent, reduce the fiscal deficit, if implemented effectively and efficiently.

Chemical industry: Hits and misses There were no proposals that would directly benefit the chemical sector, despite several requirements laid out in the five-

year plan. However, the sector should benefit indirectly from the continued focus on agriculture as a priority sector and other areas such as textile, infrastructure and water purification. The Finance Minister has proposed to provide setting up of apparel parks along with the textile parks, technology upgradation fund scheme, various investment and infrastructure proposals, ` 1,400 crore towards setting up water purification plants, etc, which would indirectly benefit the chemical sector.

Various macroeconomic proposals could boost the economy and thereby the chemical sector. However, the expectations from government for fast tracking investment in Petroleum, Chemicals & Petrochemical Investment Regions (PCPIRs) did not

find place in Budget 2013, despite the fact that there has been a decrease in FDI in chemical industry during the April to October of FY 2012-13 ($ 789.4 million) as compared to corresponding period for the previous FY ($ 7,007.6 million). However, additional deduction of 15 per cent to manufacturing companies investing more than ` 100 crore in new plant and machinery, as defined under the proposed new provision, is a welcome proposal for chemical manufacturers.

Moreover, tax proposals that would have incentivised R&D in the chemical sector, especially related to specialty chemicals, REACH registrations, application/end-use R&D, clinical trials undertaken outside the approved facilities, and income generated from exploitation

of IP to incentivise companies to retain/commercialise existing patents/develop new innovative patented products, were conspicuously absent despite the fillip that they could have provided to the Indian economy. Hence, from the chemical sector’s perspective, there was much left to be desired.

Overall, I would rate* the Budget 3 on 5; however with respect to the chemical sector, it would be 2 on 5.

Aashish Kasad is the Tax Partner – Chemicals Practice at Ernst & Young Pvt Ltd. For details, contact Padma Chourey on

email: [email protected]

In order to find solutions to two dampeners – slowing GDP growth and widening fiscal deficit – in India’s success story, the focus of this year’s Budget was on macro-economic issues. However, from chemical industry point of view, there were no major announcements in this Budget.

Fiscal prudence For growth sustenance

*Rating scale: 1- Unsatisfactory; 2 - Below expectations; 3 - Satisfactory; 4 - Above expectations; and 5 - Significantly exceeds expectations

Budget ImpactOil & gas


L K Gupta

T he Union Budget 2013, presented by the Finance Minister, P Chidambaram, is along the expected lines. It appears to have been prepared with an eye on the general elections likely next

year, with a focus on infrastructure development and welfare schemes targeted at women, youth, scheduled castes and tribes, disabled people, and minority community.

Well-directed welfare schemes It is encouraging to see that the government’s increased spent on welfare projects without commensurate raising of taxes have come from the reduction of subsidy bill post partial deregulation of diesel and putting a cap on the number of subsidised cooking gas cylinders. Also, from a humble

beginning as a pilot project last year, the direct cash transfer scheme has now touched 11 lakh lives.

Although there is still a long way to go before the entire nation is mapped, once fully implemented, this will allow the government to continue its welfare schemes for the needy and yet control its subsidy bill by eliminating wastage.

Reintroduction of investment allowance for investments in plant and machinery of over ` 100 crore will encourage new investments and is a step in the right direction. The Finance Minister has shown his serious intent on implementing GST by earmarking a sum of ` 9,000 crore for compensation to the state governments for the revenue loss on account of CST. This is a welcome move as this is expected to herald a more predictable and uniform tax structure across the country.

Impact on oil & gas industryFor the oil & gas sector, the government has re-emphasised the need for a natural gas pricing policy. More clarity on this as well as the shale gas policy is eagerly awaited, as we believe India, which imports about 80 per cent of its oil & gas needs, cannot wait any longer to develop its own natural resources towards meeting its energy requirement. We were hopeful that the Finance Minister would view our request for removing service tax on service providers to Exploration & Production (E&P) companies favourably, since that drains away a substantial part of the funds committed for exploration.

What’s up for upstream sector?For the upstream sector, the Budget has been largely neutral in the absence of any specific announcement targeted at the sector, which is among the largest contributors in terms of direct taxes as well as Forex earner for the country. We are disappointed that the Finance Minister has not removed the tax anomaly between branded and unbranded fuel, given that such fuel have been proved to increase engine efficiency and enhance its life, thereby reducing consumption.

The Finance Minister has cleared the confusion around classification of imported coal for tax purpose and has proposed a uniform 2 per cent Customs Duty and 2 per cent Countervailing Duty (CVD) for both, steam coal as well as bituminous coal. This would increase the cost of power as the present duty on steam coal was only 1 per cent.

The ultimate deregulation of petroleum sector will lead to increased competition, thereby benefiting the consumers in the long run in terms of improved service and competitive prices.

L K Gupta is the Managing Director & CEO of Essar Oil Ltd – a fully integrated oil & gas company of international scale with strong presence across the hydrocarbon value chain from exploration & production to refining and oil retail.

For details, contact Rabin Ghosh on email: [email protected]

The Budget has indicated a move towards a more predictable and uniform tax structure across the country. While it has announced some positive measures to boost investments in infrastructure and manufacturing sector, the oil & gas industry was expecting more clarity on policy and pricing fronts.

Clarity on poliCy and priCing, the missing link

Budget Views


Partha Basu, Chief Finance Officer and Whole-time Director on Board, Akzo Nobel India

Ashish Gharpure, Director – Marketing & Operations, Aker Powergas Pvt Ltd

Kapil Mehan, Managing Director, Coromandel International Ltd

On par with industry expectations?This year’s Budget had no big ticket announcement, but boosted confidence of achieving GDP growth of 6.1-6.7 per cent in 2013-14. Against this backdrop, Prasenjit Chakraborty and Mahua Roy take stock of the sentiments the Budget evoked among industry veterans and their views on its expected outcome.

Rating scale: 1- Unsatisfactory; 2 - Below expectations; 3 - Satisfactory; 4 - Above expectations; and 5 - Significantly exceeds expectations

Rating: Some proposals in the Union Budget 2013 actively seeking to boost the rural spend will help the paints & pigments sector to grow. Especially, the Budget proposal to offer an additional interest deduction for first time house owners

will encourage substantial growth in the real estate and housing sector. This will effectively see rise in demand for related industries such as paints, cement, brick, etc. This announcement, thus, comes as a positive for the overall coatings industry. However, it is difficult to say whether or not it will give investments in the paints & pigments sector a boost, as eligibility limit for investment allowance appears too high for the sector.

Rating: The Union Budget 2013 is particularly an infrastructure-friendly Budget. The announcement regarding the investment allowance of 15 per cent for investments in excess of ` 100 crore comes as a positive for all

sectors. Besides, the government’s decision to clear the blocked New Exploration Licensing Policy (NELP) projects is also admirable. It will effectively help in reviving the investment climate in the overall oil & gas industry. Given the increased domestic demand for natural gas, the encouragement for shale gas projects is also welcomed. All these come as good news for the EPC industry.

Rating: Overall, the Budget for agriculture is quite encouraging with various schemes like National Food Security Mission/Eastern Area Green Revolution getting carried forward with higher allocations. Moreover, target of agricultural lending to ` 7 lakh crore will be encouraging

for the farming sector. This creates a good environment for enhanced demand of fertilisers. Revised estimates provide for additional subsidy payout of ` 5,000 crore during FY 13. This will, to some extent, help fertiliser companies overcome liquidity crunch. However, this still leaves a huge gap of unpaid subsidy bills, which get carried over into 2013-14. These are estimated to be around ` 20,000 crore, hence higher allocation of Budget for next year would have been better.

Amit Kapur, Director, Everest Group

Rating: Government’s focus on farm sector, higher spends under various plans, and expansion of agri-loan & interest subvention schemes should ensure robust agrochemicals demand. Increased allocation of ` 37,330 crore

to the Ministry of Health & Family Welfare as well as ` 1,069

crore to the Department of Ayush might trickle down to the pharma, chemical and biotech sectors. Considering the scale of investments required, companies with expansion plans or ongoing projects may benefit from the 15 per cent investment allowance proposed to be allowed as deduction on investments of ` 1 billion and above made in plant and machinery during the period from April 1, 2013, to March 31, 2015, especially for large petrochemical plants.

Budget Views


Omkar P Herlekar, Whole-Time Director, Omkar Specialty Chemicals Ltd

V Gokul Das, Managing Director, HRS Process System Ltd

Ravi Kapoor, Managing Director, Heubach Colour Pvt Ltd

Zarir Langarana, COO - Chemicals, India, Tata Chemicals Ltd

Rating scale: 1- Unsatisfactory; 2 - Below expectations; 3 - Satisfactory; 4 - Above expectations; and 5 - Significantly exceeds expectations

Rating: Populism is fast becoming the ‘new vocabulary’ of the political community. It perceivably manifested from the Union Budget 2013-14 presented by Union Finance Minister P Chidambaram. The Budget seemed more like election-

nomics and less of economics. I feel that it was more of a ‘now-you-see; now-you-hope’ fiscal statement as it virtually failed to offer any fillip to the specialty chemicals sector. Going by the

so-called fiscal-acrobats, the specialty chemicals sector is visibly left to figure out the exact starting line from where they want to propel. The Budget essentially failed to provide any elbow-room to the sector.

As the adage goes ‘the devil is in the details’. Budget 2013-14 was sort of a fiscal window-dressing for the incumbent government. Taking a sneak peek into the Budget clutter, I feel that it does not trigger any positive corollaries for the specialty chemicals industry as it has with great finesse dodged the core issues faced by our industry, which was expecting specific fiscal prudence.

Rating: Overall, it is an average Budget. Some of the measures such as containing fiscal deficit, investment in infrastructure, healthcare, education, agriculture, MSME refinancing limits hike, continued work on GST, etc, are

welcome. These are generic, which will have some impact on chemical industry. However, the industry was expecting much

more direct measures and, hence, is disappointed. The industry is passing through a difficult phase with no major investment. The Budget could have fast tracked setting up of chemical parks to attract investment and also provide cheaper fund to the industry to enhance growth. Other area was ‘zero duty’ on import of some chemicals to propel local industry. We hope some details emerging in the coming days on the New Industrial Corridor and other investment opportunity will help the chemical industry.

Rating: Overall, the Union Budget 2013 is rated below expectations, however it has not given any big negative shocks. There are very few things of much significance except for the announcement of higher surcharge in

corporate tax. The pigment & dyes industry in India stands the

chance to be a leading player in the world, subject to investments in R&D, clean manufacturing and value addition with high-end products. This requires a special boost from the government as the rewards would be seen apparently. This would be in the form of rebates for research-based efforts and developing technology for high-end products as well as for better waste treatment technologies. This has not been addressed in the Budget and it would have given a boost for this industry.

Rating: While there has been no major announcement specifically for the chemical sector, the 15 per cent investment allowance for investment of more than ` 100 crore in plant and machinery may spur some positive

investment activity within the manufacturing sector. The exemption of service tax on Goods Transport Agency (GTA)

services for movement of a key commodity, salt, is also likely to bring some benefits. The resolve to move to a GST regime in a time-bound manner is a welcome step. The focus on building infrastructure is bound to have a rub-off effect on the manufacturing sector in general with a time lag dependent on individual areas of play within the sector. Also, one might see a re-phasing of investment plans based on the incentive that has been announced. Though, of course, they would continue to be driven by strong fundamentals of feasibility.

Special FocuS


Plant maintenanceMirroring profitable returns from safety .................................................................................................30

Welding Process Ensuring equipment integrity for safe production ...................................................................................32

maintenance services outsourcing A helping hand to maintain productivity ................................................................................................34

interface - mike Baldi, chief cyber security architect, Honeywell Process solutions“Regulations will drive companies to install robust industrial cyber security program” ...........................36

Safety & Maintenance

Special FocuS plant maintenance


Prasenjit Chakraborty

M aintenance is a s i gn i f i c an t and inevitable link in productivity chain.

Industries in general and chemical units in specific have serious common safety concerns with reference to the efficacy of maintenance. In a wider spectrum, maintenance encompasses a plethora of activities – routine service, repair (minor or major), overhaul, cleaning of equipment from inside (tanks, vessels, reactors), replacement of parts, accessories, ongoing addition, alteration, breakdown fixation, emergency control, corrective action, etc. Most of these are handled by an organisation’s engineering, maintenance wings (and in certain specific cases by the process personnel).

“There have been instances of serious mishaps or even catastrophic incidents due to unplanned, poorly documented, unscheduled, inappropriate, incomplete, below par or poorly executed maintenance. All these reasons have been identified as root cause of disaster,” says K N K Murthy, Safety Consultant.

Emerging trendsWith the advent of new technologies, machines or equipment in the chemical industry, the issue of safety and maintenance has got more prominence. Murthy strongly feels that many of the existing techniques are fairly adequate and time tested; however, they are being reviewed, updated, amended and, of course, modernised through adoption of new methods, technologies coupled with the application of specialised machinery,

tools, systems and better administrative controls, procedures, and practices. For example, nowadays more scientific remote operated inspection and testing devices are adopted such as laser technology for thickness survey, self-actuated or robotised welding machines and at times, replacement of welding by safer and less intensive cold work (eg, on line injection of leak sealing materials on pressurised pipe lines, vessels etc).

Besides, computerisation has helped in documentation and preservation of equipment-wise history data to strengthen the existing predictive system. Proper maintenance of plant equipment can significantly reduce the overall operating cost, while boosting the productivity of the plant. “A planned maintenance programme helps to increase plant reliability, reduce production downtime, enhance throughput, improve safety & quality conditions, and increase lifecycle of assets. In recent times, proper plant maintenance using IT-enabled tools has helped improve productivity,” says V Gokul Das, Managing Director, HRS Process Systems Ltd.

There are different types of maintenance such as proactive, preventive, etc. Proactive maintenance concentrates on the monitoring and correction of root causes to equipment failures. This strategy is designed to extend the useful age of the equipment to reach the wear-out stage by adoption of a high level of operating precision. IT enabling includes evaluation of data, market demand of product, production schedule and machine running times. This helps in real-time plant maintenance and improving productivity.

Proactive maintenanceRisk management plays an important role in today’s process industry. Proper risk management programme ensures that there is perfect balance and synergy at achieving quality product and improved productivity vis-a-vis human safety, longer equipment lifecycle and zero breakdown. “In chemical industry,

Illu

strat

ion: S

achi

n Pa

ndit

No word is sufficient to describe the significance of plant maintenance in the chemical industry. With the passage of time, plant maintenance procedures are also evolving. Today, new methods and technologies, especially IT-related, are being utilised for the maintenance of plant, which not only ensures productivity but also increases bottom line.


Plant maintenance

risk management is critical to the plant operation because any error in risk evaluation can lead to accident and be fatal to human life and environment. Most of the processors have modernised their lines to enhance plant operation and improve product quality and ensure reduced risk. These days, much importance is given to plant design and equipment selection, right at the time of project planning to ensure accident-free running,” says Das.

Keeping safety aspect in mind, various companies are constantly coming out with new devices to ensure hassle-free process operation. Take the example of LANXESS, where safety is a core value and not merely a function. “Most importantly, safety at LANXESS is not just one department’s responsibility but is a mandate and priority, right from the Board of Management to the workers at the plant. There are well laid-out directives from the Board of Management of LANXESS, compliance to which is mandatory for every employee. This also includes contractual staff, and safety measures related to the distribution, storage, transport and handling of raw materials, finished goods as well as other materials. All plant and process designs are approved only after conducting adequate Process Hazard Analysis (PHA) studies,” says Namitesh Roychoudhary, Vice President - IEA (Industrial & Environmental Affairs) & Capital Investments, LANXESS India Pvt Ltd.

In its endeavour to ensure safety, LANXESS in association with DuPont Sustainable Solutions has come out with a programme called Xact. Xact is aimed at creating awareness on the

topic and developing comprehensive safety management, enabling systematic identification of risks with appropriate counter measurements and ensuring regular checks by professional safety experts using cutting-edge technologies. “This programme is meant to transform the safety culture at LANXESS into a more proactive one. The Xact programme is based on 22 elements of safety, 12 of which are cultural elements. This implies that greater emphasis is laid on the behavioural aspects of all stakeholders towards improving safety,” explains Roychoudhary. It has well laid-out procedures for management of change in technology and facility. Latest technologies are in use for automation, production and processes. All processes and safety protocols used are proven and well-established in other countries and are uniform for all LANXESS plants across the globe. Well-defined HSE metrics are in place for reporting on safety standards. “We are also in the process of implementing Responsible Care at both our sites at Nagda in MP and Jhagadia in Gujarat,” he reveals.

Risk managementAccording to Murthy, Risk Management (RM) has already replaced the conventional injury prevention-driven safety governance in highly hazardous chemical processing units. “The proactive approach of RM is getting duly reflected from the conceptual stage of the plant through selection of technology, process, quality control, maintenance, etc,” he says. The technique and methodology of modern risk assessment studies include all the aspects of safety with reference to people, machines, production strategy, etc. The element-wise coverage pattern could be as follows:

People: Training, competency enhancement with respect to hazard identification, risk assessment analysis, job safety analysis, standard operating procedures duly complemented by practical drills including execution of mock-up exercises

Machines: Selection of items having additional safety features including interlocks along with the documentation and issue of service manual highlighting safety features and work instructions to maintain them

Process & operation (production): Selection of process with inherent safety features such as use of less hazardous materials, processing of hazardous materials in less severe conditions pertaining to pressure, temperature, run-away scenarios, etc

Focus areas for IndiaIn today’s competitive world, undertaking adequate process safety measures in production plant has become mandatory due to the risk of various untoward incidents. Adopting process safety not only saves human lives in plant (which can happen due to wrong operation) but also enhances the production efficiency. “This involves understanding the risk involved against process requirement – define personnel and processing safety norms, evaluate technology and finally decide on the machinery to install. This will ensure better plant reliability, quality product, safety of workmen and environment,” exhorts Das.

Walking the extra mile by establishing best practices based on industry-specific mandates such as formulation of maintenance schedules and strict adherence to the same could make all the difference.

Email: prasenjit.chakraborty@ network18publishing.com

Risk management has already replaced the conventional injur y prevention-driven safety governance in highly

hazardous chemical processing units.

K N K MurthySafety Consultant

The Xact programme is meant to transform the safety culture at LANXESS into a more proactive one. It is

based on 22 elements of safety, 12 of which are cultural elements. This implies that greater emphasis is laid on the behavioural aspects of all stakeholders towards improving safety.

Namitesh RoychoudharyVice President - IEA & Capital Investment, LANXESS India Pvt Ltd

Special FocuS Welding process



W elding is an essential manufacturing process performed in almost every major industry. Welding technology is the application of the art and science of joining metals. It plays an

important role in the fabrication and construction of nuclear and fossil fuel power plants, heavy equipment, agricultural machinery, petrochemical plants, floating and underwater vessels, automobiles, etc. Specifically anything involving metals, from miniature electronic devices to sophisticated space projects, require the skills of the expert welding technologist. And when it comes to the chemical industry, weld quality and integrity are critical to safety in an extremely wide range of products and structures.

Welding technology has evolved dramatically over the years; hence the need for skilled welders in the chemical

industry is greater than ever. According to Dhananjay Patil, Head - Quality Control, Raj Process Equipments and Systems Pvt Ltd, welding is a process that joins the material by causing coalescence. The workpieces are melted and filler material is added in it, which is also in the molten form and on cooling it becomes a strong joint.

Welding is an important part of all chemical plants. In a chemical plant, there are many assembled parts of the metal, which are combined together by welding. If the welding is not proper or defective, it can lead to a disaster. Improper welding may result in serious accidents such as causing leakage in joint that can further result in spillage of the material. And if the material is hazardous, it can cause harm to people. If welding is weak, it could also lead to explosion of the vessel. “Welding has to be proper in every respect. If finishing of the welding is not proper, it may lead to material deposition and scaling of the surface. This, over a period, makes the joint weak, which could be harmful,” points out Patil. Defective welding may lead to contamination of the process material as well.

The processesTaking due cognizance of the fact, companies are taking steps to make welding process foolproof. Take the example of Raj Process, which is one of the leading manufacturers of process equipment and turnkey plants. In its endeavour to provide quality welding, Raj Process follows Shielded Metal Arc Welding (SMAW), which is a manual arc welding process wherein a consumable electrode coated in flux is used to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. “As the weld is laid, the flux coating of the electrode disintegrates, giving off vapours that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination,” says Patil.

Another process is Gas Tungsten Arc Welding (GTAW). This is an arc welding process that uses a non-consumable tungsten electrode to produce the weld. The weld area is protected from atmospheric contamination by an inert shielding gas (argon or helium), and a filler metal is normally used. A constant current welding power supply produces energy, which is conducted across the arc through a column of highly ionised gas and metal vapours known as plasma. Similarly, Metal Inert Gas Welding (MIGW) is an arc welding process, which uses carbon dioxide to protect the weld pool from oxidisation during the welding process.

To carry all such operations require skills, which is possible through training. “We train our welders before issuing any job to them and based on the performance of the welder, jobs are given. We strictly follow the standards as per ASME and have a strong procedure for welder training,” says Patil. There are various parameters for training welders. For instance, Welder Procedure Specification (WPS) is a document, which has a

Welding plays a crucial role in ensuring safety at chemical plants. If done with accuracy, it prevents leakage, eliminates chances of mixing of different fluids, and keeps other hazards at bay, all of which could lead to process upset.

Ensuring equipment integrity for safe production

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description of the welding procedure. The purpose of the document is to guide welders to the accepted procedures so that repeatable and trusted welding techniques are used. A WPS is developed for each material alloy and for each welding type used. Similarly, Procedure Qualification Record (PQR) is a document that contains details of the welding test. “It also includes the details of all the parameters of welding variables for each process involved and all the destructive test results,” says Patil. And Welder Performance Qualification (WPQ) specifies essential requirements, ranges or approval, test conditions, acceptance requirements and certification details.

Welding techniquesWelding techniques used for chemical process industry are Tungsten Inert Gas (TIG), Metal Inert Gas (MIG), submerged arc welding etc. According to V Gokul Das, Managing Director, HRS Process Systems Ltd, “Most of these techniques are decades old; however, the welding tools, fixtures and automation have changed drastically to the extent of having robotic welding machines. In the process equipment industry, the essential requirement is for controlling temperature, power consumption and other consumables to enable a quality weld. Today, there are several welding machines available, which help in enabling these,” he says. HRS uses PulseTIG welding machines for most of its equipment fabrication and specialised orbital welding machines for hygienic process equipment and piping. These enable good quality welding, thus ensuring safety of chemical plant. “Welding has a key role in ensuring safety in chemical plants. It enables reduction of open joints in a plant, which can lead to leakage of process fluids and can result in accident. Welding eliminates mixing of different fluids, which can also result in process upsets,” points out Das.

Over a period, welding segment has also witnessed the advent of new technologies. K N K Murthy, Safety Consultant, concludes, “Welding constitutes an effective and proven maintenance practice to ensure reliability and integrity of all metallic components susceptible to abuse, stress and strain. New techniques are available using automatically operating laser heat transfer technology, which can be used for faster cutting, welding work.”


Welding has a key role in ensuring safety in chemical plants. It enables reduction of open joints in a plant, which can lead to leakage of process fluids and can result in accident. Welding eliminates mixing of

different fluids, which can also result in process upsets.

V Gokul DasManaging Director, HRS Process Systems Ltd

Special FocuS Maintenance services outsourcing



O utsourcing of maintenance work is not new to the chemical industry, only the dimension has

changed. Earlier, the outsourcing was mainly on the labour front, ie number of workers required for shutdown or maintenance of a plant. Over a period, the industry has witnessed the emergence of

companies that provide special services for maintenance work. Today, plants are highly automated that resulted in drastic reduction of manpower. And people associated with maintenance work are no longer with such companies and are part of organisations (sometimes it is on job basis) which offer maintenance services. This seems a viable option for chemical companies.

Brighter side of outsourcing“Today, outsourcing is a key word in reducing cost and at the same time enabling expert guidance for services. Chemical plant maintenance services have always been a mixture of in-house maintenance and outsourcing. In-house maintenance takes care of day-to-day maintenance activity whereas outsourced maintenance services are required during periodic plant shutdown or emergency,” says V Gokul Das, Managing Director, HRS Process Systems Ltd.

Association with professional maintenance company gives the

advantage of gaining expert advices and reviews. In addition, outsourcing also enables a company to gain greater control over costs and results. “We advise customers to go for an ‘annual maintenance contract ’ with manufacturers of key equipment, which helps them to overcome such problems. In large units, high technical expertise is available. However, in terms of high-end machinery with variable capacity and

product processing, post-sales service tie-up with manufacturers becomes essential,” points out Das. During the engineering phases, the selection of equipment and their characteristics can have a major impact on safety & maintenance.

According to K N K Murthy, Safety Consultant, outsourcing of many functions including maintenance services have become the order of the day considering the ease in getting skilled personnel. The other benefits of outsourcing include:o Cost-effectiveness, especially when

the functions are of continuous, routine, mundane nature; and availability of skilled manpower as and when required

o Seasonal or staggered tasks, which is all the more significant when it comes to routine or shutdown maintenance of plants and equipment

o Outsourcing is prevalent in many common services such as repair, upkeep of air-conditioning equipment,

water coolers, building maintenance, insulation work, housekeeping, etc

Areas of concernHowever, outsourcing also has its negative sides. According to Murthy, a major area of concern in outsourcing maintenance is sustaining the feeling of belongingness among the workforce, especially since their association is short-lived and they feel aggrieved

about the major divide in terms of remuneration and perks as compared to regular employees. It has been noticed that cost aspect becomes an important criterion while selecting a company for maintenance work. “Quality of work suffers since the selection of agency highly depends on commercial aspects as compared to quality, competency, skill or hands-on experience on the specific jobs being executed,” laments Murthy. It has also been observed that at times certain periodical maintenance functions being carried out by accredited competent personnel from outside (as per statutory provisions) do not get the required direct attention from the principal employers.

Of late, it has been seen that the Indian companies have also taken steps for plant safety. But lot more needs to be done. “The lifecycle study of equipment must also be given priority to facilitate decisions to go for repeated maintenance or replacement of equipment, spares or accessories,” observes Murthy.


A helping hand to maintain productivity

It has been observed that maintenance work outsourcing for chemical plant is not only cost-effective but also facilitates smooth running of the plant. Added advantage is the advice from experts that ensures product quality, safety, plant efficiency, productivity, etc.

Special focuS interface - Mike Baldi


How important is cyber security for chemical industry?Today, there are several instances of security breaches being reported all over the world and industrial control systems are becoming primary targets. In fact, there are suspected cyber attacks on critical industrial installations in some countries.

While traditional security solutions have been used for banking & financial institutions, these solutions cannot be used in the industrial control system environment such as refineries and

chemical plants. What works best is industrial cyber security that helps minimise vulnerability to cyber attacks, improves recovery, and reduces loss of view & control.

How is application whitelisting different from antivirus? Antivirus works against known threat of malware but it has limitations. While antivirus can limit virus attack, it cannot prevent attack from unknown or new virus. Even if one changes the signature of known virus, antivirus will not be able to detect the threat.

But application whitelisting does the opposite. It protects from unwanted intrusions by permitting only applications and executable files that are considered safe and on an ‘approved list’ to run, while blocking everything

else. Whitelisting solutions have been deployed in business IT environments for years, but their introduction into automation control systems is relatively new. Hence, application whitelisting can complement the antivirus software and provide additional protection to the system against known as well as unknown virus/malware.

However, just having whitelisting and antivirus are not enough. They should be combined with other protection solutions depending upon the need.

What are Honeywell’s offerings with application whitelisting?Honeywell is committed to helping customers strengthen their cyber security by providing best-in-class technology in a manageable and scalable fashion. Last year, Honeywell announced a fully-certified application control and whitelisting solution to help combat viruses and malware from attacking its Experion Process Knowledge System (PKS) control system platform, thus providing an additional layer of protection for industrial systems and networks.

What steps should be taken to set up cyber security? For carrying out assessment of a plant, the company can appoint an IT security expert who understands process control environment, risks involved in such set-ups and also find out security lapses in

the existing set-up. After the assessment is done, depending upon the existing security set-up and requirements of additional protection to fill the need gap, one can incorporate more security programs.

Also, it is important that users who find difficulty in their control systems (ie if they are at risk or have faced virus attack) contact their vendors to fix the problem because vendors understand the process control environment and are in a better position to solve the cyber security challenges.

Are present regulatory frameworks effective in preventing cyber threats? Cyber attacks are difficult to prove and by the time it is proved, the damage has already been done. Hence, it is important to prevent such attacks. Governments in the US and many other countries have realised the threat of cyber attacks and hence are actively supporting initiatives to find solutions to such challenges. Regulations will drive companies who run critical installations to install robust cyber security program to defend against any virus/malware attack.

Even in India, the government has recognised the importance of protecting critical installations against cyber attacks, and is taking steps to devise strategies to protect such installations.


Regulations will drive companies to install

robust industrial cyber security program…says Mike Baldi, Chief Cyber Security Architect, Honeywell Process Solutions (HPS). He is the primary focal point for HPS product & customer cyber security issues, and is on the Board of International Society of Automation (ISA) Security Compliance Institute. In this conversation with Rakesh Rao, Baldi explains the importance of industrial cyber security in chemical industry.



R PL, a leading phosphatic fertiliser manufacturer in India, has one of its plants located at Loni Kalbhor, which is 25 km away from Pune railway station. This facility is one of the oldest phosphatic

fertilisers manufacturing units in India – in existence for over 40 years – popularly known as ‘Rama Krishi Rasayan’. The plant is spread over approximately 16 acre of land and fully integrated with all requisite facilities such as own railway siding etc.

The facility manufactures powder SSP, granular SSP, mixture fertilisers, sulphuric acid, oleum, etc. For SSP, the total production capacity is 1,32,000 MT per annum with rock phosphate as key raw material. Similarly, for granular SSP, Nitrogen, Phosphorous and Potash (NPK) mixture fertilisers, the total production capacity is 1,20,000 MT per annum. The

plant also produces sulphuric acid with Double Contact Double Absorption (DCDA) process as sulphur is the key raw material. Sulphuric acid is one of the raw materials for manufacturing phosphatic fertilisers. Besides, it manufactures 23 per cent oleum as value-added product from sulphuric acid plant. “Our sulphuric acid plant has its own captive power generation system, with steam turbo generator imported from Nadrowski, Germany, wherein electricity is generated exothermically in the process of production of sulphuric acid, which partly caters to the plant requirement. In addition, the company has its own DG set that can cater to the power requirement of the plant in case of emergency,” says Satish R Chimote, General Manager (Works), Rama Phosphates Ltd.

Productivity enhancement programme In order to enhance productivity, RPL is continuously monitoring and reviewing production processes with respect to breakdown analysis. Besides, debottlenecking of the streams is being carried out to enhance productivity. For example, in SSP plant, it has augmented rock grinding capacity from 12 TPH to 14.5 TPH with modification in mill circuit. Similarly, in sulphuric acid plant, it has replaced conventional acid cooler with plate heat exchanger, thereby enhancing the plant running hours. “When it comes to world-class management tools & systems, RPL follows First In First Out (FIFO) & Just In Time ( JIT) practices in engineering stores and to control inventory levels,” claims Chimote.

R&D strengthThe specific areas in which R&D activities are carried out by the company include improvement in quality of the existing products and development of new product mix to meet market demands. “We have introduced a special additive in SSP manufacturing process to improve the product quality and maintain free flow characteristic of material to minimise caking tendencies,” claims Chimote. Besides plate heat exchanger, a natural draft cooling tower for acid cooling is installed in sulphuric acid plant for the improvement of product quality and has helped in water conservation. “We have installed moisture separator in gas scrubbing system in our SSP plant, which is first-of-its-kind in SSP industry to minimise stack appearance,” states Chimote.

The facility has a full-fledged quality control laboratory where a range of sophisticated equipment is installed. The laboratory, in addition to monitoring the norms for air and liquid effluents, which

Research & Development (R&D) forms an integral part of manufacturing at Rama Phosphates Ltd (RPL). Recently, the company has introduced a special additive in Single Super Phosphate (SSP) manufacturing process to improve the product quality and maintain free flow characteristic of material to minimise caking tendencies.

Banking on process innovations for fruitful gains

Rama Phosphates LtdFaciLity Visit

SSP plant with 50 metre high RCC bricklined chimney


Rama Phosphates Ltd

are laid down by State Pollution Control Board, monitors quality of incoming raw material, intermediates & final product on a regular basis as per Fertiliser Control Order (FCO) & Indian Standard (IS). The process parameters are checked at regular intervals and accordingly suggestions are given to ensure consistency in quality production.

Safety and manpower training In order to provide better health and safety to its employees in the plant, RPL has constituted a Safety Committee that involve active participation of workers as well as management representatives. The committee meets periodically and the minutes of the meeting are maintained. The suggestions and observations regarding safety and health are studied, examined and implemented. It regularly conducts health check-up of its employees, as well as monitors ambient air quality around the plant at regular intervals.

Apart from this, RPL provides training to its workers on waste management and safe handling of hazardous waste. It also makes workers understand the importance of industrial hygiene. “Personnel engaged in handling of hazardous chemicals are well-trained and able to respond in an unlikely event of emergencies. We have developed safe work practices in controlling hazards during operation and maintenance,” says Chimote.

Strategic location The availability of its own railway siding, and strategic location of the plant have put

the company in the most advantageous position as it can bring its basic raw material rock phosphate from the mines located far away in Rajasthan. It also facilitates to transport imported rock phosphate from nearby ports of Mumbai. The facility is located around main SSP consumption area, hence provides location advantage. SSP is mainly consumed and applied in crops such as sugarcane, banana, onion, soyabean and cotton.

With increased area for soyabean, a short duration cash crop for farmers is proving as boon for SSP industry. Long duration crops, sugarcane and banana, are main source of SSP consumption. “Primary marketing of SSP and NPK mixture fertilisers manufactured at Rama’s Pune facility is done in Maharashtra and North Karnataka,” says Jaswantsingh Sidhu, Head-Marketing, Rama Phosphates Ltd.

According to him, Maharashtra alone has SSP consumption of 9.20 lakh MT (2011-12) with average consumption of 7.50 lakh MT for SSP & 7 lakh MT for NPK mixture fertilisers in last five years. “Consumption of SSP in North Karnataka is approximately 1 lakh MT. In spite of tough competition from other SSP manufacturers, our brand’s popularity has remained unaffected,” he claims.

Rama Phosphates, with its brand ‘Suryaful’, is established for more than 30 years. The plant is located in a strategic position, hence gives the company logistical advantage. “Because of this, we can deliver our products faster to our customer base of more than 250, approximately 250 plus

active dealers and around 1,000 active retailers. Crop diversity also helps the company to keep its inventory level at minimum round the year, with an aim to market minimum 25 per cent marketshare in Western Maharashtra and Marathwada region, and minimum 15 per cent marketshare in Khandesh and Vidarbha regions of Maharashtra. We have around 20 per cent marketshare in North Karnataka,” says Sidhu. It is taking all necessary steps to achieve numero uno status in SSP sector.

“We always treat our workers as a part of our family; such attitude not only helps us in delivering quality products but also gives them a sense of belongingness. We want to serve farming community and enhance prosperity through our quality products, so that we can achieve self-sufficiency in agricultural production,” concludes D J Ramsinghani, Chairman & Managing Director, Rama Phosphates Ltd.

Photo: Nachiket Gujar


We always treat our workers as a part of our family; such attitude not only helps us in delivering quality products but also

gives them a sense of belongingness. We want to serve farming community and enhance prosperity through our quality products, so that we can achieve self-sufficiency in agricultural production.

D J RamsinghaniChairman & Managing Director

Powder SSP fertiliser packing unitSSP plant fluorine scrubbing section and silica recovery unit

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InsIght & OutlOOk


Fine chemicals Sustainability, the catalyst for cost-effective innovations ......................................................................42

Personal care ingredientsFine chemicals taking ‘special’ care .......................................................................................................44

agrochemicals Harvesting success with high-quality solutions ....................................................................................48

roundtableSpecial skill-sets, need of the hour for fine chemicals sector! ...............................................................52

market slowdown Devising effective business plans with product innovations ..................................................................54

Fine ChemiCals


Mahua Roy

T he lines of distinction between global audience and those in India are fast diminishing. Value for

money has anyway been one of the key attributes an Indian consumer looks at. But now it is coupled with the demand for sustainable and green products. The fine & specialty chemicals industry is innovating towards development of niche products to deliver such requirements

suiting the forward nature of consumers. But the biggest driver for growth remains pharmaceutical solutions.

Aiding pharmaceuticals sectorBASF announced the launch of a production line for precious metal-based fine chemical catalysts at the company’s manufacturing site in Mangalore. These catalysts are important for the efficient production of active pharmaceutical ingredients. “India is a significant growth market for the pharmaceutical industry.

As population expands, the need for new and cost-effective life-saving drugs is also on a rise. By introducing a new production line for precious metal-based fine chemical catalysts in India, we will expand our offerings to meet the needs of local pharmaceutical producers,” said Prasad Chandran, Chairman, BASF Companies in India and Head - South Asia.

By definition, fine chemicals are those that can generally be produced on a large scale, and measured in thousands of tonne per year. Fine chemicals manufacturing is typically carried out in batch processes, with synthesis being followed by separation and purification steps. Pharmaceuticals have always been the largest market for the fine chemicals industry. Besides, it is likely that pharmaceutical intermediates will account for over two-thirds of the fine chemicals market by 2014. Agrochemical intermediates represent the second-largest category among fine chemicals, the majority of which are used in the manufacture of pesticides, herbicides, insecticides, fungicides and fumigates.

Another area of new development for fine & specialty chemicals is that of molecular biology offerings. Application areas such as oncology, vaccines, RNAi, biologics and molecular diagnostics, are becoming increasingly important. As both large and small biopharmaceutical companies are becoming increasingly risk- and cost-averse, especially when it comes to projects requiring high capital investment, such as manufacturing, investments in this sector are rolling large. The prospects for fine & specialty chemicals manufacturing are bright in India.

Redefining innovationThe need for chemical manufacturers to focus on innovation in order to maintain competitiveness is the prime strategy. Recent times have shown that the conventional approach to R&D for product innovation was no longer sufficient to achieve a useful return on investment. Products today have shorter lifecycles and disappear or convert into commodities more quickly than in the past. So there

Sustainability, the catalyst for

cost-effective innovations

InSIght & OutlOOk Fine chemicals

The role of fine and specialty chemicals has increased manifold in almost every industry. Its knowledge-driven nature has huge scope of leading to cutting-edge solutions for the consumers. A spate of innovations has led to the growth of this sector where new product launches concentrate on sustainability and value for money.


Fine chemicals

is a need to bring new products into the market to maintain a certain margin and have a substantial competitive edge. “Earlier, R&D meant innovation and a new molecule was automatically a new material or application that people desired. Today, a new molecule is nothing – it is just an invention. Companies need the capabilities to turn inventions into innovations, and this involves the whole company – sales, marketing and manufacturing – not just the R&D department,” adds Chandran.

The specialty chemicals industry is heavily knowledge-driven and relies on R&D efforts for product innovations. This industry is witnessing dynamics in strategies to focus on higher bottom lines. An interesting observation was made at Endura, an Italian fine chemicals company. Recently, many of the leading fine & specialty chemical manufacturers have started to focus on small-scale complex products, an area where advanced technologies are required. Endura announced that it would commercialise a technology that encapsulates insecticide into very small crystals. The encapsulation delays the release of insecticides, thus enabling an enzyme inhibitor to disable the enzymes that insects use to block pesticides. Moreover, Endura will also promote the concept of microencapsulated piperonyl butoxide. Microencapsulation is a niche technology and this sector is pushing its acceptance. And this is just one example of the changing mindset of the sector.

“It is heartening to see that the Indian region’s profile in use of advanced, cutting-edge chemical technologies is changing

– from chemicals and technologies lower on the scale of advancement, many sectors are moving towards high-end products and solutions that are now used globally,” adds Frank Lelek, President - India Region, Evonik Industries.

Speaking from specialty chemicals perspective, he notes that the chemical categories in demand are in line with key developments in this region right now. “In the past few years, we have seen increasing demand for MetAMINO – amino acids that are used as feed additives, which is in step with the increasing consumption by expanding Indian middle class. Also, as infrastructure and mobility pick up speed in the region, we have seen demand move upward for engineering plastics such as VESTAMID, our TEGO range coatings additives, oil additives and precipitated silica. As the regional growth continues, we see that the demand will keep pace in all these areas,” he states. Innovation has helped the fine and specialty chemicals industry deliver excellent results towards functionality, sustainability and value for money.

Sustainable solutions rule“From the sustainability point of view, we see a lot of changes. Technology to harness renewable energy, particularly wind and solar power, is gaining wider acceptance in the region. This spells strong growth for relevant chemical segments, such as amine hardeners and bonding pastes for rotor blades,” says Lelek. For instance, the estimated life span of an individual wind turbine is 20-25 years. Specialty chemical manufacturers are complementing the research of power generation industry to address this critical issue. Today’s resins, adhesives and coatings need to meet the challenge of a 20-year life span requirement; this means they must have acceptable fatigue performance. Or, silicone encapsulation using Ethylene Vinyl Acetate (EVA) to protect solar cells can improve durability and cell efficiency through better UV transparency. Sustainable solutions of tomorrow depend upon the specialty chemical innovations from today.

“Sustainability is an important prerequisite for business success in today’s world. Companies that conduct business sustainably and act responsibly will be more successful than their competitors in the long run,” adds Chandran.

Offering high value for money or multiple functionalities is another demand by Indian consumers across all industries. This is pushing the fine & specialty chemical manufacturers to offer tailor-made solutions addressing this key demand. By providing efficiency of resources, value for money can be established. “Another trend we observe is that Indian companies are now keener than ever on resource efficiency. They are willing to go the extra mile to provide more value to end-customers, thus creating demand for high-performance specialty chemicals. Automotive sector is evolving rapidly in using advances in high-performance polymers to cater to the evolved, high-end buyers. An example of that could be the tyre coatings that reduce rolling resistance, resulting in lower fuel consumption. We see a lot of interest from Indian companies in these products today than before,” adds Lelek.

ROHACELL, Evonik’s brand of rigid foam used with carbon fibres in sandwich structures, can effectively reduce the weight of vehicle parts by up to 70 per cent. Tyres produced with its latest silica-silane technology have lower rolling resistance than conventional tyres. All these create value for money proposition for the customers as also for end-consumers. And this has been possible due to the innovation brought about by the fine and specialty chemicals industry.


Indian companies are now keener than ever on resource efficiency. They are willing to go the extra mile to provide

more value to end-customers, thus creating demand for high-performance specialty chemicals.Frank lelekPresident - India Region, Evonik Industries

Sustainability is an important prerequisite for business success in today’s world. Companies that conduct business

sustainably and act responsibly will be more successful than their competitors in the long run.

Prasad ChandranChairman, BASF Companies in India and Head - South Asia

InsIght & OutlOOk Personal care ingredients


Mahua Roy

T he Indian market is a wonderful case study for marketers. The rich variety of consumers, their

psyche, sheer number, buying behaviour, everything exhibits wide diversity. The personal care industry has successfully created products that have become a part of the everyday regime of consumers. But now the companies are innovating further to offer niche products to the consumers by studying how they think. The skin care and hair care product categories have seen simplistic innovations to help create differentiation while delivering functionality, thanks to

the backing by the fine and specialty chemicals industry.

The Indian personal care ingredients market is currently estimated at around $ 300-350 million, as per Tata Strategic Management Group (TSMG). The major constituents can be classified as active ingredients, lipid layer enhancers, shine concentrates, waxes, protein products, opacifiers, thickeners, chelating agents, UV light stabilisers, humectants, cream bases, solvents, polymers, surfactants, etc.

“The Indian consumer has a particular loyalty when it comes to products branded on the ‘green’ or natural platform. As a result, these products are doing extremely well

in India,” says Rajiv Subramanian, Principal – Consumer & Retail, TSMG. This is creating huge opportunities for the fine and specialty ingredients to help sustain this fuelling demand. “Other trends, such as consumers demanding better performance from products, thereby needing a minimum addition of the active ingredients, is also a trend,” adds Subramanian.

Skin care gets more attractiveThe skin care industry is seeing massive development in India, which is to the tune of a whopping 18 per cent growth rate. The product differentiation in this category is unmatched. A small category like facewash, which was once considered a fledgling category having around ` 100 crore market size five years ago, has become a ` 1,000 crore market. As per research by the Kline Group, of the $ 600-million specialty surfactants market, only about 10 per cent of the raw ingredients available in this category is naturally derived. Growth in the naturally-derived segment is expected to register nearly 4 per cent CAGR through 2013. What consumers demand increasingly, especially in India, are those products, which effectively reduce skin and eye irritation. This has helped the entire baby-care range to develop as well.

Besides, foaming properties in hair and skin care rinse-off products are gaining traction, particularly in the mass market product categories. As a result, specialty surfactant ingredients, such as alkyl polyglucoside (APG), supplied by Cognis, Clariant and Croda are seeing high demand. APGs are manufactured from plant-derived materials such as vegetable oils and starch. “India is one of the first markets where we tailored our products specifically for the local market needs. In recent years, Clariant has stepped up its efforts in localising its products and dedicated to the growing domestic market in India. Our market enablers are not just in selling a product, but that of offering concepts, which help our consumers – the formulators – to

Making a particular product part of the everyday regime of consumers is what the personal care industry has mastered. But now it has gone one step ahead. It is steadily converting the behaviour of consumers into friendly products. And the fine and specialty chemicals sector is heavily backing this unique trend.

Fine chemicals taking ‘special’ care


personal care ingredients

develop products in line with the end-consumer needs. Velvet & fresh Aristoflex polymers that show unique fresh sensorics for thickening and texture enhancement, giving the skin a fresh and velvety feel has been launched recently by Clariant in India,” said Dr Alexander Snell, Head - ICS Business in India, Clariant.

Next set of popular ingredients are emollients, which are effective in facial creams, cleansers, wipes and other skin care products for their moisturising, softening and anti-aging properties. In this category, the naturally derived ingredients have a stronger share at just over 50 per cent of the market, around $ 400 million. This market is expected to grow by more than 3.5 per cent CAGR through 2013.

There is a general movement in the industry away from synthetics and animal-based ingredients such as lanolin. BASF recently launched its new personal care brand Care Creations. More than 30 product formulations, designed for applications including skin care and hair care demonstrate how consumer needs can inspire solutions from the world of chemistry. “With improved purchasing power and greater awareness, today’s Indian consumers are demanding high quality personal care products that also help them save time and resources,” says Prasad Chandran, Chairman, BASF Companies in India and Head - South Asia. BASF is one of the largest manufacturers of UV filters matching the challenging market demands for sunscreens that provide broad-spectrum protection and high photostability along with ease of use and skin care properties.

“Another new trend is the attractiveness of skin care products themselves. Colours and other visible ingredients are creating a unique differentiation of the product categories to attract consumers. Most new launches in the past year had exfoliating beads or other such attractive ingredients in the products. To aid this further, Clariant launched diamonds & pearls Aristoflex TAC, which is an effective suspending agent for surfactant systems. It stabilises wax pearls and bubbles in liquids,” adds Dr Snell.

Hair care gets safer“The emerging middle class is increasingly seeking premium products. Also, there is steady demand for hair colourants. Of course, the keyword in this industry revolves around natural/organic products,” adds Subramanian.

Gone are the days when conditioning and styling products were considered premium and used sparingly. Moving forward, hair care market in India is anticipated to grow at a 20 per cent CAGR during 2011-2014 to reach around ` 208 billion by 2014. In fact, in last five years, the hair care segment, especially shampoos, saw the maximum number of new launches in India as compared to any other FMCG category. The trend to notice in this category is that there is more activity of milk- and silk-based ingredients than active botanicals.

Another category, fixative ingredients used in hair sprays and other hair styling products are more of a challenge when it comes to developing an effective and safe natural alternative. As of now, synthetics like vinyl, acrylic and polyurethane polymers, make up 99 per cent of the active ingredients in the market. However, specialty chemicals derived from corn starch-based formulas are the new areas of research in this category.

What’s next?Rapid advances in the area of nanotechnology are helping researchers bring about huge breakthroughs in biotechnology. This has the potential

to further enable development of organic- based specialty chemicals. “Nano-scaled encapsulation techniques are being utilised to develop better delivery systems for active ingredients to the intended target area. Also, strong demand for multi-functional products is being witnessed. These include silicones, which offer improved sensory characteristics, and surfactants that have anti-oxidant and anti-inflammatory properties,” says Dr Jyoti Vora, Head, Department of Biochemistry, Ramnarain Ruia College.

An area of concern is that active ingredients are highly unstable in formulations due to their biodegradability. Thus, the adaptation of active ingredients into such formulations is a cost-intensive and risky process. “The incorporation of an active ingredient requires that the ingredient does not negatively react with any other component of the formulation. It is also dependent on the surrounding pH, heat transfer occurring within the ingredients, and flow characteristics of the formulation,” adds Dr Vora. Such a complex weaving of characteristics could cause degradation rapidly. This has given rise to highly sophisticated delivery systems that are not always within the reach of local producers due to the inability to pass on product prices to consumers. The continued instability of active ingredients causes a loss of product efficiency, unless significant investments are made in the same.


Another new trend is the attractiveness of skin care products themselves. Colours and other visible ingredients are creating

a unique differentiation of the product categories to attract consumers. Most new launches in the past year had exfoliating beads or other such attractive ingredients in the products.

Dr alexander snellHead - ICS Business in India, Clariant

The emerging middle class is increasingly seeking premium products. Also, there is steady demand for hair

colourants. Of course, the keyword in this industry revolves around natural/organic products.rajiv subramanianPrincipal – Consumer & Retail, TSMG

InsIght & OutlOOk Agrochemicals

Mahua Roy

H asn’t the number and variety of exotic, pulpy, colourful fruits shot up at your local vendor’s cart

or the shelves at the supermarket? Also, hasn’t the availability of beautiful flowers visibly increased at your local florist? Well, industry figures back your findings too. India’s horticulture production has crossed an all-time high of over 240 million tonne in 2012, as per Ministry of Food Processing Industries (MoFPI). It has helped the country earn ` 14,000 crore as exports too. And the floriculture industry is growing at a Compounded Annual Growth Rate (CAGR) of about 30 per cent, and is likely to cross the ` 8,000-crore mark by 2015, as per industry body ASSOCHAM. What does this mean for the agrochemical industry? And, we have not even started to state the opportunities in the area of staples and other crops.

Imminent growth “The agrochemicals industry in India, estimated to be between $ 1.5 and 1.7

billion in 2012, is expected to grow at a CAGR of 7.5 per

cent for the period 2010-2014. In agrochemicals, insecticides

occupy the largest marketshare of approximately 55 per cent,” elaborates

Gayathry Ravishankar, Senior Consulting Analyst, Chemicals, Materials & Foods Practice, Frost & Sullivan (F&S).

As per figures released by a FICCI study, in India, there are about 125 technical grade manufacturers, 800 formulators, with over 1,45,000 distributors, serving almost a million farmers in the country. Almost 60 technical grade pesticides are being manufactured indigenously. “The top 10 companies in this industry occupy almost 85 per cent of the marketshare,” adds Ravishankar. Besides, about 20 Indian agrochemical producers are active in the international markets. However, the bigger challenge lies in getting the products registered. In recent times, partnerships and outright buyouts have helped hasten market entry. The good news is that, the value of exports has now effectively crossed $ 2 billion and continues to grow at double-digits, somewhat similar to the pharmaceuticals industry.

Cashing in on the trendsMany unique trends have emerged in the past years, which have altered the dynamics of this industry. The top five are enlisted as follows:

Hot on horticulture: “One of the biggest trends has been the huge growth in horticulture industry in India. Horticulture crops require more care than feed crops and are more susceptible to attacks, especially fungal outbreaks,” says Kapil Mehan, Managing Director, Coromandel International Ltd. This has led to an increase in demand for specialised products. The market share of fungicides has increased by almost 6 per cent between 2004 and 2012.

Functional products rule: “Farmers are more open to experimenting with products today. They are open to explore products that promise value-addition. This has created a lot of activity in the market and a lot of players have emerged, thus opening up the market altogether. This is good for the industry,” says Rajnish Sarna, Executive Director, PI Industries Ltd. Increased R&D investments for the development of new molecules, which are low dosage, high potency, is the way forward for this industry. “The functionality achieved by half kg of agrochemicals for one acre, can today be achieved by just 50 gm. Besides, development of environment-friendly pesticides, which break down easily and are safe, are the biggest areas of R&D concentration for this industry,” adds Mehan.

Labour costs on the rise: One of the biggest challenges faced by the agriculture industry is low availability of

Agrochemical segment, one of the most traditional industries in India, has witnessed several changes owing to recent trends in the farm sector. It

has created a steady growth rate for this industry. But it still has a long way to go to match up to global standards. But the good news is India provides all the conducive opportunities!

Harvesting success with high-quality

solutions

48 Chemical World | March 2013


Agrochemicals

labour, which has led to a steep increase in labour costs. “As labour wages have shot up, chemical control of weeds is the biggest opportunity area for agrochemicals. Herbicides or weedicides are the fastest growing segment for agrochemicals,” adds Mehan. The herbicide industry has been growing steadily at 15 per cent in India, with an estimated market size of ` 2,000 crore.

Patent expiry: The Indian companies have concentrated on marketing generic and off-patent products. About 70 per cent of all pesticides used in India are generics, and India has developed competencies in the generics market. It is now a net exporter of pesticides. By 2014, many molecules are likely to go off patent throwing the market open for generic players. “The total viable opportunity through patent expiry is estimated at over $ 3 billion,” says Ravishankar.

Priority no 1 – Generate more awareness: Though there are ample opportunities, the agrochemical market is plagued by unique challenges. The biggest one is low awareness. The pesticide industry is working capital-intensive as the seasonal nature of demand for pesticides forces

companies to maintain large inventory levels. Moreover, the farmers require long credit periods as farmers have little surplus money left for purchasing pesticides, as these are the last inputs in agriculture operation. However, companies are concentrating on increasing the awareness levels of farmers to adopt integrated pest management. “About ` 50,000 crore worth agri-produce is lost to pest attacks annually in India. A holistic approach is needed to cut down this whopping figure. With our team of around 2,000 professionals, we educate farmers about safer products, safety gear and efficient use of agrochemicals. We even arrange for webinars by experts at our kiosks,” adds Mehan.

Evidently, the biggest priority for the agrochemical industry is to open up this category as a whole. The market for pesticides is highly price-sensitive and less brand-conscious as it largely caters to farmers. However, farmers need to be educated and made aware of the usage and quality of pesticides. Moreover, due to the prevalence of spurious pesticides in the market, brand awareness becomes critical for the Indian manufacturers. “We spend about 5 per cent of our annual revenues in extension activities to educate the farmers. We inform them about application strategies. Even if we manage to salvage 30 per cent of the produce that is wasted to pest attacks annually, just imagine the rise in production India can witness,” says Sarna.

“Another challenge faced is high price and lack of affordable pesticides for small-time farmers. Affordable pesticides and small volume packages will help the farmers to adopt the current agrochemical solutions,” adds Ravishankar.

Innovation, the differentiatorR&D investments in Indian agrochemical industry are extremely low – at less than 1 per cent of sales. Also, most of this is for quality control and analysis. Even for an industry with a generics focus, this is dangerously low. As patent expiries happen by 2014, generics will definitely rule the marketshare. However, innovation will act as a differentiator for those wanting to create leadership. One of the areas the

industry is concentrating on is that of water-based pesticides. This sustainable range of pesticides can help tackle several environmental issues for the industry. Coromandel International Ltd has its own indigenous technologies for water-based pesticide product, with brands such as Ninja, Marvin, Solvo SC, Hexanil SC and Corazole SC. DuPont has come up with two new herbicides – Resolve Q and Require Q – which are effective against a greater variety of plant diseases than traditional herbicides and can be used in more types of weather. Syngenta has developed the IZM (isopyrazam) fungicide with advanced double-binding properties, which combines binding to the fungal target site for high potency against disease, with binding to leaf wax for long lasting and durable results. Currently used in Barley, Syngenta is aiming to extend use for disease control in wheat.

The insecticide Entrust Naturalyte developed by Dow AgroScience has an active ingredient as effective as many synthetic compounds against pests that harm certain kinds of corn, potatoes. BASF’s F500 fungicide blocks the transport of electrons in the fungus’ mitochondria, thereby reducing the supply of energy to the fungus and killing it. With this molecular approach, a single fungicide can function well against a range of different plant diseases in a wide array of cultivated plants. Bayer CropScience has released a product, Oberon, which protects plants from pests while leaving little residue on the food or in the fields. Concentration on organic farming is also opening up opportunities for specialised organic manures.


Farmers are more open to experimenting with products today. They are open to explore products that promise value-

addition. This has created a lot of activity in the market and a lot of players have emerged, thus opening up the market.

Rajnish SarnaExecutive Director, PI Industries Ltd

As labour wages have shot up, chemical control of weeds is the biggest oppor tunity area for agrochemicals.

Herbicides or weedicides are the fastest growing segment for agrochemicals.Kapil MehanManaging Director, Coromandel International Ltd

Another challenge faced is high price and lack of affordable pesticides for small-time farmers. Affordable pesticides

and small volume packages will help the farmers to adopt the current agrochemical solutions.

Gayathry RavishankarSenior Consulting Analyst, Chemicals, Materials & Foods Practice, F&S

InsIght & OutlOOk Roundtable


Special skill-sets, need of the hour for fine chemicals sector!

The fine and specialty chemicals sector has high growth potential in India, but is facing talent shortage. It is expected to grow at 15 per cent in the country and this translates to a huge demand for specialised skill-sets and job opportunities. Mahua Roy finds out from experts how the industry is getting ready to tackle the challenge.

While it is evident that the shortage of talent is a real challenge, the solution lies in building up ‘Brand Chemistry’ right at the school level. Besides, codesigning curriculums and encouraging R&D activities with academic institutions can also be a solution because the specialty chemicals sector is heavily research-oriented.

Editorial takE

Steve StilliardVice President and Managing Director,

Indian Subcontinent, Huntsman

The fine chemicals sector requires talent across all skill-sets in order to meet the market’s demand for innovation. The chemical industry must shed any stigma of being anti-environmental and drive the message of progressive contributions to society. Also, the opportunity for personal development in the cross-functional team culture should be highlighted. Building stronger links with the academic institutions – both science and humanities – must be a priority. At Huntsman, our approach is to allow personal growth within the role by offering a flexible environment, with a readinesss to accept failure as a learning tool. This requires risk assessment, but enables individuals to test themselves and build confidence in an accelerated way. Growth in the chemical industry is so much more than shaking test tubes and installing new reactors. It is one of the richest seams of complex teamwork across functions in industry.

Hussain TinwalaNational Practice Head - Engineering &

Manufacturing, TeamLease Services Pvt Ltd

The chemical industry is facing a talent crunch. This industry has low brand awareness. We see a low uptake of chemical courses. It is also rare to see a B-school graduate who has a degree in chemical engineering or higher chemistry. Another observation is that the top chemical companies consider few top colleges for talent and have quite a traditional approach towards hiring. The openness to hiring from other sectors is minimal. Even hiring from other chemical subsectors is rare. For example, in general, a specialty chemicals company scouts for talent only in the same domain and not from say, polymers or pharma industry. It is necessary to create a diversified workplace with multi-talented people who can offer a different perspective to challenges. Hiring from B/C tier institutes can somewhat help solve the issue, because, once that happens, the institutes will automatically upgrade their quality.

Venkatesh ParasuramHead, HR and Legal,

Evonik India

Yes, there is definitely a crunch, since today the demand for talent in specialty chemical industry exceeds supply. The crunch varies in certain areas and is more acute pertaining to certain skill-sets, specifically in technology training, R&D and sales-marketing profiles. The immediate need is for a better connect between academia and industry; and the industry needs to initiate it.

At Evonik, we have made a concerted effort to provide every opportunity to our associates to experience different profiles, and work in different regions. On the academic front, I see that many Indian universities are now striving to stay relevant to the industry needs. More efforts are required to initiate technology training, curriculum co-design, and meaningful collaborative research initiatives. However, more specialised technical courses, such as coating technician, are the need of the hour.

InsIght & OutlOOk Market slowdown


Avani Jain

T he current uncertainty in the global economy leading to market slowdown is casting dark shadows on the Indian

chemical industry. With the traditional markets such as the US, Europe, etc not providing ample export opportunities, Indian chemical manufacturers are exploring strategies to survive amid the market slowdown. Satish Wagh, Chairman, Chemexcil, and Chairman & Managing Director, Supriya Lifescience Ltd, notes,

“India is one of the most important destinations for global chemical companies. As we stand at the financial year-ending of 2012-2013, it can be said that while oil prices remained at high level throughout the year, prices of petrochemicals have shown a downward trend. This has been largely influenced by the weak EU economies and volatility in the US.”

The Indian market started on a slow note in the beginning of 2012, but showed signs of recovery in the second half of the year. These included industries such as automotive and paints & coatings to name a few. “Overall, petrochemicals sales showed growth of 10-12 per cent as compared to last year. Specialty chemicals segment continued to face the limitations of feedstock availability. With the overall slowdown in the Indian economy and its resultant impact on the end-user industries, specialty chemicals segment witnessed moderate growth,” he adds.

Sustaining during slowdownThe Indian chemical industry ranks sixth globally in terms of volume. Growing at an average rate of 12.5 per cent, it

contributes 5 per cent to the country’s GDP. Wagh avers, “There cannot be any effective standard business plan for the chemical companies in India to sustain growth during the slowdown. Every chemical will require a different strategy as this industry comprises basic, specialty and knowledge chemicals. Further, Indian chemical industry caters to a wide range of end-user industries producing various commodities such as pharmaceuticals, fertilisers, textiles, plastics, polymers, agrochemicals, paints, dyes etc. However, the basic strategies remain the same such as strong green approach, robust R&D, etc. Further, favourable government initiatives can help the industry. These few factors will help the Indian chemical industry to build its own strategy for effective growth and sustaining during slowdown.”

Understanding market needs To facilitate India’s march from being agrarian to an industrialised economy while providing huge employment opportunities, the chemical industry is one of the oldest in India and is

Industry experts believe that the market slowdown is here to stay at least for another two to three years. Hence, it is important for the Indian chemical manufacturers to devise strategies to survive during this period by focussing on long-term goals and product innovations.

Devising effective business

plans with product

innovations

There cannot be any ef fective standard business plan for the chemical companies in India to sustain growth

during the slowdown. Every chemical will require a different strategy as this industry comprises basic, specialty and knowledge chemicals.

Satish WaghChairman, Chemexcil, and CMD, Supriya Lifescience Ltd


Market slowdown

significant in contributing to the economic development of the country.

Wagh states, “It is seen that during turbulent times, the development of any industry depends upon how well the companies understand the consumer needs and how effectively they have positioned their products in the minds of the consumers. In the chemical industry, specialty chemicals segment is growing at a rapid space as this segment manufactures the products as per the needs of the consumers.”

He adds, “On the other hand, knowledge chemical segment remains largely insulated during the global economic downturn and holds bright prospects. These chemicals comprise mainly agrochemicals and pharmaceuticals. This segment has made prominent headway in the area of R&D and technological innovation. Knowledge-based chemicals are now manufactured as per global standards. In fact, Indian products are now in great demand across the world.”

Tapping the domestic marketWith dwindling exports to developed markets, chemical companies can explore domestic markets instead. The demand for chemicals in India is founded on a strong domestic demand rather than on exports. Wagh observes, “The opportunities for the chemical industry in India are manifold. Today, India is the third-largest market for chemicals in Asia and is expected to grow further. With the increased purchasing power, consumers are demanding good quality of goods and those products, which improve their quality of life and status. This offers tremendous scope for innovations in the chemical industry.”

The government has been emphasising on the opening up of the manufacturing sector in India. “In the Draft National Manufacturing Policy, which is a recent development, government has spelled out its desire to improve the contribution of manufacturing sector to the overall GDP growth rate of India, which is estimated

to grow from current 16 per cent to 25 per cent by 2022. This coupled with an awakening among industry players will provide a major fillip to the growth of the Indian chemical industry. Valued at $ 108 billion in 2011, the sector is poised to grow at a CAGR of 9 per cent per annum,” he adds.

Transforming challenges into opportunitiesIn these turbulent times of market slowdown, it is important to look at domestic market and consolidate one’s presence. Also, entrepreneurs need to be careful in pursuing growth. It can be concluded that the growth of Indian chemical industry will be sustained, if consumer needs are kept in mind and products are manufactured as per the market requirements. Also, product innovation can help chemical companies survive successfully during the market slowdown.


AutomAtion trends Case study - Qatar Fertiliser Company

Chemical World | march 201356

Deepak Makhijani

F ounded in 1969 as a joint venture between the Government of Qatar and a number of foreign shareholders, QAFCO is a

large-scale venture in the petrochemical sector, established with a view to diversify the economy and utilise the region’s enormous gas reserve. After successfully implementing several expansion projects over the past three decades, the company has evolved into a world-class fertiliser producer. QAFCO is now owned 75 per cent by Industries Qatar (IQ) and 25 per cent by Yara Netherlands.

With a sizable annual production capacity of two million metric tonne (MT) of ammonia and three million MT

of urea from four ammonia and four urea plants, QAFCO is now the world’s largest single-site producer of urea.

To cater to the world markets, which are showing increased fertiliser consumption patterns, QAFCO currently seeks to maximise its production of granular urea as opposed to urea pills. Currently, the company exports ammonia and urea to more than 35 nations across the globe.

QAFCO pursues a policy of retaining existing customers while forging ties with new ones. This has enabled the company to maintain a large network of distributors, with utmost care being taken to ensure that all are satisfied with the quality of QAFCO’s products, services and level of commitment.

Troubleshooting issuesThe aqua ammonia storage facility had state-of-the-art instrumentation such as ammonia (NH3) analyser, radar level transmitter and earthing switch. During the testing & commissioning, the facility experienced malfunctioning of the system that needed to be sorted out using problem solving techniques.

NH3 analyser: The NH3 analyser application is to determine the percentage concentration of ammonia in liquid ammonia that is about 20 per cent as the downstream process requirement. The analyser was strategically placed to improve the process and purity of the end-product. During the production of ammonia, the gases pass through the steam reformer, high and low temperature shift converters, and amine scrubber before entering the ammonia synthesis process. The NH3 analyser is extremely well-suited to make the CH4, CO and CO2 measurements using Non-Dispersive Infrared (NDIR) photometric detectors. Typical analysis ranges after the methanator are 0 to 10 ppm CO and 0 to 5 ppm CO2. Abnormally high concentration levels are alarming. Ammonia concentration can be measured using NDIR photometric detector in the analyser.

Since this is hazardous area, the analyser is to be housed in purge/pressurisation systems for these applications. These analysers with the state-of-the-art technology ensure more efficient production, longer catalyst life and higher quality product.

During testing and commissioning of the system, NH3 analyser was malfunctioning as the condensate was getting accumulated in the sample line and same was damaging the sensor. A Hazard and Operability (HAZOP) study was conducted and it suggested suitable modifications in the form of bypass line for condensate. On sensing moisture in the sample flow line, the bypass valve was opened to prevent moisture particles from getting accumulated in the sensor probe.

The aqua ammonia storage facility at Qatar Fertiliser Company (QAFCO) experienced malfunctioning of instruments such as ammonia analyser, radar type level transmitter, and earthing switch at the time of testing and commissioning of the system. However, by deploying the right measures, the issues were resolved on time resulting in timely completion of the project.

Troubleshooting instrumentation issues for smooth project completion


Case Study - Qatar Fertiliser Company

Testing of radar type level transmitter: The radar type level transmitter using non-contact microwave radar type technology is easy to use and understand. It offers a real alternative to existing technologies such as differential pressure transmitters and displacers.

Since the application involves liquid ammonia and the liquid medium contains suspended solid particles, the radar type level transmitter was the right fit solution for the application requirement. This transmitter is non-contact type, making it versatile, extremely reliable and suitable for such applications where the liquid will contain suspended solid particles during storage or processing.

The radar transmitter was installed wrongly. It was removed and installed at the other end. The same transmitter was working perfectly well after being placed in the correct orientation.

Testing of earthing leakage switch: An earth leakage relay is an electronic

or electromechanical device that detects the current flowing to earth (also referred to as ground). If this earth leakage current is above a preset level (and carries on for a preset time) the relay is tripped – this may switch on an alarm signal – or more usually it simply disconnects the supply. Currents may flow to earth due to a fault condition or because several individual items connected to the supply have a small leakage to earth.

In the ammonia storage facility during transfer of material from the storage tank to the truck vehicle, it is important to check before starting the loading operation that the grounding of the tank vis-à-vis the truck vehicle is proper and there is no residual current resulting in hazards. For the same purpose, the earth probe is connected to the truck vehicle and the earth leakage switch; in case of residual current, it gives an alarm to stop the loading operation.

The earth switch cable connector was broken during trial run and

the probe was giving a faulty red alarm. The breakage was repaired using cable connector probe of same size and reinstalled. As a result, the earthing connection was re-established and it gave a green signal indicating the loading operation could be started.

Mission accomplishedThus, the project was successfully completed and the malfunctioning of the instruments was done just in time, resulting in timely completion of the project and meeting the project schedule requirements of the customer.

Deepak Makhijani is a consultant having 15 years work experience in executing several EPC contracts with

leading oil & gas and pharmaceutical companies in India and abroad.Email: [email protected]


Avani Jain

T he chemical industry is now witnessing a difficult energy scenario. This is because not only energy prices are

steadily going up, thereby upsetting the economics of operations, but also there are problems in procuring energy sources such as coal and natural gas due to shortage conditions. In fact, besides raw materials, the energy cost is considered to be the second-largest operating expense in a chemical manufacturing plant. In order to become globally cost-competitive, chemical manufacturers are on a drive to reduce energy costs. During the past few years, induction of energy-efficient technologies has led to the dramatic reduction in the use of energy in the chemical process industry. In most of the segments within the industry, pumping systems take up almost 50 per cent of the energy used. Hence, pumping operations has been a primary target for energy conservation.

Normally, a company may not consider pumping systems to save on energy cost. But, it is estimated that pumps actually consume around 10 per cent of the world’s energy, more

in fact, than any other type of equipment. Hence, it is imperative to optimise inefficient pumping systems, which can save energy and reduce overall cost of processing.

Changing scenarioFew years ago, pump technology was not advanced; chemical industry’s growth was also low and energy shortage was

not a big issue like it is today. However, now the scenario has changed and energy conservation has become a daunting task. Thus, usage of efficient pumping system for ensuring energy efficiency has become a necessity.

Sanjeev Srivastava, Associate Vice President (Development), Doshion Ltd, notes, “The pump industry has witnessed a phenomenal growth and maturity over the years. Earlier, big, bulky, Mild Steel (MS) or Mild Steel Rubber Lined (MSRL) pumps were used, but today this market is completely taken over by lightweight high-efficiency sheet metal pumps with multiple impellers. Keeping in mind the energy-efficiency aspect and technological changes, we offer pumps that give superior performance and consume less energy than other products.”

The selection criteriaPumping system efficiency depends on the performance of motor, pump, pipe and valves. Proper selection of pumps & motor (without oversizing) and appropriate pipe size can keep the pump set close to Best Efficiency Point (BEP). While high-capacity, low-head pumps have reasonably good efficiency, medium and low-capacity pumps have relatively low efficiency.

Process engineers calculate the flow that the pump has to handle and the head it has to develop. The manufacturer then selects the pump that meets process engineers’ specifications at around its BEP. Further provision of variable speed arrangement for reducing speed can help decrease power consumption, which is proportional to the cube of the pump speed. Apart from energy efficiency, the operation of pump near or at BEP is necessary since the pump is most stable under this condition. Moreover, it improves the overall life of the pump and reduces maintenance cost.

The right pumping systemThe critical consideration for energy efficiency in a pumping system is the matching of pump set to the load handled. Most pumping systems incur excessive

Improving pump performance is one of

the fundamental steps to controlling energy costs and meeting

increasingly stringent regulatory norms.

Pumping systemsEnErgy ManagEMEnt

In the chemical process industry, use of energy-efficient equipment is gaining popularity. This is because achieving energy efficiency by totally eliminating power wastage and enhancing process efficiency is a relevant and much-needed strategy to reduce manufacturing costs. In such a scenario, adopting energy-efficient pumping systems can help to a large extent.


Pumping systems

operating costs as they use more energy than they should. Larger than necessary pumps are specified in the name of safety and reliability, which results in pump systems that operate sub-optimally. It has been observed that oversizing is the single biggest culprit of pumps wasting energy. Thus, it is important to conduct efficiency tests on priority pumps in a plant, identify misapplied or oversized pumps, estimate energy savings and determine the cost-effectiveness of each improvement.

The wastage of energy due to oversizing of pump can be taken care of at the design stage itself by proper selection of pump with duty point lying in the range of 80-110 per cent of BEP, with a provision of variable speed drive arrangement and use of highly efficient motors. Further, pumping system includes not only the pump but also pipe, control valves, functional system and other instruments. Hence, adequate attention should be given to such equipment also.

Need for a comprehensive approachAt present, conventional practices influence pump selection, placing a high premium on initial investment than lifecycle cost. Normally, the prime mover and pumps are designed for best efficiency; but when it is used, people do not consider the system efficiency. Due to wrong selection of pump sets, the efficiency of the system drops to the lowest level.

People consider only the price advantage while selecting the pump sets, and do not use proper size as recommended by experts. Chemical pumps are normally selected based on various criteria. The material and shape of the impeller & diffuser should be designed to suit the chemical property of the liquid that is being pumped.

For most applications, the market for high-efficiency pumps and energy-efficient motors exists. However, these are expensive because of their sophisticated design and superior materials. Since

energy constitutes major cost in the entire lifecycle of a pumping system, initial installation should not be the sole criterion for purchasing a pump. A Lifecycle Cost (LCC) approach should be employed while procuring a pump, which should be extended to the electric motor. LCC includes capital, operating and maintenance costs over the lifecycle of the pump.

Improving pump performance is one of the fundamental steps to controlling energy costs and meeting increasingly stringent regulatory norms. Since energy availability is a major challenge faced by the industries these days, adopting energy-efficient pumps is the need of the hour. Efficient pump systems can ensure energy efficiency, if there is proper selection, sizing, operation and maintenance of pumps. Ensuring that a pump operates close to BEP under all situations is the key to energy conservation in pumping systems.


POLICIES & REGULATIONS Responsible Care


Rakesh Rao

W h i l e c h e m i c a l compan i e s a re engaging themselves to satisfy shareholders’

clamour for higher returns, they have also understood the importance to do so responsibly and sustainably. In their quest to achieve sustainable growth, many companies in India are joining Responsible Care programme – a voluntary self-regulatory initiative aimed

at continuous improvement in the areas of health, safety and environment. Launched in Canada in 1985 to address public concerns about the manufacture, distribution and use of chemicals, Responsible Care has since spread to over 60 economies across the world. At global level, International Council of Chemical Associations (ICCA) launched the Responsible Care Global Charter in 2006 at the UN-led International Conference on Chemicals Management in Dubai.

Learning to be responsibleGlobally in past few years, Responsible Care concept made rapid strides. Joining the global bandwagon, Indian Chemical Council (ICC) has revived its Responsible Care initiative in 2011, which was first introduced in India in 1993. Indian companies are responding equally well to this initiative. Sanjay Choudhary, Chief Technology and Sustainability Officer, Tata Chemicals, says, “When ICC became member of Responsible Care Initiative of ICCA, USA, Tata Chemicals became signatory

to the Responsible Care Charter of ICC and put in place the internal audit process for compliance to the various codes. The chemical industry is contributing to the global economy and is essential to living and meeting the expectations of the Tata Group purpose of ‘Improving Quality of Life’. We at Tata Chemicals found the Responsible Care initiative as enabler for continuous improvement in HSE performance, together with open and transparent communication with stakeholders.”

Responsible Care expects product stewardship across the value chain from the chemical producer. He adds, “The chemical industry’s supply chains are quite fragmented, diffused and unorganised in some segment and there are certain things that chemical companies cannot change about their supply chains to any significant degree like where the customers are, and where they buy their raw materials from. There are challenges in management practices of some of the unorganised services provided by contractors and transporters.”

Partners in collaboration Big chemical companies, such as Tata Chemicals, Reliance Industries, BASF, which have vast supply chain network spread across the globe, are looking for better collaboration with their suppliers to ensure adherence to Responsible Care initiative. Choudhary says, “In case of Tata Chemicals, with its Living, Industry, Farm Essentials (LIFE) portfolio of products, the supply chain is quite challenging with business to business, business to customers and business to farmers sales.

ResPonsibLe CaRe Code Responsible Care commits companies, national chemical industry associations and their partners to:o Continuously improve the

environmental, health, safety and security knowledge and performance of technologies, processes and products over their lifecycles so as to avoid harm to people and the environment

o Use resources efficiently and minimise waste

o Report openly on performance, achievements and shortcomings

o Listen, engage and work with people to understand and address their concerns and expectations

o Co-operate with governments and organisations in the development and implementation of effective regulations and standards, and to meet or go beyond them

o Provide help and advice to foster the responsible management of chemicals by all those who manage and use them along the product chain

Source: European Chemical Industry Council (Cefic)

Incentivising HSE performance for better compliance

Responsible Care – a global voluntary initiative in Health, Safety and Environmental (HSE) performance – is gaining momentum in India as chemical manufacturers brace for sustainable growth. However, for wider acceptance, experts believe that the government should offer incentives for chemical companies adopting this green initiative.


Responsible Care

This poses challenges but also gives us the opportunity to understand the complete supply chain, which is not only limited to offering products but extends to solutions and services. These extended relationships offer the opportunity to partner and collaborate. We have found that such partnering and collaborations offer solution to the challenges and the forums such as Responsible Care and Global Compact Network India can facilitate the dialogue between the supply chain partners.”

ICC has already got more than 100 companies on board in support of the initiative, of which 17 have passed the audit process and are allowed to use the Responsible Care logo – a way of differentiating the elite from the commoners. Choudhary says, “At Tata Chemicals, we believe that Responsible Care helps industry in managing sustainability to meet the world’s growing need for essential chemicals and the products those chemicals make possible. Tata Chemicals is one of the first Responsible Care logo holder chemical companies in India and we found it helps in ensuring that we have systems and processes to meet the criteria of various codes as well as gives us the confidence to engage with the stakeholders in a transparent manner.”

Experts believe Responsible Care can be one of the important differentiators for Indian companies, which want to increase the presence across the globe. “If not a differentiator, Responsible Care can certainly be an enabler for global acceptance of Indian chemical industry. We find that increasingly the Middle East and Chinese chemical producers are adopting Responsible Care and reporting their performance on the Responsible Care metrics. Going forward, this would be essential requirement than differentiator. However, the opportunity to differentiate will come from leading in the Responsible Care performance. The increasing globalisation of supply chains would demand compliance. The possible shift of chemical processing to the US in future on the back of shale

gas discoveries will raise the standards further,” opines Choudhary.

integrating with global supply chain While the internal operations of Indian chemical units have become much safer with adoption of the ISO and OHSAS standards, Responsible Care aims at making them safe even outside the factory boundaries. This can be game changer for chemical manufacturers who aspire to become major players on the global landscape, where regulations are increasingly becoming stringent. Hence, in last few years, many Indian companies have acquired or taken steps to Responsible Care certification. Choudhary elaborates, “This has been the result of the engagement with the Responsible Care process by some of the leading companies in India that volunteered for the logo and the resulting peer pressure on the fellow chemical companies.”

With the chemical industry in India achieving the double-digit growth, despite the depression in the West, the supply chains of many global chemical producers are running through India. “This is creating growing interest in the global community in Responsible Care in the Indian chemical industry. The global industry is becoming increasingly interested in compliance of Indian industry with Responsible Care principles to comply with the international norms for long-term growth in the global market. Some of the initiatives such as Registration, Evaluation, Authorization of Chemicals (REACH) legislation of European Union, Global Harmonized System (GHS), etc are also creating interest in Responsible Care as enabler,” he adds.

incentivising safety So has the time come for India to have regulation, which mandates chemical manufacturers to adhere to norms that are in line with Responsible Care, a voluntary initiative? Choudhary says, “Regulations can create the minimum national standards or norms and do

not encourage the global leadership or advocacy and encourage best practices. This can be best achieved by the non-mandatory and voluntary processes such as National Chemical Policy, National Voluntary Guidelines for Responsibility of Business, Technical Regulations, and Chemical Safety Rating etc. Such initiatives with engagement of the industry will be more effective in driving Responsible Care in addition to the sanctions.”

Globally, there is a drive towards sustainability, and chemical companies have become environment-conscious. While there is an agreement in the Indian chemical industry that manufacturers should act responsibly, there is also need to differentiate such responsible companies through an Indian equivalent of Responsible Care certification. Experts feel that policy or regulation should be such that companies (both Indian as well as MNCs), which are complying and acting responsibly, should be incentivised for growth and not be treated at par with those who do not. Many believe that the government should offer incentives for chemical companies, which adopt Responsible Care. Choudhary concludes, “If the government can work out incentives, it will help large number of SMEs to improve compliance. However, the large producers would look for recognition and some support such as priority for growth plans and expeditious environmental clearances, self-declarations and third party certification instead of regulatory inspections.”


Increasingly the Middle East and Chinese chemical producers are adopting Responsible Care and reporting their

performance on the Responsible Care metrics. Going forward, this would be essential requirement than differentiator.

Sanjay ChoudharyChief Technology and Sustainability Officer, Tata Chemicals

Strategy talent development


Sangeeta Lala

T he chemical industry is one of the largest manufacturing industries in the world. The people’s

dependence on the chemical industry today surpasses all frontiers – from toothpaste to drinking water to clothes, food, automobiles, homes, etc – every solution in our lives uses a plethora of products, which are chemical in nature. By its application and usage, chemical sector is among the ever-changing dynamic forces in any economy. It defines growth by feeding all sectors that are critical for development and livelihood.

India in the last decade has scaled to being one of the top destinations for chemical manufacturing as well as consumption. Recent studies show that the industry is worth above $ 100 billion in India and is slated to become one of

the top three globally within the next five years. Obviously, it will not be an easy task nor would it happen without its set of challenges. The challenges to sustain this pace of growth would revolve around innovation, demand and growth. The investments are huge and can be broadly categorised into the following needs:o Infrastructure (investing for

factories, special zones, roads, ports, transportation and so on)

o Technology (investing in greenfield projects, R&D initiatives, etc)

o Regulatory and tax related (for ease of procurement of raw material, capacity building and availability)

o Human resources and people investment

The people investmentFocussing on the people aspect in this industry revolves around two primary features. The industry is

highly interdependent (ie customers of chemical companies are other chemical companies), so are its skills and qualification, which are highly interdependent and exchangeable in nature. The industry and its people are both highly global in nature in exposure and demand.

These points raise an important need for the industry, at a macro level, to come together and invest in developing the flow of ready resources for the years to come. It calls for development, hiring, recognition and continuous training to bridge these gaps. If one looks at the typical areas of manpower, across all the sub-industry classifications, it indicates what can be flexible and placed across any organisation and industry, provided the basic qualifications and skills are met.

Need fulfilmentThe need of the hour is to develop, hire, grow and retain.

Develop talent pool: This industry is estimated to require more than four million skilled resources within the next decade and the industry needs to develop institutes to impart education for technical courses (ITI, diploma, vocational) and focus on developing high-tech classrooms, and administration & faculty. Moreover, there is a need to explain and offer the long-term value proposition to potential hires as well as engage in internship and apprenticeship programmes.

With the chemical industry in India slated to become one of the top three globally within the next five years, the road ahead is full of challenges. It is important to take the right steps at every level, strategise plans, and most importantly invest in people by following the success mantras to develop, hire, grow and retain.

Qualification and skill-sets for different domainsTechnical Core – Non-technical Non-core – Non-technical

R&D BD & sales Admin, front officeDevelopment(formulation, scientist)

Marketing Accounts & finance, taxation

Operators - ITI Materials & inventory Payroll & benefitsOperators - diploma Purchase HR, IR & personnelEngineers Bagging & labels Customer care/servicesChemist Procurement, supply, sourcing MIS/data entry/languageQuality Godown, factories & warehouse TradeFacilities Exim relatedMaintenance AnalyticsMaterials IT/SAP/ERP


Talent development

Hire the right talent: Talent is currently limited by way of the available pool and students passing out of technical institutes. The chemical sector and vagaries of this industry’s working conditions add to the fact that youngsters do not flock to appropriate jobs even after having the technical qualification. This results in the need for programmes smartly linked to the education system such as internship, contract to permanent hire, attracting the right people etc.

It is essential to introduce organised contractual/temporary workforce to take care of seasonal, volume and other demands of people. This segment then becomes an experienced force to be taken as future employees utilised across all allied industries. Hiring at base levels/industry events can help, because then one can pick the people who are genuinely interested in technical jobs, and thereby act as an effective tool for recruiting top talent. It is also important to explore rural, tier 2 and tier 3 cities, as

well as look online because of the global nature of skilled and niche manpower.

Growth recommendations: The first step is leadership development at an accelerated pace that can drive the volumes. This requires careful identification and hiring from allied and diverse industries. Integration of talent across levels and cultures; high level of employee engagement; in-house skill development are other essentials.

Retention plan: Various retention measures are required to keep the employees engaged and secure. It should go beyond mere hygiene and should include risk identification (hiring at right time, cost of attrition and so on); statutory and safety hygiene to sensitise resources; and continued assessment and skilling in core competency development in chemical industry. It is also vital to invest in employer branding, as more and more organisations operate within the same space, and skills become inter-changeable and there is a gap in supply of people. Other suggestions

include managing diversity in teams across ages (old vs young), in cultures (factory vs corporate, white vs blue collar) and so on; attracting past employees, alumni, referencing within a niche technical group; and offering the flexibility in work schedules and remote operations.

Taking the right callUnderstanding and implementing the workforce needs of this industry is an important tool as a gap in even one of the critical investment areas (infrastructure, people, government, policies) would mean losing out on the leadership call knocking on our frontiers today.

Sangeeta Lala is Co-Founder & Senior Vice President at TeamLease Services. She heads the Sourcing SBU (Strategic Business Unit),

handling both permanent and temporary hiring needs for corporate across India. Email: [email protected]

Tips & Tricks Fire prevention


Workplaces wherein large amounts of flammable materials are stored or used can present a greater hazard than those where the amount kept is small.

It is important to identify all flammable materials that are in the workplace so that proper controls can be put in place.

Where there is a possibility of the presence of flammable gas/vapour, conduct a full risk assessment and consider the need for gas detection

equipment. Where gas detection equipment is needed, ensure it is properly installed, maintained and serviced.

Reduce quantities of flammable materials to the smallest amount necessary for running the business and keep away from escape routes.

Store remaining stocks of highly flammable materials properly outside, in a separate building, or separated from the main workplace by fire-resisting

construction. Provide clearly marked separate storage for flammable chemicals, gas cylinders, and waste materials. Train employees on safe storage, handling and use of flammable materials.

The quantity of flammable liquids in workrooms should be kept to a minimum. F lammable liquids, including empty or part-

used containers, should be stored safely. Small quantities of flammable liquids can be stored in the workroom, if in closed containers in a fire-resisting (eg metal) bin or cabinet fitted with means to contain any leaks.

Larger quant i t ies should be stored in a properly designated store, either in the open air (on well-ventilated, impervious ground, away

from ignition sources) or in a suitably constructed storeroom.

Where large quantities of flammable liquids are used they should, where possible, be conveyed by piping them through a closed system. Where a

connection in such a system is frequently uncoupled and remade, a sealed-end coupling device should be used.

Flammable liquids should not be decanted within the store. Decanting should take place in a well-ventilated area set aside for this purpose,

with appropriate facilities to contain and clear up any spillage.

Container lids should always be replaced after use, and no container should ever be opened in such a way that it cannot be safely resealed.

Flammable liquids should be stored and handled in well-ventilated conditions. Where necessary, additional properly designed exhaust ventilation should be provided to reduce vapour concentration level in the air.

Storage containers should be kept covered and proprietary safety containers with self-closing lids should be used for dispensing and applying

small quantities of flammable liquids.

There should be no potential ignition sources in areas where flammable liquids are used or stored. Any electrical equipment used in these areas,

including fire alarm and emergency lighting systems, needs to be suitable for use in flammable atmospheres.

Reference:o Health & Safety Authority, Ireland


T oday, fire protection forms an integral part of a modern strategy for survival and competitiveness.

Whenever a fire or explosion takes place in areas with large quantities of highly flammable materials (liquids, gases or solids), common preventive and mitigating measures might not be sufficient to avoid substantial property and business loss or serious environmental impact. Hence, one has to be extra careful while dealing with flammable materials. Given below are some useful tips to prevent fire due to inept handling of hazardous materials.

Handy tips for safe Handling of flammable materials

Flammable materials can cause fires and explosions in a production facility, which can lead to substantial property damage and subsequent business interruption. Hence, great care should be taken in the storage, handling and use of flammable materials to prevent fire.

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Projects


Information courtesy: Tendersinfo.com1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, IndiaTel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]

FertiliserFertilisers And Chemicals Travancore Ltd (FACT)Project typeNew facilityProject newsFACT intends to set up an ammonia-urea complex at the Kochi division as a part of its plans to revive urea production. The proposed complex will consist of an ammonia plant of capacity 2,000 tpd and a urea plant of 3,500 tpd. The cost of this venture is expected to be ` 4,500 crore. Project location Kochi, KeralaProject cost ` 4,500 crore Implementation stage Planning

Contact details :Fertilisers And Chemicals Travancore LtdFACT Corporate Office Udyogamandal EloorKochi 683 501 Kerala Tel: 0484-2546983 Email: [email protected] ----------------------------------------Methylamine Alkyl Amines ChemicalsProject type New facilityProject news Chemicals maker Alkyl Amines Chemicals is planning to set up a methylamine manufacturing facility at Dahej in Gujarat with an estimated investment of ` 250 crore. The company has acquired the land in Dahej and the plant is expected to commence production within next three years.Project location Dahej, GujaratProject cost ` 250 croreImplementation stagePlanning

Contact details :Alkyl Amines Chemicals207/A Kakad Chambers, 132 Dr Annie Besant Road, Worli, Mumbai 400018 Maharashtra Tel: 022-24925564Email: [email protected] ----------------------------------------Pesticides & drugs SRF LtdProject type New facilityProject news SRF Ltd is planning to invest ` 1,000 crore over the next four years to set up a plant at Dahej in Gujarat. The plant will mostly produce fluorine-based specialty chemicals for customers in Europe, Japan and the US. These specialty chemicals will be used as intermediates in the manufacture of pesticides and drugs. Project location Dahej, GujaratProject cost ` 1,000 croreImplementation stage Planning

Contact details:SRF LtdVillage & PO Jhiwana, Tehsil: Tijara, Dist Alwar 301 019 Rajasthan Tel: 01493-220288/517838 Fax: 01493-221125/517837 Email: [email protected] ----------------------------------------PolyurethaneBASF India LtdProject type New facilityProject newsBASF India Ltd, the leading chemical company, will invest ` 1,000 crore to set up a new chemical production site at the Dahej Petroleum, Chemicals and Petrochemicals Investment Region (PCPIR) in Gujarat. The new site will

be an integrated hub for polyurethane manufacturing and will also house production facilities for care chemicals and polymer dispersions for coatings & paper. Project location Dahej, GujaratProject cost ` 1,000 croreImplementation stage Planning

Contact details: BASF India LtdUnit I, Plot No. 6214/6216 GIDC Phase IV, Ankleshwar 393 002 GujaratTel: 02646-221890Fax: 02646-250464 Email: inorganics@basf.com----------------------------------------Speciality lubricants and release agentsFreudenberg GroupProject type Capacity expansionProject news Freudenberg Group plan to invest ` 130 crore in its speciality chemical plant at Mysore by 2016. The plant manufactures speciality lubricants, release agents and maintenance products for auto, energy and food industries. This investment would be for expansion of capacity from 3,000 tonne per annum to 20,000 tonne per annum.Project location Mysore, KarnatakaProject cost ` 130 croreImplementation stagePlanning

Contact details:Freudenberg & Co. Kommanditgesellschaft Höhnerweg 2-4 D-69469 Weinheim, Germany Tel: +49(0)6201-80-4049 Fax: +49(0)6201-88-4049 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, IndiaTel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]

Reciprocating pumpsOrg : Oil and Natural Gas Corporation Ltd (ONGC)TRN : 14901058Desc : Supply of reciprocating pumpsBOD : March 21, 2013Loc : Sivasnagar, Assam BT : Domestic (NCB)_______________________________________________

Stepless capacity control system in reciprocating compressorOrg : Indian Oil Corporation Ltd (IOCL)TRN : 14921271Desc : Provision of stepless capacity control system in reciprocating compressorBOD : March 25, 2013Loc : Chirang, AssamBT : Domestic _______________________________________________

Evolved Gas Analysis unitOrg : Department of Atomic EnergyTRN : 14900949Desc : Supply, installation and commissioning of Tg-IR based Evolved Gas Analysis (EGA) unit along with complete software and hardwareBOD : March 25, 2013Loc : Mumbai, MaharashtraBT : Domestic _______________________________________________

Fluidised Catalytic Cracking UnitOrg : Bharat Petroleum Corporation Ltd (BPCL)TRN : 14956958Desc : Provision of reactor regenerator package of fluidised catalytic cracking unit BOD : March 26, 2013Loc : Mumbai, MaharashtraBT : Domestic_______________________________________________

ChlorinatorsOrg : North Western RailwayTRN : 14830534Desc : Provision of two chlorinators and repairs to parts of existing chlorinators at various locationsBOD : March 26, 2013Loc : Bikaner, RajasthanBT : Domestic

Heat exchangerOrg : Ordnance Factory BoardTRN : 14961151Desc : Supply of heat exchanger for sac unit of Nigu plant, Madhya PradeshBOD : March 28, 2013Loc : Hoshangabad, Madhya PradeshBT : Domestic _______________________________________________

Chlorine dosing systemOrg : Military Engineer ServicesTRN : 14960579Desc : Provision of electrically operated granular based chlorine dosing system at various installations under AGE B/R New MangaloreBOD : March 28, 2013Loc : Kannur, KeralaBT : Domestic _______________________________________________

Gas analysis system based on gas chromatographOrg : Bharat Coking Coal Ltd (BCCL)TRN : 14610470Desc : Procurement of gas analysis system based on gas chromatographBOD : March 28, 2013Loc : Jharkhand BT : ICB_______________________________________________

Nitrogen gas generatorOrg : Defence Materials and Stores Research and Development Establishment (DMSRDE)TRN : 14766374Desc : Provision of nitrogen gas generator Ng2 and Ng1BOD : April 5, 2013Loc : Kanpur, Uttar PradeshBT : Domestic_______________________________________________

Carbon sulphur determinatorOrg : Directorate General of Quality AssuranceTRN : 14732984Desc : Supply of carbon sulphur determinatorBOD : April 9, 2013Loc : DelhiBT : Domestic

EvEnt List


NatioNal

ChemProtech 2013An international event on chemical processing technology and equipment to be held concurrently with fine and specialty chemicals trade fair, Chemspec; April 11-12, 2013; at Bombay Exhibition Centre, Mumbai

For details contact:Krunal GodaKoelnmesse YA Tradefair Pvt Ltd1102, 11th Floor, DLH ParkS V Road, Near MTNL OfficeGoregaon(W), Mumbai 400062Tel: 022-28715207Fax: 022-28715222Email: [email protected]

Vinyl india 2013International conference for polyvinyl chloride (PVC) and chlor-alkali

industries; April 11-12, 2013; at Hotel Grand Hyatt, Mumbai

For details contact:Nidhi VermaElitePlus Business Services Pvt Ltd61, Radheya, 14th Road, Plot 359, Khar (West), Mumbai 400 052Tel: 022-26000556Fax: 022-26000556 Email: [email protected]

Poly indiaA trade show for plastics and petrochemicals industries; April 25-27, 2013; at Chennai Trade Centre, Chennai

For details contact:Federation of Indian Chambers of Commerce & Industry Federation House

1 Tansen Marg, New Delhi Tel: 011-23738760/23738770 Fax: 011-23320714 Email: f [email protected]

analytica anacon india 2013International trade fair for laboratory technology, analysis, biotechnology and diagnostics; November 12-14, 2013; at Bombay Exhibition Centre, Mumbai

For details contact:Avisha DesaiProject Manager MMI India Pvt LtdLalani Aura, 3rd Floor, 34th Road, Khar (West) Mumbai 400 052 Tel: 022-42554710Email: [email protected]

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.

HyderabadAndhra Pradesh,

May 31-June 3, 2013

The trade exposition on chemical plant, equipment and process industry; June 07-10, 2013; at Surat International Exhibition & Convention

Centre, Surat, Gujarat

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

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


Kuwait oil and Gas Summit & exhibitionAn exhibition & conference focussing on the development, diversification and growth of the oil & gas industry of Kuwait; April 28-30, 2013; at Kuwait Regency Palace Hotel, Kuwait City

For details contact:The CWC Group LtdRegent House, Oyster Wharf 16-18 Lombard Road, London, The UKTel: +(44)-(20)-79780000Fax: +(44)-(20)-79780099Email: [email protected]

Petro.t.ex africaFocussed event on refineries & oil and related technology; May 14-16, 2013; at Gallagher Convention Centre, Midrand, South Africa

For details contact:Exhibition Management ServicesPO Box 650302 Benmore, JohannesburgSouth Africa Tel: +(27)-(11)-7837250 Fax: +(27)-(11)-7837269Email: [email protected]

China adhesiveAn exhibition focussing on latest development on adhesive and sealant products, chemicals and raw materials for adhesives & sealants; September 25-27, 2013; at Shanghai Everbright Convention & Exhibition Center, Shanghai

For details contact:CCPIT Sub-Council of Chemical IndustryBuilding 16, Block 7, Hepingli Dongcheng DistrictBeijing, ChinaTel: +(86)-(10)-64275419Email:[email protected]

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

EvEnt rEport Engineering Expo Aurangabad 2013


Nishi Rath

I t was in 1960 that the region of Marathwada was merged with Maharashtra. This was the time when the industrial development

of Marathwada began. Over time, the Maharashtra Industrial Development Corporation (MIDC) acquired land and set up industrial estates, which provided a boost to the region’s tremendous growth. Aurangabad is now one of the classic examples of efforts towards balanced industrialisation with factors such as

availability of labour, comparatively lower cost for setting up base and a developing market attracting an array of industries to the city. Additionally, the presence of renowned MNCs and domestic giants in Aurangabad has further catalysed the city’s industrial growth by offering Small & Medium Enterprises (SMEs) a boost.

Reflecting the city’s industrial growth was the second edition of Engineering Expo Aurangabad. Held during February 22–25, 2013, at Ayodhya Nagari Grounds, the four-day Expo was inaugurated in the presence of an esteemed set of Guests of Honour

including Kala Ojha, Mayor, Aurangabad; Sanjay Shirsat, MLA, Aurangabad West; Pradeep Jaiswal, MLA, Aurangabad Assembly Constituency; G M Ambhore, Director, MSME Development Institute; P Udayakumar, Director, The National Small Industries Corporation; Sudhanva Jategaonkar, Associate Vice President, Network 18 Publishing; and Vijay N Jaiswal, President, Aurangabad Industrial Suppliers Association (AISA).

The inauguration also witnessed the presence of Sunil Raithatha, President, Chamber of Marathwada Industries and Agriculture (CMIA); Dr Uday Girdhari, President, Marathwada Association of Small Scale Industries and Agriculture (MASSIA); Adesh Palsingh Chabda, President, Aurangabad Zilla Vyapari Mahasang; and Mansingh Pawar, Past President, MASSIA, among others.

Officially approved Organised by Network 18 Publishing with AISA as supporting partner, the Expo played host to various industry giants and market leaders who showcased their best products and services at the trade show. Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, also graced the Expo. He said, “Engineering Expo Aurangabad has become a platform for new industries developing in the region. It has also proved to be the best platform for students as it gives them exposure to the real industrial world. I feel more events on similar lines should be organised in the near future.”

Rajendra Darda, MLA & Minister of School Education, Government of Maharashtra, also marked his presence in Engineering Expo Aurangabad. “The whole experience here was worth the visit. The Expo was well organised and provided a platform for local entrepreneurs. We look forward to many more such events,” he added.

Bright future for SMEs According to experts, the historical background of the place helps attract foreign investors. Aurangabad boasts of a strong brigade of young and enthusiastic

Since the last few years, Aurangabad has emerged as one of the fastest growing industrial hubs. The region already has a huge industrial presence with a large number of engineering services, auto ancillary and pharmaceutical research companies setting up facilities here. The ever-evolving industrial scenario and the enterprising spirit of its entrepreneurs have helped Aurangabad grow into an industrial area of repute. Taking it further, Engineering Expo Aurangabad 2013 proved to be the right ‘growth tonic’ for boosting the region’s industrial might. A report...

AurAngAbAd February 22-25, 2013

Ayodhya nagari grounds

Exhibiting Aurangabad’s unparalleled potential

Dignitaries unveil the Exhibitors’ Directory at the inauguration of Engineering Expo Aurangabad 2013


Engineering Expo Aurangabad 2013

first-generation entrepreneurs, who not only implement new ideas but also steer the growth. “Aurangabad has a lot of potential when it comes to the industries. The small scale industries here have a great future. They are keen to grow and play a key role in the growth of any particular region,” said Udayakumar.

Engineering Expo Aurangabad focused on providing SMEs an opportunity to demonstrate their capabilities, to offer a platform to industries across the country and enable exhibitors to formalise business alliances for mutual growth. “The trade show truly opened up a new world of opportunities for the small and medium scale industries here. The enthusiasm among exhibitors was encouraging. It was a good experience to be a part of this grand show,” asserted Shirsat.

Upbeat exhibitorsThe exhibitors were overwhelmed by the positive response they received from the visitors. They were looking forward to generating more business gauging from the enquiries that they received at the Expo. Manoj Kumar, Director, Apex Group, who exhibited at the trade show, said, “We have had a lot of enquiries; I cannot gauge how many will turn out to be good business leads, but yes, I am pleased with all the enquiries. It proves that we have managed to attract the target customers and create our brand visibility.”

Another exhibitor, Nitin Bagul, Director, Technovision Instrumentation Solution Pvt Ltd, expressed, “We participated in Engineering Expo Aurangabad last year as well; it helped us build good contacts. Aurangabad is an industrial hub and the number of industries is increasing by the day. This is a good place for such an event; only awareness among the masses has to be increased.”

Anand Pahade, Proprietor, Chintamani Electricals, who also exhibited at the trade show, said, “We participated in this trade show as we wanted to create our brand image on which customers can bank on. The response we have received has been mixed. Expos such as these should work towards creating awareness among the masses in Aurangabad.”

Initiatives in action… Engineering Expo Aurangabad saw some great initiatives in action. The ‘National Vendor Development Programme’ acted as a crowd puller both in terms of exhibitors and visitors. Organised by the MSME Development Institute, Ministry of MSME, Government of India, the event became an instant hit. It saw participation from organisations such as Western Railways, State Transport, Hindustan Petroleum Corporation Ltd, Indo German Tool Room and Central Institute of Plastics Engineering and Technology.

Speaking at the event, Ambhore stated, “Our main objective is to identify and explore the business opportunities in the highly competitive area. We also encourage benchmarking for meeting the challenges in the best way.”

Engineering Expo Aurangabad was not all about exhibitors but it also offered a lot to the visitors.

Visitors make the most of ExpoCommenting on how an Expo of this stature acts as a growth catalyst, Mayur Parikh, Senior Manager Marketing, Sah Petroleum Ltd, explained, “Exhibiting companies fully utilised this platform at the Expo. Such trade shows always help the industrial circuit of a particular region. It was great to be part of the Expo as a visitor.”

Another visitor opined that the turnout, despite the recession, was commendable. “Taking into consideration the recession, the turnout was good. Engineering Expo is a great platform for small and medium scale industries to connect and understand the market requirements,” averred Abhay Sharma, Director, Extreme Ro System Pvt Ltd.

Students too had a great chance to gets hands-on experience at the Expo. Starting from market trends to new technology, the Expo turned out to be a helpful lesson for them. “Students can learn a lot here; where else can they find the latest technologies and machines at one place?” opined Ojha.

Marking a new beginningAdding another feather to its cap, Engineering Expo came to an end with a promise to come back with more enthusiasm and better opportunities for Aurangabad. The next edition of Engineering Expo will be held in Hyderabad, Andhra Pradesh, during May 31 to June 3, 2013.


Pan-India participation by 223 exhibitors

Spread across more than 10,914 sqm

18,528 business visitors from across India

Business transacted worth ` 74.78 crore

More than 11,533 business leads generated

8,500+ products displayed from different industries

More than 90,000 kg machinery moved in for display

Highlights of this edition

Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, being felicitated with a memento by Network 18 Publishing and AISA team

EvEnt rEport Engineering Expo Aurangabad 2013 - panel Discussion


Nishi Rath

A urangabad has carved a niche for itself among the industrial leaders in the country. In the era of

liberalisation and intensive competition, Aurangabad is resolutely addressing the challenge of moving to a higher growth trajectory in the industry. Taking a peek into this growth story, Network 18 Publishing with support from Aurangabad Industrial Suppliers Association (AISA) organised a panel discussion on the sidelines of Engineering Expo Aurangabad 2013. Held at Taj Presidency on February 22, 2013, the panel discussion served as food for thought for more than 150 industry leaders and professionals.

Some of leading industry experts such as Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; S G Rajput, GM, District Industries Center (DIC) & Superintendent Industries Officer, Aurangabad; Mukund Kulkarni, Director, Expert

Global Solutions and Ex-President Chamber of Marathwada Industries and Agriculture (CMIA); P Udayakumar, Director, The National Small Industries Corporation (NSIC) and Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd, enlightened the audience on the opportunities Aurangabad can provide. The panel discussion was moderated by Archana Tiwari-Nayudu, Editor, Network 18 Publishing.

Is Aurangabad underrated?The first non-stick pan came from Aurangabad; one of the best white goods brands and electronics is offered by this city; it also supplies the best microfinishing machines, which also compete with the world’s best. However, it seems to lack visibility. “We export to 72 countries and, in the last two years, Aurangabad-based organisations have done acquisitions overseas. But we are still understated because we have been underestimating ourselves. It is high time we move ahead,” said Kulkarni.

“We have created brands, but were never given that status. This is because we were overshadowed by major industrial hubs such as Mumbai and Pune. But I think it is time for us to come out of that shadow and prove our calibre,” observed Bhogale.

Taking the discussion ahead, Tambolkar added, “There is no denying that Aurangabad is underrated as a manufacturing hub, one of the reasons being the presence of various first-generation entrepreneurs. Every business has to go through a cycle and most of them are completing the cycle now. So, this is the time.”

Giving the discussion a twist, Udayakumar said, “I look at it in a positive way. In the age of competition, it can be seen as an opportunity. Entrepreneurs can focus on their resources and future plans, when no one looks at you as a threat.”

Technology takes the leadAccording to the panelists, investing in technology and innovation will take Aurangabad to a new level. “What we have focussed on is right investment and right technology; investing in the latest technology will always pay back in the long term. This strategy has helped us too,” added Tambolkar.

Speaking up for technology, Bhogale stated, “Investing in technology is one of the reasons why we have witnessed growth. Aurangabad is a good mix of innovation and tradition. There are people who have innovatively managed their traditional ways. That has given them a competitive edge.”

Kulkarni added, “Investing in the best technology is key; the short-term costs may be higher, but the long-term gain is what people should be looking at. Managing time, quality, productivity and safety will also make us competitive.”

The panel discussion received an overwhelming response from the industry, who actively participated as the audience. The insightful discussion was followed by a lively question and answer session.


A panel discussion was organised on the sidelines of Engineering Expo Aurangabad 2013. Held on February 22, 2013, the panel discussion focussed on the topic, ‘Trade, trends and technologies: Gauging Aurangabad on the critical parameters’. A report…

Gauging Aurangabad on the critical parameters

(L-R) Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd; SG Rajput, GM, DIC & Superintendent Industries Officer, Aurangabad; Archana Tiwari-Nayudu, Editor, Network 18 Publishing; Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; P Udayakumar, Director, NSIC; and Mukund Kulkarni, Director, Expert Global Solutions & Ex-President, CMIA, voice their views at the panel discussion

Book Review


This book gives a detailed overview about the structure of the chemical industry. It covers the important chemical principles, products, processes and relevant statistics. Each contributor draws on his extensive industrial experience to give a balanced coverage, which is both easy to read as well as authoritative. The text makes liberal use of illustrative additions such as chemical structures, figures and tables. This edition contains chapters on quality, safety and environmental issues. It also contains a special chapter on chlor-alkali, sulfur and nitrogen industries, reflecting the importance of these industries today.

An interesting feature of this compilation is its inclusion of biocatalysis and advanced biotechnology. This book is an important resource for students in the field of various branches of chemistry.

Available at: Sci-Tech Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai 400 053 Tel: 022-66970507/26735260, Telefax: 022-26735424, Email: [email protected]

The chemical industryEdited by: Alan Heaton

Price: ` 2,995

In the wake of the necessity for high purity chemicals to be used in various applications, this book acquires special importance. It has been keeping engineers, scientists, chemists, biochemists and students up to date with the purification of the chemical reagents and the processes for their purification. Also there is a special guide about critical safety and hazards for the safe handling of chemicals. This book provides expanded coverage of the latest chemical products and processing techniques, safety and hazards. It outlines strategies that can help improve efficiency, results and safety by providing critical information for day-to-day lab and processing work.

The book contains special sections on distillation and recrystallisation techniques, chromatography, purification of organic, inorganic, metallo-organic and biochemical compounds. A special inclusion in this book is the section on chemical methods used in purification.

Reviewer: Nita Mehta, Associate Professor, Chemical Engg Dept, Thadomal Shahani Engg College

Purification of laboratory chemicals

Authors: W L F Armarego and Christina Chai Price: ` 9,230

Products


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

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

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

eg. CW Pump and send it to 51818

Laboratory bottlesLoba life glassco laboratory bottles are chemically resistant and stable. When fitted with a plastic pouring ring, dripping can be totally eliminated. As there is only one size screw thread for all bottles from 100 ml, the screw caps and pouring ring are fully interchangeable. The bottles, pouring rings and caps are autoclavable and sterilisable. These bottles are mechanically strong, chemically resistant and are provided with plastic pouring ring for drip-free operation.

Loba Chemie Pvt LtdMumbai - MaharashtraTel: 022- 22151010 Email: [email protected]: www.lobalife.com

PTFE-lined valvesFluoropolymer FEP, PFA, PTFE-lined SGI/WCB/SS pipes, valves and fittings are manufactured using technical know-how and raw material for appropriate application of the resin. They have low co-efficient of friction, chemical inertness, excellent weathering resistance, zero water absorption, are non-toxic, non-inflammable, self-sealant and approved by international food and drugs regulatory authorities.

Supremo Line & ControlAhmedabad – GujaratTel: 079 – 22205282, 22205181Email: [email protected]: www.supremoproduct.com

Before taking delivery of any machine, one must

take trials of the product for a short time. This

will help determine the product’s efficiency and

effectiveness.

Sharayu Sawant (Director)Shruti Flexipack Pvt Ltd

Chemical transfer pumpCFP series pump in SS 316 material is used for handling mild corrosive chemicals and various other liquids in different industries such as chemical, petrochemical, steel plants, printing houses, pharmaceuticals and food

processing etc. The main features of the pump are high efficiency, good performance and reliability. The pump is available from 0.25 HP to 10 HP in different capacities in monoblock and bare pump design. All the wetted parts are made of graded SS 316 material. The sealing is by mechanical seal of different face combination of carbon, ceramic, GFT, silicon, tungsten etc. The pump can be used for high temperature application of up to 250oC. Special pumps are also available with casing steam jacketing and with flameproof motors.

Taha Pumps & ValvesSurendranagar – GujaratTel: 02752 – 240233Mob: 09825599415/09825829875Email: [email protected], [email protected]: www.tahapumps.com

Lubricant additives and reactive surfactantsThe lubricant additive is an organo-molybdenum compound developed with original technology. It can reduce friction and help save fuels, minimise metal wear & extend machine life. The additive gives good lubricity performance even under severe conditions, prevent degradation of oil, and extend oil life.

Adeka India Pvt LtdMumbai - MaharashtraTel: 022-40263301Email: [email protected]: www.adekaindia.com

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Terms & Conditions: Your Subscription will start from the next available issue. Network18 Media & Investments Ltd. will take utmost care to dispatch the copies safely. Network18 Media & Investments Ltd. does not take the responsibility of any postal delays and damaged copies dispatched. For more information contact Network18 Media & Investments Ltd. subscription department. Above rates are valid in India only.

Products


Corrosion-free cable management systemAeron FRP cable tray management system is developed for long lasting performance in challenging environments where corrosion & chemical resistance and lasting mechanical performance are key

requirements. Ladder type as well as perforated cable trays with wide range of sizes to select from is offered.

Aeron Composite Pvt LtdAhmedabad – GujaratTel: 09909988266Email: [email protected]: www.aeroncomposite.com

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.

Hapman Systems Pvt LtdVadodara – GujaratTel: 0265 – 2517505Email: [email protected]: www.hapman.in

Chemical compound for cleaning and finishing machinesA wide range of cleaning chemicals is used in various machines and equipment such as vibratory finishing machines, tumbling barrels, ultrasonic equipment, washing machines, spray cleaning equipment, etc. These chemicals are used for various functions such as cleaning, degreasing, descaling, deburring, brightening, etc.

Ashok IndustryMumbai – MaharashtraTel: 022–26232133Mob: 9892848669Email:[email protected]: www.ashokindustry.com

Products


One must consider the cost of the product before

purchasing so as to secure definite and assured

returns over a period of time.

Manisha Kadam (Assistant Manager)Ashok Industry

Hot and cold zinc phosphating chemicalThe zinphophos – hzp is designed to provide heavy zinc phosphate coating with thickness of 300 mg/sq ft within 15 to 20 minutes on iron and mild steel components by simple immersion method. A dense, heavy adherent coating is obtained by

this method and prevents excessive wear and tear of moving parts of machinery. This coating serves as base for paints as well as for rust preventive oil coating. It is operated at a temperature of 85o to 95oC. It is available in packages weighing between 5 and 40 kg.

Priyadharishini ChemicalsCoimbatore, Tamil Nadu Tel: 0422-2567040/2567114Mob: 09443022310/09865222310Email: [email protected], [email protected]: www.prichem.in

In-line homogeniser systemIn-line homogeniser system allows smooth changeover from laboratory to production plant. The homogeniser allows the user to select from seven different mixing technologies using a variety of available mixing heads, all with

programmable speed control to determine the best mixing function for the process. It offers a great variety of applications for many different mixing and particle size reduction processes. It also eliminates the need to purchase separate mixers – operates as both a batch mixer and in-line mixer. The compact, tabletop design minimises space requirements. This

dispersing and mixing system was developed to meet the needs of research scientists and mixing specialists within the pharmaceutical, cosmetics, chemical, and food industries who need to use the same methods from initial formulation to mass production.

Cole-Parmer India Pvt LtdMumbai - Maharashtra Tel: 022-67162224/2222, Fax: 022-67162211Email: [email protected] Website: www.coleparmer.in

DegreaserA wide range of alkaline, solvent-based and water-based degreasers is available, which feature metal-safe and fire-boil safe range and cleans, emulsifies, degreases the toughest of thick burnt greases. It has minimum odour; is reusable, biodegradable and economical on dilution. The degreaser is an excellent substitute for caustic soda, kerosene, diesel, CTC etc. The degreaser range includes Magna 100 hard surface cleaner, which is an alkaline-type detergent that emulsifies, absorbs and floats away the toughest of greases and oils. The Magna 106 alkaline degreaser is a powerful liquid degreaser that avoids most of the risks common to powerful cleaners and with anticorrosion properties. The Magna big blue, high power, emulsifiable solvent degreaser is used to clean heavy engine parts, blocks and related components in shipyards, oilrigs, etc. The Magna Husky is an ideal cleaning compound formulated to clean all types of filtering equipment, deep fat fryers, ovens, greasy vents, etc.

Ecochem Innovative Solutions & ServicesMumbai – MaharashtraTel: 022-23880007, Mob: 09322294436Email: [email protected]

Rotary evaporatorThe rotary evaporator is used for distilling a wide range of liquids. It has an attractive appearance backed by innovative features in the areas of safety, functionality and ergonomics. The evaporator automatically lifts the receiving flask out of the heating bath if the power cuts off. This means that the ongoing test and any distillate already produced are unaffected by the stoppage. The patented geometry of the distillation condenser also provides a larger cooling surface area for distillation. The associated heating bath is ergonomic and safe.

IKA India Pvt LtdBengaluru - KarnatakaTel: 080-26253925, Mob: 09845387684Email: [email protected]: www.ikaindia.in

Products


Fume extraction and scrubbing systemsThe packed tower absorption system removes gaseous pollutants such as HCl, Cl2, ClO2, SO2, NH3, NOx, HCN, H2S, mercaptans and amines. The typical absorption unit consists of a packed absorption tower, recycle tank, heat exchanger, recirculation pumps and

ID/FD fan. The gaseous stream flows upward through a packed bed tower while the scrubbing liquid flows downward by gravity over the packing. The incoming liquid is distributed over the tower cross-section using a liquid distributor. Gases leaving the packed sections are passed through a mist eliminator to remove the moisture entrainment before discharging to the outlet gas connection at the top of the tower. The scrubbing liquid is stored in recycle tank and circulated using recirculation pumps. As most of the absorption processes are exothermic, a heat exchanger is necessary to remove the heat of absorption. The fume extraction and scrubbing system can be used in the agrochemical plants, plastics, paint and varnish plants, soap and detergent plants, sulphuric acid plants, fertiliser manufacture, nitric acid and ammonia plants, acid pickling plants, welding electrode plants, foundry, boilers, process heaters, catalyst regenerators, flares, reactors, storage tanks.

Trans Tech Projects Pvt LtdPune – MaharashtraTel: 020-65002534/65008534Email: [email protected]: www.transtechprojects.com

Flameproof magnetic drive chemical pumpPMD/SMD series seal-less magnetic drive pump with flameproof electric motors is suitable to use in hazardous industrial environment in different industries for handling toxic and fuming liquids/chemicals. Due to the use of

high power rare earth magnets, this range of pumps is made seal-less in design and give zero leakage during operation. Since there is no shaft seal, there is no leakage or breakdown. Also, the seal-less feature ensures handling of wide variety of liquids, which conventional seal type pump cannot handle. The pump is ideal to handle corrosive chemicals, acids, dyes, solvents, petrol, kerosene, etc. The motors comply with Indian Standard specification IS 2148 for Gas groups I, IIA, IIB, II C. Typical applications are in industries such as chemical, pharmaceuticals, petroleum, dyeing and printing, electroplating, photo processing, solvent extractions, etc. The pump is available in capacity of 50 LPM up to 2,000 LPM having maximum head of 60 m. Special application pumps can also be designed as per customer requirement and import substitute.

Taha Pumps & ValvesSurendranagar – GujaratTel: 02752 – 240233Mob: 09825599415/09825829875Email: [email protected]; [email protected]: www.tahapumps.com

Products


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

case, it does not represent the views of Chemical World

Statement about ownership and other particulars about newspaper/periodical, namely Chemical World as required to be published in the first issue of every year after the last day of February.

Form IV (See Rule 8) (Press and Reg. of Books Act, 1867)1. Place of Publication: Ruby House, ‘A’ Wing, JK Sawant Marg,

Dadar (West), Mumbai - 400 0282. Periodicity of Publication: Monthly3. Printer’s Name: Mr Mohan Gajria Nationality: Indian Address: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West),

Mumbai - 400 0284. Publisher’s Name: Mr Lakshmi Narasimhan Nationality: Indian Address: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West),

Mumbai - 400 0285. Editor’s Name: Mr Manas Bastia Nationality: Indian Address: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (West),

Mumbai - 400 0286. Names and addresses of individuals who own the newspaper

& partners or shareholders holding more than 1% of the total capital: Network18 Media & Investments Limited** is the owner of the publication, namely Chemical World, having its registered office at 503, 504 & 507, 5th Floor, Mercantile House, 15, K G Marg, New Delhi - 110 001.

Details of the shareholders of Network18 Media & Investments Limited who hold more than 1% of the paid up equity capital of the Company as on 28-02-2013 are given below:a. RRB Mediasoft Private Limited, 403, Prabhat Kiran, 17, Rajendra

Place, New Delhi - 110 008b. RB Mediasoft Private Limited, 403, Prabhat Kiran, 17, Rajendra Place,

New Delhi - 110 008c. RB Media Holdings Private Limited, 403, Prabhat Kiran, 17,

Rajendra Place, New Delhi - 110 008d. Watermark Infratech Private Limited, 403, Prabhat Kiran, 17,

Rajendra Place, New Delhi - 110 008e. Colorful Media Private Limited, 403, Prabhat Kiran, 17, Rajendra

Place, New Delhi - 110 008f. Adventure Marketing Private Limited, 403, Prabhat Kiran, 17,

Rajendra Place, New Delhi - 110 008g. Shinano Retail Private Limited, 4th Floor, Court House,

Lokmanya Tilak Marg, Dhobitalao, Mumbai - 400 002h. Nexg Ventures India Private Limited, C-157, Industrial Area,

Phase - VII, Mohali, Punjab - 160 055i. Arizona Global Services Private Limited, 1204, 12th Floor,

Hemkunt Chambers, 89, Nehru Place, New Delhi - 110 019j. Acacia Banyan Partners, Citibank N A, Custody Services, 3rd Floor,

Trent House, G Block, Plot No. 60, BKC, Bandra (East), Mumbai - 400 051k. Independent Media Trust (held in the name of its trustee),

Empire Complex, 1st Floor, 414, Senapati Bapat Marg, Lower Parel, Mumbai - 400 013

l. Network18 Media Trust (held in the name of its trustee), 503, 504 & 507, 5th Floor, Mercantile House, 15 Kasturba Gandhi Marg, Delhi - 110 001

m. Network18 Group Senior Professional Welfare Trust (held in the name of its trustee), 503, 504 & 507, 5th Floor, Mercantile House, 15 Kasturba Gandhi Marg, Delhi - 110 001

I, Lakshmi Narasimhan, hereby declare that all particulars given above are true to the best of my knowledge and belief.

Dated: 22nd February 2013

LAKSHMI NARASIMHANSignature of the publisher

** ownership of this magazine stands transferred from Infomedia Press Limited (formerly known as Infomedia18 Limited) (hereinafter “Infomedia”) to Network18 Media & Investments Limited (Network18) in pursuance of the scheme of arrangement between Network18 and Infomedia and their respective shareholders and creditors, as approved by the Hon’ble High Court of Delhi and the necessary approval of Ministry of Information and Broadcasting is being obtained.

Flexible screw conveyorThe helix flexible screw conveyor has only one moving part. The conveyor can be disassembled in less than 20 minutes for cleaning and maintenance. It can achieve lengths of up to 80 ft long. A wide range of auger styles and sizes ranging from 2 to 8 inches in diameter is offered. The product meets stringent standards and has USDA certifications. It is one of the most economical conveyors and can be used in many applications.

Hapman Systems Pvt LtdVadodara – GujaratTel: 0265 – 2517505Email: [email protected], Website: www.hapman.in

Drum dryerA range of drum dryers is available with quality standards and optimum effectiveness. This range is broadly accepted by prospective clients due to the fine efficient performance, robust construction and longer service life. The dryer is available as per customised specification and also at industry leading prices. Moreover, the range of dryers is manufactured using finest quality raw material sourced from reliable vendors after an appropriate inspection process. The range is manufactured using superior quality raw material and is used to convert liquid material into dry flakes.

Tridev IndustriesAhmedabad - GujaratTel: 079-25895865, Mob: 09978917299Email: [email protected] Website: www. tridevindustries.com

Vapour phase corrosion inhibitorCorobit-VP is a vapour phase corrosion inhibitor used for prevention of rust and corrosion of ferrous and non-ferrous metals. It is available in powder form and when sprinkled in enclosed systems, it emits vapours that form invisible protective film on surrounding metallic surfaces, thus preventing corrosion.

Ashok IndustryMumbai – MaharashtraTel: 022 – 26232133, Mob: 09892848669Email:[email protected]: www.ashokindustry.com

List of Products


Sl. No. Product Pg. No. Sl. No. Product Pg. No. Sl. No. Product Pg. No.Acoustic enclosure ................................ BCAgitator .................................................... BICAir-cooled heat exchanger ........................FICAir-cooled steam condenser ......................FICAluminium oxide ceramic composite ...... 3, 57Amino acid analyser .................................... 84Atomic absorption spectrophotometer ........ 84Automatic and contained discharge ............ 33Ball check valve ...................................... 59Ball valve ......................................... 13, 59, 63Bellow and dip-pipe ...................................... 4Bend ............................................................ 63Butterfly valve ................................. 13, 59, 63Cake pressing ......................................... 33Check valve ................................................. 13Chemicals and pharmaceuticals .................. 79Chemical compound for cleaning and finishing machines ...................................... 77Chemical pump ........................................... 77Chemical transfer pump .............................. 74Continuous or batch filtration .................... 33Contract manufacturing facility ............ 45, 47Cooling tower ...........................................FICCorrosion-free cable management system .. 77Degreaser ............................................... 78Diaphragm valve ................................... 59, 63Drum dryer ................................................. 80Dry van pump ............................................BCE/P positioner ........................................ 77End cap ....................................................... 63Evaporator .................................... 19, 37, BICExhibiiton - Plastivision 2013 .................... 28FEP/PFA/PVDF material ...................... 59Filter cock ................................................... 63Fitting .......................................................... 59Flameproof magnetic drive chemical pump 79Flexible screw conveyor ............................... 80Flow indicator ............................................. 63Fluid ............................................................ 22Foot valve .................................................... 63Forged steel valve ........................................ 13FRP battery stand, cable tray ...................... 55FRP canopy, grating ................................... 55FRP handrails and fencing ......................... 55FRP ladder, luminaries ............................... 55FRP piping .................................................. 35FRP pole and mast ..................................... 55

FRP storage tank ........................................ 55FRP structural profile ................................. 55Fume extraction and scrubbing systems ..... 79Gas chromatography ............................... 84Gasket ......................................................... 59Gate valve .................................................... 13Gear, gear box ............................................. 22Gear motor .................................................. 22Geared and flexible coupling ...................... 22Globe valve .................................................. 13Hastealloy .............................................. 13Heat exchanger ........................................ BICHot and cold zinc phosphating chemical ... 78HPCL production ....................................... 84Impeller .................................................. 63Industrial ceramic .................................... 3, 57Industrial machinery plants and equipment 79In-line homogeniser system ........................ 78Laboratory bottles ................................... 74Large diameter welded pipe ........................ 79Laser particle size analyser .......................... 84Limit switch ................................................ 77Lined valve .................................................. 13Lined valve and pipe fitting .......................... 4Long neck pipe end .................................... 63Lubricant additives and reactive surfactants ........74Mixing and drying ............................. 19, 37Monel .......................................................... 13Monoblock pump ........................................ 77Multi-stage cake washing ........................... 33Nickel aluminium bronze ........................ 13Nitrile glove................................................. 17Non-metallic pump ..................................... 77Non-return valve ..................................... 4, 63P/P positioner ........................................ 77Pipe ............................................................ 59Piping system from polypropylene ................ 6Plug valve .............................................. 13, 59Pneumatic conveyor .................................... 77Pole ring ...................................................... 63Pollution control equipment .................... BICPolypropylene process pump ....................... 77Pressure and vacuum filtration .................... 33PTFE, PTFE bush ..................................... 59PTFE lined valve and pipe fitting .......... 74, 4Pump ....................................................77, BC

Pump for chemical equipment .................... 11Pumping solution ........................................ 53PVDF pump ............................................... 77Recruitment ..................................... 49, 51Reducer ....................................................... 63Rod ............................................................ 59Roots blower ..............................................BCRotary evaporator ........................................ 78Rotary gear pump........................................ 77Scoop ..................................................... 63Seamless pipe .............................................. 79Self-priming mud pump ............................. 77Self-priming sewage pump ......................... 77Sheet ............................................................ 59Showel ......................................................... 63Slip-on flange .............................................. 63Spade ........................................................... 63Spectrophotometer ...................................... 81Spiral cum helical gear box ......................... 22Spray dryer ............................................... BICStainless steel pipe....................................... 79Strainer .......................................................... 4Super duplex ................................................ 13Swing check valve ....................................... 59Tee ....................................................... 63Teflon-lined ball valve .................................. 4Teflon-lined butterfly valve, check valve ...... 4Teflon-lined sampling valve .......................... 4Teflon-lined valve and pipe fitting ............... 4Tefzel HHS isotactic PP material ................ 6Thermoplastic valve ...................................... 6Titanium ..................................................... 13Trade show .................................................. 64Tube ...................................................... 59, 79‘U’ tube ................................................... 79Vacuum booster pump .......................... BCVacuum or hot gas drying........................... 33Vacuum system ..........................................BCValve ...................................................... 59, 63Valve positioner ........................................... 77Vapour phase corrosion inhibitor ............... 80Vertical glandless pump .............................. 77Washer ................................................... 63Welded pipe ................................................ 79Worm gear .................................................. 22‘Y’ type strainer ....................................... 63

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

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

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

List of Advertisers

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


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

Aeron Composite Pvt Ltd 55

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E: [email protected]

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Analytical Technologies Limited 84

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Anup Engineering 79

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Chemical & Process World 64

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Chemical Process Piping Pvt Ltd. 35

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Cole-Parmer India 17

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Dev Engineers 77

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Dishman Pharmaceuticals Ltd 45;47;49;51

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Elecon Engineering Company Ltd 22

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Everest Blowers BC

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Flucon Automation 77

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Food & Pharma Specialities 19;37

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G M Engineering 13

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Hi-Tech Applicator 4

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Jyoti Ceramic Industries Pvt Ltd 3;57

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Paharpur Cooling Towers Ltd FIC

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Parth Poly Valves Pvt. Ltd 63

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Pentair Water India Pvt Ltd 11

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Raj Process Eqpts & Systems(P) Ltd BIC

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W: www.rajprocessequipment.com

Shanbhag And Associates 53

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Supremo Polymer Industries 59

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Suraj Limited 79

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W: www.surajgroup.com

Toshvin Analytical Pvt Ltd 81

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UNP Polyvalves India Pvt Ltd 6

T: +91-265-2649248


W: www.polyvalve.com

Waters (India) Private Limited 8

T: +91-80-28371900


W: www.waters.com

Documents

Chemical World - March 2013