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Alkali BulletinAlkali Bulletin(For Restricted Circulation) August 2018Volume XL No. 08

AMAI August 18 final.indd 1 05-Oct-18 1:59:44 PM

Dear Reader

AMAI organised a seminar on “New Developments in Chlor-alkali Processes” on 9th and 10th August at Chandigarh. The event was well-attended with over 155 participants from more than 70 companies. As in earlier seminars, the event included a concurrent exhibition and a plant visit hosted by Siel Chemical Complex for all participants. Shri Amit Dhaka, IAS, Managing Director of Punjab Alkalies & Chemicals Ltd. inaugurated the seminar. We gratefully acknowledge the support received from the Department of Chemicals & Petrochemicals for the event. We also convey our grateful thanks to Mr. A.K. Mehra and the plant team of Siel Chemical Complex, Rajpura for generously hosting the visit for all participants to their chlor-alkali unit. The seminar included many insightful presentations by experts. This issue carries a report on the proceedings of the seminar.

The RCEP trade negotiations entered an important phase with another round of lists being exchanged for tariff concessions. The RCEP trade agreement would cover 40 per cent of global GDP and over 42 per cent of the world’s population. The RCEP will thus be the cynosure of everyone. India has a trade deficit with as many as 10 of the RCEP grouping of 16 countries. According to the commerce ministry data, India’s trade deficit (difference between imports and exports) with seven countries – Indonesia, Thailand, China, Japan, South Korea, Australia and New Zealand which are part of the RCEP grouping, increased in 2017-18 compared to the previous year. The trade gap with China alone was USD 63.12 billion in 2017-18 compared to USD 51.11 billion in 2016-17. Also India has the highest trade deficit with China even without any formal trade pact. With the Alkali and Chlorovinyl industries already facing the adverse impact of tariff concessions offered in earlier trade agreements, AMAI has been representing strongly against ceding any concessions in the ongoing negotiations.

Continuing our technical series on corrosion control, this issue carries the second and concluding part of the article on forms of corrosion in industry and their control. It is estimated that the global cost of corrosion is USD 2.5 trillion equivalent to roughly 3.4% of the global gross domestic product. In India, the losses on account of corrosion are estimated at 4 to 5% of GDP which is more than Rs. 6 lakh crore. Apart from economic losses, safety gets compromised and the life of equipment is significantly reduced. The chlor-alkali has taken significant measures to control corrosion, which have contributed to safety and loss prevention. Awareness and monitoring followed by prevention measures are important tools that go a long way in reducing risks and costs due to corrosion. AMAI had organised a seminar on corrosion in alkali industry some time back. This, along with the articles on corrosion in this magazine supplement the efforts of the industry in its journey on improving safety and loss prevention.

K. Srinivasan

Secretary General


I. ARTICLES & FEATURES AMAI Seminar on “New Developments in Chlor-Alkali Processes” held in Chandigarh on 9-10 August 2018 – A Report on Seminar Proceedings by Harjeet Kaur Anand, Joint Director (Tech.), AMAI 2

Plastics Industry: Proactive approaches to tackle waste issue – Ravi Raghavan, Editor, Chemical Weekly 11

Forms of Corrosion in Industry and their Prevention (Part-2) - Dr. S.K. Chakravorty, Consultant (Plant Engineering) 15

Utilising Waste Heat - Industrial efforts to optimise energy use 21

25th AMAI Training Workshop on “Safe Handling of Chlorine” at Bilaspur 25

SHE Committee Plant Visit to Punjab Alkalies & Chemicals Ltd. – A Report 27

Incident Report No.100: Chlorine Release during Production Upset 28

Beacon-Messages for Manufacturing Personnel 30

II. NEWS DIGEST“Make-In-India” - Significant Achievements in Chemical and Petrochemicals 32

India-Italy trade ties set to deepen 32

Regime change in Pak raises industry’s expectations 33

RCEP: India must safeguard its interests 33

Fossil fuel market due for overhaul 34

Govt. looking to tweak PCPIR Policy 35

Regional Comprehensive Economic Partnership: ‘Understanding China key to a better position’ 35

Huge demand for CECRI’s lithium-ion cells 36

Top grade limestone deposit found under Arabian Sea 37

India needs transparent industrial pollution data, regulation reforms 38

NITI Aayog & CII to develop a roadmap to spur innovation 39

Trade deficit at five-year high of $18 billion in July on oil imports 39

Petrochem hub policy will be made more attractive, says official 40

Air pollution may cost India over $500 billion a year 40

DCM Shriram to invest Rs 1,300 cr to expand sugar, chemical biz 41

2 years after enacting law, Centre unlocks Rs 66,000 crore green fund 41

Chlorine Emergency Response Network Toll free no. 1800-11-1735

CONTENTS


Vibrant Guj ‘19 to focus on bilateral trade 42

Anti-dumping duty on ‘methylene chloride’ from US, EU extended by one year 42

Tata Chemicals bag Award 43

US-China trade war can make indian products competitive 43

India may defer imposing US tariffs by 45 days 43

Global Greening is terrible 44

Nuberg bags $53 mn chlor alkali, calcium chloride project in Saudi 45

GHCL Limited among the best workplaces in India 46

Gujarat Fluorochemicals Ltd. – India is largest producer of Chloromethanes 46

India to be among top 3 pharma markets by 2020 46

III. UPCOMING SEMINARS/CONFERENCES/WORKSHOPSCICAC to organise 7th China Internatinal Chlor-Alkali Conference on 17-19 October, 2018 in 47 Kunming, Yunnan – AMAI is Media Partner

Argus Media to organise Chlor-Alkali Conference 2019 on 29-30 January 2019 in London - AMAI 48 is Supporting Partner

Alkali Bulletin August, 2018

Disclaimer: Information published in this magazine is reproduced from various sources. Every effort is made to minimize errors while reproducing for publication in Alkali Bulletin. However, readers are requested to verify and make appropriate enquiries and satisfy themselves about the veracity of information published in this magazine before use. The publisher or AMAI will not be responsible for decisions taken by readers based on information published in Alkali Bulletin.


Alkali Bulletin August, 2018

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Chemicals can’t react if they do not come into con-tact with each other. If there is no agitation in a reactor, the reaction will be slow or stop, and unreacted chemicals will accumulate. In an exo-thermic reaction this is a serious hazard. If you re-start the agitator, there will be a lot of unreacted material available and the reaction may be very fast. Your cooling system may not be able to remove the heat fast enough to control the reactor temperature.

Mixing is clearly important in a vessel containing a multi-phase mixture such as liquid-solid or organic-aqueous liquid phases. It is also important if the materials in the vessel are mutually soluble. In the pictures below, balsamic vinegar, which is completely soluble in water, is added to water without mixing. The vinegar sinks to the bottom of the glass and does not form a uniform solution until the mixture is stirred with a spoon.

If you lose agitation in a reactor, batch or continuous, get technical assistance before re-starting the agitator. Gather some data to share with technical experts to help decide on the appropriate action. For example, how long was the agitator off, what was added to the vessel while it was off, what is the temperature and pressure history of the vessel?

Recognize that loss of agitation can be a problem in other vessels even if there is no intended reaction. Without agitation, there can be large temperature and concentration differences in the vessel. This can cause freezing on cooling surfaces, boiling near heating surfaces, precipitation of solids from a solution, or settling of solids from a slurry. Variation in composition of material fed from an improperly mixed vessel to other equipment can cause operating or safety issues in downstream process units.

Heating or cooling of a vessel without agitation is likely to be inefficient, and temperature indication may be inaccurate if the vessel contents are not mixed.

This issue sponsored by

http://www.aiche.org/CCPS/Publications/Beacon/index.aspxMessages for Manufacturing Personnel

Keep your reactor agitated for safety!

www.aiche.org/ccps

August 2018

©AIChE 2018. All rights reserved. Reproduction for non-commercial, educational purposes is encouraged. However, reproduction for any commercial purpose without express written consent of AIChE is strictly prohibited. Contact us at [email protected] or 646-495-1371.

The Beacon is usually available in Afrikaans, Arabic, Catalan, Chinese, Czech, Danish, Dutch, English, Filipino, French, German, Greek, Gujarati, Hebrew, Hindi, Hungarian, Indonesian, Italian, Japanese, Korean, Malay, Marathi, Mongolian, Persian (Farsi), Polish, Portuguese, Romanian, Russian, Spanish, Swedish, Telugu, Thai, Turkish, Urdu, and Vietnamese.

What if your agitator fails?In 1993 in a German factory, o-chloronitrobenzene was reacted with

caustic soda dissolved in methanol to produce o-nitroanisol in a 36 m³ (9500 US gal) batch reactor. This reaction is exothermic (generates heat), and the addition of caustic normally took place at about 80 °C over 5 hours.

Surprisingly, a batch did not require cooling! In fact, rather than needing cooling to maintain the required batch temperature, steam heating was required. Then it was found that the agitator had not been on during the caustic addition. The reactants were not properly mixed (1). The agitator was started, the unreacted chemicals were mixed (2), and the batch temperature quickly increased, exceeding 160 °C (320 °F). At the elevated temperature a different, also exothermic, reaction occurred. 10 m³ (2650 US gal) of reactor contents were vented to the atmosphere through a

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pressure relief valve. A large area, including nearby residences, was contaminated. Nobody was injured, but health risk concerns remain. Direct costs were about 40 million DM (in 1993, equivalent to about US $ 38 million today).

1 2

Reference Gustin, J-L., “How the Study of Accident Case Histories Can Prevent Runaway Reaction Accidents to Occur Again.” IChemE Symposium Series No. 148, pp. 27-40, 2001.


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Published by ALKALI MANUFACTURERS ASSOCIATION OF INDIA3rd Floor, Pankaj Chambers, Preet Vihar Commercial Complex, Vikas Marg, Delhi 110092Ph: 011- 22432003, 22410150Email: [email protected]; [email protected];website: www.ama-india.org

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