Coperion delivers compounding plants to BASF in South Korea

In the past decade, Coperion GmbH in Stuttgart has delivered, installed, and launched several compounding plants for BASF to manufacture engineering plastics. For a new compounding plant in South Korea, BASF relied once again on Coperion's expertise. In September of 2015, the plant was handed over within the contractually agreed timeframe. Since then, BASF has been successfully processing high-quality polyamides.

Planning and implementation of the entire plant, all under one roof, Coperion delivered the entire production facility to BASF. The project scope included planning, assembly, and start-up, as well as verification of guaranteed performance data under production conditions. Furthermore, the scope of supply and performance included all equipment and structures to be installed. The entire utility supply was also included, encompassing not only electricity, but also compressed air, exhaust air purification, and pelletizing water circulation, including cooling. All applicable standards and legal regulations for the construction and operation of compounding facilities in South Korea were observed throughout the project.

Throughout the compounding plant, proven Coperion processes and components are used for energy-efficient conveying of raw materials. New to this plant is the use of high-precision Coperion K-Tron feeders. These ensure continuous precise feeding of raw materials according to a predetermined formula into the heart of each line – the ZSK twin-screw extruder. Following subsequent pelletization and drying, the finished product is carefully transported to the product silos. From there, the pellets are fed into the fully automated IBP 250 FFS bagging and palletizing system, which handles weighing, filling, marking, testing, and palletizing processes in a single unit. During the planning of the facility, careful attention was paid to ensure that all steps in the process were optimally coordinated.

Coperion established a specialized team 10 years ago for just such projects. The team is composed of specialists from several international company locations who complement each other in process and plant planning, project management, and coordination of the assembly, as well as the start-up. Using this global network ensures that the best possible solutions are realized – always taking local circumstances and opportunities into account – for clients at every location around the globe.

EMC to merge with Williamson Magor engineering subsidiaries

The BM Khaitan-controlled Williamson MagorBSE 1.59 % Group's engineering arms and transmission tower maker EMC Ltd are being merged to create a giant engineering joint venture with a turnover of Rs 6,000-7,000 crore. According to a notice sent to stock exchanges, EMC, McNally Bharat Engineering (MBEL) and McNally Sayaji Engineering (MSEL) will merge into Kilburn Engineering.

While EMC is controlled by Manoj Toshniwal, Williamson Magor group owns MBEL, MSEL and Kilburn Engineering. According to some sources, the merged entity will be jointly run by the Khaitans and Toshniwal. The Khaitans and Toshniwal declined to comment on the issue. If approved, the merged entity will become a complete solution provider for power plants as well as power transmission units, material handling and specialised drying equipment.

They said the two parties decided to make Kilburn Engineering the holding company primarily because it does not have any crossholdings. EMC holds about 30% of McNally Bharat Engineering's equity capital, while McNally Bharat holds shares of McNally Sayaji. The Khaitans and the Toshniwals have decided to form a committee with representatives from the companies being merged. 

BPCL plans to spend Rs 10,000 crore to boost its refining capacity

Bharat Petroleum Corporation (BPCL), India's second biggest state refiner, plans to spend about Rs 10,000 crore in 2016-17 to expand and upgrade its refining capacity and augment its marketing infrastructure, its finance chief has said. 

"We need to invest in infrastructure to meet the growing demand in the market," said P Balasubramanian, director (finance) at BPCL, which has made about Rs 9,500 crore in capital expenditure in the current fiscal year. Indian refiners and fossil fuel retailers have been working on adding new capacity to cater to the rapidly rising fuel demand in the country. 

The petroleum product consumption had grown by 10% till January this fiscal year. An expansion underway at Kochi refinery will take about 40% of the BPCL's planned capex for 2016-17. The refinery is adding 6 million tonne per annum (MTPA) to the existing capacity of 9.5 MTPA. BPCL's total capacity is about 27.5 million tonne. 

Another Rs 1,000 crore would go towards upgrading other refineries to help them produce higher grade fuels that meet Euro IV and VI emission norms. The government wants all state refiners to make available Euro IV fuels across the country next year and Euro VI by 2020. 

About Rs 1,000 crore would be utilised by the company's upstream business managed by Bharat Petroresources that has just bought nearly 10% stake in an east Siberian field owned by Rosneft. The balance funds would be deployed in building a petrochemicals unit, pipelines, marketing terminals and depots, and procuring cooking gas cylinders. 

Sika opens new mortars and concrete admixtures plant in Vancouver, Canada

Switzerland-based chemical company Sika has opened a new mortars and concrete admixtures plant in Vancouver, Canada.

With the new plant, which is the company's fourth facility in Canada, Sika expects to serve the Pacific Northwest, a region that includes the cities of Vancouver, Seattle and Portland.

The new plant fulfils the company's continued supply chain strategy in North America by expanding production capacities in conurbations and major cities in the area.

The facility features a modular mortar plant and liquid concrete admixture, blending equipment for producing a wide range of concrete admixtures, as well as a quality control laboratory, a warehouse and office space for administrative and sales personnel.

The newly opened mortars and concrete admixtures plant, covering an area of 30,000ft², will produce a broad range of cementitious mortars and grouts including SikaTop, Sikacrete, SikaQuick, SikaRepair, SikaSet, Sika MonoTop, Sika Level, and SikaGrout.

NTPC in expansion mode in South

NTPC Limited is on a major expansion of its generation capacity in the southern region with first of the three 800 MW units at the Kudgi project in Karnataka and 200 MW of solar power generation at NP Kunta in Anantapur district of Andhra Pradesh to be operational by March. 

NTPC has an operating capacity of 6,465 MW and is working on 9,000 MW capacity in the South, including two 4,000 MWeach in Telangana and AP, 1,000 MWof solar and another 2,400 MWin Karnataka.

In an exclusive interaction with BusinessLine, R Venkateswaran, Executive Director of NTPC Southern Region, explained, "The first unit of 800 MW at Kudgi, which envisages a total installed of 2,400 MW (3x800) will be commissioned by March and the next two units within six months gap each. This will add to the southern capacity and ease up the power supply situation in South partially."

Venkateswaran, said, "Work on several projects has been taken up simultaneously in the South and these include 1,600 MW thermal power project at Ramagundam in Telangana, and setting up of a Greenfield 4,000 MW (4x1000 MW) coal fired thermal power project at Pudimadaka in Andhra Pradesh."

Explaining the current status, Venkateswaran said, "NTPC has secured environmental clearance for the 1,600 MW at Ramagundam, where we have 2,600 MW of installed capacity. Orders have been placed for main plant equipment, boilers etc., and January 29 has become the Zero Date. The Environmental Impact Assessment studies are being conducted for the balance 2,400 MW (3 unit of 800 MW). Once all these units are installed, the Ramagundam project will have total capacity of 2,600 MW plus 4,000 MW, and become the largest single location plant when completed."

Pudimadaka

"We are working on the 4,000 MW (4x1000) thermal power project at Pudimadaka in AP. The environment studies have been completed and minor clearances are awaited. We are considering developing a jetty to transport coal and looking at using the blended imported and domestic coal. We are in discussions with the state government," he said.

NTPC is working on two major solar parks in Andhra Pradesh of 1,000 MW each in Anantapur and Kurnool. Of the 1,000 MW plant at NP Kunta in Anantapur, 200 MW will be ready by March and 50 MW by April. And 750 MW will be awarded soon.

"Another 1,000 MW solar park has been awarded under the National Solar Mission at Kurnool. In addition, we are looking at another 500 MW park in Kadapa," he explained.

Andamans

NTPC has set up a 5 MW solar farm in Port Blair and has been called upon to set up a 100 MW solar park in Andamans. In the phase one, 50 MW will be set up and another 50 MW in phase II.

Emami Cement begins work on 2 MTPA plant

Emami Cement on Friday formally began construction work on its 2 million tonnes a year cement unit at Panagarh in Burdwan district of West Bengal. 

In a statement, Emami said that West Bengal Chief Minister Mamata Banerjee formally laid the foundation stone for the ₹500-crore project. The unit is being set up on 65 acres of land, provided by West Bengal Industrial Development Corporation at Panagarh. Apart from a grinding unit, it will also have a 10 MW coal-fired power plant.

AkzoNobel to acquire BASF's Industrial Coating Business

AkzoNobel today has made an agreed offer to acquire BASF's Industrial Coatings business for €475 million.

The transaction would include technologies, patents and trademarks, as well as securing supply to customers worldwide. Two manufacturing plants - one in the UK and one in South Africa - would also be transferred to AkzoNobel. The business generated revenue of about €300 million in 2015 and supplies products for a number of end uses, including coil, furniture foil and panel coatings, wind energy and general industry, and commercial transport.

Tea and coffee merchants, Taylors of Harrogate, contacted Vortex Global a few years ago to assist in improving a tea transfer system at their North Yorkshire, UK plant.

Staff at the Vortex office were contacted by Taylors, who had identified the Wye Line Diverter from the Vortex website as a potential alternative for their tea transfer system. Taylors were then visited by Vortex representatives just 90 minutes after this initial enquiry.

At the plant, the blended tea was transferred to each packaging machine by a dedicated vacuum system. The project was to combine these two systems into one, reducing the number of vacuum pumps and pipework whilst not affecting the quality, taste or structure of the tea in any way.

Following the decision that the 2-Way Wye Line Diverters offered the best solution to reduce costs and energy consumption, Taylors were able to test a set of four diverters on a trial basis for several weeks. At the end of this period, Taylors confirmed that the diverters were performing to expectation and placed a further order for eight more Wye Line Diverters. Taylors added “Dry leaf tea is a very abrasive material and we certainly valued the trial service that Vortex provided, so that we could evaluate them in use with our product. They also fitted the valves with abrasion resistant liners to help us get around the potential problem.”

By using 2-Way Wye Line Diverters in pairing together new manufacturing and packaging lines, Taylors reduced power consumption and noise in the production hall by eliminating three 4.3kW electric motors.

Due to the continuing growth in the UK tea market plans, Taylor’s purchased several, additional Vortex Wye Line Diverters in 2015.  The original wye lines and the newly installed wye lines are all working exceptionally well.

How Does an Iris Valve Work?

Most of us are familiar with the iris diaphragm, a simple mechanism that can expand or decrease the opening of a circular hole. Common examples are camera shutters and the irises in our eyes, which both control the entry of light. Maybe you have seen spaceship iris doors opening and closing in sci-fi films. The iris mechanism is also present in the world of dry bulk solids handling, where it’s called an iris valve. The iris valve’s function is to gently control the discharge of free flowing powders, granules, and pellets — including chemicals, food and dairy products, pharmaceuticals, minerals, and plastics — in gravity-flow applications.

The Mechanics of the Iris Valve

The iris valve consists of a metal-cased valve body enclosing two concentric rings, connected by a flexible sleeve of material. One end of the sleeve is fixed inside the valve body. The other end is attached to a control ring that is manipulated by an external handle. As the handle is rotated through a 180-degree arc, the sleeve is twisted to the point that it becomes a flat, tight solid barrier.

Unlike a conventional slide gate or butterfly valve, where a blade or disc crosses and obstructs the column of flowing material, the iris valve has a circular opening that closes toward the center of the material column. When the iris valve opens, its circular opening creates a small “cone” of material that flows directly into the receiving container’s center, providing easier container filling.

Iris valves are typically actuated manually and are offered in two main handle options: an external twist or quick-lock handle. With the twist handle, the operator rotates the handle to control the valve’s opening in an infinite number of positions across the 180-degree arc. The quick-lock handle incorporates a locking mechanism. It allows quicker actuation to a limited number of set points on the valve body. A handwheel may be used to manually open larger-diameter iris valves. Iris valves equipped with a pneumatic or electric actuator have significantly higher costs than manual valves. However, the actuator may be linked by any of several methods to a PLC or other control system to suit the application.

Component Construction Materials

The valve components can be made of various materials to suit your application.

Valve body. The iris valve body is commonly constructed of aluminum. The aluminum may be anodized or Teflon™ coated to suit a direct-contact application with a caustic environment. Type 304 and 316L stainless steels are also available for sanitary applications but have a significantly higher cost than aluminum. Some iris valve suppliers offer aluminum valve bodies in which only the material-contact areas are lined with stainless steel, which reduces the valve’s cost.

Control ring and handle materials. The iris valve control ring can be made of polycarbonate, bronze, or stainless steel, depending on the supplier. The ring’s external twist or quick-lock handle, as well as the locking mechanism on a quick-lock handle, can also be made of polycarbonate, bronze, or stainless steel. Carefully selecting construction materials for these components will prevent operating problems.

Sleeve materials. The sleeves for iris valves are available in a variety of materials to accommodate a range of bulk handling requirements. A sleeve made of two layers of fabric is often used to handle a fine powder that generates dust. Iris valves are typically available in, but are not limited to, the following types of sleeve materials:

NylonTeryleneTeflonUrethaneBuna-N (Nitrile) RubberNatural Rubber

It is important to consult your supplier on which sleeve material is best for handling specific applications, as some of the least assuming materials can be caustic or abrasive for certain sleeve materials.

Evaluating the Pros and Cons of an Iris Valve

While the iris valve can be an efficient and cost-effective means of controlling the discharge of dry bulk solids in many applications, it does have limitations. Before selecting an iris valve, consider these pros and cons.

Pros:

Inexpensive when manually actuated.Light-weight and disassembles easily, making it easy to install, clean, and maintain, especially in confined areas.Ideal for use with friable and explosive materials. (In applications handling explosive materials, the valve and surrounding equipment must be properly grounded to avoid electrostatic discharges, and when the valve is equipped with an electric actuator or controls, these must meet applicable NEMA standards in the US or ATEX standards in European Union countries.)Unobstructed opening that opens and closes toward the valve’s center, allowing the discharged material to evenly fill containers.

Cons:

Unable to handle high-volume, continuous material flow.Cannot handle heavy, abrasive material.Cannot close through a standing column of material.Cannot handle frequent open-close cycles in direct contact applications.Cannot support heavy equipment suspended from it.Has a bolt-hole mounting pattern that usually differs from supplier.Other Considerations

Torque: Iris valves are subject to torsional stress, especially as they are being closed. Handles and locking mechanisms made of polycarbonate are subject to distortion and breakage. Polycarbonate control rings are subject to the same problems. For applications that require a lot of torque pressure, a stainless steel handle and mechanism is best.

Construction Material: Iris valves containing bronze control rings are subject to metal flaking inside the valve due to the metal-on-metal contact between the bronze control ring and the metal valve body. This can lead to damaged sleeves, introduction of foreign material and erratic actuation of the valve. A stainless steel control ring will provide longer service life, and a Type 316L stainless steel control ring is best for handling corrosive materials.

Mounting to existing equipment: Most iris valves have standard bolt hole-mounting patterns offered as a standard, however, this pattern may differ from manufacturer to manufacturer. Mating spool pieces and ferrule type connections can also be applied to the valve to match mounting requirements.

Is an Iris Valve right for you?

For help determining whether the iris valve is right for any dry bulk material application, consult an iris valve supplier. Based on the details provided, the supplier can determine if the iris valve is the correct valve choice. If it is, work closely with the supplier to select the right valve components, construction materials, and actuation method to keep the iris valve operating smoothly and efficiently in your handling operation.

Clariant expands in masterbatch

Clariant announced plans on Feb. 18 to raise production of masterbatch for high temperature plastics, one day after the Swiss group said its 2015 sales were hit by the strong Swiss franc and global economic uncertainty.

Specialty chemicals producer Clariant said it plans to invest more than CHF 7.5 million ($7.54 million) in Europe, Asia and North America to expand production capacity in color and additive masterbatches for use in engineering resins and high-temperature plastics like PEEK (polyether ether ketone). The largest part of the investment will be made at plants in Shanghai, Singapore, and at two plants in the U.S., although Clariant did not break down the investment at these facilities.

“Global demand for high-temperature plastics and compatible masterbatches is booming,” said Jeff Saeger, who heads the expansion program for Clariant. “Fueled by new products in the automotive, small consumer electronics and electrical markets, the use of engineering materials is growing at annual rates of 7 or 8 percent, well above the growth rate of the plastics industry as a whole. Clariant has state-of-the-art capabilities in the United States to handle these materials and will now leverage that experience and expertise around the world.”

The three U.S. masterbatch plants referenced by Saeger are in Holden, Mass.; Lewiston, Maine; and Albion, Mich.; these plants, said Clariant, “already have vast knowledge and experience in working with both engineering and high-temperature materials [processed at temperatures of 300°C or higher]”.

However, Clariant continued: “Capabilities in Asia have previously been more limited, focusing mainly on engineering materials (like ABS, polycarbonate and certain nylons), which are processed at moderate temperatures. Customers in this region have therefore often had to source the more advanced products from overseas and thereby facing longer product development and delivery times. That is about to change.”

The group said that in Shanghai, it is installing new equipment and implementing procedures required for masterbatch production based on engineering and high temperature resins. The new production lines and associated capabilities are expected to be ready for start-up by the end of 2016.

In the U.S., Clariant installed equipment for processing fluoropolymers in Lewiston, Maine, in late 2015. It said new lines for specialty engineering compounds and black masterbatch for high-temperature resins will be added in Holden, Massachusetts, beginning in the first quarter of 2016.

Mitsui Chemicals Reorganises Operations into Five sectors

Mitsui Chemicals announced on Friday that it is reorganizing into five new sectors: healthcare; mobility; food and packaging; basic materials; and new business and product creation.

The company says the restructuring, which takes effect on 1 April 2016, is part of a plan to achieve maximum synergies. As part of the changes, the company is combining basic chemicals, petrochemicals, and Mitsui Chemicals & SK Polyurethanes under the basic materials business sector. The fine & performance chemicals division will be dissolved and its businesses transferred.

Perstorp plans world scale pentaerythritol plant in India

Perstorp said on Friday that it has signed a memorandum of understanding with the Maharashtyra Industrial Development Corp. to evaluate investment in a world scale plant for the production of pentaerythritol (penta) in India. The company has been participating in the ‘Make in India’ event, promoting investments in the country. Perstorp says that the market for coatings is growing fast in India and building a world scale production plant would be an important part of Perstorp’s ambitious plan to strengthen the position in the Asian Market.

Shree Cement wins limestone mining lease

Shree Cement has won the first ever non-coal mining lease allocated through the auction route, by offering to pay the Chhattisgarh government around Rs284 for every tonne of limestone production from the Karhi Chandi mine that has an estimated reserve of 255 million t spread over 242 hectares.

In addition to this sum, it would have to pay royalty, contribute to the district mineral foundation and national mineral exploration trust once the company starts mining.

The bidding lasted more than five hours. A total of 192 bids were submitted. At least five cement firms were in the mix in the final round of bidding according to sources.

DNS Capital Acquires IMI Holding

DNS Capital announces the acquisition of IMI Holding Corp. (IMI Holdings), the parent company of Industrial Magnetics Inc.(IMI), Prater Industries Inc., and Sterling Controls Inc., from Chattanooga-based private equity firm, River Associates Investments LLC.

Terms of the transaction were not disclosed. DNS Capital is the investment office and internal merchant bank for the business enterprise of Gigi Pritzker and Michael Pucker.
 
Headquartered in Boyne City, MI, IMI is a leading provider of highly engineered solutions for magnetic separation and material handling, particle processing, and process automation applications. The company’s products are used to handle, separate, lift, and process a diverse array of materials across a range of markets. Applications of the company’s expertise include metal removal, ingredient/particle sorting and sizing, and product purity/quality control. IMI serves a number of industries, including food processing, industrial MRO, conveying, bulk material, and aggregate handling and recycling, among others. IMI’s products and solutions improve operating efficiency, reduce costs, increase product purity and safety, and protect manufacturing equipment from damage and degradation.