Alkali BulletinAlkali Bulletin(For Restricted Circulation) November 2018Volume XL No. 11

Dear Reader,

During our Prime Minister’s visit to Singapore for the Regional Comprehensive Economic Partnership (RCEP) Summit in mid-November 2018, he assured support for early conclusion of the negotiations. This news was followed by the announcement of deferment of the negotiations to 2019. The Indian industry has been watching the developments with keen interest, given that the partner countries have been bargaining hard for more concessions from us. The anxiety was not misplaced – the trade deficit with FTA partner countries have widened significantly. A recent report says that India’s trade deficit with the RCEP bloc is more than US$100 billion which is almost two-thirds of the total trade deficit. China, an important partner in RCEP accounts for US$63 billion of this deficit. India’s exports to China were US$ 13 billion compared to imports of US$77 billion. The heavily skewed trade is compounded by the composition of traded products. A good portion of India’s exports to China comprises of ores and minerals, salt & sulphur whereas imports from China are majorly value-added products like electronics and capital goods.

The dominance of Japan, China and Korea (all three in RCEP) in exports of alkalies and PVC to India has been worrying the domestic industry. Japan and Korea already have FTAs with India which has seen an increase in exports to India. In the case of caustic soda, the combined share of Japan and China has increased from a little over 30% in 2015-16 to about 42% in 2016-17 and to over 60% on 2017-18. The Chinese capacity is over ten times India’s, with a huge exportable surplus. The large quantities of imports of caustic soda and soda ash have adversely affected capacity utilisation of these industries. AMAI has been conveying these concerns to the government.

Two closely watched developments that have a bearing on India’s trade are the escalation of trade tensions between the US and China, and the re-imposition of the US sanctions against Iran. While the US granted waiver in India’s imports of oil from Iran, its trade tensions with China has the potential to disrupt global trade dynamics. It is hoped that the tensions ease soon.

Continuing our series of articles on corrosion prevention in the alkali industry, this issue carries an article on designing plant and equipment for corrosion prevention.

AMAI has tied up with Argus Media for their upcoming “Argus Chlor-Alkali 2019” international conference to be held on 29-30 January 2019 at UK. The Indian market continues to generate interest globally and it is only appropriate that AMAI partnered for the conference. Details of the event are published in this issue.

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I. ARTICLES & FEATURES

Designing Plant and Equipment for Corrosion Prevention - Dr. S.K. Chakravorty, 2 Consultant (Plant Engineering)

Investor summits have been key to Gujarat’s growth 9

Union Minister Mr. Ananth Kumar Passes Away 11

Report on Safe Transportation of Hazardous Goods Training Program for Drivers at TGV SRAAC Limited – 13 A Report by B.B.Gantayat, Sr. G.M (Safety),TGV SRAAC Limited

Incident Report No.104: Incident of Chlorine Tonner Loaded Truck Trolley 14

Beacon-Messages for Manufacturing Personnel 16

II. NEWS DIGESTGeneral

Four petrochemical regions attract Rs 1.83 lakh crore investments, create 3 lakh jobs: Government 18

Essel to set up Rs. 700-cr. desalination plant in Gujarat 18

Govt. developing industrial park rating system to boost competitiveness 18

Modern bioenergy - the overlooked giant of the renewable energy field 19

India says ready to import more gas and oil from the US 19

Great Eastern Energy Corp announces shale gas exploration project in West Bengal 20

“Energy efficiency saves the environment and makes businesses more competitive” 20

Lanxess to invest `1,250 crore in India 20

Make-in-Odisha summit brings in investment promises of `4,20,000 cr 20

Focus on incentivising water use efficiency: Water Resources Secretary 21

US waiver on Iran oil gives government comfort till polls 21

Chemicals and Petrochemicals

D.V. Sadananda Gowda assumes charge of Chemicals Ministry 21

Environmental groups say dangerous levels of mercury found in skin creams sold on e-commerce sites 22

T.N. has potential to become chemical industry hub: officials 22

KLJ Group building new chloro-toluene derivative facility at Jhagadia 22

Member Units

Tata Chemicals launches Centre of Excellence to safeguard marine biodiversity 22

Tata Chem plans capex of Rs. 2,400 cr. 23

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

CONTENTS

III. NOTIFICATIONS/PRESS RELEASES/ MEMORANDAAnti Dumping Duty Notification dated 20th November, 2018 - Initiation of Sunset Review investigation concerning imports of PVC Suspension Grade Resin from China PR, Thailand and USA 25

IV. UPCOMING SEMINARS/CONFERENCES/WORKSHOPSArgus Media to organise Chlor-Alkali Conference 2019 on 29-30 January 2019 in London - AMAI is Supporting Partner 27

ENMORE to organise 13th International Chlor-Alkali and Vinyl Conference on 25-26 February 2019 in Kuala Lumpur, Malaysia - AMAI is Media Partner 28

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.

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Alkali Bulletin November 2018 | 1

What happened? What can you do?

This issue sponsored by

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

Small changes can cause a big consequence!

www.aiche.org/ccps

November 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 ccps_beacon@aiche.org 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.

Accumulation of small changes leads to an explosionIn September 2012, at an industrial site in Himeji, Japan, a 70 cu m (18,500 US gal) fixed roof acrylic acid (AA) tank

exploded, and a fire followed. There was one fatality, a fire-fighter. 36 people were injured – 2 policemen, 24 fire-fighters, and 10 plant workers. The tank was destroyed and nearby facilities were significantly damaged (Photo 1). There were no major impacts to the neighborhood and environment.

The tank provided intermediate storage between two distillation columns for purifying AA. Originally the tank had been used at full capacity. The contents were cooled and mixed by pumping from the bottom of the tank to the top. Later, the normal operating level was reduced to a level below the cooling coil. The contents were no longer recirculated to the top of the tank, but instead to a nozzle near the bottom that was also used to connect a level gauge (Drawing 2).

At the time of explosion, the plant was conducting a test of the downstream distillation column, which required stopping feed from this tank. The level of the tank gradually increased to its original operating level. Without recycle to the top of the tank, the AA above the cooling coils was not mixed and cooled. The temperature of the incoming AA was believed to be below the onset temperature for polymerization, and the AA contained polymerization inhibitor. However, the temperature in the tank increased, especially at the top. The tank eventually over pressurized and exploded.

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Originally the pipe feeding the tank was hot water jacketed to provide freeze protection, but this was changed to steam.

Removal of a steam trap made temperature control unreliable. The top layer was no longer mixed with cooler AA, and stayed

warm from incoming AA. There are two exothermic AA self-reactions – dimerization

and polymerization. Polymerization inhibitor does not stop the dimerization reaction. Experiments showed that heat from dimerization raised the temperature sufficiently to start a runaway polymerization reaction.

The hazard of heat from dimerization was not recognized, so recirculation to the top of tank was not resumed.

The tank had no temperature indicator. The first indication of a problem was observation of AA vapors escaping from the top vent on the tank.

Never make any changes to your plant, even changes you think are small, without following your plant Management of Change (MOC) procedures.

When you see any change in your plant, ask if there has been an MOC review. If there has been, and you were not informed of the change, tell your supervisor. You should always be informed of changes in your plant that impact your job.

If something is different from normal operation, confirm operating procedures or ask your supervisor what to do.

Accumulation of small changes can cause an incident with a big consequence. All small changes must be identified and the risk to the total system analyzed and adequately managed.

Courtesy of Nippon Shokubai

Photo 1: Destroyed AA TankReference: Nippon Shokubai Co., Ltd. Himeji Plant Explosion and Fire at Acrylic Acid Production Facility Investigation Report March 2013.

Drawing 2: Only the bottom of the tank was cooled, the liquid above became hot

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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: hkanand@ama-india.org; info@ama-india.org;website: www.ama-india.org

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