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1
FORM-I
For
PROPOSED DYES & DYES INTERMEDIATES,
PIGMENTS, SPECIALITY CHEMICALS &
PESTICIDE INTERMEDIATES UNIT
of
M/s. ALPS CHEMICALS PVT. LTD.
PLOT NO. DP-102/103, G.I.D.C. SAYKHA,
TALUKA: VAGRA, DISTRICT: BHARUCH, GUJARAT
Prepared by:
Aqua-Air Environmental Engineers Pvt. Ltd. (Pollution Control Consultants & Engineers)
Reg. Office: 403, Centre Point, Nr. Kadiwala School, Ring Road,
Surat – 395 002, Gujarat, India Fax: +91 261 2707273 / 3987273
Tel: + 91 261 3048586 / 2460854 / 2461241
E-mail: [email protected] Visit us at: www.aqua-air.co.in
2
APPENDIX I
FORM 1
(I) Basic Information
Sr.
No.
Item Details
1. Name of the Project/s M/s. Alps Chemicals Pvt. Ltd.
2. S. No. in the Schedule 5(f) & 5(b)
3. Proposed
capacity/area/length/tonnage to be
handled/command area/lease
area/number of wells to be drilled
Dyes
Acid Dyes = 500 MT/Month
Direct Dyes = 1,000 MT/Month
Reactive Dyes = 250 MT/Month
Disperse Dyes = 500 MT/Month
Solvent Dyes = 50 MT/Month
Dye Intermediates = 250 MT/Month
Pigments = 500 MT/Month
Specialty Chemicals = 200 MT/Month
Pesticide Intermediates = 100 MT/Month
Total Production = 3,350 MT/Month
4. New/Expansion/Modernization New
5. Existing capacity/area etc. Not Applicable
6. Category of project i.e. ‘A’ or ‘B’ ‘A’
7. Does it attract the general condition? If
yes, please specify.
Not Applicable
8. Does it attract the specific condition? If
yes, please specify.
Not Applicable
9. Location Plot No. DP-102/103, GIDC Saykha, Taluka: Vagra,
District: Bharuch, Gujarat.
Plot/Survey/Khasra No. Plot. No. DP-102/103
Village Saykha
Tehsil Vagra
District Bharuch
State Gujarat
10. Nearest railway station/airport along
with distance in kms.
Nearest Railway Station: Bharuch = 20 kms
Nearest Airport: Baroda = 75 kms
11. Nearest Town, city, District
Headquarters along with distance in
km
Nearest Town: Bharuch = 20 kms
Nearest District Head quarter: Bharuch = 20 kms
12. Village Panchayats, zilla parishad,
Municipal corporation, Local body
Village: Saykha, Taluka: Vagra, District: Bharuch,
Gujarat.
3
13. Name of the applicant M/s. Alps Chemicals Pvt. Ltd.
14. Registered address Plot No. 612, Phase 4, GIDC, Vatva, Ahmedabad-
382445
15. Address for correspondence:
Name Mr. Chinmay Bhuta
Designation (Owner/Partner/CEO) Director
Address Plot No. 612, Phase 4, GIDC, Vatva, Ahmedabad
Pin Code 382445
E-Mail [email protected]
Mobile No. +919998228999
Fax No. --
16. Details of Alternative Sites examined, if
any location of these sites should be
shown on a topo sheet.
No
17. Interlinked Projects No
18. Whether separate application of
interlinked project has been
submitted?
Not Applicable
19. If Yes, date of submission Not Applicable
20. If no., reason Not Applicable
21.
Whether the proposal involves
approval/clearance under: If yes,
details of the same and their status to
be given.
(a) The Forest (Conservation) Act,
1980?
(b) The Wildlife (Protection) Act,
1972?
Not Applicable, as the project is located in notified
industrial estate.
22. Whether there is any Government
order/policy relevant/relating to the
site?
No
23. Forest land involved (hectares) No
24. Whether there is any litigation pending
against the project and/or land in
which the project is propose to be set
up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if
any and its relevance with the project.
No
4
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which
will cause physical changes in the locality (topography, land use, changes in water
bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes
/No?
Details thereof (with approximate quantities
/ rates, wherever possible) with source of
information data
1.1 Permanent or temporary change in
land
use, land cover or topography
including
increase in intensity of land use (with
respect to local land use plan)
No Proposed Project is within Saykha GIDC
Estate.
1.2 Clearance of existing land, vegetation
and buildings?
Yes Minor site clearance activities shall be carried
out to clear shrubs and weed.
1.3 Creation of new land uses? No --
1.4 Pre-construction investigations e.g.
bore houses, soil testing?
No --
1.5 Construction works? Yes Plant layout is attached as Annexure-1.
1.6 Demolition works? No --
1.7
Temporary sites used for construction
workers or housing of construction
workers?
No --
1.8 Above ground buildings, structures or
Earthworks including linear structures,
cut and fill or excavations
Yes Plant layout is attached as Annexure-1.
1.9
Underground works including mining
or tunneling?
No --
1.10 Reclamation works? No --
1.11 Dredging? No --
1.12 Offshore structures? No --
1.13 Production and manufacturing Yes List of Products is attached as Annexure-2
and manufacturing process is attached as
Annexure-3.
1.14 Facilities for storage of goods or
materials?
Yes Dedicated storage area for storage of Raw
Materials and finished products, solvents, etc.
shall be provided.
1.15
Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes Effluent Treatment Plant & MEE system will
be installed to treat effluent so as to achieve
the GPCB norms.
Details of Effluent Treatment Plant are
attached as Annexure-5.
5
Details of Hazardous waste management and
disposal is attached as Annexure-6.
1.16
Facilities for long term housing of
operational workers?
No --
1.17 New road, rail or sea traffic during
construction or operation?
No --
1.18 New road, rail, air waterborne or
other airports etc?
No --
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No --
1.20 New or diverted transmission lines or
pipelines?
No --
1.21
Impoundment, damming, converting,
realignment or other changes to the
hydrology of watercourses or
aquifers?
No --
1.22 Stream crossings? No --
1.23
Abstraction or transfers or the water
form ground or surface waters?
Yes No ground water shall be used. The
requirement of raw water will meet through
Saykha GIDC Authority.
1.24
Changes in water bodies or the land
surface affecting drainage or run-off?
No --
1.25
Transport of personnel or materials for
construction, operation or
decommissioning?
Yes Through hired Services.
1.26 Long-term dismantling or
decommissioning or restoration
works?
No --
1.27 Ongoing activity during
decommissioning which could have
an impact on the environment?
No --
1.28
Influx of people to an area in either
temporarily or permanently?
No This is a newly developed Industrial Area and
due to project, 150 people shall be employed
for operation.
1.29 Introduction of alien species? No --
1.30 Loss of native species of genetic
diversity?
No --
1.31 Any other actions? No --
6
2. Use of Natural resources for construction or operation of the Project (such as land, water,
materials or energy, especially any resources which are non-renewable or in short supply):
Sr.
No
Information/checklist confirmation Yes/
No?
Details there of (with approximate
quantities/rates, wherever possible) with
source of information data
2.1 Land especially undeveloped or
agriculture land (ha)
No --
2.2 Water (expected source & competing
users) unit: KLD
Yes Water requirement will meet through
Saykha GIDC Authority. Water balance is
given as Annexure-4.
2.3 Minerals (MT) No --
2.4
Construction material -stone,
aggregates, sand / soil (expected
source MT)
Yes Company shall use Sand, Stone, Cement and
Structural Steel for Construction as required.
2.5 Forests and timber (source - MT) No --
2.6
Energy including electricity and fuels
source, competing users Unit: fuel
(MT), energy (MW)
Yes Power Requirement:
Power required from DGVCL is 1000 KVA.
DG set = 1000 KVA (Stand by)
Fuel Requirement:
Coal = 50 T/Day
Diesel/Gas = 8400 L/Day
2.7 Any other natural resources
(use appropriates standard units)
No --
3. Use, storage, transport, handling or production of substances or materials, which could be
harmful to human health or the environment or raise concerns about actual or perceived
risks to human health.
Sr.
No.
Information / Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates wherever possible) with
source of information data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
Yes
Please refer Annexure-8.
3.2 Changes in occurrence of disease or
affect disease vectors (e.g. insect or
water borne diseases)
No --
3.3 Affect the welfare of people e.g. by
changing living conditions?
No --
Vulnerable groups of people who No --
7
3.4
could be affected by the project e.g.
hospital patients, children, the elderly
etc.,
3.5 Any other causes No --
4. Production of solid wastes during construction or operation or decommissioning
(MT/month)
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible) with
source of information data
4.1 Spoil, overburden or mine wastes No --
4.2
Municipal waste (domestic and or
commercial wastes) No --
4.3
Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Please refer Annexure-6.
4.4 Other industrial process wastes Yes Please refer Annexure-6.
4.5 Surplus product No --
4.6
Sewage sludge or other sludge from
effluent treatment
Yes Please refer Annexure-6.
4.7 Construction or demolition wastes No --
4.8 Redundant machinery or equipment No --
4.9 Contaminated soils or other materials No --
4.10 Agricultural wastes No --
4.11 Other solid wastes No --
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
5.1 Emissions from combustion of fossil
fuels From stationary or mobile
sources
Yes Details of flue & process gas emission are
attached as Annexure-7.
5.2 Emissions from production processes Yes Details of emission from process are
attached as Annexure-7.
5.3 Emissions from materials handling
including storage or transport
Yes All liquid raw materials shall be procured in
bulk tankers and shall be transferred
through a closed circuit pipe lines by
pumps.
Solid raw material shall be handled in
closed charging rooms with proper
8
ventilation and charged through close
pipeline into reactors.
5.4 Emissions from construction
activities including plant and
equipment
No --
5.5
Dust or odors from handling of
materials including construction
materials, sewage and waste
No --
5.6 Emissions from incineration of waste No --
5.7 Emissions from burning of waste in
open air (e.g. slash materials,
construction debris)
No --
5.8 Emissions from any other sources No --
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details there of (with approximate
Quantities /rates, wherever possible) With
source of source of information data
6.1
From operation of equipment e.g.
engines, ventilation plant, crushers
Yes Acoustic enclosures shall be provided for DG
set.
6.2 From industrial or similar processes Yes All machinery / equipment shall be well
maintained, shall have proper foundation
with anti vibrating pads wherever applicable
and noise levels within permissible limits.
Acoustic enclosures shall be provided for DG
set.
6.3 From construction or demolition No --
6.4 From blasting or piling No --
6.5 From construction or operational
traffic No
--
6.6 From lighting or cooling systems No --
6.7 From any other sources No --
9
7. Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible) with
source of information data
7.1
From handling, storage, use or
spillage of hazardous materials
Yes All the raw material shall be stored
separately in designated storage area and
safely. Dyke walls shall be provided around
raw materials storage tanks for containing
any liquid spillage.
Other materials shall be stored in bags /
drums on pallets with concrete flooring and
no spillage is likely to occur.
Please refer Annexure-8.
7.2
From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
No Sewage shall be treated in Septic Tank &
Soak Pit.
7.3
By deposition of pollutants emitted
to air into the land or into water
No --
7.4 From any other sources No --
7.5 Is there a risk of long term build up of
pollution in the environment from
these sources?
No
--
8. Risks of accident during construction or operation of the Project, which could affect
human health or the environment:
Sr.
No
Information/Checklist confirmation
Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible) with
source of information data
8.1 From explosions, spillages, fires, etc.
from storage, handling, use or
production of hazardous substances
Yes The risk assessment will be carried out and
all mitigate measures shall be taken to avoid
accidents.
8.2 From any other causes No --
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No --
10
9. Factors which should be considered (such as consequential development) which could lead
to environmental effects or the potential for cumulative impacts with other existing or
planned activities in the locality
Sr.
No.
Information/Checklist confirmation Yes/
No?
Details thereof (with approximate
quantities / rates, wherever possible) with
source of information data
9.1 Lead to development of supporting
facilities, ancillary development or
development stimulated by the
project which could have impact on
the environment e.g.:
* Supporting infrastructure (roads,
power supply, waste or waste water
treatment, etc.)
• housing development
• extractive industries
• supply industries
• other
Yes Site is located in Saykha GIDC, shall have
entire required infrastructure.
This industrial zone is having existing road
infrastructure, power supply are to be
utilized.
Local people will be employed and no
housing is required.
Please refer Annexure–9.
9.2
Lead to after-use of the site, which
could have an impact on the
environment
No --
9.3 Set a precedent for later
developments No --
9.4 Have cumulative effects due to
proximity to Other existing or planned
projects with similar effects
No --
11
(III) Environmental Sensitivity
Sr.
No.
Information/Checklist confirmation Name /
Identity
Aerial distance (within 25 km). Proposed
Project Location Boundary.
1 Areas protected under international
conventions national or local
legislation for their ecological,
landscape, cultural or other related
value
Yes Site is located in Saykha GIDC, Village:
Saykha, Taluka: Vagra, District: Bharuch,
Gujarat.
2 Areas which are important or sensitive
for Ecological reasons - Wetlands,
watercourses or other water bodies,
coastal zone, biospheres, mountains,
forests
No Site is located in Saykha GIDC, Village:
Saykha, Taluka: Vagra, District: Bharuch,
Gujarat.
Forest area of Rajpipla is 75 kms away.
3 Areas used by protected, important or
sensitive species of flora or fauna for
breeding, nesting, foraging, resting,
over wintering, migration
No Site is located in Saykha GIDC, Village:
Saykha, Taluka: Vagra, District: Bharuch,
Gujarat.
4 Inland, coastal, marine or
underground waters
Yes Arabian Sea = 35 kms
River Narmada = 12 kms
5 State, National boundaries No --
6 Routes or facilities used by the public
for to recreation or other tourist,
pilgrim areas.
No --
7 Defense installations No --
8 Densely populated or built-up area Yes Bharuch city = 5 lakh population
9 Areas occupied by sensitive man-
made land community facilities)
No --
10 Areas containing important, high
quality or scarce resources (ground
water resources, surface resources,
forestry, agriculture, fisheries,
tourism, tourism, minerals)
Yes
The project being in notified industrial area
does not affect agricultural land.
11 Areas already subjected to pollution
or environmental damage. (those
where existing legal environmental
standards are exceeded)
Yes Site is located in Saykha GIDC, Village:
Saykha, Taluka: Vagra, District: Bharuch,
Gujarat.
12 Are as susceptible to natural hazard
which could cause the project to
present environmental problems
(earthquake s, subsidence ,landslides,
flooding erosion, or extreme or
adverse climatic conditions)
No --
12
13
ANNEXURES
1 PLANT LAYOUT
2 LIST OF PRODUCTS WITH PRODUCTION CAPACITY
3 BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH
FLOW DIAGRAM
4 WATER CONSUMPTION AND WASTEWATER GENERATION
5 DESCRIPTION OF EFFLUENT TREATMENT PLANT AND MEE SYSTEM
6 DETAILS OF SOLID HAZARDOUS WASTE MANAGEMENT AND DISPOSAL
7 DETAILS OF FLUE AND PROCESS GAS EMISSION
8 DETAILS OF HAZARDOUS CHEMICAL STORAGE FACILITY
9 SOCIO ECONOMIC IMPACTS
10 PROPOSED DRAFT TERMS OF REFERENCE
14
ANNEXURE: 1
_____________________________________________________________________________
PLANT LAYOUT
15
ANNEXURE: 2
________________________________________________________________________
LIST OF PRODUCTS WITH PRODUCTION CAPACITY
Sr. No. Name of Product Proposed Capacity
Dyes
Acid Dyes
500 MT/Month
1 Acid Black 1
2 Acid Black 52
3 Acid Black 63
4 Acid Black 71
5 Acid Black 84
6 Acid Black 107
7 Acid Black 172
8 Acid Blue 158
9 Acid Brown 75
10 Acid Brown 161
11 Acid Brown 165
12 Acid Brown 355
13 Acid Brown 425
14 Acid Brown 432
15 Acid Brown 434
16 Acid Green 104
17 Acid Orange 74
18 Acid Orange 142
19 Acid Red 97
20 Acid Red 357
21 Acid Violet 90
22 Acid Yellow 42
23 Acid Yellow 59
24 Acid Yellow 194
Direct Dyes
1 Direct Black 40
2 Direct Black 168
3 Direct Blue 71
4 Direct Green 26
5 Direct Orange 15
6 Direct Orange 118
16
7 Direct Red 81 1000 MT/Month
8 Direct Red 239
9 Direct Red 254
10 Direct Violet 9
11 Direct Violet 35
12 Direct Yellow 11
13 Direct Yellow 44
Reactive Dyes
1 Reactive Black B
250 MT/Month
2 Reactive Red-195
3 Reactive Golden Yellow-145
4 Reactive Golden Yellow Her
5 Reactive Orange H2R
Reactive Blue
6 Blue 3R
7 Blue F4R
8 Blue HERD
9 Blue 221
10 Blue HEGN
11 Blue LFNG
12 Blue BF
13 Blue BFN
14 Blue 2B
Reactive Golden Yellow
15 Golden Yellow R
16 Golden Yellow RNL
Reactive Navy Blue
17 Navy Blue 2G
18 Navy Blue XLE
19 Navy Blue RGB
Disperse Dyes
1. Azo Dyes
a. Yellow Dyes
b. Orange Dyes
c. Red Dyes
d. Blue Dyes
e. Violet Dyes
17
f. Green Dyes
500 MT/Month
g. Black Dyes & Mixtures
2. Anthraquinones/Condensed Dyes
a. Yellow Dyes
b. Orange Dyes
c. Red Dyes
d. Blue Dyes
e. Violet Dyes
f. Green Dyes
g. Black Dyes & Mixtures
3. Cyanation Dyes
a. Yellow Dyes
b. Orange Dyes
c. Red Dyes
d. Blue Dyes
e. Violet Dyes
f. Green Dyes
g. Black Dyes & Mixtures
Solvent Dyes
1 Solvent Blue 35
50 MT/Month
2 Solvent Blue 104
3 Solvent Blue 122
4 Solvent Green 3
5 Solvent Orange 60
6 Solvent Orange 86
7 Solvent Red 52
8 Solvent Red 135
9 Solvent Red 168
10 Solvent Red 195
11 Solvent Red 207
12 Solvent Violet 13
13 Solvent Violet 14
14 Solvent Yellow 33
15 Solvent Yellow 157
16 Solvent Yellow 163
17 Solvent Orange 58
18 Solvent Red 127
18
19 Solvent Black 27
Dye Intermediates
1 H Acid
250 MT/Month
2 J Acid
3 6 Nitro 1-Diazo, 2-Naphthol, 4-Sulphonic
Acid
4 Vinyl Sulphone
5 Pyrazolones
a. 2:5 Dichloro 4 Sulpho Phenyl 3 Methyl 5
Pyrazolone
b. 2 Chloro 5 Sulphophenyl 3 Methyl 5
Pyrazolone
c. 1,3 Sulpho Phenyl 3 Methyl 5 Pyrazolone
d. 1,4 Sulpho Phenyl 3 Methyl 5 Pyrazolone
e. 1:3 Phenyl Methyl 5 Pyrazolone
Pigments
1 Activated CPC Blue
500 MT/Month
2 CPC Blue
3 Alpha Blue (15:0 and 15:1)
4 Pigment Beta Blue (15:3)
5 Pigment Beta Blue (15:4)
6 Copper Phthalocyanine Pigment Green-7
7 Pigment Violet 23
8 Pigment Red 122
9 Pigment Violet 19
10 Solsperse 5000
11 Carbazole
Speciality Chemicals
1 2,4-Dichloro Phenyl Acetic Acid
200 MT/Month
2 2,4-Dichloro Phenyl Acetyl Chloride
3 2,4,6-Trimethyl Phenyl Acetyl Chloride
4 2,3,4,5-Tetrachloro Benzoyl Chloride
5 3,4,5 Trimethoxy Benzyl Chloride
Pesticide Intermediates
1. 2-Amino Benzo Nitrile
2. 2-Amino-5-Bromo Benzo Nitrile
19
3. 2,4,6-Trimethyl Benzaldehyde 100 MT/Month
4. Indoline
5. 5-(1-Carboxy Ethyl)-2-(Phenylthio)Phenyl
Acetic Acid
TOTAL 3350 MT/Month
20
LIST OF RAW MATERIALS
Sr. No. Product Name MT/MT
Acid Dyes
Acid Black 1
1 H-Acid 0.337
2 Caustic lye 0.096
3 PNA 0.150
4 Hydrochloric acid, 30% 0.650
5 Aniline 0.097
6 Sodium Nitrite 0.158
7 Water 1.100
8 Ice 2.400
9 Soda ash 0.200
Acid Black 52
1 6-Nitro 0.446
2 Beta Napthol 0.214
3 NaOH 0.321
4 Basic Chromium Sulphate 0.268
5 Steam 2.160
6 Water 1.800
7 Ice 1.690
8 Salicylic Acid 0.055
Acid Black 63
1 5-NAP 0.500
2 Hydrochloric acid, 30% 1.140
3 Ice 2.000
4 Sodium Nitrite 0.230
5 Beta Napthol 0.478
6 Caustic lye, 48% 0.800
7 Chrome Salam 1.500
8 Water 2.000
Acid Black 71
1 Sodium Bi-sulphite 0.357
2 Formaldehyde 0.250
3 Gamma Acid 0.365
4 J-Acid 0.064
5 Soda ash 0.070
6 Sodium Picramate 0.384
7 Sodium Dichromate 0.140
8 Sulphuric acid, 98% 0.108
9 Sorbitol 0.060
10 Sodium Formate 0.066
21
11 Hydrochloric acid, 30% 1.000
12 Sodium Nitrite 0.123
13 Water 2.000
14 Ice 1.500
Acid Black 84
1 Sodium bi-sulphite 0.365
2 Formaldehyde 0.245
3 Gamma acid 0.473
4 4NAPSA 0.431
5 Hydrochloric acid 30% 0.122
6 Sodium Nitrite 0.130
7 Soda ash 0.422
8 Ice 4.200
9 Water 3.700
Acid Black 107
1 Sodium Picramate 0.227
2 Beta Napthol 0.160
3 Hydrochloric Acid 0.360
4 Caustic Flakes 0.075
5 Sodium Nitrite 0.075
6 Ice 1.00
7 6-Nitro 0.360
8 Beta Napthol 0.183
9 Caustic Lye 22.50
10 Chromuim Formate 0.325
11 Sulphuric Acid 0.120
12 Oxalic Acid 0.045
13 Salicylic Acid 0.033
14 Water 1.150
Acid Black 172
1 6-Nitro 0.446
2 Beta Napthol 0.214
3 NaOH 0.321
4 Basic Chromium Sulphate 0.196
5 Water 1.20
6 Ice 1.50
Acid Blue 158
1 Naptha Sultan 0.489
2 Caustic potash 0.555
3 Ammonium Sulphate 0.066
4 1-2-4 Diazo acid 0.555
5 Sodium Bi-chromate 0.445
6 Sulphuric acid, 98% 0.333
22
7 Sorbitol 0.213
8 Sodium Formate 0.206
9 Ice 1.80
10 Water 1.80
11 Soda ash 0.10
Acid Brown 75
1 H-Acid 0.240
2 Soda ash 0.050
3 Sodium Nitrite 0.176
4 Hydrochloric acid, 30% 1.230
5 Resorcinol 0.084
6 Caustic lye, 48% 0.550
7 Picramic acid 0.168
8 PNA 0.125
9 Water 1.150
10 Ice 3.00
Acid Brown 161
1 Anthranilic acid 0.154
2 Sulphuric acid, 98% 0.140
3 Formaldehyde, 32% 0.061
4 Sodium Nitrite 0.156
5 Resorcinol 0.120
6 Caustic lye, 48% 0.234
7 Sulphanilic acid 0.189
8 Hydrochloric acid 0.412
9 CuSO4. 5H2O 0.284
10 Water 2.450
11 Ice 3.900
Acid Brown 165
1 H-Acid 0.076
2 Caustic lye, 48% 0.0200
3 Sodium Nitrite 0.144
4 Hydrochloric acid, 30% 1.012
5 Resorcinol 0.070
6 Picramic acid 0.114
7 Paranitro Aniline 0.112
8 Water 2.350
9 Ice 3.200
10 Ferric chloride 0.261
Acid Brown 355
1 4-NAPSA 0.333
2 PMP 0.264
3 Hydrochloric acid, 30% 0.256
23
4 Sodium Nitrite 0.100
5 Caustic lye, 48% 0.420
6 Sodium Acetate 0.128
7 Potassium chloride 1.438
8 6-Nitro-1-Diazo acid 0.375
9 Beta Napthol 0.188
10 BCS, 16% 0.437
11 Salicylic acid 0.026
12 Sodium Formate 0.106
13 Water 4.515
14 Ice 3.500
15 Steam condensate 2.500
Acid Brown 425
1 Anthranilic acid 0.170
2 O.T.5 SA 0.250
3 Sodium Nitrite 0.180
4 Hydrochloric acid, 30% 0.700
5 Resorcinol 0.150
6 Soda ash 0.350
7 Salicylic acid 0.188
8 Caustic Flakes 0.057
9 Chromium Fluoride 0.128
10 Liq. Ammonia 0.078
11 Ice 2.000
12 Water 1.800
Acid Brown 432
1 Anthranilic acid 0.170
2 Resorcenol 0.150
3 Lorrent acid 0.285
4 Hydrochloric acid, 30% 0.970
5 Sodium Nitrite 0.175
6 Soda ash 0.350
7 Salicylic acid 0.188
8 Caustic soda Flakes 0.057
9 Chromium Fluoride 0.128
10 Liq. Ammonia 0.078
11 Ice 2.300
12 Water 2.300
Acid Brown 434
1 Sodium Picrame 0.296
2 Resorcinol 0.145
3 Mix cleave acid 0.336
4 Hydrochloric acid, 30% 0.925
24
5 Sodium Nitrite 0.210
6 Sulfamic acid 0.002
7 Caustic flakes 0.140
8 Caustic lye 0.189
9 Ferrous sulphate 0.260
10 Water 1.800
11 Ice 3.000
Acid Green 104
1 Sodium Picramate 0.405
2 Dahl's Acid 0.419
3 Sodium Nitrite 0.138
4 Hydrochloric acid, 30% 0.650
5 Ice 3.350
6 Caustic Flakes 0.216
7 Cobalt Sulphate, 20% 0.295
8 Water 3.250
Acid Orange 74
1 4-NAPSA 0.530
2 Hydrochloric acid, 30% 0.600
3 Sodium Nitrite 0.170
4 PMP 0.425
5 Caustic lye, 48% 0.553
6 Sodium Acetate 0.205
7 Ice 2.500
8 Salicylic acid 0.060
9 BCS, 16% 0.900
10 Water 2.200
Acid Orange 142
1 Water 1.980
2 Ice 2.750
3 4NAPSA 0.363
4 Hydrochloric acid 0.096
5 Sodium Nitrite 0.116
6 Sulphamic acid 0.002
7 PMP 0.290
8 Caustic lye, 48% 0.152
9 Sodium Acetate 0.140
10 Sodium dichromate 0.136
11 Sorbitol 0.065
12 Sodium Formate 0.063
13 Salicylic acid 0.039
Acid Red 97
1 BDSA 0.455
25
2 Beta Napthol 0.387
3 Hydrochloric acid, 30% 1.230
4 Sodium Nitrite 0.185
5 Caustic Flakes 0.108
6 Water 2.625
7 Ice 1.500
Acid Red 357
1 6NAPSA 0.358
2 Sodium Nitrite 0.109
3 PMP 0.280
4 Caustic lye, 48% 0.164
5 Sodium Acetate 0.253
6 Green solution 0.450
7 Water 2.350
8 Ice 1.200
9 Salicylic acid 0.018
Acid Violet 90
1 1-2-4 Diazo acid 0.400
2 PMP 0.304
3 Ammonium Sulphate 0.045
4 Salicylic acid 0.054
5 BCS, 16% 0.266
6 Caustic lye, 48% 0.378
7 Water 3.200
Acid Yellow 42
1 BDSA 0.360
2 PMP 0.410
3 Hydrochloric acid, 30% 1.000
4 Sodium Nitrite 0.150
5 Caustic Flakes 0.280
6 Sodium Acetate 0.460
7 Water 2.300
8 Ice 4.750
Acid Yellow 59
1 Anthranilic acid 0.150
2 PMP 0.194
3 BCS, 16% Cr. 0.208
4 Formic acid, 85% 0.450
5 Ice 1.500
6 Sodium Nitrite 0.078
7 Hydrochloric acid, 30% 0.250
8 Caustic lye, 48% 0.550
9 Water 1.050
26
10 Dispersing agent 0.600
Acid Yellow 194
1 4NAPSA 0.476
2 AAA 0.381
3 Sodium Nitrite 0.148
4 Hydrochloric acid, 30% 0.295
5 Cobalt Sulphate, 20% 0.476
6 Caustic lye, 48% 0.390
7 Ice 2.600
8 Water 2.600
Direct Dyes
Direct Black 40
1 PAA 0.150
2 Gamma acid 0.465
3 Mix Cleave acid 0.223
4 Hydrochloric acid, 30% 2.500
5 Sodium Nitrite 0.215
6 Caustic lye 0.263
7 Soda ash 0.475
8 Sulphamic acid 0.014
9 Caustic Flakes 0.350
10 Water 2.050
11 Ice 4.000
Direct Black 168
1 FC Acid 0.307
2 H-Acid 0.307
3 Sodium Nitrite 0.236
4 Hydrochloric acid, 30% 0.953
5 Aniline Oil 0.093
6 Soda ash 0.561
7 MPD 0.114
8 Ice 3.700
9 Water 1.900
Direct Blue 71
1 C-Acid 0.336
2 Napthyl Amine 0.170
3 Mix Cleave Acid 0.220
4 Hydrochloric acid, 30% 1.050
5 Sodium Nitrite 0.300
6 J-Acid 0.260
7 Caustic soda lye, 48% 0.050
8 Caustic Flakes 0.050
9 Water 2.600
27
10 Ice 3.900
Direct Green 26
1 BHK Acid 0.434
2 H-Acid 0.234
3 Hydrochloric acid, 30% 0.900
4 Sodium Nitrite 0.052
5 Caustic lye, 48% 0.057
6 Soda ash 0.177
7 PAPA's acid 0.154
8 Cyanuric chloride 0.110
9 Reaction oil 0.015
10 Aniline Oil 0.086
11 Ice 2.900
12 Water 3.600
Direct Orange 15
1 PNTOSA 0.818
2 Caustic Flakes 0.750
3 Formaldehyde, 35% 0.850
4 Dichlone 0.025
5 Spent Acid, 50% 1.800
6 Ice 1.000
7 Water 1.500
Direct Orange 118
1 p-Cresidine-o-Sulphonic acid 0.231
2 Hydrochloric acid, 30% 0.350
3 Sodium Nitrite 0.087
4 Sodium bi-carbonate 0.475
5 J-Acid Urea 0.315
6 Water 3.000
7 Ice 3.500
Direct Red 81
1 PAABSA 0.308
2 Caustic lye, 48% 0.210
3 Sodium Nitrite 0.083
4 Hydrochloric acid, 30% 0.308
5 J-Acid 0.279
6 Benzoyl Chloride 0.257
7 Sodium Acetate 0.308
8 Sodium bi-carbonate 0.308
9 Soda ash 0.062
10 Water 2.800
11 Ice 2.000
Direct Red 239
28
1 Browner's acid 0.250
2 caustic lye, 48% 0.100
3 Sodium Nitrite 0.095
4 Hydrochloric acid, 30% 0.550
5 J-Acid Urea 0.292
6 Soda bi-carb, 25% 0.250
7 Soda ash, 20% solu. 0.100
8 Water 2.500
9 Ice 3.500
Direct Red 254
1 PAABSA 0.406
2 Caustic lye 0.200
3 Hydrochloric acid 0.874
4 Sodium Nitrite 0.102
5 J-Acid 0.351
6 Soda ash 0.300
7 Water 2.700
8 Ice 4.700
Direct Violet 9
1 Sulphanilic acid 0.180
2 p-Cresidine 0.150
3 n-Phenyl J Acid 0.327
4 Hydrochloric acid, 30% 0.800
5 Sodium Nitrite 0.145
6 Sodium Acetate 0.200
7 Caustic lye, 48% 0.298
8 Soda ash 0.175
9 Ice 3.800
10 Water 1.900
Direct Violet 35
1 C-Acid 0.331
2 p-Cresidine 0.150
3 n-Phenyl-J Acid 0.327
4 Hydrochloric acid, 30% 0.850
5 Sodium Nitrite 0.147
6 Sodium Acetate 0.200
7 Caustic lye, 48% 0.298
8 Soda ash 0.175
9 Ice 2.500
10 Water 2.000
Direct Yellow 11
1 PNTOSA 0.290
2 Caustic Flakes 0.213
29
3 Nitrobenzene 0.016
4 Tri-Butyl Amine 0.021
5 Di-Ethanol Amine 0.160
6 Sulphuric Acid-70% 0.500
7 Water 3.250
8 Steam 0.150
Direct Yellow 44
1 MAMA'S Acid 0.787
2 BIS (Trichloro Methyl) Carbonate 0.375
3 Sodium Bi-Carbonate 0.625
4 Water 6.500
Reactive Dyes
Reactive Black B
1 Vinyl Sulphone 0.400
2 HCl 0.100
3 Sodium Nitrite 0.100
4 H Acid 0.230
5 Sodium BI Carbonate 0.230
6 Salt 0.140
Reactive Red-195
1 Vinyl Sulphone 0.240
2 NaHCO3 0.210
3 Cynauric Chloride 0.150
4 H Acid 0.270
5 Na2CO3 0.090
6 STA Diazo 0.290
7 NaCl 0.050
Reactive Golden Yellow-145
1 K Acid 0.390
2 Sodium Nitrite 0.070
3 HCl 0.080
4 MUA 0.160
5 Cynauric Chloride 0.190
6 VS 0.290
Reactive Golden Yellow HER
1 K Acid 0.390
2 Sodium Nitrite 0.070
3 HCl 0.080
4 MUA 0.160
5 Cynauric Chloride 0.190
6 DASDA 0.350
Reactive Orange H2R
1 NMJ Acid 0.290
30
2 Sodium Hydroxide 0.050
3 Acetic Anhydride 0.120
4 Sulpho Tobias Acid 0.350
5 HCl 0.080
6 Sodium Nitrite 0.080
7 NaHCO3 0.190
8 NaOH 0.050
9 Cyanuric Chloride 0.210
10 NH4OH 0.040
Reactive Blue
Blue 3R
1 H Acid 0.032
2 Antifoam 0.005
3 Sulfamic Acid 0.001
4 SPD Oil 0.002
5 DDC Oil 0.010
6 Soda Ash 0.045
7 Sodium Sulphate 0.484
8 Sodium Bi Carbonate 0.041
9 Sodium Nitrite 0.049
10 Copper Sulphate 0.249
11 Caustic Soda 0.067
12 HCl 0.037
13 DMAVS 0.234
14 Acetic Anhydride 0.146
Blue F4R
1 Cynauric Chloride 0.064
2 Oil HS 0.001
3 4 ADPSA 0.082
4 H Acid 0.100
5 Vinyl Sulphone 0.107
6 Antifoam 0.004
7 Sulfamic Acid 0.001
8 SPD Oil 0.002
9 DDC Oil 0.001
10 Soda Ash 0.113
11 Sodium Sulphate 0.600
12 Sodium Nitrite 0.021
13 Caustic Soda 0.025
14 HCl 0.125
Blue HERD
1 Cynauric Chloride 0.144
2 Oil HS 0.003.
31
3 6 AAPSA 0.106
4 4 Sulpho Hydrogen 0.133
5 Antifoam 0.003
6 Sulfamic Acid 0.001
7 SPD Oil 0.003
8 DDC Oil 0.010
9 Soda Ash 0.095
10 Sodium Sulphate 0.280
11 Sodium Bi Carbonate 0.120
12 Sodium Nitrite 0.030
13 Copper Sulphate 0.112
14 Caustic Soda 0.257
15 HCl 0.199
16 PPDDSA 0.069
Blue 221
1 Cynauric Chloride 0.109
2 Oil HS 0.002
3 6 AAPSA 0.171
4 NEPBE 0.178
5 4 Sulpho Hydrogen 0.231
6 Antifoam 0.005
7 Sulfamic Acid 0.001
8 SPD Oil 0.003
9 DDC Oil 0.010
10 Soda Ash 0.125
11 Sodium Sulphate 0.285
12 Sodium Bi carbonate 0.212
13 Sodium Nitrite 0.047
14 Copper Sulphate 0.191
15 Caustic Soda 0.308
16 HCl 0.363
Blue HEGN
1 Cynauric Chloride 0.156
2 Oil HS 0.003
3 Aniline 2,4 Di Sulpho Acid 0.206
4 Antifoam 0.005
5 Blue 198 Base 0.200
6 SPD Oil 0.003
7 DDC Oil 0.020
8 Soda Ash 0.173
9 Sodium Sulphate 0.427
10 Sodium Bi Carbonate 0.076
Blue LFNG
32
1 Cynauric Chloride 0.176
2 Oil HS 0.003
3 Aniline 2,5 Di Sulpho Acid 0.239
4 Meta Base Ester 0.296
5 Antifoam 0.005
6 Blue 198 Base 0.250
7 SPD Oil 0.005
8 DDC Oil 0.010
9 Soda Ash 0.200
10 Sodium Sulphate 0.037
11 Sodium Bi Carbonate 0.270
12 Caustic Soda 0.032
13 HCl 0.100
Blue BF
1 Cynauric Chloride 0.078
2 Oil HS 0.001
3 H Acid 0.120
4 Vinyl Sulphone 0.117
5 STA 0.119
6 Antifoam 0.002
7 Sulfamic Acid 0.001
8 SPD Oil 0.003
9 DDC Oil 0.010
10 Soda Ash 0.151
11 Sodium Sulphate 0.290
12 Sodium Nitrite 0.055
13 Caustic Soda 0.0015
14 HCl 0.285
Blue BFN
1 Cynauric Chloride 0.100
2 Oil HS 0.002
3 H Acid 0.136
4 MPDSA 0.100
5 Meta Base Ester 0.149
6 STA 0.155
7 Antifoam 0.005
8 Sulfamic Acid 0.001
9 SPD Oil 0.004
10 Soda Ash 0.130
11 Sodium Sulphate 0.240
12 Sodium Bi carbonate 0.088
13 Sodium Nitrite 0.070
14 Caustic Soda 0.045
33
15 HCl 0.062
Blue 2B
1 4 Sulpho Hydrogen 0.364
2 Antifoam 0.005
3 Sulfamic Acid 0.001
4 Sulpho OAVS 0.453
5 SPD Oil 0.010
6 Soda Ash 0.113
7 Sodium Bi carbonate 0.287
8 Sodium Nitrite 0.079
9 Copper Sulphate 0.331
Reactive Golden Yellow
Golden Yellow R
1 MPDSA 0.312
2 Vinyl Sulphone 0.467
3 Antifoam 0.005
4 SPD oil 0.005
5 Sulfamic Acid 0.001
6 Sodium Bi Carbonate 0.140
7 HCl 0.103
8 Caustic Lye 0.066
9 Sodium Nitrite 0.070
Golden Yellow RNL
1 A. MPDSA 0.238
2 Vinyl Sulphone 0.298
3 Antifoam 0.004
4 SPD oil 0.004
5 DDC Oil 0.020
6 Sulfamic Acid 0.001
7 HCl 0.237
8 Caustic Lye 0.162
9 Sodium Sulphate 0.176
10 Sodium Nitrite 0.072
Reactive Navy Blue
Navy Blue 2G
1 H Acid 0.196
2 2,5 DMAVS 0.222
3 Vinyl Sulphone 0.176
4 Antifoam 0.006
5 Sulfamic Acid 0.001
6 SPD Oil 0.004
7 DDC Oil 0.020
8 Caustic Lye 0.027
34
9 Sodium Bicarbonate 0.136
10 Sodium Nitrite 0.088
11 HCl 0.157
12 Sodium Sulphate 0.230
Navy XLE
1 H Acid 0.116
2 Antifoam 0.010
3 Sulfamic Acid 0.002
4 MPDSA 0.175
5 Cynauric Chloride 0.175
6 Oil HS 0.002
7 Ortho Toluidine Sul. Acid 0.175
8 SPD Oil 0.004
9 Caustic Lye 0.070
10 Sodium Bicarbonate 0.291
11 Sodium Nitrite 0.065
12 HCl 0.297
Navy RGB
1 H Acid 0.204
2 Vinyl Sulphone 0.193
3 Antifoam 0.005
4 Sulfamic Acid 0.001
5 SPD Oil 0.004
6 DDC Oil 0.020
7 OAVS 0.234
8 Caustic Lye 0.026
9 Sodium Bicarbonate 0.166
10 Sodium Nitrite 0.098
11 HCl 0.179
12 Sodium Sulphate 0.199
Disperse Dyes
Azo Dyes
1 Amines 0.250
2 Acid 0.400
3 Ice 2.000
4 Sodium Nitrite 0.100
5 Couplers 0.280
6 Alkali 2.150
7 Auxilieries 0.400
Anthraquinones / Condensed Dyes
1 Solvent 2.000
2 Amines 0.250
3 A.Q.R.M 1 0.400
35
4 R.M.2 0.100
5 R.M.3 0.150
6 Auxiliaries 0.400
Cyanation Dyes
1. Solvent 1.500
2. Mono/R.M. Product 0.250
3. Sodium Cyanide 0.200
4. Sodium Bisulphite 0.250
5. Alkali 0.150
6. Wet Cake 1.400
7. D.A Auxiliaries 0.200
Solvent Dyes
Solvent Blue 35
1 Methanol 1.454
2 Quinizarine 0.563
3 Leuco Quinizarine 0.140
4 n-Butyl amine 0.512
5 Nitrobenzene 0.085
6 Water 6.363
Solvent Blue 104
1 ODCB 0.789
2 Quinizarine 0.421
3 Leuco Quinizarine 0.105
4 Mesidine 0.605
5 Methanol 1.578
6 Water 7.894
Solvent Blue 122
1 Iso propyl alcohol 1.960
2 Quinizarine 0.392
3 Leuco Quinizarine 0.098
4 P-amino acetanilide 0.637
5 HCl 0.098
6 Water 9.803
Solvent Green 3
1 Butanol 2.474
2 Quinizarine 0.463
3 Leuco Quinizarine 0.129
4 Para Toluidine 0.567
5 Water 6.597
6 HCl 0.309
Solvent Orange 60
1 o-Xylene 2.666
2 Phthalic Anhydride 0.575
36
3 1:8 Diamino Naphthalene 0.606
4 Methanol 5.296
5 Water 4.545
Solvent Orange 86
1 O-Xylene 2.714
2 Quinizarine 1.071
3 Methanol 0.714
4 Water 6.428
Solvent Red 52
1 o-Xylene 2.234
2 6-Bromo Anthrapyridone 0.978
3 Para Toluidine 0.382
4 Potassium acetate 0.468
5 Methanol 5.446
6 Water 14.893
7 HCl 0.340
Solvent Red 135
1 o-Xylene 2.080
2 TCPA 0.760
3 1:8 DAN 0.400
4 Methanol 0.480
5 Water 4.800
Solvent Red 168
1 o-Xylene 0.857
2 1-Chloro AQ 0.833
3 Mono cyclohexylamine 0.404
4 Sodium Acetate 0.259
5 Methanol 3.809
6 Water 11.904
Solvent Red 195
1 3 Methoxy Propyl Amine 0.447.76
2 Tri Ethyl Amine 0.125
3 Amogh FP-165 0.395
4 Methanol 0.419
5 HCl 0.559
6 Sulfuric Acid 1.865
7 Sodium Nitrite 0.156
8 Acetic acid 1.791
9 Propionic Acid 0.298
10 Diazo component 0.425
11 Ice + Water 45.709
Solvent Red 207
1 o-Xylene 0.976
37
2 1:5 DCAQ 0.725
3 Mono cyclohexylamine 0.627
4 Sodium Acetate 0.493
5 Methanol 5.093
6 Water 11.627
7 Acetic Acid 0.116
Solvent Violet 13
1 Butanol 3.157
2 Quinizarine 0.752
3 Leuco Quinizarine 0.015
4 Para Toluidine 0.394
5 Zinc 0.034
6 HCl 0.842
7 Water 15.789
Solvent Violet 14
1 ODCB 0.838
2 1:8 DCAQ 0.645
3 Para Toluidine 0.564
4 Pot. Acetate 0.709
5 HCl 0.483
6 Water 9.677
7 Methanol 2.580
Solvent Yellow 33
1 ODCB 0.888
2 Phthalic anhydride 0.555
3 Quinaldine 0.555
4 Methanol 2.222
5 Water 6.250
Solvent Yellow 157
1 o-Xylene 2.472
2 Tetra Chloro Phthalic Anhydride 0.727
3 Quinaldine 0.443
4 Methanol 1.818
5 Water 8.181
Solvent Yellow 163
1 n-Butanol 2.946
2 1:8 DCAQ 0.678
3 Potassium Carbonate 0.401
4 Thiophenol 0.535
5 o-Xylene 1.785
6 Water 9.821
Solvent Orange 58
38
1 APMS 0.420
2 HCl 0.466
3 Sodium Nitrite 0.160
4 Caustic soda 0.233
5 m-Cl PMP 0.500
6 Chrominating Agent 0.066
7 Water + Ice 50.000
Solvent Red 127
1 Diazo Acid 0.250
2 PMP 0.187
3 Caustic soda 0.150
4 Chrominating Agent 0.035
5 Salicylic Acid 0.032
6 Rhodamine 0.500
7 2-EHA 0.110
8 Water 62.500
Solvent Black 27
1 4 NAP 0.217
2 5 NAP 0.217
3 Sodium Nitrite 0.185
4 HCl 0.535
5 Water 0.525
6 B-Naphthol 0.402
7 Caustic Soda 0.100
8 Chrominating Agent 0.065
9 2-Ethyl Hexyl Amine 0.127
10 Salicylic Acid 0.335
Dyes Intermediates
H Acid
1 Napthelene 0.123
2 Spent Sulphuric Acid 16.800
3 Oleum 0.659
4 Nitric Acid 0.328
5 Caustic Lye 2.511
6 Glaubber Salt 1.159
7 Iron Powder 0.221
8 Soda Ash 0.193
9 Caustic Flakes 0.521
10 Methanol 0.232
J Acid
1 Tobias Acid 0.124
2 Oleum 0.379
3 Caustic Flakes 0.086
39
4 Caustic lye 0.056
5 Sulphuric Acid 0.140
6 Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid
1 β-Napthol 0.830
2 Caustic Lye 0.330
3 Sodium Nitrate 0.660
4 Sulphuric Acid 0.830
5 Sodium -bi-Sulphite 1.670
6 Oleum-23% 0.830
7 Nitric Acid (70%) 0.420
Vinyl Sulphone
1 Acetanilide 0.630
2 Thionyl Chloride 0.630
3 Caustic Soda Lye 1.060
4 S.B.S 1.380
5 Ethylyn Oxide 0.330
6 Sulphuric Acid 0.740
2:5 Dichloro 4 Sulpho Phenyl 3 Methyl 5 Pyrazolone
1 2.5 Dichloro Aniline 0.022
2 Oleum 0.072
3 NaNO2 0.009
4 Soda Ash 0.022
5 SBS 0.031
6 Caustic Soda Lye 0.032
7 H2SO4 0.036
8 Ester 0.015
9 HCL 0.049
2 Chloro 5 Sulpho Phenyl 3 Methyl 5 Pyrazolone
1 6 Chloro Metanilic Acid 0.031
2 NaNO2 0.011
3 Soda Ash 0.036
4 SBS 0.048
5 Ester 0.017
6 Caustic Soda Lye 0.019
7 HCL 0.186
1, 3 Sulpho Phenyl 3 Methyl 5 Pyrazolone
1 Metanilic Acid 0.023
2 NaNO2 0.009
3 Soda Ash 0.045
4 SBS 0.035
5 Ester 0.015
6 HCL 0.138
1, 4 Sulpho Phenyl 3 Methyl 5 Pyrazolone
40
1 S . Acid 0.023
2 NaNO2 0.009
3 Soda Ash 0.045
4 SBS 0.035
5 Ester 0.015
6 HCL 0.138
1:3 Phenyl Methyl 5 Pyrazolone
1 Aniline 0.019
2 NaNO2 0.014
3 Soda Ash 0.068
4 SBS 0.051
5 Ester 0.022
6 HCL 0.208
Pigments
Activated CPC Blue
1 CPC Blue Crude 1.000
CPC Blue
1 Phthalic Anhydride 1.075
2 Carbomide salt / NH3 Gas 1.505
3 Cuprous Chloride 0.193
4 Ammonium Molybdate 0.030
5 Dilute H2SO4 (25 to 30%) 2.500
Alpha Blue (15:0 and 15:1)
1 CPC Blue Crude 1.050
2 H2SO4 4.810
Pigment Beta Blue (15:3)
1 CPC Blue Crude 1.030
2 Dilute HCl 0.013
3 Caustic Soda 0.015
4 IBA /xylene 0.500
Pigment Beta Blue (15:4)
1 CPC Blue Crude 0.834
2 Modified Sulpho 0.067
3 Xylene 0.033
4 HCl 0.117
Copper Phthalocyanine Pigment Green-7
1 Aluminum Chloride 1.825
2 Cupric chloride 0.080
3 CPC Blue Crude 0.555
4 MCB 0.060
5 Caustic flakes 0.079
6 HCl 0.475
7 NaOH 0.155
41
Pigment Violet 23
1 Carbazole 1.100
2 Mono Chloro Benzene 2.000
3 Caustic Soda Lye 1.300
4 Di Ethyl Sulphate 1.000
5 Dilute Nitric Acid 1.220
6 Ortho Di Chloro Benzene 1.000
7 Sodium Acetate 0.500
8 Benzene Sulphonyl 0.524
9 ODCB 1.200
10 Methanol 1.750
Pigment Red 122
1 Dimethyl Succinylo Succinate 0.400
2 Para Toludine 0.440
3 HCl 0.030
4 Methanol 2.800
5 Caustic Soda 0.300
6 Phosphoric Acid 1.600
7 Dimethyl Formamide 5.000
Pigment Violet 19
1 Dimethyl Succinylo Succinate 0.400
2 Aniline 0.385
3 HCl 0.030
4 Methanol 2.800
5 Caustic Soda 0.300
6 Dimethyl Formamide 5.000
Solsperse 5000
1 Copper Pthalocynine 1.000
2 Oleum 5.000
Carbazole
1 HCl 0.530
2 Aniline 0.385
3 Sodium Nitrite 0.031
Speciality Chemicals
2,4-Dichloro Phenyl Acetic Acid
1 2,4-Dichloro Benzyl Chloride 1.230
2 Tri ethyl Amine 0.090
3 Sodium Hydroxide 0.276
4 Sodium Cyanide 0.315
5 Hydro Chloric Acid (30%) 0.850
6 Toluene 0.150
7 Sodium bi Carbonate 0.090
2,4-DichloroPhenyl Acetyl Chloride
42
1 2,4-Dichloro Phenyl Acetic Acid 1.100
2 Sodium Hydroxide 0.480
3 Toluene 0.050
4 Thionyl Chloride 0.700
2,4,6-Trimethyl Phenyl Acetyl Chloride
1 2,4,6-Trimethyl Phenyl Acetic Acid 1.060
2 Toluene 1.500
3 Thionyl Chloride 0.871
4 Sodium Hydroxide 0.525
2,3,4,5-Tertrachloro Benzoyl Chloride
1 Pthalic Anhydride 0.635
2 OR Tetra Chloro Pthalic Anhydride 1.224
3 Chloro Sulphonic Acid 0.635
4 Chlorine Gas 1.218
5 Ethylene Dichloride 0.635
6 Caustic Soda Flakes 0.178
7 HCL30% 0.165
8 Di Methyl Formamide 2.200
9 Thionyl Chloride 0.110
10 Toluene 0.500
3,4,5 Trimethoxy Benzyl Chloride
1 3,4,5-Trimethoxy Benzyl Alcohol 1.000
2 HCL 30% 1.250
Pesticide Intermediates
2-Amino Benzo Nitrile
1 Toluene 0.840
2 PhosphorousPenta chloride 0.026
3 Sodium Hydroxide 0.015
4 2-Aminobenzamide 0.015
2-Amino-5-Bromo Benzo Nitrile
1 Dimethyl Formamide 2.400
2 2-Aminobenzonitrile 0.690
3 N-Bromo succinimide 1.035
4 Toluene 1.600
5 Hexane 0.140
2,4,6-Trimethyl Benzaldehyde
1 Mesitylene 3.360
2 Choral 1.134
3 Titanium Tetrachloride 1.460
4 Soda Ash 0.672
5 Acetone 0.160
6 Tetra Ethyl Benzyl Ammonium Chloride 0.010
Indoline
43
1 2-Chloro Phenethyl Amine 1.700
2 Liquid Ammonia 25% 4.800
3 Copper Chloride 0.050
5-(1-Carboxyethyl)-2-(phenylthio) Phenyl Acetic Acid
1 2-Phenylthio-5-propionyl Phenyl Acetic
Acid
1.350
2 Liquid Bromine 0.875
3 Trimethyl Ortho formate 1.150
4 Zinc-Dust 0.060
5 Caustic Soda Flakes 0.175
6 Sulphuric Acid 0.900
7 Toluene 0.410
8 Methanol 0.750
9 Ethylene Dichloride 1.500
44
ANNEXURE: 3
BRIEF MANUFACTRING PROCESS, CHEMICAL REACTION AND MASS BALANCE WITH FLOW
DIAGRAM
Acid Dyes:
1. Acid Black 1
Manufacturing Process:
(A) Preparation of PNA Diazo:
1. Make a clear solution of PNA in hydrochloric acid.
2. Cool to 0 C with ice and diazotize it with sodium nitrite.
3. Destroy excess Nirite before first coupling.
4. Make clear solution of H-Acid with soda ash.
5. Above PNA diazo coupled with H-Acid solution at 0 to 5 C, then,
6. This coupled mass is stirred for 3hr.
(B) Preparation of Aniline Diazo:
1. Make Aniline Hydrochloride with hydrochloric acid.
2. Cool to 0 C with ice and diazotize it with sodium nitrite.
3. Destroy excess nitrite before second coupling.
4. This Aniline diazo charge in to first coupled mass.
5. Adjust pH 8.5 – 9.50 with soda ash.
6. Heat to 80 C temp of second coupled mass.
7. Spray dry the reaction mass.
45
02N NH2+ HCl + NaNO 2 N N Cl- 02N
P-Nitroaniline P-Nitrodiazonium Chloride
NH2 + HCl + NaNO 2 N NCl-
Aniline Benzenediazonium Chloride
OH NH2
HO3S SO 3H
C.Lye
NaO3S SO 3Na
OH NH2
OH NH2
NaO3S SO 3Na
N N NO2 + Anilinediazo
NO2N N
SO3H SO 3H
OH NH2
N N
Acid Black - 1
Chemical Reaction:
46
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 H-Acid 337.50 Product 1000.00
2 Caustic lye 96.00 Gas / Evaporation 4189.00
3 PNA 150.00
4 Hydrochloric acid, 30% 650.00
5 Aniline 97.50
6 Sodium Nitrite 158.00
7 Water 1100.00
8 Ice 2400.00
9 Soda ash 200.00
TOTAL 5189.00 5189.00
47
2. Acid Black 52:
Manufacturing Process:
Preparation of coupling component:-
Charge 6 - Nitro in the MSRL vessel. Add water and ice in it.
Preparation of coupling component:-
Charge B- Napthol in the MSRL vessel with caustic lye.
Coupling:-
Charge 6-Nitro slurry to the B – Napthol slurry. Keeping the temperature between 0 to 5 C by
adding of ice.
Chromination:-
Add Basic Chromium Sulfate and Salicylic acid in coupled mass and heat to 100 C and maintain
the pH 3.0-3.5.
Check the completion of reaction on paper chromatography.
Spray Drying:
Send the total mass for the drying purpose.
48
Chemical Reaction:
49
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 6-Nitro 358.00 Product 1000.00
2 Beta Napthol 172.00 Effluent 4581.00
3 NaOH 258.00
4 Basic Chromium Sulphate 215.00
5 Steam 1733.00
6 Water 1445.00
7 Ice 1356.00
8 Salicylic Acid 44.00
TOTAL 5581.00 5581.00
50
OH
NH2O2N+ HCl + NaNO2
Diazotisation
5-100CO2N N
OH
N Cl-
5-Nitro 2-Amino Phenol (5NAP) Diazo of 5NAP
OH
Coupling N NO2N
OH OH
Chromination
NO2N N
O2N N N
O
O
OO
Cr+3
Acid Black - 63
3. Acid Black 63:
Manufacturing Process:
• Prepare 5-NAP diazo with help of HCL, Sodium nitrite and ice at temp 5-10° C.
• Destroy the excess nitrite by using Salfamic acid.
• Prepare coupler solution (Beta Napthol) in alkaline media at 60° C.
• Add coupler solution to diazo at 8-10° C.
• Stir for overnight.
• Heat to 70° C and add chrom liquid.
• Further heat to 100° C and maintain for 3hr.
• Check the completion of reaction on TLC.
• The above reaction mass is spray dried.
Chemical Reaction:
51
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 5-NAP 500.00 Product 1000.00
2 Hydrochloric acid, 30% 1140.00 Gas / Evaporation 7648.00
3 Ice 2000.00
4 Sodium Nitrite 230.00
5 Beta Napthol 478.00
6 Caustic lye, 48% 800.00
7 Chrome Salam 1500.00
8 Water 2000.00
TOTAL 8648.00 8648.00
52
4. Acid Black 71:
Manufacturing Process:
Gamma Acid and J-Acid block solution:
• Prepare Gamma Acid and J-Acid solution in water with Soda ash then block with sodium
bi-sulphite and formaldehyde.
• Stir for 2-3 hr.
Picramic acid diazo:
• Prepare Picramic acid diazo with help of Hydrochloric acid(30%), ice and Sodium Nitrite
solution.
• Keep the temp 5-10 C.
• Destroy the excess nitrite by Sulphamic acid.
Coupling:
• Transfer Picramic Acid diazo to Gamma Acid solution.
• Keep the temp to 10C.
• When coupling is over, stir for overnight.
Chromination:
• Coupled mass is chrominated in presence of Sodium Dichromate and Glucose as a
Oxidizing agent at temp 95-100 C.
• Time depend up on the tone required of the final product.
Drying:
• When the chromination is OK.
• Spray dry the reaction mass.
53
Chemical Reaction:
OH
NH2
SO3H
+ HCHO + NaHSO3H
SO3H
NH.CH2.SO3H
OH
Gamma Acid & J-Acid Mixture Blocked Soln. of Gamma & J-Acid Mixture
OH
NH2
NO2
O2N
+ HCl + NaNO2 Diazotisation
Temp 5-70C
NO2
NO2
N
OH
N Cl-
+
Picramic Acid
Coupling N
OH
N
NO2
NO2 OH
NH.CH2.SO3H
SO3H
Chromination
SO3H
NH.CH2.SO3H
NO2
NO2
N
OH
N
N N
NO2
NO2
NH.CH2.SO3H
SO3H
O O
O OCr+3
Acid Black - 71
54
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Sodium Bi-sulphite 357.00 Product 1000.00
2 Formaldehyde 250.00 Gas / Evaporation 5487.00
3 Gamma Acid 365.00
4 J-Acid 64.00
5 Soda ash 70.00
6 Sodium Picramate 384.00
7 Sodium Dichromate 140.00
8 Sulphuric acid, 98% 108.00
9 Sorbitol 60.00
10 Sodium Formate 66.00
11 Hydrochloric acid, 30% 1000.00
12 Sodium Nitrite 123.00
13 Water 2000.00
14 Ice 1500.00
TOTAL 6487.00 6487.00
55
OH
NH2
SO3H
+ Formaldehyde + Sodium Bisulphite
SO3H
NH.CH2.SO3H
OH
Gamma Acid Blocked Gamma Acid (Sulpho methylamino)
HO3S OH
NH2
NO2
+ HCl + NaNO2 Diazotisation
5-100C
NO2
N N Cl-
SO3H OH
4-Nitro-2-Amino Phenol-6-Sulphonic Acid (4NAPSA) 4-NAPSA Diazo
+
SO3H OH
N N
NO2
OH
NH.CH2.SO3H
SO3H
Monoazo
Chromination
SO3H
NH.CH2.SO3H
SO3H
N N
NO2
HO3S
N N
NO2
NH.CH2.SO3H
SO3H
O
O
O O
Cr+3
Acid Black - 84
5. Acid Black 84:
Manufacturing Process:
1. Gamma acid: Prepare Gamma acid solution with help of soda ash and blocking take
place by sodium bi-sulphite and formaldehyde.
2. Blocked solution act as a coupler.
3. Prepare diazo of 4-NAPSA: in the presence of 30% Hydrochloric acid and Sodium nitrite.
4. Coupling: Transfer 4-NAPSA diazo to Gamma acid solution in alkali medium. Check
completion of coupling reaction.
5. Chromination of above coupled mass is carried out with chrome solution at temp 90-
100° C and check the completion of metallization.
6. Spray dry the above reaction mass.
Chemical Reaction:
56
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Sodium bi-sulphite 365.00 Product 1000.00
2 Formaldehyde 245.00 Gas / Evaporation 9088.00
3 Gamma acid 473.00
4 4NAPSA 431.00
5 Hydrochloric acid 30% 122.00
6 Sodium Nitrite 130.00
7 Soda ash 422.00
8 Ice 4200.00
9 Water 3700.00
TOTAL 10088.00 10088.00
57
6. Acid Black 107
Manufacturing Process:
• Prepare Sodium Picramate diazo with HCl, Sodium Nitrite and ice at 0-5 C.
• Stir for 2hr.
• Destroy the excess nitrite by Sulfamic acid solution.
• Prepare Beta Napthol solution in alkaline media at 60 C.
• Transfer Beta Napthol solution to diazo slowly in 30 min keeping temp 5-10 C.
• Stir monoazo reaction mass for 8-10 hr.
• Transfer monoazo reaction mass to asymmetric complexing vessel Step-1.
• Prepare 1:1 chrom complex of 6-NDA+Beta Napthol (Step-2) as couple 6-NDA slurry and
Beta Napthol in alkaline media.
• Above monoazo reaction mass subjected to metallization with chromium formate in
acidic condition.
• Transfer self isolated chrome complex to asymmetric complexing vessel Step-2.
• Mix above step-1 and step-2 and heat to 100 C.
• Check the completion of the reaction by TLC.
• Spray dry the material.
58
NO2 OH
NH2
NO2
+ HCl+NaNO2+Ice
Dioazotization
NO2
N
OHNO2
N.Cl- +
OH
Picramic Acid(4:6 Dinitro-2-Aminophenol)
Beta Naphthol
Coupling
OH
N
NO2 OH
N
NO2
Monoazo
OH
NH2N
NO2
HO3S
OH
+
HO3S
NO2
OH
N N
OH
Chromination
Basic & Acidic 1:1
O
N N
O
Cr+3
1:1 Cr Complex of 6NDA
Beta Naphthol
+ Monoazo
NO2
N
NO2
N
O O
Cr
O O
N N SO3H
NO2Acid Black - 107
Chemical Reaction:
59
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Sodium Picramate 227.00 Product 1000.00
2 Beta Napthol 160.00 Gas / Evaporation 3343.00
3 Hydrochloric Acid 360.00
4 Caustic Flakes 75.00
5 Sodium Nitrite 75.00
6 Ice 1000.00
7 6-Nitro 360.00
8 Beta Napthol 183.00
9 Caustic Lye 22500
10 Chromuim Formate 325.00
11 Sulphuric Acid 120.00
12 Oxalic Acid 45.00
13 Salicylic Acid 33.00
14 Water 1150.00
TOTAL 4343.00 4343.00
60
7. Acid Black 172:
Manufacturing Process:
Preparation of Diazo component:-
Charge 6 - Nitro in the MSRL vessel. Add water and ice in it.
Preparation of coupling component:-
Charge B- Napthol in the MSRL vessel with caustic lye.
Coupling:-
Charge Beta Napthol slurry to 6-Nitro slurry, Keeping the temperature between 5 to 10 C by
adding of ice.
Chromination:-
Add Basic Chromium Sulfate in monoazo mass and heat to 95 C for the completion of
metallization.
Spray Drying:
Send the above mass for the spray drying purpose.
61
Chemical Reaction:
62
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 6-Nitro 446.40 Product 1000.00
2 Beta Napthol 214.28 Gas / Evaporation 2878.10
3 NaOH 321.00
4 Basic Chromium Sulphate 196.42
5 Water 1200.00
6 Ice 1500.00
TOTAL 3878.10 3878.10
63
SO3H NH2
Diazotisation
H2SO4 + NaNO2& Hydrolysis
SO3H OH
+
OH
SO3HH2N
Peri Acid Suetan 1:2:4 Diazo Acid
CouplingN SO3H
OHSO3H OH
N
Monoazo1:1 Chromination inAcidic Medium
N
HO3S O
O
SO3HN
Cr+3
Acid Blue 158
8. Acid Blue 158:
Manufacturing Process:
• Naptha sultan is hydrolysed with the help of caustic potash at temp 95-100° C.
• Maintain temp 95-100° C for 6 hr.
• Cool to room tem.
• Charge 1:2:4 Diazo acid at 25-30° C, slowly in 1.5 hr.
• Stir for 6-8 hr and to complete the coupling.
• Adjust pH 8-9 with hydrochloric acid.
• Add chrome liquid which is previously prepared in another vessel.
• Heat to 100° C.
• Maintain temp to 10-12 hr.
• Check reaction mass for the completion of reaction on TLC.
• If TLC is OK, adjust pH 4.5-5.0 with soda ash.
• Sprays dry the above mass.
Chemical Reaction:
64
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Naptha Sultan 489.00 Product 1000.00
2 Caustic potash 555.00 Gas / Evaporation 5562.00
3 Ammonium Sulphate 66.00
4 1-2-4 Diazo acid 555.00
5 Sodium Bi-chromate 445.00
6 Sulphuric acid, 98% 333.00
7 Sorbitol 213.00
8 Sodium Formate 206.00
9 Ice 1800.00
10 Water 1800.00
11 Soda ash 100.00
TOTAL 6562.00 6562.00
65
9. Acid Brown 75
Manufacturing Process:
(A) H-Acid diazo:
1. Make a clear solution of H-Acid with soda.
2. Add sodium Nitrite in the solution and make reverse diazo in Hydrochloric acid and ice.
3. Destroy excess Nitrite before first coupling.
4. Above H-Acid diazo coupled with Resorcenol at pH 12-13 with caustic lye.
5. This coupled mass is stirred for 3hr.
(B) Preparation of Sodium Picramate diazo:
6. Make Sodium Picramate Hydrochloride with hydrochloric acid.
7. Cool to 0C with ice and diazotized it with Sodium nitrite.
8. Destroy excess Nitrite before second coupling.
9. This Picramate diazo charge in to first coupled mass.
10. Adjust pH 8.9 with caustic lye.
(C) Preparation of PNA diazo:
11. Make a clear solution of PNA in Hydrochloric acid.
12. Diazotized it with sodium nitritebefore third coupling, destroy excess Nitrite.
13. After completion of third coupling, spray dry the reaction mass.
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 H-Acid 240.00 Product 1000.00
2 Soda ash 50.00 Gas / Evaporation 5773.00
3 Sodium Nitrite 176.00
4 Hydrochloric acid, 30% 1230.00
5 Resorcinol 84.00
6 Caustic lye, 48% 550.00
7 Picramic acid 168.00
8 PNA 125.00
9 Water 1150.00
10 Ice 3000.00
TOTAL 6773.00 6773.00
66
10. Acid Brown 161
Manufacturing Process:
Anthranilic acid:
• First Anthranilic acid has been made solution in 98% Sulphuric acid, in continuous
stirring.
• Block with Formaldehyde and maintain for 3-4 hr.
• Then make tetrazo of Anthranilic acid with help of Sodium Nitrite in presence of ice to
maintain temp of tetrazo.
• Further tetrazo coupled with Resorcinol solution, which is cleared in water and also with
caustic lye in alkaline medium.
• When coupling is OK.
• Add couple mass diazo of 2.4 Sulfanilic acid which is made by help of Hydrochloric acid,
Sodium nitrite and ice.
• After then metallization with copper sulphate.
• The above reaction mass is then spray dried.
67
NH2
COOH
Condensation
HCHO/H2SO4
C OOH
H2N CH2
OHC O
NH2Tetrazotisation
2
OH
OH
Coupling
Resorcinol
OH
OH
N N
O
COH
CH2
OHOC
N N
OH
OH
2
NH2
SO3H
HCl + NaNO2
Diazotisation
SO3H
N N Cl
OH
OH
N N
C OOH
CH2
OHC
O
NN
OH
OH
N
N
SO3H
Metall izationCuSO4.5H2O
SO3H
N
N
N
N
SO3HSO3H
N
N
OH
O
N N
O
COH
CH2
OOC
N N
OH
OH
Cu
Acid Brown - 161
Chemical Reaction:
68
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Anthranilic acid 154.50 Product 1000.00
2 Sulphuric acid, 98% 140.08 Gas / Evaporation 7102.96
3 Formaldehyde, 32% 61.80
4 Sodium Nitrite 156.56
5 Resorcinol 120.00
6 Caustic lye, 48% 234.50
7 Sulphanilic acid 189.52
8 Hydrochloric acid 412.00
9 CuSO4. 5H2O 284.00
10 Water 2450.00
11 Ice 3900.00
TOTAL 8102.96 8102.96
69
11. Acid Brown 165:
Manufacturing Process:
H-Acid diazo:
• Prepare H-Acid diazo with help of caustic lye, Hydrochloric acid, ice and Sodium Nitrite
solutions, keeping the temp 5-10 C.
Picramic acid diazo:
• Picramic acid diazo with help of Hydrochloric acid and Sodium Nitritesolution, ice and
maintain the temp to 5-7 C.
PNA diazo:
• PNA diazo prepare in Hydrochloric acid, ice and Sodium Nitrite solution keeping temp 5-
10 C.
Coupler solution:
• Prepare Resorcinol solution in water and stir to get clear solution.
• Add ice to get temp 0 C, then transfer H-Acid diazo.
• Stir for 2hr.
• Then add Picramic acid diazo and PNA diazo gradually.
• First couple mass maintaining pH alkaline by using caustic lye and temp 10 C.
• When coupling is over, heat to 80-90 C.
Metalization:
• Metalize the coupled mass with Ferric chloride, when test and tone is OK.
Drying:
• Spray dry the above mass.
70
OH NH2
SO3H SO3H
Diazotisation
HCl + NaNO2 Ice
SO3H SO3H
OH N N Cl
+
OH
OH
H-Acid
1st Coupling
SO3H
OH
HO3S
N N
OH
OH
N
N
OH
NO2NO2
2nd Coupling
OH
NO2
NO2
H2N
Picramic Acid
NH2
NO2
HCl + NaNO2 Ice
Diazotisation
+
Cl NN
NO2
3rd Coupling
NO2NO2
OH
N
N
OH
OH
NN
OH
SO3H
SO3H
N N NO2
Metall izationFeCl3
80-85OC
NO2 NN
SO3H
SO3H
O
N N
O
OH
N
N
OH
NO2NO2
Fe
Acid Brown 165
Chemical Reaction:
71
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 H-Acid 76.00 Product 1000.00
2 Caustic lye, 48% 200.00 Gas / Evaporation 6539.20
3 Sodium Nitrite 144.20
4 Hydrochloric acid, 30% 1012.00
5 Resorcinol 70.00
6 Picramic acid 114.00
7 Paranitro Aniline 112.00
8 Water 2350.00
9 Ice 3200.00
10 Ferric chloride 261.00
TOTAL 7539.20 7539.20
72
12. Acid Brown 355:
Manufacturing Process:
• Prepare 4-NAPSA diazo with the help of hydrochloric acid and sodium nitrite in presence
of ice at 5-10 C.
• Prepare PMP coupler solution with caustic lye and cool to 10 C with ice.
• Add coupler to diazo mass at temp 5-10 C.
• Stir for overnight to complete the coupling.
• Charge 1:1 chrom complex of 6-Nitro+Beta and heat to 95-100 C.
• Maintain temp till it is OK.
• Adjust qty of chrome complex according to monoazo of 4NAPSA to PMP.
• Spray dry the reaction mass.
Chemical Reaction:
OH
NH2
NO2
SO3HDiazotisation
HCl + NaNO2
SO3H OH
N=N-Cl
NO2
+
CH3
O
NO2 N=N
OH
SO3H
NN
NN
OH
CH3
Orange Monoazo
Coupling
Diazo 4 NAPSA 1-Phenyl 3-Methyl5-Pyragolone
4-Nitro 2-aquizoPhenyl 6-Sulphonic Acid
NO2
SO3H
OH
N=N +
OH
Coupling
NO2
SO3H
OH
N=N
OH
N=N
O
NO2
SO3H
Chlorination
O
Cr
6 Nitro 1:2:4Diazo Acid
B NaphtholMonoazo
Cr
O
SO3H
NO2
O
N=N
+
NO2
SO3H OH
N=N
NN
O
CH3
N=N
O
NO2
SO3H
O
Cr
OO
N
N
CN=N
SO3H
NO2. 3 Na +
Acid Brow n 355
73
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 4-NAPSA 276.00 Product 1000.00
2 PMP 219.00 Effluent 3726.00
3 Hydrochloric acid, 30% 520.00 Water Losses 1924.00
4 Sodium Nitrite 83.00
5 Caustic lye, 48% 348.00
6 Sodium Acetate 106.00
7 6-Nitro-1-Diazo acid 311.00
8 Beta Napthol 156.00
9 BCS, 16% 362.00
10 Salicylic acid 22.00
11 Sodium Formate 88.00
12 Water 2915.00
13 Ice 1244.00
TOTAL 6650.00 6650.00
74
13. Acid Brown 425:
Manufacturing Process:
• Make a Anthranilic acid diazo with Hydrochloric acid and sodium nitrite in the presence
of ice.
• Destroy the excess nitrite by Sulfamic acid.
• Dissolve Resorcinol in water, Soda and ice.
• Transfer diazo to Reesorcinol, alkaline solution.
• This first coupled mass, further couple with OT 5SA diazo.
• Prepared OT 5SA diazo with hydrochloric acid, sodium nitirte and ice.
• Destroy the excess nitrite by sulfamic acid.
• Transfer in to first coupled mass.
• Stir over night.
• Coupled mass then chrominated with Chromium Fluoride at 95-100 C.
• Spray dry the reaction mass.
Chemical Reaction:
NH2
C=OH
O
+ HCl + NaNO2N=N-Cl
C-OH
O
+
OH
OH
Anthranilic Acid
NH2
SO3H
Cl-N=N
CH3
SO3H
OH
OH
N=N
O
C-OH
Anthranilic Acid Diazo Resorcinal Monoazo
C-OH
N=N
OH
OH
O
N
N
CH3NaNO2
HCl
CH3
SO3H
O.T. 5 S.A O.T. 5 S.A Diazo
SO3H
CH3
N=N
OH N=N
C
O
Cr
O
O
O
3+
O
C
O
N=N OH
N
SO3H
CH3
Acid Brown 425
Chlorination
75
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Anthranilic acid 170.00 Product 1000.00
2 O.T.5 SA 250.00 Gas / Evaporation 5051.00
3 Sodium Nitrite 180.00
4 Hydrochloric acid, 30% 700.00
5 Resorcinol 150.00
6 Soda ash 350.00
7 Salicylic acid 188.00
8 Caustic Flakes 57.00
9 Chromium Fluoride 128.00
10 Liq. Ammonia 78.00
11 Ice 2000.00
12 Water 1800.00
TOTAL 6051.00 6051.00
76
14. Acid Brown 432
Manufacturing Process:
• Make Anthranilic acid diazo with HCl, Sodioum nitrite and ice at temp 5-10 C.
• Remove excess nitrite with sulfamic acid.
• Dissolve Resorcenol in water, ice and Soda ash.
• Transfer diazo to Resorcinol solution in alkaline media.
• This first coupled mass is further coupled with Lorrent Acid diazo.
• Prepare Lorrent Acid diazo with HCl, Sodium nitrite and ice at 5-7 C.
• Remove excess nitrite with sulfamic acid and then coupled with first coupled mass.
• Stir over night.
• Coupled mass is chrominated with Chromium Fluoride at 95-100 C.
• Spray dry the above chrominated mass.
Chemical Reaction:
NH2
COOH
+ HCl + NaNO2
N=N-Cl
C=O
OH
+
OH
OH
Anthranilic Acid Resorcinol
C-OH
O
N=N
OH
OH
NH2
SO3H
NaNO2
HCl
Cl-N=N
SO3H
OH
OH
N=N
O
C-OH
N
N
SO3H
N=N
C
O O
OH
O
Cr
OO
OH
N
N
N=N
C
O
Acid Brown 432
Chlorination
77
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Anthranilic acid 170.00 Product 1000.00
2 Resorcenol 150.00 Gas / Evaporation 6151.00
3 Lorrent acid 285.00
4 Hydrochloric acid, 30% 970.00
5 Sodium Nitrite 175.00
6 Soda ash 350.00
7 Salicylic acid 188.00
8 Caustic soda Flakes 57.00
9 Chromium Fluoride 128.00
10 Liq. Ammonia 78.00
11 Ice 2300.00
12 Water 2300.00
TOTAL 7151.00 7151.00
78
15. Acid Brown 434
Manufacturing Process:
• Make Anthranilic acid diazo with HCl, Sodioum nitrite and ice at temp 5-10 C.
• Remove excess nitrite with sulfamic acid.
• Dissolve Resorcenol in water, ice and Soda ash.
• Transfer diazo to Resorcinol solution in alkaline media.
• This first coupled mass is further coupled with Lorrent Acid diazo.
• Prepare Lorrent Acid diazo with HCl, Sodium nitrite and ice at 5-7 C.
• Remove excess nitrite with sulfamic acid and then coupled with first coupled mass.
• Stir over night.
• Coupled mass is chrominated with Chromium Fluoride at 95-100 C.
• Isolate the product with salt.
• Filter the isolated mass in filter press.
• Collect the wet cake and dry.
Chemical Reaction:
OHNO2
NO2
NH2 + HCl + NaNO2 + Ice
Diazotisation
NO2 OH
N=N-Cl
NO2
+
OH
OH
Picraunic Acid(4:6 Dinitro 2-anino Phenol)
Diazo of Picraunic Acid Resorcinol
NO2 OH
N=N
NO2
OH
OH
Diazotisation
HCl + NaNO2
NH2
SO3H
1st Coupling
2nd Coupling
Monoazo 1:1 Cleve's Acid
NO2
N=N
NO2 OH OH
OH
N
N
SO3H
Metallization
O
OH
NN
O
Fe 3 +
NO2
NO2
N
N
SO3H
Acid Brow n 432
79
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Sodium Picrame 296.00 Product 1000.00
2 Resorcinol 145.00 Gas / Evaporation 6303.00
3 Mix cleave acid 336.00
4 Hydrochloric acid, 30% 925.00
5 Sodium Nitrite 210.00
6 Sulfamic acid 2.00
7 Caustic flakes 140.00
8 Caustic lye 189.00
9 Ferrous sulphate 260.00
10 Water 1800.00
11 Ice 3000.00
TOTAL 7303.00 7303.00
80
16. Acid Green 104
Manufacturing Process:
• Prepare diazo of Sodium Picramate with the help of Hydrochloric acid, Sodium Nitrite
and ice.
• Before coupling destroy the excess nitrite by sulfamic acid.
• Sodium Picramate diazo coupled in alkaline medium with (Oxy Larrent acid) Dahl’s acid.
• When coupling is over confirmed the test.
• Metallized the coupled mass with cobalt sulphate.
• Spray dry the above reaction mass.
Chemical Reaction:
NO2 OH
NH2
NO2
Diazotisation
5-7 CHCl + NaNO2
NO2 OH
N=N-Cl
NO2
+
NH2
SO3H
NO2 OH
N=N
NO2
NH2
SO3H
Picranic Acid Diazo of Picranic Acid 2-Amino-5-Naphthalene (4:6 Dinitro Sulphonic Acid2-Amino Phenol)
Coupling
NO2
NO2O
N=N
SO3H
NH
CO
NH O
SO3H
N=N
NO2
NO2
Acid Green 104
81
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Sodium Picramate 405.00 Product 1000.00
2 Dahl's Acid 419.00 Gas / Evaporation 7723.00
3 Sodium Nitrite 138.00
4 Hydrochloric acid, 30% 650.00
5 Ice 3350.00
6 Caustic Flakes 216.00
7 Cobalt Sulphate, 20% 295.00
8 Water 3250.00
TOTAL 8723.00 8723.00
82
17. Acid Orange 74
Manufacturing Process:
• Prepare 4-NAPSA diazo with HCL, Sodium nitrite and ice.
• Destroy the excess nitrite by sulfamic acid.
• Prepare PMP solution in alkaline media and add sodium acetate.
• Add coupler solution to diazo slowly in 1hr.
• Stir over night.
• Heat to 70 C and add Salicylic acid followed by BCS powder.
• Prepare chrome complex at 100 C in acidic condition.
• Cool to room temp and adjust pH to 7.5 to 8.0.
• Spray dry the above reaction mass.
Chemical Reaction:
NO2
NH2
OHSO3H
+ HCl + NaNO2
NO2
N=N-Cl
OHSO3H
+ N
NO
CH3
+ NaOH
CH3
NN
OH
+ 4 NAPSA Diazo
4-Nitro 2-Amino Phenol6-Sulphonic Acid
1-Phenyl 3-Methyl 5-Pyrazolone
NO2
SO3H
N=N
O
NN
O
Cr
H2O H2O H2O
CH3
Acid Orange 74
83
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 4-NAPSA 530.00 Product 1000.00
2 Hydrochloric acid, 30% 600.00 Gas / Evaporation 7143.00
3 Sodium Nitrite 170.00
4 PMP 425.00
5 Caustic lye, 48% 553.00
6 Sodium Acetate 205.00
7 Ice 2500.00
8 Salicylic acid 60.00
9 BCS, 16% 900.00
10 Water 2200.00
TOTAL 8143.00 8143.00
84
18. Acid Orange 142
Manufacturing Process:
• Prepare 4-NAPSA diazo with HCL, Sodium nitrite and ice at 5-10° C.
• Destroy the excess nitrite by using sulfamic acid.
• Prepare coupler solution (PMP) in alkaline media.
• Make buffer with sodium acetate.
• Cool to 10° C with ice.
• Add coupler solution to diazo slowly in 1hr.
• Stir for overnight.
• Heat to 70° C and add chrom liquid.
• Further heat to 100° C.
• Maintain temp for 2hr.
• Check the completion of reaction on TLC.
• Spray dry the reaction mass.
Chemical Reaction:
SO3H OH
NH2
NO2
+ HCl + NaNO2
NO2
OHSO3H
N=N-Cl NN
CH3
O
+ NaOH
CH3N
NOH
4-Nitro 2-Amino Phenol6-Sulphonic Acid(4 NAPSA)
1-Phenyl 3-Methyl 5-Pyrazolone
NO2
N=N
SO3H OH
NN
CH3
O
+ Salicylic Acid & Green Solution
N=N
NO2
SO3H O O
NN
CH3
Cr
O OSO3H
NN
NO2
NN
CH3
Acid Orange 142
85
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Water 1980.00 Product 1000.00
2 Ice 2750.00 Gas / Evaporation 5196.59
3 4NAPSA 363.60
4 Hydrochloric acid 96.25
5 Sodium Nitrite 116.35
6 Sulphamic acid 2.72
7 PMP 290.90
8 Caustic lye, 48% 152.71
9 Sodium Acetate 140.00
10 Sodium dichromate 136.35
11 Sorbitol 65.00
12 Sodium Formate 63.63
13 Salicylic acid 39.08
TOTAL 6196.59 6196.59
86
19. Acid Red 97
Manufacturing Process:
1. Tetrazo of BDSA prepared in presence of Hydrochloric acid, Sodium nitrite and Ice.
2. Coupling component: Dissolve Beta Napthol in water and caustic flakes to get clear
solution.
3. Coupling: Transfer tetrazo to Beta Napthol solution in alkaline medium, stir overnight.
4. Next day spray dry the above reaction mass.
Chemical Reaction:
NH2
SO3H
NH2
SO3H
HCl + NaNO2
Cl.N=N
SO3H
SO3H
N=N-Cl +
OH
Coupling
N=N
OH
SO3H
SO3H
N=N
OH
Acid Red 97
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 BDSA 455.00 Product 1000.00
2 Beta Napthol 387.00 Gas / Evaporation 5490.00
3 Hydrochloric acid, 30% 1230.00
4 Sodium Nitrite 185.00
5 Caustic Flakes 108.00
6 Water 2625.00
7 Ice 1500.00
TOTAL 6490.00 6490.00
87
20. Acid Red 357
Manufacturing Process:
• Prepare 6NAPSA diazo with Sodium nitrite and ice.
• Prepare PMP solution in alkaline media and buffered with sodium acetate.
• Add coupler solution to diazo slowly in 1 hr.
• Stir for 8-10 hr to complete the coupling.
• Add Green solution and further heat to 100 C.
• Maintain temp for 2-3 hr, check completion of metallization on TLC.
• SPD the material.
Chemical Reaction:
NO2 OH
NH2
SO3H
NaNO2
Diazotisation
NO2 OH
N=N-Cl
SO3H
+ N
NO
CH3Coupling
SO3H
N=N
OHNO2
NN
OH
CH3Chlorination
NO2
N=N
SO3H
O
NN
CH3
O
Cr
OO
NN
N=NCH3
SO3H
NO2
Ph
Acid Red 357
88
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 6NAPSA 358.00 Product 1000.00
2 Sodium Nitrite 109.25 Gas / Evaporation 4183.76
3 PMP 280.59
4 Caustic lye, 48% 164.20
5 Sodium Acetate 253.72
6 Green solution 450.00
7 Water 2350.00
8 Ice 1200.00
9 Salicylic acid 18.00
TOTAL 5183.76 5183.76
89
21. Acid Violet 90
Manufacturing Process:
• Prepare solution of PMP in water with help of caustic lye to get clear solution.
• Charge Ammonium Sulphate followed by addition of 1-2-4 Diazo acid 300 kg.
• After that Chrominated with BCS at 90-100 C.
• Spray dry the above reaction mass.
Chemical Reaction:
OH
N=NaSO3H
Coupling NN
CH3
O+
OH
N=NSO3H
NN
CH3
OH
Ph
Chlorination
1:2:4 Diazo Acid 1-Phenyl 3-Methyl Pyrazolone Monoazo
N=N
NN
CH3SO3H
O O
Cr
O O
NN
CH3
Ph
SO3HN=N
Acid Violet 90
90
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 1-2-4 Diazo acid 400.00 Product 1000.00
2 PMP 304.00 Gas / Evaporation 3647.00
3 Ammonium Sulphate 45.00
4 Salicylic acid 54.00
5 BCS, 16% 266.00
6 Caustic lye, 48% 378.00
7 Water 3200.00
TOTAL 4647.00 4647.00
91
22. Acid Yellow 42
Manufacturing Process:
1. Prepare Tetrazo of BDSA in presence of Hydrochloic acid, Sodium Nitrite and Ice.
2. Dissolve PMP in water in presence of caustic flakes to to get clear solution and add
Sodium Acetate.
3. Transfer tetrazo to coupler.
4. Stir over-night.
5. Check completion of coupling reaction.
6. Spray dry the above reaction mass.
Chemical Reaction:
NH2
SO3H
NH2
SO3H
HCl + NaNO2
Cl-N=N
SO3H
SO3H
N=N-Cl
O
CH3
NN N
N
CH3 N=N
SO3H
N=N
SO3H
NN
CH3
OO
Acid Yellow 42
92
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 BDSA 360.00 Product 1000.00
2 PMP 410.00 Gas / Evaporation 8710.00
3 Hydrochloric acid, 30% 1000.00
4 Sodium Nitrite 150.00
5 Caustic Flakes 280.00
6 Sodium Acetate 460.00
7 Water 2300.00
8 Ice 4750.00
TOTAL 9710.00 9710.00
93
23. Acid Yellow 59
Manufacturing Process:
• Prepare Anthranilic acid diazo with help of Hydrochloric acid, sodium nitrite and ice.
• Destroy the excess nitrite by sulphamic acid.
• Prepare PMP solution in alkaline medium and add sodium acetate.
• Add diazo solution to coupler solution in course of an hour.
• The dye further metallized with BCS.
• Check the completion of metallization.
• Neutralize reaction mixture with caustic lye.
• Cool to 50º C and dispersing agent AB-300.
• Spray dry the above reaction mass.
Chemical Reaction:
NH2
C=O
OH
HCl + NaNO2 N=N-Cl
C=O
OH
+ NN
CH3
O
N=N
NN
CH3
OHC
O OH
Anthranilic Acid Diazo of Anthranilic Acid 1-Phenyl 3-Methyl Pyrazolone
Monoazo
Chlorination
N=N
NN
CO
OO
Cr
ON
N
CH3 N=N
O
C=O
Acid Yellow 59
94
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Anthranilic acid 150.00 Product 1000.00
2 PMP 194.00 Gas / Evaporation 4030.00
3 BCS, 16% Cr. 208.00
4 Formic acid, 85% 450.00
5 Ice 1500.00
6 Sodium Nitrite 78.00
7 Hydrochloric acid, 30% 250.00
8 Caustic lye, 48% 550.00
9 Water 1050.00
10 Dispersing agent 600.00
TOTAL 5030.00 5030.00
95
24. Acid Yellow 194
Process Description:
4-NAPSA diazo:
• Prepare 4-NAPSA diazo with help of Hydrochloric acid and sodium nitrite in presence of
ice to maintain temp.
AAA Coupler solution:
• Make clear solution of AAA with help of caustic lye.
• 4-NAPSA diazo coupled with AAA in alkaline medium and then metallization with cobalt
sulphate at 80-90 C for 3-4 hr.
• When test is OK.
• Spray dry the above reaction mass.
Chemical Reaction:
OHSO3H
NH2
NO2
HCl + NaNO2OHSO3H
N=N-Cl
NO2
+ Aceto AcetanilideOH SO3H
NO2
N=NCH
C
O
NH Ph
C
O
CH3
+ Cobalt Sulphate CoSO4.7H2O
NO2
SO3HO
N=NCH
C
O
-Ph HN
C
CH3 O
Co
OSO3H
NO2
N=N HC C
C
O
- CH3
O
NHPh
Acid Yellow 194
96
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 4NAPSA 476.00 Product 1000.00
2 AAA 381.00 Gas / Evaporation 6366.00
3 Sodium Nitrite 148.00
4 Hydrochloric acid, 30% 295.00
5 Cobalt Sulphate, 20% 476.00
6 Caustic lye, 48% 390.00
7 Ice 2600.00
8 Water 2600.00
TOTAL 7366.00 7366.00
97
Direct Dyes:
1. Direct Black 40
Manufacturing Process:
PAA Diazo:
• Prepare PAA diazo with help of Hydrochloric acid (30%) and Sodium Nitrite in presence
of ice.
• Couple this diazo to clear solution of Gamma Acid in alkaline medium.
• When coupling is over, and test is OK.
• Heat the first coupled mass to 90-100° C, in presence of caustic flakes for 4-5 hr for
hydrolysis, when OK.
• Cool to room temp.
• Further hydrolysis the mass acidify and make diazo with help of Hydrochloric acid, 30%,
ice and Sodium Nitrite.
• When diazo is OK, stir for 3-4 hr.
• Destroy the excess nitrite by Sulfamic acid.
• Then couple with Mix cleave acid in mild alkaline medium and then with final coupling
with Gamma acid in alkaline medium.
• Presipitated product is then spray dried.
98
Chemical Reaction:
NH2CH3.C.HN
O
+ HCl + NaNO2
O
CH3.C.HN N=N.Cl Coupling
NH2
SO3H
OH
P-Amino Acetanilide P-Acetanilide Diazonium Chloride Gamma Acid
CH3.C.HN
O
N=N
SO3H
OH
NH2
SO3H
NH3
OH
N
NH2
N=
Hydrolysis
Caustic Lye
SO3H
NH2
&
OH
NH2
SO3H
Mix Clever Acid Complex I
Gamma Acid Complex II
N
N
NH2
N=N
OH
SO3H
SO3H
Direct Black 40
N=N
OH
NH2
SO3H
Tetrazotisation
HCl + NaNO2
Monoazo
99
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 PAA 150.00 Product 1000.00
2 Gamma acid 465.00 Gas / Evaporation 9705.00
3 Mix Cleave acid 223.00
4 Hydrochloric acid, 30% 2500.00
5 Sodium Nitrite 215.00
6 Caustic lye 263.00
7 Soda ash 475.00
8 Sulphamic acid 14.00
9 Caustic Flakes 350.00
10 Water 2050.00
11 Ice 4000.00
TOTAL 10705.00 10705.00
100
2. Direct Black 168
Manufacturing Process:
• Prepare FC Acid tetrazo with help of Hydrochloric acid, sodium nitrite and ice.
• FC Acid tetrazo coupled with H-Acid solution in acidic medium.
• Stirred over night.
• Further coupled with Aniline diazo in alkaline medium and subsequently final coupling
with MPD in mild alkaline medium.
• When coupling is confirmed OK.
• Then Spray dry the reaction mass.
Chemical Reaction:
SO3H
NHNH2 NH2
N=N-Cl N=N-Cl
HCl + NaNO2
Tetrazotisation
NH2 OH
Soda
pH 6.5-7.0
NH2 OH
SO3NaSO3NaSO3H SO3H
H - Acid
+ Tetrazo of F.C. Acid
OH NH2
SO3H SO3H
N=N NH N=N-Cl + NH2 + HCl + NaNO2 N=N Cl
Aniline
N=N
OH NH2
SO3H SO3H
N=N
SO3H
NH N=N-Cl +
NH2
NH2/OH
NH2
NHN=N
SO3H SO3H
OH NH2
N=N N=N
OH/NH2
Direct Black 168
101
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 FC Acid 307.00 Product 1000.00
2 H-Acid 307.00 Gas / Evaporation 7171.00
3 Sodium Nitrite 236.00
4 Hydrochloric acid, 30% 953.00
5 Aniline Oil 93.00
6 Soda ash 561.00
7 MPD 114.00
8 Ice 3700.00
9 Water 1900.00
TOTAL 8171.00 8171.00
102
3. Direct Blue 71
Manufacturing Process:
C-Acid diazo solution:
• Prepare diazo of C-Acid with help of Hydrochloric acid (30%) and Sodium Nitrite solution
in presence of ice.
αNapthylamine solution:
• Prepare αNapthylamine clear solution by heating with Hydrochloric acid (30%) and
water.
• Clear pinkish solution.
First coupling:
• Transfer αNapthylamine solution to C-Acid diazo keeping temp to 10° C under
continuous stirring.
Monoazo diazo:
• Prepare diazo of first coupled mass with help of Sodium nitrite and ice.
• When diazo is ready.
• Add to Mix cleave acid clear solution.
• When coupling is over, make disazo of aforesaid coupling mass with help of
Hydrochloric acid, ice and Sodium Nitrite.
J-Acid solution:
• Prepare J-Acid solution in water, ice and caustic lye.
• Transfer disazo to J-Acid solution in alkali condition.
• Check the completion of reaction.
Drying:
• Spray dry the reaction mass.
103
Chemical Reaction:
SO3H
NH2 SO3H
+ HCl + NaNO2
SO3H
SO3HN=N-Cl
NH2
SO3H
SO3HN
N
NH2
HCl + NaNO2
C-Acid C-Acid Diazonium Chloride Naphthylamine
Monoazo
SO3H
SO3HN
N
N=N-Cl
+ SO3H
NH2
N
N
SO3H
SO3H
N
N
SO3HNH2 Direct Blue 71
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 C-Acid 336.00 Product 1000.00
2 Napthyl Amine 170.00 Gas / Evaporation 7171.00
3 Mix Cleave Acid 220.00
4 Hydrochloric acid, 30% 1050.00
5 Sodium Nitrite 300.00
6 J-Acid 260.00
7 Caustic soda lye, 48% 50.00
8 Caustic Flakes 50.00
9 Water 2600.00
10 Ice 3900.00
TOTAL 8936.00 8936.00
104
4. Direct Green 26
Manufacturing Process:
• BHK acid is diazotized with help of Hydrochloric acid, sodium nitrite in presence of
ice.
• The above mass is coupled with H-Acid in alkaline medium.
• Then the dye is isolated, dissolved in water.
• The above is then condensed with cyanuric chloride.
• The remaining two halogen atoms of the cyanuric chloride moles are substituted by
condensation with p-Amino Phenyl azo salicylic acid and Anilin Oil respectively.
• The resultant reaction mass is then spray dried.
Chemical Reaction:
N=NOSO2
SO3H SO3H
CH3
OCH3
NH2
PhO2S O N=N
SO3H SO3H
OCH3
CH3
BHK Acid Monoazo Diazo of BHK Acid
+
OH NH2
SO3H SO3H
H - Acid
CH3
PhO2S O N=N
OCH3
N=N
OH NH2
SO3H SO3H
+
C
N N
C C-Cl
N
Cl
Diazo BHK H Acid Cyanuric Chloride
CH3
OCH3
SO3H SO3H
PhO2S O N=N N=N
SO3H SO3H
OH NH
1 st
Condensation
2 nd
Condensation
PAPAS
NH2 N=N OH
C=O
OHPAPAS
Condensation
3 rd
Aniline
NH2
Aniline
Hydrolysis
NaOH
105
OH N=N
SO3H SO3H
CH3
O CH3
N=N
OH NH
SO3H SO3H
CN C
N C
N
NH Aniline
NH N=N OH
C=O
OH
Direct Green 26
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 BHK Acid 434.00 Product 1000.00
2 H-Acid 234.00 Gas / Evaporation 7719.00
3 Hydrochloric acid, 30% 900.00
4 Sodium Nitrite 52.00
5 Caustic lye, 48% 57.00
6 Soda ash 177.00
7 PAPA's acid 154.00
8 Cyanuric chloride 110.00
9 Reaction oil 15.00
10 Aniline Oil 86.00
11 Ice 2900.00
12 Water 3600.00
TOTAL 8719.00 8719.00
106
5. Direct Orange 15
Manufacturing Process:
• Prepare FC Acid tetrazo with help of Hydrochloric acid, sodium nitrite and ice.
• FC Acid tetrazo coupled with H-Acid solution in acidic medium.
• Stirred over night.
• Further coupled with Aniline diazo in alkaline medium and subsequently final coupling
with MPD in mild alkaline medium.
• When coupling is confirmed OK.
• Then Spray dry the reaction mass.
Chemical Reaction:
CH3
SO3H
NO2
Condensation
In presenceof caustic soda
CH=CHNO2
SO3H
NO2
SO3H
n
Condensed product of 2-Phenyl 5-Nitro benzeneSulphonic Acid
Reaction withHCHO reduction
N=N CH=CH
SO3H
N=N
SO3H
CH=CH
SO3H SO3H
N=N
n
Direct Orange 15
107
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 PNTOSA 818.00 Product 1000.00
2 Caustic Flakes 750.00 Gas / Evaporation 5743.00
3 Formaldehyde, 35% 850.00
4 Dichlone 25.00
5 Spent Acid, 50% 1800.00
6 Ice 1000.00
7 Water 1500.00
Total 6743.00 6743.00
108
6. Direct Orange 118
Manufacturing Process:
1. Diazotization of p-Cresidine-o-Sulphonic acid: p-Cresidine-o-Sulphonic acid is diazotized
in presence of Hydrochloric acid and Sodium Nitrite.
2. Just before coupling make CR and SI –ve with sodium bi-carbonate.
3. Coupler solution: Take water and add J-Acid Urea and make uniform solution.
4. Add Sodium bi-carbonate.
5. Receive above diazo mass in course of 45 min.
6. Stir overnight.
7. Heat to 80° C.
8. Stir for 2hr.
9. Spray dry the above reaction mass.
109
Chemical Reaction:
Me NH2
OMeSO3H
+ HCl + NaNO2
Me N=N-Cl
OMeSO3H
P-Cresidine O-Sulphonic Acid P-Cresidine O-Sulphonic Diazonium Chloride
OH
SO3H
NH-C-NH
O OH
SO3H
+ NaHCO3
J Acid Urea
OH
SO3Na
NH-C-NH
O
OH
SO3Na
+ 2 Cl-N=NMe
SO3HOMe
J Acid Urea Disodium Salt
Me
N=N
OMe SO3H SO3H
OH
NH-C-NH
O
OH
SO3
N=N
OMe SO3H
Me
Direct Orange 118
110
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 p-Cresidine-o-Sulphonic acid 231.00 Product 1000.00
2 Hydrochloric acid, 30% 350.00 Gas / Evaporation 6958.00
3 Sodium Nitrite 87.00
4 Sodium bi-carbonate 475.00
5 J-Acid Urea 315.00
6 Water 3000.00
7 Ice 3500.00
TOTAL 7958.00 7958.00
111
7. Direct Red 81
Manufacturing Process:
1. Prepare clear solution of J-Acid.
2. Benzolyte with Benzoylchloride at 18-20 °C.
3. Check completion of Benzoylation.
4. Prepare reverse Diazo of p-Aminoazobenzene-4-Sulphonic acid with help of caustic lye,
hydrochloric acid, ice and sodium nitrite.
5. Add Diazo mass to coupler solution.
6. Stir for 2 hr till coupling is completed.
7. Spray dry the above reaction mass.
Chemical Reaction:
SO3H N=N NH2 + HCl + NaNO2 N=NSO3H N=N Cl
4 4' p-Amino Azo Benzene Sulphonic Acid
OH
SO3H NH2
+ C-Cl
O
J Acid Benzoyl Chloride
OH
SO3H
NH-C
O + SO3H N=N N=N-Cl
Benzoylated J Acid
N=NSO3H N=N
OH
SO3H NH-C
O
Direct Red 81
112
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 PAABSA 308.00 Product 1000.00
2 Caustic lye, 48% 210.00 Gas / Evaporation 5923.00
3 Sodium Nitrite 83.00
4 Hydrochloric acid, 30% 308.00
5 J-Acid 279.00
6 Benzoyl Chloride 257.00
7 Sodium Acetate 308.00
8 Sodium bi-carbonate 308.00
9 Soda ash 62.00
10 Water 2800.00
11 Ice 2000.00
TOTAL 6923.00 6923.00
113
8. Direct Red 239
Manufacturing Process:
Bronner’s Acid:
• Make clear solution of bronner’s Acid with caustic lye.
• Add Sodium Nitrite in the solution and make reverse diazo in Hydrochloric acid and ice
to maintain diazo at temp 5-7° C.
Coupler solution:
• Prepare J-Acid Urea solution in water, stir to form good slurry.
• Transfer diazo to coupler solution in alkali medium.
• When coupler is over, stir over night.
Drying:
• Spray dry the above reaction mass.
Chemical Reaction:
NH2
SO3H
2 + NaNO2 + HCl
N=N-Cl
SO3H
2
Bronner's Acid
SO3H
N=N
OH
SO3H
NH-C-NH
O
OH
N=N
SO3H SO3H
Direct Red 239
114
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Browner's acid 250.00 Product 1000.00
2 caustic lye, 48% 100.00 Gas / Evaporation 6637.50
3 Sodium Nitrite 95.00
4 Hydrochloric acid, 30% 550.00
5 J-Acid Urea 292.50
6 Soda bi-carb, 25% 250.00
7 Soda ash, 20% solu. 100.00
8 Water 2500.00
9 Ice 3500.00
TOTAL 7637.50 7637.50
115
9. Direct Red 254
Manufacturing Process:
PAABSA solution:
• Prepare solution of PAABSA by caustic lye.
• Stir and add Sodium Nitrite in the solution and make reverse diazo in Hydrochloric acid
and ice.
• Just before coupling destroy excess nitrite by sulfamic acid.
Coupler solution:
• Prepare J-Acid solution with help of caustic soda lye.
• Transfer the diazo to coupler solution in alkali medium.
• When coupling is over, heat the coupling mass.
Drying:
• Spray dry the above reaction mass.
Chemical Reaction:
SO3H N=N NH2 + HCl + NaNO2
P-Aminoazo Benzene 4-Sulphonic Acid
SO3H N=N N=N-Cl
P-Aminoazo Benzene 4-Sulphonic Acid
+
SO3H
NH2
OH
J Acid
SO3H N=N N=N
OH
NH2
SO3H
Direct Red 254
116
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 PAABSA 406.25 Product 1000.00
2 Caustic lye 200.00 Gas / Evaporation 8633.85
3 Hydrochloric acid 874.00
4 Sodium Nitrite 102.00
5 J-Acid 351.60
6 Soda ash 300.00
7 Water 2700.00
8 Ice 4700.00
TOTAL 9633.85 9633.85
117
10. Direct Violet 9
Manufacturing Process:
Sulfanilic acid diazo:
• Prepare diazo of sulfanilic acid in presence of Hydrochloric acid, Sodium Nitrite and ice.
p-Cresidine solution:
• Prepare solution of p-Cresidine in water.
• Couple with Sulfanilic acid diazo.
• Stir continuously.
• When coupling is over make monoazo diazo by adding Hydrochloric acid and Sodium
Nitrite solution in presence of ice.
• Stir monoazo diazo for 4-5 hr to consume sodium nitrite.
• After that destroy excess nitrite by adding sulfamic acid.
• Final coupling will take place with n-Phenyl J-Acid in alkaline medium.
• After completion of coupling, heat to 70° C.
• Spray dry the above reaction mass.
Chemical Reaction:
SO3H NH2 + NaNO2 + HCl SO3H N=N-Cl + CH3
Me
NH2
OCH3(OMe)
P-Cresidine
Sulphanilic Acid
SO3H N=N
Me
NH2
OMe
Monoazo
HCl + NaNO2
N=NSO3H
Me
N=N Cl
OMe
Monoazo Diazo
+
Ph NH2 SO3H
OH N-Phenyl J Acid
SO3H N=N
Me
N=N
OMe SO3H
NH-Ph
OH
Direct Violet 9
118
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 Sulphanilic acid 180.00 Product 1000.00
2 p-Cresidine 150.00 Gas / Evaporation 6975.00
3 n-Phenyl J Acid 327.00
4 Hydrochloric acid, 30% 800.00
5 Sodium Nitrite 145.00
6 Sodium Acetate 200.00
7 Caustic lye, 48% 298.00
8 Soda ash 175.00
9 Ice 3800.00
10 Water 1900.00
TOTAL 7975.00 7975.00
119
11. Direct Violet 35
Manufacturing Process:
C-Acid diazo:
• Prepare diazo of C-Acid in presence of Hydrochloric acid (30%) Sodium Nitrite and ice.
P-Cresidine:
• Make solution of p-Cresidine in water.
• Then couple with C-Acid diazo.
• Stir continuously.
• When coupling is over, make monoazo diazo by adding Hydrochloric acid and Sodium
nitrite solution in presence of ice.
• Stir monoazo diazo for 4-5 hr.
• Then destroy excess sodium nitrite adding sulfamilic acid.
• Final coupling will take place with n-Phenyl J-Acid solution in alkaline condition.
• After completion of final coupling, heat to 70° C.
• Spray Dry the above reaction mass.
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 C-Acid 331.00 Product 1000.00
2 p-Cresidine 150.00 Gas / Evaporation 5978.00
3 n-Phenyl-J Acid 327.00
4 Hydrochloric acid, 30% 850.00
5 Sodium Nitrite 147.00
6 Sodium Acetate 200.00
7 Caustic lye, 48% 298.00
8 Soda ash 175.00
9 Ice 2500.00
10 Water 2000.00
TOTAL 6978.00 6978.00
120
n
CH3
SO3H
NO2
+ NaOH O2N CH CH NO2
SO3NaSO3Na
P-Nitro TolueneO-Sulphonic AcidP.N.T.O.S.A
Direct Yellow - 11
Alkaline Condensation of 4-Nitro Toluene-2-Sulphonic Acid
12. Direct Yellow 11
Manufacturing Process:
STEP-1: CONDENSATION
1. Take water in vessel and add caustic lye, then add PNTOSA slowly and after complete
charging check pH.
2. Adjust pH 8.00 and temp to 55° C and maintain for 1 hr.
3. Then charge caustic for condensation.
4. After complete charging bring the temp to 66° C and maintain for 3 hr.
5. Then add 50% Sulphuric acid for reduction, at pH 2.00, maintain for 2 hr.
STEP-2:
1. Take Nitrobenzene and Amine in vessel, then add above condensed mass slowly and
after complete charging, complete the reduction by adding extra amine and check for
separation.
2. Then stop the stirrer and give 3.00 hr of settling time.
STEP-3:
1. Take DEA + water in vessel and add above mass (Dye + NB + Amine) slowly in vessel and
stop when water level is reached.
2. Then stop addition and transfer the water in to Multi Effect Evaporator.
3. Complete the reduction by adding extra DEA and adjust pH at 8.50.
4. Stop the stirrer for 7.00 hr.
5. Recover dye from bottom and send for packing.
6. The balanced Nitrobenzene + Amine use in next batch.
Chemical Reaction:
121
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 PNTOSA 290.00 Product 1000.00
2 Caustic Flakes 213.00 Liquid Effluent (Recycled) 3600.00
3 Nitrobenzene 16.00
4 Tri-Butyl Amine 21.00
5 Di-Ethanol Amine 160.00
6 Sulphuric Acid-70% 500.00
7 Water 3250.00
8 Steam 150.00
TOTAL 4600 4600
122
13. Direct Yellow 44
Manufacturing Process:
• Prepare MAMA’s acid solution in water.
• To this solution charge Bis (Trichloro Methyl) Carbonate.
• Charge Sodium Bi-carbonate.
• Heat to 70° C slowly in 4-5 hr.
• Stir at 70° C for 6hr.
• Heat to 80-85° C and maintain for 1hr.
• The above reaction mass is spray dried.
Chemical Reaction:
N=N
SO3H
NH2
OMe
Methylamino Azobenzenem-Sulphonic Acid
+ Cl3-C-O C O-C-Cl3
O
(MAAMSA)
Bis (Trichloro Methyl Carbonate)
Condensation in presence of
Sodium Bicarbonate
at 60-80 C
SO3H
N=N NH C
O
OMe
NH N=N
OMe SO3H
Direct Yellow 44
Mass Balance:
Sr. No. Input Qty (Kg) Output Qty (Kg)
1 MAMA'S Acid 787.00 Product 1000.00
2 BIS (Trichloro Methyl)
Carbonate 375.00 Gas / Evaporation
7287.00
3 Sodium Bi-Carbonate 625.00
4 Water 6500.00
TOTAL 8287.00 8287.00
123
Reactive Dyes:
1. Reactive Black B
Manufacturing Process:
Diazotization of Vinyl Sulphone by Hydro Chloric Acid, Sodium Nitrite, Ice and Water. This
mixture is known as diazotization of VS. Coupling of Diazo - 1 with H Acid. This is known as
Coupler 1. Send the liquefied material of coupler 1 for spray drying activity. Finally the powder
material is placed into bags.
Chemical Reaction:
124
Mass Balance:
1400 Kgs Finished product Reactive Black B
Water : 250 Kgs
Vinyl Sulphone : 562 Kgs
Ice : 500 Kgs
HCl : 146 Kgs
Sodium Nitrite : 138 Kgs
Ice : 1000 Kgs
Total : 2596 Kgs
VESSEL: 1 (Diazo of Vinyl
Sulphone)
VS Diazo : 657 Kgs
Salt Generation : 177 Kgs
Water Generation : 72 Kgs
Water + Ice : 1750 Kgs
Total : 2596 Kgs
VESSEL: 2 (Coupling with
H Acid) 3433 Kgs
Reactive Black B : 991 Kgs
Salt : 434 Kgs
Water + Ice : 1876 Kgs
CO2 Liberate : 132 Kgs
Total : 3433 Kgs
H acid : 319 Kgs
Sodium Bi Carbonate : 318 Kgs
Salt : 200 Kgs
Total : 837 Kgs
Spray Drying
Spray drying Loss 1901 Kgs
Including Ice & water qty.
with 25 Kgs product loss.
125
2. Reactive Red - 195
Manufacturing Process:
Take initial water and chrge Vinyl Sulphone in it. Then adjust pH by sodium Bi Carbonate. Take
water in another vessel. Then add Cynuric Chloride in it. Couple both the solution. This is known
as coupler-1. Then copupled this mass with H acid solution. This is known as coupler-2. Then
prepare Diazo of Sulpho Tobias Acid. Then couple the coupler-2 with STA Diazo. Send the
liquefied material of coupler-1 for spray drying activity. Finally the powder material is packed
into bags.
Chemical Reaction:
• Cynuration
126
• Coupling Cynurated Vs with H Acid
• Preaparation of STA Diazo
127
• Coupling of Coupler 1 with STA Diazo
128
Mass Balance:
Water: 600 Liter
Vinyle Sulphone: 84 Kgs
Sodium Bi Carbonate: 84 Kgs
Total: 965 Kgs
Water: 900 Liter
Cynuric Chloride: 184.5 Kgs
Total: 1084.5 Kgs
VS Slurry: 903 Kgs
Water Generation: 18 Liter
CO2 Genearation: 44 Kgs
(Go to Air)
Total: 965 Kgs
Cynuric Chloride Solution
Total: 1084.5 Kgs
Vessel-1
921 Kgs
Vessel-2
1084.5 Kgs
Coupling-1
2005.5 Kgs
H Acid: 319 Kgs
Water: 700 Liter
Total: 1019 Kgs
Coupler: 451 Kgs
Water Genration: 18 Liter
HCl Generation: 36.5 Kgs
Water: 1500 Liter
Total: 2005.5 Kgs
Coupling-2
3130.5 Kgs Na2CO3: 106 Kgs CO2 Generation: 44 Kgs (Air)
Coupler: 777.5 Kgs
Water Genration: 36 Liter
HCl Generation: 73Kgs
Water: 2200 Liter
Coupling-3
4599.5 Kgs CO2 Generation: 88 Kgs (Air)
NaHCO3: 168 Kgs
Water: 900Liter
STA Diazo: 350.5 Kgs
NaCL: 58.5 Kgs
Water: 36 Liter
Coupler: 1135.5Kgs
Water Genration: 108 Liter
HCl Generation: 109.5 Kgs
Water & Ice: 3100 Liter
NaCL: 58.5 Kgs
Total: 4511.5 Kgs
129
Spray Drying
Reactive Red 195 (Including Salt): 1194 Kgs
Spray Drying Loss
Water Genration: 108 Liter
HCl Generation: 109.5 Kgs
Water & Ice: 3100 Liter
Total: 3317.5 Kgs
130
3. Reactive Golden Yellow - 145
Manufacturing Process:
Take water in a Vessel. Then add K acid, Sodium Nitrite, HCL in it. The Diazo of K Acid is coupled
with MUA. This is known as coupler-1. This coupler is Cynurated by Cynuric Chloride. This
cynurated mass is coupled with VS. After condensation the liquefied material is sending for
spray drying. Finally the powder material is packed into bags.
Chemical Reaction:
• Diazo of K–Acid
131
• Coupling with Meta Urido Aniline
• Cynuration
132
• Condensation with Vinyl Sulphone
133
Mass Balance:
Water : 1000 Liter
K Acid : 383 Kgs
SodiumNitrite : 69 Kgs
HCl : 73 Kgs
Ice : 1000 Kgs
Total : 2525 Kgs
K Acid Diazo : 430.5 Kgs Water
Generation : 36 Liter Salt
Generation : 58.5 Kgs Water &
Ice : 2000 Liter
Total : 2525 Kgs
VESSEL : 1
2525 Kgs
Coupling – 1
2676 Kgs
MUA : 151 Kgs
Coupler: 545 Kgs
HCl Generation: 36.5 Kgs
Salt : 58.5 Kgs
Water : 2036 Liter
Total : 2676 Kgs
Coupling - 2 : 2860.5
Kgs
Cynuric Chloride : 184.5
Kgs
Coupler: 693 Kgs
HCl: 73 Kgs
Water: 2036 Liter
Salt: 58.5 Kgs
Condensation with Vinyl
Sulphone
VS: 218 Kgs
Reactive Yellow145: 937.5 Kgs
Water: 2036 Liter
HCl Generation: 109.5 Kgs
NaCl: 58.5 Kgs
Total: 3141.5 Kgs
Spray drying
Spray Drying Loss
HCl Generation: 109.5 Kgs
Water: 2036 Liter
Product Loss: 25 Kgs
Total: 2170 Kgs
Reactive Yellow 145(Including Salt):971Kgs
134
4. Reactive Golden Yellow HER
Manufacturing Process:
Take water in vessel. Then add K acid, Sodium Nitrite, HCL in it. The Diazo of K acid is coupled
with MUA. This is known as coupler-1. This coupler is Cynurated by Cynuric Chloride. This
Cynurated mass is coupled with VS. After filtration the effluent will go to ETP. The wet cake is
condensed with DASDA. The liquefied material is sending for spray drying. Finally the powder
material is packed into bags.
Chemical Reaction:
• Diazo of K–Acid
• Coupling with Meta Urido Aniline
135
• Cynuration
• Condensation with DASDA
136
Mass Balance:
Water: 1000 Liter
K Acid: 383 Kgs
Sodium Nitrite: 69 Kgs
HCl: 73 Kgs
Ice: 1000 Kgs
Total: 2525 Kgs
VESSEL : 1 2525 Kgs
K Acid Diazo: 430 Kgs
Water Generation: 36 Liter
Salt Generation: 58.5 Kgs
Water & Ice: 2000 Liter
Total: 2525 Kgs
Coupler: 545 Kgs
HCl Generation: 36.5 Kgs
Salt: 58.5 Kgs
Water: 2036 Liter
Total: 2676 Kgs
Coupling-1 2672Kgs MUA : 151
Filtration 2116 liter waste water
will go to ETP
Cynuric Chloride:
184.5Kgs
Coupling – 2
744.5Kgs
Coupler: 708 Kgs
HCl: 36.5 Kgs
DASDA: 344 Kgs Condensation with DASDA
Spray drying
Reactive Yellow HER: 1000.5 Kgs
HCl Generation: 73 Kgs
Total: 1073.5Kgs
Reactive Yellow HER (Including Salt):
9715 Kgs
Spray Drying Loss
HCl Generation: 73 Kgs
Product Loss: 29 Kgs
Total: 102 Kgs
137
5. Reactive Orange H2R
Manufacturing Process:
Acetylation of N Methyl J Acid: Charge real quantity of NMJ acid into Water. And take pH 7 By
use of 20 % solution of NaOH. Then add Ice and take temperature 15 degree C. and then charge
Acetic Anhydride then stir for 6 Hrs. then check unreacted NMJ acid. If it is OK then take pH by
use of 20 % solution os NaOH Flakes.
Diazotization of Sulpho Tobias Acid: Charge real quantity of S.T.A in water. Then charge HCL. In
the solution. Then slowly charge sodium Nitrite solution till SI positive stable and Cr Positive.
Coupling: Add Acetyl NMJ solution to S.T.A. Diazo. After completion of adding take pH 6.5 by
Sodium Bi Carbonate. After adjusting pH it till Diazo negative in coupling test.
Hydrolysis: heat the coupled mass to 40-45 degree C and then charge NaOH flakes and then
heat 80 degree c and maintain the mass for 3-4 Hrs. till hydrolysis completion. After completion
of hydrolysis adjust pH 7 by use of HCL.
Base Dissolving: Take upper filter w/c into water and stir the material till clear on spot.
Cynuration of Upper Clear Base Solution: Take Cynuric Chloride into water with Ice. Then add
upper clear base solution slowly and stir the material. Then take pH 6.5 by use of soda solution.
After completion of Cynuration reaction the mass will be transferred for condensation process.
Condensation: Add Ammonia solution into the Cynuration mass and stir the material to
complete condensation. Then after the mass is send for spray drying activity for obtain finished
product.
Chemical Reaction:
• Activation of NMJ
138
• Di Azotization of STA
• Coupling Acetyl-N-Methyl J Acid with STA Diazo
139
• Hydrolysis
140
Mass Balance:
Water : 1500 Liter
NMJ Acid : 253 Kgs
Sodium Hydroxide : 40 Kgs
Acetic Anhydride : 102 Kgs
Total : 1895 Kgs
Acetyl NMJ Acid : 317 Kgs
Water Generation : 18 Liter
CH3COOH Generation : 60 Kgs
Water : 1500 Liter
Total : 1895 Kgs
STA Diazo : 350.5 Kgs
Salt generation : 58.5 Kgs
Water + Ice : 1800 Kgs
Water generation : 36 Liter
Total : 2245 Kgs
CO2Generation 88 Kgs (Go to Air) Coupling : 4308 Kgs
Coupler : 675 Kgs
Salt generation 58.5 Kgs Water
Generation : 90 Liter
CH3COOH Generation : 60 Kgs
HCl Generation : 36.5 Kgs
Water & Ice : 3300 Liter
Total : 4220 Kgs
NaHCO3 : 168 Kgs
VESSEL : 2 (Preparation of SAT Diazo)
2245 Kgs VESSEL : 1 (Asetylation of NMJ Acid)
1895 Kgs
NaOH : 40 Kgs Hydrolysis : 4260 Kgs
Base of Orange M.R : 633 Kgs
Salt generation :58.5 Kgs
Water Generation : 90Liter
CH3COOH Generation : 60 Kgs
CH3COONaGeneration : 82 Kgs
HCl Generation : 36.5 Kgs
Water & Ice : 3300 Liter
Water : 800 Liter
Sulpho Tobias Acid : 303 Kgs
HCl : 73 Kgs
Sodium Nitrite : 69 Kgs
Ice : 1000 Kgs
Total: 2245 Kgs
141
Filtration Effluent goes to ETP: 3469 Liter
Cyutric Chloride : 184.5 Kgs
Water : 4000 Liter
Ice : 1000 Kgs
Total : 5184.5 Kgs
Wet Cake including Salt
and Moisture : 791 Kgs
Cynuration : 5975.5 Kgs
NH4OH Solution : 35 Kgs Reactive Orange M2R : 859 Kgs
Water &Ice : 5080 Liter
HCl : 36.5 Kgs
Total : 5975.5 Kgs
Isolation : 6010.5 Kgs
Reactive Orange H2R (Including Salt):
869.0 Kgs
Spray drying Loss:
Water & Ice : 5080
Liter HCl : 36.5 Kgs
Product Loos : 25 Kgs
Total : 5141.5 Kgs
Base of Orange M.R : 633 Kgs
Salt generation :58.5 Kgs
Water Generation : 90 Liter
CH3COOH Generation : 60 Kgs
CH3COONaGeneration : 82 Kgs
HCl Generation : 36.5 Kgs
Water & Ice : 3300 Liter
142
� REACTIVE BLUE
1. BLUE 3R
PROCESS DISCRIPTION
H acid is cynurated & coupled with dizotized vinyl sulphone. Product condensed
with metanilic acid & spray deried.
CHEMICAL REACTION
(A- SO
2
CH
2
CH
2
OSO
3
H )
A
OCH
3
CH
3
NH
2
+ +
2HClNaNO
2
+
OH
NH
2
SO
3
H SO
3
H
+
CH
3
CH
3
CO
O
CO
+
NaHCO
3,
CuSO
4
CH
3
OCH
3
A
NN
SO
3
HSO
3
H
NH
2
OCH
3
OH
Cu
+ 2NaCl + 3H
2
O + CO
2
CH
3
COONa+
143
NH
SO
3
H
NH
2
+
+
NaNO
2
2HCl
++
+
SO
3
HSO
3
H
NH
2
OH
ClCl
Cl
N
NN
AH
2
N+
NaHCO
3,
Na
2
CO
3
SO
3
H
NH
N N
OH
SO
3
H SO
3
H
NH
N N
N
Cl
NH
A
(A- SO
2
CH
2
CH
2
OSO
3
H )
2NaCl + 3H
2
O + CO
2
+
Reactive BLUE F4R
2. BLUE F4R
PROCESS DISCRIPTION
4 ADAPSA Diazo H acid is coupled with H-Acid, cynurated condensed with vinyl
sulphone ester & spray deried.
CHEMICAL REACTION
3.
144
3. BLUE HERD
PROCESS DISCRIPTION
4 Sulpho Anthranilic acid hydrozone is coupled with 6-AAPSA diazo product
obtained is completed with copper Sulphate. The mass filtered wet caked
hydrolysis and base is condensed with Cynurated metanilic Acid & with cynurated
PPDDSA. Product obtained & spray dried.
CHEMICAL REACTION
145
++
2HCl
NaNO
2
+
+
+
SO
3
H
OH
NH
NaOHCuSO
4
O
N
OH
C
SO
3
H
H
2
N
HO
NHCOCH
3
ClCl
Cl
N
NN
+
(A- SO
2
CH
2
CH
2
OSO
3
H )
A
NH
C
2
H
5
+
NaHCO
3 ,
Na
2
CO
3
N N
N
Cl
SO
3
H
NH
O
N
N
O
N
N
Cu
O
SO
3
H
O
N
C
2
H
5
A
+ CO
2
2NaCl + 3H
2
O+
Na
2
SO
4
+
4. BLUE 221
PROCESS DISCRIPTION
4 Sulpho Anthranilic acid hydrozone is coupled with 6-AAPSA diazo product
obtained is complexed with copper Sulphate. The mass filtered wet caked
hydrolysis and base is condensed with N Ethyl Meta Base Ester.
CHEMICAL REACTION
146
SO
3
H
SO
3
H
H
3
OS
NH
2
O
N
N
O
SO
3
H
H
2
NCH
2
CH
2
NH
Cl
Cl
NHCH
2
CH
2
NH
2
2
+
Cl
N N
N
Cl
Cya Chloride
+
Cl
2
NaHCO
3
, Na
2
CO
3
H
3
OS
SO
3
H
NH
Cl
N
NN
HNCH
2
CH
2
NH
Cl
Cl
SO
3
H
O
N
N
O
SO
3
H
NHCH
2
CH
2
NH
Cl
N
NN
NH SO
3
H
SO
3
H
+ 2NaCl + Na
2
SO
4
+ CO
2
Reactive Blue HEGN
5. BLUE HEGN
PROCESS DISCRIPTION
Aniline 2, 4 Disulphonic Acid Is Cynurated & Condensed with Blue 198 Base &
Spray dried.
CHEMICAL REACTION
147
NH
2
SO
3
H
SO
3
H
NH
2
A
NHCH
2
CH
2
NH
2
Cl
Cl
H
2
NCH
2
CH
2
NH
SO
3
H
O
N
N
O
SO
3
H
2
2
+
+
2
Cl
+
Cya Chloride
Cl
N
NN
Cl
(A- SO
2
CH
2
CH
2
OSO
3
H )
MBVSE
NaHCO
3
, Na
2
CO
3
SO
3
H
SO
3
HNH
N N
N
NHCH
2
CH
2
NH
SO
3
H
O
N
N
O
SO
3
H
Cl
Cl
HNCH
2
CH
2
NH
N N
N
NH
SO
3
H
H
3
OS
NH
A
A
NH
+ CO
2
2NaCl
+
Reactive Blue FGN
6. BLUE LFNG
PROCESS DISCRIPTION
Aniline 2,4 Disulphonic Acid Is Cynurated & Condensed With Blue 198 Base &
Spray dried.
CHEMICAL REACTION
148
H
2
N
NH
2
SO
3
H
A
2NaNO
2
4HCl
OH
NH
2
SO
3
H
NH
2
NH
2
SO
3
H
++
+
++
+
Cl
N
NN
Cl Cl
SO
3
H
SO
3
H
MPDSA
CYA CHLORIDE
H-Acid
NaHCO
3
, Na
2
CO
3,
NaOH
SO
3
H
SO
3
H
NN
SO
3
HSO
3
H
OHNH
2
N N NH
N N
N
Cl
SO
3
H
NH
A 2NaCl + 3H
2
O + CO
2
+
Reactive Blue FB
(A- SO
2
CH
2
CH
2
OSO
3
H )
STA
7. BLUE BF
PROCESS DISCRIPTION
MPDSA Is Cynurated & Condensed With Vinyl Sulphone. Product diazotized &
coupled with H acid, Product again coupled with Sulfo Tobias Acid & spray dried.
CHEMICAL REACTION
149
+
SO
3
H
NH
2
H
2
N
ClCl
N N
N
Cl
+
+
SO
3
H
NH
2
SO
3
H
NH
2
A
+
+ 4HCl
2NaNO
2
H-Acid
SO
3
H
SO
3
H
+
NH
2
OH
MPDSA
CYA CHLORIDE
(A- SO
2
CH
2
CH
2
OSO
3
H )
STA
NaHCO
3
, Na
2
CO
3,
NaOH
NN
NH
2
OH
SO
3
H SO
3
H
N N
SO
3
H
SO
3
H
SO
3
H
NH
NH
Cl
N
NN
A
+
+ CO
2
2NaCl + 3H
2
O
Reactive Blue BFN
8. BLUE BFN
PROCESS DISCRIPTION
MPDSA is Cynurated & Condensed with Vinyl Sulphone. Product diazotized &
coupled with H acid, Product again coupled with Sulfo Tobias Acid & spray dried.
CHEMICAL REACTION
150
9. BLUE 2B
PROCESS DISCRIPTION
MPDSA is Cynurated & Condensed With Vinyl Sulphone. Product diazotized &
coupled with H acid, Product again coupled with Sulfo Tobias Acid & spray dried.
CHEMICAL REACTION
151
Mass Balance:
Sr.
NO.
Raw
Materials
Total Input Quantity (Kg)
BLUE
3R
BLUE
F4R
BLUE
HERD
BLUE
HEGN
BLUE
LFNG
BLUE
221
BLUE
BF
BLUE
BFN
BLUE
2B
1 Cynauric
Chloride
- 64 144.5 156 176 109 78 100 -
2 Oil HS - 1 3 3 3 1 1 2 -
3 Aniline 2,4 Di
Sulpho Acid
- - - 206 - - - - -
4 Aniline 2,5 Di
Sulpho Acid
- - - - 239 - - - -
5 4 ADPSA - 82 - - - - - - -
6 6 AAPSA - - 106 - - - - - -
7 NEPBE - - - - - - - - -
8 4 Sulpho
Hydrogen
- - 133 - - - - - 364
9 H Acid 32 100 - - - 168 120 136 -
10 MPDSA - - - - - - - 100 -
11 Vinyl Sulphone - 107 - - - 164 117 - -
12 Meta Base
Ester
- - - - 296 - - 149 -
13 STA - - - - - 167 119 155 -
14 Antifoam 5 4 3 5 5 2 2 5 5
15 Blue 198 Base - - - 200 250 - - - -
16 Sulfamic Acid 1 1 1 - - 1 1 1 1
17 Sulpho OAVS - - - - - - - - 453
18 SPD Oil 2 2 3 3 5 3 3 4 10
19 DDC Oil 10 10 10 20 10 10 10 - -
20 Soda Ash 45 113 95 173 200 211 151 130 113
21 Sodium
Sulphate
484 600 280 427 37 100 290 240 -
22 Sodium
Bicarbonate
41 - 120 76 270 - - 88 287
23 Sodium Nitrite 49 21 30 - - 77 55 70 79
24 Copper
Sulphate
249 - 112.5 - - - - - 331
25 Caustic Soda 67 25 257 - 32 21 15 45 -
26 HCl 37 125 199 - 100 261 285 62 -
27 DMAVS 234 - - - - - - - -
28 Acetic
Anhydride
146 - - - - - - - -
29 PPDDSA - - 69 - - - - - -
Total 1586 1255 1566 1269 1623 1295 1247 1287 1643
152
Sr.
NO.
TOTAL MASS
REMOVED
Total Output Quantity (Kg)
BLUE
3R
BLUE
F4R
BLUE
HERD
BLUE
HEGN
BLUE
LFNG
BLUE
221
BLUE
BF
BLUE
BFN
BLUE
2B
1 Total Water
Evaporated
73 41 174 45 106 83 60 98 121
2 CO2 Evolved during
Reaction
40 47 102 112 224 87 62 100 197
3 Salt Formation
during reaction,
Removed from NF
273 162 250 107 268 120 120 84 320
4 Organics removed
from NF
200 5 40 5 25 5 5 5 5
5 Total Finished
Product
1000 1000 1000 1000 1000 1000 1000 1000 1000
Total 1586 1255 1566 1269 1623 1295 1247 1287 1643
153
� REACTIVE GOLDEN YELLOW
1. Golden Yellow R
Process Description
Vinyl Sulphone diazotized coupled with MPDSA and spray dried.
Chemical Reaction
PBVSE
+NH
2
A NaNO
2
2HCl
+
+ NH
2
SO
3
H
NaHCO
3
,NaOH
N N
A
NH
2
NH
2
SO
3
H
NH
2
+ 2NaCl + 3H
2
O + CO
2
Reactive Golden Yellow R
MPDSA
2. Golden Yellow RNL
Process Description
Vinyl Sulphone ester is diazotized & coupled with Acetyl MPDSA and spray dried.
Chemical Reaction
Acetyl MPDSA
SO
3
H
NH
2
+
+
2HClNaNO
2
A NH
2
+
PBVSE
NHCOCH
3
NaHCO
3
+ CO
2
2NaCl + 3H
2
O+
NH
2
SO
3
H
A
NN
NHCOCH
3
Reactive Golden Yellow RNL
154
Mass Balance:
Input:
Sr. No. Raw Materials Total Input Quantity (Kg)
Golden Yellow RNL Golden Yellow R
1 A. MPDSA 238 -
2 MPDSA - 312
3 Vinyl Sulphone 298 467
4 Antifoam 4 5
5 SPD oil 4 5
6 DDC Oil 20 -
7 Sulfamic Acid 1 1
8 Sodium Bi
Carbonate
237 140
9 HCl 162 103
10 Caustic Lye - 66
11 Sodium Sulphate 176 -
12 Sodium NItrite 72 70
Total 1212 1169
Output:
Sr. No. Total Mass
Removed From
Reaction & Process
Total Output Quantity (Kg)
Golden Yellow RNL Golden Yellow R
1 Total Water
Evaporated
88 96
2 CO2 Evolved during
Reaction
124 73
3 Total Finished
Product
1000 1000
Total 1212 1169
155
PBVSE
NH
2
A
NH
2
NH
2
OCH
3
A
+ + +
4HCl2NaNO
2
(A- SO
2
CH
2
CH
2
OSO
3
H )
DMAVSE
OH
NH
2
SO
3
H SO
3
H
+
H-Acid
NaHCO
3
, NaOH
NNA
SO
3
HSO
3
H
NH
2
OH
N N
SO
3
H
OCH
3
A + CO
2
2NaCl + 3H
2
O+
NAVY Blue 2G
� REACTIVE NAVY BLUE
1. Navy Blue 2G
Process Description
Vinyl Sulphone ester & DMAVS are diazotized & coupled with H Acid and spray
dried.
Chemical Reaction
156
2
NH
2
SO
3
H
NH
2
Cya Chloride
2
Cl Cl
Cl
N
NN
+ H
2
N
CH
3
SO
3
H
+ 2
2NaNO
2
4HCl
++
H-Acid
+
SO
3
HSO
3
H
NH
2
OH
MPDSA
OTSSA
Na
2
CO
3
, NaOH
H
3
OS
CH
3
NH
N N
N
Cl
NH
OH
NH
2
SO
3
H SO
3
H
SO
3
H
N N NN
SO
3
H
NH
N N
N
Cl
NH
CH
3
SO
3
H
+ 3H
2
O + CO
2
Navy Blue XLE
2. NAVY BLUE XLE
Process Description
Vinyl Sulphone ester & DMAVS are diazotized & coupled with H Acid and spray
dried.
Chemical Reaction
157
3. NAVY BLUE RGB
Process Description
Vinyl Sulphone ester & OAVS ester are diazotized & coupled with H Acid and
spray dried.
Chemical Reaction
DMAVSE
(A- SO
2
CH
2
CH
2
OSO
3
H )
+
A
OCH
3
NH
2
NH
2
PBVSE
A + +
4HCl2NaNO
2
OH
NH
2
SO
3
H SO
3
H
+
H-Acid
NaHCO
3
NAVY Blue RGB
A
OCH
3
NN
OH
NH
2
SO
3
H SO
3
H
N N
A
+ 2NaCl + 3H
2
O
158
Mass Balance:
Input:
Sr.
No.
RAW MATERIALS TOTAL INPUT QUANTITY (kg)
NAVY BLUE 2G NAVY RGB NAVY XLE
1 H Acid 196 204 116
2 2,5 DMAVS 222 - -
3 Vinyl Sulphone 176 193 -
4 Antifoam 6 5 10
5 Sulfamic Acid 1 1 2
6 MPDSA - - 175
7 Cynauric Chloride - - 175
8 Oil HS - - 2
9 Ortho Toluidine Sul. Acid - - 175
10 SPD Oil 4 4 4
11 DDC Oil 20 20 -
12 OAVS - 234 -
13 Caustic Lye 27 26 70
14 Sodium Bicarbonate 136 166 291
15 Sodium Nitrite 88 98 65
16 HCl 157 179 297
17 Sodium Sulphate 230 199 -
1263 1329 1388
Output:
Sr.
No.
RAW MATERIALS TOTAL OUTPUT QUANTITY (kg)
NAVY BLUE 2G NAVY RGB NAVY XLE
1 Total Water Evaporated 87 71 130
2 CO Evolved during Reaction 71 87 156
3 Salt formation during the
reaction removed from NF
95 161 92
4 Organics removed from NF 10 10 10
5 Total Finished Product 1000 1000 1000
1263 1329 1388
159
Disperse Dyes:
1. AZO Dyes
Manufacturing Process:
1. Preparation of Hydrochloride &Diazonium Salt compounds For Monoazo Dyes:
DM water/ Process water is charged in Reaction vessel. Then required quantity of Amines as
mentioned in Raw Material list Annexure (A) is charged. Then required quantities add Acid
[HCL / H2SO4 / Nitric] is added & it is stirred for 4-5 hrs to form good suspension of
Hydrochloride. Now Crushed ICE is added to reduce temperature 0 to 5 Deg.C. Then Sodium
Nitrite is slowly added keeping Congo red paper positive & S.I. paper slightly positive
&stirred for 1-2 hrs at 0 to 5 Deg.C. Now diazo is ready for coupling.
2. Preparation of Coupler compound:
In Coupling reaction vessel, required quantity of Process / DM water is taken & required
quantity of coupler as mentioned in Raw Material list Annexure is added. Then little
quantity of eighter alkali or acid is added to make soluble & buffer to maintain coupling
condition. Then crushed ICE is added to reduce temperature 15 to 20 Deg.C
3. Coupling:
Now in above coupling reaction vessel previously prepared diazo mass is slowly received in
2-3 hrs. Keeping temperature 5 to 10 Deg.C & is stirred to complete coupling reaction.
Reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for further
treatments
4. Grinding in Sand / Beed Mills / Homozinizer
Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /
Homozinizer. Now the mass is eighter directly converted in Liquid & standardization to
Dispatch as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to
dispatch as a Powder form.
160
Mass Balance:
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 1000 kg
Amines 250 kg
Acid 400 kg
ICE 1000 kg
Sodium Nitrite 95kg
Water 500 kg
Coupler 275 kg
Alkali / Acid 150 kg
ICE 1000 kg
Water for Washing 4670 kg ML to ETP
2000 kg 2000 kg wet cake
Auxiliaries 400Kg
Press Cake 2000 kg
1400 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 9070 kg 9070 kg
Diazotization
Diazo Reaction
Vessel
I Coupling
Reaction Vessel
Filtration &
Washing
Spray drying Unit
Sand Mills Unit
161
2. Anthraquinones / Condensed Dyes
Manufacturing Process:
In suitable reaction vessel, require quantity water Or suitable solvent like Dimethyl Form amide
/ Toluene / Xylene is taken .Then mono azo mass or condensing Product is condensed with
require condensed products as mentioned in raw material list Annexure (A) at require
parameters. After completion of condensation, Solvents are Distilled out for Re-Use &
remaining reaction mass is filtered, washed with Water. Filtrate & Washing is send to ETP for
further treatments.
Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /
Homozinizer. Now the mass is eighter directly converted in Liquid & standardization to Dispatch
as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to dispatch as a
Powder form.
Mass Balance:
FLOW CHART WITH MATERIAL BALANCES [Mono Azo]:
INPUT IN KGS OUTPUT IN KGS
Water 800 kg
Amines 150 kg
Acid 200 kg
ICE 1000 kg
Sodium Nitrite 50kg
Cold Water Wash 1000 kg 2000 kg ML to ETP
1200 kg Press cake
Water 500 kg
Press Cake 1200 kg
Couplers 100kgs
ICE 500 kg
700 kg water recycled to first stage
Auxiliaries’
For STD 200Kg 1800 kg Finish Product
Total 5700 kg 5700 kg
Diazotization
Diazo Reaction
Vessel
Reverse Osmosis
Unit
Standardization
Filter press
I Coupling
Reaction Vessel
162
3. Cyanation Dyes
Manufacturing Process:
In a suitable reaction vessel require quantity water OR suitable Solvents like Dimethyl Form
amide / Methanol taken. Then mono azo OR AQ Product mass is charged & further condensed
with Sodium Cyanide. After Completion Of complete consumption of Sodium Cyanide, Solvent
is distilled out for Re-Use & reaction mass is filtered. ML is collected in separate Vessel for
Killing / Detoxification of traces cyanide with Sodium Bisulphite. Again it is filtered. Ml is send to
ETP for further treatment.
Press cake is mixed with Dispersing agents/ auxiliaries & grinded in Sand Mills / Beed Mills /
Homozinisers. Now the mass is eighter directly converted in Liquid & standardization to ispatch
as A Liquid Dyes OR if powder require, it is directly straightway Spray Dried to dispatch as a
Powder form.
163
Mass Balance:
INPUT IN KGS
OUTPUT IN KGS
Solvent 1500 kg
Mono/R.M.Product 250 kg
Sodium Cyanide 200 kg
Water 750 kg
1425 kg solvent recycle
Water 500 kg
Sodium Bisulphite 250 kg
Alkali 150 Kg
1400 kg Wet cake
Water 1000kg Reslury
Wet Cake 1400kg
Water for Washing
2500 kg 775 kg ML ETP
3300 kg ML to ETP
1600 kg wet cake for Sand
D.A Auxiliaries 200Kg mill
Press Cake 1600 kg
800 kg Water evaporation
in Spray Drying
1000 kg Finish Product
Total 10300 kg 10300 kg
Reaction Vessel
Detoxification
Vessel
Sand Mills Unit
Spray drying Unit
Solvent recovery
system
Re-Slurry
Filter Press
Filter press Filter press
164
O
O
OH
OH
2C4H9 NH2
Quinizarine(M.Wt. 240)
n-Butylamine (M.Wt. 73)
HN
HN
C4H9
C4H9
O
O
H2O
Solvent Blue 35 (M.Wt. 350)
Solvent Dyes:
1. Solvent Blue 35
Manufacturing Process:
A mixture of Quinizarine and Leuco Quinizarine is reacted with n-Butyl amine using methanol as
a solvent. The product is then filtered and washed with water. The wet cake is dried and
pulverized to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Blue 35
Sr. No. Input Kg Output Kg
1 Methanol 1454.55 Solvent Blue 35 1000
2 Quinizarine 563.63 Methanol Recovered 1420.05
3 Leuco Quinizarine 140 Butyl Amine Recovered 498.10
4 n-Butyl amine 512.72 Effluent 5641.40
5 Nitrobenzene 85.45 Loss on drying 545.45
6 Water 6363.64 Residue 15.00
Total 9120 Total 9120
165
O
O
OH
OH
2
H3C
NH2
CH3
CH3
Quinizarine(M.Wt. 240)
Mesidine(M.Wt. 135)
O
O
HN
HN
CH3
CH3
CH3CH3
CH3
CH3
H2O
Solvent Blue 104 (M.Wt. 474)
2. Solvent Blue 104
Manufacturing Process:
A mixture of Quinizarine and Leuco Quinizarine is reacted with Mesidine using ODCB as a
solvent. The reaction mass is then oxidized using air. The product is isolated using methanol. It
is then filtered and washed with water. The wet cake is dried and pulverized to get the finished
product.
Chemical Reaction:
Mass Balance:
Solvent Blue 104
Sr. No. Input Kg Output Kg
1 ODCB 789.47 Solvent Blue 104 1000
2 Quinizarine 421.05 ODCB Recovered 774.78
3 Leuco Quinizarine 105.26 Methanol Recovered 1541.05
4 Mesidine 605.26 Effluent 7410.46
5 Methanol 1578.95 Loss on drying 657.89
6 Water 7894.74 Residue 10.52
Total 11394.70 Total 11394.70
166
OHO
OHO NH2
NHCOCH3
Quinizarine(M.Wt. 240)
p-Amino Acitanilide (M.Wt. 150)
O OH
O NH NHCOCH3
H2O
Solvent Blue 122 (M.Wt. 372)
3. Solvent Blue 122
Manufacturing Process:
A mixture of Quinizarine & Leuco Quinizarine is reacted with p-amino acetanilide using Iso
propyl alcohol as a solvent. The reaction mass is then oxidized using air. The product is then
isolated using water. It is then filtered and washed with water. The wet cake is dried,
pulverized and sieved to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Blue 122
Sr. No. Input Kg Output Kg
1 Iso propyl alcohol 1960.78 Solvent Blue 122 1000
2 Quinizarine 392.15 IPA Recovered 1915.74
3 Leuco Quinizarine 98.04 Effluent 8201.72
4 P-amino acetanilide 637.25 Los on drying 1862.74
5 HCl 98.04 Residue 10.00
6 Water 9803.92
Total 12990.20 Total 12990.20
167
Quinizarine(M.Wt. 240)
O OH
O OH
NH2
CH3
p-Toluidine(M.Wt. 107)
NHO
NHO CH3
CH3
H2O
Solvent Green 3 (M.Wt. 418)
4. Solvent Green 3
Manufacturing Process:
A mixture of Quinizarine & Leuco Quinizarine is reacted with Para Toluidine using Butanol as a
solvent. The product is isolated by distilling off the Butanol; it is then filtered and washed with
HCl. The wet cake is dried, pulverized and sieved to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Green 3
Sr. No. Input Kg Output Kg
1 Butanol 2474.23 Solvent Green 3 1000
2 Quinizarine 463.91 Butanol Recovered 2440.51
3 Leuco Quinizarine 129.89 Effluent 6790.78
4 Para Toluidine 567.01 Loss on drying 298.96
5 Water 6597.94 Residue 12.00
6 HCl 309.27
Total 10542.25 Total 10542.25
168
C
O
C
O
ONH2NH2
Phthalic Anhydride (M.Wt. 148)
1:8 Diamini Napthalene (M.Wt. 158)
C
N
C
N
O
H2O
Solvent Orange 60 (M.Wt. 270)
5. Solvent Orange 60
Manufacturing Process:
Phthalic anhydride is reacted with 1: 8 Diamino Naphthalene using o-Xylene as a solvent. The
product is isolated using methanol. It is then filtered and washed with water. The wet cake is
dried and pulverized to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Orange 60
Sr. No. Input Kg Output Kg
1 o-Xylene 2666.67 Solvent Orange 60 1000
2 Phthalic Anhydride 575.75 o-Xylene Recovered 2610.33
3 1:8 Diamino Naphthalene 606.06 Methanol Recovered 5216.70
4 Methanol 5296.97 Effluent 4448.72
5 Water 4545.45 Loss on drying 400
6 Residue 15.15
Total 13690.90 Total 13690.90
169
O OH
Quinizarine(M.Wt. 240)
o-Xylene
Solvent Orange 86 (M.Wt. 240)
OHO
O OH
OHO
6. Solvent Orange 86
Manufacturing Process:
Crude Quinizarine is refluxed using o-Xylene as a solvent. The resulting product is then filtered
and washed with methanol followed by hot water wash. The wet cake is dried and pulverized to
get the finished product.
Chemical Reaction:
Mass Balance:
Solvent orange 86
Sr. No. Input Kg Output Kg
1 O-Xylene 2714.29 Solvent orange 86 1000
2 Quinizarine 1071.43 O-xylene recovered 2680.02
3 Methanol 714.28 Methanol recovered 696.14
4 Water 6428.57 Effluent 6245.26
5 Loss on drying 150
6 Residue 157.15
Total 10928.57 Total 10928.57
170
N
NC
HC
O
CH3
BrO
CH3
NH2
6-Bromo Anthrapyridone (M.Wt. 340)
p-Toluidine(M.Wt. 107)
KOH
O
HN
CH3
CH3
KBr H2O
O
Solvent Red 52 (M.Wt. 366)
7. Solvent Red 52
Manufacturing Process:
6-Bromo Anthrapyridone is condensed with Para Toluidine using o-Xylene as a solvent. The
product is isolated by adding methanol. It is then filtered & washed with water. The wet cake is
dried & pulverized to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Red 52
Sr. No. Input Kg Output Kg
1 o-Xylene 2234.04 Solvent Red 52 1000
2 6-Bromo Anthrapyridone 978.74 o-Xylene Recovered 2196.38
3 Para Toluidine 382.97 Methanol Recovered 5375.95
4 Potassium acetate 468.08 Residue 25.53
5 Methanol 5446.81 Aqueous effluent 15189.46
6 Water 14893.60 Loss on drying 957.44
7 HCl 340.42
Total 24744.76 Total 24744.76
171
O
Cl O NH2
O
Cl
Cl
Cl
+
NH2
Tetra Chloro Phthalic Anhydride (M.Wt. 286)
1:8 Diamino Naphthalene(M.Wt. 158)
Cl
Cl
ClOCl
C
N
C
N+ H2O
Solvent Red 135 (M.Wt. 408)
8. Solvent Red 135
Manufacturing Process:
Tetra Chloro Phthalic Anhydride is reacted with 1:8 Di Amino Naphthalene using o-Xylene as a
solvent. The product is filtered and washed with water. The wet cake is dried and pulverized to
get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Red 135
Sr. No. Input Kg Output Kg
1 o-Xylene 2080 Solvent Red 135 1000
2 TCPA 760 o-Xylene Recovered 2010
3 1:8 DAN 400 Methanol Recovered 466
4 Methanol 480 Effluent 4524
5 Water 4800 Loss on drying 504
6 Residue 16
Total 8520 Total 8520
172
O
O
Cl NH2
+
1-Chloro Anthraquinone (M.Wt. 242.5)
Mono Cyclo Hexyl Amine (M.Wt. 99)
Sodium Acetate
HN
O
O
+ +NaCl H2O
Solvent red 168 (M.Wt. 305)
9. Solvent Red 168
Manufacturing Process:
1-Chloro Anthraquinone is condensed with mono cyclohexylamine using o-Xylene as a solvent.
The product is isolated using methanol and then filtered. It is then washed with water. The
wet cake is dried and pulverized to give the finished product.
Chemical Reaction:
Mass Balance:
Solvent Red 168
Sr. No. Input Kg Output Kg
1 o-Xylene 857.14 Solvent Red 168 1000
2 1-Chloro AQ 833.33 o-Xylene Recovered 834.28
3 Mono cyclohexylamine 404.76 Methanol Recovered 3755.25
4 Sodium Acetate 259.52 Residue 14.28
5 Methanol 3809.52 Aqueous effluent 10608.12
6 Water 11904.80 Loss on drying 1857.14
Total 18069.07 Total 18069.07
173
S+
H3C CN
H3COOC NH2
CN
CH3
HN NH
(CH2)3
OCH3OCH3
(CH2)3
Diazo Compound (M.Wt. 196)
Coupler Component (M.Wt. 292)
1. H2SO4 + NaNO2
2. Coupling
NH3COOC
CNH3C
S
(CH2)3
OCH3 OCH3
(CH2)3
NHHN
CH3
N CN
Solvent Red 195 (M.Wt. 499)
10. Solvent Red 195
Manufacturing Process:
The diazo component is diazotized using Sulfuric acid and Sodium nitrite. It is then coupled with
Coupler 195 in the acidic medium. It is filtered and washed till neutral. The wet cake is dried.
The product is then pulverized to get the finished product.
Chemical Reaction:
174
Mass Balance:
Solvent Red 195
Sr. No. Input Kg Output Kg
1 3 Methoxy Propyl Amine 447.76 Solvent Red 195 1000
2 Tri Ethyl Amine 125 Aqueous Effluent 48194.04
3 Amogh FP-165 395.52 Loss on drying 3000
4 Methanol 419.77
5 HCl 559.70
6 Sulfuric Acid 1865.67
7 Sodium Nitrite 156.71
8 Acetic acid 1791.04
9 Propionic Acid 298.50
10 Diazo component 425.37
11 Ice + Water 45709
Total 52194.04 Total 52194.04
175
+
OCl
NH2O Cl
1:5 Dichloro Anthraquinone (M.Wt. 277)
Mono Cyclo Hexyl Amine (M.Wt. 99)
Sodium Acetate
HNO
NH O
+ NaCl + H2O
Solvent Red 207 (M.Wt. 402)
11. Solvent Red 207
Manufacturing Process:
1:5 Dichloro Anthraquinone is condensed with mono cyclohexylamine using o-Xylene as a
Solvent. The product is isolated using methanol and then filtered. It is then washed with water.
The wet cake is dried and pulverized to give the finished product.
Chemical Reaction:
Mass Balance:
Solvent Red 207
Sr. No. Input Kg Output Kg
1 o-Xylene 976.74 Solvent Red 207 1000
2 1:5 DCAQ 725.58 o-Xylene Recovered 957.90
3 Mono cyclohexylamine 627.90 Methanol Recovered 4986.04
4 Sodium Acetate 493.02 Residue 13.95
5 Methanol 5093.02 Aqueous effluent 10842.08
6 Water 11627.90 Loss on drying 1860.46
7 Acetic Acid 116.27
Total 19660.43 Total 19660.43
176
12. Solvent Violet 13
Manufacturing Process:
A mixture of Quinizarine and Leuco Quinizarine is reacted with Para Toluidine using Butanol as a
solvent in the presence of HCl & Zinc. The product is filtered and washed with dilute HCl &
water. The wet cake is dried and pulverized and sieved to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Violet 13
Sr. No. Input Kg Output Kg
1 Butanol 3157.89 Solvent Violet 13 1000
2 Quinizarine 752.63 Butanol Recovered 2905.26
3 Leuco Quinizarine 15.78 Effluent 16766.58
4 Para Toluidine 394.73 Loss on drying 300
5 Zinc 34.21 Residue 15.00
6 HCl 842.10
7 Water 15789.50
Total 20986.84 Total 20986.84
S olv ent V io le t 13 (M.W t. 329)
H2 O+
O
O HN
p-Toluid ine(M.W t. 107)
Quinizarine(M.W t. 240)
OHO NH2
O
+
OH CH3
CH3
177
CH3
CH3
+
O
NH2O
1:8 Dichloro Anthraquinone (M.Wt. 277)
p-Toluidine(M.Wt. 107)
HNO
O
+ H2O
Solvent Violet 14 (M.Wt. 418)
Cl Cl
2
Potassium Acetate
NHH3C
+ KCl
13. Solvent Violet 14
Manufacturing Process:
1:8 Dichloro Anthraquinone is reacted with Para Toluidine using ODCB as a solvent. The product
is isolated using methanol. It is then filtered and washed with water. The wet cake is dried and
pulverized to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Violet 14
Sr. No. Input Kg Output Kg
1 ODCB 838.71 Solvent Violet 14 1000
2 1:8 DCAQ 645.16 ODCB Recovered 818.64
3 Para Toluidine 564.52 Methanol Recovered 2534.58
4 Pot. Acetate 709.67 Effluent 10872.58
5 HCl 483.87 Loss on drying 258.08
6 Water 9677.42 Residue 16.12
7 Methanol 2580.65
Total 15500 Total 15500
178
O +N CH3
O
O
Phthalic Anhydride (M.Wt. 148)
Quinaldine(M.Wt. 143)
C
CH
C
N+ H2O
Solvent Yellow 33 (M.Wt. 273)
14. Solvent Yellow 33
Manufacturing Process:
Phthalic anhydride is reacted with Quinaldine using ODCB as a solvent. The product is isolated
using methanol. It is then filtered and washed with water. The wet cake is dried and pulverized
to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Yellow 33
Sr. No. Input Kg Output Kg
1 ODCB 888.88 Solvent Yellow 33 1000
2 Phthalic anhydride 555.55 ODCB Recovered 865.54
3 Quinaldine 555.55 Methanol Recovered 2180
4 Methanol 2222.22 Effluent 6079.44
5 Water 6250 Loss on Drying 333.34
6 Residue 13.88
Total 10472.20 Total 10472.20
179
O
Cl O
O
Cl
Cl
Cl
+
Tetra Chloro Phthalic Anhydride (M.Wt. 286)
Quinaldine(M.Wt. 143)
Cl
Cl
Cl
O
OCl
CHN
Solvent Yellow 157
CH3N
15. Solvent Yellow 157
Manufacturing Process:
Tetra Chloro Phthalic anhydride is reacted with Quinaldine using O-Xylene as a solvent. The
product is isolated using methanol. It is then filtered and washed with water. The wet cake is
dried and pulverized to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Yellow 157
Sr. No. Input Kg Output Kg
1 o-Xylene 2472.73 Solvent Yellow 157 1000
2 Tetra Chloro Phthalic
Anhydride
727.27
o-Xylene Recovered 2419.09
3 Quinaldine 443.63 Methanol Recovered 1776.36
4 Methanol 1818.18 Effluent 8026.36
5 Water 8181.82 Loss on drying 400.00
6 Residue 21.82
Total 13643.63 Total 13643.63
180
Cl O
2
SHCl
O
+
1:8 Dichloro Anthraquinone (M.Wt. 277)
Thiophenol(M.Wt. 110)
O
SOS
Solvent Yellow 163 (M.Wt. 424)
16. Solvent Yellow 163
Manufacturing Process:
1:8 Dichloro Anthraquinone is reacted with Thiophenol using n-Butanol as a solvent. The crude
is filtered and purified using 0-Xylene. The product is filtered and washed with water. The wet
cake is dried and pulverized to get the finished product.
Chemical Reaction:
Mass Balance:
Solvent Yellow 163
Sr. No. Input Kg Output Kg
1 n-Butanol 2946.43 Solvent Yellow 163 1000
2 1:8 DCAQ 678.57 n-Butanol Recovered 2911.43
3 Potassium Carbonate 401.78 o-Xylene Recovered 1735.42
4 Thiophenol 535.71 Effluent 10265.64
5 o-Xylene 1785.71 Loss on drying 250.00
6 Water 9821.43 Residue 7.14
Total 16169.63 Total 16169.63
181
OH
NH2
SO2CH3
2-Amino Phenol 4-N-Methyl Sulfone (M.Wt. 187)
1. Diazotization
2. Coupling m-Chloro DMP
3. Chromination
CN
N C
CH
CH3
OH
(M.Wt. 208.5)
CH3
CN
N C
CH
Cl
Cl
N N
SO2CH3
O
Cr
O
Solvent Orange 58 (M.Wt. 861)
O
CN
N C
C
O
N N
SO2CH3
Cl
CH3
17. Solvent Orange 58
Manufacturing Process:
2 Amino Phenyl Methyl Sulfone is diazotized and coupled with m-Chloro PMP. It is then
metalized, filtered and washed with water. The wet cake is dried and pulverized to get the
finished product.
Chemical Reaction:
182
Mass Balance:
Solvent Orange 58
Sr. No. Input Kg Output Kg
1 APMS 420 Solvent Orange 58 1000
2 HCl 466.66 Effluent 49346.7
3 Sodium Nitrite 160 Loss on drying 1500
4 Caustic soda 233
5 m-Cl PMP 500
6 Chrominating Agent 66.66
7 Water + Ice 50000
Total 51846.7 Total 51846.7
183
N
O
SO3H
N CN
N C
CH
OH
Phenyl Methyl Pyrazolone (PMP) (M.Wt. 174)
Diazo Acid(M.Wt. 250)
1. Chromination
2. Co Precipitation with Rhodamine
3. Condensation with Primene (M.Wt. 200)
Solvent Red 127
CH3
N N
O
C N
NC
C
O
O
Cr
O
SO3HNN
CN
N C
C
CH3
Primene
+
Rhodamine
18. Solvent Red 127
Manufacturing Process:
Diazo acid is coupled with Phenyl Methyl Pyrazolone. It is metallized and then condensed with
Rhodamine and 2-Ethyl Hexyl Amine. It is then filtered and washed with water. The wet cake is
dried and pulverized to get the finished product.
Chemical Reaction:
184
Mass Balance:
Solvent Red 127
Sr. No. Input Kg Output Kg
1 Diazo Acid 250 Solvent Red 127 1000
2 PMP 187.5 Effluent 61265
3 Caustic soda 150 Loss on drying 1500
4 Chrominating Agent 35
5 Salicylic Acid 32.5
6 Rhodamine 500
7 2-EHA 110
8 Water 62500
Total 63785 Total 63765
185
OH
NH2
NO2
O2N
OH
NH2
4-Nitro, 2-Aminophenol (M.Wt. 154)
5-NItro 2-Aminophenol (M.Wt. 154)
1. Diazotization
2. Coupling with B-Napthol (M.Wt. 144)
OH
3. Chromination
4. 2-Ethyl Hexylamine (M.Wt. 129)
N
O
Cr
NO2N
O
NN
O
O
NO2
CH3
CH C2H5
(CH2)4
NH2
Solvent Black 27
19. Solvent Black 27
Manufacturing Process:
Mixture of 4 NAP & 5 NAP is diazotized and coupled with B-Naphthol. It is then chrominated. It
is then condensed with 2-Ethyl Hexyl Amine. The product is filtered and washed with water.
The wet cake is dried and pulverized to get the finished product.
Chemical Reaction:
186
Mass Balance:
Solvent Black 27
Sr. No. Input Kg Output Kg
1 4 NAP 217.5 SOLVENT BLACK27 1000
2 5 NAP 217.5 EFFLUENT STEAM 52185
3 SODIUM NITRITE 185 LOSS ON DRYING 1500
4 HCl 535
5 WATER 52500
6 B-NAPHTHOL 402.5
7 CAUSTIC SODA 100
8 CHROMINATING AGENT 65
9 2-ETHYL HEXYL AMINE 127.5
10 SALICYLIC ACID 335
Total 54685 Total 54685
187
Dyes Intermediates:
1. H Acid
Manufacturing Process:
The process steps involve Sulphonation, Nitration, Neutralization, Filtration, Reduction,
concentration, Autoclaving and Isolation.
(a) Sulphonation: Naphthalene is charged in the cast iron sulphonator and sulphuric acid with
oleum is charged at low temperature to have reaction with monohydrated acid. The reaction
mass is then heated to 170 degree centigrade and 65% oleum is charged. The temperature is
maintained for about 3 hours. On completion of the reaction it is taken for nitration.
(b) Nitration: Nitration is carried out in CI vessels. The sulphonated mass is reacted with Nitric
acid at controlled temperature. The mass is then taken to neutralizer.
(c) Neutralization: This reaction is carried out in a MSRL brick lined vessel. The excess acid is
reacted with limestone to get gypsum.
(d) Filtration: The gypsum is then precipitated out and separated in horizontal vacuum filter
and is thoroughly washed with water.
(e) Reduction: The nitro mass thus obtained is reduced to amino compound by iron powder
and HCL in hot condition.
After completion of the reaction the mass is filtered to remove iron oxide sludge.
(f) Concentration: The amino solution is concentrated in the multiple effect evaporators to a
desired level for hydrolysis.
(g) Autoclaving: The concentrated mass is hydrolyzed under pressure of 6-7 kg/cm2 with
caustic soda at a temperature of 170 degree centigrade.
(h) Isolation: The hydrolyzed product obtained from the autoclave is reacted with Sulphuric
acid or HCL for an acidic p H of about 2.Hacid is thereby precipitated and filtered through
vacuum filters and washed to obtain wet cake of H acid. The wet cake is finally dried to get the
product.
188
Chemical Reaction:
189
190
2. J Acid
Manufacturing Process:
Tobias Acid is sulphonated by 23% Oleum, hydrolyzed by water and the wet cake is autoclaved
with caustic flakes. After autoclaving the mass is isolated with the help of 98% H2SO4. It is then
filtered, centrifuged and dried to obtain J acid.
Chemical Reaction:
191
Mass Balance:
192
Mass Balance:
Input Qty (Kg) Output Qty (Kg)
Tobias 1389 Product 1000
Oleum 23% 4243 Spent Acid 8750
Caustic Flake 958 Effluent 13055
Caustic Lye 625
H2SO4 98% 1563
Water 14028
Total 22806 Total 22806
193
3. 6-Nitro, 1-Diazo, 2-Napthol, 4-Sulphonic Acid
Manufacturing Process:
First of all takes water 500 lit. Then we add caustic lye 400 kgs. Heats upto 60c. Then we charge
b- Naphthol 1000 kgs. Add into reduce temp. upto 0c is block approx.- 25 Blanks. Then we
charge sodium nitrite 500 kgs. Then we charge sulphuric acid 500 kgs. Then charge sodium-bi-
sulphide 2000 kgs. Then salt 500 kgs. Then again sulphuric acid 1000 kgs.
Then discharge in Nutch. After filter take we take in vessel. Add sodium nitrite 300 kgs. Filter in
filter press isolate with sulphuric acid 500 kgs. Filter in nutch centrifuge that is 1-diazo.
Take oleum 23% 1000 kgs charge above 1-diazo. Then cool to 0 to 10c by chilling plant. Charged
nitric acid 500 kgs. dumped in 20 block ice. Filter in nutch centrifuge wet cane in 6-Nitro, 1-
Diazo, 2-Napthol, 4-Sulphonic Acid.
194
Mass Balance:
Input Qty (Kg) Output Qty (Kg)
β-Napthol 833.33 Product 1000
Caustic Lye 333.33 Effluent 4166.70
Sodium Nitrate 666.67 Process Sludge 833.30
Sulphuric Acid 833.33
Sodium-bi-Sulphite 1666.67
Oleum-23% 833.33
Nitric Acid-70% 416.67
Salt 416.67
Total 6000 Total 6000
195
4. Vinyl Sulphone
Manufacturing Process:
Acetanilide is charged into chlorosulphonic acid below 30 degree centigrade. After the addition
the temperature is raised to 50-55 degree centigrade and maintained for 4 hrs. It is cooled and
drowned over ice and filtered. The acetyl sulphochloride is charged into a slurry of sodium
bisulphate and made neutral with caustic and the pH is maintained at 7. Eyhylene oxide is
passed into the solution maintaining pH 7 by adding H2SO4. When the reaction is complete, it is
filtered and dried .It is further clarified by heating with calculated quantity of H2SO4 and then
pulverized. The final product is packed as Para base Vinyl Sulphone.
Chemical Reaction:
196
Mass Balance:
197
NH2
HSO3
Cl
Cl
2:5 DCASA
NaNO2
HCl
N=NCl
HSO3
Cl
Cl
SBS
Soda Ash
Cl
Cl
NH-NHSO3NH
HSO3
HCl
NHNH2
HSO3
Cl
Cl
MAA
NH-N=C-CH3COCH3
Cl
Cl
HSO3
HCl
N
N=C-CH3
C
CH2
O
Cl
Cl
HSO3
2:5 DCSPMP
5. Pyrazolones
a. 2:5 Dichloro 4 Sulpho Phenyl 3 Methyl 5 Pyrazolone
Manufacturing Process:
• Take water and oleum in the vessel and then add slowly 2.5 Dichloro Aniline.
• Then diazotize it with sodium nitrite at 0˚C.
• Pour diazo for neutral reduction into solution of SBS and soda ash.
• Heat at 80˚C and carry out hydrolysis by HCl.
• Then do formation of hydrazine with M.A.A Ester.
• Then isolation with HCl.
• Then cool it down and filter out the material.
Chemical Reaction:
198
Mass Balance:
2:5 DICHLORO 4 SULPHO PHENYL 3 METHYL 5 PYRAZOLONE
Sr. No. Inlet Kgs Outlet Kgs
1 2.5 Dichloro Aniline 700 2:5 Dichloro 4 Sulpho Phenyl 3
Methyl 5 Pyrazolone 1400
2 Oleum 2250 Waste Water to ETP 16560
3 NaNO2 310 SO2 585
4 Soda Ash 700
5 SBS 975
6 Caustic Soda Lye 1000
7 H2SO4 1150
8 Ester 475
9 HCL 1550
10 Water + Ice 9435
Total 18545 Total 18545
199
NH2
Cl
HSO3
6 CMA
NaNO2
HCl
Cl
HSO3
N=NCl
Soda Ash
SBS
Cl
NH-NHSO3NH
HSO3
HCl
NHNH2
Cl
HSO3
MAA
NH-N=C-CH3COCH3
Cl
HSO3
HCl
N
N=C-CH3
C-CH2
O
CL
HSO3
OCSPMP
b. 2 Chloro 5 Sulphophenyl 3 Methyl 5 Pyrazolone
Manufacturing Process:
• Take water and oleum in the vessel and then add slowly 6 Chloro Metanilic Acid.
• Then diazotize it with sodium nitrite at 0˚C.
• Pour diazo for neutral reduction into solution of SBS and soda ash.
• Heat at 80˚C and carry out hydrolysis by HCl.
• Then do formation of hydrazine with M.A.A Ester.
• Then isolation with HCL.
• Then cool it down and filter out the material.
Chemical Reaction:
200
Mass Balance:
2 CHLORO 5 SULPHO PHENYL 3 METHYL 5 PYRAZOLONE
Sr.
No. Inlet Kgs Outlet Kgs
1 6 Chloro Metanilic Acid 750 2 Chloro 5 Sulpho Phenyl 3 Methyl
5 Pyrazolone (900 Kgs 100%) 1060
2 NaNO2 265 Waste Water 9135
3 Soda Ash 850 SO2 690
4 SBS 1150
5 Ester 420
6 Caustic Soda Lye 450
7 HCL 4400
8 Water + Ice 2600
10885 10885
201
NH2
HSO3
NaNO2
HCl
HSO3
N=NCl
Soda Ash
SBS
NH-NHSO3NH
HSO3
HCl
NHNH2
HSO3
MAA
NH-N=C-CH3COCH3
HSO3
HCl
N
N=C-CH3
C-CH2
O
HSO3
1:3 SPMP
c. 1,3 Sulpho Phenyl 3 Methyl 5 Pyrazolone
Manufacturing Process:
• Take water and oleum in the vessel and then add slowly Metanilic Acid.
• Then diazotize it with sodium nitrite at 0˚C.
• Pour diazo for neutral reduction into solution of SBS and soda ash.
• Heat at 80˚C and carry out hydrolysis by HCl.
• Then do formation of hydrazine with M.A.A Ester.
• Then isolation with HCL.
• Then cool it down and filter out the material.
Chemical Reaction:
202
Mass Balance:
1,3 SULPHO PHENYL 3 METHYL 5 PYRAZOLONE
Sr.
No. Inlet Kgs Outlet Kgs
1 Metanilic Acid 750 1,3 Sulpho Phenyl 3 Methyl 5
Pyrazolone (1000 Kgs 100%) 1400
2 NaNO2 305 Waste Water 9040
3 Soda Ash 1450 SO2 675
4 SBS 1125
5 Ester 485
6 HCL 4400
7 Water + Ice 2600
11115 11115
203
NH2
HSO3
NaNO2
HCl
HSO3
N=NCl
Soda Ash
SBS
NH-NHSO3NH
HSO3
HCl
NHNH2
HSO3
MAA
NH-N=C-CH3COCH3
HSO3
HCl
N
N=C-CH3
C-CH2
O
HSO3
1:4 SPMP
d. 1,4 Sulpho Phenyl 3 Methyl 5 Pyrazolone
Manufacturing Process:
• Take water and oleum in the vessel and then add slowly S. Acid.
• Then diazotize it with sodium nitrite at 0˚C.
• Pour diazo for neutral reduction into solution of SBS and soda ash.
• Heat at 80˚C and carry out hydrolysis by HCl.
• Then do formation of hydrazine with M.A.A Ester.
• Then isolation with HCL.
• Then isolation with HCL.
• Then cool it down and filter out the material.
Chemical Reaction:
204
Mass Balance:
1,4 SULPHO PHENYL 3 METHYL 5 PYRAZOLONE
Sr.
No. Inlet Kgs Outlet Kgs
1 S. Acid 750 1, 4 Sulpho Phenyl 3 Methyl 5
Pyrazolone (1000 Kgs 100%) 1400
2 NaNO2 305 Waste Water 9040
3 Soda Ash 1450 SO2 675
4 SBS 1125
5 Ester 485
6 HCL 4400
7 Water + Ice 2600
11115 11115
205
NH2
NaNO2
HCl
N=NCl
Soda Ash
SBS
NH-NHSO3NH
HCl
NHNH2
MAA
NH-N=C-CH3COCH3
HCl
N
N=C-CH3
C-CH2
O
PMP
e. 1:3 Phenyl Methyl 5 Pyrazolone
Manufacturing Process:
• Take water and oleum in the vessel and then add slowly Aniline.
• Then diazotize it with sodium nitrite at 0˚C.
• Pour diazo for neutral reduction into solution of SBS and soda ash.
• Heat at 80˚C and carry out hydrolysis by HCl.
• Then do formation of hydrazine with M.A.A Ester.
• Then isolation with HCL.
• Then cool it down and filter out the material.
Chemical Reaction:
206
Mass Balance:
1:3 PHENYL METHYL 5 PYRAZOLONE
Sr.
No. Inlet Kgs Outlet Kgs
1 Aniline 500 1:3 Phenyl Methyl 5 Pyrazolone
(875 Kgs 100%) 1150
2 NaNO2 378 Waste Water to ETP 11376
3 Soda Ash 1798 SO2 800
4 SBS 1333
5 Ester 601
6 HCL 5456
7 Water + Ice 3260
13326 13326
207
Pigments:
1. Active CPC Blue
Manufacturing Process:
CPC Blue Crude is to be charged in the ball mill. Where sheering, hammering and grinding
process occurs and as a result finest particles of Activated CPC Blue is obtained, which is called
Activated CPC Blue. In this process no chemical process or reaction is involved but it is a
physical process by which desired particles shape and size are attained. In this way, after the
physical process, such obtained Activated CPC Blue is to be discharged from the grinding mill
and packed in HDPE Bags/Drums.
Chemical reaction:
Mass Balance:
Input Qty (Kg) Output Qty (Kg)
CPC Blue Crude 1000.0 Activated CPC Blue 1000
Total 1000.0 1000.0
208
2. CPC Blue
Manufacturing Process:
Phthalic Anhydride, Urea and solvent (TCB/NB/ONT) are mixed in the vessel equipped with
heating arrangement (by Thermopack Boiler for circulation of high temperature oil) and stirrer.
Cuprous Chloride and ammonium Molybdate are then added.
The mixture is heated up slowly for 20 hours at 180 C temperatures. Ammonia gas and carbon
dioxide gas is liberated with the formation of Phtahlamide at 135 C temp. Formation of Copper
phthalocyanine takes place at a temp. 185 C with release of Ammonia gas & carbon dioxide gas.
The Ammonia gas & carbon dioxide gas is scrubbed through series of scrubbers under water
circulation. The reaction mass is stirred till formation of Copper Pthalocyanine is completed.
The reaction mass is then transferred to rotary vacuum drier and solvent is recovered
completely under vacuum from rotary drier. The dried powder of Copper phthalocyanine is
then purified in MSRL brick lined vessel by treating it with acidic effluent (diluted sulphuric Acid)
generated during manufacture of pigment Apha Blue. The resulting mixture is filtered in filter
press and wet cake is washed with either the effluent generated during Beta Blue manufacture
and finally with fresh water till the soluble Salt are removed. Filtrate is transferred to ETP for
treatment, while the wet press cake of CPC Blue is dried in tray dryer/spin flash dryer,
pulverized and packed into HDPE bags.
Chemical reaction:
209
Mass Balance:
210
3. Alpha Blue (15:0 and 15:1)
Manufacturing Process:
Acid Pasting:
Receive 70% sulphuric acid in glass line vessel,cool sulphuric acid. add copper phthalocyanine.
Maintain temperature as per requirement.stirring is done for 4 hours, drown in water.
Filtration:
Filter above material in pp filter press,wash with water till neutral pH.
Pigmentation:
Charge acid free press cake in treatment vessel with required quantity of water, take pH 8-8.5
with caustic & add Tri-Lauryl ammonium sulphate ( Emulsifire) Now increase temperature to
90°c.maintain temperature for 4 hrs.
Filtration:
Filter material in pp filter press, wash with water properly till desired conductivity.
Drying:
Dry above cake in spin flash dryer or Tray dryer as per requirement.
Pulverising:
If material is tray dry then pulverise on micro pulveriser & collect in poly propylene bag.
Blending:
Take dry finished alpha blue powder as per quality requirement for mixing and blend powder
for atleast 2 hours in blender for proper mixing.
Chemical Reaction:
211
Mass Balance:
212
4. Pigment Beta Blue (15:3)
Manufacturing Process:
CPC Blue crude is used for manufacturing of Beta blue. It is taken into ball mil for grinding.
Here the particle size of the material gets reduced. The grinded material is taken into the
reactor with caustic Flakes. Caustic flakes are used to get alkaline pH.
The alkaline pH results in better dispersion of particles for pigmentation. The mass is refluxed
for pigmentation. Here the color of the material gets enhanced due to fine tuning with xylene /
IBA.
After completion of reflux, the mass is distilled for recovery of xylene / IBA. After recovery of
xylene / IBA, the mass is neutralized with hydrochloric acid to increase the particle size of beta
blue.
The whole mass is washed and filtered in filter press and washed with water properly till
desired conductivity.
Wet cake from filter press is dried in dryer / SFD. Dried cake is the pulverized and packed for
dispatch.
Chemical Reaction:
213
Mass Balance:
214
5. Pigment Beta Blue (15:4)
Manufacturing Process:
CPC blue crude is used for manufacturing of Beta blue. It is taken into ball mil for grinding. Here
the praticle size of the material gets reduced. The grinded material is taken into the reactor
with caustic Flakes, add-1, add-2, sulpho CPC & wood rosin with xylene solvent. The alkaline pH
results in better dispersion of particles for pigmentation. The mass is refluxed for pigmentation.
Here the colour of the material gets enhanced due to fine tuning with xylene.
This is only a physical process and does not involve any chemical reaction. After completion of
reflux, the mass is distilled for recovery of xylene. After recovery of xylene, the mass is
neutralized with hydrochloric acid to increase the particle size of beta belue. The whole mass is
filtered and washed in filter press. Wet cake from filter press is dried in dryer/SFD. Dried cake is
the pulverized and packed for dispatch.
Chemical Reaction:
215
Mass Balance:
216
6. Copper Phthalocyanine Pigment Green-7
Manufacturing Process:
Chlorination:
In a glass line vessel Aluminum chloride, vacuum salt, cupric chloride are collected then copper
phthalocyanine blue is added & continue chlorination is done by maintaining temperature as
per requirement. Remove sample & check end point; stop chlorination & drown in process
water. From this process by product HCL gas is generated which is scrubbed.
Filtration:
Above materialism filtered in pp filter press, and washed with water till filtrate is aluminum
free.
Pigmentation (Distillation):
Aluminum free press cake is charged in treatment vessel with required quantity of water, take
pH 12-12.5 with caustic & add oleic acid (Emulsifier) Now increase temperature to continue
reflux for 12hrs. Complete distillation & filter batch.
Filtration:
The material is filtered in pp filter press and washed with water properly till desired
conductivity.
Drying:
Above cake is dried in spin flash dryer or Tray dryer as per requirement.
Pulverizing:
If material is tray dry then pulverize on micro pulverized & collect in poly propylene bag.
Blending:
Take dry finished powder as per quality requirement for mixing and blend powder for least 2
hours in blender for proper mixing.
Chemical Reaction:
217
Mass Balance:
218
219
7. Pigment Violet 23
Manufacturing Process:
Ethylation:
Ethylation of Carbazole (Di- Benzo Pyrole) is carried out in Mono Chloro Benzene on solvent and
Di Ethyl Sulfate in ethylating agent in presence of Alkali. This step will give slurry of Ethyl
Carbazole. Reaction Temp. is 30º C to 130ºC.
Nitration:
Nitration of above slurry is carried out in Mon Cjloro Benzene media on solvent and dilute Nitro
Acid as nitrating agent. This step will give wet cake of Nitro cabazole, Reaction Temp os 25 º C -
75 º C.
Reduction:
Reduction of above wet cake is carried out in Ortho Di Chloro Benzene media and Solvent and
Hydrogen gas and Raney Nikel as reducing agent. After neutralization and filtration of above
reduced mass slurry will get reduction mass mother Liquor. This step will give Amlno Ethyl
Carbazole as mother liquor. Reaction Temp. is 25 º C - 95 º C.
Condensation and Cyclisation:
Above mother liquor is condensed with Chloronil and Sodium Acetate is used as Acid Binding
Agent. At high temp. and in presence of Benzene Sulfonil Chloride above condensed mass will
cyclised. After hot filtration, Methanol and hot water washing will get crude Pigment Violet 23
will get Crude Pigment Violet 23 Reaction Temp is 5 º C to 85 º C.
Pigmentation:
Above dry crude is grinded in kneader with salt in presence of Diethylation glycol will give cake
of kneading mass.
Acid Treatment:
Make slurry of above cake in hot water and hydrochloric acid. After filtration and hot water
washing will give wet cake of Pigment Violet 23.
Drying:
After drying of above wet cake in Spin Flash or Tray Dryer will give powder form of Pigment
Violet 23.
220
Chemical Reaction:
221
Mass Balance:
222
223
224
8. Pigment Red 122
Manufacturing Process:
Condensation:
DMSS condensed with peratoludine & HCl in present of methanol this step will give wet cake
reaction temperature 30 degree centigrade to 80 degree centigrade.
Oxidattion:
Above wetcake oxidize with R. salt, caustic flakes in present of methanol & filter it this step will
give slurry & this slurry isolate with HCl & filter it & washed it & dry it. Reaction temperature 30
degree centigrade to 90 degree centigrade.
Cyclisation:
Above dry materials cyclised with (P2O5 + H3PO4) PPA (poly phoshphoric acid) & drowing in
MSRL BL & Filter it & washed it & unload wet cake reaction temperature 30 degree centigrade
to 150 degree centigrade.
Pigmentation:
Above wet cake pigmentation with IBA + water & recovered IBA & Filter it & dry it. It is pigment
red-122 reaction temperature 30 degree centigrade to 120 degree centigrade.
225
Chemical Reaction:
226
Mass Balance:
227
228
229
9. Pigment Violet 19
Manufacturing Process:
Condensation:
DMSS condensed with Aniline & HCL in present of Methanol this step will give Wet cake
Reaction temperature 30ºC to 80ºC.
Oxidation:
Above Wet cake oxidize with R. salt, Caustic Flakes in present of Methanol & filter it this step
will give Slurry & this slurry Isolate with HCL & Filter it & washed it & Dry it. Reaction
temperature 30ºC to 90ºC.
Cyclisation:
Above Dry materials cyclised with (P2O5 + H3Po4) PPA (Poly Phosphoric Acid) & Drawing in
MSRL BL & Filter it & washed it & unload wet cake Reaction Temperature 30ºC to 150ºC.
Pigmentation:
Above Wet cake Pigmentation with IBA + water & recovered IBA & filter it & washed it & Dry it.
It is Pigment Voilet-19 Reaction Temperature 30ºC to 120ºC.
230
Chemical Reaction:
231
Mass Balance:
232
233
234
10. Solsperse 5000
Manufacturing Process:
Sulphonation:
Charge olieum in CI reactor. Cooled it to 25°C and then slowly charged Copper Pthalocynine
keeping temperature below 35°C. Then heat it to 65-70°C slowly. Then Keep this temperatures
for Six Hours. Check Sulphonation test. Then cool it to 40°C. Then dumped this mass in to
MSRLTL reactor in presence of Ice and keeping temperature below 5°C stir for two hours and
then filtered of in Filter press. Then give washing to W/C till congo +Ve ( 4.0 pH). Unload the
wet Cake.
Condensation:
Make slurry of above wet cake in water and then heat it to 50°C. Stir it well till it becomes
properly mix. Then charge Quaternary Amine slowly keeping temperature 50°C and pH 8.5.
Then Stir it for Four hours. And then filtered it in filter Press. Washed it with DM water till it is
salt free. Then unload it from Filter Press and dry it in Spin Flash Dryer.
Chemical Reaction:
235
236
Mass Balance:
237
11. Carbazole
Manufacturing Process:
Aniline to Phenyl Hydrazine:
Take Aniline in MSRLTL reactor in Presence of Ice and water. Make it diazotized with Kgs
Hydrochloric Acid and Sodium Nitrite. Check and confirm Diazotization by Confirmative test
with SI Paper. Then make Sodium Sulphite Solution in presence of Caustic Lye and charge it in
above Diazo Mass. Then Heat it to 60°C till the reaction complete. Then acidify it with
Hydrochloric Acid. And then filter it as W/C.
Phenyl Hydrazine to Tetra Hydro Carbazole
Take Cyclohexenon in SS reactor and heat it to reflux. Add of Acetic acid and again reflux it.
Then slowly charged Phenyl Hydrazine and then again reflux it for two hours. Then cool it to
room temperature and filter it in Filter Press and washed it with water. Then dumped the filter
Press and dried it in tray dryer.
Tetra Hydro Carbazole To Carbazole
Take Tetra Hydro carbazole in SS reactor and the charge Raney Nickel as catalyst. Then heat it
and maintain the temperature for 6 Hours and then dumped reaction mass in water. Then Filter
of Carbazole. And purify it with Acetone.
Chemical Reaction:
238
Mass Balance:
239
240
Speciality Chemicals:
1. 2,4 – Dichloro Phenyl Acetic Acid
Manufacturing Process:
2,4-Dichlorobenzyl chloride is reacted with Sodium cyanide to make 2,4-Dichlorobenzyl
cyanide.
2,4-Dichlorobenzyl cyanide is then hydrolyzed with caustic soda to make 2,4-
Dichlorophenylacetic acid.
Chemical Reaction:
241
Mass Balance:
242
2. 2,4 – Dichloro Phenyl Acetyl Chloride
Manufacturing Process:
2,4-Dichlorophenyl acetic acid is chlorinated with Thionyl chloride, using toluene as solvent to
convert it to 2,4-Dichlorophenyl acetyl chloride. The product is isolated after recovery of
toluene by doing high vacuum distillation and pure product is collected separately.
Chemical Reaction:
Mass Balance:
243
3. 2,4,6-Trimethyl Phenyl Acetyl Chloride
Manufacturing Process:
2,4,6-Trimethylphenyl acetic acid is chlorinated with thionyl chloride to convert it to 2,4,6-
Trimethylphenyl acetyl chloride using Toluene as solvent.
Chemical Reaction:
Mass Balance:
244
4. 2,3,4,5 - Tertrachloro Benzoyl Chloride
Manufacturing Process:
2,3,4,5-Tetrachloro phthalic anhydride is hydrolyzed with caustic flakes to 3,4,5,6- Tetrachloro
phthalic acid which is decarboxylate to make 2,3,4,5-Tetrachloro benzoic acid .This benzoic acid
is then reacted with thionyl chloride to make 2,3,4,5-Tetrachloro benzoyl chloride (TCBOC).
Chemical Reaction:
245
Mass Balance:
246
5. 3,4,5 Trimethoxy Benzyl Chloride
Manufacturing Process:
3,4,5 Trimethoxy benzyl alcohol is reacted with HCl to produce pure 3,4,5 Trimethoxy benzyl
chloride.
Chemical Reaction:
Mass Balance:
247
Pesticide Intermediates:
1. 2-Amino Benzo Nitrile
Manufacturing Process:
2-Amino-benzamide is dehydrated with phosphorus pentachloride. After reaction completion,
reaction mixture was quenched in water and pH was adjusted up to 6.5-8.5 Separate the
organic layer, Product was distilled off under reduce pressure after distillation of solvent.
Chemical Reaction:
Mass Balance:
248
2. 2-Amino-5-Bromo Benzo Nitrile
Manufacturing Process:
2-Amino-benzonitrile is brominated with N-bromosuccinimide in presence of solvent DMF.
After reaction completion, DMF is recovered, added water and filter the crude product. Crude
product was crystallized with toluene to get the pure material.
Chemical Reaction:
249
Mass Balance:
250
3. 2,4,6 - Trimethyl Benzaldehyde (Mesitaladehyde)
Manufacturing Process:
Chloral and mesitylene are reacted in presence of Titanium chloride.Product obtained is
isolated after quenching ,mass is hydrolyzed with soda ash to make product mesiatldehyde.
Distilled mesitsldehyde is mixed with acetone to get 84 % concentration.
Chemical Reaction:
251
Mass Balance:
252
4. Indoline
Manufacturing Process:
2-Chlororphenethyl amine is reacted with aq. ammonia in autoclave with presence of Copper
chloride to produce indoline. After washing this crude mass is distilled under reduced pressure
to get pure Indoline.
Chemical Reaction:
Mass Balance:
253
5. 5-(1-Carboxy Ethyl)-2-(Phenylthio) phenyl Acetic Acid (DIACID)
Manufacturing Process:
2-Phenylthio-5-propionyl phenyl acetic acid (PPP) interacts with bromine, Trimethyl
Orthoformate (TMOF) in presence of Zn to produce Diester, then Diester hydrolise with help
sodium hydroxide flakes then acidified with acid to produce Diacid.
Chemical Reaction:
254
Mass Balance:
255
ANNEXURE: 4
WATER CONSUMPTION AND WASTE WATER GENERATION
Sr.
No.
Category Proposed Scenario (KL/Day)
Water Consumption Waste Water Generation
1. Industrial
Process 987 974
Boiler 100 03
Cooling 68 01
Washing 04 03
Total (Industrial) 1159 981
2. Gardening 10 00
3. Domestic 15 12
Total 1184 994
256
Water Balance Diagram:
974 KL/Day 03 KL/Day 01 KL/Day 03 KL/Day
925 KL/Day
49 KL/Day
MEE Salt
* SS & MEE = Solvent Stripper & Multiple Effect Evaporator
Raw Water
1184 KL/Day
Domestic:
15 KL/Day
Washing:
04 KL/Day
Effluent Treatment Plant
932 KL/Day
Gardening:
10 KL/Day
SS & MEE*:
331 KL/Day
Industrial:
1159 KL/Day
Cooling:
68 KL/Day
Boiler:
100 KL/Day
Process:
987 KL/Day
To Septic Tank/
Soak Pit Tank:
12 KL/Day
RO Treated -
650 KL/Day
RO Reject -
282 KL/Day
MEE
Condensate -
280 KL/Day
ATFD
257
ANNEXURE: 5
DESCRIPTION OF EFFLUENT TREATMENT PLANT AND MEE SYSTEM
PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)
PROCESS DESCRIPTION:
Low COD Stream
1) The low COD stream (932 KLD) shall be passed through Screen Chamber (SC) where manual
screen (S) shall be provided to remove floating material. Then effluent shall be collected in
Collection cum Equalization Tank-1 (CET-1). Pipe grid is provided at bottom of the CET-1 to
keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers
(B-01) shall supply air through diffusers to pipe grid.
2) Then after, equalized wastewater shall be pumped to Neutralization Tank-1 (NT-1) where
the continuous addition and stirring of Lime solution is done (to maintain neutral pH of
wastewater) from Lime Dosing Tanks (LDTs) as per requirement. Then after, neutralized
wastewater shall go to Flash Mixer-1 (FM-1). Alum & Poly shall be dosed from Alum Dosing
Tank (ADT) and Poly Dosing Tank (PDT) respectively by gravity into FM-01 to carry out and
flocculation by using a Flash Mixer-1. Then effluent shall be sent to Primary Clarifier (PCL)
where coagulated wastewater shall be settled. Clear supernatant from Primary Clarifier
shall be passed in Aeration Tank-01 (AT-01).
3) Here, Biodegradation of organic matter of the wastewater shall be carried out by bacteria
(suspended growth) in the AT-1. The aeration tank provides proper mixing and supplies
oxygen to the microorganisms in the dissolved form through the fine bubble diffusers. A
constant feed rate shall be maintained in the aeration tank. A sludge percentage of around
25 to 30 % by volume shall be maintained in the aeration tank. Also MLSS and MLVSS ratio
shall be maintained to ensure active microorganisms growth. Various nutrients like Urea
and DAP shall be added from Nutrient Dosing Tanks (NDTs) regularly so as to ensure proper
growth of the microorganisms. Oxygen shall be supplied by 2 nos. of air blowers (B-02)
through diffusers. Air blowers also keep MLSS in suspension.
258
4) Then the overflow of the Aeration Tank-1 shall be diverted into the Secondary Clarifier-1
(SCL-1) for biomass separation. An appropriate retention time is given to the effluent to
ensure proper settling. The sludge settles down into the bottom of the SCL-1 and required
amount of settled sludge shall be recycled back into the aeration tank-1 to maintain desired
concentration of biomass. Excess biomass shall be pumped to sludge sump (SS).
5) Then after, overflow (clear supernatant) of SCL-1 shall be sent to Aeration Tank-2 (AT-2).
Here, again biodegradation of left out organic matter of the wastewater shall be carried out
by bacteria (suspended growth) in the AT-2 and for that oxygen shall be supplied by two
nos. of blowers (B-03) with help of diffusers. Then after, wastewater shall go to Secondary
Clarifier-2 (SCL-2) from AT-2. Here, the suspended solids shall be settled. Activated sludge
shall be removed from bottom of SCL-2 and pumped to AT-2 to maintain MLSS and
remaining will be sent to SS. Nutrients will be added from NDTs to Aeration Tank-2 for
growth of Bacteria if require.
6) Then after, overflow (clear supernatant) of SCL-2 shall be collected in Intermediate Sump
(IS). Then effluent from the IS-1 shall be passed through Multi Grain Filter (MGF) and
Activated Carbon Filter (ACF) to remove SS and other impurities. Filter water is collected to
RO Feed Tank (RFT) and then pumped to RO Unit (large capacity) for further treatment.
Treated water from RO will collected in RO Treated Water Tank (ROTWT-1) and will be
reuse in process. RO reject will be sent to MEE Feed Tank (MFT) for further treatment.
7) The primary and secondary sludge from the sludge sump shall be pumped to the Filter
Presses (FP-01-A/B) for sludge dewatering. We will provide two nos. Filter presses to use
alternately. The sludge cake shall be collected and packed into the plastic bags and stored
in the HWSA for ultimate disposal to TSDF. The leachate from the FP-01-A/B shall be
collected in Drain Pit and then pumped back to collection cum equalization tank (CET-01)
for further treatment.
259
High TDS Stream
1) The high TDS (49 KLD) stream shall be collected in Collection cum Equalization Tank-2 (CET-
2). Pipe grid is provided at bottom of the CET-2 to keep all suspended solids in suspension
and to provide proper mixing. 2 nos. of Air Blowers (B-04) shall supply air through diffusers
to pipe grid.
2) Then after, equalized wastewater shall be pumped to Neutralization Tank-2 (NT-2) where
the continuous addition and stirring of Lime solution is done (to maintain neutral pH of
wastewater) from Lime Dosing Tanks-1 (LDTs-01) as per requirement by gravity. Then after,
neutralized wastewater shall go to Flash Mixer-2 (FM-2). Alum and poly shall be dosed from
Alum Dosing Tank -1(ADT-01) and Poly Dosing Tank (PDT) by gravity into FM-2 to carry out
coagulation by using a Flash Mixer. Then after, coagulated wastewater shall be settled in
Primary Tube Settler (PTS). Sludge settled at bottom shall be sent to Sludge Sump.
3) Clear supernatant from Primary Tube Settler (PTS) shall be collected in Holding Tank (HT).
Then effluent shall be pumped to Stripper (S) for removal of solvent. After that effluent
shall collected in MEE Feed Tank (MFT) where RO reject water shall be mixed with it. Then
effluent shall be sent to four stages Evaporator (MEE). Condensate from MEE shall be
collected in Condensate Tank and then reuse in washing. Solid from Agitated Thin Film
Dryer (ATFD-01) shall be collected and stored in HWSA for ultimate disposal to TSDF.
260
ETP Units (for Low COD Stream) Q= 932 m3/day
Sr.
No.
Name of Unit Nos. Size of Tanks
L x B x D(LD+FB) In m
MOC
1 Screen Chamber (SC) 1 3.5 x2.0 x (0.05+0.5) RCC M25 with A-A Bk. Lining
2 Collection Cum Equalization
Tanks-1 (CETs-1)
1 12.0 x7.8 x (2.5+0.7) RCC M25 with A-A Bk. Lining
3 Neutralization Tank-01 (NT-01) 1 3.0 x 3.0 x (3.5+0.5) RCC M25 with A-A Bk. Lining
4 Flash Mixer-1 (FM-1) 1 3.0 x 3.0 x (3.5+0.7) RCC M25
5 Primary Clarifier (PCL) 1 9.0 dia x (3.5 +0.5) RCC M25
6 Aeration Tank -1(AT-1) 1 24.0 x 13.0 x (4.5+0.5) RCC M25
7 Secondary Clarifier-1 (SCL-1) 1 9.5 dia x (3.5 +0.5) RCC M25
8 Aeration Tank-2 (AT-2) 1 17.0 x 13.0x (4.5+0.5) RCC M25
9 Secondary Clarifier-2 (SCL-2) 1 9.0 dia x (3.5 +0.5) RCC M25
10 Intermediate Sump (IS) 1 6.0 x 4.3 x (3.0+0.5) RCC M25
11 Multi Grain Filter (MGF) 1 48 m3/day MSEP
12 Activated Carbon Filter (ACF) 1 48 m3/day MSEP
13 RO Feed Tank (RFT) 1 12.0 x 7.8 x (2.5+0.5) RCC M25
14 UF & RO Unit (RO) 1 46 m3/hr SS
15 Sludge Sump (SS) 1 6.0 x 4.3 x (3.0+0.5) RCC M25
16 Drain Pit(DT) 1 2.0 x 2.0x (2.0+0.5) RCC M25
17 Filter Press(FP) 2 75 m3/day PP
18 Lime Dosing Tanks (LDTs) 2 2000 lit HDPE
19 Alum Dosing Tank (ADT) 1 1500 lit HDPE
20 Poly Dosing Tank (PDT) 1 1000 lit HDPE
21 Nutrient Dosing Tanks (NDTs) 2 1000 lit HDPE
261
ETP Units (for High TDS Stream) (49 m3/day)
Sr.
No.
Name of Unit Nos. Size of Tanks
L x B x D(LD+FB) In m
MOC
22 Collection Cum Equalization
Tank-2 (CET-2)
1 4.5 x 2.7 x (2.0+0.5) RCC M25 with A-A Bk. Lining
23 Neutralization Tank-02 (NT-02) 1 1.3 x 1.3 x (1.0+0.5) RCC M25 with A-A Bk. Lining
24 Flash Mixer-2 (FM-2) 1 1.3 x 1.3 x (1.0+0.7) RCC M25
25 Primary Tube Settler (PTS-1) 1 2.5 x 2.0 x (1.5 + 1.0
+0.5)
RCC M25
26 Holding Tank(HT-1) 1 5.0 x 3.0 x (3.0+0.5) RCC M25
27 Stripper (ST-01) 1 50 m3/day SS 316L
28 ME Feed Tank (MFT-01) 1 4.0 x 4.0 x (3.0+0.5) RCC M25
29 Multiple Effect Evaporator
(MEE) with strippers &
Agitated Thin Film Dryer
(ATFD)
1 Set 50 m3/hr SS 316 L
262
Schematic Flow Diagram of Effluent Treatment Plant:
263
MEE SYSTEM
PROCESS DESCRIPTION:
Capacity: 331 KL/Day
Industry has installed Multi Effect Evaporator for the treatment of industrial effluent (as an
additional facility) having capacity of 331 KL/Day. The condensate water generated from the
MEE shall be used in process.
Neutral effluent after salt recovery is passed through three stages evaporator (two falling film +
one forced circulation) and the evaporated water and reuse in plant for is collected in an
Evaporated Water Collection Tank and then recycled to plant after filtering through carbon
filter.
In the first effect 7.0 kg/cm2 steam pressure is used to evaporate water. Evaporated water in
the form of steam of 2.0 kg/cm2 is used to evaporating the effluent in second stage at
atmospheric pressure. Evaporated water from the second stage is used for evaporating waste
water in the third stage under vacuum of 650 to 700 mm Hg. Finally evaporated water from the
third stage is condensed in the steam condenser. Condensate is collected in the recovery tank
which is reuse in the plant process.
Concentrated mass (Organic and Inorganic) is sending for the spray dryer.
Design of MEE:
No. of Effects : 3 (2 Falling Film + 1 Forced Circulation)
Waste Handling Capacity : 49 KL/Day
Feed Rate : 16 KL/Hr
Feed Concentration : 12 % TDS
Feed Temperature : 35 o C
Product Rate : 6400 KL/Hr
Product Concentration : 40 %
Product Temperature : 55-65 o
C
Water Evaporation Rate : 9600 KL/Hr
264
Characteristics of Effluent:
Dilute Stream:
Parameter Untreated
(Dilute
Stream)
After
Primary
Treatment
After
Secondary
Treatment
After
tertiary
Treatment
RO
Permeate
pH 3-10 6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5
Temperature (o
C) 30 31 30 30 30
COD (mg/L) 9,000 3,200 950 250 34
BOD3
(mg/L) 3,600 2,600 600 200 16
TDS (mg/L) 3,500 3,100 2,900 2,500 140
Suspended Solids
(mg/L)
155 90 60 15 10
Concentrated Stream:
Parameter Untreated
(Concentrated
Stream)
After
Solvent
Stripper
After
Neutralized
Effluent
MEE
Condensate
pH 3-10 5-10 6.5-8.5 6.5-8.5
Temperature (o
C) 32 30 30 30
COD (mg/L) 91,500 68,625 48,625 210
BOD3
(mg/L) 15,200 13,500 11,200 25
TDS (mg/L) 74,000 74,000 71,000 220
265
ANNEXURE: 6
DETAILS OF HAZARDOUS SOLID WASTE MANAGEMENT AND DISPOSAL
Sr.
No.
Type of Hazardous
Waste
Quantity Hazardous
Waste
Category
Storage, Collection & Disposal
1. ETP Sludge 1000 MT/Month
35.3 Collection, Storage, Transportation
& and Disposal to nearest TSDF site
(M/s. SEPL)
2. MEE Salt 400 MT/Month 35.3 Collection, Storage, Transportation
& and Disposal to nearest TSDF site
(M/s. SEPL)
3.
Sludge from Wet
Scrubber
50 kg/Month 26.1 Collection, Storage, Transportation
& and Disposal to nearest TSDF site
(M/s. SEPL)
4. Distillation Residue 215 MT/Month 36.1 Collection, Storage, Transportation
& co-processing in cement
industries or sent to common
Incineration Site (M/s. SEPPL)
5. Spent Carbon 100 kg/Month 36.2 Collection, Storage, Transportation
& co-processing in cement
industries or sent to common
Incineration Site (M/s. SEPPL)
6.
Iron Sludge 500 MT/Month 26.1 Collection, Storage, Transportation
& Sell to Cement Industries
7. Gypsum Sludge 1700 MT/Month 26.1 Collection, Storage, Transportation
& Sell to Cement Industries
8. Inorganic Salt 300 MT/Month -- Collection, Storage, Transportation
& Disposal to nearest TSDF (M/s.
SEPL)
9. Spent Acid
Dilute HCl
(Pigment Green 7 –
25-28%)
1850 MT/Month
26.3
Will be used in production of Direct
Black 40 (Direct Dyes)
Dilute H2SO4
(Alpha Blue – 25-30%)
4600 MT/Month Will be used in production of H
Acid (Dyes Intermediates) & CPC
Blue (Pigments)
266
Spent Phosphoric Acid
(PV 19 or 122)
1500 MT/Month
Collection, Storage, Transportation
& Sell to end user
Aluminum Chloride
Solution
(PG 7 – 28-30%)
2825 MT/Month
-- Collection, Storage, Transportation
& Sell to end user or used in
making Aluminium Hydroxide
Sodium Hypochlorite
(PG 7 – 10-11%)
1400 MT/Month -- Collection, Storage, Transportation
& Sell to end user
Liq. Ammonia
(Indoline)
550 MT/Month -- Collection, Storage, Transportation
& Sell to end user
Ammonium
Carbonate (CPC Blue)
2400 MT/Month -- Collection, Storage, Transportation
& Sell to end user
Sodium Sulphite 25 MT/Month -- Collection, Storage, Transportation
& Sell to end user
Sodium Acetate 25 MT/Month -- Collection, Storage, Transportation
& Sell to end user
Acetic Acid 70 MT/Month -- Will be used in production of
Solvent Red 195 (Solvent Dyes)
10. Used Oil 0.05 MT/Month 5.1 Collection, Storage, Transportation
& Sell to GPCB registered re-
processor or used for low grade
lubrication of machinery
11. Discarded
Drum/Containers/Car
boys Plastic
bags/Liners
Bags:
400 Nos./Month
Drums:
100 Nos./Month
33.3 Collection, Storage, Transportation,
Decontamination & Sell to GPCB
authorized Vendor
267
ANNEXURE: 7
DETAILS OF FLUE & PROCESS GAS EMISSION
Details of Flue Gas Emission:
Sr.
No.
Stack Attached to Type and
Quantity of fuel
Stack
Height (m)
Stack
Dia. (m)
Pollutant Air Pollution
Control Measures
1 Steam Boiler
IBR (3 TPH)
Coal = 10 MT/Day 30 0.6 PM<150 mg/Nm3
SO2<262 mg/Nm3
NOx<92 mg/Nm3
Water scrubber,
Bag Filter, Multi
Cyclone Separator
2 Steam Boiler
IBR (6 TPH x 2)
Coal = 40 MT/Day 30 0.6 PM<150 mg/Nm3
SO2<262 mg/Nm3
NOx<92 mg/Nm3
Water scrubber,
Bag Filter, Multi
Cyclone Separator
3 Thermic Fluid
Heater (TFH)
(10 kcal/hr x 6)
Diesel = 3 KL/Day 12 0.45 PM<150 mg/Nm3
SO2<262 mg/Nm3
NOx<92 mg/Nm3
--
4 Spin Flash Dryer
(SFD)
(0.75 TPH x 7)
Diesel = 3 KL/Day 15 0.45 PM<150 mg/Nm3
--
5
Spin Flash Dryer
(SFD)
(0.3 TPH x 4)
Diesel = 0.4 KL/Day 15 0.45 PM<150 mg/Nm3
--
6 Spray Dryer
(192 Trays x 5)
Diesel = 1 KL/Day 8 0.45 PM<150 mg/Nm3
--
7 Spray Dryer
(1200 lit/hr x 4)
Diesel = 2 KL/Day 15 0.45 PM<150 mg/Nm3
--
Details of Process Gas Emission:
Sr.
No.
Name of the
process vessel
Stack Height
(m)
Stack Dia.
(m)
Pollutant
Air Pollution
Control Measures
1 Process Vent - 1 15 0.15 SO2<40mg/Nm3 Two Stage Scrubber
2 Process Vent - 2 15 0.15 NH3<175mg/Nm3 Two Stage Scrubber
3 Process Vent - 3 15 0.15 HCl<20 mg/Nm3 Two Stage Scrubber
4 Process Vent - 4 15 0.15 HBr<5mg/Nm3 Two Stage Scrubber
268
ANNEXURE: 8
DETAILS OF HAZARDOUS CHEMICAL STORAGE FACILITY
Sr. No. Hazardous Chemicals Type of Hazard MOC of Storage Actual Size Stored Quantity
1 Hydrocholoric Acid Corrosive HDPE/PPFRP 25 MT
(2 Nos.)
50 MT
2 Sulphuric Acid Corrosive MS Tank 20 MT
(2 Nos.)
40 MT
3 Caustic Soda Lye Corrosive MS Tank 20 MT 20 MT
4 Formaldehyde Flammable MS Tank 20 MT
(2 Nos.)
40 MT
5 Liq. Ammonia Toxic MS Tank 10 MT 10 MT
6 Aniline Corrosive Drums 200 kg
(10 Nos.)
2 MT
7 Methanol Flammable MS Tank 10 MT 10 MT
8 o-Xylene Flammable MS Tank 10 MT 10 MT
9 Acetic Acid Corrosive Drums 200 kg
(15 Nos.)
3 MT
10 Nitric Acid Corrosive Tank 5 MT 5 MT
11 Oleum-23 % Corrosive MS Tank 25 MT
(2 Nos.)
50 MT
12 Toluene Flammable MS Tank 10 MT
(2 Nos.)
20 MT
13 Chlorine Toxic Tonner 900 kg
(05 Nos.)
4.5 MT
14 EDC Flammable MS Tank 20 MT 20 MT
269
ANNEXURE: 9
SOCIO - ECONOMIC IMPACTS
1) EMPLOYMENT OPPORTUNITIES
The manpower requirement for the proposed project is expected to generate some permanent
jobs and secondary jobs for the operation and maintenance of plant. This will increase direct /
indirect employment opportunities and ancillary business development to some extent for the
local population. This phase is expected to create a beneficial impact on the local socio-
economic environment.
2) INDUSTRIES
Required raw materials and skilled and unskilled labors will be utilized maximum from the local
area. The increasing industrial activity will boost the commercial and economical status of the
locality, to some extent.
3) PUBLIC HEALTH
The company regularly examines, inspects and tests its emission from sources to make sure that
the emission is below the permissible limit. Hence, there will not be any significant change in the
status of sanitation and the community health of the area, as sufficient measures have been
taken and proposed under the EMP.
4) TRANSPORTATION AND COMMUNICATION
In brief, as a result of the proposed project there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be taken
under the EMP. The proposed project is not expected to make any significant change in the
existing status of the socio - economic environment of this region.
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ANNEXURE: 10
PROPOSED DRAFT TERMS OF REFERENCE
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various
industries, surface water bodies, forests etc.
• Project cost
• Project location and Plant layout.
• Water source and utilization including proposed water balance.
• Product spectrum (proposed products along with production capacity) and process
• List of hazardous chemicals.
• Mass balance of each product
• Storage and Transportation of raw materials and products.
2. Description of the Environment and Baseline Data Collection
• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall in 5
km area.
• Existing environmental status Vis a Vis air, water, noise, soil in 5 km area from the project site.
For SPM, RSPM, SO2, NOx.
• Ground water quality at 5 locations within 5 km.
• Complete water balance
3. Socio Economic Data
• Existing socio-economic status, land use pattern and infrastructure facilities available in the
study area were surveyed.
4. Impacts Identification And Mitigatory Measures
• Identification of impacting activities from the proposed project during construction and
operational phase.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
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6. Risk Assessment
• Objectives and methodology of risk assessment
• Details on storage facilities
• Process safety, transportation, fire fighting systems, safety features and emergency
capabilities to be adopted.
• Identification of hazards
• Consequence analysis through occurrence & evaluation of incidents
• Disaster Management Plan.
7. Information for Control of Fugitive Emissions
8. Post Project Monitoring Plan for Air, Water, Soil and Noise.
9. Information on Rain Water Harvesting
10. Green Belt Development plan