Annexure-I. List of Products. Name of Products Existing Proposed Total

Transcription

1 Annexure-I List of Products Sr. o. ame of Products Existing Proposed Total Reactive and Direct Dyes 1. Reactive Black-B Direct Orange Direct Orange Direct Orange Reactive Red Reactive Yellow-FG Acid Dyes 7. Acid Black Acid Blue Acid Brown Acid Brown Acid Brown Acid Brown Acid Brown Acid Brown Acid Orange Acid Red 357 Dyes Intermediates 17. PAABSA DSDA 19. Sodium apthoniate Total M/s. Dutt Chemical, Vatva 1

2 List of Raw Material Sr. no. Product name Raw Material ame Quantity MT/MT Reactive and Direct Dyes 1 Reactive Black B VS HCl Sodium itrite H-Acid Soda Ash Direct Orange 26 Aniline HCl Sodium itrite J-Acid Urea Soda Ash Direct Orange 36 P cresidieno sulphonic acid HCl Sodium itrite J-Acid Urea Sodium Bicarbonate Direct Orange 39 PABSA DSDSA Hypochlorite Caustic Soda flax HCl Salt Reactive Red 198 SPVS HCl Sodium itrite Sulphamic acid J-acid soda ash Caustic lye Dicamol SD Reactive Yellow FG Vinyl Sulphone HCl Sodium itrite SPCP Sulphamic Acid Soda Bi Carbonate Caustic lye Acid Dyes 7 Acid Black 210 PA HCl Sodium itrite H. Acid Soda Ash DASA Caustic Flakes MPD Acid Blue 158 aptha Sultan M/s. Dutt Chemical, Vatva 2

3 Caustic potash Diazo acid Soda ash Sodium Bi-chromate Sulphuric acid, 98% Ammonium Sulphate Sodium Formate Sorbitol ACID BROW 161 Anthranilic acid Sulphuric acid Formaldehyde itrite Resorcinol Caustic Flakes Aniline 2,4 SO3H HCl Soda Ash Salicylic Acid B.C.S Acid Brown 165 H. Acid HCl itrite Resorcinol C.F Sodium Picramate HCl Sodium itrite PA HCl itrite Ferrous Sulphate Acid Brown APSA Hydrochloric acid Sodium itrite PMP Caustic lye Sodium Acetate itro-1-Diazo acid Salicylic acid Beta apthol ACID BROW 425 Anthranilic acid HCl itrite Resorcinol Soda Ash O.T. 5 SA Salicylic Acid B.C.S Caustic Flakes Acid Brown Anthranilic Acid HCl M/s. Dutt Chemical, Vatva 3

4 itrite Resorcinol Soda Ash Laurent Acid Salicylic Acid Chromium Fluoride Liquid Ammonia Caustic Flakes Acid Brown Sodium Picramate HCl Resorcinol itrite Mix cleave acid Caustic Lye Ferrous Sulphate Acid Orange 74 4 APSA HCl Sodium itrite PMP Sodium Acetate Caustic Lye Salicylic acid BCS Powder Acid Red APASA HCl itrite PMP Caustic Flakes Salicylic Acid B.C.S Dyes Intermediates 17 PAABSA Sodium bisulphite % Formaldehyde Aniline oil Salt Sulphonic Acid % HCl Sodium bicarbonate Sodium nitrite DSDSA PTOSA Soda Ash Caustic lye Sodium Hypochlorite Sulphuric Acid Sodium apthoniate ODCB Aplha apthyl Amine Sulphuric acid Soda ash M/s. Dutt Chemical, Vatva 4

5 Annexure-II Manufacturing Process (A)Reactive Dyes 1. Reactive Black B: Manufacturing Process: Diazotization: Charge VS in reaction vessel along with water and add HCl. Stir for half hour & cool it to 0 C and add ao 2 solution with checking SI & CR +ve. Maintain it for half hour then make SI ve. Coupling: Charge H Acid in VS diazo and stir for 6 hour at temp 0 C. Spray Dryer: All liquid transfer into spray dryer for spray. Standardization: The spray dried powder charged in blender and de dusted by anti-dusting oil. Chemical Reaction: DIAZOTIZATIO H 2 =Cl + 2 HCl + ao 2 Ice SO 2 CH 3 CH 3 OSO 3 H Temp C + 2 H 2 O + 2aCl SO 2 CH 3 CH 3 OSO 3 H Vinyl Sulphone Diazotized Vinyl Sulphone Solution of H Acid H 2 OH H 2 OH SO 3 H + 2aOH SO 3 H Ice Temp C SO 3 a SO 3 a + 2H 2 O H Acid Clear Sodium Salt Solution of H. Acid Coupling =Cl H 2 OH 2 + SO 2 CH 3 CH 3 OSO 3 H SO 3 a SO 3 a + 2aHCO 3 Ice Temp C H 2 OH H 3 OSO 2 HC 2 HC 2 OS = = SO 2 CH 2 CH 2 OSO 3 H SO 3 a SO 3 a + 2H 2 O + 2CO 2 + acl M/s. Dutt Chemical, Vatva 5

6 Mass Balance: Mass Balance of Reactive Black B Input Kg Kg Output VS 310 HCl 250 Sodium itrite 65 Diazotization Ice 900 Water 800 H-Acid 215 SODA ASH 310 Ice 1100 Coupling Spray dryer 2950 Drying Loss Packing 1000 Reactive Black 5 Total M/s. Dutt Chemical, Vatva 6

7 2. Direct Orange 26 : Manufacturing Process: Diazotization: Charge Aniline in reaction vessel along with water and add HCl. Stir for two hour & cool it to 0 C and add ao 2 solution with checking SI & CR +ve. Coupling: Charge J-Acid Urea in the diazo mass and add soda ash to maintain the ph throughout the process. Filter the dye. Spray Dryer: All liquid transfer into holding tank and send for spray dryer. Standardization: The spray dried powder charged in blender and de dusted by anti-dusting oil. Mass Balance: Mass Balance of Direct Orange 26 Input Kg Kg Output Aniline 315 HCl 510 Sodium itrite 75 Diazotization Ice 900 Water 1000 J-Acid Urea 365 SODA ASH 280 Ice 1000 Coupling Spray dryer 3445 Drying Loss Packing 1000 Direct Orange 26 Total M/s. Dutt Chemical, Vatva 7

8 3. Direct Orange 36: Manufacturing Process: Prepare P cresidieno sulphonic acid with help of Hydrochloric acid, sodium nitrite and ice. Diazo mass is coupled with j acid urea solution in acidic medium. Stir overnight. When coupling is confirmed then Spray dry the reaction mass. The spray dried powder charged in blender and de dusted by anti-dusting oil and sent for packing. Mass Balance: Mass Balance of Direct Orange 36 Input Kg Kg Output P cresidieno sulphonic acid 385 HCl 410 Sodium itrite 85 Diazotization Ice 900 Water 1300 J-Acid Urea 365 Sodium Bicarbonate 210 Ice 750 Coupling stirring Spray dryer 3405 Drying Loss Packing 1000 Direct Orange 36 Total M/s. Dutt Chemical, Vatva 8

9 4. Direct Orange 39: Manufacturing Process: Take water in MS autoclaved vessel and heat to 50 o C. ow charge PABSA and heat to 90 o C and stir for 3 hours. Charge DSDSA and keep temperature below 90 o C. Maintain heat to o C and stir for 12 hours. Check for the completion of reaction. If not then further maintain temperature and continue to stir for 4 hours. When reaction is over, transfer it to dumping vessel. If material is thick, then add extra water. Adjust ph 6.5 to 7 by HCl. Add hypochlorite solution. Temperature may be 80 o C. Isolate by salt. Filter, suck well. Mass Balance: Mass balance of Direct Orange 39 Input KG Output KG PABSA 410 DSDSA 290 Water 1300 Reaction Vessel Hypochlorite 290 Caustic Soda flax 154 HCl 190 Water 850 Drowning Salt 850 Isolation Drying & Packing Drying Loss 3334 Direct Orange Total M/s. Dutt Chemical, Vatva 9

10 5. Reactive Red 198: Manufacturing process: J Acid Cynuration: Charge J Acid in reaction vessel along with water and stir for ½ hr now cool to 0 0 C and make clear solution by aoh lye ph is 7.2. Prepare Cynuric Chloride emulsion at 0 0 C and receive J Acid clear solution in 4 hr and stir up to cynuration ok. Diazotization: Charge SPVS in reaction vessel along with water and added HCl stir ½ hr. and cool it 0 0 C added ao2 soln check SI & CR +ve stir for ½ hr make SI ve by sulfamic acid. Coupling: VS diazo transfer in to condense mass below 3 0 C and ph maintain by CS Lye 6.5 stir for 4 hr. check strength and tone. Spray Dryer: All liquid transfer in to holding tank for spray. Standardization: Charge spray dried powder in Ball Mill and de dusted by anti-dusting oil. Chemical Reaction: SO 3 a HO H 2 SO 3 a + Cl Cl Cl SO 3 a HO Cl Cl SO 3 a = HO H Cl + H 2 SO 2 CH 2 CH 2 OSO 3 H + H SO 3 H (V.S.Diazo) SO 3 H Metanilic Acid SO 3 H H H HO Cl = SO 3 a SO 3 a SO 2 CH 2 CH 2 OSO 3 H M/s. Dutt Chemical, Vatva 10

11 Mass Balance: Mass Balance of Reactive Red 198 IPUT KG OUTPUT KG SPVS 320 HCl 285 Sodium itrite 75 Sulphamic acid 5 water 1150 Diazotization of SPVS J-acid 210 soda ash 55 CS Lye 85 Water 1000 Preparation of J- Acid Ice 1200 Cs lye 150 Coupling SD Drying loss 3549 Spray Drying Standardization & Packing Reactive Red Total M/s. Dutt Chemical, Vatva 11

12 6. Reactive Yellow-FG: Manufacturing process: Diazotization: Charge VS to a MSRL reaction vessel along with water and ice to maintain temperature 0 to 5 0 C. Then Hydrochloric Acid will be added followed by Sodium itrite powder gradually till diazotization completed, which can be confirmed by starch iodide paper. Any excess nitrite will be removed by adding 1 to 2 kg Sulfamic Acid just before coupling. Keep temperature 0 to 5 0 C throughout the diazotization reaction. Coupling: Charge SPCP with Caustic lye to the diazotized mass and stir it keeping the temperature 0 to 5 0 C by adding of ice. Spray Drying: The final product is recovered by RO and then transferred to the spray drying holding tank and spray dry. Packing: The final product is then packed in HDPE bags / M.S. Drums / Plastic Carboys / Paper cartoon boxes. Chemical Reaction: 1. Diazotization H 2 =-Cl + 2HCl + ao 2 Ice Temp C + 2H 2 O + 2aCl SO 2 CH 2 CH 2 OSO 3 H Vinyl sulphone SO 2 CH 2 CH 2 OSO 3 H Diazotized vinyl sulphone 2. Coupling =-Cl + SO 3 a C Oa CH C SO 2 CH 2 CH 2 OSO 3 H COOa Diazotized vinyl sulphone SO 2 CH 2 CH 2 OSO 3 H SO 3 a C Oa C = C COOa Re. Yellow FG M/s. Dutt Chemical, Vatva 12

13 Mass Balance: Mass Balance Reactive Yellow FG IPUT KG OUTPUT KG Vinyl Spulphone 350 HCL 215 Sodium itrite 85 SPCP 320 Sulphamic Acid 4 Water 1100 Ice 1300 Diazotization SPCP 350 SODA BI CARB 65 CS LYE 135 Ice 1200 Coupling RO/UF Waste Water for reuse 1774 Spray Drying Drying loss 2350 Standardization & Packing Reactive Yellow FG 1000 TOTAL M/s. Dutt Chemical, Vatva 13

14 (B) Acid Dyes 7. Acid Black 210: Manufacturing Process: Diazotization: Prepare PA and HCL in water with Sodium nitrite. Keep the temp 0-5 o C. 1 st Coupling: Add H acid in the diazotized mass and add soda ash. 2nd Coupling: Further coupled mass and add DASA and Hydrochloric acid in the coupler. To make an alkaline medium add caustic flakes in it. 3nd Coupling: Mass is coupled with MPD. Drying: When the coupling is OK. Product is transfer into RO and then Spray dry the reaction mass. Mass Balance: Mass Balance of Acid Black 210 IPUT KG OUTPUT KG PA 250 HCL 140 Sodium itrite 85 Ice 800 Water 950 DIAZOTIZATIO H.acid 250 Soda Ash 85 Water 950 1st COUPLIG DASA 220 HCL 180 Caustic Flakes 110 Ice 750 2nd COUPLIG Water 550 MPD 115 3rd COUPLIG RO Water for reuse 2485 SPRAY DRYIG Drying loss 1950 ACID BLACK TOTAL M/s. Dutt Chemical, Vatva 14

15 8. Acid Blue 158: Manufacturing process: aphtha sultan is hydrolyzed with the help of caustic potash at temp C for 6 hr. Cool to room temperature. Charge 1:2:4 Diazo acid at C, slowly in 1.5 hr. Stir for 6-8 hrs. and to complete the coupling. Adjust ph 8-9 with hydrochloric acid. Add chrome liquid which is previously prepared in another vessel. Heat for 100 C. Maintain temperature hr. Check reaction mass for the completion of reaction on TLC. If TLC is OK, adjust ph with soda ash. Spray dry the above mass. Chemical Reaction: SO3H H2 SO3H OH OH Diazotisation H2SO4 + ao2 & Hydrolysis H2 + SO3H Peri Acid Suetan 1:2:4 Diazo Acid SO3H OH OH Coupling SO3H Monoazo 1:1 Chromination in Acidic Medium SO3H HO3S O Cr+3 O Acid Blue 158 M/s. Dutt Chemical, Vatva 15

16 Mass Balance: Mass Balance of Acid Blue 158 IPUT KG OUTPUT KG aptha Sultan 415 Caustic potash 510 Ice 900 Water Diazo acid 550 Soda ash 85 Sodium Bi-chromate 125 Sulphuric acid, 98% 350 Ammonium Sulphate 85 Water 1100 Sodium Formate 225 Sorbitol 250 Diazotization Coupling Chromination RO/UF Spray Drying Standardization & Packing Wastewater for reuse 2145 Drying Loss 2450 Acid Blue Total M/s. Dutt Chemical, Vatva 16

17 9. Acid Brown 161: Manufacturing process: Anthranilic Acid diazotized with HCl, itrite at 0 0 C temp. Stir for 1 hour, and then couple with Resorcinol in alkaline medium at 50 C temp. Stir for 2 hours, then make diazo of Aniline 2:4 SO 2 H with HCl, itrite & Ice at 5 0 C temp. Stir for 1 hour then coupled with first coupling in alkaline medium. Stir for 4 hours, Heat at 80 0 C then metalized with copper sulphate solution at 80 0 C in alkaline medium stir for 4 hours, clarify R/O s/dryer it. Chemical Reaction: Anthranilic condensation with Formaldehyde & make Diazo Anthranilic Acid Dizo Coupling with Resorcinol Aniline 2:4 Disulphonic Acid Diazo II Coupling M/s. Dutt Chemical, Vatva 17

18 Above Mono azo Metallized with copper Sulphate at 85ºC temp at alkaline medium Mass Balance: Mass Balance of Acid Brown 161 IPUT KG OUTPUT KG Anthranilic acid 193 Sulphuric acid 193 Formaldehyde 77 itrite 97 Water 900 Ice 1250 Resorcinol 150 Caustic Flakes 120 Ice 1500 Aniline 2,4 SO3H 347 HCL 175 Sodium itrite 95 Soda Ash 150 Water 900 Ice 750 Salicylic Acid 50 B.C.S 200 Diazotization Ist coupling 2nd coupling Chromination RO/UF Spray Drying Wastewater for reuse 3297 Drying loss 2850 Acid Brown TOTAL M/s. Dutt Chemical, Vatva 18

19 10. Acid Brown 165: Manufacturing Process: H. Acid Diazotized with HCl, itrite & Ice at 5ºC temp. Stir for 1-1/2 hours. After 1-1/2 hour coupling with Resorcinol in alkaline medium stirrer 2 hours a picramate Diazo coupling with first coupling in alkaline medium stirrer for 2 hours. After 2 hours PA Diazo coupled with second coupling at 6.5 ph stirrer 6 hours. After 6 hours heat at 80ºC. Above couple mass metalized with Ferrous Sulphate s soln at 5.5 ph. Stir for 3 hour after 3 hour isolated with salt collect W/C & make slurry & sprays dry it. Chemical Reaction: H ACID Diazo H Acid diazo Coupling with resorcinol II Coupling with a picramate diazo PA DIAZO III COUPLIG M/s. Dutt Chemical, Vatva 19

20 ABOVE DYE.METALISED WITH FRRROUS SULPHATE Mass Balance: Mass Balance of Acid Brown -165 IPUT KG OUTPUT KG H. Acid 310 HCl 185 itrite 69 Ice 900 Water 900 Diazotization Resorcinol 110 C.F st Coupling Sodium Picramate 250 HCl 90 Sodium itrite 75 Ice 850 Iind Coupling PA 138 HCl 110 itrite 70 Ice 850 IIIrd Coupling Water 500 Ferrous Sulphate 260 Ferigation RO/UF wastewater for reuse 2707 Spray Drying Drying loss 2100 Acid Brown Total M/s. Dutt Chemical, Vatva 20

21 11. Acid Brown 355: Manufacturing Process: 6 itro solutions with Ice is coupled with Beta aphthol clear solon in alkaline medium starrier 2 hour. After 2 hours crimination with salicylic Acid & B.C.S at ºC temp starrier. 16 hour. After 16 hours filter & collect w/c. 4 APASA diazotize with HCl, nitrite at 0ºC temp. Stir for 1-1/2 hour. PMP so in coupled with 4 APASA diazo at 5.5 ph 7ºC temp. Stirrer - 8 hour. After 8 hour isolated with salt and filter it. Above both w/c are. Mix with water and heat 85-90ºC temps take ph-5-5 with c. lye. Stirrer - 4 hour. After 4 hour check test of chromination & then s/dryer it. Chemical Reaction: APSA Diazo 1. APSA Diazo coupling with Prazolone PMP(Orange Base) 2. 6 itro Coupling with Beta apthol and this couple mass chroimination with B.C.S (BK 52 (1:1 Base) 3. Above product chelating with Orange Base at 95ºC temp in neutral medium. M/s. Dutt Chemical, Vatva 21

22 Mass Balance: Mass Balance of Acid Brown 355 IPUT KG OUTPUT KG 4-APSA 275 hydrochloric acid 310 sodium nitrite 85 Ice 850 Prepare 4-APSA diazo PMP 220 caustic lye 150 Water 900 Sodium Acetate 110 Ice 750 Prepare PMP coupler solution Coupling 6-itro-1-Diazo acid 315 Salicylic acid 85 Beta apthol 150 Charging Heating Spray Drying Drying Loss 3200 Standardization & Packing Acid Brown Total M/s. Dutt Chemical, Vatva 22

23 12. Acid Brown 425: Manufacturing Process: Anthranilic acid Diazotized with HCl itrite at 0 0 C temp with Ice Stirrer 1 hour, Resorcinol coupled with this Diazo in alkaline medium at 5 0 C Stirrer 2 hour, O.T.S SA Diazo with HCl itrite and Ice at 0 0 C temp stirrer 1-1/2 hour this Diazo coupled with first coupling in alkaline ph at 5 0 C temp stirrer 6 hour. After 6 hour heat 90 0 C-95 0 C and metalized with salicylic acid and B.C.S at 5.5 ph maintain for 4 hour, After 4 hour test. If test is ok, then clarify, R.O. and S/Dryer it. Chemical Reaction: 1. Anthranilic Acid Diazo 2. First Coupling with Resorcinol 3. II Coupling with Ortho Toludine 5. Sulphonic Acid M/s. Dutt Chemical, Vatva 23

24 Mass Balance: Mass balance of Acid Brown 425 IPUT KG OUTPUT KG Anthranilic acid 150 HCL 110 itrite 75 Ice 850 Water 1100 Resorcinol 117 Soda Ash 330 Water 900 Anthranilic Acid Diazo 1st COUPLIG O.T. 5 SA. 210 HCL 185 itrite 75 Water 750 Ice 850 Salicylic Acid 110 B.C.S. 320 Caustic Flakes 55 2nd COUPLIG Chromination Clarification RO/UF Spray Drying wastewater for reuse 2357 Drying loss 2830 Acid Brown TOTAL M/s. Dutt Chemical, Vatva 24

25 13. Acid Brown 432: Manufacturing process: Anthranilic Diazotized with HCl, itrite & Ice at 0 C temp. Stir for 1-1/2 hours, Resorcinol Coupling with this Diazo in alkaline medium at 50C temp. Laurent Acid Diazotized with HCl, itrite & Ice, at 5 0 C temp. stir for 2 hour. After 2 hour, this Diazole coupling with first coupling at eutral ph at 7 0 C temp stirrer for 6 hour. After 6 hours, heat at 90 0 C temp metalized with salicylic acid chromium fluoride. If crimination tests ok, then clarify /R/o/ Spray Dryer it. Chemical Reaction: 1.Anthranilic Acid Diazo 2.Ist Coupling with Resorcinol 3. Laurent Acid Diazo 4.IInd Coupling 5.Above metalized with salicylic acid & chromium fluoride M/s. Dutt Chemical, Vatva 25

26 Mass Balance: Mass Balance of Acid Brown Input Kg Output Kg Anthranilic Acid 230 HCl 150 itrite 80 Ice 900 Water 1300 Anthranilic Acid Diazo Resorcinol 150 Soda Ash 285 Ice 900 Ist coupling Laurent Acid 310 HCl 150 itrite 95 Ice 1150 IInd Coupling Salicylic Acid 185 Chromium Fluoride 185 Liquid Ammonia 250 Caustic Flakes 35 Chromination RO wastewater for reuse 2405 Spray Drying drying loss 2950 Acid Brown Total M/s. Dutt Chemical, Vatva 26

27 14. Acid Brown 434: Manufacturing process: Sodium picrmate Diazotized with HCl, itrite at 0 0 c temp stirrer -1.5 hour then couple with picramate diazo in alkaline medium 1.6 cleave acid diazotized of, itrite & Ice at 0 0 c temp this diazo coupled with first coupling at 3 0 C temp. stir. 6 hrs. heat 80 0 temp. Metalized with ferrous sulphate solution in natural medium stir. 4 hrs. If test ok then isolated with common salt. Filter collect w/c, make slurry it, then spray dryer it. Chemical Reaction: 1. a Picramate Diazo 2. a Picramate Diazo coupling with Resorcinol 3. 1:6 Cleaves Acid Diazo + coupling 4. Above Dye Metalized with Ferrous sulphate M/s. Dutt Chemical, Vatva 27

28 Mass Balance: Mass Balance of Acid Brown IPUT KG OUTPUT KG Sodium Picramate 190 HCl 95 Resorcinol 145 itrite 75 Ice 850 Water 950 Sodium picramate diazo Mix cleave acid 310 HCl 250 Sodium itrite 45 Water 850 Diazo of Mix Cleave Ice 700 Caustic Lye 85 Coupling Ferrous Sulphate 160 Metallisation Spray Drying Drying loss 3705 Acid Brown Total M/s. Dutt Chemical, Vatva 28

29 15. Acid Orange 74: Manufacturing process: Prepare 4-APSA 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 o 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: O2 O2 SO3H OH H2 + HCl + ao2 SO3H OH =-Cl + O CH3 + aoh OH CH3 + 4 APSA Diazo 4-itro 2-Amino Phenol 6-Sulphonic Acid 1-Phenyl 3-Methyl 5-Pyrazolone O2 SO3H O = O CH3 Cr H2O H2O H2O Acid Orange 74 M/s. Dutt Chemical, Vatva 29

30 Mass Balance: Mass Balance of Acid Orange 74 IPUT KG OUTPUT KG 4 APSA 530 HCl 600 Sodium itrite 170 Ice 1250 Preparation of 4- APSA diazo PMP 425 Sodium Acetate 205 Caustic Lye 180 Ice 650 Water 1200 Prepare PMP solution & Coupling Stirring Salicylic acid 60 BCS Powder 900 Heating Ice 1100 Cooling RO/UF Wastewater for reuse 3790 Spray drying Drying loss 2480 Standardization & Packing Acid Orange Total M/s. Dutt Chemical, Vatva 30

31 16. Acid Red 357: Manufacturing process: 6 itro 2 Amino phenol, 4 SO 3 H (6 APASA) diazotized with HCl and sodium nitrite at 0 0 C temp. Stirrer for 2 hours then coupled with PMP Clear solution in alkaline medium. Above coupled mass chrominated with salicylic Acid and B.C.S at 95 0 C temp. for 4 hours. Maintain after 4 hour Check test. If ok then take ph 6.5, Clarify/Ro/Spray-dry it. Chemical Reaction: 6 APASA diazo + 6 itro 2 Amino phenol 4 Sulphonic Acid 6APSA diazo coupling with PMP Above coupling mass chromination with B.C.S at 90ºc temp. M/s. Dutt Chemical, Vatva 31

32 Mass Balance: Mass Balance of Acid Red IPUT KG OUTPUT KG 6 apasa 385 HCl 110 itrite 95 Ice 1300 Water 1100 Diazotization PMP 315 Caustic Flakes 110 Ice 1450 Ist coupling Salicylic Acid 55 B.C.S. 280 Caustic Flakes 65 Chromination RO/UF wastewater for reuse 1415 Spray Drying Drying loss 2850 Acid Red Total M/s. Dutt Chemical, Vatva 32

33 C) Dyes Intermediates 17. PAABSA: Manufacturing process: Take sodium bisulphite solution in MS vessel. Charge 37% formaldehyde in 0.5 hr & adjust ph 7.Temperature may rise up to o C.Stir well and add aniline oil in 1 hr. Temperature may rise up to o C.Stir for 3 hrs. then charge salt. Stir for 2 hours. Filter in nutch, suck well & centrifuge for the OMEGA cake. In a PP vessel take stir able water. Add Sulphonic Acid. Stir well & add 30% hydrochloric acid. Charge sodium nitrite powder in 2-3 hours keeping temperature 0-5 o C by using ice. When diazo is ready, transfer to completion vessel. In a PP vessel take stir able water. Charge above wet cake of OMEGA. Stir well and adjust ph 6.5 to 7 by adding sodium bicarbonate. Stir well. Charge ice to maintain temperature of 0-2 o C. ow receive Diazo solution in 2-3 hours keeping ph 6.5 to 7 and temperature 0-2 o C. When coupling is over salt out. Stir well, filter to nutch, suck well, and centrifuge the cake. In a MSRL vessel take water & charge 98% Sulphonic acid. Heat to 90 o C by live steam. ow charge above coupling cake in 1-2 hours keeping temperature o C. Stir for 3 hours at 90-95oC then filter to notch, suck well, centrifuge the cake. Chemical Reaction: H 2 Aniline + ahso 3 + HCHO HCH 2 SO 3 H Omega H 2 Aniline + ao 2 + HCl =-Cl SO 3 H HCH 2 SO 3 H =-Cl + SO 3 HCH 2 H = SO 3 H Omega SO 3 H SO 3 HCH 2 H = SO 3 H H 2 SO 4 H 2 = SO 3 H Para Amino Azo Benzene4-Sulphonic Acid M/s. Dutt Chemical, Vatva 33

34 Mass Balance: Mass Balance of PAABSA IPUT KG OUTPUT KG Sodium bisulphite % Formaldehyde 410 Aniline oil 385 Salt 450 Steam 650 Reaction vessel Filtration & Centrifugation Wastewater 1000 Sulphonic Acid % HCl 560 Sodium bicarbonate 115 Sodium nitrite 350 Ice 900 P.P. vessel Filtration & Centrifugation Wastewater 2520 Drying & Packing Drying Loss 950 PAABSA 1000 Total M/s. Dutt Chemical, Vatva 34

35 18. DSDA: Manufacturing process: In this process, first water is taken into open vessel. Then PTOSA and caustic lye, soda ash is added gradually as per requirement at the same time, oxygen is also added gradually as per requirement. Sulphuric acid is charged then this solution is transferred to filter press to removal of water. After removing water, material is transferred to centrifuge followed by dryer to obtain Di-itro Stilbene Di Sulphonic Acid (DSDSA). Chemical Reaction: CH 3 SO 3 a SO 3 a 2 O 2 + O 2+ H 2 SO 4 + 2aOH O 2 CH=HC O 2 Air Sulphuric Acid Caustic Lye SO 3 a Sodium Salt of PTOSA DSDSA + + 4H 2 O Water a 2 SO 4 Sodium Sulphate Mass Balance: Mass balance of DSDSA IPUT KG OUTPUT KG PTOSA 950 Soda Ash 120 Caustik lye 45 Ice 900 Sodium Hypochlorite 1800 Sulphuric Acid 450 Oxidation Water 1000 wastewater 3115 Filtration Wet cake formation Standardization & Packing Drying Losss 1150 DSDSA 1000 TOTAL M/s. Dutt Chemical, Vatva 35

36 19. Sodium apthoniate: Manufacturing Process: Alpha naphthyl Amine is Sulphonated with Sulphuric Acid in ODCB at higher temp convert aphthionic acid. Distil ODCB with water as azeotropic mixtures, followed by neutralization with sodium Carbonate (Soda Ash). Collect 1st cut ODCB from bottom and send for Acid treatment (AT).Filter the mass. Collect in isolation vessel and Cool the mass. Filter it in utch and CF it gives cold water wash to get Sodium aphthionate. Collect filtrate take in aphthionate isolation vessel add dil. Sulphuric acid. Filter the mass and collect W/C as A. Charge collected A in a vessel. Chemical Reaction: Mass Balance: Mass Balance of Sodium apthoniate Input KG Output KG ODCB 1200 Aplha apthyl Amine 450 Sulphonation Sulphuric acid 410 Soda ash 550 Water 2720 eutralization Sulphuric acid 350 Isolation Filtration Waste Water 3810 Drying Drying loss 870 Sodium apthoniate 1000 Total M/s. Dutt Chemical, Vatva 36

37 Annexure-III Water Balance Diagram Total fresh water consumption 32.0 KLD (16.0 KLD Fresh water + 16 KLD recycle) Domestic 2.0 Process 12 Washing 10.0* Boiler 6.0 Greenbelt 1.0 Soak pit 1.8 Ice Steam Water retained with RM 3.5 Total Volume 22.5 Dyes Intermediates 4.0 Dyes 18.5 Drying Loss 1.0 Drying Loss 8.5 RO 18.5 Spray drying for product recovery Permeates water 10* 10.0 Water/steam loss 1.0 Blow down ETP ETP = Close loop recycle Evp at common facility RO 11.0 Permeates water 6.0* 5.0 To CETP Vatva M/s. Dutt Chemical, Vatva 37

38 Sr. o. Source Water Balance-Water Consumption Water Consumption Existing (KL/day) Water Consumption After expansion (KL/day) 1. Domestic Green Belt Industrial A Process B Boiler C Washing Total Industrial TOTAL ( ) Recycle Water Fresh water requirement Sr. o. Water Balance-Wastewater Generation Source W/w Generation Existing (KL/day) W/w Generation After expansion (KL/day) 1. Domestic Industrial A Process * B Boiler C Washing Total Industrial Effluent sent to the common evaporation facility Total Industrial TOTAL (1 +2) * 3.0 KLD wastewater of dyes intermediates will be primarily treated in ETP-1, after treatment, it will be sent to the common evaporation facility for final treatment and disposal. M/s. Dutt Chemical, Vatva 38

39 Sr. o. Type of Waste 1. ETP sludge 2. Discarded Containers Liner/Bag s Annexure-IV Details of Hazardous waste & its disposal Source Category o. as per HWM rules, 2016 ETP MT/Month Raw material Quantity Existing Proposed Total o/month 0.05 MT/Month 9.9 MT/Month 400 o/month MT/Month 10 MT/Month 500 o/month MT/Month Method of Disposal Collection, Storage, Transportation, Disposal on TSDF Collection, Storage, Decontamination, Transportation, Disposal by selling to Authorized Recycler. 3. Used Oil Plant & machiner ies Lit/Year 88 Lit/Year 100 Lit/Year Collection, Storage, Transportation, Disposal by selling to Registered Reprocess M/s. Dutt Chemical, Vatva 39

40 Sr. o. Stack attached to Existing Scenario Flue Gas Stacks 1. Steam Boiler (400 Kg/Hrs) 2. Hot air generator (8 lakh KCal/hr) Process Gas stack 1 Spray Dryer (1000 liter/hr) Annexure-V Details of Air Pollution Fuel Type Stack Height, in m APC measures Probable emission Fire wood SPM< 150 mg /m 3 G:1000 SCM/day Proposed Scenario after expansion Flue Gas Stacks-Proposed 1. Steam Boiler (1.0 Ton/Hrs) 2. Hot air generator (4 lakh KCal/hr) SO 2 < 100 PPM O X <50 PPM 11 SPM< 150 mg /m Cyclone separator and two stage water scrubber Agro waste/ Briquettes 4.5 TPD Agro waste/ Briquettes 3.0 TPD Process Gas Stacks-Proposed 1. Spray Dryer (1000 liter/hr) Direct firing PG 1000 SCM /Day SO 2 < 100 PPM O X <50 PPM PM< 45 mg /m SPM< 150 mg /m 3 SO 2 < 100 PPM O X <50 PPM 11 SPM< 150 mg /m 3 15 Cyclone separator and two stage water scrubber SO 2 < 100 PPM O X <50 PPM SPM< 150 mg /m 3 SO 2 < 100 PPM O X <50 PPM M/s. Dutt Chemical, Vatva 40

41 Annexure VI Land Possession Document