Dye Industry

• A dye is a colored substance that has an affinity to the substrate to

which it is being applied
• Dyes are used primarily in the production of consumer products,
including paints, textiles, printing inks, paper, and plastics
• Both dyes and pigments are colored because they absorb some
wavelengths of light more than others
• Different types of Dyes :
 Natural
 Synthetic
 Organic

• Natural dyes are made from plant sources

Roots, bark, leaves, and wood

• Synthetic dyes are man-made, made from synthetic resources such as

petroleum by-products and earth minerals
• Organic dyes are mainly organic compounds having range of application
like organic dye laser and camera sensor

• Acidic dyes are water-soluble anionic dyes that are applied to fibers such
as silk, wool, nylon
• Basic dyes are water-soluble cationic dyes that are mainly applied
to acrylic fibers
Factor affecting dye colour :
• Fibre type used
The dye and the fiber used have to be compatible. The polyesters fibre
provide a very good result with substantive dyes

• Dye type used

The way the dye is fixed on the fiber is a factor affecting the dye colour
fastness: the bigger is the dye molecule the easier it will fix on the fiber

• Tone
The color fastness depends on the dye quantity present on the fiber
Optical Brightners

• Theses are the chemical compounds that absorb light in ultraviolet and
violet region of the electromagnetic spectrum
• Re-emit light in blue region by fluoroscene
• Common classes of these compound are stilbene
• Brighteners are commonly added to laundry detergents to make the
clothes appear cleaner
Factors Influencing Productivity :
• Controllable Factors
1. Product Factor
2. Plant and Equipments
3. Technology
4. Material and Energy
5. Human factors
6. Work methods
7. Managements style
• Uncontrollable Factors
1. Structural Adjustments
 Includes economics and social changes
 Shift in labour from agricultural to manufacturing sector
 Industrial Compititiveness

2. Natural Resources
 Manpower, land and raw materials

3. Government and Infrastructure

History of BASF

• 1st interaction of BASF with India came in Textile colors during 1890
• Later in 1943, R.A.Cole pvt. Ltd. Incorporated that later become BASF
India limited
• It has more than 390 production sites in different continents including
Asia, Europe, America, Africa and Australia
• BASF has successfully partnered India’s progress for over a century, with
13 of BASF's 14 global businesses maintaining a local presence in India
today
• In 2014, BASF registered sales of €1.1 billion to customers in India.
• Mangalore site is largest manufacturing site in south Asia
• BASF total revenue is about 5 lakh million rupees
• India alone share 9.4% ( 47,000 million rupees ) of total revenue.
• It is the largest chemical producer in the world
• It’s RnD file 3-5 paper every day, BASF invest around 1953 million per
year in there RnD
• Ankleshwar site has capacity of 16000 TPA
Production sectors
• Chemicals
 Petrochemicals
o Ethylene
o Propylene
o Butadiene
o Benzene
o Monomers ( isocyanates , ammonia, caprolactam, adipic acid, chlorine, urea, glues and caustic
soda, sulfuric and nitric acid)
• Performance Products
 Dispersion and pigments
 Care chemicals
 Nutrition and health
 Performance chemical division (Anti oxidants, pigments and flame retardant for
plastic applications)

• Functional material and solutions

 Catalysts (Automotive and process catalyst)
 Construction chemicals
• Agricultural solutions
 Fungicide
 Herbicide
 Insecticide

• Oil and Gas

Business comparison

• Chemicals
Revenue
BASF (2015)- 14670 million euro
RIL petrochemical (2015)- 11643 million euro

• Performance product
BASF (2015)- 15648 million euro
• Functional material and solutions
BASF(2015)- 18523 million euro

• Agricultural solutions
BASF (2015)- 5820 million euro
UPL sales(2015)- 470 million euro

• Oil and Gas

BASF(2015)- 12998 million euro
RIL(2015)- 1063 million euro
Optical Brightner
Production process
1. Firstly we make a slurry of Cyanuric Chloride(CC) using ice to lower
down the temperature, after that using scrubber to take out dust and
lastly neutralizing it using caustic soda

2. The first chlorine of Cyanuric Chloride is reactive in acidic condition

Now the discharge from neutralization is added in DASDA in
condensation reactor 1
Conditions:
• PH Maintained: 4.5-5.5
• Temperature: 0-5 degree C
• Slightly Exothermic Reaction
• %Conversion: 98%
• Reaction time: 2 Hr

By product formed in this reaction is HCL to tackle it we use Na2C03 to

convert it into NaCl, C02, H2O Lastly C02, H2O scrubbed off in scrubber.
3. Now to replace 2nd chlorine of CC we use Aniline but now the condition
has been switched to Basic. Second condensation reaction takes place in
reactor 1 only

Conditions:
• PH Maintained: 9-10
• Temperature: 15 degree C
• No Heat Released
• %Conversion: 96%
• Reaction Time: 2Hr
4. Now to replace 3rd chlorine of CC we use Amine in Basic Condition in
reactor 2.

Conditions:
• PH Maintained: 9-10
• Temperature: 60-65 degree C
• No heat Released
• %Conversion: 92%
• Reaction Time: 2 Hr
5. After the Condensations reaction are done we do Precipitation using HCL
we perform Acidification and rest is sent to Filter Press in which we get
solid cake in leaf filter with upto 55-60% moisture

6. Now using belt we send it to Formulation Unit which after doing

Clarifications using leaf filter (Removing Impurity) is sent to Storage Tank

7. In case we want product in solid form we directly send cake from Filter
Press to Integrated Fluidized Bed hence making slurry with H2O, Lastly
evaporating water using spray dryer and send final product in Powder
Form in Storage tank
Azo dyes
Pergasol
Productions process
1. Firstly the diazotization of amine is done with HCl and NaNO2, to favor
the production we usually prefer acidic medium at the beginning by
controlling PH

2. Now and chemicals combine to produce dyes and due to acidic

medium there is little formation of salt which is tackled by membrane
separation
3. Membrane separations process separates salt impurity and pass high
density dye for Nano Filtration followed by Ultra Filtration

NANO FILTRATION
This method is used when we have slurry in our stream and solid is our
product. In this we use filter press to gain solid particle and the solid
retain on plate and liquid goes to effluent treatment plant. The final
output comes in form of cake
ULTRA FILTRATION
This method is used when we have solution form of flow not slurry. Till
here input has 2-3% of salt so we cannot separate soluble and insoluble
components. Anything which is soluble goes in mother liquor. After this
final dyes is send to Formulation

4. The colour of the dye is completely dependent on Raw material used.

Pergafast
Production process
1. The developer used to make pergafast are
• Meta Amine Phenol (Powder)
• Pera Toluene Sulphonil (Liquid)
• Pera Toluene Sulphonate (Powder)

2. The reaction involved here is tosylation which is slightly exothermic. The

1st and 2nd additive are directly put in reactor while 3rd one is manually
charged.
3. The reactor temperature is set up at 75 degree C, the exothermicity of
the reaction is not sufficient enough to maintain the reactor
temperature. So we use steam to bring temperature to required level

4. After the reaction happened the purgafast remains in soluble form

which is first acidified and sent to precipitation coloumn, the transfer is
done through air pressure
5. Now the slurry is sent to filter press from where two streams are
separated solvent and solid, former one is sent to ETP and latter one is
sent to slurry tank with the help of belt which contains 45% moisture

6. Now again we make the slurry of solid with methanol with 2:1
composition, which helps to remove impurity and moisture

7. The slurry is now sent to dryer of which we have 3 units inside we have
mesh so slurry retains on mesh and methanol comes down and gets
collected in separate vessel and cake gets accumulated with dryer
8. The dryer used is vacuum because product is sensitive to temperature.
In this we start heating in jacket inside agitator which can be lift up and
down using hydraulics

9. Once drying is done it is unloaded in De lumper because of lump

formations during drying, and atlast we send it to Nota Blender for
uniformity of product
Multi Effect Evaporator
• A machine for efficiently using the heat from steam to evaporate water
• water is boiled in a sequence of vessels, each held at a lower pressure
than the last
• In BASF 6 effect evaporator is used
Filter Press
• An Industrial filter press is a tool used in separation processes
• Specifically in solid/liquid separation using the principle of pressure
drive, provided by a slurry pump
• The slurry needed to be dewatered is injected into the center of the
press and each chamber filled
Thank You
Amit sachan
Rampal Dahiya
Shashi kant kumar