THE first Sauradip Chemical Industries Fellowship visiting fellowship Lecture was held on 15th April 2019 at ICT Mumbai. Welcoming the participants, Professor Dr. G.S. Shankarling, Head, Department of Dyestuff Technology thanked Dr. Kishore Shah, Chairman, Sauradip Chemical Industries for introducing series for Dyestuff Technology and Textile processing.
Dr. Kishore Shah speaking on the occasion said that they have introduced this Fellowship lecture series, wherein every year eminent persons from industry would give a lecture with the aim of having interaction between industry and academia.
Mr Rajive Shah Managing Director, Sauradip Chemical Industries Pvt Ltd spoke on the trust of developing “Sustainable Products for a greener planet“ as the core of Sauradip philosophy.
Mr Jaideep Shah Executive Director, Sauradip Chemical Industries Pvt Ltd called up on having positive attitude which is important in life. Further he spoke on offering World class service to customs should be at heart of every company and how world class companies strive to achieve the same.
Prof (Dr) G.D.Yadav- Vice Chancellor – ICT introduced the chief guest Dr Nilesh Mistry Chief Technology Officer, Lonsen Kiri Chemicals Industries Ltd. Prof Yadav praised Dr. Kishore Shah for generous donation for renovation of Polymer and Surface Coating Post Graduate and undergraduate Laboratories.
Dr Nilesh Mistry presented the maiden lecture on Challenges of Dyestuff Industry – A sincere effort towards accepting challenges. He gave lucid insights in 12 areas on challenges to dyestuff industry and Lonsen Kiri for overcoming the same in a competitive world and innovation leadership followed by showcasing aerial view of the factory plant and equipment and operations. The following is the gist of his talk.
Pharma vs. dyes industry: Pharma requires products with 99.5% purity (GC, HPLC, Mass, IR) as they are intended for human consumption. Dye industry does not require pure products as such, and shade matching is done by mixing with brighter shade e.g. Standard Red dye with bluer tone. Multifibre (nylon shade) testing of dyes (Reactive Black WNN) with different tones and desired matching with use of impurities (7-13%) assessed by HPLC.
Dyes and Intermediates industry: China is the largest manufacturer followed by India (share of 16% world production). India is leader in production and export of reactive dyes whereas China with disperse dyes, azo dyes and dyes intermediates. Vinylsulphone and H-Acid are key raw materials. Besides export and import, India's production capacity of Vinylsulphone and H-Acid are less than demand. Volatility in the price of VS is in the range of 250 enhanced to 415. H-Acid production cost is 400 which shot up to 1300 owing to closure of Chinese companies and increased demand.
European, Japanese and Indian dyes industry – Methodology: Reactive Black 5. Testing in-process whereas Japanese do not follow in-process testing since use of right quality raw materials and quantity according to standard parameters gets the desired product without variation. Chemicals have specific physical and chemical properties. This cannot be followed in India since raw materials are purchased from various sources with different quality, solid contents, insoluble and the batches should conform to same quality.
Achieve best results and grow with the industry: Best chemistry principles results in best output. For optimisation of reaction, stoichiometric calculation (molar ratio of chemicals) may be followed to avoid undesirable by-products apart from any required by-products. Allow maximum possible concentration (30-35%) e.g. with 10-15% solid contents, same batch can be produced but output is less resulting in less competitiveness. Therefore, effective utilisation of available reactors, equipment capacity, occupancy of equipment and time set are important.
Lonsen-Kiri follows improvement in different areas: Coal consumption (1.87 kg per plant per 1 kg product in 2013 reduced to 0.75 kg in 2019). Further, 1.1 kg reduced to 0.7 kg using good coal quality with calorific value besides particle size for effective utilisation. Next step is water conservation for effective utilisation by planning pattern e.g. red dye production without change of products to preclude washing in plant. This has resulted in reduction of water consumption from 17 Kl per I ton to 9 KL in 5 years making it competitive against other manufacturers. Solid waste reduction – powder on spray drying may release dust particles into atmosphere. Hence, modification and investment in spray dryer, solid content of liquid is reduced, solid waste from 3% to 1% resulting in saving of Rs.5 crores per annum.
Usage of solid waste: Various steps in intermediates synthesis generate acidic effluent, which is neutralised with alkali to sodium sulphate followed by filtration. Recovered salt has been consumed, 4 tons for 36 tons; 8 tons for 51 tons Black mix dyes, thereby saving in cost of disposal besides waste and purchase.
Liquid waste: RO Membrane process generates permeate containing 2-3% dye (molecular weight of 800-900) which was recovered and concentrated to 15-30% for use in mix dye (Black mix contains yellow, orange).
Environmental protection: Though, they have permission to discharge around 200 KL treated water to effluent channel, they have a self-imposed Zero Liquid Discharge since last 4 years. Effluent is collected into ETP, segregated, treated in multi-effect evaporator and distilled off to 70% of distilled water having 25% COD, TDS is reused in production. 30% concentrate is spray dried in-house or at external agency before disposal to landfilling site.
Occupational Health and Safety: This is done of employees by regular audits. Safety and Fire-fighting are equally important for prevention of accidents. Regular training of fire-fighting besides lectures are conducted to this effect.
Water conservation: Videos were shown on rain water harvesting (by gutters) for collection of water in pond during monsoon and environment protection. This is pure water which they reuse in processing. They celebrate Environment Day and Tree Plantation Day.
Storage area: To achieve the highest production, storage of raw materials segregated category wise (acidic or alkaline) and finished goods product wise are necessary. For commitment to customers in the next 3 months, yearly production planning, storage capacity and money for strategic purchase are important. Raw materials are purchased in advance. Finished material packed directly from spray drying units into pallets (500 tons) for despatch. Besides storage and raw materials, good work place is a must without obstacles and colour contamination.
Awards and Excellence: From Gujarat Chief Minister in 2015-2018 and Quality award. GPCB quotes their company to others to maintain environment and cleaner chemistry.
Proposing a vote of thanks, Prof R.V.Adivarekar, Department of Fibres and Textile Processing Technology offered special thanks to Dr.Mistry, Prof Yadav and Dr.Kishore Shah. Mr.V.D.Patil (President Indian Specialty Chemical Manufacturers' Association) hosted high tea. The lecture ended with question-answers session and National Anthem. ( With inputs from Dr.K.S.Murthy, Pidilite Industries Ltd)