A small scale industry manufacturing Dye Intermediate, in Gujarat. Producing 4-4 Diamine sulfonalide (DASA) as its main product, which is used in manufacturing of Dyes and Pharmaceuticals. The plant is having a capacity of 50 MT/Month capacity.

After attending the Orientation Programme conducted by Gujarat Cleaner Production Center, The owner of industry decided to go for implementation of various CP-tools in his industry.

Process

At first Acetanilide is Sulphonated with Chlorosulphonic Acid which produce Sulphonyl Chloride, simultaneously production of P-Phenyle Diamine takes place in another vessel by using P-Nitro Aniline and other chemicals. Both the products are condensed and then hydrolyzed for the final product, which is then isolated, filtrated, centrifuged, dried and packed.

CP-Programme

After complete study of process as per CP-methodology potentials for CP-options were developed and evaluated afterwards. After economical and technical feasibility analysis few options were suggested to industry and the results that we got are tremendous and very valuable for industry in current situation prevailing in the Global Market.

CP-Results

• Condensation and hydrolysis were the two different stages, which requires more time for process, more power and more quantity of water. It was decided to make both this operation together. The implementation gives following results. Reduction in process time by 8 hours/batch, power supply by 10 HP effluent quantity ,and 8000 liters of water has been saved which has also reduced. Now the batch size has been increased from 1240Kg to 1500 Kg and numbers of batches/month has been also increased from 20 to 25. Due to this the production capacity has been increased. Handling loss has been also eliminated. The overall result in terms of money is Rs. 6,50,000/year and lots of environmental benefits gained by the industry.
  
  
• The Ice consumption was also high enough to concentrate over it (16 MT/Batch of ice worth Rs. 410/MT was consumed). A CP option of installation of chilling plant was also suggested which required investment of Rs.3,00,000 (one time) maintenance costs Rs.1,92,000. The unit has been saving Rs.19,68,000/year by eliminating the ice consumption, saving energy by 64,000 units/year and reduction in effluent load.
  
  
• Earlier clothes were used in three neutch for filtration operation. These cloths were sent to solid waste site after 6-7 batches. The options of using Porous Tiles instead of Filter cloth was accepted by industry. An investment of Rs.4,50,000 (one time) is made for that. Now company is saving Rs.1, 28,284/year (pay back period of 3.5 years) , reduction in filtration time by 4 hours and power saving of 2040 units/year. Reduction in the quantity of solid waste and improvement in quality of filtration are the environmental benefits gained by company.
  
  
• The huge amount of By-product namely Gypsum was the another problem faced by company. An improvement in Gypsum quality could be useful for company to sell out. The filter press has been installed. This implementation has improved the quality of Gypsum, reduced the quantity of solid waste and manual handling of it. It has saved energy of 2 lacs Kcal/year. The company is selling Gypsum and earning money through it.
  
  
• Good house-keeping options were also suggested to industry, which have been successfully implemented by the industry. These options were implemented at the cost of Rs.60,000 which gives savings of Rs. 4,37,000 and environmental savings like reduction in COD, TDS, water and energy etc.

Summary:- Economical benefits Investment : Rs. 8,10,700 (one time) Saving :Rs.58,03,050/year Environmental benefits Reduction In TDS : 2,14,200 Kg/Year Reduction in Spent : 9,00,000 Litre/year Acid Generation Reduction in COD : 7158 Kg/year Water Conservation : 6,70,000 lit/year Energy Conservation : 67,318 Units/Year