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AD

BP
KU
MD
PC1
PC2
PK
SM
SP
VB
VM

Abhay Deshpande
Baliram Powar
Kamlesh Upadhyaya
Manmath Deolalkar
Pritesh Chauhan
Pradeep Chauhan
Prashant Kadam
Sandipan Mandre
Shreya Pradhan
Vinay Bhandari
Vikin Meshram

Sr. #

Product Group

DMA-X Powder
1

DMA-X Conc.

UP Liquid
JUP Liquid
UP Conc.
PW Liquid
BHT-HC Liquid
BHT-HST Conc.
DP Slurry

BMK Powder

SI Liquid
4

ABP Liquid
BBU 450

2B Powder
5

Action Item

SFP-U Liquid
SFP Powder

4BB Conc.
7

4BB 125
4BB 59% 370

UBR Liquid
8

DSP Liquid

9
10

BSU Liquid
MST Liquid

End Date

SM

September 15, 2015

Analysis of final dried DMA-X powder after Roha trials.

SM

To be communicated after Roha pilot trials.

Application testing of the final dried DMA-X powder.

SM

To be communicated after Roha pilot trials.

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

To be communicated after Roha pilot trials.

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

To be communicated after Roha pilot trials.

Ammendment of the SoPs with the new Raw Material quantities.

BP, PK

To be communicated after Roha pilot trials.

Changes in the BoM for concerned products.

PC1, PC2

To be communicated after Roha pilot trials.

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

To be communicated after Roha pilot trials.

Plan and undertake a batch for UP acidified wet cake as per the proposed stoichiometry.

BP

September 24, 2015

Preparation of UP liquid using the wet cake.

SM

September 26, 2015

Analysis and application testing of the UP liquid against all standard specifications.

SM

October 15, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

Ammendment of all concerned SoPs with the new Raw Material quantities.

BP, PK

Changes in the BoM for concerned products.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

November 01, 2015

Plan and undertake a batch for BMK Powder as per the proposed stoichiometry.

BP

September 15, 2015

Analysis and application testing of BMK Powder against all standard specifications.

SM

September 30, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

Ammendment of SoP for BMK Powder with the new Raw Material quantities.

BP, PK

October 20, 2015

Changes in the BoM for products based on BMK Powder.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

November 01, 2015

Plan and undertake a batch for ABP Powder as per the proposed stoichiometry.

BP

September 21, 2015

Sampling of the ABP liquid after nanofiltration (before spray drying)

BP

September 21, 2015

Analysis and application testing of ABP Liquid and Powder against all standard specifications.

SM

October 10, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

Ammendment of SoPs for all concerned products with the new Raw Material quantities.

BP, PK

October 20, 2015

Changes in the BoM for all concerned products.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

November 01, 2015

Plan and undertake a batch for 2B Conc. (Local) as per the proposed stoichiometry.

BP

September 22, 2015

Analysis and application testing of 2B Conc. (Local) against all standard specifications.

SM

October 12, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

2B Conc. (Local) Ammendment of SoPs for all concerned products with the new Raw Material quantities.

AS Liquid

Responsibility

Analysis report of DMA-X Yellow cake (DMA-X # 15033).

BP, PK

October 20, 2015


October 20, 2015

October 20, 2015

October 20, 2015

October 20, 2015

Changes in the BoM for all concerned products.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

November 01, 2015

Plan and undertake a batch for AS Liquid as per the proposed stoichiometry.

BP

September 23, 2015

Plan and undertake a batch for IJAS Liquid as per the proposed stoichiometry.

BP

BP to confirm

Analysis and application testing of ABP Liquid and Powder against all standard specifications.

SM

October 13, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

Ammendment of SoPs for all concerned products with the new Raw Material quantities.

BP, PK

October 20, 2015

Changes in the BoM for all concerned products.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

November 01, 2015

Plan and undertake a batch for 4BB Conc. as per the proposed stoichiometry.

BP

September 16, 2015

Analysis and application testing of 4BB Conc. against all standard specifications.

SM

September 30, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

Ammendment of SoPs for all concerned products with the new Raw Material quantities.

BP, PK

October 20, 2015

Changes in the BoM for all concerned products.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

November 01, 2015

Plan and undertake a batch for UBR Liquid as per the proposed stoichiometry.

BP

September 24, 2015

Analysis and application testing of UBR Liquid against all standard specifications.

SM

October 15, 2015

Review of the results and further correction in the stoichiometry as needed.

AD, VB, BP, SM

October 15, 2015

Confirmation of saving potential considering all current grades based on the basic product.

AD, BP, PC1, PC2

October 16, 2015

Ammendment of SoPs for all concerned products with the new Raw Material quantities.

BP, PK

October 20, 2015

Changes in the BoM for all concerned products.

PC1, PC2

Add a row in the tracking sheet to track the savings.

PC1, PC2, SP

Batch to be planned in October


Batch to be planned in October

October 20, 2015

October 20, 2015

October 20, 2015

October 20, 2015


November 01, 2015

AD
BP
KU
MD
PC1
PC2
PK
SM
SP
VB
VM

Sr. #

Abhay Deshpande
Baliram Powar
Kamlesh Upadhyaya
Manmath Deolalkar
Pritesh Chauhan
Pradeep Chauhan
Prashant Kadam
Sandipan Mandre
Shreya Pradhan
Vinay Bhandari
Vikin Meshram

Product

2
3
4
5

UP Liquid
JUP Liquid
PW Liquid

Action Item
Decision to replace UP liquid, JUP Liquid, PW Liquid and BHT-HC Liquid with EFD Liquid
(Different e-values). To be discussed with marketing

BHT-HC Liquid

7
8

Initial quantity of Solamine-A required (3MT) to be planned at Roha in co-ordination with


Mr. Vikin Meshram.
Regular quantity to be determined as per the production plan.
Regular production to be planned at Roha.
Ammendment in the current SoPs of the existing products to incorporate changes
regarding formulation.

3
4
UP Conc.
5
6
1

AD, PK, MD, VM

September 18, 2015


September 18, 2015

BP, PK, VB
PK, MD

VB

Confirmation of the savings considering all concerned products.

September 28, 2015

AD, BP, PC1, PC2, VB

PC1 to confirm and inform SP about the savings to be included


in the tracking sheet.

PC1, PC2, SP

SP to present the status of savings in every operations Review


meeting.
Potassium salt is not mandatory.
Entire quantity can be replaced by Sodium salt.
Sulphuric acid saving to be taken out.

October 01, 2015

To determine whether Potassium salt is mandatory.


Replacement of K+ by Na+ for non mandatory requirements.
Corrected saving potential considering split.
Ammendment in the SoP for replacement of KOH by NaOH.
Communication regarding the launch of product as a sodium salt replacing the product
as a potassium salt.

September
September
September
September

September 18, 2015

VB

Confirmation of the savings considering all concerned products.

September 18, 2015

AD, BP, PC1, PC2, VB

PC1 to confirm and inform SP about the savings to be included


in the tracking sheet.

Add a row in the tracking sheet to track the savings.

September 20, 2015

PC1, PC2, SP

SP to present the status of savings in every operations Review


meeting.

Nanofiltration of 5kg reaction mass till 100 e-value, to be continued till minimum salt
content with addition of fresh DM water if required.
Salting of 5kg reaction mass followed by filtration to get the wet cake.

11,
11,
15,
18,

2015
2015
2015
2015

BP to confirm the date.

7
8
9
10
11
12

Material obtained in all the above four activities (point # 2, 3, 4 and 5) to be used to
develop formulations for new MST Liquid (90 e-value).
Stability testing of the formulated liquids.
Application testing of the stable liquids.
Final conclusion based on the test results.
Plant trials for the new MST Liquid formulation.
Communication regarding the launch of product as a sodium salt replacing the product
as a potassium salt.
Confirmation about the saving potential.

13

2
3
4

SI Liquid

8
9
10
11
12
13
14
1

UBR Liquid

8
9
10

BP to inform AD once the sample is available for further work.

Duration: 1 week.

AD, SM
AD
AD

Duration: 1 week.

AD

AD to send the samples to Dahej QC for evaluation.


SM to circulate the report on the stability and application
testing.

To be decided.
To be decided.

SM
SM
AD, BP, SM, VB
AD, BP

To be decided.

VB

To be decided.

AD, BP, PC1, PC2, VB

PC1 to confirm and inform SP about the savings to be included


in the tracking sheet.

To be decided.

Duration: 1 month.

PC1, PC2, SP

SP to present the status of savings in every operations Review


meeting.

September 11, 2015

SM

Decision to go ahead with the development of Urea Free SI Liquid.

September 11, 2015

AD, SM, VB

All the Urea Free ABP formulations (Urea Free SI Liquid) were at
par with regular SI Liquid.
Decided to go ahead with further development.

15kg reaction mass after III condensation to be taken out for laboratory trials.

September 14, 2015

BP

Nanofiltration of 5kg reaction mass in laboratory unit till maximum achievable e-value
irrespective of salt content. No fresh DM water to be added during nanofiltration.

September 19, 2015

AD, SM

Nanofiltration of 5kg reaction mass in laboratory unit till maximum achievable e-value
and minimum salt content by adding fresh DM water if required.

September 19, 2015

AD, SM

September 19, 2015

AD

September 25, 2015

AD

AD to send the samples to Dahej QC for evaluation.

SM
SM
AD, BP, SM, VB

SM to circulate the report on the stability and application


testing.

Acidification and filtration of 5kg reaction mass to get the wet-cake.


Material obtained in all the above three activities (point # 2, 3, 4 and 5) to be used to
develop formulations for Urea Free SI Liquid (130 e-value).
Stability testing of the formulated liquids.
Application testing of the stable liquids.
Final conclusion based on the test results.
Communication regarding the launch of new formulation replacing the urea based
formulation.
Plant trials for the Urea Free ABP Liquid formulation.

October 10, 2015


October 15, 2015
October 15, 2015

BP to inform AD once the sample is available for further work.

To be decided.

VB

To be decided.

AD, BP

Confirmation about the saving potential.

To be decided.

AD, BP, PC1, PC2, VB

PC1 to confirm and inform SP about the savings to be included


in the tracking sheet.

Add a row in the tracking sheet to track the savings.

To be decided.

PC1, PC2, SP

SP to present the status of savings in every operations Review


meeting.

10kg reaction mass after III condensation to be taken out for laboratory trials.

BP

Review stability and application testing of urea free ABP Liquid formulations.

Add a row in the tracking sheet to track the savings.

BP, VB, SM
AD, BP, SM, VB
AD, BP, PC1, PC2, VB
BP, PK, SM

AD, SM

Salting and acidification of 5kg reaction mass followed by filtration to get wet cake.
MST Liquid

3
4
5
6
7

VB

September 16, 2015

BP, PK, SM

Nanofiltration of 5kg reaction mass till 100 e-value, irrespective of the salt content. No
fresh DM water to be added during nanofiltration.

6
7

September 16, 2015

September 25, 2015

10kg reaction mass after nanofiltration in plant (e-value 140) to be taken out for
laboratory trials.
Formulation development for replacement of PEG-600 by Solamine-A.
Stability testing of the formulated liquids.
Application testing of the stable liquids.
Final conclusion based on the test results.
Communication regarding the laundh of new formulations replacing the urea containing
formulations.
Plant trials for the new UBR Liquid formulation.

September 24, 2015

BP

September 24, 2016

BP

Will be decided on October 15, 2015.

BP to inform AD once the sample is available for further work.


October 3, 2015
October 17, 2015
October 22, 2015
October 22, 2016

AD
SM
SM
AD, BP, SM, VB

October 23, 2015

VB

6
7
8
9
10

DP Slurry

AD to send the samples to Dahej QC for evaluation.


SM to circulate the report on the stability and application
testing.

To be decided.

AD, BP

Confirmation about the saving potential.

To be decided.

AD, BP, PC1, PC2, VB

Add a row in the tracking sheet to track the savings.

To be decided.

PC1, PC2, SP

SP to present the status of savings in every operations Review


meeting.
The solutions of slurry formulations based on BMK were found
to be turbid. AD to develop the formulations based on UP
acidified wet-cake and send the samples to Dahej QC for
evaluation.

2
3
4
5

Remarks
Quality of EFD Liquid samples tested so far (e-value 105, 115,
137, 180, 210, etc.) confirmed to be at par with the competitor
samples, including light fastness.

September 25, 2015

20kg reaction mass after III condensation to be taken out for laboratory trials.

4
5

Responsibility

Communication regarding the launch of new formulations replacing the urea based
formulations.

Add a row in the tracking sheet to track the savings.

1
2

Target Date

Will be discussed on October 15, 2015.


PC1 to confirm and inform SP about the savings to be included
in the tracking sheet.

Development for slurry formulations based on UP acidified wet-cake.

September 19, 2015

AD

Stability testing of the formulattions.


Application testing of the stable formulations.
Final conclusion based on the test results.
Pilot trials for new formulation of DP slurry.
Calculation of the indirect savings as a result of simple and shorter process.
Planning for the regular production of Solamine-D.
Communication regarding the laundh of new formulations replacing the urea containing
formulations.

October 03, 2015


October 03, 2015
October 03, 2015
October 24, 2015
October 30, 2015
November 07, 2015

SM
SM
AD,
AD,
AD,
AD,

November 07, 2015

VB

Correction in the saving potential (RM and processing cost).

November 07, 2015

AD, BP, PC1, PC2, VB

PC1 to confirm and inform SP about the savings to be included


in the tracking sheet.

Add a row in the tracking sheet to track the savings.

November10, 2015

PC1, PC2, SP

SP to present the status of savings in every operations Review


meeting.

SM to circulate the report on the stability and application


testing.
BP, SM, VB
BP
BP, KU, PC1, PC2
BP, PK, VM

Product

Projected
Volume (TPA)

Stoichiometry Correction
Annual
Rs./kg
potential
(Rs. In Lakh)

Additive Replacement
Annual
Rs./kg
potential
(Rs. In Lakh)

Process Modification
Annual
Rs./kg
potential
(Rs. In Lakh)

Overall Potential
Annual
Rs./kg
potential
(Rs. In Lakh)

DMA-X Powder

928

3.46

32.09

0.00

0.00

3.46

32.09

DMA-X Conc.

307

4.45

13.67

0.00

0.00

4.45

13.67

UP Liquid

2495

0.74

18.43

0.29

7.20

1.06

26.42

2.09

52.06

JUP Liquid

NA

0.80

0.00

0.31

0.00

1.18

0.00

2.28

0.00

UP Conc.

407

3.15

12.82

10.56

42.99

14.55

59.22

28.26

115.03

196

1.27

2.48

21.56

42.25

3.76

7.36

26.58

52.10

SI Liquid

1235

0.64

7.89

0.33

4.07

0.00

0.97

11.96

AS Liquid

653

0.90

5.88

0.00

0.00

0.90

5.88

1540

0.69

10.64

0.00

0.00

0.69

10.64

BSU Liquid

15

0.60

0.09

0.00

1.37

0.21

1.97

0.30

UBR Liquid

39

2.45

0.96

3.78

1.47

5.44

2.12

11.66

4.55

PW Liquid

320

0.54

1.73

3.14

10.06

6.51

20.82

10.19

32.61

4BB Conc.

573

2.27

13.01

0.00

7.40

42.38

9.67

55.39

BMK Powder

892

2.90

25.84

0.00

18.92

168.73

21.81

194.58

ABP Liquid

4728

0.66

30.99

0.00

0.00

0.66

30.99

SFP Powder

95

3.65

3.46

0.00

0.00

3.65

3.46

2B Powder

758

1.31

9.94

0.00

7.35

55.72

8.66

65.66

DSP Liquid

1472

1.53

22.53

0.00

2.28

33.58

3.81

56.11

BBU 450

1656

2.31

38.18

0.00

6.93

114.79

9.24

152.97

BHT-HC Liquid

NA

1.11

0.00

7.58

0.00

11.28

0.00

19.97

0.00

2B Conc. (Local)

191

1.95

3.72

0.00

17.00

32.47

18.95

36.19

BHT-HST Conc.

331

3.13

10.35

21.48

71.08

12.51

41.41

37.11

122.84

4BB 125

NA

0.85

0.00

0.00

4.63

0.00

5.48

0.00

4BB 59% 370

NA

2.49

0.00

0.00

12.60

0.00

15.09

0.00

2212

0.71

15.68

2.43

53.73

0.00

3.14

69.41

Categorywise total (Rs. In Lakh)


280.38
Already implemented in plant (DMA-X / AS / IJAS / JAS /
64.96
UBR / DSP / MST)
Convinsingly established at laboratory scale

232.87

605.23

92.42

147.87

MST Liquid

SFP-U Liquid

DP Slurry

1118.48

Cells highlighted in
Cells highlighted in

Product

Indicate potential saving in individual catagory


Indicate quantities of raw materials (existing and target)

Potential for Stoichiometry Correction


Stiochiometry (Mole RM/mole CC)
RM Reduction (kg)
Benefits
Reduction
Saving
Raw Material
Current Potential Current Target
(kg RM/Bx) (Rs./kg Product)
Aniline
0.992
0.95
750
718
32
Morpholine
1.060
0.95
750
672
78
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

Aniline
0.992
0.95
750
718
32
Morpholine
1.060
0.95
750
672
78
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

Aniline
0.928
0.892
702
675
27
DEA
1.189
1.048
1015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

Aniline
0.928
0.892
702
675
27
DEA
1.189
1.048
1015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

Not Applicable

0.72
3.73

Not Applicable

4.45

Not Applicable

1500

0.74

0.15 Caustic Potash


0.59 Urea
Solamine-A
1500

500
3,300
0

0
0
818

-2.37
-5.60
7.68

0.29

93
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

0.85

Provision for layer separation.


Use of Stiochiometric quantity of H 2SO4.

0.21

Acidification of aq. Layer to recover free acid


for recycle.

1.06

0.80

0.16 Caustic Potash


0.64 Urea
Solamine-A
1500

500
3,300
0

0
0
818

-2.55
-6.03
8.27

0.31

93
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

0.96 Provision for layer separation.


Use of Stiochiometric quantity of H 2SO4.
0.21
Acidification of aq. Layer to recover free acid
1.18 for recycle.

10.56

93
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

13.06 Provision for layer separation.


No acidification and filtration.
1.49
Acidification of aq. Layer to recover free acid
14.55 for recycle.

21.56

75
80
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

Overall Potential Benefit: Rs. 2.28/kg


Aniline
0.928
0.95
702
675
27
DEA
1.189
0.95
1,015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.63 Caustic Potash


2.52 Sulphuric acid
3.15
1500

500
445

0
0

-10.10
-0.46

Needs to be discussed.

Overall Potential Benefit: Rs. 28.26/kg


2,5-ADSA
0.976
0.966
2,920
2,890
30
Morpholine
1.103
0.92
1,040
868
172
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

1.27

0.18 DEA
1.09 MEG
PEG-6000
2000 Solamine-A

1,500
3,000
4,500
0

0
0
0
1,398

-4.03
-7.50
-17.25
7.23

3.45 Nanofiltration after III condensation.


No salting.
0.31
3.76

Overall Potential Benefit: Rs. 26.58/kg


Sulphanilic acid
1.024
1
2,400
2,344
56
DEA
1.082
0.96
1,540
1,366
174
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.15 Urea
0.48 Solamine-A

4,000
0

0
661

-3.86
3.53

0.64

0.33

Not Applicable.

2500

Overall Potential Benefit: Rs. 0.97/kg


2,5-ADSA
0.976
0.966
2,920
2,890
30
Diethylamine
1.096
0.92
867
728
139
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.43
0.47
0.90

Not Applicable.

Not Applicable.

2000

Overall Potential Benefit: Rs. 0.9/kg


2,5-ADSA
0.976
0.966
2,920
2,890
30
Diethylamine
1.096
0.92
867
728
139
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.15
0.54
0.69

Not Applicable.

Not Applicable

2000

Overall Potential Benefit: Rs. 0.9/kg


2,5-ADSA
0.976
0.966
2,920
2,890
30
Diethanolamine
1.885
1.72
2,146
1,958
188
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.16
0.45
0.60

Not Applicable.

2000

74
80
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

1.11 recovery of second crop from ML


Recycle of II crop after III condensation.
0.27

83
86
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

5.31

1.37

Overall Potential Benefit: Rs. 1.97/kg


Sulphanilic acid
1.024
1
2,400
2,344
56
DIPA
1.165
0.96
2,100
1,730
370
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.16 PEG-600
2.29 Solamine-A

1,650
0

0
650

-7.44
3.66

2.45

3.78

2500

0.12
5.44

Overall Potential Benefit: Rs. 11.66/kg


Aniline
0.928
0.8924
702
675
27
DEA
1.189
1.0476
1,015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.11 Caustic Potash


0.43 Urea
0.54
Solamine-A
1500.00

500
5,650
0

0
0
815

-1.73
-7.00
5.59

3.14

93
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

6.33

Provision for layer separation.


Use of Stiochiometric quantity of H 2SO4.

0.18

Acidification of aq. Layer to recover free acid


for recycle.

6.51

Overall Potential Benefit: Rs. 10.19/kg


Aniline
1.005
0.97
760
733
27
Monoethanolamine
1.141
0.97
566
481
85
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.43
1.84
2.27

Not Applicable.

1500

88.4
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

6.03 Isolation of II crop by acidification.


Recycle of II crop after III condensation.
1.37

85.3
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

15.30 Isolation of II crop by acidification.


Recycle of II crop after III condensation.
3.61

7.40

Overall Potential Benefit: Rs. 9.67/kg


Aniline
1.005
0.97
760
733
27
DEA
1.125
0.97
960
828
132
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.53
2.37
2.90

Not Applicable

1500

18.92

Overall Potential Benefit: Rs. 21.81/kg


Sulphanilic acid
1.024
1
2,400
2,344
56
DEA
1.082
0.95
1,540
1,352
188
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.15
0.51
0.66

Not Applicable

Not Applicable.

2500

SFP
Powder

Overall Potential Benefit: Rs. 0.66/kg


0.78
2.87
3.65

Not Applicable.

Not Applicable

2000

Overall Potential Benefit: Rs. 3.65/kg


0.75
0.56
1.31

Not Applicable.

2000

81
90
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

5.29 Isolation of II crop by acidification.


Recycle of II crop after III condensation.
2.06

80
86
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

2.14

83.5
87
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

5.67

7.35

Overall Potential Benefit: Rs. 8.66/kg


Sulphanilic acid
1.024
1
2,400
2,344
56
DIPA
1.165
0.96
2,100
1,730
370
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.10
1.43
1.53

Not Applicable

2500

0.14
2.28

BBU 450

Overall Potential Benefit: Rs. 3.81/kg


Sulphanilic acid
1.024
1
2,400
2,344
56
DEA
1.082
0.96
1,540
1,366
174
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

BHT-HC
Liquid

DSP
Liquid

Not Applicable

1500

Overall Potential Benefit: Rs. 2.09/kg

Metanilic acid
1.066
1
2,000
1,875
125
DEA
1.085
0.95
1,235
1,081
154
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

Aniline
0.928
0.892
702
675
27
DEA
1.189
1.048
1,015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

2B
Conc.
(Local)

0.56
2.90
3.46

Overall Potential Benefit: Rs. 4.45/kg

2,5-ADSA
0.976
0.966
2,920
2,890
30
Diethylamine
1.096
0.92
867
728
139
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

BHT-HST
Conc.

Potential for Additives Replacement


Potential for Process Improvement / Modification
Additives (kg/Bx.)
Benefits
Yield
Savings
Changes Proposed
RMC
Saving
Current Proposed
Current Potential (Rs./kg)
(Rs./kg) (Rs./kg)

Additive

Overall Potential Benefit: Rs. 3.46/kg

2B
Powder

ABP
Liquid

BMK
Powder

4BB
Conc.

PW
Liquid

UBR
Liquid

BSU
Liquid

SFP-U
Liquid

AS
Liquid

SI
Liquid

MST
Liquid

UP
Conc.

JUP
Liquid

UP
Liquid

DMA-X
Conc.

DMA-X
Powder

0.56
1.75
2.31

Not Applicable

2500

1.26
6.93

Overall Potential Benefit: Rs. 9.24/kg

1.11

0.22 Caustic Potash


0.89 Urea
Triethanolamine
1500 Solamine-A

500
1,650
1,100
0

0
0
0
836

-3.55
-4.20
-11
11.17

7.58

93
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

10.69 Provision for layer separation.


Use of Stiochiometric quantity of H 2SO4.
0.59
Acidification of aq. Layer to recover free acid
11.28 for recycle.

80
90
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

12.14 Isolation of II crop by acidification.


Recycle of II crop after III condensation.
4.86

Overall Potential Benefit: Rs. 19.97/kg


Metanilic acid
1.040
1.00
1950
1875
75
DEA
1.541
1.408
1754
1603
151
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.87
1.08
1.95

Not Applicable.

2000

17.00

Overall Potential Benefit: Rs. 18.95/kg


Aniline

0.928

0.892

702

675

27

0.63 Caustic Potash

500

-10.03

90
21.48

95

10.09 Provision for layer separation.

BHT-HST
Conc.
4BB 125
4BB
59%
370

DEA
1.189
1.048
1,015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

3.13

2.50 Urea
Triethanolamine
1500 Solamine-A

1,650
1,100
0

0
0
791

-11.85
-31.03
31.42

21.48

Total PPC reduction


(Rs./kg)
Total benefit (Rs./kg)

Use of Stiochiometric quantity of H 2SO4.


2.42
Acidification of aq. Layer to recover free acid
12.51 for recycle.

Overall Potential Benefit: Rs. 37.11/kg


Aniline
1.013
0.97
766
733
33
Monoethanolamine
1.141
0.97
566
481
85
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.19
0.66
0.85

88
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

Not Applicable.

1500

3.65 Isolation of II crop by acidification.


Recycle of II crop after III condensation.
0.99
4.63

Overall Potential Benefit: Rs. 5.48/kg


Aniline
1.013
0.97
766
733
33
Monoethanolamine
1.141
0.97
566
481
85
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.56
1.94
2.49

88
95
Total PPC reduction
(Rs./kg)
Total benefit (Rs./kg)

Not Applicable.

1500

9.69 Isolation of II crop by acidification.


Recycle of II crop after III condensation.
2.91
12.60

DP
Slurry

Overall Potential Benefit: Rs. 15.09/kg


Aniline
0.928
0.8924
702
675
27
DEA
1.189
1.0476
1,015
894
121
Total Potential Benefit (Rs./kg)
Quantity of cyanuric chloride per batch for indicated RM quantities (kg)

0.71

0.14 Caustic Potash


0.57 Xanthan Gum
Solamine-D
1500

500
25
0

0
0
176

Overall Potential Benefit: Rs. 3.14/kg

-2.27
-1.38
1.23

2.43

Not applicable

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