Annexure-I

List of Products

Sr. MT/Month
Name of the Product
NO.
(A) Reactive Dyes
1 Reactive Blue 198. 50
2 Reactive Blue FNG. 50
3 Reactive Blue 19. 40
4 Reactive Blue 49. 50
5 Reactive Blue 220 50
6 Reactive Blue 221 50
7 Reactive Blue 222 50
Total (A) 340
(B) Dyes Intermediates
8 PNCBOSA 30
9 Chloranil Condense 30
10 Blue HEGN (198) Base 25
11 Aniline 2:4 DSA. 30
12 Aniline 2:5 DSA 30
13 Oxy-Sulphone 30
14 M. Acid 20
15 Blue - 49 BASE 20
16 Metanillic acid 20
17 4-Sulpho Anthralinic Acid 50
18 4-Sulpho Hydrazone 50
19 Sulpho O.A.V.S./ Sulpho V.S./ Sulpho J- Acid/ 30
Sulpho Gamma Acid
20 3;5 DABA 10
Total (B) 375
Total (A + B) 715

M/s. Metachem Industries, Khambhat 1

 List of Raw Materials
Sr. Product name Raw Materials Name MT/Month
no.

1 Reactive Blue 198 Blue HEGN (198) W/C 54.50

(HEGN) Soda Ash 21.0
Aniline 2:4 DSA 10.0
Cy. Chloride 8.25
S.B.C. 4.75
Celsolin Oil 0.50
2 Reactive Blue FNG Blue Base 198 W/C 63.50
Soda Ash 30.0
Aniline 2: 5 DSA 14.0
Cynuric Chloride 10.40
Celsolin Oil 0.50
MBVS Ester 15.0
Sodium Bicarbonate 11.50
3 Reactive Blue 19 Oxy Sulphone 31.0
Oleum (23%) 32.0
Sulfuric Acid (98%) 7.6
Salt 34.8
CaCO3 6.4
Oxilic Acid 3.6
Soda Bicarbonate 4.0
4 Reactive Blue 49 Blue 49 W/C 27.5
Soda Ash 10.0
Cy. Chloride 5.0
Metanilic Acid 5.0
5 Reactive Blue 220 Sulpho OAVS 13.5
Sodium Nitrite 3.5
HCl (30%) 27.5
4-Sulpho Hydrazone 19.5
Caustic Lye (48%) 4.5
Soda Ash 5.0
6 Reactive Blue 221 6-Acetyl OAPSA 11.5
CS Lye (48%) 2.0
HCl (30%) 61.5
Sodium nitrite 3.5
Sulphamic acid 0.1
Sodium acetate 5.0
Soda Ash 10.0
4-Sulpho Hydrazone 15.0
Copper sulphate 12.5
CS Flakes 16.0
Salt 32.5

M/s. Metachem Industries, Khambhat 2

 Cyanuric Chloride 7.5
Tamol 0.4
N-Ethyl MBVS 12.8
Soda Bi Carb 7.8
Dicamol 2.3
7 Reactive Blue 222 MPDSA 6.8
Cyanuric Chloride 6.6
Soda ash 6.5
Celsolin Oil 0.2
M.B.V.S. 10.0
NaHCO3 6.5
NaNO2 5.0
HCl (30%) 18.0
H-Acid 10.5
Sodium Acetate 14.8
S. T. A. 10.0
Dyes Intermediates
8 PNCBOSA PNCB 21.5
65% Oleum 23.6
Salt 30.0
9 Chloranil E.D.A. 150.0
Condense PNCBOSA 30.0
SBC 16.2
HCl (30%) 45.0
Ac. Acid 3.0
C.I.P. 15.0
Soda Ash 15.0
Chloranil 12.0
10 Blue HEGN (198) Sulfuric Acid (98%) 9.4
Base Oleum (23%) 70.0
Chlo. Cond. 25.0
Sodium per Sulfate 18.8
11 Aniline 2, 4 DSA Sulphanilic Acid 25.5
Oleum 23% 75.0
12 Aniline 2, 5 DSA Metanilic Acid 25.5
Sulfuric Acid (98%) 30.0
Oleum 65% 36.0
Hyflow 0.3
Activated Carbon 1.4
Sodium Sulphate 25.5
13 Oxy Sulphone Bromamine Acid 25.5

M/s. Metachem Industries, Khambhat 3

 M.B. V.S. Acid 16.5
Soda Bi carbonate 25.5
CUCl2 0.3
Celsolin Oil 0.3
Copper Bronze 0.2
HCl (30%) 60.0
Salt 7.5
14 M. Acid Macitinline Acid 11.4
H2SO4 56.0
W.N.A. 17.6
NaOH 3.0
Iron Powder 30.0
Ac. Acid 7.0
Soda Ash 7.0
Ac. Carbon 0.5
HCl 30.0
Hydro Powder 0.3
15 Blue 49 Base Bromamine Acid 20.0
M-Acid 32.5
Soda Ash 13.6
Cuprous Oxide 2.0
Celsolin Oil 0.3
Coomon Salt 7.6
Dicamol 0.8
N2 Gas 1.3
HCl (30%) 54.0
16 Metanilic Acid Nitro benzene 18.0
Oleum (65%) 19.6
Soda Ash 1.0
Lime Stone Powder 22.0
Iron Powder 2.5
HCl (30%) 2.0
Soda Ash 3.5
Sulphuric Acid 1.8
17 4 O.N.T. 90.0
SulphoAnthranilic Oleum (65%) 99.0
Acid Sulfuric Acid (70%) 175.0
NaOH 107.5
18 4 4 SulphoAnthranilic Acid 50.0
Sulphohydrazene HCl (30%) 110.0
Sodium Nitrite 15.0
Sodium bisulphite 42.5
Caustic Soda 24.0
Benzaldehyde 30.0
19 Sulfo OAVS OAVS 37.5
Oleum Acid (65%) 66.4
Sulphuric Acid 54.4

M/s. Metachem Industries, Khambhat 4

 KCl 19.5
20 3,5 DABA Benzoic Acid 12.0
Nitric Acid 10.9
Sulphuric Acid(98%) 23.4
Iron Powder 16.4
HCl (30%) 19.5
Soda Ash 9.0

M/s. Metachem Industries, Khambhat 5

 Annexure-II
Manufacturing Process
(A) Reactive Dyes

1. Reactive Blue 198

Manufacturing Process:
Blue 198(HEGN) base W/C condensate with Cynuration of aniline 2:4 DSA& then
clarify, standardize& spray dryer.

Chemical Reaction:

M/s. Metachem Industries, Khambhat 6

 Mass Balance:
Mass Balance of Reactive Blue 198 (HEGN)

INPUT KG OUTPUT KG

Blue HEGN (198) W/C 1090

Soda Ash 50 Base Slurry
Water 3700

Aniline 2:4 DSA 200

Soda Ash 120
Cy. Chloride 165
S.B.C. 95 Cyanuration
Celsolin Oil 10
Ice 1800
Water 1000

Soda Ash 250

Condensation

RO permeate reuse 4180

R/O

Drying loss 3300

Spray Drying
Reactive Blue 198 (HEGN) 1000

Total 8480 8480

M/s. Metachem Industries, Khambhat 7

2. Reactive Blue FNG

Manufacturing Process:

Blue 198 base W/C condense with Cynuration of aniline 2:5 DSA & then cond. With
M.B.V.S ester then clarify & std. & spray dryer.

Mass Balance:

Mass Balance of Reactive Blue FNG

INPUT KG OUTPUT KG

Blue Base 198 W/C 1270

Soda Ash 55 Base Slurry
Water 3500

Aniline 2: 5 DSA 280

Soda Ash 270
Cynuric Chloride 208
S.B.C. 150 Cyanuration
Celsolin Oil 10
Ice 1750
Water 1000

Soda Ash 275 1st

Condensation

MBVS Ester 300

Sodium Bicarbonate 80 M B V S Solution
Water 550

2nd
Condensation

RO permeate reuse 5408

R/O

Drying loss 3290

Spray Drying Reactive Blue 198
(HEGN) 1000

Total 9698 9698

M/s. Metachem Industries, Khambhat 8

3. Reactive Blue 19

Manufacturing Process:

Esterification of Oxy-sulphonedry powder in presence of Oleum (23%) & sulphuric

Acid (98%) at 35 ͦC for 36 hrs. When reaction is over dump ester/mass in brian
solution at 0 ͦC to 2 ͦC slowly. After dumping over check PPT & then filter in F.P.
check spot of filtrate. After filtration give air to tight press cake. Dump press cake
in reaction with water of 10 ͦC. Then take pH 4.0 to 4.5 by CaCO3. Then filter slurry.
Collect filtrate in another vessel. Charge oxilic acid &take pH 4.0 to 4.5 by soda bi
carbonate. Then clarify slurry and collect filtration in R/O & then spray dryer.

Mass Balance:
Mass Balance of Reactive Blue 19

INPUT KG OUTPUT KG

Oxy Sulphone 775

Oleum (23%) 800 Esterfication SO2 Gas 350
Sulfuric Acid (98%) 190

Water 3550 Drawning & Effluent to ETP 3200

Salt 870 Filteration

Water 3250 Gypsum Sludge 550

1st Slurry
CaCO3 160

Oxilic Acid 90
Soda Bicarbonate 100 2nd Slurry
Water 650

RO permeate reuse 2135

R/O

Drying loss 3200

Spray Dryer
Reactive Blue 19 1000

Total 10435 10435

M/s. Metachem Industries, Khambhat 9

4. Reactive Blue 49

Manufacturing Process:
Dump B-49 base press W/c in vessel with cold water 15 ͦC & take pH 7.0 to 7.2.
Check clear solution. Check real base by N. V. Then cool to 0 ͦC to 2 ͦC by external
chilling. Charge Cy. Chloride close main hole and stir for ½ hrs. Take pH 7.0 to 7.2
by soda solution and maintain for 4 hrs. Check N. V. of solution. It is 0.2%. If okay
then charge metanilic acid clear solution as fast as possible. Maintain pH 7.0 to 7.2
by soda solution. If pH stable start slowly heat up to 35 ͦC to 40 ͦC. check sample
and clarify.

Chemical Reaction:
Blue 49

O NH 2 O NH 2
N
SO 3 H Cl Cl 0 °C - 2 °C SO 3 H

+ N N
CH 3 CH 3
N
HN NH 2 Cl O HN NH Cl
O

CH 3 CH 3 CH 3 N N
CH 3
SO 3 H SO 3 H Cl

O NH 2
NH 2 NH 2
SO 3 H

+ +
CH 3 SO 3 H
N
O HN NH Cl SO 3 H
(50%) (50%)
CH 3 N N
CH 3
SO 3 H Cl

0 °C - 5 °C

O NH 2
SO 3 H

CH 3
N
O HN NH NH

CH 3 N N
CH 3
SO 3 H Cl SO 3 H

M/s. Metachem Industries, Khambhat 10

 Mass Balance:

Mass Balance of Reactive Blue 49

INPUT KG OUTPUT KG

Blue 49 W/C 550

Soda Ash 200
Cy. Chloride 100 Condensation
Metanilic Acid 100
Water 2000

Water 200 Solid Waste 10

Clarifier

Drying loss 2140

Spray Drying
Reactive Blue 49 1000

Total 3150 3150

M/s. Metachem Industries, Khambhat 11

5. Reactive Blue 220

Manufacturing Process:

4 sulphohydrazine is coupled with sulpho OAVS ester Diazo and product is

complexed with copper sulphate and spray dryer.

Mass Balance:

Mass balance of Reactive Blue 220

INPUT KG OUTPUT KG

Sulpho OAVS 270

Sodium Nitrite 70
Diazotization of
HCl (30%) 550
Supho OAVS
Water 1400
Ice 1900

4-Sulpho Hydrazone 390

Caustic Lye (48%) 90 4 - Sulpho
Soda Ash 100 Hydrazone
Ice 1250 Solution
Water 1050

Copper sulphate 150

Coupling
Steam 350

RO permeate reuse 3450

R/O

Drying loss 3120

Spray Drying
Reactive Blue 220 1000

TOTAL 7570 7570

M/s. Metachem Industries, Khambhat 12

6. Reactive Blue 221

Manufacturing Process:

4 SulphoHydrazone is coupled with 6-Acetyl OAPSAdiazo and product is complexed

with copper sulphate. Then mass is filtered and w/cake is hydrolysis & base is
condensed with N-ethyl meta base ester and spray dryer.

Chemical Reaction:

M/s. Metachem Industries, Khambhat 13

 Mass Balance:

Mass Balance of REACTIVE BLUE 221

INPUT KG OUTPUT KG

6-Acetyl OAPSA 230

CS Lye (48%) 40
HCl (30%) 580
Sodium nitrite 70
Diazotization of 6-
Sulphamic acid 2
Acetyl OAPSA
Sodium acetate 100
Soda Ash 50
Water 750
Ice 850

4-Sulpho Hydrazone 300

HCl (30%) 650 4-Sulpho
Soda ash 100 Hydrazone
Ice 800 Solution
Water 700

Copper sulphate 250

CS Flakes 320 Coupling
Hot water 580

Salt 650 Isolation & Effluent 3400

Soda ash 50 Filteration

Cyanuric Chloride 150

Tamol 7 Base Cyanuration
Water 2000

N-Ethyl MBVS 255

Condensation
Soda Bi Carb 155

Dicamol 45 Solid waste 100

Clarifier

RO permeate reuse 2000

R/O

Drying loss 3184

Spray Drying
Reactive Blue 221 1000

Total 9684 9684

M/s. Metachem Industries, Khambhat 14

7. Reactive Blue 222

Manufacturing Process:

MPDSA is cynurated with cynuric chloride at 5 ͦC& further condensed with M.B.V.S.
Ester. Then this product diazotized & coupled with H-acid to getcoupling mass-1.
S.T.acid is diazotized & further coupled with coupling mass-1 to get coupling mass-
2 which spraydried.

Chemical Reaction:

M/s. Metachem Industries, Khambhat 15

 Mass Balance:
Mass Balance of Reactive Blue 222

INPUT KG OUTPUT KG

MPDSA 135
Cyanuric Chloride 132
Soda ash 60 Cyanuration of
Celsolin Oil 3 MPDSA
Water 750
Ice 750

M.B.V.S. 200
M. B. V. S. Cle.
NaHCO3 60
Solution
Water 400

NaHCO3 70
Condensation 1

NaNO2 50
Diazotization of
HCl (30%) 300
Cond. Mass
Ice 750

H-Acid 210
Soda Ash 70 H-Acid Cle.
Ice 210 Solution
Water 380

Sodium Acetate 145

Coupling 1

S. T. A. 200
HCl (30%) 60
S.T.A.
NaNO2 50
Diazotization
Ice 380
Water 380

Sodium Acetate 150

Coupling 2

RO permeate reuse 1915

R/O

Drying loss 2980

Spray Drying
Reactive Blue 222 1000

Total 5895 5895

M/s. Metachem Industries, Khambhat 16

(B) Dyes Intermediates

8. PNCBOSA

Manufacturing Process:
PNCB is sulphonated in presence of Oleum (65%) at 120 ͦc to 125 ͦC. Maintain for 8
hrs. then dump s/mass in water & salting & filter &C.F.

Mass Balance:

Mass balance of PNCBOSA

INPUT KG OUTPUT KG

PNCB 715 SO2 Gas 80

Sulphonation
65% Oleum 785

Ice 1200 Spent Acid (30 - 35%) 2500

Dumping
Water 2800

Salt 1000 Effluent 3795

Isolation
Water 1400

PNCBOSA (As is real 1525

Wet Cake of
basis 1000 Kg)
PNCBOSA

Total 7900 7900

M/s. Metachem Industries, Khambhat 17

9. Chloranil Condense

Manufacturing process:

PNCBOSA is condensed with E.D.A. at 116ͦC& the mass is then isolate with HCl.
Product obtain is then reduction with C.I.P. when reaction is over filter red. Mass &
collect liq. This liq. Clarify & further condense with chloranil at 60ͦC. When reaction
over filter the mass & dry & Pulv. final product obtained.

Chemical Reaction:

Mass Balance:

Mass balance of Chloranil Condense

INPUT KG OUTPUT KG

E.D.A. 5000
PNCBOSA 1000 E.D.A. E.D.A. Recovered 4400
SBC 250 Condensation
Water 1800

HCl (30%) 1500 Effluent 6990

Isolation
Water 2500

Ac. Acid 100

C.I.P. 500 Iron Sludge 1250
Reduction
Soda Ash 500
Water 3500

Chloranil 400 Effluent 4500

SBC 290 Chlo. Cond.
Water 2000

Drying Loss 1200

Drying
Chloranil Condensate 1000

Total 19340 19340

M/s. Metachem Industries, Khambhat 18

10. Blue HEGN (198) Base

Manufacturing process:

Chlo. Cond is cyclisation in presence of Oleum (23%), Sulphuric acid (98%) &
sodium per sulphate at 18ͦC, when reaction over dump this mass in cold water
(20'c)as fast aspossible. Then temp. goes up to 50ͦC. When dumping over stir for
15minutes & start filter. Then wash with tap water up to congo paper faint. Then
dump press cake invessel & take pH 5.0 to5.5by soda ash & then spray dry and
final product obtain.

Chemical Reaction:
(I) Cyclisation:-
SO3Na O
NH2CH2CH2NH O NH
+
NH O NHCH2CH2NH2
O SO3Na

( Chlo. Cond )

NH2 CL O SO3H
NH O NHCH2CH2NH2

NH2CH2CH2NH O NH
SO3H O CL NH2

[ Blue HEGN (198) Base ]

M/s. Metachem Industries, Khambhat 19

 Mass Balance:

Mass Balance of Blue HEGN (198) Base

INPUT KG OUTPUT KG

Sulfuric Acid (98%) 375

Oleum (23%) 2800 SO2 Gas 90
Cyaclization
Chlo. Cond. 1000
Sodium per Sulfate 750

Ice 2500 Effluent 11305

Water 3000 Drawning

Water 3000 Slurry

Soda Ash 150 Preparation

Drying loss 1180

Drying
Reactive Blue 198 (HEGN) 1000

Total 13575 13575

M/s. Metachem Industries, Khambhat 20

11. Aniline 2,4 DSA

Manufacturing process:

Sulphalinic Acid is sulphonated with Oleum (23%) at different temp. & then this
mass is dump in water. Aniline 2:4 DSA is isolated & cool. Filter slurry in Nutch &
wash & C.F.

Chemical Reaction:
NH 2 NH 2
SO 3 H
+ H 2S 2O 7
+ H2O
+ SO 3
Oleum Water Sulphur Trioxide
SO 3 H SO 3 H

Sulphanilic Acid Aniline 2, 4-Disulphonic Acid

Mass Balance:

Mass balance of Aniline 2, 4 DSA

Input KG Output KG

Sulphanilic Acid 850

Oleum 23% 2500 Sulphonation SO2 Gas 50

Water 3000 Drawning

Spent sulfuric acid(45-50%) 4200

Filtration &
Water 1000 Effluent 1450
Washing

Wet Cake of Aniline 2:4 DSA (As is real 1650

Aniline 2:4 DSA basis 1000 Kg)

Total 7350 7350

M/s. Metachem Industries, Khambhat 21

12. Aniline 2,5 DSA

Manufacturing process:

Metalinic acid is sulphonated with sulphuric acid &Oleum(65%). Then mass is

dump in water give tri sulphonic acid is hydrolised to get aniline 2:5 DSA. It is
isolatedwith salt & filter & wash &C.F.

Chemical Reaction:
NH 2 NH 2
SO 3 H
+ H 2 SO 4
+ H 2O + SO 3
HO 3 S + H 2S 2O 7 HO 3 S Water Sulphur Trioxide
SO 3 H
Metanilic Acid
Aniline 2, 4, 5-Trisulphonic Acid

NH 2 NH 2

SO 3 H SO 3 H
+ H 2O
+ H 2 SO 4
HO 3 S HO 3 S Sulphuric Acid
SO 3 H
Aniline 2, 5-Disulphonic Acid
Aniline 2, 4, 5-Trisulphonic Acid

Mass Balance:

Mass balance of Aniline 2, 5 DSA

Input KG Output KG

Metanilic Acid 850

Sulfuric Acid (98%) 1000 Sulphonation SO2 Gas 80
Oleum 65% 1200

Hyflow 10
Activated Carbon 45 Spent Acid 5185
Hydrolysis
Steam 850
Water 3100

Water 1600 Solid waste 250

Clarification

Sodium Sulphate 850

Isolation
Steam 700

Filtration & Effluent 3070

Centrifuge

Wet Cake of Aniline 2:5 DSA (As is 1620

Aniline 2:5 DSA real basis 1000 Kg)

Total 10205 10205

M/s. Metachem Industries, Khambhat 22

13. Oxy Sulphone

Manufacturing process:
Bromamine acid is condense with meta base cond. & cuprous chloride & S.B.C. at
72 ͦC for 10 hrs. When reaction over transfer cond. / mass in MS + RL+BL vessel.
Then charge HCl to get pH 1.5 to 1.0. Then heat 90 C for boil up. Then cool to 70
C and filter slurry in F. P. when filter over. Give wash of 5% salt solution gradually.
Then give air and dump F. P. Take water and charge press cake & spray dryer.
Final Powder obtain.

Chemical Reaction:
(I) Bromamine Condensation:-
O NH2
NH2
SO 3H + NaHCo3
+ CuCl2
SO 2CH2CH2OH

O Br
( Bromamine Acid ) ( M. Base Condense )

O NH2
SO 3H

O NH

SO 2CH2CH2OH

( Oxy. Sulphone )

M/s. Metachem Industries, Khambhat 23

 Mass Balance:

Mass balance of Oxy Sulphone

Input KG Output KG

Bromamine Acid 850

M.B. V.S. Acid 550
Soda Bi carbonate 850
Bromamine
CUCl2 10
Condensation
Celsolin Oil 10
Copper Bronze 5
Water 1000

HCl (30%) 2000

Salt 250 Isolation Effluent 7275
Water 2000

Water 2000
Slurry

Drying Loss 1250

Drying
Oxy Sulphone 1000

Total 9525 9525

M/s. Metachem Industries, Khambhat 24

14. M. Acid

Manufacturing process:
Macitinline acid is nitrated by nitric acid & H2SO4. Then isolate N. Mass in chilled
water. Filter &C.F. Nitro w/cake. Then this nitro w/cake reduction in presence of
C.I.powder & acetic acid at 80ͦC. Then filter reduction Mass & collect amino
solution. Check N.V.& set N.V. 7.0 to7.5%. Isolate by HCl (30%) at 3.0 to3.5pH.
Check f/l. Then heat 75ͦC& check f/l 0.2% to0.3%.

Chemical Reaction:

(I) Sulphonation:-
CH3
CH3

H2S2O7 SO3H
+ + H2SO4
H3C CH3 H2SO4
H3C CH3

( Mesitylene Acid )

(II) Nitration:-
CH3
CH3
O 2N SO 3H
SO 3H 2(HNO3) + 2(H2O) + H2SO4
+ H2SO4 H3C CH3
H3C CH3
NO 2

(III) Reduction:-

CH3 CH3
SO 3H H2 N SO 3H
O 2N
Fe/HCl/H2O
+ Na2CO3 CH3
H3C CH3 H3 C

NO2 NH2

2,4,6 Trimethyl m Phenylene

diamine
[M-Acid]

M/s. Metachem Industries, Khambhat 25

 Mass Balance:

Mass balance of M. Acid

Input KG Output KG

Macitinline Acid 570

H2SO4 2800 Nitration NO2 200
W.N.A. 880

Water 1500
Isolation
Ice 2200

Spent Acid 4500

Filteration & C. F.

NaOH 150
Nitro slurry
Water 1500

Iron Powder 1500 Iron Sludge 2900

Ac. Acid 350
Soda Ash 350 Reduction
Ac. Carbon 25
Water 650

Isolation

HCl 1500 Effluent 4540

Filteration & C. F.
Hydro Powder 15

Drying Loss 850

Drying
M Acid 1000

Total 13990 13990

M/s. Metachem Industries, Khambhat 26

15. Blue 49 Base

Manufacturing process:
Bromammine acid is condense with M. Acid at 8.5 to 9.0pH in presence of copper
oxide & nitrogen gas purging. At 72ͦC slowly by slowly external heating. The
reaction take 12 to 15hrs.check unreacted bromamine content. If nil then charge
common salt & Dicamol & stop stirrer. Filter mass & wash press cake by hot water.
Collect filtrate in another vessel. Charge HCl (30%) to get pH 4.0 to 4.2 to isolate
M-acid. Start filter in F.P. &collect filtrate in another vessel. (Press cake is recover
m-acid use for next batch). Check volume & take pH 1.0 by HCl(30%) charging.
Check spot & startfilter. Give wash of 30% HClsolution gradually.Give slow air &
dump F.P. Cake in vessel with water. Take pH 4.5 by soda ash & spray dryer.

Chemical Reaction:
(I) Bromamine Condensation:-
NH2 SO3H
O
SO3H H3C CH3
+ + CuO + N2 gas + Na2Co3
H2N NH2
O Br CH3

( Bromamine Condensation ) ( M- Acid )

O NH2
SO3Na

CH3
O NH NH2

H3C CH3

SO3Na

( Blue 49 Base )

M/s. Metachem Industries, Khambhat 27

 Mass Balance:

Mass Balance of Blue 49 Base

INPUT KG OUTPUT KG

Bromamine Acid 1000

M-Acid 1625
Soda Ash 500
Cuprous Oxide 100
Condensation of
Celsolin Oil 15
Bromamine Acid
Coomon Salt 380
Dicamol 40
N2 Gas 65
Water 3200

Wash Water 1500 Solid Waste 950

Filteration

HCl (30%) 1500 Recovered M-Acid 1150

1st Isolation
Wash Water 2500

HCl (30%) 1200 Waste Water 11850

2nd Isolation
Wash Water 2200

Water 1800
Slurry
Soda Ash 180

Drying loss 2855

Spray Drying
Blue 49 Base 1000

Total 17805 17805

M/s. Metachem Industries, Khambhat 28

16. Metanilic Acid

Manufacturing process:
Nitro Benzene reacted with Oleum (65%) at 105 ͦCfor 4 hrs. Maintain Check TLC &
acidity. Then dump S/mass water + lime powder + Soda ash solution slowly at 60
C to 80 C. Take pH 7.0 by lime powder & stir for 1 hrs. Filter slurry in nutch &
wash with hot water. Collect nitro solution. Check N V and real. Then reduction of
nitro solution in presence of iron powder & HCl. Heat mass up to 95 C and check
clear spot and A. R. + B. R. by N. V. ok. Then charge soda ash to get pH 8.5 to
9.0 to –Ve test. Filter mass in F. P. and wash with hot water and receive amino
solution & check N. V. & real charge sulphuric acid slowly to get pH 1.5 Material
isolate. Check F/L & filter slurry in nutch. Then C. F. & Dry in SFD

Chemical Reaction:
(I) Sulphonation:-
NO2
NO2 NO2

H2S2O7 + Na2CO3
+ H2SO4
SO3H
SO3Na

(II) Reduction:-

NO2 NH2

+ 2Fe + HCl + Fe2O3 + NaCl + CO2 + H2O

SO3Na
SO3Na

( Aniline 2 Sulphonic Acid )

Metalinic Acid

M/s. Metachem Industries, Khambhat 29

 Mass Balance:

Mass Balance of Metanilic Acid

INPUT KG OUTPUT KG

Nitro benzene 900 SO2 Gas 40

Sulphonation
Oleum (65%) 980

Soda Ash 50
Lime Stone Powder 1100 Drawning CO2 Gas Evap. 150
Water 500

Hot Water 500 Gypsum Sludge 3120

Filteration

Iron Powder 125

HCl (30%) 100 CO2 Gas Evap. 50
Reduction
Soda Ash 175
Water 750

Hot water 700 Iron Sludge 450

Filteration

Sulphuric Acid 90 CO2 Gas evap. 25

Isolation
Water 2400

Filteration & Wastewater to ETP 2385

Centrifugation

Drying loss 1150

Drying
Metanilic Acid 1000

Total 8370 8370

M/s. Metachem Industries, Khambhat 30

17. 4 SulphoAnthranilic Acid

Manufacturing process:
O.N.T. is sulphonated with sulphuric acid (98%) and leum (65%) at 65 C maintain
for 12 hrs. Then S/mass is dilute in water and hydrolyze by NaOH and water. Then
clarify it, isolate material by 70% sulfuric acid then filter & C.F.

Chemical Reaction:
CH 3
CH3 COOH
NO 2
NO 2 NH2
Sulphonation Hydrolysis
+ H2SO 4 + H2SO 4.SO 3
-2SO 3
Sulphuric Acid Oleum
Ortho Nitro Toluene -2H2O
SO 3H SO 3H

4-Sulpho Anthranilic Acid

Mass Balance:

Mass balance of 4 Sulpho Anthranilic Acid

Input KG Output KG

O.N.T. 1800
Oleum (65%) 1980 Sulphonation
Sulfuric Acid 1000

Water 2700 Dil Sul. Acid (40-45%) 4850

Dumping

Water 3500
Hydrolysis
NaOH 2150

Sulfuric Acid (70%) 2500

Isolation

Wash Water 1800 Filteration & Spent Acid (32-35%) 10430

Centrifugation

Drying Loss 1150

Drying
4 Sulpho Anthranilic Acid 1000

Total 17430 17430

M/s. Metachem Industries, Khambhat 31

18. 4 SulphoHydrazone

Manufacturing process:
4 Sulpho Anthranilic Acid is diazotize by sodium nitrite and HCl. Then it is coupled
by S. B. S. in presence of C. S. Lye (48%). Then mass is reacting with
benzaldehyde & HCl to get product.

Chemical Reaction:

(I) Diazotisation:-

COOH COOH
NH2 N=NCL

+ NaNo2 + 2(HCl)

SO3H SO3H

( 4- Sulpho Anthralanic Acid )

(II) Reduction:-
COOH
COOH
NHNH2
N=N-CL + SBS + NaOH

SO 3H
SO 3H

(III) Condensation:-
COOH
COOH CHO
N=N-CH
NHNH2

+
SO3H
SO 3H
(Benzaldehyde)
( 4- Sulpho Hydrozone )

M/s. Metachem Industries, Khambhat 32

 Mass Balance:

Mass balance of 4 Sulpho hydrazene

Input KG Output KG

4 Sulpho Anthranilic Acid 1000

HCl (30%) 1200
Diazotization
Sodium Nitrite 300
Ice 1700

Sodium bisulphite 850

Coupling
Caustic Soda 480

Benzaldehyde 600 SO2 Gas 300

HCl (30%) 1000 Benzolation CO2 Gas 250
Ice 1900

Wash Water 480 Filtration & Effluent 6830

Centrifuge

Drying Loss 1130

Drying & Packing
4 Sulpho Hydrozene 1000

Total 9510 9510

M/s. Metachem Industries, Khambhat 33

19. Sulpho OAVS / Sulpho VS / Sulpho J Acid / Sulpho gamma Acid

Manufacturing process:

OAVS is sulphonated with Sulphuric acid (98%), oleum (65%) at 140 ͦC then dump
s. mass in cold water below 10 ͦC to 15 ͦC. Then salting by KCl & check F/L& filter &
C.F.

Chemical Reaction:

Sulpho OAVS

(I) Sulphonation:-
NH2 NH2
OCH3
OCH3 H2S2O7
+ H2SO4 HO3S
SO2CH2CH2OSO 3H
SO 2CH2CH2OSO 3H

( OAVS ) ( Sulpho OAVS )

Sulpho VS

(I) Sulphonation:-

NH2 NH2

H2S2O7 SO3H
+ H2SO4

SO2CH2CH2OSO 3H SO2CH2CH2OSO 3H

( Sulpho V.S )

Sulpho J Acid
(I) Sulphonation:-
OH
OH
H2S2O7
+ H2SO4
H 2N H 2N SO 3H
SO 3H
SO3H
( J. Acid )
( Sulpho J- Acid )

M/s. Metachem Industries, Khambhat 34

 Sulpho gamma Acid

(I) Sulphonation:-
OH OH
NH2 H2S2O7 NH2
+ H2SO4
NO3S HO 3S SO 3H

( Gamma Acid )
( Sulpho Gamma Acid )

Mass Balance:
Mass Balance of Sulfo OAVS

INPUT KG OUTPUT KG

OAVS 1250 SO2 282

Sulphonation
Oleum Acid (65%) 2212
Sulphuric Acid 1812

KCl 650
Water 1500 Dumping
Ice 2500

Wash water 1500 Filtration & Spent acid (32-35%) 9642

Centrifuge

Wet cake of Sulpho OAVS (As is 1500

Sulpho OAVS real basis1000 Kg)

Total 11424 11424

M/s. Metachem Industries, Khambhat 35

20. 3:5 DABA

Manufacturing process:

Benzoic acid is nitrated in presence of Nitric acid & Sulphuric acid. When reaction
over transfer n/mass in water & isolated. Filter & C.F. Then reduction of nitro
compound in presence of iron powder &HCl (30%). Then maintain temp up to
reduction over. When reduction overcharge soda ash to -ve iron test. Then filter
mass in F.P. & wash with water. Collect amino in isolation vessel. Isolate by HCl
(30%) &filter & get final product.

Chemical Reaction:
(I) Nitration:-

COOH COOH
HNO3
+
H2SO4
O 2N NO2

(II) Reduction:-
COOH
COOH
Fe/HCl/H2O
+ H2 N
Na2CO3 NH2
O 2N NO2

( 3:5 DABA )

M/s. Metachem Industries, Khambhat 36

 Mass Balance:

Mass Balance of 3,5 DABA

INPUT KG OUTPUT KG

Benzoic Acid 1200

Nitric Acid 1090 Nitration NO2 Gas 180
Sulphuric Acid(98%) 2336

Water 2500
Drawning

Wash Water 1000 Filtration & Spent Acid(35-40%) 3744

Centrifuge Effluent 1500

Iron Powder 1636

HCl (30%) 1000 Iron Sludge 4000
Reduction
Soda Ash 900
Water 1800

HCl (30%) 950 Waste water to ETP 2952

Isolation

Filtration &
Centrifuge

Drying loss 1036

Drying
3,5 DABA 1000

Total 14412 14412

M/s. Metachem Industries, Khambhat 37

 Annexure-III
Water Balance Diagram
Total fresh water consumption
233.0 KLD (123 KLD Fresh water + 110 KLD recycle)

Domestic Process Scrubber Washing Utility Greenbelt

5.0 128 10.0 25.0* 50.0 15.0

Soak pit
4.0
7.0
Boiler Cooling
SBS (30-35%)
10.0 40
25
4.0 Steam

Ice 30
Water
retained with
RM 71

Total Volume 233

Water/steam
loss

Dyes Dyes 1.0

Spent
6.0 Blow
H2SO4 Intermediates 89
down
55 144
50 25
RO Permeates
Drying Loss 83 water 44 25
12.0

Spray drying 10
Drying
for product Bleed
Loss 39 3.0
recovery off

77
ETP
77+ 3.0 + 25.0 +25.0 + 1.0+ 10 =141

Permeates
RO water 85.0*
141

Evaporation Salt
Spray Dryer
loss 54.25 1.75
56.0

M/s. Metachem Industries, Khambhat 38

 Break up of Water Consumption& Waste Water Generation

Sr. Source Water Waste Water

No. Consumption generation
(KLD) (KLD)
1. Domestic 5.0 4.0
2. Green Belt 15 --
3. Industrial
A Process 128 102
B Scrubber 10 3.0
C Boiler 10 1.0
D Cooling 40 10
E Washing 25 25
Total Industrial 213 141
Total (1 +2 + 3) 233 145
Less recycle 110 --
Actual fresh water 123 --
consumption

M/s. Metachem Industries, Khambhat 39

 Annexure-IV
Hazardous waste details

Sr. Type of Category Quantity Method of Disposal

No. Waste No. as per Proposed
HWM rules,
2016
1. ETP Waste 35.3 200 MT/month Collection, Storage, Transportation,
Disposal at TSDF site.
2. Salt ofSpray 35.3 46 MT/month Collection, Storage,Transportation,
Dryer disposal at TSDF site.
3. Process Iron 26.1 145 MT/month Collection, Storage, Transportation,
Sludge disposal at TSDF site or to Cement
industries for co-processing.
4. Process 26.1 84 MT/month Collection, Storage, Transportation,
Gypsum disposal at TSDF site or to Cement
Waste industries for co-processing.
5. Sodium Bi 26.3 182 Collection, Storage and partly reuse
sulfite KL/Month in-house and partly will be sold to
(30-35%) actual users under Rule-9.
6. UsedOil 5.1 0.5 KL/Year Collection,
Storage,Transportation,sell to
registered re-processors or use for
lubrication within premises.
7. Discarded 33.3 600 Collection, Storage,Transportation,
Containers/ Nos./month Sell to registered recyclers.

Liners/Bag 1.0 MT/month

8. Spent Acid B-15 1430 Collection, Storage,Transportation
MT/month and will be sold to actual users
under Rule-9.

M/s. Metachem Industries, Khambhat 40

 Annexure-V
Details of Air Pollution
Sr. Stack Fuel Type Stack APC Probable emission
No. attached to Height, measures
in m
Flue Gas Stacks
1. Steam Boiler Coal/ Bio fuel 30 Multi SPM<150 mg/Nm3
(2 TPH) – 2 10 TPD Cyclone SO2<100 ppm
nos. Dust NOx<50 ppm
(1 stand by) Collector
2. Ho Air Coal/ Bio fuel 30 Bag Filter SPM<150 mg/Nm3
Generator – 2 TPD each SO2<100 ppm
4 Nos. NOx<50 ppm
(4.5 Lakhs
Kcal/hr each)
3. Ho Air Coal/ Bio fuel 30 IN built SPM<150 mg/Nm3
Generator – 14 TPD each Cyclone SO2<100 ppm
2 Nos. Separator & NOx<50 ppm
(25 Lakhs Bag Filter
Kcal/hr each)
4. D G Set HSD – 70 lit/hr. 15 -- SPM<150 mg/Nm3
(500 kVA) SO2<100 ppm
NOx<50 ppm
Process Gas Stacks
1. Process Vessel -- 20 Two Stage SO2<40 mg/Nm3
(Sulphonation) Water
Scrubber &
Alkali
Scrubber
2. Process Vessel -- 20 Two Stage NOx<25 mg/Nm3
(Nitration) Alkali
Scrubber
3. Process Vessel -- 20 Two Stage SO2<40 mg/Nm3
(Isolation) Alkali
Scrubber
4. Spin Flash -- 20 In PM<45 mg/Nm3
Dryer – 4 Nos. builtcyclone
separator&
bag filter
5. Spray Dryer -- 30 In built PM<45 mg/Nm3
For effluent cyclone
(2500 lit/hr.) separator &
bag filter

M/s. Metachem Industries, Khambhat 41