PIGMENT ALPHA BLUE
Manufacturing Process: Charge Sulphuric acid in Glasslined jacketed vessel and add required quantity of grinded CPC blue in 4 hours maintaining the temperature of 50oC. Continue stirring till CPC gets dispersed in acid. Transfer the batch in drawning vessel containing sufficient water to make final concentration of 25% acid. Filter the mass through filter press and wash with water to bring pH 5.5. Charge wet cake in wooden vat containing water and add dispersing agent. Heat with live steam and bring pH to neutral with the help of caustic. Filter the slurry and wash with water. Wet cake is dried through spin flash dryer and packed in HDPE bags or Jumbo Bags.
CPC Beta Blue
Ball Milling: Copper Phthalocyanine Blue is milled along with vacuum salt below 70oC. It is unloaded and transferred for pigmentation.
Solvent pigmentation: The milled powder is treated with Solvent at 90oC.
Filtration & Washing: The mass is filtered off in filter press, washed upto neutral pH.
Drying: The wet cake is dried is spin flash drier & finally packed.
Manufacturing Process for CPC Blue: First charge Orho Nito Toluene from storage tank through pump in close system. Then, charge Orho Nito Toluene into the Glass-lined vessel by gravity & start stirring process. Then charge phthalic anhydride, cuprous chloride, urea and ammonium molybdate through conveyer in glass-lined vessel. Then heating is started in jacket by hot oil circulation at temp 190-2000oC. temperature is controlled by pneumatic system with temp-controller which controls valves automatically.
(Provide safety valves in jacket for hot oil). No pressure is developed during this reaction in the vessel. During this reaction in this vessel, ONT vapors scrubbing & condensing system have been providing in our plant. After the reaction is complete, the mass is cooled by cold oil circulation in jacket. Ammonium gas liberated during the process is scrubbed with water to recover liquor ammonium as a byproduct.
DISTILLATION: The cooled material is than drained into rotary vacuum dryer for the recovery of Orho Nito Toluene. The mass is heated by steam in dryer. During this process, the jacket temperature is controlled, which control valves automatically safety with temperature is controlled by pneumatic system with temperature controller, which control valves automatically. Safety valve on jacket to provide for hot oil. After recovery of Ortho Nitro Toluene, the material is discharged in powder from.
ACID TREATMENT: Change Sulphuric acid from storage tank receiver tank through pump is close system, in rubber lined vessel and start stirring. Charge the powder material through conveyor into remove salt impurity with the help of Sulphuric acid.
FILTERATION: Discharge the material into filter press for filtration. After filtration and after removing Sulphuric acid from the wet cake, discharge the wet cake in spin flash dryer by gravity.
DRYING: The wet cake is charged by gravity & dried, operated by hot air (Temp. 100-1500oC) .the powder from material is packed in HDPE bags & stitched by stitching machine.
Manufacturing of Phthalocyanine Green-7 involve various unit operations and chemical reaction, which are briefly described as below.
Chlorination: In this stage Copper phthalocyanine blue is converted to Copper phthalocyanine green by chlorination reaction. Chlorination of Copper phthalocyanine blue is carried out in a glass lined vessel of 3000lit. The raw materials anhydrous Aluminum chloride, Sodium chloride, CPC Blue, cupric chloride is charged lot wise into the reactor with continuous stirring. Aluminum chloride and sodium chloride are used as solvent while cupric chloride is used as catalyst. Heating is provided simultaneously to melt the mixture up to 150 to 1600oC. Chlorine gas is then bubbled through the mixture. Temperature is maintained around 1700oC for 40 hours. Batch is tested at defined intervals for reaction completion. At the end of reaction chlorination is stopped. The gaseous emission from the gas-lined vessel will be taken to two-stage counter current scrubber for recovery of Hydrochloric acid and unreacted chlorine gas is scrubbed in alkaline scrubber. The hydrochloric acid of 5-7% strength is used in drowning operation and neutralizing the alkaline effluent stream at ETP. Thus, HCl is consumed within the premises.
Drowning: Hydrochloric acid (5-7%) are taken in to MSRLBL (mild steel rubber line and bricklined) drowning vessel & stir water for about 1hr. Then it filtered out to filter press.
Filtration 1: The cooled reaction mixture from drowning vessel is taken to a filter press. The filtrate Aluminum chloride solution is collected in storage tank and it is converted into PAC. The cake is washed with fresh water. The washing of filter press goes to ETP. The crude wet cake of copper phthalocyanine green is transferred in the distillation vessel.
Purification/Pigmentation: The crude press cake of copper phthalocyanine green is charged into distillation/pigmentation vessel. The pH of the mass is adjusted to 11 using caustic flakes. Dispersing agent Emulsolic Eco and Lorel Alcohol is then charged. The mixture is stirred and heated up to 1000oC temp and refluxed for 8 hrs. This is followed by distillation and solvent recovery for 12 hrs. The mono chloro benzene and water mixture is collected in the receiver and recycle it.
Filtration 2: Slurry from distillation vessel is taken to the filter press. Washing is provided to the filter cake till the pH of wash water is neutral. Filtrate and wash water, which are both, alkaline are taken to the ETP. The treated water from ETP is subjected to R.O. The R.O. permeates to recycle back and R.O. rejected send to MEE followed by ATFD.
Drying: Finished product to be dried in spin flash dryer and then packing into suitable packing