Detailed Project Report (DPR) on liquid sulphur black dye

LIQUID SULPHUR BLACK DYE
[CODE NO 3430]


Sulfur dyes are most commonly used dyes manufactured for cotton in terms of volume. They are cheap, generally have good wash-fastness, and are easy to apply. Sulfur dyes are predominantly black, brown, and dark blue. Red sulfur dyes are unknown, although a pink or lighter scarlet color is available.

The most important member of the class is Sulfur Black 1. It is produced by the reaction of 2, 4-dinitrophenol and sodium sulfide in hot water. Like many sulfur dyes, details on the chemical reactions are poorly understood. It is accepted that the sulfide reduces the nitro groups to aniline derivatives, which are thought to form indophenol-containing intermediates that are further crosslinked by reaction with sulfur. The result are insoluble, high molecular weight species. Sulfur Black 1 is imperfectly understood, and the material is probably heterogeneous. It is speculated to be a polymer consisting of thianthrene and phenothiazine subunits.

Sulfur dyes are water-insoluble. In the presence of a reducing agent and at alkali pH's at elevated temperature of around 80°C, the dye particles disintegrate, which then becomes water-soluble and hence can be absorbed by the fabric. Sodium sulfide or sodium hydrosulfide are suitable reducing agents. Common salt facilitates the absorption. After the fabric is removed from the dye solution, it is allowed to stand in air whereupon the dye is regenerated by oxidation. The regenerated parent dye is insoluble in water. Oxidation can also be effected in air or by hydrogen peroxide or sodium bromate in a mildly acidic solution.

The low water solubility is the basis of the good wash-fastness of these dyed fabrics. These dyes have good all round fastness except to chlorine bleaches. Because the dye is water-insoluble, it will not bleed when washed in water and will not stain other clothes. The dye, however, may have poor fastness to rubbing. The dyes are bleached by hypochlorite bleach.

The  sulphur dyes have been in use as cotton dyes  for  over ninety years.  As far as the application is concerned the sulphur dyes  are  akin to the vat dyes since they  are  water  insoluble substances which first must be reduced to a soluble form by means of sodium sulphide, which is applied to cotton fibre and the  dye being regenerated by oxidation (in air). This group of dyes  is produced  by  heating relatively simple aromatic substance with sulphur or a sulphur compound where by aromatic  rings  are  by disulfphide or disulphoxide bridges. These links are converted by  the  action  of sodium sulphide into -SNa groups,  smaller  water soluble  molecules  being  produced. On oxidation in air  the molecules are linked together once more as sulphides.

COST ESTIMATION

Plant  Capacity                                                         :       12.00 MT./day
      
land & Building (3000 Sq.ft)                                  :    Rs.   3.89 Cr
Plant & Machinery                                                   :    Rs.   1.53 Cr
Working Capital for 1 Month                                  :    Rs.   4.05 Cr
Total Capital Investment                                        :    Rs.   9.58 Cr
Rate of Return                                                          :    36%
Break Even Point                                                      :    43%

INTRODUCTION    
TYPICAL CONDITION FOR THE THIONATION ARE AS FOLLOWS:    
STRUCTURE AND PROPERTIES OF SULFUR DYES    
SULFUR DYES    
CHEMICAL STRUCTURE:-    
PROPERTIES OF SULFUR DYES    
MAIN PROPERTIES OF THE SULFUR DYES ARE AS FOLLOWS:    
FASTNERS PROPERTIES:-    
ESTIMATION OF SULFUR DYES    
USES AND APPLICATION OF LIQUID SULPHUR BLACK DYE    
APPLICATION OF SULPHUR DYE    
SPECIFICATION OF LIQUID SULPHUR BLACK DYE    
CHARACTERISTICS AND FEATURES OF LIQUID SULPHUR BLACK DYE    
CONSTITUTION    
MECHANISING OF THE FORMATION OF SULFURE DYES:-    
FORMATION OF SULFUR BLACK DYE FROM DIPHENYLAMINE DERIVATIVES    
1.   DIPHENYL FORMATION:-    
II. THIS DIPHENYL FORMATION:-    
III A) THIS DIPHENYLAMINE DERIVATIVE:-    
B)  BLUE DYESTUFF FORMATION (WITH OUT LIBERATION OF NH3    
C) BLACK DYESTUFF FORMATION (WITH LIBERATION OF NH3)    
SULFUR SIDE CHAINS    
CARBON LINKAGE:-    
MECHANISM OF DYE APPLICATION    
SULPHIDE REDUCING AGENTS    
NON-SULPHIDE REDUCING AGENTS    
GLUCOSE    
MERCAPTOETHANOL    
ALKYLATION OF SULPHUR DYEINGS    
OXIDATION OF SULPHUR DYES    
DICHROMATE    
IODATES    
CHLORITE    
HYDROGEN PEROXIDE    
REDUCTION IN CHEMICALS    
MARKET SURVEY    
INSTALLED CAPACITY AND PRODUCTION OF SULPHUR BLACK    
DETAILED EXPORT DATA OF SULPHUR BLACK LIQUID    
PRESENT MANUFACTURERS/SUPPLIERS OF SULPHUR BLACK DYE    
SULPHUR BLACK    
CHARACTERISTICS:    
APPLICATION:    
STORAGE:    
GENERAL PROPERTIES:    
REACTION ON CELLULOSE:    
AFTER TREATMENT:    
FASTNESS PROPERTIES:    
METHOD OF APPLICATION:    
MANUFACTURING PROCESS    
OF SULPHER BLACK (LIQUID)    
GRAIN STANDARDIZATION    
PROCESS FLOW DIAGRAM    
DETAILS OF SULFUR BLACK DYE    
SOLUBILISED SULFUR BLACK DYE    
HEALTH & SAFETY ASPECTS    
ECOLOGY    
TOXICOLOGY    
B.I.S. SPECIFICATION    
1.   SCOPE:    
2.   COLOUR FASTNERS RATING:    
3.   METHODS OF TEST:    
4.   MAKING:    
TABLE - I COLOUR FASTNESS RATING    
SULPHUR DYE EFFLUENT    
OXIDATION TREATMENT    
BACTERIAL TREATMENT    
CHEMICAL OXIDATION    
TREATMENT TECHNOLOGIES AND EMISSION GUIDELINES
   IN DYE MANUFACTURE    
AIR EMISSIONS    
LIQUID EFFLUENTS    
SOLID HAZARDOUS WASTES    
EMISSIONS GUIDELINES    
AIR EMISSIONS    
LIQUID EFFLUENTS    
TABLE EMISSIONS FROM DYE MANUFACTURING    
TABLE EFFLUENTS FROM DYE MANUFACTURING    
SOLID WASTES    
AMBIENT NOISE    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
2,4 DINITROCHLOROBENZENE    
SODIUM SULFIDE    
CAUSTIC SODA LYE    
LABORATORY CHEMICALS    
SUPPLIERS OF PLANT AND MACHINERY    
REACTION VESSELS    
MIXING VESSEL    
FILTER PRESS    
BOILER    
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS    
D.G. SET    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET