ANNEXURE III
DETAILS OF PRODUCTION AND MANUFACTURING PROCESS
1. RSF Intermediate
Manufacturing process: Check and prepare a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing. Charge the required quantity of Formaldehyde into the clean vessel, followed by Urea and Glyoxal 40% and diethylene glycol. The temperature is increased to 60-80 C under constant stirring. The process is continued for 5-6 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. If specification is reached fill product in containers, to be used for further formulations of finished product.
Chemical Reaction
Material Balance
Input Output Formaldehyde 0.40 RSF Urea 0.20 Reaction Vessel 1.00 Intermediate Glyoxal 0.40 Total 1.00 Total 1.00
Process Flow Diagram
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) 2. NFF-T Intermediate Manufacturing process: Check and prepare a clean and dry vessel. Remove oxygen from the vessel with nitrogen flushing. Charge the required quantity of glyoxal 40%and water into the clean vessel under constant stirring. Cool the vessel and add N, N-dimethyl urea until homogenous mixture is achieved. The temperature is maintained below ambient temperature and reaction is further continued for 2-4 hours under catalytic concentration of citric acid. Take sample for quality check and if required specifications are not meet, continue reaction further for 1 hour and again check for quality. If specification is reached fill product in containers, to be used for further formulations of finished product.
Chemical Reaction
Material Balance
Input Output Dimethyl Urea 0.40 NFF-T Reaction Vessel 1.00 Glyoxal 40% 0.60 Intermediate Total 1.00 Total 1.00
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) Process Flow Diagram
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) 3. Atecryl 1467 Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity of Formalin under constant stirring. Then add required quantity of Melamine and maintain pH at required level using formic acid. Raise temperature to 80-120C and continue reaction for around 2-3 hrs. Take sample for quality check and if required specifications are not meet, continue reaction further for 1-2 hr and again check for quality. If specification is reached fill product in containers, to be used for further formulations of finished product.
Chemical Reaction
Material Balance
Input Output Formaldehyde 0.55 Melamine 0.25 Reaction Vessel Atecryl 1467 1.00 Formic acid 0.20 Total 1.00 Total 1.00
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) Process Flow Diagram
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) 4. UC 100 Intermediate Manufacturing process: Check and maintain a clean and dry vessel. Charge required quantity of stearic acid and maintain temperature at 55-80C under constant stirring. Then add required quantity of Diethylenetriamine and ethanolamine. Raise temperature up to 160C-170C and continue reaction for around 3-4 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1-2hour and again check for quality. Maintain required pH using acetic acid and If specification is reached fill product in containers, to be used for further formulations of finished product.
Chemical Reaction
Material Balance
Input Output Stearic acid 0.80 UC 100 1.00 Diethylenetriamine 0.15 Reaction Vessel intermediate Monoethanolamine 0.06 Acetic acid 0.08 Water Loss 0.09 Total 1.09 Total 1.09
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) Process Flow Diagram
Water distillate
ETP
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) 5. NP 100 Intermediate Manufacturing process: Check and maintain a clean and dry vessel. Charge required quantity of stearic acid and maintain temperature up to 55-80C under constant stirring. Then add required quantity of diethanolamine and mono ethanolamine. Raise temperature up to 160-170C and continue reaction for around 3-4 hours. Take sample for quality check and if required specifications are not meet, continue reaction further for 1-2 hr and again check for quality. Maintain required pH using acetic acid and If specification is reached fill product in containers, to be used for further formulations of finished product.
Chemical Reaction
Material Balance
Input Output Stearic acid 0.78 NP 100 1.00 Diethanol amine 0.19 Reaction Vessel intermediate Monoethanolamine 0.07 Water Loss 0.04 Total 1.04 Total 1.04
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) Process Flow Diagram
Water distillate
ETP
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) 6. Sorbitan mono stearate ester Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity Sorbitol-70% and Stearic Acid in to a clean reactor under continuous stirring maintained at temperature to 50- 60C. Raise the temperature to 130 – 150C and maintain for 3-5 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If theacid value is within specification cool the mass to 40°C and unload in to the required pack size for further formulation.
Chemical Reaction
Material Balance
Input Output Sorbitol 70% 0.5 Sorbitan mono stearate 1.00 Stearic Acid 0.7 Reaction Vessel ester Water Loss 0.20 Total 1.20 Total 1.20
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) Process Flow Diagram
Water distillate
ETP
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) 7. Sorbitan mono Oleate ester Manufacturing process: Check and maintain a clean and dry vessel. Charge the required quantity Sorbitol-70% and oleic Acid in to a clean reactor under continuous stirring maintained at temperature to 50- 60C. Raise the temperature to 130 – 150C and maintain for 3-5 hours, water of reaction is collected in receiver. After complete collection of water check for Acid Value. If required acid value is not achieved continue reaction further for 1-2 hours If theacid value is within specification cool the mass to 40°C and unload in to the required pack size for further formulation.
Chemical Reaction
Material Balance
Input Output Sorbitol 70% 0.5 Sorbitan mono oleate 1.00 Oleic Acid 0.7 Reaction Vessel ester Water Loss 0.20 Total 1.20 Total 1.20
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ) Process Flow Diagram
Water distillate
ETP
M/S. Dystar India Pvt. Ltd., Plot No. 3002/A,GIDC Ankleshwar, Bharuch (GJ)