Annexure-I
List of Products Sr. Name of Products End use Quantity No. (MT/Year) (MT/month) 1 Bromination and Chlorination of Alcohols Fine chemicals 3500 291.7 such as; and agro 1.1. Ethyl Bromide; intermediates 1.2. n-Propyl Bromide; 1.3. Iso Propyl Bromide; 1.4. n-Butyl Bromide; 1.5. Iso Butyl Bromide; 1.6. Sec-Butyl Bromide; 1.7. n-Hexyl Bromide; 1.8. n-Heptyl Bromide; 1.9. n-Octyl Bromide; 1.10. n-Decyl Bromide; 1.11. Lauryl Bromide; 1.12. Cetyl Bromide; 1.13. Myristyl Bromide; 1.14. Stearyl Bromide; 1.15. 1,2 Dibromo Ethane; 1.16. 1,3 Dibromo Propane; 1.17. 1,4 Dibromo Butane; 1.18. 1,5 Dibromo pentane; 1.19. 1,6 Dibromo Hexane; 1.20. 1 Chloro 2 Ethyl Hexane; 1.21. 6 Chloro 1 Hexanol; 1.22. 3 Chloro Propanol; 1.23. 1,6 Dichloro Hexane; 1.24. Cyclo Propyl Methyl Bromide;
Sr. Name of Products End use Quantity No. (MT/Year) (MT/month) 1.25. Cyclo Pentyl Bromide; 1.26. Cyclo Pentyl Chloride; 1.27. 6-bromohexanol; 1.28. 8-bromooctanol; 1.29. 10-bromodecanol; 2 Bromination of Organic Acids and Esterification thereof Fine chemicals 3500 291.7 such as; 2.1 2 Bromo propionic Acid; 2.2 2 Bromo Propionyl Bromide; 2.3 5 Bromo Valeric Acid; 2.4 2 Bromo Hexanoic Acid; 2.5 Sodium 2 Bromo Propionate; 2.6 Ethyl 3 Bromo Propionate; 2.7 Methyl 2 Bromo Butyrate; 2.8 Ethyl 2 Bromo Butyrate; 2.9 Ethyl 4 Bromo Butyrate; 2.10 Methyl 2 Bromo Iso Butyrate; 2.11 Ethyl 2 Bromo Iso Butyrate; 2.12 Iso Propyl 2 Bromo Iso Butyrate; 2.13 Ethyl 2 Bromo Valerate; 2.14 Methyl 2 Bromo valerate 2.15 Ethyl 5 Bromo Valerate; 2.16 Tert-Butyl 2 Bromo Iso Butyrate; 2.17 Methyl 2 Bromo Caproate; 3 Grignards Formation from Organic Halides Fine chemicals 1000 83.3 such as; 3.1 Methyl Magnesium Chloride 3M in THF; 3.2 Methyl Magnesium Bromide 1.5M in THF; 3.3 Ethyl Magnesium Chloride 2M in THF;
Sr. Name of Products End use Quantity No. (MT/Year) (MT/month) 3.4 Ethyl Magnesium Bromide 2M in THF; 3.5 Vinyl Magnesium Bromide in 1M in THF; 3.6 Isopropyl Magnesium Chloride 1M in THF; 3.7 Phenyl Magnesium Bromide 2M in THF; 3.8 n-Butyl Magnesium Chloride 1M in THF; 3.9 Iso Propyl Magnesium Chloride–Li Cl Complex 1.3M in THF; 3.10 Iso Propyl Magnesium Bromide 1M in THF; 4 Halogen Exchange Reactions Fine chemicals 2000 166.7 such as; and agro 4.1 1 Bromo 2 Chloro Ethane; intermediates 4.2 1 Bromo 4 Chloro Butane; 4.3 1 Bromo 5 Chloro Pentane; 4.4 1 Bromo 6 Chloro Hexane; 4.5 Bromo Fluoro Methane; 4.6 Methylene Dibromide; 4.7 Bromo Chloro Methane; 4.8 5 Iodo Valeric Acid Ethyl Ester; 4.9 2 Bromo Hepta Fluoro Propane; 4.10 2 Methyl Allyl Bromide; 5 Addition of Halogen and Halogen Acids across Double Fine chemicals 2500 208.3 Bonds and agro such as; intermediates 5.1 Ethylene Dibromide; 5.2 Phenyl Ethyl Bromide; 5.3 1Bromo 3 Chloro Propane; 5.4 n-Hexyl Bromide; 5.5 n-Octyl Bromide; 5.6 n-Decyl Bromide;
Sr. Name of Products End use Quantity No. (MT/Year) (MT/month) 5.7 Cyclo Pentyl Bromide; 5.8 Cyclo Pentyl Chloride; 5.9 1,2 Dibromo 3 Chloro Propane; 5.10 1,2 Dibrmo hexa fluoro Propane; 5.11 1,4 dibromo 2 butene; 5.12 1,1 Dibromo 3 chloro Propane; 6 Bromination or Chlorination of Cyclic and Aromatic Fine chemicals 2500 208.3 Compounds with or Without Functional Groups and agro such as; intermediates 6.1 Bromo Benzene; 6.2 Di Bromo Benzene; 6.3 Ethyl 4 Bromo Methyl Benzoate; 6.4 1 Bromo 4 Chloro Benzene; 6.5 p- Bromo Toluene; 6.6 4 Bromo O Xylene; 6.7 2 Chloro 1,4 Naphthaquinone; 6.8 1 Bromo 4 Fluoro Benzene; 6.9 4 Bromo Methyl 2 Cyano Biphenyl (Bromo OTBN); 6.10 1 Bromo 3,4 Dichloro Benzene; 6.11 Deca-DPE; 6.12 Tribromophenol; 6.13 1 Bromo 2 4 difluorobenzene; 6.14 4 bromo benzyl bromide; 6.15 2 bromo 4 fluoro aniline; 6.16 4 nitrobenzyl bromide; 6.17 Deca bromodiphenyl oxide; 6.18 4 bromo phenol; 6.19 4 bromo anisole; 6.20 TBBE DGE;
Sr. Name of Products End use Quantity No. (MT/Year) (MT/month) 6.21 Tetra bromo phthalic anhydride; 7 Dehydrohalogenation of Organic Halides with or without Fine chemicals 1000 83.3 functional Group Such as; 7.1 Vinyl Bromide; 7.2 Vinyl Bromide in 25% THF; 7.3 Vinyl Chloride ; 7.4 4 Bromo 1 Butene ; 7.5 6 Bromo 1 Hexene; 7.6 7 Bromo 1 Heptene; 7.7 8 Bromo 1 Octene; 7.8 5 Bromo 1 Pentene; 8 Advance Intermediates from Category 1 to 7 Fine chemicals 2000 166.7 Such as; and agro 8.1 6 Methoxy 2 Naphthaldehyde; intermediates 8.2 2 Fluoro 5 Bromo Benzonitrile; 8.3 Ethyl 4- (dimethyl amino) Butyrate; 8.4 Bromo Acetal; 8.5 6 Bromo Hexyl Trimethyl Ammonium bromide; 8.6 1 Bromo 3 Phenoxy Propane; 8.7 6 Chloro 2 Hexanone; 8.8 n-Octyl Amine; 8.9 Bifenthrin Alcohol; 8.10 Ethyl 7 Chloro 2 Oxo Heptanoate; 8.11 1 Bromo 6 Methyl Heptane; 8.12 Methyl 3 Oxo Pentanoate; 8.13 TBC; 8.14 3,4 DFBA; 8.15 Homophthal;
Sr. Name of Products End use Quantity No. (MT/Year) (MT/month) 8.16 L-valine OTBN; 8.17 Tetrazole; 8.18 DEMBB; 8.19 Tetralone; 8.20 6 Chloro hexanol tetra hydro pyran derivative; 8.21 3 bromo propyl trimethyl ammonium bromide; 8.22 6 bromohexanol tetra hydro pyran derivative; 8.23 8 bromohexanol tetrahydropyran derivative; 8.24 10 bromo tetrahydro pyran derivative; 8.25 2-amino-3’,4’-difluorobiphenyl 9 2-Cyclopropyl 6-Methyl Phenol Fine chemicals 60 5 and agro intermediates 10 R&D -- 600 50 Total 18660 1555
Annexure-II Manufacturing Process 1) Bromination and Chlorination of Alcohols
1.1) Ethyl Bromide Manufacturing Process: Ethyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Ethyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Ethyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-OH + HBr CH3-CH2-Br + H2O Ethyl Alcohol Hydrobromic Acid EthylBromide Water M.W. : 46 M.W. : 81 M.W.:109 M.W. :18 Mass Balance: Input Kg Output Kg Ethyl Alcohol 1815 Reactio Ethyl Bromide 4300 Hydrobromic Acid (48% 10880 n Recovered HBr (24%) 8395 Total 12695 Total 12695
Ethyl Bromide 4300 Ethyl Bromide 4280 Water Water 2000 Water to ETP 2020 Wash Total 6300 Total 6300
Ethyl Bromide 4280 Vacuum Main Product 3900 Distillati Residue 380 Total 4280 on Total 4280
1.2) n Propyl Bromide ManufacturingProcess: n-Propyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC.
When unreacted n-Propyl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure n-Propyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-CH2-OH + HBr CH3-CH2-CH2-Br + H2O n- PropylAlcohol Hydrobromic Acid n-Propyl Bromide Water M.W. : 60 M.W. : 81 M.W. : 137 M.W. : 18 Mass Balance:
Input Kg Output Kg n- Propyl Alcohol 2410 n - Propyl Bromide 4935 Reaction Hydrobromic Acid (48%) 8900 Recovered HBr (16%) 6375 Total 11310 Total 11310
n-Propyl Bromide 4935 n-Propyl Bromide 4900 Water 2000 WaterWash Water to ETP 2035 Total 6935 Total 6935
n-Propyl Bromide 4900 Main Product 4240 Vacuum Residue 660 Distillation Total 4900 Total 4900 1.3) Iso Propyl Bromide ManufacturingProcess: Isopropyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted iso Propyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Iso-Propyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3 CH3
CH-OH + HBr CH-Br + H2O
CH3 CH3 Iso Propyl Alcohol Hydrobromic Acid Iso-PropylBromide Water M.W. : 60 M.W. : 81 M.W.:123 M.W. :18 Mass Balance:
Input Kg Output Kg Iso - Propyl Alcohol 2200 Iso - Propyl Bromide 4510 Reaction Hydrobromic Acid (48%) 9835 Recovered HBr (23%) 7525 Total 12035 Total 12035
Iso-Propyl Bromide 4510 Iso-Propyl Bromide 4490 Water Water 2000 Water to ETP 2020 Wash Total 6510 Total 6510
VENT 4490 Vacuum Main Product 4150 Iso-Propyl Bromide Distillati
on Residue 340 Total 4490 Total 4490
1.4) n Butyl Bromide ManufacturingProcess: n-Butyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed at, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted n-Butyl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure n-Butyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-CH2-CH2-OH + HBr CH3-CH2-CH2-CH2-Br + H2O n- Butyl Alcohol Hydrobromic Acid n-Butyl Bromide Water M.W. : 74 M.W. : 81 M.W. : 137 M.W. : 18 Mass Balance:
Input Kg Output Kg n- Butyl Alcohol 2665 n - Butyl Bromide 4935 Reaction Hydrobromic Acid (48%) 8945 Recovered HBr (21%) 6675 Total 11610 Total 11610
n-Butyl Bromide 4813 n-Butyl Bromide 4790 Water Water 2000 Water to ETP 2023 Wash Total 6813 Total 6813
n-Butyl Bromide 4790 Main Product 4150 Vacuum Residue 640 Distillation Total 4790 Total 4790
1.5) Iso Butyl Bromide ManufacturingProcess: Isobutyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Iso Butyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temp. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Iso-Butyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3 CH3
CH-CH2-OH + HBr CH-CH2-Br + H2O
CH3 CH3 IsoButylAlcohol HydrobromicAcid Iso-ButylBromide Water M.W.:74 M.W.: 81 M.W.:137 M.W. :18 Mass Balance:
Input Kg Output Kg Iso - Butyl Alcohol 2565 Iso - Butyl Bromide 4748 Reaction Hydrobromic Acid (48%) 9550 Recovered HBr (24%) 7367 Total 12115 Total 12115
Iso Butyl Bromide 4748 Iso Butyl Bromide 4720 Water Water 2000 Water to ETP 2028 Wash Total 6748 Total 6748
Iso Butyl Bromide 4720 Main Product 4390 Vacuum Residue 330 Distillation Total 4720 Total 4720 1.6) sec Butyl Bromide ManufacturingProcess: Sec-Butyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted sec-butyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Sec-Amyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction: OH Br
CH3-CH2-CH-CH3 + HBr CH3-CH2-CH-CH3 + H2O sec-Butyl Alcohol Hydrobromic Acid sec-Butyl Bromide Water M.W. : 74 M.W. : 81 M.W. :137 M.W. :18 Mass Balance:
Input Kg Output Kg sec-Butyl Alcohol 2785 sec - Butyl Bromide 5155 Reaction Hydrobromic Acid (48%) 9165 Recovered HBr (20%) 6795 Total 11950 Total 11950
Sec - Butyl Bromide 5155 Sec-Butyl Bromide 5140 Water Water 2000 Water to ETP 2015 Wash Total 7155 Total 7155
Sec - Butyl Bromide 5140 Main Product 4790 Vacuum Residue 350 Distillation Total 5140 Total 5140
1.7) n Hexyl Bromide ManufacturingProcess: n-Hexyl Alcohol is taken in aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted n-Hexyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure n-Hexyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-CH2-CH2-CH2-CH2-OH + HBr CH3-CH2-CH2-CH2-CH2-CH2-Br + H2O n-Hexyl Alcohol HydrobromicAcid n-HexylBromide Water M.W. :102 M.W.: 81 M.W.: 165 M.W. :18 MassBalance:
Input Kg Output Kg n-Hexyl Alcohol 2850 n - Hexyl Bromide 4610 Reaction Hydrobromic Acid (48%) 8940 Recovered HBr (28%) 7180 Total 11790 Total 11790
n-Hexyl Bromide 4610 n-Hexyl Bromide 4590 Water Water 2000 Water to ETP 2020 Wash Total 6610 Total 6610
n-Hexyl Bromide 4590 Main Product 4150 Vacuum Residue 440 Distillation Total 4590 Total 4590
1.8) n Heptyl Bromide ManufacturingProcess: n-Heptyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted n-Heptyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organiclayer
taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure n-Heptyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-CH2-CH2-CH2-CH2-CH2-OH + HBr CH3-CH2-CH2-CH2-CH2-CH2-Br + H2O n-Heptyl Alcohol Hydrobromic Acid n-Heptyl Bromide Water M.W. : 116 M.W. : 81 M.W. : 179 M.W. : 18 Mass Balance:
Input Kg Output Kg n-Heptyl Alcohol 2870 n - Heptyl Bromide 4430 Reaction Hydrobromic Acid (48%) 8640 Recovered HBr (30%) 7080 Total 11510 Total 11510
n-Heptyl Bromide 4430 n-Heptyl Bromide 4400 Water Water 2000 Water to ETP 2030 Wash Total 6430 Total 6430
n-Heptyl Bromide 4400 Main Product 4040 Vacuum Residue 360 Distillation Total 4400 Total 4400 1.9) n Octyl Bromide ManufacturingProcess: n-Octyl Alcohol is taken in Aqueous Hydro bromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted n-Octyl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure n-Octyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-OH + HBr CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-Br+ H2O n - Octyl Alcohol HydrobromicAcid n-OctylBromide Water M.W. : 130 M.W. : 81 M.W. : 193 M.W. : 18 Mass Balance:
Input Kg Output Kg n Octyl Alcohol 3400 n Octyl Bromide 5048 Reaction Hydrobromic Acid 8155 Hydrobromic Acid (27.5%) 6507 Total 11555 Total 11555
n Octyl Bromide 5048 n Octyl Bromide 5030 Water Water 2000 Water to ETP 2018 Wash Total 7048 Total 7048
n Octyl Bromide 5030 Main Product 4620 Vacuum Residue 410 Distillation Total 5030 Total 5030 1.10) n Decyl Bromide ManufacturingProcess: n-Decyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted n-Decyl alcohol is less than 1% HBr acid additionis stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure n-Decyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-OH+ HBr CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-Br + H2O n- Decyl Alcohol Hydrobromic Acid n-Decyl Bromide Water M.W. : 158 M.W. : 81 M.W. : 221 M.W. : 18 Mass Balance:
Input Kg Output Kg n- Decyl Alcohol 4300 n - Decyl Bromide 6015 Reaction Hydrobromic Acid(48%) 7045 Recovered HBr (20%) 5330 Total 11345 Total 11345
n-Decyl Bromide 6015 n-Decyl Bromide 6000 Water Water 2000 Water to ETP 2015 Wash Total 8015 Total 8015
n-Decyl Bromide 6000 Main Product 5400 Vacuum Residue 600 Distillation Total 6000 Total 6000
1.11) Lauryl Bromide ManufacturingProcess: Lauryl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Lauryl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Lauryl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-(CH2)11-OH + HBr CH3-(CH2)11-Br + H2O LaurylAlcohol Hydrobromic Acid Lauryl Bromide Water M.W.:186 M.W. :81 M.W. : 249 M.W. : 18 Mass Balance:
Input Kg Output Kg Lauryl Alcohol 4500 Lauryl Bromide 6025 Reaction Hydrobromic Acid (48%) 6235 Recovered HBr (22%) 4710 Total 10735 Total 10735
Lauryl Bromide 6025 Lauryl Bromide 6000 Water Water 2000 Water to ETP 2025 Wash Total 8025 Total 8025
Lauryl Bromide 6000 Main Product 5560 Vacuum Residue 440 Distillation Total 6000 Total 6000
1.12) Cetyl Bromide ManufacturingProcess: Cetyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Cetyl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing.
The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Cetyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-(CH2)15-OH + HBr CH3-(CH2)15-Br + H2O Cetyl Alcohol Hydrobromic Acid CetylBromide Water M.W. : 242 M.W. : 81 M.W. : 305 M.W. : 18 Mass Balance:
Input Kg Output Kg Cetyl Alcohol 4865 Cetyl Bromide 6132 Reaction Hydrobromic Acid (48%) 5365 Recovered HBr (23%) 4098 Total 10230 Total 10230
Cetyl Bromide 6132 Cetyl Bromide 6120 Water 2000 WaterWash Water to ETP 2012 Total 8132 Total 8132
Cetyl Bromide 6120 Main Product 5785 Vacuum Residue 335 Distillation Total 6120 Total 6120
1.13) Meristyl Bromide ManufacturingProcess: Myristyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Myristyl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Myristyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-(CH2)13-OH+ HBr CH3-(CH2)13-Br + H2O MyristylAlcohol Hydrobromic Acid Myristyl Bromide Water M.W.:214 M.W. :81 M.W.:277 M.W. :18 Mass Balance:
Input Kg Output Kg Myristyl Alcohol 4350 Myristyl Bromide 5630 Reaction Hydrobromic Acid (48%) 6440 Recovered HBr (28%) 5160 Total 10790 Total 10790
Myristyl Bromide 5630 Myristyl Bromide 5605 Water Water 2000 Water to ETP 2025 Wash Total 7630 Total 7630
Myristyl Bromide 5605 Main Product 5230 Vacuum Residue 375 Distillation Total 5605 Total 5605
1.14) Stearyl Bromide ManufacturingProcess: Stearyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Stearyl Alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Stearyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH3-(CH2)17-OH + HBr CH3-(CH2)17-Br + H2O StearylAlcohol HydrobromicAcid StearylBromide Water M.W. : 270 M.W.: 81 M.W. :333 M.W. :18 Mass Balance:
Input Kg Output Kg Stearyl Alcohol 5100 Stearyl Bromide 6290 Reaction Hydrobromic Acid (48%) 4945 Recovered HBr (22.5%) 3755 Total 10045 Total 10045
Stearyl Bromide 6290 Stearyl Bromide 6200 Water Water 2000 Water to ETP 2090 Wash Total 8290 Total 8290
Stearyl Bromide 6200 Main Product 5500 Vacuum Residue 700 Distillation Total 6200 Total 6200 1.15) 1,2 Dibromo Ethane ManufacturingProcess: Ethylene Glycol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Ethylene Glycol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure 1,2 Dibromo Ethane thus obtained is packed in 200 litDrums. Chemical reaction:
OH-(CH2)2 - OH + 2 HBr Br - (CH2)2 -Br + 2H2O Ethyleneglycol HydrobromicAcid 1,2 Dibromo Ethane Water M.W.:62 M.W.:162 M.W. :188 M.W. : 18 X 2 = 36 Mass Balance:
Input Kg Output Kg Ethylene Glycol 1500 1,2 Dibromo Ethane 4550 Reaction Hydrobromic Acid (48%) 12305 Recovered HBr(21%) 9255 Total 13805 Total 13805
1,2 Dibromo Ethane 4550 1,2 Dibrpmo Ethane 4530 Water Water 2000 Water to ETP 2020 Wash Total 6550 Total 6550
1,2 Dibromo Ethane 4530 Main Product 4170 Vacuum Residue 360 Distillation Total 4530 Total 4530
Alternate ManufacturingProcess
Ethylene gets generated from Step 2 of 2-Cyclopropyl 6-Methyl Phenol. It will be reacted with bromine to get 1,2 Dibromo Ethane. Br Br H2C CH2 Br + Br
Ethylene Bromine 1,2-dibromoethane
M.Wt. : 28.05 M.Wt. :159.8 M.Wt.: 187.86
Input Kg Output Kg Ethylene 1000 1,2-Dibromo ethane 6690 Br2 5690 Reaction Total 6690 Total 6690
1,2-Dibromo ethane 6690 1,2-Dibromo ethane 6685 Water 3345 Water wash HBr Water (Reuse) 3350 Total 10035 Total 10035
1,2-Dibromoethane 6685 Product 6550 Vaccum Residue 135 Distillation Total 6685 Total 6685
1.16) 1,3 Dibromo Propane ManufacturingProcess: 1,3 Propanediol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted 1,3 Propanediol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1,3 Dibromo Propane thus obtained is packed in 200 litDrums. Chemical reaction:
OH-(CH2)3- OH + 2HBr Br - (CH2)3 - Br + 2H2O 1,3 - Propanediol Hydrobromic Acid 1,3 DiBromoPropane Water M.W. : 76 M.W. : 162 M.W. : 202 M.W. : 18 X 2 = 36 Mass Balance:
Input Kg Output Kg 1,3 Propanediol 1800 1,3 DiBromoPropane 4785 Reaction Hydrobromic Acid (48%) 11770 Recovered HBr(20%) 8785 Total 13570 Total 13570
1,3 DiBromoPropane 4785 1,3 DiBromoPropane 4750 Water Water 2000 Water to ETP 2035 Wash Total 6785 Total 6785
1,3 DiBromoPropane 4750 Main Product 4370 Vacuum Residue 380 Distillation Total 4750 Total 4750 1.17) 1,4 Dibromo Butane ManufacturingProcess: 1,4 Butanediol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted 1,4 Butanediol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1,4 Dibromo Butane thus obtained is packed in 200 litDrums. Chemical reaction:
OH-(CH2)4- OH + 2HBr Br - (CH2)4 - Br + 2H2O 1,4 - Butanediol Hydrobromic Acid 1,4 DiBromoButane Water M.W. : 90 M.W. : 162 M.W. : 216 M.W. : 18 X 2 = 36 MassBalance:
Input Kg Output Kg 1,4 Butanediol 2040 1,4 DiBromodecane 4895 Reaction Hydrobromic Acid (48%) 11320 Recovered HBr (21%) 8465 Total 13360 Total 13360
1,4 DiBromoButane 4895 1,4 DiBromoButane 4850 Water Water 2000 Water to ETP 2045 Wash Total 6895 Total 6895
1,4 DiBromoButane 4850 Main Product 4455 Vacuum Residue 395 Distillation Total 4850 Total 4850 1.18) 1,5 Dibromo Pentane ManufacturingProcess: 1,5 Pentanediol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed at 25oC - 30oC, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted 1,5 Pentanediol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer containing HBr is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1,5 Dibromo Pentane thus obtained is packed in 200 litDrums. Chemical reaction:
OH-(CH2)5-OH + 2 HBr Br - (CH2)6-Br + 2H2O 1,5-Pentanediol Hydrobromic Acid 1,5DiBromoPentane Water M.W.:104 M.W. :162 M.W.:230 M.W. : 18 X 2 =36 Mass Balance:
Input Kg Output Kg 1,5 Pentanediol 2200 1,5 Dibromo Pentane 4865 Reaction Hydrobromic Acid (48%) 10835 Recovered HBr (21%) 8170 Total 13035 Total 13035
1,5 Dibromo Pentane 4865 1,5 Dibromo Pentane 4850 Water Water 2000 Water to ETP 2015 Wash Total 6865 Total 6865
1,5 Dibromo Pentane 4850 Main Product 4510 Vacuum Residue 340 Distillation Total 4850 Total 4850 1.19) 1,6 Dibromo Hexane ManufacturingProcess: 1,6 Hexanediol is taken in a reactor to that Sulphur is added and Bromine addition is done over a period of time to get 1,6 Dibromo Hexane to which water washing isgiven. The Organic Layer is taken for Fractionation to get Pure 1,6 Dibromo Hexane and Aqueous layer is recycled or sold as a ByProduct. Chemical reaction:
3Br2 + S + 4H2O 6HBr + H2SO4
3OH-(CH2)6-OH + 6HBr 3 Br - (CH2)6-Br + 6H2O
3OH-(CH2)6-OH + 3Br2 + S 3 Br - (CH2)6 - Br + H2SO4 + 2H2O 1,6-Hexanediol Bromine Sulphur 1,6 DiBromohexane SulphuricAcid Water M.W.:354 M.W.:480 M.W. :32 M.W. : 732 M.W.:98 M.W. :36 Mass Balance: Input Kg Output Kg 1,6 Hexanediol 6945 1,6 DiBromoHexane 14190 Bromine 9305 Reaction Sulphuric Acid 1900 Sulphur 620 Water 780 Total 16870 Total 16870
1,6 DiBromoHexane 14190 1,6 DiBromoHexane 14150 Water Water 5000 Water to ETP 5040 Wash Total 19190 Total 19190
1,6 DiBromoHexane 14150 Main Product 12720 Vacuum Residue 1430 Distillation Total 14150 Total 14150 1.20) 1 Chloro 2 Ethyl Hexane ManufacturingProcess:
2 Ethyl Hexanol is taken in reactor. To this Thionyl Chloride is added, after addition of required amount of Thionyl Chloride over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted 2 Ethyl Hexanol is less than 1% thionyl Chloride addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and aqueous layer containing is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1 Chloro 2 Ethyl Hexane thus obtained is packed in 200 litDrums. Chemical reaction:
CH2-CH3 CH2-CH3
OH-CH2-CH-CH2-CH2-CH2-CH3 + SOCl2 Cl-CH2-CH-CH2-CH2-CH2-CH3+ SO2 + HCl 2 EthylHexanol ThionylChloride 1 Chloro 2EthylHexane Sulphur Di Oxide HydrochloricAcid M.W. : 113 M.W. : 119 M.W.:131.5 M.W.:64 M.W. :36.5 Mass Balance:
Input Kg Output Kg 2 Ethyl Hexanol 5250 1 Chloro 2 Ethyl Hexane 5980 Thionyl Chloride 5410 Reaction Sulphur Di Oxide 2975 Water 3955 HCl (30%) 5660 Total 14615 Total 14615
1 Chloro 2 Ethyl Hexane 5980 1 Chloro 2 Ethyl Hexane 5950 Water Water 2000 Water to ETP 2030 Wash Total 7980 Total 7980
1 Chloro 2 Ethyl Hexane 5950 Main Fraction 5490 Vacuum Residue 460 Distillation Total 5950 Total 5950
1.21) 6 Chloro 1 Hexanol ManufacturingProcess: 1,6 Hexanediol is taken in Aqueous Hydrochloric Acid. To this Gaseous HCl is passed, after passing required amount of HCl acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted 1,6 Hexanediol is less than 1% HCl acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organiclayer
taken for Purification and Aqueous layer containing HCl is recycled to next Batch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 6 Chloro 1 Hexanol thus obtained is packed in 200 litDrums. Chemical reaction:
OH-(CH2)6- OH + HCl OH - (CH2)6-Cl + H2O 1,6 - Hexanediol HydrochloricAcid 6 Chloro1hexanol Water M.W. : 118 M.W.:36.5 M.W.:136.5 M.W. :18 Mass Balance: Input Kg Output Kg 1,6 Hexanediol 1920 6 Chloro 1 Hexanol 2221 Reaction HCl (20%) 10430 HCl (15%) 10129 Total 12350 Total 12350
6 Chloro 1 Hexanol 2221 6 Chloro 1 Hexanol 2200 Water Water 500 Water to ETP 521 Wash Total 2721 Total 2721
6 Chloro 1 Hexanol 2200 Main Product 2030 Vacuum Residue 170 Distillation Total 2200 Total 2200 1.22) 3 Chloro Propanol ManufacturingProcess: 1,3 Propanediol is taken in reactor. To this Thionyl Chloride is added over a given period of time, after addition of required amount of Thionyl Chloride the mass is analyzed for completion of reaction onGC. When unreacted 1,3 Propanediol is less than 1% Thionyl Chloride addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 3 Chloro 1 Propanol thus obtained is packed in 200 litDrums. Chemical reaction:
OH-CH2-CH2-CH2-OH+ SOCl2 OH-CH2-CH2-CH2-Cl + SO2 + HCl 1,3-Propanediol ThionylChloride 3 Chloro1Propanol SulphuricAcid Hydrochloric Acid M.W.:76 M.W. :119 M.W. :94.5 M.W. :64 M.W. :36.5
Mass Balance:
Input Kg Output Kg 1,3 Propanediol 4770 3 Chloro 1 Propanol 5931 Thionyl Chloride 7470 Reaction Sulphur Di Oxide 4019 Water 5350 Hydrochloric Acid (30% 7640 Total 17590 Total 17590
3 Chloro Propanol 5931 3 Chloro 1 Propanol 5900 Water Water 2000 Water to ETP 2031 Wash Total 7931 Total 7931
3 Chloro 1Propanol 5900 Main Product 5350 Vacuum Residue 550 Distillation Total 5900 Total 5900 1.23) 1,6 Dichloro Hexane ManufacturingProcess: 1,6 Hexanediol is taken in a reactor. To this Thionyl Chloride is added over a given period of time, after adding required amount of Thionyl Chloride the mass is analyzed for completion of reaction onGC. When unreacted 1,6 Hexanediol is less than 1% Thionyl Chloride addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature Organic layer taken for Purification and Aqueous layer containing HCl is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure 1,6 Dichlorohexane thus obtained is packed in 200 litDrums. Chemical reaction:
OH-(CH2)6-OH + 2SOCl2 Cl - (CH2)6- Cl + 2SO2 + 2HCl 1,6-Hexanediol ThionylChloride 1,6DiChlorohexane SulphurDiOxide Hydrochloric Acid M.W.:118 M.W.:238 M.W.:155 M.W.:128 M.W. :73 Mass Balance:
Input Kg Output Kg 1,6 Hexanediol 4580 1,6 DiChloroHexane 6015 Thionyl Chloride 9235 Reaction Sulphur Di Oxide 4965 Water 995 HCl (35%) 3830 Total 14810 Total 14810
1,6 DiChloroHexane 6015 1,6 DiChloroHexane 6000 Water Water 2000 Water to ETP 2015 Wash Total 8015 Total 8015
1,6 DiChloroHexane 6000 Main Product 5300 Vacuum Residue 700 Distillation Total 6000 Total 6000 1.24) Cyclo Propyl Methyl Bromide ManufacturingProcess: Cyclo Propyl Methyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed in it, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction on GC. When unreacted Cyclo Propyl Methyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Cyclo Propyl Methyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction:
CH2-OH CH2-Br
+ HBr + H2O
Cyclo PropylMethylAlcohol HydrobromicAcid Cyclo Propyl MethylBromide Water M.W. :72 M.W. :81 M.W. : 135 M.W. : 18 Mass Balance:
Input Kg Output Kg Cyclo Propyl Methyl Alcohol 2400 Cyclo Propyl Methyl Bromide 4500 Reaction Hydrobromic Acid (48%) 9375 Recovered HBr (24%) 7275 Total 11775 Total 11775
Cyclo Propyl Methyl Bromide 4500 Cyclo Propyl Methyl Bromide 4470 Water Water 2000 Water to ETP 2030 Wash Total 6500 Total 6500
Cyclo Propyl Methyl Bromide 4470 Main Product 4110 Vacuum Residue 360 Distillation Total 4470 Total 4470
1.25) Cyclo Pentyl Bromide ManufacturingProcess: Cyclo Pentyl Alcohol is taken in Aqueous Hydrobromic Acid. To this Gaseous HBr is passed in it, after passing required amount of HBr acid over a given period of time the mass is analyzed for completion of reaction onGC. When unreacted Cyclo Pentyl alcohol is less than 1% HBr acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature Organic layer taken for Purification and Aqueous layer containing HBr is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Cyclo Pentyl Bromide thus obtained is packed in 200 litDrums. Chemical reaction: CH-OH CH -Br
+ HBr + H2O
Cyclo Pentyl Alcohol Hydrobromic Acid CycloPentylBromide Water M.W. : 86 M.W. : 81 M.W.:149 M.W. :18 Mass Balance:
Input Kg Output Kg Cyclo Pentyl Alcohol 3000 Cyclo Pentyl Bromide 5195 Reaction Hydrobromic Acid (48%) 9595 Recovered HBr (24%) 7400 Total 12595 Total 12595
Cyclo Pentyl Bromide 5195 Cyclo Pentyl Bromide 5170 Water Water 2000 Water to ETP 2025 Wash Total 7195 Total 7195
Cyclo Pentyl Bromide 5170 Main Product 4790 Vacuum Residue 380 Distillation Total 5170 Total 5170 1.26) Cyclo Pentyl Chloride ManufacturingProcess: Cyclo Pentyl Alcohol is taken in Aqueous Hydrochloric Acid. To this Gaseous HCl is passed to it, after passing required amount of Hydrochloric acid over a given Period of time the mass is analyzed for completion of reaction on GC. When unreacted Cyclo Pentyl alcohol is less than 1% Hydrochloric acid addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temp. Organic layer taken for Purification and Aqueous layer containing HCl is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler impurities under Vacuum, the Product is fractionated. Pure Cyclo Pentyl Chloride thus obtained is packed in 200 litDrums. Chemical reaction: CH-OH CH -Cl
+ HCl + H2O
Cyclo Pentyl Alcohol Hydrochloric Acid CycloPentylChloride Water M.W. : 86 M.W. : 36.5 M.W.:104.5 M.W. :18 Mass Balance:
Input Kg Output Kg Cyclo Pentyl Alcohol 1800 Cyclo Pentyl Chloride 2190 Reaction Hydrochloric Acid (20%) 11480 Recovered HCl (15%) 11090 Total 13280 Total 13280
Cyclo Pentyl Chloride 2190 Cyclo Pentyl Chloride 2170 Water Water 1000 Water to ETP 1020 Wash Total 3190 Total 3190
Cyclo Pentyl Chloride 2170 Main Product 1985 Vacuum Residue 185 Distillation Total 2170 Total 2170
1.27) 6-bromohexanol ManufacturingProcess: Hexane diol is added to aq HBr and Toluene mixture. On completion of reaction Organic and aq layers separated. Aq layer is recycled for the next batch. The product is crysatllized from organic layer. Crystallized mass is filtered and dried Mother liquor is taken for Recovery of Toluene. Chemical reaction:
Mass Balance:
Input Kg Output Kg Kmol Next Step TreatmentRemark Hexanediol 1180 10 Organic layer 4310 For crystallization Aq HBr 48% 2531 Reactio Aqueous layer 1901 For recycle to next batch Toluene 2500 n
Total 6211 6211
Organic layer 4310 Crydstall Wet cake 1540 For Drying ization Mother liquor 2770 For Toluene recovery and Total 4310 filtratio 4310
Mother Liqur 2770 Toluene 2100 For next batch Toluene Residue 670 For incineration recover y Total 2770 Total 2770
Wet cake 1540 Dried product 1500 8.3 Pack and sale Loss 40 Drying Total 1540 Total 1540
1.28) 8 -bromo hexanol ManufacturingProcess: Octane diol is added to aq HBr and Toluene mixture. On completion of reaction Organic and aq layers separated. Aq layer is recycled for the next batch. The product is crysatllized from organic layer. Crystallized mass is filtered and dried Mother liquor is taken for Recovery of Toluene.
Chemical reaction: Toluene
OHCH2CH2CH2CH2CH2CH2CH2CH2OH + Aq HBr Crystallization OHCH2CH2CH2CH2CH2CH2CH2CH2Br + H2O 1,8 Octanediol Hydrobromic acid 8 Bromohexanol Water MW 146 MW 81 MW 209 MW 18
Mass Balance:
Input Kg Output Kg Kmol Next Step TreatmentRemark Octanediol 1460 10 Organic layer 4590 For crystallization Aq HBr 48% 2531 Reactio Aqueous layer 1901 For recycle to next batch Toluene 2500 n
Total 6491 6491
Organic layer 4510 Crydstall Wet cake 1740 For drying ization Mother liquor 2770 For Toluene recovery and Total 4510 filtratio 4510
Mother Liqur 2770 Toluene 2155 For next batch Toluene Residue 615 For Incineration recover y Total 2770 Total 2770
Wet cake 1740 Dried product 1700 8.13 Pack and sale Loss 40 Drying Total 1740 Total 1740 1.29) 10-bromodecanol ManufacturingProcess: Decane diol is added to aq HBr and Toluene mixture. On completion of reaction Organic and aq layers separated. Aq layer is recycled for the next batch. The product is crysatllized from organic layer. Crystallized mass is filtered and dried Mother liquor is taken for Recovery of Toluene. Chemical reaction:
Toluene
OHCH2CH2CH2CH2CH2CH2CH2CH2CH2CH2OH + Aq HBr Crystallization OHCH2CH2CH2CH2CH2CH2CH2CH2CH2CH2Br + H2O 1,10 Oecanediol Hydrobromic acid 10 Bromodecanol Water MW 174 MW 81 MW 237 MW 18
Mass Balance:
Input Kg Output Kg Kmol Next Step TreatmentRemark Decanediol 1740 10 Organic layer 4870 For crystallization Aq HBr 48% 2531 Aqueous layer 1901 For recycle to next batch Reaction Toluene 2500
Total 6771 6771
Organic layer 4870 Wet 1896 For drying Crydstalliz Mother liquor 2974 For Toluene recovery ation and drying Total 4870 4870
Mother Liqur 2974 Toluene 2100 For next batch Toluene Residue 874 For Incineration recovery Total 2974 Total 2974
Wet cake 1896 Dried product 1850 7.8 Pack and sale Loss 46 Drying Total 1896 Total 1896 2) Bromination of Organic Acids and Esterification there of
2.1) 2-Bromo Propionic Acid Manufacturing Process: Propionic Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Propionic Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Propionic Acid. The Hydrobromic acid thus generated is recycled. The Crude 2-Bromo Propionic Acid so obtained is subjected to Fractionation to get pure 2-Bromo Propionic Acid. Chemical reaction:
CH3-CH2-COOH + Br2 CH3-CH(Br)-COOH + HBr n- Propionic Acid Bromine 2 Bromo Propionic Acid Hydrobromic Acid M.W. : 74 M.W. : 160 M.W. : 153 M.W. : 81 Mass Balance: Input Kg Output Kg Propionic Acid 3300 2 Bromo Propionic Acid 6825 Bromina Bromine 7135 Hydrobromic Acid (48%) 7525 tion Water 3915 Total 14350 Total 14350
2 Bromo Propionic Acid 6825 Main Product 6345 Fraction Residue 480 ation Total 6825 Total 6825 2.2) 2-Bromo Propionyl Bromide ManufacturingProcess: Propionyl Bromide is taken in a Reactor to that the Bromine addition is
done over a given Period of time. The progress of Reaction is monitored on GC. When the Propionyl Bromide Content is 1% the Bromine addition is stopped to get the 2-Bromo Propionyl Bromide. The Hydrobromic acid thus generated isrecycled. The Crude 2-Bromo Propionyl Bromide so obtained is subjected to Fractionation to get pure 2-Bromo PropionylBromide. Chemical reaction:
CH3-CH2-C=O-Br + Br2 CH3-CH(Br)-C=O-Br + HBr Propionyl Bromide Bromine 2 Bromo Propionyl Bromide Hydrobromic Acid M.W. : 137 M.W. : 160 M.W. : 216 M.W. : 81
Mass Balance:
Input Kg Output Kg Propionyl Bromide 5705 2 Bromo Propionyl Bromide 8995 Brominati Bromine 6660 Hydrobromic Acid 48% 7025 on Water 3655 Total 16020 Total 16020
2 Bromo Propionyl Bromide 8995 Main Product 8195 Fractionati Residue 800 on Total 8995 Total 8995
2.3) 5-Bromo Valeric Acid ManufacturingProcess: Valerolactone is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Valerolactone Content is 1% the Bromine addition is stopped to get 5-Bromo Valeric Acid. The Hydrobromic acid thus generated isrecycled. The Crude 5-Bromo Valeric Acid so obtained is subjected to fractionation to get pure 5-Bromo ValericAcid. Chemical reaction:
+ HBr Br-CH2-(CH2)3-COOH
Valerolactone Hydrobromic Acid 5 Bromo ValericAcid M.W. :100 M.W. :81 M.W. : 181 Mass Balance:
Input Kg Output Kg Valerolactone 4000 Brominatio 5 Bromo Valeric Acid 7240 Hydrobromic Acid 8790 n Hydrobromic Acid (18%) 5550 Total 12790 Total 12790
5 Bromo Valeric Acid 7240 Main Product 6600 Fractionatio Residue 640 n Total 7240 Total 7240 2.4) 2-Bromo Hexanoic Acid ManufacturingProcess: Hexanoic Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC.
When the Hexanoic Acid Content is 1% the Bromine addition is stopped to get the 2-Bromo Hexanoic Acid. The Hydrobromic acid thus generated is recycled. The Crude 2-Bromo Hexanoic Acid so obtained is subjected to fractionation to get pure 2-Bromo HexanoicAcid. Chemical reaction:
CH3-(CH2)4-COOH + Br2 CH3-(CH2)3-CH(Br)-COOH + HBr n-HexanoicAcid Bromine 2 Bromo Hexanoic Acid Hydrobromic Acid M.W.:116 M.W. :160 M.W. : 195 M.W. : 81 Mass Balance:
Input Kg Output Kg n- Hexanoic Acid 4210 2 Bromo Hexanoic Acid 7080 Brominati Bromine 5805 Hydrobromic Acid (48%) 6210 on Water 3275 Total 13290 Total 13290
2 Bromo Hexanoic Acid 7080 Main Product 6890 Fractiona Residue 190 tion Total 7080 Total 7080 2.5) Sodium 2 Bromo Propionate ManufacturingProcess: Propionic Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Propionic Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Propionic Acid. The Hydrobromic acid thus generated is recycled. Sodium Methoxide addition is done to the 2-Bromo Propionic Acid so formed. The addition of Sodium Methoxide is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Propionic acid content is 1% the Sodium Methoxide addition is stopped. The Sodium 2-Bromo Propionate so obtained is taken for fractionation to get the Pure Sodium 2-BromoPropionate. Chemical reaction:
CH3-CH2-COOH + Br2 CH3-CH(Br)-COOH + HBr n- Propionic Acid Bromine 2 Bromo Propionic Acid Hydrobromic Acid M.W. : 74 M.W. : 160 M.W. : 153 M.W. : 81
CH3-CH(Br)-COOH + CH3 - O -Na CH3-CH(Br)-COONa + CH3-OH 2BromoPropionicAcid Sodium Methoxide Sodium2BromoPropionate Methanol M.W. : 153 M.W. : 54 M.W. : 175 M.W. :32
Mass Balance: Input Kg Output Kg Propionic Acid 2575 2 Bromo Propionic Acid 5325 Brominati Bromine 5570 Hydrobromic Acid (48%) 5875 on Water 3055 Total 11200 Total 11200
2 Bromo Propionic Acid 5325 Sodium 2 Bromo Propionate 6090 Sodium Methoxide 6265 Reaction Recovered Methanol 5500 Total 11590 Total 11590
Sodium 2 Bromo Propionate 6090 Main Product 5650 Distillatio Residue 440 n Total 6090 Total 6090
2.6) Ethyl 3 Bromo Propionate ManufacturingProcess: Propiolactone is taken in a Reactor to that the Hydrobromic Acid addition is done over a given Period of time. The progress of Reaction is monitored on GC. When the Propiolactone Content is 1% the Hydrogen Bromide addition is stopped to get 3-Bromo Propionic Acid. The Hydrobromic acid thus generated isrecycled. The Ethanol addition is done to 3-Bromo Propionic Acid so formed. The addition of Ethanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 3-Bromo Propionic acid content is 1% the Ethanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Ethyl 3-BromoPropionate. Chemical reaction:
+ HBr Br-CH2-CH2-COOH
Propiolactone Hydrobromic Acid 3 Bromo PropionicAcid M.W. : 72 M.W. : 81 M.W. : 153
Br-CH2-CH2-COOH + CH3-CH2-OH Br-CH2-CH2-COO-CH2-CH3 + H2O 3 Bromo Propionic Acid Ethanol 3 Bromo Propionic Acid Ethyl Ester Water M.W. : 153 M.W. : 46 M.W: 181 M.W: 18
Mass Balance:
Input Kg Output Kg Propiolactone 3450 Brominati Crude Ester 8675 Hydrogen Bromide (48%) 9835 on and Recovered Ethanol 2025 Ethanol 4230 Esterificat Hydrogen Bromide (12%) 6815 Total 17515 Total 17515
Crude Ester 8675 Main Product 7985 Fractionat Residue 690 ion Total 8675 Total 8675
Recovered Ethanol 2025 Ethanol 1400 Ethanol Residue 275 Recovery Water fraction 350 Total 2025 Total 2025
Residue 965 Main Fraction 405 Residue Residue 560 Recovery Total 965 Total 965 2.7) Methyl 2 Bromo Butyrate ManufacturingProcess: n-Butyric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Butyric Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Butyric Acid. The Hydrobromic acid thus generated is recycled. The Methanol addition is done to 2-Bromo Butyric Acid so formed. The addition of Methanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Butyric acid content is 1% the Methanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Methyl 2-BromoButyrate. Chemical reaction:
CH3-CH2-CH2-COOH + Br2 CH3-CH2-CH-(Br)-COOH + HBr n- Butyric Acid Bromine 2 Bromo Butyric Acid Hydrobromic Acid M.W. : 88 M.W. : 160 M.W. : 167 M.W. : 81
CH3-CH2-CH-(Br)-COOH + CH3-OH CH3-CH2-CH-(Br)-COO-CH3 + H2O 2 Bromo Butyric Acid Methanol 2 Bromo Butyric Acid Methyl Ester Water M.W. : 167 M.W. :32 M.W: 181 M.W: 18 Mass Balance:
Input Kg Output Kg n-Butyric Acid 3520 Brominatio Crude Ester 7240 Bromine 6400 n and Recovered Methanol 1720 Methanol 3000 Esterificati Hydrobromic Acid (48%) 6750 Water 2790 on Total 15710 Total 15710
Crude Ester 7240 Main Product 6720 Fractionati Residue 520 on Total 7240 Total 7240
Recovered Methanol 2390 Dist.Methanol 1440 Methanol Water Fraction 450 Recovery Residue 500 Total 2390 Total 2390
Residue 1400 Main Product 550 Residue Residue 850 Recovery Total 1400 Total 1400 2.8) Ethyl 2 Bromo Butyrate ManufacturingProcess: n-Butyric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Butyric Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Butyric Acid. The Hydrobromic acid thus generated is recycled. The Ethanol addition is done to 2-Bromo Butyric Acid so formed. The addition of Ethanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Butyric acid content is 1% the Ethanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Ethyl 2-BromoButyrate. Chemical reaction:
CH3-CH2-CH2-COOH + Br2 CH3-CH2-CH-(Br)-COOH + HBr n- Butyric Acid Bromine 2 Bromo Butyric Acid Hydrobromic Acid M.W. : 88 M.W. : 160 M.W. : 167 M.W. : 81
CH3-CH2-CH-(Br)-COOH + CH3-CH2-OH CH3-CH2-CH-(Br)-COO-CH2-CH3 + H2O 2 Bromo Butyric Acid Ethanol 2 Bromo Butyric Acid Ethyl Water M.W. : 167 M.W. : 46 M.W: 195 M.W: 18
Mass Balance:
Input Kg Output Kg n-Butyric Acid 3520 Crude Ester 7800 Bromination Bromine 6400 Recovered Ethanol 2390 and Ethanol 4230 Hydrobromic Acid (48%) 6750 Esterification Water 2790 Total 16940 Total 16940
Crude Ester 7800 Main Product 6900 Fractionation Residue 900 Total 7800 Total 7800
Recovered Ethanol 2390 Ethanol 1440 Ethanol Water Fraction 450 Recovery Residue 500 Total 2390 Total 2390
Residue 1400 Main Product 550 Residue Residue 850 Recovery Total 1400 Total 1400 2.9) Ethyl 4 Bromo Butyrate ManufacturingProcess: Butyrolactone is taken in a Reactor to that the Hydrogen Bromide addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Butyrolactone Content is 1% the Hydrogen Bromide addition is stopped to get 4-Bromo Butyric Acid. The Hydrobromic acid thus generated isrecycled. The Ethanol addition is done to 4-Bromo Butyric Acid so formed. The addition of Ethanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 4-Bromo Butyric acid content is 1% the Ethanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Ethyl 4 Bromo Butyrate. Chemical reaction:
CH2 -CH2-CH2 + HBr Br-CH2-CH2-CH2-COOH O C =O Butyrolactone Hydrobromic Acid 4 Bromo Butyric Acid M.W. : 86 M.W. : 81 M.W. : 167
Br-CH2-CH2-CH2-COOH + CH3-CH2-OH Br-CH2-CH2-CH2-COO-CH2-CH3 + H2O 4 Bromo Butyric Acid Ethanol 4 Bromo Butyric Acid Ethyl Ester Water M.W. : 167 M.W. : 46 M.W: 195 M.W: 18 Mass Balance:
Input Kg Output Kg Butyrolactone 3520 Brominati Crude Ester 7980 Hydrogen Bromide (48%) 9655 on and Recovered Ethanol 2350 Ethanol 4230 Esterificat Hydrobromic Acid (18%) 7075 Total 17405 Total 17405
Crude Ester 7980 Main Product 7320 Fractionat Residue 660 ion Total 7980 Total 7980
Recovered Ethanol 2350 Ethanol 1420 Ethanol Water Fraction 430 Recovery Residue 500 Total 2350 Total 2350
Residue 1160 Main Product 500 Residue Residue 660 Recovery Total 1160 Total 1160 2.10) Methyl 2 Bromo Iso Butyrate ManufacturingProcess: Iso-Butyric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Iso Butyric Acid Content is 1% the Bromine addition is stopped to get the 2-Bromo Iso-Butyric Acid. The Hydrobromic acid thus generated isrecycled. The Methanol addition is done to 2-Bromo Iso-Butyric Acid so formed. The addition of Methanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Iso Butyric acid content is 1% the Methanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Methyl 2 Bromo IsoButyrate. Chemical reaction:
(CH3)2-CH-COOH + Br2 (CH3)2-CH-(Br)-COOH + HBr Iso- ButyricAcid Bromine 2 Bromo Isobutyric Acid Hydrobromic Acid M.W. : 88 M.W. : 160 M.W. : 167 M.W. : 81
(CH3)2-CH-(Br)-COOH + CH3-OH (CH3)2-CH-(Br)-COO-CH3 + H2O 2 Bromo Isobutyric Acid Methanol Methyl 2 Bromo IsoButyrate Water M.W. : 167 M.W. :32 M.W:181 M.W: 18 Mass Balance:
Input Kg Output Kg Iso-Butyric Acid 4400 Brominat Crude Ester 9050 Bromine 8000 ion and Recovered Methanol 1665 Methanol 3265 Esterificat Hydrobromic Acid (48%) 8435 Water 3485 ion Total 19150 Total 19150
Crude Ester 9050 Main Product 8000 Fractiona Residue 1050 tion Total 9050 Total 9050
Recovered Methanol 1665 Methanol 970 Methanol Water Fraction 350 Recovery Residue 345 Total 1665 Total 1665
Residue 1395 Main Product 555 Residue Residue 840 Recovery Total 1395 Total 1395 2.11) Ethyl 2 Bromo Iso Butyrate ManufacturingProcess: Iso-Butyric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Iso Butyric Acid Content is 1% the Bromine addition is stopped to get the 2-Bromo Iso-Butyric Acid. The Hydrobromic acid thus generated isrecycled. The Ethanol addition is done to 2-Bromo Iso-Butyric Acid so formed. The addition of Ethanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo iso Butyric acid content is 1% the Ethanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Ethyl 2 Bromo IsoButyrate. Chemical reaction:
(CH3)2-CH-COOH + Br2 (CH3)2 - CH - (Br) -COOH + HBr Iso- Butyric Acid Bromine 2 Bromo IsobutyricAcid Hydrobromic Acid M.W. : 88 M.W. : 160 M.W. : 167 M.W. : 81
(CH3)2-CH-(Br)-COOH + CH3-CH2-OH CH3-CH2-CH-(Br)-COO-CH2-CH3 + H2O 2 Bromo Isobutyric Acid Ethanol Ethyl 2 Bromo Isobutyrate Water M.W. : 167 M.W. : 46 M.W: 195 M.W: 18 Mass Balance:
Input Kg Output Kg Iso-Butyric Acid 3520 Brominatio Crude Ester 7800 Bromine 6400 n and Recovered Ethanol 2390 Ethanol 4230 Esterificatio Hydrobromic Acid (48%) 6750 Water 2790 n Total 16940 Total 16940
Crude Ester 7800 Main Product 6900 Fractionati Residue 900 on Total 7800 Total 7800
Recovered Ethanol 2390 Ethanol 1440 Ethanol Water Fraction 450 Recovery Residue 500 Total 2390 Total 2390
Residue 1400 Main Product 550 Residue Residue 850 Recovery Total 1400 Total 1400 2.12) Iso Propyl 2 Bromo Iso Butyrate ManufacturingProcess: Iso-Butyric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Iso Butyric Acid Content is 1% the Bromine addition is stopped to get the 2-Bromo Iso-Butyric Acid. The Hydrobromic acid thus generated isrecycled. The Iso propyl alcohol addition is done to 2-Bromo Iso-Butyric Acid so formed. The addition of Iso Propyl Alcohol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Iso Butyric acid content is 1% the Iso propyl Alcohol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Iso Propyl 2 Bromo IsoButyrate. Chemical reaction:
(CH3)2-CH-COOH + Br2 (CH3)2-C-Br-COOH + HBr Iso-ButryicAcid Bromine 2 Bromo iso butryic Acid Hydrobromic Acid M.W. : 88 M.W. : 160 M.W. : 167 M.W. : 81
(CH3)2-C-Br-COOH + (CH3)2-CH-OH (CH3)2-C-Br-COO-CH-(CH3)2 + H2O 2 Bromo iso butryicAcid Iso Propyl Alcohol IsoPropyl2BromoIsoButyrate Water M.W. : 167 M.W. : 60 M.W:209 M.W: 18 Mass Balance:
Input Kg Output Kg Iso - Butyric Acid 6000 Brominat Crude Ester 14250 Bromine 10910 ion and Rec Iso Propyl Alcohol 2500 Iso Propyl Alcohol 6585 Esterificat HBr Gas (49%) 11500 Water 4755 ion Total 28250 Total 28250
Crude Ester 14250 Main Product 11825 Fractiona Residue 2425 tion Total 14250 Total 14250
Recovered Iso Propanol 2500 Iso Iso Propanol 2000 Propyl Water Fraction 400 Alcohol Residue 100 Total 2500 Recovery Total 2500
Residue 2525 Main Product 975 Residue Residue 1550 Recovery Total 2525 Total 2525 2.13) Ethyl 2 Bromo Valerate ManufacturingProcess: Valeric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Valeric Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Valeric Acid. The Hydrobromic acid thus generated isrecycled. The Ethyl alcohol addition is done to 2-Bromo Valeric Acid so formed. The addition of Ethyl Alcohol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Valeric acid content is 1% the Ethyl Alcohol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Ethyl 2 Bromo Valerate. Chemical reaction:
CH3-(CH2)3-COOH + Br2 CH3-CH2-CH2-CH(Br)-COOH + HBr Valeric Acid Bromine 2 Bromo Valeric Acid Hydrobromic Acid M.W. : 102 M.W. : 160 M.W. : 181 M.W. : 81
Br-CH2-(CH2)3-COOH + CH3-CH2-OH CH3-(CH2)3-CH(Br)-COO-CH3 + H2O 2 Bromo ValericAcid Ethanol Ethyl 2 Bromo Valerate Water M.W. : 181 M.W. : 46 M.W. : 209 M.W. : 18 Mass Balance:
Input Kg Output Kg Valeric Acid 3855 Brominatio Crude Ester 7900 Bromine 6050 n and Rec. Ethanol 2290 Ethanol 4025 Esterificati Hydrobromic Acid (48%) 6375 Water 2635 on Total 16565 Total 16565
Crude Ester 7900 Main Product 7430 Fractionati Residue 470 on Total 7900 Total 7900
Rec. Ethanol 2290 Dist. Ethanol 1440 Ethanol Water Fraction 170 Recovery Residue 680 Total 2290 Total 2290
Residue 1150 Main Product 450 Residue Residue 700 Recovery Total 1150 Total 1150 2.14) Methyl 2 Bromo Valerate ManufacturingProcess: Valeric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Valeric Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Valeric Acid. The Hydrobromic acid thus generated isrecycled. The Methanol addition is done to 2-Bromo Valeric Acid so formed. The addition of Methanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Valeric acid content is 1% the Methanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Methyl 2 Bromo Valerate. Chemical reaction:
CH3-(CH2)3-COOH + Br2 CH3-(CH2)2 + HBr Valeric Acid Bromine 2Bromo Hydrobromic Acid M.W. : 102 M.W.:160 M.W.:181 M.W. :81
CH3-(CH2)2 CH(Br)-COOH + CH3-OH CH3-(CH2)2 + H2O 2 Bromo Valeric Acid Methanol Methyl2 Water M.W. : 181 M.W.: 32 M.W.:195 M.W. :18 Mass Balance:
Input Kg Output Kg Valeric Acid 4365 Brominati Crude Ester 8350 Bromine 6850 on and Rec. Methanol 1640 Methanol 3010 Esterificat Hydrobromic Acid (48%) 7225 Water 2990 ion Total 17215 Total 17215
Crude Ester 8350 Main Product 7760 Fractionat Residue 590 ion Total 8350 Total 8350
Rec. Methanol 1640 Dist. Methanol 1340 Methanol Water Fraction 180 Recovery Residue 120 Total 1640 Total 1640
Residue 710 Main Product 135 Residue Residue 575 Recovery Total 710 Total 710 2.15) Ethyl 5 Bromo Valerate ManufacturingProcess: Valerolactone is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Valerolactone Content is 1% the Bromine addition is stopped to get 5-Bromo Valeric Acid. The Hydrobromic acid thus generated isrecycled. The Ethanol addition is done to 5-Bromo Valeric Acid so formed. The addition of Ethanol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 5-Bromo Valeric acid content is 1% the Ethanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Ethyl 5 BromoValerate. Chemical reaction:
+ HBr Br-CH2-(CH2)3-COOH
Valerolactone HydrobromicAcid 5 Bromo ValericAcid M.W.:100 M.W.: 81 M.W. :181
Br-CH2-(CH2)3-COOH + CH3- CH2-OH Br-CH2-(CH2)3-COO- CH2-CH3+ H2O
5 BromoValericAcid Ethanol Ethyl 5BromoValerate Water M.W.:181 M.W.:46 M.W.:209 M.W. :18 Mass Balance:
Input Kg Output Kg Valerolactone 4000 Brominati 5 Bromo Valeric Acid 8360 Hydrobromic Acid 8790 on and Hydrobromic Acid (16%) 6270 Ethanol 3825 Esterificati Recovered Ethanol 1985 Total 16615 Total 16615
Crude Ester 8360 Main Product 7775 Fractionat Residue 585 ion Total 8360 Total 8360
Rec. Ethanol 1985 Dist. Ethanol 1585 Ethanol Water Fraction 235 Recovery Residue 165 Total 1985 Total 1985
Residue 750 Main Product 125 Residue Residue 625 Recovery Total 750 Total 750
2.16) t-Butyl 2 Bromo Iso Butyrate ManufacturingProcess: Iso Butyric Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the Iso Butyric Acid Content is 1% the Bromine addition is stopped to get the 2-Bromo Iso Butyric Acid. The Hydrobromic acid thus generated isrecycled. The T-Butyl Alcohol addition is done to 2-Bromo Iso butyric Acid so formed. The addition of t-Butyl alcohol is carried out over a given period of time; the progress of reaction is monitored onGC. When the 2-Bromo Iso butyric acid content is 1% the t-Butyl addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Iso Propyl 2 Bromo IsoButyrate.
Chemical reaction:
CH3 CH3
CH-COOH + Br2 C(Br)-COOH + HBr
CH3 CH3 Iso Butyric Acid Bromine 2 Bromo IsButyricAcid Hydrobromic Acid M.W. : 88 M.W.:160 M.W.:167 M.W. :81
CH3 CH3 CH3 CH3
C(Br)-COOH + CH3 C-OH C(Br)-COO-C CH3 + H2O
CH3 CH3 CH3 CH3 2 Bromo Iso Butyric Acid tButanol t-Butyl 2 Bromo Iso Butyrate Water M.W. : 167 M.W. :74 M.W: 223 M.W: 18 Mass Balance:
Input Kg Output Kg Iso Butyric Acid 2110 Brominatio Crude Ester 5340 Bromine 3830 n and Recovered t-Butanol 3730 t Butyl Alcohol 5500 Esterificati Hydrobromic Acid (48%) 4040 Water 1670 on Total 13110 Total 13110
Crude Ester 5340 Main Product 4890 Fractionati Residue 450 on Total 5340 Total 5340
Recovered t-Butanol 3730 Ethanol 2830 t - Butanol Water Fraction 350 Recovery Residue 550 Total 3730 Total 3730
Residue 1000 Main Product 290 Residue Residue 710 Recovery Total 1000 Total 1000
2.17) Methyl 2 Bromo Caproate ManufacturingProcess: Caproic Acid is taken in a Reactor to that the Bromine addition is done over a given Period of time. The progress of Reaction is monitored onGC. When the caproic Acid Content is 1% the Bromine addition is stopped to get 2-Bromo Caproic Acid. The Hydrobromic acid thus generated is recycled. The Methanol addition is done to 2-Bromo Caproic Acid so formed. The addition of Methanol is carried out over a given period of time; the progress of reaction is monitored onGC.
When the 2-Bromo Caproic acid content is 1% the Methanol addition is stopped. The Crude Bromo Acid ester obtained is taken for fractionation to get the Pure Methyl 2 BromoCaproate. Chemical reaction:
CH3-(CH2)4-COOH + Br2 CH3-(CH2)3-CH(Br)-COOH + HBr Caproic Acid Bromine 2 Bromo Caproic Acid Hydrobromic Acid M.W. : 116 M.W. : 160 M.W. : 195 M.W. : 81
CH3-(CH2)3-CH(Br)-COOH + CH3-OH CH3-(CH2)3-CH(Br)-COO-CH3 + H2O 2 Bromo Caproic Acid Methanol Methyl 2 Bromo Caproate Water M.W. : 195 M.W. :32 M.W. : 209 M.W. : 18 Mass Balance:
Input Kg Output Kg n- Hexanoic Acid 6000 Brominat Crude Ester 10810 Bromine 8275 ion and Rec. Methanol 1825 Methanol 3475 Esterifica Hydrobromic Acid (48%) 9480 Water 4365 tion Total 22115 Total 22115
Crude Ester 10810 Main Product 8975 Fractiona Residue 1835 tion Total 10810 Total 10810
Rec. Methanol 1825 Dist. Methanol 1135 Methanol Water Fraction 600 Recovery Residue 90 Total 1825 Total 1825
Residue 1925 Main Product 770 Residue Residue 1155 Recovery Total 1925 Total 1925
3) Grignards Formation from Organic Halides 3.1) Methyl Magnesium Chloride 3M inTHF Manufacturing Process: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Methyl Chloride in 4 to 5 hours maintaining the temperature 55oC – 60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
CH3 -Cl + Mg CH3- Mg-Cl MethylChloride Magnesuim Methyl Magnesium Chloride M.W.:50.5 M.W.:24 M.W. :74.5 Mass Balance:
Input Kg Output Kg Methyl Chloride 726 Methyl Magnesuim Chloride 4882 Magnesium 345 Reaction in THF THF Solution 3811 Total 4882 Total 4882
3.2) Methyl Magnesium Bromide 1.5 M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Methyl Bromide in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
CH3-Br + Mg CH3- Mg-Br MethylBromide Magnesium Methyl Magnesium BromidM.W.:95 M.W.:24 M.W. :119 Mass Balance:
Input Kg Output Kg Methyl Bromide 683 Methyl Magnesuim Bromide 4685 Magnesium 172 Reaction in THF THF Solution 3830 Total 4685 Total 4685
3.3) Ethyl Magnesium Chloride 2 M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Ethyl Chloride in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
CH3 - CH2 - Cl + Mg CH3 - CH2 - Mg - Cl Ethyl Chloride Magnesium Ethyl Magnesium Chloride M.W. : 64.5 M.W. : 24 M.W. : 88.5 Mass Balance: Input Kg Output Kg Ethyl Chloride 618 Ethyl Magnesuim Chloride 4380 Magnesium 230 Reaction in THF THF Solution 3532 Total 4380 Total 4380 3.4) Ethyl Magnesium Bromide 2 M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Ethyl Bromide in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
CH3 - CH2 - Br + Mg CH3 - CH2 - Mg - Br Ethyl Bromide Magnesium Ethyl Magnesium Bromide M.W. : 109 M.W. : 24 M.W. : 133 Mass Balance:
Input Kg Output Kg Ethyl Bromide 1045 Ethyl Magnesuim Bromide 4785 Magnesium 230 Reaction in THF THF Solution 3510 Total 4785 Total 4785
3.5) Vinyl Magnesium Bromide 1M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Vinyl Bromide in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
CH2 = CH - Br + Mg CH2 = CH - Mg -Br Vinyl Bromide Magnesium Vinyl Magnesium Bromide M.W. : 107 M.W. : 24 M.W. : 131 Mass Balance: Input Kg Output Kg Vinyl Bromide 513 Vinyl Magnesuim Bromide 4533 Magnesium 109 Reaction in THF THF Solution 3911 Total 4533 Total 4533 3.6) Iso Propyl Magnesium Chloride 1M inTHF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Iso Propyl Chloride in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
CH3 CH3 CH-Cl + Mg CH - Mg - Cl
CH3 CH3 IsoPropylChloride Magnesuim Iso Propyl Magnesium Chloride M.W.:78.5 M.W. :24 M.W. : 102.5
Mass Balance: Input Kg Output Kg Iso Propyl Chloride 377 Iso Propyl Magnesuim Chloride 4312 Magnesium 115 Reaction in THF THF Solution 3820 Total 4312 Total 4312
3.7) Phenyl Magnesium Bromide 2M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Phenyl Bromide in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction: Br MgBr
+ Mg
Phenyl Bromide Magnesuim Phenyl Magnesuim Bromide M.W. : 157 M.W. : 24 M.W. : 181 Mass Balance:
Input Kg Output Kg Phenyl Bromide 1504 Phenyl Magnesuim Bromide 4985 Magnesuim 225 Reaction in THF THF Solution 3256 Total 4985 Total 4985
3.8) n Butyl Magnesium Chloride 1M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add n-Butyl Chloride in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels.
Chemical reaction:
CH3-(CH2)3-Cl + Mg CH3-(CH2)3- Mg -Cl n-Butyl Chloride Magnesium n- Butyl Magnesium Chloride M.W. : 92.5 M.W. : 24 M.W. : 116.5 Mass Balance: Input Kg Output Kg n-Butyl Chloride 444 n-Butyl Magnesuim Chloride 4303 Magnesium 114 Reaction in THF THF Solution 3745 Total 4303 Total 4303 3.9) Iso Propyl Magnesium Chloride -LiCl Complex 1.3M in THF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Iso Propyl Bromide in 4 to 5 hours and add Lithium Chloride maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels. Chemical reaction:
(CH3)2-(CH)-Cl + Mg + Li.Cl (CH3)2-(CH)- Mg -Br . LiCl IsoPropylChloride Magnesuim Lithium Chloride Iso Propyl Magnesium Chloride Li Cl M.W. :78.5 M.W. :24 M.W. :42.5 M.W. : 145 Mass Balance:
Input Kg Output Kg Iso Propyl Chloride 377 Iso Propyl Magnesuim Chloride 4428 Magnesium 115 Li Cl complex in THF Reaction Lithium Chloride 204 THF Solution 3732 Total 4428 Total 4428
3.10) Iso Propyl Magnesium Bromide 1M inTHF ManufacturingProcess: Take in a clean reactor under Nitrogen Blanketing required amount of THF. To THF add clean Magnesium turnings. Start stirring and raise the temperature to 55oC – 60oC. Add required amount of catalyst and add Iso propyl Bromide in 4 to 5 hours maintaining the temperature 55oC –60oC. Maintain for 2 hours check the quality if OK cool to 30oC and pack in 200 Lit MS PP lined barrels.
Chemical reaction:
CH3 CH3 CH-Br + Mg CH - Mg - Br
CH3 CH3 Iso Propyl Bromide Magnesuim Iso Propyl Magnesium Bromide M.W. : 123 M.W. :24 M.W. : 147 Mass Balance:
Input Kg Output Kg Iso Propyl Bromide 585 Iso Propyl Magnesuim Bromide 4510 Magnesium 114 Reaction in THF THF Solution 3811 Total 4510 Total 4510
4) Halogen ExchangeReactions
4.1) 1 Bromo 2 Chloro Ethane ManufacturingProcess: 1,2-Dibromo Ethane is taken in water containing (salt) Sodium Chloride. The mass is stirred for a given stipulated time. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 1 Bromo 2 Chloro Ethane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halide Exchange reaction for nextbatch. Chemical reaction:
Br-C2H4-Br + NaCl Br-C2H4-Cl + NaBr 1,2- DiBromo Ethane SoduimChloride 1 Bromo 2ChloroEthane Sodium Bromide M.W.:188 M.W.:58.5 M.W.:143.5 M.W. :103 Mass Balance: Input Kg Output Kg 1,2 - Di Bromo Ethane 3760 1 Bromo 2 Chloro-Ethane 2870 Soduim Chloride 1170 Reaction NaBr Solution (43%) 4790 Water 2730 Total 7660 Total 7660
1 Bromo 2 Chloro Ethane 2870 1 Bromo 2 Chloro Ethane 2850 Water Water 1000 Water to ETP 1020 Wash Total 3870 Total 3870
1 Bromo 2 Chloro Ethane 2850 Final Product 2540 Vacuum (Washed) Residue 310 Distillation Total 2850 Total 2850 4.2) 1 Bromo 4 Chloro Butane ManufacturingProcess: 1,4 Dibromo Butane is taken in water containing (salt) Sodium Chloride. The mass is stirred for a given stipulated time. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure.
Pure 1 Bromo 4 Chloro Butane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Br-C4H8-Br + NaCl Br-C4H8-Cl + NaBr 1,4- DiBromo Butane Soduim Chloride 1 Bromo 4 ChloroButane SodiumBromide M.W.:216 M.W. :58.5 M.W. : 171.5 M.W. : 103 Mass Balance:
Input Kg Output Kg 1,4 - Di Bromo Butane 3455 1 Bromo 4 Chloro-Butane 2740 Soduim Chloride 935 Reaction NaBr Solution (43%) 3830 Water 2180 Total 6570 Total 6570
1 Bromo 4 Chloro Butane 2740 1 Bromo 4 Chloro Butane 2700 Water Water 1000 Water to ETP 1040 Wash Total 3740 Total 3740
1 Bromo 4 Chloro Butane 2700 Final Product 2380 Vacuum (Washed) Residue 320 Distillation Total 2700 Total 2700
4.3) 1 Bromo 5 Chloro Pentane ManufacturingProcess: 1,5 Dibromo Pentane is taken in water containing (salt) Sodium Chloride. The mass is stirred for a give Stipulated time. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 1 Bromo 5 Chloro Pentane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Br-C5H10-Br + NaCl Br-C5H10-Cl + NaBr 1,5- DiBromo Pentane Soduim Chloride 1 Bromo 5 ChloroPentane SodiumBromide M.W.:230 M.W. :58.5 M.W. : 185.5 M.W. : 103 Mass Balance:
Input Kg Output Kg 1,5 - Di Bromo Pentane 3450 1 Bromo 5 Chloro - Pentane 2785 Soduim Chloride 880 Reaction NaBr Solution (43%) 3600 Water 2055 Total 6385 Total 6385
1 Bromo 5 Chloro Pentane 3385 1 Bromo 5 Chloro Pentane 3350 Water Water 1000 Water to ETP 1035 Wash Total 4385 Total 4385
1 Bromo 5 Chloro Pentane 3350 Final Product 3015 Vacuum (Washed) Residue 335 Distillation Total 3350 Total 3350
4.4) 1 Bromo 6 Chloro Hexane ManufacturingProcess: 1,6 Dibromo Hexane is taken in water containing (salt) Sodium Chloride. The mass is stirred for a given stipulated time. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 1 Bromo 6 Chloro Hexane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Br-C6H12-Br + NaCl Br-C6H12-Cl + NaBr 1,6- DiBromoHexane Sodium Chloride 1 Bromo 6 ChloroHexane SodiumBromide M.W.:244 M.W. :58.5 M.W. : 199.5 M.W. : 103 Mass Balance:
Input Kg Output Kg 1,6 - Di Bromo Hexane 3660 1 Bromo 6 Chloro -Hexane 2995 Soduim Chloride 880 Reaction NaBr Solution (43%) 3600 Water 2055 Total 6595 Total 6595
1 Bromo 6 Chloro Hexane 2995 1 Bromo 6 Chloro Hexane 2950 Water Water 1000 Water to ETP 1045 Wash Total 3995 Total 3995
1 Bromo 6 Chloro Hexane 2950 Final Product 2605 Vacuum (Washed) Residue 345 Distillation Total 2950 Total 2950
4.5) 1 Bromo 1 Fluoro Methane ManufacturingProcess: 1,1 Dibromo Methane is taken in water containing (salt) Sodium Fluoride. The mass is stirred for a given stipulated time. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 1 Bromo 1 Fluoro Methane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Br-CH2-Br + NaF Br-CH2-F + NaBr 1,1- Di Bromo Methane SoduimFluoride 1 Bromo 1 FluoroMethane SodiumBromide M.W. : 174 M.W.:42 M.W. :113 M.W. : 103 Mass Balance: Input Kg Output Kg 1,1 - Di Bromo Methane 6660 1 Bromo 1 Fluoro Methane 4325 Soduim Fluoride 1610 Reaction NaBr Solution (51 %) 7695 Water 3750 Total 12020 Total 12020
1 Bromo 1 Fluoro Methane 4325 1 Bromo 1 Fluoro Methane 4300 Water Water 1000 Water to ETP 1025 Wash Total 5325 Total 5325
1 Bromo 1 Fluoro Methane 4300 Vacuum Main Product 4040 (Washed) Distillati Residue 260 Total 4300 on Total 4300 4.6) Dibromo Methane ManufacturingProcess: Methylene Dichloride is taken in water containing (salt) Sodium Bromide. The mass is stirred for a given stipulated time. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure Methylene Dibromide thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Cl-CH2-Cl + 2 NaBr Br-CH2-Br + 2NaCl Methylene Di Chloride Sodium Bromide MethyleneDiBromide Soduim Chloride M.W. : 85 M.W. : 206 M.W.:174 M.W. :117 Mass Balance: Input Kg Output Kg Methylene Di Chloride 1470 Methylene Di Bromide 3007 Sodium Bromide 3560 Reaction NaCl Solution (20%) 10328 Water 8305 Total 13335 Total 13335
Methylene Di Bromide 3007 Methylene Di Bromide 2990 Water Water 1000 Water to ETP 1017 Wash Total 4007 Total 4007
Methylene Di Bromide 2990 Main Product 2800 Vacuum (Washed) Residue 190 Distillation Total 2990 Total 2990 4.7) Bromo Chloro Methane ManufacturingProcess: 1,1, Dibromo methane is taken in water containing salt (Sodium Chloride). The mass is stirred for a given Stipulated Time. Progress of reaction is monitored by GC, on achieving the desired result the mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 1 Bromo 1 Chloro Methane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Br-CH2-Br + NaCl Br-CH2-Cl + NaBr 1,1- Di Bromo Methane SoduimChloride 1 Bromo 1 ChloroMethane Sodium Bromide M.W. : 174 M.W. :58.5 M.W. :129.5 M.W. : 103 Mass Balance:
Input Kg Output Kg 1,1 - Di Bromo Methane 5220 1 Bromo 1 Chloro Methane 3885 Soduim Chloride 1755 Reaction NaBr Solution (43%) 7185 Water 4095 Total 11070 Total 11070
1Bromo1ChloroMethane 3885 1 Bromo 1 Chloro Methane 3870 Water Water 1000 Water to ETP 1015 Wash Total 4885 Total 4885
1Bromo1ChloroMethane 3870 Main Fraction 3585 Vacuum (Washed) Residue 285 Distillation Total 3870 Total 3870 4.8) Ethyl 5 Iodo Valerate ManufacturingProcess: 5-Bromo Valeric Acid Ethyl ester is taken in water containing (salt) Sodium Iodide. The mass is stirred at around 40oC to 55oC for 8 to 9 hours. Progress of reaction is monitored by GC, on achieving the desired result the reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 5-Iodo Valeric Acid Ethyl Ester thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
Br-CH2-CH2-CH2-CH2-COO-CH2-CH3 + NaI I-CH2-CH2-CH2-CH2-COO-CH2-CH3 + NaBr 5 Bromo Valeric AcidEthylEster SoduimIodide 5 Iodo Valeric Acid EthylEster Sodium Bromide M.W.:209 M.W.:150 M.W. :256 M.W. : 103 Mass Balance:
Input Kg Output Kg 5 Bromo Valeric Acid Ethyl Ester 3405 5 Iodo Valeric Acid Ethyl Ester 4170 Sodium Iodide 2445 Reaction NaBr Solution (23%) 7380 Water 5700 Total 11550 Total 11550
5 Iodo Valeric Acid Ethyl Ester 4170 5 Iodo Valeric Acid Ethyl Ester 4150 Water Water 2000 Water to ETP 2020 Wash Total 6170 Total 6170
5 Iodo Valeric Acid Ethyl Ester 4150 Main Fraction 3760 Vacuum (Washed) Residue 390 Distillation Total 4150 Total 4150
4.9) 2 Bromo HeptaFluoro Propane ManufacturingProcess: 1,2 Dibromo HexaFluoro Propane is taken in water containing salt (Potassium Fluoride). The mass is stirred for a given stipulated time. Progress of reaction is monitored by GC, on achieving the desired resultthe reaction mass is taken for Phaseseparation. Organic Phase containing desired halide is taken for fractionation under reducedpressure. Pure 2-Bromo HeptaFluoro Propane thus obtained is packed in 200 Kg HDPE Barrels; Intermediate fractions obtained from fractional distillation are again taken for Halogen Exchange reaction for nextbatch. Chemical reaction:
F F F F F F F - C - C - C-F + KF F - C - C - C-F + KBr
Br BrF F BrF 1,2 Dibromo HexaFluoroPropane Potassium Fluoride 2 Bromo HeptaFluoroPropane Potassium Bromide M.W. : 310 M.W. : 58 M.W, :249 M.W. : 119 Mass Balance:
Input Kg Output Kg 1,2 Dibromo HexaFluoro Propane 9085 2 Bromo HeptaFluoro Propane 7300 Reaction Potassium Fluoride (30%) 5665 Potassium Bromide (46%) 7450 Total 14750 Total 14750
2 Bromo HeptaFluoro Propane 7300 2 Bromo HeptaFluoro Propane 7285 Water Water 4000 Water to ETP 4015 Wash Total 11300 Total 11300
2 Bromo HeptaFluoro Propane 7285 Main Product 6600 Vacuum Residue 685 Distillation Total 7285 Total 7285
4.10) Methyl Allyl Bromide ManufacturingProcess: Sodium Bromide solution is taken in a glass lined reactor. 2Methylallylchloride is added and striied till reaction is complete On completion of reaction aqueous and organic layers separated. Aqueous layer is recycleed to next batch till Sodium Chloride reaches to saturation. After 3 recycles sent to ETP for Treatment. Organic layer after wash taken for distillation to get pure product. Recovered unreacted 2methylallylchloride is recycled to next batch. Chemical reaction:
CH3 CH3
CH2=C CH2Cl + NaBr CH2=C CH2Br + NaCl 2 Methyl allyl chloride Sod.Bromide 2 Methyl allyl bromide Sod Chloride MW 90.5 MW 103 MW 135 MW 58.5
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark 2 Methyl allyl chloride 905 10 Organic layer 1600 For water wash Sodiumbromide 1030 Reaction Aq Layer 1335 Recycle for 3 batches Water 1000 and then to ETP Total 2935 2935
Organic layer 1600 Organic layer 1580 For Distillation Water 500 Water Water 520 Recycle to next batch Wash Total 2100 Total 2100
Organic layer 1580 Finished Good 980 For sale Vacuum Unreacted Material 400 recycle to next batch Distillation Residue 200 Total 1580 Total 1580
5) Addition of Halogen and Halogen Acids across Double Bonds
5.1) 1,2 Di Bromo Ethane Manufacturing Process: Unsaturated Hydrocarbon such as Vinyl Bromide is taken in a Glass lined reactor. To this mass concentrated Hydro Bromic Acid is added over a given period of time. On Completion of addition of Hydro bromic Acid to the mass is maintained for a given stipulated time. The progress of reaction is monitored onGC. On Completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure Ethylene Dibromide thus obtained is packed in 200 Lit HDPE Barrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
CH2 = CH - Br + HBr Br - CH2- CH2- Br Vinyl Bromide Hydrogen Bromide 1,2 Di Bromo Ethane M.W. : 107 M.W. 81 M.W. : 188 Mass Balance: Input Kg Output Kg Vinyl Bromide 11020 1,2 Di Bromo Ethane 19365 Reaction Hydrogen Bromide 8345 Total 19365 Total 19365
1,2 Di Bromo Ethane 19365 1,2 Di Bromo Ethane 19300 Water Water 4000 Water to ETP 4065 Wash Total 23365 Total 23365
Final Product 17900 Vacuum 1,2 Di Bromo Ethane 19300 Residue 1400 Distillation Total 19300 Total 19300 5.2) Phenyl Ethyl Bromide ManufacturingProcess: Unsaturated Hydrocarbon such as Phenyl Ethene is taken in a Glass lined reactor. To this mass concentrated Hydro Bromic Acid is added over a given period oftime. On Completion of addition of Hydrobromic Acid the mass is maintained for a stipulated time. The progress of reaction is monitored onGC.
On Completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure Phenyl Ethyl Bromide thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
C6H5-CH=CH2 + HBr C6H5-CH2-CH2-Br PhenylEthene HydrobromicAcid Phenyl EthylBromide M.W.:104 M.W.:81 M.W. :185 Mass Balance: Input Kg Output Kg Phenyl Ethene 7500 Phenyl Ethyl Bromide 12480 Reaction Hydrobromic Acid 4980 Total 12480 Total 12480
Phenyl EthylBromide 12480 Phenyl Ethyl Bromide 12450 Water Water 4000 Water to ETP 4030 Wash Total 16480 Total 16480
Phenyl EthylBromide 12450 Main Fraction 11500 Vacuum Residue 950 Distillation Total 12450 Total 12450 5.3) 1 Bromo 3 Chloro Propane ManufacturingProcess: Unsaturated Hydrocarbon such as Allyl Chloride is taken in a Glass lined reactor. To this mass concentrated Hydrobromic Acid is added over a given period oftime. On Completion of addition of concentrated Hydrobromic Acid the mass is maintained for a stipulated time. The progress of reaction is monitored on GC. On Completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure 1 Bromo 3 Chloro Propane thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
CH2 = CH - CH2 - Cl + HBr Br - CH2- CH2- CH2 -Cl Allyl Chloride HydrogenBromide 1 Bromo 3 ChloroPropane M.W. : 76.5 M.W.81 M.W. :157.5 Mass Balance:
Input Kg Output Kg Allyl Chloride 7050 1Bromo3Chloropropane 14515 Reaction Hydrogen Bromide 7465 Total 14515 Total 14515
1Bromo3Chloropropane 14515 1Bromo3Chloropropane 14480 Water Water 4000 Water to ETP 4035 Wash Total 18515 Total 18515
Final Product 13235 Vacuum 1Bromo3Chloropropane 14480 Residue 1245 Distillation Total 14480 Total 14480
5.4) n-Hexyl Bromide ManufacturingProcess: Unsaturated Hydrocarbon such as n-Hexene is taken in a Glass lined reactor. To this mass concentrated Hydro Bromic Acid is added over a given period oftime. On completion of addition of Hydrobromic Acid the mass is maintained for a stipulated time. The progress of reaction is monitored onGC. On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure n-Hexyl Bromide thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
CH2 = CH - CH2-CH2-CH2-CH3 + HBr Br - CH2 - CH2 - CH2-CH2-CH2-CH3 n - Hexene Hydrogen Bromide n - Hexyl Bromide M.W. :84 M.W. 81 M.W. : 165 MassBalance:
Input Kg Output Kg n- Hexene 5385 n-Hexyl Bromide 10575 Reaction Hydrogen Bromide 5190 Total 10575 Total 10575
n - Hexyl Bromide 10575 n - Hexyl Bromide 10500 Water Water 4000 Water to ETP 4075 Wash Total 14575 Total 14575
n - Hexyl Bromide 10500 Main Product 9600 Vacuum Residue 900 Distillation Total 10500 Total 10500 5.5) n-Octyl Bromide ManufacturingProcess: Unsaturated Hydrocarbon such as n-Octene is taken in a Glass lined reactor. To this mass concentrated Hydro Bromic Acid is added over a given period oftime. On completion of addition of Hydrobromic Acid the mass is maintained for a stipulated time. The progress of reaction is monitored onGC. On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure n-Octyl Bromide thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
CH2=CH-CH2-CH2-CH2-CH2-CH2-CH3 + HBr Br-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH3 n -Octene Hydrogen Bromide n - Octyl Bromide M.W. :112 M.W. 81 M.W. : 193 Mass Balance:
Input Kg Output Kg n- Octene 6000 n-Octyl Bromide 10340 Reaction Hydrogen Bromide 4340 Total 10340 Total 10340
n - Octyl Bromide 10340 n - Octyl Bromide 10300 Water Water 4000 Water to ETP 4040 Wash Total 14340 Total 14340
n - Octyl Bromide 10300 Main Product 9400 Vacuum Residue 900 Distillation Total 10300 Total 10300
5.6) n-Decyl Bromide ManufacturingProcess: Unsaturated Hydrocarbon such as n-Decene is taken in a Glass lined reactor. To this mass concentrated Hydro Bromic Acid is added for a given period oftime. On completion of addition of Hydrobromic Acid the mass is maintained for a stipulated time. The progress of reaction is monitored onGC. On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure n-Decyl Bromide thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
CH2=CH-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH3 + HBr Br-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH2-CH3 n-Decene HydrogenBromide n - DecylBromide M.W.:140 M.W.81 M.W. :221 Mass Balance: Input Kg Output Kg n- Decene 6300 n-Decyl Bromide 9945 Reaction Hydrogen Bromide 3645 Total 9945 Total 9945
n - Decyl Bromide 9945 n - Decyl Bromide 9930 Water Water 4000 Water to ETP 4015 Wash Total 13945 Total 13945
n - Decyl Bromide 9930 Main Product 9100 Vacuum Residue 830 Distillation Total 9930 Total 9930 5.7) Cyclo Pentyl Bromide ManufacturingProcess: Unsaturated Hydrocarbon such as Cyclo Pentene is taken in a Glass lined reactor. To this mass concentrated Hydrobromic Acid is added over a given period oftime. On completion of addition of concentrated Hydrobromic Acid the mass is maintained for a stipulated time. The progress of reaction is monitored on GC.
On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure Cyclo pentyl Bromide thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the HydrobromicAcid. Chemical reaction:
+ HBr Br CycloPentene HydrobromicAcid Cyclo Pentyl Bromide M.W.:68 M.W.:81 M.W. :149 Mass Balance: Input Kg Output Kg Cyclo Pentene 3500 Cyclo Pentyl Bromide 7670 Hydrobromic Acid 4170 Reaction Cyclo Pentane 2950 Cyclo Pentane 2950 Total 10620 Total 10620
Cyclo Pentyl Bromide 7670 Cyclo Pentyl Bromide 7650 Water Water 3000 Water to ETP 3020 Wash Total 10670 Total 10670
Cyclo Pentyl Bromide 7650 Main Product 7050 Vacuum Residue 600 Distillation Total 7650 Total 7650 5.8) Cyclo Pentyl Chloride ManufacturingProcess: Unsaturated Hydrocarbon such as Cyclo Pentene is taken in a Glass lined reactor. To this mass concentrated Hydrochloric Acid is added over a given period oftime. On completion of addition of concentrated Hydrochloric Acid the mass is maintained for a stipulated time. The progress of reaction is monitored on GC. On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure Cyclo pentyl Chloride thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the Hydrochloric Acid. Chemical reaction:
+ HCl Cl CycloPentene HydrochloricAcid Cyclo Pentyl Chloride M.W.:68 M.W.:36.5 M.W. :104.5 Mass Balance:
Input Kg Output Kg Cyclo Pentene 3500 Cyclo Pentyl Chloride 5375 Hydrochloric Acid 1875 Reaction Cyclo Pentane 3000 Cyclo Pentane 3000 Total 8375 Total 8375
Cyclo Pentyl Chloride 5375 Cyclo pentyl Chloride 5355 Water Water 2000 Water to ETP 2020 Wash Total 7375 Total 7375
Cyclo Pentyl Chloride 5355 Main Product 4915 Vacuum Residue 440 Distillation Total 5355 Total 5355
5.9) 1,2 Dibromo 3 Chloro propane ManufacturingProcess: Unsaturated Hydrocarbon such as 2,3 Dibromo Propene is taken in a Glass lined reactor. To this mass concentrated Hydrochloric Acid is added for a given Period oftime. On completion of addition of Hydrochloric Acid the mass is maintained for a given stipulated time. The progress of reaction is monitored onGC. On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure 1,2 Dibromo 3 Chloro propane thus obtained is packed in 200 Lit HDPEBarrels. Alternatively this material can be packed in smaller packing such as 50 Lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the Hydrochloric Acid. Chemical reaction:
CH2=C(Br)-CH2-Br + HCl Cl-CH2-CH(Br)-CH2-Br 2,3 DiBromo Propene Hydrochloric Acid 1,2 Di Bromo 3 Chloro Propane M.W. : 200 M.W. 36.5 M.W. : 236.5 Mass Balance:
Input Kg Output Kg 2,3 Di Brome Propene 15840 1,2 Di Bromo 3 Chloro Propane 18730 Reaction Hydrochloric Acid 2890 Total 18730 Total 18730
1,2 Di Bromo 3 ChloroPropane 18730 1,2 Di Bromo 3 Chloro Propane 18700 Water Water 4500 Water to ETP 4530 Wash Total 23230 Total 23230
Final Product 17100 Vacuum 1,2 Di Bromo 3 ChloroPropane 18700 Residue 1600 Distillation Total 18700 Total 18700
5.10) 1,2 Dibromo HexaFluoro Propane ManufacturingProcess: Unsaturated Hydrocarbon such as HexaFluoro Propane is taken in a Glass lined reactor. To this mass Liquid Bromine is added for a given Period of time. On completion of addition of Bromine the mass is maintained for a given stipulated time. The progress of reaction is monitored onGC. On completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure 1,2 Dibromo HexaFluoro propane thus obtained is packed in 200 Lit HDPEBarrels. Chemical reaction:
F2C=CF-CF3 + Br2 (Br)F2C-CF(Br)-CF3 HexaFluoro Propene Bromine 1,2 Dibromo HexaFluoro Propane M.W. : 150 M.W. 160 M.W. : 310 Mass Balance:
Input Kg Output Kg HexaFluoro Propane 8770 1,2 Dibromo HexaFluoro Propane 18125 Reaction Bromine 9355 Total 18125 Total 18125
1,2 Dibromo hexaFluoro Propane 18125 1,2 Di Bromo HexaFluoro Propane 18100 Water Water 5000 Water to ETP 2025 Wash Total 23125 Total 20125
1,2 Di Bromo HexaFluoro Propane 18100 Main Product 16850 Vacuum Residue 1250 Distillation Total 18100 Total 18100
5.11. 1,4 Di Bromo-2-butene
ManufacturingProcess:
Bromine is taken in glass lined reactor. Butadiene slowly added to Bromine till entire Bromine is reacted. Product is distilled under vacuum after water wash.
Chemical reaction: MDC
CH2 = CH - CH = CH2 + Br2 Br - CH2- CH = CH - CH2- Br 1,3 Butadiene Bromine 1,4 Dibromo-2-butene M.W. : 54 MW 160 MW 214 Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark 1,3 Butadiene 1080 20 Organic mass 4280 For Washings Bromine 3200 Reaction
Total 4280 Total 4280
Organic mass 4280 Organic mass 4200 For Distillation Water 500 Water Water 580 For recycle to next batch, after 5 batches Wash send to ETP Total 4780 Total 4780
Organic mass 4200 Finished good 4080 For packing and sale Vacuum Distillation Residue 120 For incineration Total 4200 4200
5.12. 1,1 Di Bromo 3 Chloro Propane
ManufacturingProcess
Unsaturated Hydrocarbon such as 1- Bromo 3 Chloro Propene is taken in a Glass lined reactor. To this mass concentrated Hydrobromic Acid is added for a given Period of time.
On Completion of addition of Hydrobromic Acid the mass is maintanied for a given Stipulated time. The progress of reaction is monitered on GC.
On Completion of reaction Organic and aqueous layers are separated. Organic phase is taken for fractionation. Pure 1,1 Dibromo 3 Chloro propane thus obtained is packed in 200 Lit HDPE Barrels.
Alternatively this material can be packed in smaller packing such as 50 lit / 100 Lit carboys or drums. Aqueous layer is taken for next batch to recycle the Hydrochloric Acid. Chemical reaction:
Mass Balance:
Input Kg Kmol Output Kg 1-Bromo-3-Chloropropene 8420 54 1,1 Di Bromo 3 Chloro Propane 12820 Hydrobromic Acid 4400 54 Reaction
Total 12820 Total 12820
1,1 Di Bromo 3 Chloro Propane 12820 1,1 Di Bromo 3 Chloro Propane 12800 Water 4000 Water 4020 Water Wash
Total 16820 Total 16820
LB Impurities 150 1,1 Di Bromo 3 Chloro Propane 12800 Vacuum Main Fraction 12000 Distillation Residue 650 Total 12800 12800
6) Bromination or Chlorination of Cyclic and Aromatic Compounds with or Without FunctionalGroups
6.1) Bromo Benzene ManufacturingProcess: Benzene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted Benzene content is less than 1% Bromine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Bromo Benzene thus obtained is packed in 200 litDrums. Chemical reaction: Br
+ Br2 + HBr
Benzene Bromine Bromo Benzene Hydrobromic Acid M.W. : 78 M.W. : 160 M.W. : 157 M.W. : 81 Mass Balance:
Input Kg Output Kg Benzene 3285 Bromo Benzene 6610 Bromine 6730 Reaction HBr (48%) 7085 Water 3680 Total 13695 Total 13695
Bromo Benzene 6610 Bromo Benzene 6550 Water 2000 Washing Water Washings to ETP 2060 Total 8610 Total 8610
Bromo Benzene 6550 Final Product 6020 Vacuum (Washed) Residue 530 Distillation Total 6550 Total 6550
6.2) Di Bromo Benzene ManufacturingProcess:
Benzene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted Benzene content is less than 1% Bromine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Di Bromo Benzene thus obtained is packed in 200 litDrums. Chemical reaction: Br
+ 2Br2 + 2HBr Br Benzene Bromine p Di Bromo Benzene HydrobromicAcid M.W.:78 M.W.:320 M.W.:236 M.W. : 162 Mass Balance: Input Kg Output Kg Benzene 1950 p DiBromo Benzene 5870 Bromine 7960 Reaction HBr (48%) 8440 Water 4400 Total 14310 Total 14310
p Di Bromo Benzene 5870 p Di Bromo Benzene 5850 Water 3000 Washing Water Washings-ETP 3020 Total 8870 Total 8870
p Di Bromo Benzene 5850 Main Product 5350 Vacuum (Washed) Residue 500 Distillation Total 5850 Total 5850 6.3) Ethyl (4 Bromo methyl) Benzoate ManufacturingProcess: 4-Methyl Benzoic acid is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted 4-Methyl Benzoic acid content is less than 1% Bromine addition is stopped and reacted with Ethanol to get Ethyl 4 Bromo Methyl Benzoate.
The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure Ethyl 4 Bromo Methyl Benzoate thus obtained is packed in 200 litDrums. Chemical reaction:
COOH COOH
+ Br2 + HBr
CH3 CH2-Br 4 Methyl Benzoic Acid Bromine 4 Bromo MethylBenzoicAcid Hydrogen Bromide M.W. : 136 M.W. : 160 M.W.:215 M.W. :81
COOH COO - CH2 -CH3
+ CH3 - CH2-OH + H2O
CH2-Br CH2-Br 4BromoMethylBenzoicAcid Ethanol Ethyl 4 BromoMethylBenzoate Water M.W. : 215 M.W. : 46 M.W.:243 M.W. :18 Mass Balance:
Input Kg Output Kg 4 Methyl Benzoic Acid 7500 Ethyl 4 Bromo Methyl Benzoate 13400 Bromine 8825 HBr (48%) 9310 Reaction Ethanol 2540 Water 3845 Total 22710 Total 22710
Ethyl 4 Bromo Methyl Benzoate 13400 Ethyl 4 Bromo Methyl Benzoate 13350 Water 4000 Washing Water Washings to ETP 4050 Total 17400 Total 17400
Ethyl 4 Bromo Methyl Benzoate 13350 Main Product 12165 Vacuum (Washed) Residue 1185 Distillation Total 13350 Total 13350
6.4) 1 Bromo 4 Chloro Benzene ManufacturingProcess: Chloro Benzene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC.
When unreacted Chloro Benzene content is less than 1% Bromine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1 Bromo 4 Chloro Benzene thus obtained is packed in 200 litDrums. Chemical reaction: Cl Br
+ Br2 + HBr Cl ChloroBenzene Bromine 1 Bromo 4Chloro Benzene Hydrobromic Acid M.W.:112.5 M.W.:160 M.W.:191.5 M.W. : 81 Mass Balance:
Input Kg Output Kg Chloro Benzene 4450 1 Bromo 4 Chloro Benzene 7575 Bromine 6330 Reaction HBr (48%) 6675 Water 3470 Total 14250 Total 14250
1 Bromo 4 Chloro Benzene 7575 1 Bromo 4 Chloro Benzene 7550 Water 3000 Washing Water Washings to ETP 3025 Total 10575 Total 10575
1 Bromo 4 Chloro Benzene 7550 Final Product 6950 Vacuum (Washed) Residue 600 Distillation Total 7550 Total 7550
6.5) p Bromo Toluene ManufacturingProcess: Toluene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted Toluene content is less than 1% Bromine additionis stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch.
Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 4 Bromo Toluene thus obtained is packed in 200 litDrums. Chemical reaction:
CH3 CH3
+ Br2 + HBr Br
Toluene Bromine 4 -Bromo Toluene Hydrobromic Acid M.W. : 92 M.W. : 160 M.W. : 171 M.W. : 81 Mass Balance:
Input Kg Output Kg Toluene 6940 4 Bromo Toluene 5310 Bromine 4970 Reaction Unreacted Toluene 4085 Water 2725 HBr (48%) 5240 Total 14635 Total 14635
4 Bromo Toluene 9395 4 Bromo Toluene 9350 Water 3000 Washing Water Washings to ETP 3045 Total 12395 Total 12395
Dist Toluene 3900 4 Bromo Toluene 9350 Vacuum Final Product 5290 (Washed) Distillation Residue 160 Total 9350 Total 9350 6.6) 4 Bromo O-Xylene ManufacturingProcess: O-Xylene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted O-Xylene content is less than 1% Bromine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 4 Bromo O- Xylene thus obtained is packed in 200 litDrums. Chemical reaction:
CH3 CH3
CH3 + Br2 CH3 + HBr
Br O - Xylene Bromine 4 -Bromo O - Xylene Hydrobromic Acid M.W. :106 M.W. : 160 M.W. : 185 M.W. : 81 Mass Balance:
Input Kg Output Kg O - Xylene 5900 4 Bromo O Xylene 10295 Bromine 8905 Reaction HBr (48%) 9390 Water 4880 Total 19685 Total 19685
4 Bromo O Xylene 10295 4 Bromo O Xylene 10250 Water 3000 Washing Water Washings 3045 Total 13295 Total 13295
4 Bromo O Xylene 10250 Vacuum Main Product 9410 (Washed) Distillati Residue 840 Total 10250 on Total 10250 6.7) 2 Chloro 1,4Naphthaquinone ManufacturingProcess: 1,4 Naphthaquinone is taken in a Reactor. To this Liquid Chlorine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted 1,4 Naphthaquinone content is less than 1% Chlorine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 2 Chloro 1,4 naphthaquinone thus obtained is packed in 200 litDrums. Chemical reaction: O O Cl
+ Cl2 + HCl O O 1,4Naphthoquinone Chlorine 2 Chloro1,4 Naphthoquinone Hydrochloric Acid M.W.:158 M.W. :71 M.W. : 192.5 M.W. : 36.5
Mass Balance:
Input Kg Output Kg 1,4 Naphthaquinone 8745 2Chloro1,4Naphthoquinone 10655 Chlorine 3930 Reaction HCl (30%) 4210 Water 2190 Total 14865 Total 14865
2 Chloro 1,4 Naphthoquinone 10655 2Chloro1,4Naphthoquinone 10600 Water 4000 Washing Water Washings to ETP 4055 Total 14655 Total 14655
2 Chloro 1,4 Naphthoquinone 10600 Final Product 9750 Vacuum (Washed) Residue 850 Distillation Total 10600 Total 10600
6.8) 1 Bromo 4 FluoroBenzene ManufacturingProcess: Fluoro Benzene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted Fluoro Benzene content is less than 1% Bromine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1 Bromo 4 Fluoro benzene thus obtained is packed in 200 litDrums. Chemical reaction: F Br
+ Br2 + HBr F
Fluoro Benzene Bromine 1 Bromo 4 Fluoro Benzene Hydrobromic Acid M.W. : 96 M.W. : 160 M.W. : 175 M.W. : 81 Mass Balance:
Input Kg Output Kg Fluoro Benzene 3850 1 Bromo 4 Fluoro Benzene 7020 Bromine 6415 Reaction HBr (48%) 6765 Water 3520 Total 13785 Total 13785
1 Bromo 4 Fluoro Benzene 7020 1 Bromo 4 Fluoro Benzene 7000 Water 3000 Washing Water Washings to ETP 3020 Total 10020 Total 10020
1 Bromo 4 Fluoro Benzene 7000 Final Product 6450 Vacuum (Washed) Residue 550 Distillation Total 7000 Total 7000
6.9) 4 Bromo methyl 2 Cyano biphenyl (Bromo OTBN) ManufacturingProcess: 4 Methyl 2 Cyanobiphenyl is Brominated in Presence of Hydrogen Peroxide to get 4 Bromo Methyl 2Cyanobiphenyl. The 4-Bromo Methyl Biphenyl is given Ethyl Acetate washings and subjected to Drying. 4 Bromo Methyl Biphenyl is then packed in 50 Kg PPEBags. Chemical reaction:
CH3+ Br2 + H2O2 CH2Br +H2O CN CN OTBN Bromine Hydrogen Peroxide 4 bromomethyl2Cyanobiphenyl Water M.W.:193 M.W. :160 M.W. : 34 M.W.:272 M.W. : 18 Mass Balance:
Input Kg Output Kg OTBN 500 4 Bromomethyl 2 Cyanobiphenyl 825 Bromine 250 (Bromo OTBN) Methylene Dichloride 3250 Methylene Dichloride 3250 Reaction Hydrogen peroxide (30%) 410 Water 1335 Water 1000 Total 5410 Total 5410
4 Bromomethyl 2 Cyanobiphenyl 4075 4 Bromomethyl 2 Cyanobiphenyl 650 (Bromo OTBN) + MDC Solvent Methylene Dichloride 3240 Recovery Residue 185 Total 4075 Total 4075
4 Bromomethyl 2 Cyanobiphenyl 650 4 Bromomethyl 2 Cyanobiphenyl 600 Ethyl (Bromo OTBN) Rec. Ethyl Acetate 1240 Acetate Ethyl Acetate 1250 Residue 60 Total 1900 Washings Total 1900
4 Bromomethyl 2 Cyanobiphenyl 600 4 Bromomethyl 2 Cyanobiphenyl 550 (Bromo OTBN) (Bromo OTBN) Drying Moisture 50 Total 600 Total 600
Ethyl Acetate 1240 Ethyl Ethyl Acetate 1210 Acetate Residue 30 Total 1240 Recovery Total 1240
6.10) 1 Bromo 3,4 Dichloro Benzene ManufacturingProcess: 1,2 Dichloro Benzene is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analyzed for completion of reaction onGC. When unreacted 1,2 Dichloro Benzene content is less than 1% Bromine addition is stopped and taken for Waterwashing. The Organic is taken in to the Glass lined reactor and water is added. This mass was stirred at room temperature for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to nextBatch. Organic Layer is then taken for Fractionation after removal of Low Boiler Impurities under Vacuum, the Product is fractionated. Pure 1 Bromo 3,4 Dichloro Benzene thus obtained is packed in 200 litDrums. Chemical reaction:
Cl Br Cl
+ Br2 Cl + HBr Cl 1,2DichloroBenzene Bromine 1 Bromo 3,4 Dichloro Benzene HydrobromicAcid M.W.:147 M.W.:160 M.W.:226 M.W. :81 Mass Balance:
Input Kg Output Kg 1,2 Dichloro Benzene 5720 1 Bromo 3,4 Dichloro Benzene 8795 Bromine 6225 Reaction HBr (48%) 6565 Water 3415 Total 15360 Total 15360
1 Bromo 3,4 DichloroBenzene 8795 1 Bromo 3,4 Dichloro Benzene 8750 Water 3000 Washing Water Washings to ETP 3045 Total 11795 Total 11795
1 Bromo 3,4 DichloroBenzene 8750 Final Product 7980 Vacuum (Washed) Residue 770 Distillation Total 8750 Total 8750
6.11) Decabromo diphenyl ethane (DECA-DPE)
ManufacturingProcess: S Diphenyl ethane is taken in a Reactor. To this Liquid Bromine is added or a given period of time after addition of required amount of Bromine the mass is analysed for completion of reaction on GC. When unreacted Diphenyl ethane content is less than 1 % Bromine addition is stopped and taken for Water washing The Organic is taken in to the Glass lined reactor and water is added. Organic Layer is then taken for Fractionation after removal of Low Boiler Impuritries under Vacuum, the Product is fractionated. Pure DECA - DPE thus obtained is packed in 200 for about 30 mins. Organic layer taken for Purification and Aqueous layer is recycled to next Batch.
Chemical reaction:
CH2 CH2 Br Br
+ 10 Br2 Br CH2CH2 Br + 10HBr
Br Br Br Br Br Br Diphenyl ethane Bromine Decabromo diphenyl ethane (DECA-DPE) Hydrobromic Acid M.W. : 182.7 M.W. : 160 M.W. : 971 M.W. : 81
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark Diphenyl ethane 1000 5.47 DECA-DPE CRUDE 5547 for Purification EDC 3450 HBr (48%) 5503 for Bromination / Sale Reaction Bromine 5000 EDC Recovered 3400 Water 5000 Total 14450 Total 14450
DECA-DPE CRUDE 5547 Pure DECA-DPE 5000 5.15 for Distillation Vac Residue 547 For incineration Distillation Total 5547 Total 5547
6.12) Tri Bromo Phenol
ManufacturingProcess: Bromine is added to Phenol , HBr thus generated is scrubbed in water to get 48% HBr. Crude after scrubbing HBr is taken for Distillation , Moiten Tribromo Phenol is flaked using flaker
Chemical reaction:
OH Br Br 3Br2 3HBr Br Phenol MW 94 Bromine 160 Tri Bromo Phenol 331 MW81 480 243
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Phenol 1144 12.17 Crude 3792 for Purification Bromine 5362 Reactio 48% HBr 5654 for Bromination / Sale Water 2940 n
Total 9446 Total 9446
Crude Tri Bromo Phenol 3792 Finished product 3630 10.96677 for Distillation Vac Residue 162 For incineration Distillati on 3792
6.13) 1Bromo 2,4 diflouro benzene
ManufacturingProcess: Brominr is added to Di flouro benzene and MDC Mixture , HBr thus generated is scrubbed in water to get 48% HBr. Crude Di Flouro Bromophenol is taken for Distillation ,di flouro bromo benzene is collected after fractionation.
Chemical reaction:
Br F F Br2 MDC HBr F F 1,3 Diflourobenzene Bromine 160 1 Bromo 2,4 di flouro benzene MW 193 MW 81 MW 114 Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark 1,3 diflouro benzene 1363 10.04 Crude product 5337 for Distillation Bromine 1600 48% HBr 1681 for Bromination / Sale Reaction MDC 3000 Water for HBr 1055 Total 7018 Total 7018
Crude product 5337 Finished product 1723 Finished Good Vac Distilled MDC 2800 Recycle to next batch Distillation Residue 814 For incineration Total 5337 5337
6.14) 4 Bromo Benzyl bromide
ManufacturingProcess: Bromine is added to Bromotoluene, H2O2 and MDC Mixture , On completion of reaction mass is taken forMDC recovery. Crude product obtained after MDC recovery is flurried with IPA , mass is cooled and filtered Solid is dried and packed. Mother liquor is taken for IPA recovery
Chemical reaction:
Br
2 Br2 H2O2 MDC 2 2H2O
Br Br 4 Bromo toluene MW 160 MW 34 4 Bromo Benzyl bromide MW 250 MW18 MW 171 171 X 2 =342 250 X 2 = 500 18 X 2 =36
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Benzyl bromide 510 3.00 Organic mass 3988 for Distillation Bromine 480 Water layer 219 To ETP Reaction H2O2 217 MDC 3000 Total 4207 Total 4207
Organic mass 3988 Crude mass 1188 For reslurry with IPA MDC Distilled MDC 2800 Recycle to next batch recovery Total 3988 3988
Crude mass 1188 Finished good 680 Finished good IPA 3000 IPA slurry & Mother liquor 3508 to recover IPA filtration Total 4188 4188
Mother liquor 3508 IPA 2800 Recycle to next batch Residue 708 For incineration IPA recovery Total 3508 3508
6.15) 2Bromo 4 flouro Aniline
ManufacturingProcess: 4 Flouro aniline is taken MDC along with Sod perborate and catalyst. Bromine is added at reflux , when recation is complete water is added. Aqueous and organic layers separated, Organic layer washed with water and taken for MDC recovery and distillation of 2 bromo 4 flouro aniline
Chemical reaction:
NH2
NH2 Br
HO O - O OH MoO3 2 NaHBO3 + 2H2O Na B B Na + Br2 MDC HO O - O OH KBr F F 4 Flouro aniline MW 111 Sod Per Borate MW 188 Bromine MW 160 (80) 2 Bromo 4 flouroaniline MW 190 Sod Hydrogen Borate 77 (154) MW 36 Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark 4 Flouroaniline 1110 10.00 Organic layer 3900 For washing Sod per borate 1880 Aqueous layer 2890 For sale to recover Sod Borate Step 1 Bromine 800 Reaction MDC 2000 Water for salt 1000 6790 6790
Organic layer 3900 Organic Layer 3850 For distillation Water 500 Aq layer 550 For ETP Washing
Total 4400 4400 *After 5 batches all awashings are combined and taken for water distillation , residue is incinerated
Organic layer 3850 Finished Good 1520 Finished Good Vac MDC recovered 1600 Recycle to next batch Distillation Residue 730 Incineration Total 3850 Total 3850 6.16) 4 Nitrobenzyl Bromide
ManufacturingProcess: Bromine is added to mixture of nitrotoluene and hydrogen peroxide in MDC. On completion of reaction MDC is distilled out and kept ready to recycle for next batch. To the , crude mass IPA is added cooled and filtered to get finished product. Mother liquor is taken for IPA recovery.
Chemical reaction:
Br MDC 2 Br2 H202 2 2H20
NO2 NO2 4 nitro toluene MW 137 MW 160 MW 34 4 nitro benzyl bromide 216 MW36 137 X 2 = 274 216 X2 = 432
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark 4 nitro toluene 1670 12.19 Organic layer 5682 For MDC recivery step 2 MDC 3000 Step 1 Water 219 to ETP H202 207 Reaction Bromine 1024 Total 5901 5901
Organic layer 5682 Crude mass 2982 For slurry in IPA MDC 2700 Recycle in next batch Step 2 MDC Recovery 5682 5682
Crude mass 2982 Finished good 2295 10.63 Finished good IPA slurry IPA 3000 Mother liquor 3687 To recover IPA & filtration Total 5982 5982
Mother liquor 3687 IPA 2800 Recycle to next batch IPA Residue 887 For incineration recovery 3687 3687
6.17) Deca Bromo Diphenyl Oxide
ManufacturingProcess: Bromine is added to MDC and diphenyl oxide mixture on completion of reaction taken for filtration. Slurry of product in MDC is filtered , Wet material is dried at 60 C and packed. MDC is taken for distillation , recovered MDC is taken for next batch and residue is taken for incineration.
Chemical reaction:
Br Br O MDC Br O Br 10 Br2 10HBr Br Br Br Br Br Br 1,2 Diphenyl Oxide MW 170 160 X 10 = 1600 Deca Bromo Diphenyl Oxide MW 960 MW 810
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark Di phenyl Oxide 510 3.00 Organic mass 5880 Water washing and MDC recovery MDC 3000 Step 1 48% HBr 5062 For bromination or sale Bromine 4800 Reaction Water for HBr 2632 Total 10942 10942
Organic mass 5880 wet mass 2680 Wet material Mother liquor 3200 For MDC recovery Step 2 Filtration
5880 5880
Wet solid 2680 Dried solid 2580 2.69 Finished good Loss on drying 100 Loss Drying 2680 Total 2680
Mother liquor 3200 MDC 2700 Recycle to next batch MDC Residue 500 For incineration recovery 3200 3200
6.18) 4 Bromo Phenol
Manufacturing Process: Bromine is added to Phenol on completion of reaction taken for distillation Distillation is carried at reduced pressure to get Finished product. HBr generated is scrubbed in water to get 48% HBr.
Chemical reaction:
OH OH
Br2 HBr
Br Pheno MW 94 Bromine MW 160 4 Bromo Anisol MW 173 Hydrobromic acid MW 81
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Phenol 1880 20.00 Organic mass 3460 For distillation Bromine 3200 Step 1 48% HBr 3375 For bromination or sale Water for HBr 1755 Reaction
Total 6835 6835
Organic mass 3460 Finished product 3120 18.03 Packed for sale Residue 340 For incineration Step 2 Distillation
3460 3460 6.19) 4 Bromo Anisole
ManufacturingProcess: Bromine is added to Anisol on completion of reaction mass taken for distillation. Distillation is carried at reduced pressure to get Finished product. HBr generated is scrubbed in water to get 48% HBr .
Chemical reaction:
OCH3 OCH3
Br2 HBr
Br Anisol MW 108 Bromine MW 160 4 Bromo Anisol MW 187 Hydrobromic acid MW 81
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark Anisol 2160 20.00 Organic mass 3740 For distillation Bromine 3200 Step 1 48% HBr 3375 For bromination or sale Water for HBr 1755 Reaction
Total 7115 7115
Organic mass 3740 Finished product 3380 18.07 Packed for sale Residue 360 For incineration Step 2 Distillation
3740 3740
6.20) TBBA DGE ( Tetra Bromo Bisphenol A Di Glycidyl Ester )
ManufacturingProcess:
Tetrabromo bisphenol is taken in Toluene and alkali. Epichlorohydrin is added to the mixture of Toluene and bisphenol mixture containing Sodium Hydroxide. Mass is refluxed till reaction is complete. On completion of reaction organic and aqueous layers are separated. Oragnic layer is cooled solids filtered and dried. Mother liquor is taken for toluene recovery, residue obtained after toluene recovery is taken for incineration
Chemical reaction:
Br Br Br Br Cl NaOH HO OH + 2 O O + 2NaCl +2H2O O O O Br Br Toluene Br Br
C15H12Br4O2 C3H5ClO C21H20Br4O4 543.87 92.52 656.0 79-94-7 106-89-8 40039-93-8
Tetrabromobisphenol A Epichlorohydrin Tetra bromo Bisphenol A Diglycidyl Ester
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Tetrabromobisphenol A 2720 5.00 Organic mass 6645 For distillation Toluene 3000 Aqueous layer 2388 For water recovery Step 1 Epichlorohydrin 925 Reaction Sodium Hydroxide 45% 888 Water 1500 Total 9033 9033
Organic mass 6645 Wet cake 3310 Taken for drying Step 2 Mother liquor 3335 Tkaen for Toluene recovery Crystallizati on and filtration. 6645 6645
Wet cake 3310 Dried solid 2900 4.42 Finished good Loss on drying 410 Loss Drying 3310 Total 3310
Mother liquor 3335 Toluene 2820 Recycle to next batch MDC Residue 515 For incineration recovery 3335 3335
Aqueous layer 2388 Water 1500 Recycle to next batch MDC Wet salt 1388 Residue for incineration recovery 2388 2888
6.21) Tetrabromophthalicanhydride
ManufacturingProcess: Phthalic anhydride is taken in 65% Oleum Bromine is added and kept at 40 -45 C till completion of reaction. Sulphur dioxide is scrubbed in NaOH. Mass is drowned in chilled water Solid washed with water and dried at 60 C. Aqueous layer + washings are neutralized to pH 7.0 and sent for recovery of Sodium Sulphate. Chemical reaction:
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Phthalic anhydride 450 3.04 Reaction mass 2528 For distillation Bromine 973 Sod bisuphite solution 2520 For sale Step 1 Oleum 1350 Reaction 45% Caustic soda lye 275 Water 2000 Total 5048
Reaction mass 2528 Wet cake 1400 Taken for drying Chilled water 3000 Step 2 Mother liquor 4628 Tkaen for neutralization Water for washing 500 Drowning and filtration 6028 6028
Wet cake 1400 Dried solid 1180 2.54 Finished good Loss on drying 220 Loss Drying Total 1400
Mother liquor 4628 27-32% Na2SO4 soln 11739 For Sodium sulphate recovery 45% Caustic lye 2311 Neutraliza Water 4800 tion Total 11739 11739
7) Dehydro-halogenation of Organic Halides Optionally with or without functional Group
7.1) Vinyl Bromide ManufacturingProcess: Take 1,2 Dibromo Ethane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated Vinyl Bromide is packed in 200 Lit HDPEBarrels. Chemical reaction:
Br - (CH2)2 - Br + NaOH Br-CH=CH2 + NaBr + H2O 1,2 - Di Bromo Ethane Sodium Hydroxide VinylBromide SodiumBromide Water M.W. : 188 M.W. : 40 M.W.:107 M.W.:103 M.W. :18 Mass Balance:
Input Kg Output Kg 1,2 DiBromo Ethane 3760 Vinyl Bromide 2140 NaOH 800 Sodium Bromide (48%) 4285 Reaction Water 1865 Methanol 400 Methanol 400 Total 6825 Total 6825
Vinyl Bromide 2140 Vinyl Bromide 2100 Water Water 1000 Water to ETP 1040 Wash Total 3140 Total 3140
Vinyl Bromide 2100 Main Product 2020 (Washed) Distillation Residue 80 Total 2100 Total 2100
7.2) Vinyl Bromide in THF 25% ManufacturingProcess: Take 1,2 Dibromo Ethane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer.
Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated Vinyl Bromide is packed in 200 Lit HDPEBarrels. Chemical reaction:
Br - (CH2)2 - Br + NaOH Br-CH=CH2 + NaBr + H2O 1,2 - Di Bromo Ethane Sodium Hydroxide VinylBromide SodiumBromide Water M.W. : 188 M.W. : 40 M.W.:107 M.W.:103 M.W. :18 Mass Balance:
Input Kg Output Kg 1,2 DiBromo Ethane 3420 Vinyl Bromide in THF25% 2597 NaOH 730 Sodium Bromide (48%) 3903 Water 1700 Reaction Methanol 365 Methanol 365 THF 650 Total 6865 Total 6865
Vinyl Bromide in THF 25% 2597 Vinyl Bromide in THF25% 2580 Water Water 1000 Water to ETP 1017 Wash Total 3597 Total 3597
Vinyl Bromide in THF 25% 2580 Vinyl Bromide in THF25% 2405 (Washed) Distillation Residue 175 Total 2580 Total 2580 7.3) Vinyl Chloride ManufacturingProcess: Take 1,2 Dichloro Ethane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated Vinyl Chloride is packed in 200 Lit HDPEBarrels. Chemical reaction:
Cl - (CH2)2-Cl + NaOH Cl-CH=CH2 + NaCl + H2O 1,2 - DiChloroEthane SodiumHydroxide Vinyl Chloride SodiumChloride Water M.W.:99 M.W. :40 M.W.:62.5 M.W.:58.5 M.W. :18 Mass Balance:
Input Kg Output Kg 1,2 Dichloro Ethane 2255 Vinyl Chloride 1425 NaOH 910 Sodium Chloride(35%) 3860 Reaction Water 2120 Methanol 400 Methanol 400 Total 5685 Total 5685
Vinyl Chloride 1425 Vinyl Chloride 1410 Water Water 1000 Water to ETP 1015 Wash Total 2425 Total 2425
Vinyl Chloride 1410 Main Product 1315 (Washed) Distillation Residue 95 Total 1410 Total 1410 7.4) 4 Bromo 1 Butene ManufacturingProcess: Take 1,4 Dibromo Butane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated 4 Bromo 1 Butene is packed in 200 Lit HDPEBarrels. Chemical reaction:
Br - (CH2)4-Br + NaOH Br-CH2-CH2-CH=CH2 + NaBr +H2O 1,2 - Di Bromo Butane SodiumHydroxide 4 Bromo1Butene SodiumBromide Water M.W.:216 M.W.:40 M.W.:135 M.W.:103 M.W. :18
Mass Balance:
Input Kg Output Kg 1,4 DiBromo Butane 3890 4 Bromo 1 Butene 2430 NaOH 720 Sodium Bromide 1855 Reaction Water 1680 Water 2005 Methanol 400 Methanol 400 Total 6690 Total 6690
4 Bromo 1 Butene 2430 4 Bromo 1 Butene 2400 Water Water 1000 Water to ETP 1030 Wash Total 3430 Total 3430
4 Bromo 1 Butene 2400 4 Bromo 1 Butene 2290 (Washed) Distillation Residue 110 Total 2400 Total 2400 7.5) 6 Bromo 1 Hexene ManufacturingProcess: Take 1,6 Dibromo Hexane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated 6 Bromo 1 Hexene is packed in 200 Lit HDPEBarrels. Chemical reaction:
Br - (CH2)6-Br + NaOH Br-C5H9=CH2 + NaBr +H2O 1,6 - Di Bromo Hexane SodiumHydroxide 1 Bromo 6 Hexene SodiumBromide Water M.W.:244 M.W.: 40 M.W.:163 M.W.:103 M.W. :18 Mass Balance: Input Kg Output Kg 1,6 DiBromo Hexane 3905 1 Bromo 6 Hexene 2610 NaOH 640 Sodium Bromide 1650 Reaction Water 1495 Water 1780 Methanol 400 Methanol 400 Total 6440 Total 6440
1 Bromo 6 Hexene 2610 1 Bromo 6 Hexene 2600 Water Water 1500 Water to ETP 1510 Wash Total 4110 Total 4110
1 Bromo 6 Hexene 2600 1 Bromo 6 Hexene 2500 (Washed) Distillation Residue 100 Total 2600 Total 2600
7.6) 7 Bromo 1 Heptene ManufacturingProcess: Take 1,7 Dibromo Heptane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated 7 Bromo 1 Heptene is packed in 200 Lit HDPEBarrels. Chemical reaction:
Br - (CH2)7- Br + NaOH Br-CH2-CH2-CH2-CH2-CH2-CH=CH2 + NaBr + H20 1,7 - DiBromoHeptane SodiumHydroxide 7 Bromo SodiumBromide Water 1HepteneM.W.: 258 M.W.:40 M.W. :177 M.W.: 103 M.W. :18 Mass Balance:
Input Kg Output Kg 1,7 DiBromo Heptane 3870 7 Bromo 1 Heptene 2655 NaOH 600 Sodium Bromide (48%) 3215 Reaction Water 1400 Methanol 400 Methanol 400 Total 6270 Total 6270
7 Bromo 1 Heptene 2655 7 Bromo 1 Heptene 2640 Water Water 1500 Water to ETP 1515 Wash Total 4155 Total 4155
7 Bromo 1 Heptene 2640 7 Bromo 1 Heptene 2535 (Washed) Distillation Residue 105 Total 2640 Total 2640 7.7) 8 Bromo 1 Octene ManufacturingProcess: Take 1,8 Dibromo Octane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitored on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueouslayer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated 8 Bromo 1 Octene is packed in 200 Lit HDPEBarrels. Chemical reaction:
Br - (CH2)8-Br + NaOH Br-C7H13=CH2 + NaBr +H2O 1,8 - Di Bromide Octane SodiumHydroxide 1 Bromo 8 Octene SodiumBromide Water M.W.:272 M.W.:40 M.W.:191 M.W.:103 M.W. :18 Mass Balance:
Input Kg Output Kg 1,8 DiBromo Octane 4488 1 Bromo 8 Octene 3152 NaOH 660 Sodium Bromide (48%) 3656 Reaction Water 1660 Methanol 402 Methanol 402 Total 7210 Total 7210
1 Bromo 8 Octene 3152 1 Bromo 8 Octene 3100 Water Water 2000 Water to ETP 2052 Wash Total 5152 Total 5152
1 Bromo 8 Octene 3100 1 Bromo 8 Octene 3035 (Washed) Distillation Residue 65 Total 3100 Total 3100
7.8. 5-Bromo 1 Pentene
ManufacturingProcess: Take 1,5 Dibromo pentane in a Reactor add dilute Methanolic Caustic over a given period of time. On completion of NaOH addition stir the mass for a stipulated time. Reaction completion is monitered on GC, if found Ok add water. Settle the mass and separate lower Organic layer and Top aqueous layer. Aqueous layer is taken for Sodium Bromide recovery and Organic layer for Product Purification. Distilled Unsaturated 5 Bromo 1 Pentene is packed in 200 Lit HDPE Barrels
Chemical reaction:
Br - (CH2)5 - Br + NaOH Br-CH2-CH2-CH2-CH=CH2 + NaBr + H2O 1,5 - Di Bromide Pantane Sodium Hydroxide 1 Bromo 5 Pentene Sodium Bromide Water M.W. : 230 M.W. : 40 M.W. : 149 M.W. : 103 M.W. : 18
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark 1,5 DiBromo Pentane 3910 17 Crude 2574 For Washing NaOH 660 Sodium Bromide (48%) 3656 Sold as By Product Reaction Water 1660 Methanol 402 Methanol 402 Total 6632 Total 6632
Crude 2574 Crude Pentene 2122 For Distillation Water 2000 Water 2452 * To ETP Water Wash Total 4574 Total 4574
Crude Pentene 2122 Finished Good 2000 13.4 Packaging (Washed) Residue 122 ** Incinerated Distillation
Total 2122 Total 2122
8) Advance Intermediates from Category 1 to7
8.1) 6 Methoxy 2 Naphthaldehyde ManufacturingProcess: 2 Methyl Naphthalene is Brominated to get 6 Bromo 2 Methyl Naphthalene. This on reaction with Sodium Methoxide will give 6 Methoxy 2 Methyl Naphthalene. This on Controlled Oxidation will give 6 Methoxy 2Naphthaldehyde. Chemical reaction:
CH3 CH3
+ Br2 + HBr Br 2Methyl Naphthalene Bromine 6Bromo2MethylNaphthalene Hydrobromic Acid M.W. : 142 M.W. :160 M.W. : 221 M.W. : 81
CH3 CHO
+ NaOCH3 + NaBr
Br CH3O 6 Bromo 2 Naphthalene Sodium Methoxid 6 Methoxy Naphthaldehyde Sodium Bromide M.W. :221 M.W. : 54 M.W. : 186 M.W. : 103
CH3 CHO
+ O2 + H2O
Br CH3O 6 Bromo2Naphthalene Oxygen 6 Methoxy Naphthaldehyde Water M.W. :221 M.W. :32 M.W. : 186 M.W. : 18
Mass Balance:
Input Kg Output Kg Naphthaldehyde 3805 6 Bromo Naphthaldehyde 5920 Bromine 4285 Reaction HBr (48%) 4520 Water 2350 Total 10440 Total 10440
6 Bromo Naphthaldehyde 5920 6 Methoxy Naphthaldehyde 4605 Sodium Methoxide 1445 Sodium Bromide 2760 Reaction Methanol 3375 Methanol 3375 Total 10740 Total 10740
6 Bromo Naphthaldehyde 4605 6 Methoxy Naphthaldehyde 4980 Oxygen 855 Reaction Water 480 Total 5460 Total 5460
6 Methoxy Naphthaldehyde 4980 Main Product 4900 Drying Moisture 80 Total 4980 Total 4980
8.2) 2 Fluoro 5 BromoBenzonitrile ManufacturingProcess: 2 Chloro benzonitrile is reacted with Potassium Fluoride Solution (30%) to get 2 Fluoro Benzonitrile which is then brominated to get 2 Fluoro 5 Bromo Benzonitrile. 2 Fluoro 5 Bromo Benzonitrile is then washed and then Fractionated to get Pure Product which is then packed in 200 Lit HDPEBarrels. Chemical reaction: CN CN Cl F + KF + KCl
2 ChloroBenzonitrile PotassiumFluoride 2FluoroBenzonitrile PotassiumChloride M.W. : 137.5 M.W. : 58 M.W.:121 M.W. :74.5
CN CN F Br F
+ Br2 + HBr
2 Fluoro Benzonitrile Bromine 2Fluoro5BromoBenzonitrile Hydrogen Bromide M.W. : 121 M.W. : 160 M.W.:200 M.W. :81 Mass Balance:
Input Kg Output Kg 2 Chloro Benzonitrile 3445 2 Fluoro 5 Bromo Benzonitrile 5010 Potassium Fluoride (30%) 4845 Potassium Chloride (35%) 5255 Reaction Bromine 4015 HBr (48 %) 4240 Water 2200 Total 14505 Total 14505
2 Fluoro 5 Bromo Benzonitrile 5010 2 Fluoro 5 Bromo Benzonitrile 5000 Water 2000 Washing Water Washings 2010 Total 7010 Total 7010
2 Fluoro 5 Bromo Benzonitrile 5000 Main Fraction 4520 Vacuum (Washed) Residue 480 Distillation Total 5000 Total 5000
8.3) Ethyl 4 -(dimethylamino) Butyrate ManufacturingProcess: Ethyl 4 Bromo Butyrate is reacted with Dimethyl amine 30% in Presence of Ethyl Acetate to get Ethyl 4 (dimethylamino) Butyrate and Dimethyl ammonium Bromidesalt. Ethyl 4 (dimethylamino) Butyrate is the given Ethyl Acetate washings and then Packed in 200 Lit HDPEBarrels. Ethyl acetate washings are the fractionated to get Dist. EthylAcetate. Chemical reaction:
+ - CH3-CH2-O-C=O-(CH2)3-Br + 2 NH - (CH3)2 CH3-CH2-O-C=O-(CH2)3-N - (CH3)2 + NH2(CH3)2 Br Ethyl 4 Bromo Butyrate Dimethyl Amine Ethyl 4 -(dimethylamino) Butyrate Dimethyl Ammonium Bromide M.W. : 195 M.W.:90 M.W. :159 M.W. : 126 Mass Balance:
Input Kg Output Kg Ethyl 4 Bromo Butyrate 1840 Ethyl 4 dimethylamino Butyrate 1500 Dimethyl Amine 850 Reaction Dimethyl Ammonium Bromide 1190 Ethyl Acetate 1985 Ethyl Acetate 1985 Total 4675 Total 4675
Ethyl 4 dimethylamino Butyrate 1500 Ethyl 4 dimethylamino Butyrate 1490 Ethyl Acetate 1000 Filtration Washings 1010 Total 2500 Total 2500
Ethyl Acetate Washings 2995 Ethyl Ethyl Acetate 2865 Acetate Residue 130 Total 2995 Recovery Total 2995
8.4) BromoAcetal
Manufacturing Process: Vinyl Acetate is reacted with Bromine and Methanol to get Bromo Acetal and Methyl Acetate Mixture, which is then given Sodawashing. Then the mixture is then fractionated to get Bromo Acetal and Methyl Acetoacetate; Bromo Acetal is then packed in 200 HDPEBarrels. Chemical reaction:
CH2 =CH-O-C(=O)-CH3 + Br2 + 3CH3OH Br-CH2-CH(OCH3)2+ H2O +CH3COOCH3 + HBr VinylAcetate Bromine Methanol BromoAcetal Water MethylAcetate Hydrogen BromidM.W:86 M.W.:160 M.W.:32X3:96 M.W.:169 M.W.:18 M.W.:74 M.W. :81 Mass Balance:
Input Kg Output Kg Vinyl Acetate 430 Bromo Acetal & Methyl Acetate 1140 Methanol 832 HBr (16%) 2622 Bromine 800 Reaction Water 1700 Total 3762 Total 3762
Bromo Acetal & methyl Acetate 1140 Bromo Acetal & Methyl Acetate 1060 Water Soda solution 400 Washings to ETP 480 Washing Total 1540 Total 1540
Bromo Acetal & Methyl Acetate 1060 Bromo Acetal 668 Vacuum Methyl Acetoacetate 342 Distillation Residue 50 Total 1060 Total 1060
8.5) 6 Bromo Hexyl Trimethyl Ammonium bromide ManufacturingProcess: Aqueous Trimethyl Amine is reacted with 1,6 Dibromo Hexane to get 6
Bromo Hexyl Trimethyl AmmoniumBromide. The Material is then Filtered and Dried to get the Final Product which is then packed in 50 Kg HDPEDrums. Chemical reaction:
Br-C6H12-Br + N(CH3)3 Br-(CH3)3N-C6H12-Br 1,6 DiBromoHexane TrimethylAmine 6 Bromo Hexyl Trimethyl Ammonium Bromide M.W.:244 M.W.: 59 M.W. :303 Mass Balance:
Input Kg Output Kg 1,6-Dibromohexane 2540 DBH crude 1070 Reaction Trimethyl amine Gas 350 6BHTMAB 1820 Total 2890 Total 2890
6BHTMAB 1820 6BHTMAB 1800 DBH crude 1070 Filtration DBH crude 1090 Total 2890 Total 2890
DBH crude 1090 1,6 Dibromohexane 950 Distillation Residue 140 Total 1090 Total 1090
8.6) 1 Bromo 3 Phenoxy Propane ManufacturingProcess: 1,3 Dibromo Propane is taken in a reactor to that Phenol is added and then Sodium Hydroxide solution (40%) is added to get 1 Bromo 3 Phenoxy Propane. The Product is then given the Water washing Layer separation is done. Organic Layer is taken for Fractionation and Aqueous Layer is separated to get Sodium BromideSolution. Organic Layer is fractionated to get Pure 1 Bromo 3 PhenoxyPropane. Chemical reaction:
OH O-CH2-CH2-CH2-Br
Br-CH2-CH2-CH2-Br + + NaOH + NaBr + H2O
1,3 Dibromo Propane Phenol Sodium Hydroxide 1 Bromo 3 Phenoxy Propane Sodium Bromide Water M.W. : 202 M.W. : 94 M.W. : 40 M.W. : 215 M.W. : 103 M.W. : 18
Mass Balance:
Input Kg Output Kg 1,3 Dibromo Propane 3780 1 Bromo 3 Phenoxy Propane 4022 Phenol 1760 Reaction Sodium Bromide (55%) 3390 Sodium Hydroxide (40%) 1872 Total 7412 Total 7412
1 Bromo 3 Phenoxy Propane 4022 1 Bromo 3 Phenoxy Propane 4010 Water Water 1000 Water to ETP 1012 Wash Total 5022 Total 5022
1 Bromo 3 Phenoxy Propane 4010 Main Product 3675 Vacuum Residue 335 Distillation Total 4010 Total 4010
8.7) 6 Chloro 2 Hexanone ManufacturingProcess: Methyl Acetoacetate is reacted with 1 Bromo 3 Chloro Propane to get Potassium Carbonate to get an Intermediate stage which is then further reacted with Hydrochloric Acid to get 6 Chloro 2Hexanone. Chemical reaction:
CH3-CO-CH2-CO-O-CH3+ Br-(CH2)3-Cl +K2CO3 2Methyl5,6Dihydro4H + HBr + KCl +KHCO3 MethylAcetoacetate 1 Bromo 3 ChloroPotassium Pyrane3Carboxylicacid HydrobromicAcid Potassium Potassium Propane Carbonate MethylEster Chloride biCarbonate M.W.:116 M.W. 157.5 M.W. :138 M.W. : 156 M.W.:81 M.W. : 74.5 M.W. :100
2 Methyl 5,6 Dihydro 4H + HCl Cl-(CH2)4 - O = C- CH3 + CH3-OH + CO2 Pyrane 3 Carboxylic acid Hydrochloric Acid Methyl Ester 6 Chloro 2 Hexanone Methanol Carbon Di Oxide M.W. : 156 M.W. : 36.5 M.W. : 134.5 M.W. : 32 M.W. : 44
Mass Balance:
Input Kg Output Kg Methyl Acetoacetate 655 Intermediate Stage 881 1 Bromo 3 Choro Propane 890 HBr 458 Potassium Carbonate (30%) 2600 Reaction KCl 421 IPA 2515 KHCO3 2385 IPA 2515 Total 6660 Total 6660
Input Kg Output Kg Intermediate Stage 881 6 Chloro 2 Hexanone 760 HCl (40%) 525 Reaction CH3-OH and Water 398 CO2 248 Total 1406 Total 1406
8.8) n OctylAmine
Manufacturing Process: n-Octyl Bromide in reacted with Liquor Ammonia to get n-OctylAmine. Chemical reaction:
CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-Br + NH3 CH3-CH2-CH2-CH2-CH2-CH2-CH2-CH2-NH2 + HBr n-OctylBromide Ammonia n-OctylAmine Hydrobromic Acid M.W. : 193 M.W. :17 M.W. : 129 M.W. : 81 Mass Balance: Input Kg Output Kg n Octyl Bromide 6435 n Octyl Amine 4300 Ammonia (20%) 2830 Reaction Hydrobromic Acid (48%) 5625 Water 660 Total 9925 Total 9925
n Octyl Amine 4300 n Octyl Amine 4250 Water Water 2000 Water to ETP 2050 Wash Total 6300 Total 6300
n Octyl Amine 4250 Main Product 3900 Vacuum Residue 350 Distillation Total 4250 Total 4250 8.9) Bifenthrin Alcohol ManufacturingProcess: Charge 2,6 Dichloro toluene in reactors and slowly add Mg metal. Stir entire mass for completion of thereaction. After completion of the reaction 2 MgCl 6 chloro toluene will be obtained. This mass is further react with Bromo benzene. During the reaction Mg is replaced and 2 benzene 6 chloro benzene will be obtained and MgBrCl is obtained as byproduct. 2 benzene 6 chloro benzene is further react with Mg and convert in to 2 benzene 6 magnesium chloride benzene. This mass is further react with formaldehyde and get finalproduct. Chemical reaction:
CH3 Cl Cl + Mg Cl MgCl
2,6 Dichloro Toluene Magnesium 2 Magnesium Chloro,6 Chloro Toluene M.W, : 162 M.W. : 24 M.W. : 186
CH3 Br Cl MgCl + Cl + Mg.Br.Cl
2MagnesiumChloro,6ChloroToluene Bromo Benzene 2 Benzene 6 Chloro Benzene Magnesium Bromo Chloride M.W. : 186 M.W. : 157 M.W. : 203.5 M.W. : 139.5
Cl + Mg MgCl
2 Benzene 6 Chloro Benzene Magnesium 2 Benzene 6 Magnesium Chloride Benzene M.W. : 203.5 M.W. : 24 M.W. : 227.5
CH3
MgCl + HCHO + H2O CH3 +
Mg.Cl.OHHO -CH2
2Benzene6MagnesiumChlorideBenzene Formaldehyde Water BifenthrinAlcohol MagnesiumChloroOxide M.W.:227.5 M.W.:30 M.W.:18 M.W.:199 M.W. :76.5
Mass Balance: Input Kg Output Kg Dichloro Toluene 5000 Bifenthrin Alcohol 6140 Magnesium 1480 Mg.Br.Cl 4305 Bromo Benzene 4845 Mg.Cl.OH 2360 Reaction Formaldehyde (60%) 1480 Rec. THF 4550 THF 4550 Total 17355 Total 17355
Bifenthrin Alcohol 6140 Bifenthrin Alcohol 6115 Water 2000 Washing Water to ETP 2025 Total 8140 Total 8140
Bifenthrin Alcohol 6115 Main Product 5565 Vacuum Residue 550 Distillation Total 6115 Total 6115 8.10) Ethyl 7 Chloro 2 Oxo Heptanoate ManufacturingProcess: Ethyl Acetoacetate is reacted with 1 Bromo 5 Chloro pentane in Presence of Potassium carbonate to get Ethyl 7 Chloro Heptanoate which is then reacted with Nitrosyl Sulphuric acid and Formaldehyde to get Ethyl 7 Chloro 2 hydroamino Heptanoate.
This is then purified with Formaldehyde to get Ethyl 7 Chloro 2 Oxo Heptanoate. Chemical reaction:
2 CH3-CO-CH2-COO-C2H5 + 2Br-(CH2)5-Cl +K2CO3 2 Cl-(CH2)5-CH(COCH3)(COO-C2H5) + 2KBr + CO2 +H2O EthylAcetoacetate 1BromoChloro Potassium Ethyl 7 Chloro 2 (1 oxomethyl) Heptanoate Potassium Carbon Water Pentane Carbonate Bromide DiOxide M.W.:130X2 M.W. 185.5X2 M.W.:138 M.W.:234.5X2 M.W. :119X2 M.W.:44 M.W. :18
Cl-(CH2)5-CH(COCH3)(COO-C2H5) + HNO5S + H2O Cl-(CH2)5-C= NOH (COO-C2H5) + CH3COOH + H2SO4 Ethyl 7 Chloro 2 (1 oxomethyl) NitrosylSulphuric Water Ethyl7Chloro2hydroxyiminoHeptanoate AceticAcid Sulphuric Heptanoate Acid Acid M.W.:234.5 M.W.:127 M.W.:18 M.W.:221.5 M.W.:60 M.W. :98
Cl-(CH2)5-C= NOH (COO-C2H5) + HCHO Cl-(CH2)5-CO-COO-C2H5 + CH2=NOH Ethyl 7 Chloro 2 hydroxyimino Heptanoate Formaldehyde Ethyl7Chloro2OxoHeptanoate N-MethylideneHydroxylamine M.W. : 221.5 M.W.:30 M.W.:206.5 M.W. : 45`
Mass Balance:
Input Kg Output Kg Ethyl Acetoacetate 2080 Ethyl 7 Chloro 2(1-oxomethyl)- 3750 1 Bromo 5 Choro Pentane 2965 Heptanoate Potassium Carbonate 1105 Reaction Potassium Bromide 1905 Carbon Di Oxide 352 Water 143 Total 6150 Total 6150
Ethyl 7 Chloro 2(1-oxomethyl)- Ethyl 7 Chloro 2(Hydroxyamino)- 1875 1770 Heptanoate Heptanoate Nitrosyl Sulphuric Acid 1160 Reaction Acetic Acid 480 Toluene 2000 Sulphuric Acid 785 Toluene 2000 Total 5035 Total 5035
Ethyl 7 Chloro 2(Hydroxyamino)- Ethyl 7 Chloro 2 oxo Heptanoate 1650 1770 Heptanoate N-Methylidene Hydroxyl amine 360 Reaction Formaldehyde (35%) 685 Water 445 Toluene 2000 Toluene 2000 Total 4455 Total 4455
8.11) 1 Bromo 6 Methyl Heptane ManufacturingProcess: 1,5 Dibromo Pentane is reacted with Iso Propyl Magnesium Bromide over a Period of time. The Progress of reaction is monitored byGC. The Product is then packed in 200 Lit HDPEBarrels. Chemical reaction:
Br-(CH2)5-Br + (CH3)2-CH-Mg-Br (CH3)2-CH-(CH2)5-Br + Mg Br2 1,5 Di Bromo Pentane Iso Propyl Magnesuim Bromide 1 Bromo 6 methyl Heptane Magnesium Di Bromide M.W. : 230 M.W. : 147 M.W. : 193 M.W. : 184
Input Kg Output Kg 1,5 Di Bromo Pentane 4052 1 Bromo 6 Methyl Heptane 3400 Iso Propyl Magnesium 16683 Reaction Magnesium Bromide 17335 -Bromide in THF Total 20735 Total 20735
1 Bromo 6 Methyl Heptane 3400 Water 1 Bromo 6 Methyl Heptane 3350 Water 1000 Washing Washings to ETP 1050 Total 4400 Total 4400
Magnesium Bromide in THF 17335 Magnesium Bromide 3200 Distillation THF 14000 Residue 135 Total 17335 Total 17335
8.12) Methyl 3 Oxo Pentanoate ManufacturingProcess: Chlorination of Butyl Methyl Ketone is carried out to get Chloro Derivative. This on Cynation gives CyanoCompound. The Cyano Compound on Hydrolysis and Esterification gives Methyl 3 Oxo pentanoate. Chemicalreaction:
CH3- CH2- C(=O)-CH3 + Cl2 CH3 - CH2- C(=O) - CH2 Cl + HCl EthylMethylKetone Chlorine Ethyl Chloro Methyl Ketone Hydrochloric Acid M.W:72 M.W. :71 M.W. : 106.5 M.W. : 36.5
CH3 - CH2- C(=O) -CH2Cl + NaCN CH3- CH2- C(=O) - CH2 CN + NaCl Ethyl ChloroMethylKetone Sodium Cyanide Ethyl Cyano MethylKetone Sodium Chloride M.W.:106.5 M.W. :49 M.W. : 97 M.W. : 58.5
CH3- CH2- C(=O) -CH2CN + H2SO4 + 2H2O CH3-CH2-C(=O)-CH2COOH + NH4HSO4 Ethyl CyanoMethylKetone SulphuricAcid Water 3 Oxo Pentanoic Acid Ammonium Bisulphite M.W.:97 M.W.:98 M.W. :36 M.W. : 116 M.W. : 115
CH3- CH2 - C(=O) -CH2 COOH + CH3-OH CH3- CH2 - C(=O) - CH2COOCH3 + H2O 3 OxoPentanoicAcid Methanol Methyl 3 OxoPentanoate Water M.W.:116 M.W. :32 M.W. : 130 M.W. : 18
Mass Balance:
Input Kg Output Kg Butyl methyl ketone 3055 Methyl 2 oxo Pentanoate 5515 Chlorine 3015 Hydrochloric Acid 1545 Sodium Cyanide 2075 Sodium Chloride 2475 Reaction Sulphuric Acid (65%) 6375 Ammonium Bisulphite 4860 Methanol 1355 Water 1480 Total 15875 Total 15875
Methyl 3 Oxo Pentanoate 5515 Methyl 3 Oxo Pentanoate 5500 Water Water 2000 Washings to ETP 2015 Washing Total 7515 Total 7515
Methyl 3 Oxo Pentanoate 5500 Main Product 5025 Vacuum Residue 475 Distillation Total 5500 Total 5500 8.13) Tetrabenzolcyclen (TBC)
ManufacturingProcess: n Benzylethanol amine is taken in cyclohexane to this mixtire sulphuric acid is added the mass is treated with PTS and Ethanol to get crude TBC. Crude mass is crystallized. Cyclohexane, Ethanol and Ethyl acetate are recovered from Mother liquor.
Chemical reaction:
CH2NHCH2CH20H
Cyclohexane+ H2SO4 + PTS + Ethanol 4H20
4 M n Benzylethanolamine M.W. :151 X4 =604 Tetrabenzolcyclen (TBC) MW 532 Water MW 18 X2 = 72
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark n Benzylethanolamine 950 6.29 Crude TBC 893 for Purification Cyclohexane 5160 Mixture of solvent 12000 for recovery Reaction PTS 840 Water 57 to ETP Ethanol 6000 Total 12950 12950
Crude TBC 893 Pure TBC 500 0.94 Finished Goods Ethyl acetate 6500 Recovered Ethyl acetate 6893 For recovery Crystallization Totak 7393 Total 7393
Mixture of solvent 12000 Ethanol 5390 Recycled Cyclohexane 5520 Recycled Distillation Residue 1090 Incineration 12000 Total 12000
Recovered Ethyl acetate 6893 Ethyl acetate 6045 Recycled Distillation Residue 848 Incineration 6893 Total 6893
8.14) 3,4 diflourobenzaldehyde (3,4 DFBA)
ManufacturingProcess: Diflourotoluene is reacted in vap phase with Bromine under UV light to dibromo resultant dibromo along with Hydrobromic acid reacted with calcium carbonate to get crude. Crude is taken in water organic layer is separated . Separated organic layer is taken for distillation. Aqueous layer is taken for calcium bromide recovery.
Chemical reaction:
CH3 Br CHBr CHO
2Br2 + 2HBr + CaCO3 + 2CaBr2 2CO2 H2O F F MW 100 F F F 100 X 2= 200 F Diflouro Toluene MW Br2 MW Intermediate 3,4 MW MW44x2=88 MW 18 128 160x2=320 Diflourobenzald 200X2=400 ehyde MW 142
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Diflourotoluene 3378 26.39 Crude Product 3700 Purification Bromine 8448 Mother Liquor 14130 Recovery of CaBr2 Reaction Caocium Carbonate 5340 CO2 2336 Gas Scrubber Water 3000 Total 20166 20166
Crude Product 3700 Finished Good 3000 21.13 Vac Risidue 700 Incineration Distillation Total 3700 Total 3700
Mother liquor 14130 Cailium Bromide> 45% 11250 Sale Water collected 2880 Recycle to next batch Distillation 14130 Total 14130
8.15) 2 carboxymethyl - 5-methoxybenzoic acid (Homophthal)
ManufacturingProcess: 2bromommethoxybenzoic acid is taken Ethyl acetoacetate on completion of reaction NaOH is added crude acid is filtered. Crude mass is crystallized in Xylene. Mother liquor on distillation gave ethyl acetate. Xylene is recovered by distillation.
Chemical reaction:
CH3O COOH NaBr C2H5OH CH3COOH
CH3COCH2COOC2H5 + NaOH + HOH Br 231 KG 130 KG 40 KG 18 KG 210 KG 103 KG 46 KG 60 KG 2 Bromo5methoxy Ethyl acetoacetate NaOH Water 2 Carboxymethyl-5 -methyl Sod Bromide Alcohol MW 46 Acetic acid benzoic acid MW 231 MW 130 MW 40 MW 18 benzoic acid MW 210 MW 103 MW 60
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step Treatment Remark Br methoxy Benzoic acid 4680 20.26 Crude product 4260 for Purification Ethyl aceto acetata 2763 Mother liquor 4359 for recovery Reaction NaOH 810 Water 366 Total 8619 8619
Crude Product 4260 Finished product 3000 14.29 Packed for sale Xylene 12780 Crystallizati Xylene Mother Liq 14040 For recovery on Total 17040 Total 17040
Mother liquor 4359 Ethyl acetate 1113 Sale Sod Bromide soln 1660 Sale Distillation Residue 1586 incineration 4359 Total 4359
Xylene Mother Liquor 14040 Xylene 11980 Recycled Distillation Residue 2060 incineration 14040 Total 14040
8.16) L Valine methyl eater - OTBN Hydrochloride
ManufacturingProcess: L Valine is taken in Methanol and thionyl chloride is reacted, Generated SO2 is scrubbed in Sod Hydroxide. Crude L-Valine Hydrochlorde is reacted with OTBN in ethyl acatete along with K2CO3 Crude product is washed with water. Organic layer is cooled filtered and dried, Mother liquor is taken for recovery of Ethyl acetate. Aqueous layer containing KBr is sold.
Chemical reaction:
COOH COOCH3 + SOCl2 +CH3OH 2NaOH NaHSO3 NH2 NH2.HCl L- Valine Thionyl Chloride Methanol MW 40 L Valine methyl ester MW 104 MW 117 MW 119 MW 30 X2=80 hydrochloride -Intermediate
CN COOCH3 Br COOCH3 CN K2CO3 NH KHCO3 KBr NaCl H20 NH2.HCl HCl Bromo OTBN MW 272 Inermediate MW 138 MW 100 MW 119 MW58.5 MW18 L-Valine methyl ester OTBN MW 356.5 2.1) Process Description :
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark L Valine 535 4.57 Crude valine.HCl 800 reaction CBMB Methanol 915 Mother Liquor 936 Methanol recovery
Thionyl Chloride 598 Reaction NaHSO3 (17%) 3023 Sale NaOH 211 Step 1 Water 2500 Total 4759 Total 4759
CBMB 1015 3.73 Crude in EA 4563 For crystallization L Valine Hydrochloride 800 Water washings Ethyl Acetate 2210 Reaction wih KBr 18% 3043 Sale Potassium carbonate 1151 Step 2 Water for washing 2430 Total 7606 Total 7606
Crude in Ethyl acetate 4563 Finished Goods 1100 3.08 Sale Mother Liquor 3463 For recovery Crystallization 4563 4563
Mother Liquor 3463 Ethyl acetate 1800 Recycled Distillation Residue 1663 incineration 3463 Total 3463
Methanol recovery 936 Methanol 790 Recycle to next batch Distillation Residue 146 Residue for incineration 936 Total 936
8.17) Tetrazole
ManufacturingProcess: In Monochloro bezene OTBN is taken and charged NaN3 . To this mixture further added Tri Butyl Stanous chloride and Trityl Chloride along woth Triethylamine and continued till completion of reaction. Mass is filtered on centrifuge solid is taken for crysatllization Mother liquor for solvent recovery Crude is taken in MIBK for crystallization. Crude is dissolved in MIBK heated to reflux cooled to 0C and filtered and washed with MIBK. White solid dried in RCVD.
Chemical reaction:
N N N Ph C N C Ph CN Ph Cl 1. MCB Br CH3 + NaN3 Sn (C4H9)3 + Cl - C (Ph)3 + Trirthylamine + Bromo + NaCl TEASn(Cl)(C4H9)3 Dimethyl Hydantoin 2.MIBK Hydantoin
OTBN MW193 Sod Azide Tri butyl Stanous- Trityl Chloride Tiethylamine MW 285 Tetrazole MW 557 MW 58.5 MW425 MW 125 1M MW 65 Chloride MW 325 MW 278.5 100 142.50 1 M 1M 1M 1M 1M 0.5 M 62.5
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark OTBN 870 4.51 Crude of step 1 6920 Next reaction MCB 5640 Sod azide 410 Reaction Step 1
Total 6920 Total 6920
Crude of step 1 6920 Crude cake 1280 For crystllization Tin tributyl chloride 570 Aq wash 2100 ETP Trityl chloride 1350 Mother liquor (MCB) 8305 MCB recovery Reaction Triethylamine 579 Step 2 Dibromo hydantoin 578 Water for washing 1688 Total 11685 Total 11685
Crude cake 1280 Product with solvent 1050 For drying MIBK 2250 Mother liquor (MIBK) 2480 Crystallization Total 3530 Total 3530
Product with solvent 1050 Finished good 1000 Sale Drying in RCVD MIBK 50 Recycle Total 1050 Total 1050
Mother Liquor (MCB) 8305 DistilledMCB 5076 recycle Distillation Residue 3229 Incineration Total 8305 8305
Mother liquor (MIBK) 2480 Distilled MIBK 1915 recycle Distillation Residue 565 Incineration 2480
8.18) 2-Bromo-1,3-Diethyl-5-methyl-benzene (DEMBB)
ManufacturingProcess: 2,6 diethy4 mrthyl aniline is diazotized and brominated with HBr to get Bromo diethyl methyl benzene.
Chemical reaction: HCl OH + O O + NaNO2 N NaCl
C5H12O NaNo2 HCl C5H11NO2 NaCl 88.2 69 36.5 117.5 58.5 [71-41-0] [7632-00-0] Br
NH2 NH2 HBr
HBr
ODCB
C11H17N C11H17N HBr C11H15Br 163.3 81 244.3 227.2 [24544-08-9] [10035-10-6] [314084-61-2]
Mass Balance: Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark Sodium Nitrite 528 7.65 Organic layer 1592 For distillation DEMA 968 6 Aqueous layer 2158 ETP Pentanol 58 HBr 48% 1048 6 Reaction Water 1000 ODCB 148 Total 3750 3750
Organic layer 1592 Pure product 1000 4.41 Finished Good ODCB 120 Recycle in next batch Distillation Residue 472 Incineration Total 1592
8.19) 4-(3,4-Dichlorophenyl)-3,4-dihydro-1(2H)-napthalenone [Tetralone]
ManufacturingProcess: 1 Naphthol is reacted with 1,2 Dichlorobenzene using AlCl3 as Catalyst to Tetralone Final material is crystllized using Isopropanol
Chemical reaction:
Mass Balance:
Input Kg Kmol Output Kg Kmol Next Step TreatmentRemark 1 Naphthol 790 5.50 Organic layer 3786 For distillation of ODCB ODCB 3006 Aqueous layer 4350 For isolation of Sod aluminate AlCl3 1840 Water 2500 Reaction
Total 8136 Total 8136
Organic layer 3786 ODCB 1986 Recycle to next batch ODCB Crude product 1800 for Crystallization recovery Total 3786 3786
Crude Product 1800 Wet cake 1120 For drying Crystllization Isopropyl alcohol 2000 Mother liquor 2680 For recovery of Isopropyl alcohol and filtration Total 3800 Total 3800
Wet cake 1120 Finished product 1000 3.44 To warehouse Loss 120 Drying Total 1120 Total 1120
Mother liquor 2680 Iso propyl alcohol 1700 recycle to next batch Isopropyl Residue 980 Incineration alcohol recovery Total 2680 Total 2680
8.20) 6Chlorohexanol THP derivative
ManufacturingProcess: Tetrahydrofuran is added to 6 chlorohexanol and MDC Mixture. On completion of reaction reaction mixture is washed with water. Organic layer is taken for distillation and aqueous layer for ETP.
Chemical reaction:
MDC
OHCH2CH2CH2CH2CH2CH2Cl + o Reflux O CH2CH2CH2CH2CH2CH2Cl 6 Chlorohexanol Tetrahydropyran 6ChlorohexanolTHP Derivative MW 136.5 MW 84 MW 220.5
Mass Balance:
Input Kg Output Kg Kmol Next Step TreatmentRemark 6 Chlorohexanol 1365 10 Organic layer 3605 For Distillation Tetrahydropyran 840 Aqueous layer 1100 To ETP Reaction MDC 1500 Water 1000 Total 4705 Total 4705
Organic layer 3605 MDC 1380 For recycle to next batch Finished Good 1790 8.13 for sale Distillation Residue 435 for Incineration Total 3605 Total 3605
8.21) 3 Bromo propyl Trimethyl Ammonium Bromide
ManufacturingProcess: Trimethyl Amine is reacted with 1,3 Dibromo Propane to get 3 Bromo PropylTrimethyl Ammonium Bromide. The Material is then Filtered and Dried to get the Final Product which is then Packed in 50 Kg HDPE Drums
Chemical reaction:
Br- CH2-CH2-CH2- Br + N(CH3)3 Br- (CH3)3N -CH2-CH2-CH2-Br 1,3 Di Bromo Propane Trimethyl Amine 3 Bromo Propyl Trimethyl Ammonium Bromide M.W. : 202 M.W. : 59 M.W. : 261
Mass Balance: Input Kg Output Kg Kmol Next Step TreatmentRemark 1,3-Dibromopropane 2020 10 3BPTMAB 1480 For Filtration Trimethyl amine Gas 350 6 DBP Crude 890 Distillation Reaction
Total 2370 Total 2370
3BPTMAB 1480 3BPTMAB 1445 Packing DBP Crude 890 Filtration DBP Crude 925 Distillation and drying Total 2370 Total 2370
DBP Crude 925 1,3 Dibromopropane 845 Internal Consumption / sale Distillation Residue 80 *Incinerated Total 925 Total 925
8.22) 6Bromohexanol THP derivative
ManufacturingProcess: Tetrahydrofuran is added to 6 Bromohexanol and MDC Mixture. On completion of reaction reaction mixture is washed with water. Organic layer is taken for distillation and aqueous layer for ETP.
Chemical reaction:
MDC
OHCH2CH2CH2CH2CH2CH2Br + o Reflux O CH2CH2CH2CH2CH2CH2Br 6 Bromohexanol Tetrahydropyran 6BromohexanolTHP Derivative MW 181 MW 84 MW 265 Mass Balance
Input Kg Output Kg Kmol Next Step TreatmentRemark 6 Bromohexanol 1810 10 Organic layer 4050 For Distillation Tetrahydropyran 840 Aqueous layer 1100 To ETP Reaction MDC 1500 Water 1000 Total 5150 Total 5150
Organic layer 4050 Wet cake 2335 For drying Crystalliza Mother Liquor 1715 For MDC recovery tion Total 4050 Total 4050
Wet cake 2335 Dried product 2233 8.43 Pack and sale Loss 102 Drying Total 2335 Total 2335
Mother liquor 1715 MDC 1280 Recycle to next batch MDC Loss 70 Recovery Residue 365 For incineration Total 1715 Total 1715
8.23) 8 Bromo octanol THP derivative
ManufacturingProcess: Tetrahydrofuran is added to 8 Bromo octanol and MDC Mixture. On completion of reaction mixture is washed with water. Organic layer is taken for distillation and aqueous layer for ETP.
Chemical reaction:
MDC
OHCH2CH2CH2CH2CH2CH2CH2CH2Br + o Reflux O CH2CH2CH2CH2CH2CH2CH2CH2Br 8 Bromo octanol Tetrahydropyran 8 BromooctanolTHP Derivative MW 209 MW 84 MW 293 Mass Balance
Input Kg Output Kg Kmol Next Step TreatmentRemark 8Bromooctanol 2090 10 Organic layer 4330 For Distillation Tetrahydropyran 840 Aqueous layer 1100 To ETP Reaction MDC 1500 Water 1000 Total 5430 Total 5430
Organic layer 4330 Wet cake 2615 For drying Crystallizat Mother Liquor 1715 For MDC recovery ion Total 4330 Total 4330
Wet cake 2615 Dried product 2515 8.58 Pack and sale Loss 100 Drying Total 2615 Total 2615
Mother liquor 1715 MDC 1280 Recycle to next batch MDC Loss 70 Recovery Residue 365 For incineration Total 1715 Total 1715
8.24) 10 Bromo decanol THP derivative
ManufacturingProcess: Tetrahydrofuran is added to 10 Bromo octanol and MDC Mixture. On completion of reaction mixture is washed with water. Organic layer is taken for distillation and aqueous layer for ETP.
Chemical reaction:
MDC
OHCH2CH2CH2CH2CH2CH2CH2CH2CH2CH2Br + o Reflux O CH2CH2CH2CH2CH2CH2CH2CH2CH2CH2Br 10 Bromo decanol Tetrahydropyran 10 BromodecanolTHP Derivative MW 237 MW 84 MW 321 Mass Balance:
Input Kg Output Kg Kmol Next Step TreatmentRemark 10 Bromo decanol 2370 10 Organic layer 4610 For Distillation Tetrahydropyran 840 Aqueous layer 1100 To ETP Reaction MDC 1500 Water 1000 Total 5710 Total 5710
Organic layer 4610 Wet cake 2895 For drying Crystalliza Mother Liquor 1715 For MDC recovery tion Total 4610 Total 4610
Wet cake 2895 Dried product 2795 8.7 Pack and sale Loss 100 Drying Total 2895 Total 2895
Mother liquor 1715 MDC 1280 Recycle to next batch MDC Loss 70 Recovery Residue 365 For incineration Total 1715 Total 1715
8.25) 2-amino-3',4'-difluorobiphenyl
Manufacturing process:
Stage 1: Bromine is slowly added to precharged 1,2-difluorobenzene and iron powder. Agitation is continued till complete consumption of bromine. Then traces of excess bromine is removed by sodium metabisulfite followed by water wash. Obtained organic layer is fractonated to get pure fraction which is used in next stage of process.
Stage 2: Charged THF, Mg and iodine all at once. Slowly added step-1st in the reaction mass. On addition, trimethyl borate is added. Slowly added dil. HCl in the mass. Organic mass with THF is used in next stage.
Stage 3: Charged 2-chloronitrobenzene, PdCl2, caustic lye all at once. Heat mass and hold for 24 hrs. Distill out THF and water. Charge isobutanol and charcoal then filter it and crystallized it. Crystallized material is filtered.
Stage 4: Step-3rd with toluene and Pt/C are charged. Hydrogen gas is passed thought it. Then filtered mass on completion of reaction. Distilled toluene to get product.
Chemicalreaction:
Reaction Scheme Step-1st Br
+ Br Br + HBr F F F F 1,2-difluorobenzene 4-bromo-1,2-difluorobenzene Step-2nd Br HO OH B H CO 3 OCH 3 THF Mg Br + + B + HCl + 2 H2O + 2 H C OH OCH + 3 F 3 Mg Cl F F F 193 24.3 103.9 36.5 18 157.9 139.7 32.04
Step-3rd – HO OH O B + Cl O O N + N – O Na BO NaCl + + 3 NaOH F + 3 H2O + 2 2 + F F F 157.9 157.5 40.0 235.2 18.0 88.8 58.4 – Step-4th O + O N H2N
Pt/C F 3 F 2 H2O + H2 +
F F
205.2 36.0 235.2 2 Mass Balance:
Input Kg Operation Output Step-1st 1,2-difluorobenzene 970.0 Charge all at once Iron powder 49.9
Bromine 1441.9 Bromine addition
HBr gas 729.3 (Sale) in process testing dissolved in water NaHSO3 98.0 Kill excess bromine Water wash 300.0
Separation Aqueous 398.0 (Discard)
Fraction-1 90 (Recycle) Fractionation Fraction-3 127 (Recycle) Fraction-2 1470 Kg Residue 45 (Incineration) Step-2nd THF 6638.3 Charge all mass Mg 183.5 Iodine (as catalyst) 5.0
Trimethylborate 792.7 Addition of Trimethyl borate dilute HCl solution 1091.0 Slowly addition
Aqueous 3411.0 (Discard) Separation dilute HCl wash 545.0 Aqueous 560.0 (Discard) Washing 6755 kg
Step-3rd 2-chloronitrobenzene 1076.3 Charge all at once Caustic lye 715.0
PdCl2 1.3 Charge all at once Triphenyl phosphine 19.1
Heat mass & hold for 24 hrs
Distillation of THF Rec THF 6638.0 and water Water 760.0 993.4 kg Isobutanol 6691.0 Charge isobutanol Charcoal 5.0
Waste charcoal 6.3 (Recycle) Catalyst recovery for Pd recovery After Recovery 6711.0 t-butanol 6691.0 (Recycle) Filtration and Mother liquor (Incineratio drying Residue 20 n) 1148 kg Step-4th Toluene 4672.0 Charge all at once Pt/C 3.2
Hydrogenation H2 gas 30.7
Filtration (catalyst Pt/C (Recycle) 3.2 (Recycle) removal)
Distillation under Rec Toluene 4672.0 (Recycle) vacuum Water 179.0 (Recycle) Final Product 1000 Kg
9) 2-Cyclopropyl 6-Methyl Phenol
Manufacturing process:
Stage 1: Reaction of O-Cresol with Paraformaldehyde in Presence of Magnesium Chloride & Triethylamine in Chlorobenzene(MCB) to get FOC .
Stage 2: FOC further react with Vinyl magnesium Chloride in Tetrahydrofuran will generate HAOC.
Stage 3: HAOC further react with Hydrobromic acid solution (in Acetic acid) in presence of acetic anhydride will generate DPOC.
Stage 4: DPOC will react with Mg Turning in presence of Tetrahydrofuran will generate CPOC.
Stage 5: CPOC will further reacts with sodium hydroxide solution in methanol will generate 965R crude. 965R Crude further distilled to get final Pure 2- Cyclopropyl -6- Methyl Phenol.
Chemicalreaction:
Reaction Scheme Step-1st OH OH
H3C H3C CHO Mono Chlorobenzene + MgCl + Et N + CH OH MgCl 2 3 2 -(CH2O)-n + 3 + Et3N + 2
O-Cresol Magnesium Triethyamine FOC Mol. wt : 108.14 Paraformaldehyde Chloride Mol. wt : 136.147 Step-2nd OH OH HO
H3C CHO CH H3C 2 THF + 2 CH =CH-Mg-Cl CH2 2 + MgCl + 2 H2C
HAOC FOC Vinyl magnesium Chloride Molecular weight : 164.20 Molecular weight : 136.147
Step-3th OH HO OAc Br Br CH H3C 2 H3C
+ 2 HBr Acetic anhydride + 1 H2O + CH3COOH
HAOC (DPOC) Molecular weight : 164.20 Molecular weight : 350.04 Step-4th OAc Br Br OAc
H3C H C THF 3 + Mg MgBr + 2
(DPOC) CPOC Molecular weight : 190.23
Step-5th OAc OH H3C H3C Methanol + 1 NaOH + CH3COONa
CPOC 965R Molecular weight : 190.23 Molecular weight : 148.20
Mass Balance:
O-Cresol 1000 Mono Chloro benzene 1000 Magnesium Chloride 880.44 MgCl2 1867.5 Triethyl amine 935.73 CH2=CH2 gas 225 Intermediate satge - 1 Paraformaldehyde 554.83 Methanol + water mixture 1916 Mono chloro benzene 1000 TEA 935 Water 550
Vinyl magnesium chloride Solution 4986.5in THF MgBr2 1482 HBr in Acetic acid 3252 Intermediate satge - 2 Acetic Anhydride 821
Dil NaOH solution 2522 THF +Toluene mixture 5289 Iodine (as catalyst) 1 Inert Solid 10 EDB (1,2-Dibromoethane) 1 Residue 121 Mg Turning 196 Intermediate satge - 3 Methanol 500 THF 450 Celite 10
Dil HCl 2350 Product 1077 Dil NaHCO3 solution wash 750 Toluene + Acetic acid Mixture1715 30% Acetic acid solution 2067 Final product Toluene 500 Toluene 2000 Wastewater 8034 Sodium Acetate 656
Total 24827.5 24827.5
Annexure-III
Water Balance
Sr. Source Water Wastewater No. Consumption Generation (KLD) (KLD) 1. Domestic 45 40* 2. Green Belt 12+40* -- 3. Industrial A Process 121 78 B Scrubber 34 5 C Boiler 80 10 D Cooling Tower 200 50 E Washing 30 30 Total Industrial 465 173 TOTAL (1 +2 + 3) 562 213 Reuse water 40* - Freshwater 522 - requirements
Water Balance Diagram
Total water consumption = 562 KLD (Fresh water 522 KLD + Reuse water 40 KLD)
Scrubber Greenbelt Domestic Process 34 Washing Utilities 45 12 + 40* 121 30 280
Liquor of HBr STP HBr HBr 26 40* 14 17 (16 to 30%) Used SBS (45-48%) captively 6
To greenbelt HCl* NaOCl 1 24 HCl* Boiler Cooling 8 Spent H2SO4 80 200 Used 5 captively
Salt solution Blow Bleed to recovery down off 55 10 50
Process 78 5
ETP 78 + 5 + 30 + 10 + 50 = 173
173 KLD to GIDC Drainage
Annexure-IV Hazardous waste details
Sr. Type of Waste Quantity Method of Disposal No. 1. ETP waste 50 MT/month Collection, storage & disposal at TSDF site approved by GPCB. 2. Process/distillation 1100 Collection, storage & disposal at CHWIF or residue MT/month co-processing. 3. Discarded containers/ Barrels-5000 Collection, storage, decontamination and barrels/ nos./month disposal by selling to registered recyclers. liners Liner-500 kg/month 4. Used Lubricating Oil 1.0 Kl/year Collection, storage & use within premises as lubricant/sell to registered recycler. 5. Liquor of HBr 676 Collection, storage, transportation and (<30%) MT/month sold to actual end users under Haz Waste Rules 9. 6. Sodium hypochlorite 26 Collection, storage, transportation and MT/month sold to actual end users under Haz Waste Rules 9.
7. Spent H2SO4 130 Collection, storage, transportation and MT/month sold to actual end users under Haz Waste Rules 9. 8. Acetic acid 25 Collection, storage, transportation and MT/month sold to actual end users under Haz Waste Rules 9. 9. Inorganic salts like 445 Collection, storage, and send to own (Sodium Bromide, MT/month inorganic plant for product recovery Magnesium Bromide, (within premises) having GPCB consent Potassium Bromide, no. 98568 (non-EC activity). Calcium Bromide, Sodium Sulphate, Sodium Bisulfite, Ammonium Bisulphite, Potassium Bicarbonate)
Annexure-V Details of Air Pollution
Sr. Stack attached to Stack Fuel Fuel APC Pollutant No. Height Used Consumption measure in m Rate Flue gas stacks 1 Boiler 30 PNG 10000 -- SPM<150 (3 nos.) (common SCM/day mg/Nm3
(2 TPH each) stack) FO* 380 SO2<100 ppm Kg/hr NOX<50 ppm 2 D G set 21 HSD 60 Lit/hrs. -- (250 KVA x 3) each Process vent 3 Halogen Specific 16 m - - Water & HBr<20 mg/Nm3 Reaction Plant each Alkali HCl<20 mg/Nm3 (4 nos) Scrubber 3 Br2<2 mg/Nm 3 Cl2<9 mg/Nm
3 4 Common Reaction & 16 m - - Water & SO2<40 mg/Nm Multi-purpose Plant each Alkali HBr<20 mg/Nm3 (4 nos) Scrubber HCl<20 mg/Nm3 3 Br2<2 mg/Nm 3 Cl2<9 mg/Nm 5 Common stack 16 m - - Alkali HBr<20 mg/Nm3 attached to suction of each Scrubber HCl<20 mg/Nm3 work place area Br <2 mg/Nm3 (2 nos) 2 6 Bromine scrubber 16 m - - Two HBr<20 mg/Nm3 stage 3 Br2<2 mg/Nm Alkali Scrubber * in case of unavaibility of natural gas
Annexure-VI Terms of Reference (TOR)
Standard TOR prescribed by Ministry of Environment, Forest and Climate Change
Outward No:498923,14/03/2019 Outward No:498923,14/03/2019 Outward No:498923,14/03/2019 Outward No:498923,14/03/2019 Outward No:498923,14/03/2019 Outward No:498923,14/03/2019 Outward No:498923,14/03/2019