Dyestuff Industry (Part - 1) | Chemical Technology - Chemical Engineering PDF Download

Dyestuff Industry

The dyestuff industry plays important role in the overall growth of chemical industry. The preparation and usage of dyestuff is one the oldest forms of human activities. The usage of natural dyestuff dates back to the bronze age. Dye flax fibres have been found in the Republic of Georgia dated back in a prehistoric cave 36,000 BP. Archeological evidence shows that particularly In India and Phoenicia, has been extensively carry out for over 5000 years. The dyes were obtains from animal, vegetable or mineral origin with no or little processing. First synthetic organic dye, mauveine, was discovered by William Henry Perkin in 1856 .

There is also mention of dye in the Bible and other works of classical antiquity. It was in 2600 BC when earliest written records of the use of dyestuffs were found in China. Synthetic dyestuffs now available in several hues are amongst the oldest chemicals produced by man [Lalbhai, 2007]. Textile, carpet and garment industry is one of the largest and most prominent sectors as major portion of the dyes are used in textile industry, growth of the textile industry has a direct impact on the growth of dyes stuff industry.

Textile dyestuff had a worldwide market of around US $ 5.7 billion. Largest categories are reactive and disperse dyes that accounts for about 44% of total value. Asia pacific represents largest share and accounts for about 40% global share. At a production of 130,000 MT per annum, Indian due stuff industry contribute to just 7% of the world’s global production. Installed and production capacity of dyes and dyestuffs are given in Table M-IX 2.1.  Dyes are the coloured, ionizing and aromatic organic compounds which has affinity to the substrate to which it is being applied. The dye is generally applied in an aqueous solution which may also require a mordant for improving the fastness of the material on which it is applied. Classification of dyes is given in Table M-IX 2.2.

Colors are an integral part of human perception and life. Much before the invention of synthetic dyestuffs, natural and vegetable colors were in use in India for centuries. Chromphone in Important Class of Dyes is given Table M-IX 2.3 . Perkins development of the first synthetic dye in 1856 led to the birth of European dyestuffs industry and use of synthetics dyes widely extended to all textiles substrates. The well-development textile industry in India soon started use of synthetic dyes and depended on imported organic dyestuffs till forties. The start up of Arlabs ltd., in 1940, followed by other dyestuffs companies in fifties and sixties led to the establishment of the indigenous industry. In the development phase that followed subsequently, India slowly emerged as the supplier of dyestuffs.

Demand and Supply

The overall production capacity of dyestuffs is 200,000 tonnes per annum. With the ever increasing standards of quality and reliability, Indian dyestuffs industry meets more than 95% of the domestic requirement, out of which textile industry consumes nearly 60% and the remaining is shared by paper, leather & other consumer industries. As far as pigments are concerned, the market size is 115,000 tonnes. Production of pigments and major dyes is shown in Figure M-IX 2.1. The main consumer industries are printing inks, paints, plastics, rubber, etc., accounting for 70% of the end use. Table M-IX 2.5 shows various dyes intermediate and their structure, methods of preparation and their uses.

Pigments Production, India (‘000 tonnes) Production of Major Dyes (‘000 tonnes)

Figure M-IX 2.1: Production of Pigments and Major Dyes

Table M-IX 2.1: Installed and Production of Dyes and Dyestuffs (000’ MT)

TableM-IX 2.4 Process  Application Based Dyes

Dyes Intermediate: Various Dyes Intermediate and their Structure, Methods of Preparation and their Uses is given in Table M-IX 2.4 

Table M-IX 2.5: Various Dyes Intermediate and their Structure, Methods of Preparation and their Uses 

Product	Derivatives	Structure	Method of pr ep aration	Purpose
Benzene	4-aminobenzene (sulfonic acid)		Sulfanilic acid is a grey crystalline solid produced from sulfonation of aniline	It is used to make dyes and sulpha drugs
	N-N-Dimethyl aniline (DMA)		1. Initially it was prepared by heating aniline and iodomethane. 2. Industrially it was produced by alkylation of aniline with methanol in the presence of an acid catalyst.	derivative of aniline DMA is a key precursor to commercially important triarylmethane dyes such as Malachite green and Crystal violet
Toluene	Ortho chloro Benzoic acid		1. It may be synthesized by the oxidation of 2-chloro toluene with potassium permanganate. 2. It can also be synthesized by diazotation which fallows Sandmeyer reaction.	As an intermediate in manufacture of drugs especially Mefenamic Acid & also in the manufacture of dyes & pigments.
	P-Nitro-benzoic acid		1. It is prepared by oxidation of 4-nitrotoluene using oxygen or nitric acid as an oxidant.  2. Alternatively it can also be prepared by nitration of ploy styrene fallowed by oxidation of alkyl substituent.	as a dye intermediate, dying carrier, disinfectant additive, penetrating agent and pesticides and manufacturing other compounds
	5-amino-2- chlorotoluene-4-sulfonic acid(Cacid)		p-toluenesulfonic acid, undergo nitrification followed by reduction so after that filtrate hydrochloride acid was crystallized into 2-amino5-chloro-p-toluenesulfonic acid	It is an important Intermediate of manufacturing red organic pigments (C.I. Pigment red 48:2) and some dyestuffs.
Naphthale ne	α- naphthol (1-naphthol) or  1-Hydroxylnaphthalene		1. α- napthol is manufactured by heating 1-nathalenesulfonic acid with caustic alkali or  2. heating 1-napthylamine with water under pressure.	directly in making several dyes and are converted into numerous dye intermediates, as well as into tanning agents, antioxidants, and antiseptics
	β-naphthol 2-hydroxy naphthalene		β-napthol is manufactured by fusing 2-nathalenesulfonic acid with caustic soda.
	1-amino-8- napthol-4, 6-disulfonic acid(K-acid)		1-naphthylamine -4,6,8-3 acid with sodium carbonate solution and in three naphthylamine sodium and at 178-184° C using sodium hydroxide solution for alkali fusion	As azo dyes, reactive dyes and organic pigments intermediates, mainly used in the production of cationic dyes, reactive red K-2G other
	1-amino-8- napthol-3, 6-disulfonic acid(H-acid)		an important dye intermediate, is produced from naphthalene by a combination of the unit processes of sulfonation, nitration, reduction, and hydrolysis.	H Acid is used in the manufacture of a large number of azo dyes and pigments.
	1-napthyl amine- 8 sulfonic acid (Peri Acid)		Naphthylamine is an aromatic amine which can be obtained from nitronaphthalene (with iron and hydrochloric acid) or naphthol with sodium acetate, ammonium chloride.	Is used directly in making several dyes and converted into numerous dye intermediates, as well as into tanning agents.
	1-napthyl amine- 6-sulfonic acid (cleve's acid)
	1-napthyl amine- 7-sulfonic acid(1, 7-Cleve's Acid)
	5-amino-2- chlorotoluene-4-sulfonic acid(Cacid)		p-toluenesulfonic acid, undergo nitrification followed by reduction so after that filtrate hydrochloride acid was crystallized into 2-amino5-chloro-p-toluenesulfonic acid	It is an important Intermediate of manufacturing red organic pigments (C.I. Pigment red 48:2) and some dyestuffs.
	2-napthol-3,6-two sodium salt(R acid)		Its produced from naphthalene by a combination of the unit processes of sulfonation, nitration, reduction, and hydrolysis.	R-salt is an important dye intermediate used in the manufacture of a large number of azo dyes and pigments.
Anthraqui none	1,4-dihydroxy anthraquinone (quinizarin or Solvent Orange 86)		1. It is prepared by reaction of phthalic anhydride and 4-cholorophenol fallowed by hydrolysis of the chloride. 2. It can also be prepared less efficiently from phthalic anhydride and hydroquinone.	an intermediate for the synthesis of indanthrene- and alizarin-derived dyes
	1,4-diamino anthraquinone		1,4- Diaminoanthraquinone is reacted with sodium dithionite to produce 1,4-diamino-2,3-dihydroanthraquinone.	ananthraquinone dye used with Disperse Red 9 in colored smoke to introduce a violet color. It is also used in dyes and marine flares.