1. SAFETY MEASURES UNDERGONE BY CLARIANT
ENVIRONMENT SAFETYHEALTH AFFAIRS (ESHA)
Various safety taken by Clariant .
I. ENVIRONMENT
There are mainly 4 types of pollution. They are as follows.
1) Soil Pollution: Various raw materials which are hazardous to the
environment and many other chemicals harmful for human beings are treated
in pigment ,leather and textile plants.
The sludge that is created from all the sites are not thrown out directly but
they are sent directly to the Mumbai Waste Management sites .There these
sludge are taken out and treated accordingly such that all the waste materials
such as hazardous & non hazardous materials are separated out. Then these
are converted into useful soil which are used as landfills in various parts of
the city
2) Water Pollution: Large amounts of water is required for the treatment of the
plants as well as large amount of water is accumulated from all the plants
.These are directly sent to Water treatment plant installed in the Plant site.
The processes involving are
i. removal of toxic/hazardous chemicals
ii. checking level of COD'S and BOD'S and decreasing these level
iii. final product , which is water free from any impurities. The water is
then sent to the MIDC(Maharastra Industrial Development
Corporation) and they will decide the usage of water.
Note: The standard method for indirect measurement of
the amount of pollution (that cannot be oxidized biologically) in a sample of
water.
The chemical oxygen demand test procedure is based on the
chemical decomposition of organic and inorganic contaminants, dissolved or
suspended in water. The result of a chemical oxygen demand test indicates the
amount of water-dissolved oxygen (expressed as parts per
million or milligrams per liter of water) consumed by the contaminants, during
two hours of decomposition from a solution of boiling potassium dichromate.
The higher the chemical oxygen demand, the higher the amount of pollution in
the test sample. For the contaminants that can be oxidized biologically,
the biological oxygen demand (BOD) method is used.

2. 3) Air Pollution: In these plants there is a system which follows many processes.
The chemicals such as pigments or dyes when prepared may contribute
towards air pollution.
Clariant has installed Jet Scrubbers which are used for the treatment of these
chemicals .They reach in such a way that the end process formed is water at
the pipes and they get releases as water vapour to the atmosphere.
Note: Through special motive nozzles a scrubber medium is injected and
distributed at the top of the Jet scrubber tower to produce a maximum
gas/liquid exchange area and drops with a high relative speed to the gas flow.
Due to the high energy input, the Jet scrubber tower can aspirate and convey
gases and vapours by itself. This injector effect enables the cleaning of flue
gases without a loss in pressure in the gas flow. Thus, there is generally no
requirement for a mechanical ventilator for conveying the gases.
At the same time, the quenching effect leads to the cooling of the gases or
vapours. Water evaporates into the gas stream and the gas stream is cooled to
the cooling limit temperature. Vapours can be cooled and condensed by heat
conduction.
At the modified model (quenching), gases with up to 1.300°C can be cooled
and cleaned in one procedure.
On the way through the scrubber tube, the pollutants are absorbed into the
fluid. In the case of the chemical absorption the harmful substances are
chemically bound.
Separation degrees of up to 98 % per scrubber stage are reachable.
By using the effect of inertial separation, solid particles or drops in the area of
the motive nozzles are separated at fast flying drops of the scrubber fluid by a
collision with them. In this way, particles with a diameter ≥ 5µm can be fully
separated.
The gas and liquid have to be separated in a centrifugal separator arranged
downstream at the end of the Jet scrubber tube.

3. 4) Noise Pollution: If any machine does not operate properly such that they
create any disturbing noise , the instrumentation engineers are called and they
find solutions the problem.
II. SAFETY
This is for the safety of every individual and for the company.
Protective Personal Equipments(PPE'S) are given to every person who enters the
premises of the Site. They include Shoes resistant to acid &oil, goggles to protect
spilling of any harmful substances falling on the eyes. Safety Helmets are also given
so that the head is well covered from any hard substances .Rubber gloves are given
necessary.
III. HEALTH
Health is a major concern for every individual working in the plant. Whenever a
person enters the plant he/she has to know the emergency exits, first aid box, shower
to wash away if any harmful substance falls on the body. If any accident occurs take
all the safety precautions and report to the Infirmary centre as soon as possible.
IV. AFFAIRS
Every individual should have self integrity & dignity of himself. Discipline should be
maintained thought the period of one's stay.
Mobile phones are not allowed inside as they create sparks and can create any
destruction in the plant.

4. PIGMENT PLANT
DRYING CHAMBER , FILTRATION AND DISCHARGE
The operations in this are
 Filtration
 Dumping
 Discharge
 Packing
Filtration
 Almost 8% of slurry comes from the batching process and
passes through the plate & frame filter press.
 mother liquor passes out by doing this operation.
 cake from this process gets collected at plates
 it maybe red or yellow
 the filter cloth required for the filtration is changed and
replaced after every one year
 there is a washing plate and a normal plate used in this process
 hydraulic pump is used in this operation, 150 HP is the power
required for the pump
What is filter press?
A filter press is a tool used in separation processes, specifically
in solid/liquid separation using the principle of pressure drive,
provided by a slurry pump. The filter press is used in fixed-
volume and batch operations, which means that the operation
must be stopped to discharge the filter cake before the next
batch can be started. The major components of a filter press are
the skeleton and the filter pack. The skeleton holds the filter
pack together while pressure is being developed inside
the filtration chamber. The chamber however can only hold a
specific volume of solids.

5. Plate and frame filter press
A plate and frame filter press is the most fundamental design, and many now refer it
as a "membrane filter plate". This type of filter press consists of many plates and
frames assembled alternately with the supports of a pair of rails. The presence of a
centrifuge pump ensures the remaining suspended solids do not settle in the system,
and its main function is to deliver the suspension into each of the separating chambers
in the plate and frame filter. For each of the individual separating chambers, there is
one hollow filter frame separated from two filter plates by filter cloths. The
introduced slurry flows through a port in each individual frame, and the filter cakes
are accumulated in each hollow frame. As the filter cake becomes thicker, the filter
resistance increases as well. So when the separating chamber is full, the filtration
process is stopped as the optimum pressure difference is reached. The filtrate that
passes through filter cloth is collected through collection pipes and stored in the filter
tank. Filter cake (suspended solid) accumulation occurs at the hollow plate frame,
then being separated at the filter plates by pulling the plate and frame filter press
apart. The cakes then fall off from those plates and are discharged to the final
collection point.
Cake discharge can be done in many ways. For example: Shaking the plates while
they are being opened or shaking the cloths. A scraper can also be used, by moving
from one chamber to another and scraping the cake off the cloth. At the end of each
run, the cloths are cleaned using wash liquid and are ready to start the next cycle
Drying Chamber
 the drying equipment used is Tray dryer.
 the product (cake) is filled in trays
 it is then taken in trolleys
 Inside the tray dryer there are 2 compartments , each
compartment consisting of steaming coils present all
over the surface of the tray dryer.
 fans are also present inside these 2 compartments
 depending on the material composition it is dries
accordingly. For example some products require 40, 48,
60 hours for drying
 after the drying process is complete products are then
tested in the laboratory , it should have 1%-1.5%
moisture content.

6. Tray Dryer
A tray Dryer is an enclosed insulated chamber in which trays are placed on top of each other
in trolleys. Tray Dryer are used where heating and drying are essential parts of manufacturing
process in industries such as Chemicals, Dye stuff, Pharmaceutical, Food Products, Colours
etc. The material to be dried either wet or solids are placed in the trays. Heat transfer is by
circulation of hot air by electric heaters or steam in radiator coils. Blower fans are installed
inside to ensure proper circulation and transfer of heat. A control panel to control the
temperature and other parameters is fixed outside the dryer. These dryers are available in
Mild Steel, Stainless Steel or construction. Tray dryer is used for drying of pigments, food,
bakery, electrodes, chemical and plastic powders.
DESCRIPTION
The Drying ovens are normally available with choice of heating mode, as electrically heated /
steam heated & thermic fluid heated..
In electrically heated model, digital temperature controller provided with digital timer to
facilitate working day and night. In steam & thermic fluid heated model, digital temperature
indicator is provided with digital timer , but the temperature controller is not supplied with
the machine.
AIR CIRCULATION
A highly effective re circulating air system is provided. The heated air, is re circulated with
fresh air in selected proportions for optimum drying. The system is designed so that the
materials at the top & the bottom dry simultaneously.
Uniform air circulation, controlled temperature, sturdy construction and large working space
are the valuables of the oven which is suitably designed to cover wide temperature range,
loading and unloading is faster and simple. In higher capacities trays trolley rolls in and out
of the chamber. For continuous operation a spare trolley can be had for loading while the
drying cycle is taking place.
Discharge
 some products are taken in trays
 after the products are dried , they are kept on pans from which they
can get transferred
 they have two mechanism such a lifting upwards & falling backwards
 after the products have gone through drying operation they are filled
in drums
 they are labelled accordingly

7. a. Product name
b. Batch no
c. Manufacturing date
Noodler
 this mechanism is used to make the material in a noodle form
 it is done so that drying operation will take place very easily
 more surface area means increase in drying rate.
BATCHING PROCESS
Batching process mainly refers to the process involving making the batch products
required for industrial use.
Mainly three methods are followed in this batching process. They are
1) Base Dissolution & Diazotisation
2) Coupler Dissolution
3)Coupling
Base Dissolution & Diazotisation
 Certain substances like HCl and various other reagents were already
poured into the vessel overnight,
 a stirrer is kept so that stirring process is ensured .
 to check the presence of nitrate , 2-3 drops of nitrating reagent is
poured on the filter paper and the sample is poured onto it. It should
show a blue colour.
Coupler Plant
 the vessel should be maintained at 90°c-95°c
 the lines for caustic soda, HCl, acetic acid , rosin are opened
 there is a software developed such that only vessel should receive all
the chemicals so that all the other valves are closed of other vessels and
the chemicals do not enter those vessels.

8. Coupler
 After the centrifugal pump is switched on such that it gets filtered in the plate filter
 temperature should be maintained
 then the required temperature and pH is maintained.
 later a sample of the product is taken then its coupling reaction is tested in the
laboratory.
 later it is then stirred for 2 hours , then the batch is prepared then later transferred for
the filtration.
Different types of valves present are Butterfly valve, Globe valve , Ball valve. Globe
valve is mainly used for the steam line .Different of lines present are 30% NaNo2 ,
40% NaOH , 3 BAR AIR and rosin etc.
Water is present to flush down the chemicals present at the sides so that everything
gets transferred from the sides of the vessel. Filter aids are present and are used for
the purification process in clarifiers .Different types of pumps used are reciprocating
pump , diaphragm pump, centrifugal pump. Finally coupling reaction is checked to
see whether coupling reaction has taken place or not. It is done in the laboratory.
Exhaust is present at the top to collect the hot air and then release into the
atmosphere. The exhaust circulates the air. The stirrer is used to stir the pigment/dye.
It can be operated in first, second & third gear.
TANK FARM
Tank Farm mainly refers to the storage of raw materials in large tanks.
The raw materials used are
a. Acetic acid
b. Sodium Nitrite(NaNo2)
c. Hydrochloric acid(HCl)
d. Caustic Soda(NaOH)
e. Water

9. From the tanks each raw material is transferred to lines which is then used for the batch
process.
 There is a meter reading which indicates the volume or level of raw material which
has been filled by the raw material in the large tank.
 Pumps used are air operating pump, sub pump
 Valves are present to regulate the flow of raw material and so that flow takes place
very easily.
 Pumps are switched on to fill the raw material inside the tank
 Stocks are taken for each raw material at the starting of the day.
 The initial reading of each raw material .
 Dilution is done for certain raw material .For ex 45% NaOH is converted to 40%
NaOH, 35% HCl is converted to 30% HCl.
 Dilution is done by passing water in the tank and passing it or one hour.
 It is then tested in the lab , if not diluted again the dilution process has to be
continued.
 Jet scrubber are installed near the tank
 one for the plant and one for the batch process. Its main function is take out the
effluent and pass it into the atmosphere without causing any pollution.
DCBH-Dichlorobenzidine Dihydrocoride .

10. NEW PREPARATION PLANT
The processes involved are
i. Standardisation
ii. Addition
iii. Milling
 All the types of pigments are prepared. They blue, black , green
 For black there are 14 varieties, blue- 10 varieties, green-5 varieties
 After all the drying operation and the process finishes in the pigment plant
and the process continues in the new preparation plant.
 Here it is fully atomised only 1% is manual work
 The solid particles after milling is converted into its milling form
 It is done to reduce the size of particles so that the pigment size will be
evenly distributed.
 After the standardisation & addition process then it goes for milling
 It is filled in drums , which are local markets and some are exported.
 There are Macmillan vessels and Dyno Vessels.
 In dyno vessel the capacity intake is more.
 In Macmillan the milling process is vertical whereas the Dyno vessel it is
horizontal.
 Oils are present which are also known as filter oils which dissolve the
impurities.
 A 2 layer is formed such that oil remains at the top and water at the
bottom.
 The dust and impurities gets separated inside the scrapper.
 Feed pump is used for this process.
 Some materials may be viscous the pump has to be used so the
particles come down for milling process.
 0.5 N/m2 is the pressure applied to make the viscous particle come
down.
 Air operating pump is also used.
For example the product CC FP Green 631. First the charging process
we add water, H27, glacial acetic acid. Then it is stirred for one hour
till the uniform composition is done. Then it is sent for charging which
takes at most for 24 hours. Then it comes for milling process , 30°c
should be maintained. In MM-13 the std size is 1.2-1.3 mm whereas in
dyno it is 0.6-0.7mm. For ex in MM-13 the product flows from the
pipe into the pump, the pump then send the material. From where it is
then sent to a non return valve where it is sent to a small vessel where

11. it is chilled. The duration for milling may be 12 hours, 40 hours. It
mainly depends on the product. Now the product is then sent to the
Process control lab , they check the requirement. Then the
manual(instruction) sheet is given from the quality control lab. In this
process the materials like H2O , H27 etc are added. It is then sent for
filtration process to filter out the sand. It is then filled in drums . They
may be 10 kg , 60 kg and they are labelled according to the industrial
purpose.

12. BAND DRYER
This place mainly is used for drying the material.
 The material first is washed and then the washed material is then sent through the
noodler.
 The noodler converts the product into noodle form so that surface is more for drying
operation.
 Inside the band dryer there are steaming coils present at both sides and they are used
for the drying operation.
 There are 4 band dryers , 3 are for yellow pigment and one is for red pigment.
 They are all atomised whereas one is manual work.
 There is a plate & frame filter press for the filtration process.
 A belt conveyor is there at the bottom so that all the products are circulated.
 The materials from the batch process is filtered in the plate & frame filter .
 Hydraulic pump is used in the operation for filtration.
 There are 6 zones inside the band dryer
z1, z2, z3 :They are maintained at a temperature of 130°c
z4,z5,z6:They are maintained at a temperature of 70-90°c.
 Materials from the batch process comes for the filtration.
 After that the products go into a kneader vessel.
 In one band dryer there is a rotary vessel, other band dryer has breaker and
they get transferred into the noodler.
 A stirrer is present inside the band dryer it rotates at a particular speed.
 There are 81 no of plates.
 There is a dust catcher connected to the plates.
 Each valve in the band dryer has a specific function one maybe used for steam
whereas the other may be used for water.
 Time for drying is 12 hours for each set of material it takes minimum 2 hours
to get dried.
 Then it is collected and tested in the laboratory. They are then filled in drums
according the industrial purpose.

13. EX-PLANT
The production process of brown pigment. It mainly takes place in 4 stages.
i. First stage: The acid chloride formation where the raw material is reacting with an
inorganic compound in a solvent medium under certain specific conditions . This
reaction happens in a glass line reactor (R1000) which requires more material and
man hours ( around 70 hours).
ii. Second stage: Amine solution preparation this took place in a separate reactor R786
where the amine solution was made and then later transferred to R1000.
iii. Third stage: Filtration , where the reaction from R1000 was transferred to filters
A,B,C,1,2,3 depending upon the availability : filtration took place followed by
specific washing procedures to remove the impurities , un reacted materials , salts and
moisture. The filtration cycle time was longer.
The working of filters
Filling: The vessel was filled with unfiltered product and circulated through the
overflow nozzle for an even suspension.
Pre Filtration: The suspension was circulated through the filter elements to produce a
porous pre coat layer.
Filtration: The filtrate passes through the building filter cake; filter plate and spacer
ring area to the hollow shaft and filtrate outlet.
Heel Volume Filtration: After filtration/washing , the heel liquid was recycled by
pumping into the vessel head from the bottom outlet, with the help of filtration
pressure produced by compressed gas. Product recovery is maximized by this process
which was quicker and more efficient.
Washing: The wash liquid followed the same route as in filtration . Force washing
using the heel volume filtration method reduced the wash liquid volume.
Moisture removal: The cake can be heated and dried in the vessel using hot gases.

14. Slurry Cake Discharge
The wet cake was flung from the rotating places , cascaded to the bottom and exited
through the discharge nozzle aided by a suitable solvent. Hydraulic pump is used for
the discharge.
The Fourth stage: Drying and Packaging
The materials were dried , size reduced according to specifications, cooled and
packed.
Recovery and Recycling
In the production process large quantity of solvent and alcohols were required around
32m3 and 16.8m3 respectively.
Due to environment effluent and economic factors the solvent and alcohol were
recovered, recycled and reused.

15. SOME OF THE PRODUCTS MADE AT THE ROHA SITE
Fine PastePreparationPaste
Hydropillic, highly concentrated readily pourable pigment containing non ionic / anionic
wetting agents and dispersing agents . They mix readily into aqueous media to form stable
dispersions. They are miscible with one another in any ratio.
Their main purpose is the coloration of synthetic resin emulsion paints, wood stains , latex ,
soaps etc
FPH
Pigment Preparations
Water based binder-free pigment preparation based on non-ionic/ anionic wetting and
dispersing agents. They are available in four basic colours ie Yellow , Red , Blue , Green.
They are miscible with each other in any ratio.
They are most suitable for economy grade emulsions paints and distempers.
CC YELLOW FINE PASTE 511
CC YELLOW FINE PASTE 509
CC RED FINE PASTE 535
CC RED FINE PAST E 548
CC VIOLET FINE PASTE 591
CC BLUE FINE PASTE 612