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VAT DYES
V
at dyes one of the
important class in the
synthetic dyes
produced. These dyes are
characterised by their insolubility
in water. They are applied to the
fabric in a reduced, soluble form,
which has affinity for the
substrate and after the reduced
dye been absorbed, the fabric is taken out from the dye bath and left in the air or
immersed in solution, of a mild oxidising agent to reproduce the dyeing column. Vat
dyes are, in general, fast to washing to light, etc.
Until early times of the present century, the only vat dyes known were those related
to indigo. But due to the constant research work in the field, a new class,
anthraquinone dyes was found and is of much prominence these days.
Indigo was first a naturally cultivated dye which was principally grown in our country.
Indigo has become quite important in dyeing full shades of navy blue on wool, for
uniform cloth of good fasteners. While dyeing, it is reduced by hydrosulphite, to make
the alkali soluble leuco derivative or to make indigo white.
As in the case of other dyes, vat dyes is mainly the final application in textile industry
and more than 90% of the entire Vat dyes produced are consumed by the textile
units located in various parts of the country.
Market Survey
Presently, the following are the units engaged in the manufacture of the Vat dyes in
our country:
1. M/s Amar Dye Chern Ltd., Rang Udyan, Sital Devi Temple Rd., Mahim, Bombat-
16.
2. M/s Aromatics and Dyes Indus., Plot No. 19, Block 10/ Road No. 4/ Udyognagar/
Udhna, Surat.
3. M/s Attic Industries Ltd., P.O. Atul 396020, Dist. Valsad, Gujarat.
4. M/s Associated Chemicals Indus., Opp. Vijay Mills, Naroda Road, Ahmedabad -
380025
5. M/s Central Dyes Products (P) Ltd., Ruvaj ari Road, Bhavnagar, Gujarat.
6. M/s Chemical and Dyestuff Industries, Kalia Kuva, College Road, Nadiad, Gujarat.
8. M/s Harish and Co., Anand Bhavan, Mangnath Street, Junagadh - 362001.
9. M/s Indian Dyestuffs Ind. Ltd., Mafatlal Centre, Nariman Point, Mumbai-21.
10. M/s Indian Chemi Dyes Industries, Plot No. 6-B, Govt. Ind. Estate, M.G. Road,
Mumbai.
11. M/s Jakovan Industries, Dutta Mandir Road, Bhadup, Mumbai - 78.
12. M/s Makwell, 310/312, Samuel Street, 2nd Floor, Vadgadi, Mumbai - 400 003.
13. M/s National Chemical Industries Pvt. Ltd., 210, Najafgarh Road, Industries Area,
Delhi-IS.
Process of Manufacture
Vat dyes are made up of any organic colouring matter (with the exception of basic
and sulphur colours) which is capable of undergoing a reversible reduction-oxidation
cycle without serious colour loss or change of shade. No general formula can be
written for a vat dye. It is almost always a coloured organic compound containing two
or more keto groups (i) which are alkali to give leuco compound (ii) which has affinity
for cellulosic fiber. In many cases this affinity extends also to other fibers such as
wool, nylon, 'Orlon' acrylic fiber and even to cellulose acetate.
Vat dyes are insoluble in water, solubilised by treatment with caustic soda and
reducing agent, usually hyposulphite, the resulting leuco compounds have affinity for
textile fiber, on exposure to air leuco compound inpregnated fiber reoxidises to the
insoluble parent dye. Vat dyes mainly belong to indigoid and anthra quinoid classes
and are characterised by high fastness, specially anthraquinoids, most valuable for
dyeing and printing cotton, wool and silk pH is kept below a point at which damage to
protein fiber may occur.
Some of the important formulations and their process of manufacture are given here
under:
Vat Brown BR
Vat brown BR is a reddish-brown paste or powder. It dyes cotton, linen and silk from
a dark purlish-brown alkaline 'Hydrosulphite vat, Cold or at 600C, is reddish-brown of
excellent fastness to washing, light, chlorine and acids.
Vat Corinth B
It is a dark paste or violet black powder. It dyes cotton, linen silk from a cold reddish
brown alkaline Hydrosulphite vat liac or neliotrope of excellent fastness to washing,
light and chlorine.
Vat Bordeaux B
It is a dark brownish-red paste or brown powder. It is used in dyeing cotton, linen, silk
and artificial silk from a cold brownish-red alkaline Hydrosulphite vat bordeaux red
fast to washing, light and chlorine.
Vat Red-BT
It is a dark bluish-red paste, or brown powder, then dye. It dyes cotton from a
yellowished cold alkaline Hydrosulphate vat moderately bright pink to bluish-red, fast
to washing, light acids, alkalies and chlorine, rendered rather yellower by soaping at
the boil.
A mixture of 150 parts of 4-brown-N-Methyl-anthrapyridone (obtained by the action of
alkali on acetyl methyl amino-4-bromoanthraquinone), 100 parts of calcium hydroxide
5 parts of copper chloride and 2000 parts of naphthalene is boiled for 3 hours. The
product is filtered hot washed with alcohol, dilute hydrochloric acid and water. It is
then purified further by crystallisation from aniline.
Vat Pink-B
It is a dark paste or bluish-red powder. It dyes cotton from a cold yellowish red
alkaline Hydrosulphate vat bluish pink of only moderate fastness to light and soap.
Vat Scarlet-R
Vat Violet 3B
It is dark violet paste or powder. It dyes cotton, linen and silk from a reddish-brown
alkaline Hydrosulphite vat cold or at 40-50"C violet. It is used for dyeing delicate lilac
and bluish-violet shades of good fastness to light, in the manufacture of lakes in
admixture with usual substrate.
It is an orange-red paste or powder. It dyes cotton, linen and silk from a cold reddish-
orange alkaline Hydrosulphite vat bright orange.
Vat Orange RB
It is a brownish-red paste or brown powder. It dyes cotton from a cold red alkaline
Hydrosulphite vat level brownish-orange, fast to washing, light, acids and alkalies. It
is used in conjunction with Algol Red B for, Turkey red shades.
Vat Yellow G
It is a yellow paste of yellow powder when dry. It dyes cotton from a cold yellowish-
red alkaline Hydrosulphite vat fast yellow although not exceptionally past tp light. It is
also used for dyeing silk.
Indanthrane Blue RS
The chlorine fastness or indanthrene blue varies directly with the purity of the
aminoanthraquinone used. Also the finished dye can be purified by treating it in
concentrated sulfuric acid solution and with oxidising agent (manganese dioxide,
etc.) which destroys the impurities. Such purified dyes are marketed as indanthrene
brilliant blue. They are somewhat stronger and have better chlorine fastness, then
the original dye. The use of potassium acetate was first proposed by a scientists
pope (1910) who also pointed out the advantage of using an oxidising agent in
addition to the acetate or formate. It is essential that the fusion is not carried out at
too high a temperature or for too long a time. Hence, in the plant only small batched
are run, e.g. about 20 kgs. The reaction vessels are either pure nickle or stainless
steel.
Nitrobenzene is run into the reaction vessel from a measuring tank and 1-
chloroanthraquinone, 1, 4 sodium acetate, soda ash and the copper catalyst are
added. The batch is heated to 2100C and held for 10 to 15 hours. The contents of the
kettle are then fed to a rotary vacuum dryer where the nitrobenzene is distilled and
recovered. The dry trainthrimid is ground in a micropulverizer and boiled in dilute
hydrochloric acid to remove salts. This purification step is filtered and washed in a
filter press and dried in a vacuum chamber dryer.
Carbozolation is affected in a glass-lined jacketed kettle. Pyridine 15 fed into the tank
from a measuring tank. Aluminium chloride is poured in from a chain-hoisted drum,
and the temperature is held at 1350C until a sample taken from the melt shows the
same appearance as a sandard sample. The melt sample is boiled with 30% sodium
hydroxide diluted and filtered. The residue is dried on a porous plate and compared
with the standard.
When the reaction is complete, the mixture is pressed into an acid-proof brick-lined
vessel containing caustic soda solution charged from a measuring tank.
A solution of sodium hyphchlorite is run in form another measuring tank, and the
slurry is boiled for about an hour. An excess of sodium bisulfite is sometimes added
to remove excess bleach and the slury is filtered in an iron filter press. The finished
dye is washed and standardised.
Standardisation of Vat Dyes
Only 12 to 15% of vat dye production is sold as dry powders. The over whelming
majority of the output is sold in paste form in varying concentrations, from 10 to 30%
dye. Surface active agents, humectants or other additives may also be included.
In the case of Brown, BR, immediately after the chemical synthesis is complete, the
pulp is charged into stainless steel kettles and the concentration is adjusted
approximately. It is ground in a micropulveriser until the desired particle size and
consistency are attained and then returned to the pasting kettle. Samples are
examined in the laboratory and the strength and shade are finally adusted. The
finished paste passes through a 200 mesh screen into drum for shipping.
Powders are also ground in a micropulveriser, but they are blended in horizontal
powder mills.
Economics of the project
A. Capacity
1. Cost of land and site development of 1000 sq.m. land @ Rs. 25 per sq.m. 25,000
2. Building and shed with 300 sq.m. plinth/area @ Rs. 1000 per sq.m. 3,00,000
3. Other civil works including internal and external approach roads, equipment
foundations, boundary wall/fencing and factory gate, etc.
D. Projecting Cost
J. Financial Implications
M. Profitability
Sodium Acetate
2. M/s Vibgyor Dye Co., 39/13, Eswaran Koil, Street, P.B. No. 257, Erode-I, Tamil
Nadu.
3. M/s Hindustan Fine Chemicals, 8-A, Western India House, Sir P.M. Road,
Bombay-I.
4. M/s Thakoreal Bhagat & Co., Eranada Hall, Kapasia Bazar, Ahmedabad-2.
5. M/s Gujarat Dye Chern Corporation, 638/6, Dalal Building, Kapasia Bazar,
Ahmedabad-2.
Pyridine
6. M/s Wavner Hindustan Ltd., Belwandi House, 254-B, Annie Besant Rd., P.B. No.
9116, Wodi, Bombay-25.
7. M/s Considered Solvents and Chemicals Co., 52/58-Baby Gennu Road, Jivaraj
Shamji Bldg., Bombay-2.
8. M/s Chandrakant Brox., 408, Vaishali Apartments, 4th Floor, Pareker Street,
Bombay-400004.
Aluminium Chtoride
9. M/s Acid Sales Corpn., 7, Paramesawr, Plot No. 353/20, R.B. Mehta Marg,
Ghatjopar East, Bombay-72.
12. M/s Wesix Chemicals, Marshall Building, 3rd Floor, G.P.O. Box No. 1423, 20,
Ballard Road, Bombay-400001.
Hydrochloride
14. M/s The Ahmedabad Mfg. & Calico, Printing Co. Ltd., Post Box No. 12,
Ahmedabad-22.
Soda ash
Caustic Soda
17. M/s Mettur Chemicals and Industrial Corpn., Mettur Dam-2, Salam Dt., Tamil
Nadu.
20. M/s Durgapur Chemicals, 6, Rusell Street, Calcutta-16. (Other chemicals from
various parts of the country).
2. M/s Bird and Co. Pvt. Ltd., Process Engineering Division, Dakhinchari, Calcutta-
48.
3. M/s De Smet (India) Pvt. Ltd., Shrinikotan, Dr. A. Besant Road, Bombay-10.
4. M/s Kalpana Boilers and Chemicals Plant Mfg. Co., 0-9/11, Bhadram Nagar, S.V.
Road, Malad West, Bombay-64.
7. M/s Mirch Process Plants Pvt. Ltd., Delstar, Hughes Road, Bombay-26.