Abstract
The pilot plant study of cleaner production (CP) process of a dyes intermediate, Fast Bordeaux GP Base (2-nitro-p-anisidine), is presented in this work. The existing production process with acetic anhydride as raw material generates highly polluting (high chemical oxygen demand), huge-volume effluent, and thus the treatment is expensive. In the proposed process, raw material acetic anhydride in acetylation step is replaced with acetic acid. The reaction conditions like reaction time (3 h), temperature (120∘C) and molar ratio of p-anisidine and acetic acid (1 : 3.58) are optimized in the laboratory scale and implemented in pilot plant. The extent of conversion has been monitored by nitrite value test, and purity of product mixture is measured with thin-layer chromatography (TLC). The acidic wastewater quantity is dramatically reduced by incorporating recycling in washing scheme, and thus water consumption is reduced. Reduction in wastewater generation and reduction/elimination of treatment cost is also observed. Chemical oxygen demand (COD) of the effluent stream is reduced by the recovery of by-products sodium acetate and spent acid. The technoeconomical feasibility studies show that the proposed CP options are highly economical and environmental friendly.
Highlights
Progress in the understanding of the phenomena of pollution and modifications to the ecosystem has revealed that environmental impacts must be seen from a product and process design point of view [1, 2]
Various cleaner production approaches that can be applied in production processes include raw material substitution [7], equipment modification [8], technological modification [9], by-product recovery, and recycling [10]
Cleaner production techniques of raw material substitution and recovery and recycling operation have been used in the current study for the manufacturing of Fast Bordeaux GP Base
Summary
Progress in the understanding of the phenomena of pollution and modifications to the ecosystem has revealed that environmental impacts must be seen from a product and process design point of view [1, 2]. Environmental management has concentrated on the development of production system by a new approach of pollution prevention or cleaner production It is closely connected with efficient utilization of materials and energy to eliminate as much as possible toxic substances, reducing quantity and toxicity of emissions and waste before these substances leave the process [3]. To reduce the impact of high water consumption, industries have been searching for alternative methods by adopting systems and technologies to control and treat (clean-up or end-of-pipe) the pollutant emissions generated by production processes. These pollution techniques require additional energy and materials, and disposal of resulting waste has negative influence on the society [4, 5]. The acetylation reaction conditions such as reaction time, temperature, molar ratio of reactants have been optimized in the lab scale and applied in pilot plant scale
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