Industry Overview
Sulfur black dyes are high-molecular-weight polymeric colorants produced through reactions involving sulfur or sulfides with phenols and amines. They are widely used in textile dyeing, particularly for cotton-based fabrics, because of their cost effectiveness, ease of application, and generally good wash-fastness. Sulfur dyes are water-insoluble in their original form and are converted into soluble leuco forms under alkaline conditions using reducing agents such as sodium sulfide, sodium hydrosulfide, glucose, or sodium polysulfide. Common salt can facilitate dye absorption, while subsequent oxidation regenerates the insoluble parent dye within the fiber.
Sulfur Black 1 and Sulfur Black T are important representatives of this dye class. Their manufacture involves complex reactions and produces heterogeneous, high-molecular-weight products whose exact chemical structures are not completely established. Sulfur black dyes are predominantly used to produce black, brown, and dark blue shades, with black being particularly important commercially. Their low water solubility contributes to good wash-fastness, although resistance to chlorine bleaching and, in some cases, rubbing can be limited. Sulfur black may also cause tendering of cotton under certain treatment conditions.
The sulfur dye industry has been associated with cotton dyeing for more than ninety years. Commercial significance is attributed to relatively inexpensive raw materials, straightforward preparation, economical dyeing, and favorable fastness properties. The industry is influenced by developments in textile, chemical, and polymer sectors, as well as growth in cotton-based textile production and technological advancements in dye manufacture and application.
Cost Estimation
| Particulars | Cost / Value |
|---|---|
| Plant Capacity | 8 Ton/Day |
| Land & Building (3000 sq.mt.) | Rs. 1.89 Cr |
| Plant & Machinery | Rs. 1.27 Cr |
| Working Capital for 1 Month | Rs. 2.81 Cr |
| Total Capital Investment | Rs. 6.13 Cr |
| Rate of Return | 38% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- TYPICAL CONDITION FOR THE THIONATION ARE AS FOLLOWS:
- STRUCTURE AND PROPERTIES OF SULFUR DYES
- SULFUR DYES
- CHEMICAL STRUCTURE:-
- PROPERTIES OF SULFUR DYES
- MAIN PROPERTIES OF THE SULFUR DYES ARE AS FOLLOWS:
- FASTNERS PROPERTIES:-
- ESTIMATION OF SULFUR DYES
- USES AND APPLICATION OF LIQUID SULPHUR BLACK DYE
- APPLICATION OF SULPHUR DYE
- SPECIFICATION OF LIQUID SULPHUR BLACK DYE
- CHARACTERISTICS AND FEATURES OF LIQUID SULPHUR BLACK DYE
- FEATURES
- CONSTITUTION
- MECHANISING OF THE FORMATION OF SULFURE DYES:-
- FORMATION OF SULFUR BLACK DYE FROM DIPHENYLAMINE DERIVATIVES:-
- 1. DIPHENYL FORMATION:-
- II. THIS DIPHENYL FORMATION:-
- III A) THIS DIPHENYLAMINE DERIVATIVE:-
- B) BLUE DYESTUFF FORMATION (WITH OUT LIBERATION OF NH3
- C) BLACK DYESTUFF FORMATION (WITH LIBERATION OF NH3)
- SULFUR SIDE CHAINS
- CARBON LINKAGE:-
- MECHANISM OF DYE APPLICATION
- SULPHIDE REDUCING AGENTS
- NON-SULPHIDE REDUCING AGENTS
- GLUCOSE
- MERCAPTOETHANOL
- ALKYLATION OF SULPHUR DYEINGS
- OXIDATION OF SULPHUR DYES
- DICHROMATE
- IODATES
- CHLORITE
- HYDROGEN PEROXIDE
- REDUCTION IN CHEMICALS
- MARKET OVERVIEW OF SULPHUR BLACK
- MARKET DRIVERS:
- MARKET RESTRAINTS:
- PRODUCTION OF SULPHUR BLACK
- EXPORT OF SULPHUR BLACK
- IMPORT OF SULPHUR BLACK
- NET IMPORT OF SULPHUR BLACK
- TOP FIVE EXPORT DESTINATIONS (2018-19) OF SULPHUR BLACK (MT)
- TOP FIVE IMPORT DESTINATIONS (2018-19) OF SULPHUR BLACK (MT)
- PRESENT MANUFACTURERS/SUPPLIERS OF SULPHUR BLACK DYE
- SULPHUR BLACK
- CHARACTERISTICS:
- APPLICATION:
- STORAGE:
- GENERAL PROPERTIES:
- REACTION ON CELLULOSE:
- DYEING:
- REMARKS:
- AFTER TREATMENT:
- FASTNESS PROPERTIES:
- METHOD OF APPLICATION:
- PRECAUTIONS FOR SAFE HANDLING:
- SEQUENCES OF SULFUR BLACK MANUFACTURE
- MANUFACTURING PROCESS OF SULPHUR BLACK
- REACTION
- POLY SULPHIDE PREPARATION
- SODIUM SALT DINITRO PHENOLATE PREPARATION
- FINAL REACTION
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF SULPHER BLACK (LIQUID)
- GRAIN STANDARDIZATION
- PROCESS FLOW DIAGRAM
- DETAILS OF SULFUR BLACK DYE
- SOLUBILISED SULFUR BLACK DYE
- HEALTH & SAFETY ASPECTS
- ECOLOGY
- TOXICOLOGY
- B.I.S. SPECIFICATION
- 1. SCOPE:
- 2. COLOUR FASTNERS RATING:
- 3. METHODS OF TEST:
- LIGHT:
- 4. MAKING:
- TABLE - I COLOUR FASTNESS RATING
- 1. SCOPE
- 2. PRINCIPLE:
- 3. SAMPLING:
- 4. TEST PIECE:
- 5. STANDARD PATTERNS:
- TABLE - I SHALL BE USED FOR THIS TEST DYES FOR STANDARD PATTERNS
- 6. APPARATUS:
- 7. PROCEDURE:
- 1. SCOPE
- 2. PRINCIPLE
- 3. SAMPLING
- 4. APPARATUS
- 5. REAGENTS:
- 6. PREPARATION OF TEST SPECIMENTS
- SULPHUR DYE EFFLUENT
- OXIDATION TREATMENT
- BACTERIAL TREATMENT
- CHEMICAL OXIDATION
- TREATMENT TECHNOLOGIES AND EMISSION GUIDELINES IN DYE MANUFACTURE
- AIR EMISSIONS
- LIQUID EFFLUENTS
- SOLID HAZARDOUS WASTES
- EMISSIONS GUIDELINES
- AIR EMISSIONS
- LIQUID EFFLUENTS
- TABLE EMISSIONS FROM DYE MANUFACTURING
- TABLE EFFLUENTS FROM DYE MANUFACTURING
- SOLID WASTES
- AMBIENT NOISE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF 2,4 DINITROCHLOROBENZENE
- SUPPLIERS OF SODIUM SULFIDE
- SUPPLIERS OF CAUSTIC SODA LYE
- SUPPLIERS OF LABORATORY CHEMICALS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF REACTION VESSELS
- SUPPLIERS OF MIXING VESSEL
- SUPPLIERS OF FILTER PRESS
- SUPPLIERS OF BOILER
- SUPPLIERS OF LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS
- SUPPLIERS OF D.G. SET
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Sulfur black dyes are high-molecular-weight polymeric colorants primarily used for dyeing textile fibers. They are generally water-insoluble in their parent form and are converted into soluble leuco forms under alkaline reducing conditions before application. Sulfur Black 1 and Sulfur Black T are important members of this dye class. Their commercial importance comes from economical manufacture, relatively low dyeing cost, ease of application, and generally good wash-fastness. They are particularly significant in cotton textile dyeing.
Sulfur black dyes are applied to cotton by first reducing the water-insoluble dye into a soluble form under alkaline conditions. Reducing agents such as sodium sulfide or sodium hydrosulfide are commonly used, while common salt can facilitate absorption by the fiber. After the fabric has absorbed the reduced dye, it is exposed to air or another suitable oxidizing treatment. Oxidation regenerates the insoluble parent dye inside the fiber, producing the required shade and contributing to the characteristic wash-fastness of sulfur-dyed fabrics.
Sulfur black dyes are widely used because they combine economical dyeing with useful fastness and straightforward application. They are especially suitable for cotton and can produce deep black shades at relatively low cost. Their low water solubility after oxidation helps limit bleeding during washing and supports good wash-fastness. The report also identifies ease of preparation, economical dyeing, and favorable resistance to several agencies as important reasons for their commercial significance. However, chlorine bleach resistance and rubbing fastness can present limitations.
The manufacturing route described in the report uses aromatic raw materials together with sulfur compounds and alkaline chemicals. For sulfur black products of the Sulfur Black T type, 2,4-dinitrophenol, sodium sulfide, and sulfur are identified as important materials. The report also describes the preparation of dinitrophenol from 2,4-dinitrochlorobenzene using caustic soda, with an alternative route involving aqueous caustic soda, sodium sulfide, and sulfur. The precise composition of commercial sulfur black products can vary with manufacturing and thionation conditions.
The main properties of sulfur black dyes include water insolubility in the parent state, good wash-fastness, economical application, and the ability to produce deep black shades on cotton. They generally show good resistance to light, acids, alkalies, scouring, and milling, although performance varies with the particular product and application conditions. Sulfur black dyes can have poor resistance to chlorine bleaching and may exhibit limited rubbing fastness. Under certain conditions, some sulfur black products can also contribute to tendering of cotton fibers, making appropriate oxidation and after-treatment important.
Sulfur black dye manufacturing requires controlled management of air emissions, liquid effluents, solid hazardous wastes, and workplace safety. The report specifically addresses sulfur dye effluent, oxidation and treatment methods, bacterial treatment, chemical oxidation, air emissions, liquid effluents, solid wastes, and ambient noise. Safe handling also requires appropriate process controls, equipment, storage practices, personal protective measures, and waste-management procedures. Actual treatment requirements should be established according to the specific process chemistry, applicable environmental requirements, and characteristics of the generated waste streams.
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