silica fertilizer It was in 2003 that National Chemical Laboratory (NCL) scientistMohan Dongare developed a solid catalyst to be used in analternative process to make nitro benzene. By virtue of being amore environment-friendly and less expensive process he haddeclared that companies could save at least Rs 40 crore annually,using this method. Five years down the line, recognition through FICCI Lockheed MartinInnovation Award 2008, that gave him a silver medal in May thisyear, has helped boost the visibility of his product and rekindledinterest in the chemical industry. We certainly hope this award will help us in transferring thisprocess to the industry. Some companies like Hindustan OrganicChemical Limited (HOCL) and Chematur Engineering Company, Swedenhave expressed interest in knowing more about the process, saidDongare. In 2003, the Narmada Chematur Fertilizer Company in Gujarat hadbegun talks with NCL about Dongares green process that makes nitrobenzene. At that time, we were short of funds. Now, we have mergedwith Gujarat Narmada Fertilizer Company (GNFC) and can invest inR&D, said N B Patel, chief manager, GNFC. A senior HOCL manager said that they would have to examine thecommercial viability of the process. While Dongare is sure that hisprocess would save these chemical companies a lot of money, companyofficers have said that potential pitfalls in industry transferwould revolve around the money they would have to pay to NCL astechnology transfer fee, royalty for seven years thereafter, costsfor setting up a new plant infrastructure and so on. Dongare is aware that the royalty and technology transfer fee couldprove to be a dampener. However, he said the economics favour hisproduct in the present-day market. In 2003, the liquid catalystused sulphuric acid was not very expensive at Rs 4 per kg.Against that, sulphuric acid costs Rs 12 per kg today while dilutedsulphuric acid waste after the reaction would sell at Rs two perkg. Companies should be able to save Rs 40 crore per year at aconservative estimate, Dongare said. Further, this process eliminates the effluents, which in turn doesaway with the effluent treatment costs. Nitrobenzene is used inmajor chemical processes from making the foam of car seats tomaking of rubber, dyes, herbicides, explosives and fibres. Dongarehas removed the liquid catalyst sulphuric acid required to helpthe reaction from the equation and introduced a solid catalyst that leaves no waste and is reusable for at least six months. This kind of research is going on everywhere in the world. Solidcatalysts are known to be environment-friendly and economical.Other researchers have been using amino-based solid catalysts,which sparks off a reaction in itself, rendering itself inactive.Our silica-based catalyst is more effective. Lab tests have shownthat it remains active for at least 1,000 hours, Dongare said. Dongare believes that the money it saves will eventually do thetalking. Nitrobenzene sells like hot cakes in the chemicalindustry. The turnover of the industry in the US is at least 30million pounds, he said. In India, the major companies puttogether would produce up to 1,50,000 tonnes of nitro benzene everyyear.
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