FORM 2
THE PATENTS ACT, 1970 (39 of 1970]
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION
A novel and environment friendly "Zero Solid Discharge" treatment used in dyes and dyes intermediate industries.
2. APPLICANT
Name Nationality Address
AMBUJA INTERMEDIATES LTD A company registered in India under The Companies Act. 10-11-12-13, 4-D SQUARE MALL, 3rd Floor, Visat Gandhinagar Highway, Sabarmati, Ahmedabad, Gujarat
Name Nationality Address
AMBUJA A company registered 10-11-12-13, 4-D SQUARE MALL,
INTERMEDIATES LTD in India under The 3rd Floor, Visat Gandhinagar
Companies Act. Highway, Sabarmati, Ahmedabad,
Gujarat
3. PREAMBLE TO THE DESCRIPTION
"COMPLETE SPECIFICATION"
The following specification particularly describes the invention and the manner in which it is to be performed.

4. DESCRIPTION FIELD OF THE INVENTION
The present invention is related to dyes and dyes intermediate industry wherein toxic organic effluent is generated at large scale. The invention relates to a novel method of treatment given to such toxic organic effluent and to make it harmless to the environment. Moreover, to convert such effluent into valuable by-products.
BACKGROUND OF INVENTION AND PRIOR ART
Dyes and dyes intermediate industries are one. of the largest field in all the time generating effluent at the large scale. The effluent of dyes and dyes intermediate contain toxic organic compounds, inorganic salts, acid and water. If such waste are not disposed carefully, it can be extremely hazardous to human health as well as to the environment. Any inaccuracy may comprehensively affect human health, animals, sea creatures, plants, natural water resources and overall environment.
In the closest known prior art, the said effluent is incinerated or spray dried and finally interred in government approved solid land-fill sites.
Specifically, in the prior art, the said effluent is first treated for removal of inorganic salts. Then the effluent is neutralized with hydrated lime to remove acid in the form of gypsum. The gypsum is filtered off and filtrate is concentrated. The concentrated effluent rich in organic compounds and some inorganic salts is either

incinerated or spray dried. The incinerated or spray dried powder / solid waste is carefully & securely packed in bags and interred in government approved solid land-fill sites.
DRAWBACK OF THE PRIOR ART
In the prior art, substantial manpower are involved in the processed of treatment given to the hazardous effluent generated by the dyes and dyes intermediate industries. Such treatment must be processed under strict attentive conditions. It deserves intensive awareness and consciousness during the treatment in prior art. There are serious chances of accidental circumstances as well as human error in such treatment. Any inaccuracy may end into the critical hazard to their health.
The manpower involved in such treatment process, must strictly follow the safety manual and carefully maintain the safety instruction at work place. Further, though the safety regulations have been followed strictly, there are chances of long term risk to their health.
Moreover, the respective Government Authorities have applied safety regulations and guidelines for the disposal of effluent generated in dye and dye stuff industries. Accordingly, such effluent must be processes, treated, disposed and interred to the approved land-fill sites strictly. The effluent is processed through specific treatment and finally converted into powder / solid waste and interred in government approved solid land-fill sites.

However, the solid waste contains toxic organic compounds. In the event of natural disasters like earthquakes and floods, the secured solid land-fill site can get damaged allowing for seepage of water. The solid waste dissolves in the water re-generating the toxic effluent. The effluent can contaminate the underground water-table leading to highly polluted water at large scale.
Moreover, the overall process of safe disposal of effluent are expensive and consumes energy at the extent scale, which is again affecting the environment.
Solution Provided in Present Invention
The present invention is protecting environment from the hazardous toxic chemical waste, specifically, Carbonaceous Powder generated in dyes and dyes intermediate industries.
- The present invention is recovering the valuable chemicals namely Acid Catalyst "AC [ - SO3H , - OH ]" and salt from the "Carbonaceous Powder"
- The present invention is recycling and reusing water during the entire process.

OBJECTS OF THE INVENTION
The principle object of the present invention is to safeguard environment from the hazardous effects of effluents generated in dyes and dyes intermediate industries.
Another object of the present invention is to avail safe and environment friendly novel process of treatment for organic effluents generated in dyes and dyes intermediate industries.
Another object of the invention is to destroy the toxicity of the organic compounds present in the effluent.
The further object of the invention is to overcome the possible risk of environmental hazard in the event of natural disasters like earthquakes and floods. Whereas the solid waste of secure land-fill sites may dissolve in the water re-generating the toxic effluent.
Another object of the present invention is to eliminate the generation of toxic solid waste in dyes and dyes intermediate industries. This invention obviates the implementation of interring solid toxic waste in land-fill sites. Whereas such land can be usable for farming, housing and other general purposes.

Another object of the present invention is to simplify the waste management operation officially implemented in dyes and dyes intermediate industries. Wherein the waste management is complicated and multi-operation task starting from factory up to land-fill sites. Moreover, the present invention will save the expenses associated to effluent disposal process. Which includes various expenses namely transportation, labor, handling, packing, disposal charges etc.
Another object of the present invention is to convert the waste effluent into usable by-product and to avail the benefit of valuable products. At the end of the invented process certain by-products namely (i) Acid Catalyst Carbon, (ii) Sodium Sulfate Sodium Chloride-
"NaCl".
Summary of the Invention
The present invention converts chemical waste material into non-hazardous, usable chemical material. Specifically, the present invention converts "Carbonaceous Powder" into carbon catalyst and inorganic salts.
The Carbonaceous Powder which contains toxic chemicals, is a kind of effluent generated in various chemical industries.
The present invention recovers Acid Catalyst "AC [ - SO3H , - OH ]" and salt from the "Carbonaceous Powder" containing toxic organic

compounds. Further, the present invention is aimed to reuse the water during the entire process.
Detailed Description of the Invention
The present invention converts Carbonaceous Powder into non-toxic, useful chemicals. Carbonaceous powder is a kind of effluent containing toxic chemicals which is generated in various chemical industries including dyes and dyes intermediate industries, pharmaceutical industry, pigment industry, sugar industry, distillery industry and textile industry.
Depending on particular industry, the Carbonaceous Powder may contain OH, NH2, S03H, S03Na , CH(CH2-CH3)n, Cl , Br , I, F , Azo, Diazo and metal complex.
The present invented process mainly performs three major tasks.
Carbonization of Carbonaceous Powder - To recover Acid Catalyst "AC [ - SO3H, - OH ]" from Carbonaceous
Powder
To separate salt from water
Wherein, the conversion process comprises of various steps as described below.
a) Carbonization:

Carbonaceous Powder is carbonized in heating chamber at 350°C to 650°C in presence of a non-reactive gas, Nitrogen "N2". In this step, the mixture of Carbonaceous Powder is converted into carbon and salt by aforesaid heating process.
b) Drowning in water:
The mixture of carbon and salt is drowned in water having 80°c to 90°C of temperature.
c) Separation of salt and carbon
Salt and carbon are having different property while droned in water. Salt is having property of being soluble in water at the given temperature while carbon is insoluble in water.
At the end of this step, the mixture of effluent is divided into two parts using filter press. The salt "Na2S04 , NaCl" is separated in form of liquid by dissolving in water. And the carbon catalyst Acid Catalyst "AC [ -SO3H, -OH ]" is separated in form of solid powder.
d) Distillation of water
Finally the water containing salt is processed through distillation. Wherein water is distilled using two alternate options namely "multi-effect evaporator" and "Force Circulation Evaporator". During this step, 50% to 7.0% of water will be distilled from liquid. Such water

will be reused in step "b" as described above. The remaining material is "salt solution" containing mainly salt mixed with 50% to 30% of water depending on particular distillation process used to distill water.
e) Belt Filter Process
The belt filter process is mainly for solid/liquid separation processes, particularly the dewatering of salt solution in present invention.
The process of filtration is primarily obtained by passing a pair of filtering belts through a system of rollers. The system takes a salt-solution as a feed, and separates it into a water and a solid salt.
Brief Description of drawing
Figure 1: Indicates the invented process of A novel and environment friendly "Zero Solid Discharge" treatment used in dyes and dyes intermediate industries.
Detailed Description of drawing
Figure 1 indicated the flow chart of a novel and environment friendly "Zero Solid Discharge" treatment used in dyes and dyes intermediate industries. Wherein "Carbonaceous Powder"[1] is carbonized in Heating Chamber(2) at 350°C to 650°C in presence of a non-reactive gas, Nitrogen "N2". Wherein the carbonaceous powder is converted

into carbon and salt. The mixture of carbon and salt is sent to 'water drowning container"(3) and drowned in water having 80°C to 90°C of temperature. The mixture is further sent to "Filter Press"(4). Wherein the salt "Na2S04, NaG"(5) is separated in form of liquid by dissolving in water. And the carbon catalyst Acid Catalyst "AC [ -SO3H, -OH ]" (6} is separated in form of solid powder. Liquid of "Na2SO4, NaG"(5) is further sent to "Holding Tank"(7) and distilled using either "multi-effect evaporator"(8] or "Force Circulation Evaporator"(9). During this step, 50% to 70% of water will be distilled (10) from liquid. Such water will be reused in "water drowning container" (3) as described above. The remaining material is "Salt Solution"(ll) containing mainly salt mixed with 50% to 30% of water depending on particular distillation process used to distill water. Finally, Salt Solution(ll) is passed through "Belt Filter"(12) process. "Belt Filter"(12) is mainly for solid/liquid separation processes, particularly the dewatering of salt solution in present invention. The process of filtration is primarily obtained by passing a pair of filtering belts through a system of rollers. At the end of process, "Na2S04" (13) and water (14) are separated.

We Claim
Claim-l Method of Carbonization of Carbonaceous Powder, whereas carbonaceous Powder is a kind of toxic effluent generated in various chemical industries including dyes and dyes intermediate industries, pharmaceutical industry, pigment industry, sugar industry, distillery industry and textile industry. Wherein the Carbonaceous Powder may contain OH, NH2, S03H, S03Na , CH(CH2-CH3)n, Cl, Br , I, F , Azo, Diazo and metal complex depending on particular industry.
Claim-2 Method of carbonization of carbonaceous power as described in claim-l wherein the carbonaceous power is converted into carbon and salt by heating in chamber at 350°C to 650°C in presence of a non-reactive gas, Nitrogen "N2".
Claim-3 Method of separating salt and carbon from the mixture processed in claim-2. Wherein the mixture is drowned in to water at 80°C to 90°C temperature and salt is dissolved in water due to water-soluble property of salt. At the same time carbon is insoluble to water. Wherein salt "Na2SO4 , NaCl" is separated in liquid form and carbon catalyst "AC [ -SO3H, -OH ]" is separated in solid powder form.
Claim-4 Method of distillation of water from mixture of "salt & water" generated as per claim-3. Wherein water is distilled using two alternate options namely "multi-effect evaporator" and "Force Circulation

Evaporator". 50% to 70% of water will be distilled from liquid. Wherein, the remaining material is "salt solution" containing mainly salts "Na2S04, NaCl" mixed with 50% to 30% of water depending on particular distillation process used to distil water.
Claim-5 Inorganic salts "Na2SO4, NaCl" obtained according to claim-3, and claim-4.