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PROJECTS ON OFFER BY NSTEDB IN CHEMICALS 

MANUFACTURE OF LINDANE 

1.0 Introduction of the Product  

Benzene Hexachloride Technical grade (BHC-Technical) is a universally used insecticide more potent than D.D.T., Heptachlor and Aldrin the three popular insecticide prevalent in the country. BHC is a persistent contact insecticide with fumigant action. It is found very effective in controlling- garden insects, house flies, mosquitoes and larvae. BHC's insecticide properties are derived from a Gamma Isomer called Lindane present in it. The Lindane is a odourless concentrate, formulate as 1%-2% dusting powders and 10%-20% emulsifiable concentrates. Lindane can be used on all types of crop plants.  

2.0 Indian Industry status  

The general term "Pesticides" includes insecticides, fungicides, rodenticide, molluscicides and weedicides. Today 44 technical grade pesticides are manufactured in the country. Among the south Asian and African countries excluding Japan, India is the largest manufacturer of basic pesticide chemicals.  

Till date 1,82,135 tpa capacity for the production of various pesticides has been licensed out of which 1,67,474 tpa is installed. There are 23 large plants, 50 medium scale plants and 1350 small scale units. Most of the small scale units undertake manufacture of conventional formulations, mostly as dust powders and to a limited extent, wettable powders and emulsifiable concentrates. 

3.0 Market & Demand Aspects  

The Insecticides Association of India has compiled a market study in respect of 10 major pesticides & insecticides. The pesticides covered under this study are BHC, Lindane, DDT, Matathion, Fenitrothion, Dimenthorate, Phosphamidon, DDVP, 2-4D Zineb and Zinc phosphide. The Association has ascertained that the demand growth rate of these pesticides had been @ 6% per annum in the past and keeping in view the additional agricultural programme proposed by the Ministry of Agriculture, the future average demand growth rate has been estimated at 8%. Accordingly the requirement of technical grade pesticides may rise to 2,64,290 tonne by 2000 AD.  

At present no reliable data is available about the existing formulations in the small scale sector. On the basis of information collected recently by the office of the Development Commissioner for small scale industries a list of 1354 units have been compiled. As per Pesticide Formulators Association of India the installed capacity in the small scale sector is 5,60,000 tpa in dusting powders, 1,90,000 wettable powder. 

4.0 Manufacturing process and sources of Technology  

Lindane is manufactured by dissolving BHC Technical (13% to 26% Gamma) in xylene 5% solvent and then concentrating the solution in a retort vessel. The concentrated solution is filtered in a reverse centrifuge, the slurry on the centrifuge contains very high percentage of Gamma Isomer. To obtain the Gamma Isomer in pure form, the slurry is fed to a fractional crystalliser with alcohol to obtain crystals of pure Lindane. The crystals are dried in a shelf drier.  

The yield from this around 9 to 11%.  

Technology Source  

This technology is available from:  

Central Food Technological Research Institute,  
MYSORE-570013, INDIA.  

5.0 Raw materials and utilities  

B.H.C. Technical, Rectified spirit Industrial Alcohol and xylene 5% are raw materials in this process.  

The raw materials and utility requirements are anticipated as follows:  

Basis : One Metric tonne of Lindane  
   

B.H.C.(Technical)	10 tonne
Rectified spirit	0.5 tonne
Xylene 5%	1.0 tonne
Steam	1.25 - 1.5 tonne
Power	150 - 200 KWH
Water	7000 Kltr

  
6.0 Plant & Machinery requirements  

The plant & machinery required for this project are indigenously available and can be listed as follows.  
   

	Rs. in Lacs.
Wet grinder mixer	0.40
Conditioning drum with agitator	0.15
Retort type extractor	1.75
Fractional distillation column	1.50
Centrifuge (reverse flow type)	0.45
Shelf Drier	1.00
Spent liquor storage vessel	0.10
TOTAL	5.35

  
Besides the above, chemical testing laboratory equipments, volumetric weighing pots, and a baby boiler will be required which will cost Rs.0.75 lakhs.  

The machineries can be procured from some of the following suppliers,  

M/s.Gansons Limited,  
46/C, Everest Chowranghee Road, Calcutta-700016.  

M/s. Frigmair Engineers,  
Bharat House, 104, Appolo Street, Fort Bombay-1.  

7.0 Manpower  

This is a batch type process working on 2 shifts per day for 300 days in a  year, the total manpower requirement is estimated as 18 persons which includes 4 administrative staff, 6 skilled persons and 8 unskilled workers.  

8.0 Financial Parameters  
  

Installed capacity	300 MT/year
Working days per year	300 days, 2 shift/day
Annual Sales Realisation	Rs.24.00 lacs.
Annual Raw materials	Rs. 14.00 lacs.
Utilities	Rs. 1.57 lacs.
Annual Salaries & wages	Rs.2.34 lacs.
Connected load 35 HP
Working Capital	Rs. in Lacs.
Raw Material	1.17
Utilities	0.13
Salaries & Wages	0.20
Stock Finished Goods	1.20
Working Expenses	0.05
TOTAL	2.75
Estimated Cost of Project	Rs. in Lacs.
Land	0.70
Building (800 Sq.ft)	1.20
Plant & Machineries	6.10
Other Fixed Assets	0.10
Margin money for working capital	0.90
TOTAL	9.00
Finance Mix	Rs. in Lacs.
Equity Capital	3.00
Term loan from Bank	6.00
TOTAL	9.00
Bank finance and working capital	1.85
Interest on term loan & Working capital/year	1.45
Marketing & Adm. Expenses	1.60
Net Profit	3.04
Break Even Capacity	42.68%

  
9.0 Basis of Project selection  

This project is recommended on the following basis:  

• This is an agricultural input project and therefore with more & more investment in the agriculture sphere by the central & state Governments and also by individuals and farmers, the demand for Lindane will increase considerably.
    
• Lindane is a pesticide of the future with the ban on toxic pesticides in developed countries, this is bound to happen in India also. Lindane being a non toxic but potent pesticide will thus have good future prospects.
    
• So far the product was being manufactured by large scale plants resulting in high cost of production making Lindane a costly farm input. Now with the break through in technology Lindane can be available on affordable cost to farmers.