Page 57 - TEXtalks International July/August 2022

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The Origin alkaline wastewater helps to neutralize the acid
125 years ago, Indigo was derived from the Indigo wastewater from BASF whilst BASF monitors the
plant, which was cultivated in huge plantations on the wastewater flow and guaranties a full protection of
Indian subcontinent. The complicated extraction the environment.
process and the high market demand urged for an
industrial synthesis of Indigo. It took over 17 years of Sustainability topics continue to be the fundamental
development and enormous financial investment – basis for DyStar’s operations. Industrial automation,
around 18 million Gold Marks, an amount exceeding the integration into the BASF supply for key Trützschler Group SE expands Board of Directors
the company's share capital of the day – before the intermediates, loops for recycling of solvents and
first Indigo Pure BASF was manufactured and environmental protection facilities, integrated Energy
brought into the market in July 1897. Management System (DIN ISO 50001), the
state-of-the-art waste gas treatment are some
The Highly Efficient Indigo Production Plant significant efforts that make DyStar the last notable
The Indigo production plant in Ludwigshafen is manufacturer of the coveted blue dye outside of
unique. It is the oldest and yet possibly the most China.
efficient Indigo production plant that is still in
operation today. DyStar continues this great heritage The Process Based on Heumann Synthesis
of Indigo excellence in the same production facilities, The current process is similar to the process from
where the BASF started back in 1897. Remaining the 125 years ago. DyStar is producing according to the
last dyestuff producer in Europe, DyStar “Heumann Synthesis” which consists of two raw
manufactures Indigo in a way that is paved with materials used as the basis for this synthesis. The
continuous innovations and improvements. For first one is PGN (Phenyl-glycine-nitrile), which is
example, the waste gas treatment plant is catalyst delivered by BASF via pipeline, and the other one is
based and burns the carbon content in the waste gas pure sodium, delivered by railway tankers. After the
from the aniline recovery process. With an effective first reaction steps using both raw materials,
energy management system, DyStar started to saponification of PGN, and amidation of Sodium with Dr. Ulrich Schwenken. CEO. Trützschler Group SE Heinrich Krull. COO. Trützschler Group SE
integrate carbon dioxide usage into their energy Ammonia, the two solid products are brought
consumption. This is important as they continue to together in a melting vessel. And the Indigo The Trützschler Group SE has appointed Dr. Ulrich post-merger integration. As COO, he will be responsi-
work on the reduction of their primary energy production starts following an oxidation step. Next, the Schwenken and Heinrich Krull to its Board of Direc- ble for the areas of Production, Purchasing and
consumption as well as on carbon dioxide emission. product goes through a filtration step. During filtration, German Review tors with effect from July 1, 2022. Dr. Schwenken will Logistics, Quality Assurance as well as Supply Chain. German Review
the Indigo paste will be filtered and washed to reduce serve as Chief Executive Officer (CEO). Heinrich Krull
The strategic location of the Indigo plant is unique the content of alkaline and aniline. Hydrogenation is will serve as Chief Operations Officer (COO). “We are delighted to welcome Dr. Schwenken and
too. Today, the plant remains embedded in the further applied to get a solution approximately 20% Mr. Krull to the Board of Directors. Both will bring
functional network of supply and discharge within the Indigo content. The evaporated content delivers the Dr. Schwenken will assume responsibility for Devel- diverse expertise to strengthen the development of
BASF Site in Ludwigshafen. premium product DyStar Indigo Vat 40 % Solution. opment, Digitalization, IT and Corporate Communica- the company for future growth. We wish them great
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Alternatively, the 20% solution delivers a side-product tions. As a doctoral graduate specialized in engineer- success in their new tasks,” says Dr. Roland Münch,
Nearly all raw materials continued to be delivered by named Indigo Grain 60%, which is used for DyStar’s ing, he has many years of experience in automotive Chairman of the Supervisory Board of Trützschler
pipeline. None of the raw materials are delivered by other production processes. and mechanical applications. Since 2008, he has Group SE.
trucks, except for Sodium being supplied by railway held various management positions in the areas of
tankers. Operationally, this has resulted in a large From Solid to Indigo Solution with a new organic reducing agent. This technology ning of the Indigo process. DyStar’s core expertise is Service, Sales and Development at companies Until his scheduled retirement at the end of 2022, Dr.
reduction of the Carbon footprint. In addition, this In 1998, after almost a century of synthetic Indigo represents the first salt-free Indigo dyeing process in the reason that they decided to take over the production including Porsche AG and Volkswagen AG, where his Dirk Burger will act as Co-CEO to Dr. Schwenken.
network also guarantees a high recycling rate of powder application, DyStar set one of the most history, by complete elimination of hydrosulphite in of Sodium Amide at the Ludwigshafen plant. responsibility covered a range of key topics such as
waste chemicals, which are used in other plants as remarkable milestones in Indigo history by the application of Indigo. Furthermore, the DyStar digital transformation. Most recently, Dr. Schwenken The responsibilities of the Board of Directors of
raw material or can be fully recycled. DyStar mainly introducing the first pre-reduced DyStar Indigo Vat Indigo Coat, the DyStar Indigo 4B Coll liq and the 125 Years of Indigo Excellence served as CSO, CTO and CDO at Leistritz AG, and Trützschler Group SE as of July 1, 2022 are as
recycles Ammonia water solution, Aniline, n-Methyl 40% Solution to the market. A technology that DyStar 60% Vat Grains are the results of decades of was responsible for the strategic focus on innovative follows: Dr. Ulrich Schwenken (CEO) is responsible
Aniline, Potassium- and Sodium hydroxide. This transforms Indigo into its soluble Leuco form by continuous innovation and Indigo chemical This year, DyStar celebrates the 125th Anniversary of growth areas. for Development, Digitalization, IT and Corporate
Sodium hydroxide recovery is a multi-effect using Hydrogen as the reducing agent instead of engineering. Synthetic Indigo. Together with their Subject Matter Communications; Dr. Dirk Burger will take over the
evaporation and dewatering process, resulting in a Hydrosulphite. This innovation made the Indigo ready Experts, DyStar will drive sustainability as their core Mr. Krull joined Trützschler Group SE in September role of Co-CEO to Dr. Schwenken until the end of
100% salt, which is used as a melt in further to use for the dyeing process, which is more Reformulated Sodium Amide to Meet Industry Needs competency so as to continue to enable key stake- 2020. As a graduate engineer for production 2022; Dr. Ralf Napiwotzki (CFO) is responsible for
production steps. sustainable, efficient, and much safer for the workers Another milestone reached in the history of Indigo holders, direct customers, Brand and Retailers, engineering and management with international Finance and Controlling, Human Resources, Legal
in the Denim Mills. It also resulted in more stable relates to Sodium Amide, which is one of the main manufacturers, and wider supply chain to benefit experience in mechanical and production site and Compliance; Alexander Stampfer (CSO) is
As a site partner of the BASF, DyStar discharges dyeing processes with less shade variations. intermediates used from the start of the Indigo synthesis from the efficient process and production. engineering, he has comprehensive expertise related responsible for Sales, Marketing and Service;
wastewater into the highly sophisticated, central process. Sodium Amide was also reformulated for the to operations. He also has extensive experience of Heinrich Krull (COO) is responsible for Production,
effluent-treatment-plant (ETP) on the same premises. DyStar’s recent development for the Denim Industry pharmaceutical industry in 2008. The basics of how to DyStar and Cadira are registered trademarks of production technologies, including in-depth knowl- Purchasing and Logistics, Quality Assurance as well
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This is a win-win situation for both parties. Their “Cadira Denim” combines this pre-reduced Indigo produce Sodium Amide were known since the begin- DyStar Colours Distribution GmbH, DE. edge of Lean Management methods and expertise in as Supply Chain.
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