Pure Tech India InstaPure Coolant Recovery System for recovery and reuse of water soluble coolants Uniqueness defined a green technology Initiative

Introduction: Metal working fluids gets contaminated during use in machine tool by the following: a. Tramp Oil, b. Machined dust and c. Bacteria Coolant concentration is generally between 2 – 5 %. Coolant is disposed even before coolant property is lost. Coolant needs Deemulsion and treatment to meet Pollution Control Board norms before final disposal. Coolant can be cleaned of its contaminants for reuse back in the machine tool as emulsion. Proper coolant cleaning schedule extends the life of coolant. Uniqueness defined a green technology Initiative www. puretechindia.com

Coolant Contaminant sources and their diagnosis: Tramp Oil: Source: Hydraulic line leakages, Guide Way lube, Lube points over flow, Tool Magazine, Chuck lube overflows, Workpiece coating oil overflow. Diagnostic procedure: Visual observation, Generally in lab using Petroleum ether test. On line using Oil in water monitors using Light distraction in a sample cell. Machined dust: Source: Work piece machining. Tool wear, atmospheric dust Diagnostic procedure: Millipore test, Spectrometer and visual observation. Bacteria: Source: Water, Anaerobic bacteria because of Oil contamination Diagnostic procedure: In Laboratory using bacteria test and in site using dipslides. Uniqueness defined a green technology Initiative www. puretechindia.com

Coolant emulsion parameters: Introduction: Emulsions have certain parameters like pH, Total Dissolved solids, coolant concentration for use in various machining operations. As the coolant quality degrades, these values also tend to change resulting in loss of efficiency in machine tool. Diagnostic procedure: The parameters can be measured using devices like pH meter, TDS meter and Refractometer (Brix Scale meters) Result Inference: The results of the parameters on comparison with the new made up coolant will help in maintaing the treatment efficiency to suit the machine tool and coolant condition. InstaPure Systems are supplied with online ph and TDS meters; separate hand held device for concentration maintenance. These help in maintaining the coolant treatment efficiency. Uniqueness defined a green technology Initiative www. puretechindia.com

Coolant recovery general process: Coolant for recovery Oil removal Machined dust removal Bacterial Disinfection Coolant for reuse Desorber, Tramp Oil remover, Activated Carbon filter SS Bag filter with SS filter media (InstaTrap filters) UV Bacterial Disinfection Unit (Bactdisinfect unit) Component in our Equipment Uniqueness defined a green technology Initiative www. puretechindia.com

Operational Sequence: The machine tool on which the coolant is to be treated is identified and the InstaPure (Coolant recovery system) is wheeled near the machine tool. Water soluble coolants from machine tool is sucked out through Vacuum suction system present in the recovery system. This coolant is stored in the collection tank. Once suction phase is over, the coolant enters Desorber for oil removal. Desorber (Oil water separator) is a gravity based system removing free oil, unstable emulsion and microscopic oil particles from the coolant. The outlet from Desorber is stored in the Prep Tank. From Prep Tank, the coolant is pumped into the Tramp Oil Separator for micro free oil removal. The outlet from tramp oil remover is fed into backwashable bag filter of 25 micron filtration efficiency. This outlet enters the backwashable bag filter for 5 and 2 micron machined dust removal. After filtration, the coolant passes through the bacterial disinfection unit. The coolant after disinfection can be reused for machining as emulsion with initial concentration of coolant which was inside the machine tool sump. Uniqueness defined a green technology Initiative www. puretechindia.com

Vacuum Suction Unit: Vacuum Unit: Electrically operated vacuum motor with collection tank as a single unit. The collection tank capacity is 200 litres. The tank is provided with chip trap and motor protection seal to prevent coolant entry into Vacuum motor. Uniqueness defined a green technology Initiative www. puretechindia.com

Desorber Liquid Flow Illustration- with CPI Interceptors: ELEVATION VIEW PLAN VIEW Oily coolant Inlet Oil less Coolant Outlet Oil less coolant Outlet Oil Outlet Activated Carbon Pre- Filter SS Coalesce r CPI Interceptors Sludge Settling Slanted Baffle Plate for flow conversion Sludge Settling Oil trapped in funnel coolant flow inside Desorber Sludge Oily coolant Inlet Uniqueness defined a green technology Initiative www. puretechindia.com

Tramp Oil removal: Tramp Oil Remover: Pressure membrane system where the coolant with oil is passed through oleophilic membrane and oil particles are trapped inside the membrane. Activated Carbon cartridge: Coolant passed through carbon for microscopic oil particles removal. Uniqueness defined a green technology Initiative www. puretechindia.com

Suspended Solids Removal: Stainless Steel backwashable filter of capacity 25, 5 and 2 microns. Filter media made from SS316 Dutch woven filter cloth One time investment media washed and reused again and again Uniqueness defined a green technology Initiative www. puretechindia.com

Bacterial Disinfection (Bactdisinfect): U-V Disinfection unit: Coolant is passed in front of UV light as thin film exposing bacteria to them. UV light at a wavelength of 253 nm penetrates the DNA of bacteria killing it. The heat generated at that point vaporizes the bacteria without leaving any residue. Uniqueness defined a green technology Initiative www. puretechindia.com

Schematic flow chart of Treatment Process: Waste Coolant Storage Tank Feed Pump Coolant Storage Tank Desorbe r Prep Tank Process Pump Tramp Oil Remover Activated Carbon Filter25 micron Bag Filter5 & 2 micron Bag Filter Bacterial Disinfection Unit Treated Coolant for reuse Cleaning Liquid Tank Backwash Effluent for ETP Cleaning Pump Tramp Oil for Disposal Uniqueness defined a green technology Initiative www. puretechindia.com

System Illustration: Uniqueness defined a green technology Initiative www. puretechindia.com

Our Customers: M/s L & T Komatsu Ltd, Bangalore M/s Tyco Sanmar Ltd, Viralimalai, Trichy M/s Bharat Heavy Electricals Limited, Haridwar M/s Rane Madras Limited, Varnavasi, Kancheepuram district. M/s Wipro Infrastructure Engineering Limited, Sriperumbudur. M/s Compatible Solutions LLP, Singapore Uniqueness defined a green technology Initiative www. puretechindia.com

Benefits: Waste coolant converted to usable coolant. Nearly 85% of the coolant is recovered for reuse. (the losses are due to evaporation, tramp oil and chip drag out). There is no process losses. Coolant can be removed for treatment as and when bacterial contamination is observed, refreshed and reused back in the machine tool. Coolant can be recycled till the coolant loses it’s property and emulsion breaks. There is no change in concentration because of treatment. There is no need for conventional coolant treatment requiring emulsion breakage. Systems are modular and can be augmented for increased capacities. Uniqueness defined a green technology Initiative www. puretechindia.com

Thank You For Queries, Please contact: E- Mail: (Photographs shown are taken from our supplied equipments and there are feature additions taking place in each new equipment manufactured)‏ Uniqueness defined a green technology Initiative www. puretechindia.com