Pure Tech India

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Pure Tech India
a green technology Initiative
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InstaPure Coolant Recovery System for recovery
and reuse of water soluble coolants
www.puretechindia.com
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Introduction
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• 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.

a green technology Initiative
www.puretechindia.com
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Coolant Contaminant sources and their diagnosis
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• 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.

a green technology Initiative
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Coolant emulsion parameters
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• 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.

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

a green technology Initiative
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Vacuum Suction Unit
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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.
a green technology Initiative
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Desorber Liquid Flow Illustration- with CPI
Interceptors
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Oil trapped in funnel
Oily coolant Inlet
Oil Outlet
Sludge Settling
Oil less Coolant Outlet
coolant flow inside Desorber
Slanted Baffle Plate for flow conversion
Sludge
ELEVATION VIEW
CPI Interceptors
PLAN VIEW
Oily coolant Inlet
SS Coalesce r
Sludge Settling
Activated Carbon Pre- Filter
Oil less coolant Outlet
Oil Outlet
a green technology Initiative
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Tramp Oil removal
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• 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.

a green technology Initiative
www.puretechindia.com
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Suspended Solids Removal
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• 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

a green technology Initiative
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Bacterial Disinfection (Bactdisinfect)
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• 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.

a green technology Initiative
www.puretechindia.com
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System Illustration
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a green technology Initiative
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Our Customers
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• 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

a green technology Initiative
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Benefits
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• 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
  its 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.

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

a green technology Initiative
www.puretechindia.com