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	NATIONAL METALLURGICAL LABORATORY MADRAS CENTRE (An ISO 9001:2008 Organisation)
TECHNOLOGIES AVAILABLE FOR COMMERCIALIZATION at NML Madras Centre      Column flotation for the beneficiation of low-grade ores    Electrolytic Reactor for Purification of Industrial Effluents    Removal of pollutants from industrial effluents    Electroless nickel alloy and composite plating    Electrolytic colouring of titanium and its alloys    TiO2 nano-tubular arrays on Ti and its alloys    Zero waste phosphating process Column Flotation Process/Device Column Flotation for the Beneficiation of Low-Grade and Finely Disseminated Ores. Area Mineral Processing Uses (i) Enrichment of ores by flotation, (ii) Flotation of ores and minerals, (iii) Quality and quantity improvement in mineral processing circuits, (iv) Flotation of base metal ores (Cu, Pb, Zn ors), iron ores (hematite, magnetite, BHQ, etc.), beach sand minerals (sillimanite) & industrial minerals (limestone, barite, etc.) Salient Features The merits of the flotation column includes improved metallurgical performance in terms of grade and recovery, effective cleaning action, smaller floor space, low capital investment, less operational and maintenance cost and easier control. Improved metallurgical performance is assured by column flotation as a result of (i) Less entrainment and entrapment through froth washing, (ii) Independent control of operating variables, (iii) Flotation of course and slimes particles, (iv) Can also be used as roughers and scavengers. Reduced running costs as a result of (i) No moving parts, (ii) Lower reagent consumption, (iii)Lower energy consumption. Reduced capital costs as a result of (i) Lower residence time, (ii) Higher gas holdup, (iii) Substantial reduction in floor area and (iv) One stage of column flotation is equivalent to 3 stage conventional flotation Scale of Development Pilot Scale Major Raw Materials Pilot Plant Facility Major Plant Equipment/Machinery Column with variable height, Indigenous sparging system, Microprocessor based level control, Auto pneumatic sampling, Digital flow measuring systems - air, water, feed, Centralized control panel Details of specific application For the beneficiation of Low-Grade and finely disseminated ores. Status of Development Completed Ecological/Environmental Impact (if any, specify briefly) No Patenting details Patent filed Commercialisation Status Laboratory scale – 74mm diameter- 10kg/h treatment capacity (4 Nos. at NMLMC, NML-JSR, GVIT-Kolar & NEIST-Jorhat). Pilot scale – 500mm diameter-1ton/h capacity (2 Nos. At NMLMC & RBSSN-Hospet, for low-grade iron ore) Commercial scale – 1250mm diameter-150TPD capacity (Installed 3 Nos. at IREL-Chatrapur, Orissa, for sillimanite; Calpro-Salem, for limestone & IREL-Chavra, Kerala, for sillimanite). Installation of a 2500mm diameter column for the beneficiation of barite is in progress at Mangampet, A P. Techno-Economics Available on demand Key words Column Flotation, Beneficiation, Mineral Processing Electrolytic Reactor for Purification of Industrial Effluents Process/Device Electrolytic Reactor for Purification of Industrial Effluents. Area of Technology Waste Utilization Uses For purification of effluents from tannery, textile, restaurants, paint and printing Salient Features The electrolytic reactor is useful for the purification of industrial effluents / wastewater generated from tanneries, textile units and metal finishing & processing industries. The dissolved inorganic and organic pollutants and suspended solids can be removed. Even colloidal particles could be effectively coagulated and separated by floatation. Most of the water can be recovered and reused. Easy construction, Separation is faster compared to conventional coagulation and floatation. Even colloidal particles could be effectively coagulated and separated. Dissolved organics could be mineralized without the addition of oxidants externally. Scale of Development Pilot scale Major Raw Materials Effluents from tannery, textile, restaurants, paint and printing Major Plant Equipment/Machinery Electrolytic reactor, Separator Details of specific application For purification of industrial effluents. Status of Development Pilot scale test reactor was designed and extensively field tested for the treatment of tannery effluents. Ecological/Environmental Impact (if any, specify briefly) Since the electron is the main reagent, the secondary contamination could be avoided by electrocoagulation. The oxidants ozone, hypochlorite and Fenton reagent, nascent oxygen necessary for the mineralization of organic compounds could be generated insitu. Patenting details Patent Filed Commercialisation Status Ready for commercialisation Techno-Economics Available on demand Removal of pollutants from industrial effluents Process/Device Removal of pollutants from industrial effluents by electrochemical technology Area of Technology Environment Uses Removal of pollutants from wastewater Salient Features Micron size and sub micron size particles including low density fats and proteins dispersed in water can be easily separated. Dissolved organic compounds in water can be effectively oxidized and removed.The advantages of the process are (i) no need for external addition of oxidizing agents/chemicals, (ii) require less space and easy construction, (iii) pathogenic bacteria present in wastewater can be Simultaneously eliminated and (iv) the resultant water can be recycled Scale of Development Pilot scale (1M3/h) Major Raw Materials Aluminum rods and plates, steel rods and plates, stainless steel and Ti based rods and plates, perspex or poly propylene sheet. Major Plant Equipment/Machinery Conditioner, pumps, rectifier/DC Power supply unit, Valves Details of specific application Purification of wastewater Status of Development Pilot plant was designed and the technology was demonstrated in the tannery industries situated in Ambur, Erode and Chennai. Ecological/Environmental Impact (if any, specify briefly) Nil Patenting details Patent Filed Commercialisation Status Ready for commercialisation Techno-Economics Available on demand Key words Suspended Solids, Electrocoagulation, Electrooxidation, Wastewater Treatment, Effluents Zero Waste Phosphating Process Process/Device Zero waste phosphating process Area Metal finishing, Surface engineering Uses Pre-treatment for paint coating and Corrosion Protection Salient Features No solid or liquid waste is generated in the process, Contains no toxic chemical accelerators, Energy efficient and eco-friendly, Continuous operation with easy replenishment and control, Composite coating offers corrosion protection by barrier layer and sacrificial protection mechanisms Scale of Development Pilot scale Major Raw Materials Mineral acids, consumable anodes Major Plant Equipment/Machinery Direct current source (Rectifier) having a potential range of 0-60 V Metal anodes of suitable geometry Details of specific application Pre-treatment for paint coating, Corrosion protection Status of Development Ready for commercialization Ecological/Environmental Impact (if any, specify briefly) Acidic solutions. They should be neutralized before discharge. Patenting details Nil Commercialisation Status Ready for commercialisation Techno-Economics Available on demand Key words Phosphate Coating, Composite Coating, Zero Waste Process, Corrosion Protection TiO2 nanotubular arrays on Ti and its alloys Process/Device TiO2 nanotubular arrays on Ti and its alloys Area Surface engineering Uses i)Dye sensitized solar cells, (ii) Controlled drug delivery Biomedical applications (iii) Sensors and (iv) Self-cleaning photo catalytic surfaces and devices Salient Features TiO2 nanotubular structure with varying tube length and diameter with high aspect ratio can be prepared on the surface of Ti and its alloys by using optimum electrochemical treatment Scale of Development Laboratory scale Major Raw Materials Ti and its alloys, mineral acids, fluorides and special additives Major Plant Equipment/Machinery Direct current source (Rectifier) having a potential range of 0-60 V, stainless steel cathodes of suitable geometry, Cooling systems Details of specific application solar cells, drug delivery, Sensors, etc. Status of Development Completed Ecological/Environmental Impact (if any, specify briefly) Acidic solutions. They should be neutralized before discharge. Patenting details Nil Commercialisation Status Ready for commercialisation Techno-Economics Available on demand Key words Titanium, Titanium Alloys, Nanotubular Structure, Anodization, Drug Delivery, Solar Cells, Implant Applications Electrolytic Colouring of Titanium Process/Device Electrolytic colouring of titanium and its alloys Area Surface engineering, anodization, metal finishing Uses Colour coding of electronic components Jewellery applications (for aesthetics) Salient Features A variety of colours can be imparted on the surface of titanium and its alloys by suitably varying the operating conditions. The coating is uniform, adherent and abrasion resistant. Scale of Development Pilot scale Major Raw Materials Ti and its alloys, mineral acids, fluorides and special additives Major Plant Equipment/Machinery Direct current source (Rectifier) having a potential range of 0-60 V Stainless steel cathodes of suitable geometry Cooling systems Details of specific application Colour coding of electronic components Jewellery applications (for aesthetics) Status of Development Ready for commercialization Ecological/Environmental Impact (if any, specify briefly) Acidic solutions. They should be neutralized before discharge. Patenting details Nil Commercialisation Status Ready for commercialisation Techno-Economics Available on demand Key words Titanium, Titanium Alloys, Electrolytic Colouring, Colour Coding Electroless Nickel Alloy Process/Device Electroless nickel alloy and composite plating Area Surface engineering Uses Corrosion and Wear resistant coatings Salient Features High hardness of the order of 600 HV0.2 in as-plated condition Excellent wear resistance Very good corrosion resistance in acid and saline environments Scale of Development Laboratory and pilot scale Major Raw Materials Nickel salts, reducing agents, complexing agents, stabilizers, special Additives, alkaline solution Major Plant Equipment/Machinery Direct current source (Rectifier) having a potential range of 0-60 V, Heating coils and control systems, Sparger tubes and compressor, Tanks made of polypropylene for cleaning, pre-treatment, plating and rinsing, Exhaust systems, Conveyor systems Details of specific application Corrosion and Wear resistance for engineering, automotive, textile, components Status of Development Ready for commercialization (Process can be optimized according to customer requirements) Ecological/Environmental Impact (if any, specify briefly) Acidic solutions. They should be neutralized before discharge. Nickel salts, reducing agents and stabilizers need to be treated properly before discharge Patenting details Nil Commercialisation Status Ready for commercialisation Techno-Economics Available on demand Key words Electroless Plating, Composite Coating, Corrosion Resistance, Wear Resistance
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