Emulsion Coolant Recovery System-InstaPurefor Recovery and Reuse of water soluble coolants.

Pure Tech India,A-5, Trec step, Thuvakudi, Trichy -620 015Telephone:00 91-431 320 6753; Telefax: 00 91-431 250 1100E-Mail: contact@puretechindia.com; website: www.puretechindia.com

Introduction:

• Water soluble coolants get contaminated during course of operation in machine tools.

• Major cause of disposal is bacterial contamination felt by bad smell and skin irritation.

• Coolant is forced for disposal and treatment.• The idea behind the system is to apply the concept of

“Treat and Reuse” instead of “Treat and Dispose”.• Recovered coolant is fit for reuse; back in the machine

tool.• Recovery rate as high as 85%.• Recovered coolant can be reused many times till the

coolant oil loses it’s properties and the emulsion gets broken.

Contaminants and their removal:• Tramp Oil:

Essentially due to lube oil present in machine tool. Removed by: 1. Desorber;2. Tramp Oil Remover;3. Activated Carbon Filter.

• Suspended Solids: Due to machining action. Removed by:1. Stainless Steel washable strainer;2. Tramp Oil Remover (till 40 microns);3. Stainless Steel washable Bag Filter (25,5 and 2 microns);

• Bacteria: Due to water mixed for emulsion and suitably aided by Tramp oil. Removed by:

1. UV Dis-infection.

Coolant

BacteriaTramp Oil

Suspended Solids

Operational Sequence:

• 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 floating oil removal.• Then it passes through filtration systems.• After filtration, the coolant passes through the bacterial

disinfection unit.• The coolant after disinfection can be reused for

machining.

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.

Tramp Oil removal:

• Desorber:

Gravity based system to remove majority of free floating tramp oil. Oil removed through an adjustable funnel provided in the system. Separated oil can be sold.

Desorber Liquid Flow Illustration- with CPI Interceptors:

ELEVATION VIEW

PLAN VIEW

Oily Liquid Inlet

Oily Liquid Inlet

Oil less Liquid Outlet

Oil less Liquid Outlet

Oil Outlet

Oil Outlet

Activated Carbon Pre- Filter

SS Coalescer

CPI Interceptors

Sludge Settling

Slanted Baffle Plate for flow conversion

Sludge Settling

Oil trapped in funnel

Liquid flow inside Desorber

Sludge

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.

Tramp oil remover Activated carbonfilter

Suspended Solids Removal:

• Suction Strainer:Stainless Steel washable strainer of filtering capacity 150 microns

• Tramp Oil Remover:In addition to its application of Tramp oil removal, the membrane consists of filter cloth which filters the suspended solids level to less than 40 microns.

• Bag Filter:Stainless Steel backwashable washable filters of capacities:

25 microns5 microns2 microns

SS Bag filtersTramp oil remover Activated carbon filter

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

Bag Filter:

Bacterial Disinfection:

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.

Schematic flow chart of Treatment Process:

Waste Coolant Storage Tank

Feed Pump

Coolant Storage Tank

Desorber

Prep Tank

Process Pump

Tramp Oil Remover

Activated Carbon Filter

25 micron Bag Filter

5 & 2 micron Bag Filter

Bacterial Disinfection

Unit

Treated Coolant for

reuse

Cleaning Liquid Tank

Backwash Effluent for

ETP

Cleaning Pump

Tramp Oil for Disposal

System Illustration:

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

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.

Thank You

For Queries, Please contact:E- Mail:

contact@puretechindia.com(Photographs shown are taken from our supplied equipments

and there are feature additions taking place in each new equipment manufactured)