Pure Tech India

InstaPure Coolant Recovery Systemfor recovery and reuse of water soluble coolants

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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.

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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.

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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.

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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

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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.

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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.

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Desorber Liquid Flow Illustration- with CPI Interceptors:

ELEVATION VIEW

PLAN VIEW

Oily coolant Inlet

Oil less Coolant Outlet

Oil less coolant Outlet

Oil 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

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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.

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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

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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.

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Schematic flow chart of Treatment Process:

Waste Coolant Storage Tank

Feed Pump

Coolant Storage Tank

Desorber

Prep Tank

Process Pump

Tramp Oil RemoverActivated Carbon Filter 25 micron Bag Filter5 & 2 micron Bag FilterBacterial Disinfection Unit

Treated Coolant for reuse

Cleaning Liquid Tank

Backwash Effluent for ETP

Cleaning Pump

Tramp Oil for Disposal

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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

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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.

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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)

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