Leather
industry CLRI,
Chennai—CSIR 1.
Acrylic soft binder Acrylic
soft binder is a useful chemical in the finishing of clothing, gloving, upper
leather etc. It is used as a binder material for pigment
fixing in leather finishing operation. SEU is 1 tonne per day (one shift
basis). 2.
Alcrotan & alutan Alcrotan
is a high performance chromium aluminium-based synthetic tanning agent which is
used as a retanning as well as self tanning material. Alutan is an aluminium-based
agent containing aluminium (9-11% Al2O3)
and a syntan to which the metal iron is irreversibly complexed. This is a freely
soluble colourless product. This is useful in the retaining of several kinds of
leathers and has particular importance in suede leather manufacture. SEU is 200
TPA of each chemical. 3.
Binder RS acrylic emulsion as binder Acrylic
resin emulsion is very important chemical for leather auxiliary manufacturer as
the same is used as a binder in finshed leather manufacture. SEU 500 kg/day (2
shift operation). 4.
Lacquer CA
‘Lacquer
CA’ is used for top coat finishes for leather. The technique developed is simple
and does not involve complicate unit operations. SEU 150 kg/shift.
5.
Sulphited oil fat liquor
Fat
liquors from marine oil using the sulphitation process have versatile application
suitable for vegetable tanned, chrome retanned upper leather and light leathers.
Capital required is Rs. 1.2 lakhs. Minimum economic plant size is 15 tonnes/yr.
This oil is a good substitute for imported oils. 6.
Syntans Synthetic
tanning materials generally known as syntans are used in a number of operations
in leather industry like pickling agent. Bleaching of vegetable tanned leather,
pre-tanning for vegetable leathers, bleaching of E.I. skins, reduction of sludge
in the tanning pits, imparting fullness to leathers. SEU would be a plant having
a capacity of 500 tonnes per annum (single shift) 7.
Urethane varnish based
on castor oil To
get good shine and superior gloss on leather goods, this varnish is ideal. the
varnish also gives protection to leather and gives highly water resistant, smooth
and polishable finished surface. 25 tonees of this varnish is required every year
and the capital investment will be Rs. 1.65 lakhs. No import of raw material is
required.
Marine
Chemicals Industry
CSMCRI,
Bhavnagar—CSIR 1.
Alginic acid/sodium alginate
Sodium
alginate is used in large quantities in food and textile industry. The process
developed is simple and consists of treatment of cleaned and dry sea-weeds with
hydrochloric acid followed by washing and extracting with mild alkali.
According
to the fresh estimates the SEU for this industry is 200 kg/day. 2.
Bromine Bromine
is used in the manufacture of inorganic bromides for use in pharmaceutical and
photographic industries. Organic bromides are used as fumigants. The process is
based on sea bittern which is available from salt works. SEU for this industry
is 90 tonnes per annum. 3.
Epsom salt from sea bittern
Epsom
salt (magnesium sulphate) finds applications in tanning of leather and dyeing
of textile. CSMCRI, Bhavnagar has developed a novel process for the manufacture
of epsom salt using sea bittern as raw material. A plant having capacity of 5
TPD has been estimated to cost Rs. 15 lakhs. 4.
Light basic magnesium carbonate Light
basic magnesium carbonate finds application in rubber industry and in the manufacture
of cigarette and in quality papers. The process developed utilises sea bittern
as the raw material which is available in plenty. SEU for this industry is 30
tonnes per annum. 5.
Potassium schoenite Potassium
schoenite is a double suphate of potassium and magnesium. It contains 22.24% potassium
oxide and 90% magnesium oxide. It is being used as potash fertilizer in Western
countries. Potassium schoenite is specially suitable for crops that do not tolerate
chlorine such as tobacco, potato, sugarcane, etc. It is prepared from mixed salts
obtained by evaporation of sea bitterns. Suggested economic unit for this industry
is 10 tonnes of potassium schoenite per day. 6.
Sodium sulphate from Sels mixts Sodium
sulphate is used in the manufacture of paper. A small quantity is required for
detergent, in glass and textiles industry. The new process is based on the utilisation
of Sels mixts which is a by-product of marine salt industry of the country. Suggested
optimum capacity of the plant is 2,400 tonnes of sodium sulphate per annum.
7.
Zeolite-A Zeolites
are crystalline hydrated alumino silicates. The most important property of zeolite
is its adsorption characterisitics and it can act as molecular-sieve, selectively
adsorb or reject molecules based on differences in shape and other properties
such as polarity. These characteristics of zeolite have resulted in its principal
use as water softening agent in detergent industry and other sectors.
The
mostly used "phosphate builder" in detergent industry, sodium tripolyphosphate
(STPP) in recent years, has been found to have polluting effect on the environment
and led to the enacting of legislative measures in many countries to stop or curtail
the use of this chemical in detergent. This
has created an upsurge of interest in the builder Zeolite-A for the detergent
industry and the demand grown significantly. The technology developed can produce
Zeolite from sodium aluminate liquor of aluminium industry or from alumina
itself.
Mechanical
Engineering Industry
BHEL,
Tiruchirapalli
1.
Small capacity rice husk fired tube FBC boilers Low
grade fuels like high ash coal, lignite, as well as agro-waste such as rice husk,
groundnut shell, saw dust, pith, bagasse etc., may well be used for producing
energy that can be harnessed effectively for steam generation. With precisely
keeping this in mind, the fluidized bed combustion technology has been develop
at BHEL and has proved successfully beyond measure. The
technology of fluidized bed combustion was earlier available only to large steam
users. It was realized medium and small process steam users would find it just
beneficial to have access to this technology. The result is the fluidized bed
combustion (FBC) boilers that have developed to cater to the economical and efficient
technology needs saving crores of rupees every year. CBRI,
Roorkee—CSIR 2.
Brick extrusion machine and automatic reel type cutting table
The
brick extrusion machine is of double deck design with provision for vacuum chamber
and straight barrel for housing of the main auger. The brick extrusion machine
is of semi-automatic type and has an automatic reel type cutting table. The cost
of production of the brick extrusion machine has been estimated at about Rs. 7
lakhs and that of cutter about Rs. 2 lakhs. 3.
Coconut husk chipping
machine The
machine developed performs the chipping of the coconut husk without separation
of the pith. The pith embedded in the coconut husk fibres contains reactive ingredients
which during the process of making particle board undergo a chemical change and
impart sufficient bond strength between the chips to form a strong board.
CFTRI,
Mysore—CSIR 4.
Citrus fruit juice extractor The
Institute has developed a machine which can extract juice from oranges and other
citrus fruits. The process is based on extracting pure juice, ideal for concentration
and can be used for fruit products and in confectioneries. The other grade which
contains slight percentage of peel oil can be used for preparation of concentrates
in evaporators. The fabricating cost of the extractor of capacity 10,000 fruit/hr
is estimated at Rs. 1 lakh while the annual cost of processing 18,000 tonnes of
fruit juice is estimated at Rs. 48,650 excluding raw material and packing.
CMERI,
Durgapur—CSIR 5.
Automatic submerged arc welding machine The
submerged arc welding machine is a portable machine consistig of three subassemblies
namely, welding head, a voltage controller and a carriage. The machine utilises
are voltage as the basic control parameter for the relative movement of the electrode
with reference to the variation of the arc length. The machine has a welding speed
of 10 to 150 cm per minute and can be used with both AC/DC power source. The prototype
has been successively tested. 6.
Hydraulic bolt tensioner Presently
conventional tightening equipment viz. ordinary wrenches, spanners and torque
wrenches are used, but these do not ensure uniform tightening. Hydraulic bolt
tensioner is an equipment for tightening bolts at desired stress avoiding any
torsional effect. Hydraulic bolt tensioner are widely used in the chemical and
process plant, general engineering industries, automobile industry, etc. The technology
is suitable to those parties who have not workshop facilities with them and wish
to diversify the range of their product. The total cost of the project for a plant
capacity of 600 units per yaer is nearly Rs. 6 lakhs. 7.
Hydraulic coil expanding and spreading machine Hydraulically
operated coil expanding and spreading machine is meant for forming the closed
loop stator coil automatically in single operation that ensures exact and identical
coil and simplifies the manufacturing process leading to increase in productivity
with quality effectiveness. The total capital investment on a plant of capacity
30 machines per annum is Rs. 1 crore. 8.
Portable oxy-gas cutting machine Portable
power driven machine running on rails has been developed for oxy-gas cutting of
plates upto
75 mm thickness. It can be used for straightline and circular
cuts. The speed varies from 15 to 90 cm per minute. The cutter adjustments are
5 cm vertical and 7.5 mm transverse and the level adjustment of 70%. The weight
of the machine is 5 kg excluding the weight of torch. The manufacturing cost of
the machine excluding the torch would be around Rs. 1,500. The prototype has been
successfully tested at the Institute. 9.
TIG cutting machine The
constricted arc TIG cutting machine can be used for cutting of stainless steel
upto 20 mm thickness and aluminium and copper upto 35 mm thickness. The constricted
arc cutting method employs a constricted arc between tungsten electrode and the
work piece with a high velocity gas stream. The arc is concentrated and localised
upon a small arc operation of the job to be cut. The high arc temperature melts
the metal. The machine is of portable nature and has a cutting speed of 20-250
cm per minute. The maximum current is 500 amperes, at 70-100 volts. The cost of
manufacture of this machine may be around Rs. 50,000, excluding power source.
The prototype has been successfully tested. 10.
Tractor The
tractor has been designed at CMERI. The tractor uses two cylinder air-cooled Kirloskar
engine and has a novel type of single level automatic depth-cum-draft control
hydraulic system. The tractor has been fully tested at Tractors, Testing and Training
Centre, Budni. CMTI,
Bangalore 11.
Auto balance for grinding wheels Auto
balance is an electronic device with which it is possible to balance the grinding
wheels directly on the machine under operating conditions to such orders
that the resulting vibration due to residual imbalance is less than 0.3 mm. It
is possible to achieve balancing of the wheel to the claimed accuracy in a short
duration of about 10 to 15 minutes as compared to the existing time consuming
cut and try methods. 12.
Ball nose end mill Ball
nose end mills are commonly and extensively used for cutting tools on CNC milling
machines and machining centres. These are essential for production of sculptured
surfaces required on components such as dies and moulds. 13.
CNC simulator The
PC-AT based simulator can be used by training institute to train the personnel
on operation and programming of CNC machines having FANUC OT/OM control systems.
The simulator consists of a key based resembling FANUC OT/OM operator panel and
a software package. The simulator key based has PC-AT interface. The simulator
software runs on IBM PC-AT with MS-DOS operating system. 14.
Globoidal indexing unit There
are several types of mechanisms that can be used for indexing, like cranks, lever,
gears, ratchets and cams to achieve intermittent motion of the follower. The globoidal
indexing unit offers a combination of ruggedness, speed, accuracy and controlled
output motion. These are highly reliable, accurate , fast and compact.
15.
Keyless drill chuck The
drill chucks, which are commonly used in industries are of the key type. There
is no consistency in gripping force extered by the operation in these chunks for
tightening. Self-tightening feature of keyless chunk ensures sufficient gripping
force because any increase in torque on drill mill further tighten the drill in
the chunk. 16.
Linear motion guideways The
conventional sliding contact guideways are inadequate to meet the present day
requirements of machine tools which are being used to furnish products with a
very close tolerance limits. The linear motion guideway meets the high precision
requirements of machine tools with the use of rolling contact guideways.
17.
Recessing head Recessing
head is a machine tool accessory by which single or multiple internal grooves
can be machined accurately in rotary as well as non-rotary jobs. The automatic
recessing head has been specially designed for grooving operations in bores ranging
from dia 15 to 40 mm. It is suitable for a wide variety of recessing operations.
The tool can be used as a rotary tool on drilling and boring machines or as a
non-rotary tool on turret lathes. 18.
Thread rolling head Thread
rolling is a technique of forming threads by cold forming, wherein the material
is stressed by applying pressure beyond its elastic limit, thereby making the
material flow to the thread profile. The thread rolling head enables rolling of
threads on conventional machine tools like turret lathes and centre lathes.
19.
Universal tooling systems The
frequent changes in the workpiece specifications for limited production in metal
working industry lead to consequent modifications in the tooling. The frequent
change in the designs of permanent type of jigs and fictures prove to be very
expensive. It consists of several building-block and clamping elements in the
form of base plates, angle plates, indexing devices, V-blocks, jack screws, bush
plates, bushes etc. 20.
Vibratory stress relieving equipment The
vibrating stress relieving equipment is used for relieving residual stresses present
in castings and welded structures to obtain the dimensional stability. General
workshop facilities are required for fabrication of the device. CRRI,
New Delhi—CSIR 21.
Automatic road unevenness recorder The
automatic road unevenness recorder is used to obtain speedy and complete record
of unevenness of runway and highway pavements and other similar surface. It comprise
of a single wheeled trailer mounted on a chassis towed by a vehicle at a speed
of 30 km/h. The unit gives a quick and permanent record of the quality of the
paved surfaces, pin points the irregularities on existing highways and the reading
is free from human error. The capital outlay for 15 recorders per year is
Rs. 12 lakhs. The cost of production of one unit is about Rs. 1.5 lakhs.
IARI,
New Delhi 22.
Pusa seeder Several
designs of seed drills came into market but could not gain wide popularity because
of their exhorbitant cost. The design developed at IARI, New Delhi is simple in
operation and construction. The seed damage is less and has higher mechanical
efficiency. IIP,
Dehradun—CSIR 23.
Vacuum guard It
is a device for guarding the vacuum in a system and is used as a safety valve
in vacuum distillation unit. It can be taken up a side product in a mechanical
workshop producing any other item. IIT,
Delhi 24.
Instantaneous braking system for 3-phase induction motors Braking
of motors within a very short duration is quite essential for many industries
like printing industries, process industries, mining, engineering industries etc.
As such, a system has been developed based on the phenomena ‘capacitor self-excitation’
for braking motors within a duration of 0.5 to 2 seconds depending on the process
conditions. The system employs multi-stage braking process. It has several advantages
over the conventional mechanical and electrical braking systems. This could be
used for motors upto capacity of 50 hp. By making suitable adjustments in the
control circuit and also by addition of more capacitors, the system could be employed
even for braking motors of higher capacity. The cost of the system ranges from
Rs. 1,000 to Rs. 10,000 depending on the capacity of the motor.
IIT,
Kharagpur 25.
Continuous cashewnut sheller The
shelling (breaking and removal of shell without causing any damage to the kernel)
produces great problem in cashew processing because nuts are of irregular shape
and kernels are brittle in nature and highly vesicant cashewnut shell liquid (CNSL)
comes out during operations. A
continuous cashewnut sheller has been developed. It has a capacity of processing
18 kg/hr of end product with shelling efficiency of 70 percent. It provides 50%
whole, 22% split and 28% brokens. The machine consists of hopper, shaft, screw,
converyor, rubber padded wooden fixed discs, spring casing , pulley and frame.
The size of the machine is 1.2 m x 1.2 m x 1 m and weight is about 50kg.
26.
Low cost portable weighbridge A
quick evaluation of axle loads of commercial vehicles moving over roads is necessary
for detecting overloading of trucks for enforcement of Motor Vehicles Act against
overloading. The legal axle weight limit is 10.2 tonnes. The axle load data is
also useful in evaluating the equivalent number of standard axle loads for design
of flexible pavements as per IRC guidelines. Imported portable weighbridges are
being used by various organisations for weighing axle loads of commercial vehicles
for pavement design. IIT, Khargagpur has developed a low cost portable wighbridge
to determine the axle load of vehicles.
27.
Sun tracking device for solar photovoltaic and solar thermal collectors
The
commercially available tracking system make use of servomotors with feedback controllers,
and add substantially to the overall cost of a Solar Energy System. They also
require a power supply, and a sophisticated level of maintenance. A low cost device
which does not use electricity has been fabricated for tracking the Sun.
In
this system the collectors are mounted in a symmetrical fashion to minimise the
effect of wind guests. A prototype of the system has been fabricated and tested
over nearly three years. The system tracks the sun within 0.5 degrees throughout
the day. IIT,
Madras 28.
Spiral grooved grinding wheel The
quality and accuracy of machine part finished by grinding is significantly affected
by wheel wear. While peripheral wear in a grinding wheel is a common phenomenon
in all-grinding operations, full cylindrical plunge grinding is characterized
by an additional from of wear, the corner wear. The corner wear is generally faster
than the peripheral wear thus requiring frequent redressing of the grinding wheel
and resulting in rapid loss of wheel life. A
new technique has been developed for reducing the rate of corner wear by using
grinding wheels with helical grooves cut on one of the side faces so as to ensure
a spiral pattern of air flow. Such wheels have been found to give much increased
life.
29.
Fludized abrasive polishing The
fuidized abrasive polishing method can be adopted to fluidize abrasive particles
and use the medium for material processing. Though the concept appears similar
to sand blasting or AJM, there are major differences between them, and this process.
The main purpose of sand blasting is to clean the work piece surface whereas fluidized
abrasive polishing truncates the surface peaks and improves the surface finish.
The second major difference is that the particle size in sand blasting is larger
than that of the abrasive particles
used in this method. MERADO,
Ludhiana, CMERI, Durgapur—CSIR
30.
Automatic cloth cutting machine The
electric cloth cutting machines are deployed extensively in the modern garment
manufacturing industrties for cutting of cloth according to a desired pattern
for mass scale production of garments. The machine also finds application for
cutting leather, rexine and rubber for imparting desired shape for manufacture
of various goods. The total capital investment on a plant of capaicty of 500
machines per annum is Rs. 20 lakhs.
31.
Industrial sewing machine The
machines is ideally suitable for sewing all types of closing seams on differrent
garments and hosiery goods. The following type of operations can be performed
simultaneously and continuously with this machines:
i)
Stitching "closing seams" with double chain lock stitch, Type
401.
ii)
Edge trimming for equal margin from seam.
iii)
Over edging "trimmed edges" with three thread over lock stitch,
Type 504. The
total capital investment on a plant of capacity of 3,000 machines per annum is
estimated at Rs. 2 crores. NGRI,
Hyderabad—CSIR
32.
Bore hole logger The
device is used for the measurement of two electrical properties (potential and
resistivity) in the bore hole. The system consist of a downhole electrode, logging
cable, winch measuring sheave ground electrode, cable motion sensing system, depth
indicator, strip chart recorder, square wave constant current generator, static
potential and resistivity separation module. RDSO,
Lucknow—Min. of Railways 33.
Freight bogies for high speed operation This
is an imporved bogie meant for goods stock of railways, suitable for high speed
operation and improved riding. It has a suspension system enabling smoother running
of goods stock with longer travel springs and damping means and a torsion plant
to improve vertical and lateral riding. Excessive wear on rails and wheel flanges,
uneven and excessive wear on general bearings will be prevented and occurrence
of battering and breaking up of dust guards, layrinths etc., reduced.
34.
Improved flushing valve The
new system consist of an additional attachment which mixes small quantity of liquid
disinfectant with water before the end of the flushing operation. The product
can be used in conjunction with existing flushing valves, flushing system, water
closets of the railway coaches as well as lavatories of residential buildings.
35.
Retractable anchoring and locking device Retractable
anchoring and locking device is used for locking containers of railway rolling
stock. The device can also be used on containers transported by any general engineering
workshop having facilities for obtaining casting. The present market price is
around Rs. 2,000 for single fitting and Rs. 3,000 for double fitting.
36.
Semi-automatic anchoring and locking devices for containers used in rail
and road vehicles
The
device developed automatically locks and container having ISO type corner fittings
for use with rail wagons or road vehicles when lowered and deposited on the wagon
thereby eliminating any risk of the container being inadvertantly despatched in
unlocked state.
Metallurgy
Industry
BHEL,
Hyderabad
1.
Ceramic coating on metallic welding nozzles Copper
welding nozzles are used in the submerged arc welding process. The tip of the
nozzle become red during welding. The nozzle frequently touches the job and gets
struck. The nozzle material goes in the weld. This weakens weld and damages the
nozzle. BHEL has developed nozzles with ceramic coating which have much longer
life. A four layer coating of aluminium oxide etc. carried out at a very
high temperature by a plasma flame argon gas. CC
for 45 pieces per day is Rs. 11.15 lakhs (excluding land and building).
CECRI,
Karaikudi—CSIR
2.
Aluminium alloy anodes for cathodic protection Aluminium
alloy anodes are used for the cathodic protection of steel structures in sea water
and also sea-going vassels. At present
cathodic protection is on limited scale, although the need for such a protection
is being realised by the Naval and
Port authorities. With the adoption of such a protection the estimated demand
of aluminium alloy anodes is expected to be 1,000 tonnes per annum. CECRI has
developed a suitable alloy of aluminium, zinc and mercury for cathodic protection.
The new process envisages the melting of aluminium and the alloy ingeredients
in suitable proportions.The equipment required for the process is indigenously
available and with the exception of mercury other raw materials are also indigenously
available. 3.
Aluminium, zinc, mercury alloy anodes for cathodic protection
The
aluminium alloy anodes are used for the cathodic protection of submerged steel
structures in sea water and also in a sea-going vessels. Cathodic protection is
being adopted for the protection of ships and marine steel structures like sheet
piles and oil drilling platforms.The new process envisages the melting of aluminium
and the alloying ingredients in a suitable proportion. The melted alloy is then
cast in different size and shapes depending upon the requirement.
4.
4.
Calcuium carbide
Calcium
carbide is an important chemical used in large quantities by many user industries.
Its reaction product
with water viz. acetylene finds enormous applications in welding and cutting
of materials like iron and steel. It is produced by reacting lime/limestone with
a carbonaceous material like charcoal/coke in a 3 phase refractory lined electric
arc furnace. Calcium carbide produced is tapped in molten form into cast iron
chills. 5.
Chromate treatment of zinc and die cast zinc alloy Zinc
and die cast zinc alloy such as automobile parts and others like gas regulators,
carburettor parts are required to get chromate film for corrosion protection with
pleasing decorative appearance. The process developed by CECRI is very simple
and involves the treatment of automobile parts after degreasing and pickling at
a temperature of 30-35OC
for a duration of 20-60 sec. A large
scale trial was carried out with a carburettor firm in Madras and they were satisfied
with the treatment. Suggested economic unit for this industry is for the production
of 3 tonnes of the product per annum. 6.
Copper plating of stainless
steel Stainless
steel vessels because of its corrosion and tarnish resistance properties are widely
used and preferred to copper, and brass vessels by house-wives and hotel staff.
Periodical tanning of the interior surface of the stainless steel vessel is not
required as in the case of copper/brass vessels. In spite of these advantages
stainless steel is a poor thermal conductor and also lacks uniform heat dissipation.
These draw-backs may be eliminated by depositing a suitable metal of high thermal
conductivity with sufficient thickness on the part of the vessel coming into contact
with the heating zone. The coated metal not only boosts the conductivity of the
stainless steel but also eliminates hot spots. A copper (II) chloride strike bath
has been developed to suit large-scale production in industry. The adhesion of
copper on stainless steel is excellent and another added advantage is the operation
at room temperature. After this strike from copper (II) chloride, the stainless
steel is further coated with copper from copper sulphate bath. The unplated portions
are masked with wax. 7.
Electrolytic chromium Chromium
powder is used for the preparation of special type of welding electrodes. The
process broadly consists in depositing chromium in the form of brittle sheets
from chromic acid containing known amount of sulphate ions. SEU for the industry
is for the production 22.5 tonnes of chromium per annum. The total investment
is estimated at Rs. 26 lakhs. 8.
Electrolytic preparation of iron powder Electrolytic
iron powder finds extensive application as reductant in the manufacture of sintered
compacts and welding electrodes and also for special flame cutting operations.
The process consists in electrolysis of ferrous chloride solution using mild steel
anode and stainless steel cathodes. 9.
Magnesium alloy anodes for cathodic protection
Though
aluminium alloy anodes and zinc anodes are comparatively cheaper, their uses are
limited fairly to low resistance media. Aluminium alloy anodes can be used only
in saline water whereas magnesium with its high open circuit potential can be
used in ordinary water and also in soils of high resistivity. Magnesium along
with other constituents like aluminium and zinc are melted in a steel container
in a pit furnace and cast into anodes of required shape and size. 10.
Method of making cupric (Cu) silver
(Ag) and chloride (Cl) ion sensitive electrodes Ion
sensitive electrodes are used as electro-analytical probes for ionic concentration
measurements in solution. The electrodes have a wide range of applications. The
process developed at CECRI consists in preparing non porous membrane discs of
suitable diameter and thickness from the active materials containing silver sulphide
or a composite of sulphide or silver chloride. The composites are pressed under
vacuum and the resulting membrane are assembled to electrodes. SEU for this industry
is production of 1,500 electrodes per year. 11.
Misch metal Misch
metal is a mixture of metals in the rare earths group such as cerium, lanthanum
etc. It finds exclusive application in production of cigar lighter flints, in
the preparation of hand granades, tracer bullets and in casting industry as an
addition agent. In admixture with magnesium, it is used for production of spheroidal
cast iron. The
product made according to the process developed at the Institute has been found
to be suitable for the manufacture of flint and other applications. The main raw
material required for the production of misch metal is rare earths chloride obtained
as a by-product after separation of thorium from monazite sands which are available
in the coastal area of Kerala and Orissa. The mixed hydroxides of rare earths
are converted into hydrated chloride and is marketed by Indian Rare Earths Ltd.,
Bombay. The other raw materials required are calcium chloride, ammonium chloride
and graphite. 12.
Paint removing jelly
Steel
structures are painted to protect them from atmospheric corrosion. Before repainting,
the old paints are removed. A paint removing
jelly based on plant carbohydrates and proteins has been developed. It
can be applied with brush, is quite cheap and can be washed with running water.
13.
Sodium metal The
knowhow for the production of sodium metal has been worked out at this Institute.
A 2500 A cell has been designed, fabricated and operated successfully. The process
consists in electrolysing mixtures of barium chloride, calcium chlorides and sodium
chloride in an improved cell. Optimum conditions have been worked out for obtaining
sodium metal at an average current efficiency of 60-65 and the energy requirement
is 18 kwh/kg. Sodium
metal finds use in drugs and pharmaceuticals, sodium-sulphur batteries, in the
preparation of sodium peroxide, sodium cyanide, in the production of metals like
thorium, zirconium, uranium and lanthanum, as coolant in atomic reactors, in the
manufacture of tetra ethyl lead and tetra methyl lead. 14.
Zinc metal from by-product zinc compounds
Considerable
amount of zinc metal is lost as skimming and dross during galvanising of this
iron tubes. India cannot afford to throw away this waste. The process developed
consists in the electrolysis of a suspension of finally divided waste in an alkaline
solution between an iron anode and a stainless steel cathode. Zinc is either obtained
in the form of powder or sheet by suitably adjusting the conditions. SEU for this
industry is 250 kg zinc per day. 15.
Zinc powder by direct reduction of
zinc oxide/hydroxide/carbonate Zinc
powder is extensively used in paints. It has other applications also. In India,
the natural resources of zinc are lean and are not sufficient to meet the demand
of the country. An electrolytic process for the reduction of zinc compounds, the
oxide and hydroxide in particular, has been developed by the laboratory. Zinc
compounds are the by-product of paint industry, galvanising industry and chemical
industry. CFRI,
Jealgora—CSIR 16.
Pelletised coke A
process for the production of agglomerates from middlings or rejects of coking
coal has been developed. The product does not give much smoke and could be used
as domestic and industrial fuel. The process broadly consists of powdering the
coal, mixing with organic binder, pelletising, drying and carbonising. Investment
for setting up a production capcaity of 100 TPD plant is about Rs. 85-90 lakhs.
17.
Weather resistant, smokeless, hard
and moulded fuels
A
process has been developed for the production of coke briquettes which could be
used as industrial and domesticfuels. The process consists of crushing of coke
breeze to desired size, mixing with organic binder in suitable proportions, briquetting
and curing at specified condition. The briquettes conform to the prescribed standards
of metallurgical fuel and comparable with BP hard coke except in regard to volatile
matter and porosity. Material
balance for a production capacity of 40 TPD of briquettes and design/drawing for
20 TPD curing over have been prepared. Cost of plant and machinery is approx.
Rs. 40 lakhs for a 40 TPD production capacity. CGCRI,
Calcutta—CSIR 18.
High alumina cements by new technique
of sintering
High
alumina refractory cement with alumina ranging from 45-50%, 65-66% and 72-78%
are suitable for making high quality high alumina castables for application at
temperatures ranging from 1300o
to 1800oC.
The Institute has developed a new sintering technique for the production of high
alumina cement from bauxite/technical or hydrated alumina and limestone or calcite
at a lower temperature of sintering i.e. 1300-1500oC.
The capital investment for a plant of capacity 1,000 MT/year is Rs. 72 lakhs.
19.
Synthetic high alumina aggregates
The
Institute has developed a new process or producing high alumina aggregates (54-66%
Al2O3)
that minimises the use of sintering temperatures and the overall cost of production.
High
alumina aggregates produced by this process are suitable for making high quality
refractory bricks, shapes and monolithics for applications in the vulnerable region
of iron and steel cement, chemical and other industries where high temperature
and corrosive atmosphere are involved. The
total capital investment for a plant of capacity 5,000 TPA is Rs. 2 crores.
CSIO,
Chandigarh—CSIR 20.
Cu-Zn-Al shape memory alloy
It
is a new class of engineering material which when lightly deformed in its lower
temperature martensite state/reheated above a certain critical temperature regains
its original shape. During this shape recovery, it exerts a usable force or displacement
which can be incorporated into varieties of heat sensitive devices for warning,
control detection, etc. It is also a substitute for many bimetal applications.
For a small-scale production of about 20 kg of finished product per month the
plant and machinery will cost about Rs. 6 lakhs excluding the cost of induction
melting furnace. IIT,
Kharagpur 21.
Nanometoer stabilized zirconia production process India
has a vast reserve of the mineral containing Zirconium dioxide (ZrO). It is an
important ceramic raw material. It is used for high temperature insulation in
furnace, container in metallurgy to operate at high temperature (>1600oC).
It is a future material of many movable componet at high temperature for automotive
industry. Mechanical strength is better than steel, can withstand temperature
upto 2200oC.
Nanosized zirconia is not available commercially in India. It gives easier sintering
for making dense component. All raw materials are available indigenously.
IIT,
Mumbai 22.
Chromised steel Chromising
process consists of depositing chromium on an article made of steel or any other
suitable material or alloy from a vapourised or a liquefied chromium halide at
a temperature of 1000 to 1100oC.
The
product thus produced can be used as gas cooking and furnace parts, flue and exhaust
pipes, heat exchangers, castings, forging, etc. It can also be used an corrosion
resistance material for automotive mufflers parts fuel tanks, for laundry machines,
textile machinery, etc. It can also be used as wear resistance material for transmission
chain roll (made from mild steel and then chromised) chromised tools like files,
taps, dies, fuel injection plates, etc. SEU is 0.3 tonne of substrate metal i.e.
25,000 sq. cm. of chromising area per day of 3 shifts. The
capital investment required for the plant and equipment is estimated at Rs. 81
lakhs, excluding the cost of land and building and working capital is Rs. 4 lakhs.
IPR,
Gandhinagar, Gujarat 23.
Coating of metalware and plastics by silicon dioxide film through plasma
chemical vapour deposition The
process developed at IPR involves deposition of glass like coating using a plasma
reactor. The plasma reactor is specially designed to produce a thin long lasting
coating of silicon dioxide on the surface of plastic and metal substrates. These
transparent glass like coating provide excellent protection against corrosion
and oxidation environment. In addition they are extremely coherent and have very
good adherence to the substrate. These hard coating also provide good scratch
resistance and this property is of great advantage for decorative brassware as
it retains the shiny appearance for a long time. The application of silicon dioxide
coatings is not confined to brassware, but covers a wide range of industrial and
household articles. This coating can protect metals and alloys from corrosive
environment. Acrylic and polycarbonate which are transparent polymers, but have
poor scratch resistance, quartz like coating make their surface scratch proof
without affecting their transparency. The plant and machinery cost for a unit
which coats 250 pieces per batch having area of
100 sq. cm. each in Rs. 41,75,000. 24.
Sub-micron aluminium nitride powder through plasma arc process
Aluminium
nitride is an advanced ceramic with high thermal conductivity. It has room temperature
thermal conductivity of 3.2 watts/cm K which is comparable to that of copper.
It also has very high chemical and thermal stability. Sintered parts manufactured
from Aluminium Nitride ceramics are used for Nozzles, thermocouple protecting tubes, crucibles and boats.
Aluminium Nitride-Aluminium cermet materials often display enhanced physical properties
in comparison with single phase ceramic. It has got a number of industrial application
in various other industries like electronic, refractories etc. The plant &
machinery cost for a unit to produce 24 tonnes per annum of Aluminium Nitride
is estimated at Rs. 80 lakhs. 25.
Method of etching a substrate by plasma process Plasma
surface treatment is finding increasing widespread industrial applications as
it can produce a number of benefits as compared to conventional or non-plasma
related methods of accomplishing the same result. Plasma etching enhances the
surface reactivity and particulars in polymers it creates free radicals and active
functional groups on the surface which increases adhesion properties. A few polymers
which have been etched by this process are Teflon, Polypropylene, Acrylic, PVC,
etc. The plant and machinery cost for the Plasma Etching system is estimated at
Rs. 25 lakhs. 26.
26. Production of spheroidal metal powder through plasma melt centrifugal
automisation process
Metal
powders are used for applications such as catalysts, as additive in paints, surface
coating etc. Powders are processed in the form of components such as gears, bushes
etc. which are used as structural components in various industries including automobiles,
household appliances, electrical machines, office equipment etc. The powders can
be processed to obtain special products such as porous filters, brake pads etc.
Metal powders can be combined with ceramic powders ot other materials to form
composites. The powders produced through this process contain high degree of sphericity
and involves direct conversion of metal bar into powder. The plant and machinery
cost for a unit to produce 24 tonnes per annum of Metal Powder is estimated at
Rs. 60 lakhs. NCL,
Pune—CSIR 27.
Foundry core binder (Sinol core binder)
Foundry
core binder is specifically used in steel foundries for high dimensional accuracy
and finish to moulded parts. Foundry core binder is prepared by the polymerisation
of cashewnut shell liquid. SEU is one tonne per day. NML,
Jamshedpur—CSIR 28.
Air and nitrogen atomised extra fine non-ferrous metal powders
The
straight non-ferrous metal powders are made by the process of atomisation, wherein
a stream of molten pre-alloyed metal as atomized by a stream of pressurized fluid
under properly controlled conditions to yield the desired mesh sizes, sieve analysis,
particle shape and other required physical properties. CC for 1,000 tonnes aluminium
powder per year will be Rs. 1.25 crores. 29.
Aluminium base sacrificial anode for
cathodic protection It
is an aluminium alloy and contains upto a maximum of 5% alloying elements. The
alloy in a cast conditions has excellent driving voltage and no tendency to get
polarized. It
is used for the protection from corrosion of ship hull, underground pipeline heat
exchanger tubes, harbour installations etc. The
alloy can be commercially prepared in aluminium foundry without requiring any
special equipment or arrangement. Once cast the material is ready for the use
as galvanic anode in service. Little
capital investment is needed if the melting and casting facilities are available
with the existing plant. 30.
Calorising of mild/low steel for corrosion
& oxidation protection Used
for high temp. & corrosive application in H2SO4,
SO2/SO3
plant, refineries, coal gassification, cars/vehicles exhausts, etc. Technology
is environment freindly. Capacity, running metres 30,000 of 50 mm dia, plant &
machinery cost (in existing unit). 31.
Catalytic oxygen scavenger
Capable
of removing oxygen from water to the extent of 96%. Useful in corrosion prevention
of steam generator, water circulating system, automobile, radiators, boilers,
etc. Capacity, lit./day 100, plant
& machinery cost - Rs. 3 lakhs. 32.
Clay graphite stopper heads
‘NML
Flovel-35’ & ‘NML Flovel-50’ Clay
graphite stopper heads are used for controlling the flow of molten steel during
teeming process through nozzles fitted at the botton of ladle. These stopper give
better performance than fire caly stopper heads under stringent service conditions.
Demand is expected to be 300 tonnes per annum. SEU is 200 tonnes per annum and
capital outlay is Rs. 36 lakhs. 33.
Copper clad aluminium sheet and strip
Copper
clad aluminium sheet has good electrical and thermal property as well as light
weight and good solderability. Clad metal can be used to replace copper in a number
of conventional uses leading to conservation of copper. The other uses of clad
metal are halftone printing plates, decorative tiles and trips, pots and pans,
costume jewellery, badges, radiating fins, etc. Copper
clad aluminium sheet is produced by cold roll bounding of copper sheet with aluminium
sheet. Adequate surface preparation is essential before roll bonding is done.
34.
Dense carbon aggregate and paste
The
material namely dense carbon aggregate can be used for carbon products like electrodes,
solderberg paste cathode lining, carbon aggregate with its low-ash content and
good strength as well as electrical and physical properties possesses almost all
the requisite characteristics for use as a raw material in place of imported anthracite.
The
process as worked out briefly consists of the unit processes employed in traditional
carbon industries. Basic ingredients are reduced to a specific fitness, conditioned
with a binder, briquetted and then heat-treated according to a specified schedule
at a maximum temperature which varies with the nature of basic materials employed.
The heat-treated briquettes are then crushed and graded as per the needs of the
consuming industry and the product thus obtained is called dense carbon aggregate.
35.
Dental amalgam alloy The
product in the amalgamated condition is used for filling up the cavity of the
decayed teeth. The raw material in the purest form are melted in a furnace. Melt
is stirred thoroughly before pouring. Pouring is done in mould. The ingot is then
homogenised, processed for obtaining proper particle size followed by suitable
heat-treatment. Laboratory scale investigation has been completed. Successful
clinical service trial was conducted at Tata Main Hospital.
36.
Electrolytic manganese dioxide
Electrolytic
manganese dioxide is used mainly as depolariser in dry cells. Dry cell manufacture
are mostly importing this item at present. Approximate demand for this item is
7,000 TPA. The
process developed broadly consists of reduction of manganese ore at high temp.
in the presence of the fuel oil or coke oven gas, leaching with sulphuric acid
for removal of impurities and electrolysing with suitable electrodes. NML has
developed the process at a level of 50 kg/day of EMD. Approximately
investment for setting up a production capacity of 2,500 TPA is Rs. 16-18 crores.
37.
Electrolytic manganese metal
Electrolytic
manganese metal has a high degree of purity and is suitable as a manganese additive
for the manufacture of ferrous non-ferrous alloys. The process has been developed
for the production of electrolytic manganese metal of 99.5% purity from low grade
manganese ore. The ore is first reduced then leached in the spent liquor that
comes out of the electrolytic cells. The leached solution is purified for removal
of impurities. Then it is electrolysed to give pure manganese metal. CC for 1,000
tonnes EMM per year, production will be about Rs. 7.5 crores. 38.
Extra fine zinc dust “Distilled
zinc dust is very fine zinc powder with upto 98% below 45 microns having spherical
particles. Its main use is in Paint Industry and it is also used in sodium hydrosulphite
and pharmaceutical industry. The estimated cost of the plant having 1,000 MT per
annum capacity is about Rs. 1.3 crores. 39.
Improved graphite crucibles
Graphite
crucible are widely used for melting brass and other non-ferrous alloy in iron
and steel foundries. National Metallurgical Laboratory, Jamshedpur has developed
process for the manufacture of clay bonded and carbon bonded crucibles. 40.
Inoculants designated as NML-PM 122 for aluminium/aluminium alloys (in
the wire form) An
incoculant in the wire form has been developed for aluminium/aluminium alloys.
The practice of inoculation in aluminium and its alloy melts is to achieve grain
refinement and hence to obtain cast structure with uniform finer grain size. The
finer grain size enhances the thermochemical properties, reduces the risk of tearing,
cracking into mould etc. The demand has been estimated as 400 tonnes of conventional
inoculants. Its production can be taken up by units having facilities for melting
and wire drawing of aluminium and its alloys by putting up additional melting
and annealing furnaces. 41.
Nickel magnesium alloy
The
process developed at NML, Jamshedpur envisages the production of alloy by alloying
nickel, magnesium and misch metal. The molten alloy is cast at the appropriate
temperature into steps or any shape in metallic moulds. When solidified it can
be stored and is ready for use. Little capital investment is needed if the melting
equipment is available with the existing unit. 42.
Reactive NML filters for
aluminium and its alloys
Aluminium
and its alloys are always associated with dissolved hydrogen, oxide and dross
inclusion which deteriorate their mechanical properties, workability and service
performance. In order to improve the cleanliness of the melt, National Metallurgical
Laboratory has developed certain reactive filters which have been successfully
tried on commercial scale. The salient features of the filter media are (i) high
yield of good quality product i.e. better surface finish, low inclusion and dissolved
gas content, (ii) reduction of sodium level in the filtered material, and (iii)
grain refining of the filtered material. 43.
Recovery of lead from battery scrap The
process recovers above 90% lead metal with metal purity around 98%. The byproduct—Iron
sulphide is recovered as solid sulphide which can be used for the manufacture
of H2S.
For the pollution control measures, the process requires dust catching systems
alongwith smelting furnace. Capacity, 900
TPA, Plant & machinery cost -
Rs. 50 lakhs. 44.
Recovery of vanadium pentoxide from vanadium sludge of alumina industry
Vanadium
is an important metal which finds extensive uses in the form of metal, oxides
and alloys. Vanadium pentoxide is used mostly as catalyst in sulphuric acid manufacture,
for the production of ferro-venadium and titanium vanadium-aluminium alloy and
other vanadium compounds. Vanadium
pentoxide produced has been compared with imported V2O3
of equivalent specification and found to be equally good. V2O5
has been found conforming to the refined grade. 45.
Sponge iron production based on vertical retort direct reduction
Sponge
iron is used in mini steel plants for production of steel. Based on the installed
capacity of mini steel plants in the country approximate demand for sponge iron
is about 1 million. TPA. NML has developed the process for producing sponge iron
based on vertical retart direct reduction (VRDR) process. The process has advantages
like low cost of production, less energy consumption, higher productivity per
unit volume of reactor, increased percentage metallisation, use of non coking
coal etc. The process is based on the reduction of iron oxide by solid reductant.
Trials have been carried out on a pilot plant scale producing about 1 tonne per
day of sponge iron. 46.
Stainless steel powder Stainless
steel powder is made from stainless steel scraps. It is used in automobile industries.
NML process is a chemical process and is not based on atomisation. Yield obtained
is 95-96%. 100 kg/day unit can be installed initially with provision of expansions
with an investment of Rs. 18 lakhs approximately. 47.
Vinyl coated steel and aluminium The
coated steel and aluminium can be utilized in instrument and equipment casing,
electrical panelling and ducting, panelling in coaches and buses, etc.
The
knowhow developed for production of vinyl coated steel and aluminium sheets involves
a process comprising of (i) pretreatment of steel/aluminium sheets, (ii) production
of chemical conversion coatings such as phosphating or chromating, (iii) application
of primer followed by baking, and (iv) application of a finish coat followed by
baking at appropriate temperature. A
small scale industrial unit capable of producing 12,000 sheets of 1 sq. metre
unit area per year based on
2 shift operations a day and 300 working days
in a year is estimated to cost Rs. 6.25 lakhs. QWMS,
Chennai 48.
Process to treat molasses based effluent to remove colour by chemical and
membrane technology The
treatment of effluent to produce permeate water, where the colour of the effluent
having a psychological impact on the public is removed. This can be used as process
water, thus creating a zero pollution atmoshere and is eco-friendly. The quality
obtained also conforms to the standards of the Pollution Control Board. Capacity,
m3/day
400, Plant & machinery cost -
Rs. 1.75 crores.
RRL, Bhubaneshwar—CSIR 49.
Beneficiation of graphite
Graphite
in its pure form is employed in the production of various articles such as crucibles,
muffles, saggars, electrodes, paints, pencils, etc. The knowhow gives 96 to 98%
of pure graphite per annum. Estimated capital outlay is Rs. 2.62 lakhs. 50.
Electrolytic iron powder High
purity iron powder is used in chemical industries as a catalyst, automobile industries,
welding electrodes, etc. The process developed at RRL, Bhubaneswar, consists in
the conversion of acid free iron chloride into ferrous chloride. The ferrous chloride
is used as a catholyte and saturated solution of sodium chloride is used as anolyte.
The anode and cathode chambers are separated by using a suitable porous diaphragm.
Stainless steel sheets and graphite are used as cathode and anode respectively.
The deposited iron is removed in the form of brittle flakes which are subsequently
ground to the desired size. The process has been studied on bench scale and 200
gm of iron powder per day has been produced. Suggested economic unit for this
industry is for the production of 30 tonnes of iron powder per annum.
51.
High purity graphite
High
purity graphite finds application in special grade electrodes and brushes, lubricants,
sintered product, explosives, nuclear field, etc. Graphite powder (90-96%), hydrochloride
acid, the hydrofluoric acid and sodium chloride are main raw materials required.
SEU for this industry is 250 tonnes of 90% graphite per annum. RRL,
Bhopal—CSIR | 
