Alkali Material & Metal Division (AMMD) is involved in process development & intensification of chemical plants, material synthesis for ITER, fluidization based Chemical Vapor Deposition (CVD), granulation and organic & mercury vapour adsorption.
F-CVD process has been successfully deployed for simultaneous coating of alumina on inner and outer surfaces of multiple numbers of SS and MS pipes/tubes of size ranging from 12.5 mm to 38 mm. The experimental results were gravimetrically analyzed and characterized by SEM-EDS. Uniform coating thickness of 20 μm was achieved. Based on the experimental results, a DPM-FDM model has been developed to determine deposition of alumina on inner and outer substrate surfaces.
TCE vapor is generated during the synthesis of mixed oxide fuel and lithium pebbles by sol-gel process, which has low TLV in air. Experiments were conducted for the adsorption and recovery of TCE vapor on activated carbon particles in packed, fluidized and circulating fluidized bed. It was found that, >90% of TCE vapor in air can be adsorbed and recovered in circulating fluidized bed. A mathematical model on the concentration and temperature behaviour of packed and fluidized bed on adsorption of the TCE vapour was developed and the model has been validated with the experimental results.
Sorbent materials for mercury respirators cartridge containing materials viz., humic acid coated Fe3O4 nano-particles, calcium alginate biocomposite, bio-hybrid of silica and microbial cells were synthesized and tested for their suitability for the adsorption of elemental and ionic mercury from contaminated effluents. From the experimental study it was found humic acid coated Fe3O4 nano-particles has absorption capacity of mercury is 343.71μg/g which about two times that of activated charcoal particles. Further experiments are being conducted with other materials. For purification of mercury contaminated liquid waste, a bio-hybrid material of nano silica and S. cerevisiae cells was synthesized, characterized and its mercury sorption capacity was found to be 185.19 mg/g.
Synthesis of lithium titanate pebbles is carried out in a continuous rotary synthesizer at PDL building, DD complex, AMMD. The system consists of feed bunker, rotary air lock valve, screw feeder, rotating tube with internal flights and external annular stationary heaters, product collection container and cooling system. The material of construction of all these sub systems is stainless steel of grade 304. Critical parameters of rotary synthesizer such as angle of inclination and rotation speed were optimized to achieve good quality of synthesized single monoclinic phase Li2TiO3
An automatic granulation plant having a capacity of 25 kg of Li2TiO3 is installed at PDL Building, DD complex, AMMD. The granulation plant consists of various equipments such as loading and feeder vessel, pumping system, mixer, extruder, spheronizer, fluid bed dryer and vibro shifter. To ensure repeatability of product quality, all the operations starting from kneading of dough to segregation of pebbles is automatically controlled with PLC based control system with least human intervention.
Sintered lithium titanate pebbles are produced through semi-automated synthesis and granulation process. The material properties of produced lithium titanate pebbles, with respect to density, porosity, specific surface area, grain size, diameter, spherecity and crushing load conforms to the specification of TBM
A process, named as ‘Solid State Reaction Process’ (SSRP) has been developed to synthesize, fabricate and sintered solid breeder materials viz. lithium titanate (also called lithium meta-titanate, Li_2 TiO_3) and lithium ortho-silicate (Li_4 SiO_4).
Packed Fluidization process has been developed to enhance the rate of heat transfer in pebble bed.
A process has been developed for the adsorption, recovery and reuse of organic vapor in multi-stage circulating fluidized bed (MSCFB) of activated carbon particles.
A Fluidization-based Chemical Vapor Deposition (FCVD) process has been developed for the thin film coating of compounds like Silicon Carbide (SiC) and alumina (Al_2 O_3) on the surface of different substrates viz. Graphite, Stainless Steel, Zircaloy, Inconel etc.