"PERMALOC" MAGIC WITH 3D CHEMISTRY- TREATMENT OF SPENT METAL WORKING FLUIDS

“PERMALOC” 3D Magic with green Chemistry for Emulsified Oily Waste Metal Working Fluids

My fascination with 3D technology began in college when I studied lasers as part of my graduate studies. Since then, anything related to 3D has continued to captivate me. From the early days of 3D laser holograms to the advent of 3D movies and 3D printing, the evolution of this technology has been remarkable. Now, I am excited to share my interest in 3D chemistry, specifically its application in handling waste metal working fluids and sludge.

🌍Ionic’s “Permaloc” Technology - Revolutionizing Environmental Protection with 3D Green Chemistry!🌍

In our quest for a cleaner and greener planet, innovative solutions are essential. One such groundbreaking approach is the use of polymeric 3D chemistry in treating difficult-to-handle oily emulsified waste metal working fluids, commonly known as machine coolants. But what makes this process so special and why has it piqued my interest since 1987? Let me share my story.

I first encountered this milky grey or white, foul-smelling fluid with a rotten egg-like odor when I was assigned to visit a major global auto component manufacturing company in Bangalore way back in the year 1987. My task was to conduct a feasibility study using electrocoagulation and a special oil coalescer with oleophilic resin beads. Unfortunately, neither technology worked for this application.

Before delving into the 3D magic and chemistry, it's important to understand the basics of metal working fluids. These fluids are essential for machining metals, acting as lubricants and coolants. They come in various types, brands, compositions, and concentrations, each specific to different machining operations. The major component is oil in emulsified form, along with extreme pressure additives, emulsifiers, surfactants, biocides, and corrosion inhibitors. Spent metal working fluids contain tramp oil, bacteria, fungi, heavy metals, and other hazardous substances, making them difficult to treat.

The hunt for suitable technologies began with physio-chemical methods, which were labor-intensive and had limitations such as the inability to meet regulatory compliance limits for oil and high TDS of treated water. This led to the adoption of ultra-filtration (UF) membrane processes, which could separate oily components but not dissolved constituents like biocides and surfactants. UF membranes also faced challenges like fouling and the need for frequent cleaning.

To address these limitations, industries adopted MVR vacuum distillation (VDE) evaporators. This technology uses mechanical vapor compressors to evaporate water content, producing a clear distillate and a concentrated reject. However, the distillate still required further treatment to meet discharge norms, and the process had its own set of challenges.

Recognizing the need for a better treatment technology, Ionic developed the “Permaloc” process using polymeric 3D chemistry. The process converts the liquid spent metal working fluids into a stabilized gel by a polymeric chemical reaction and finally to a dry powder form for convenient safe disposal as you will see in the images below.

This innovative approach offers several advantages:

1. Enhanced Environmental Safety: Permaloc green chemistry forms a strong, stable matrix that encapsulates harmful contaminants, preventing them from leaching into the environment. This results in cleaner soil and safer water sources.
2. Improved Disposal: By reducing the plasticity and swelling of soils, Permaloc creates a more stable and durable ground, ensuring long-term sustainability.
3. Boosted Mechanical Strength: The addition of Permaloc enhances the compressive strength of treated materials, allowing them to withstand harsh environmental conditions.
4. Sustainable Practices: Permaloc treatments are eco-friendly, reducing the need for harmful chemicals and lowering the carbon footprint.
5. Versatility: This process can be applied to various industrial and municipal sludges, making it a versatile solution for different environmental challenges.
6. Automated Process: The fully automated process minimizes human error and is cost-effective.
7. Peace of Mind: Permaloc provides a reliable and sustainable solution, meeting regulatory compliance requirements and addressing the challenges associated with the treatment and disposal of spent metal working fluids.

By leveraging the power of Permaloc green chemistry, Ionic is paving the way for a cleaner, safer, and more sustainable world. Let's continue to innovate and protect our planet for future generations! 🌱💧