CSIR Central Glass & Ceramics Research Institute (CSIR-CGCRI)

Review of the Eleventh Plan Projects

Projects of the Eleventh Five Year Plan

• Supra-Institutional Project (SIP 0023)

– Ceramic Materials for Emerging Technologies involving Liquid and Gas Separation

• Network Projects – Photonics for Communication, Laser and Sensor

Technology (NWP 0026) (CSIR-CGCRI, CSIR-NAL, CSIR-SERC, CSIR-NIIST, CSIR-CSIO)

– Non-oxide Ceramic based Advanced Structural Materials for Application in Armours (NWP 0029) (CSIR-CGCRI, CSIR-AMPRI, CSIR-SERC)

Ceramic Materials for Emerging Technologies Involving Liquid and Gas Separation

[Category: SIP-23; Budget: Rs 15.47 crore]

– Task-I: Development of technology for manufacturing monolith/support structures.

Achievements: • Technology for manufacturing 19 channel monolithic support tube

based on high alumina composition • Development of clay alumina based ceramic capillary membrane and

their application as gas-liquid contactor • Development of gas liquid membrane contactor for CO2 capture. • Development of clay alumina based ceramic hollow fibre membrane

for use as membrane reactor for hydrogen production and separation • Preparation of ceramic ultra-filtration membrane (UF)

– Task-II: Development of Industrial Waste Water Purification

Technology based on Ultra-filtration Membrane. Achievements:

• Ceramic membrane technology for purification of rice bran oil – hexane miscella.

– Task-III: Development of Chemically and Thermally Stable Zeolite Membranes for Gas Separation

– Achievements: • Synthesis of zeolite crystals based on optimized techniques

and their detailed characterization • Zeolite membranes were prepared and characterized • Alumina and silica sols were prepared for their use as buffer

layers • Interlocked NaA and MFI membranes were prepared • Reactor systems (planer & tubular configuration) for carrying

out gas permeation and separation was fabricated

Thread-ball-like HS Urchin-shaped HS Flower-like HS Condition 1 Condition 2 Condition 3 NaA zeolite coated tube (inside)

NaA powders

– Task-IV: Development of MIEC-based Dense Ceramic Membrane Technology for Gas Separation

Achievements:

• Knowledgebase generated for synthesis of zeolite powders of varying characteristics and preparation of ceramic supported zeolite membrane by the hydrothermal technique.

• Development of membranes with encouraging properties towards gas permeation and separation behaviour

• The custom designed reactor systems were found to be highly effective for gas permeation and separation studies

Anticipated MIEC Membrane Assembly

Fi

(Dissociation Layer

(Association Layer)

Porous Support

MIEC Membrane Assembly

(Dissociation Layer

(Association Layer)

Porous Support

(Dissociation Layer

(Association Layer)

Porous Support

MIEC Membrane Assembly

• Task-V: Development of SiC based cellular structures from Plant derived Cellulosic Material for possible use in IGCC technology.

– Following SCI-Journal papers published

• P. K. Mandal, R. Majumdar, K. K. Mukherjee, O. P. Chakrabarti and H. S. Maiti, “An ultralight porous alumina ceramic in the image of jute stem” J. Ceram. Proc. Res., 10 [4], 457-461 (2009)

• A. Maity, D. Kalita, T. K. Kayal, T. Goswami, O. P. Chakrabarti, H. S. Maiti

and P. G. Rao, “Synthesis of SiC ceramics from processed cellulosic bio-precursor” Ceramics International, 36[1] 323-331 (2010).

• A. Dey, N.Kayal and O.P.Chakrabarti, “Preparation of porous SiC ceramics

by an infiltration technique”, Ceramics International 37[1] 223-230 (2011).

• A. Dey, N.Kayal and O.P.Chakrabarti, “Preparation of porous mullite bonded SiC ceramics by an infiltration technique”, Journal of European Ceramic Society (to be communicated)

Objectives

Development of Fibre Bragg grating based sensor technology for structural health monitoring in strategic and civilian sectors. (CGCRI, NAL, SERC and CSIO)

Development of Erbium doped fibre amplifier (EDFA) for telecom application and high power fibre laser. (CGCRI)

Development of specialty photonic crystal fibre (PCF) for super continuum source and bio-sensors (CGCRI and NIIST)

Photonics for Communication, Laser and Sensor Technology

[Category: NWP-26; Budget: Rs 13.22 crore]

9

Embeddable strain sensor for civil structure Embeddable temperature isolated strain

sensor for civil structure

Packaged FBG sensors developed for concrete and steel structures

Surface mountable strain sensor for steel structure (weldable type)

Surface mountable strain sensor for steel structure (Adhesive type)

Characterization of the developed sensors have been done at CSIR-NAL, CSIR-SERC

BD coupon UD coupon

FBG strain sensors for composite structure: ongoing work with ISAC, ISRO

:Development for tunable laser source

12

High speed FBG Interrogation System

Two set of high P2O5 doped optical fibers having core diameter around 40.0 micron with P2O5 doping level of 13-14 mol% shows recovery within ±5-10%

Testing is underway at DLJ

A prototype model of fiber optics based dosimeter developed with Defence Lab. Jodhpur

Non-oxide Ceramics Based Advanced Structural Materials For Applications In Armor

[Category: NWP-29; Budget: Rs 10.22 crore]

Genesis of the project

Experience from earlier project on the development of AlN armor tiles (DRDO).

Interests from Defence Agencies especially Defence Equipment Production Agencies and some DRDO laboratories.

Market Potential of the ceramic armor. (US market $628million, 2010) Potential of CSIR laboratories.

Breach Barrel

Target Chamber

Catcher System

Gas Gun Shock experiments conducted to find HEL of 10 µm grain size alumina

Shock recovery experiments deliberately conducted at 6.5, 12 and 16 GPa (3.2 -8 times HEL) on

a 10 µm alumina The fragments collected by a dedicated catcher system. Detailed characterization by XRD, SEM, FE-SEM, TEM and nanoindentation A new damage model was developed to explain the deformation mechanism

List of technologies developed at CSIR-CGCRI during the 11th Five Year Plan

Nd-doped Phosphate Laser Glass for High Power Laser All stipulated properties achieved with optimized composition One lit melt standardized. A number of glass blocks supplied to RRCAT 5 lit melting facility established (including cullet preparation, fine annealing and

final processing). Melting in 5 lit scale with bottom pouring and casting will be started very soon.

Nd2O3 (3 wt%)

250 x 90 x 40 mm3 160 x 15 x 15 mm3 Nd2O3 (2.2 wt%)

5 liter induction furnace installed Inset: Bottom drain tube heating

FINISHED Nd-GLASS ROD At RRCAT

Ф 20mm x 300mm

Radiation Shielding Window Glass

Viewing of the system/equipment for monitoring/ remote operation with protection from radiation exposure

1. Technology successfully demonstrated to produce high density (d= 5.2

g/cc) stabilized and unstabilized RSW glass. 2. Pilot scale facility established to produce glass blocks of sizes up to

400×400×100 mm and 700×700×35 mm. 3. 17 MT of RSW glass blocks of varying sizes supplied to BARC, DAE.

Pouring of melt into pre-heated mould

RSW glass blocks of 400 × 400 × 100 mm sizes

Biggest size RSW glass block of 700 × 700 × 35 mm size

Total Ceramic Innovis Hip

Bipolar

Scheme

Pre-operative Post-operative

Biomedical Implants

Development of an Appropriate Body Mix Through Part, and/or Complete Replacement of Ukraine Clay In Body Composition Granito

Ceramic Tile Production by CSIR-CGCRI Naroda Outreach Center

Development of a tailored technology that immensely benefited the tile industries of Morvi, Thangarh and Himmatnagar regions in Gujarat

• Number of production units: from 14 in 2005 to 64 in 2011

• Ukraine clay requirement reduced: from about 20% to a bare 1% level

• Monthly import of Ukraine clay reduced from 11,590 to 3500 m-tons

• Production of tiles per month: increased by 6 folds (from 25 million m2 per month to 150 million m2)

• The net profit margin per manufacturing unit alone rose by: Rs 3.56 crores per annum per unit

Major Spinoffs

Fired tiles coming out of roller hearth during tile manufacturing

Packing of finished product

VISIT OF DG,CSIR TO NARODA CENTER

Glass bead making: From wood fired traditional kiln to LPG fired kiln

Scenario at Khurja Ceramic Cluster – Kilns

– Tunnel – 100 – Shuttle – 40 – Down Draft– 50

– Oil Consumption – 18000KL/Year – No equipment or method to assess the

furnace environment – Lack of knowledge about the flue gases – Dense loading – Improper KF : W ratio – No oil & air pressure gauges – Leakage & poor insulation CSIR-CGCRI Interventions: Flue gas analysis

• Work Done – 158 kilns – Initial Flue gas levels were determined – After analyzing the data, suggestions were

given to adjust the air and fuel settings in the kilns

– Flue gas levels were checked after the modifications and the benefits noted

• Impact : – Total fuel saving per year

• Rs 69.7 L • 174 KL • Redn. in CO2 emission to atmosphere

- 482 MT ( CO2 emission : 2.77 kg/lit diesel)

Introducing Bone China manufacturing capability

• No Bone China Ware Plant Till 1992 in Khurja • T&D in formulation, manufacturing and firing

and qulity up-gradation led to setting up of 16 manufacturing plants today

• Reduction in firing hours through technological up-gradation of kilns

• Introduction of bone china ware plant .

• Flue gas analysis

• Capability augmentation in glass bead making

Khurja Outreach Centre - Success Stories

Technology developed during last one year

Special Glass Nodules For Nuclear Waste Immobilization

Process technology developed for making special glass nodules (frits) with desired properties

Production has been taken up in collaboration with M/s. H. R. Johnson, Mumbai and 3.5 Ton of materials have been supplied to Tarapur Unit

DAE likes to place order immediately for further 10 tons

Negotiation is going on for transfer of the technology to HRJ

Proposed Model: Production by HRJ with direct order from BARC + Certification of the quality by CGCRI

Borosilicate glass nodules developed at

CGCRI Kolkata

Exchange of Technology Transfer document with M/s H

R Johnson

Glass Nodules produced by M/s H R

Johnson