Centre for Nanomaterials (CNM)

Overview

ARCI has embarked on world class product development, “Silica aerogel flexible sheets” for thermal insulation application with the objectives of indigenization under the ‘Make in India’ initiative. Silica aerogel is an ultra-low density nanoporous material known for its best thermal insulation property in wide range of temperatures from cryo to high. In spite of all the potential benefits of aerogels, its commercial use was restricted due to its fragile nature. ARCI’s product made up of fiber-aerogel composite overcomes this limitation by making it mechanically stronger and flexible. The silica aerogel in this product has a special property of infra-red radiation reflection which helps to minimize the radiation by thermal conduction at high temperature. The product possesses all the properties ideally required as the best thermal insulation material such as low thermal conductivity, corrosion resistance, chemical resistance, good compressive strength, light weight, moisture resistance, fire resistance etc

Key Features

• Thickness : 5 – 25 mm
• Thermal stability : - 50to 800 oC
• Thermal conductivity : 0.04W/mK at RT (Transient plane method)
• Density : 0.2 g/cc
• Good Mechanical strength: Can take ~ 80 N force and elongation of 5mm
• Neutral in pH (water vapours passing through show pH 7) Non-corrosive
• Hydrophobic; if immersed in water for 5 hours, < 1% water is retained in the sheet
• Breathable

Potential Applications

• Thermal insulation in sectors like
• Industrial like power plants, oil & gas industry
• Architectural
• Automotive
• Defence and Aerospace
• Heat / cold storages

Intellectual Property Development Indices (IPDI)

• Aerogel sheet production up-scaled to 300 x 3000 mm size
• Tailored to achieve all the characteristics for ideal insulation material
• Technology transferred to an Indian Industry for commercialization 

Photo of Aerogel Flexible Sheet Roll

Fire Protection Property of aerogel sheet

Major Patents / Publications

Major Patents*

• Indian Patent No. 305898 : An improved process for producig silica aerogel thermal insulation product with increased efficiency, Neha Hebalkar,
• International patents filed in Russia, UAE, South Africa, USA, Malaysia, Japan, China, Mexico, Brazil, Indonesia

Overview

Ultrafine aluminum powder (UFAP) is commonly used in a wide variety of applications like rocket propellant additives, thermite mixtures, paints and hydrogen generation, etc due to its reduced ignition delay and temperature thus leading to complete combustion of particles. Though UFAP can be synthesized by a number of techniques, radio frequency induction plasma (RFIP) offers inherent advantages over other techniques. The purity of the powder is ensured since RFIP setup has no electrodes. The productivity is also reasonably high ~0.5-1 kg/hr, depending upon the material and its feed rate. The precursor powder carried by a carrier gas passes through the injection probe and gets delivered into the plasma chamber. The vaporized precursor is then subjected to a drastic quench as it comes out of plasma chamber.

Key Features

• Ultra fine Al increases burning rates; required for solid or liquid propellant
• Import embargo
• ARCI has got capability to make Al nano powder in kg levels
• Ability to tailor the particle size and its distribution
• Metallic aluminium content as high as 90%
• Predominantly displays an exothermic peak compared to micron sized Al powder

Potential Applications

• Propellant additives for both solid as well as liquid propellants
• Sintering additives
• Coating applications
• Thermite welding applications
• Hydrogen generation

Intellectual Property Development Indices (IPDI)

• Synthesis of powder at kg levels was demonstrated 
• One kg of powder delivered to SF Complex, Jagdalpur, DRDO for field trials

SEM morphology of ultra fine Al powder

Thermal characteristics of ultra fine Al powder in comparison with micron sized powder

Major Patents / Publications

Major Publications

• P.Sai Karthik, S.B. Chandrasekhar, D. Chakravarty, PVV Sriniuvas, VSK. Chakravadhanula, TN Rao, Propellant grade ultrafine aluminium by RF induction plasma, Advanced Powder Technoilogy, 29, 804-12, 2018

Overview

Photoelectrochemical electrodes with solar photon absorptivity and long sustainability (>1000hrs) are being developed to achieve 7% solarto-hydrogen (STH) ratio. Nanostructured semiconductors/chalcogenides and composites (CdS, CdSe, Ga-In phosphide) are being considered for the development of efficient photoelectrochemical cells (PEC). There is need to develop stable photoelectrode or improve the life of known systems (Fe2O3, II-VI metal chalcogenide as CdS, CdZnS). CdS/ CIGS/Si are efficient systems which need to be modified by nanostructuring for sustainable performance. This is best suited with nano-(Ti/Ni oxide) and nano-MoS2 based systems.

Key Features

• Spray pyrolysis and Simple solution process for large electrode film deposition
• High solar absorption and improved stability
• Scalable manufacturing process

Potential Applications

• Solar PEC H2 generator, fuel for cooking, cutting, welding
• Optical material for absorber, photo-chromic display, LED, solar cell
• CO2 conversion to usable fuel
• Pollutant removal under solar light, water purification,
• Petroleum industries

Intellectual Property Development Indices (IPDI)

• Performance is validated at laboratory scale
• Sustainable performance under simulated conditions 
• STH of > 3% for stable performing electrodes

Simple method to obtain electrodes with improved chemical stability

Performance characteristic Nano-modified electrodes

Major Patents / Publications

Major Patents*

• Borse, P.H,et.al. Effective Fabrication of conducting polymer modified CdS photoanodes for photoelectrochemical cell, Thin Solid Films 2018; 661(1), 84-91
• Borse, P.H,et.al. Ultrathin MoS2-MoO3 nanosheets functionalized CdS photoanodes for effective charge transfer in photoelectrochemical (PEC) cells , Jou Mat Chem A 2017; 5 (4), 1541-1547
• Indian patent granted on " Method of Deposition of double perovskite of Sr Fe Nb-O film on substrate by spray coating technique & the coated substrate thereof” invented by P.H.Borse, - IN 2014DE01151A, Nov 6, 2015
• Borse, P.H.et.al Stable hydrogen generation from Ni- and Co-based co-catalysts in supported CdS PEC cell Dalton Transactions, 2016; 45 (27), 11120-11128
• Borse PH. et.al. Nanoniobia modification of CdS photoanode for an efficient and stable photoelectrochemical cell. Langmuir 2014;30(51):15540-15549

Overview

Two dimensional nanosheet like structure in sulfides of transition metals like tungsten and molybdenum have shown wide range of attractive properties, which can be harnessed for various applications as catalyst or lubricant in petrochemical and automotive sectors, electrode material for Li-ion batteries and electrocatalyst for hydrogen evolution reaction (HER), etc. However, the absence of commercially viable routes for their synthesis in bulk quantity and reproducible quality has been a major issue hindering their commercial exploitation. Recently, a novel technique has been developed by ARCI to generate such 2D structure in WS2 and MoS2. The process offers unique control capabilities to synthesize tailor-made 2D nanolayered structure in these sulfides in bulk amount. Based on the application and/or required properties, the size and thickness of these nanosheets can be altered by changing various process control parameters.

Key Features

• Synthesis of pure as well as mixed WS2/MoS2 nanosheet powders
• Synthesis of doped-WS2/MoS2 nanosheet powders
• Reasonably good oxidation resistance
• Synthesis of 2D-nanostructured other transition metal sulphides feasible
• Scalable process for bulk production

Potential Applications

• Solid lubricant for aerospace and automotive sector
• Solid lubricant for forging and other manufacturing processes
• Additive to automobile Lub-oil
• Additive to grease for improved performance under high shear stress
• Petrochem catalyst
• Electrocatalyst for HER
• Li-ion battery electrode
• Self-lubricating composites and coatings (metallic/ceramics/polymer)
• Sensors and actuators

Intellectual Property Development Indices (IPDI)

• Stability in air validated at laboratory scale
• Consistency of the powder grade tested
• Scaled-up reactor successfully commissioned and tested for bulk production of 2DWS2/MoS2

Microstructure of typical 2D-WS2nanosheets by ARCI method

Scaled-up reactor for bulk production of 2D-WS2 and MoS2

Major Patents / Publications

Major Patents*

• . J. Joardar and M.S. Sylvester, Indian Patent (Ap. No. 1703/DEL/2012).

Overview

ZnO varistors is a polycrystalline ceramic over-voltage protection device whose primary function is to sense and regulate over voltage surge. The device is used in small electronics circuits to large transmission lines due to its high nonlinear current-voltage characteristics with large energy dissipation capabilities. ARCI have developed high performance varistors from nanopowders using novel process and compositions. The process of making doped ZnO nanopowder is very simple (single step) and cost effective. The synthesis parameters and compositions have been optimized for lightening arrestor application at pilot scale level. These nanopowders can be sintered at much lower temperatures with lesser time compared to commercial micron-powders. Breakdown field of 21 kV/cm, low leakage current density of 0.7 µA/cm2 and coefficient of nonlinearity greater than commercial (90) have been obtained.

Key Features

• Patented technology 
• Lower sintering temperature and time compared to micron powders 
• Order of magnitude higher breakdown field, 2-3 times coefficient of nonlinearity and comparable leakage current density

Potential Applications

• Power engineering 
• Automobile industry 
• Household electronics 
• Telecommunications

Intellectual Property Development Indices (IPDI)

• Electrical properties tested
• Scale-up to pilot level

Varistor disc comparison of ARCI and commercial sample

I-V characteristic comparison of ARCI and commercial varistors

Major Patents / Publications

Major Publications

• An improved process for the preparation for doped ZnO nanopowder useful for the preparation of varistors, K. Hembram, T.N. Rao and R. Sundaresan, Indian Patent No. 254913. 
• Improved composition and method of preparation of high performance ZnO varistors, K. Hembram, A.R. Kulkarni, R. S. Srinivasa and T.N.Rao, Indian Patent No. 339072
• K. Hembram, T.N.Rao, R.S. Srinivasa and A. R. Kulkarni, High performance varistor made from doped ZnO nanopowders by pilot-scale flame spray pyrolyser: sintering, microstructure and properties, Journal of the European Ceramic Society, 35 (2015), 3535-3544.

Overview

Sintered Fe-Cu based cerametallic friction materials/pads for clutch and brakes of commercial heavy vehicles like trucks and tractors are presently being imported. These friction pads are riveted to steel back plates and fixed to the carrier plates before assembling in the clutch housing. The life of the friction pad is limited to the depth of the rivet; limiting 100% utilisation of the friction material/pad and with usage, the failure is initiated along the rivet hole. Further, rigid bonding introduces a little discomfort arising out of judder while driving. The project involves innovative methods of replacing riveted clutch buttons with bonding of friction cookies directly onto the clutch plate, dispensing with the requirement of the additional steel back plate. A patented technology with reduced number of processing steps with compositional change and indigenous equipment design has been developed to increase driving comfort along with increased life of clutch system.

Key Features

• Use of non carcinogenic materials 
• Improved wear and coefficient of friction 
• Fe-based sintered pad 
• Flexibility of single or dual sintered friction pads 
• Indigenous equipment for processing 
• Reduced post sintering operations 
• Production level manufacturing process

Potential Applications

• Clutch and brakes of heavy commercial vehicles 
• Aircraft brakes 
• Passenger vehicles like buses 
• Wind mill applications 
• Railways
• Military tanks

Intellectual Property Development Indices (IPDI)

• Performance and stability are validated at laboratory scale 
• Prototype level demonstrated 
• Scale up design of equipment and technology available

Indigenously designed Multi Piston Hot Press

Weight loss of friction pad with distance

Major Patents / Publications

Major Publications

• Malobika. K and A. Siva Kumar, ‘A Process and a Multi Piston Hot Press for Producing Powder Metallurgy Components, such as Cerametallic Friction Composites’, application no. 3844/DEL/2011, dtd. 28.12.2011

Overview

Oxide dispersion strengthened (ODS) Ferritic-Martensitic/Ferritic/Austenitic steels are endowed with high temperature strength and resistance to creep, fatigue, oxidation and hot corrosion. Hence, these steels are potential candidates for the components in nuclear reactors, gas and ultra super critical steam turbines which are exposed to temperatures up to about 700C. The high temperature properties of ODS steels are due to the fine grained microstructure, nanosized oxide (Y-Ti-O complex) dispersoids and stability of the microstructure at high temperatures. ARCI has embarked on major programmes for development and demonstration of technologies for the manufacture of blades for ultra super critical steam turbines, clad tubes of fast breeder reactor and high pressure compressor and low pressure turbine blades for gas turbines.

Key Features

• High operating temperature of 650-700°C
• High yield strength and creep resistance 
• Potential candidates to replace nickel based super alloys 
• Resistance to swelling under irradiation 
• Established manufacturing processes

Potential Applications

• Blades for ultra super critical steam turbines 
• High pressure compressor and low pressure turbine blades of gas turbines 
• Clad tubes for nuclear reactors
• Structural materials for fusion reactors 
• Other high temperature applications

Intellectual Property Development Indices (IPDI)

• Established manufacturing processes at pilot plant scale 
• Performance and stability are validated at prototype level 
• Further evaluation is underway

500 MW first stage ODS steel blade

Clad tube of Fast breeder reactor

Major Patents / Publications

Major Patents*

• S. Santra, S. Amirthapandian, A. J. London, B. K. Panigrahi, R.M. Sarguna, S.Balaji, R.Vijay, C. S. Sundar and C. Grovenor, Effect of Ti and Cr on dispersion and structure of oxide nano-particles in model ODS alloys, Acta Mater. 97 (2015) 223-233.
• M. Nagini, R. Vijay, Koteswararao V. Rajulapati, K. Bhanu Sankara Rao, M. Ramakrishna, A.V. Reddy and G. Sundararajan, Effect of process parameters on microstructure and hardness of oxide dispersion strengthened 18Cr ferritic steel, Metall Mater. Trans. A, 47 (2016) 4197-4209
• K. Suresh, M. Nagini, R. Vijay, M. Ramakrishna, Ravi C. Gundakaram, A.V. Reddy and G. Sundararajan, Microstructural studies of oxide dispersion strengthened austenitic steels, Mater. Design, 110 (2016) 519-525.
• M. Nagini, R. Vijay, Koteswararao V. Rajulapati, A.V. Reddy and G. Sundararajan, Microstructure-mechanical property correlation in oxide dispersion strengthened 18Cr ferritic steel, Mater. Sci. Eng. A, 708 (2017) 451-459.
• M. Nagini, K.G. Pradeep, R. Vijay, A.V. Reddy, B.S. Murthy, G. Sundararajan, A combined electron microscopy, atom probe tomography and small angle X-ray scattering study of oxide dispersion strengthened 18Cr ferritic steel, Mater. Char., 164 (2020) 110306

Overview

Silica aerogels are world’s best thermal insulation materials. These are nanoporous material with ultra low density. Literally aerogels mean air filled gels. Monolithic pure silica aerogels are highly fragile in nature and this was the major decelerating factor for its commercial use. This led to make new usable forms of silica aerogel namely flexible sheets made up by fibre reinforcement and granular aerogel. ARCI has embarked on world class product of silica aerogel flexible sheets and it is under commercialization. Granular silica aerogels are also developed at ARCI using a novel method for which the patent has been applied. Granular silica aerogel can be very conveniently used in many ways such as by filling them around the object to be insulated or these can be sandwiched between metal, glass, wood plates, fabric etc. and also can be used as an additive to paints, cement, bricks, insulation panels etc.

Key Features

• Granule size : ~ 1 mm (Tuneable) 
• Packing density: 0.07 g/cc 
• Thermal stability : - 200 oC to 800 oC 
• Surface area: ~ 800 m2/g 
• Thermal conductivity: 0.03 W/mK at RT (transient plane method) 
• Colour : Translucent or opaque or black (depending on functionality)
• In-situ carbon doping for IR opacification possible
• Hydrophilic or hydrophobic

Potential Applications

Thermal insulating

• Paints
• Building material such as cement, bricks, wall plaster etc
• Window panel
• Textiles 
• Heat / cold storages

Intellectual Property Development Indices (IPDI)

• ~ 1kg of silica aerogel granules can be produced in one batch from presently available lab production facility

Optical Image of silica aerogel granules

SEM image showing highly porous morphology in silica aerogel granules

Major Patents / Publications

Major Publications

• Indian Patent No. 290370 : Improved method for producing carbon containing silica aerogel granules, Neha Hebalkar

Overview

Low cost and eco-friendly solar active photocatalytic material is highly desirable for generating hydrogen fuels. Nanostructured ferrite (Fe2O3, MFe2O4) and composite systems are potential candidates which gives high yield from water splitting. Titanates (TiO2) lack the ability to absorb the visible light photons and hence there is need to identify and develop efficient photocatalysts. Fe2O3 and II-VI metal chalcogenide (CdS, CdZnS) systems exhibit ability to absorb solar light photons as well as proper band energetics to split water molecule. They can be used in slurry type solar hydrogen generator.

Key Features

• Eco-friendly photocatalyst
• Rapid process to synthesize nanocrystalline photocatalyst
• Scalable process

Potential Applications

• Solar Hydrogen generator, Fuel gas-cooking, cutting, welding 
• Optical material for absorber, photo-chromic display, optical sensor
• Photo-decomposition- Pollutant removal , water purification

Intellectual Property Development Indices (IPDI)

• Performance is validated at laboratory scale
• Improved efficiency

Schematic of rapid photocatalyst synthesis produced by microwave sintering

Optical response of Visible light active photocatalysts

Major Patents / Publications

Major Patents*

• Dom, R., Kim H.G. and., Borse, P.H, Photo Chemical Hydrogen Generation from Orthorhombic CaFe2O4 Nanoparticles Synthesized by Different Methods , Chemistry Select 2017; 2 (8), 2556-2564
• Dom, R, Chary, AS , Borse, PH. Solar hydrogen generation from spinel ZnFe2O4 photocatalyst: Effect of synthesis methods. INTERNATIONAL JOURNAL OF ENERGY RESEARCH 2015;39(10):1378-1390
• Borse PH et.al.. Synthesis of a hydrogen producing nanocrystalline ZnFe2O4 visible light photocatalyst using a rapid microwave irradiation method. RSC Advances 2012;2(33):12782-91
• Borse PH, et al.. Fabrication of CaFe2O4/MgFe2O4 bulk heterojunction for enhanced visible light photocatalysis. Chemical Communications 2009(39):5889-91

Overview

Even though iron aluminides possess low density with very good oxidation/ corrosion resistance and low cost, they are not commercialised due to insufficient strength and ductility at room temperature (RT) as well as high temperatures (HT). Several attempts are made by researchers from last few decades to enhance the RT ductility and HT strength of iron aluminides without any notable success. ARCI successfully improved these properties of iron aluminides by refining the grain structure and also introducing nano oxide dispersoids, which helps in the retension of fine grained structure to improve strength and ductility.The oxide dispersion strengthened iron aluminides (ODS Fe3Al) alloys have exhibited excellent room temperature tensile properties, with yield strength of 1100 MPa and ultimate tensile strength of 1600 MPa and ductility of 16 %, when compared to other Fe3Al alloys produced around the world. The high temperature tensile properties of the ODS Fe3Al alloys upto 700⁰C are superior when compared to commercially used high temperature materials.

Key Features

• High operating temperature of 650-700oC
• Light weight
• High yield strength and creep resistance
• Potential candidates to replace nickel based super alloys
• Excellent oxidation and corrosion resistance

Potential Applications

• Blades for ultra super critical steam turbines
• High pressure compressor and low pressure turbine blades of gas turbines
• Furnace crucibles
• Other high temperature applications

Intellectual Property Development Indices (IPDI)

• Established manufacturing processes at pilot plant scale
• Performance and stability are validated at coupon level
• Further evaluation is underway

EBSD map and TEM bright field image which show fine oxide particles of ODSFE3AL

Variation of strength with temperature

Major Patents / Publications

Major Patents*

• Oxide Dispersion Strengthened Iron Aluminides with High Strength and Ductility and Method of Preparation of the Same, P. Vijaya Durga, S. S. Sharma, K. Satya Prasad, A. V. Reddy and R.Vijay, Indian Patent Application No. 202011044124, 09/10/2020.

Major Publications

• P. V. Durga, K. Satya Prasad, S.B. Chandrasekhar, A.V. Reddy1 S.R. Bakshi and R. Vijay, “Microstructural and Mechanical Properties of Oxide Dispersion Strengthened Iron Aluminides Produced by Mechanical Milling and Hot Extrusion” in Journal of alloys and compounds 834 (2020) 155218.

Overview

Slurry fuels, which consists of hydrocarbon fuel and high-energy metallic elements, are considered as potential candidates to increase the energy density of conventional hydrocarbon fuels for air breathing propulsion applications.. Nano sized additives having large surface to volume ratio facilitate more contact area for rapid oxidation and hence their addition to fuel improves the thrust and overcomes the problems of ignition delay, burning time. Among various nano additives nano boron is considered as potential additive to liquid fuels due to its higher volumetric heat generation. Though nano boron can be made with other techniques, cryo milling method offers distinct advantages. Advantages of cryo mill are 1) powder is protected from oxidation during and after milling as it takes place in liquid nitrogen, 2) simple process and involves mass production, 3) handling of the powder after the milling is not difficult, 4) inexpensive process

Key Features

• Average particle size of nano boron is 200-300 nm
• Purity of the boron > 95%
• Surface area of the powder > 10.5 m2 /g
• Dispersable in hydrocarbon fuel
• Handling of the powders is not difficult
• Capability to produce in large quantities.

Potential Applications

• Slurry fuels for propellant applications
• Alloys and Composites

Intellectual Property Development Indices (IPDI)

• Synthesized and characterized the nano boron at laboratory
• Testing of the nano boron at industry is underway

SEM image of Nano boron

Thermal properties of Nano boron

Major Patents / Publications

Major Patents*

• Patent application No:201911025690 dated 27/06/2019 titled “ Process for producing the nano boron by cryo milling” S.Sudhakara sarma, R.Vijay, T.N.Rao.

Major Publications

• S.Sudhakara Sarma, Joydip Joardar, R.Vijay, T.N.Rao, “Preparation and characterization of nanoboron by cryo milling” Advance Powder Technology, Vol 31, 2020, P 3824-3832

Overview

Additive manufacturing (AM) is fast emerging as a key manufacturing process to produce near-net shaped metallic components, where three dimensional components are built by adding the material layer by layer. While it is universally acknowledged that the quality of final AM component depends on the quality of the metallic powder that one starts with, the specific attributes of this powder quality are not understood. Additionally, the process yields in manufacturing of metallic powders for AM are generally very low (<20%). At present nickel-based superalloy powders (IN718, IN625 and CM247LC) for AM are being produced by a few reputed companies from USA, Switzerland, Germany, Canada and UK. However, each company produces its own tailor made powders with a given process. ARCI, having the state of the art inert gas atomiser facility is in the process of developing powders for AM.

Key Features

• Ease of manufacture of near-net shaped components by AM using powders
• Powder requirements are currently being met by imports and are expensive
• At present, there are no manufacturers of gas atomized powders in general, and Ni based superalloy powders, in particular, in India.
• Make in India

Potential Applications

• Aerospace
• Defence
• Biomedica
• Automobile

Intellectual Property Development Indices (IPDI)

• Synthesis of powder (at 10 kg levels were demonstrated)
• Powders are undergoing trials on AM studies

SEM morphology of IN718, IN625 and SS403 powders produced at ARCI.

Overview

The concept of electric vehicle powered by Super capacitor alone as well as hybrid has been designed, integrated and demonstrated during on road conditions. To integrate the super capacitor bicycle,18 commercial SC (Maxwell) cells with individual cell specifications of 3400 F, 2.85 V and 3.85 Wh (stored energy) were procured, connected in series to obtain a module with 51.4 V and 69 Wh sufficient to run the electric motor in the bicycle. Further, the capacitor management system (CMS) has been developed to regulate the voltage and current in each cell during charge/discharge cycles. In order to extend the driving range of E-bike to 2.5 km, boost converter has been designed to boost up the voltage by recovering the remaining stored energy in SC module. Parallely, hybrid module has been developed containing 3 Lead acid batteries (12V 14Ah: 3 pack) connected in series with 3 super capacitors (2.7V, 650F, 0.66 Wh). The super capacitors aids in cranking as well during acceleration. The developed bicycles have been successfully tested during on-road conditions.

Key Features

Super capacitor powered EV:

• No. of cells in module:18 cells connected in series
• Total stored energy: 69 Wh
• Usable energy: 27.0 Wh
• Nominal voltage, V: 51.3 V
• Charging time: 4 minutes
• Driving range: 2.5 Km with booster circuit

Hybrid EV:

• Lead acid battery (36 V 14 Ah) has limitations in terms of life and power delivery
• Initial high power delivery (400 W) reduces the life time of lead acid battery
• SC (2.85 V; 650 F) provides high power (400 W) delivery for initial cranking during start and acceleration thus increasing lifespan
• On-road charging (2 Wh per charge) and peak power delivery while running
• Hybrid EV has a maximum speed of 25 kmph with motor capacity of 250 W

Potential Applications

• Automotive transport (electric bicycles, mini-bus, etc.)

Intellectual Property Development Indices (IPDI)

• Super capacitor bicycle has been integrated and demonstrated.
• Booster circuit has been designed to extend the range of super capacitor E-bicycle
• Super capacitor module has been adopted in addition to lead acid battery pack for initial cranking and acceleration.

Super capacitor powered Electric Bicycle

Hybrid (super capacitor assisted and lead acid battery powered) E-bicycle.

Overview

Lithium ion batteries play an important role in the field of electric vehicle (EV) industries due to their high energy density and power density in comparison to other secondary batteries. As there is a great demand for large quantities of electrode materials for EV application, ARCI is working on development of nano-structured electrode materials in large scale by cost-effective processes. Lithium titanium oxide (LTO) has emerged as a promising anode material for high-power LIBs owing to its abundance, low manufacturing cost, thermal stability, excellent cycle life of 20000 cycles and safety. LTO is also known as a ‘zero-strain’ material because it undergoes negligible volume change during charginf/discharging, which ensures an extremely long cycle life. Further, LTO anode based Li-ion batteries can work under harsh ambient temperatures (-30 to +55°C) and exhibit recharge efficiency exceeding 98%, compared to other carbon based anode materials. Hence, it is ideal for Indian climatic conditions where the temperature reaches 45-48 0C in summer, which is a motivating factor for indigenous LTO materials development. ARCI focused on developing the simple, economical scalable and energy efficient technique for production of LTO anode with improved electronic conductivity using TiO2 and Li2CO3 as precursors. The advantages of high energy milling method are short processing time, low contamination, high relative velocity of balls and high energy input. Further, ARCI’s technology has been tuned to be adaptable to any sort of precursers ARCI’s LTO has been validated in half cell and its performance was found to be very promising in terms of high specific capacity (170 mAh/g), good rate capability (20C) and long cyclic stability (upto 1000 cycles), which is better than the performance of coomercial LTO obtained from Geylon, China as it exhibits capacity of only 113 mAh/g with poor rate capability. Further LTO based LIB device (20 mAh capacity) fabricated in combination with high voltage cathode exhibited 80% retention of capacity after 1000 cycles. The production cost of ARCI’s LTO is comparable with the cost of imported LTO (~ 20 USD) by utilizing the pilot plant facility for the production of LTO at a level of 72kg/day. Patents are filed in India, USA, Japan, China, Germany and South Korea. A private company, who is making LTO based LIB for Hybrid Vehicle application is very much interested in ARCI’s LTO technology and efforts are underway for possible technology transfer.

Key Features

• Large scale production (2.5 Kg/batch) of lithium titanate (LTO) by high energy milling process
• Simple, economic and scalable processing method.
• Electrochemical performance of LTO is higher than commercial LTO material
• Capable of delivering high power performance
• Prototype LTO electrodes of 30 m length was prepared using LIB plant facility.
• LTO based LIB device (20 mAh capacity) with high voltage cathode
• 80% retention of capacity after 1000 cycles

Potential Applications

• High power density and thermally stable anode for electric hybrid electric vehicles
• Other portable devices where LIB s are used.

Intellectual Property Development Indices (IPDI)

• Performance and stability are validated at laboratory scale
• Scale-up has been carried out successfully
• Prototype testing is under process using pilot plant facility.

Major Patents / Publications

Major Patents*

• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, Indian Patent Application No. 201711006147 dated 27.12. 2017.
• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, PCT International Application No. PCT/IN2018/050080 dated 17.02.2018.
• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, US Patent Application No. 16/463,088 dated 22rd May 2019 based on PCT International Application No. PCT/IN2018/050080 dated 17.02.2018.
• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, Japan Patent Application No. 2019-520394dated 16th April 2019 based on PCT International Application No. PCT/IN2018/050080 dated 17.02.2018.
• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, Chinese Patent Application No. CN201880004507 dated 22nd July 2019 based on PCT International Application No. PCT/IN2018/050080 dated 17.02.2018.
• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, Germany Patent Application No. 112018000205 T5 dated 14th August 2019 based on PCT International Application No. PCT/IN2018/050080 dated 17.02.2018
• A method of producing high performance lithium titanate anode material for lithium ion battery applications, S. Anandan, P.M. Pratheeksha, R. Vijay and Tata N. Rao, South Korea Patent Application No. 10-2019-0121291dated 25thOctober2019 based on PCT International Application No. PCT/IN2018/050080 dated 17.02.2018.

Major Publications

Overview

Lithium ion batteries play an important role in the field of electric vehicle (EV) industries due to their high energy density and power density in comparison to other secondary batteries. Though there exists a great demand for large quantities of electrode materials for EV application, many research groups focus on basic (lab scale R&D) research rather than large scale production of electrode materials. In contrast, ARCI focuses mainly on development of nano-structured electrode materials in large scale by cost-effective processes. Among cathode materials, LiFePO4 becomes promising for electric vehicle batteries due to their high energy density, structural and thermal stability.ARCI successfully developed a rapid, simple and cost-effective process to prepare in-situ carbon coated LiFePO4 (C-LFP) in large scale by adopting solid-state high-energy milling technique. The C-LFP so developed shows promising electrochemical properties in terms of high charge discharge capacity, excellent rate capability and long cyclic stability and hence it may be suitable for high energy as well as high power density lithium-ion battery application. The method developed for synthesizing C-LFP in this invention has the advantage of being cost effective, single step, and fast processing due to high kinetic energy system used for milling of powders.

Key Features

• Methods which can produce 2kg of nano-powders were used for large scale production of carbon coated LiFePO4 (C-LFP)material.
• The method was found to be economical simple and scalable.
• Has the potential to fine tune the properties of cathode produced.
• Electrochemical performance of C-LFP at par with commercial C-LFP and the method is scalable.
• Prototype LIB cells fabrication & demonstration using indigenous C-LFP material.

Potential Applications

• High energy density cathode for electric vehicles
• High power density cathode for marine application
• Other portable devices where LIB s are used.

Intellectual Property Development Indices (IPDI)

• Performance and stability are validated at laboratory scale
• Scale-up has been carried out successfully
• Prototype testing is under process using pilot plant facility.

Major Patents / Publications

Major Patents*

• Method of producing in-situ carbon coated lithium iron phosphate cathode material for Li-ion Batteries and the product thereof, S. Anandan, R. Vijay and Tata N. Rao, Indian Patent Application No. Application number 202011056608 dated 28th December 2020

Major Publications

Overview

Super capacitors have been recognized as promising energy storage devices due to their fast charge-discharge time, very high power density and long life cycle period. It is commercially available but widespread usage is restricted by their high cost and low energy density. These drawbacks can be mitigated by developing a new class of high performance carbon electrodes which consist of a combination of materials produced from abundant, cheap and environmentally friendly resources with low processing costs. ARCI focuses mainly on the development of large scale process to convert various bio-wastes into a high surface area porous carbon material with graphitic structure suitable for super capacitor application. ARCI successfully synthesized high performance porous carbon materials using bio-waste like jute stick, cotton fabric by a simple chemical activation process. The resulting carbon material delivers excellent super capacitor performance in terms of capacitance, rate capability and cyclic stability in comparison to commercial activated carbon material. Also, ARCI in collaboration with HPCL has developed graphene-like activated porous carbon from petroleum coke (Petcoke) by a low-cost chemical activation process and demonstrated its superior electrochemical properties in comparison to commercial supercapacitor grade carbon. Petcoke, a by-product in oil refining process, is a rich carbon source material (> 90%) and also contains significant amount of sulfur impurity. There is an environmental concern of using petcoke as low cost fuel in cement and steel industries due to the emission of hazardous CO2 and SOx gases. Alternatively, use of petcoke for energy storage application abates the emission problem while finding a high value addition to it. A semi-pilot plant involving various equipments such as the coating machine, Semi-auto winding machine, Grooving machine, Sealing machine, flattening machine, Electrolyte filling machine etc are installed at ARCI and are functional for fabricationg cylindrical supercapacitor cells. Large scale synthesis of materials in Kg level is optimized to make carbon slurry and the jelly rolls obtained from coated electrodes are laser welded to achieve large area electrical contact to terminals and demonstrated the first indigenous 1200 F supercapacitor that performs on par with a benchmark commercial supercapacitor. For comparison, the performance of commercial supercapacitor device obtained from market was also validated under similar experimental conditions and the indigeneous device exhibits performance onpar with the commercial device. Cyclic Voltammetry studies were performed at 1 mV/s for both indigenous cell and commercial cell. The capacitance was calculated to be 1198 F at 1 Amp. for indigenous ARCI cell with a voltage window of 2.7 V. The total energy stored is about 1.2 Wh for indigenous ARCI cell with a energy density of 5.01 Wh/Kg, whereas the energy stored for commercial device is about 1.18 Wh with a energy density of 4.5 Wh/Kg.

Key Features

• Facile synthesis of porous carbon by a simple chemical activation process
• Graphene like structured carbon, high surface area, large pore volume
• Conversion of abundant solid waste into useful carbon material
• Specific capacitance, rate capability and cyclic stability higher than commercial carbon
• High energy density based supercapacitor
• Scalable manufacturing process
• First Indigenous 1200 F supercapacitor

Potential Applications

• Automotive transport (electric bus, electric bicycles, electric cars)
• Consumer electronics (voltage stabiliser, grid power buffer, street lamps)
• Energy recovery (trams, cranes, tractors)
• Memory backup for static random-access memory (SRAM)

Intellectual Property Development Indices (IPDI)

• Synthesis and electrochemical performance of porous carbon at laboratory scale
• Scale-up of porous carbon from bio-waste is underway

Major Patents / Publications

Major Patents*

• K. Nanaji, V. Pavan Srinivas, S. Anandan, T. Narasinga Rao, K. Narayanan, B. Ramachandra Rao and M. Pramanik “Method of producing nanoporous graphene sheet-like structured high and low surface area carbon sheets from petroleum coke” (Patent number: No.202011007399 dt. 20/2/2020).
• S. Anandan, K. Nanaji, and T. Narasinga Rao, “Method of producing graphene like structured nanoporous carbon material from Jute stick based bio-waste for Energy Storage applications and the product thereof” (Patent number: No.E-2/276//2018/DEL dt. 16/2/2018).
• Mani Karthik, Ravula Vijay, Tata Narasinga Rao, “Method of producing porous particles-fibers carbon composites for supercapacitor applications and the product thereof (Patent number: No. 202011027265 dt. 26/06/2020).

Major Publications

• K. Nanaji, Varadaraju U.V, Tata N. Rao, S. Anandan “Robust, Environmentally Benign Synthesis of Nanoporous Graphene Sheets from Biowaste for Ultrafast Supercapacitor Application”, ACS Sustainable Chemistry & Engineering, 2019, 7, 2516-2529.
• K. Nanaji, Hari Mohan. E, Sarada V. B, Varadaraju U.V, N. Rao Tata, Anandan. S, “ One step synthesized hierarchical spherical porous carbon as an efficient electrode material for lithium ion battery”, Materials Letters, 2019, 237, 156-160.
• K. Nanaji, Tata N. Rao, Varadaraju U.V, S. Anandan, “Jute sticks derived novel graphitic porous carbon nano sheets as Li-ion battery anode material with superior electrochemical properties” International Journal of Energy Research, 2020, 44, 2289-2297
• M. Vijayakumar, A. Bharathisankar, D. S. Rohita, K. Nanaji, Tata N. Rao, M. Karthik, "Achieving High Voltage and Excellent Rate Capability Supercapacitor Electrodes Derived from Bio-renewable and sustainable Resource" ChemistrySelect, 2020, 5, 8759-8772.
• E. Hari Mohan, K. Nanaji, S. Anandan, B.V. Appa Rao, Tata N. Rao “Porous Graphitic Carbon Sheets with High Sulfur Loading and Dual Confinement of Polysulfide Species for Enhanced Performance of Li-S Batteries” Journal of Materials Science, 2020, 55, 16659-16673.
• T. Mitravinda, K.Nanaji , S. Anandan, A. Jyothirmayi, Ch. Sai Kiran, Tata N Rao, Chandra Sharma, “Facile synthesis of corn silk derived nanoporous carbon for an improved supercapacitor performance”, Journal of The Electrochemical Society, 2018, 165 (14), A3369-A3379.
• E. Hari Mohan, K. Nanaji, S. Anandan, S.V. Bulusu, B.V. Appa Rao, T.N. Rao, One-step Induced Porous Graphitic Carbon Sheets as Supercapacitor Electrode Material with Improved Rate Capability, Materials Letters, 2019, 236, 205-209
• Manavalan Vijayakumar, Ammaiyappan Bharathisankar, Duggirala Sri Rohita, Tata Narasinga Rao, Mani Karthik, Conversion of Biomass Waste into High Performance Supercapacitor Electrodes for Real-Time Supercapacitor Applications, ACS Sustainable Chemistry & Engineering, 2019, 7, 17175-17185.
• Manavalan Vijayakumar, Ravichandran Santhosh, Jyothirmayi Adduru, Tata Narasinga Rao, Mani Karthik, Activated carbon fibres as high performance supercapacitor electrodes with commercial level mass loading, Carbon, 2018, 140, 465-476.
• K. Nanaji, A. Jyothirmayi, U.V. Varadaraju, Tata N. Rao, S. Anandan, “Facile synthesis of mesoporous carbon from furfuryl alcohol-butanol system by EISA process for supercapacitors with enhanced rate capability”, Journal of Alloys and Compounds, 2017, 723, 488-497
• K. Nanaji, Varadaraju U.V, Tata N. Rao, S. Anandan, “Pore size engineered three dimensional ordered mesoporous carbons with improved electrochemical performance for supercapacitor and lithium ion battery applications” ChemistrySelect, 2019, 4, 10104 -10112

Overview

As part of visible-light active material developmental activity, highly visible light active photocatalysts, based on titanium dioxide nanostructure material containing carbon, C-TiO2 core-shell nanoparticles by an in-situ Lyothermal process has been synthesized for photo catalytic self cleaning applications. Self-cleaning property of visible light photocatalysts incorporated fabric has been evaluated for the decomposition of gas phase acetaldehyde (CH3CHO) under visible-light illumination. Neither decrease in the concentration of CH3CHO nor increase in the concentration of CO2 is observed with commercial TiO2. In contrast, complete decomposition of acetaldehyde observed for composite (TiO2 with carbon nanoparticles) incorporated fabric under the illumination of indoor and outdoor light. The application of developed visible light active material could be extended to paint applications for the removal of VOCs.

Key Features

• A method of producing highly visible light active photocatalysts, C-TiO2 core-shell nanoparticles by an in-situ Lyothermal process.
• Evaluation of photocatalytic self cleaning property of C-TiO2 incorporated textile fabric for decomposition of volatile organic compounds (gaseous acetaldehyde).
• Photocatalytic performances of C-TiO2 are on par with commercial visible-light driven photocatalysts for the decomposition of volatile organic compounds under UV, visible and solar light illumination

Potential Applications

• Self-cleaning Application (textile, paint) for the removal of volatile organic compounds
• Anti-bacterial (Hospital) application

Intellectual Property Development Indices (IPDI)

• Developed a simple, cost-effective and large scale process to synthesize visible-light active titanium dioxide nanostructure material containing carbon
• Successfully evaluated for evaluated prototype sample (C-TiO2 incorporated textile fabric) for self-cleaning photocatalytic decomposition of gaseous acetaldehyde.

Self-cleaning performance of modified titania coated fabric under In-door light illumination.

Self-cleaning performance of modified titania coated fabric under outdoor light illumination.

Major Patents / Publications

Major Publications

• Method of producing nanostructured C-TiO2 composite material for visible light active photocatalytic self-cleaning applications, Indian Patent Application No. 201811011478 dated 28th March, 2018.
• Efficient ZnO-based visible-light-driven photocatalyst for anti-bacterial applications” ACS Appl. Mater. Interf. 6, 13138-13148, 2014.
• Facile one step route for the development of in-situ co-catalyst modified Ti3+-self doped TiO2 for improved visible-light photocatalytic activity, ACS Appl. Mater. Interf. 8,27642-27653, 2016.
• Energy Level Matching for Efficient Charge Transfer in Ag Doped Ag Modified TiO2 for Enhanced Visible Light Photocatalytic Activity, J. Alloys and Compounds , 794, 662-671, 2019

Overview

Tungsten based structural components are commercially being prepared from wrought tungsten by hot-pressing/sintering followed by hot rolling at high temperatures. An alternate simple PM processing route comprising of blending, milling, reduction and spark plasma sintering could be adopted for fabricating such components. The advantage of such processing is retention of fine grain size with uniform distribution and no abnormal grain growth leading to improved hardness and strength in the sintered components. The role of additives was found to be critical in achieving properties identical to that of hot rolled components. The powder composition and the processing conditions was optimized. Microstructural investigations through SEM and EBSD were carried out to explain the enhanced densification at much lower temperatures and were correlated with the mechanical properties achieved.

Key Features

• Fabricated in sizes of 20, 50 and 95 mm diameter upto 10 mm thickness
• Density 98.5% of theoretical with grain size 2-3 µm
• Hardness > 450 HVN and TRS ≥ 750 MPa achieved
• Additives play an important role in attaining properties
• Milling, reduction and sintering steps are involved
• Scaled up process for commercial applications
• Alternate PM based route for fabricating W-components

Potential Applications

• Strategic applications

Intellectual Property Development Indices (IPDI)

• Processing and properties are validated at laboratory scale
• Coupon level demonstrated
• Scaled up technology available

W-plates fabricated by SPS

EBSD showing fully dense fine grained microstructure

Major Patents / Publications

Major Publications

• Dibyendu Chakravarty, PVV Srinivas and R. Vijay, ‘Method of fabricating tungsten based composite sheets by spark plasma sintering technique for making components’, Indian Patent application no. 201911014933, dtd. 13.04.2019
• Ultrahigh transverse rupture strength in tungsten-based nanocomposites with minimal lattice misfit and dual microstructure, Int. J. Ref. Metals New Mater. 95, 105454, 2021.

Overview

Titanium and its alloys are the most commonly used materials for dental implants. Although the biological performance of these alloys are extremely good, there are potential immunologic and aesthetic compromises with titanium implants. The material currently explored to replace titanium alloys is yttria-stabilized zirconia (YSZ) due to its tooth-like colour, hardness, toughness, corrosion resistance and osseointegration. However, the lack of long-term stability of YSZ in presence of body fluid is a major disadvantage. Hydroxyapatite (HA) is another material having extremely good biocompatibility and osseointegration but possess extremely poor mechanical properties. To achieve the benefits of each of these materials and nullify their drawbacks, it is envisaged to develop functionally graded materials (FGM) of Ti-alloy/zirconia, zirconia-HA and HA/Ti-alloy using the spark plasma sintering (SPS) process. Their physical and mechanical properties, microstructure analysis and in-vitro biocompatibility tests will be carried out to investigate the feasibility of each of these FGMs as possible dental implants by comparing their performance with existing commercial implants.

Overview

Electrocatalyst allows the low-cost production of hydrogen from water. However, water electrolysis require platinum to speed up hydrogen generation and long-term reaction. Low abundancy and high-cost limits use of platinum in large scale area. Therefore, exploration of low-cost and efficient electrocatalyst for the hydrogen generation is a prerequisite for large scale hydrogen fuel generation. 2D layered transition metal dichalcogenides like MoS2, WS2, MoSe2 and its composite systems shows superior catalytic activity towards hydrogen generation. These systems show advantage of abundance, easily synthesizable, low cost and eco-friendliness.

Key Features

• Eco friendly 2D layered electrocatalyst – MoS2, MoSe2, Hybrid , Doped System
• Easy scalable synthesis process
• Improved hydrogen evolution efficiency w.r.t. bulk MoS2, & as competitive with Platinum

Potential Applications

• Energy generation – hydrogen production
• Automotives- Lubricants, Li-batteries & Supercapacitor.
• Sensor application –Flexible/Wearable electronics.

Intellectual Property Development Indices (IPDI)

• Electrocatalytic hydrogen generation at laboratory scale.
• Coupon level of testing in simulated conditions

(a) SEM image of synthesized 2D layers MoS2 nanosheets; and (b) Efficient electrocatalytic hydrogen generation using nanosheet MoS2 - at coupon level.

Major Patents / Publications

Major Publications

• Gupta, J., Das D. and, Borse, P.H, Nanosheets Decorated MoS2 Micro Balls: Effect of 1T/2H Composition, Chemistry Select 2020; 15 (38), 11764-11768
• Pareek A., Dom, R, Gupta J, Chandran J, Adepu V. and , Borse, P.H. Insights into renewable hydrogen energy: Recent advances and prospects. Materials Science for Energy Technologies 2020;3 : 319-327

Overview

Oxide dispersion strengthened (ODS) austenitic steels are endowed with high temperature strength and resistance to creep, fatigue, oxidation and hot corrosion. Hence, these steels are potential candidates for the ultra-super critical steam turbines, which are exposed to temperatures up to about 700 °C. The high temperature properties of ODS steels are due to the fine-grained microstructure, nanosized oxide (Y-Ti-O complex) dispersoids and stability of the microstructure at high temperatures. ARCI has embarked on major programs for development and demonstration of technologies for the manufacture of blades for ultra-super critical steam turbines, high-pressure compressor and low-pressure turbine blades for gas turbines.

Key Features

• High operating temperature of 650-700 °C
• High yield strength and creep resistance
• Potential candidates to replace nickel based super alloys
• Established manufacturing processes

Potential Applications

• Blades for ultra super critical steam turbines
• High pressure compressor and low pressure turbine blades of gas turbines
• Other high temperature applications

Intellectual Property Development Indices (IPDI)

• Established manufacturing processes at pilot scale
• Performance and stability validation at prototype level underway

Major Patents / Publications

Major Publications

• K. Suresh, M. Nagini, R. Vijay, M. Ramakrishna, Ravi C. Gundakaram, A.V. Reddy and G. Sundararajan, Microstructural studies of oxide dispersion strengthened austenitic steels, Mater. Design, 110 (2016) 519-525.

Overview

With the anticipated increase in the renewable wind and solar energy supercapacitors with high specific capacitance and cycle stability have increasing demands to balance the energy storage requirements. NiCo2O4 based electrode materials with excellent electrochemical performance and high theoretical specific capacitance values serve as emerging tool for various applications like HEV’s and back-up systems. Further, electrodeposition is a cost-effective mode of synthesis both with respect to the materials employed and the equipment used. The technology aims at the synthesis of binder free electrodeposited NiCo2O4 electrode materials for supercapacitors along with the fabrication of device for practical applications

Key Features

• Cost effective synthesis strategy
• High specific capacitance (1977 F/g at 1 A/g by half cell and 91.5 F/g at 0.5 A/g by full cell)
• High power density (7.5 kW/kg at 10 A/g)
• Good capacitive retention of the ASC (74% retention for 5000 cycles)

Potential Applications

• Start-Stop systems
• HEV’s
• UPS and back-up systems
• Electronics
• ASC device performance and stability for 5000 cycles has been validated at lab scale

Intellectual Property Development Indices (IPDI)

Morphology and Electrochemical Characterizations

Major Patents / Publications

Major Publications

Overview

Aqueous supercapacitors with enhanced energy densities are much needed for their non-toxic and environmental benignity. Metal oxide based pseudocapacitors enhance the specific capacitance and energy density of the device by enlarging the potential window of aqueous electrolyte beyond 1.0 V along with faradic participation. Manganese oxide is an attractive material among the oxide materials used as electrode in supercapacitors because of its high specific capacity, non-toxicity, earth abundance and environmental compatibility. In the present work, β-MnO2 nanostructures have been electrodeposited on activated carbon paper as a binder and additive-free electrodes. Further, the effect of redox mediator in the electrolyte is assessed by fabricating ASC with various molar ratios of KI.

Key Features

• Economic synthesis strategy
• Wide active voltage window
• Energy density of 38.31 Wh/kg at a power density of 3.28 kW/kg
• Excellent capacity retention of 83.3% for 10,000 continuous CD cycles

Potential Applications

• Start-Stop systems
• HEV’s
• UPS and back-up systems
• Electronics
• ASC device performance and good retention for 10000 cycles have been validated at lab scale.

Intellectual Property Development Indices (IPDI)

FESEM image, CV and CD ofMnO2 device

Overview

Masks are playing a major role as personal protective equipment needed to fight against the COVID-19 pandemic. Ag-Cu/CuO nanoparticles have been coated on fabrics by two different processes including nano-suspension coatings using nanopowders synthesized by Flame spray pyrolysis (FSP) and electroless coating process. Prototype masks are prepared for demonstration as shown in figure 1(a). Very uniform coatings have been achieved on the fabric by both processes (Figure 1 (b)). The nanoparticles coated fabrics are tested for their antibacterial efficacy using ASTM E2315 (99.7% disinfection of bacteria in 30 seconds) as shown in Figure (c) and anti-viral (SARS CoV-2) efficacy. The nanoparticles coated fabrics are found to exhibit anti-bacterial properties even after 30 washes and anti-viral properties showed more than 75% efficacy compared to uncoated fabric.

Key Features

• Scalable process
• Antibacterial efficacy : 99.7 % in 30 sec
• Anti-viral (SARS CoV-2 efficacy : ) > 75% compared to uncoated fabric
• Cost effective

Potential Applications

• Self-disinfection mask
• Personal protective equipment (PPE)
• Hospital textiles

Technology Readiness Level (TRL)

• Scale-up to pilot scale
• Validated for antibacterial and antiviral efficacy

Intellectual Property Development Indices (IPDI)

Figure 1: (a) Prototype masks showing nanoparticle coated fabric, (b) (b) FESEM images of nanoparticle coated fabrics and (c) Antibacterial testing of nanoparticle coated fabrics using ASTM E2315 (d) anti-viral efficacy of nanocoated fabric.

Major Patents / Publications

Major Publications

Overview

Polymer nanofiber coatings on standard filtration medium have significantly improved the performance of automotive air filters. Nanofibers having diameter less than 500 nm with extremely high specific surface area, adequate porosity and small pores make them suitable candidates for high performance air filters because of high filtration efficiency and dust holding capacity with minimum pressure drop. Tiny particles in the order of less 0.5 µm can easily be trapped in electro spun nanofibers due to high surface to volume ratio.

Key Features

• High surface area 
• High filtration efficiency 
• High surface cohesion 
• Simple and scalable manufacturing process 
• Present productivity at ARCI: 500X1000 Sq mm/min

Potential Applications

• Automotive air filters 
• Mining vehicles cabin air filters

Intellectual Property Development Indices (IPDI)

• Performance and stability are validated at laboratory scale 
• Performance was tested at industry.

Nanofibers covers the micron size pores of base medium and traps the fine particles.

Performance characteristic of nanofiber coatings.

Major Patents / Publications

Major Patents*

• A novel method for measurement of porosity in nanofiber mat using pycnometer in filtration”, S.Sudhakara Sarma, T.N.Rao, Journal of engineered fibres and fabric, vol 8, issue 4,2013. 
• Fabrication of compound nanofibers for antibacterial applications in filtration, S. Sudhakara Sarma, IJETAE,vol 4, issue 5, 2014.

Overview

A novel titanium dioxide based material has been developed at ARCI for self cleaning application. The titania particles are micrometer in size but possess all the special properties due to nanostructure. This drastically minimizes any risk related to nanotoxicology and still provides all the benefits of nano size which makes it safe for processing, handling and use. Micron sized titania spheres are prepared by self assembly of rutile phased titania nano rods as a major part and decorated with particles of anatase phased titania and silver or silver chloride on its surface. This structure and morphology gives rise to multifunctionality such as self cleaning, antimicrobial, UV protection and brightener. This product has been proved for its high efficiency in “Self Cleaning” property. This technology was transferred to one Indian Industry and successfully commercialized for textile applications. The same material can be extended to many other applications.

Key Features

• Titania microspheres suspension in water at neutral pH
• Efficient photocatalyst
• Anti-bacterial
• UV absorber
• Visible light reflector
• Simple and scalable chemical synthesis
• Novel process for which patent is applied

Potential Applications

• Self cleaning textiles
• Air purification
• Water purification
• Organic effluent treatment 
• Additive to exterior building paint for self cleaning walls

Intellectual Property Development Indices (IPDI)

• Self cleaning and other properties validated at lab scale
• Scale-up upto 200 g per batch production established at lab scale
• Successfully commercialized for textile application 

SEM Image of Titania Microspheres

Methylene blue dye degradation by photocatalytic activity • 2 wt% TiO2 suspension • 0.48% Methylene Blue • Exposed to morning sunlight

Major Patents / Publications

Major Publications

• Indian Patent No. 282988 : Improved method of producing highly stable aqueous nano titania suspension, Neha Yeshwanta Hebalkar and Tata Narasinga Rao
• Indian patent 291408 : Improved process for the preparation of bi-functional silica particles useful for antibacterial and self cleaning surfaces , Neha Hebalkar, Tata Narasinga Rao, Application No. 3071/DEL/2010
• Indian Patent No. 291408 : Method of producing multifunctional, self assembled, mixed phse titania spheres, Neha Hebalkar, Tata N. Rao