Centre for Advanced Powder Metallurgy (CAPM)
Silica Aerogel Sheets for Thermal Insulation Application
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
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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
Ultrafine Aluminum Powder for Propellant Applications
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
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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
2D-Nanolayered Transition Metal Sulfides (2D-NTMS)
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
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Major Patents / Publications
Major Patents*
- . J. Joardar and M.S. Sylvester, Indian Patent (Ap. No. 1703/DEL/2012).
Fe- based cerametallic friction pads for clutch plates of heavy vehicles
Overview
Sintered Fe-Cu based cerametallic friction materials/pads for clutch and brakes of commercial heavy vehicles likes trucks and tractors are presently being imported. These friction pads are rivetted 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. Thus, 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 process 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 constantly higher than slip coefficient
- 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
Technology Readiness Level (TRL):
- Performance and stability are validated at laboratory scale
- Prototype level demonstrated
- Scale up design of equipment and technology available
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/ consistency at coupon level
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Major Patents / Publications
Major Patents*
- Malobika. K and A. Siva Kumar, ‘Multi Piston Hot Press for Producing Powder Metallurgy Components by sintering the green-powder Metallurgy Compacts”, application no. 3844/DEL/2011, dtd. 28.12.2011, grant no. 379250 dtd. 13/10/2021
Major Publications
Oxide Dispersion Strengthened Steels for High Temperature Applications
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
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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
Oxide Dispersion Strengthened Iron aluminides for High Temperature Applications
Overview
Iron aluminides(Fe 3 Al) are potential candidates for high temperature applications due to its light weight, low cost and attractive properties such as high strength, resistance to oxidation, sulfidation and corrosion. However, poor ductility, inadequate creep resistance and low fracture toughness limit their commercial applications. Ductility and strength of Fe 3 Al are significantly improved not only at room temperature but also at high temperatures (up to 700C) by incorporating fine grain structure and stable nano-sized complex oxide dispersoids (Y-Ti-O and Y-Al-O) in Fe 3 Al matrix. The material (ODS Fe 3 Al) exhibited good oxidation resistance up to 1150C. The creep fatigue interaction studies indicated that ODS-Fe3Al can be used as turbine blades up to 550 and as furnace crucibles up to 1150C. Long term creep properties are being evaluated.
Key Features
- High operating temperature of 650-700C
- Light weight
- Exhibits yield strength of 1090 MPa and elongation of 16% at RT
- Exhibits yield strength of 165 MPa and elongation of 56% at 700C
- 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
- Other high temperature applications like furnace crucibles and plates
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
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Design, Integration and Demonstration of Super capacitor Powered and Hybrid Electric Vehicles
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.
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Large Scale Production of Lithium Titanate (Li4Ti5O12) Electrode Materials by Cost-effective & High Energy Milling Process
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.
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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
Development of High Performance Carbon coated LiFePO4 by a Cost-effective and Scalable Process
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.
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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
Development of Porous carbon for high performing Supercapacitors
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
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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
Self-cleaning Evaluation of Visible-light-driven Modified Titania for Textile Application
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.
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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
Tungsten- based plates by spark plasma sintering
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
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
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.
Functionally graded dental implants by SPS
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 issues 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. To achieve the benefits of each of these materials and nullify their drawbacks, functionally graded materials (FGM) of Ti-alloy/zirconia, was developed using the spark plasma sintering (SPS) process. Their physical and mechanical properties, microstructure analysis and in-vitro biocompatibility tests were carried out and compared with existing commercial implants. The Ti-alloy/zirconia bi-layered component yielded excellent mechanical properties like strength, hardness and in-vitro biological properties like cytotoxicity, hemolysis and cell proliferation at par with those of commercially available dental implants.
Key Features
- A simple PM process to fabricate metal-ceramic FGMs in one step was explored for the first time
- High density, good hardness, strength and excellent biological properties were achieved in the Ti-alloy/zirconia components.
- The concept of developing new dental implant from existing MRI compatible materials could be demonstrated
Potential Applications
- Dental implants
Technology Readiness Level (TRL) :
- Processing and properties are validated at laboratory scale
- Coupon level demonstrated
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- 1. R. Jayasree , K. Raghava, M. Sadhasivam, P.V.V. Srinivas, R. Vijay, K.G. Pradeep, T.N. Rao, D. Chakravarty, “Bilayered metal-ceramic components for dental implants by spark plasma sintering,” Mater. Lett. 344, 134403, 2023.
- Bilayered dental implants and process for the preparation thereof, patent application no. 202341014475 dated 03-03-2023.
Electrodeposited nanostructured NiCo2O4 based supercapacitor
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)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Publications
- Batteries and Supercaps, 2020, 3, 1209– 1219
Nanostructured MnO2 electrode for Supercapacitor Applications
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)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Self-disinfecting Nanoparticle Coated Face Masks for Combating COVID-19
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)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Publications
Indian patent draft under preparationTungsten fibre reinforced tungsten composites by spark plasma sintering
Overview
Tungsten has extensive usage in strategic applications. However, it’s application is limited to a great extent due to lower toughness and this can be improved by incorporating new ductile phases and fibres into the tungsten matrix. Tungsten fibre reinforced tungsten (Wf-W) composite is developed at ARCI to overcome brittleness issues in tungsten. This work involves spark plasma sintering of Wf-W composites using bare and oxide-coated tungsten mesh of 100 µm diameter stacked as alternate layers between the tungsten powders. An optimum volume fraction of Wf is envisaged to yield at least double the fracture toughness of pure tungsten, alongside high thermal conductivity and good high temperature mechanical properties such as UTS, YS, fracture strength and elongation. Detailed microstructural and mechanical property investigations were carried out to validate the concept of extrinsic toughening in such composites.
Key Features
- Fabricated with Wf weight fraction up to 10%
- Density: ≥ 18 g/cc obtained with grain size: ≤ 20 µm
- Hardness: > 400 HVN and thermal conductivity ≥ 150 w/MK achieved
- Process can be scaled up for commercial applications
- Alternate PM based route for fabricating Wf-W composites
Potential Applications
- Plasma facing components
- High temperature applications
Technology Readiness Level (TRL) :
- Processing and property evaluation on at laboratory scale
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Nano-Hydroxyapatite Powders for Biomedical Applications
Overview
Hydroxyapatite (HAP) is a biocompatible ceramic widely used in medicines for many diseases, drug delivery, coating on implants, etc., due to its chemical composition comparable to that of teeth and bone. Nano-HAP nanopowders are advantageous over the micron sized powders due to high surface area. ARCI has developed scalable technology for the production of Hydroxyapatite (HAP) and β-Tricalcium Phosphate nanopowders for biomedical, pharma/nutraceutical applications. The powder production is demonstrated up to kilogram level on pilot scale using Flame Spray Pyrolysis (FSP) unit
Key Features
- Scalable Process
- Average particle size of 23 nm
- High purity
- Medical grade
- HAP and Beta-TCP mixture could be prepared
Potential Applications
- Bone tissue engineering
- Bone void fillers, Orthopedic and dental implant coating
- Desensitizing agent in post teeth bleaching
- Remineralizing agent in toothpastes
- Early carious lesions treatment
- Drug and gene delivery
Technology Readiness Level (TRL):
- Processing and properties are validated at laboratory scale
- Coupon level demonstrated
- Scaled up technology available
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Nano fertilizer by Cryo-milling
Overview
Nano fertilizers are emerging as new generation fertilizers for low dosage, soil restoration, conservation of phosphorous nutrients, and reduction in imports. The nano Di-ammonium phosphate fertilizer (n-DAP) is developed and its efficacy is demonstrated successfully at the lab level. The n-DAP was prepared by a novel cryo-milling process at ARCI without altering the chemical structure, and tested at University of Hyderabad. Nano-sized DAP produced at ARCI has a particle size 5000 times lesser and specific surface area 14000 times greater than that of commercially available DAP (C-DAP). The n-DAP enhanced the growth of monocot (wheat) and dicot (tomato) plants. The improved agronomic factors such as higher leaf biomass, longer shoot, shorter root, and extraordinary efficacy were observed with n- DAP for 75% lesser input than C-DAP.
Key Features
- New solution to reduce the excessive use of fertilizers in agriculture.
- Production of n-DAP by cryo-milling process
- Better performance.
- Higher efficacy
- Plant requires 75% lesser dosage than commercial DAP
- Feasible process for up scaling
Potential Applications
- Agriculture sector
Technology Readiness Level (TRL)
- Processing and properties are validated at laboratory scale
- Pilot scale production is under progress
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- 1 Singh NRR, Sreedhara SudhakaraSarma, Tata Narsinga Rao T, Pant H, Srikanth VVSS, and Kumar R* (2021) Cryo-milled nano-DAP for enhanced growth of monocot and dicot plants. Nanoscale Advances, 3, 4834 – 4842
Silica Aerogel Granules and Powders for Thermal Insulation Application
Overview
Key Features
- Granule size : ~ 1 mm (Tuneable)
- Powder size: ≥ 10 µm
- Packing density: 0.03 - 0.07 g/cc
- Thermal stability : - 200 to 800 C
- Surface area: ~ 800 – 1500 m 2 /g
- Thermal conductivity: 0.03 W/mK at RT (transient plane method)
- Hydrophilic or hydrophobic, as per requirement
- Colour : Translucent or opaque or black (depending on functionality)
Potential Applications
Thermal insulating
- Paints
- Building material such as cement, bricks, wall plaster etc
- Window panels
- Textiles
- Heat / cold storages
Technology Readiness Level:
- 1kg of silica aerogel granules can be produced in one batch from presently available lab production facility with properties mentioned above
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Publications
- Indian Patent No. 290370 : Improved method for producing carbon containing silica aerogel granules, Neha Hebalkar
Air stable, hydrocarbon fuel dispersible nano boron powder
Overview
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
Technology Readiness Level (TRL):
- Synthesized and characterized tha nano boron at laboratory
- Testing of the nano boron at industry is underway
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/ consistency at coupon level
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- Process for producing the nano boron by cryo milling,” * S.Sudhakara sarma, R.Vijay, T.N.Rao, Indian patent no;391804, granted date;11/03/2022
- S.Sudhakara Sarma, Joudip Joardar, R.Vijay, T.N.Rao, “preparation and characterization of nano boron by cryo milling” * Advanced Powder Technology, Vol 31, 2020, P 3824-3832.
CuO-Ag Nanocomposite Powders for Antimicrobial Applications
Overview
Key Features
- Destroys ≥ 99.2% against SARS-CoV-2 (CCMB), Destroys ≥ 99.997% H1N1 (BUREAU VERITAS)
- Kills ≥ 99.9% gram positive and negative bacteria (NABL Accredited Laboratory)
- Bacterial Filtration Efficiency: ≥ 99.7%
- Particulate Filtration Efficiency at 0.3 µm: ≥ 99.3
- Breathability: 61.2 Pa/cm2
- Splash resistance and water repellent and Classified as class 1 in flammability test
- Safe and harmless to skin and body (in-vivo test by SITRA)
- Reusable > 20 washes and Leaching of particles: allowed limit
Potential Applications
- Self-disinfection mask
- Medical suits
- Medical textiles and sports textiles
- Wound healing
Technology Readiness Level (TRL):
- Processing and properties are validated at pilot scale
- Pilot level demonstrated
- Scaled up technology available
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing instimulated conditions
- Check repeatability/ consistency at coupon level
- Prototype testing in real-life conditions
- Check repeatability/ consistency at prototype level
- Reassessing feasibility (IP, competition technology, commercial)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- K. Hembram, P. Haripriya, N. Sneha , B. V. Sarada, H.H.Krishnan and T.N. Rao, Synthesis of ceramic-metal nanocomposites for developing self-disinfecting fabrics against SARS-CoV-2 (under review)
Development of Biodegradable Alloys and Processes for Implants
Overview
Key Features
- Temporary implant; Elimination of secondary surgery
- Avoid stress-shielding and thrombosis
- Excellent mechanical properties and degradation rate
- Non-cytotoxic to HOS cells
Potential Applications
- Implant Materials for Bone Surgery: Plates, Screws, Pins, etc.
- Stents: Vascular, Coronary, Ureteral, Prostatic, Pancreatic and Biliary, Colon etc.
- Tissue Engineering : Hard and Soft Tissue Anchors /Scaffold
Technology Readiness Level (TRL):
- Processing and properties are validated at laboratory scale
- Coupon level demonstrated
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- Improved Method of Preparation for Biodegradable Mg-Zn-Zr Alloys with Superior Degradation, Biocompatible and Mechanical Properties (A patent to be filed).
- D. Spandana, Hemin Desai, D. Chakravarthy, R.Vijay and K. Hembram, Fabrication of a Biodegradable Fe-Mn-Si Alloy by Field Assisted Sintering, Advanced Powder Technology, 31, 12, 4577-4584, 2020
Porous alumina-polymer beads for toxic fluoride removal from drinking water
Overview
Excess fluoride level in ground water used for drinking is causing serious health problems in several states of India. The permissible limit of fluoride in drinking water, as per WHO, is 1 ppm. The fluoride content is found to be in the range of 2 to 20 ppm in different regions of India. The processes like reverse osmosis, ion exchange, etc., used for removal of fluoride require special equipment and periodic maintenance and is not affordable to all. There is a necessity for a “point-of-use” device for instant removal of fluoride from drinking water specially for travellers, pregnant women and school children. Alumina in the form of bohemite structure is known to be the best fluoride adsorption material. ARCI has developed alumina-polymer cross-linked beads with high porosity for removal of fluoride from water. A porous structure having high surface area increases the contact volume of water thereby improving the removal rate and efficiency. The polymer crosslinking arrests the leaching of alumina in to water.
Key Features
- Simple process
- Bead size: 1-2 mm, spherical
- Surface area: 240 m2/g
- Mesoporous
- Primary particle size: 10-30 nm
- Chemical composition: Bohemite corsslinked polymer
- Can remove 10 ppm fluoride from water in 2-30 mins depending on the volume
Potential Applications
- Toxic fluoride removal for safe drinking water
Technology Readiness Level (TRL):
- Processing and properties are validated at laboratory scale
- Coupon level demonstrated
- Field trials on lab prototype are in progress
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/ consistency at coupon level
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Development of High Performance Electrode Materials for Sodium Ion Battery Applications
Overview
Sodium ion batteries (SIBs) are considered to be next generation energy storage devises due to promising electrochemical performance, safety, low- cost and sustainability. They can be made from widely available and inexpensive resources for use in grid energy and heavy electric vehicle applications. Research is going on around the world to develop suitable electrode materials and electrolytes to achieve specific energy and cycle life similar to that of LIBs. ARCI embarked on major research to develop different cathode materials such as Polyanionic compounds with long cycle (>500 cycles) life and layered sodium transition metal oxides with high specific capacity (>160 mAh/g) and hard carbon with low sodium insertion potential (<0.2 V vs. Na/Na + ) and high specific capacity (>250 mAh/g) as anode using novel chemical methods. Electrochemical performances of these materials have been investigated using indigenously developed non-aqueous based electrolyte.
Key Features
- Abundance of Sodium; Low-cost
- High specific energy and power density; good rate capability; long cycle life
- High thermal stability and safe-in operation
Potential Applications
- Grid energy storage (EES); Stationary energy storage
- Heavy electric vehicles
- Strategic applications
Technology Readiness Level (TRL):
- Sodium vanadium phosphate (~500 g/batch) of specific energy ~357 Wh/kg with cyclic stability >500 cycle at 1 C-rate
- Sodium vanadium fluorophosphate (~500 g/batch) of specific energy ~425 Wh/kg at 5 C-rate (70% capacity retention after 500 cycles)
- Electrolytes with high ionic conductivity (>10 -3 S/cm) and electrochemical stability window (>4.2 V) has been prepared and tested
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- Microwave assisted sol-gel process for preparing in-situ carbon coated electrode materials and the product there of,” (2019) Bijoy Kumar Das, P. Laxman Manikanta, N. Lakshmipriya, R. Gopalan, G. Sundararajan, Indian Patent 201911008004 and European Patent: 20763813.1 (FER filed); Japanese Patent: 2020-550159 and Korean Patent: 10-2497808 (Granted).
- "High Energy-Power Characteristics of Hierarchical Nitrogen-Doped Mesoporous Carbon Decorated Sodium Vanadium Phosphate in Full cell level", P Laxman Mani Kanta, M Venkatesh, Satyesh Kumar Yadav, Bijoy Das*, R Gopalan, Applied Energy 334 (2023)120665.
- “Unusual Case of Higher Cyclic Stability at a Wider Voltage Window in Sodium Vanadium Phosphate” P Laxman Mani Kanta, N Lakshmi Priya, Prajeet Oza, M Venkatesh, Satyesh Kumar Yadav, Bijoy Das*, G Sundararajan, R Gopalan, ACS Appl. Energy Mater. 4 (2021) 12581-12592
Large Scale Production of Lithium Titanate (Li 4 Ti 5 O 12 ) Electrode Materials by Cost- effective & Solid State Process
Overview
Lithium ion batteries, which are critical to electric vehicles, play an important role in electric mobility. ARCI developed a simple, economical, scalable and energy efficient process for the production of LTO anode material by high energy ball milling with performance at par with commercial LTO. Subsequently LTO based 1.5 Ah 26650 cell as well as 0.45 Ah Pouch cells have been fabricated and validated. Large scale production process was established and demonstrated under public private partnership. The resulting LTO delivers superior rate capability of 137 mAh/g at 10C with long cyclic stability. Patents were filed in India as well as globally and were granted recently.
Key Features
- Large scale production (10-15 Kg/batch) of LTO by high energy milling process
- Simple, economic and scalable processing method.
- Electrochemical performance of LTO is higher than commercial LTO material
- Capability to deliver high power
- Evaluated the performance of the materials on 1.5 Ah 26650 cells as well as
Potential Applications
- High power density and thermally stable anode for electric hybrid vehicles
- Other portable devices where LIBs are used.
Technology Readiness Level (TRL):
- Performance and stability are validated at laboratory scale
- Scale-up has been carried out successfully
- Prototype devices of various form factors are being fabricated and validated
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/consistency at coupon level
- Prototype testing in real-life conditions
- Check repeatability/consistency at prototype level
- Reassessing feasibility (IP, competition technology,commercial)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Publications
- A method of producing high performance lithium titanate anode material for lithium ion battery applications” Indian Patent No. 365560 (granted) dated 28-04-2021, PCT International Application No. PCT/IN2018/050080; US Patent No.11001506 (granted) dated 11/05/2021; Germany Patent Application No. 112018000205 T5; Japan Patent No.7121734 (granted) dated 09-08-2022; Chinese Patent No. IIC190527 (granted) dated 01/12/2021; South Korea Patent No.03079 (granted) dated 29/12/2022.
Development of high performance C-LFP by cost-effective and scalable solid state process
Overview
As part of ATMANIRBHAR BHARAT for electric mobility, ARCI has developed an innovative and low-cost technology for the production of in-situ carbon modified Lithium Iron Phosphate (C-LFP) as a cathode material for Lithium-ion batteries. The technology was demonstrated on large scale (10 Kg/batch) successfully in collaboration with an Indian Powder Metallurgy Industry under public private partnership. The electrochemical performance of large scale synthesized C-LFP exhibits a capacity of 1.75 and 1.45 Ah at formation and 1C current rate respectively. ARCI has filed a patent application (202011056608) in India on 28th December 2020 and subsequently filed a PCT Application (PCT/IN2021/051138) on 6th December 2021. The Indian patent application now stands granted with the number 412586 dated 28th November 2022. The technology is already transferred to M/s. Allox Minerals Pvt. Ltd., Hyderabad on non-exclusive basis in India and is ready for transfer to other industries.
Key Features
- Single step solid-state synthesis process to produce carbon coated LiFePO4 (C-LFP) material.
- Simple, Scalable and Economical process.
- Tunable process to produce C-LFP with desired properties for various applications
- Electrochemical performance of C-LFP are at par with commercial C- LFP
Potential Applications
- High energy density cathode for electric vehicles
- High power density cathode for marine application
- Other portable devices where LIB s are used.
Technology Readiness Level (TRL):
- Performance was validated at pilot scale
- LIB cell prototypes were made and validated by third party
- Technology was transferred on non-exclusive basis
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/consistency at coupon level
- Prototype testing in real-life conditions
- Check repeatability/consistency at prototype level
- Reassessing feasibility (IP, competition technology,commercial)
- Initiate technology transfer
- Support in stabilizing production
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- Filed a patent application (202011056608) titled "Method of producing in-situ carbon coated lithium iron phosphate cathode material for lithium-ion batteries and the product thereof" in India on 28 th December 2020 and subsequently filed a PCT Application (PCT/IN2021/051138) on 6th December 2021. The Indian patent application now stands granted with the number 412586 dated 28 th November 2022; US Patent Application No. 18/254,730 dated 29 th May 2023; Australia Patent Application No. 2021412505 dated 1 st May 2023; Europe Patent Application No. 21914895.4 dated 9 th June 2023; UAE Patent Application No. P6001377/2023 dated 6 th June 2023.
Development of petcoke derived porous C for high performance supercapacitors
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 has developed graphene-like activated porous carbon by a low-cost chemical activation process using petroleum coke (petcoke), which is a great value addition for the waste disposed in large quantities in oil industry. The resulting carbon material delivers excellent super capacitor performance in terms of capacitance, rate capability and cyclic stability in comparison to
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 and waste petcoke into useful carbon material
- Specific capacitance, rate capability and cyclic stability higher than commercial carbon
- High energy density based supercapacitor
- Scalable manufacturing process
Potential Applications
- Automotive transport (E-rickshaw, electric bus, electric bicycles, electric cars) and drones
- Consumer electronics (power tools, voltage stabiliser, grid power buffer, street lamps)
- Energy recovery through regenerative braking systems (trams, cranes, tractors)
- Memory backup for static random-access memory (SRAM)
Technology Readiness Level (TRL):
- Successfully scaled-up (1kg/batch) of porous carbon from petcoke
- Fabricated supercapacitors of 1200 F and demonstrated on E-bicycle
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/consistency at coupon level
- Prototype testing in real-life conditions
- Check repeatability/consistency at prototype level
- Reassessing feasibility (IP, competition technology,commercial)
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Development of High Energy 1200F Supercapacitor using Petcoke Derived Porous Carbon
Overview
Petcoke-based 1200 F supercapacitor device has been developed using high performance porous activated carbon electrodes indigenously, which will be commercially attractive for Electric Vehicles (EVs) industry. The supercapacitor device with the specifications of 1200 F, 2.7 V and 1.2 Wh has been fabricated successfully from petcoke derived carbon. Electrochemical testing reveals that the performance of indigenous supercapacitor device is on par with the performance of world-class commercial supercapacitors (1200F). 16 numbers of 1200 F indigenous supercapacitors were connected in serial to assemble the module with specifications of 75 F, 43 V and 19.2 Wh for E-Bicycle demonstration with the driving range of 1-2 km.
Key Features
- High capacitance >1200F supercapacitor developed for the first time in India
- Novel Tab less welding technology adopted for the fabrication of high power supercapacitor
- Specific capacitance, rate capability and cyclic stability at par with commercial carbon
- Supercapacitor module of 43 V was made
- Designed voltage balancing circuit to control the voltage during
Potential Applications
- Automotive transport (E-rickshaw, electric bus, electric bicycles, electric cars) and drones
- Consumer electronics (power tools, voltage stabiliser, grid power buffer, street lamps)
- Energy recovery (trams, cranes, tractors)
- Memory backup for static random-access memory (SRAM)
Technology Readiness Level (TRL):
- Successfully fabricated indigenous supercapacitor with 1200F at par with commercial supercapacitor
- Assembled a supercap module and demonstrated for EVs application
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
- Check repeatability/consistency at coupon level
- Prototype testing in real-life conditions
- Check repeatability/consistency at prototype level
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- ranslational materials research - From laboratory to product: A 1200 F cylindrical supercapacitor from petroleum coke derived activated carbon sheets, Journal of Energy Storage 55 (2022) 10565.
- Petroleum coke as an efficient single source for High Energy and High Power Li-ion Capacitors” Energy & Fuels, 35, 9010-9016, 2021.
- A High-Energy Density Li-Ion Hybrid Capacitor Fabricated from Bio-Waste Derived Carbon Nanosheets
Powders for Additive Manufacturing
Overview
Key Features
- Powder requirements are currently being met through imports and powders are expensive.
- Gas atomizer produces wide variety of powders for various applications.
- Narrow fraction of powders taken after sieving based on the AM process.
- A contribution to “Make in India” program of the government of India.
Potential Applications
- Automobile
- Biomedical
- Aerospace
- Defence
Technology Readiness Level:
- Synthesis of powder (in 10 kg batches) demonstrated.
- Components are being made by AM
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Oxide Dispersion Strengthened Austenitic Steels for High Temperature Applications
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 of about 700 C. The high temperature properties of ODS steels are due to the fine-grained microstructure, stable nano sized oxide(Y-Ti-O complex) dispersoids and stability of the microstructure at high temperatures. ARCI has embarked on major program for development and demonstration of technologies for the manufacture of blades for ultra-super critical steam and gas turbines.
Key Features
- High operating temperature of 650-700 °C
- High yield strength of 300 MPA at 700° C
- Good oxidation resistance
- Potential candidates to replace nickel based super alloys
Potential Applications
- Blades for ultra-super critical steam turbines
- High pressure compressor and low pressure turbine blades of gas turbines
- Other high temperature applications
Technology Readiness Level:
- Established manufacturing processes at pilot scale
- Performance and stability validation at prototype level underway
Intellectual Property Development Indices (IPDI)
- Basic concepts and understanding of underlying scientific principles
- Short listing possible applications
- Research to prove technical feasibility for targeted application
- Coupon level testing in stimulated conditions
| Status | 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
Major Patents / Publications
Major Patents*
- S. Ganesh, P. Sai Karthik, M. Ramakrishna, A.V. Reddy, S.B. Chandrasekhar, R. Vijay, “Ultra-high strength oxide dispersion strengthened austenitic steel”, Materials Science and Engineering A, 814 (2021) 141192.
- P.S. Ninawe, S. Ganesh, P. Sai Karthik, S.B. Chandrasekhar, R. Vijay, “Microstructure and mechanical properties of spark plasma sintered austenitic ODS steel”, Advanced Powder Technology, 33 (2022) 103584.
- P. Sai Karthik, S. Ganesh, P. S. Ninawe, M. Battabyal, S. B. Chandrasekhar, R. Vijay, “Microstructure and mechanical properties of austenitic ODS steel processed using Ni–20Cr”, Journal of Materials Research, DOI:10.1557/s43578-023-00938-6, 2023
