Claims:WE CLAIM:
1. A method (10) for recycling sludge waste to obtain forging lubricant comprising:
receiving dry sludge powder from forging process; (20)
removing iron and iron oxides from the dry sludge powder to obtain first powder, wherein the first powder comprises a predefined amount of graphite;(30)
milling the first powder using ball milling technique to obtain second powder, wherein the second powder comprises a predefined amount of two-dimensional graphene; (40) and
adding a predetermined amount of graphite to the second powder to obtain a mixture; (50)
converting the predetermined amount of graphite present in the mixture to graphene using the ball milling technique to obtain the forging lubricant. (60)
2. The method (10) as claimed in claim 1, wherein removing iron and iron oxides from the dry sludge powder to obtain the first powder comprises removing iron and iron oxides from the dry sludge powder using a magnetic removal technique.
3. The method (10) as claimed in claim 1, wherein the first powder comprises carbon 55 percent to 67 percent and graphite 5 percent to 10 percent.
4. The method (10) as claimed in claim 1, wherein the ball milling technique comprises a mechanochemical ball milling technique.
5. The method (10) as claimed in claim 1, wherein milling the first powder using ball milling technique to obtain second powder comprises milling the first powder to convert 5 percent to 10 percent of three-dimensional graphite into two-dimensional graphene.
6. The method as claimed in claim 1, wherein converting the predetermined amount of graphite present to less than 5 percent graphene using the ball milling technique.
7. The method (10) as claimed in claim 1, wherein the forging lubricant obtained from the recycle sludge is operable at a temperature ranges from 200 degree Celsius to 500 degree Celsius and 2500-ton pressure.

Dated this 14th day of November 2019

Vidya Bhaskar Singh Nandiyal
Patent Agent (IN/PA-2912)
Agent for applicant
, Description:BACKGROUND
[0001] Embodiment of a present disclosure relate to forging and more particularly to a method for recycling sludge waste to obtain forging lubricant.
[0002] The water-based lubricant is obtained from the sludge waste. The sludge waste is a waste product which is collected from the forging waste which contains lots of oils, iron debris, carbons and other elements in traces including moisture. The sludge is composed mainly by graphite particles and, after dehydration, resulted in a material with possibilities for safe discharge, recycling or reuse. However, to discard the sludge waste is a time-consuming process, involved lots of cost and there are stringent policies from the environmental board to avoid any contamination to the environment. Since, the sludge waste contains carbon wastes it has to discard by giving that material to authorized private body to discard the same as it is coming under hazardous waste.
[0003] Hence, there is a need for an improved method for recycling sludge waste to obtain forging lubricant to address the aforementioned issue(s).
BRIEF DESCRIPTION
[0004] In accordance with an embodiment of the present disclosure, a method for recycling sludge waste to obtain forging lubricant is provided. The method includes receiving dry sludge powder from forging process. The method also includes removing iron and iron oxides from the dry sludge powder to obtain first powder, wherein the first powder includes a predefined amount of graphite. The method further includes milling the first powder using ball milling technique to obtain second powder, wherein the second powder comprises a predefined amount of two-dimensional graphene. The method further includes adding a predetermined amount of graphite to the second powder to obtain a mixture. The method further includes converting the predetermine amount of graphite present in the mixture to graphene using the ball milling technique to obtain the forging lubricant.
[0005] To further clarify the advantages and features of the present invention, a more particular description of the invention will follow by reference to specific embodiments thereof, which are illustrated in the appended figures. It is to be appreciated that these figures depict only typical embodiments of the invention and are therefore not to be considered limiting in scope. The invention will be described and explained with additional specificity and detail with the appended figures.
BRIEF DESCRIPTION OF DRAWINGS
The disclosure will be described and explained with additional specificity and detail with the accompanying figures in which:
[0006] FIG. 1 is a flow chart representing the steps involved in a method for recycling sludge waste to obtain forging lubricant in accordance with an embodiment of the present disclosure.
[0007] Further, those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the figures by conventional symbols, and the figures may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the figures with details that will be readily apparent to those skilled in the art having the benefit of the description herein.
DETAILED DESCRIPTION OF THE INVENTION
[0008] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the figures and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as would normally occur to those skilled in the art are to be construed as being within the scope of the present invention. It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.
[0009] The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such a process or method. Similarly, one or more devices or sub-systems or elements or structures or components preceded by "comprises... a" does not, without more constraints, preclude the existence of other devices, sub-systems, elements, structures, components, additional devices, additional sub-systems, additional elements, additional structures or additional components. Appearances of the phrase "in an embodiment", "in another embodiment" and similar language throughout this specification may, but not necessarily do, all refer to the same embodiment.
[0010] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention belongs. The system, methods, and examples provided herein are only illustrative and not intended to be limiting.
[0011] Embodiments of a present disclosure relate to a method for recycling sludge waste to obtain forging lubricant. The method includes receiving dry sludge powder from forging process. The method also includes removing iron and iron oxides from the dry sludge powder to obtain first powder. The method further includes milling the first powder using ball milling technique to obtain second powder, wherein the second powder comprises a predefined amount of graphite. The method further includes converting the predefined amount of graphite to graphene using the ball milling technique to obtain the forging lubricant.
[0012] FIG. 1 is a flow chart representing the steps involved in a method (10) for recycling sludge waste to obtain forging lubricant in accordance with an embodiment of the present disclosure. The method (10) includes receiving dry sludge powder from forging process in step 20. As used herein, the dry sludge powder is a waste product which is collected from the forging waste which includes lots of oils, iron debris, carbons and other elements in traces including moisture. The method (10) also includes removing iron and iron oxides from the dry sludge powder to obtain first powder in step 30. The first powder includes a predefined amount of graphite. In one embodiment, removing iron and iron oxides from the dry sludge powder to obtain the first powder may include removing iron and iron oxides from the dry sludge powder using a magnetic removal technique. In the presence of the strong external magnetic field, the iron and iron oxides are removed from the dry sludge powder.
[0013] In some embodiment, the first powder may include carbon about 67 percent and graphite about 5 percent to 10 percent. The method (10) further includes milling the first powder using ball milling technique to obtain second powder in step 40. The second powder includes a predefined amount of two-dimensional graphene. In one embodiment, milling the first powder using ball milling technique to obtain second powder may include milling the first powder to convert 5 percent to 10 percent of three-dimensional graphite into two-dimensional graphene. In such embodiment, the ball milling technique may include a mechanochemical ball milling technique. As used herein, mechanochemical ball milling utilize mechanical force to achieve chemical processing and transformations. The mechanochemical ball milling technique is a process, in which the moving balls apply their kinetic energy to the milled material, break chemical bonding and produce fresh surfaces by fracturing material particles. The dangling bonds on the newly created surfaces are usually chemically reactive.
[0014] Furthermore, the method (10) includes adding a predetermined amount of graphite to the second powder to obtain a mixture in step 50. The method further includes converting the predetermined amount of graphite present in the mixture to graphene using the ball milling technique to obtain the forging lubricant in step 60. In one embodiment, converting the predetermined amount of graphite to less than 5 percent graphene using the ball milling technique In some embodiments, the forging lubricant obtained from the recycle sludge may be operable at a temperature ranges from 200 degree Celsius to 500 degree Celsius and 2500-ton pressure.
[0015] The important factors during the forging process such as thin film formation after spraying the die lubricant, component ejection, flushing the debris and very importantly die wear pattern is significantly achieved compared with the existing lubricant.
[0016] Various embodiments of the method for recycling the sludge waste to obtain forging lubricant described above enables optimized method to separate the carbon sources from the sludge and develop hybrid nano graphite lubricant from the sludge waste. The method provides materializing the isolated carbon sources into a compatible friction modifier for forging properties.
[0017] Furthermore, the developed product is used in the forging application as a lubricant. The obtained product is graphite-based lubricant which suits to the temperature range of 200 to 500 degree Celsius may be up to 1000 degree Celsius.
[0018] The Uniqueness of the lubricant is that the raw material used in this formulation was recycled from the sludge waste that is “collective waste from forging process”. The method is used to isolate the desired carbon source from the sludge waste and enhanced the property of the recycled waste. The isolated carbon is having better lubricity and that is the important factor for the lubricant which is used in the forging application.
[0019] Moreover, the method recycled the sludge to the three-dimensional and two-dimensional hybrid carbon nanomaterials which acts as a frication modifier, followed by identifying the other additives which are compatible to perform their roles along with the friction modifier to perform as a forging lubricant
[0020] In addition, the method provides maintaining the wear pattern of the dies similar to the existing lubricant. The method is environment friendly as it saves environment by recycling the waste. The application of the method is in hot and cold forging
[0021] It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the disclosure and are not intended to be restrictive thereof.
[0022] While specific language has been used to describe the disclosure, any limitations arising on account of the same are not intended. As would be apparent to a person skilled in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein.
[0023] The figures and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, the order of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts need to be necessarily performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples.