Important Highlights of Major Programmes
Super Capacitor Production Facility
KCCL has been presently engaged in the setting up of plant/equipment for the commercial production of Super Capacitors and expanding our laboratory facility for Super Capacitor material development. We had been associated with various National Laboratories like C-MET (Centre for Material for Electronic Technology) for the development of commercial scale Supercapacitor manufacturing technology. Presently using in-house R&D experience we are setting up the process equipment and building for the commercial production of Super Capacitor with a first phase investment of Rs. 1800 lakhs (including R&D equipment and expenditure of Rs.600 lakhs) which is funded by Govt. of Kerala.
Rectangular Film Capacitor Production Facility
The demand for high end performance fire proof type film capacitors is growing exponentially. Our R&D team had studied various existing set back and failure mode of film capacitor in general. We were able to develop various special testing devices other than conventional testing equipment with which we were able to modify the specification of some major raw material and existing processing method. Based on this R&D studies now we are setting up the process equipment and raw materials for the commercial production of capacitors.
Process Automation: De-Duster cum static electricity neutralizer for MPP finished capacitor element
We had been facing wire terminal soldering problem due to left over zinc dust on the zinc electrode plate of the film capacitors element after the Arc Metal Spray process. For this conventional hand held compressed air gun is used to remove the adhering zinc dust manually. This process is not enough to produce 100% consistent results and is having health risk for the operators due to the air borne zinc dust. Another issue is the overall static charge induced on the film during winding operations. Unlike normal positive-negative pair polarisation of encapsulation compound during potting process. In order to overcome these issue KCCL had developed a method with compressed air curtain and high voltage ionised air blow on the element. After confirming the performance in the lab we have designed a semi-automatic machine for this purpose. Fabrication of this unit using in-house tool room facility is going on.
Self-healing film based motor start capacitor for emerging extra heavy duty application
Start capacitors are used for single phase induction motors where high starting torque is required. KCCL had been producing a wide range of start capacitors- aluminium electrolytic version which is rated for 1.7% duty cycle. Recently the demand for heavy duty start capacitors (duty cycle 2.2 and above) is growing rapidly. With aluminium electrolytic capacitors it is not possible to increase the duty cycle cost effectively. The best alternative is to develop start capacitor at higher duty with self-healing film technology. In order to develop quality product a good R&D studies is required on the various raw material. Some additional test and manufacturing equipment also required for successful launching of the product in the market.
BOPP film vacuum metallization plant
Due to the shortage of high end performance HT type BOPP film in India we have been importing this item for class ‘C’ and above category MPP capacitors production. The surface roughening process (corona treatment of the film surface) for better metal coating adhesion is a critical process as per our year of experience. Roughness should not be too high (not more than 600 nanometre depth pit) or too low. The equipment required for these data measurement is based on film’s wetting quality (tiny liquid drop’s angle of contact measurement). This is a very costly equipment and as per our knowledge most of the manufacturers are using simple ink based film’s ink adhesion checking method which gives an approximate indication only. We had developed a chemical treatment followed by photo electric based film’s light scattering extent measuring system for this purpose in our R&D lab for judging the extend of surface roughening of film. With years of R&D studies on various extend corona treated film with this equipment database, it has been confirmed very effective for optimizing the extent of treatment on various type of film and thereby confirming the long term performance of the processed capacitors with these film. We can use this technology effectively to produce best quality film by ourselves and to reduce import. We had submitted a project proposal to Govt. of Kerala for setting up a vacuum metallization of BOPP film plant at KCCL with an investment of Rs.1000 lakhs which includes some additional R&D activities (Rs.140 lakhs).
Lithium ion battery production facility
KCCL has been presently engaged in the construction of Super Capacitor plant which is expected to complete by 2023. As per the existing technical evaluation nearly 65% of the equipment and facilities like 0.5% RH dry room, electrode slitting machines, impregnation systems, terminal assembly system, testing system etc. can also be used for the production of lithium ion batteries. We had submitted a project proposal to Govt. of Kerala for future investment in Lithium ion batteries. The expected project cost is Rs.2000 lakhs which includes R&D’s equipment and studies (Rs.350 lakhs).
Development of Super heavy duty KVAR rating up to 10KVAR utilizing the added performance of the special encapsulation compound with very high resistance to ionic migration
The project was initially proposed to start by 2020. However due to Covid-19 pandemic issue we are forced to reschedule the project to year 2022. Industrial power correction capacitors require very high end performance due to the continuous application (100% duty cycle in the power lines). Even though these capacitors are designed for heavy duty application, the KVAR value is found reducing over the period of application. This is mainly due to the lowering of capacitance of the MPP capacitors connect in delta or star configuration inside this KVAR unit. We have pin pointed the cause of capacitance deterioration and a new type of encapsulation compound had been developed (encapsulation compound with high resistance to ionic migration and high resistance to ageing due to atmospheric weathering). With this new concept we can develop a Super Heavy duty KVAR capacitor for industrial application with extra high reliability.
Collaborative projects with external R&D agencies
Centre for Materials for Electronics Technology (C-MET), Thrissur
We had been supporting C-MET for developing Carbon aerogel super capacitor. An MOU had been signed with C-MET on 10.03.2016 for providing industrial support for this project up to 31.07.2017. We had extended our manufacturing, R.M test facilities and R&D efforts for this project during this period. We had successfully modified our Elcos –Element winding machine for the stitching and winding operations for C-MET developed Super Capacitor Electrode and proved that it is industrially acceptable with some improvements.