«TORNADO»OUR CRAFT IS THE POWER OF NATURE!

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The main scope of our activities is utilisation and commercialisation of the unique technology of disintegration of particles in the air-vortex streams named by us “Tornado” which can prove its advantage in the following areas:- grinding super-hard materials and alloys, polymers and composites, including recycled materials;- Manufacturing micro-powders for metallurgy and additive technologies;- Dressing of ores and extracting the necessary elements, as well as from industrial waste;- Experimental production of rare composites and pre-pregs (pre-impregnated), including ceramic composites and magnetic-composites;- Production of metallic nanotubes, including on the basis of scaly, creation and introduction of new materials based on them;- Production and utilisation of mining and processing plants under field in the country with the aim of ore dressing;- Research and application of new ways of biological protection of plants;- You can get more acquainted with capabilities of our method of disintegrations in the section “Technology” of our website:http://www.tornado.co.com

We are open to cooperation and welcome new opportunities opened up by the new partners and customers from around the world.

TECHNOLOGY

One of the most common methods of processing materials is their grinding. There are practically no industry where this method would not be required. Since it is extremely difficult to extract valuable elements and materials that are in a bounded state just using a rough grinding alone (which, respectively, leading to high losses), one of the main tasks in this respect is, to achieve an opportunity to

fine and ultra-fine grinding.

The conventional shredders, based on the principle of mechanical action have almost reached upscale of their technological limits. The main target in our researches during last years was to develop new technologies and know-hows for obtaining of products with qualitatively new utilisation properties. Such developments would be applicable in the nano-technologies which become to a main trend in the forthcoming technological revolution.

Our new technology of grinding, or better called disintegration of particles ensures creation of new materials with qualitatively new (sometimes specially pre-set) properties aimed to intensify the physico-chemical reactions with the release of the crushed product to gain micron-levels highly homogeneous (uniform), suspensions, emulsions and powders, or manufacturing of technical tools that allow achieving of these properties on the cost effective and environmentally friendly manner.

Our technology is highly effective in terms of costs and performance, since it allows to radically improve the efficiency and to gain new products that can not be manufactured through using traditional methods.

The result of our long-term Research and advanced Development Processes followed by many testings led to completion of the industrial unit named «Tornado» for receiving of classified micro-powders or for dressing of the «heavy-extractable» elements, precious metals as the rare earths through the «dry-method» of disintegration.

The invented new technology is a breaking-through innovation which allows to gain dressing or grinding or to extracting of elements from ores, water, sewage, techno-genic waste and to defragment the particles

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to the size of 5-1 micron as gaining of micro powders of the rare-earths, variously compounded micro powders or grinding of nano-tubes or fullerenes.

The process of enrichment and disintegration is free of use of water and harmful chemical components such as acid or caustic etc.. The production process is clean and environmentally friendly.

TechnologyThe starting material from the charging hopper (2) through the dispensing mechanism (3) enters the operating bin with the mixing device (4) and is subsequently milled in the vortex mill VM2 (5). The energy source of the resonance vortex mill is compressed air, which is delivered from a compressor (1) through a filtration system. The milled material through the corresponding device (6) enters into the vortex separator (7), where finely and coarsely milled powders are separated. Coarsely milled pieces (I) return to the charging hopper (2), and finely milled pieces are collected for the cyclone (8) and scrubber (10) and are subsequently gathered in receiving hoppers (II) and (III). The rotor filter (9) completely settles the water mist at the scrubber exit, which provides a water mist generator (11). Through an air exhauster (12) and a sound absorber (13) the purified air enters the atmosphere.

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The following can be used as an energy source (of the mill operating environment):

- air expelled under pressure;- any inert gas expelled under pressure;- steam under high pressure (superheated steam);- producer gas generated by a reciprocating engine.

The following can be used as a settling liquid in the scrubber:

- water;- water with special additives (such as surface active agents);- alcohol;- water/alcohol mixture;- other specialized liquids based on the properties of the material that is being milled and specificities of its subsequent processing.

Benefits

Resonance-vortex milling

In resonance vortex mills a new technology, non-contact milling of materials, is being used, in which the milling processes are performed by means of an air vortex, artificially produced in an enclosed space of the processing chamber of the vortex mill.

The equipment, which was created on the basis of resonance vortex milling technology, makes it possible to mill any material, from wheat grain to diamonds. The phenomenon of crushing materials of any hardness is attributable to the creation of zones in the vortex mill that have a pressure gradient of up to hundreds of thousands of atm’s, the generation of multi-stage resonance, and the impact of particles. These effects are similar to those that develop in the air of a tornado column created by nature. During 20 years of experimental research, milling processes were developed for more than 40 types of

materials.

The first (adiabatic) mechanism of milling materials in the vortex mill is the exertion of the pressure gradient, which ensures pulverization to a particle size of 0.1 micron. The granules of the initial material, with a size of up to 5 mm, go through the input port (4), enter the hollow space of the processing chamber/mill (1), into which a gas flow is pumped (3) at a pressure of 4-6 atm. In the circular space air successively goes through a series of resonance cavities (6), which generate undulating vibrations and form zones of “tornadic” vortexes. In the tornadic zone so-called “vacuum threads” are formed, on the border of which arises an ultra-high gradient (drop) of pressure (up to hundreds of thousands of atm’s). Upon entry into a zone of such a pressure drop, a breakdown of the material particles occurs, the mechanism of which can be compared to the mechanism for pulverizing a material specimen with specification of its strength properties in mechanical experimental units for milling.

The second (resonance) milling mechanism is related to the generation of undulating vibrations in the mill with a frequency range from sonic to hypersonic (100 MHz and higher). In such a wide spectrum of vibrations for milled material particles of

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Mechanics of a resonance vortex mill (Fig. 1)

any size, a frequency is found equal to the resonance frequency of a particle. This mechanism is able to carry out milling down to ultra-fine pieces, measured in hundredths and thousandths of microns (0.01-0.001 microns).

The third (impact) milling mechanism of material is mutual particle impact. At resonance vortex mills, particle impact brings an insignificant contribution into the process of breaking down materials. At the currently widespread torsion (blast) mills (Japanese production, for example), this mechanism is essential.

Benefits and Features

The resonance vortex mill is a gas-dynamic mill in which cascaded adiabatic resonance impact milling is implemented, with impact velocities close to the threshold of breakdown.

If for torsion (blast) mills the use of compressed air at pressures of 0.7-1.4 MPa is characteristic, then in the vortex mill a similar effect is reached with 0.2-0.6 MPa, which substantially decreases expenses and makes it possible to obtain particularly fine powders, which cannot be obtained by other methods.Due to adiabatic expansion, a decrease in temperature of the work environment

occurs, which makes it possible to prevent local heating and thermal degradation of the material that is being milled.The milling chamber does not contain rotating and chafing parts, which significantly increases its operational life, simplifies its construction, facilitates its maintenance and cleaning, and makes it possible to avoid milling foreign materials into the final product;Constructional decisions applied to equipment production ensures a significant reduction in electric power expenses for the production of powders in comparison with counterparts.In several conditions the mill can fulfill the function of a high-efficiency mixer.

For the milling of non-homogeneous materials, such milling conditions are possible when, due to resonance, various components are milled to various sizes, which allows them to be separated. For example, in the milling process, coal can be freed from inclusion of quartzites; for grain milling, the husk can be preserved.

Know-how

Personal know-how used by the company in the construction of the milling systems – the developed and tested work methods with various materials

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AirOutput Air

Input material

3

2

7

6

Air

Output material

6

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There is a group of patents on the method and equipment, there are active patents and submitted requests, and there is a large number of original construction designs for various elements of the milling systems, such as:

resonance vortex mills of various types and various productivity rates for various working environments and materialsvortex separators without moving parts of various types, able to collect powders with sizes down to 1 micronmist generators – make it possible to produce stable dispersions of various liquids in the air or another gasscrubber with a mist generator – provides for the moistening and depositing of particles through liquid dispersion, designed to collect particles with sizes smaller than 1 micron.Rotor filter – a mechanism for deposits from liquid dispersion after the scrubberscrew feeders of various types – mechanisms for the supply of the starting material into the mill, including screw feeders with the function of refrigeration (combined with the evaporators of liquid nitrogen)movable disintegrators (mechanical mills) of original construction for milling various materials (list). Disintegrators do not contain seals in their construction, producible in production and operation.

ProductsProcessed materials

HARD MATERIALS

Carbon (diamond) – is milled to a size smaller than 1 micron. Experiments were conducted jointly with the Poltavsky diamond factory.

Magnetic ferrite – the resonance vortex milling method is used for milling magnetic ferrite in a specially manufactured ceramic

(non-magnetic) chamber, resulting in a magnetic ferrite powder with a size of 5 microns.

Silicon (mineral) – gravel of 5 mm is milled to a powder of 50-60 microns, which is used in the production of water purification filters as a sorbent.

Pure semiconductor silicon – from crumbs of 1-5 mm, a powder of 10 microns is obtained for subsequent processing.

Ceramic of various compositions – with this method granules of 1-3 mm are reduced to a size of 50-100 microns so that the raw material is prepared for baking.

Titanium carbide – an initial powder of 500 microns is milled to powders of various sizes down to 1 micron, collected by a scrubber into water with specialized additives.

Granite, basalt – the starting material is gravel of 5 mm, which is milled into a powder of less than 60 microns, then melted in a flow of hot gases with the formation of stone filaments. This innovative technology of obtaining fibers without a stone melting furnace is in the development stage.

Titanium dioxide – from an initial powder of 300 microns, a powder of 5 microns is obtained. Developmental work was conducted using steam as a working medium, replacing compressed air. Trials were conducted jointly with “Sumykhimprom”.

Quartz sand – quartz dust of 5-10 microns was obtained for specialized purposes.

Hard alloys BK6, BK8, BK12, and BK20 – parts of an instrument manufactured from hard alloys for subsequent processing mill to sizes of 5-10 microns, and the resulting powder is reused in the processes of powder metallurgy.

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RECYCLING OF VARIOUS MATERIALS

PCB fiberglass – recycling of printed circuit boards is done for the dismantling of electronic components. The boards are preliminarily milled by cutting them to sizes of 5-10 mm. Then, using resonance vortex technology, the fiberglass and polymeric enclosures of microchips and other components are milled during processing, and there is a separate collection of the powders: separately the powder is a presented mixture of polymers, fiberglass and ceramic, and another powder presents itself as a mixture of metallic fragments, non-milled residue of electronic components, and conductor lines.

Composite goods in bakelite resins (“carbolite” goods) – recycling is the milling of crushed material to a powder of 10 microns, with subsequent additives in the molding powder.

Glass – from glass fragments of 1-5 mm (scraps from glass manufacturing) a powder of 20-30 microns is obtained for technological purposes, such as for use in the production of glass-reinforced plastics.

Abrasive discs in a bakelite bond – abrasive discs preliminarily crushed to a size of 5-10 mm are milled. The process provides for the separation of the abrasive material from the bakelite bond, an additional milling of the abrasive grains to a specified size, and distinct separation of the abrasive powder and bakelite dust.

Abrasive discs in a ceramic bond – abrasive discs preliminarily crushed to a size of 5-10 mm are milled to specified sizes. In the process of milling, depending on the mode, the ceramic bond is broken down and the abrasive grains are milled.

Paper – milling of previously coarsely ground paper waste was conducted with the

resonance vortex method. With this method raw materials for dry building composites were obtained – paper powder presented as segments of pulp fibers with a length of 5-10 microns. During the course of the work a mechanical disintegrator for paper was also developed that is not sensitive to the presence of staples and cardboard covers, which is used for the preliminary milling of paper, resulting in “paper cotton.” This type of milling makes it possible, for example, to process laminated paper with waterproof films.

Rubber crumb – several types of rubber crumb obtained by processing automobile tires are milled to rubber dust of particle sizes 30-50 microns. Milling is carried out with preliminary cooling by liquid nitrogen, and an evaporator is combined with screw feeder equipment for the starting material. By virtue of an extremely small amount of milling time and the effect of adiabatic cooling, the discharge of liquid nitrogen is only 40-50 grams for a kilogram of milled rubber.

MATERIALS WITH PARTICULAR CHARACTERISTICS

Teflon (Ftoroplast 3, Ftoroplast 5) – the starting material for milling is a large powder, and shavings are milled into the powder with particle sizes of 5-10 microns; the resulting powder is used as an additive for lubricating oil. Experiments were conducted in milling ftoroplast with preliminary radiation processing, which improved the properties of the resulting powders. Tests of the oil with additives of the powders that resulted from the given technology demonstrate very good results: upon raising the velocities and temperatures, the lubricating properties improve and friction decreases.

Cement – micro-cement is obtained for specialized purposes by milling regular cement to a size of 10 microns, raising the cement grade.

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Chalkstone – the initial chalkstone powder of 200 microns is milled to a size of 1-2 microns, 3-5 microns, and 5-10 microns.

Graphite – crude (natural) graphite is milled to a size of 1-3 microns; the prepared powder was collected with the aid of a vortex separator.

Mica – crude mica is milled to a powder of 10 microns for use as a dye pigment.

Iron oxide pigments – were milled to a size of 5 microns, and a pigment paste was obtained using the deposit in the scrubber.

Chrome pigments – are milled to a size of 5 microns, and a pigment paste was obtained using the deposit in the scrubber.

Resin – is milled to a size of 10-15 microns, which is possible for a readily fusible resin by virtue of the adiabatic cooling in the milling process.

Gunpowder, rocket fuel, explosives – ammunition is salvaged, and milling is performed with the introduction of additives lowering the potency of gunpowder and explosives, which make the resulting mixture non-explosive. A specialized resonance vortex mill was tested with an “external” vortex in order to extract the gunpowder from casings.

Coal – crushed coal with a particle size of 5-10 mm is milled to a size of 5 microns (or larger, depending on the use of burners). With the aid of a vortex separator the quartzites are separated, which allows for enrichment of the coal immediately preceding the burning. This makes it possible to substantially decrease the quantity of refuse burnout in the burn products. The innovative

technology is in the development stage.

PHARMACEUTICAL INDUSTRY

Medicinal herbs – various medicinal herbs are processed and milled (0.5-0.3 mm), with a concentrated breakdown of cell walls, which for many types of herbs allows for a concentrated extraction through brewing, the possibility for extraction at lowered temperatures, the increase of medicinal potency, etc. The technology makes it possible to divide herbs according to grain type. For example, leaves and stems can be milled to various sizes with subsequent division, and the like.

Wild rose – dried fruits of the wild rose are milled into uniform powders – 100 microns for pharmaceutical purposes.

Dried wood mushrooms – for pharmaceutical purposes, powders of 40-50 microns are produced from dried mushrooms, which is impossible to carry out by another milling method due to the particular structure of the mushroom.

Cuttlebone – crushed cuttlebone was milled to a powder of 30 microns.

FOOD INDUSTRY

Tea leaves – development is underway for the grinding of tea leaves to the size of 2-3 mm, with a breakdown of cell walls. This provides for concentrated fermentation and extraction during tea brewing (improvement of the characteristics up to 10 times). Through the processing of the tea manufacturing by-products, it is possible to obtain fine powders for tea bags, instant tea, and low-grade stock – tea that is good for granulation. The resonance vortex milling method can be placed at the heart of the new technology for processing tea leaves. Research was conducted jointly with the

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Georgia Institute of Tea.

Dried fruit - powders of 50-100 microns are obtained from various dried fruits for the food industry.

Wheat, rye, buckwheat, oats, rice, and corn – resonance vortex milling technology makes it possible in one operation to obtain bread stuff of 5-10 microns or larger, used for specialized purposes in the foodstuff industry. It is possible to mill grains together with the husk or with separation from the husk, and the separations occur within the framework of one process. The output rate achieved during experimental work is up to one ton an hour. Separate milling of the husks is possible, which is especially important, for example, for the milling of rice grain husks with the goal of their subsequent usage.

Cocoa beans are ground together with sugar in order to obtain a soluble beverage. By virtue of the joint milling, the sugar absorbs and preserves the cocoa oil, which makes it possible to preserve the taste and qualitative composition.

Coffee beans are ground together with sugar in order to obtain a soluble beverage. By virtue of the joint milling, the sugar absorbs and preserves the oil, which makes it possible to preserve the taste and qualitative composition.

Red pepper is milled to 10 microns for specialized purposes (as an irritant agent, for example) or to 50 microns for food additives.

Sugar – milling of lump sugar into powdered sugar is performed in one operation.

Table salt – a fine powder of 5-10 microns is obtained from coarse crystal table salt for specialized purposes without thermal treatment, and without crystallization and evaporation.

LIQUIDS

Diesel and fuel oil - with a high productivity rate diesel oil is dispersed in the air, with a drop size of 0.1-0.4 microns, which provides for a more complete burning of the oil. A prototype of a large-torch burner was tested, the construction of which does not contain thin openings, meaning that impurities and pollutants do not affect the work of the burner.

Water – water is dispersed in the air at 0.1-0.2 microns; with this method an artificial water mist results. Generators of the mist have been tested and are being used in high-efficiency scrubbers; results are achieved when the water mist is preserved in a confined space over the course of many hours.

Standardized:

- Nickel superalloys (eg. Inconel 718, Rene, etc.) parts for aeronautical and stationary turbines;

- Cobalt-based alloys for use in medicine, dentistry and manufacturing of sputtering targets;

- Powders for plasma spraying (eg. NiCrAlY, CoCrAlY, etc.) for the plasma deposition of protective coatings on parts made of heat-resistant alloys;

- Powders for the pellet industry (eg. 17PH, 316L) for automotive mass production parts;

- Sintering composition in powder layers (eg. Cobalt alloys, precious metals) to be used in AM – machines;

- High-alloy steels (eg. Tool steel, HSS) with a very high content of carbides;

- Non-ferrous metals eg. copper or tin alloys for various applications;

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-powders for reactive metals – Ti, Zr, Hf, V, Pt, Ir, Nb, Mo, and so on.

Micro powders 1 to 10 microns:diamond powders, boron carbide powders, and titanium, niobium, zirconium and so on. polymer modifiers from bio-polymers to engineering polymers (smart polymers) milling high-purity metals for the electronics industry and catalysts:

example – the ultra-micro powder of pure copper 99, 99

micropowder of molybdenum:

PRODUCTS

The unit (set of equipment) for milling is manufactured in accordance with an order based on these technical requirements:

materialinitial size of particles,

degree of milling,required productivity.In the process of forming a technical proposal, technological tests are conducted: a small quantity of material provided by the client is processed for verification of the technological effectiveness, the received samples are examined, and the customer is provided with:

a sample of the resulting powder,analysis data: breakdown, presence of impurities,conclusions about the possibility of using resonance vortex milling for work with the given materialServices:

Preparation of samples (milling materials provided by the client) in research purposes.

Development of specialized milling technology.

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Services:Preparation of samples (milling materials provided by the client) in research purposes.

Development of specialized milling technology.

Examples of the resultsAs an example there are the graphs of allocation the dimensions of fragments for samples of

various materials

Silica xerogel (initial size 2mm)

Coal (initial size 10mm)The results of the analysis of the samples of coal with a high concentration of mineral impurities, ground with the resonance vortex mil.The graphs of the distribution show that the size of the coal particles is in the 0.5-10 micrometers range, and the size of the mineral constituents’ particles is in 100-1000 micrometers range, that allows to concentrate the coal in the milling stage.

Silicium dioxide (initial size 2,5mm)The different curves correspond to the different settings of resonance mill.

Hard alloys BK8 (initial size 2mm)

Titanium carbide (initial size 0,3mm)

Steel St.3 (initial size 5mm)

Aluminum oxide (initial size 0,5mm)

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Hard alloys BH10 (initial size 3mm)

Titanium dioxide (initial size 2mm)

Tuff (initial size 5mm)

Medical glass (initial size 5mm)

Silicium carbide (initial size 5mm)

Chromium oxide (initial size 2mm)

Silicon (initial size 5mm)

Chalkstone (Calcium Carbonate)

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CONTACTS

MAIN OFFICE

TORtec® ltd.20, Medousis Str. 6302 Larnaca, CyprusReg.No.- HE 341168 | VAT: 10341168J

info@tornado.co.comhttp://www.tornado.co.com

Tel.: + 357 246 33 944; + 357 99 127784

MANUFACTURING

HI-TECH INOVACE s.r.o.

Praha 9, Cakovice, Oderska 1099/15, 196 03, Impera ParkCZECH REPUBLICVAT: CZ24751855

info@innoprogress.com www.innoprogress.com Tel.: + 420 774 335 304

Synthetic diamond

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