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24&il lPbF A PRIMER ON METALWORKING FLUIDS

Sassan Moradi an Eng i neer i ng & Development Manager

Research Metal Fluids Company LaVergne, TN

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PRESENTED AT: "Metalworking Fluids'' March 12-14, 1991 Dearborn, M I

Courses and C1 in ics Department One SME Drive, P.O. Box 930 Dearborn, M I 48121-0930

I \ SPONSORED BY: The Society o f Manufacturing Engineers j

i Phone: (313) 271-1500 FAX: (313) 271-2861

INTRODUCTION TO METAL REMOVING AND

METAL WORKING DYNAMICS

THE UNITED STATE ALONE ANNUULY USES IN EXCESS OF 150 MILLION TONS OF STEEL IN ADDITION TO OTHER TYPES OF METALS.TIIESE METALS ARE BEING TRANSFORMED INTO CONSUMER PRODUCTS BY FORGING,ROLLING~ROLL FORMING,DRAWINGpPUNCHING, METAL CUTTING AND THE GRINDING PROCESS. DUE TO TEE WIDE RANGE AND MODE OF DEFORMATION EXPERIENCED IN THE MANUFACTURING PROCESS (WHICH BEEN EVOLVED TO SHAPE AND FORM METALS) AND BECAUSE O F THE DIVERSITY AND COMPLEXITY OF TBE METAL REMOVING PROCESS THE REQUIREMENTS PLACED ON THE

THIS ACCOUNTS FOR A VERY WIDE RANGE OF COMMERCIALLY AVAILABLE FLUIDS FROM WHICH MANDFACTURERS MUST SELECT FROM. METAL WORXING FLUID8 ARE A TOOL OF PRODUCTION AND APPLIED TO:

LUBRICANTS ANI) COOLANTS ARE EXTREMELY DIVERSE.

1. PROVIDE AN ADEQUATE COOLING ACTION

2- PROVIDE A TOLERABLE TOOL AND DIE LIFE

3. PRODUCE A SATISFACTORY SURFACE TEXTURE FOR THE PRODUCT

4. MAXIMIZING ECONOMICAL PRODUCTION PARALLEL TO AN ESTABLISHED QUALITY STANDARD.

TEE TWO MOST IMPORTANT ROLES OF METAL WORKING FLUID ARE TO COOL AND LUBRICATE AND THIS IS BEST ACCOMPLISHED VIA A WATER AND MINERAL OIL BASED TYPE LUBRICANT.

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TABLE OF CONTENTS

* INTRODUCTION TO METAL REMOVING & METAL WORKING DYNAMICS

* CLASSIFICATION OF METAL REMOVAL PROCESS * CUTTING & GRINDING MECHANICS; * COOLING & LUBRICATION MECHANISM

* PARAMETERS IN FORMULATING METAL-WORKING FLUIDS * CLASSES OF METAL-WORKING LUBRICANTS;

* STRAIGIIT OIL * SOLUBLE OIL * SEMI-SYNTHETIC * SYNTHETIC * FATTY OIL

* METAL FORMING LUBRICANT * LIQUID * NON-LIQUID

* EMULSION * CAUSES OF RANCID COOLANT & PREVENTION

* CONTROL OF BACTERIA GROWTH

* PERFORMANCE TESTING OF METAL-WORKING FLUIDS * WASTE TREATMENT * WASTE TREATMErJT OF METAL-WORKING FLUID

* TREATMENT METHODS * ENVIRONMENTAL CONCERNS IN DISPOSAL OF COOLANT * WASTE REDUCTION PROGRAM

CUTTING AND GRINDING MECBAWICS

THE STUDY HAS SHOWN T&AT THERE IS A SIMILARITY IN TEE BASIC FUNCTION AND DEMANDS OF THE CUTTING AND GRINDING PROCESS. THIS EXISTS REGARDLESS OF DIFFERENCES IN TEE GEOMETRY AND MECHANICS OF THESE TWO PROCESSES.BOTE PROCESSES GENERATE

SOME REMOVED BY CEIPS.IN CONSIDERATION OF HEAT EVOLVED

ADDITIVES SUCH, AS CHLORINE AND SULFUR USED TO REDUCE TEE HEAT AND MAKE AVAILABLE THE NEEDED PEYSICAL LUBRICATION FOR EXTENDING THE TOOL LIFE AND PRODUCTION OF WORKPIECE WITH AN

THIS IS BEING MEASURED BY AN INDEX CALLED "GRINDING RATIO" AND IS DEFINED AS "TIIE VOLUME OF WORKPIECE MATERIAL REMOVED PER UNIT VOLUME OF WHEEL WEAR".TEE GRINDING RATIO IS BEING INFLUENCED BY THE CONCENTRATION OF ACTIVES IN THE METAL

METAL WORKING FLUID ARE MORE IMPORTANT IN ONLY REDUCING

PROPERTY IS ONLY A SECONDmY CONSIDERATION. CUTTING IS A PROCESS WHEREBY MATERIAL IS REMOVED IN BULK FOR

EEATPAND MOST HEAT IS TRANSFERRED INTO THE WORKPIECE AND

RESULTING FROM THESE PROCESSESfiTHERE ARE CONVENTIONAL

ADEQUATE SURFACE FINISH.

WORKING FLUIDoTHE POINT IS BEING DEBATED IF ADDITXVES IN THE

GRINDING FORCES AND IMPROVING FINISHPAND THE COOLING

TEE CRmTION OF FRESH SURFACESoMOST METAL CUTTING PROCESS RESULT IN A CflIP CUTTING FLUID ACTION (1) *CUTTING OILS ARE CONSIDERED ONLY AS A LUBRICANT (WATERLESS-STRAIGHT OIL) y ONLY

FRICTIONPNOT IN THE SHEAR ZONEoTEE VERY BASIC PRINCIPAL IS TO REDUCE TaAT GENERATION IN TEE ZONE OF SLIDING

IN REMOVING CHIPS FROM THE WORKED METALLIC PART BY MEANS OF DISTINCTLY SHAPED CUTTING EDGES OF THE TOOL. GRINDING ON THE OTHER HAND IS AN ABRASIVE PROCESS,RHEREBY TEE MATERIAL IS REMOVED FROM THE WORKPIECE VIA ABRASIVE GRAINS . THE CHIPS RESULTED FROM GRINDING PROCESS ARE READILY DISCERNIBLE UNDER A MICROSCOPE.

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CLASSIFICATION OF METAL REMOVAL PROCESS

MACHINING

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HONING

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TURNING MILLING

DRILLING PLANING

SHAPING BROACHING

TAPPING

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15 . TRE

PARAMETERS IN FORMULATING

METAL REMOVING / WORKING FLUID

WORKPIECE METALLURGY

TOOL MATERIAL AND GEOMETRY

METHOD OF FLUID APPLICATION

SURFACE FINISH REQUIREMENT

DIMENSIONAL TOLERANCE

PRODUCTION RATE

TOOL LIFE

WHEEL LIFE

CORROSION-FERROUS AND WON-FERROUS

COST

CLEANLINESS OF MACHINE AND WORKPIECE

TOXICITY

CROSS CONTAMINATION OF OTHER SYSTEM

MULTIPLE USE

DISPOSAL AND RECOVERY

"METAL WORXING" DENOTATION DESCRIBES TWO DISTINCT MECB2WICS;ONE IS A CHIP FORMING SOMETIMES CALLED METAL REMOVING AND TEE OTHER IS A NON-CHIP FORMING PROCESS WHICH IS CALLED METAL FORMING.

T?IE "METAL W0RKING"PHRASE IIAS BEEN APPLIED IN DESCRIBING BOTH METAL REMOVING AND METAL FORMING .

WHILE THE GRINDING WHEEL IS REMOVING METAL FROM THE WORKPIECEPTHE WHEEL ITSELF IS BEING CONSUMED BY W E A R MECHANISMS :

1- DEVELOPMENT OF FLAT AREA ON ABRASIVE GRAIN

2 . LOSS OF A GRAIN FRAGMENT

30 FORMATION OF NE% CUTTING EDGE

TEE PRINCIPAL ADVANTAGES OF CUTTING OIL ( WATERLESS ) OVER AQUEOUS FLUIDS ARE TEAT SUPERIOR SURFACE FINISHES AND LONGER

FLUID AND THE GROUND PARTS ARE HIGH WITH STRAIGHT OIL. RECENT REGULATORY CHANGES AFFECTING THE DISPOSAL OF USED OILSpTOGETHER WITH TEE IDENTIFICATION OF SOME CHLORINATED

UNACCEPTABLE A8 INDUSTRIAL LUBRICANT.

WHEEL LIFE ARE OBTAINED-THE BULK TEMPERATURES OF BOTH THE

PARAFFINS AS-CARCINOGENSpSUGGEST TEAT THEY EVENTUALLY BECOME

COOLING AND LUBRICATION MECEANISM

IN GENERAL TEMPERATURE REDUCTION OF THZ CHIP AND TOOL ARE REGISTERED IN TEE CUTTING AND GRINDING ZONE,WITH AN IMPACT ON REDUCING PLASTICITY AND INCREASING TEE CUTTING AND

FRICTION BETWEEN SURFACES WHICH ARE IN RELATIVE MOTION, GRINDING FORCES-LUBRICANTS HAVE A TENDENCY TO REDUCE

SO FAR,AS TO OUR DISCVS$ION,WHICE I8 MAINLY CENTERED AROUND MECIUWISMS AND DYNAMICS OF CUTTING AND GRfNDINGpA8 WELL AS METAL WORICING FLUIDS,WE NOW BEGIN TO EXPLORE IN MORE DETAIL THE ACTION OF METAL WORKING FLUID. TEE ONE OF THE FUNCTIONS OF THE METAL WORKING FLUID(AQUE0US) IS TO KEEP THE TOOL AND WORKPIECE APART.THIS CONDITION HAS BEEN KNOWN AS ggADBESION REDUCTION".DUE TO THE COMPLEXITY OF VARIOUS METAL WORKING MECHANICS,IT I8 DEEMED NECESSARY TO DEVELOP A LUBRICANT WITH SUCH CIIARACTERISTICS TO ADDRESS THE DEMAND-

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STRAIGHT OIL

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CUTTING OILS ARE SERIES OF PRODUCTS WHICH CONTAIN "NO WATER" AND ARE USED IN APPLICATIONS WHERE A GREAT DEAL OF METAL IS

BROACHING,GEAR HOBBING,AND THREADING. REMOVED IN A SHORT PERIOD OF TIME; MILLING,DRILLING,TOING,

COMPOSITION:

MINERAL OILS /

ONE OR MORE MINERAL OILS PROPORTIONED TO GIVE A SPECIFIC

CATEGORIES; VISCOSITYIAND BASE OIL CAN BE DIVIDED INTO TWO GENERAL

10 NAPHTHENIC MINERAL OIL

2. PARAFINIC MINERAL OIL

BOTE TYPES OF MINERAL OIL ARE BEING USED IN THE

STRAIGHT OIL,MINERAL OILS ARE THE 80 % OF THE TOTAL FORMULA. THE OTHER COMPONENTS OF CUTTING OILS ARE AS FOLLOWS;

MANUFACTURING OF WATER SOLUBLE COOLANTSoIN FORMULATING A

CELORINATED PARAFFIN ACTIVE SULFUR CARRIERS INACTIVE SULFUR CARRIERS FRICTION MODIFIERS TACKINESS MODIFIERS VISCOSITY INDEX MODIFIERS ANTI WELD ADDITIVES ODORANTS POLAR ADDITIVES

SULFO- CHLORINATED CUTTING OILS ARE EXCELLENT IN PROVIDING LUBRICATION IN LOW SPEED AND LOW CLEARANCE WHICH NORMALLY

GROWTH OF BACTERIA WHICH PROMOTES RANCIDITY IS NIL EXCEPT WHEN CONTAMINATED WITH WATER. CUTTING OILS CONTAINING ACTIVE SULFUR ARE NOT SUITED FOR USE ON NON-FERROUS METALS DUE TO THE REACTIVITY OF ACTIVE SULFUR WITH COPPER AND ITS ALL0YS.A NON-BULFUR CONTAINING CUTTING OIL IS RECOMMENDED FOR USE ON FERROUS METALS.THERE ARE ADDITIVES SUCH AS A COPPER DEACTIVATOR AND SULFUR REDUCING AGENT WHICH CAN MAKE THE USE OF SULFURIZED CUTTING OIL POSSIBLE ON NON- FERROUS METALS.

REQUIRES HIGH SURFACZ FINISHoSINCE THEY CONTAIN NO WATER

CLASSES OF

METAL WORKING LUBRICANTS

METALWORKING FLUIDS ARE DIVIDED INTO TWO MAIN GROUPS HAVING AS MANY AS 5 OR MORE CLASSES;

I o METAL REMOVING LUBRICANTS

l o STRAIGHT OIL-(WATERLESS) 20 SOLUBLE OIL-(EMULSION) 30 SEMI~SYNTEETIC~(SEMI~CHEMICAL)~(MICRO EMULSION) 4. SYNTHETIC-(TRUE SOLaTION)-(CEEMICAL SOLUTION) 5 . FATTY OIL-(EMULSION)

11. METAL FORMING LUBRICANTS

A= LIQUID

A l o STRAIGHT OIL-(WATERLESS) A2. SOLUBLE OIL-(EMULSION)

A4. SYNTHETIC-(TRUE SOLUTION)-(CaEMICAL SOLUTION) A30 SEMI~SYNTEETIC~(SEMI~CEEMICAL)~(MICRO~ULSION)

A50 FATTY OIL-(EMULSION)

8. NON-LIQUZD

Al. PASTES A20 COATING A30 SOLID LUBRICANT A40 GASEOUS

SO FAR THERE HAS NOT BEEN A UNIVERSAL DEFINITION IN THE FIELD OF METAL WORKING, THE CLASSES OF LUBRICANTS IN BOTH METAL REMOVING AND FORMING PROCESSES ARE TEE SAME EXCEPT FOR

ARE BEING EXCLUSIVELY USED IN VARIOUS METAL STAMPING AND DRAWING OPERATIONS,

TXE NON-LIQUID CLASSESoTHE NO#-LIQUID CLASSES OF LUBRICANTS

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SOLUBLE OIL

MINERAL OILS WHICH HAVE BEEN BLENDED WITH ADDITIVES TO FORM A STABLE MICELLE WHEN MIXED WITH WATER-THESE PRODUCTS ARE USED AS A "COOLANT" IN MACHINING AND GRINDING OPERATIONS.

COMPOSITION:

MINERAL OIL

CORROSION INHIBITORS WETTING AGENTS/SURFACTANTS COUPLING AGENTS/EMULSIFIERS FOAM DEPRESSANT BIOCIDES FUNGICIDES ODORAElTS

LUBRICITY/E.PoADDITIVES 70.0 TO 80.0 5.0 TO 2 0 . 0 0.2 TO 200 2.0 TO 7.0 5 . 0 TO 1000 0.2 to 1.0 0 . 5 TO 2.0 0 . 5 TO 200 0.1 TO 0.3

SOLUBLE OILS ARE SUPPLIED AS A CONCENTRATE AND ARE MIXED WITH WATER FROM 2.0 TO 20 PERCENT BY VOLUME-WHEN SOLUBLE OILS ARE BLENDED WITH WATER IT FORMS AN OPAQUEtMILKY WHITE EMULSION. THEY FORM LARGE OIL IN WATER DROPLETS AND ARE RELATIVELY COARSE EMULSIONSoTHE OPAQUE APPEARANCE IS RESULTING FROM THE SIZE OF EMULSIFIED PARTICLESIWHICH IS LARGE ENOUGH TO REFRACT LIGHT AND CREATE THE MILKY APPEARANCE-THE EMULSION RESULTING FROM SOLUBLE OILS ARE LOOSE AND NOT STMLE.

SOLUBLE OILS HAVE BEEN RECOMMENDED FOR ROUGHING AND LESS EXACTING I.E~MILLING,TURNING,DRILLING~AND BORING OPERATIONS ON THE EASIER TO MACHINE ALLOYSeTHEY ARE MOSTLY CONSIDERED AS GENERAL PURPOSE PRODUCTS AND CAN BE USED ON FERROUS AND NON-FERROUS ALLOYS.

SOLUBLE OILS HAVE TENDENCY TO EMULSIFY TRAMP OIL IN GREATER PERCENTAGEStAND PROVIDE A MESSY WORK AREAoTHE EMULSIONS OF SOLUBLE OILS ARE DESIGNED TO COOL THE WORKPIECES,TOOLS AND CEIPS WHILE PROVIDING SOME DEGREE OF LUBRICATION.THEY ALSO

RUSTING OF MACHINE COMPONENTS AND PROVIDE TEMPORARY CORROSION PROTECTION OF THE WORKPIECE.

FLUSH CHIPS FROM THE WORK AREAS ON THE MACHINEtCOMBAT

THE EoP- ADDITIVES SUCH AS CHLORINE,SULFUR,PHOSPHORUS AND ESTERS ARE USED FOR HEAVY DUTY OPERATIONSOSOLUBLE OILS ARE BEING CONSIDERED AS AN ALTERNATIVE TO STRAIGHT OILS IN MANY TRADITIONAL OPERATIONS SUCH AS HEAVY DUTY GEAR CUTTING AND

THE SKIN FROM DEFATTENING. BROACHINGoTHE OILINESS IS CONSIDERED A PLUS IN PREVENTING

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TEE PRINCIPAL SOURCE OF LUBRICATION IS PROVIDED VIA USE OF ADDITIVES SUCH AS CHLORINE AND SULFUR.CHLORINE IS MORE ACTIVE T8AN SULFUR,AND FORMS TIfE EXTREME PRESSURE LUBRICANT AT TEMPERATURES LESS THAN 3OO(DEGREESoF)*SULFUR ON THE OTHER HSLND PROVIDES AN E.P. LUBRICANT(IR0N SULFIDE) AT MUCH HIGHER TEMPERATUREoTHE TEMPERATURE RANGE AT WHICH IT BECOMES UNSTABLE DEPENDS UPON~SIZE~THERMOSTABILITY AND MOST OF ALL TEE CIIEMISTRY OF THE MOLECULE.

DISPOSALpFIRE HAZARDIMIST AND HOUSEKEEPING PROBLEMS ARE THE REA80NS THAT HAVE CAUSED CONCERN AMONGST END USERS SPECIFICALLY REG-ING CUTTING OILS, .

ADVANTAGES :

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9.

EXPEDITIOUS HEAT REMOVAL (COOL PART) RESULT IN HOLDING DOWN THE SIZE.

EXCELLENT CLEANLINESS OF MACHINE COMPONENT/PARTS PLUS CORROSION CONTROL.

GOOD FLUSHING ACTION TO REMOVE SWARF AND CLEAN GRIWDING UEEEL.

TRANSLUCENT EMULSION PROVIDES GOOD WORXPIECE VISTBILITY.

LESS RESIDUE THAN SOLUBLE OILS-HELPS IN REDUCING MACEINE COMPONENT STICXING.

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GOOD FINE SETTLING,

EASE OF EMULSIFICATION.

MODERATE TRAMP OIL REJECTION,

GOOD RESISTANCE TO RANCIDITY-EXTENDING SUMP LIFE.

DISADVANTAGES:

1. FOAMS WHEN MIXED WITH LESS THAN 150 PPM HARD WATER.

2. LESS OILINESS CAN CONTRIBUTE TO DEFATTENING OF THE. SKIN.

3. EMULSIFICATION OF MOST GREASES.

SEMI-SYNTHETIC

SEMI-SYNTHETICS ARE BLENDED PRODUCTS WHICH USUALLY CONTAIN MINERAL OIL FOR L ~ R I C I T Y 8 ~ VARIOUS SYNTHETIC AND ORGANIC COMPOUNDS TO IMPROVE CORROSION PROTECTfON8LUBRICITY,CLEANING AND LONG SUMP LIFEoNORMALLY,WBEN MIXED WITH WATER THEY TEND TO FORM A TRANSLUCENT TO HAZY EMULSION.

PARTICLE SIZES ARE MUCH SMALLER THAW SOLUBLE OILS AND FORM A MORE STABLE EMULSION.SEM1-SYNTHETICS ARE MORE TOLERANT OF HARD WATER AND THE EMULSION WILL SELDOM FORM A HARD WATER SOAP OR PRECIPITATE.BECAUSE OF THE HIGH LEVEL OF SURFACTANT AND EMULSIFIERS EMPLOYED IN FORM-TION WORK,USING A FOAM DEPRESSANT IS ALMOST A MU8T80THERWISE FOAMING CAN BE EXPERIENCED.

SEMI-SYNTHETIC METAL WORKING FLUIDS CONTAIN THE SAME ADDITIVES AND FUNCTIONAL CHEMICALS USED IN THE MANUFACTURING OF A SOLUBLE OIL-THE BASES FOR MAJOR DISTINCTION BETWEEN A SEMI-SYNTHETIC AND SOLUBLE OIL ARE THAT IT CONTAINS MUCH LESS MINERAL OIL(S TO 30 % W T / W T ) AND UP TO 60 % WATER.

WATER IS THE CHIEF COMPONENT IN A SEMI-SYNTHETIC CONCENTRATE USED TO FORM THE EMULSION OR DISPERSION OF OIL.

SEMI-SYNTHETICS ARE AN EXCELLENT CHOICE BETWEEN SOLUBLE OIL AND A SYNTsETIC COOLANTSRTHEY ARE NORMALLY USED AT THE RATIO OF SO TO 1 0 ~ 1 MIXED WITH WATER.

SEMI-SYNTHETICS ARE RECOMMENDED FOR A MORE EXACTING PROCESS SUCH AS HONINGtMACEINING FERROUS(SOFT),NON~FERROUStCUTTINGp OPERATION (TAPPINGpDRILLING,THEADING) AND TUBE FORMING.

FATTY OIL I 8 1 1

FATTY OIL FLUIDS HAVE LOW MINERAL OIL CONTENT SUBSTITUTED

APPEARANCE AWD PERFORM LIKE SOLUBLE OILS- WITH POLAR ADDITIVES-THEY FORM A LARGE OIL GLOBULEIOPAQUE

POLAR ADDITIVES :

ANIMAL FATS:THESE ADDITIVES ARE USED AS BOUNDARY LUBRICmS TO REDUCE FRICTIONoTHEY ARE DERIVED FROM FATTY TISSUE OF CATTLEVSHEEPVAND SWINEITHE FATS ARE SATURATED AND REMAIN SOLID OR SEMI-LIQUID AT ROOM TEMPERATURE-

VEGETABLES : 1

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MARINE:

DRYING OIh:

ARE OBTAINED BY CRUSHING AND RENDERING THE SEEDS

OILS CONTAIN SMALL PERCENTAGE FAT THAT IS NOT AND WHOLE FRUIT OF SPECIBIC PLANTS-THESE

SATURATED 0

AS IT INDICATES,CONSIST OF FATTY TISSUE OF

A HIGH DEGREE OF UNSATURATION.THE WAXY PHYSICAL APPEARANCE AND FISHY ODOR IS

SOURCE OF BOUNDARY LUBRICANT.

MARINE ANIMALVFISH AND WtIALESoTHEY CONTAIN

TYPICAL-THEY ARE CONSIDERED AN EXCELLENT

FORM A TOUGH ELASTIC SOLID FILM WHEN EXPOSED TO OPEN AIR-THEY MUST BE FURTHER PROCESSED PRIOR TO USE IN METAL WORKING FLUIDS.

NON-DRYING OIL: CONTAIN THE LEAST AMOUNT OF UNSATURATED FATS AND WILL NOT FORM A TOUGH ELASTIC FZLM UPON EXPOSURE TO THE OPEN AIR.THEY ARE

CASTOR OIL-SINCE THEY CONTAIN LOW LEVEL OF UNSATURATION IT IS BEING USED EXTENSIVELY IN FORMULATING SOLUBLE AND CUTTING OILS.

EXTRACTED FROM PALM OIL,COCONUT,AND

SYNTHETIC

SYNTHETIC METAL WORKING FLUIDS ARE THE CLASS OF PRODUCT THAT

KIND" AND ANY ADDITIVES EXTENDED OR BLENDED WITH MINERAL 0IL.TEESE CLASSES OF METAL WORKING FLUIDS SHOULD CONSIST OF SUCE ADDITIVES RESULTING FROM SYNTHESIS RATHER NATURALLY OCCURRING RAW MATERIALS.

DOES NOT CONTAIN "MINERAL OIL","NO FATTY COMPOUNDS OF ANY

AN leEMULSIFIABLE SYNTHETIC" FLUID SEOULD NOT BE CLASSIFIED AS A SYNTEETIC METAL WORKING COOLANT.

EMULSIFIABLE SYNTHETIC FLUIDS DO NOT CONTAIN "OIL",BUT FATTY AND OTEER POLAR ADDITIVES ARE USED IN TEE MANUFACTURING PROCESS-AN OPAQUE APPEARANCE AND MANY OF ITS PERFORMANCE PROPERTIES ARE SIMILAR TO OIL CONTAINING FLU1DS.A TRUE SYNTHETIC FLUID WHEN MIXED WITH WATER FORMS A TRANSPARENT SOLUTION.

TEE "~SIFIABLE SYNTHETIC" IS BEST TO BE CLASSIFIED IN A SEPARATE CATEGORY SUCE AS "FATTY OIL" SINCE M3wy DIFFERENT KINDS EXIST IN TEE MARKET TODAY.

SYNTHETIC FLUIDS DO NOT OFFER PEYSICAL LUBRICATION AND ARE NOT RECOMMENDED FOR HEAVY DUTY OPERATIONS AMINE SALTS, AMINE CARBOXYLATE,SURFACTANTS~CORROSION INEIBITORSPAND WATER (>SO%)ARE COMMON RAW MATERIALS USED IN FORMULATING SUCH FLUIDS.

SYNTHETIC FLUIDS OFFER EXCELLENT WORK VISIBILITY,LONGER SUMP LIFE,CLEANER WORK AREA AND MACXINE COMPONENTS.THEY ARE MOST SUITED FOB LIGHT DUTY MACBINING AND GRINDING OPERATIONS.

I METAL FORMING LUBRICANT

ARE GROUP OF LUBRICANTS CONSISTENT OF MINERAL OIL,CHLORINE, FATS,SULFUR AND OTHER ADDITIVES MENTIONED IN DESCRIBING THE METAL REMOVING FLUID8.THEY ARE USED AS I8 OR EXTENDED WITH WATER.

/ NON-LIQUID LUBRICANT

SOLID LUBR1CANTS:TEEY'RE A THIN FILM LUBRICANTSpMOLYBDENUX DISULFIDE,GLASS,METAW;IC SOAP,GRAPHITE AND FLUROCARBON TO A SURFACE.THEY ARE USED IN OPERATIONS SUCH AS WIRE DRAWING,EXTRUSION, COLD HEATING AND BAR DRAWINGoTHEY ARE APPLIED IN THE FORM OF POWDER /SUSPENSIONo THE CARRIER CAN BE EITHER MINERAL OIL OR SOLVENT WITH RAPID EVAPORATION RATE.

PASTES: THEY ARE THE RESULT OF AN INVERT EMULSIONfWATER IN OIL

PIGXENTS: CONSIST OF MICA,SODIUX CARBONATE AND GRAPHITE WITH VARYING PARTICLE SIZEStSUSPENDED IN MINERAL OIL OR SOLVENT.

CUTTING OIL COMPOSITION

MINERAL OIL 70 TO 80 S W T I M I

I n3T016+wT/wT I

SEMI-SYNTHETIC COMPOSITION

MINERAL OIL 6 TO 30 lb

COuPLlNa mENT 7 TO 10 s BURFAClANf/WRflNd MENT 6 tCn0 Yb

EXTREME PRESSUFtE ADDITIVE 6 TO l0 U

VHTER 0.8.

SOLUBLE OIL COMPOSITION

E.P. ADDITIVES 6 TO 20%

OTHER ADDITIVES 2 TO 7%

SYNTHETIC COMPOSITION

WTER 0. 8.

8URFACfANT 6 TO 10 K WETTING ABENT 6 TO 10 W

COUPLINQ BENT8 7 TU 10 W E. P. ADDlllM 6 TD 10 K

CORROSION INHIBKOR 2 TO 10 K

OTHER AOOITIVE 1.6 TO 3 K u

b OIL MOLECULE8 -

OIL SOLUBLE EMULSIFIER8 -

SOLUBLE OIL

YlUTER MOLECULE8 - OIL SOLUBLE MOLECULES -

SCHEMATIC REPRESENTATION SCHEMATIC REPRESENTATION

SYNTl

WATER MOLECULE

SCHEMATIC REPRESENTATION

MOLECULE

SCHEMATIC REPRESENTATION

EMULSION

EMULSIONS HAVE BEEN RESTRICTED FOR A LONG TIME TO SYSTEMS OF ONE LIQUID DISPERSED IN ANOTHER IN THE FORM OF EMULSION

MIXING METAL WORKING FLUIDS IN WATER WE WILL ATTEMPT TO DISCUSS THE LIQUID IN LIQUID EMULSIONS.

DROPLETSOTO BETTER UNDERSTAND THE EMULSION FORMED FROM

DISPERSION OF ONE LIQUID IN ANOTHER REQUIRES SUCH ADDITIVES CALLED EMULSIFIERS OTHERWISE A DISPERSION OF ONE LIQUID IN ANOTHER IS EXTREMELY UNSTABLE-IN THE CASE OF A STRAIGHT OIL

PERCEIVED AS AN OIL AND WATER PHENOMENON WEERE TEE DROPLETS WlWN ONE ATTEMPTS TO FORM AN EMULSION,THE BEHAVIOR IS

GATHER-IN USING AN EMULSIFIER WE WILL ATTEMPT TO MARE THE INSOLUBLE MATERIAL,SOLIJBLE-

H-L-B. SYSTEM : TO SAVE TIME IN AN EMULSIFIER SELECTION, THE SCHEME WAS DEVELOPED IN THE 1940'8 BY

ASSIGN A NUMBER TO THE INGREDIENT OR COMBINATION OF INGREDIENTS YOU WANT TO

OR BLEND OF EMULSIFIERS HAVING THE SAME

DEGREE OF SOLUBILITY IN WATER OR OIL;

"HYDROPHILE-LIPOPHILE BALANCE. ''

ICI-USoTHE H.L.B. SYSTEM ENABLES YOU TO

EMULSIFY,AND SELECTING AN EMULSIFIER

NUMBEROTHIS NUMBER ALSO IMPLIES THE

THE LETTERS H.L.B. STANDING FOR

EMULSIFIER : THE NATURAL IMMISCIBILITY OF 01s AND WATER NECESSITATES THE USE OF SUCH COMPOUNDS WHICH CAN KEEP THEM IN CLOSE

AGENT AND DEPENDING ON ITS TYPE,CAUSE THE MICROSCOPIC DROPLETS OF ONE LIQUID TO SUSPEND IN THE OTHER.

CONTACT-THE EMULSIFIERS ACT AS A WETTING

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CAUSES OF RANCID COOLANT AND PREVENTION

MOST COOLANT IS TYPICALLY DISCHARGED DUE TO BACTERIAL GROWTH

SURFACE OF THE COOLANT AND ALLOW ANAEROBIC CONDITIONS TO AND NOT A LOSS OF COOLANT PROPERTIESOTRAMP OIL CAN COVER THE

FORMoANAEROBIC BACTERIA PRODUCES HYDROGEN SULFIDE,WHICE SMELLS LIKE ROTTEN EGGSYAND CAN IRRITATE THE SKIN.

PROPER COOLANT MAINTENANCE CAN PREVENT BACTERIAL GROWTH.

MAINTENANCE WYLL BE HARD TO PERFORM.CO0LANT MAINTENANCE ALSO REQUIRES A COMMITMENT OF EMPLOYEES TO A MAINTENANCE

HOWEVER,IF NUMEROUS KINDS OF COOLANT ARE BEING USEDYCOOLANT

PROCEDURE AND SCHEDULE FOR IT TO SUCCEED.

COOLANT MAINTENANCE CONSISTS OF :

1. REGULAR REMOVAL OF TRAMP OIL / METAL CHIPS FROM THE SUMP

2. CONTROL OF BACTERIA GROWTH

3. MAINTAINING THE COOLANT TO WATER RATIO

THESE STEPS ARE INTERDEPENDENT AND MUST BE SIMULTANEOUSLY FOLLOWED FOR THIS PROGRAM TO SUCCEED.

REMOVAL OF TRAMP OIL

BELT AND DISK SKIMMERS ARE THE MOST COMMONLY USED DEVICES

THEY MAY NEED TO MODIFIED TO ALLOW ACCESS FOR TEE EQUIPMENT. IDEALLY,SKIMMERS SHOULD BE PLACED NEAR THE COOLANT PUMP SINCE PUMPING WILL CAUSE TEE OIL TO DRIFT TOWARD IT. TIMERS C M ALSO BE PLACED ON SKIMMING DEVICES SO EXCESSIVE AMOUNTS OF COOLANT ARE NOT REMOVED WITE THE TRAMP OIL.

FOR OIL REMOVALODEPENDING ON THE DESIGN OF THE MACHINE SUMPS

REMOVAL OF METAL CEIPS

METAL CEIPS MUST ALSO BE REMOVED ON A ROUTINE BASIS.NOT ONLY DO THEY INTERFERE WITH THE MACHINING OPERATIONS,THEY ALSO

FROM ENTERING THE SUMP BY PLACING SCREENS OVER THE COOLANT ENTRANCES TO TEE SUMP OR OVER THE EXITS FROM THE HOLDING TRAYS.THEY CAN ALSO BE REMOVED FROM THE SUMP USING RACKING OR VACUUMING EQUIPMENT.

SERVE AS A SITE FOR BACTERIAL GROWTH.CHIP8 CAN BE PREVENTED

I

1

I

BACTERIA GROWTH IN MWF NO BIOCIDE

BACTERIA / ML l .CmOe*lO

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FUNGI GROWTH IN MWF WITH FUNGICIDE

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CONTROL OF BACTERIAL GROWTH

BACTERIAL GROWTH IS ALSO CONTROLLED BY CLEANING THE SUMP WITH STEAM OR CXEMICALS WHEN THE SPENT COOLANT IS REPLACED,THE USE OF BIOCIDES,PH ADJUSTMENT OF THE COOLA"

SUMP THEY MAY NEED TO BE MODIFIED TO ALLOW ACCESS FOR THE AND ADEQUATE CIRCULATION OF COOLANToIN ORDER TO CLEAN TXE

CLEANING TOOL8

BIOCIDE USE:

THE ULTIMATE TREATMENT PROCESS AND DISPOSAL POINTS MUST BE

TESTING KITS ARE AVAILABLE AND CAN HELP ENSURE THAT EXCESSIVE AMOUNTS OF BIOCIDES ARE NOT ADDED TO TEE COOLANT.

KEPT IN MIND WHEN CHOOSING A BIOCIDEoINEXPENSIVE BACTERIAL

PH CONTROL:

CONTROLLING TEE PH WILL REDUCE THE NEED TO USE BIOCIDE. A DROP IN PH INDICATES BACTERIA GROWTH-THE PH LEVEL SHOULD BE MEASURED FREQUENTLY AND ADJUSTED TO TEE MANUFACTURERS PERFORMANCE LEVELOTHE PE CAN BE CHECKED USING PH PAPER OR AN PORTABLE PE METERoTEE PH CAN BE RAISED USING A CAUSTIC SODA OR SODIUM HYDROXIDE SOLUTION.

COOLANT CIRCULATION:

A MIXER OR AERATING DEVICE TO CIRCULATE THE COOLANT WILL HELP ENSURE AN OXYGEN ENRICHED ENVIRONMENT IN A SUMP WHERE

SHOULD ALSO MONITOR THE MIX PH SINCE AERATING CAN CAUSE DROP

SUCH AS HYDROGEN PEROXIDE IS RECOMMENDED PRIOR TO LONG SHUT DOWN PERIODSOTHIS WILL HELP PREVENT THE GROWTH OF ANAEROBIC BACTERIA.

COOLANT TURNOVER IS NOT HIGHoIN ADDITION TO AERATIONPONE

IN PXpIN TEE PRESENCE OF DISSOLVED CARBON DIOXIDE.ADD1TIVES

PERFORMANCE TESTING OF METAL-WORKING FLUIDS

LABORATORY TESTING IS USUALLY THOUGHT OF AS INVOLVING SUCH MEASUREMENTS OF PHYSICAL AND CHEMICAL PROPERTIES AS PH, VISCOSITY,DENSITY AND SPECIFIC GRAVITY,COLOR,ACID NUMBER, ALKALI NUMBER,ETC.UNDOUBTEDLY THESE TESTS MUST BE INCLUDED IN THE DEVELOPMENT PROCESS FOR MANY METALWORKING FLUID.

MAY,- OFTEN SHOULD BE PERFORMED ON METALWORKING FLUIDS BEFORE ANY ATTEMPT IS MADE TO FIELD-TEST A NEW FLUID.

HOWEVER,THERE ARE NUMEROUS OTHER TEST PROCEDURES THAT

WE BELIEVE ‘THAT THE LEAST-WELL UNDERSTOOD ASPECT OF LABORATORY TESTING OF METALWORKING FLUIDS IS THE TESTING OF METALWORKING FLUID PERFORMANCE ON INSTRUMENTS AND APPARATUS DESIGNED TO CLOSELY SIMULATE THE ACTUAL CONDITIONS UNDER . WEICE THE LUBRICANT WILL BE U8ED.A PROPERLY-SELECTED SERIES OF TESTS CAN REMOVE ALL BUT TEE FAINTEST DOUBT AS TO WHETHER . A NEPO PRODUCT WILL PERFORM WELL IN FIELD TESTS.

THERE IS A WIDE ASSORTMENT OF TEST DEVICES INTENDED TO BE

USED ARE INCLUDED: UTILIZED FOR THIS SORT OF TESTING*SEVERAL E-LES WE HAVE

FALEX PIN-AND-V-BLOCK LUBRICANT TESTER: THIS IS PROBABLY THE SINGLE MOST WIDELY USED LUBRICANT TEST 8YSTEM.A NUTCRACKER LIKE LEVER MECHANISM HOLDS TWO STEEL V-BLOCKS IN FOUR-LINE

CLAMP WITH A RATCHET ADVALSCE APPLIES A LOAD TO THE V-BLOCKS THROUGH THE LEVER MECIIAN1SM.A GAUGE ON THE CLAMP INDICATES THE AMOUNT OF LOAD,WHILE A SECOND GAUGE REPORTS THE FRICTIONAL FORCES BETWEEN THE TEST SPECIMENS AS THE AMOUNT OF TORQUE TRANSMITTED FROM THE JOURNAL TO THE BLOCKS. THE TOOTHED WHEEL OF THE RATCHET CAN BE USED LIKE A MICROMETER TO MEASURE THE AMOUNT OF WEAR ON THE - TEST SPECIMEWS,WITH EIGHTEEN TEETH INDICATING 0.001 INCHES OF WEAR.TBE TEST SPECIMENS AND THEIR SUPPORTS ARE IMMERSED IN A

STARTED.TYPICALLY,TESTS INVOLVE EITHER INCREASING THE LOAD

AT A SPECIFIED LOAD FOR A SPECIFIED TIME AND MEASURING THE WEAR ON THE TEST SPECIMENS.

CONTACT WITH A STEEL JOURNAL ROTATING AT 290 RoPoM. A SCREW-

SAMPLE OF THE LUBRICANT TO BE TESTED,- TBE MACHINE IS

REGULARLY UNTIL THE LUBRICANT FAILSROR OPERATING THE MACHINE

CHECKING COOLANT CONCENTRATION

MAINTAINING THE PROPER COOLANT-TO-WATER RATIO IS CRITICAL TO EFFICIENT COOLANT PERFOREIANCE.REFRACTOMETER8 ARE FAIRLY INEXPENSIVE AND SIMPLE DEVICES WHICH CAN PROVIDE ACCURATE

PROPORTIONING DEVICES ARE ALSO AVAILABLE WHICH WOULD ENABLE MEASUREMENTS OF COOLANT CONCENTRATIONS 0 IN ADDITION8 COOLANT

MORE ACCURATE MIXING OF SOLUTIONS.

OTHER CONSIDERATIONS

IN CASES WHERE TEE SUMP IS INACCESSIBLE AND CAN NOT BE MODIFIED(making oil/chip removal and cleaning difficult) A DIFFERENT COOLANT MAY STILL PROVIDE A LONGER LIFE IN THE SAXE ENVIRONMENT.

WHEN LOOKING AT PURCIIASING NEW MACHINE TOOLStTHE ACCESS TO THE COOLANT SUMP AND EASE OF PERFORMING MAINTENANCE SHOULD BE GIVEN HIGH PRIORITY.STUDIES BAVE SHOWN TEAT SUMPS CONSTRUCTED OF SHEET METAL WITH ROUNDED CORNERS ARE EASIER TO CLEAN.

A CENTRAltIZED SUMP FOR SEVERAL MACHINING OPERATIONS MAY ALSO EASE MAINTENANCE OPERATION ANI] REDUCE CAPITAL COSTS FOR MAINTENANCE EQUIPMENT.

THE COOLANT AT SOME POINT WILL BECOME SPENT AND REQUIRE TREATMENT FOR DISPOSAL . HOWEVER 8 THE OVERALL VOLUME OF SPENT COOLANT COULD BE REDUCED AS MUCH AS 80 % WITH PROPER MAINTENANCE PROGRAM IN PLACED.

II 1 1 1 I I 1

J I I 1 I I I

BRASS LOCKING PIN

- JOURNAL REVOLVES AT 290 R.P.M

Exploded View of V-Blocks and Jwmal Arrangement, Falex Lubricant Tester.

Illustration used w i t h permission of Faville-LeVally Corporation

FALEX 4-BALL WEAR TEST : THIS DEVICE ROTATES A SINGLE BALL BEARING AGAINST THREE SIMILAR BALL BEARINGS HELD STATIONARY BY THE TEST FIXTURE.THE LOAD APPLIED TO THE ROTATING

WHICH THE TEST TAKES PLACE CAN ALL BE CONTROLLED. THE BEARINGS ARE ARRANGED TETRAHEDRALLY AND ARE IMMERSED IN

BY MEASURING THE SIZE OF THE SCARS LEFT ON THE STATIONARY BEARINGS.

BEARINORTHE DURATION OF THE TESTRAND THE TEMPERATURE AT

TEE LUBRICANT BEING TESTEDOTHE TEST RESULTS ARE DETERMINED

FALEX TAPPING TOROUE TEST : THIS TEST IS DESIGNED TO EVALUATE CUTTING OILS BY MEIP8URING THE AMOUNT OF TORQUE REQUIRED TO CUT INTERNAL TEREADS IN A STANDARDIZED NUT BLANK-HIGHER LEVELS OF LUBRICITY ARE INDICATED BY LOWER TORQUE READINGSOTEE AVERAGE TORQUE READING FOR A SERIES OF

EFFICIENCY RATING RELATIVE TO A STANDARD OIL. TESTS WITH THE SAMZ LUBRICANT IS USED TO CALCULATE AN

S.L.T. DRAW BEAD SIMULATOR : THIS DEVICE WAS DESIGNED SPECIFICALLY TO EVALUATE DRAWING LUBR1CANTS.A BEAD IS FORMED IN A METAL STRIP BY DRAWING IT TXROUGH A DIE AT SPEED TYPICAL OF PRODUCTION 0PERATIONS.DRAWING FORCE IS RECORDED A8 A FUNCTION OF DISTANCE TRAVELLEDRAND AN EFFICIENCY RATING RELATIVE TO A 1200 SUS NAPTHENIC OIL REFERENCE ST2WDARD IS CALCULATED . OLSEN LIMITED DOME-HEIGHT TEST : THE OLSEN DEVICE USES A

UNIT PERMITS RAM DEFLECTION IN THOUSANDTHS OF AN INCH TO BE

TO SIMULATE AN EXTREME PRESSURE DRAWING OPERATION.

RAM TO FORM A DIMPLE IN SHEET METAL TEST 8PECIMENS.THE TEST

RECORDED AS A FUNCTION OF THE LOAD ON THE RAM-IT IS DESIGNED

I I I I I 1 I I I 1 I I I ! I

I

TORQUE

SECTION SEALS WIT OF ROUNO

SPECIMEN TABLE

O'RING

EXPLODED VIEW OF SPECIMEN ALIGNMENT

FALEX Tapping Torque Tester

Illustration used with permission of Faville-LeVally Corporation

e . . . . . , . . . . . . ...._ .. . . ,: . . . . . . . . . . .:..... . . . . . . . .... . . . . . . . .. , . ... . . . . . . . . . . . . . . ... .. . . ...

TORQUE ' t LOAD

4 BALL WEAR TEST ADAPTER

U s e d with FALEX Model # 6 T e s t e r

Illustration used with permission of Faville-LeVally Corporation

FLUID SELECTION GUIDE

NOTE: METALLUROY-TOOLINQ-METAL HARDNESS-ARE THE DETERMINING FACTOR

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WASTE TREATMENT

"COLLECTION AND OR SEGREGATION OF FLUIDS FOR THE PURPOSE OF REDUCING POLLUTANTS IN WATER PEASE AND SLUDGE."

POLLUTION OR POLLUTANTS : IS AN ELEMENT, ELEMENTS COMPOUND OR SELECTIVE GROUP OF COMPOUNDS WEICE ARE UNDESIRABLE AT AN ESTABLISHED LEVEL TO THE ENVIRONMENT;

CITY SEWER AIR STORM SEWER GROUND n T E R CREEK LANDFILL RIVER LAKE

HEAVY METAL SOAPS : LOOSELY CALLED METAIILIC SOAPSPARE TEOSE FORMED BY METALS EEAVIER THAN SODIUM(M.W. 22.98).ALUMINUM,

SOLUBLE AND AS A RESULT FORM AN SLUDGE IN THE RIVERBEDS. CALCIUM,COBALT,LEAD,AND ZINC THESE SOAPS ARE NOT WATER

a I b b

WASTE M IN 1 MI Z AT1 ON

VIA 1

L

L II B II

MECHANICAL AND CHEMICAL

PROCESS

1 u

I 1 I 1;

U I I I I I I I I I I

e WHY OILY WASTE IS NOT DESIRABLE:

1. WATER CONTAINING OIL WASTE IS UNDESIRABLE FOR USE IN A BOILER AND COOLING TOWER.

2. OILY FILM ON THE SURFACE OF WATER BLOCKS TEE PASSAGE LIGHT AND OXYGEN ABSORPTION THEREBY RETARDING THE GROWTH OF AQUATIC LIFE AND THE PROCESS CALLED PHOTOSYNTHESIS

3. THROUGH DIRECT CONTACT THE OILY WASTE WATER IS TOXIC TO AQUATIC LITE.

/ 4. HIGHER L&EL OF OILY WASTE WATER ARE A FIRE HAZARD.

DISCHARGE LIMITS;

1. STATEIFEDERALtAND LOCAL GOVERNMENTS LIMIT OIL RANGING FROM 0 TO 30 PPM WEEN DISCEARGED TO SURFACE WATERtTO DISCIIARGE IN THE SANITARY SEWER IT IS 100 PPM.

2. SINCE OIL AND GREASE ADD TO BIOLOGICAL OXYGEN DEMAND AND CHEMICAL OXYGEN DEMAND, THERE I8 A PENALTY IMPOSED ON INDUSTRIES WITH HIGH DISCHARGE LEVEL OF B.0.D AND C.0.D.

WASTE TREATMENT OF METAL WORKING FLUIDS

OIL IS A TROUBLESOME WASTE WATER COMPONENT WITH WHICH OUR INDUSTRY MUST BE CONCERNED,ATTENTION GIVEN RECENTLY TO THE ENVIRONMENT AND DEMANDING ACCOUNTABILITY FROM THOSE WHO ARE

ON THIS SUBJECT MATTER.IN THIS SECTION WE WILL BE EXPLORING THE AVAILABLE AVENUES IN ACHIEVING THE WASTE MINIMIZATION

RESPONSIBLE BY THE FEDERAL GOVERNMENTpHAS PUT THE SPOT LIGHT

GOALS

THIS PROBLEM DESERVES SPECIAL ATTENTION DUE TO THE -FOLLOWING;

1, THE NUMBER OF INDUSTRIES WHICH GENERATE OILY WASTE

2. THE COSTS INVOLVED IN REMOVING OIL

3. THE DETRIMENTAL EFFECTS OF WASTE ON THE EHVIRONMENT

4. LIMITS ON DISCHARGE LEVEL INTO THE LOCAL UTILITY SYSTEM

TYPE OF OIL WASTE;

1. FUELS

2. PROCESSING FLUIDS,QUINCH OILS,COOLANTS,RUST INHIBITORS AND ALXALINE CLEANERS,

3. SOLVENTSpVARIOUS PAINT THINNERSpLUBRICANTSpEYDRAULIC OILS

SPENT COOLANT TREATMENT: COOLANT TREATMENT INVOLVES THE BREAKING OF THE OIL/WATER EMULSION.THE WATER PORTION MAY BE SEWERED PROVIDED TfIAT IT MEETS LOCAL SEWER REGULATION8,WHILE THE OIL PORTION MAY BE HANDLED BY A WASTE OIL FACILITY.

P

P

INORGANIC CHEMICALS

ALUM / IRON SALTS

FeCl 3

v * 3H 0 Fe(OH) + 3HCI 2 3

TREATMENT METHODS

THEY ARE NUMEROUS METHODS AVAILABLE TO TREAT METAL WORKING

AIND EVAPORATORS ARE WIDELY USED TREATMENTS. FLUIDS.AMONG THESES METHODS ARE ACID/ALUM,ULTRAFILTRATION

ACID/ALUM-CHEMICAL TREATMENT :

ALUM AND IRON SALTS HAVE BEEN THE TRADITIONAL INORGANIC

WATER IN THE TYPICAL PH RANGE USED FOR CLARIFICATION,THEY PROVIDE AN INEXPENSIVE SOURCE OF POSITIVE(CATION1C) C-GE

CBEMICALS USED IN COAGULATION AND FLOCCULATION.WHEN ADDED TO

CAUSING CHARGE NEUTRALIZATION AND COAGULATION TO OCCUR.

THE EQUATION FOR THESE REACTIONS ARE AS FOLLOWS:

{SEE SECTION FOR CHARTS AND TABLES)

THIS PROCESS STARTS WITH THE ADDITION OF AN ACID TO ADJUST

ORGANIC POLYMERS ARE ADDED WITH SLOW MIXING SO PARTICLES CAN THE PH DOWN TO -4.0 SUBSEQUENTLY,INORGANIC COAGULANTS OR

AGGREGATE-METAL SALTS USED AS INORGANIC COAGULANT ARE ALUM, LIMEIFERRIC CHLORIDE,AND BENTONITE. IONIC POLYMERS SUCH AS ACRYUIDE MONOMER AND ACRYLIC ACID ARE USED IN COMBINATION WITH OR IN PLACE OF METAL SALTS.

TEERE ARE SOME PRACTICAL DRAWBACKS THAT REDUCE THE

THESE CHEMICALS HOLDS WATER VERY TIGHTLY THEREFORE IT IS DIFFfCULT TO SEPARATE.THIS PROCESS IS CALLED DEWATERING.

ATTRACTIVENESS OF INORGANIC CHEMICALS.THE SLUDGE PRODUCED BY

INORGANIC CHEMICALS OCCUPY A VERY LARGE SPACE AND CONTRIBUTE TO THE SLUDGE WEIGHT-IN ADDITION TO REMOVING THE DIRT FROM

OF THE SLUDGE,OF WHICH THE TOTAL MA88 CAN BE 65 TO 85 %

ONE THIRD OF THE WEIGBT OF ALUM.

SOLUTION,AN END USER WHO USES ALUM MUST DEWATER AND DISPOSE

METAL SALTS-POLYMER COULD PROBABLY REDUCE THE SLUDGE MASS TO

ULTRAFILTRATION

A

MECHANICAL PROCESS

A PROCESS WHICH MEETS ZERO MANIFESTING GOALS AND COMPLIES WITH FEDERML,RCRA REQUIREMENTS,AS WELL AS STATE AND LOCAL DISCEARGE REGULATIONS.AN ULTRAPILTRATION EQUIPMENT OPERATES ON THE FOLLOWING PRINCIPAL8;A DEVICE CONSISTING OF A SEMI-

REMOVING,EXULSIPIED,UNEMULSIFIED,SUSPENDED SOLIDS FROM ALL TYPES OF METAL WORKING FLUIDS AND OTHER SOLUTION SUCH AS MOP WATER AND CLEANERS.

PERMEABLEIPRESSURE ACTIVATED PROCESS WHICH IS CAPABLE OF

THIS SYSTEM IS MOST DESIRABLE FOR SOLUBLE OIL AND SEMI- SYNTHETIC METAL WORKING FLUID8.BOWEVER IT IS NOT RECOMMENDED FOR TREATMENT OF SYNTHETIC FLUIDS.

THE TECHNOLOGY OF POLYMER TREATMENT

POLYELECTROLYTES

THESE COMPOUNDS ARE CHARGE CARRIERS IN AQUEOUS S0LUTIONS;AS PRIMARY cOAGuLANTS8TBEY ATTRACT A POSITIVE(CATI0NIC)CHARGE FOR NEUTRALIZATION OF THE ANIONIC(NEGAT1VE) ON THE SURFACE OF SOLID PARTICLES IN AN AQUEOUS SOLUTION.

CaARGE FOUND

THIS ALSO HOLDS TRUE FOR MONOMERIC COMPOUNDS SUCH AS ALUM OR

CARBON CIIAIN OR BACKBONEONON-IONIC POLYMERS ARE USUALLY ANIONIC POLYMERS PREPARED IN A MANNER SO AS TO INCLUDE THE

IRON SALTSOTHE P O L m I C COMPOUNDS EXIST AS CHARGES ALONG A

MINIMUM ANIONIC CEARGE ON THE CARBON BACKBONE.

AFTER THE POSITIVE CHARGE HAS BEEN NEUTRALIZED 24ND THE

NEAR 2ERO.THE PROCESS OF FLOCCULATION NOW IS OCCURRING BY COMBINING THESE SMALL AGGLOMERATE8 INTO MUCH LARGER

SUSPENSION HAS BEEN COAGULATEDITEE OVERALL CHARGE WILL BE

PARTICLES THAT WILL RAPIDLY SETTLE OUT OF THE WATER.

TEE SLUDGE MASS FOR POLYMERIC COMPOUNDS ARE MUCH LESS OVER METAL SALTS WHICH RESULTS IN A MORE ACCEPTABLE COAGULATION. ,POLYMERIC ADDITIVES HAVE TEE ABILITY TO TIE MORE THAN ONE AGGLOMERATION OF PARTICLES WHICH MAKES USE OF THIS TYPE OF COMPOUND OVER METAL SALTS MORE ATTRACTIVE.

POLYMER TYPES:

1. DRY POLYMERS: DRYlGRANULAR POLYMERSlONCE THEY WERE THE STANDARD FORM OF TREATMENTOTHEY ARE NOT POPULAR DUE TO BECOMING DAMP AND CLOGGING TEE FEED LINES.

1

- 1

- 1

- 1 2. EMULSION POLYMERS: SINCE THESE POLYMERS ARE ORGANIClTHEY

ARE SOLUBLE IN ORGANIC SOLVENTS AT A HIGH PERCENTAGE OF CONCENTRATION. EMULSIFIERS ARE BEING USED IN GETTING

LIFE OF NOT MORE THAN FOUR MONTHS CAN BE EXPECTED OF EMULSION POLYMERS.

A REASONABLY STABLE EMULS1ON.A SHELF

KEY FaTORS IN SELECTING AN ULTRAFILTRATION

JGALLONS TRUlTED PER DAY

JTOTAL AMOUNT OF OIL (FREE & EMULSIFIED)

JAMOUNT Of SOLIDS

JFLUX RATE

ULTRAFILTRATION STAQES OF EFFLUENT PRODUCED

J OILY WASTEWATER EMULSION 'AS RECEIVED'

JFREE OIL AND SUSPENDED SOLI08 FEMOVED

JDISCHARGE TRAMP OIL

J PERMMTE FROM THE ULTRAhLTRATION

J EFFLUENT AFTER POST-TREATMENT SUITABLE FOR SEWER DISPOSAL

ULT RAFl LTR AT1 ON FEATURES

JNO HAZMDOUS CHEMICALS REQUIRED

J HIGHLY EFFICIENT MEMBRANE MODULE

4 TURNKY SYSTEM

J 'PRE-TREATMENV-'POST-TRMTMENT

AUTOMATIC CLEANING CYCLE

JMlCRoPRoCESSES

4360 TO 800 GALLONS PER DAY OUT PUT

ULTRAFILTRATION BENEFITS

PROLONGS LIFE OF WASHWATERS AND IMPROVE8 EFFECTIVENESS

REDUCES COST OF Wi9SHWTER DETERGENTS, HEATING & DISPOSAL

REDUCTION OF OILY WASTE WATER UP TO 96 W

0 SYSTEM EFFLUENT 'WATER' CAN BE DISCHAfX3ED TO SEWER

COOLANT RECYCLING

SYSTEM PAYBACK 9 TO 14 MONTHS

i P

I bl

h ULTRAFILTRATION

APPLICATION

JMACHINING AND GRINDING

/PRIMARY METALS

/METAL FINISHING AND PLATING

/DIE CASTING

J S TAMPING

JWASTE COLLECTION

J TRANSPORTATION

A TYPICAL SEWER ORDINANCE MAY MONITOR THE FOLLOWING:

JB1,OLOGICAL OXYGEN DEMAND

-/ CHEMICAL OXYGEN DEMAND

-/DISCHARGE FLOW RATE

-/SUSPENDED SOLIDS

J P H

TYPICAL ULTRAFILTRATION PERFoRMANCE

ACCEPTABLE LEVELS OF POLLUTANTS TO SANITARY SEWER

B.O.D.

C.O.D.

S.S.

PH

250 PPM +f- 100 PPM

600 PPM * +I- 260 PPM

260 PPM +/- 100 PPM

6.6 TO 8.0

B.O.D. : BIOLOGICAL OXYGEN DEMAND C.O.D. : CHEMICAL OXYGEN DEMAND

S.S. : SUSPENDED SOLIDS

800 COD 88 OIL.- PH

lJaM"- 600 100

1100 1660 20 (10

2600 110 0.0 0-0

TYPICAL PERFORMANCE OF ACID / ALUM TREATMENT

Boo COD 8s OIL mEAaE PH

O W I 0 0 1100 1600 200 10

woo (IO ea 8.0

1 - I I I

ENVIRONMENTAL CONCERNS IN DISPOSAL OF

COOLANTS FROM METALWORKING OPERATIONS

OTHER REGULATED PARAMETERS:

J CADMIUM I

JCHROMIUM

J COPPER

J CYANIDE

J LEAD

J MERCURY

J NICKEL

J SILVER

J ZINC

ABOVE E L E M E N T 8 A R E CONBIDERED A 8 H E N Y METALa

ON-SITE TREATMENT

ON-SITE TREATMENT IS A VIABLE ALTERNATIVE WHEN THE WASTEWATER FROM THE TREATMENT PROCESS CAN BE DISCHARGED TO A

HAVE CONTROL OVER WASTE D1SPOSAL;IT CAN UTIIjIZE COMPANY’S TECXNICAL PEOPLE AND EQU1PMENT;AND IT PROVIDES CONTROL OVER

MUNICIPAL SEWER SYSTEMoWRY TREAT COOLANT ON-SITE? YOU WOULD

DISPOSAL COSTS.

TEE FIRST STEP IS TO FILE AN APPLICATION WITH THE LOCAL

MUNICIPALITY ,WILL CONTAIN THE FOLLOWING LIMITATIONS: SEWER AUTHORITY FOR A PERM1T.A TYPICU PERMIT FROM TEE LOCAL

FOR STATE OF TENNESSEE

PARAMETER

LEAD CADMIUM CdPPEEZ CHROMIUM NICKEL ZINC OIL & GREASE PH

LIMIT (mcr/L)

0.72 0.004 0 . 3 0 0 . 6 6 0.34 0 . 6 5 10.0 TO 100.0 5.5 TO 9.5

LIMITATIONS CAN RANGE TWO TO TBREE TIMES HIGfIER.AND,IN SOME CASESnTHE LIMITATION8 CAN BE MORE STRINGENToMONITORING OF THE DISCfIARGE IS USUALLY REQUIRED.

DO FED- PRETREATXENT METAL FINISHING APPLY TO COOLANTS? IF TEE MANUPACTURING FACILITY CONDUCTS TEE FOLLOWING OPERATIONSIFEDER2& STANDARDS APPLY: ELECTROPLATING, ELECTROLESS PLATING,ANODI!ZING,AND PRINTED CIRCUIT BOARD MANUFACTURING . MANY MUNICIPALITIES HAVE SURCEARGES FOR EXTRA STRENGTH

THAN 250 PPM ARE CONSIDERED EXTRA STRENGTH WASTES. WASTES. WASTES TEAT HAVE A BIOLOGICAL OXYGEN DEMAND GREATER

ENVIRONMENTAL CONCERNS IN DISPOSAL OF COOLANTS FROM METALWORKING OPERATIONS

BACKGROUND

THE FOCUS OF THIS SECTION IS TO PROLONG THE USE OF COOLANTS.

POINT.THE IMPROPER DISPOSAL CAN RESULT IN SIGNIFICANT FINES HOWEVERITHERE MAY BE A NEED TO DISPOSE OF COOLANTS AT SOME

AS WELL AS TREMENDOUS LIABILITIESoDISCBARGE OF WASTE INTO A SURFACE STREAM OR GROUNDWATER CAN RESULT IN UP TO $25,000.00 PER DAY PINE,AND UP TO THREE OR MORE YEARS IMPRISONMENT.

THERE ARE SEVERAL PARAMETERS OF CONCERN IN DISPOSING OF COOLANTSeTHEY INCLUDE HEAVY METALSPOIL AND GREASE,= BIOCIDESoTHE HEAVY METALS THAT CAN LEACH OUT DURING A MACHINING OPERATION INCLUDE THE FOLLOWING PARAMETERS:

LEAD CADMIUM COPPER NICKEL ZINC

OIL AND GREASE IN COOLANTS CAN BE PART FROM TRAMP OILaTRAMP OIL IS A RESULT OF

OF THE PRODUCT OR HYDRAULIC OIL AND ~

WAY OIL ENTERING THE MACHINE COOLANT SYSTEM.

BIOCIDES ARE USED IN MANY COOLANTS TO HELP CONTROL BACTERIA. BACTERIA CAN DEGRADE THE CHEMICAL MAKEUP OF COOLANTS.

PHENOL IS OF PARTICULAR CONCERN BECAUSE OF ITS AFFECT ON AQUATIC LIFE.

TEEREFOREPBACTERIA CONTROL IN SOME COOLANTS IS DESIRABLE-

DISPOSING OF A COOLANT MUST BE DONE IN ACCORDANCE WITH LOCAL,STATE,AND FEDERAL REGULATION.FOR EXAMPLE IN THE STATE OF TENNESSEE,DISPOSAL OF COOLANTS OR ANY PROCESS WASTE TO A SEPTIC TANK AND FIELD LINE SYSTEM IS ILLEGAL.

ANY DISCElARGE OF WATER TO A SURFACE STREAM REQUIRES A PERMIT FROM THE RUNOFF FROM A MANUFACTURING PLANT REQUIRES A PERMIT.

LOCAL WATER POLLUTION CONTROL DEPARTMENT-IN FACT,

DISC-GE TO A SURFACE STREAM IS GENERALLY NOT A VIABLE ALTERNATIVE FOR DISPOSAL OF COOLANTS.THIS IS BECAUSE OF THE STRINGENT TREATMENT REQUIRED TO MEET DISCEARGE LIMITATIONS

DISCHARGE ON A PERIODIC BASIS AND FILING OF REPORTS IS EXPENSIVE AND TIME CONSUMING.

TO SURFACE STR&AMB.ADDITIONALLY,THE MONITORING OF THE

(I

I I I t

METAL WORKING FLUIDS WASTE REDUCTION PROGRAM

BEFORE AN EFFECTIVE WASTE REDUCTION PROGRAM CAN BE DEVELOPED ACCURATE AND CURRENT INFORMATION ON WASTE GENERATION MUST BE EDITED-SOME OF THE INFORMATION WHICH SHOULD BE COLLECTED IS LISTED IN TABLE(A) A LOG CAN BE USED TO KEEP TRACK OF HOW MUCH OF EACH FLUID IS USED BY EACH MACHINE.USING A LOG TO TRACK OIL USAGE WILL HELP IDENTIFY WHY FLUID8 ARE BEING DUMPED-TEIS MAY POINT OUT AREAS FOR BETTER FLUID MANAGEMENT, TRAINING~MAINTEPS~E~CE,ETCOALSO~ONE AREA WHICH SHOULD BE STRESSED IN &E SURVEY IS HOW THE FLUID IS HANDLED AFTER IT

WITE STRAIGHT OIL~OR RECOVERED AND REUSED.

LEAVES TEE MACHINE- FOR EXAMPLE8 IS IT SEGREGATEDRPOURED INTO A TRENCII OR CENTRAL SUMP,DISCEARGED TO A CITY SEWERIMIXED

BASED ON TEE RESULTS OF THE ASSESSMENT8A WASTE REDUCTION PROGRAM FOR METALWORKING FLUID CAN BE DEVELOPED-AN ACTIVE SYSTEM CAN MAINTAIN FLUID PERFORMANCE OVER EmENDED PERIODS OF TIME AND MAY EVEN ELIMINATE THE GENERATION OF SPENT

(1) A METALWORKING FLUID MANAGEMENT PROGRAM AND (2) A FLUID RECOVERY SYSTEM.

FLUID-SUCE A PROGRAM IS COMPRISED OF TWO MAJOR COMPONENTS:

TABLE (B) LISTS SOME COMPONENTS OF A COMPREHENSIVE METAL-

ANY PROGRAM IS TO EDUCATE AND TRAIN THE MACHINE OPERATORS ON WORKING FLUID MANAGEMENT PROGRAM-THE KEY TO THE SUCCESS OF

PROPER FLUID MANAGEMENT PROCEDURES-THEY SHOULD BE INFORMED OF THE PURPOSE OF THE PROGRAM,HOW IT AFFECTS THEMNAND THE BENEFITS TO THE COMPANY AS WELL AS TO THEMSELVES-THE MAWAGEMENT PROGRAM SHOULD BE DEVELOPED WITH INPUT FROM THE MACHINE OPERATOR AS WELL AS TEE FOREMAN AND SUPERVISOR-THIS WILL HELP OVERCOME WORKER RESISTANCE TO TEE PROGRAM.

ONE OF THE FIRST STEPS IN ESTABLISHING A FLUID MANAGEMENT PROGRAM IS TO CORRECT ANY MACHINE-CAUSED FAILURE IN THE FLUID-THIS CAN INCLUDE EXCESS LEVELS OF TRAMP OIL OR SOLIDS BUILDUP-MOST TRAMP OIL COMES FROM LEAKING FITTINGS WHICII ALLOW HYDRAULIC FLUID,LUBRICATING OILS AND GREASES INTO THE METALWORKING FLUID-AN EFFECTIVE EQUIPMENT MAINTENANCE PROGRAM SHOULD BE A PART OF ANY FLUID MANAGEMENT PROGRAM. THIS SHOULD INCLUDE A PREVENTIVE MAINTENANCE PROGRAM TO REPLACE SEALS OR OTHER COMPONENTS,TIGHTEN FITTINGS,AND INSPECT FOR LEAKS.ALL EXISTING TRAMP OIL REMOVAL DEVICES AND TEE SUPPORT EQUIPMENT MUST BE REGULARLY INSPECTED AND PROPERLY OPERATED

TREATMENT OF COOLANTS INCLUDE TEE FOLLOWING OPTIONS:

1. ACID ALUM SPLIT 2 0 ULTRAFILTRATION 3. CENTRIFUGATION 4. REVERSE OSMOSIS 5 . EVAPORATION

WASTE OIL SEPARATED FROM TEE WATER PHASE CAN BE DISPOSED OF FAIRLY CHEAPLY SINCE IT HAS A FUEL VALUE-TEERE ARE PRESENTLY NO REGULATIONS LIMITING THE DISPOSAL OF NONlfAZARDOUS WASTE OIL . OFF-SITE DISPOSAL

WHY USE OFF-SITE DISPOSAL? SOMETIMES ON-SITE TREATMENT PRIOR TO DISPOSAL IS NOT FEASIBLE.EffAMPLES OF THIS ARE WHEN A

SO SMALL THAT A TREATMENT PROGRAM WOULD BE TOO EXPENSIVE. IN SOME CASES A COMPANY WANTS AN INACTIVE ROLE IN WASTE

COMPANY HAS NO TECHNICAL RESOWRCESpOR TEE VOLUME OF WASTE IS

DISPOSAL EFFORT.

TEE FIRST STEP IN USING OFF-SITE TREATMENT IS TO CHOOSE A

CEARA~ERIZE TEE WASTE FROM A CONTENT AND TREATABILITY DISPOSAfr FIRMmTHE FIRST STEP THIS FIRM WILL TAKE IS TO

STANDP0INT.THIS CBARACTERIZATION OF TIIE WASTE COOLAWT WILL DETERMINE IF IT IS A HAZARDOUS WASTE UNDER RCRA REGULATION.

BELOW IS A LISTING OF HAOARDOUS WASTE LEVELS FOR METALS:

PARAMETER LIMITATION (mu/L)

ARSENIC CADMIUM CHROMIUM LEAD

5 . 0 1.0 5 . 0 5 . 0

IF TXiE WASTE COOLANT IS NONEIAZARDOUS,IT CAN BE DISPOSED OF WITEIOUT MEETING ANY REGULATORY REQUIREMENTS.IF THE WASTE COOLANT IS HAZARDOUSpTEERE ARE REQUIREMENTS FOR REGISTRATION REPORTING,EMERGENCY PLANNINGITRAINING ,ETC.,ADDITIONALLY,IN

THE AMOUNT OF HAZARDOUS WASTE GENERATEDOFOR A SMALL GENERATOR OF HAZARDOUS WASTE,FEZS

SOME STATES (i . e. . state of Tennessee) TEERE ARE FEES BASED ON

CAN APPROACE $1000.00 PER YEAR.

3

I

I 1 I I I I I

TABLE(A):INFORMATION ON METALWORKING WASTE GENERATION

FOR EACH MACHINE:

A1 A2. A3 A4 A5 A6 A7 A8 0

A9 A10

TYPE OF METALWORKING FLUID USED. ACTUAL WATER TO FLUID MIX RATIO USED. SIZE OF SUMP. FREQUENCY OF SUMP CLEAN-OUT. FREQUENCY OF MAKE-UP ADDED. INSPECTION F0R:HYDRAULIC AND LUBRICATION OIL LE2iXAGE; SUMP AND FLUID CONDITI0N;FLUID LEAKAGE OR SPILUGE; EFFECTIVENESS OF MACHINE COOLANT CLEANING SYSTEM- REASON FOR FLUID BEING DUMPED. FLUID CL,EANING DEVICES USED.

FACILITY INFORMATION:

CHEMICAL OnGEN DEMAND OF EACH METALWORKING FLUID. HOW FLUID IS REMOVED FROM MACHINES AND WHERE TAKEN INSPECT FLUID STORAGE AREAS.

CHIP BANDLING PROCEDURE. GALLONS OF FLUID USED PER WEEK. COST OF WASTE FLUID DISPOSAL. COST OF VIRGIN FLUID. CURRENT WASTE MANAGEMENT TECENIQUES.

HANDLING OF WASTE HYDRAULIC FLUID.

TO.

TABLE(B):COMPONENTS OF A FLUID MANAGEMENT PROGRAM

Bl B2.

B4 . B5 . B6 . B7. B8. B9 .

B3

ASSIGN RESPONSIBILITY OF FLUID CONTROL TO ONE INDIVIDUAL TRAINING ON FLUID HANDLING MACHINE INSPECTION AND MAINTENANCE COOLANT SUMP CLEANING TECHNIQUE SELECT BEST COOLANT FOR OPTIMUM PERFORMANCE WEERE POSSIBLE USE DIONIZED WATER FOR COOLANT MIX INSTALL PROPER ADDITIVE PROGRAM MINIMIZE INFLUX OF CONTAMINANT IN HOUSE CHEMICAL ANALYSIS PROGRAM

CRITERIA FOR FLUID REMOVAL ALSO HAVE TO BE ESTABLISHED,THIS CAN BE BASED ON THE EXPERIENCE THE MACHINE OPERATOR AND CARRIED OUT ON A REGULARLY SCHEDULED BASIS OR BY SOME PREDETERMINED BASIS (i.e,number of hours of operation, results of a quality test,etc.).REGARDLESS OF TBE METHOD SELECTED0 A RECORD MUST BE KEPT OF THE FREQUENCY OF CIUUIGES

IDENTIFY PROBLEM AREAS. FOR EACH MACHINEoTHIS WILL HELP TRACK FLUID USAGE AND

RESPONSIBILITY FOR FLUID ADDITIONIREMOVAfi AND RECOVERY SHOULD BE UNDER TEE CONTROL OF A SINGLE PERSON OR TEAMOTHIS WILL ALLOW FOR PROPER FLUID MAKEUPISUMP CLEAN-OUT0PROPER HANDLINGOREP&ACEMENT OF FLUID WHEN ACTUALLY NEEDED,-

NUMBER OF FLUID TYPES WILL GREATLY SIMPLIFY THIS PROCESS AND ANY RECOVERY 0PERATION.A CENTRAL OIL STORAGE/RECOVERY AREA WITH FEED AND RETURN LINES TO EACH MACHINE CAN GREATLY

INSURE SEGREGATION OF WASTE FLUID BY TYPE-USING THE MINIMUM

IMPROVE MATERIAL HANDLING AND REDUCE FLUID LOSS. ALTERNATIVELYtA SINGLE OR SPLIT CHAMBER SUMP CLEANER CAN BE USED TO TRANSPORT THE FLUID BETWEEN THE MACHINE AND THE RECOVERY SYSTEMoDEIONIZED WATER SHOULD BE USED FOR MAKEUP TO

,,.REDUCE SALT BUILD UP IN - 1

ONCE A METALWORKING FLUID MANAGEMENT PROGRAM IS IN PLACE, TEEN A RECOVERY SYSTEM CAN BE USED TO RECLAIM THE SPENT FLUID.TEERE ARE A NUMBER OF TECHNIQUES WHICH CAN BE USED ON SITE TO RECOVER COOLANTSoTHESE INCLUDE SETTLINGpFILTRATION0 HYDROCYCLONE,CENTRIFUGATION AND MAGNETIC FILTERSOTHE SELECTION OF THE TYPE OF UNIT(S) WHICH WILL BE USED TO RECOVER THE WASTE FLUID WILL DEPEND ON THE LEVEL OF CONTAMINANTS(such as tramp oil,solids,and bacteria) IT CONTAINS AND THE FLUID SPECIFICATIONS THAT MUST BE MET. IF THERE IS NOT MUCE OIL OR SOLIDSlTHEN AN INEXPENSIVE SETTLING TANK0SKIMMER OR COALESCING PLATE SEPARATOR MAY BE USEDoIF VERY HIGH COOLANT SPECIFICATIONS MUST BE METPTHEN A CENTRIFUGATION SYSTEM MAY BE NECESSARY.

THESE SYSTEMS MAY BE PURCHASED INDIVIDUALLY OR AS A COMPLETE

NUMBER OF OPTIONS INCLUDING AN AUTOMATIC COOLANT CONCENTRATE

AND FILL/EMPTY CONTROLS,PASTEURIZATION FOR BACTERIA CONTROL.

SKID-MOUNTED SYSTEM-THESE SYSTEMS ARE AVAILABLE WITH A

ADDITION~DEIONIZED WATER SYSTEMS FOR MAKEUP,AUTOMATIC TIMES

BIBLIOGRAPHY

1.CUTTING AND GRINDING FLU1DS:SELECTION AND APPLICATION. R.K.SPRINGBORN,EDITOR.AMERICAN SOCIETY OF TOOL AND MANUFACTURING ENGINEERSy1967.

2.W.H.NORTHCOTT."A TREATISE ON LATHES AND TURNING."(LONDON: LONGMANS GREEN AND COMPANY,1868).

3.A.MALLOCK,"THE ACTION OF CUTTING TOOLS."PROC.ROYAL SOC.,33 (1881)

4.F.W.TAYLOR,ON THE ART OF CUTTING METALS,ASME,NEW YORK,NEW, NEW YORK,1906

3-SYNTHETIC METAL WORKING LUBRICANTS,R.V.SINGH,HINDUSTAN ALUMINUM CORPORATION LTD.,INDIA

6.USE OF SOLUBLE OILS FOR GRINDING TO SOLVE DIFFICULT MACHINING PROBLEMS-V-LAVARINA,MOBIL OIL ITALIANA S.P.A., ITALY .

7,APPLICATION OF CUTTING AND GRINDING FLUIDS,R.A.HOLSTEDT. UNION OIL COMPANY OF CALIFORNIA,USA.

AUTHOR WOULD LIKE TO ACKNOWLEDGE THE CONTRIBUTION OF JOHN POHLMAN O F ANGUS CHEMICAL COMPANY IN BIOCIDE STUDY DATA.