U.S. patent application number 12/956455 was filed with the patent office on 2011-09-29 for process for metalworking fluid from heavy alkylate.
This patent application is currently assigned to Council of Scientific & Industrial Research. Invention is credited to Onkar Nath Anand, Ashok Kumar Gupta, Arun Kumar Singh.
Application Number | 20110237471 12/956455 |
Document ID | / |
Family ID | 44657123 |
Filed Date | 2011-09-29 |
United States Patent
Application |
20110237471 |
Kind Code |
A1 |
Singh; Arun Kumar ; et
al. |
September 29, 2011 |
PROCESS FOR METALWORKING FLUID FROM HEAVY ALKYLATE
Abstract
The present invention relates to composition of metalworking
fluid based on heavy alkyl benzenes having 20 to 22 alkyl carbon
atoms and process for the preparation thereof. The heavy alkyl
benzene based, less toxic, soluble metalworking fluid composition
comprises heavy alkyl benzene, emulsifier, lubricity booster,
antioxidant, fungicide, extreme pressure additive, antirust,
co-surfactant, coupling agent and alkali component. The process
comprises tailoring the heavy alkyl benzene, removing of insoluble
matter from the heavy alkylate, addition of emulsifier, additives,
coupling agent and co-surfactant, homogenizing the mixture at
20-120.degree. C., followed by conditioning of the soluble metal
working fluid concentrate which can be used as emulsion in
water.
Inventors: |
Singh; Arun Kumar;
(Dehradun, IN) ; Anand; Onkar Nath; (Dehradun,
IN) ; Gupta; Ashok Kumar; (Dehradun, IN) |
Assignee: |
Council of Scientific &
Industrial Research
New Delhi
IN
|
Family ID: |
44657123 |
Appl. No.: |
12/956455 |
Filed: |
November 30, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10810387 |
Mar 26, 2004 |
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12956455 |
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Current U.S.
Class: |
508/154 ;
508/216 |
Current CPC
Class: |
C10M 2219/044 20130101;
C10M 2207/026 20130101; C10M 2209/103 20130101; C10M 2215/06
20130101; C10M 2223/12 20130101; C10M 2215/041 20130101; C10N
2010/12 20130101; C10M 169/04 20130101; C10M 2207/103 20130101;
C10M 2207/40 20130101; C10M 2215/223 20130101; C10N 2010/04
20130101; C10M 173/02 20130101; C10M 2207/023 20130101; C10N
2010/02 20130101; C10M 2205/22 20130101; C10M 2201/062 20130101;
C10M 2207/126 20130101; C10N 2040/22 20130101; C10M 2219/083
20130101; C10M 2207/022 20130101; C10M 2207/046 20130101; C10M
2207/10 20130101; C10M 2203/065 20130101; C10M 2219/024 20130101;
C10M 2207/402 20130101; C10M 2215/064 20130101; C10M 2223/121
20130101; C10M 2219/04 20130101; C10M 2205/223 20130101; C10N
2070/02 20200501; C10M 2219/0406 20130101; C10M 2215/042 20130101;
C10M 2223/045 20130101; C10M 2207/021 20130101 |
Class at
Publication: |
508/154 ;
508/216 |
International
Class: |
C10M 169/04 20060101
C10M169/04 |
Claims
1. A process for metalworking fluid from a heavy alkylate,
concentrate composition comprising; (a) heavy alkylate having C20
to C22 alkyl carbon atoms on benzene ring, to replace mineral oil,
in the concentration range of 40 to 85 weight percent of the metal
working fluid concentrate, (b) at least one sulfonate or oleate
emulsifier in the range of 10 to 40 weight percent of the
metalworking fluid concentrate, (c) a synergetic combination of
additives, (c1) at least one vegetable oil lubricity booster
component in the concentration range of 2-10 percent of metal
working fluid concentrate, (c2) an alkyl phenol or aromatic amine
antioxidant component is in the concentration range of 50-500
mg/kg, (c3) a phenol fungicide component in the concentration range
of 50-500 mg/kg, (c4) an organic sulfide or phosphosulfurized metal
salt extreme pressure additive component in the concentration range
of 50-500 mg/kg in the metal working fluid concentrate, (c5) a
triazole or sulfonate antirust component in the concentration range
of 50-500 mg/kg in the metal working fluid concentrate, (c6) an
alcohol co-surfactant component in the range of 1-10 weight percent
of metal working fluid concentrate, (c7) a sulfonate coupling agent
in the range of 0.5 to 10 weight percent of metal working fluid
concentrate, (c8) alkali or alkaline earth metal salt component in
the range of 8-10 weight percent of metal working fluid
concentrate, (d) said process comprises the steps of tailoring the
heavy alkylate, removing of insoluble matter from the heavy
alkylate followed by addition of emulsifier and vegetable oil to
obtain the mixture; homogenising the resultant mixture at a
temperature in the range of 30 to 100 degree Celsius; for about one
hour with stirring; adding the antioxidant, fungicide, extreme
pressure additives, anti trust component, co-surfactant, coupling
agent, alkali, followed by addition of water to make up the
quantity about 1 kg; homogenizing the mixture for about 30 minutes,
adjusting the pH to 7-9 by addition of sodium carbonate; and
cooling the resultant metal working fluid at room temperature,
wherein the composition is suitable for use as soluble metalworking
fluid as admixture or emulsion with water in concentration range
from 20 to 80 weight percent.
2. The composition as claimed in claim 1, wherein the heavy
Alkylate is a non-toxic lube oil component having heavy alkyl
benzene of C20-C22 alkyl carbon atom, a heavy fraction by-product
separated from detergent class alkyl benzene during manufacture,
wherein the Heavy alkyl benzene consists of a mixture of
substituted benzenes, wherein the Benzene is substituted with alkyl
chain wherein the Alkyl chains are straight-chain paraffin or
branch-chain paraffin, and average of C20-C22 alkyl carbon atom, at
single or two places of benzene ring, and no poly-aromatics or
olefin compounds are present in the heavy alkylates.
3. The composition as claimed in claim 1, wherein the emulsifier is
selected from the group consisting of heavy alkylate sodium
sulfonates, sodium carboxylate, sodium oleate, triethanolamine
oleate, diethanolamine oleate or dodecyl toluene sodium sulfonate
or mixtures thereof.
4. The composition as claimed in claim 1, wherein the lubricity
booster is a vegetable oil selected from the group consisting of
karanja oil, neem oil, rice-bran oil, castor oil or mixtures
thereof.
5. The composition as claimed in claim 1, wherein the antioxidant
component is selected from the group consisting of an alkyl phenol,
aromatic amine, substituted tetrazole selected from 2,6-ditertiary
butyl phenol, 2,6-ditertiary p-cresol, diphenylamine, Tertiary
butyl phenol amino tetrazole and 2,6-dioctyl phenylene diamine or
mixtures thereof.
6. The composition as claimed in claim 1, wherein the fungicide
component is a phenol or phenolic acid selected from the group
consisting of o-cresol, phenol, m-cresol and cresylic acid or
mixtures thereof.
7. The composition as claimed in claim 1, wherein the extreme
pressure additive component is an organic sulphide or
phosphosulfurized metal salt selected from the group consisting of
dibenzyl disulphide, sulfurized vegetable oil, phosphosulfurized
decyl oleate molybdate and phosphothio pentadecyl phenol molybdate
or mixtures thereof.
8. The composition as claimed in claim 1, wherein the anti-rust
component is a triazole or sulfonate selected from the group
consisting of 1H-benzotriazole, ditertiary butylated
1H-Benzotriazole, calcium petroleum sulfonate and calcium heavy
alkylate sulfonate or mixtures thereof.
9. The composition as claimed in claim 1, wherein the co-surfactant
component is a alcohol selected from the group consisting of
isopropanol, n-butanol, iso-butanol, iso-amyl alcohol,
2-ethyl-1-hexanol, mono & poly glycol such as diethylene glycol
and tri ethylene glycol or mixtures thereof.
10. The composition as claimed in claim 1, wherein the coupling
agent component is sulfonates (molecular weight less than 350)
selected from the group consisting of ligno sulfonate, petroleum
sulfonate, sodium dodecyl benzene sulfonate and sodium lauryl
sulphate or mixtures thereof.
11. The composition as claimed in claim 1, wherein the alkali
component is an alkali and alkaline earth metal salt selected from
the group consisting of sodium carbonate, sodium hydrogen
carbonate, calcium carbonate and calcium oxide or mixtures
thereof.
12. The composition as claimed in claim 1, wherein the composition
is suitable for use as soluble metal working fluid as emulsion or
admixture with water in concentration range from 20 to 80 weight
percent and useful for metal cutting, drilling, lathing, grinding
or machining.
13. Process for metalworking fluid from heavy alkylate, concentrate
as claimed in claim 1, said process comprises the steps of; (a)
tailoring the commercially available heavy alkylate, commercial
heavy alkylates was fractionated by vacuum distillation, which
should be done at 1 bar or 760 mm Hg vacuum and about 210.degree.
C., first 5 to 50 percent by weight cut and last 5 percent by
weight cut should be left and middle cut of 55 to 90 percent by
weight should be taken for formulation, (b) removing of insoluble
or oxidized matter from the heavy alkylate followed by addition of
emulsifier and vegetable oil to obtain the solution; (c)
homogenising the resultant mixture at a temperature in the range of
30 to 100.degree. C. for about one hour with stirring of force
equivalent to 1300 RPM for 2 litre material; (d) adding the
antioxidant, fungicide, extreme pressure additives, anti trust
component, co-surfactant, coupling agent, alkali; (f) adjusting the
pH of the solution to 7-9 by addition of sodium carbonate; and (e)
followed by addition of water to make up the quantity about 1 kg,
and homogenising the mixture for about 30 minutes and cooling the
resultant metal working fluid at room temperature.
14. The process as claimed in claim 13, wherein the concentration
of heavy alkyl benzene component is in the range of 40 to 85 weight
percent of the metalworking fluid concentrate.
15. The process as claimed in claim 13, wherein the concentration
of emulsifier component is in the range of 10 to 40 weight percent
of the metalworking fluid concentrate.
16. The process as claimed in claim 13, wherein the concentration
of vegetable oil component for lubricity boost is in the range of 2
to 10 weight percent of the metalworking fluid concentrate.
17. The process as claimed in claim 13, wherein the concentration
of antioxidant component is in the range of 50 to 500 mg/kg of the
metalworking fluid concentrate.
18. The process as claimed in claim 13, wherein the concentration
of fungicide component is in the range of 50 to 500 mg/kg of the
metalworking fluid concentrate.
19. The process as claimed in claim 13, wherein the concentration
of extreme pressure additive component is in the range of 50 to 500
mg/kg of the metalworking fluid concentrate.
20. The process as claimed in claim 13, wherein the concentration
of anti-rust component is in the range of 50 to 500 mg/kg of the
metalworking fluid concentrate.
21. The process as claimed in claim 13, wherein the concentration
of co-surfactant component is in the range of 1 to 10 weight
percent of the metalworking fluid concentrate.
22. The process as claimed in claim 13, wherein the concentration
of coupling agent component is in the range of 0.5 to 10 weight
percent of the metalworking fluid concentrate.
23. The process as claimed in claim 13, wherein the concentration
of alkali component is in the range of 0.5 to 8 weight percent of
the metalworking fluid concentrate.
Description
PRIORITY
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 10/810,387 filed Mar. 26, 2004, the entire
disclosure of which is hereby incorporated by reference.
FIELD OF INVENTION
[0002] The present invention relates to a process for metalworking
fluids from heavy alkylate. More particularly this invention
relates to composition of soluble metalworking fluid and process
for its preparation based on less-toxic heavy alkyl benzenes having
20 to 22 alkyl carbon atoms to replace mineral oil. This soluble
metalworking fluid composition comprises heavy alkylate, emulsifier
lubricity booster, antioxidant, fungicide, extreme pressure
additive, antirust, co-surfactant, coupling agent and alkali
component. The process comprises tailoring the heavy alkylate,
removing of insoluble matter from the heavy alkylate, addition of
emulsifier, additives, coupling agent and co-surfactant,
homogenizing the mixture at 20-120.degree. C., followed by
conditioning of the soluble metal working fluid concentrate which
can be used as emulsion in water in 20:80 ratio.
BACKGROUND AND PRIOR ART
[0003] The speed of machining could be greatly increased if the
cutting surface is kept cool and lubricated. Water can be regarded
as the first cutting fluid because of its high specific and latent
heats to give it unique potential cooling power and also it is
available everywhere at low cost. However, due to poor wetting
efficiency, water alone can't cool the metal surface with its full
ability. Another serious disadvantage is the formation of rust on
iron and steel surfaces. Modern development has led to the
introduction of advanced water-oil emulsion incorporating special
chemicals, which considerably improve its wettability, lubrication,
high cooling power, rust inhibiting and detergency properties.
These concentrates and their emulsions in water are known as
`Soluble Oil` or "soluble metalworking fluid". They are ideal for
general machining process where Cooling, Lubrication, Cleaning and
extreme pressure characteristics are essential requirements.
[0004] Traditionally, the mineral oils and petroleum sulfonates
have been the basic source of metalworking fluid formulations. The
petroleum based lubricating oils and sulfonates are hydrocarbons of
varying composition consisting of naphthenes, paraffins and
aromatics. The sulfonates formed by sulfonation of aromatic
components in these lubricating oil streams act as oil/water
emulsifiers. Various additives, which are primarily chemicals of
defined composition or structure, are added also to improve the
physico-chemical properties and performance of soluble metalworking
fluids. Petroleum based soluble oils; generally suffer from many
disadvantages such as higher toxicity to the environment, poor
biodegradability and ever-changing characteristics with changes in
crude oil composition. The other types of lubricants known as
synthetic lubricants are designed for use in extreme conditions of
temperature, pressure, radiation or chemical environment and have
excellent lubricity and thermal stability. The synthetic lubricants
are relatively costly as compared to petroleum based lubricants.
Polyglycols, polybutenes, dibasic acid esters, fluoropolymers,
polyol esters, phosphate esters, silicones, poly-alpha olefins etc.
are commonly used synthetic lubricants for various applications.
Some of the synthetics are also toxic to environment and are not
readily biodegradable. Similar disadvantages are found with
Petroleum sulfonates which are by-products of sulfonation of
lubricating oils also suffer from inconsistent emulsification and
compatibility characteristics due to ever-changing composition of
the lubricating oils.
[0005] Keeping in the view the environmental concerns and improved
performance, consistency in structural and performance
characteristics, there is a need to develop alternative lubricant
and emulsifier component for metalworking fluids, which are less
toxic and low cost which show equivalent or improved performance to
mineral oil or synthetic lubricant based metalworking fluids.
[0006] The use of Heavy alkyl benzene as a lubricant is very
limited. Recently, the Heavy Alkyl Benzene alkaline earth metal
sulfonates are in use as detergent-dispersant-anti rust additive in
various types of lubricants but not for metalworking fluids.
[0007] Reference may be made to M/S Petresa, Madrid, Spain,
(www.petresa.es) wherein they are marketing heavy alkylate under
the brand name of `PETRENE` to be use as thermal fluid, transformer
oil, refrigerating oil, sulfonation feedstock and lubricating
greases but not for metalworking fluids but not teaches the soluble
metalworking fluids.
[0008] Reference may be made to M/s Chevron, U.S.A. Inc., (San
Ramon, Calif.) has U.S. Pat. No. 6,187,981 "Process for producing
aryl alkanes and arylalkanes sulfonates, compositions produced
there from, and uses thereof". Wherein this invention is a process
for producing aryl-alkanes. This invention also provides process
that to produce modified alkyl benzene sulfonates, which can be
used as detergents but not teaches the soluble metalworking
fluids.
[0009] Chevron, U.S.A. Inc., (San Ramon, Calif.) has U.S. Pat. No.
6,392,109 "Synthesis of alkyl benzenes and synlubes from
Fischer-Tropsch products" which is for an integrated process for
producing alkyl benzenes, sulfonated alkyl benzenes and/or
alkylcyclohexanes from syngas and used as detergents and/or
dispersants but not teaches the soluble metalworking fluids.
[0010] There are sufficient guiding literatures in this field.
Although there is very less background available for utilization of
heavy alkyl benzene (by-product) but for soluble cutting oil there
are sufficient literature, but not teaches the soluble metalworking
fluids from heavy alkylate, such as: [0011] U.S. Pat. No.
6,858,569--Yokota, 22 Feb. 2005 [0012] U.S. Pat. No.
4,589,990--Zehler, 20 Dec. 1986 [0013] U.S. Pat. No.
5,171,903--Koyama, 15 Dec. 1992 [0014] U.S. Pat. No.
5,877,130--Kohara, 2 Mar. 1999 [0015] U.S. Pat. No.
6,245,723--Sigg, 12 Jun. 2001 [0016] U.S. Pat. No.
6,605,575--Yamota, 12 Aug. 2003 [0017] U.S. Pat. No.
6,383,991--Hashimoto, 7 May 2002 [0018] U.S. Pat. No.
6,242,391--Fukutani, 5 Jun. 2001
[0019] In view of the growing concern about the environment, there
is a need for less-toxic lubricant component for metalworking
soluble oil based on Heavy alkyl benzene, which is a new
application of the heavy alkylate. It will not only reduce the
toxicity of soluble oil but also will be more cost effective than
mineral oil because of improved and consistent performance because
both the mineral oil component and the sulfonates made from these
alkylates can be tailored to obtain a high performance product of
consistent quality. It is an additional benefit to the alkylate
industry.
OBJECTS OF THE INVENTION
[0020] The main object of the present invention is to provide a
process for metalworking fluids from heavy alkylate.
[0021] Another object of the present invention is to provide heavy
alkylate based less toxic lubricant component metalworking
fluids.
[0022] Still another objects of the present invention is to provide
a new application to the heavy alkylate (a by-product or waste
product).
[0023] Yet another object of the present invention is to provide
new composition of metalworking fluid for the benefit of
metalworking and alkylate manufacturing industries.
SUMMARY OF INVENTION
[0024] Accordingly the present invention provides a process for
metalworking fluids from heavy alkylate concentrate composition
comprising; (a) heavy alkyl benzenes having C20 to C22 alkyl carbon
atoms on benzene ring, to replace mineral oil, in the concentration
range of 40 to 85 weight percent of the metal working fluid
concentrate, (b) at least one sulfonate or oleate emulsifier in the
range of 10 to 40 weight percent of the metalworking fluid
concentrate, (c) a synergetic combination of additives, (c1) at
least one vegetable oil lubricity booster component in the
concentration range of 2-10 percent of metal working fluid
concentrate, (c2) an alkyl phenol or aromatic amine antioxidant
component is in the concentration range of 50-500 mg/kg, (c3) a
phenol fungicide component in the concentration range of 50-500
mg/kg, (c4) an organic sulphide or phosphosulfurized metal salt
extreme pressure additive component in the concentration range of
50-500 mg/kg in the metal working fluid concentrate, (c5) a
triazole or sulfonate antirust component in the concentration range
of 50-500 mg/kg in the metal working fluid concentrate, (c6) an
alcohol co-surfactant component in the range of 1-10 weight percent
of metal working fluid concentrate, (c7) a sulfonate coupling agent
in the range of 0.5 to 10 weight percent of metal working fluid
concentrate, (c8) alkali or alkaline earth metal salt component in
the range of 8-10 weight percent of metal working fluid
concentrate, (d) a process comprises the steps of; tailoring the
heavy alkylate, removing of insoluble matter from the heavy
alkylate followed by addition of emulsifier and vegetable oil to
obtain the mixture; homogenising the resultant mixture at a
temperature in the range of 30 to 100 degree Celsius; for about one
hour with stirring; adding the antioxidant, fungicide, extreme
pressure additives, anti trust component, co-surfactant, coupling
agent, alkali, followed by addition of water to make up the
quantity about 1 kg, homogenizing the mixture for about 30 minutes,
the pH of the solution should be adjusted to 7-9 by addition of
sodium carbonate and cooling the resultant metal working fluid at
room temperature, wherein the composition is suitable for use as
soluble metalworking fluid as admixture or emulsion with water in
concentration range from 20 to 80 weight percent.
[0025] In an embodiment of present invention the heavy Alkylate is
a non-toxic lube oil component having heavy alkyl benzene of
C20-C22 alkyl carbon atom, a heavy fraction by-product separated
from detergent class alkyl benzene during manufacture. Heavy alkyl
benzene mainly consists of mixture of substituted benzenes. Benzene
is substituted with alkyl chain. Alkyl chains are straight-chain
paraffin or branch-chain paraffin, average of C20-C22 alkyl carbon
atom, at single or two places of benzene ring. No poly-aromatics or
olefin compounds are present in the heavy alkylates.
[0026] In yet another embodiment the emulsifier is selected
preferably from the group consisting of heavy alkylate sodium
sulfonates, sodium carboxylate, sodium oleate, triethanolamine
oleate, diethanolamine oleate or dodecyl toluene sodium sulfonate
or mixtures thereof.
[0027] In yet another embodiment the lubricity booster is a
vegetable oil selected preferably from the group consisting of
karanja oil, neem oil, rice-bran oil, castor oil or mixtures
thereof.
[0028] In yet another embodiment the antioxidant component is
selected preferably from the group consisting of an alkyl phenol,
aromatic amine, substituted tetrazole selected from 2,6-ditertiary
butyl phenol, 2,6-ditertiary p-cresol, diphenylamine, Tertiary
butyl phenol amino tetrazole and 2,6-dioctyl phenylene diamine or
mixtures thereof.
[0029] In yet another embodiment the fungicide component is a
phenol or phenolic acid selected preferably from the group
consisting of o-cresol, phenol, m-cresol and cresylic acid or
mixtures thereof.
[0030] In yet another embodiment the extreme pressure additive
component is an organic sulphide or phosphosulfurized metal salt
selected preferably from the group consisting of dibenzyl
disulphide, sulfurized vegetable oil, phosphosulfurized decyl
oleate molybdate and phosphothio pentadecyl phenol molybdate or
mixtures thereof.
[0031] In yet another embodiment the anti-rust component is a
triazole or sulfonate selected preferably from the group consisting
of IH-benzotriazole, ditertiary butylated 1H-Benzotriazole, calcium
petroleum sulfonate and calcium heavy alkylate sulfonate or
mixtures thereof.
[0032] In yet another embodiment the co-surfactant component is a
alcohol selected preferably from the group consisting of
isopropanol, n-butanol, iso-butanol, iso-amyl alcohol,
2-ethyl-1-hexanol, mono & poly glycol such as diethylene glycol
and tri ethylene glycol or mixtures thereof.
[0033] In yet another embodiment the coupling agent component is
sulfonates (molecular weight less than 350) selected preferably
from the group consisting of ligno sulfonate, petroleum sulfonate,
sodium dodecyl benzene sulfonate and sodium lauryl sulphate or
mixtures thereof.
[0034] In yet another embodiment the alkali component is an alkali
and alkaline earth metal salt selected preferably from the group
consisting of sodium carbonate, sodium hydrogen carbonate, calcium
carbonate and calcium oxide or mixtures thereof.
[0035] In yet another embodiment the composition is suitable for
use as soluble metal working fluid as emulsion or admixture with
water in concentration range from 20 to 80 weight percent and
useful for metal cutting, drilling, lathing, grinding or
machining.
[0036] In yet another embodiment the process comprises the steps
of; (a) tailoring the commercially available heavy alkylate,
commercial heavy alkylates was fractionated by vacuum distillation,
which should be done at 1 bar or 760 mm Hg vacuum and about
210.degree. C., first 5 to 50 percent by weight cut and last 5
percent by weight cut should be left and middle cut of 55 to 90
percent by weight should be taken for formulation, (b) removing of
insoluble or oxidized matter from the heavy alkylate followed by
addition of emulsifier and vegetable oil to obtain the solution;
(c) homogenising the resultant mixture at a temperature in the
range of 30 to 100.degree. C. for about one hour with stirring of
force equivalent to 1300 RPM for 2 litre material; (d) adding the
antioxidant, fungicide, extreme pressure additives, anti trust
component, co-surfactant, coupling agent, alkali, (f) the pH of the
solution was adjusted to 7-9 by addition of sodium carbonate, (e)
followed by addition of water to make up the quantity about 1 kg,
and homogenising the mixture for about 30 minutes and cooling the
resultant metal working fluid at room temperature.
[0037] In yet another embodiment the concentration of heavy alkyl
benzene component is in the range of 40 to 85 weight percent of the
metalworking fluid concentrate.
[0038] In yet another embodiment the concentration of emulsifier
component is in the range of 10 to 40 weight percent of the
metalworking fluid concentrate.
[0039] In yet another embodiment the concentration of vegetable oil
component for lubricity boost is in the range of 2 to 10 weight
percent of the metalworking fluid concentrate.
[0040] In yet another embodiment the concentration of antioxidant
component is in the range of 50 to 500 mg/kg of the metalworking
fluid concentrate.
[0041] In yet another embodiment the concentration of fungicide
component is in the range of 50 to 500 mg/kg of the metalworking
fluid concentrate.
[0042] In yet another embodiment the concentration of extreme
pressure additive component is in the range of 50 to 500 mg/kg of
the metalworking fluid concentrate.
[0043] In yet another embodiment the concentration of anti-rust
component is in the range of 50 to 500 mg/kg of the metalworking
fluid concentrate.
[0044] In yet another embodiment the concentration of co-surfactant
component is in the range of 1 to 10 weight percent of the
metalworking fluid concentrate.
[0045] In yet another embodiment the concentration of coupling
agent component is in the range of 0.5 to 10 weight percent of the
metalworking fluid concentrate.
[0046] In yet another embodiment the concentration of alkali
component is in the range of 0.5 to 8 weight percent of the
metalworking fluid concentrate.
DETAILED DESCRIPTION
[0047] The speed and quality of machining could be greatly
increased if the cutting surface is kept cool and lubricated.
Modern development has led to the introduction of advanced
water-oil emulsion incorporating special chemicals, which
considerably improve its wettability, lubrication, high cooling
power, rust inhibiting and detergency properties. These
concentrates and their emulsions in water are known as `Soluble
Oil` or "soluble metalworking fluid" or "soluble cutting oil" or
"metalworking fluid". It is a water based lubricants or functional
fluid. They are ideal for general machining process where Cooling,
Lubrication, Cleaning and extreme pressure characteristics are
essential requirements. It is useful for metal cutting, drilling,
lathing, grinding or machining.
[0048] There are three main components of this metalworking fluid;
oil, emulsifier, and additives. The soluble metalworking fluids
marketed in form of concentrates, which is converted in to milk
like stable emulsion by mixing it with water before use. The
performances of metalworking fluid depend upon the nature of
emulsion. Soft metal (Aluminium, copper, etc) needs corrosion free
diluted emulsion and hard metal (steel, iron, etc) needs
thick-emulsion for better machining. Small colloidal particles of
oil in water are the key for better performance. The main object of
the present invention is to provide heavy alkylate based less toxic
new composition of metalworking fluids particularly soluble cutting
oil. This development will also provide a new application to the
by-product heavy alkylate and increased the value of this
by-product i.e. heavy alkyl benzene. The components of metalworking
fluid/soluble cutting oil are as follows:
[0049] HEAVY ALKYL BENZENE: Heavy alkyl benzene (HAB) or heavy
alkylate is produced as by-products during the preparation of
linear alkyl benzene sulfonates for detergent industry. The
alkylation reaction of C10-C14 olefin with benzene results in side
reactions to give dialkyl benzenes and alkylated condensed ring
derivatives. These products are generally in the range of 5 to 15
percent of the total alkylates depending upon the reaction
conditions and purity of reactants employed. Heavy alkyl benzene
mainly consists of substituted benzenes as determined by HPLC, UV,
IR and RI analysis given in Table-1. The typical properties such as
density, kinetic viscosity, viscosity index, refractive index, pour
point, molecular weight and distillation characteristics were given
in Table-2. No poly-aromatics or olefin compounds are present in
the heavy alkylates. These heavy alkylates have been acquired from
the Indian market.
TABLE-US-00001 TABLE 1 Typical Relative Content of Alkyl Benzenes
and Alkyl Napthalenes HAB-I HAB-II Components IR UV 254 IR UV 254
Alkyl Benzenes % by wt. 84 .+-. 2 84 .+-. 2 93 .+-. 2 90 .+-. 2
Alkyl Napthalenes % by wt. 15 .+-. 2 16 .+-. 2 7 .+-. 2 10 .+-.
2
TABLE-US-00002 TABLE 2 Typical Characteristics of Heavy Alkyl
Benzenes Characteristics HAB-I HAB-II Density at 15.degree. C.
0.8839 0.8813 K. Viscosity Cst at 40.degree. C. 28.95 26.93 K.
Viscosity Cst at 100.degree. C. 4.50 4.31 Viscosity Index 37 32
Pour Point .degree. C. (-)27 (-)25 Molecular wt. 365 .+-. 5 361
.+-. 5 Distillation range .degree. C. 225-440 226-515 (ASTM D1160)
Refractive index at 20.degree. C. 1.4946 1.4916
[0050] The heavy alkylate have average structure of 20 to 22 carbon
atoms as side alkyl chain attached to benzene ring. Structure of
heavy alkyl benzene, based on analysis, is as follows:
##STR00001##
[0051] Where the position of substitution is not fixed, R+R1=carbon
atom 20, 21, or 22. It is the average. The total carbon number of
heavy alkyl benzene was calculated as A+R=6+20, 6+21 and 6+22 i.e.
26, 27 and 28.
[0052] This HAB is available as waste product or by-product at very
low cost. One example of cost of HAB is $ 40 per 100 litres, which
is very less in comparison to detergent grade LAB thus it is a loss
to manufacturer. Converting it to metalworking fluid, which has a
market rate around $ 240 per 100 litres will compensate for the
loss of manufacture due to unwanted product HAB. So, conversion or
utilization of HAB for metalworking fluid is a value addition to
HAB. HAB has one more benefit over mineral oil that it is a less
toxic product. As per information provided by M/S Gulf Farabi
Petrochemical Co. Ltd, Jubail Industrial City--31961, Kingdom of
Saudi Arabia, MDSD of HAB, CAS#: 84961-70-6, EINECS No.: 284-660-7,
classified HAB as less toxic. As per wikipedia online: European
Council Regulation (EC) 1488/94 led to it being extensively
evaluated. The report concludes that there are no concerns for the
environment or human health. There is no need for further testing
or risk reduction measures beyond those currently practiced. LAB
was therefore de-classified and was removed from Annex 1 in the
28th ATP (Directive 2001/59). Petroleum lube oil is categorized as
toxic product due to presence of condensed ring. HAB component
gives lubricity property to the soluble cutting oil/metalworking
fluid. To replace the petroleum lube or mineral lube with heavy
alkyl benzene is a beneficial step.
[0053] HAB is a non toxic product. As per OSHA-USA, HAB is not
listed in hazardous chemical while mineral oil and its mist are in
hazardous product list. The toxicity of mineral oil or mineral oil
based cutting oil can affect the lungs of experimental animals, and
certain mineral oils are carcinogenic. Petroleum oil is essentially
innocuous when it comes in contact with rabbit corneas. Mineral oil
mists derived from highly refined oils appear to have a low acute
and sub-acute toxicity in experimental animals. The oral LD(50) is
100 mg/kg (rodent). The dermal LD(50) is 150 mg/kg (rodent).
Exposure to mineral oil mists can cause eye, skin, and upper
respiratory tract irritation as well as central nervous system
effects in humans. In addition, certain mineral oils are
carcinogenic in humans. In comparison to mineral product, HAB oral
LD (50) is 15 g/kg. The toxicity of HAB sulfonate oral LD(50) is
438 mg/kg (Rat). So, HAB and HAB sulfonate are less toxic than
mineral oil even highly refined mineral oil. Use of oleate with HAB
will also reduce toxicity. Another benefit in utilizing HAB is
value addition. Adding some vegetable oil or mono-ester from
vegetable oil will be additional advantage but it will increase the
cost of soluble cutting oil concentrate. Its percentage in
concentrate depends on the nature of emulsifier. This component is
needed to provide lubricating properties to the soluble cutting oil
or emulsified metalworking fluid.
[0054] The concentration of heavy alkyl benzene component is in the
range of 40 to 85 weight percent of the metalworking fluid
concentrate.
[0055] EMULSIFIER: Emulsifier is to produce oil-water stable
emulsion but it should not be harmful to metal surface or
operators. The emulsifier component is selected from heavy alkylate
sodium sulfonates, sodium carboxylate (caprylic or mix fatty acid
from vegetable oils particularly from ricebran, neem, mahua,
karanja, castor, linseed and jatropha), ammonium oleate, sodium
oleate, triethanolamine oleate, di-ethanolamine oleate or Dodecyl
Toluene sodium sulfonate or mixtures thereof. Oleate is fatty acid
salt and its combination will be more eco-friendly. Similarly HAB
sulfonate and dodecyl toluene sulfonate are less toxic than
petroleum sulfonate. Emulsifier blended with the oil. It is needed
in formulation to achieve stable water-HAB emulsion. Emulsifier is
necessary for easy formation of HAB-water emulsion, to provide
detergency, wettability and chips removal properties to the
emulsion.
[0056] The concentration range of emulsifier component is 10 to 40
weight percent of the metalworking fluid concentrate.
[0057] LUBRICITY BOOSTER: Lubricity is also known as antiwear. It
protects two rubbing metal surfaces from wear and tear. From the
experiment it was found that lubricity of HAB is quite good but in
oil state. In oil/water emulsion state the percentage of HAB
becomes very low and a suitable lubricity booster is needed to
provide suitable lubricity even in low concentration in emulsion
form. lubricity booster component, a vegetable oil, is mixed in the
metalworking fluid to improve the lubricity characteristic in the
metalworking fluid. Vegetable oil is a triester/triglyceride and
well known for its high lubricity. It can be considered as
additive. It will further reduce the toxicity of the formulation
because vegetable oil is an eco-friendly product. the vegetable oil
component for lubricity booster is a karanja oil, neem oil,
rice-bran oil, Mahua oil, castor oil or mixtures thereof. These are
non edible oil and can used for industrial purpose.
[0058] The concentration of vegetable oil component for lubricity
boost is in the range of 2 to 10 weight percent of the metalworking
fluid concentrate.
[0059] ADDITIVE: the role of additives are very complex. Some time
it is needed to enhance the performance as in the case of extreme
pressure additive, some time it is act as reserve strength as in
the case of lubricity booster, some time it act as reducer of bad
effect as in the case of anti-oxidant/anti-fungal agent/etc. and
these are compatible to each other and with HAB. So, synergistic
combination of additive is needed, which should be compatible to
HAB and its emulsion in water. There are several specialty additive
combinations are available in market but its synergistic effect
with HAB is not known. So, various additives are tested with HAB
and its emulsion in water and some additives are found compatible
with HAB and its emulsion. If this combination is available in
market then there is no harm to utilize those additive packs. The
recommended additive components are:
ANTIOXIDANT: at least one antioxidant/stabilizer additive is mixed
in the fluid is an alkyl phenol or aromatic amine or substituted
tetrazole selected from 2,6-ditertiary butyl phenol, 2,6-ditertiary
p-cresol, Diphenylamine, Tertiary butyl phenol amino tetrazole and
2,6-dioctyl phenylene diamine or mixture thereof. The anti-oxidant
will protect oil and other organic chemical from oxidation to loose
their characteristics.
[0060] The concentration of antioxidant component is in the range
of 0.005 to 0.05 weight percent of metalworking fluid
concentrate.
[0061] FUNGICIDES: a fungicides, is also mixed with fluid to
prevent the mould and bacterial growth in the emulsion. The
fungicide component is a phenol or phenolic acid selected from
o-cresol, phenol, m-cresol and cresylic acid or mixture
thereof.
[0062] The concentration of fungicide component is in the range of
0.005 to 0.05 weight percent of metalworking fluid concentrate.
[0063] EXTREME PRESSURE ADDITIVE: During metalworking like cutting,
rubbing, drilling, etc. the metal surfaces experience high load to
develop cold-welding and deformation of surfaces. It deteriorates
the quality of product. Extreme pressure additive prevents the
cold-welding. At least one extreme pressure additive component is
an organic sulphide or phosphosulfurized metal salt selected from
dibenzyl disulphide, sulfurized vegetable oil, phosphosulfurized
decyl oleate molybdate and phosphothio pentadecyl phenol molybdate
or mixture thereof. Extreme pressure additive, is mixed with the
fluid to protect cutting-tools while metalworking at high
temperature and load.
[0064] The concentration of extreme pressure additive component is
in the range of 0.005 to 0.05 weight percent of metalworking fluid
concentrate.
[0065] ANTIRUST ADDITIVE: In the moist atmosphere of high
temperature, metals are prone to rust particularly iron. To
minimize rusting, antirust component is used at least one antirust
additive is mixed to the fluid for preventing iron metal surface
from rusting. The anti-rust component is a triazole or sulfonate
selected from 1H-benzotriazole, ditertiary butylated
IH-Benzotriazole, calcium petroleum sulfonate and calcium heavy
alkylate sulfonate.
[0066] The concentration of anti-rust component is in between 50 to
500 mg/kg.
[0067] CO-SURFACTANT: It is for increasing the strength of
emulsifier. In concentrate it is useful for solubilization of water
and water soluble component in oil (HAB). In oil/water emulsion it
helps in producing smaller droplets of oil in water and makes it
more stable. A co-surfactant is needed to increase the stability of
oil-water micro-emulsion micelles and to enhance the action of the
emulsifier. The co-surfactant component is an alcohol selected from
isopropanol, n-butanol, iso-butanol, iso-amyl alcohol,
2-ethyl-1-hexanol, mono & poly glycol such as diethylene glycol
and tri ethylene glycol or mixture thereof.
[0068] The concentration of co-surfactant component is in the range
of 1 to 10 weight percent of the metalworking fluid
concentrate.
[0069] COUPLING AGENT: It is a water soluble component to help main
the emulsifier by increasing its range and decreasing the cost of
emulsifier. To enhance oil-water coupling or emulsification. Mixing
of a coupling agent has additional advantage in formation of
oil-water emulsion and act as a booster with main emulsifier. The
coupling agent component is sulfonates (molecular weight less than
350) selected from ligno sulfonate, petroleum sulfonate, sodium
dodecyl benzene sulfonate and sodium lauryl sulphate.
[0070] The concentration of coupling agent component is in the
range of 0.5 to 10 weight percent of the metalworking fluid
concentrate.
[0071] ALKALI: it is optional component and used when water
hardness is higher. If the concentrate is formulated for use in
soft-water (hardness below 100 mg/litre--demineralised water) then
alkali is not needed. If formulation is targeted for higher
hardness then alkali component is needed for emulsion stability.
The quantity of alkali will depend on type of hardness and its
effect on emulsifier precipitation. When by experiment the quantity
of alkali requirement is fixed for one range of hardness then it
will remain constant. Use of extra alkali for soft water will give
solution (more transparent with pale straw color) like emulsion,
which may not be acceptable to market. The pH of the fluid must be
alkaline, preferably 7 to 10 for stability of the components
particularly emulsifiers. So, if required, an aqueous alkali is
added the alkali component is an alkali and alkaline earth metal
salt selected from sodium carbonate, sodium hydrogen carbonate,
calcium carbonate, calcium oxide or mixture thereof.
[0072] The concentration of alkali component is in the range of 0.5
to 8 weight percent of the metalworking fluid concentrate.
[0073] PROCESS FOR CONCENTRATE: For tailoring of the commercially
available heavy alkylate, it should be fractionated by vacuum
distillation, which should be done at 1 bar or 760 mm Hg vacuum and
about 210.degree. C., first 5 to 50 percent by weight cut and last
5 percent by weight cut should be left and 55 to 90 percent by
weight middle cut should be taken for formulation. This is needed
because lower fraction contains un-reacted paraffin and olefin
impurity, which will reduce the emulsion stability. Moreover, the
flash point of this fraction is very low also. It is better to
separate this fraction. Higher/last 5% fraction contains
polymerised, oxidized and high molecular weight compound content.
During high temperature distillation or fractionation some
oxidation, darkening and polymerization may takes place. So,
purification of HAB is required. The methods are micro filtration,
column chromatography, distillation, etc. The preferred method is
to pass HAB from an absorbent column. The absorbent material can be
silica-gel or clay or any other suitable absorbent. After passing
from absorbent column the heavy alkyl benzene is mixed with
selected emulsifier. The Emulsifier should not contain
moisture/water of more than 2%. Mixing should be done at 1200 rpm
stirring of lab stirrer. On larger scale equivalent force is
required. The mixture is homogenized at 30 to 100.degree. C.
(preferably at 70.degree. C. for one hour) for 30 minutes to one
hour with stirring to obtain clear solution. At that temperature
"Lubricity booster" should be added. Then, a coupling agent in the
fluid should be added with continued stirring.
[0074] Now an additive package is added i.e. addition of mixture of
antioxidant, fungicide, extreme pressure additive, antirust
additive and co-surfactant are added. The mixture is further
homogenized for 30 minutes. If the emulsifier has no moisture then
1 to 2% water is added to improve the strength of mixture, which is
a micro-emulsion. Care should be taken to keep the quantity to a
ratio of 100% and further homogenized for 30 minutes. The pH of the
solution should be 8 to 9. If it is lower, then, it is adjusted to
7-9 preferable 8 to 9 by adding sodium carbonate. If pH is higher,
lower it by addition of oleic acid. The solution is cooled down to
room temperature with stirring. After the addition of all the
components the mixture is homogenized. Then it is conditioned by
keeping it at room temperature for 24 hours undisturbed. The final
product is a soluble metalworking fluid concentrate or soluble
cutting oil concentrate. It should be stored in a vessel. It is
verified that this formulation meets the requirement of Bureau of
Indian Standard (BIS) IS 1115. At the time of use the dilute
emulsion of the soluble oil may be prepared by mixing the
concentrate in water with vigorous agitation for 1 to 5 minutes in
the ratio of 20:80 to 80:20 as per requirements of the metal work
and nature of metal. For general metalworking purpose 20:80 ratio
of concentrate: water will be suitable. For production of
water--HAB emulsion or workable soluble cutting oil, concentrate
should be shaken/stirred in water at-least for two minutes.
[0075] EMULSION PREPARATION: emulsion of the soluble cutting oil
may be prepared by: [0076] I. Mixing/stirring the concentrate fluid
with 20 to 80 weight percent water to convert the fluid into
emulsion. [0077] II. Water should be soft i.e. of hardness up to
100. [0078] III. Temperature of water should be in the range of 10
to 40.degree. C. [0079] IV. Stirring should be 1300 RPM for 2 litre
volume or equivalent force. [0080] V. Time should be 2 to 5
minutes. [0081] VI. The emulsion is useful as soluble cutting
oil.
[0082] It will be apparent from the foregoing that the present
invention provides non-toxic lubricant component by using heavy
alkyl benzene and useful for making formulation for metalworking
soluble oil. This invention further provides a suitable new
application for heavy alkyl benzene as a by-product to increase its
value.
[0083] The invention will now be further described by the following
examples, which are given only for the purpose of illustration and
not intended to limit the scope of the invention.
[0084] Although the invention has been described in conjunction
with examples and by reference to the embodiments thereat it is
evident that many alternatives, modifications and variations will
be apparent to those skilled in art in light of the foregoing
description, accordingly it is intended in the invention to embrace
these and all such alternatives, variations and modifications as
may fall with in the spirit and scope of the appended claims.
EXAMPLE 1
[0085] TAILORING OF HEAVY ALKYLATE: 1 Kg. of commercial heavy
alkylates (A), a heavy waste of detergent class linear alkyl
benzene (LAB), was fractionated by vacuum distillation. The heavier
cut, 0.65 Kg. (having 65 weight percent of total alkylate) was
taken for base-stock preparation. The typical properties of the
alkylate are:
Density at 15.degree. C., gm/ml: 0.8805, Kinetic viscosity at
40.degree. C., cst: 52.73, Viscosity index: 40. Refractive index at
20.degree. C.: 1.49026, Pour point: (-)36.degree. C., Molecular
weight: 441.+-.5, Distillation range: 415.degree. C. above,
Poly-aromatics or olefinic compounds: Negligible.
EXAMPLE 2
[0086] TAILORING OF ALKYLATE: 1 Kg. of commercial alkylates (B),
waste alkyl benzene from other stream of detergent class linear
alkyl benzene (LAB), was fractionated by vacuum distillation. The
heavier cut, 0.6 Kg. (having 60 weight percent of total alkylate)
was taken for base-stock preparation. The typical properties of the
alkylate are:
Density at 15.degree. C., gm/ml: 0.8806, Kinetic viscosity at
40.degree. C., cst: 50.11, Viscosity index: 55, Refractive index at
20.degree. C.: 1.49106, Pour point: (-)33.degree. C., Molecular
weight: 428.+-.5, Distillation range: 400.degree. C. above,
Poly-aromatics or olefinic compounds: Negligible
EXAMPLE 3
[0087] TAILORING OF HEAVY ALKYLATE: 1 Kg. of commercial heavy
alkylates (C), a heavy waste fraction of detergent class linear
alkyl benzene (LAB) from other stream, was fractionated by vacuum
distillation. The heavier cut 0.7 Kg (having 70 weight percent of
total alkylate) was taken for base-stock preparation. The typical
properties of the alkylate are:
Density at 15.degree. C., gm/ml: 0.8807, Kinetic viscosity at
40.degree. C., cst: 48.32, Viscosity index: 46, Refractive index at
20.degree. C.: 1.49028, Pour point: (-)30.degree. C., Molecular
weight: 441.+-.5, Distillation range: 395.degree. C. above,
Poly-aromatics or olefinic compounds: Negligible
EXAMPLE 4
Preparation of Base Oil (A)
[0088] Tailored heavy alkylate of example-1 was passed through
silica gel column to remove oxidized product or treated with
absorbent clay such as fuller's earth by mixing and thoroughly
stirred for 50 minutes at 80.degree. C. and filtering it through
G-4 sintered glass funnel. The typical physico-chemical
characteristics of the heavy alkylate are:
Kinetic viscosity at 40.degree. C., cst: 55, Viscosity index: 143,
Oxidation Stability, IP 48/97: Pass (increase in viscosity 0.9%),
Pour point: (-)24.degree. C., RoBOT test 95.degree. C.: 250
minutes, Flash point: 158.degree. C.: Acid number, mg KOH: 0.005,
Poly-aromatics or olefinic compounds: Negligible
EXAMPLE 5
Preparation of Base Oil (B)
[0089] Tailored alkylate from example-2 was passed through silica
gel column to remove oxidized product or treated with absorbent
clay such as fuller's earth by mixing and thoroughly stirred for 50
minutes at 80.degree. C. and filtering it through G-4 sintered
glass funnel. The typical physico-chemical characteristics of the
base oil are:
Kinetic viscosity at 40.degree. C., cst: 52, Viscosity index: 120,
Oxidation Stability, IP 48/97: Pass (increase in viscosity 0.78%),
Pour point: (-)27.degree. C., RoBOT test 95.degree. C.: 210
minutes, Flash point: 155.degree. C., Acid number, mg KOH: 0.005,
Poly-aromatics or olefinic compounds: Negligible
EXAMPLE 6
Preparation of Base Oil (C)
[0090] Tailored alkylate from example-3 was passed through silica
gel column to remove oxidized product or treated with absorbent
clay such as fuller's earth by mixing and thoroughly stirred for 50
minutes at 80.degree. C. and filtering it through G-4 sintered
glass funnel. The typical physico-chemical characteristics of the
blended base oil are:
Kinetic viscosity at 40.degree. C., cst: 53, Viscosity index: 131,
Oxidation Stability, IP 48/97: Pass (increase in viscosity 0.9%),
Pour point: (-)24.degree. C., RoBOT test 95.degree. C.: 220
minutes, Flash point: 156.degree. C., Acid number, mg KOH: 0.005,
Poly-aromatics or olefinic compounds: Negligible
EXAMPLE 7
Preparation of Metalworking Concentrate (A1)
[0091] The base oil (A) 65 grams (in 65 weight percent) was mixed
with heavy alkyl benzene sodium sulfonate 21 gram (in 21 weight
percent) and karanj oil 5 grains (5 weight percent of metalworking
fluid concentrate) as component for lubricity. The mixture was
homogenized at 30 to 100.degree. C. for one hour with stirring to
obtain clear solution. Then ligno sulfonate as coupling agent in
concentration of 1 gram (in 1.0 weight percent of the fluid), 2,6,
ditertiary butyl 4 methyl phenol 0.05 gram (0.05 weight %) as
antioxidant, phenol 0.05 grain (0.05 weight %) as fungicide,
(dibenzyl disulfide 30 weight %+Sulfurized neem oil 30 weight
%+Molybdenum salt of phosphosulfurized decyl oleate 40 weight %) in
0.05 grams (0.05 weight %) as extreme pressure additive,
1H-benzotriazole 0.05 gram (0.05 weight %) as antirust additive and
iso-butanol grams (5.0 weight percent of the metalworking fluid
concentrate) as co-surfactant were added. The mixture was further
homogenized for 30 minutes. 2.7 grams (2.7 weight percent) of water
was added during mixing as solubilization promoter and the fluid
further homogenized for 30 minutes. The pH of the solution was
adjusted to 7-9 by adding sodium carbonate 0.1 gram (0.1 weight
percent). The solution was cooled down to room temperature with
stirring.
EXAMPLE 8
Preparation of Metalworking Concentrate (A2)
[0092] The base oil (A), 60 grams (in 60 weight percent) was mixed
with sodium oleate 24 grams (in 24 weight percent) and neem oil
8.36 grams (8.36 weight percent of metalworking fluid concentrate)
as component for lubricity. The mixture was homogenized at 30 to
100.degree. C. for one hour with stirring to obtain clear solution.
Then sodium dodecyl benzene sulfonate as coupling agent 1.0 gram
(in concentration of 1.0 weight percent of the fluid), 2,6,
ditertiary butyl phenol 0.006 gram (0.006 weight %) as antioxidant,
cresylic acid 0.005 grain (0.005 weight %) as fungicide, (dibenzyl
disulfide 30 weight %+Sulfurized neem oil 30 weight %+Molybdenum
salt of phosphosulfurized decyl oleate 40 weight %) 0.025 gram
(0.025 weight %) as extreme pressure additive, ditertiary butylated
1H-benzotriazole 0.004 gram (0.004 weight %) as antirust additive
and isobutanol 5.5 grams (5.5 weight percent of the metalworking
fluid concentrate) as co-surfactant were added. The mixture was
further homogenized for 30 minutes. 3.0 grams (3.0 weight percent)
of water was added during mixing as solubilization promoter and
further homogenized for 30 minutes. The pH of the solution was
adjusted to 7-9 by adding sodium carbonate 0.1 gram (0.1 weight %).
The solution was cooled down to room temperature with stirring.
EXAMPLE 9
Preparation of Metalworking Concentrate (A3)
[0093] The base oil (A) in 65 grams (65 weight percent) was mixed
with dodecyl toluene sodium sulfonate in 20 grams (20 weight
percent) and ricebran oil 1.78 grams (1.78 weight percent of
metalworking fluid concentrate) as component for lubricity. The
mixture was homogenized at 30 to 100.degree. C. for one hour with
stirring to obtain clear solution. Then lauryl sulfonate as
coupling agent in concentration of 5 grams (5 weight percent of the
fluid), 2,6, ditertiary p-cresol 0.005 grams (0.005 weight %) as
antioxidant, cresylic acid 0.005 gram (0.005 weight %) as
fungicide, (dibenzyl disulfide 30 weight %+Sulfurized neem oil 30
weight %+Molybdenum salt of phosphosulfurized decyl oleate 40
weight %) 0.005 gram (0.005 weight %) as extreme pressure additive,
calcium petroleum sulfonate 0.005 gram (0.005 weight %) as antirust
additive and (iso amyl alcohol+ethylene glycol 50/50 by weight) 5
grams (in 5 weight percent of the metalworking fluid concentrate)
as co-surfactant were added. The mixture was further homogenized
for 30 minutes. 2.7 grams (2.7 weight percent) of water was added
during mixing as solubilization promoter and further homogenized
for 30 minutes. The pH of the solution was adjusted to 7-9 by
adding calcium oxide 0.5 gram (0.5 weight %). The solution was
cooled down to room temperature with stirring.
EXAMPLE 10
Preparation of Metalworking Concentrate (A4)
[0094] The base oil (A), 51 gram (in 51 weight percent) was mixed
with sodium salt of fatty acid from ricebran oil (carboxylate) 30
grams (in 30 weight percent) and castor oil 5 grams (5 weight
percent of metalworking fluid concentrate) as component for
lubricity. The mixture was homogenized at 30 to 100.degree. C. for
one hour with stirring to obtain clear solution. Then sodium
petroleum sulfonate (molecular weight 400-430) as coupling agent in
concentration of 5.417 grams (5.417 weight percent of the fluid
concentrate), diphenyl amine 0.048 grams (0.048 weight %) as
antioxidant, o-cresol 0.005 grams (0.005 weight %) as fungicide,
(dibenzyl disulfide 30 weight %+Sulfurized neem oil 30 weight
%+Molybdenum salt of phosphosulfurized pentadecyl phenol 40 weight
%) 0.025 grams (0.025 weight %) as extreme pressure additive,
calcium heavy alkyl benzene sulfonate 0.005 gram (0.005 weight %)
as antirust additive and (iso butanol+ethylene glycol 50/50 by
weight) in 5 grams (5 weight percent of the metalworking fluid) as
co-surfactant were added. The mixture was further homogenized for
30 minutes. 3 grams (3.0 weight percent) of water was added during
mixing as solubilization promoter and further homogenized for 30
minutes. The pH of the solution was adjusted to 7-9 by adding
sodium carbonate 0.5 grain (0.5 weight %). The solution was cooled
down to room temperature with stirring.
EXAMPLE 11
Preparation of Metalworking Concentrate (A5)
[0095] The base oil (A), 50 gram (in 50 weight percent) was mixed
with sodium salt of fatty acid from neem oil (carboxylate) 31.16
grams (in 31.16 weight percent) and karanja oil 5 gram (5 weight
percent of metalworking fluid concentrate) as component for
lubricity. The mixture was homogenized at 30 to 100.degree. C. for
one hour with stirring to obtain clear solution. Then ligno
sulfonate as coupling agent 5 gram (in concentration of 5 weight
percent of the fluid), ditertiary butyl phenol amino tetrazole
0.013 gram (0.013 weight %) as antioxidant, phenol 0.005 gram
(0.005 weight %) as fungicide, (dibenzyl disulfide 30 weight
%+Sulfurized neem oil 30 weight %+Molybdenum salt of
phosphosulfurized decyl oleate 40 weight %) 0.009 gram (0.009
weight %) as extreme pressure additive, ditertiary butyl
1H-benzotriazole 0.013 gram (0.013 weight %) as antirust additive
and (isobutanol+ethylene glycol 50/50 by weight) 5 grains (in 5
weight percent of the metalworking fluid concentrate) as
co-surfactant were added. The mixture was further homogenized for
30 minutes. 3.3 grams (3.3 weight percent) of water was added
during mixing as solubilization promoter and further homogenized
for 30 minutes. The pH of the solution was adjusted to 7-9 by
adding calcium carbonate 0.5 grain (0.5 weight %). The solution was
cooled down to room temperature with stirring.
EXAMPLE 12
Preparation of Concentrate (B1)
[0096] The base oil (B) 62 grams (in 62 weight percent) was mixed
with heavy alkyl benzene sodium sulfonate in 20 grams (20 weight
percent) and neem oil 5 grams (5 weight percent of metalworking
fluid concentrate) as component for lubricity. The mixture was
homogenized at 30 to 100.degree. C. for one hour with stirring to
obtain clear solution. Then sodium dodecyl benzene sulfonate as
coupling agent in concentration of 5 grams (5 weight percent of the
fluid), 2,6, dioctyl phenylene diamine 0.005 gram (0.005 weight %)
as antioxidant, cresylic acid 0.005 gram (0.005 weight %) as
fungicide, dibenzyl disulfide 0.005 gram (0.005 weight %) as
extreme pressure additive, 1H-benzotriazole 0.005 gram (0.005
weight %) as antirust additive and (iso butanol+isopropyl alcohol
50/50 by weight) 5 grams (in 5 weight percent of the metalworking
fluid concentrate) as co-surfactant were added. The mixture was
further homogenized for 30 minutes. 2.5 grams (2.5 weight percent)
of water was added during mixing as solubilization promoter and
further homogenized for 30 minutes. The pH of the solution was
adjusted to 7-9 by adding sodium carbonate 0.48 gram (0.48 weight
%). The solution was cooled down to room temperature with
stirring.
EXAMPLE 13
Preparation of Metalworking Concentrate (B2)
[0097] The base oil (B) 63 grams (in 63 weight percent) was mixed
with heavy alkyl benzene sodium sulfonate 21 grams (in 21 weight
percent) and ricebran oil 2 gram (2 weight percent of metalworking
fluid concentrate) as component for lubricity. The mixture was
homogenized at 30 to 100.degree. C. for one hour with stirring to
obtain clear solution. Then (ligno sulfonate+sodium dodecyl benzene
sulfonate 50/50 by weight) as coupling agent 5.5 grams (in
concentration of 5.5 weight percent of the fluid), 2,6, ditertiary
butyl 4 methyl phenol 0.043 gram (0.043 weight %) as antioxidant,
m-cresol 0.003 gram (0.003 weight %) as fungicide, Molybdenum salt
of phosphosulfurized decyl oleate 0.045 gram (0.045 weight %) as
extreme pressure additive, ditertiary butyl 1H-benzotriazole 0.009
gram (0.009 weight %) as antirust additive and (iso
butanol+ethylene glycol 50/50 by weight) 5 grams (in 5 weight
percent of the metalworking fluid concentrate) as co-surfactant
were added. The mixture was further homogenized for 30 minutes. 2.9
grains (2.9 weight percent) of water was added during mixing as
solubilization promoter and further homogenized for 30 minutes. The
pH of the solution was adjusted to 7-9 by adding sodium carbonate
0.5 gram (0.5 weight %). The solution was cooled down to room
temperature with stirring.
EXAMPLE 14
Preparation of Metalworking Concentrate (B3)
[0098] The base oil (B) 52 grains (in 52 weight percent) was mixed
with triethanolamine oleate in 30 grams (30 weight percent) and
acetylated castor oil 5 grams (5 weight percent of metalworking
fluid concentrate) as component for lubricity. The mixture was
homogenized at 30 to 100.degree. C. for one hour with stirring to
obtain clear solution. Then (ligno sulfonate+sodium dodecyl benzene
sulfonate 50/50 by weight) as coupling agent in concentration of 5
grams (5 weight percent of the fluid), (2,6, ditertiary butyl 4
methyl phenol+diphenyl amine 50/50 by weight) 0.028 grams (0.028
weight %) as antioxidant, cresylic acid 0.01 gram (0.01 weight %)
as fungicide, Molybdenum salt of phosphosulfurized pentadecyl
phenol 0.027 gram (0.027 weight %) as extreme pressure additive,
1H-benzotriazole 0.025 gram (0.025 weight %) as antirust additive
and (iso butanol+ethylene glycol 50/50 by weight) 5 grain (in 5
weight percent of the metalworking fluid concentrate) as
co-surfactant were added. The mixture was further homogenized for
30 minutes. 2.41 grams (2.41 weight percent) of water was added
during mixing as solubilization promoter and further homogenized
for 30 minutes. The of the solution was adjusted to 7-9 by adding
calcium oxide 0.5 grain (0.5 weight %). The solution was cooled
down to room temperature with stirring.
EXAMPLE 15
Preparation of Metalworking Concentrate (B4)
[0099] The base oil (B) 50 grams (in 50 weight percent) was mixed
with diethanolamine oleate 31 grams (in 31 weight percent) and neem
oil 5 grams (5 weight percent of metalworking fluid concentrate) as
component for lubricity. The mixture was homogenized at 30 to
100.degree. C. for one hour with stirring to obtain clear solution.
Then ligno sulfonate as coupling agent in concentration of 5 grams
(5 weight percent of the fluid), (2,6, ditertiary butyl 4 methyl
phenol+diphenyl amine 50/50 by weight) 0.028 gram (0.028 weight %)
as antioxidant, o-cresol 0.018 gram (0.018 weight %) as fungicide,
(dibenzyl disulfide 30 weight %+Sulfurized neem oil 30 weight
%+Molybdenum salt of phosphothio pentadecyl phenol 40 weight %)
0.027 gram (0.027 weight %) as extreme pressure additive,
ditertiary butyl 1H-benzotriazole 0.027 gram (0.027 weight %) as
antirust additive and (iso butanol+ethylene glycol 50/50 by weight)
5 grams (in 5 weight percent of the metalworking fluid concentrate)
as co-surfactant were added. The mixture was further homogenized
for 30 minutes. 3.4 grams (3.4 weight percent) of water was added
during mixing as solubilization promoter and further homogenized
for 30 minutes. The pH of the solution was adjusted to 7-9 by
adding calcium carbonate 0.5 gram (0.5 weight %). The solution was
cooled down to room temperature with stirring.
EXAMPLE 16
Preparation of Metalworking Concentrate (B5)
[0100] The base oil (B) 54 grams (in 54 weight percent) was mixed
with sodium salt of fatty acid from karanj oil (carboxylate) 27.9
grams (in 27.9 weight percent) and neem oil 5 grams (5 weight
percent of metalworking fluid concentrate) as component for
lubricity. The mixture was homogenized at 30 to 100.degree. C. for
one hour with stirring to obtain clear solution. Then lauryl
sulfonate as coupling agent in concentration of 5 grams (5 weight
percent of the fluid), (2,6, ditertiary butyl 4 methyl
phenol+diphenyl amine 50/50 by weight) 0.035 grams (0.035 weight %)
as antioxidant, cresylic acid 0.005 grams (0.005 weight %) as
fungicide, dibenzyl disulfide 0.035 gram (0.035 weight %) as
extreme pressure additive, 1H-benzotriazole 0.025 gram (0.025
weight %) as antirust additive and (iso butanol+ethylene glycol
50/50 by weight) 5 grams (in 5 weight percent of the metalworking
fluid concentrate) as co-surfactant were added. The mixture was
further homogenized for 30 minutes. 3.4 grams (3.4 weight percent)
of water was added during mixing as solubilization promoter and
further homogenized for 30 minutes. The pH of the solution was
adjusted to 7-9 by adding sodium carbonate 0.5 gram (0.5 weight %).
The solution was cooled down to room temperature with stirring.
EXAMPLE 17
Preparation of metalworking concentrate (C1)
[0101] The base oil (C) 51 grams (in 51 weight percent) was mixed
with sodium oleate 30 grams (in 30 weight percent) and neem oil 5
grams (5 weight percent of metalworking fluid concentrate) as
component for lubricity. The mixture was homogenized at 30 to
100.degree. C. for one hour with stirring to obtain clear solution.
Then ligno sulfonate as coupling agent in concentration of 5 grams
(5 weight percent of the fluid), (2,6, ditertiary butyl 4 methyl
phenol+diphenyl amine 50/50 by weight) 0.035 gram (0.035 weight %)
as antioxidant, (cresylic acid+phenol 50/50 by weight) 0.005 gram
(0.005 weight %) as fungicide, (dibenzyl disulfide 30 weight
%+Sulfurized neem oil 30 weight %+Molybdenum salt of
phosphosulfurized decyl oleate 40 weight %) 0.035 gram (0.035
weight %) as extreme pressure additive, ditertiary butyl
1H-benzotriazole 0.025 gram (0.025 weight %) as antirust additive
and (iso butanol+ethylene glycol 50/50 by weight) 5 grams (in 5
weight percent of the metalworking fluid concentrate) as
co-surfactant were added. The mixture was further homogenized for
30 minutes. 3.4 grams (3.4 weight percent) of water was added
during mixing as solubilization promoter and further homogenized
for 30 minutes. The pH of the solution was adjusted to 7-9 by
adding calcium carbonate 0.5 gram (0.5 weight %). The solution was
cooled down to room temperature with stirring.
EXAMPLE 18
Preparation of Metalworking Concentrate (C2)
[0102] The base oil (C) 54 grams (in 54 weight percent) was mixed
with mixed emulsifier (heavy alkyl benzene sodium sulfonate 50
weight %+sodium oleate 50 weight %) 27 grams (in 27 weight percent)
and karanja oil 5 grams (5 weight percent of metalworking fluid
concentrate) as component for lubricity. The mixture was
homogenized at 30 to 100.degree. C. for one hour with stirring to
obtain clear solution. Then ligno sulfonate as coupling agent 5
grams (in concentration of 5 weight percent) of the fluid, (2,6,
ditertiary butyl 4 methyl phenol+diphenyl amine 50/50 by weight)
0.035 grain (0.035 weight %) as antioxidant, o-cresol 0.005 grain
(0.005 weight %) as fungicide, (dibenzyl disulfide 30 weight
%+Sulfurized neem oil 30 weight %+Molybdenum salt of
phosphosulfurized decyl oleate 40 weight %) 0.025 gram (0.025
weight %) as extreme pressure additive, 1H-benzotriazole 0.035
grain (0.035 weight %) as antirust additive and (iso
butanol+ethylene glycol 50/50 by weight) 5 grams (in 5 weight
percent of the metalworking fluid concentrate) as co-surfactant
were added. The mixture was further homogenized for 30 minutes. 3.4
grams (3.4 weight percent) of water was added during mixing as
solubilization promoter and further homogenized for 30 minutes. The
pH of the solution was adjusted to 7-9 by adding sodium carbonate
0.5 gram (0.5 weight %). The solution was cooled down to room
temperature with stirring.
EXAMPLE 19
Preparation of Metalworking Concentrate (C3)
[0103] The base oil (C) 52 grams (in 52 weight percent) was mixed
with sodium salt of acetylated fatty acid from castor oil
(carboxylate) 29 grams (in 29 weight percent) and neem oil 5 grams
(5 weight percent of metalworking fluid concentrate) as component
for lubricity. The mixture was homogenized at 30 to 100.degree. C.
for one hour with stirring to obtain clear solution. Then sodium
dodecyl benzene sulfonate as coupling agent in concentration of 5
gram (5 weight percent of the fluid), (2,6, ditertiary butyl 4
methyl phenol+diphenyl amine 50/50 by weight) 0.025 gram (0.025
weight %) as antioxidant, phenol 0.005 gram (0.005 weight %) as
fungicide, dibenzyl disulfide 0.035 gram (0.035 weight %) as
extreme pressure additive, ditertiary butyl 1H-benzotriazole 0.035
gram (0.035 weight %) as antirust additive and (iso
butanol+ethylene glycol 50150 by weight) 5 grams (in 5 weight
percent of the metalworking fluid concentrate) as co-surfactant
were added. The mixture was further homogenized for 30 minutes. 3.4
gram (3.4 weight percent) of water was added during mixing as
solubilization promoter and further homogenized for 30 minutes. The
pH of the solution was adjusted to 7-9 by adding calcium carbonate
0.5 gram (0.5 weight %). The solution was cooled down to room
temperature with stirring.
EXAMPLE 20
Preparation of Metalworking Concentrate (C4)
[0104] The base oil (C) 59 grams (in 59 weight percent) was mixed
with mixed emulsifier (heavy alkyl benzene sodium sulfonate in 33
weight %+sodium oleate in 33 weight %+triethanolamine oleate in 34
weight %) 22 grams (in 22 weight percent) and karanja oil 5 grams
(5 weight percent of metalworking fluid concentrate) as component
for lubricity. The mixture was homogenized at 30 to 100.degree. C.
for one hour with stirring to obtain clear solution. Then ligno
sulfonate as coupling agent in concentration of 5 grams (5 weight
percent) of the fluid, (2,6, ditertiary butyl 4 methyl
phenol+diphenyl amine 50/50 by weight) 0.035 grams (0.035 weight %)
as antioxidant, m-cresol 0.005 gram (0.005 weight %) as fungicide,
(dibenzyl disulfide 30 weight %+Sulfurized neem oil 30 weight
%+Molybdenum salt of phosphosulfurized decyl oleate 40 weight %)
0.025 gram (0.025 weight %) as extreme pressure additive,
(1H-benzotriazole+calcium heavy alkylbenzene sulfonate 50/50 by
weight) 0.035 gram (0.035 weight %) as antirust additive and
(diethylene glycol+ethylhexanol 50/50 by weight) 5 grams (in 5
weight percent of the metalworking fluid concentrate) as
co-surfactant were added. The mixture was further homogenized for
30 minutes. 3.4 gram (3.4 weight percent) of water was added during
mixing as solubilization promoter and further homogenized for 30
minutes. The pH of the solution was adjusted to 7-9 by adding
sodium carbonate 0.5 gram (0.5 weight %). The solution was cooled
down to room temperature with stirring.
EXAMPLE 21
Preparation of Metalworking Concentrate (C5)
[0105] The base oil (C) 53 grams (in 53 weight percent) was mixed
with mixed emulsifier sodium salt of fatty acid from (karanj oil 50
weight %+ricebran oil 50 weight %) (carboxylate) 28 grams (in 28
weight percent) and ricebran oil 5 grams (5 weight percent of
metalworking fluid concentrate) as component for lubricity. The
mixture was homogenized at 30 to 100.degree. C. for one hour with
stirring to obtain clear solution. Then ligno sulfonate in
concentration of 5 gram (5 weight percent of the fluid), (2,6,
ditertiary butyl 4 methyl phenol+diphenyl amine 50/50 by weight)
0.035 gram (0.035 weight %) as antioxidant, cresylic acid 0.005
gram (0.005 weight %) as fungicide, (dibenzyl disulfide 30 weight
%+Sulfurized neem oil 30 weight %+Molybdenum salt of
phosphosulfurized pentadecyl phenol 40 weight %) 0.025 grain (0.025
weight %) as extreme pressure additive, 1H-benzotriazole 0.035
grain (0.035 weight %) as antirust additive and diethylene glycol 5
grams (in 5 weight percent of the metalworking fluid concentrate)
as co-surfactant were added. The mixture was further homogenized
for 30 minutes. 3.4 grams (3.4 weight percent) of water was added
during mixing as solubilization promoter and further homogenized
for 30 minutes. The pH of the solution was adjusted to 7-9 by
adding sodium hydrogen carbonate 0.5 grain (0.5 weight %). The
solution was cooled down to room temperature with stirring.
EXAMPLE 22
Preparation of Soluble Cutting Oil (Metalworking Fluid)
Emulsion
[0106] The soluble oil concentrate then mixed with water in various
ratio and shaken to produce oil-water emulsion. This emulsion was
evaluated for its different characteristics. There are thousands of
results out of which results of only three samples are given here.
The soluble oil concentrate A1, B1 and C1 are diluted in water of
harness 400 mg/litre. 10 grams of soluble oil concentrate was mixed
with 90 ml of water and stirred for 2 minutes according to standard
method. It was found that the characteristics of the concentrate
and emulsion are at par with the specifications.
EXAMPLE 23
TABLE-US-00003 [0107] TYPICAL CHARACTERISTICS OF SOLUBLE OIL Total
Acid WSD Reactable K. Viscosity No- mg on Flash Sulphur SN
Formulation 40.degree. C. - Cst KOH Ash % HFRR Clarity
Point-.degree. C. at 100.degree. C. 1 A-I 23.3 NIL 0.009 0.368
Clear 210 NIL 2 B-I 26.2 NIL 0.008 0.473 Clear 215 NIL 3 C-I 24.5
NIL 0.006 0.396 Clear 213 NIL TYPICAL EVALUATION OF SOLUBLE OIL
Cast Saponification Copper Deposit Emulsion iron rust value - Low
temp Frothing SN Formulation corrosion test stability Test mg KOH
Stability Test 1 A-I <1 NIL Pass Pass 4.8 Pass Pass 2 B-I <1
NIL Pass Pass 4.5 Pass Pass 3 C-I <1 NIL Pass Pass 4.6 Pass
Pass
* * * * *