SEMI-SYNTHETIC AND SYNTHETIC COOLANT SUBSTITUTION
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| Overview: | Semi-synthetic and synthetic
coolants typically have longer useful lives, and thus require fewer
changeouts than conventional oil-based cutting fluids. Semi-synthetic and
synthetic coolants are also more resistant to problems such as rapid
bacterial growth, which is often the reason coolants are disposed of
prematurely. At a typical shop, the personnel change cooling fluid when it
emits a rancid odor. The odor is caused by anaerobic bacterial growth and
does not indicate that the cutting fluid has lost its cooling and
lubricating properties. However, the presence of these microorganisms over
a period of time can cause coolants to degrade. The resulting adverse
condition of the coolant include foul odors, clogged transfer lines,
changes in pH, and splitting emulsions. These conditions can affect the
quality of the final product.
The coolant is typically removed from the cutting machine's sumps when the odor of the bacterial growth bothers shop personnel. On average, the coolant is removed from the cutting machines every 3 weeks. The time between fluid change is usually 2 to 3 weeks in the summer months, while it is extended to 3 to 4 weeks during the winter. This is due to the variance of temperature and moisture, both of which affect the rate of bacterial growth. Several DOD facilities have switched to a semi-synthetic coolant with considerable success. Personnel at Portsmouth Naval Shipyard in New Hampshire, Code 120, have tested semi-synthetic coolants including Castrol TLS-995 and Blaser SwissLube 400. This effort was conducted as part of a NAVSEA machine shop modernization program to determine cutting fluid pollution prevention alternatives among eight naval shipyards. The results showed that the semi-synthetic coolant had been in use for over 6 months without changeout or experiencing the bacterial growth problems encountered at other facilities which use oil-based coolants. By switching to a semi-synthetic coolant that would last 6 months, an activity can reduce the amount of coolant waste by almost 90%, as evidenced at NADEP Norfolk. Both synthetic and conventional oil-based coolants may be characterized as hazardous due to the product’s formulation. Waste reduction is achieved as a result of longer service life of synthetic coolants compared to oil-based coolants. Either formulation may be a characteristic hazardous waste. Under 40 CFR Part 279, "Used Oil Management Standards," used oil is defined as oil refined from crude (or any synthetic oil), used as a lubricating, hydraulic, or heat transfer fluid, and has become contaminated through use. Coolants may be managed under these regulatory provision and recycled as opposed to disposed. | |||||||||||||||||||||
| Compliance Benefit: | A facility will use less
semi-synthetic and synthetic coolants than a traditional coolant since
they do not need to be changed out as often. Since less coolant should be
stored on site, a facility may decrease the possibility they will meet any
reporting thresholds for those chemical under 40 CFR 355 and EO
12856.
The compliance benefits listed here are only meant to be used as a general guideline and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g. the amount of workload involved. | |||||||||||||||||||||
| Materials Compatibility: |
No materials compatibility issues were identified. | |||||||||||||||||||||
| Safety and Health: | There are mild dermal
and eye irritation effects associated with these compounds. Personal
protective equipment should be used. Consult your local industrial health
specialist, your local health and safety personnel, and the appropriate
MSDS prior to implementing this technology.
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| Benefits: |
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| Disadvantages: |
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| Economic Analysis: | The extra expenditure in
purchasing semi-synthetic and synthetic coolants is offset by the savings
incurred from by the reduced frequency of coolant replacement. For this
economic analysis, the synthetic cutting fluid prices were provided by DLA
and the oil-based cutting fluid prices were obtained through vendors. The
labor time for replacement of cutting fluids and recycling data were based
on estimates provided by the Portsmouth Naval Shipyard
Assumptions:
Annual Operating Cost Comparison of Synthetic and Oil-based Cutting Fluids
Economic Analysis Summary Annual Savings for Synthetic: $15,872 Click Here to view an Active Spreadsheet for this Economic Analysis and Enter Your Own Values. To return from the Active Spreadsheet, click the reverse arrow in the Tool Bar. | |||||||||||||||||||||
| ApprovingAuthority: | Approval is controlled
locally and should be implemented only after engineering approval has been
granted. Major claimant approval is not required.
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| NSN/MSDS: |
*There are multiple MSDSs for most
NSNs. | ||||||||||
| Points of Contact: | Navy: Mr. Richard Collette Shop 31, Bldg.300 Portsmouth Naval Shipyard Portsmouth, NH 03804-5000 Phone: (207) 438-5330 Fax: (207) 438-5321 Email: lightbodyb@psns.navy.mil |
| Vendors: | This is not meant to be a complete
list, as there are other manufacturers of this type of
equipment.
Castrol Industrial East Inc. 775 Louis Dr. Warminster, PA 18974 Phone: (215) 443-5220 or (800) 464-3070 Fax: (215) 443-7094 URL: http://www.castrolindustrialna.com/ |
| Milacron Manufacturing
Technologies 2090 Florence Ave. P.O. Box 63716 Cincinnati, OH 45206-2425 Phone: (513) 487-5000 Fax: (513) 487-5057 URL: http://www.milacron.com/ | |
| Spartan Chemical Co., Inc. 1110 Spartan Drive Maumee, OH 43537-0110 Phone: (800) 537-8990 or (419) 531-5551 Fax: (419) 536-8423 URL: http://www.spartanchemical.com/ | |
| D. A. Stuart Inc. 43 Upton Road Scarborough, Ontario, M1L2C1 CANADA Phone: (416) 757-3226 FAX: (416) 757-3220 URL: http://www.dastuart.com/
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| Sources: | None listed
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