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: | The
substitution of synthetic and semi-synthetic coolants for conventional coolants may
allow for longer intervals between change outs, thereby reducing coolant consumption and waste
generation. If the waste is determined to be hazardous, then generating less of
it helps facilities meet the requirements of waste reduction under RCRA, 40 CFR 262 and
Executive Order 13148, and may also help facilities reduce both their
generator status and the number of applicable requirements (i.e.,
recordkeeping, reporting, inspections, transportation, accumulation time,
emergency prevention and preparedness, emergency response) under
RCRA, 40 CFR 262. Moreover, since less coolant would need to be stored
on site, a facility is less likely to meet the reporting thresholds of
SARA Title III (40 CFR 300, 355, 370, and 372).
A decrease in coolant stored on site may also put a facility
below threshold amounts for the requirement to develop and implement a
Spill Prevention, Control and Countermeasure Plan under 40 CFR 112.
The compliance benefits listed here are only meant to be used as general guidelines 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.
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| Safety and Health: | Mild dermal
and eye irritation effects are 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:
Table 1. Annual Operating Cost Comparison of Synthetic and Oil-Based Cutting Fluids
Economic Analysis Summary
Click
Here to view an Active Spreadsheet for this Economic Analysis and
Enter Your Own Values. | |||||||||||||||||||||
| NSN/MSDS: |
*There are multiple MSDSs for most NSNs. The MSDS (if shown above) is only meant to serve as an example. To return from the MSDS, click the Back arrow on the Tool Bar. | |||||||||||||||||||||
| Approving Authority: | Appropriate
authority for making process changes should always be sought and obtained prior to
procuring or implementing any of the technologies identified herein.
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| Points of Contact: | For more information | |||||||||||||||||||||
| Vendors: | This is not meant to be a complete
list, as there are other manufacturers of this type of
equipment.
D. A. Stuart Inc. 4580 Weaver Parkway Warrenville, IL 60555 Phone: (630) 393-0833 FAX: (630) 393-8888 E-mail: sales@dastuart.net Service: Manufactures Dascool 2003 | |||||||||||||||||||||
| Milacron Inc. 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/ | ||||||||||||||||||||||
| 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/
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| Related Links: |
None
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| Sources: | Vendors, August 2002. |