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Metalworking Fluid
Additives
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ly, in order to receive that designation,
they must perform equal to or better MWF ADDITIVES AFFECTED BY NEW REGULATIONS
than conventional alternatives. About
5 percent of all lubricants in the EU According to John Nussbaumer, Dover Chemical’s technical service manager for metal-
are now being sold as EAL oil-in-water working, future regulations regarding MWFs will most likely affect the area of chlorinated
emulsions, primarily as vegetable-based paraffins (CPs). Chlorinated paraffins, which are a staple of the metalworking fluid indus-
formulations, and their market share is try, work in a wide range of metalworking applications in both water-based and oil-based
growing. formulations. There are currently four classifications of CPs:
Minimum quantity lubrication • Short-chain. Those with a carbon chain distribution <14
(MQL) techniques represent another
growing class of EALs. MQL typical- • Mid-chain. Those with a carbon chain distribution of 14-17
ly involves sprays of compressed air • Long-chain. Those with a carbon chain distribution of 18-20
and a small amount of oil to provide • Very long-chain. Those with a carbon chain distribution that is >20 (this is a
the function of an MWF without the new classification).
large amount of waste. The limita-
tion of MQL systems is that they don’t “We have already seen short-chain CPs eliminated from use in MWFs,” Nussbaumer
cool well, so they are only suitable for says. “Currently the mid- and long-chain CPs are under review. However, it does not
low-speed, low-impact machining op- appear that any action will be taken on either classification in the near to midterm. The
erations that do not require significant main focus on mid-chain CPs likely will center on the amount of short-chain olefin that
heat removal. Current research is fo- is present in C-14 alpha olefin when it is produced. The content of short-chain olefin is
cused on developing new approaches already typically <1 percent. Very long-chain CPs will be reviewed at a later date, but it
that extend the applicability of MQL to does appear that no action will be taken on very long-chain CPs.”
more demanding machining processes.9
HEALTH EFFECTS
MWFs are vulnerable to microorganism Inhalation of MWF mist or aerosol on the adverse effects of long-term in-
contamination. This can create direct may cause lung, nose and throat irri- halation exposure to a commercially
health risks for workers from infection, tation. In general respiratory irritation available fluid will no doubt lead to
inhalation of bio-aerosols and indirect involves some type of chemical interac- further questions about metalworker
risks from skin contact with biocides tion between the MWF and the human health associated with inhalation ex-
used to control the microorganisms. respiratory system. Exposure to MWFs posure to cutting fluids. It will also
Some 1.2 million workers in machine has also been associated with asthma. be interesting to see what short- to
finishing, machine tooling and other Work-related asthma is one of today’s medium-term impact the recently an-
metalworking and metal-forming op- most prevalent occupational disorders, nounced changes to chemical control
erations are potentially exposed at any leading to significant costs in health- legislation in Taiwan and Korea will
time.10 care and workers compensation.13 have on the Asia-Pacific region.”
Skin and airborne exposures to Studies that may not be relevant
MWFs have been implicated in irrita- today have suggested an association THE PARTICULAR PROBLEM OF
tion of the skin, lungs, eyes, nose and between working with MWF chem- BIOCIDES AND CHLORINE
throat. Conditions such as dermatitis, istry and practices that were phased Without biocides, water-based MWFs
acne, asthma, hypersensitivity pneu- out decades ago and certain cancers.14 would be breeding grounds for bacterial
monitis, irritation of the upper-respi- Because of a demonstrated latency pe- and fungal organisms. These organisms
ratory tract and a variety of cancers riod, these studies have relied on health would lead to metabolic destruction
have been associated with exposure to reports of workers exposed decades of some active ingredients and reduce
MWFs.11 The severity of health prob- earlier when airborne concentrations MWF performance. While ordinary
lems is dependent on factors such as of MWFs were much higher than they microbes pose little infection risk for
the kind of fluid, the degree and type of are today. The composition of MWFs workers, particularly hazardous species
contamination and the level and dura- also has changed dramatically over the have caused worker illness. Thus, water-
tion of the exposure.12 years—with many chemicals (i.e., ni- based MWFs require biocides to curb
Two types of skin diseases associ- trite) since removed because of health these organisms. No one would argue
ated with MWF exposure are acne and concerns.15,16 that biocides are effective. The goal is
contact dermatitis. People working Mick Wragg, senior global product to minimize biocides because excessive
with water-based, synthetic and semi- steward for The Lubrizol Corp., says, concentrations carry their own health
synthetic MWFs are most at risk for “The recent publication in the U.S. by risks, ranging from acute dermatitis to
developing contact dermatitis. The National Toxicology Program17 more severe conditions.
Wolves have about 280 million scent cells. Humans have about 5 million. 43
We create
chemistry
that makes
lubricant
formulators love
ester and PAG
base stocks.
www.basf.com/lubes
Nussbaumer concludes, “Another and downstream users as a result of them so benign that most label warnings
issue with CP alternatives is appear- classification and labeling legislation, and most health hazards are gone leaves
ance. The vast majority of CPs are very especially in the European market. Spe- a relatively ineffective product.”
light in color. Most of the CP alterna- cifically there are two types of chemistry Nussbaumer says, “Right now at
tives have an ASTM color that is darker. included in this: formaldehyde-releasing Dover Chemical we are focusing on
This becomes an issue when the end- biocides where the concern is associ- synergies. When we talk about syner-
user needs to see what is happening at ated with the carcinogenic potential gies, we are looking at the combina-
the tool/workpiece interface. Another of released formaldehyde and boron- tion of additives to enhance the per-
area where CPs are more effective than containing ionic compounds where the formance of a fluid. We do not see the
their alternatives is cost. There is cur- concern is associated with the alleged use of mid-chain chlorinated paraffins
rently no cost-effective CP alternative reproductive hazard of boric acid.” being affected by regulations in the
offered to the market.” near to mid-term. We see the use of
Mott agrees, “In many cases the al- WHAT IS TO COME long and very long-chain chlorinated
ternative chemistries are not as effec- FOR MWF ADDITIVES? paraffins continuing for the foreseeable
tive and/or are higher cost and can be Government regulation of MWFs future. Prior to any new regulations
much more difficult to formulate with. (particularly their additives) is almost restricting their usage, additional re-
The industry has long struggled with certain to tighten. This creates a co- search and evaluation will be required
chlorine replacement technologies, nundrum for formulators who need to determine whether such regulation
which simply cannot perform as well to produce fluids that perform well for is necessary.”
as chlorinated paraffins on certain al- extended periods and also protect the
loys and applications. Chlorine replace- machinery, workpiece, environment Jeanna Van Rensselar heads her
ments are almost always more expen- and most of all the workers. And these own communication/public
sive on a treat-rate basis and cannot MWFs need to do all this at a cost that relations firm, Smart PR
replace chlorine in all applications.” is palatable in the marketplace. Communications, in Naperville,
Wragg adds, “Increasingly, we are Eckard concludes, “There are op- Ill. You can reach her at
seeing certain classes of metalworking tions, but cost is the real issue. Especial- jeanna@smartprcommunica-
chemistry being targeted by regulators ly with antimicrobial materials, making tions.com.
REFERENCES
1. The Globally Harmonized System (GHS) is designed to replace 11. Ibid.
classification and labeling standards used in different countries 12. From http://en.wikipedia.org/wiki/Cutting_fluid.
with consistent criteria for classification and labeling on a global
level. 13. From Metalworking Fluids, Centers for Disease Control and Preven-
tion. Taken from www.cdc.gov/niosh/topics/metalworking/.
2. Registration, Evaluation, Authorization and Restriction of Chemi-
cals (REACh) is a European Union regulation that addresses the 14. From Metalworking Fluids: Safety and Health Best Practices Manual,
production and use of chemical substances and their potential U.S. Department of Labor. Taken from www.osha.gov/SLTC/metal-
impacts on both human health and the environment. workingfluids/metalworkingfluids_manual.html#e.
4. From Current Advances in Sustainable Metalworking Fluids Research 16. ILMA rebuttal: From Comments of the Independent Lubricant Manu-
by Steven J. Skerlos, et al. Taken from http://people.virginia.edu/~ facturers Association (ILMA) on “Metalworking Fluids: Summary of
afc7r/pubs/Sustainable%20Metalworking%20Fluids%20FINAL.pdf. Nomination for Review: NTP 12th Report on Carcinogens, September
2003 Submitted by Report on Carcinogens Group, NIEHS.” Taken
5. Ibid. from www.ilma.org/about/ntp_comments.pdf.
6. Ibid. 17. The National Toxicology Program (NTP) is an inter-agency pro-
7. From Chp. 17: Regulatory Aspects of Metalworking Fluids, Metal- gram run by the U.S. Department of Health and Human Services to
working Fluids, 2nd edition, edited by Jerry P. Byers, p. 400. coordinate, evaluate and report on toxicology within public agen-
8. From Metalworking Fluids, TERC. Taken from www.tercenter.org/ cies.
pages/metalworking.cfm. 18. From Hypersensitivity Pneumonitis: Is There an Association with
9. From Current Advances in Sustainable Metalworking Fluids Research Triazine Biocides and Mycobacteria in Metalworking Fluids? A White
by Steven J. Skerlos, et al. Taken from http://people.virginia.edu/ Paper Produced by the Safety, Health, Environmental Regulatory
~afc7r/pubs/Sustainable%20Metalworking%20Fluids%20FINAL.pdf. Affairs Committee of the Independent Lubricant Manufacturers
Association (ILMA). Taken from www.ilma.org/about/white_paper_tri-
10. From Metalworking Fluids, Centers for Disease Control and Pre-
azine_biocide.pdf.
vention. Taken from www.cdc.gov/niosh/topics/metalworking/.
A wolf’s jaw has a crushing pressure of nearly 1,500 psi compared with about 750 psi for a large dog. 45