Increased Productivity Through Chemistry. Steve Lowery Tower Oil & Technology Co.

Transcription

1 Increased Productivity Through Chemistry Steve Lowery Tower Oil & Technology Co.

2 Outline Green/Bio-Based Lubricants Pros/Cons Vanishing Oil Replacements V.O.C. Free Cost Effectiveness Real World Uses Case Studies Cost Savings Process Review

3 Green Lubricants Vegetable Seed Oils Steady Increase in Use Range of Applications Synthetic Technically Speaking Renewable Resource Bio-Based Free of Petroleum Oil

4 Green Lubricants Marine & Animal Based Growing Industry Range of Applications Easily Modified Expanded Use Synthetic Renewable Resource Bio-Based Free of Petroleum Oil

5 Initiatives & Regulations Supporting Bio-Based Lubricants 2009 California SCAQMD Rule California Bills 1879 & Registration, Evaluation, and Authorization of Chemicals (REACH) USDA BioPreferred The Canadian Environmental Protection Act Toxic Substance & Control Act (TSCA)

6 Bio-Based Defined U.S. Department of Agriculture Composition In Whole or Significant Percentage Consisting of: Plant Animal Marine

7 Bio-Based Defined Metalworking Lubricants - USDA Classifications Soluble, Semi-Synthetic, or Synthetic Contain Minimum 40% General Purpose 57% High Performance Straight Oil Products 66% Minimum Content

8 Bio-Based vs. Biodegradable Synonymous Bio-Based, Renewable Resource, Green Biodegradable Readily - Rapid & Complete Ultimately Additives/Ingredients Petroleum, Esters, Amines, Glycols, EP Additives

9 Bio-Based vs. Biodegradable Promote Environmental Benefits They Do Not Guarantee Safety Biodegradability Bio-Based Content Gain a Full Understanding

10 Benefits of Bio-Based Lubes Enhanced Lubricity Reduces Friction & Wear Lower Levels of Lubricity Additives Extreme Pressure Additives

11 Benefits of Bio-Based Lubes Higher Viscosity Index Stability over Temperature Range Petroleum Oil VI Vegetable Based VI Lower VI More Change in Viscosity at High & Low Temperatures Higher VI Less Change in Viscosity at High & Low Temperatures

12 Limiting Factors Thermal Instability Unstable at Higher Temperatures if Untreated Bio-Engineered Seeds Bio-Processing Technologies Oxidation Additives Antioxidants

13 Trends of Green Lubricants Straight Oils - Available for Many Years Recent Trend Water Extendible Fluids Reduced Friction Greater Wear Resistance Reducing Extreme Pressure Additives

14 What does it all mean? Lower Overall Coefficient of Friction Easier to Clean Parts Lower Washer Temperatures Lower Cleaner Concentrations Better Rust Protection Better Weld Through Lower Costs

15 Pure Renewable Exclusive Use of Renewable Resources Remove the Extreme Pressure Additives Chlorine, Phosphorous, Sulfur Rely Wholly on Boundary Film Lubrication Soybean Based Lubricants

16 Green Lubricants Demand on Foreign Oil Lessens US Farmers Contribute to Industrial Engine Performance Characteristics Less Toxic to Environment Easier to Dispose Lessened Health Risks

17 Vanishing Oil Replacements

18 Many Varieties - Many Names Disappearing Compounds Vanishing Oils Evaporatives Solvents Numerous Operations Drawing, Forming, Punching, Perforating Leave a Clean Dry Part

19 What is a Vanishing Oil? Carrier Petroleum Distillate Evaporates Controls Drying Time Lubricity Additives Wetting Boundary Film Lubrication Extreme Pressure Additives Corrosion Inhibitors Metal Passivators

20 Residues Dependant on Additives Dry to the Touch Oily Sticky Non-Existent

21 Application Methods Drip, Spray, Roller Caution to use only Airless Sprayers Heat Generated in Operation Facilitate Drying Too Little Applied Evaporate before Operation Completed Galling or Tool Wear Too Much Applied Wet Parts Packing Wet Drying Time Effected

22 Categorizing Flash Point Lowest Temperature at which enough vapors to ignite if ignition source. 105ºF, 125ºF, and 140ºF Lower Flash = Faster Drying Flammability Rating: 2 Drying Time <20 minutes to hours

23 Speeding Up the Drying Influence Evaporation Rate Heat from Process Fans Heat Tunnels Air Knives Enough Lube to do the Job More is Not Better

24 V.O.C. Issues Vanishing Oils High Level of V.O.C. s Volatile Organic Compounds React with Nitrogen Oxides (NOx) Ground Level Ozone Smog EPA & Clean Air Act Non-Attainment Areas Reduce Emissions Eliminate

25 V.O.C. Regulations National Clean Air Regulatory Agenda (CARA) & Regulatory Framework for Air Emissions Reduce Emissions of VOC s Regulations to limit VOC Concentrations Aligning VOC Concentration Limits in Cooperation with United States Source

26 Complying with Regulations Pursue Necessary Permits Use Oil & Wash Parts Scrubbing Systems Incineration Carbon-Adsorption Technology Switch to Better Chemistry????

27 V.O.C. Free Alternative Water Extendible Synthetic Fluids Mimic Benefits of Solvent-Based Fluids Wetting Lubricity Drying Time Need to Evaluate Water Source All water is not the same

28 Water - Knowledge Type of Water Soft or Hard (Calcium and Magnesium) Treated Water Reverse Osmosis, Deionized, Softened Microbial Growth Staining, Spotting, Rusting

29 Latest Technology V.O.C. Free Vanishing Fluids Green Fluid Technology Direct Replacement for Solvent Based Lubricants No V.O.C. permits or fees required

30 Green Fluid Technology HMIS Rating Comparison Typical Vanishing Oil Health - 1 Flammability - 2 Reactivity - 0 ACGIH TLV ppm OSHA PEL ppm VOC Free Vanishing Fluid Health - 0 Flammability - 0 Reactivity - 0 ACGIH TLV n/a OSHA PEL n/a ACGIH TLV Threshold Limit Values - Guidelines in making decisions regarding safe levels of exposure to various chemical substances. Health based values OSHA PEL Enforceable Permissible Exposure Limits protect against exposure to hazardous substances. Based on 8 hour time weighted average

31 Green Fluid Technology No Special Ventilation Required Normally Dries Twice as Fast Does not Contain Chlorine, Sulfur or Phosphorus Excellent Corrosion Protection High Lubricity Factor All Metal Safe Odorless

32 Case Studies

33 Vanishing Oil Support Brackets G30 G90 Galvanized Progressive Die Airless Spray System Parts go direct to Assembly Current Lube Petroleum Based Vanishing Oil Used as Supplied Goals Eliminate White Rust on Parts Eliminate Smell of Current Vanishing Oil

34 Water Extendible Synthetic Run at 9:1 Ratio / 10% Solution No White Rust in Over 6 months of use Some parts stacked flat Reduced Smell Issue Eliminated V.O.C. s from Plant Non-Flammable Overwhelming Acceptance

35 Switch to a Greener Fluid HSLA thick Multiple Draws Tough Part Tool Life Concerns Parts Deburred Prior to Assembly Using Chlorinated Soluble 7:1 Tough to Clean Short Term Rust Protection - Suspect

36 Switch to a Greener Fluid Switched to a Vegetable Based Soluble 7:1 Reduced Chlorinated Paraffins by half Easier to Clean Obtained desired Rust Protection No change in Tool Life Cost Savings 0.25 Lubricants Cleaning Coefficient of Friction Chlorinated Solube Oil Bio-Based Soluble Oil Time (seconds)

37 Vanishing Oil Replacement Galvanized & Aluminum Material Progressive Dies Airless Spray Applied Parts stacked, some shipped to Mexico Goals Eliminate V.O.C. s Exceeded permitted levels several times per year. Costly Permits Health Concerns from EHS

38 V.O.C. Free Vanishing Fluid Eliminated Costly Permits Required Cost Savings No White Rust or Staining Needed to add air knives for Aluminum No change in Tool Life Overwhelming Operator Acceptance

39 Vanishing Oil Replacement HRS up to.090 Galvanized Aluminum.035 Airless Sprayer System Stacked, Nested, Sent to Assembly Concerns about V.O.C. s Looking for Healthier Alternative

40 V.O.C. Free Vanishing Fluid Replaced with V.O.C. Free Vanishing Fluid No Change in Process Comparative Tool Life Less Expensive Alternative than Previous Lubricant Healthier Shop Atmosphere Faster Drying Time

41 Thank You Are there Any Questions? Steve Lowery Tower Oil & Technology Co.