Forward Thinking
New approaches to coolants are dramatically reducing resource use
Stimulated by the need to meet the challenges of sustainable production, there is a wave of new thinking, technologies, and processes influencing manufacturers. One such concept is Resource-Efficient Manufacturing (REM) – doing more with less and finding viable reuse and recycling technologies to conserve materials. These REM innovations are helping large-scale manufacturers meet stringent environmental targets and are increasing their competitiveness.
The metalworking fluid industry is already playing an essential role in REM by providing smart, sustainable solutions towards resource efficiency. One global leader in metalworking fluids, Quaker Chemical, is putting sustainable chemistry into action by helping customers on issues of energy efficiency, waste reduction, safety, and durability through new approaches to coolant and cleaner use.
Rethinking Coolant and Cleaner Use Incremental improvements in machining operations costs and sustainability can be obtained through conventional controls, such as closely monitoring and upgrading to more bio-stable coolants to extend sump life. But to achieve dramatic ecological and economic benefits, a completely new way of working is needed.
Product manager, Laurent Ilievski*, talked about how Quaker developed a new approach to coolants and cleaners. “Most manufacturers mainly operate on a linear use of materials – they employ a process where they inventory dedicated coolants and cleaners, they use them, and then dispose of them. We knew to get the resource reductions our customers were looking for, we would have to rethink that whole process and change it from start to finish.”
The approach Quaker devised is called 2PAQ. It includes a
compatible, two-part coolant/cleaner that is used for a wide variety of operations. The fluid, when used as a cleaner, can be repurposed in the cutting fluid tanks for top-ups – therefore it is used twice. Ilievski said, “The result can be as much as a 90% reduction in waste generation. This is dramatic, especially for customers with CNC units connected to large – 100,000 or 200,000 litres – centralised systems.”
In traditional coolant/cleaner use, dedicated fluids are used for each purpose and disposed after one use.
The 2PAQ approach has helped Quaker’s customers to be both eco-efficient and economically efficient. First, by reducing wastewater quantities, 2PAQ customers improve their environ- mental compliance. Second, the customers will see savings in a number of sources: • Water consumption is minimised because the cleaners are reused for the makeup of the top-up emulsions.
• Energy and wastewater treatment costs are reduced because significantly lower quantities need to be treated.
• Capital investments in wastewater treatment equipment can be reduced or eliminated.
Ilievski added, “One of our customers was planning to install a larger evaporator. Once 2PAQ was in place, they not only stopped running their evaporator for the equivalent of three months in a year – saving the related electrical expenses – they eliminated the need for a new evaporator.”
Furthermore, 2PAQ has been shown to enhance machining performance especially in the foaming behaviour and stability of the emulsion. Ilievski continued, “This same customer, who uses a boron-free version of 2PAQ, added tank-side additives just once during the last year, and this was for maintenance purposes during the summer break. That’s a very significant improvement for them.”
The Essentials of 2PAQ The 2PAQ concept is based on the versatility of its chemical components and a new way of working. A two-component fluid replaces many (sometimes 20 or more) dedicated fluids that a manufacturer uses for machining operations. 2PAQ is formulated in different solution ratios of the alkaline and oil phases mixed into water to prepare emulsions – to meet a wide variety of different coolant/cleaner needs.
For example, for operations that require higher levels of lubrication, the ‘oil phase’ is used at a higher ratio to provide a more robust, high- performance micro- emulsion for machining cast iron, steel, and aluminium alloys.
2PAQ’s versatility also allows it to be used as a process cleaner. When the cleaner solution becomes saturated, instead of being disposed of, it is added to the coolant tank to aid with volume control (top-up).
With the versatility of 2PAQ, Quakercool Oil HR and Quakercool W Alca are used for a wide variety of applications. The cleaner is recirculated into the coolant tank to be used again.
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LUBE MAGAZINE No .110 AUGUST 2012
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