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Mapping and development of alternatives to chlorinated lubricants in the metal industry (KLORPARAFRI)

3 Demands and specifications for non-chlorinated lubricants

3.1 Introduction to chapter 3

The objective of chapter 3 is to describe the technical criteria set up by project partners in this project in order to be able to identify non-chlorinated lubricants exhibiting promising lubricating properties in the metal processes in focus and to identify lubricants suitable for testing in simulating and process technical tests and in production at Danfoss A/S.

In addition, the objective of chapter 3 is to describe the health and environmental criteria set up by project partners in this project in order to define an acceptable lubricant in a health and environmental context. Based on criteria set up for acceptable lubricants, those with obvious unwanted health and environmental properties could be deselected for production test.

3.2 Technical demands and specifications for non-chlorinated lubricants

A three stage technical identification and priority of proposed alternative lubricants has been performed in the project based on specified technical criteria initially set up by project partners.

In the first step, an identification of lubricants was made based on technical supplier documentation. The primary focus was on non-chlorinated lubricants with promising lubricating properties in heavy-duty forming operations in stainless steel etc. as specified in chapter 2. However, attention was also paid to secondary lubricant properties such storage stability and aggressiveness to common construction materials etc, in addition to the lubricants' compatibility with application conditions in the subsequent technical tests and with conditions at Danfoss A/S.

In the second step, the technical efficiency of proposed lubricants that passed step one was tested in two technical tests described further in chapter 6. Lubricants exhibiting promising lubricating properties based on the results in the technical test where selected for a full scale production test at Danfoss A/S.

In the third step, lubricants selected in step 2 were tested in a full scale production test at Danfoss A/S. The test, which is described further in chapter 6, was performed without adjustment of the production.

Thus, lubricant systems which exhibited promising lubricant properties in specified metal forming operations based on supplier information but did not comply with the technical test conditions for instance regarding application, were not technically tested in this project.

For the selection of alternative lubricants, the following technical criteria were set up:

Primary technical criteria:

  • Technical performance in specified metal forming operations with the materials focused on in this project
  • Flammability: flash point > 100°C (lubricants must not cause any fire hazard)

Secondary technical criteria:

  • Corrosion of machines: When used, the lubricants must not cause corrosion on machine parts or tools, or in any other way be aggressive to regular construction materials. Corrosion caused by lubricants is often seen in relation to materials made of plastics or rubbers and with paints and lacquers.
  • Stability: The lubricants must not cause growth to bacteria or fungus, nor cause other problems due to oxidation.
  • Storage stability: The lubricants must be stable during a storage period of at least 3 months (20°C). If the lubricant is phase separated, it is a demand that the properties of the lubricant can be regenerated by stirring.

Demands specific for Danfoss A/S:

  • Application: To obtain a simplified way of application, it is a demand that the lubricant of the wet film type (see chapter 2) can be applied with the existing equipment, implying that the viscosity must not be too high (70-175 cSt at 40°C). Lubricants of higher viscosity (up to 600 cSt at 40°C) can only be tested in the simulative tests. Lubricants of the dry film type (see also chapter 2) must be able to dry within 5 to 10 seconds.
  • Degreasing: It is a demand that alkaline detergents can be used for degreasing of the formed work pieces (alkalic washing plants). During the degreasing process, there must not be formation of foam.
  • Disposal: it is endeavoured that the degreasing process water does not contain any compounds requiring any special disposal technique or process.

3.3 Health and environmental demands and specifications for non-chlorinated lubricants

A health and environmental evaluation at the screening level was carried out for proposed alternative lubricants that passed step 1 of the technical identification and priority of suitable non-chlorinated lubricants and for which sufficient compositional information had been obtained from the supplier. The results of the screening of the proposed lubricants are described in chapter 8.

A health and environmental evaluation has been performed for components commonly occurring in non-chlorinated lubricants for heavy-duty metal forming. The results of the health and environmental assessment of representative lubricant components are described in chapter 7.

Both the screening of proposed lubricants and the assessments of representative lubricant components involve health and environmental rating systems. The assessment methods including the rating systems are described in chapters 7 and 8.

Exposure assessments have been carried out in the working environment for four substances representing two types of components that typically occur in non-chlorinated lubricants for heavy-duty metal forming. The method and results are described in chapter 9.

In the project, criteria for an acceptable lubricant in a health and environmental context were defined by the project partners. In the project, there is a focus on the inherent health and environmental properties of chemical substances. The parameters, on which the health and environmental assessments of the proposed non-chlorinated lubricants and representative lubricant components are based, in addition to criteria for health and environmental acceptable lubricants, are described in sections 3.3.1 and 3.3.2, respectively.

3.3.1 Health parameters and criteria for non-chlorinated lubricants

Health parameters

The following parameters are included in the health evaluation of proposed non-chlorinated lubricants and representative lubricant components. As mentioned above, all parameters and criteria focus on inherent properties of substances and products.

  • Physical/chemical properties
  • Acute toxicity
  • Corrosive and irritating effects
  • Sensitizing effects
  • Carcinogenic effects
  • Mutagenic effects
  • Reproduction toxic effects
  • Other effects from repeated exposure.

The health evaluation is based on principles in the EU health classification of chemical substances and preparations (11).

Health criteria

Substances and products with the following effects, classifications and health scores should be avoided:

  • Carcinogenic, mutagenic or reproduction toxic substances in categories 1 through 3. This includes substances and products with a classification in categories Carc1-3, Mut1-3 or Rep1-3 corresponding to health score 5 (see also chapter 7 for description of health score).
  • Substances with a high acute toxicity or toxicity at repeated exposure. This includes substances classified with the risk phrases R23–28, R39, R48 or R64 corresponding to health scores 3, 4 or 5 (see also chapter 7).
  • Substances with corrosive effects or irritating to the respiratory tract. This includes substances classified with the risk phrases R34-35 and R37 corresponding to health scores 3 or 4 (see also chapter 7).
  • Substances with sensitizing effects. This includes substances classified with the risk phrases R42 and R43 corresponding to health scores 4 or 5 (see also chapter 7).
  • Flammable products (flash point < 100°C).

Substances and products which, based on adequate data, do not comply with the above-mentioned criteria and thus are assigned health score 1 or 2 are considered as good alternatives to chlorinated lubricants in a health context.

3.3.2 Environmental parameters and criteria for non-chlorinated lubricants

As in the health assessment of lubricants and lubricant components, the environmental assessment focuses on the inherent properties of substances and products.

The following parameters are included in the environmental evaluation.

  • Ready biodegradability
  • Bioaccumulation or
  • Potential bioaccumulation (Log Pow)
  • Toxicity to algae, fish and crustaceans or other aquatic organisms
  • Physical and chemical properties.

The environmental evaluation is based on principles in the EU environmental classification of substances and preparations (11) and the global classification system (OECD 2001).

Substances and products with high toxicity to aquatic organisms (EC50 < 10 mg/l) and substances that are not readily biodegradable or bioaccumulate (BCF > 500, Log Pow > 4) should be avoided. According the EU environmental classification system, these substances are classified as dangerous to the environment (N) with risk phrase R50: “Very toxic to aquatic organisms” or R51: Toxic to aquatic organism” and risk phrase R53: “May cause long-term adverse effects in the aquatic environment (N;R50/53 or N;R51/53). These classifications correspond to environmental scores 4 and 5 respectively (for a description of environmental scores, see also chapter 7).

 

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Version 1.0 October 2005, © Danish Environmental Protection Agency