New Lubricants, New Cleaning Challenges

The predicted national trend is toward lubricants that are less volatile. In July, 2010, the South Coast Air Quality Management District in California (SCAMQD) adopted Rule 1144 to reduce industrial VOC emissions resulting from the use of metalworking fluids and lubricants (refer to Table 1 for details). The Independent Lubricant Manufacturers Association (ILMA) collaborated with SCAQMD on developing test methods for the new rule.

 

National Impact

But why is an organization concerned with issues that extend throughout North America and beyond now getting involved with a regional regulation? John Burke, director of engineering services at Houghton International Inc. (Valley Forge, Penn.), explains that ILMA became involved because “we believe that California is a trendsetter. When we realized the rule would spread across the country, we felt we should be involved.” Mr. Burke adds that “whether or not the company is regulated directly, it becomes an ethics issue. Companies can no longer say, ‘this is just California.’ They can now say, ‘a community of 6 million people abide by this standard.’ Lots of companies have the policy of using the lowest, best standard. SCAQMD just set the best standard.”

 

By the beginning of 2011, metalworking fluids used in the SCAQMD area must be labeled as to VOC content, but it seems likely that major suppliers of lubricants will include VOC content on the label irrespective of where the product is used.

 

Michael Pearce, certified lubrication specialist at Dodge Oil (Maywood, Calif.), adds that “it’s the right thing to do. Rule 1144 represents a big victory for the environment with relatively little cost to industry.” Mr. Pearce goes on to explain that most of the impacted solvents include mineral spirits/Stoddard solvent, methyl ethyl ketone or toluene that are used in vanishing fluids or as a diluents in rust preventatives (RPs). He adds that “with RPs, it is possible to use aqueous-based lubricants as long as the part is put away completely dry because entrapped water compromises the RP.”

 

 

Cleaning Challenges

Mr. Burke notes that during rule development, “the emphasis was on minimizing emissions, not on cleaning issues.” It stands to reason that if less of a process fluid evaporates into the air, more of it will remain on the part. The heat and forces involved in fabrication can result in more adherent residue. This means more cleaning issues. Mr. Burke notes that “removing the newer lubricants is likely to be challenging. Because oils with higher viscosity don’t couple as well with detergents, new cleaning chemistries will be needed. People who are concerned with cleaning parts will have to put on their thinking caps.”

Mr. Pearce adds that, in contrast with traditional petroleum based products, bio-based metalworking fluids inherently contain double bonds. He adds that, “to avoid breakdown and formation of adherent varnishes, it is important to use highly processed, high-oleic content, vegetable-based lubes. This increases the cost of the product significantly.”

 

Understanding the Impacts

A technical program is planned for first quarter 2012 at SCAQMD in (Diamond Bar, Calif.). The program will include technical/scientific reports as well as manufacturing findings and case studies. Mr. Pearce cautions that “this is not a sales seminar for lubricants or for cleaning techniques. We’re looking for success stories, we’re looking for failures, we’re looking for documented impact on the cost of metal parts.” Those involved in metal fabrication should look for the upcoming call for papers on aqmd.gov and ILMA.org and consider participating.

 

This Means You

Mr. Pearce concludes that “anybody who hears about Rule 1144 and says ‘this doesn’t apply to me’ is living in complete denial. This rule could be adopted anywhere in the country. Regulators are apt to say that if they can use low VOC fluids in California, they can use them anywhere.”