Metal Working Fluid producers are facing new and emerging technologies, as well as human health, safety, and environmental regulations. Some people of the industry are of the view that these challenges can not be overcome.
Metal Working Fluid can be classified as four types: Oil Soluble Metal Working Fluid, Water Soluble Semi Synthetic Cutting Fluid, Water Soluble Fully Synthetic Cutting Fluid and Emulsion Metal Working Fluid by different application.
The metal working fluid industry is in trouble. More and more metal working equipment is turned to the use of water-based processing solutions, but the processing fluid producers are not able to use some of the ingredients that achieve the high efficiency and longevity of the product.
The metal working fluid marketer faces a similar pressure to other oil marketer. The user wants the processing liquid to be used for higher temperature and wear larger working environment, and can reduce the deposition and prolong the oil change period. They also wanted to reduce the production of waste, especially hazardous waste.
The faster the working speed of the tool, the higher the temperature; the more new the tool material, such as the hard alloy, the ceramic, the greater the wear. These work situations require stronger cooling, and people prefer water-based processing solutions, as water has stronger heat transfer performance than mineral oil.
The common lubricating oil and the cooling liquid are mixed and flow in the working area, but the micro-lubrication is not the case, and the friction is reduced by forming a lubricating film on the tool and the workpiece, so that the temperature is reduced; and the forming condition of the lubricating film is quite different from the current working condition. At the same time, 3D printing, material deformation, and dry cutting do not require lubricating oil, so the size and revenue of the entire processing liquid market are shrinking, and the funds used to study the new products have also been reduced.
The outbreak of the storm began with the introduction of regulations, one of which is the application of a biohazard-killing agent enacted by the European Chemical Agency, which severely limits the use of most of the biocides, which can be used to prevent the generation of various biofilms from water-based processing solutions, Bacteria that affect the stability of the emulsion and the production of toxins and odours. The Grand View Research firmundefineds report shows that the annual output of the global metal working fluid in 2018 is $107.5 billion, and by 2025, the annual output is expected to reach 3.65 million tons and a value of $1.4 billion.
Unable to meet demand
The cause of this situation is that the manufacturer choice can not be reconciled with the market demand. The user wants the product to have a long service life, but most of the biocides that will release formaldehyde are listed as a Class 1b carcinogen by the biocide regulations and must be labeled with a hazard warning.
In addition, the workshop wants to use soluble oil with a stable emulsifying property, but most of the emulsifiers are biodegradable and can be decomposed by bacteria. The oil manufacturer can ensure the emulsification and lubricity by various means, and the surface-active components of these functions can reduce the aging of the oil or the foam generated when the water quality is changed (the calcium and magnesium ion content of the local tap water) changes.
Most of the components currently used are natural product derivatives and have good biodegradability. A petrochemical substitute, as its name implies, is not a natural product. Reducing the biodegradability means extending the life of the fluid. Both of these means are contrary to the sustainable goals of many of the major consumers and OEMs.
Insufficient water supply
In the world, several metal working industries will face greater water shortages by 2040, when the use of water may be severely restricted. Italy and Ukraine are in high-risk areas, and their metal-working industries will also be seriously affected. The risks of Spain, Turkey, Greece, North Africa (except Egypt), the Middle East, India and Pakistan are also very high. Together with the OECD forecast that, by 2050, manufacturing water will grow by 40%, and metal-working fluid enterprises and their suppliers naturally need to face several important issues.
It is not intended to be of course converted into oil-based processing fluids. Oil-based processing solutions are not able to cope with the high temperature conditions mentioned above, and their oil mist may also cause health, safety and environmental problems and, in addition, there will be a risk of health problems and slips when it falls to the wall and equipment surface. But for now, the most important issue of the biocide regulation is that it may be the biggest problem ever faced by a metal-working fluid producer. in accordance with that regulation, all raw materials listed as the formaldehyde release body, however, are not all the processing liquid and the formaldehyde _ in the European market must be labeled with the H350 hazard statement code and the serious health hazard warning sign. All of the workshops in Germany will stop using these processing solutions.
At the same time, the boric acid has been decreasing in recent years, and the list of substances used to limit the use of automobile and aviation OEM is also expanding. One person in the industry indicated that the enterprise, in accordance with the REACH certification of the European Chemical Agency (chemical registration, assessment, licensing and limitation), required the use of a compliant substance to protect the health of the staff and to establish a list of grey, red and black levels, Inclusion of substances that are harmless to the human body but which have an impact on the reputation of the company.
At present, many of the raw materials with the sterilization effect belong to the fungicide, not the bacteria-killing agent. This means they can protect the oil in the tank, but will not affect the oil concentration.
Change the business model
The rest of the industry called for a change in the current business model, and they think the business should stop taking everything as a business secret. They propose to promote more cooperation among end users, metal working equipment and tool suppliers, workshops, and processing liquid suppliers.
The implementation of these two approaches requires the industry to cooperate fully in the use of preservatives in the workshop and the shortening of the life of the process fluid. The former is feasible, but it is necessary to train or install the automatic replenishment system of the working fluid. Both of these approaches are attractive, but small businesses may not be able to bear the added cost of any one. Shortening the life of the processing fluid means a waste of emphasis, which requires downstream users to change their continuous requirements for the supplier.
Another suggestion they put forward is whether the formaldehyde release body determined by the REACH regulation is authorized for the formulation of various metalworking fluids, which requires the approval of the consumer and trade union.
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