Carbide Processors Coolant Book

Managing Coolants from Machining and Grinding Operations, Cermet Saws, Carbide Processors, Inc.
Home l Coolant Management
Managing Coolants from

Machining and Grinding Operations
Thomas J. Walz, President
Northwest Research Institute, Inc. / Carbide Processors, Inc.
3847 S. Union Ave. Tacoma, WA. 98409
(800) 346-8274 (253) 476-1338 Fax (253) 476-1321
tomwalz@email.msn.com l www.carbideprocessors.com
Call if you have a problem not solved here. We charge for consulting
but we are always happy to talk a while for free.
Preface and Warning
This is a work in progress. It is written as a general overview on coolant

management for manufacturing management and similar. As we do more
research and solve more problems this will grow and change.
Improper coolant management costs industry billions of dollars each year

in decreased machine life, increased rework, increased reject parts and
increased consumables such as tools. It is also extremely important for
safety and health reasons as well as environmental reasons.
There are a great many medical and legal issues here. I am not a doctor,
nor a lawyer, nor am I holding myself out as an expert on any of these
issues. I am writing this as someone who uses coolants and builds
coolant management systems. I do not take any liability whatever for
anything connected with this.
Think of this as advice from someone who has the same problems you
have, but has worked for years to find really good solutions. This
material has helped a great many people to run more profitable shops
over the years. Hopefully it will do the same for you.
http://www.carbideprocessors.com/Coolant/book/ (1 of 3) [7/23/2005 11:12:48 PM]

Sincerely,
Thomas J. Walz
President
Table of
Contents
Chapter Title Page
Benefits of Overall Cleanliness Especially Coolant
1 4
Filtering
2 Case Studies: Annual Cost and payback calculations 10
3 How You Get The Benefits 20
4 Cutting Costs with Coolant Management 26
5 What Coolant Is and Does 28
6 Types Of Coolants 32
7 Example of a Synthetic Coolant 39
8 Coolant Selection 40
9 Water Quality 43
10 Parts Of A Coolant Management Program 47
11 How To Get Coolant Where You Need It 53
12 Why Coolants Become Unusable 55
13 Sump Cleaning 62
14 Cleaning Systems 64
15 Example: Filtering Carbide Grinding Coolant 71
16 Kinds of Filters 73
17 Filtering EDM fluids 80
18 Testing 81
19 Sample Coolant Analysis 89
20 One Bottle Coolant Testing 91

21 Disposal Of Used Fluids And Sludge 93

22 Health and Safety Concerns 94
23 Example: A Good Material Safety Data Sheet 104
24 Air Collection Information and Equipment 112
25 Disposal And Environmental Issues 114
26 Kinds Of Waste Disposal 128

Chapter 1: Managing Coolants, Carbide Processors, Inc. for filter systems, coolant, testing,
Home l Coolant Management next chapter ->
Chapter 1
Benefits of Overall Cleanliness

Especially Coolant Filtering
The savings in proper cleanliness, general maintenance as well coolant

management and filtering can be as high as 20% of the annual expenses in
the following areas.
Benefits of managing coolants

Make more money
1. Longer Machine Life

2. Longer time between rebuilds
3. Less downtime
4. Less equipment replacement
5. Faster operation
6. Faster cycle times
7. Fewer tool replacements
Better quality
8. Measured as the smoothness of the worked surface

9. Measured in SPC consistency
10. Produce better overall quality work
11. Reduced rework
12. Reduced scrap
13. Tighter tolerances
Greater Lubricity with clean coolant
14. No burning
http://www.carbideprocessors.com/Coolant/book/01.htm (1 of 9) [7/23/2005 11:12:51 PM]

15. Clean coolant will also help prevent problems with heating
of the tools.
16. Less heat during machining therefore less change in surface
condition
17. Smoother cuts and grinds
Reduced consumable costs
18. Longer tool run life per sharpening

19. Longer tool life
20. Longer coolant life
21. Longer grinding wheel life
22. Less dressing required
23. More parts per dollar of raw material
Reduced Labor
24. Less machine maintenance

25. Less tool maintenance
26. Less finishing required
Cleaner workplace
27. Perhaps increased operator safety

28. Retards bacteria growth
29. Eliminate smells
30. Help eliminate noise
Fewer problems than shops that use dirty coolants.
31. Less OSHA exposure

32. Less EPA exposure
33. Less waste
34. Cleaner waste
35. Lower coolant disposal or recycling costs

36. Reduces non-coolant waste and waste disposal costs

37. Turn an expense into income
When and Why to Filter

In grinding operations you want to filter out all the particles that are larger
than 10% of the grit size of the wheel, or 10% of the tightest dimension
specified. A way to explain this is the tire and 2x4 analogy. An automotive
tire is about twenty inches in diameter. If you run over the two-inch
dimension (10%) of a 2x4 you will feel a bump. The little divider bumps
(wake-up bumps, turtles) in roads are generally much less than an inch and
you sure feel those.
If particles of any size come between the tool and the work it will tend to
damage both the tool and the surface of the work. The same way that a
rock in your shoe will try to make a hole in both your foot and the shoe.
Machine damage is much harder to quantify. One way of determining

acceptable particle size is to ask; what grit sandpaper you would allow to
be used on the hydraulic cylinders of the machine. As the coolant gets
sprayed it gets on extended hydraulic cylinders, and is then abraded as the
cylinder moves in and out.
Filtering in Carbide Tool Grinding

Operations
If you use Filter to this
Wheel grit size
wheel grit level
in microns
(Sieve) Size in microns
100 150 15
200 75 7
400 38 4
635 20 2
What you need to filter out of your sump or what's tearing up your
machinery

Dust in the air at 1,000

Out of the sump
magnification
The big chunks on the left are broken diamond and the little bright spots
are tungsten carbide. This was collected in a carbide tool grinding
operation. Diamond and tungsten carbide both have a lot of sharp fracture
edges, which means they are extremely abrasive. The right picture is the
same material, but the diamond and tungsten carbide are glued into chunks
with oil and grease. Some of these are one micron (1/25,000 inch) or less.
They are small enough to get anywhere such as cylinders, bearing,
bushings, controls, etc.
Particles per cubic centimeter in Dirty, Filtered and Unused Coolant


You cannot tell coolant condition just by looking at it

When you put new motor oil in your car it looks clean and clear, just as
new coolant looks clean and clear. After a few hundred miles the oil in
your car looks dirty, but it is still good for a couple thousand miles at least.
It looks dirty at about 10% to 20% of its useful life but it really has 80%,
or 90% of its life left.
Because the particles in coolant are so small, the coolant looks dirty when
there are as few as 30,000 particles per cubic centimeter. In fact really
dirty coolant can have as many as 75,000,000 particles per cubic
centimeter.
If you let the coolant stand for a couple days, most of the particles will
filter out and settle on the bottom.
However, many of these particles are so small that they will float forever.
Comparison of Sumps
Filtered
Unfiltered sump
Sump
1 - 2% tramp oil
Surface Clean
film

10%
5 - 7 % coolant
Mixture coolant
70 - 80% water
90% water
None Nerve agent

based
Added chemicals
Bactericides
Fungicides
Growths None Bacteria colonies

Algae blooms
Sump bottom Clean 10 - 15% sludge
Metal All metals Arsenic

contamination less than Cadmium
(Dissolved & 1% Barium
chelated metals) Mercury
Silver
Selenium
Lead
Chromium

Typical unfiltered Same coolant - filtered

Unused coolant
coolant 3 hours
Reduce Diamond Wheel Costs - Save $3,000 to $10,000 per year
A good grinding operation will still dump huge amounts of oil and grease
into the sump. We ran a test on a high production machine. In twenty-two
days of double shift we pulled out about ten pounds of oil and grease. This
oil and grease clogs the wheel. Clogged wheels mean slower grinds, worse
quality, and shorter wheel life. Clean coolant increases diamond wheel life
by at least 30% overall, and as much as 50% depending on the wheel and
the application. This is a saving of 25% to 35% in annual diamond wheel
cost. Removes oils and greases.
Longer Coolant Life - Save $1,000 a year per machine + the saving in
labor.
If you filter your coolant, you will get much longer life. In actual tests we
see coolant last six months and it is still doing an excellent job. This saves
you on coolant costs, and the maintenance of sump cleaning and coolant
changing.
West Coast Saws in Tacoma, WA has been running our filter units for
three years on five machines with a unit full time on each machine. They
estimate that they save $5,500 a year in coolant costs not counting the
tremendous saving in labor from fewer cleanings and coolant changes.
Increase Machine Life - Save $2,000 to $8,000 per year
The big advantage in clean coolant is that it protects the machine. Dirty
coolant can shorten machine life by 5% to 7% a year. Saw and tool
grinding generates a huge amount of very small, very abrasive particles.
These particles get into the coolant and then are sprayed all over.

These particles get into controls, cylinders, rods and bearings where they
increase wear and reduce quality. The CP 2002 removes particle down to
one micron, and removes them with incredible efficiency.
Why people love our coolant filtration systems
"The air in the office doesn’t seem to have that oily smell anymore."
Kathie Rundstrom
Co-owner of Paso Robles Carbide in California
"The grinds are smoother, our wheels stay cleaner, and the oil and
grease on our machinery is less than it was."
Alastair McLean
Shop Foreman at Cal Saw Canada in B.C. (They now own 3 of our units.)
"I don’t have to clean my glasses as often as I did before."

Greg Sprague
Head Sawfiler for Potter Lumber in New York State (They’ve had their
system 4 months.)
"In approximately an hour, the color of the coolant went from dark
gray to green."
Scott Whiting
Scott’s Sharpening Service in Arizona
He was amazed at how fast and efficient his system was, and could hardly
wait to tell us.

Chapter 2
Case Studies: Annual Cost And Payback

Calculations
Case Study 1. Adding filter systems in a carbide tool grinding operation
A shop with six grinders for saws and tools bought six filter units for
$9,000. They bought an additional $600 in cleanable, reusable filters.
They had been spending $10,800 a year in coolant use and disposal.
Their coolant use and disposal dropped to $500. This is a saving of
$10,000, which paid for the original investment. The labor of filter
maintenance was less than the labor of sump cleaning and recharging.
This shop does ultra-precise grinding. The six machines had a
depreciated value of about $550,000 dollars. (This is considerably less
than replacement cost, and uses IRS depreciation schedules.) This is a
savings of $55,000 a year in machine life. The shop estimated another
$10,000 a year in savings on grinding wheels because of longer wheel
life and less need to dress the wheel since they did not gum up as rapidly.
The shop also estimates that they can work about 5% faster with no
burning.
Coolant Management - Annual Cost Calculations

Filter coolant and recycle instead of waste disposal
(Note: These results are several years old, and the costs of filtering are
dramatically lower now so the savings are much greater now.)
Cost of filter
units
Filter unit 995.00
Filter costs 780.00

Filter change
120.00
labor
Total 1,895.00
Unmanaged Managed Managed
Coolant Coolant Coolant
(Change every 3 (No changes in (Change every
weeks) a year) 6 weeks)
(17 changes per (8.5 changes
year) per year)
Costs
Coolant 637.50 150.00 318.75
Labor 170.00 85.00
Disposal
Hazardous waste 2,754.00 None
Recycled coolant None 459.00
Totals 3,561.50 150.00 862.75
Cost Reduction
If you change your coolant every three weeks, and have the used coolant
hauled away as hazardous waste, then you will spend $3,561.50 per year
on every grinder or machine with a thirty-gallon sump. In a shop with
five machines this is $17,800 per year. If you change the coolant every
six weeks, and have it hauled away as ordinary waste, then you will
spend $4,300 per year for five machines. This is a saving of $13,500 per
year.
Assumptions
1. One machine with a thirty-gallon sump
2. Coolant cost at $25 per gallon
3. Coolant is mixed about 20:1 so it costs about $37.50 to charge a sump after each change
4. Labor is at $20 an hour and it takes a half hour to drain, clean and recharge a sump
5. Disposal costs

A. Hazardous waste is $300 per each 55-gallon barrel

B. Grinding coolant is $90 per each 55-gallon barrel
Unmanaged coolant is not filtered, and is hauled away as hazardous waste. Managed coolant is
filtered at least one hour a day, and is classified as used grinding coolant for disposal.
Cost of running the filter system

Electricity cost
115 v x 8.2 amps = 943 watts
App 1 kilowatt
Electricity at $0.05 per kilowatt-hour. (Our rate is $0.039)
Electricity is $2.00 per week per 40 hour shift = $8.00 per month
Filter cost is:
1 - three micron filter every week = $10.00 - $20.00 a month
2 - filters, one five micron and one ten micron = $40.00 a month
Labor for filter change is fifteen minutes once a week = 60 minutes a
month.
Before
Example 1
40-gallon sump
Changed every three weeks - 17 times a year
Uses 4 gallons of coolant at $20 gallon = $80
Changed every three weeks - 45 min. at $70 per hour
Disposal of 40 gallons at $1.50 / gallon = $60
Annual coolant = $1,360
Annual labor = $1,190
Annual disposal = $1,020
Total = $3,570
Example 2
With filtering the coolant life goes from three weeks to six weeks.
Change time goes from 45 minutes to 15 minutes.
Annual coolant = $ 680

Annual labor = $ 297.50

Annual disposal = $ 1,020
Total = $ 1,997.50
Savings = $1572.50 annually
Example 3
Untreated Waste vs. Filtered, Treated Waste
Case A. Unfiltered & Untreated

5 grinders
40 gallon sumps
Change every 3 weeks
Total is 3400 gallons
Case B Filtered, Separated & Evaporated

5 grinders
40-gallon sumps
Change every six weeks
1700 gallon
Sell sludge for $0.10 to $0.15 per pound = $170 income
Decant oil and sell
Evaporate the water per PSAPCA and DO Ecology
Left 170 gallons of waste at $1.50/ gallon = $255
A shop can easily have 500 gallons of used coolant that is disposed of as
hazardous waste. Separation and evaporation can reduce this to a salable
product and leave only 50 gallons of hazardous waste. This is a
considerable financial savings for the business. It also reduces hazardous
waste, which is a good thing for society in general.
A coolant filter system that costs fifteen hundred dollars can save its
price in coolant alone in under a year.

A coolant filter system can totally replace the need for a separate oil
skimmer at no extra cost.
A coolant filter system costing a thousand dollars can recover more

than its price in metals in under a year.
Case Study 2. Adding A Settling Tank And Oil Separator In A

Machine Shop
A machine shop that installed a settling tank to remove solids from
coolants, and an oil separator to remove tramp oils, is now saving over
$26,800 a year in reduced material, labor, and disposal costs.
Case Study 3. Adding an Oil Skimmer In A Machine Shop

A machine shop installed oil skimmers to remove tramp oil from its
machine coolants and to prolong coolant life. The coolant is now
disposed once a year, rather than 3 to 6 times a year, cutting the shop's
coolant disposal and purchase costs up to 83%.
Case Study 4. Adding a Chip Wringer In A Machine Shop

A machine shop handling 20,600 gallons of coolant per year installed a
chip wringer to recover excess coolant on aluminum chips. The capital
investment of $233,500 paid for itself in less than a year.
Case Study 5. A Complete Fluid Management Program In A Full

Service Machine Shop
A full service machine shop performs metalworking operations on a
variety of metals including; aluminum, brass, steel, stainless steel and
cast iron. The facility employs 22 people, operates 35 to 40 machines
(both CNC and manual) and runs one shift Monday through Friday.
Being located in a rural setting, the facility lies beyond municipal
sanitary sewer system connections. Consequently, few options exist for
disposing of spent metalworking fluid. At considerable expense,
(estimated to be approximately $1,500 to $2,000 per month), spent

cutting fluid that had to be disposed as hazardous waste through a

permitted hazardous waste company.
Due to the regulatory burden and expense associated with disposal of

spent cutting fluid as a hazardous waste, the shop eventually purchased a
batch recycling system for $8500, and a sump sucker for approximately
$3750. A fluid management program, tailored to suit the shop's needs,
was also developed and implemented at the facility.
Fluid Monitoring And Maintenance
One semi synthetic fluid is presently used for practically all

metalworking operations performed at the facility. Water used for
preparing the fluid and replenishing evaporation losses is treated only by
an industrial water softener. Due to the success of the program,
management personnel deemed no additional water treatment necessary.
During early stages of developing the fluid management program,

samples of the fluid were periodically submitted to a laboratory to
monitor biological contamination. Fluid concentration and pH were also
monitored using a refractometer and pH meter. Biological and pH
monitoring eventually ceased after it became apparent that the
management program resulted in a dramatic decrease in biologic
contamination and consistent fluid pH. Monitoring at the facility now
consists of using a refractometer for concentration control and fluid
inspections by machine shop personnel. Machine operators are also
responsible for thoroughly cleaning out the machines each month.
Recycling
Fluid from each machine sump is recycled at least weekly, and often
twice a week. When metalworking operations involve metals that readily
degrade fluid quality (such as cast iron), fluid recycling is performed on a
daily basis. One employee is responsible for fluid recycling and fluid

management record keeping.
The fluid recycling procedure used by the facility begins by removing

cutting fluid from the machine sump with a sump sucker. After the fluid
is pumped out, the sump is immediately recharged with recycled fluid.
Fluid to be recycled is then transferred from the sump sucker into a batch
treatment-recycling unit for tramp oil removal, particulate filtration,
biocide addition, and concentration adjustment.
The recycling unit consists of several compartments including an initial

skimmer tank; a filtration bag; a coalescer compartment equipped with a
series of weirs; an oil skimmer and aerator; and a polishing tank for
biocide and concentration adjustment. Fluid first passes through the
initial skimmer tank where a skimmer pump removes any free-floating
tramp oil. Fluid from the skimmer tank is then pumped through a 100
micron cloth filter bag, (for particulate removal), into the coalescer tank
where a set of weirs force the fluid to pass through coalescing media for
removal of dispersed tramp oil. Tramp oil surfacing to the top of the
coalescer compartment is then removed with a disk oil skimmer. The
coalescer compartment is also equipped with an aerator to prevent
anaerobic bacteria from degrading the fluid while in the recycling unit.
Finally, fluid then enters the polishing compartment where biocide and
concentration adjustments are made. When cutting fluid in a sump needs
recycling, fluid from the polishing compartment is pumped into a mobile
container and used to recharge the machine sump being serviced.
In addition to recycling cutting fluid, all tramp oil recovered by the

facility is provided to a used oil marketer, and metal cuttings are
provided to a scrap metal dealer for recycling.
Results
Since acquiring the recycling unit and establishing the fluid management

program approximately three years ago, the facility has realized the
following benefits:
A. No waste cutting fluid has been generated at the facility since

implementing the fluid management program. This has eliminated the
regulatory burden and expense associated with offsite disposal of spent
cutting fluid as a hazardous waste.
B. Facility purchases of fluid concentrate dropped from approximately

250 - 300 gallons per year to only 100 gallons per year.
C. A noticeable improvement in the employee work environment has

occurred at the facility. Since establishing the program, no incidents of
dermatitis have been experienced by employees.
D. Consistent product quality and production tolerances have been

realized by the facility. The facility has also experienced fewer problems
in achieving low machining tolerances.
Based on these benefits and the costs associated with implementing a

fluid management program, machine shop management personnel
estimate the program paid for itself within two years.
Case Study 6. Small Manufacturing Facility

In 1990, a small manufacturing facility located in central Iowa purchased
recycling equipment to prolong the life, and improve the quality of the
semi synthetic fluid used for its machining operations.
Fluid quality problems experienced in the shop included; employee

dermatitis, a haze in the machining area from fluid smoking, and short
fluid life.
Failed metalworking fluid was also hauled away as hazardous waste at a

disposal cost of $75 per drum.
Just prior to 1990, the total sump capacity for the facility was
approximately 150 gallons and approximately 1,300 gallons of coolant
were used annually. In 1994 the number of machines used by the facility
doubled, increasing the total sump capacity to 300 gallons. The facility
now operates six chip-making machines, (including five CNC lathes and
one CNC mill) for its cast iron and mild steel metalworking operations.
Fluid and waste management

At a cost of approximately $42,000, fluid-recycling equipment was
purchased and installed at the facility. A fluid management program was
also started for the machine shop. A designated coolant technician is now
responsible for pumping out machine sumps, operating the coolant
recycling unit, and monitoring/adjusting coolant concentration at the
recycling unit with a refractometer. Deionized water is used for preparing
the fluid, and replenishing evaporation losses.
Once a month, coolant from each machine sump is pumped out for
recycling using a sump sucker. The fluid is then transferred into the
settling tank of the coolant-recycling unit for particulate removal. The
settling tank is also equipped with a belt skimmer to remove any free-
floating tramp oil. After twelve hours in the settling tank, the coolant is
drawn through a centrifuge where any residual tramp oil is removed for
transfer into a 55?gallon drum. Finally, the coolant enters the bottom
chamber of the recycling unit where the fluid concentration is
automatically adjusted. No biocide adjustments are performed on the
recycled fluid, and no other monitoring is performed at the facility. If a
problem is experienced with fluid quality, a sample is collected and
submitted to the fluid supplier for analysis.
At their discretion, machine operators are responsible for adding make-up

coolant or deionized water at the machine sump. Tramp oil recovered by
the facility is provided to a used oil marketer and metal cuttings are
provided to a scrap metal dealer for recycling.

Results
The facility has realized the following benefits since acquiring the
recycling equipment and establishing the fluid management program:
A. Fluid life has been prolonged at the facility and very little, if any,
requires disposal. The facility also tested the fluid and obtained
permission from local wastewater treatment authorities to discharge small
amounts of cutting fluid to the sanitary sewer system when necessary.
B. Although the total sump capacity for the facility doubled since
installing the recycling equipment, the facility's annual fluid consumption
has increased by only 200 gallons (a 15 percent increase in fluid
consumption with a 100 percent increase in sump capacity).
C. Management personnel estimate the recycling system paid for itself

within two years.
D. No more cases of dermatitis have been reported by employees, and

the haze in the machining area has been eliminated.
Areas For Improvement

Although the fluid management practices already performed at the
facility have significantly reduced consumption rates, and virtually
eliminated the need to dispose of fluid, management personnel plan to
keep refining the program. Management identified the following as areas
for improvement:
A. Although machines are thoroughly cleaned out once a year,

management intends to increase this cleanout frequency to at least twice
a year in an effort to reduce the frequency at which fluid is currently
recycled.
B. The facility intends to fabricate external sumps for its machines. The
internal sumps on the machines are very inaccessible, requiring

significant amounts of downtime for cleaning. Use of external sumps will
better accommodate more frequent cleanout schedules, and reduce the
amount of downtime required for cleaning.
C. Management will continually work with employees in an effort to

maintain employee support for the fluid management program.
Case Study 7. Another Manufacturing Operation With A Complete

Program
In 1986, management personnel at a manufacturing facility began to
review and revise their machining operations in an effort to improve
efficiency, reduce waste and reduce costs. Currently, the facility employs
130 people (100 machinists/assemblers and 30 management personnel)
and operates 63 chip-making machines with individual sumps. Sump
capacities range from 20 to 1,300 gallons, and the total sump capacity for
the facility is approximately 4,100 gallons.
Originally the facility used nine different coolants and had several chip
making operations. Employees often reported cases of dermatitis, and a
heavy haze existed throughout the shop.
The facility also disposed of approximately 775 gallons of coolant every

three months as hazardous waste. Hand operations were subsequently
changed to automated lines and the number of metalworking fluids used
by the facility was reduced to two semi synthetic coolants and one
straight oil.
Management personnel and the facility's fluid supplier also performed a

detailed analysis identifying the benefits and cost savings associated with
establishing a fluid management and recycling program for the facility.
In 1990, a fluid management, and recycling program was implemented.

A coolant technician position was created specifically for the purpose of

maintaining the program. Coolant is viewed as a machine tool and the
responsibilities of the coolant technician are considered of equal
importance to that of the machine operator. In order to gain employee
support for the program, a teamwork atmosphere is encouraged, and
employees regularly attend fluid management seminars conducted by the
coolant manufacturer.
Fluid Monitoring, Maintenance and Recycling

All machines are now on a monthly cleanout schedule, which is
maintained by the facility's dedicated coolant technician. Other
responsibilities of the coolant technician include keeping a daily service
log, and monitoring for bacterial growth, water hardness, and pH on a
daily basis. Each machine operator has a refractometer at the machine
and is responsible for checking coolant concentration. Deionized water
and coolant makeup lines are piped to each workstation so that machine
operators can readily replace evaporation / splash losses, and adjust fluid
concentration at the sump.
Each month, the coolant in each sump is vacuumed out with a sump
sucker. After they are pumped out, machines are thoroughly washed out,
rinsed with clean water and recharged with fresh coolant. Coolant
recovered from machine sumps is transferred to the settling tank of the
coolant recycling system. Particulates in the coolant are allowed to settle
out for approximately 12 hours while free floating tramp oil is skimmed
off of the top with a belt skimmer. The coolant is then drawn through a
centrifuge, where any residual tramp oil is transferred to a holding barrel.
Finally, the coolant is transferred to the bottom chamber where its
concentration is automatically adjusted.
During the facility's 1995 shutdown, coolant from the facility's machine
sumps was completely replaced with new coolant. The first time in five
years! It is now anticipated that the coolant will only need to be
completely changed out every 3 to 5 years. The fluid recycling and

management program also eliminates the need to dispose of the spent

coolant as hazardous waste. To dispose of the fluid, the oil is separated
out of the coolant, and provided to a used oil marketer for recycling or
energy recovery. The remaining water phase is then acceptable for
discharge to the municipal sanitary sewer system.
In addition to recycling the semi synthetic coolant, the facility also filters
and reuses the straight oil used for the facility's automatic screw
machines. Straight oil is reused for approximately 3 years before being
provided to a recycler.
Equipment Modifications
In addition to purchasing the coolant recycling system and providing
coolant and deionized water lines to each work station, the following
equipment modifications were made at the facility to prevent fluid from
spoiling:
A. Most of the machines have been modified so that the sumps are
external, and there are no hard to reach areas where coolant can become
trapped and promote bacterial growth.
B. Some of the older machines have also been equipped with skimmers
for removing tramp oil right at the machine sump.
C. The facility's 1,300 gallon sump was equipped with its own filtering
system and centrifuge for particulate and tramp oil removal.
D. Metal chips generated by the facility are either spun dry using a
centrifuge, or the fluid is allowed to drain off through the use of magnetic
chip conveyors. Chips are then collected and provided to a scrap metal
dealer. Fluid from grinding operations is passed through a vacuum
filtration system for particulate removal. Fines collected from this
operation are land filled. Any tramp oil recovered at the facility is
provided to a used oil marketer.
Results
The facility has realized the following benefits since acquiring the

recycling equipment, and establishing the fluid management program:
A. Not one documented case of dermatitis has been reported since 1990,
and the haze that once existed in the shop has been completely
eliminated.
B. No hazardous waste is generated from the facility's chip-making
operations.
C. Costs for purchasing and installing the recycling system were
recovered in approximately 6 to 8 months.

Chapter 3
How You Get The Benefits

1.Longer machine life
A machine that can go ten years without a problem in a clean shop may
need a major rebuild in as few as five years in a dirty shop.
Precision machines are priced from a few thousand dollars to many

millions. The life of the machine as well as the life between rebuilds, is
an important economic consideration.
An inescapable fact is that all machines are sensitive to wear. All the
materials in any machine are susceptible to wear from diamond, and
carbide dust as well as other particles. No machine can entirely eliminate
exposure to particles if the particles are small enough.
Machining and grinding produce a large number of very small particles.

Chips and dust from carbide, ceramics, or cobalt/chrome alloys is
different, but equally bad. Tests show that most of these particles are
under ten microns in size. Ten-micron particles easily get under seals and
work their way into bearings, slides, ball screws, bushings, ways, and
hydraulic cylinders. Dirty coolant can cut the life of a machine in half. A
machine can go ten years without a problem in a clean shop. The same
machine in a dirty shop can need a major rebuild in as few as five years.
Machine coolants need to be filtered for the same reason that oil in a car
engine needs to be filtered. The oils or coolant trap small, abrasive
particles. Unless these particles are removed, they abrade away critical
surfaces.
A large number of these particles are produced in the original operation.

If the coolant is not filtered, then the dirty coolant carries these particles

back up into the work area. As the coolant gets between the work piece,
and the work, these particles are ground and reground. They get finer and
finer. The finer they get the easier it is for them to get into critical spaces,
and destroy machine tolerances.
Machining creates big chips. Everyone has some sort of program to

handle big chips. Even the worst shops shovel them out of the way when
they start to bury the machine. Unfortunately, many people think that all
you need to do is to remove the big chips.
Every big chip means lots of small chips the same way boulders are
surrounded by little rocks. It is the little chips that do the most damage. A
great deal of expense is incurred by particles of tools, dust and metals
that are too small to see or feel. Probably the greatest source of unnoticed
damage is the grit in coolant that gets sprayed on, and into machines.
Several hundred times more damage is done by chips too little to see
than is done by big chips.
2.Longer time Between Rebuilds
3.Less down-time
As the machine wears out, it will break down more often which means
more down time.
4.Less equipment replacement

If equipment lasts longer then there is less need for replacement.
5.Faster operation
6.Faster cycle times
7.Fewer tool replacements

Dirty coolant loses its lubricity, which means it allows more heat to be
generated. In addition, dirty coolant also loses its ability to carry heat
away from the work area. Increased friction, increased heat, and impact
with particles in dirty coolant all contribute to greatly increased tool
wear. The microscopic grit produced during machining is like fine sand.
You can run faster at cooler temperatures if you are using coolant that
does not have sand in it. Your tools will last longer if they are just cutting
metal without having to work with sand, and grit in the way.
Better quality
9.Measured as the smoothness of the worked surface
Parts machined with clean coolant typically have better surfaces than
parts where the tool was scratching the surface with the grit in the
coolant. It also eliminates the instances where the occasional very large
particle puts a big scratch on the surface.
10.Measured in SPC consistency

Clean coolants mean the tools stay more nearly the same size for a longer
period of time.
In an operation where a drill makes fifty holes once an hour, the first hole
will be a certain size. As the drill heats up the tendency will be for the
following holes to get slightly larger. As the material heats with the
drilling and then cools after the drilling, it will tend to grow during
drilling, making the holes bigger and then shrink after drilling, which will
shrink the holes. At the same time wear tends to make the drill smaller.
11.Produce better overall quality work

Clean coolant means less staining, less rust and less flash rust. There are
also instance where operators will rush work, reduce coolant use or
eliminate coolant entirely, because it stinks so badly or it bothers their
skin.
12.Reduced rework
Better work the first time means less rework.

13.Reduced scrap
Tighter tolerances and reduced defective parts.
14.Measured as tighter tolerances

Less heat, less tool wear, lower tool deflection, lower thermal expansion
of the tool, and lower loss of rigidity due to heating all mean better
quality.
Greater Lubricity with clean coolant

15.No burning
16.Clean coolant will also help prevent problems with heating of the
tools.
Improperly managed coolants lose their lubricity. Lubricity obviously
reduces friction, which reduces heat, which can reduce or eliminate the
possibility of burning.
17.Less heat during machining, therefore, less change in surface

condition
Some materials are more heat sensitive than others are. During
machining there can be a skin effect created where the skin of the part is
different than the underlying material. This can come about in two ways.
The first way is similar to heat-treating. The heat of machining causes a
difference in the surface. The second way is similar work hardening.
Classically as material was hammered it changed consistency. As
material is cut in drilling, milling, turning or other operations the surface
can be changed. Sometimes this is desirable and sometimes not. In either
case, it is something that should be controlled.
18.Smoother cuts and grinds

Greater lubricity means less tool drag and tool grab during machining
and greatly helps to reduce chatter.

Reduced consumable costs

19.Longer tool run life per sharpening
20.Longer tool Life
21.Longer coolant life

Properly managed coolant can be used for months and sometimes years.
Clean coolant lasts much longer than dirty coolant. A good machine shop
will get six months to a year out of its coolant. This is a big saving on
coolant for most shops and an even bigger saving on labor. We have seen
a grinding shop go from a coolant change every three weeks to a coolant
change every six months for an improvement of eight to one. This shop
bought six thousand dollars of our filter systems and saved ten thousand
dollars the first year.
22.Longer grinding wheel life
23.Less dressing required

The oils and greases in dirty coolants clog grinding wheels and dull tools,
which means they wear out faster. Dirty coolant is a slurry of metallic
sand. A sharp tool that is run in clean coolant will stay sharper longer
than the same tool that is run in a slurry of coolant and metallic sand.
Tools of any kind wear faster if there is abrasive in the coolant. Even fine
abrasive such as the low micron range will wear a tool out faster. The
longer a tool stays sharp the longer it will be between replacements and
sharpening or dressing. Dressing and sharpening wear tools out so the
more you can cut with the fewer sharpening or dressings the better off
you are.
24.More parts per dollar of raw material

Less scrap, tighter tolerances and reduced tool breakage all reduce scrap
and rework.
Reduced Labor

25.Less machine maintenance

Machines run better; longer so there are fewer breakdowns. They stay
cleaner so there is less cleaning. Properly managed coolant dramatically
reduces the need for coolant changes and sump cleaning.
26.Less tool maintenance

The tools stay sharper, longer.
27.Finishing operations can be reduced or eliminated

Better finishes off the machine, mean less post machining work.
In a dirty shop the machines will go bad faster. Then what will happen is
that the machine will get sloppier. It will perform work to looser
tolerances. Looser tolerances mean uneven work so the tool will dull
faster and the tool will be more likely to chip or break. Sloppy machines
are also more likely to produce poor quality parts that need more
finishing.
Cleaner workplace
28.Perhaps increased operator safety
We are not experts, but a lot of experts think this is both true and
important.
There are a million to a million and a half people in the US who are
exposed to grinding and machining coolants. These coolants and their
contaminants cause skin rashes, allergic reactions, epidermal scarring,
lung scarring, emphysema, severe emphysema and death.
Top quality, trained, healthy employees are valuable assets to a firm.
Dr. Susan Kennedy, at the University of British Columbia has recently

done industrial hygiene surveys that indicate that the problems with
cobalt exposure in coolants are much greater than the government
recognizes.

An unfiltered sump could end up being about 25 to 30% sludge and

particles. The sludge and sharp particles hurt everybody when it gets into
their lungs. These are little sharp particles that do physical damage.
There is also a problem with dissolved cobalt. It causes hard metal

disease. (Hard metal diseases are different from heavy metal diseases
although both are often linked to industrial practices.). According to Ed
Chessor of the British Columbia Workers’ Compensation Board, about 1
or 2 % of the population is particularly susceptible to cobalt. They are in
much greater danger than the average person is. This is somewhat similar
to the fact that some people are much more susceptible to damage from
bee stings.
Filtering grinding coolant makes the workplace safer. It does not make
the workplace safe. Every workplace is different and you need to have
individual assessments done to adequately ensure worker safety.
The safety and health issues are incredibly important and very complex.
If you have any concerns you should call in a consultant from the
government or a private consultant to do a thorough analysis.
29.Retards bacteria growth

Proper coolant management removes bacteria before they grow much,
removes the places where they like to grow, maintains the chemistry of
the coolant so it is harder for them to grow and removes the materials
bacteria like to eat.
Bacteria grow in dirty sumps for two reasons. The sludge is an excellent
place for it to grow. Tramp oils seal off the coolant and keep air out of it.
Filtering coolant prevents bacteria growth by removing the sludge where
bacteria grow. Filtering also removes tramp oils, which create an
anaerobic environment as well as providing food for the bacteria.
30.Eliminate smells

Coolant stinks because it has bacteria in it that eat the oil and grease. The
bad smell is waste material from the bacteria. Bacteria are in the air so
you cannot keep them out of the sump completely. The bacteria that
create the worst smell are anaerobic, which is from the Greek meaning
"without air". They grow best under water without air. Filtering keeps the
coolant stirred up and keeps mixing air in. This keeps oxygen in the
coolant and further prevents bacteria growth.
31.Help eliminate noise

If you keep grit out, lubricity up, and if your tools and machines are in
good shape you are much more likely to hear low hums rather than
louder rasping.
Fewer problems than shops that use dirty coolants.

32.Less OSHA exposure
OSHA likes clean workplaces. OSHA also likes businesses that are
making serious, successful efforts to provide good workplaces.
33.Less EPA exposure
34.Less waste
35.Cleaner waste
36.Lower coolant disposal or recycling costs
37.Reduces non-coolant waste and waste disposal costs

The use of cutting, grinding and machining fluids results in the estimated
creation of well over ten million gallons of waste annually.
38.Turn an expense into income

One of the major expenses of the private sector firms is the cost of
disposing of used grinding coolant. Most firms were having it hauled
away as hazardous waste. They voluntarily had the waste classified as

hazardous because it was the safest course. One of these companies had
been involved in Superfund clean up that cost them about $50,000.This
was a company that did about $700,000 a year in sales at the time. The
clean up took all the cash reserve and created a debt load that took three
years to pay. They were most eager to avoid any new environmental
trouble.
The use of cutting, grinding and machining fluids results in the estimated
creation of well over ten million gallons of waste annually.
Used coolant has four several components. The dirty coolant. 5 - 10%
Solid waste 10 - 25%
Tramp oil 1 -5 %
Water 8-95 %
Filtering takes out the solid waste. The waste from grinding carbide tools
can be dried and sold for $0.10 to $0.15 per pound.
A shop can easily have 500 gallons of used coolant that is disposed of as
hazardous waste. Separation and evaporation can reduce this to a salable
product and leave only 50 gallons of hazardous waste. This is a
considerable financial saving for the business. It also reduces hazardous
waste, which is a good thing for society in general.
Most companies are spending a lot more money on coolant management

than they should. In many cases the coolant is used three weeks and then
hauled away as a hazardous waste at $300 a barrel. In other cases a
similar operation will use coolant six weeks or more. When it is dirty it is
separated and hauled away to be recycled at $75 to $90 a barrel.
If coolant is not handled properly the business can face a one-time fine of
up to $25,000 for having hazardous waste without a license. The
company can face fines of up to $10,000 a day until the problem is
resolved. The EPA has also started looking for executives to send to jail

for waste handling violations.

Chapter 4
Cutting Costs with Coolant Management

There are four simple steps to cutting costs. These are proper settings,
maintenance of equipment, proper air handling and proper coolant
management.
1. Make sure the settings are proper. It is common to find coolant nozzles
that are pointed in the wrong place. To compensate for this the stream of
coolant is increased. A smaller stream of coolant that is aimed properly is
more effective than a bigger stream pointed in the wrong direction.
2. Make sure the air collection equipment you already have is working
properly. Equipment that is not turned on or plugged up does not do you
any good. Some machines are so dirty that you cannot see the air intakes
any longer. Older, dirty machines may have air intakes that are buried
under years of crud. There are several new air handling machines that are
portable, inexpensive and easy to use.
Make sure air and dust collection vents are as close to the work as
possible. Moving a vent four inches away from the work cuts the
efficiency of the vent in half.
The first sign of an expensive operation is the color of the air. The dirtier
the air is the more expensive the operation is. Haze is a combination of
everything that is eating up the equipment. The thicker the haze, the
faster the equipment is being destroyed. This haze is made of
consumables such as coolant, tool and wheel particles and fumes.
If there are enough of these to get in the air so you can see them then
there are definitely more than enough of these to get into the equipment

and cause excessive wear. Even if the air appears to be clean, there can
still be as considerable number of extremely fine particles. Micro
photographic analysis of airborne dust from a machining and grinding
operation shows bits of tungsten carbide, diamond, ceramic dust and
metals as small as one micron. These are much too small to see or feel,
but they are an excellent size to penetrate seals and damage smooth
surface in hydraulics, slides, ways and bearings.
There should not be any haze, mist or smell in a well-run operation.
3.Do your maintenance. When routine maintenance is done in a good

shop the oil and greases that is taken off looks new or almost new. The
outside of the machine just needs a wipe or a gentle scrub at most. There
is no caked material. Remember we are talking precision machines and
very fine abrasive particles. If you can see any wear then it is too late.
In the most profitable shops they pretty well filter constantly, wipe the
machines down as they go several times a day, wipe the machines down
completely daily and clean them well once a week with a rebuild,
lubrication and greasing and calibration every month.
4.Coolant needs to be maintained at the proper level, it needs to be kept

at the proper concentration and it needs to be kept clean. Dirty coolant
can have as many as 75,000,000 microscopic abrasive particles per cubic
centimeter. These particles turn coolant into the same kind of liquid that
water jets use to cut through solid steel. Dirty coolant wears out faster,
smells worse, does not cool as well, does not lubricate as well and is
much more likely to contribute to rework or scrap parts.
Air and coolant quality are as important in a shop as in an automobile

engine and for the same reasons. Cars have air intake filters and oil filters
to keep dirt and metal particles from damaging the engine. Good shops
have air cleaners and coolant filter systems for the same reasons.

Overall cleanliness
The first step is overall cleanliness. This is a larger subject than coolant
cleanliness. A big part of dirt in a shop is sprayed coolant. However there
can be other sources of dirt such as road dust. Chips, normal dust and
accumulated dirt. More and more good shops look more like operating
rooms than anything else.
The difference can easily be 7% to 10% a year between a really clean

shop and a dirtier shop. This is $7,000 to $10,000 on $100,000 worth of
equipment. Anyone who has bought new equipment lately knows that
$100,000 is not much money anymore. The additional wear problem
compounds over the years. A machine may have a ten-year life between
rebuilds if treated well. If the shop air is dirty, or if the coolant is not
filtered constantly, it can rapidly cut the life in half.
Cleanliness directly tells you how much life you are getting out of your
machines. It indirectly tells you how much waste there is and how good
the work is.
If the dust and coolant are getting loose then they are also getting into
sensitive areas such as bearings and eating up machines. It is pretty easy
to see how rapidly the machines are wearing out inside by the build-up
on the outside.
Coolant management
Coolant management covers several areas and we will cover them in the
following chapters.

Chapter 5
What Coolant Is and Does

To reasonably evaluate the choices available in cutting and grinding
fluids, it's good to remember why you're using coolants in the first place.
Metal removal techniques generate friction, which in turn generates heat,
and excessive heat in metal removal is always a detriment. Consequently,
to provide proper size control and desired shape and finish, cutting and
grinding fluids must properly fulfill two important cutting functions:
lubrication and cooling.
Lubrication is important because external friction, or metal-to-metal

contact, generates approximately a third of the heat that results from
cutting. Internal friction, or the resistance of the metal atoms to
movement when the metal is deformed in the shear zone, is responsible
for generating two-thirds of the heat. When the cutting zone is properly
lubricated, cutting becomes more efficient, thereby reducing external
friction and, to a lesser extent, lowering internal friction.
To reduce internal friction, chlorine, sulfur, and phosphorous atoms in

straight oil and in extreme pressure (EP) coolant additives penetrate the
micro cracks in metallic surfaces, thereby preventing the rebonding of
metal atoms displaced in the cutting process and reducing the power
needed to form a chip. Also, by lubricating the chip/tool and tool flank /
cut surface interfaces, the angle of the shear plane increases and, as a
result, the area of the shear plane decreases. As the shear plane area
decreases, the power required to form a chip decreases and so does the
heat generated.
The cooling effect provided by cutting and grinding fluids is necessary to

remove heat from the tool, chip, and work piece. This cooling extends

tool life primarily by preventing tools from exceeding their critical

temperature range while in the cut. Beyond the critical temperature, tools
soften and wear rapidly and fail to meet tolerances for surface finish and
part size. Cooling effects also help keep the part thermally stable, aiding
in the control of part size. With so many parts today being finish
machined, (e.g., engine blocks and transmission cases), without
subsequent processing, the fluid's ability to keep the part dimensionally
stable during machining is all the more critical. In these cases, there is no
offset for heat-treating to fall back on.
The primary function of cutting fluid is temperature control through

cooling and lubrication. Application of cutting fluid also improves the
quality of the work piece by continually removing metal fines and
cuttings from the tool and cutting zone.
Temperature Control
Laboratory tests have shown that heat produced during machining has a
definite bearing on tool wear. Reducing cutting-tool temperature is
important since a small reduction in temperature will greatly extend
cutting tool life.
As cutting fluid is applied during machining operations, it removes heat

by carrying it away from the cutting tool / work piece interface. This
cooling effect prevents tools from exceeding their critical temperature
range beyond which the tool softens and wears rapidly. Fluids also
lubricate the cutting tool/work piece interface, minimizing the amount of
heat generated by friction. A fluid's cooling and lubrication properties are
critical in decreasing tool wear and extending tool life. Cooling and
lubrication are also important in achieving the desired size, finish and
shape of the work piece.
No one particular fluid has cooling and lubrication properties suitable for
every metalworking application. Straight oils provide the best lubrication,
but poor cooling capacities. Water, on the other hand, is an effective

cooling agent, removing heat 2.5 times more rapidly than oil alone.
Water is a very poor lubricant and causes rusting. Soluble oils or
chemicals, which improve lubrication, prevent corrosion and provide
other essential qualities must be added in order to transform water into a
good metalworking fluid.
Removal Of Cuttings And Particulates

A secondary function of metalworking fluid is to remove chips and metal
fines from the tool/work piece interface. To prevent a finished surface
from becoming marred, cutting chips generated during machining
operations must be continually flushed away from the cutting zone.
Application of cutting fluid also reduces the occurrence of built-up edges.

Built up edges cause increased friction and changes the cutting geometry
of the machine tool. This affects work quality and often results in poor
surface finish and inconsistencies in work piece size. Metalworking
fluids decrease the occurrence of built up edges by providing a chemical
interface between the machine tool and work piece.
Fluid Properties
In addition to providing a good machining environment, a cutting fluid
should also function safely and effectively during machining operations.
Corrosion Protection
Cutting fluids must offer some degree of corrosion protection. Freshly
cut ferrous metals tend to rust rapidly since any protective coatings have
been removed by the machining operation. A good metalworking fluid
will inhibit rust formation to avoid damage to machine parts and the work
piece. It will also impart a protective film on cutting chips to prevent
their corrosion and the formation of difficult-to-manage chunks or
clinkers.
To inhibit corrosion, a fluid must prevent metal, moisture and oxygen

from coming together. Chemical metalworking fluids now contain

additives, which prevent corrosion through formation of invisible,

nonporous films. Metalworking fluids to prevent corrosion from
occurring produce two types of invisible, nonporous films. These include
polar and passivating films. Polar films consist of organic compounds
(such as amines and fatty acids), which form a protective coating on a
metal's surface, blocking chemical reactions. Passivating films are
formed by inorganic compounds containing oxygen (such as borates,
phosphates and silicates). These compounds react with the metal surface,
producing a coating that inhibits corrosion.
Stability and Rancidity Control

In the early days of the industrial revolution, lard oil was used as a
cutting fluid. After a few days, lard oil would start to spoil and give off
an offensive odor. This rancidity was caused by bacteria and other
microscopic organisms that grew and multiplied within the oil. Modem
metalworking fluids are susceptible to the same problem.
No matter how good the engineering qualities of a coolant, if it develops

an offensive odor it can cause problems for management. The toxicity of
a fluid may also increase dramatically if it becomes rancid due to
chemical decomposition, possibly causing the fluid to become a
hazardous waste. Fluid rancidity shortens fluid life and may lead to
increased costs and regulatory burdens associated with fluid disposal.
A good cutting fluid resists decomposition during its storage and use.
Most cutting fluids are now formulated with bactericides and other
additives to control microbial growth, enhance fluid performance and
improve fluid stability.
Transparency And Viscosity

In some operations, fluid transparency or clarity may be a desired
characteristic for a cutting fluid. Transparent fluids allow operators to see
the work piece more clearly during machining operations.

Viscosity is an important property with respect to fluid performance and

maintenance. Lower viscosity fluids allow grit and dirt to settle out of
suspension. Removal of these contaminants improves the quality of the
fluid recirculating through the machining system. This can impact
product quality, fluid life and machine shop productivity.
Health and Safety Considerations

Workers in machining operations are continually exposed to cutting fluid.
A fluid must be relatively non-toxic, non-flammable and non-misting to
minimize health and safety risks.
Toxicity
Most metalworking fluids are not highly toxic. The fluid becoming
rancid, super concentrated, or contaminated usually causes toxicological
problems associated with metalworking fluids. The main routes of
exposure for metalworking fluid include inhalation (via vapor, smoke or
mist), ingestion and skin absorption. Dermatitis and respiratory problems
are the most frequent health problems of machine shop personnel.
Due to the variety of ingredients contained in metalworking fluids, it is

often very difficult to anticipate whether the fluid will affect individuals
constantly exposed to this material. The Material Safety Data Sheet
(MSDS) for a metalworking fluid contains important health and safety
information and should be reviewed as a first step in fluid selection.
Flammability
Machining operations typically generate a significant amount of heat,
which can cause cutting fluids to smoke and/or ignite. A fluid should
have a high flashpoint to avoid problems associated with heat damage,
the production of smoke, or fluid ignition.
Misting
High-speed metalworking operations such as grinding may atomize fluid,
creating a fine mist, which can be an inhalation hazard for machine tool

operators. Misting also creates a dirty work environment by coating

equipment and the surrounding work area. Non-misting fluids provide
safer working conditions for the machine operator.

Chapter 6
Types Of Coolants
Cutting fluids have been used extensively in metal cutting operations for
the last 200 years. In the beginning, cutting fluids consisted of simple oils
applied with brushes to lubricate the machine tool. Occasionally, lard,
animal fat or whale oil was added to improve the oil's lubricity. As
cutting operations became more severe, cutting fluid formulations
became more complex. Today's cutting fluids are special blends of
chemical additives, lubricants and water formulated to meet the
performance demands of the metalworking industry.
There are now several types of cutting fluids on the market, the most
common of which can be broadly categorized as cutting oils or water-
miscible fluids. Water-miscible fluids, including soluble oils, synthetics
and semi synthetics, are now used in approximately 80 to 90 percent of
all applications. Although straight cutting oils are less popular than they
were in the past, they are still the fluid of choice for certain metalworking
applications
Essentially there is water, water with oil and synthetic coolants. Adding
oil or synthetic materials to the water does several things. It adds rust
preventative, it helps carry away the heat, it more effectively removes
particles, it helps prevent corrosion and it retards or prevents bacteria and
fungus build up.
Oil is superior in applications where heat transfer is critical. The most

common, extreme example of this is tapping deep holes. It is extremely
difficult to get a good flow of material across the work face in this
application so the coolant must provide maximum lubricity and heat
transfer. In this application it is also very easy to control the spray and to

keep the coolant away from the operator since all the work takes place in
a deep, sealed hole.
Synthetic coolants are superior in applications such as grinding where a

strong flow across the workface is both possible and desirable. The
synthetic coolants do not transfer heat as well as oils, but the flow
possible in grinding applications more than makes up for that. In
addition, open grinding such as flat, exposed surfaces throws a great deal
of coolant into the air in various size droplets. Oil based coolants are
more likely to trap and contain metals and particles. In addition, there is
the problem in breathing petroleum products.
Specific synthetic lubricants can be superior in terms of lubricity and heat

transfer to petroleum based products. Perhaps the most common example
is the synthetic products available for automotive applications. In high
performance automobile engines such as CorvetteÒ engines the dealers
strongly recommend synthetic lubricants over natural, petroleum
lubricants because of the extreme requirement for lubrication and
cooling.
Some coolants are a lot easier to test than others. Some coolants show a
color change as the amount of dissolved coolant gets greater. Some
coolants trap particles and float them in suspension a lot better than
others. Some coolants are safer than others and some work better for
grinding. Some are also much safer to breathe and dispose of. For the
purposes of easy testing we recommend clear coolants.
The most common metalworking fluids used today belong to one of two
categories based on their oil content:
● Oil Based Fluids including straight oils and soluble oils

● Chemical Fluids including synthetics and semi synthetics
Fluids vary in suitability for metalworking operations. For example,

petroleum - based cutting oils are frequently used for drilling and tapping
operations due to their excellent lubricity while water- miscible fluids
provide the cooling properties required for most turning and grinding
operations.
Oil Based Cutting Fluids

Straight Oils - 100% Petroleum Oil
Straight oils, so called because they do not contain water, are basically
petroleum or mineral oils. They may have additives designed to improve
specific properties [1,3]. Generally additives are not required for the
easiest tasks such as light-duty machining of ferrous and nonferrous
metals. For more severe applications, straight oils may contain wetting
agents (typically up to 20% fatty oils) and extreme pressure (EP)
additives such as sulfur, chlorine, or phosphorus compounds. These
additives improve the oil's wettability; that is, the ability of the oil to coat
the cutting tool, work piece and metal fines. They also enhance
lubrication, improve the oil's ability to handle large amounts of metal
fines, and help guard against microscopic welding in heavy duty
machining. For extreme conditions, additives (primarily with chlorine
and sulfurized fatty oils) may exceed 20%. These additives strongly
enhance the antiwelding properties of the product.
Advantages
The major advantage of straight oils is the excellent lubricity or
"cushioning" effect they provide between the work piece and cutting tool.
This is particularly useful for low speed, low clearance operations
requiring high quality surface finishes. Although their cost is high, they
provide the longest tool life for a number of applications. Highly
compounded straight oils are still preferred for severe cutting operations
such as crush grinding, severe broaching and tapping, deep-hole drilling,
and for the more difficult to cut metals such as certain stainless steels and
superalloys. They are also the fluid of choice for most honing operations
due to their high lubricating qualities.
Straight oils offer good rust protection, extended sump life, easy
maintenance, and are less likely to cause problems if misused. They also
resist rancidity, since bacteria cannot thrive unless water contaminates
the oil.
Disadvantages
Disadvantages of straight oils include poor heat dissipating properties
and increased fire risk. They may also create a mist or smoke that results
in an unsafe work environment for the machine operator, particularly
when machines have inadequate shielding or when shops have poor
ventilation systems. Straight oils are usually limited to low temperature,
low speed operations. The oily film left on the work piece makes
cleaning more difficult, often requiring the use of cleaning solvents.
Straight oil products of different viscosities are available for each duty
class. Viscosity can be thought of as a lubricant factor. The higher the
oil's viscosity, the greater its lubricity. Highly viscous fluids tend to cling
to the work piece and tool. This causes increased cutting fluid loss by
dragout and necessitates lengthier, more costly cleanup procedures. It can
be more efficient to choose low viscosity oil that has been compounded
to provide the same lubricity as a highly viscous one.
Soluble Oils – 60% to 90% Petroleum Oil

Soluble oils (also referred to as emulsions, emulsifiable oils or water
soluble oils) are generally comprised of 60 - 90 percent petroleum or
mineral oil, emulsifiers and other additives. A concentrate is mixed with
water to form the metalworking fluid. When mixed, emulsifiers, (a soap
like material) cause the oil to disperse in water forming a stable "oil in
water" emulsion. They also cause the oils to cling to the work piece
during machining. Emulsifier particles refract light, giving the fluid a
milky, opaque appearance.
Advantages

Soluble oils offer improved cooling capabilities and good lubrication due
to the blending of oil and water. They also tend to leave a protective oil
film on moving components of machine tools and resist emulsification of
greases and slideway oils.
Soluble oils are a general-purpose product suitable for light and medium
duty operations involving a variety of ferrous and nonferrous
applications. Although they do not match the lubricity offered by straight
oils, wetting agents and EP additives (such as chlorine, phosphorus or
sulfur compounds) can extend their machining application range to
include heavy-duty operations. Most cutting operations handled by
straight oils (such as broaching, trepanning, and tapping) may be
accomplished using heavy-duty soluble oils.
Disadvantages
The presence of water makes soluble oils more susceptible to rust control
problems, bacterial growth and rancidity, tramp oil contamination, and
evaporation losses. Soluble oils are usually formulated with additives to
provide additional corrosion protection and resistance to microbial
degradation. Maintenance costs to retain the desired characteristics of
soluble oil are relatively high. Other disadvantages of soluble oils include
the following:
When mixed with hard water, soluble oils tend to form precipitates on
parts, machines and filters.
Due to their high oil content, they may be the most difficult of the water
miscible fluids to clean from the work piece.
Misting of soluble oils may produce a dirty and unsafe work

environment, through slippery surfaces and inhalation hazards.
As a result of these disadvantages, soluble oils have been replaced in

most operations with chemical cutting fluids.

Chemical Cutting Fluids

Chemical cutting fluids, called synthetic or semi synthetic fluids, have
been widely accepted since they were first introduced in about 1945.
They are stable, preformed emulsions, which contain very little oil and
mix easily with water. Chemical cutting fluids rely on chemical agents
for lubrication and friction reduction. These additives also improve
wettability. At temperatures above approximately 390OF (2000C), these
additives become ineffective and EP lubricant additives (chlorine,
phosphorus and sulfur compounds) are utilized.
These compounds react with freshly machined metal to form chemical

layers, which act as a solid lubricant and guard against welding during
heavy-duty machining operations. Fluids containing EP lubricants
significantly reduce the heat generated during cutting and grinding
operations.
Synthetics - No Petroleum Oils

Synthetic fluids contain no petroleum or mineral oil. They were
introduced in the late 1950's and generally consist of chemical lubricants
and rust inhibitors dissolved in water. Like soluble oils, synthetics are
provided as a concentrate, which is mixed with water to form the
metalworking fluid. These fluids are designed for high cooling capacity,
lubricity, corrosion prevention, and easy maintenance. Due to their higher
cooling capacity, synthetics tend to be preferred for high heat, high
velocity turning operations such as surface grinding. They are also
desirable when clarity or low foam characteristics are required. Heavy-
duty synthetics, introduced during the last few years, are now capable of
handling most machining operations.
Synthetic fluids can be further classified as simple, complex or

emulsifiable synthetics based on their composition. Simple synthetic
concentrates (also referred to as true solutions) are primarily used for
light duty grinding operations. Complex synthetics contain synthetic

lubricants and may be used for moderate to heavy duty machining

operations. Machining may also be performed at higher speeds and feeds
when using complex synthetics. Both simple and complex synthetics
form transparent solutions when mixed in a coolant sump, allowing
machine operators to see the work piece.
Emulsifiable synthetics contain additional compounds to create

lubrication properties similar to soluble oils, allowing these fluids to
double as a lubricant and coolant during heavy-duty machining
applications. Due to their wettability, good cooling and lubricity,
emulsifiable synthetics are capable of handling heavy-duty grinding and
cutting operations on tough, difficult to machine and high temperature
alloys. The appearance of emulsifiable synthetic fluids ranges from
translucent to opaque.
Chemical agents found in most synthetic fluids include:
Amines and nitrites for rust prevention
Nitrates for nitrite stabilization
Phosphates and borates for water softening
Soaps and wetting agents for lubrication
Phosphorus, chlorine, and sulfur compounds for

chemical lubrication
Glycols to act as blending agents

Biocides to control bacterial growth.
Advantages
Synthetics provide excellent microbial control and resistance to rancidity.
They are largely nonflammable and nonsmoking with good corrosion
control and superior cooling qualities. Synthetics have greater stability
when mixed with hard water. In addition they reduce misting problems
and foaming problems.
Synthetics are easily separated from the work piece and chips, allowing
for easy cleaning and handling of these materials. In addition, since the
amount of fluid clinging to the work piece and chips is reduced, less
makeup fluid is needed to replace coolant lost to dragout.
Good settling properties allow fine particulates to readily drop out of

suspension, preventing them from recirculating and clogging the machine
cooling system. Overall, synthetics are easier to maintain due to their
cleanliness, they offer long service life if properly maintained and can be
used for a variety of machining operations.
Disadvantages
Although synthetics are less susceptible to problems associated with oil
based fluids, moderate to high agitation conditions may still cause them
to foam or generate fine mists. A number of health and safety concerns,
such as misting and dermatitis, also remain with the use of synthetics in
the shop. Ingredients added to enhance the lubricity and wettability of
emulsifiable synthetics may increase the tendency of these fluids to
emulsify tramp oil, foam and leave semi crystalline to gummy residues
on machine systems (particularly when mixed with hard water).
Synthetic fluids are easily contaminated by other machine fluids such as

lubricating oils and need to be monitored and maintained to be used
effectively.
Semi synthetics - 2% to 30% Petroleum Oil

As the name implies, semi synthetics (also referred to as semi-chemical
fluids) are essentially a hybrid of soluble oils and synthetics. They
contain small dispersions of mineral oil, typically 2 to 30 percent, in a
water dilatable concentrate. The remaining portion of a semi synthetic
concentrate consists mainly of emulsifiers and water. Wetting agents,
corrosion inhibitors and biocide additives are also present. Semi
synthetics are often referred to as chemical emulsions or preformed
chemical emulsions since the concentrate already contains water and the
emulsification of oil and water occurs during its production.
The high emulsifier content of semi synthetics tends to keep suspended

oil globules small in size, decreasing the amount of light refracted by the
fluid. Semi synthetics are normally translucent but can vary from almost
transparent (having only a slight haze) to opaque. Most semi synthetics
are also heat sensitive. Oil molecules in semi synthetics tend to gather
around the cutting tool and provide more lubricity. As the solution cools,
the molecules redisperse.
Advantages
Like synthetics, semi synthetics are suitable for use in a wide range of
machining applications and are substantially easier to maintain than
soluble oils. They provide good lubricity for moderate to heavy-duty
applications. They also have better cooling and wetting properties than
soluble oils, allowing users to cut at higher speeds and faster feed rates.
Their viscosity is also less than that of a soluble oil, providing better
settling and cleaning properties. Semi synthetics provide better control
over rancidity and bacterial growth, generate less smoke and oil mist
(because they contain less oil than straight or soluble oils), have greater
longevity, and good corrosion protection.
Disadvantages
Water hardness affects the stability of semi synthetics and may result in

the formation of hard water scum deposits. Semi synthetics also foam
easily because of their cleaning additives and generally offer less
lubrication than soluble oils.
Cutting Fluid Types Advantages vs. Disadvantages
Straight Oils
Advantages Disadvantages
Excellent lubricity Poor heat dissipation
Good rust protection Increased risk of fire
Good sump life Increased risk of smoking
Easy maintenance Increased risk of misting
Rancid resistant Oil film on work piece
Limited to low - speed, severe

cutting operations
Soluble Oils

More susceptible to rust

Good lubrication
problems
Improved cooling Susceptible to bacterial

capabilities growth
Susceptible to tramp oil

Good rust protection
contamination
General-purpose product
Susceptible to evaporation
for light to heavy-duty
losses
operations
Increased maintenance costs
May form precipitates on

machine
Misting
Oily film on work piece
Long service life
Long service life

Synthetic

Excellent microbial control Reduced lubrication
Resistance to rancidity May cause misting
Relatively nontoxic May cause foaming
Transparent May cause dermatitis
Nonflammable /
May emulsify tramp oil
nonsmoking
Good corrosion control May form residues
Easily contaminated by
Superior cooling qualities
other machine fluids
Reduced misting / foaming
Easily separated from work/

chips
Good settling / cleaning

properties
Easy maintenance
Used for a wide range of

machining applications

Semi - synthetics
Water hardness affects

Good microbial control
stability
Resistance to rancidity May cause misting
Relatively nontoxic May cause foaming
Nonflammable /
May cause dermatitis
nonsmoking
Good corrosion control May emulsify tramp oil
Good cooling May form residues
Easily contaminated by
Good lubrication
other machine fluids
Reduced misting / foaming
Easily separated from work/

chips
Good settling / cleaning

properties

Easy maintenance
Long service life
Used for a wide range of

machining applications

Chapter 7
Example of a Synthetic Coolant

Description: Ultra Synthetic 331 Grinding Coolant
This is a unique, heavy-duty synthetic coolant concentrate containing

lubricity agents, anti corrosion additives and other components to satisfy
the demands of today’s higher performance machining operations. When
diluted with water in the proper concentration, this premium product
functions as a heavy duty cutting fluid. Containing no oil, this fluid
shows distinct advantages over the more conventional “soluble” or
“emulsifiable” cutting oils commonly used in industry, particularly in the
areas of (1) ease of mixing and clean up, (2) improved solution stability,
(3) freedom from odor and rancidity, (heat) transfer, and (5) work face
visibility.
Fluids prepared from this concentrate find special uses in a variety of

metal working applications where the cooling effects of water coupled
with a balanced lubricity-corrosion protection additive package serves to
prevent chip and particle build up and wear at the critical tool-work piece
interface. This extends tool life and improves worked surface finish.
Qualities & Benefits:

1.Provides extreme pressure properties for heavy duty operations
2.Easy to mix - no special procedures required
3.Transparent for better viewing of the work piece during processing
4.Eliminates oil mist associated with petroleum oil products
5.Contains no oil, leaves no gummy residues
6.Provides a stable mixture in hard water
7.Provides excellent rust and corrosion protection
8.Rejects tramp oil easily
9.Biodegradable-for ease of disposal in primary sewage treatment

systems
10.Contains a fungicide to protect against initial fungal growth in service.
Monitoring microbial activity over extended service periods would be
advisable to determine the need for additional treatment.
11.Contains no phenols, nitrites, PCB’s or heavy metals
12.Resists sludge build up, economical
13.Distinctive blue color
14.Wash off parts in cool water
Applications:
This coolant is recommended for use in internal and external grinding as
well as form and thread grinding. It is suitable for a wide variety of
metals as well as other materials such as carbides and ceramics. The
recommended initial concentration is 20:1.With applications involving
harder materials a higher concentration may be desirable. It may be
possible to reduce the concentration if the results remain satisfactory.

Chapter 8
Coolant Selection
Coolants perform two important functions: lubrication and
cooling.Lubrication is important because metal sliding on metal produces
about 30% of the heat and the resistance of metal to being cut produces
the rest.Good lubrication reduces friction and reduces heat.This increases
tool life and helps keep the part temperature constant.Coolants reduce
friction because chlorine, sulfur, and phosphorous atoms penetrate the
metallic surfaces.This reduces friction and improves the shear angle.
Lubrication and cooling requirements vary according to the kind of

operation, kind of part, type of metal, tool material and geometry as well
as the machining parameters.Coolant effectiveness is tied in with a large
number of factors including tool size shape and material as well as the
properties of the material being worked and the machine doing the
work.Coolant selection can affect cutting energy, which increases as you
get deeper into a cut due to the increase in friction and reduce cutting
noise.
Typically good lubricants are bad at cooling and vice versa. Water is the
best coolant because it picks up the most heat, and transfers it
fastest.Water is not a good lubricant. It rusts iron and steel and it doesn't
wet and penetrate well.Oil is an excellent lubricant, but it is a poor
coolant and is flammable. A common and often good solution is to mix
oils and similar with water to get both lubrication and cooling.
In general, tool wear is caused by the continuous abrasion of chips in

front of the tool. The abrasion produced by coolant crushing is
less.Washing clears the chips and dirt away from the working
area.Mineral oils in some coolants will cause dirt to stick to the tool and
part and will pollute the environment.
Don't choose a fluid just on its initial cost but on the cost per gallon
divided by its life expectancy.Although purchase of a premium product is
initially more expensive, the long?term cost of the fluid will likely be
lower than products of inferior quality because of its superior fluid life.
During fluid selection, the benefits of a fluid's versatility should be

weighed against its performance in each metalworking application.
Because of significant improvements in fluid formulations, today's fluids
are capable of handling a wide variety of machining applications.
Machine shops that once required several types of fluids may now find
that one or two fluid types meet their needs. Consolidating the number of
fluids used in the shop simplifies fluid management.
Easy removal of the slurry, chips, etc. from the coolant is also essential.
Try to avoid coolants containing chlorinated compounds, they may

require hazardous waste disposal
Reduce the number of different coolants used in your shop, if possible.

This can cut the cost of coolant maintenance and disposal, and permit
your shop to buy in bulk.
Machining functions

● Speed, feed and depth of the cutting operation

● Type, hardness and microstructure of the
metal being machined
● Lubricity
● Cooling
● Coolant's applicable temperature operating
range
● Optimal concentration and pH ranges
● Dimensional control of parts
● Surface finishes
● Machine tool maintenance costs
● Tool wear
● Downtime for tool and wheel changes
● Power draw
● Noise
● Range of compatible materials
● Tramp oil rejection
● Ability to settle out solids
● Emulsification capability
Noncutting functions
● Corrosion inhibition
● Fluid residues
● Flammability
● Filtration
● Toxicity
● Recycling
● Resistance to bacterial growth
Operator Acceptance

● Operator safety
● Dermatitis
● Odor
● Feel
● Appearance
Financial return
● Effect on production costs
● Purchase price
● Effective life
● Usage over time
● Disposal &/or recycling
● Tool and wheel life
Coolant properties
● Ease of fluid maintenance and quality control
● Ability to separate fluid from the work and
cuttings
● Storage practices Surface tension
● Hard water resistance
● Densities
● Biodegradability
● Capacity of recycled coolant to prevent
galvanic attack
● Stability
● Foaming nature and resistance
● Precipitation properties
● Ease of disposal

Chapter 9
Water Quality
Water used in coolant mixtures should be made as pure as possible.
Hard water can and will
● Effect the quality of the end product

● Increase maintenance costs of machinery
● Decrease process efficiency
● Corrode machine tools
● Corrode machined parts
● Leave residues on machine tools
● Increase the growth rate of bacteria and fungi
● Decrease useful life of metalworking fluids
Monitoring and Maintenance
● Prepare and mix the fluid according to manufacturer's directions.

● Use quality water to dilute fluid concentrate and replenish
evaporation losses
● Monitor and maintain proper fluid concentration.
● Monitor for microbial contamination and control microbial growth
through water quality control, maintaining proper fluid
concentration and pH, routine maintenance of equipment, biocide
additions and aeration
● Monitor pH for signs of fluid degradation
● Perform regular machining system inspections and maintenance
practices, particulate removal, tramp oil control, general
housekeeping and annual cleanouts
● Prevent foaming with proper fluid concentration, quality water and

eliminating mechanical effects that agitate cutting fluid.
Even the cleanest of shop water is not pure. Average tap water can
contain 170 ppm or greater of dissolved solids. This level of
contaminants generally requires a pretreatment procedure. Calcium and
magnesium ions constitute virtually all the hardness minerals found in
water. Other elements such as iron and aluminum are minor sources, but
they can cause problems far out of proportion to their concentration.
Impurities within water, even after pretreatment, can consist of

suspended particles, colloids, dissolved inorganic solids, dissolved
inorganic gases, dissolved organics, and microorganisms.
Rainwater is soft, containing virtually no minerals. Water from lakes,

rivers and wells can be either soft or hard. It's estimated that more than
70% of U.S. public water supplies are considered hard. Water throughout
the United States is generally hard. Hardness is a measure of the
dissolved calcium, magnesium, and iron salts in water. "Soft" water
generally refers to water with a hardness ranging from 0-100 parts per
million (ppm) while "hard" water contains concentrations of 200 ppm or
more. For metalworking fluids, the ideal hardness for makeup water is
generally 80 to 125 ppm.
Foaming may become a problem when concentrate is mixed with water

having a hardness below this range, particularly in systems in which the
fluid is agitated excessively. A hardness above this range may cause
dissolved minerals to react with fluid additives, degrading fluid
performance.
Hard water minerals combine with emulsifiers contained in synthetic or

semi synthetic concentrates to form scum deposits on sumps, pipes,
filters, and even the machine. Hard water can also cause the oil to
separate out of suspension.

Since water miscible fluids may consist of up to 99% water, the quality
of the water used to dilute the concentrate is an important consideration
in fluid preparation. Dissolved minerals and gases, organic matter,
microorganisms, or combinations of these impurities can lead to
problems.
The total dissolved solids (TDS) concentration of water is also a concern

in fluid management. To maintain proper fluid chemistry, use untreated
water with an acceptable mineral content for initial fluid makeup.
Sulfates promote bacterial growth that causes fluids to become rancid. In
many areas, drinking water may have sulfate concentrations of 50 to 100
ppm. Chloride salts and sulfates at concentrations above 80 ppm
contribute to corrosion. Chloride levels are generally less than 10 ppm in
untreated water but are greatly increased by common water softening.
Phosphate concentrations above 30 ppm also react with the fluid to
stimulate bacterial growth, irritate the skin and cause rancidity. TDS
concentrations should be less than 80 ppm for chlorides and sulfates and
less than 30 ppm for phosphates.
During normal fluid use, evaporation of water increases the concentration

of the metalworking fluid. As new water is introduced to replenish
system evaporation losses, additional dissolved minerals are also added.
Consequently, the TDS concentration of a fluid builds up over time. The
greater the TDS concentration of the makeup water, the faster these
concentrations increase in the metalworking fluid.
In order to maintain proper fluid chemistry, untreated water with an

acceptable mineral content should be used for initial fluid makeup. When
replenishing evaporation losses, machine operators should add premixed
fluid, not just water, to the system. Adding fresh fluid to the system
ensures that needed additives such as rust inhibitors and emulsifiers are
maintained at desired concentrations. Demineralized or deionized water
should be used as the make up water for fluid additions to prevent TDS
levels from building up in the fluid. If tap water is continually used, the

mineral content of the coolant continues to increase. Concentrated

minerals can form deposits and soaps, gumming up the metal working
process.
Water Quality Guidelines

Hardness of 80 - 125 ppm
Less than 80 ppm chloride and sulfates
Less than 30 ppm phosphates
Improving water quality

Adsorption
Adsorption involves exposing the water to high surface areas of activated
carbon or a unique resin to tie up organics, chlorine, and colloids from
the feed water. It is used as a pretreatment to other purification
technologies that follow it. It is not used as a final step in eliminating
total organic content.
Deionization
Deionization is often referred to as a demineralization or ion exchange.
Ions are removed from the water through a series of chemical reactions
that take place as the water passes through an ion exchange resin bed.
Deionization systems typically provide water free of dissolved
inorganics.
Distillation
Distillation is the most common water purification technique. Water
undergoes phase changes during the process, changing from liquid to
vapor and back to liquid. The change from liquid to vapor prompts a
separation of water from its impurities. It effectively removes most
inorganic solids, all organics with a boiling point greater than water and
virtually all bacteria.
Reverse osmosis
Reverse osmosis occurs when water is pushed through a semi permeable

membrane using external pressures. These systems typically remove 85%

to 95% of inorganic solids, 99% of larger organic solids, and more than
99% of the solid particles, bacteria, and pyrogens.
Filtration systems
Filtration systems are classified as either a depth or membrane type.
Depth filters are made by winding fiber around a hollow and slotted tube.
As water passes through the tube, particulates are removed and held in
the fiber. Membrane filters usually have a sub micron pore size. Particles
and bacteria cannot pass through the membrane and are held on the
membrane surface.
Ultra filtration
Ultra filtration can be used for pretreating water going into an additional
purification process or it can be used at the very end of the system to
remove pyrogens. Pure water permeates the membrane, but particles,
colloidal silica, bacteria, pyrogens, and high molecular weight organics
are rejected.
Ultraviolet oxidation
Ultraviolet oxidation is a process utilizing UV light used to eliminate
trace organics and kill microbes in pure water.
Coolant Preparation
If coolant life is a problem it is a good idea to do a water analysis. Often
the water supplier can do this. It may be necessary to use treated water
such as deionized water. These types of water purification equipment
extract ions. Deionizers can use an inline tank, or a reverse osmosis unit.
Distillation may also be an option.
Home type water softeners can help by removing the minerals that
contribute to metal corrosion and/or salt deposits but they are generally
not considered thorough enough for coolant preparation.


Chapter 10
Parts Of A Coolant Management Program

The three components of a successful fluid management program are:
Administration
Fluid Monitoring and Maintenance
Fluid Recycling
Introduction
A great number of industrial processes such as grinding, milling and
turning create heat and particles. Coolants are used to keep the work
surface cool and to carry away chips and particles.
Far and away the majority of machining is done with carbide or ceramic
tools. These tools wear and microchip in use. Machining creates chips.
Tungsten carbide as used here is really particles of tungsten carbide held
in a cobalt matrix.
Typically machines and grinders are flood cooled which means that water
is flooded over the work area. This cools the work and washes particles
out of the way. The liquid is typically 90 to 95% water and 5 to 10%
coolant. The liquid runs over the work area and then down the machine
where it collects in a sump at the bottom of the machine. The liquid is
pumped out of the sump and constantly recirculated. As the work is done,
the tool material and pieces of the, metal or composite or other material
being machined collect in the sump.
If the coolant is recirculated these fine particles are pumped up to the

spray head and sprayed onto the work area. Some of the particles are
thrown into the air where they can be inhaled. Other particles are
reground into even finer particles. These recirculated chunks will cause

rougher grinds and will increase the chance of burning during grinding.
The whole area of coolant management is generally poorly understood. It

is estimated that somewhere between $100,000, 000 and $500,000,000
worth of machine value is lost each year due to improper coolant
management. $500,000 is not all that expensive a machine any more.
Improper coolant management can shorten the serviceable time between
rebuild and / or replacement by as much as 10% a year. As the need for
precision gets ever greater, the need to keep coolant cleaner is more
important than ever. When 0.001" was a tight specification coolant
filtered to ten microns was allowable. Now that specs are increasingly
closer to 0.001" coolant needs to be maintained to below one micron. Yet
a great many shops consider a system that filters to ten microns to be
state of the art.
Grinding coolant filtering is something that large, sophisticated shops

have been doing for years. The recent development of smaller, less
expensive and more efficient filter units combined with the needs for
greater quality and tighter government regulations seem to be pointing to
the day where every grinder will have a coolant filter just as every
automobile has an oil filter.
Machine coolants need to be filtered for the same reason that oil in a car
engine needs to be filtered. The oils or coolant trap small, abrasive
particles. Unless these particles are removed they abrade away critical
surfaces. If you are filtering the oil in your $20,000 car then you ought to
be filtering the coolant in your $30,000 machine for exactly the same
reasons.
Components of Fluid Management Program

Administration
1. Commit the personnel, equipment and other resources necessary for

the program.

2. Provide management reference for implementing and tracking the

program
3. Encourage employee support and participation.
4. Designate fluid management personnel to implement the program.
5. Educate personnel on things effecting fluid performance and
failure.
6. Survey the fluids, machines and sump capacities of the shop.
7. Develop a record keeping system to track the program.
8. Identify corrective action procedures and execute them
Record Keeping
Record keeping is an important aspect of fluid management, and it begins
with the initial preparation of the fluid.
Following its preparation, the pH and concentration of the fluid should be

measured and recorded. These initial readings should correspond to the
acceptable product quality ranges provided by the fluid supplier. They
also provide a baseline from which to evaluate the condition of the fluid
over time. Fluid pH and concentration measurements are compared to
"new fluid" values to assess fluid quality.
A detailed logbook documenting fluid usage information should be

maintained. Fluid management logs for each machine should include the
following information:
1. Brief description of the machine and sump/reservoir capacities

2. Type of fluid used
3. Fluid mixing ratios and initial parameter readings
4. Water quality data
5. Monitoring data including pH readings, biological monitoring data,
fluid concentration measurements and inspection observations
6. Adjustments made as part of fluid maintenance
7. Fluid recycling and/or disposal frequencies, including dates of
coolant change out and reason for change out

8. Equipment cleaning and maintenance activities, dates and

comments
9. Quantity of coolant added (both change out and periodic additions)
10. Documentation of problems that occur
11. General comments
Plant
Chemical maintenance - which includes checking:
● Water
● Bacteria growth
● Tramp oil control
● Lubricant chemistry
Physical maintenance - which includes upkeep of:
● Filtration
● Clarification
● Skimmers
● Heat exchange
● Tooling
Coolant Management System Checklist
1. Determine the fewest different coolants that can be used.

2. Check compatibility of coolant with cleaning system.
3. Find substitutes for chlorinated oils.
4. Use quality products that last longer.
5. Use a lubricant that can remain on the piece as long as necessary
6. Consider substituting hot lime bath or borax soap for oil.
7. Determine whether deionized water should be used.
8. Train employees on coolant changes. Get their feedback.
9. Train employees to keep foreign material out of coolant system.
10. Assign fluid control responsibility to one person, with backups.

Provide adequate training.

11. Use non-chlorinated biocides, pasteurization, or aeration to kill
bacteria (check with your coolant supplier). Check the effect on
your waste handler or recycler.
12. Analyze and monitor biocides, coolant composition, acidity, and
possibly bacteria levels. Keep records.
13. Adjust coolant composition and acidity as necessary. Make sumps
easy to access and sanitize (line with sheet metal, round comers,
etc.).
14. Remove coolant and sanitize the system on a regular basis. Sanitize
reservoirs, sumps, trenches, coolant feed systems, and metal
working equipment using an alkaline cleaner, steam cleaning, etc.
15. Remove metal fines from coolant and sumps on a regular basis.
16. Install vacuum devices or other coolant recovery system for
machines not on a separate coolant sump. Remove tramp oils from
coolant on a regular basis, using disk or belt skinners, coalescers,
filters, dissolved air flotation.
17. If skimming equipment cannot be placed near the pump, use a
baffle or weir system to contain the oil near the skimmers. Run
skimmers intermittently, to prevent excessive coolant loss. Perform
regularly scheduled gasket, wiper, and seal maintenance.
18. If possible hard to reach areas as well as nooks and corners should
be eliminated.
Recycling
1. Recover lost coolant from metal fines and scrap, using methods
Disposal, & such as draining, centrifuging, chip wringers, and scrap
conveyors.
2. Do not mix different waste coolants.
3. Segregate metal waste by material type.
4. Recycle oils if possible. Consider "splitting" emulsions to recycle
oil. Check with sewer utility before discharging water portion.
5. Know whether your waste coolant tests to be a dangerous waste.
6. Check with sewer utility for discharge restrictions.

7. Do not discharge to septic or storm systems or dry wells. Know
where your drains discharge.
8. Store drums and containers where they won't collect rainwater.
9. Keep Material Safety Data Sheets (from your suppliers).
10. Train employees in emergency procedures, health and safety,
regulations, and material management procedures.
11. Ask vendors for less hazardous products.
12. Contact regulatory agencies for applicable laws and assistance.
13. Use proper safety equipment and clothing.
Mixing
Coolant should always be mixed by following the suppliers' directions
and by measuring. Mixing coolant "by eye" doesn't work well enough.
Mixtures should be prepared according to the manufacturer's directions
(as obtained through the fluid supplier and/or product literature).
Mixing should always be done outside the sump. Mixing in the sump is
quick and easy method but the coolant doesn't get fully mixed and it is
almost impossible to measure fluid concentration accurately.
Fluid Concentration
If the concentration is too high it means there is too much coolant and not
enough water. This means wasted concentrate, poorer heat transfer,
foaming, reduced lubrication, residue formation and more built-up edges
for shorter tool life. Over-concentrated fluid can stain the work and / or
the machine and it increase the toxicity of the fluid, which means
increased skin irritation. Low concentration means poor lubricity, shorter
tool life, more bacterial growth activity and an increased risk of rust.
Evaporation means a loss 3% to 10% of water daily. Water and

concentrate are both lost as a result of splashing, misting and dragout.
The daily loss of coolant mixture maybe as much as 5% to 20% form all
these. This means the coolant concentration will change every day.

The coolant needs to be checked daily at the start. As the system gets
more stable weekly checks maybe appropriate. It depends on how well
your system is functioning and how much it changes from day to day.
Cooling units or chillers on machine sumps or central reservoirs reduce

evaporation losses, help extend tool life by inhibiting microbial activity
and increase the fluid's ability to remove heat.
System Inspections
Inspections of the fluid and over all system for cleanliness are important
to monitor fluid quality and avoid premature fluid failure. Operators and
maintenance personnel should both do this.
Signs, which indicate a need for fluid maintenance or recycling

Excessive tramp oil accumulation
Buildup of metal cuttings within the sump
Foaming problems
Leaky machinery
Dirt and bacterial slime accumulations
Routine Maintenance Practices

Maintaining clean machines, coolant lines and sumps is an essential part
of coolant management. Clean machines use metalworking fluids more
economically and extend fluid life. Any dirt and oil allowed to remain in
the system simply recirculates, resulting in plugged coolant lines,
unsightly machine buildup and bacterial growth
Chips and swarf

Excessive chip accumulation and swarf reduces sump volume, damages
coolant and provides an environment for bacterial growth. Excessive
solid buildup can cause increase coolant temperature. Chips and swarf
should be removed as often as possible.
Tramp oil control

Tramp oils such as hydraulic oil, lubricating oil or residual oil film from
the work piece can cause coolant to break down prematurely. These oils
provide a source of food for bacteria, interfere with the cooling capability
of the fluid and contribute to the formation of oil mist and smoke in the
workplace. Tramp oils also interfere with fluid filtration and form
residues on machining equipment. Tramp oil is controlled through
prevention and removal.
Routine preventive maintenance should be performed on machine

systems to prevent tramp oil and grease from contaminating the coolant.
Some tramp oil contamination will always occur. Tramp oil will either
"float out" when the fluid is allowed to sit for a period of time or it will
be emulsified into the coolant. Free floating tramp oil should be removed
on a regularly as part of fluid maintenance. Oil skimmers, filter systems
coalescers, or oil-absorbent pads can remove floating oils and help
remove emulsified oils.
General Housekeeping
Cutting fluid contaminants such as lubricating oils, greases and metal
particulates are an expected part of machining operations. Many of the
contaminants that cause fluids to be disposed of prematurely consist of
foreign materials such as floor sweepings, cleaners, solvents, dirt, waste
oils, tobacco, and food wastes. These contaminants have obvious
detrimental effects on fluid quality and should be eliminated through
improved housekeeping and revised shop practices. Facility personnel
should learn not to dispose of these materials in machine sumps.
Maintenance of Straight Oils

Straight oils are generally easier to maintain than water-based fluids.
Maintenance on straight oils consists of keeping the fluid free of
contaminants (such as water or tramp oils generated in other areas of the
shop), adequate particulate removal through filtration and the addition of
antioxidants. The presence of water promotes microbial growth while
tramp oil contamination dilutes the ingredients added to straight oil for

enhanced lubricity and wettability. Tramp oil contamination also

increases the viscosity of the straight oil, lowering its filterability.
Straight oils that are kept contaminant free and adequately filtered may
still require replacement due to the effect of oxidation. Oxidation of
straight oil increases its viscosity, making particulate filtration more
difficult. As a result, additives referred to as antioxidants may need to be
used to prevent oxidation from occurring.
Foaming
Sometimes the conditions are right so that the additives and surfactants in
coolants cause foaming. Foam layers are mostly air and insulate the
coolant, which prevents water from evaporating and traps heat in the
coolant.
This can seriously affect the ability to control part dimensions. Fluids are
more likely to foam when coolant concentrations are too high or when
soft water is used for coolant mixing. These combine with mechanical
effects such as agitation, air etc. to cause foaming. Foam generation
requires a surface-active liquid (one with wetting agents or emulsifiers)
and the agitation of that liquid in the presence of air. Foam control can be
tough because of high pressure and high flow rate coolant systems.
Ways to decrease foaming
1. Using a non-foaming fluid

2. Decrease coolant flow rates
3. Reduce agitation
4. Decrease fluid concentration
5. Modify airflow in the coolant stream.
6. Consider replacing high velocity nozzles with low velocity, high
volume nozzles.
7. Eliminate areas of freefalling fluid by extending return piping
outlets beneath the fluid level in the sump.

8. Replace undersized piping and eliminate sharp comers and

interruptions in fluid return lines.
9. Clean nozzles of dirt, grease, etc.
10. Make sure pumps are good
11. Check pumps and piping for air leaks
12. Keep the sump full so the pump isn't sucking air.
13. Keep phosphate based cleaners away from fluids since they can
promote foaming.
14. Use antifoaming agents such as a liquid calcium water hardener to
reduce or eliminate foaming.
15. Be careful using silicon based antifoaming chemicals since they
coat and absorb into the pores of metal surfaces.
Foaming is more likely to occur with fresh coolant because the

concentration of wetting agents is highest, and the concentration of tramp
oils, metal fines, and abrasive grains is low. Contaminants help to reduce
foaming.
With a fresh charge of coolant, it may be necessary to make tank side

additions of antifoam until the coolant gets "a little dirty" and has a
reduced tendency to foam.
When to change coolants and clean the sump

pH is less than 8.0 (normal pH range is 8.5 to 9.4)
Fluid concentration is less than 2.0% (normal is 3.0% to 12.0%)
Appearance is dark gray to black when normal is milky white, clear
green or other)
Odor is strongly rancid or sour (normal is a mild chemical odor)

Chapter 11
How To Get Coolant Where You Need It

In a huge number of cases maybe the majority, coolant is applied
improperly. Often a great amount of coolant is used improperly when
much better results would be achieved by precisely using much smaller
amounts of coolant.
Applying coolant properly and consistently is critical to grinding and

machining operations. Some of the benefits of applying coolant properly
are reducing and preventing scrap work pieces by reducing thermal
softening, burning and hardening as well as reducing cycle time and tool
wear. Improvements are seen in dimensional accuracy, throughput, part-
to-part and setup-to-setup consistency. All these mean significant cost
reduction
Areas to consider are:

Nozzle placement
Nozzle shape
Nozzle position
Nozzle angle
Nozzle edge condition
Blockage of nozzles
Nozzle wear
Discharge coefficient
Fluid condition
Coherent jet flow
Laminar flow
Air dams
Air barriers
Part-to-part consistency
Setup to setup consistency

Machine to machine consistency
Cutting fluid can be applied through manual, flood or mist application. In

manual application an operator uses an oilcan to apply cutting fluid. This
is the simplest, cheapest costly method, however; it has limited use in any
but the simplest applications and is very inconsistent. In flood cooling,
fluid is directed under pressure to the work area. Fluids can be sprayed
onto the work area as a mist. The pressure and direction of the mist
stream are also crucial to the success of the application. Coolants are
typically stored and distributed a sump in each machine or a central
system.
Testing
1.Test to see how much of the fluid pumped actually goes through the
work zone and how the flow rate through the zone compares to the flow
rate from the pump. An increase in the flow rate of the coolant pretty
well equates to an increase in coolant efficiency (52% to 53% -
difference not statistically significant).
2.Test to see what happens to the work as you change delivery

considerations.
Use a test block with sensors such as pressure, temperature, vibration etc.
inserted. Either put them into the test bloke and drill a hole the rest of the
way through or test without the hole. The tool is positioned over the test
block until it just touches the block.
The coolant and machine are turned on. The tool or wheel is traversed
back and forth several inches on either side of the hole in the set block to
see where the pressure begins to build where it peaks and where it
declines and ends.
As coolant passes between the tool and the part it is squeezed and a

pressure is developed. This pressure is measured and relates to how

properly the coolant is being applied. The more coolant that is forced into
the same size space between the tool and the part the higher the pressure.
Also compare the pressure through the space with the pressure form the
pump.
Test results
The type of nozzle can reduce temperature by 105 F from 280 F to 105
F. This means the difference between film boiling of the coolant and
consequent part damage and no film boiling and no damage. It also
means that higher metal removal rates are possible without damage to the
part or tool because of reduced temperature.
Air dams are designed to remove the layer of air, or air barrier, that can
surround a grinding wheel or tool especially at high rotational velocities,
and thus hinder coolant from entering the grinding zone. An air dam or
air scraper placed upstream of a grinding wheel created a 15%
improvement in efficiency
Heat transfer out of the work area

A key area for process improvement is heat transfer out of the work area
by coolant. Poor cooling means excess heat, which, in turn, means excess
heat and residual stress, work hardening, burn and possible structural
change in the material
High-pressure coolants can do a better job of moving heat out of the

work area than low-pressure systems. High pressure can include flow
rates up to 600 I/min. However many high-pressure systems are not
nearly as effective as they could be due to poor nozzle design and use.
An air cushion is built up around the tool or wheel, which interferes with
the application of coolant by deflecting the coolant jet. It is important that
the nozzle design and airflow as well as air dams be used to get the
coolant into the work area.

Nozzles incorporating flow deturbulence zones with a sharp edged nozzle

opening can create a laminar flow that can be directed at the work area
contact zone very precisely.
A stripper can separates the rotating air cushion from the tool. Negative
pressure results from the rotation of the wheel in the area of the opening
and the enclosing nozzle shoe drags the lubricant into the work zone.
Multiple flow nozzles and nozzles with guide jets can also improve fluid
delivery.

Chapter 12
Why Coolants Become Unusable

Coolant never really wears out. Coolant is mostly water (typically 90 -
95%) with additives.
Coolants and cutting oils become unusable when they become

excessively contaminated with bacteria, tramp oil, metal fines, or wastes.
They can break down from use, but are most commonly broken down by
bacteria growing in the system.
When a system develops a drastic change in pH, detergency, lubricity, or

odor, a bacteria check should be made.
Bacteria find their way into fluids through a variety of ways. For
instance, there are bacteria in the water used for diluting and mixing.
They thrive on wet parts and lurk in the air. Bacteria from an operator's
hands, sweat, and saliva also get into coolants.
Surprisingly, there are people who find it easy to confuse coolant sumps
and holding tanks with toilets or food disposal units. Poor housekeeping
practices add huge numbers of microorganisms to the system. Bacteria
also live in the sludge that settles in machine sumps and coolant flumes.
In short, bacteria are everywhere.
Bacteria & Fungi

Bacteria chemically alter coolants, destroying lubricants and corrosion
inhibitors, while releasing corrosive acids and salts into the fluid.
Microbial action directly affects the coolant resulting in the splitting of
emulsions, decreased pH, increased corrosion, degradation of the

ingredients in the coolant and a loss of lubricating ability within the

coolant. Odors may develop including hydrogen sulfide as a product of
the bacteria’s metabolism. Bacteria may expose workers to pathogens
and contribute to respiratory irritation and skin irritation, like dermatitis.
Work piece quality decreases, resulting in increased surface blemishes,
decreased tool life, and increase (time to treat for bacteria and repair the
equipment. The bacteria may also cause increased foaming and
separation in the system and cause clogged lines, filters, and valves.
The presence of wastes, tramp oils and metal fines can stimulate the
growth of bacteria. The life span of most metal working coolants can be
extended two or threefold with proper management techniques.
Bacteria live in the sludge that settles in machine sumps and coolant
flumes. There are more than 2,000 species of bacteria on earth, and there
is virtually no place that one species or another does not call "home."
Bacteria and other microbial organisms thrive in the environment created

by the impurities in the coolant. Tramp oil, lubricants, hydraulic oils
leaked by machinery, minerals in the water, mineral oils, fatty acids,
emulsifiers, corrosion inhibitors, other additives, discarded food and
waxes are food for microorganisms.
Microbial contamination is a major cause of fluid spoilage. All water-

miscible fluids are susceptible to microbial deterioration that can
significantly reduce fluid life. Bacteria prefer water-miscible fluids,
because they need water to grow. Without moisture, most cannot
reproduce and multiply once introduced to a new environment.
Bacteria populations can double as frequently as every 30 minutes. The

greater the bacterial growth rate in a fluid, the faster the fluid becomes
rancid. As bacteria multiply, they produce acids, which lower the pH of
the fluid, causing increased corrosion and reduced lubricity. Bacteria may
also darken the fluid significantly, resulting in stained parts.

Aerobic
Most bacteria which cause fluid to become rancid are aerobic. Aerobic
bacteria need oxygen for metabolism and efficiently destroy the coolant.
In the typical coolant system, there is no shortage of oxygen. As coolants
cycle through, they come into contact with air at the surface of sumps and
holding tanks. Fluids pick up oxygen as they are ejected from the nozzle
and just about anywhere else coolant is exposed to the air.
In the absence of oxygen, they will continue to survive, but grow very
slowly until oxygen is reintroduced. Once they can "breathe" again,
facultative bacteria will resume reproduction. Aerobic bacteria reproduce
by dividing in two approximately every 20 to 30 minutes. A single, well-
fed bacterium can produce billions of others in less than half a day.
Anaerobic
Anaerobic bacteria grow in oxygen-poor environments. They grow in
systems that are inactive for long periods of time. Inactivity allows tramp
oil to rise to the top of the sump, creating an effective barrier between the
metalworking fluid and atmospheric oxygen. Consequently, the amount
of oxygen present in the fluid decreases, aerobic bacteria die, and
anaerobic bacteria begin to flourish. They feed upon the coolant and
produce hydrogen sulfide, which produces the rotten-egg odor, which
causes Monday morning odor.
This type of bacteria grows much more slowly than the aerobic, dividing
in two approximately every four hours. Anaerobic bacteria will usually
not grow until aerobic bacteria have first attacked the fluid and the
oxygen is depleted. Some components of coolant-emulsifier systems are
naturally toxic to anaerobic bacteria; that's why adding fresh coolant
makeup to stinky coolant will "freshen up" the mix but only for a short
time.
Fungi

Besides bacterial growth, there is another whole group of

microorganisms that can infect coolants. Collectively, they are referred to
as fungus, which, in reality, is a combination of molds and yeasts.
Fungi degrade metalworking fluids by depleting rust inhibitors. Fungi

also cause musty or mildew-like odors and form slimy, rubber-like
masses on machine system components that may eventually plug fluid
lines.
While bacteria are essentially animal-like and grow rapidly as discrete

cells or particles within the fluid, fungus are plant like, growing in layers
on surfaces (e.g., inside pipes). Bacteria and fungus compete for the same
food sources, and because of bacteria's animal-like nature, they can
generally out compete fungus. As a consequence, if a coolant system has
a moderate, stable (neither rapidly increasing nor decreasing) bacterial
population, the bacteria will generally control fungal growth.
Conversely, if a coolant system has a consistently low bacterial

population and the fluid will allow fungal growth (soluble oils tend to
support bacterial growth and chemical [synthetic] fluids tend to support
fungal growth), the fluid will likely develop a significant fungal
population eventually.
Fungus can be even more of a problem than bacteria because fungal

accumulations can interfere with machine functioning and can plug
coolant filters and piping. While there are a number of effective
microbiocides that can be added to coolants to control bacteria, there are
very few effective fungicides for use in coolants.
Bacteria Control
The more rapidly bacteria grow, the faster they alter the fluid. That
makes controlling the rate of bacterial growth extremely important. If the
rate of growth is limited, the harmful effects are reduced. Biological
growth is controlled through a combination of practices. These include
water quality control, proper maintenance of fluid concentration and pH,

routine equipment maintenance, biocide treatment and aeration.
How Fluids Get Contaminated

1.Water used for mixing and diluting.
2.Sludge in the machine sump or coolant flumes.
3.Parts, tools, and other objects in contact with the fluid.
4.Operators' hands, sweat, and saliva.
5.Extraneous contaminants such as food scraps, human waste, etc.
Factors that promote the growth of bacteria include

1. Oxygen and organic nutrients.
2. Low pH (salts from water) and low temperature.
3. Lubricant carry through.
4. Poor hygiene throughout the stamping plant.
5. Hydraulic leaks, tramp oil, and greases.
6. Chemical additives.
The top 10 ways to minimize bacterial attack.

1.Select high quality, bioresistant fluids.
2.Incorporate germicides judiciously.
3.Practice good housekeeping.
4.Remove tramp oil contamination.
5.Remove fines and other particulate matter (the better the filtration, the
lower the bacterial growth).
6.Use pure, mineral free water.
7.Clean machines and sumps thoroughly and regularly.
8.Remove sludge from sumps and flumes.
9.Use coolant friendly cleaners on tools and workspace areas
10. Train machine operators on coolant maintenance.
Housekeeping
The best way to effectively control bacterial growth is good
housekeeping.

The best method for controlling biological growth is through routine

cleaning of machines, coolant lines, and sumps/reservoirs. Machines,
exhaust blowers, and hydraulic seals should also be maintained to
prevent oil leaks from contaminating the fluid.
Train your employees to keep trash, solvents, tramp oil and other foreign
material out of the coolant system.
It does little good to put fresh coolant into a dirty machine if you're only
going to suck out the old before putting in the new. This practice
provides fresh food for the bacteria that are in the swarf and sludge that
remain in the machine sump, on machine surfaces, and in the coolant
circulating systems.
Use good water

The minerals present in most water can destroy desirable coolant
properties and form deposits. In addition, Fungi feed on dissolved
minerals in water. Controlling the mineral content of the water used for
metalworking fluids can control fungi growth. Consider using deionized
water when mixing coolant formulations.
Fluid selection
One of the most important methods of keeping bacterial growth in check
is to be sure that the cutting fluid manufacturer you select uses high
purity materials for its products. Bacteria have very specific appetites and
some materials are much better food for them than others.
Fluid manufacturers that understand the biology of microorganisms select

raw materials that bacteria do not find appetizing. Coolants formulated
with materials bacteria find undesirable are less vulnerable to bacterial
attack.

Clean coolant in process

Screen out and recycle metal fines. Remove tramp oils and metal chips.
Accumulations of chips and fines in a sump promote bacterial and fungal

growth. These particulates increase the surface area available for
microbial attachment, and biocides cannot effectively reach the fluid
trapped in these chips and fines. Particulates in the bottom of a sump
become septic or rancid if not periodically removed.
Even if the majority of the fluid is free of bacteria, the sludge in the
bottom will continue to harbor bacteria and create a septic condition. This
can dissolve metals, possibly increasing the toxicity of the fluid to a level
at which disposal through a local wastewater treatment plant is no longer
permitted. Laboratory analysis will reveal whether the toxicity of the
fluid makes it a hazardous waste.
Some bacteria prefer oil as a food source, so they tend to grow rapidly in
those machines that leak substantial amounts of lubricating and hydraulic
oils. Consequently, everything should be done to reduce tramp oil
contamination. Contaminant oils and greases that do make it into coolant
should be skimmed off the surface or centrifuged out of the fluid.
Monitor your sumps

Monitor coolant quality. Know when you must add make up or additives.
Know when bacterial growth is about to get out of hand. One way to do
this is by keeping records of when and how much additives or make up
coolant are added. Signs of bacterial growth should also be recorded.
Many coolant concentrates contain biocides and pH buffers. Therefore,

preventing fluid from becoming overly diluted helps control
microorganisms.
Ideally, the pH for water miscible metalworking fluids should be kept in

the limited range of 8.6 to 9.0. This slightly alkaline range optimizes the

cleaning ability of the fluid while preventing corrosion, minimizes the

potential for dermatitis and controls biological growth. If the pH drops
below 8.5, the fluid loses efficiency, can attack ferrous metals (rusting),
and biological activity will significantly increase. A pH greater than 9.0
may cause dermatitis and corrosion of nonferrous metals.
Regular monitoring of a fluid's pH is a simple means of anticipating

problems. Fluid pH should be measured and recorded daily after the
machine is placed in operation. Steady pH readings give an indication of
consistent fluid quality. Swings in pH outside the acceptable range
indicate a need for machine cleaning, concentration adjustment or the
addition of biocide. Each action taken to adjust the pH to the desired
operating range should be documented in the machine logbook and
evaluated for effectiveness. Any rapid change in pH should be
investigated and action should be taken to prevent damage to the fluid.
Although fluid pH usually remains constant because of buffers contained

in the concentrate, it can change after initial mixing due to water
evaporation. Improper control of microbial growth will also alter fluid
pH. Byproducts of microorganisms produce offensive odors and lower
fluid pH. As the fluid becomes rancid or septic, it becomes more acidic.
Sudden downshifts in pH usually indicate increased biological activity or
a sudden change in concentration due to contamination. If coolant
concentration and pH both jump downward, the sump has been
contaminated. If coolant concentration remains fairly constant while pH
decreases, biological activity has probably increased significantly.
Weekly or biweekly monitoring is typically recommended for detection

of microbial contamination, especially during the early stages of
developing a fluid management program. With experience, machine
shops may determine that a less frequent monitoring schedule is suitable
for their operation.
Biocides & other means

Germicides can be helpful in preventing or retarding bacterial

degradation. However, very few germicides are truly effective in coolant
systems, and they must be used with great care. Moreover, those biocides
that have proven to be most effective often cannot be used in all types of
coolants.
When coolants require the addition of biocides, it's important to carefully

follow the supplier's recommendations. Do not add too little or too much
coolant. Too little can actually stimulate microbial growth, while too
much can cause operator skin irritations. In short, never add any
chemicals to your coolants without specific instructions from your
coolant supplier.
The addition of biocides inhibits biological degradation of the fluid by

controlling bacteria and fungi. Relying strictly on biocides for microbial
control is discouraged since these chemicals are expensive and can create
hazards for the operator's skin.
Generally, biocides should be used sparingly in as low a concentration as

possible. Due to the variety of bacteria that may be present in a fluid, use
of only one biocide may control certain bacterial species while allowing
others to proliferate. Random use of various types of biocides may prove
to be more effective.
Biocide treatment patterns play an important role in controlling microbial

growth. During one study on biocide
treatment patterns, fouled fluids were treated with a commercial biocide

at various concentrations and frequencies while microorganism
populations were monitored. For all biocide application rates tested, the
efficiency of antimicrobial control was found to vary widely with
treatment pattern. Less frequent doses with higher concentrations of
biocide were found to be much more effective than low level, frequent
doses.

Use pasteurization or non-chlorinated biocides to reduce the growth of

bacteria. Be aware that pasteurization cannot prevent rapid regrowth of
bacteria while biocides provide continuous protection.
Some businesses have found that using an aerator and diffuser rod
purchased at an aquarium shop can reduce bacterial growth. The aerator
is used when machines are off line for an extended period such as a
weekend.
Aeration can be used in conjunction with biocide additives to control

anaerobic microbial growth in systems during periods of inactivity.
Aeration oxygenates the fluid, producing an atmosphere hostile to the
odor producing anaerobic bacteria. While the machine is running or
sitting idle, a small pump can bubble air into the sump, either
continuously or periodically, to agitate stagnant areas within the sump.
Clean sumps
Sanitize sumps and machinery on a regular basis. Remove all old coolant
and sludges. Flush out comers. It's no use putting good coolant into
bacteria laden equipment. If necessary, retrofit sumps to make cleaning
easier by lining with sheet metal or epoxy and creating rounded corners.
If a machine is thoroughly cleaned with a proper cleaner, thoroughly

rinsed, and then filled with clean, fresh fluid, the fluid will last four to six
times longer than it would in a machine that is simply "sucked out" and
recharged with fresh coolant.
Central Systems
Central systems generally involve quantities of fluid three to five times
the amount used for an individual machine. As a result, if the bacteria in
a central system grow at the usual rate, the proportionately smaller
addition of fresh makeup will give the bacteria a greater period of time in
which to break down the coolant than would be the case with individual
machines.
Further compounding the problem, bacteria tend to settle to the bottom of

tanks. In any system where the fine metal particles and other silt settle, so
do the bacteria. This combination allows the anaerobic bacteria to
achieve full growth potential, since they have plenty of food and are far
away from the oxygen at the fluid surface.
Consequently, it is usually more difficult to control bacterial growth in

large central systems than it is in individual machine sumps. However,
proper cleaning of such systems with each coolant change and good
filtration to prevent sludge accumulation can help keep bacterial growth
under control.

Chapter 13
Sump Cleaning
The main enemy of coolant is bacteria. Get rid of the breeding grounds
for bacteria properly and you simplify your problem. The coolant should
be filtered and recycled regularly. The machines also should drained and
completely cleaned once each year. This is the traditional figure. With
really good coolant management this may not be necessary.
Collecting dirty coolant from the sump is made much easier and requires
much less time when a sump vacuum or the filter system pump is used.
The cleaning is also made more effective if the sump has rounded
corners, nowhere for microbes to hide, and is made of sheet metal
construction. To prevent weekend growth of anaerobic bacteria be the
coolant can be agitated and aerated to prevent anaerobic conditions from
forming.
Pretreatment
1.Treat the sump for bio-contamination using a biocide / fungicide and
following the manufacturer's procedures and recommendations.
2.The old fluid with the biocide should be run for a minimum of 48 to 72
hours.
3.The mixture should be dumped and disposed of safely and according to
local, state and federal regulations.
Cleaning
4.Pump the sump out.
5.Shovel out all swarf, fines and chips.
6.Clean any oily residues that remain on any surface.
7.Clean as much as you can at this point.

All areas must be cleaned no matter how hard they are to

reach. Uncleaned areas provide a source of bacteria that
rapidly attack the fluid used to refill the sump after cleaning.
8.Add your cleaner.

9.Always put water in first and add cleaner last to prevent foaming.
10.Cleaner should be hot water mixed with a good alkaline machine
cleaner.
a.) Compatible with the metalworking fluid (in case some

cleaner remains in the system after rinsing);
b.) Low-foaming to prevent pump cavitation, which is the
sudden formation and collapse of low-pressure bubbles
induced by the pump's mechanical forces;
c.) Resistant to short-term rusting between cleanout and
recharge.
11.Circulate several hours to loosen and remove any hardened deposits,

oily films, or gummy residues. The cleaner should run through the
system just like the coolant for up to 3 hours.
12.Hose down throughout the whole inside.
13.While the cleaning solution is circulating, leaking equipment should
be repaired.
14.Clean the outside of the machine.
15.Wipe down the outside with the same cleaner using a spritzer
container at the same dilution ratio
16.If possible, troublesome areas should be steam cleaned.
17.Once this step has been completed the cleaner should be dumped.
Rinsing
18.Once the machine has been thoroughly cleaned and inspected, any
residual cleaning solution must be rinsed from the equipment. Fresh
water should be circulated through the system at least twice to rinse off
any remaining cleaner.

19.Wipe cleaning solution residues from the sump.

20.Do the first rinse.
21.To protect against flash rusting, a small amount of fluid concentrate
(0.5% to 1.0%) should be added to the rinse water. This is done to
prevent any flash rust.
22.Wipe off cleaned surfaces that are not contacted by the rinse water
cycling through the system.
23.Do the second rinse.
Rinse water should then be placed in the system along with a 4.0 to 50:1
ratio of coolant to rinse the cleaning agent out.
24.This should run for approximately 15 minutes.
25.The interior of the machine should also be rinsed down with this
solution.
26.The rinse water should also be disposed of properly.
Recharging
27.During the rinsing you should mix up your coolant at the
manufacturer's suggested ratio and have it ready to place into the system
immediately after pumping out the rinsing agent. You can also add
another dose of biocide to start off.
28.After it is completely drained of the rinse solution, the system can be
charged with fresh fluid.
29.The machine should then be turned on and run for about 30 minutes so
as to get the coolant well dispersed on all parts of the exposed portions of
the machining area.
30.The fluid should then be circulated for at least 15 minutes prior to
production.
After One Week

31.After running the machine for one (1) week dump the coolant.
32.Replace the coolant again at the manufacturer's recommendation.

Chapter 14
Cleaning Systems
Contaminated fluids are directly responsible for 70% to 90% of machine
tool wear and failure. A filter system that removes contaminants as they
are generated helps keep fluids operating at peak performance. In
filtration systems for water-based coolants, a one-micron filter will also
remove bacteria.
Eliminating contaminants in oil based fluids has been proven to cut down
wear in pumps, bearings, cylinders, motors, gears, servo valves and any
metal surfaces used in or affected by the machining operation. A clean
system will always run at higher pressures and maintain higher levels of
accuracy and repeatability. Machining and part quality also become more
consistent.
Equipment to remove fluid contaminants
Equipment Contaminant Removed
Skimmers Tramp Oil
Coalescers Tramp Oil, Particulates
Settling Tanks Particulates
Magnetic Separators Particulates
Hydro cyclones Particulates

Tramp Oil, Particulates,

Centrifuges
Bacteria
Flotation Tramp Oil, Particulates
Oil absorbent pillowsTramp oil
Filtration Equipment Particulates
Factors to be considered selecting a system

1.The volume of fluid (e.g. the number and volume of sumps)
2.Particulate and tramp oil removal requirements
3.Type of material machined at the shop and hours of operation
4.Types of metalworking operations performed at the shop
5.Types of fluids used by the shop and their optimal concentrations
6.What additives will be needed?
How often a fluid must be recycled depends on the following factors:

Fluid type
Water quality
Fluid contamination
Machine usage
Machine filtration
Fluid control
Fluid age
A fluid that is stable and resists biological contamination will be able to

withstand repeated recycling and will require less recycling. Poor water
quality (water that is too hard or too soft) will cause excess dissolved
minerals to accumulate in the fluid and may require more frequent
recycling.
The level of shop productivity will also affect the frequency of recycling.

Large shops that operate at maximum capacity around the clock will need
to recycle fluids more frequently than smaller or slower shops. It is
generally recommended that coolants be recycled every two or three
weeks on average to keep coolants fresh and usable for extended periods
of time unless the coolants are filtered on a constant basis.
Large chips and very small particles

Operations such as turning and milling, where the chips are usually large,
can also generate microscopic particles.
1. An operation that makes chips will also generate extremely small
particles off the edges of the chips. 2. As the larger particles in the
coolant get recirculated and put back into the cutting area there is a
grinding mechanism. Larger particles that get between the tool and the
work surface will be ground into smaller chips as the tool works. 3.
Coolant with particles in it increases edge wear on inserts and brazed
tools. Edge wear in carbides and ceramics is a chipping / splintering
process as well as a straight wear process. This generates additional ultra
fine particulate matter.
Filtration is made difficult by:

1. Low pH often caused by gel like or saturated salts.
2. Loose emulsion, oil floating on the surface.
3. Bacteria, even when controlled, can clog filters.
4. Foreign oil contamination that is not emulsifiable.
5. Low temperature, evaporation levels, and viscosity.
6. Flakes of solids sealing the filter surface because they inhibit flow.
7. Grease residues.
8. Extremely fine particles trapped in tramp oil.
Kinds of Equipment
Skimmers
Skimmers make sense where the goal is to collect tramp and save them.

They remove tramp oils that float to the surface of cutting fluid after it
has been allowed to sit for a period of time. Skimming is most effective
when tramp oils have a low water miscibility and the cutting fluids used
by the shop reject tramp oil emulsification. Since oil has an affinity for
plastic, most skimmers consist of plastic belts or disks that are partially
submerged in the fluid. Tramp oil adheres to the skimmer as it passes
through the fluid. The tramp oil is then scraped from the skimmer with a
blade and collected for final disposition.
Coalescers
Coalescers are often used in conjunction with skimmers to enhance tramp
oil removal. Coalescers are porous media separators, which use oil-
attracting media beds, usually polypropylene, to attract oil out of. These
are often inclined corrugated plates or vertical tubes. Fluid is passed
through the coalescer at a low, non-turbulent rate. Dispersed tramp oil
droplets attach to the media and coalesce to larger droplets. Eventually
these droplets reach a size at which they rise to the top of the coalescing
unit for removal with a skimmer. Coalescer units have no moving parts,
are generally self-cleaning and may be purchased for $1,000 to $5,000.
Like skimmers, coalescers are ineffective for removing emulsified tramp

oils. They may also accumulate fine particulate matter during their
operation. If these units are not cleaned periodically, the dirty media will
provide a breeding ground for microorganisms.
Settling tanks
The simplest separation systems are settling tanks. They allow heavy
particles to settle to the bottom of a tank while allowing tramp oil and
light particles to float to the surface. Settling tanks can be equipped with
skimmers to remove the floating oil and light particulates. Chips and
other particles, which settle to the bottom, are removed using baskets or
automatic chip conveyors.
Magnetic separators

Contaminated fluid flows over slowly rotating magnetic cylinders that

extract ferrous particulates from the fluid. The ferrous particles are then
scraped from the magnetic cylinder into a bin for sale or disposal.
Nonferrous metals that pass by the magnetic cylinder are removed with
another separation process, typically settling. Magnetic works well but
magnets are relatively weak, even super magnets. The flow must be
relatively slow and thin.
Ferromagnetic metals include iron, nickel and cobalt. However these

materials can be alloyed with other metals and lose their magnetic
susceptibility.
Examples of magnetic susceptibility
Gadolinium (rare earth) + 185,000
Iron Chloride + 14,750
Depending on form of FeCl + 12,900
Iron Sulfide + 1,074
Copper Chloride + 2,370
Copper oxide - 20
These are not common metals in most machine shops. However they do
show the difference alloys can make in magnetic susceptibility. As you
get more metals alloyed it becomes more confusing. Stainless steel may
or may not be magnetic depending on what you mean by stainless steel.
A magnetic system that works well with one alloy may not work as well
with another alloy even if the two alloys appear to be very similar.
Magnetic filtering can be very good for low flows where there is a single,
highly responsive alloy being machined.
Hydrocyclones
Density differences between the cutting fluid and contaminants cause
their separation. In a hydro cyclone, cutting fluid rapidly enters a cone-
like vessel, producing a vortex that forces denser solids down and out.
The disadvantage of hydro cyclones is that they tend to emulsify tramp
oils.
Centrifuges
Centrifuges use a spinning bowl to develop the centrifugal force needed
for contaminant removal. Some centrifuge units can remove free,
dispersed and emulsified tramp oil as well as bacteria. The disadvantages
of centrifuges are the intensive maintenance required for the system and
cost. In addition, under certain conditions, centrifuges used for removal
of emulsified tramp oils may also separate fluid concentrate from the
working solution. Fluid suppliers should be consulted beforehand to
ensure centrifuging will not have a detrimental impact on fluid quality.
Flotation
Cutting fluid is aerated to achieve contaminant separation. Oil and
particulate matter adhere to the air bubbles and are carried to the surface
where they are mechanically skimmed off. This contaminant removal
process is typically used after larger and heavier particulates have been
removed by settling.
Oil absorbent fabrics or pillows

For small sumps, oil absorbent fabrics or pillows (treated to repel water
and absorb hydrocarbons) may suffice for tramp oil removal. The fabric
can be drawn across the sump pit for tramp oil removal or pillows may be
allowed to float in the sump to absorb oils. The disadvantage of using
absorbents is their subsequent need for disposal.

Filtration systems
Filtration systems are the most versatile and can be the most effective
depending on system design and use.
Filtration involves passing fluid through a material for removal of

particles as well as tramp oils and grease depending on the filter
material.
Filtration systems include vacuum, pressure and gravity filtration.

Vacuum filtration pulls fluid through a filter while pressure filtration uses
a pump to force the fluid through a filter. The filtered fluid then enters
the reservoir for redistribution. With gravity filtration systems the fluid
flows onto a blanket of filter media suspended over a reservoir tank and
particles are removed as the fluid passes through the filter.
Cartridge systems work like the oil filter system in your car. They are
simple, easy, sturdy and cheap. They do not do well in very high
volumes.
A good quality pump and filter system starts at just under a thousand
dollars and goes as high as you want to pay. There are several kinds of
filter systems. There are centrifuge systems that generally cost $10,000 or
more to buy. They spin out the particles and are very good down to ten
microns in size. Most grinding particles are under ten microns in size.
The best method of recycling is a small system for each sump that runs
constantly. Small filter systems that filter to less than one micron in size
can be purchased for less than 1% of the cost of the machine they are
protecting. This is a range from $500 to $2,000.Filter life is typically a
month or more and requires 5 to 10 minutes and $20 every couple
months. Payback can be a couple months.
There are also batch treatment systems, which are portable, or non-
portable fluid recycling units. Fluid from individual machine sumps is

treated in batches for contaminant removal. A recycle system for a small

shop can cost from $7,500 to over $15,000 depending on the equipment
options selected.
If you do not filter then you must batch treat. Typically, contaminated
fluid is removed from the machine sump using a mobile sump cleaner
(i.e. a sump sucker or high quality drum vacuum) and placed in the batch
treatment-recycling unit for contaminant removal. To keep fluid clean,
batch treatment must be done on a frequent basis. Many shops find that
batch treatment must be done two to three times as often as the fluid's life
expectancy. Thus, if a fluid lasts three months before it needs disposal, it
will need to be batch treated monthly. If the fluid only lasts two or three
weeks, it will need to be batch treated weekly.
Filter systems
In a large operation a central cyclonic or centrifugal collection system
can be more economical than individual filter systems on each machine.
What we have seen is the cyclonic or centrifugal separators are usually
very good at removing particles down to ten microns. The individual
cartridge systems remove particles from 10 microns to below one micron.
Smaller particles dissolve faster. They have a higher square-cube ratio,

which means they have much higher surface area for their volume than
larger particles.
The smaller particles are also more dangerous than larger particles.
Really big particles do not carry very far. They are much less likely to be
pumped up and recirculated. When they are in the recirculated coolant
sprayed on the grinding area they tend to fall faster.
Big particles, around 100 microns, are caught in nose hairs and in the
throat. They are not as likely to get into lungs. Really small particles,
around 1/100th micron, are breathed in and out. They are so small and
light that they tend to just float in and out. It is the particles from 10

microns to one tenth of a micron that are most apt to be breathed in and
these are the particle that we filter rout.
Oxygen and Carbon Dioxide molecules are about one one-thousandth

(1/1,000 of a micron).
When to change filters

The filter system is supposed to keep the coolant clean. As long as it is
keeping the coolant clean the filters do not need to be changed.
Three tests
1. Fill a clear bottle with coolant. Let it sit. There should be a light layer
of fine particles on the bottom.
2. Measure the flow. The flow can be very slow and still be cycling the
entire sump twice an hour.
3. The filter bag should be really dirty. It should have a layer around it
that varies from one half inch thick to three-quarters inch thick. (See flier,
please)
Filter Life
The life of a filter depends on what you are filtering and how much of it
you filter out
What matters to most users is how long the filters will last before they
need changing or replacing. This determines the actual cost of running
the unit.
The starting point is rated filter life. Filter life is rated the best average
application. In a filter system for machine coolants this would be a metal
or similar particle in otherwise clean coolant. As the coolant acquires
other dirt, particularly oil and grease the life of the filter can drastically
reduced.

Filters are designed and made with holes in them to trap particles. A good
filter is made one of two ways. Cartridge filters are a couple inches
across or more. They work by forcing the liquid through the filter from
the outside to the middle. The liquid goes through and the particles get
trapped in the filter media.
There are larger holes on the outside so that the whole depth of the filter
is available to trap particles. A bag filter is a big bag where the liquid is
pumped into the inside of the bag and then forced though the bag. The
particles are trapped inside the bag. A bag will a hold a great deal more
dirt and particles than a cartridge simply because there is more room to
put them in the middle of a bag than there is in the material wound
around a cartridge filter.
Filters do very well trapping particles. When oils and greases are allowed
to contaminate a system then the filters become “blinded”. This means
that they rapidly get a coating of oil and grease on the outside and then
the filter plugs up and will not allow any liquid to pass through it.
A filter system may work for weeks without a filter change if it is just
filtering particles. If there is oil and grease then the system may work for
a day. It can get to the point where the oil and grease will cause a system
to shut down in minutes that would ordinarily run a week.
In a grinding operation such as saw grinding it is very important to keep

oils and greases out of the coolant. This is not always possible and in
cases where it is possible the cost is not worth the effort. The big problem
with oil and grease in coolants is the effect on the grinding wheel. The oil
and grease get dispersed into the coolant during operation. This means
they are pumped up and sprayed onto the grinding area. Obviously oils
and grease are very bad for the wheel. They clog the wheel, which
shortens wheel life and increases the heat of the operation.
How many particles will accumulate in the filter before it clogs?

It depends on the particle size and the filter size.
We ran a five-micron filter followed by a one-micron filter in a dirty

sump. After three hours we had reduced the particle count from
76,000,000 to 84,000 particles per cubic centimeter. We did this by
filtering about forty gallons of coolant for three hours at about 2,000
gallons per hour. We ran the entire sump through about 50 times an hour
for three hours.
A second test took the concentration of particles from 81,000,000

particles per cubic centimeter to 49,000 particles per cubic centimeter.
As a comparison, even brand new coolant had 11,000 particles per cubic
centimeter.
One gallon is 3785.41 cu. cm. so forty gallons is 151,416.4 cu. cm.
We stirred the sump up before we took our sample so the sample

represented an average of the whole sump.
Before filtering there were about 76,000,000 particles per cu. cm. x
151,416 cu. cm. =
2,416,000,000,000 (or 2 quadrillion, 416 trillion particles) (or 2.416 x

1012) in forty gallons. After filtering we had 1,665,576,000 particles (or
one billion, 665 million, 576 thousand) or (1.665 x 109) in forty gallons.
In this case the particles left did not make much of an impression. I
suppose that the filter removed over 2 and one half quadrillion (a
quadrillion is a million times a million) particles and was still working
fine.
These are really small particles.


Chapter 15
Example: Filtering Carbide Grinding Coolant
The grinding of carbide tools is actually an extrusion process. Little

chunks of the tungsten carbide and the cobalt binder are pulled from the
carbide tool tip. These chunks form sludge in the bottom of the coolant
tank and the cobalt slowly dissolves or leaches into the coolant.
If the coolant is recirculated these fine particles are pumped up to the

spray head and sprayed onto the work area. Some of the particles are
thrown into the air where they can be inhaled. Other particles are
reground into even finer particles. These recirculated chunks will cause
rougher grinds and will increase the chance of burning during grinding.
Filtering out the chunks improves grinding coolant several ways. Shops
report that filtering doubles coolant life. This varies according to which
shops and how they measure performance, but double coolant life seems
to be a minimum performance improvement. Cleaner coolant gives
better, smoother, faster grinds and helps prevent any possibility of
burning.
Filtering grinding coolant removes chunks of tungsten carbide, cobalt and

grinding wheels. A dirty sump can have as many as eighty million
particles in a cubic centimeter. The coolant pumped out of this sump to
the spray head can still have as many twenty two thousand particles per
cubic centimeter. Filtering this coolant can remove as much as ninety
nine percent of all particulate matter.
Filtering grinding coolant prevent bacteria growth. Bacteria grow in dirty

sumps for two reasons. The sludge is an excellent place for it to grow.

Tramp oils seal off the coolant and keep air out of it. Filtering coolant
removes sludge and tramp oils and prevents bacteria growth. A filter
system prevents bacteria growth by removing the sludge where bacteria
grow. Filtering also removes tramp oils, which create an anaerobic
environment.
Filtering can change the physical characteristics of the coolant. What

changes and how much it changes depends on the filter and the coolant.
Filtering removes tramp oils from coolants and it can also remove some
lubricity from some coolants. In most cases the user decides that the
difference is minimal and is easily made up by additives.
Metal content for disposal

New Dirty Filtered
Cobalt mg/L 0.138 3,210 299
Arsenic <.05 <.05 <.1
Barium 0.702 <.02 0.421
Cadmium <.003 0.06 0.038
Chromium <.007 <.07 0.024
Lead <.04 <.04 0.09
Mercury <.001 <.001 <.001
Selenium <.08 <.8 <.16
Silver <.007 <.07 <.014

Particle counts (parts per cubic centimeter)

Size
Unfiltered Filtered Unused
(Microns)
<1 0 17,209 0
1 140,317 25,575 11
2 14,382,515 21,432 1,049
3 15,364,737 9,720 1,935
4 19,644,411 4,223 3,367
5 13,751,087 2,550 3,618
6 9,120,620 1,673 1,181
7 1,894,282 558 372
8 631,427 239 142
9 420,952 80 55
10 280,634 478 66
11 0 319 22
12 140,317 00

13 70,159 159 22
14 70,159 0 0
15 140,317 80 11
16 70,159 0 29
17 65,774 32 5
18 85,506 112 0
19 26,309 80 0
20 0 48 0
Totals 76,299,682 84,583 11,885
Notes:
1.In something as dirty as coolants the laser counter defaults to certain

numbers that are accurate relative to one another, but that may not be
exact counts to the individual particle.
2. The large number of sub-micron particles in filtered coolant reflects

the fact that this is a one-micron filter system. The tightest specifications
were typically 0.001” so one micron filtering was felt to be fine enough.

Chapter 16
Kinds of Filters
Kinds of Filters
1. Paper filters
2. String wound polypropylene filters
3. Bag filters
4. Activated carbon and other chemical filters
Paper filters
Paper filters - they absorb a lot of the essential materials out of the
coolant - we can supply these but we do not recommend them
String wound polypropylene filters

String wound polypropylene filters - these look sort of like kite string
used to look when you bought it on a stick. They are excellent filters with
a very non-reactive material. They remove particles but do not remove
chemicals.
Bag filters
The material is pumped through a bag. These are large capacity filters
and are removable and cleanable. The housing makes these more
expensive initially, but they can recover their cost rapidly in heavy use
situations.
Activated carbon and other chemical filters

Activated carbon and other chemical filters - these use chemically active
substances to remove chemicals, metals and particles form liquids. They
will also remove some of the chemicals that make coolant work well.
These can be excellent to remove contaminants and clean coolant before
final disposal.

Filters are judged on several things:
1. What they filter.

2. How much material they trap.
3. The size of the trapped particles.
4. Filter material.
5. Filter construction.
6. How long the filters last.
7. How much they cost.
1.What They Filter

Essentially there is water, water with oil and synthetic coolants. Adding
oil or synthetic materials to the water does several things. It adds rust
preventative, it helps carry away the heat, it more effectively removes
particles, it helps prevent corrosion and it retards or prevents bacteria and
fungus build up.
2. How much material they trap

How much material a filter traps depends on how it is made and what
material it is filtering. Most filters are made to collect material. They
work best if they can collect material all the way through the filter. If the
material is too greasy, or too big then it will "blind" the filter. This means
that there will be a layer or coating on the outside that will prevent
material from moving through the filter.
Some filters are made with pleats or ridges, which increases the surface
area and the amount of material that will be trapped on the surface. Other
filters are made with bigger holes on the outside and smaller holes in the
middle so they can trap particles all the way through.
3. The size of the trapped particles

Filters are rated according to the size particle they will filter out. A 20-
micron filter has 20-micron holes. It starts out filtering out everything in

the twenty-micron range. These are spun or wound cartridges. As they

get used more the holes get smaller. As the holes in a twenty-micron
filter get smaller and smaller it will filter our smaller and smaller
particles until it is filtering out particles in the one-micron range. A filter
that is shot full of twenty-micron holes is a lot more open space and a lot
less filter material than a one micron filter. This means that a twenty-
micron filter will hold a lot more material.
When a filter is rated for a particular size the rating is either "nominal" or
"absolute".
Filters may be permanent or disposable and are rated on an absolute or

nominal scale. The absolute rating of a filter refers to smallest size
particle that will be removed during filtration while nominal ratings refer
to the average particle size that will remain in the fluid after filtration.
A "nominal" five-micron filter will trap particles around 5 microns in

size. An "absolute" 5-micron filter will guarantee to trap all particle 5
microns in size and larger. An absolute 5 micron filter will go down to
maybe one micron to make sure it gets all the five micron particles.
A five-micron absolute filter will be so tight that it may be the equivalent

of a one-micron nominal filter. Because of the way filters are made the
holes vary in sizes. The only way to make sure you get every particle of a
particular size is to go way down in size and trap a lot of smaller
particles.
As filters get dirtier the holes get smaller and they trap more particles and
finer particles. A dirty filter will filter more effectively than a clean filter
until it gets so dirty that nothing can pass through it.
The smaller the filter size the more it will filter out and the faster it will
do it. A filter with larger size rating will also trap smaller particles but
just not as fast.

If you have a river and you string a fine net across it you will catch all the
grass, sticks, fish and logs.
If you take the same river and put a log across it you will catch other big
logs. When you catch enough big logs you will start catching smaller
logs. Then you will catch big sticks and smaller sticks. You may
eventually catch enough stuff to dam the river.
Filters work the same way. A 20-micron filter has bigger holes in it than
a one-micron filter. Because the holes are bigger they will hold more
material. As the holes fill up they will trap smaller and smaller particles
just like the log in the river.
A 20-micron filter will give you longer filter life and reduce costs. It will
also trap the smaller particles. It will not do as good a job of getting all
the small particles out immediately.
4. A. Selecting a filter for particle size

Filters are sized by the size of the particles they will trap as measured in
microns. A micron is a millionth of a meter. A meter is 39.37 inches so a
micron is 39.37/1,000,000. 39.37 goes into a million 25,400 times so a
micron is about one twenty five thousandth of an inch.
A five micron filter is supposed to trap anything five microns and larger.
It sort of does that. The filters are full of holes. As they get used they
collect dirt and the holes get smaller so it does a better job of trapping
particles.
Filters generally come in one, five, ten and twenty micron sizes. These
are the most common sizes. Three micron is also available some places,
but it is not as common.
The reason for using more than one filter is to spread the workload over
the two filters. Ideally the first filter will trap half the contaminants and

those will be the larger half. The second filter will trap the other half of
the contaminants consisting of the smaller particles.
Example:
Size is in microns, which is millionths of a meter, which is about
1/25,000 of an inch.
Volume of
Total Volume of
Particle in
Size Dirty Filtered Unused Particles This Size
Cubic
in Cubic Microns
Microns
<1 0 17,209 0
1 140,317 25,575 11 0.5 73,470
2 14,382,515 21,432 1,049 4.2 60,245,478
3 15,364,737 9,720 1,935 14.14 217,214,360
4 19,644,411 4,223 3,367 33.5 658,292,070
5 13,751,087 2,550 3,618 65.5 900,008,644
6 9,120,620 1,673 1,181 113.1 1,031,520,233
7 1,894,282 558 372 179.5 340,203,197
8 631,427 239 142 268.1 169,274,970
9 420,952 80 55 381.7 160,679,230

10 280,634 478 66 523.6 146,939,962
11 0 319 22 696.9
12 140,317 0 0 904.8 126,956,128
13 70,159 159 22 1,150.3 80,707,350
14 70,159 0 0 1,436.7 100,801,533
15 140,317 80 11 1,767.2 247,961,187
16 70,159 0 29 2,144.7 150,467,594
17 65,774 32 5 2,572.4 169,200,116
18 85,506 112 3,053.6 261,104,131
19 26,309 80 3,591.4 94,485,417
20 48 4,188.8
21 16 4,849.1
The total number of particles is 76,299,682.Half of that is about

38,000,000 which occurs somewhere between 3 and 4 microns. The total
volume of all particles from one to five microns is 1,835,834,020 cubic
microns. The total volume of all particles six microns and above is
3,080,301,039.
There are about five billion cubic microns of material in this sample. This
sample was taken from a dirty sump so the particle count is high,

however, the sump had never been filtered so the ratios by size are pretty
good.
About 37% of the particles are five microns and below by total volume of
the particles. In other words about 1/3 third of the mass of swarf and grit
generated by grinding will be below five microns.
To convert cubic microns to cubic inches you multiply cubic microns by

59139 X 10-12.
This is about 0.000 000 000 000 59139.
1,835,834,020 cubic microns x0.000 000 000 000 59139 = 0.0011 cu. in.
per cc
3,080,301,039 cubic microns x0.000 000 000 000 59139 = 0.0018 cu.
in.per cc
To convert cubic centimeters to cubic inches multiply cubic centimeters

by 0.061
0.0011 cu. in. per .061 cu. in. or.018 cubic inches of solids per total cubic
inch
0.0018 cu. in. per .061 cu. in. or.031 cubic inches of solids per total cubic
inch
The liquid from the sump was about 18% solids at five microns or less by
volume and about 31% solids six microns or above by volume. For a total
of 49% by volume.
There is about half as much crud by total volume at or below five

microns as there is above five microns.
A 5-micron filter will trap particles 5 microns in diameter.

Circumference = pi times diameter so this is a hole 15.7 microns around.
Volume = 4pr 3/3
Volume = 4 x 3.1416 x 2.53 / 3
Volume = 4 x 3.1416 x 15.625 / 3

Volume = 196.35 / 3
Volume = 65.45
A 10-micron filter will trap particles 10 microns in diameter.

Circumference = pi times diameter so this is a hole 31.416 microns
around
Volume = 4pr 3/3
Volume = 4 x 3.1416 x 53 / 3
Volume = 4 x 3.1416 x 125 / 3
Volume = 1570.8 / 3
Volume = 523.6
We can see that a particle that is twice the size will have eight times the
volume
5. Filter material
Paper
Paper is cheap however it readily absorbs oils and essential components
of lubricants in cutting, grinding and machining materials.
Poly filters
These are plastic materials. They will trap dirt and will not or will not
absorb oil and other essential components depending on the material
selected.
Bag filters
Various kinds of cloth sewn into bags.
Hard cellulose
Cellulose fibers compacted into an extremely hard filter with ridges.
6.Filter construction
Folded paper

Blown and molded poly filters.

Plastic that is blown into a mass sort of like cotton candy. Then it is
heated just enough so that it sticks to itself. This is a thick version of the
standard furnace filter.
String wound filters

Extruded polypropylene that is wound around a central core. It is wound
on a bias so it creates diamond shape patterns up and down the side of the
filter. These diamond shape patterns create a great deal more surface area
so these filters can absorb more material.
Folded Polyester
A plastic sheet that is folded and pleated to greatly increase the surface
area.
Roll up filter
These consist of a sheet of material that is rolled up around a core. This
sheet of material can be unwound, cleaned and then rewound for re-use.
Hard filter
A hard material filter as opposed to cloth or string wound. This filter is
ridged to provide a greater surface area. It is also graduated so that the
outer surface will trap the larger particles and the inner surfaces will trap
consecutively smaller particles.
Bag filter
These have a bag inside a canister. In bag filters the material is pumped
through a bag. These are large capacity filters and are removable and
cleanable. The housing makes these more expensive initially but you may
be able to recover their cost in heavy use situations.
Activated carbon and other chemical filters

Activated carbon and other chemical filters use chemically active
substances to remove chemicals, metals and particles from liquids. They

will also remove some of the chemicals that make the coolant work well.
A possible use for these is to remove contaminants and clean the coolant
before final disposal. They will clog very rapidly unless the coolant going
into them is extremely clean. These are generally referred to as
“polishing” filters. They are especially good at removing dissolved
metals.
7. How long the filters last

How long filters last depends on two things. What is in the liquid and
how dirty it is? A liquid with greases or oils will plug up a filter and clog
it much faster than a clean liquid will. The more dirt that is in the liquid,
the faster the filter will get full.
Basically in order of life it would be:

1.A paper filter - this will probably clog rapidly when filtering grinding
coolant because it will tend to trap all the oils, rust inhibitors and
lubricants.
2.A blown poly filter.
3.A solid, ridged filter
4.A string wound ploy filter
5.A cleanable wrapped filter
6.A bag filter
In normal sumps metal particles and other contaminants do three

things.1. They dissolve into the coolant.2. They settle on the
bottom.3.They hang suspended in the liquid.
8. How much filters cost.

Disposable filters are probably the cheapest filters to use. They are the
most expensive to buy but the labor is very low. Filters such as
wrappable filters and bag filters do not need to be replaced very often,
but they need to be cleaned regularly.
Filter selection

Comparison of cost vs. solids removed

Hard
Spun or Filter
Pleated Polyester String Wound
Blown Resin
4 sq. ft. 6 sq. Ft. Polypropylene
Polypropylene Bonded
Cellulose
Solids
removed 7.0 12.0 2.5 2.1 3.3
(oz)
Cost $ 2.25 $ 3.25 $ 2.30 $ 5.25 $ 6.00
Cost per
oz of
$ 0.32 $ 0.27 $ 0.92 $ 2.50 $ 1.82
Solids
Removed
Cleanable
& Yes Yes No No No
Reusable
Cost of filters
Size in
Microns Case Size Order Size
Filter costs 1 3 5 10

Pleated poly
4 sq. Feet surface area $ 6.75 NA $ 6.38 NA 24 24
6 sq. Feet surface area $ 9.75 NA $ 8.10 $ 8.63 24 24
Blown or spun poly $ 2.70 $ 2.55 $ 2.46 $ 2.36 40 40
Wound natural cotton $ 4.01 $ 4.01 $ 3.50 $ 3.50
Wound rayon $ 6.00 $ 6.00 $ 5.25 NA
Reusable blanket Complete

$15 ea $15 ea $15 ea $15 ea
filter set up
Extra blankets $ 5.25 NA $ 5.25 $ 5.25 6 6
Filter back pressure

A pump will generate a pressure or back pressure as it tries to pump
material through a filter. The pressure or aback pressure is measured in
psi. for pounds per square inch. The finer the filter is the greater the
backpressure will be. When filtering through a 3-micron filter the
backpressure is approximately 7 psi. When filtering through two filters
the back pressure its approximately the sum of the back pressure of both
filters so it is 5 psi for the 5 micron filter plus 10 psi for the I micron
filter at a nominal flow rate of ten gallons per minute.
As the pressure increases the flow rate will decrease. As the filters get
clogged the amount of force required to pump through them will
increase. As the filters get used and start to clog up they will also do a

better job of filtering.
At a flow rate of 10 gpm

1-micron filter creates 10 psi
3-micron filter creates7 psi
5-micron filter creates5 psi

Chapter 17
Filtering EDM fluids

The most frequently overlooked factor in the EDM process is the
filtration method used to maintain the dielectric fluid.
A typical tool and die operation had 12 EDM's, each with its own
standard paper cartridge filter or diatomaceous earth filtering system.
"The fluid was as black as coal," recalled the foreman. "Forget about
being able to see the bottom of the work tank. Two inches under the
surface everything disappeared."
Late in 1994, several Charmilles CNC (computer numerical control)

EDM’s were installed and integrated with the existing Elox, Sodick and
LeBlond Makino units. The project team also recommended installing
better EDM filtration systems to cut labor hours and disposal costs. "All
filling and draining of the machines is now via the filter and the fluid is
filtered to one micron. Even after six months of heavy use, including
applications where we pull up to 200 Amps in roughing mode, the oil is
absolutely crystal clean."
Their EDM processing showed marked improvements in machining

times and finish as well. One operator, who had relocated with his
machine from another facility, found that a wrench die that took nine
hours using EDM at his previous shop now took only seven hours at the
new shop on the exact same machine. On other applications, typical
EDM times dropped more than 20% and some as much as 40%.
http://www.carbideprocessors.com/Coolant/book/17.htm [7/23/2005 11:13:07 PM]

Chapter 18
Testing
Minimum Daily Tests
You should do this once at the start of a shift and again at the end of a shift in a one-shift
operation or once each shift in a three-shift operation. You need to keep good records.
Checking pH with meter and concentration with a refractometer takes 2 or 3 minutes and
may be enough for the daily tests.
Results requiring more testing:
If the coolant smells or if the pH has changed dramatically or if the pH is too high or too low
then you need to do a check for bacteria. There are simple test such as bio sticks that allow
you to do this easily and simply.
Why to test
Coolant changes as you use it. The water evaporates out of it. Coolant levels drop as it gets
splashed out. Coolant dissolves and chelates metals. Coolant loses its ability to lubricate. It
also loses its anti-rust ability. The pH will change which will encourage bacteria growth. It
also becomes oily and can break down faster.
The sludge in coolant means rougher grinds, more burning and much shorter diamond wheel
life. It also increase health hazards and breaks coolant down faster.
What you might see from the testing. This is what we have found in our tests.
Dirty Filtered Unused
Particle size and count 75,000,000 80,000 12,000
Turbidity 45,000 15 7.02
Viscosity 0.73 0.67 0.76
pH 8.08 8.04 8.02

Conductivity 2,210 1,508 1,683
Cobalt levels 3,210 299 0.138
Color Dark gray Green/red Green
Sludge 1/3 of depth Trace Random particles
Refractive index Depends on the coolant
Test Instruments to Analyze Coolants

Test for oils and grease
Graduated cylinder
Use a graduated cylinder. 1. Fill it to the top 2. Let it settle 3. Read the lines
Detect bearing and seal failure and help identify leaks
Light to medium oil

Emulsified oil
Heavy oil
Light grease floating
Medium grease stuck

to the sides
Heavy grease on the

bottom
Keep your coolant at the proper concentration

Refractometer
Thick coolant gets gummy and clogs diamond wheels and machines. Thin coolant allows
rust to form and bacteria to grow

Put a little coolant here and close the flap -

>
How it works
What you see - As water evaporates the coolant gets thicker. Light bends as it goes through
liquid. Thicker liquid bends light differently than thinner liquid. There is a numbered grid
or scale shown by thin lines. You will see a thicker line or the edge where a darker area
borders on a lighter area, which tells you how thick or thin the coolant mixture is.
Test Conductivityfor metal concentrations, chelated, dissolved and metal salts

Conductivity Meter
1. Stick the end in the coolant

2. Press the button
3. Read the number
4. Lower is better.
Test pH for chemical change and concentration, as well as biological activity

pH tester
pH tells you whether your coolant is acid or caustic. Either one can promote bacteria growth
and affect skin. You need to keep your coolant at the proper pH with water, make up coolant
and possibly other additives.
You use the gauge

by putting the end
in the coolant and
reading the
numbers.
You dip the paper
in the coolant and
match the color
with the supplied
chart
Ways to test coolant

How and When to Test Coolant

Run these tests daily at first. Once you get the system under control you shouldn't see
much change from day to day. Then run the tests weekly.
Outside Lab
1. Particle size and count Before coolant change
2. Turbidity Quarterly
3. Viscosity Quarterly
4. pH Quarterly
5. Conductivity Quarterly
6. Cobalt levels Before coolant change
No need - covered in other

7. Color
tests
No need - covered in other

8. Amount of sludge
tests
9. Refractive index Quarterly
I suggest quarterly. I would recommend this as a minimum. It is enough to look pretty good
to the government. If you do a lot of grinding and have a lot of exposure you might want to
consider doing this monthly. Take a sample. Test half of it with your own tests. Send half to
the lab. This will tell you how good your instruments are. These instruments go bad just like
anything else.
Before you change the coolant get a small sample. This is as bad as your coolant will get.
Send it to a lab and get an official analysis. This will tell you several things.
1.Was your coolant safe and clean when you changed it?
2.You can use this to decide if you need to change more often or less often.

Tests
1. Particle size and count
Outside lab - $60
This tells you how much of each size particle you have in your coolant. This will help tell
you how much danger you and your equipment are in. Particles below 10 microns are
inhaled very easily. The smaller particles are more likely to be suspended in the atomized
coolant that you breathe. This test is essential at least once to tell you what size filters you
need on your coolant cleaning system.
You can use a clear glass jar.

A. The more sludge you have on the bottom the more particles you have.
B.If you swirl the bottle you will get some idea of the size of the particles by just looking at
it.
Official Lab test results
Particle size and count: Dirty 75 - 80 million Filtered 80,000 - 1 million Unused
12,000
2.Turbidity
Outside lab - Turbidity$30
Turbidity is a measure of how much solid material is suspended in your coolant. This is a
less accurate version of the particle count. The particle count uses a laser and a computer to
measure the particles in a sample and divide them by size. Turbidity measures how much
light shines through the material. The more particles, the less light that gets through. Another
way to get an idea is to fill a clear glass bottle and let the coolant settle down. It will
eventually (maybe an hour or two) settle down so there is a layer of particles on the bottom.
In really dirty coolant there may be a sludge layer about half the depth of the coolant. The
bottle of filtered coolant has a layer on the bottom but it is too small to measure and I can see
through the layer in places. It covers maybe 3/4 of the area of the bottom.
In an official lab test we got the following numbers.

Dirty 45,000 Filtered 15 Unused7.02
3. Viscosity
Outside lab - Viscosity$30
This is a test of how slippery the coolant is. It is a measure of the rate of flow of a liquid due
to internal restraints on that flow. Slippery coolant is good for cutting.
Test 1
The easiest and cheapest way to do it is to use a special cup. You dip the cup in the coolant
and fill it. Then you measure the amount of time from when it starts draining until it starts
forming drops. You use a stopwatch to do this.

Test 2
You use a specially shaped tube and measure the amount of time it takes the liquid to flow
through an area.
Test 3
You get a tube with balls inside it. You measure the amount of time it takes the balls to fall.
You sometimes see this sort of thing sold in automotive stores to measure antifreeze. The
scientific tube is expensive and doesn’t work very well
4. pH
Outside lab - $20
pH is based on complex chemical analysis. It is important because almost anything you do to
a liquid changes its pH in some way. So pH is good because it is easy to measure. It is
important in this industrial process because it is pretty easy to control.
The pH scale. This is the way it works because scientists around the world agree on it. The
reason is really complicated so just remember 7 is neutral.
7 is neutral pH. Below 7 means it is acid. The further below it is the stronger the acid is.
Above 7 means it is basic. The further above 7 it is the stronger the base is.
Acids
Citric acid is Vitamin C and you drink it in orange juice. It is an acid and just a little bit
above 7.You can drink it and it is good for you. It can be concentrated to where it is harmful
but diluted in orange juice it is good. Sulfuric acid is a ways below 7 and it is battery acid. It
will eat holes in your clothes and your skin.
Bases
Dishwasher soap is a basic material as are many soaps. If you wash with them enough you
will get dishpan hands although part of the drying effect is simply from the water removing
oils from the skin. Drano or other toilet bowl cleaners are above 7 and they will eat holes in
your clothes and skin.
The easiest way to measure pH is with eter but many still use dip papers. You dip the papers
into the coolant and they change color. You then compare the color change to the chart and
that tells you what your pH is.
Official Lab test results

Dirty 8.08 Filtered 8.04 Unused8.02
Papers run from $10 to $50 depending on how accurate you want them. They can get pretty
accurate, but probably not accurate enough for these small differences. These can be pretty
accurate especially if you specify a narrow range. There is a paper that has a set of different
strips on it. The range is from 7.2 to 8.8 and has about 10 divisions in it. That should be
pretty good here.
The pH of a metalworking fluid is readily determined using litmus paper (available through
fluid suppliers or laboratory-supply companies) or a handheld pH meter. Litmus paper
provides a quick, low cost means of estimating fluid pH. Its accuracy is limited to plus or
minus one full pH unit and is not particularly effective in predicting biocide failure.
pH meters are more expensive, but provide more accurate readings. Depending on the
degree of accuracy and other desired options, pH meter kits may be purchased at a cost
ranging from as little as fifty dollars to several hundred dollars. Low to medium cost pH
meters are accurate to plus or minus 0.2 pH units, an accuracy sufficient for monitoring
biological degradation. Although high cost meters are accurate to hundredths of a pH unit,
this degree of accuracy is of little benefit with regard to fluid management.
These sell from maybe $60 to $1500.There are a whole bunch under $100.Stay away from
the really cheap ones the way you would from a really cheap anything else. $60 ought to get
you a good, basic meter.
Tips on using pH meters
1. pH electrodes must be kept wet and clean. If one dries out, soak it in water or an
appropriate buffer solution for 24 hours.
2. pH meters and testers must be calibrated with buffer solutions. It is best to use two
buffers such as pH 7 and pH 4 to make sure the meter is working properly.
3. Mix the solution and let the meter reading stabilize for 10 to 20 seconds. Take the
measurement by immersing the tip of the electrode only I inch into the solution,
4. Do not be alarmed when white crystals form on the electrode; just soak the electrode in
buffer or water.
5. Conductivity
Outside lab - Conductivity$30
This measure how well an electric current travels through the liquid. It helps tell you how
much of what is suspended in that coolant. Conductivity measures how well an electric
current travels through the fluid. The more metals in the fluid the better the current will
travel sort of. A little meter runs maybe $80.They go up to $1500.
Official Lab test results - conductivity

Dirty 2,210 Filtered 1,508 Unused 1,683
6. Cobalt, Chromium, Cadmium and other metals

You can test cobalt yourself. The rest need lab tests. You can also get some idea of the

metals in your coolant from a conductivity test.
You can buy special dip papers. You need to keep the papers refrigerated to help extend the
life of them. They work on the basis of ion exchange. You need to have the coolant sample
below 7 phylum did not need to know what pH was to measure it. You do need to measure
pH to use the dip papers. To measure Cobalt with the dip papers you have to adjust the pH to
7 or below. Most coolants seem to run on the basic side, which means above 7. This means
that you will have to add some acid to bring the pH to 7 or below.
7. Color
Color is important because if you are using the right coolant you can tell by the color change
to red or purple how much dissolved cobalt you have in it. Color is pretty easy with the right
coolant. As the coolant dissolves more and more cobalt it gets redder and redder or maybe
more and more purple. There is definitely a change towards more redness in some form.
This is actually a pretty good rough test.
All you do is put some coolant in the bottle and let it settle down. As the crud settles to the
bottom you will typically see green on top and a reddish color in the middle with the sludge
on the bottom. The redder the color the more cobalt there is.
8. Amount of sludge
This is a simple test you can do yourself to find out just how much particulate you do have
in your coolant. It is really a no cost test to get about the same results that $90 worth of lab
tests gives you. This gives you an idea how much solid material you are getting in your
lungs.
9.Refractive index
Refractometers are an inexpensive tool ($200 to $250) capable of measuring fluid
concentration. A refractometer is a portable, hand held optical device that reads a fluids'
index of refraction. The term "index of refraction" refers to a measurement of how much
light is bent as it passes through a liquid. A fluid's index of refraction changes with the
density and chemical composition of the fluid. Therefore, refractometer readings obtained
for a metalworking fluid correspond to its concentration (the higher the reading, the greater
the fluid concentration).By measuring a metalworking fluid's index of refraction, the
optimum fluid concentration can be maintained.
Refractometers are typically available though coolant suppliers and provide fast, reliable
results. Tramp oils, cleaners, hydraulic fluids and other contaminants reduce its accuracy.
Manufacturers recommend dilutions and corresponding refractometer readings for specific

operations. For example, some fluids use a 20:1 to 30:1 dilution ratio. A shop would need to
keep the fluid's refractometer reading between 1.8 and 3.0 to maintain the 20:1 to 30:1

concentration.
How to measure concentration using a Refractometer

You need:
1. Refractometer
2. Sample jar
3. Eye dropper if available
4. A small container of distilled Water
5. Refract Chart (for your particular coolant)
6. Evaluation Sheet (for record keeping)
Steps:
1. Fill sample jar with coolant sample about half way. (Sample jar should be clean.)
2. Take out the refractometer and apply distilled water to the lens to calibrate, (be sure to
cover entire lens with solution) now focus. Calibration should be zero.
3. Clean & dry off solution from refract lens.
4. Using the eyedropper, take some of the sample coolant from sample jar and apply
liberally to refract lens. Hold up to light and adjust focus. Read where the white line is
and record (i.e., 2.1). This is telling you the number of working solids in solution.
5. Refer this number to your refract sheet. The number will correspond to the dilution
ratio (i.e., dilution; 15:1 = 2.1 solids). These numbers are demo only.
6. *Adjust your coolant up or down as necessary
Titration Methods
Refractometer measurements are fast but are less accurate when the fluid is contaminated
with tramp oils. To overcome this problem, vendors of fluids have developed titration kits to
determine fluid concentration. The titration measures a specific chemical or group of
chemicals and is less affected by interferences from tramp oil or water quality. While
titration is more accurate than refractometer readings, the procedure varies by coolant, and
excess contaminants can affect accuracy.
The titration is done by taking a measured volume of fluid, adding an indicator, and then
adding the titrant drop by drop until a color change is noted. The coolant concentration is
determined from the number of drops of titrant added.
Industrial testing kits-$599

These contain:
● Four different good quality meters: pH, conductivity, viscosity, refractometer

● Two sets of test strips, pH & cobalt

● An industrial quality, waterproof stopwatch

● 12 sampling bottles
● Unlimited technical support on a toll free 800 number
Total coolant Laboratory Analysis

$272.00 will get you an analysis of your grinding coolant. This will show you what you have
in your coolant.

Chapter 19
Sample Coolant Analysis

This program is an analysis of the grinding coolant and sludge. For most
shops this is the only regulated waste they generate. Ordinary office and
business waste is generally not regulated. Industrial waste including
paints, cleaners and processing wastes are generally regulated.
Material: Used grinding coolant
Overall: Very clean coolant – should easily qualify as recyclable

material for low cost disposal – Hazardous waste reporting should not be
necessary.
Hazardous waste designation: - Not required if recycling is done. We

do not believe that this material has to be treated as hazardous waste if it
is properly recycled. Per 40 CFR Section 261.2 (e) (1) Materials are not
solid wastes when they can be shown to be recycled.
Contaminants:
Metals: Some metals are present, but it does not appear the levels are
high enough to cause problems or require classification.
Chrome: The chrome tested out to be entirely trivalent chrome within

legal limits of federally required testing. There was no hexavalent
chrome detected (legally less than 0.01 mg/L).
Oils and greases: Good - There are oils and greases present so this
material cannot usually be disposed of in a sewer or septic tank in any
circumstances. However, the oils and greases are recoverable and
recyclable.

Recommended classification: Material held for recycling
Recommended disposal: Recycling through a reputable recycler such as

Safety-Kleen @ (800) 323-5040or VWR (Van Waters & Rogers)@ (800)
909-4897.It is extremely important that you select a recycler that is legal
and trustworthy. If you have the material hauled away and it is not
handled properly you will still be liable for any damage done.
Estimated cost of disposal: One time fee to the disposal company of

approximately $300 for testing. Then $75 to $90 per barrel. (Hazardous
waste is usually $300 to $400 per barrel) Additional testing may not be
necessary with this report. It will depend on the waste hauler.
Other steps to consider:
1.Filter the coolant regularly to extend coolant life.

2.This used coolant is approximately 90% water. Evaporating the water
may make economic sense.
Need for further testing: None - Unless the materials used in this process
change the tests done here should serve to establish this as a standard or
typical batch. No further testing should be needed unless the process is
changed.
Laboratory Analysis
This is how your waste tests legally. Show this to the recycler and to the
government if they ask. This test should serve as "a standard batch" test.
Unless you change your process no further tests should be necessary.
Your Results Legal Limits
Fats, Oil and Grease, mg/L 43.8

Total Petroleum Hydrocarbons,

39.3
mg/L
Hexavalent Chromium, mg/L <0.01 None
TCLP Metals, mg/L
Arsenic (As) <0.05 5.0
Barium (Ba) 0.17 100.0
Cadmium (Cd) <0.01* 1.0
Chromium (Cr) 0.008 5.0
Lead (Pb) <0.04 5.0
Mercury (Hg)** <0.0005 0.2
Selenium (Se) <0.08 1.0
Silver (Ag) <0.007 5.0
Oil and Grease testing performed by EPA Method 413.2 (Partition

Infrared)
Total Petroleum Hydrocarbon testing performed by EPA Method 418.1
Hexavalent Chromium testing performed by Standard Method 307-B
TCLP by EPA Method 1311

Metals performed by EPA Method 6010

* Cadmium detection limit raised due to matrix effects
** Mercury analysis by EPA Method 7470
Disposal
The TCLP is a test of whether it is safe to dispose of metal containing
compounds in a landfill. It is based on how much of each metal is likely
to leach out and contaminate the surrounding area.
It may not make sense, but it is the federal standard arrived at by science
and politics. It does give a standard to measure against.
This coolant exceeds the TCLP limits for disposal in a landfill. However,
there are several methods to legally dispose of this coolant and the sludge
it contains.

Chapter 20
One Bottle Coolant Testing

We have devised a very simple test. We send you a bottle and you look at
it. That ‘s about all there is to it. This will give you quite a bit of
information.
You may see some settling in fifteen minutes. If the coolant is very clean
it may take two hours or more to get anything to settle out. The best
length of time would be to let the bottle sit for twenty-four hours. New
coolant will clean with no sludge layer, no oil layer and no reddish color.
How to run the tests.

Test 1.Fill any clear bottle or jar most of the way to top with grinding
coolant. This is not a critical measurement. Label it with the time and
source.
It might be a good idea to label the samples with the date, the machine,
type of coolant, time since last coolant change and anything else
important.
Test 2.How long does it take for particles to settle out?
See how long it takes for the particles to settle to the bottom. The finer
the particles are the longer it will take to settle. Dust will float on top of
and in water. Rocks will drop right to the bottom. This will give you
some idea of particle size. If you get a thick layer immediately and
nothing later then it is probably all particles over ten microns. If you do
not get anything on the bottom in the first minute and the sludge layer
grows over a day then you probably have particles that are all under two
or three microns.

Typically you will get a pretty good sludge layer starting in a few
minutes. That layer will continue to grow for up to an hour. After an hour
it should be pretty well all settled out however, the really fine particles
may take up to day to settle out.
Test 3.Measure the amount of sludge

Once everything has settled out measure the height of the particle layer
on the bottom. A three-inch coolant sample can settle out to have as
much as an inch or more of sludge on the bottom. The thicker the sludge
layer the more sludge there is.
Test 4.Check the top for an oily layer. Looking will tell you if you have
tramp oils in your coolant. This is really simple but it is also very
important. Oils and greases really clog filters and grinding wheels. Some
coolants could be disposed of in sewers except for the oils and greases.
Test 5.Check the color of the coolant.

This is a test for metal contamination of the coolant.
In a lot of coolants the dissolved cobalt will cause a color change and a
reddish or purplish tint. The amount of color change is related to the
amount of dissolved cobalt.
Test 6.Cobalt levels and conductivity

The amount of color change relates to the change in conductivity of the
coolant. This is important if it is being sprayed in sensitive areas. The
amount of color change relates to the amount of chelated (sort of like
dissolved) metals in the coolant.
Note; test conductivity with a meter. Other factors affect it besides

dissolved or chelated metals.
Test 7.Look at the coolant.

If you see things floating in the middle of the coolant you may have

fungal or bacteria growth.
Test 8.Shake the bottle

Once the sludge has settled out, shake the bottle and try to get the sludge
back into suspension. This will give you an idea of how much sludge
there is in relation to the ability of the coolant to carry sludge. You will
also get an idea of the amount of oiliness by how well the sludge sticks to
the walls of the bottle. Typically it will be impossible to shake the bottle
enough to get all the sludge back into suspension.

Chapter 21
Disposal Of Used Fluids And Sludge

Every 100 lb of chips and turnings contains about two to four gallons of
fluid. The EPA estimates that approximately 90% of all the fluids on the
market can be recycled which means a huge savings for industry as well
as environmental benefits.
Three primary methods of separation

1. Gravity drains - recover about 33% and is inexpensive.
2. Squeeze the liquid out with a hydraulic ram. Drier scrap in a compact
pellet
3. Centrifuge or chip wringing - fast, large volumes, 98% fluid recovery,
driest chips
Once the oil has been recovered from the chips or parts, the job is half
finished. The fluid still contains fines and dirt. The recovered fluid
should be filtered.
1. Gravity settling
The recovered liquid sits and solids settle to the bottom. The cleaner
liquid will be decanted. The wet sludge and muddy liquid will be sold to
a recycler.
2. Media filtration
The liquid passes through media, leaving solid particles behind.
3. Magnetic separators
Effective in removing magnetic materials, and leave behind other solids
such as dirt, cutting tool or grinding wheel particles, and any non-

magnetic materials. Generally only works to the 35-micron level.
4. Hydro cyclones
Usually effective only on water-based liquids, and can become clogged if
subjected to large particles.
5. Centrifuge
Parts are spun at high speed and the liquid is spun out

Chapter 22
Health and Safety Concerns

Report on a conference on hazards associated with metal working fluids.
"A symposium on the Industrial Metalworking Environment: Assessment and Control"
Nov 13-16, 1995
Sponsored by:
The American Automobile Manufacturers Association (AAMA)
Occupational Safety and Health Administration (OSHA)
The National Institute of Occupational Safety and Health
United Automobile Workers (UAW)
and fourteen other organizations.
The results have been reported as follows:

"It is well known that prolonged or repeated contact with Metalworking fluids can cause
contact dermatitis, or skin irritation. Less well known are the general effects of metalworking
fluids on operator health."
"Furthermore, representatives agreed that the severity of the distress depended not only on the
levels of bacteria and endotoxins in the fluid, but also on the amount of particulate matter in
the fluid and the amount of exposure to and control of mists. The implication of all these
findings is that bacterial populations need to be closely controlled and that filtration is as
important now as it has ever been."
"It is equally important that manufacturers take steps to minimize contamination of

metalworking fluids with tramp oils, abrasive materials, and metal fines."
In other words, an OSHA sponsored conference concluded that filtering is as important now
as it ever was and that elimination of abrasive materials and metal fines from grinding coolant
is "important.”"
Skin irritation from metalworking fluids typically comes from the skin drying because of the
detergent action of the coolant. The problem gets worse as concentration levels get higher.
Contaminants in the coolant such as lubricating and hydraulic oils, abrasive particles, metal
fines, dissolved metals (especially nickel, chromium, and cobalt), acids, and salts also
increase the potential for damage.
Epidemiology
One study seemed to indicate that exposure to metalworking fluids results in an increased risk

of esophageal, pancreatic, and rectal cancers, especially among grinder operators. Another
study done at foundries and engine plants showed increases in stomach and lung cancers, but
the cancers did not seem attributable to metalworking fluids exposure. Questions about these
studies were raised because of the many outside variables (e.g., smoking, diet influences,
ethnic origin) that were not considered and the incomplete work histories of the subjects.
Further complicating the epidemiological studies was the fact that coolants used when the
data were gathered had different formulations from those used today.
Toxicology
Alkanolamine manufacturers maintained that their research indicates alkanolamines are safe,
but the UAW expressed strong concerns about them. The results of studies presented were
largely inconclusive. Additional research was requested.
The biocides used in metalworking fluids are the most studied and regulated ingredients in
these fluids. Their toxicological profiles should certainly be considered as primary sources of
information in selecting biocides for these applications. But the end user should select
biocides in conjunction with the fluid supplier to assure compatibility of the biocides and the
fluids.
The Triazine Consortium, composed of the manufacturers and marketers of triazine biocides,
discussed the results of studies it commissioned on the relationship between triazine - biocide
use and formaldehyde exposure in the workplace. The conclusion was that triazine biocides
do not release detectable levels of formaldehyde and are safe metalworking fluids
components.
Ann Ball of Cincinnati Milacron suggested that, based on her studies, a PEL of 2Mg/M3 to
lorng/M3 would not cause pulmonary irritation in workers. While the research was well
documented, there is reason to believe that PELs below which respiratory irritation will not
be experienced will vary significantly according to the composition of the fluid, and it may be
difficult to set one PEL for all types of fluids. Further studies are needed.
Two other presenters, Dr. Don Milton of Harvard University and Dr. Peter Thorne of the
University of Iowa, dealt with the role of bacteria and their growth byproducts (endotoxins)
in causing respiratory distress among workers exposed to metalworking fluids mists. It was
concluded that virgin fluid produced less distress and irritation than did used fluid.
Furthermore, representatives agreed that the severity of the distress depended not only on the
levels of bacteria and endotoxins in the fluid, but also on the amount of particulate matter in
the fluid and the amount of exposure to and control of mists. The implication of all these
findings is that bacterial populations need to be closely controlled and that filtration is as
important now as it ever has been.
Cobalt safety & health - Cobalt Leaching

As a binder in HSS and carbide tools, nothing beats cobalt. No other material imparts the
toughness of cobalt to the tool while providing a uniform latticework of support for the hard,
wear-resistant cutting grains. The cobalt that escapes the tool is another matter. When
workers repeatedly come in contact with this free-floating cobalt, released into the shop's air
and coolant while the tool is being made or sharpened, they suffer a host of medical
problems.
In researching the problem of cobalt exposure, experts in the fields of chemistry and
metallurgy have tried to discover how the cobalt is freed from the tool matrix. Some is
released as dust during grinding and cutting operations, but researchers also have found that
some is leached by many of the amino alcohols and amine-base additives found in almost all
water-miscible machining fluids. The mechanism by which amines leach cobalt is uncertain.
One possibility is that the amines chelate cobalt, a process by which the amine molecules
chemically link up with the cobalt atoms to form a water-soluble complex. This happens most
frequently as carbide is being ground. It can also happen when carbide tools come in contact
with the machining fluid as they are being used.
When regularly exposed to fluids with amino alcohol, tungsten carbide tooling will lose the
cobalt needed to hold it together. The cobalt leached out by the amines eventually winds up
as a contaminant in the Metalworking fluid itself, causing performance, health and
environmental concerns.
In the case of Hardmetal machining, cobalt leaching can be controlled by adding inhibitors to
the fluid, such as triazoles. While this is effective initially, the inhibitor becomes depleted as
the fluid is used and loses its effectiveness. However, inhibitors do little to control cobalt
leaching during the manufacture of tungsten carbide tools, and during carbide grinding, where
metal fines are a problem.
Cobalt leaching is at the heart of three potentially costly problems. First, it reduces the
performance and life of the tool. Next, cobalt is believed to be responsible for health
problems in some workers, causing dermatitis in handling the fluid and respiratory distress
from contaminated coolant mist. Finally, wastewater disposal may become a serious matter if
cobalt levels in used fluids exceed the regulatory limit for heavy metals.
Since learning how cobalt is leached from cemented carbide, researchers have been searching
for ways to prevent the chemical reaction from taking place. They've enjoyed some success
by adding a chemical barrier to the coolant that keeps the amines from attacking the cobalt.
But the most effective solution appears to be a coolant formulated with amines that don't have
such a strong affinity for cobalt.
The Trouble With Cobalt

Modern machining practices have made it especially important to find a low-leaching
coolant. Economic and environmental pressures have forced toolmakers and tool users to use
machining fluids and fluid-handling systems that permit coolants and lubricants to be
recirculated many times. Extending fluid life significantly lowers costs by reducing the
number of times workers must shut down the line to change fluid and by minimizing the
amount of fluid the workers must throw out and replace. However, the longer the fluid is
used, the more opportunities the amines in the fluid have to grab cobalt out of the carbides
that are being machined. Over time, the cobalt in the fluid reaches hazardous levels.
As the cobalt content in the fluid rises, so do the health risks to the workers. Cobalt dust in a
shop's air is known to cause respiratory and skin problems, and it is reasonable to suspect that
the cobalt dissolved in the machining fluid will have many of the same effects. Cobalt-
contaminated fluid causes dermatitis on skin that comes in contact with it. Workers also may
suffer respiratory problems if they inhale contaminated coolant mist.
Contaminated fluid also poses risks to the environment, and because of these risks, shops may
find it more difficult and expensive to dispose of cobalt-tainted coolant. Although federal
regulations do not single out cobalt, there are regulatory limits on the amount of heavy metals
a company's effluent can contain. Should cobalt levels in a shop's wastewater rise above these
limits, federal regulators may require the shop to treat the water as hazardous waste.
Cobalt leaching is hazardous to carbide tools, as well. When the tool loses its binder, the
surface is weakened and may be subject to accelerated wear. Also, the weakened surface
structure will compromise the bond between the tool and any coating applied to it.
Industry Response
Producers of Metalworking fluids have tried to block the amine/cobalt reaction with
inhibitors such as benzozole and tolyltriazole. The inhibitors are believed to react with the
cobalt on the surface of the tool before the amines have a chance to react with the cobalt and
draw it out of the tool.
Leaching inhibitors do work. However, once an inhibiting molecule reacts with the cobalt, it
is no longer available for further reactions as the machining process exposes more cobalt.
Eventually, the inhibitor is depleted, leaving any cobalt exposed beyond this point vulnerable
to attack from the amines in the fluid.
This explains the typical performance of a metalworking fluid that contains both cobalt-
leaching amines and a leaching inhibitor. At first, the cobalt level in the fluid remains low.
But over time, leaching causes the level to reach that found in an uninhibited fluid. The
inhibitor may extend the life of the fluid, but the cobalt contamination will still force the
operator to replace the fluid before it would have to be replaced if no leaching occurred.
As an alternative, the operator can add fresh inhibitor, but this has its drawbacks as well. It's
difficult to predict when cobalt contamination will reach dangerous levels. As a result, the
operator must regularly monitor the cobalt level to determine when more inhibitor is required.
The extra inhibitor also adds to the shop's coolant costs; in a typical case, the shop will spend
about $5 per 100 gal. of coolant used for one tank side treatment.
The easiest solution would be to eliminate the amines from the metalworking fluid altogether.
Unfortunately, this is not always possible, because the amines perform vital functions better
than any other substance. During fluid formulation, amines are used as corrosion inhibitors
and emulsifiers both in their unreacted state and as key components in fluid additives. All
amines added to the solution during the formulation of a metalworking fluid remain in the
product.
The industry has tried to find substitutes to take the place of amines in metalworking fluid,
but these replacements have their own drawbacks. The only substances that approach the
performance of the original amines are inorganic substances such as potassium hydroxide, but
they are not as effective as amines in controlling fluid pH and ferrous-metal corrosion. These
replacements also are extremely caustic. Prolonged contact can chemically burn a worker's
skin.
The Right Amine

Fortunately, researchers have found that they don't have to eliminate amines completely to
reduce a Metalworking fluid's cobalt-leaching tendency. Fluid formulators seeking a rust
inhibitor or emulsifier for their products have a number of amines to choose from, and these
substances vary widely in their tendency to leach cobalt.
One study compared the cobalt-dissolving tendencies of different amines when mixed with
water in a 1% solution. Deionized water containing no amines also was tested and compared
to the results of the amine-containing solutions. At the conclusion of the test, the solution
with the highest-leaching amine had 10 times more cobalt in the fluid than the solution with
the lowest leaching amine. For this study, the researchers used methods designed to replicate
real-world results. The screening test they used to determine the amount of cobalt in the water
and the different solutions is known to correlate with results in carbide tool manufacturing
plants. During this test, water or one of the solutions was placed in a jar with swarf from an
actual carbide grinding operation. The cobalt concentration in all the swarf samples was
adjusted to yield 1500-ppm total cobalt based on the weight of the test solution. The mixture
of swarf and water or solution was then vigorously mixed on a jar roller for 5 days. At the end
of this period, the water or solution was filtered and atomic absorption was used to measure
the amount of dissolved cobalt in the filtrate.
As might be expected, deionized water leached the least cobalt. Straight water usually is not a
suitable machining fluid, however, because it can corrode work pieces and lacks lubricity.
The researchers found that the solution with the amine AMP-95 most closely matched the
performance of deionized water containing no amines. At the conclusion of the test, the
concentration of cobalt in the deionized water was 14 ppm; the concentration in the solution

with AMP-95 was 23 ppm. Dissolved cobalt levels for the other solutions were 116 ppm for
monoethanolamine, 198 ppm for mixed isopropanolamines, and 241 ppm for
triethanolamine.
Safety coolants
There seem to be many sales people in the market selling coolants that will not dissolve
cobalt. Some of them are wrong and their coolants actually dissolve more cobalt. Some of
them are partially right and their coolants dissolve cobalt more slowly than other coolants.
We do not know of any coolant that truly does not dissolve any cobalt, ever.
Most coolant is basic because cobalt dissolves in acids better than bases. However Cobalt
does dissolve in bases (also called caustic solutions). It just dissolves more slowly.
The Materials Handbook says “cobalt...is dissolved by dilute sulfuric, nitric, or hydrochloric
acids and is attacked slowly by alkalis”.
Webster’s Dictionary
“Alkalis”1. Any base or hydroxide 2.any substance than can neutralize acids, with a pH
greater than 7.0.Strong alkalis are caustic.”
7.0 is a neutral pH. It is neither acidic nor basic (caustic). A pH below 7.0 is acid. A pH
above 7.0 is basic. In our analyses of most coolants they show a pH that is slightly basic.
Usually slightly above 8.0.
Dr. Susan Kennedy of the University of British Columbia has tested various coolants. In her
opinion some of the coolants sold as safety coolants are actually worse than non-safety
coolants. In other words some coolants are sold with the claim that they dissolve less coolant
and they dissolve more coolant.
Chemical reaction
There is a chemical process called chelation. Chelation is: 1. A chemical compound in which
the central atom (usually a metal ion) is attached to neighboring atoms by at least two
coordinate bonds in such a way as to form a closed chain. or 2. To cause (a metal ion) to react
with another molecule to form a chelate.
Dissolving would mean that the Cobalt would break up into individual cobalt molecules in
the water. Chelation means that it forms unique chemical compounds. This chelation is where
we get the reddish or purplish coloration.
Bacteria
Bacteria break complex substances such as sugar down into things like alcohol. They also
break the chemicals in grinding coolants down into other things and they will use

Cobalt as part of the process.
The bacteria grow well for several reasons. First, they grow well in the undisturbed sludge
and particles in the bottom of the sump. Second, they are anaerobic (do not need air) and
grow well under water. Third, they feed on the substances in some grinding coolants. Fourth.
They really like the tramp oils. Fifth, the tramp oils seal the top of the water so that no
possible air gets to the bacteria.
Water contains oxygen in two ways. Water has oxygen as part of its chemical make up as
H2O.Water also contains dissolved oxygen. (Boiled water tastes flat because the dissolved
oxygen has been boiled out. The Boy Scout Handbook says to pour the water from one
bucket to another to get oxygen back in which will make it taste better.) Dissolved oxygen
also helps prevent the growth of anaerobic bacteria.
Filtering helps:
1.Removes the particles before they can either dissolve or chelate or react other wise in the
coolant.
2.Removes the sludge and particulate that provide a nesting bed for bacteria in the bottom of
the sump.
3.Removes the bacteria.
4.Removes the oils that the bacteria eat.
5.Aerates the mixture to help keep the oxygen content high so that the bacteria cannot grow.
Studies on human health and inhaled coolants

Dr. Susan Kennedy at the University of British Columbia had done a survey of sawmill filing
rooms. Her research seemed to show that there was a lot more danger in cobalt from tungsten
carbide tools than anyone had realized. Breathing grinding coolant with dissolved cobalt is a
real danger. Filtering the cobalt out of the coolant before it dissolves helps lessen that danger.
Breathing grinding coolant with chunks of wheel and carbide in it causes problems at least
five ways.
1.The coolant alone causes problems. It can cause a rash like dishpan hands. If you breathe in
the mists then you can get these rashes in your throat and lungs.
2.Size
The human breathing system starts at the nose, which has nostrils about a quarter inch across.
The respiratory system branches and splits and rebranches until you get down into the
smallest part of part of the lungs, which handles air molecules that are about one ten billionth
of an inch across. If you have grinding particles that are about one ten millionth of an inch
across they are going to be able to get pretty far into the lungs. These big particles block the
lungs like a basketball dropped into fish net.

3.These particles are sharp.

The particles are typically rough chunks of tungsten carbide, diamond or cubic boron nitride.
They are designed to have rough edges. The particles in grinding coolant get recirculated
when the coolant is recirculated. These little, sharp particles can get inhaled and plug up your
lungs as well as cutting and scarring lungs. The lungs are very soft and moist so that air
molecules can pass through them. The rough chinks of material tear up the soft lung tissue
causing scarring and loss of function. Breathing these rough chunks is like putting broken
glass between your lip and your gums. Washington State Department of Ecology explains
that anything below 10 microns in size will get into your lungs and lodge in the holes really
well. About 59% of the billions and billions of particles in grinding coolant are at or under 10
microns in size.
4.Allergic reactions
Coolants dissolve metals. The dissolved metals can cause allergic reactions and scarring in
your lungs, which gradually causes of loss of lung function. It appears that there is an allergic
reaction to cobalt that differs from person to person. As with all allergic reactions the effect is
much greater with some people than others. Some people die from bee stings but most people
do not. However a bee sting hurts almost everyone. It seems to be a similar thing with cobalt.
Cobalt affects some people much more than others but it is not a good thing for anyone.
5.Bacteria grow in coolant. They make it smell bad and they are a health hazard. Filtering
removes the sludge that bacteria use to breed as well as removing tramp oils that bacteria eat
and filtering keeps oxygen in the water. These are anaerobic bacteria, which means “non-
oxygen” or non- air. They do not like air so keeping the coolant aerated helps prevent their
growth.
Basic housekeeping
If you run coolant through a clean filter you can remove up to 90% of all cobalt.
Do not splash grinding coolant any harder or farther than you have to. What happens is that
grinding coolant gets sprayed onto the work as a liquid then the splashing breaks the liquid up
into really small drops (aerosols) and this is what you breathe.
Keep the coolant away from the operator. Screens, shields, air intakes and cabinets can all be
used to collect mist and prevent it from getting to an operator.
There is lots of other material in grinding coolant. There are bits of diamond or CBN from the
wheel, there is resin from the wheel and chunks of broken carbide as well as just general grit
and dirt. We found that there could be up to 75,000,000 or 80,000,000 pieces of crud in a
cubic centimeter. This would be 150,000,000,000 (150 billion) particles in a two-liter soda
pop bottle. Filtering can get out over 99% of these particles.

Grinding fumes and dust can be dangerous. Inhaling grinding coolant, whether it is clean or
dirty, can be dangerous. How dangerous it is depends on how much is inhaled, how long it is
inhaled and who inhales it.
Lungs
Your lungs look like two sacks. The left side has two lobes and the right side has three lobes.
Each lobe gets divided into thousands of little passageways. Each passageway has thousands
and thousands of little rooms going off of it. The air gets into these little rooms and gets
trapped there when you exhale. The blood is rushing past these little rooms on the outside and
the air is on the inside. The rushing blood sucks the air through the walls when you inhale and
pushes the carbon dioxide out into the room when you exhale.
You damage your lungs several ways. One way it to fill these rooms with crud so the air
cannot get in or out. Small particles get carried down into these rooms and fill them up. So
does the tar in cigarettes. The oxygen gets from your lungs to your blood only through these
little rooms. The more of them that are blocked up the less oxygen you can get into your
blood. If it gets bad enough you can start plugging up passageways and shutting down
corridors and whole sections of lung.
Another way to damage your lungs is to cut them up and then let scars form where the cuts
were. The scars in your lungs are like the scars on your hands. It is different than ordinary
skin. It does not breathe. Every time you scar lung tissue you lose some lung capacity. If you
scar enough tissue then you die from slow strangulation.
Cadmium, chrome and cobalt

Basically you do not want to eat or drink either cobalt or nickel. Cobalt and nickel are
everywhere and your body can handle a little of each but generally the less you breathe or eat
the better. An argument about which is more dangerous is sort of like arguing about whether
it is better to get hit by a school bus or a cement truck. The real answer is to avoid both.
Here are WISHA (Washington Industrial Safety and Health Act) and OSHA (Federal
occupational Safety and Health Act) permissible exposure limits in mg/cu.m (milligrams per
cubic meter)
Cadmium Chromium Cobalt Nickel
mg/cu.m Fume Dust Metal Salts Cr2 Cr3 Metal Dust Fume Insoluble Soluble
OSHA .005 .005 1 1 0.05 0.05 0.1 0.1 0.1 1 1

WISHA .005 .0025 0.5 0.5 0.05 0.05 0.05 0.05 1 0.1
The real answer is to do as many are doing and set a limit of 100 ppm (parts per million) or
100 mg/L, or whatever else your expert recommends, for cobalt in coolant and then safely
dispose of it at that level. That is really low by legal limits but it is safe and that should be
important to you and I because it is our lungs we are talking about.
Papers and Experts on Dangers of Cobalt

Here are some of the sources for information. Most of them are written well enough that you
can pick out some information even without a lot of technical background.
1. Maintenance of Stellite and Tungsten Carbide Saw Tips: Determinants of Exposure to

Cobalt and Chromium
Dr. Susan Kennedy et.al.
University of British Columbia.
Journal of the American Industrial Hygiene Association (56) July 1995
2. Toxicological Profile for Cobalt

US Dept. of Health & Human Services
Public Health Agency
Agency for Toxic Substances and Disease Registry Report # TP-91/10
3. Industrial Exposure and Control Technologies for OSHA Regulated Hazardous Substances
US Dept of Labor
March 1989
Volume 1 of 2 Substances A-1 Cobalt (CAS Number 7440-48-4)
4. Agency for Toxic Substances and Disease Registry

Public Health Service Cobalt 1048.01
5. The Respiratory Effects of Cobalt

David W. Cugell, M.D. et. al.
In Archives of Internal Medicine Vol. 150 January 1990
Request reprints:
University Hospital 339 Windermere Rd. London, Ontario Canada N6A 5A5 (Dr. Morgan)
6.Criteria for Controlling Occupational Exposure to Cobalt

Public Health Service

Center for Disease Control October 1981

For sale by Supt. of Documents, Washington DC
7.Cobalt in Hardmetal Manufacturing Dusts

Matti Koponen, et. al.
American Industrial hygiene Journal (43) 9/82
8. Exposure to Airborne Metals in the Manufacture and Maintenance of Hard Metal and
Stellite Blades
Markku Linnainmaa, et. Al.
American Industrial Hygiene Association Journal (57) February 1996

Chapter 23
Example: A Good Material Safety Data Sheet

(There are a lot of really bad MSDS sheets. If you are a manager you
need an MSDS sheet that will protect you and your employees from
hazards and that will qualify as valid during government inspections.)
Carbide Processors 331 (Citgo 33) Coolant

MSDS sheet
Trade Name; Carbide Processors 331 (Citgo 33) Coolant

Commodity code: 39-333
Synonyms: metal working fluid, grinding coolant
CAS No.: Mixture (refer to Section 1)
Date: June 8, 1996
Technical contact: 206 272-1708
Medical Emergency: 206 -272-1708, 206 565-4708,
Material Hazard Evaluation

Per OSHA Hazard Communication
Standard (29 CFR Part 1910.1200) (OHCS)
Health: This metal cooling fluid is a non-hazardous material, particularly

when diluted 1:10 to 1:20. Under rare conditions, mild, temporary eye or
skin irritation may occur. Fumes may be mildly irritating to the
respiratory system.
Precautionary statement: CAUTION: Do not ingest. Do not inhale fumes
or mist.
HMIS Rating: health 1 Flammability 0 Reactivity 0

1.0 Generic Composition / Components
Components CAS # % Hard Data

7732-
Water >50 Non-hazardous
18-5
Triethanolamine 102-71- 10-20
Oral LD50(rat): >1.0 g/kg
6
Dermal, eye: Corrosive
Inhalation: Corrosive to
mucous membranes
Rust Inhibitor Mixture 10-15 Non-hazardous
Polyoxyalkalene 9038- 7-14 Oral LD50(rat): >5 g/kg
Glycol 95-3 Dermal, Eye: irritant
Disodium 55906-
<4 Oral LD50(rat): > 9 g/kg
Mercaptothiadizole 42-8
Bactericide / Mixture <.015 Oral LD50(rat): ~ 1.5 g/kg
Fungicide Dermal: may be absorbed.
Irritant to mucous membranes and
respiratory tract
Dye Mixture <.02 Non -hazardous
Hazard Rating: Least - 0, Slight - 1, Moderate - 2, High - 3, Extreme -

4
Assignments are based on supplier evaluations per NFPA and NPCA
guidelines
NA - not applicable ND - no data NE - not established
Caution:
1. Plexiglas windows or shield have become “crazed and cracked” from
contact with this coolant. Other window or shield materials such as those
made from K-Resin are not affected.
2. Some paints or coatings on machine surfaces are dissolved or pool
after prolonged contact with this coolant. Recommended paints: Epoxy.

Not Recommended: acrylic and lacquer based coating. Questionable at

present: Oil resistant Alkyd paints.
Properties
Appearance, Concentrate (neat) Clear, Blue
Dilution (55 in Clear, blue
deionized water) (see #2)
Specific
1.07
gravity
Pounds per
8.9
gallon
Viscosity, cSt at 40° C 3.7
SUS at 100° F 17
pH
9.5
concentrate
Falex Load, 55 in tap water, ASTM
4500
D 3233
Rust test, 3% in tap water, ASTM
Pass
D 4627
Solution stability (5%), 24 hrs. At
No separation
30° F
Copper corrosion (5%), 3 hrs at
1B
122° F, ASTM D 130
Foam Test, ASTM Seq. I 90-0
D 892, Seq. II 10-0
Seq. III 20-0
Notes:
1. Values are typical unless ranges or limits are shown
2. Dilute color - With fluorescent green tint
3. Dilute solutions can be hazy if tap water is used depending on

hardness
4. Foam test - ASTM D 3801, Break in 30 sec.
Storage, Handling and Special Considerations

1. Preferred storage is indoors away from sun and heat
2. While product is not known to be hazardous under normal use, normal
precautions should be taken to avoid eye, skin and clothing contact. For
safety considerations see the product label and the material Safety Data
sheet.
Coolant fluid (Water dilution Rates)

Metal Machinability Groups
Non- Nickel Stainless Titanium alloys,
Machining
ferrous alloys Steels High
soft Nitralloy "Monel"
Operations tensile nickel
metals steels metals
austentic
stainless steels,
Cast irons Cast irons
tool steels and
and and
high
alloys, alloy steels alloy steels
tensile alloy
(to 200 (200 - 300
steels
Brinell) Brinell)
(300 - 400
Brinell)
turning, boring,
milling, forming, 20:1 10:1 10:1 10:1
drilling, sawing

Tapping, thread
rolling,
reaming, screw 20:1 20:1 10:1 10:1
cutting,
broaching
Gear /shaping,
form and thread
20:1 20:1 10:1 10:1
milling, shaving
and hobbing,
Internal and
external grinding,
form and thread 20:1 20:1 20:1 20:1
grinding
trepanning
stamping 10:1 10:1 5:1 5:1
Notes:
1. Dilution ratios are approximate and may require higher or lower water
concentrations depending on a number of factors including the e type of
metal cut, machine speed, the severity of the operation, metal hardness,
etc.
2. Not recommended for MACHINING aluminum alloys or magnesium
due to possible staining
2.0 Physical Data

Physical Hazard classification (per 29 CFR Part
1910.1200)

No
No Combustible No
Flammable
No Compressed Pyrophoric
No Organic
Gas No Reactivity
peroxide
No Explosive No Stable
No Oxidizer
Boiling point, 760 mm Hg,

°C (°F):
Specific gravity (60/60°F)
~100 (~212)
(H2O = 1):
1.07
Vapor Density (Air =1):
ND
% volatiles by volume:
~ 10
Freezing point °C (°F):
~ -25, (~ -13)
Vapor pressure mm Hg,
ND
(25 °C):
Soluble
Solubility in H2O, % by
ND
weight:
~ 9.5
Evaporation rate ( Butyl
Clear blue liquid, mild glycol odor
acetate = 1):
pH of undiluted Product:
Appearance and odor:
3.0 Fire and Explosion

Data

Flash point, COC, °C (°F) NA

Flash point, PM, °C (°F) NA
Fire point, COC, °C (°F) NA
NFPA rating Health 1, Flammability 0,
Flammable limits (% by Reactivity 0
volume in air) Lower: NA Upper: NA
Extinguishing media CO2, dry chemical, water spray
Special fire fighting Use NIOSH/MSHA approved
Procedure positive pressure self-contained
breathing apparatus
Unusual fire or Explosion Not flammable
hazard
4.0 Reactivity Data

Stability: stable
Conditions contributing to none
insatiability : incompatible with strong oxidants
Incompatibility: or acid, such as nitric or sulfuric
acid, or compounds with reactive
hydroxy functions.
Hazardous decomposition CO2 (CO under incomplete
products: combustion) (thermal unless
otherwise specified)
Conditions contributing to
None
hazardous polymerization:
Hazard Rating: Least - 0, Slight - 1, Moderate - 2, High - 3, Extremee

-4
Assignments are based on supplier evaluations per NFPA and NPCA
guidelines
NA - not applicable ND - no data NE - not established

Spill or leak Procedures

Procedures if material is spilled
Dike for later disposal
Provide adequate ventilation
Report spills to local authorities and /chemtrec/RCRA
Release into water
Will mix readily with water. Notify down-stream users of
contamination. If unable to divert clear water, build overflow dam to
contain spill substance. Continue to handle as described for land spill.
Land Spill
Create dike or trench to contain materials, or absorb with sand, clay, or
commercial absorbent. Wear boots, gloves and splash proof goggles.
Transfer to containers and neutralize the material. Flush clothing and
spill area with soap and excess water.
Waste Disposal
Neutralize liquid and dispose of in accordance with local, state and
federal regulations.
It is the responsibility of the user to determine if the material is a
hazardous waste at the time of disposal.
RCRA Emergency Hotline Number: 800 424-9346
Protective Measures During Repair and Maintenance of Contaminated
Equipment
Use good industrial hygiene procedures
Refer to section 7.0
Wash exposed skin thoroughly with soap and water
Remove soiled clothing
Use gloves if extended, direct contact is expected.
6.0 Health Hazard Data

Health Hazard Classification
(Per 29 CFR Part 1910.1200)
NO Carcinogen
NO Animal carcinogen

NO suspect carcinogen
NO Mutagen
NO Highly Toxic
NO Toxic
NO Corrosive
NO Irritant
NO Sensitizer
NO Teratogen
NO Target Organ
Product listed as Carcinogen or Potential Carcinogen by:

NTP NO IARC NO OSHA NO Other NO
Toxicity summary: slight irritant to eyes and skin

Major route(s) of entry: No effects expected
Acute Exposure Symptoms
Inhalation: No effects expected
Dermal contact: Mild temporary irritation. None expected
when diluted
Eye contact: Mild temporary reversible irritation, redness
or swelling.
Ingestion: Mild GI irritation and discomfort
Injection: irritation, erythema, edema
Chronic exposure
Chronic exposure rare in industry, unless exposure to repeated, massive
vapor concentrations from heating of FLUID above 100°C (212°F).
Other Special Effects - None Expected

Medical Conditions Aggravated by Exposure - None known
First Aid and Emergency Procedures for Acute Effect

Inhalation: Remove victim from exposure. Normally no adverse
effects expected.

Dermal contact: Wash with soap and water. Remove contaminated

clothing.
Eye contact: Immediately flush eyes with water for at least 15
minutes. Seek medical assistance.
Ingestion: Drink excess water for dilution. Seek medical
assistance.
Injection: Presents a medical emergency, seek medical aid.
Notes to Physician: Following ingestion, dilute with excess water and
neutralize fluid. Follow-up symptomatic. Under rare conditions,
polyglycols may be depolymerized metabolically. Following ingestion of
large quantities of ethylene glycol, blurred vision and blindness have been
recorded, associated with CN depression and coma, and may produce
alcohol like intoxication, progressing to dizziness, vomiting, coma and
death unless treated immediately.
7.0 Special Protection Information

Ventilation requirements: Use local and general ventilation
Permitted Threshhold Air Concentrations:
Components: ACGIH TLV-TWA 5mg/m3 OSHA-PEL
ND
Triethanolamine: ACGIH TLV-STEL ND OSHA-STEL
ND
ACGIH TLV-Ceiling ND OSHA-Peak
ND
OSHA-Ceiling ND
Specific Personal Protective Equipment
Respiratory: Approved organic respirator above the
TLV
Eyes: Safety goggles with splash shields
Dermal: Use gloves if extended direct contact is
expected
Other clothing or equipment: Boots, apron
8.0 Transportation and Special Precautions

Storage: Do not apply heat or flame to container. Keep separate from

strong oxidizing agents.
Consult appropriate Federal, State and Local authorities before reusing,
reconditioning, reclaiming, recycling or disposing of empty containers
and/or waste residues of this product.
DOT Information
Proper shipping name: Metalcutting fluid
Hazard class: Non-hazardous
Hazard identification Number: None assigned
Placard: None
Coast guard CHRIS Code: ND
9.0 Environmental Data

Product Name: 331 Coolant
Commodity code: 39-322
SARA Title III

Section 313 - Toxic Chemicals
This product does not contain toxic chemicals of Section 313 of title III of
superfund Amendments and Reauthorization Act of 1986 (SARA) and 40
CFR Part 372.
Components CAS# %
None
Section 311 - Hazard Categories

YES Not applicable
NO Acute (immediate health hazard)
NO Chronic (delayed health hazard)
NO Fire Hazard
NO Sudden release of pressure hazard
NO Reactive hazard

Section 302/(A) - Extremely Hazardous Substances

(RQ = Reportable Quantity)
(TPQ = Threshhold Planning Quantity)
This product does not contain Extremely Hazardous Substances of
Section 302/(A)
Component CAS# % RQ lbs. TPQ lbs.

None
Clean Water Act

Under Section 311 (b) (4) of the Clean Water Act, discharge of crude oil
and petroleum products in any kind of form to surface waters must be
immediately reported to the national Response Center: 800-424-8802.
Comprehensive Environmental response, compensation & liability Act

(CERCLA) - Section 102 Hazardous Substances
Component CAS# % RQ lbs. TPQ lbs.
None
New jersey Worker and Community Right-to-Know Act.

Poly<oxy(methyl-1,2-ethanediyl)> CAS# 60121-17-3
alpha butyl-omega-hydroxy-phosphate
Water CAS# 7732-18-5
Triethanolamine CAS# 102-71-6
Carboxylic Acid Salt CAS# Supplier proprietary
Carboxylic Acid Derivative CAS# Supplier
proprietary
CALIFORNIA Proposition 65 (Registry of 1992)

Contains components that occur on lists of:

Carcinogenic materials _____ YES __X___ NO

Teratogenic materials _____ YES __X___ NO
Federal Regulations
Reported in TSCA Inventory:
Product _____ YES _____ NO __X___
NA
Components __X___ YES _____ NO ______
NA
ALL STATEMENT INFORMATION, AND DATA PROVIDED IN

THIS MATERIAL SAFETY DATA SHEET ARE BELIEVED TO BE
ACCURATE AND RELIABLE, BUT ARE PRESENTED WITHOUT
GUARANTEE, REPRESENTATION, WARRANTY OR
RESPONSIBILITY OF ANY KIND, EXPRESSED OR IMPLIED. ANY
AND ALL REPRESENTATIONS AND/OR WARRANTIES OF
MERCHANTIBILITY OR FITNESS FOR A PARTICULAR PURPOSE
ARE SPECIFICALLY DISCLAIMED. USERS SHOULD MAKE
THEIR OWN INVESTIGATIONS TO DETERMINE THE
SUITABILITY OF THE INFORMATION OR PRODUCTS FOR THEIR
PARTICULAR PURPOSE. NOTHING CONTAINED HEREIN IS
INTENDED AS PERMISSION, INDUCEMENT, OR
RECOMMENDATION TO VIOLATE ANY LAWS OR TO PRACTICE
ANY INVENTION COVERED BY EXISTING PATENTS,
COPYRIGHTS OR INVENTIONS.
10.0 Labeling
Caution:
HARMFUL IF SWALLOWED. PREVENT INHALATION OF
AEROSOLS, FUMES, OR MISTS. MAY CAUSE EYE AND SKIN
IRRITATION.
HANDLING:

The addition of nitrates to formulations containing ethanolamines may

lead to the production of nitrosamines, which have been shown to cause
cancer in laboratory animals.
FIRST AID:
Inhalation: Remove victim from exposure; if respiratory irritation
develops, call physician
Prolonged Dermal Contact: Wash with soap and water, flush for several
minutes, Remove contaminated clothing.
Seek medical aid if irritation develops.
Eye Contact: Immediately flush eyes with water for at least 15 minutes.
Call physician if irritation develops
Ingestion: Administer large quantities of water and milk.
Seek medical aid.

Chapter 24
Air Collection Information and Equipment

Part of a successful coolant program is to control mist and collect it for re-
use or recycling.
The companies listed on the other side of this insert sell everything from
huge systems for major factories to very small portable systems. They
sell downdraft tables for brazing and overhead systems with collecting
arms that can be placed wherever you wish.
Three Excellent Articles
One is by John Ashe of AAF (American Air Filter) International in

Louisville, KY. (305) 443-9353. His article is Controlling Welding
Fumes in the July, 1997 issue of The Fabricator. Reprints of the article
are available by calling (800) 477-1214 and asking for reprint # APC-4-
905.
Another good article was in the December 1996 issue of the same
magazine. It was written by Joe Topmiller who is Director of Technical
support for United Air Specialists at (800) 551-5401 in Cincinnati, Ohio.
The article is Addressing Air Quality Issues in the Workplace.
The third article is on new respiratory standards by Jay G. Mears in

Modern Woodworking. (248) 244-6439. It was called: Intelligence
Report: Getting Ready for 42 CFR part 84 call MSA and is available at
(888) 867-0602.
Equipment Suppliers:

1. AAF International (American Air Filters) –(305) 443-9353 - small line

but appropriate for most shop applications - great technical support - (see
articles section above). Excellent technical advice.
http://www.aafintl.com/
2. Airflow Systems (214) 503-8008 Dallas, TX - wide variety of units,

overhead units, downdraft tables, and portable units - "Dust and fume
Exhaust" pamphlet has good technical information. Recommended for
literature. http://www.airflowsystems.com/
3. Coppus (508) 756-8391 Millbury, MA - unique, portable dust

collection systems - also employee coolers for hot areas. Unique
products. http://www.coppus.com/
4. Dust Vent, Inc. (630) 543-9007 Fax: (630) 543-1407 100 W. Fay St.,
Addison, IL 60101, Wide range of equipment and good literature.
Recommended for literature. http://www.dustvent.com
5. Eurovac - Central vacuum cleaner systems and other dust collection

equipment. http://www.eurovac.com
6. Farr Pollution Control Products (800) 479-6801 Los Angeles, CA. -

Overhead cleaning with or without arms.
http://www.farrapc.com/farr.php
7. Gardner Environmental Products (920) 485-4303 Horicon, WI -

Ceiling mounted and portable units. mail@gardnermsg.com
8. Industrial Ventilation Group (800) 610-6010 Harbor Springs, MI -

Central and portable units, downdraft tables. Recommended for
literature. http://www.unipol.com/
9. MAC Equipment, Inc. (800) 821-2476 - Huge, complete catalog.

Excellent information, great source to build your own system.

Recommended for literature. http://www.macequipment.com
10. Nederman (313) 729-3344 Westland, MI –Nice literature - looks like

nice overhead arm extraction equipment - good information on Do It
Yourself. Recommended for literature. http://www.nedermanusa.com/
11. Plymovent (732) 417-0808 New Jersey - good equipment - great free
booklet "My Pocketguide to Clean Fresh Air". Recommended for
literature. http://www.plymovent.com
12. Sly, Inc. (216) 891-3200 Cleveland, OH - Shop size central collection
systems to huge industrial systems. Recommended for literature.
http://www.slyinc.com
13. Trion (800) 421-3956 Greensboro, NC - Overhead units - they

advertise a free clean air guide.
http://www.gormanindustries.com/Trion.htm
14. United Air Specialists (800) 551-5401 Cincinnati, Ohio - Invented

the original smoke eaters for bars, etc. - Good equipment - good literature
and great technical help. Recommended for literature.
http://www.uasinc.com/

Chapter 25
Disposal And Environmental Issues

We are not attorneys. We believe this to be a good compliance plan but
we do not take any responsibility for its use, misuse or anything else. The
laws change frequently. Consult an attorney or other expert.
Hazardous waste
Congress defined "hazardous waste" in the Resource Conservation and
Recovery Act (RCRA) as a solid waste, or combination of solid wastes
which, because of its quantity, concentration, or physical, chemical, or
infectious characteristics may:
1. Cause or significantly contribute to an increase in mortality or an

increase in serious irreversible, or incapacitating reversible illness;
2. Pose a substantial present or potential hazard to human health or the
environment when improperly treated, stored, transported, disposed of, or
otherwise managed;
Hazardous wastes are defined in terms of properties of a solid waste. It

should be stressed that a solid waste need not be a solid; it can also be a
liquid, semisolid, or a contained gaseous material. To correctly manage
wastes, facilities must first determine if wastes generated by their
operations are hazardous or non hazardous. A solid waste is hazardous if
it meets one of three conditions:
1. Exhibits one or more characteristics (ignitability, corrosivity,
reactivity, or toxicity) of a hazardous waste.
2. Has been identified and listed as a hazardous waste by the
Environmental Protection Agency (EPA).
3. The waste consists of a mixture containing a hazardous waste and a
nonhazardous solid waste.

Characteristic Wastes
Characteristic hazardous wastes exhibit one or more of the following four
characteristics:
1. Ignitability
A solid waste exhibits the characteristic of ignitability if a representative
sample of the waste has any of the following properties:
a. Liquid with a flash point less than 140' F (60' C
b. Non liquid and is capable, under normal conditions, of spontaneous
and sustained combustion;
c. Ignitable compressed gas per Department of Transportation (DOT)
regulations; or
d. Oxidizer Per DOT regulations.
EPA included ignitability as a characteristic of wastes that could cause

fires during transport, storage, or disposal. Examples of ignitable wastes
include many waste solvents such as mineral spirits or naphtha. Ignitable
hazardous wastes have the EPA hazardous waste number DOO I.
2. Corrosivity
A solid waste exhibits the characteristic of corrosivity if a representative
a. Liquid with a pH less than or equal to 2 or greater than or equal to
12.5; or
b. Liquid and corrodes steel at a rate greater than 1/4 inch per year at a
test temperature of 130' F
EPA selected pH as an indicator of corrosivity because wastes with high

or low pH can directly affect human health, the environment, react
dangerously with other wastes, or cause toxic contaminants to migrate
from certain wastes. Examples of corrosive wastes include acidic wastes
and spent pickling liquor (used to clean steel during manufacture).
Corrosive hazardous wastes have the EPA hazardous waste number D002.
3. Reactivity
A solid waste exhibits the characteristic of reactivity if a representative

a. Normally unstable and readily undergoes violent change without
detonating;
b. Reacts violently with water;
c. Forms a potentially explosive mixture with water;
d. Generates toxic gases, vapors, or fumes when mixed with water
e. Contains cyanide or sulfide and generates toxic gases, vapors, or
fumes at a pH between 2 and 12.5
f. Listed by the DOT as a forbidden explosive or as a Class A
explosive or a Class B explosive
Reactivity is a characteristic that identifies unstable wastes that can pose a

problem, such as an explosion, at any stage of the waste management
cycle. An example of a reactive waste is used cyanide solution. Reactive
wastes have the EPA hazardous waste number D003.
4. Toxicity
A solid waste exhibits the characteristic of toxicity if, by using designated
test methods, the liquid waste or extract from a representative sample
contains any of the following contaminants at concentrations equal to or
greater than the corresponding regulatory limit. A specific laboratory
analytical procedure, identified as the Toxicity Characteristic Leaching
Procedure (TCLP), is used to determine the toxicity of a waste. A waste
that exhibits the characteristic of toxicity has an EPA hazardous waste
number that corresponds to the toxic contaminant(s), which cause it to be
hazardous.
TCLP Regulated

Concentration
Contaminant
(mg/1)
Arsenic 5.0
Barium 100.0
Benzene 0.5
Cadmium 1.0
Carbon tetrachloride 0.5
Chlordane 0.03
Chlorobenzene 100.0
Chloroform 6.0
Chromium 5.0
o-Cresol 200.0
m-Cresol 200.0
p-Cresol 200.0
Cresols (total) 200.0

1,4-Dichlorobenzene 7.5
1,2-Dichloroethane 0.5
1,1-Dichloroethylene 0.7
'2,4-Dinitrotoluene 0.13
Endrin 0.02
Heptachlor 0.008
Hexachlorobenzene 0.13
Hexachloro-1,3-
0.5
butadiene
Hexachloroethane 3.0
Lead 5.0
Lindane 0.4
Mercury 0.2
Methoxychlor 10.0
Methyl ethyl ketone 200.0

Nitrobenzene 2.0
Pentachlorophenol 100.0
Pyridine 5.0
Selenium 1.0
Silver 5.0
Tetrachloroethylene 0.7
Toxaphene 0.5
Trichlorethylene 0.5
2,4-D 10.0
2,4,5-TP 1.0
2,4,5-Trichlorophenol 400.0
2,4,6-Trichlorophenol 2.0
Vinyl chloride 0.2
Many small businesses such as machine shops generate fluids that may
contain heavy metals. Heavy metals refers to metals such as arsenic,
barium, cadmium, chromium, lead, mercury, selenium and silver. These

metals are hazardous due to their toxic effects on human health and the
environment. Metalworking fluids and other wastes that may contain
these metals are potential hazardous wastes and must undergo TCLP
analyses in order to make a hazardous/nonhazardous determination.
The EPA has specifically listed over 400 wastes, which are considered
hazardous because they exhibit a hazardous waste characteristic or
contain toxic constituents that are harmful to human health and the
environment. These include wastes generated from manufacturing
processes and discarded commercial chemical products. Examples of
some common listed hazardous wastes include toluene, methyl ethyl
ketone, methylene chloride and xylene.
Composite lists from 40 CFR

We downloaded official lists from a web site, compiled all the lists and
removed duplications.
If a term was listed one way on one list and another way on a different list
we kept both listings. Often the difference is a space or a capitalization.
This includes initial capitals such as Acrylonitrile & acrylonitrile.
To use this to determine compliance we take the ingredient information

off the MSDS sheets and enter it into a spreadsheet in bold type. Then we
sort A-Z. Finally we work through the list and check to see if the names
already there (non-bold type) match the names we put in (bold type). If
the spellings are identical then there will be a non-bold name next to a
bold name and we have a match.
We also included what we believe to be misspellings along with the

suggested corrected spelling.
1. (azo)bis[5-amino-4-hydroxy]-, tetrasodium salt

2. [1,1'-Biphenyl]-4,4'-diamine
3. [1,1'-Biphenyl]-4,4'-diamine, 3,3'-dichloro-

4. [1,1'-Biphenyl]-4,4'-diamine, 3,3'-dimethoxy-
5. [1,1'-Biphenyl]-4,4'-diamine, 3,3'-dimethyl-
6. [1S-[1alpha(Z),7(2S*,3R*),7aalpha]]-
7. 1-(o-Chlorophenyl)thiourea
8. 1,1,1- trichloroethane
9. 1,1,1,2-Tetrachloroethane
10. 1,1,1-trichloroethane
11. 1,1,2- trichloroethane
12. 1,1,2,2-Tetrachloroethane
13. 1,1,2-trichloro-1,2,2- trichfluoroethane
14. 1,1,2-trichloroethane
15. 1,1-dichloroethane
16. 1,1-Dichloroethylene
17. 1,1-Dimethylhydrazine
18. 1,1-Dimethylhydrazine (UDMH).
19. 1,2,3-Propanetriol, trinitrate (R)
20. 1,2,4,5-Tetrachlorobenzene
21. 1,2,4-Trichlorobenzene
22. 1,2,4-trichlorobenzene
23. 1,2:3,4-Diepoxybutane (I,T)
24. 1,2-Benzenedicarboxylic acid, bis(2-ethylhexyl) ester
25. 1,2-Benzenedicarboxylic acid, dibutyl ester
26. 1,2-Benzenedicarboxylic acid, dimethyl ester
27. 1,2-Benzenedicarboxylic acid, dioctyl ester
28. 1,2-Benzenediol, 4-[1-hydroxy-2-(methylamino)ethyl]-, (R)-
29. 1,2-Benzisothiazol-3(2H)-one, 1,1-dioxide, & salts
30. 1,2-Dibromo-3-chloropropane
31. 1,2-dichloroethane
32. 1,2-Dichloroethane
33. 1,2-Dichloroethylene
34. 1,2-Dimethylhydrazine
35. 1,2-Ethanediamine, N,N-dimethyl-N'-2-pyridinyl-N'-(2-
thienylmethyl)-
36. 1,2-Oxathiolane, 2,2-dioxide

37. 1,2-Propylenimine
38. 1,3,4-Metheno-2H-cyclobuta[cd]pentalen-2-one,
1,1a,3,3a,4,5,5,5a,5b,6-
39. 1,3,5-Trinitrobenzene (R,T)
40. 1,3,5-Trioxane, 2,4,6-trimethyl-
41. 1,3-Benzenediol
42. 1,3-Benzodioxol-4-ol, 2,2-dimethyl-,
43. 1,3-Benzodioxol-4-ol, 2,2-dimethyl-, methyl carbamate
44. 1,3-Benzodioxole, 5-(1-propenyl)-
45. 1,3-Benzodioxole, 5-(2-propenyl)-
46. 1,3-Benzodioxole, 5-propyl-
47. 1,3-Butadiene, 1,1,2,3,4,4-hexachloro-
48. 1,3-Cyclopentadiene, 1,2,3,4,5,5-hexachloro-
49. 1,3-Dichloropropene
50. 1,3-Dithiolane-2-carboxaldehyde, 2,4-dimethyl-, O- [(methylamino)-
51. 1,3-Isobenzofurandione
52. 1,3-Pentadiene (I)
53. 1,3-Propane sultone
54. 1,4,5,8-Dimethanonaphthalene, 1,2,3,4,10,10-hexachloro-
1,4,4a,5,8,8a-
55. 1,4-Dichloro-2-butene (I,T)
56. 1,4-dichlorobenzene
57. 1,4-Dichlorobenzene
58. 1,4-Diethyleneoxide
59. 1,4-Dioxane
60. 1,4-Naphthalenedione
61. 1,4-naphthoquinone
62. 1,4-Naphthoquinone
63. 1-Acetyl-2-thiourea
64. 1-Butanamine, N-butyl-N-nitroso-
65. 1-Butanol (I)
66. 1H-,1,2,4-Triazol-3-amine
67. 1-Methylbutadiene (I)
68. 1-Naphthalenamine

69. 1-Naphthalenol, methylcarbamate

70. 1-oxobutoxy]methyl]-2,3,5,7a-tetrahydro-1H-pyrrolizin-1-yl ester,
71. 1-Propanamine (I,T)
72. 1-Propanamine, N-nitroso-N-propyl-
73. 1-Propanamine, N-propyl- (I)
74. 1-Propanol, 2,3-dibromo-, phosphate (3:1)
75. 1-Propanol, 2-methyl- (I,T)
76. 1-Propene, 1,1,2,3,3,3-hexachloro-
77. 1-Propene, 1,3-dichloro-
78. 2- ethoxyethanol
79. 2,2'-Bioxirane
80. 2,3,4,6-Tetrachlorophenol
81. 2,4 dinitrophenol
82. 2,4- dinitrophenol
83. 2,4-(1H,3H)-Pyrimidinedione, 5-[bis(2-
84. 2,4,5-T
85. 2,4,5-TP (Silvex)
86. 2,4,5-Trichlorophenol
88. 2,4,6-trichlorophenol
90. 2,4-D
91. 2,4-D, salts & esters
92. 2,4-dichlorophenol
93. 2,4-Dichlorophenol
94. 2,4-Dimethylphenol
95. 2,4-dimethylphenyl
96. 2,4-Dinitrophenol
97. 2,4-dinitrotoluene
98. 2,4-Dinitrotoluene
99. 2,4-Toluenediamine
100. 2,5-Cyclohexadiene-1,4-dione
101. 2,5-Furandione
102. 2,6-dichlorophenol

103. 2,6-Dichlorophenol
104. 2,6-Dinitrotoluene
105. 2,7:3,6-Dimethanonaphth[2,3-b]oxirene, 3,4,5,6,9,9-
hexachloro1a,2,2a,3,6,
106. 2,7-Naphthalenedisulfonic acid, 3,3'-[(3,3'-dimethyl[1,1'-biphenyl]-
4,4'-diyl)bis
107. 2-Acetylaminofluorene
108. 2-Butanone (I,T)
109. 2-Butanone, 3,3-dimethyl-1-(methylthio)-, O-
[(methylamino)carbonyl] oxime
110. 2-Butanone, peroxide (R,T)
111. 2-Butenal
112. 2-Butene, 1,4-dichloro- (I,T)
113. 2-Butenoic acid, 2-methyl-, 7-[[2,3-dihydroxy-2-(1-methoxyethyl)-3-
methyl-
114. 2-chloro-1,3-butadiene
115. 2-Chloro-1,3-butadiene
116. 2-Chloroethyl vinyl ether
117. 2-chlorophenol
118. 2-Cyclohexyl-4,6-dinitrophenol
119. 2-Furancarboxaldehyde (I)
120. 2H-1,3,2-Oxazaphosphorin-2-amine, N,N- bis(2-
chloroethyl)tetrahydro-, 2-oxide
121. 2H-1,3,5-Thiadiazine- 2-thione, tetrahydro-3,5-dimethyl-
122. 2H-1-Benzopyran-2-one, 4-hydroxy-3-(3-oxo-1-phenylbutyl)-, &
salts, when
123. 2-Imidazolidinethione
124. 2-Methyllactonitrile
125. 2-Naphthalenamine
126. 2-nitropropane
127. 2-Nitropropane (I,T)
128. 2-oxo-, methyl ester.
129. 2-picoline
130. 2-Picoline

131. 2-Propanone (I)

132. 2-Propanone, 1-bromo-
133. 2-Propen-1-ol
134. 2-Propenal
135. 2-Propenamide
136. 2-Propenenitrile
137. 2-Propenenitrile, 2-methyl- (I,T)
138. 2-Propenoic acid (I)
139. 2-Propenoic acid, 2-methyl-, ethyl ester
140. 2-Propenoic acid, 2-methyl-, methyl ester (I,T)
141. 2-Propenoic acid, ethyl ester (I)
142. 2-Propyn-1-ol
143. 3(2H)-Isoxazolone, 5-(aminomethyl)-
144. 3,3'-Dichlorobenzidine
145. 3,3'-Dimethoxybenzidine
146. 3,3'-Dimethylbenzidine
147. 3,6-Pyridazinedione, 1,2-dihydro-
148. 3a,4,7,7a-tetrahydro-
149. 3-Chloropropionitrile
150. 3-Chloroproponitrile
151. 3-Iodo-2-propynyl n-butylcarbamate
152. 3-Isopropylphenyl N-methylcarbamate.
153. 3-Methylcholanthrene
154. 4(1H)-Pyrimidinone, 2,3-dihydro-6-methyl-2-thioxo-
155. 4,4'-Methylenebis(2-chloroaniline)
156. 4,6-Dinitro-o-cresol, & salts
157. 4,7-Methano-1H-indene, 1,2,4,5,6,7,8,8-octachloro-2,3,3a,4,7,7a-
hexahydro-
158. 4,7-Methano-1H-indene, 1,4,5,6,7,8,8-heptachloro-
159. 4-Aminopyridine
160. 4-Bromophenyl phenyl ether
161. 4-Chloro-o-toluidine, hydrochloride
162. 4-Methyl-2-pentanone (I)
163. 4-Pyridinamine

164. 5-(Aminomethyl)-3-isoxazolol
165. 5,12-Naphthacenedione, 8-acetyl-10-[(3-amino-2,3,6-trideoxy)-alpha-
L-lyxo-
166. 5-Nitro-o-toluidine
167. 6,9-Methano-2,4,3-benzodioxathiepin, 6,7,8,9,10,10-
168. 6a,7,7a-octahydro(1aalpha,2beta,2aalpha,3beta,6beta,6aalpha,7beta,
7aalpha)-
169. 7,12-Dimethylbenz[a]anthracene
170. 7aalpha)-, & metabolites
171. 7-Benzofuranol, 2,3-dihydro-2,2-dimethyl-
172. 7-Benzofuranol, 2,3-dihydro-2,2-dimethyl-, methylcarbamate.
173. 7-Oxabicyclo[2.2.1]heptane-2,3-dicarboxylic acid
174. 8beta,8aalpha,8balpha)]-
175. A2213
176. acenaphthalene
177. Acetaldehyde (I)
178. Acetaldehyde, chloro-
179. Acetaldehyde, trichloro-
180. Acetamide, 2-fluoro-
181. Acetamide, N-(4-ethoxyphenyl)-
182. Acetamide, N-(aminothioxomethyl)-
183. Acetamide, N-9H-fluoren-2-yl-
184. Acetic acid ethyl ester (I)
185. Acetic acid, (2,4,5-trichlorophenoxy)-
186. Acetic acid, (2,4-dichlorophenoxy)-, salts & esters
187. Acetic acid, fluoro-, sodium salt
188. Acetic acid, lead(2+) salt
189. Acetic acid, thallium(1+) salt
190. Acetone (I)
191. acetonitrile
192. Acetonitrile
193. Acetonitrile (I,T)
194. Acetophenone
195. Acetyl chloride (C,R,T)

196. Acrolein
197. acrylamide
198. Acrylamide
199. Acrylic acid (I)
200. Acrylonitrile
201. acrylonitrile
202. Aldicarb
203. Aldicarb sulfone
204. Aldrin
205. Allyl alcohol
206. Allyl chloride (3-Chloropropene)
207. allyl chloride (3-chloropropene)
208. alpha,alpha-Dimethylbenzylhydroperoxide (R)
209. alpha,alpha-Dimethylphenethylamine
210. alpha-Naphthylamine
211. alpha-Naphthylthiourea
212. Aluminum phosphide (R,T)
213. Amitrole
214. Ammonium picrate (R)
215. Ammonium vanadate
216. Aniline
217. aniline
218. Aniline (I,T)
219. Antimony
220. Argentate(1-), bis(cyano-C)-, potassium
221. arsenic
222. Arsenic
223. Arsenic acid H3AsO4
224. Arsenic oxide As2O3
225. Arsenic oxide As2O5
226. Arsenic pentoxide
227. Arsenic trioxide
228. Arsine, diethyl-
229. Arsinic acid, dimethyl-

230. Arsonous dichloride, phenyl-

231. Auramine
232. Azaserine
233. Aziridine
234. Aziridine, 2-methyl-
235. Azirino[2',3':3,4]pyrrolo[1,2-a]indole-4,7-dione, 6-amino-8-
[[(aminocarbonyl)
236. Barban.
237. Barium
238. Barium cyanide
239. Bendiocarb
240. Bendiocarb phenol
241. Benomyl
242. Benz(a)anthracene
243. benz(a)anthracene
244. Benz[a]anthracene, 7,12-dimethyl-
245. Benz[c]acridine
246. Benz[j]aceanthrylene, 1,2-dihydro-3-methyl-
247. Benzal chloride
248. Benzamide, 3,5-dichloro-N-(1,1-dimethyl-2-propynyl)-
249. Benzenamine (I,T)
250. Benzenamine, 2-methyl-
251. Benzenamine, 2-methyl-, hydrochloride
252. Benzenamine, 2-methyl-5-nitro-
253. Benzenamine, 4,4'-carbonimidoylbis[N,N-dimethyl-
254. Benzenamine, 4,4'-methylenebis[2-chloro-
255. Benzenamine, 4-chloro-
256. Benzenamine, 4-chloro-2-methyl-, hydrochloride
257. Benzenamine, 4-methyl-
258. Benzenamine, 4-nitro-
259. Benzenamine, N,N-dimethyl-4-(phenylazo)-
260. benzene
261. Benzene
262. Benzene (I,T)

263. Benzene, (1-methylethyl)- (I)

264. Benzene, (chloromethyl)-
265. Benzene, (dichloromethyl)-
266. Benzene, (trichloromethyl)-
267. Benzene, 1,1'-(2,2,2-trichloroethylidene)bis[4- methoxy-
268. Benzene, 1,1'-(2,2,2-trichloroethylidene)bis[4-chloro-
269. Benzene, 1,1'-(2,2-dichloroethylidene)bis[4-chloro-
270. Benzene, 1,2,4,5-tetrachloro-
271. Benzene, 1,2-dichloro-
272. Benzene, 1,3,5-trinitro-
274. Benzene, 1,3-diisocyanatomethyl- (R,T)
276. Benzene, 1-bromo-4-phenoxy-
277. Benzene, 1-methyl-2,4-dinitro-
278. Benzene, 2-methyl-1,3-dinitro-
279. Benzene, chloro-
280. Benzene, dimethyl- (I,T)
281. Benzene, hexachloro-
282. Benzene, hexahydro- (I)
283. Benzene, methyl-
284. Benzene, nitro-
285. Benzene, pentachloro-
286. Benzene, pentachloronitro-
287. Benzeneacetic acid, 4-chloro-alpha-(4-chlorophenyl)-alpha-hydroxy-
, ethyl ester
288. Benzenebutanoic acid, 4-[bis(2-chloroethyl)amino]-
289. Benzenediamine, ar-methyl-
290. Benzeneethanamine, alpha,alpha-dimethyl-
291. Benzenesulfonic acid chloride (C,R)
292. Benzenesulfonyl chloride (C,R)
293. Benzenethiol
294. Benzidine
295. benzo(a)anthracene

296. benzo(a)pyrene
297. benzo(b)fluoranthene
298. benzo(k)fluoranthene
299. Benzo[a]pyrene
300. Benzo[rst]pentaphene
301. benzofuranyl ester
302. Benzoic acid, 2-hydroxy-, compd. with (3aS-cis)-1,2,3,3a,8,8a-hexa
303. benzotrichloride
304. Benzotrichloride
305. Benzotrichloride (C,R,T)
306. Benzyl chloride
307. benzyl chloride
308. Beryllium powder
309. beta-Chloronaphthalene
310. beta-Naphthylamine
311. bis (2-chloroethyl) ethers
312. bis(chloromethyl) ether
313. Bis(dimethylthiocarbamoyl) sulfide
314. Bis(pentamethylene)thiuram tetrasulfide
315. Bromoacetone
316. Bromoform
317. Brucine
318. butylate
319. Butylate.
320. Cacodylic acid
321. Cadmium
322. cadmium
323. Calcium chromate
324. Calcium cyanide
325. Calcium cyanide Ca(CN)2
326. Carbamic acid, (3-chlorophenyl)-, 4-chloro-2-butynyl ester
327. Carbamic acid, [(dibutylamino)-thio]methyl-, 2,3-dihydro-2,2-
dimethyl- 7-
328. Carbamic acid, [1,2-phenylenebis (iminocarbonothioyl)]bis-,

dimethyl ester
329. Carbamic acid, [1-[(butylamino)carbonyl]-1H-benzimidazol-2-yl]-,
methyl ester
330. Carbamic acid, 1H-benzimidazol-2-yl, methyl ester
331. Carbamic acid, butyl-, 3-iodo-2-propynyl ester
332. Carbamic acid, dimethyl-, 1- [(dimethyl-amino)carbonyl]- 5-methyl-
1H-
333. Carbamic acid, dimethyl-, 3-methyl-1- (1-methylethyl)-1H- pyrazol-
5-yl ester.
334. Carbamic acid, ethyl ester
335. Carbamic acid, methyl-, 3-methylphenyl ester
336. Carbamic acid, methylnitroso-, ethyl ester
337. Carbamic acid, phenyl-, 1-methylethyl ester
338. Carbamic chloride, dimethyl-
339. Carbamodithioic acid, (hydroxymethyl)methyl-, monopotassium salt
340. Carbamodithioic acid, 1,2-ethanediylbis-,
341. Carbamodithioic acid, diethyl-, 2-chloro-2-propenyl ester
342. Carbamodithioic acid, diethyl-, sodium salt
343. Carbamodithioic acid, dimethyl-, sodium salt
344. Carbamodithioic acid, dimethyl-, tetraanhydrosulfide with
orthothioselenious acid
345. Carbamodithioic acid, methyl,- monopotassium salt.
346. Carbamodithioic acid, methyl-, monosodium salt.
347. Carbamodithiotic acid, dibutyl, sodium salt
348. Carbamodithiotic acid, dimethyl, potassium salt
349. Carbamothioic acid, bis(1-methylethyl)-, S-(2,3,3-trichloro-2-
propenyl) ester.
350. Carbamothioic acid, bis(1-methylethyl)-, S-(2,3-dichloro-2-
propenyl) ester
351. Carbamothioic acid, butylethyl-, S-propyl ester
352. Carbamothioic acid, cyclohexylethyl-, S-ethyl ester
353. Carbamothioic acid, dipropyl-, S-(phenylmethyl) ester
354. Carbamothioic acid, dipropyl-, S-ethyl ester
355. Carbamothioic acid, dipropyl-, S-propyl ester

356. Carbamothioicacid, bis(2-methylpropyl)-, S-ethyl ester

357. carbaryl
358. Carbaryl
359. carbendazim
360. Carbendazim
361. carbofuran
362. Carbofuran phenol
363. Carbofuran.
364. carbon disulfide
365. Carbon disulfide
366. Carbon oxyfluoride (R,T)
367. carbon tetrachloride
368. Carbon tetrachloride
369. Carbonic acid, dithallium(1+) salt
370. Carbonic dichloride
371. Carbonic difluoride
372. Carbonochloridic acid, methyl ester (I,T)
373. carbonyl]oxime.
374. carbosulfan
375. Carbosulfan.
376. Chlomaphazin
377. Chloral
378. Chlorambucil
379. chlorbenzene
380. Chlordane
381. Chlordane, alpha & gamma isomers
382. chlorinated fluorocarbons
383. chloroacetaldehyde
384. Chloroacetaldehyde
385. chlorobenzene
386. Chlorobenzene
387. Chlorobenzilate
388. chloroethers
389. chloroethyl)amino]-

390. chloroethylene
391. Chloroethylene
392. Chloroform
393. chloroform
394. Chloromethane
395. chloromethane
396. Chloromethyl methyl ether
397. Chromic acid H2CrO4, calcium salt
398. chromium
399. Chromium
400. chrysene
401. Chrysene
402. Copper cyanide
403. Copper cyanide Cu(CN)
404. Copper dimethyldithiocarbamate
405. Copper, bis(dimethylcarbamodithioato-S,S’)-,
406. Creosote
407. Cresol
408. Cresol (Cresylic acid)
409. Cresols
410. cresosote
411. cresylic acid
412. Crotonaldehyde
413. Cumene (I)
414. Cyanide
415. cyanide (complexed)
416. Cyanide (complexed)
417. Cyanide (complexes)
418. Cyanide (salts)
419. Cyanides (soluble cyanide salts), not otherwise specified
420. Cyanogen
421. Cyanogen bromide (CN)Br
422. Cyanogen chloride
423. Cyanogen chloride (CN)Cl

424. Cycloate
425. Cyclohexane (I)
426. Cyclohexane, 1,2,3,4,5,6-hexachloro-,
427. Cyclohexanone (I)
428. Cyclophosphamide
429. Daunomycin
430. Dazomet
431. DDD
432. DDT
433. decachlorooctahydro-
434. D-Glucose, 2-deoxy-2-[[(methylnitrosoamino)-carbonyl]amino]-
435. Diallate
436. dibenz(a)anthracene
437. dibenz(a,h)-anthracene
438. Dibenz[a,h]anthracene
439. dibenzo(a)anthracene
440. Dibenzo[a,i]pyrene
441. Dibutyl phthalate
442. Dichlorobenzene
443. dichlorobenzenes
444. dichlorobenzenes, 1,2,4-
445. Dichlorodifluoromethane
446. Dichloroethyl ether
447. dichloroethylene
448. Dichloroisopropyl ether
449. dichloromethane
450. Dichloromethane
451. Dichloromethoxy ethane
452. Dichloromethyl ether
453. Dichlorophenylarsine
454. dichloropropane
455. Dichloropropane
456. dichloropropanols
457. dichloropropene

458. Dichloropropene
459. Dieldrin
460. Diethyl phthalate
461. Diethylarsine
462. Diethylene glycol, dicarbamate
463. Diethylhexyl phthalate
464. Diethyl-p-nitrophenyl phosphate
465. Diethylstilbesterol
466. Dihydrosafrole
467. Diisopropylfluorophosphate (DFP)
468. Dimethoate
469. Dimethyl phthalate
470. Dimethyl sulfate
471. Dimethylamine (I)
472. Dimethylcarbamoyl chloride
473. Dimetilan
474. Di-n-octyl phthalate
475. Dinoseb
476. Di-n-propylnitrosamine
477. diphenylamine
478. Diphosphoramide, octamethyl-
479. Diphosphoric acid, tetraethyl ester
480. Dipropylamine (I)
481. Disulfiram.
482. Disulfoton
483. Dithiobiuret
484. Endosulfan
485. Endothall
486. Endrin
487. Endrin, & metabolites
488. Epichlorohydrin
489. Epinephrine
490. eptc
491. EPTC

492. Ethanal (I)

493. Ethanamine, N,N-diethyl-
494. Ethanamine, N-ethyl-N-nitroso-
495. Ethane, 1,1,1,2-tetrachloro-
496. Ethane, 1,1,1-trichloro-
497. Ethane, 1,1,2,2-tetrachloro-
498. Ethane, 1,1,2-trichloro-
499. Ethane, 1,1'-[methylenebis(oxy)]bis[2-chloro-
500. Ethane, 1,1-dichloro-
501. Ethane, 1,1'-oxybis-(I)
502. Ethane, 1,1'-oxybis[2-chloro-
503. Ethane, 1,2-dibromo-
504. Ethane, 1,2-dichloro-
505. Ethane, hexachloro-
506. Ethane, pentachloro-
507. Ethanedinitrile
508. Ethanethioamide
509. Ethanimidothioc acid, 2-(dimethylamino)-N-[[(methylamino)
carbonyl]oxy]-
510. Ethanimidothioic acid, 2-(dimethylamino)-N-hydroxy-2-oxo-,
methyl ester
511. Ethanimidothioic acid, N,N’- [thiobis
[(methylimino)carbonyloxy]]bis-, dimethyl
512. Ethanimidothioic acid, N-[[(methylamino)carbonyl]oxy]-, methyl
ester
513. Ethanol, 2,2'-(nitrosoimino)bis-
514. Ethanol, 2,2'-oxybis-, dicarbamate.
515. Ethanol, 2-ethoxy-
516. Ethanone, 1-phenyl-
517. Ethene, (2-chloroethoxy)-
518. Ethene, 1,1-dichloro-
519. Ethene, 1,2-dichloro-, (E)-
520. Ethene, chloro-
521. Ethene, tetrachloro-

522. Ethene, trichloro-

523. Ethyl acetate (I)
524. Ethyl acrylate (I)
525. Ethyl carbamate (urethane)
526. Ethyl cyanide
527. Ethyl ether (I)
528. Ethyl methacrylate
529. Ethyl methanesulfonate
530. Ethyl Ziram
531. Ethylene dibromide
532. Ethylene dichloride
533. ethylene dichloride
534. Ethylene glycol monoethyl ether
535. Ethylene oxide (I,T)
536. Ethylene thiourea
537. Ethylenebisdithiocarbamic acid, salts & esters
538. Ethyleneimine
539. Ethylenethiourea
540. Ethylidene dichloride
541. Famphur
542. Ferbam
543. fluoranthene
544. Fluoranthene
545. fluoranthene benzo(b) fluoranthene
546. Fluorine
547. Fluoroacetamide
548. Fluoroacetic acid, sodium salt
549. formaldehyde
550. Formaldehyde
551. Formetanate hydrochloride
552. formic acid
553. Formic acid (C,T)
554. Formparanate
555. Fulminic acid, mercury(2+) salt (R,T)

556. Furan (I)

557. Furan, tetrahydro-(I)
558. Furfural (I)
559. Furfuran (I)
560. Glucopyranose, 2-deoxy-2-(3-methyl-3-nitrosoureido)-, D-
561. Glycidylaldehyde
562. Guanidine, N-methyl-N'-nitro-N-nitroso-
563. H-Azepine-1-carbothioic acid, hexahydro-, S-ethyl ester
564. heptachlor
565. Heptachlor
566. Heptachlor (and its epoxide).
567. heptachlorodibenzofurans
568. heptachlorodibenzo-p-dioxins
569. hexachloro-1,3-butadiene
570. Hexachloro-1,3-butadiene
571. hexachloro-1,5,5a,6,9,9a-hexahydro-, 3-oxide
572. hexachlorobenzene
573. Hexachlorobenzene
574. hexachlorobutadiene
575. Hexachlorobutadiene
576. hexachlorocyclopentadiene
577. Hexachlorocyclopentadiene
578. hexachlorodibenzo- p-dioxins
579. hexachlorodibenzofurans
580. hexachlorodibenzo-p-dioxins
581. hexachloroethane
582. Hexachloroethane
583. Hexachlorophene
584. Hexachloropropene
585. hexacholroethane
586. Hexaethyl tetraphosphate
587. hexahydro- ,(1alpha,4alpha,4abeta,5beta,8beta,8abeta)-
588. hexahydro-,(1alpha,4alpha,4abeta,5alpha,8alpha,8abeta)-
589. hexavalent chromium

590. Hexavalent chromium

591. hexopyranosyl)oxy]-7,8,9,10- tetrahydro-6,8,11-trihydroxy-1-
methoxy-, (8S-cis)-
592. Hydrazine (R,T)
593. Hydrazine, 1,1-dimethyl-
594. Hydrazine, 1,2-diethyl-
595. Hydrazine, 1,2-dimethyl-
596. Hydrazine, 1,2-diphenyl-
597. Hydrazine, methyl-
598. Hydrazinecarbothioamide
599. hydro-1,3a,8-trimethylpyrrolo[2,3-b]indol-5-yl methylcarbamate
ester (1:1).
600. hydrocyanic acid
601. Hydrocyanic acid
602. Hydrofluoric acid (C,T)
603. Hydrogen cyanide
604. Hydrogen fluoride (C,T)
605. Hydrogen phosphide
606. Hydrogen sulfide
607. Hydrogen sulfide H2S
608. Hydroperoxide, 1-methyl-1-phenylethyl- (R)
609. Indeno[1,2,3-cd]pyrene
610. Iron, tris(dimethylcarbamodithioato-S,S')-,
611. isobutanol
612. Isobutyl alcohol (I,T)
613. Isodrin
614. Isolan
615. Isosafrole
616. Kepone
617. Lasiocarpine
618. lead
619. Lead
620. Lead acetate
621. Lead phosphate

622. Lead subacetate

623. Lead, bis(acetato-O)tetrahydroxytri-
624. Lindane
625. L-Phenylalanine, 4-[bis(2-chloroethyl)amino]-
626. L-Serine, diazoacetate (ester)
627. maleic anhydride
628. Maleic anhydride
629. Maleic hydrazide
630. Malononitrile
631. Manganese dimethyldithiocarbamate.
632. Manganese, bis(dimethylcarbamodithioato-S,S?)-,
633. m-Cresol
634. m-Cumenyl methylcarbamate.
635. m-Dichlorobenzene
636. Melphalan
637. Mercury
638. Mercury fulminate (R,T)
639. Mercury, (acetato-O)phenyl-
640. Meta-dinitrobenzene
641. Metam Sodium
642. metam-sodium
643. Methacrylonitrile (I, T)
644. Methanamine, N-methyl- (I)
645. Methanamine, N-methyl-N-nitroso-
646. Methane, bromo-
647. Methane, chloro- (I, T)
648. Methane, chloromethoxy-
649. Methane, dibromo-
650. Methane, dichloro-
651. Methane, dichlorodifluoro-
652. Methane, iodo-
653. Methane, isocyanato-
654. Methane, oxybis[chloro-
655. Methane, tetrachloro-

656. Methane, tetranitro- (R)

657. Methane, tribromo-
658. Methane, trichloro-
659. Methane, trichlorofluoro-
660. Methanesulfonic acid, ethyl ester
661. Methanethiol (I, T)
662. Methanethiol, trichloro-
663. Methanimidamide, N,N-dimethyl-N'-[2-methyl-4-
[[(methylamino)carbonyl]oxy]
664. Methanimidamide, N,N-dimethyl-N'-[3-[[(methylamino)-
carbonyl]oxy]phenyl]-,
665. Methanol (I)
666. Methapyrilene
667. Methiocarb
668. Methomyl
669. Methoxychlor
670. Methyl alcohol (I)
671. methyl bromide
672. Methyl bromide
673. methyl chloride
674. Methyl chloride (I,T)
675. Methyl chlorocarbonate (I,T)
676. Methyl chloroform
677. methyl ethyl ketone
678. Methyl ethyl ketone
679. Methyl ethyl ketone (MEK) (I,T)
680. Methyl ethyl ketone peroxide (R,T)
681. Methyl hydrazine
682. Methyl iodide
683. Methyl isobutyl ketone (I)
684. Methyl isocyanate
685. Methyl methacrylate (I,T)
686. Methyl parathion
687. methylcarbamate (ester), (3aS-cis)-.

688. Methylene bromide

689. methylene chloride
690. Methylene chloride
691. methylene chloride
692. methylene chloride trichloroethylene
693. Methylthiouracil
694. Metolcarb
695. Mexacarbate.
696. Mitomycin C
697. MNNG
698. molinate
699. Molinate
700. monochlorobenzene
701. monohydrochloride
702. N,N'-Diethylhydrazine
703. N.A.
704. Naphthalenamine, N,N'-bis(2-chloroethyl)-
705. naphthalene
706. Naphthalene
707. Naphthalene, 2-chloro-
708. n-Butyl alcohol (I)
709. nickel
710. Nickel carbonyl
711. Nickel carbonyl Ni(CO)4, (T-4)-
712. Nickel cyanide
713. Nickel cynaide Ni(CN)2
714. Nicotine, & salts
715. Nitric acid, thallium(1+) salt
716. Nitric oxide
717. nitrobenzene
718. Nitrobenzene
719. Nitrogen dioxide
720. Nitrogen oxide NO
721. Nitrogen oxide NO2

722. Nitroglycerine (R)

723. N-Nitrosodiethanolamine
724. N-Nitrosodiethylamine
725. N-Nitrosodimethylamine
726. N-Nitrosodi-n-butylamine
727. N-Nitrosomethylvinylamine
728. N-Nitroso-N-ethylurea
729. N-Nitroso-N-methylurea
730. N-Nitroso-N-methylurethane
731. N-Nitrosopiperidine
732. N-Nitrosopyrrolidine
733. n-Propylamine (I,T)
734. [(methylamino)carbonyl] oxime
735. O,O-Diethyl O-pyrazinyl phosphorothioate
736. O,O-Diethyl S-methyl dithiophosphate
737. O-[4- [(dimethylamino) sulfonyl]phenyl] O,O-dimethyl ester
738. o-Chlorophenol
739. o-Cresol
740. Octamethylpyrophosphoramide
741. o-Dichlorobenzene
742. ortho-dichlorobenzene
743. ortho-dichlorobenzene
744. Osmium oxide OsO4, (T-4)-
745. Osmium tetroxide
746. o-toluidine
747. o-Toluidine
748. o-Toluidine hydrochloride
749. Oxamyl
750. Oxirane (I,T)
751. Oxirane, (chloromethyl)-2 Paraldehyde
752. Oxiranecarboxyaldehyde
753. oxy]-, methyl ester, (3beta,16beta,17alpha,18beta,20alpha)-
754. oxy]methyl]-1,1a,2,8,8a,8b-hexahydro-8a-methoxy-5-methyl-, [1aS-
(1aalpha,

755. paraldehyde
756. paraldehyde
757. Paraldehyde
758. Parathion
759. p-Benzoquinone
760. p-Chloroaniline
761. p-chloro-m-cresol
762. p-Chloro-m-cresol
763. p-Cresol
764. p-Dichlorobenzene
765. p-Dimethylaminoazobenzene
766. pebulate
767. Pebulate.
768. pentachlorobenzene
769. Pentachlorobenzene
770. pentachlorodibenzo- p-dioxins
771. Pentachlorodibenzo- p-dioxins
772. pentachlorodibenzofurans
773. pentachlorodibenzo-p-dioxins
774. pentachloroethane
775. Pentachloroethane
776. Pentachloronitrobenzene (PCNB)
777. pentachlorophenol
778. Pentachlorophenol
779. pentachlorophenol and its derivatives.
780. pentachlorophenols
781. Pentanol, 4-methyl-
782. Pentrachlorophenol
783. perchloroethylene
784. Phenacetin
785. phenol
786. Phenol
787. Phenol, (3,5-dimethyl-4-(methylthio)-, methylcarbamate
788. Phenol, 2-(1-methylethoxy)-, methylcarbamate

789. Phenol, 2-(1-methylpropyl)-4,6-dinitro-

790. Phenol, 2,2'-methylenebis[3,4,6-trichloro-
791. Phenol, 2,3,4,6-tetrachloro-
792. Phenol, 2,4,5-trichloro-
793. Phenol, 2,4,6-trichloro-
794. Phenol, 2,4,6-trinitro-, ammonium salt (R)
795. Phenol, 2,4-dichloro-
796. Phenol, 2,4-dimethyl-
797. Phenol, 2,4-dinitro-
798. Phenol, 2,6-dichloro-
799. Phenol, 2-chloro-
800. Phenol, 2-cyclohexyl-4,6-dinitro-
801. Phenol, 2-methyl-4,6-dinitro-, & salts
802. Phenol, 3-(1-methylethyl)-, methyl carbamate
803. Phenol, 3-methyl-5-(1-methylethyl)-, methyl carbamate
804. Phenol, 4-(dimethylamino)-3,5-dimethyl-, methylcarbamate (ester)
805. Phenol, 4,4'-(1,2-diethyl-1,2-ethenediyl)bis-, (E)-
806. Phenol, 4-chloro-3-methyl-
807. Phenol, 4-nitro-
808. Phenol, methyl-
809. Phenol, pentachloro-
810. phenolic compounds
811. phenyl]-
812. phenylenediamine
813. Phenylmercury acetate
814. Phenylthiourea
815. Phorate
816. phosgene
817. Phosgene
818. Phosphine
819. Phosphoric acid, diethyl 4-nitrophenyl ester
820. phosphorodithioic acid esters
821. Phosphorodithioic acid, O,O-diethyl
822. Phosphorodithioic acid, O,O-diethyl S-methyl ester

823. Phosphorodithioic acid, O,O-dimethyl S-[2-(methylamino)-2-

oxoethyl] ester
824. Phosphorofluoridic acid, bis(1-methylethyl) ester
825. phosphorothioic acid esters
826. Phosphorothioic acid,
827. Phosphorothioic acid, O,O,-dimethyl O-(4-nitrophenyl) ester
828. Phosphorothioic acid, O,O-diethyl O-(4-nitrophenyl) ester
829. Phosphorothioic acid, O,O-diethyl O-pyrazinyl ester
830. Phosphorus sulfide (R)
831. Phthalic anhydride
832. Physostigmine salicylate.
833. Physostigmine.
834. Piperidine, 1,1'-(tetrathiodicarbonothioyl)-bis-
835. Piperidine, 1-nitroso-
836. Plumbane, tetraethyl-
837. p-Nitroaniline
838. p-Nitrophenol
839. polycyclic aromatic hydrocarbons
840. Potassium cyanide
841. Potassium cyanide K(CN)
842. Potassium dimethyldithiocarbamate
843. Potassium n-hydroxymethyl- n-methyldi-thiocarbamate
844. Potassium n-methyldithiocarbamate
845. Potassium silver cyanide
846. Promecarb
847. Pronamide
848. Propanal, 2-methyl-2-(methyl-sulfonyl)-, O-
[(methylamino)carbonyl] oxime.
849. Propanal, 2-methyl-2-(methylthio)-,
850. Propane, 1,2-dibromo-3-chloro-
851. Propane, 1,2-dichloro-
852. Propane, 2,2'-oxybis[2-chloro-
853. Propane, 2-nitro- (I,T)
854. Propanedinitrile

855. Propanenitrile
856. Propanenitrile, 2-hydroxy-2-methyl-
857. Propanenitrile, 3-chloro-
858. Propanoic acid, 2-(2,4,5-trichlorophenoxy)-
859. Propargyl alcohol
860. Propham
861. Propoxur
862. Propylene dichloride
863. Prosulfocarb
864. p-toluidine
865. p-Toluidine
866. pyrazol-3-yl ester
867. pyridine
868. Pyridine
869. Pyridine, 2-methyl-
870. Pyridine, 3-(1-methyl-2-pyrrolidinyl)-, (S)-, & salts
871. pyridines
872. Pyrrolidine, 1-nitroso-
873. Pyrrolo[2,3-b]indol-5-ol, 1,2,3,3a,8,8a-hexahydro-1,3a,8-trimethyl-,
874. Reserpine
875. Resorcinol
876. S-[(ethylthio)methyl] ester
877. S-[2 -(ethylthio)ethyl] ester
878. Saccharin, & salts
879. Safrole
880. salts & esters
881. Selenious acid
882. Selenious acid, dithallium(1+) salt
883. Selenium
884. Selenium dioxide
885. Selenium sulfide
886. Selenium sulfide SeS2 (R,T)
887. Selenium, tetrakis(dimethyldithiocarbamate)
888. Selenourea

889. Silver
890. Silver cyanide
891. Silver cyanide Ag(CN)
892. Silvex (2,4,5-TP)
893. Sodium azide
894. Sodium cyanide
895. Sodium cyanide Na(CN)
896. Sodium dibutyldithiocarbamate
897. Sodium diethyldithiocarbamate
898. Sodium dimethyldithiocarbamate
899. Streptozotocin
900. Strychnidin-10-one, & salts
901. Strychnidin-10-one, 2,3-dimethoxy-
902. Strychnine, & salts
903. Sulfallate
904. Sulfur phosphide (R)
905. Sulfuric acid, dimethyl ester
906. Sulfuric acid, dithallium(1+) salt
907. tars
908. Tetrabutylthiuram disulfide
909. tetrachlorobenzene
910. Tetrachlorobenzene
911. tetrachlorobenzenes
912. Tetrachlorodibenzo- p-dioxins
913. tetrachlorodibenzofurans
914. tetrachlorodi-benzofurans
915. tetrachlorodibenzo-p-dioxins
916. tetrachloroethanes
917. tetrachloroethanes
918. Tetrachloroethylene
919. tetrachloroethylene
920. tetrachlorophenols
921. Tetraethyl lead
922. Tetraethyl pyrophosphate

923. Tetraethyldithiopyrophosphate
924. Tetrahydrofuran (I)
925. Tetramethylthiuram monosulfide
926. Tetranitromethane (R)
927. Tetraphosphoric acid, hexaethyl ester
928. Thallic oxide
929. Thallium chloride Tlcl
930. Thallium oxide Tl2O3
931. Thallium(I) acetate
932. Thallium(I) carbonate
933. Thallium(I) chloride
934. Thallium(I) nitrate
935. Thallium(I) selenite
936. Thallium(I) sulfate
937. Thioacetamide
938. Thiodicarb
939. Thiodiphosphoric acid, tetraethyl ester
940. Thiofanox
941. Thioimidodicarbonic diamide [(H2N)C(S)]2NH
942. Thiomethanol (I,T)
943. Thioperoxydicarbonic diamide [(H2N)C(S)]2S2, tetramethyl-
944. Thioperoxydicarbonic diamide, tetrabutyl
945. Thioperoxydicarbonic diamide, tetraethyl
946. Thiophanate-methyl
947. Thiophenol
948. Thiosemicarbazide
949. Thiourea
950. Thiourea, (2-chlorophenyl)-
951. Thiourea, 1-naphthalenyl-
952. Thiourea, phenyl-
953. Thiram
954. Tirpate
955. Toluene
956. toluene

957. Toluene diisocyanate

958. Toluene diisocyanate (R,T)
959. toluene-2, 4-diamine
960. Toluenediamine
961. Toxaphene
962. trans-1- 2-dichloroethylene
963. trans-1,2- Dichloroethylene
964. Triallate
965. trichlorobenzene
966. trichlorobenzenes
967. trichloroethane
968. trichloroethylene
969. Trichloroethylene
970. trichlorofluoromethane
971. trichloromethane
972. Trichloromethane
973. Trichloromethanethiol
974. Trichloromonofluoromethane
975. trichlorophenols
976. trichloropropane
977. triethylamine
978. Triethylamine
979. Tris(2,3-dibromopropyl) phosphate
980. Trypan blue
981. Uracil mustard
982. Urea, N-ethyl-N-nitroso-
983. Urea, N-methyl-N-nitroso-
984. Vanadic acid, ammonium salt
985. Vanadium oxide V2O5
986. Vanadium pentoxide
987. vernolate
988. Vernolate
989. vinyl chloride
990. Vinyl chloride

991. Vinylamine, N-methyl-N-nitroso-

992. vinylidene chloride
993. Warfarin, & salts, when present at concentrations greater than 0.3%
994. Xylene (I)
995. Yohimban-16-carboxylic acid, 11,17-dimethoxy-18-[(3,4,5-
trimethoxybenzoyl)
996. Zinc cyanide
997. Zinc cyanide Zn(CN)2
998. Zinc phosphide Zn3P2, when present at concentrations greater than
10% (R,T)
999. Zinc phosphide Zn3P2, when present at concentrations of 10% or
less
1000. Zinc, bis(diethylcarbamodithioato-S,S’)-
1001. Zinc, bis(dimethylcarbamodithioato-S,S?)-,
1002. ziram
1003. Ziram

Home l Coolant Management
Chapter 26
Kinds Of Waste Disposal

Even with the best fluid management program, cutting fluid will not last
indefinitely and will eventually require disposal. Environmental
regulations are making disposal increasingly difficult. Generators are
responsible for determining if a particular waste generated at their facility
is hazardous or nonhazardous. The waste material must be tested using
standard methods or the generator must have sufficient knowledge about
the waste to assess whether it is a hazardous waste
Know whether your wastes and wastewaters are a dangerous waste.

Dissolved metals, chlorinated oils, and biocides are among the
ingredients that can require coolant to be disposed as a dangerous waste.
Avoid chlorinated oils when possible. Never mix other wastes such as
solvents into coolants. Even a small amount of a federally listed solvent
can cause a whole container or tank of coolant to be a dangerous waste.
Call your local Ecology office for advice.
Coolant and Cleaner Disposal

Industrial wastes such as coolants and sump cleaners should never be
disposed to a septic or storm system, or drywell.
Oil-water emulsion coolants can often be chemically "split" to separate

the oil from the water. It may be more economical for you to discharge
the water to the sewer and recycle the oil portion.
Check with your local sewer utility before you discharge metalworking
liquids to the sewer.
Processing of a dangerous waste coolant for disposal must be done in

accordance with regulations for treatment by dangerous waste generators

(see Ecology publication #96412, Treatment by Generators).
Following a hazardous / non-hazardous determination for the waste, an

appropriate disposal alternative may be selected. Disposal costs may
range anywhere from 25 to 50 cents per gallon for non hazardous waste
up to several hundred dollars per drum for hazardous waste. Spent cutting
fluid that is determined to be hazardous must be disposed by an EPA
permitted hazardous waste management company in accordance with
applicable federal and state regulations. Selecting a certified hauler and
treatment facility registered with the EPA is critical.
Disposal Of Nonhazardous Fluid
If the waste fluid is determined to be nonhazardous, it may be hauled to a

treatment facility or, following permission from local wastewater
treatment plant authorities, discharged to a municipal sanitary sewer
system for disposal. Spent fluid should never be discharged to a septic
tank system or dumped on the ground.
Nonhazardous fluid may also be pretreated on site prior to disposal.

Treating or condensing water miscible fluids on site prior to disposal may
reduce a shop's disposal costs and environmental liability. Techniques for
on-site treatment include chemical treatment, ultra-filtration, and
evaporation. Each process involves the removal of metal fines and other
solid contaminants, concentrating the oil phase, and discharging the
water phase to either the sanitary sewer or the atmosphere. The
concentrated oil phase can be managed as a used oil and the solids may
be disposed or reclaimed.
Disposal And Pretreatment Alternatives available for non-hazardous

water-miscible cutting fluid.

Contract Hauling and Disposal Services

Studies have shown that it may be cheaper to have small volumes of
waste fluid (less than 200 gallons) hauled away by a waste management
company for chemical treatment or incineration.
Many large machine shops opt for in-plant waste treatment, since
contract hauling and disposal services become cost prohibitive with
larger quantities of waste fluid.
Chemical treatment
Chemical treatment is the addition of chemicals, which change the nature
of the liquid waste. Simple chemical-treatment methods work well on
some wastewater. Metalworking wastes are too complex for most
treatment processes. Chemical treatment beyond pH control is generally
not an option for small facilities.
Ultrafiltration systems, Ultrafiltration systems were created for the

Metalworking industry to treat such wastes as used cutting fluids,
detergents, parts washing solutions, and other oily wastewaters. Strict
environmental laws require proper treatment prior to discharge.
Ultrafiltration systems provide effective treatment of this wastewater by
separating the water from the oily waste. The quality of water is then
ready for sewer disposal. The oily concentrate generated from
ultrafiltration may be processed for oil recovery or incinerated.
Ultrafiltration systems are usually better than chemical treatment, less

expensive than incineration and contract hauling, are easily operated and
space efficient. Units process from 100 to 300 gallons per day and cost
from $5,000 to $13,000.
Evaporators
As water miscible fluids are normally 90 to 95% water, evaporators can
be used to remove the water from waste fluid, reducing the volume of
waste requiring disposal. The advantages of evaporators include:
1. Simple to operate.
2. Use very little space.
3. Type of fluid used (synthetic, semi synthetic, or soluble oil) is not
critical.
Evaporators are generally suitable for low volumes of waste due to the
enormous amount of energy required to evaporate even a small volume
of material. Evaporators are also labor intensive when it comes to
cleaning the units. Evaporators may be a consideration when other
treatment systems do not meet a shop's needs.
Centrifuges
Centrifuges can be used to remove particulates and tramp oil from waste
fluid prior to disposal. However, centrifuges are expensive and other
contaminant removal methods such as oil skimmers are more economical
for small volumes of fluids.
Disposal as wastewater
Following approval by local wastewater treatment authorities, it may be
possible to dispose of small amounts of non-hazardous, spent cutting
fluid to the municipal sanitary sewer system.
A Waste Management Program

We are not attorneys. We believe this to be a good compliance plan but
we do not take any responsibility for its use, misuse or anything else.
The laws change frequently. Consult an attorney or other expert.
Program Components
1. A review of all MSDS sheets for compliance.

2. A computer check of nine lists and 1,962 chemicals cited in 40
CFR.
3. A document showing matches or no matches.

4. An analysis of your used coolant done by a government certified

laboratory.
5. An analysis that can serve as “An analysis of a typical batch” and
may make testing of each batch unnecessary.
6. A determination of the classification of the chrome component of
your waste as required by law.
7. A review of classification options for your waste.
8. A recommendation as to the best disposal option for your coolant.
9. References to the sections of federal law supporting these
recommendations.
10. A list of federal EPA offices and state offices for environmental
matters.
11. A list of haulers and disposal companies.
Classifying or characterizing your waste step by step
1. Gather MSDS sheets from everything that went into the coolant.
2. Call waste disposal companies and tell them that you are taking
bids to haul away ordinary grinding coolant wastes.
3. If they ask questions, just tell them that it is ordinary tool and saw
grinding and that you have MSDS sheets for everything.
Take the lowest bid from a reputable hauler.
Finding a hauler.
1. Ask other people in the same or similar industries for

recommendations.
2. Call the local city, state or Federal people and ask them for the
name of businesses that do a really good job handling waste. The
government people cannot recommend a particular hauler. They
usually have some sort of a model business program or award.
They can tell you the name of businesses like yours, that do things
well and then you can call those businesses to get the name of their

haulers.
Paperwork
This is very important because there is paperwork involved. If the hauler
does not do things properly you could be getting into even more trouble.
If the hauler takes your waste, dumps it in the woods illegally and then
gets caught you can be held responsible for cleaning up the woods even if
the hauler lied to you.
There is generally a requirement you have to sign saying that you have
taken measures to reduce waste. It may be phrased as “waste reduction”
or “minimize your waste stream” or something similar.
There are several things you can do to easily and simply comply.
1. Use safe components.

2. Manage for long life.
3. Filter and keep it clean.
4. Keep it adjusted chemically.
5. Separate the waste.
6. Evaporate the wastewater.
The requirement is that you take reasonable measures. This is very

good. Some parts of some environmental laws require using the
absolutely best technology without regard to cost.
In this case implement the steps you think are appropriate and then add
additional steps as you determine they are beneficial and / or cost
effective.
The government is different than industry. This sounds simple but it is

really important. There are two big differences. In the private sector
people are very concerned with getting things done. They are required to
make decisions and then make those decisions work. In the public sector

the employees are hired to do what the law says they are supposed to do.
The best way to keep their jobs is to do what the law says and to avoid
making any decision of their own.
If you tell them you have hazardous waste then they will agree because
that is the easiest and safest thing for them to do. If you tell them that
you have used grinding coolant and it is not hazardous waste then they
will ask to see proof. They are generally very willing to accept your
decision if you can support your decision.
If you tell them that you don’t know what is in it they will be required to
treat it in the most thorough and therefore most expensive manner
possible.
When you are asked what is in the used coolant answer by providing the
MSDS sheets from what went into the coolant.
In a tool and saw shop these would be:

Talonite is our
Coolant
trademark and
Tungsten carbide
StelliteÒ is a
Talonite® or Stellite® saw tipping, wear
registered
and knife alloys
trademark of
Tool steel
Stoody Deloro
Diamond, Borazon or cubic boron
Stellite and they
nitride wheel.
are darned fussy
Any additives to the coolant See Note
about it.
#1
Any lubricating oils and greases
Any cleaning compound used to clean the machine or the tools See Note
#2
These and water should cover it.
If you add a little bit of the wrong chemical to a sump you can turn thirty
gallons of ordinary waste (disposal cost $49 to $90 per barrel) into thirty

gallons of hazardous waste (disposal cost $164 to $300 per barrel)
Note #1 Be very careful about additives. Chemicals sold to control

fungus and bacteria can be very dangerous. These algaecides and
fungicides are often based on nerve agent compounds.
Note #2 Some of these compounds can be solvent based.
The trick is to get into the cheapest category where you can prove that
you legally belong.
Used coolant is typically sludge or particles, used coolant and tramp oils.
Filtering will remove most of the sludge. The oil can be skimmed off the
top and separated that way. The remaining liquid is probably 90 – 98%
water. This water can be evaporated off.
You can pay to have the mixture hauled away. You can separate it
yourself and maybe sell the sludge. You can possible save some money
by separating the oil.
The Laws
The environmental laws would fill several semi-trailers if you took them
all together. Environmental laws are the same as the tax laws or the
driving laws in that it is clearly and completely your obligation to know
and comply with the law.
1. Used grinding coolant is regulated under federal law. It is your obligation to identify the
used grinding coolant and to dispose of it properly.
40 CFR Ch. 1 (7-1-96 edition) Section 261.1 (c)

A "spent material" is any material that has been used and as a result of contamination can no
longer serve the purpose for which it was produced without processing;
"Sludge" has the same meaning used in section 260.10 of this chapter;
2. Under 40 CFR and it is the obligation of the producer of the coolant to be in compliance

with any and all federal, state and local regulations. The following is a direct quote from
federal law. The law is:
40 CFR Ch. 1 (7-1-96) Edition Subpart A – General 262.10 Purpose, scope, and application
(h)
Note: 2 A generator who treats, stores, or disposes of hazardous waste on-site must comply
with the applicable standards and permit requirements set forth in 40CFR parts 264, 265,
266, 268, and 270.
3. According to 40 CFR Ch. 1 (7-1-96 edition) Section 261.1 (b) (2) (i)
A material which is not identified as a solid waste in this part, or is not a hazardous waste
identified or listed in this part, is still a solid waste and a hazardous waste for purposes of
these sections if:
4. 40 CFR Ch. 1 (7-1-96 edition) Section 261.1 (b) (2) (ii)

In the case of section 7003, the statutory elements are established.
5. 40 CFR Ch. 1 (7-1-96 edition) Section 261.1 (b) (2) (ii) (c)
For the purposes of sections 261.2 and 261.6:
(1) A "spent material" is any material that has been used and as a result of contamination
can no longer (2) serve the purpose for which it was produced without processing;
Sample Test Results

Laboratory Analysis
This is how your waste tests legally. Show this to the recycler and to the
government if they ask. This test should serve as "a standard batch" test.
Unless you change your process no further tests should be necessary.
Your Results Legal Limits
Fats, Oil and Grease, mg/L 43.8
Total Petroleum Hydrocarbons, mg/L 39.3
Hexavalent Chromium, mg/L <0.01 none

TCLP Metals, mg/L
Arsenic (As) <0.05 5.0
Barium (Ba) 0.17 100.0
Cadmium (Cd) <0.01* 1.0
Chromium (Cr) 0.008 5.0
Lead (Pb) <0.04 5.0
Mercury (Hg)** <0.0005 0.2
Selenium (Se) <0.08 1.0
Silver (Ag) <0.007 5.0
Oil and Grease testing performed by EPA Method 413.2 (Partition

Infrared)
Total Petroleum Hydrocarbon testing performed by EPA Method 418.1
Hexavalent Chromium testing performed by Standard Method 307-B
TCLP by EPA Method 1311
Metals performed by EPA Method 6010
* Cadmium detection limit raised due to matrix effects
** Mercury analysis by EPA Method 7470
There may be some surprises here. The water in coolant evaporates.

Make up water is added and that evaporates. This can leave you with
high levels in your tank of whatever was a low level in the water you
added.

There can also be things show up that were in the chemicals you added
but whose concentrations were too low to be put on an MSDS sheet.
Typical Batch
40 CFR Ch. 1 Section 261.3 p. 36
There is a reference to “An analysis of a typical batch” in this section.
This section does not apply to grinding or machining wastes, but the
concept can apply to other systems.
In effect the principle here is that a process that is done the same way
each time and uses the same chemicals each time will produce the same
waste each time. Therefore it should be necessary to do a full set of tests
only once to establish the process. It shouldn’t be necessary to do a full
retesting unless the process changes. This seems to be a generally
accepted practice among waste management companies. They will
typically require a one-time testing fee when signing on a new customer.
There is definite requirement to do retesting when the process changes.
Chrome Classification
A determination of the classification of the chrome component of your
waste as required by law.
There are several kinds of chrome or chromium. Some are considerably
more reactive than others and thus they are a much bigger problem
environmentally. Chrome from tool and machining operations is almost
certainly trivalent or the safer chrome. Chrome from electro-plating
operations is more likely to be hexavalent chrome.
This test was run to establish that you have the safer chrome as per
federal law.
40 CFR Ch. 1 section 261.4 (b)

Solid wastes which are not hazardous wastes
40 CFR Ch. 1 section 261.4 (b) (6) (I)

(A) The chromium in the waste is exclusively (or nearly exclusively)

trivalent chromium; and
(B) The waste is generated from an industrial process which uses
trivalent chromium exclusively (or nearly exclusively) and the process
does not generate hexavalent chromium; and
(C) The waste is typically and frequently managed in non-oxidizing
environments.
Classification Options For Your Waste

Because of the constituents of your waste especially:
TCLP: ____________________
You have four options:
3 options as a hazardous waste generator and one option as a recycler:
Option 1:Large Quantity Generator (LGQ)

Generates more than 1,000 kg. (2,200 #) of hazardous waste per calendar
month
Generates more than 1 kg. (2.2 #) of acute hazardous waste per calendar
month
Must obtain an EPA ID #
Properly identify, package and label waste
Properly manifest, transport and dispose of waste
May store waste up to 90 days without a storage permit
Option 2:Small Quantity Generator (SQG)

Generates more than 100 kg. but less than 1,000 (220 - 2,200 #) of
hazardous waste per calendar month
Generates more than 1 kg. (2.2 #) of acute hazardous waste per calendar
month
Must obtain an EPA ID #
May store waste up to 180 days without a storage permit

Never accumulate more than 6,000 kg. of hazardous waste on property
Option 3:Conditionally Exempt Small Quantity Generators (CESQG)

If you meet essentially three requirements:
Must generate less than 100 kg. (220#) of hazardous waste per calendar
month
Must generate less than 1 kg. (1.1 #) acute hazardous waste per calendar
month
Never accumulate more than 100 kg. of hazardous waste on property
Then you have the following advantages
-Not required to obtain an EPA ID#
However you must:
-Properly identify, package and label waste
-Properly manifest transport and dispose of waste
Option 4: Recycler
Amount of material generated is not a factor
Do not need an EPA ID #
May store waste up to one calendar year
Cannot accumulate more than 1 calendar year’s worth of waste.
Advantages of Recycling
1.You do not have the cost of compliance with the hazardous waste
licensing and inspections if you do not generate hazardous waste.
2.Your disposal costs are considerably lower with recyclable material
than they are with hazardous waste. Proper classification of your waste
can be critical. We had a client who was having his used grinding coolant
hauled away as a hazardous waste at about $275 to $300 a barrel. When
he legally relabeled it as “grinding coolant for recycling” his costs
dropped to $90 a barrel.
Avoid being a hazardous waste generator

40 CFR Ch. 1 Section 261.1 (c) (4)

A material is "reclaimed" if it is processed to recover a usable product or if it is regenerated.
40 CFR Ch. 1 Section 261.1 (c) (8)

A material is "accumulated speculatively" if it is accumulated before being recycled. A
material is not accumulated speculatively, however, if the person accumulating it can show
that the material is potentially recyclable and has a feasible means of being recycled: and that
- during the calendar year (commencing on January 1) - the amount of material that is
recycled, or transferred to a different site for recycling, equals at least 75 percent by weight or
volume of the amount of that material accumulated at the beginning of the period. In
calculating the percentage of turnover, the 75 percent requirement is to be applied to each
material of the same type (e.g. slags from a single smelting process) that is recycled in the
same way.
The very best thing to do is to have your waste classified as something

besides hazardous waste. If you have hazards waste then you are required
to follow expensive testing and reporting procedures. If you meet the
requirements for reclamation then you do not have hazardous waste. The
requirements are generally pretty simple.
Used grinding coolant is probably suitable for reclamation. The metals in

the coolant and the sludge are probably also suitable for reclamation.
Requirements for classifying your used coolant and sludge, as materials

for reclamation are pretty simple.
40 CFR section 261.2 (7)

A material is "recycled" if it is used, reused or reclaimed.
40 CFR Section 261.2 (e) (1)
Materials are not solid wastes when they can be shown to be recycled
1.You have to prove there is a market for the material.

You have to prove that someone is interested in using your used coolant
and / or sludge for reclamation.
40CFR section 261.3(f)

Documentation of claims that materials are not solid wastes or are conditionally exempt from

regulation. Respondents in actions to enforce regulations implementing subtitle C or RCRA

who raise a claim that a certain material is not a solid waste, or is conditionally exempt from
regulation, must demonstrate that there is a known market or disposition for the material, and
that they meet the terms of the exclusion or exemption. In doing so, they must provide
appropriate documentation (such as contracts showing that a second person uses the material
and an ingredient in a production process) to demonstrate that the material is not a waste, or
is exempt for regulation. In addition, owners or operators of facilities claiming that they
actually are recycling materials must show that they have the necessary equipment to do so.
[50 FR 664, Jan. 4, 1985, as amended at 50 FR 33542, Aug. 20, 1985; 56 FR 7206, Feb. 21,
1991; 56 FR 32688, July 17, 1991; 56 FR 42512, Aug. 27, 1991; 57 FR 38564, Aug. 25, 1992;
59 FR 48042, Sept. 19, 1994]
Establishing a market
Sludge and swarf
If you have sludge from grinding tungsten carbide then it is worth
reclamation for the cobalt or nickel. If you are grinding knives or some of
the high chrome saw tips then the sludge has reclamation value for the
steel and the chrome.
Coolant
Safety-Kleen has a used coolant and industrial oil reclamation program.
You can contact Safety-Kleen at 800 323-5040They have 175 collection
facilities and 18 processing facilities nationwide.
Once again you do not have to use Safety-Kleen. The fact that they are
in the reclamation business proves the economic part of the reclamation
requirement.
We mention Safety-Kleen by name for several reasons. They are

national, they are good to work with and they are absolutely reputable.
There are other companies in the area that are also good and reputable.
There have also been histories of companies that were neither good nor
reputable.
Note: You are responsible for your wastes. If the waste hauler or waste
treater you select does something illegal it can, and almost certainly will,
come back on you.
2.You have to get rid of most of the material once a year.

40 CFR Ch. 1 Section 261.1 (c) (8)
: and that – during the calendar year (commencing on January 1) – the amount of material
that is recycled, or transferred to a different site for recycling, equals at least 75 percent by
weight or volume of the amount of that material accumulated at the beginning of the period. In
calculating the percentage of turnover, the 75 percent requirement is to be applied to each
material of the same type (e.g. slags from a single smelting process) that is recycled in the
same way.
Essentially you have to have at least 75% of the waste hauled away each
year.
If you do not want to recycle you need to be licensed as a hazardous

waste generator.
Reducing Disposal And Recycling Costs
Separation
Used grinding coolant is generally composed of three things.
1.Sludge
Sludge is expensive to haul away but you can sell it. Safety Kleen quoted
$900 a drum to haul it away. This is because Safety Kleen recycles the
coolant as a liquid and does not have the facilities for recycling sludges.
If you collect it and dry it then it can be worth ten cents to fifteen cents a
pound because of the metals such as cobalt, chrome and tungsten. It
generally has to be pretty dry.
If you filter out the solids then you can generally dispose of them in the
trash. We have an opinion from the State of Washington Department of
Ecology that filters from coolant filtering operations fit under the
classification of “oil filters”. They need to be gravity drained; crushed
and then they can go into the trash.
2.Water
Used coolant is generally 90% to 95% water. The recycler will haul this
away. You can also evaporate the water out.
3. Oils, greases, etc.

These can be hauled way, re-used and sometimes can be legally burned
in a power generation facility.

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Managing Coolants from Machining and Grinding Operations, Cermet Saws, Carbide Processors, Inc.

Home l Coolant Management

Managing Coolants from

Preface and Warning

This is a work in progress. It is written as a general overview on coolant

Improper coolant management costs industry billions of dollars each year

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21 Disposal Of Used Fluids And Sludge 93

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Benefits of Overall Cleanliness

The savings in proper cleanliness, general maintenance as well coolant

Benefits of managing coolants

1. Longer Machine Life

8. Measured as the smoothness of the worked surface

Greater Lubricity with clean coolant

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Reduced consumable costs

18. Longer tool run life per sharpening

24. Less machine maintenance

27. Perhaps increased operator safety

Fewer problems than shops that use dirty coolants.

31. Less OSHA exposure

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36. Reduces non-coolant waste and waste disposal costs

When and Why to Filter

Machine damage is much harder to quantify. One way of determining

Filtering in Carbide Tool Grinding

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Dust in the air at 1,000

Particles per cubic centimeter in Dirty, Filtered and Unused Coolant

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You cannot tell coolant condition just by looking at it

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None Nerve agent

Growths None Bacteria colonies

Sump bottom Clean 10 - 15% sludge

Metal All metals Arsenic

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Typical unfiltered Same coolant - filtered

Reduce Diamond Wheel Costs - Save $3,000 to $10,000 per year

Increase Machine Life - Save $2,000 to $8,000 per year

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Why people love our coolant filtration systems

"I don’t have to clean my glasses as often as I did before."

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Case Studies: Annual Cost And Payback

Coolant Management - Annual Cost Calculations

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A. Hazardous waste is $300 per each 55-gallon barrel

Cost of running the filter system

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Annual labor = $ 297.50

Savings = $1572.50 annually

Case A. Unfiltered & Untreated

Case B Filtered, Separated & Evaporated

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