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Petroleum Specialties represent a group of products which find wide application in the various processing industries. These products are primarily used in processing for manufacture of high quality finished goods. In most cases the petroleum specialties become part of the finished articles.
They impart desirable properties to raw material to facilitate their processing into finished goods.
They assist in the processing operations of the manufactured articles. They improve quality and serviceability of the materials being processed.
They generally form part of the manufactured articles imparting them desired properties.
They enhance the sales appeal of the finished articles.
Study of processes
ALPROL CONKOTE
DRAWMET
ELASTO GLAMOL HYTHERM
KOOLKUT
METAQUENCH ROLMET RUSTOP SPRAY OIL E TRIMOFIN TRIMOL UNIPRO
CUTTING OILS
CUTTING OPERATION
CUTTING OPERATION
Heat generation by external friction is reduced / minimised by placing a suitable lubrication film between the rubbing surfaces of work piece, tool and chip
Cooling / lubrication of contact surface between tool, work piece and chip results in improved finish , higher cutting speeds, depth of cut, reduced power consumption and reduced rate of tool wear.
Prevents the welding/seizure taking place between tool and work piece resulting from high pressure and high temperatures.
To lubricate the contacting surface of tool, work piece and chip To cool work piece, tool and chip To prevent local welding of metal particles to the tool
Cause no rusting and corrosion of machines, work piece and tool Cause no discoloration or staining of the metal Should not smoke or foam in use Have no objectionable odour Should not decompose chemically in use Should not be harmful to the machine operator
Internal Broaching (Greatest ) Surface broaching, pipe threading Plain Tapping, plain threading Gear Shaving, Cutting and Removing
Deep drilling
Milling Multi spindle screw machining Automatic high speed machining Drilling, shaping, single point turning Sawing , grinding (Least)
Straight cutting oils Mineral oil / Fatty oil type of cutting fluids
Koolkut 30
Koolkut 40
IS 1115: 1986
Koolkut EP 66
additives
Koolkut 70 Koolkut 80
: :
emulsifiable oil
: : :
Low viscosity oil for honing Medium viscosity oil High lubricity oil
Trimofin 20
Trimofin 21 Trimofin 23 Trimofin 25
:
: : :
Trimofin 26
Trimofin 27
:
:
Trimofin 54
Trimofin 55
Trimofin 56 Trimofin 58
:
: :
CHARACTERISTIC
SOL. FLUID
ST. OIL
Heat generation
Moderate
Low
Cooling ability
High Low
Oiliness/Lubricity High
Moderate
Chemical Activity
Moderate
High
Free sulfur
Oxidation inhibitors Emulsifiers Deodorants Bacteriacides
Viscosity
Viscosity Index Pour point
Neutralisation Number
Volatility Copper strip corrosion test
Emulsion test
Freeze test Cast iron corrosion test
Do not use hard water above 500 ppm for making emulsions
Keep pH of emulsion at 9
Remove chips and fines regularly Aerate the emulsion periodically Clean the system thoroughly when changing the oil Avoid oil blanket on the surface
When more lubrication is required between the contacting surfaces When it is necessary to reduce friction between the tool and work piece to maximum extent
In situations where it is necessary to prevent local welding of metal particles to the tool face. Sulfurized additive type straight cutting oil are best suited for this purpose
For machining of magnesium and its alloys, it is necessary to use straight cutting oils as magnesium can combine with oxygen in water and can create fire hazards
Number 1 & 2 = Non Staining Number 5 & 6 = Staining SECOND DIGIT : Number 0 Number 8 Indicative of potency scale = Lowest Potency = Highest Potency
Potency gradation based on type of EP additive and content Chlorination alone lowest potency Sulfurization with free sulfur highest potency .
* If first digit is 1 then second digit indicates % of compounding without EP additives
METAL (IRON)
WATER
OXYGEN
RUSTING - IMPLICATIONS
Costly repairs
Expensive Replacements
Repellent to water and impervious to both water vapour and gases Having sufficient thickness and strength to prevent dust or other solid particles from penetrating and coming in contact with metal surfaces So as not drain out or evaporate from the surfaces Having self-healing property
Chemically stable and should not harden to a great extent even on continued storage
Exposure
EXPOSURE
Humidity Condensation Corrosive atmosphere Duration of exposure Temperature and sunlight Exposure to Fresh/Salt water
Packaging
HANDLING
Rough handling can cause rupture of the rust preventive film and thus expose the metal surface to the atmosphere to cause rusting.
FILM CHARACTERISTICS
Oily lubricating film
Ease of removal
Sealing ability Film stability and durability
Plain smooth surfaces Parts having threads,crevices and holes Open assemblies
Light Duty
For General storage where moderate humidity prevails with occasional condensation.
Moderate Duty
Heavy Duty
Outdoor storage
USE OR COMPOSITION : : DIP PARTS IN MELTED PRODUCT VOLATILE CARRIER PLUS FILM
FORMING INGREDIENTS
OIL TYPE
EMULSION TYPE
Products
Application
Protection during shipment and subsequent storage involving For machined steel surfaces, threaded pipes, dies etc.
Method
Hot Dip
Products Applications
: :
Rustop 173, Rustop 274, Rustop 276 Indoor protection as well as inter-process/final application
Applied by
OILY TYPE
Products
Rustop 276
Rustop 285
Rustop 286 Rustop 287
Applications
Applied by
Circulation
EMULSION TYPE
Products
Applications
Applied by
:
:
: : : : :
Non Asphaltic Products Indicative of product formulation 1 for solvent based 2 for oil based 3 for greasy film type Indicating of film type and product Property
Second Digit
Third Digit
: :
QUENCHING OILS
BASICS OF HEAT TREATMENT
When steel is heated and cooled, the iron it contains undergoes a structural change. Hot steel at its critical temperature and above is a solid solution of carbon in face - centered - cubic - iron - Austenite. When Austenite is cooled rapidly it is transformed to Martensite hardest possible with body centred structure.
REDUCE BRITTLENESS
IMPROVE MACHINABILITY RELIEF OF INTERNAL STRAINS
QUENCHING MEDIUMS
Synthetic Quenchants
Petroleum quenching Oils
TEMPERATURE RANGE ( C )
: UPTO 100 UPTO 102 UPTO 260 149 - 1260 343 - 960
WATER
DISADVANTAGES
- Formation of sludge
- Quenched parts are difficult to clean - Difficulties in disposing of spent salts and wash water
Synthetic Quenchants
- Looses concentration - Expensive - Not easily available
BOILING POINT
VISCOSITY
OXIDATION STABILITY CHEMICAL STABILITY THERMAL PROPERTIES FLASH POINT
B.
C.
Liquid Cooling Stage - Formation of vapour bubbles is stopped - Cooling by conduction and convection - Rate of cooling is slower compared to VT Stage.
: :
Marquenching Oils
STRAIGHT OILS
General purpose quenching oils Compatible with cyanide carry over Can be used from ambient to 90C
COMPOUNDED OILS
Blends of straight oil and fatty oils
ADDITIVE TYPE
Blend of straight oil and additives Wetting agents Anti oxidants Detergents and Dispersants
MARQUENCHING OILS
Bath maintained at martensite temp Imparts less thermal shocks to the metal. Enables accurate and controllable quenching Lesser rejections Used mainly in automotive and bearing industries
OPERATIONAL PROBLEMS
Insufficient hardness can be due to Change in the composition of steel Insufficient heating of the metal to its critical temperature Time lag in transferring the metal from furnace to bath Thickening of oil due to oxidation / sludging / dirt Inadequate agitation
FIRE HAZARDS
Contamination with lighter oil fractions. Insufficient circulation. Hot Spots Presence of water beyond 0.5% Foaming Violent Boiling
METER READING,
SECONDS Metaquench 39 Metaquench 40 Metaquench 42 Metaquench 43 Metaquench 44 Metaquench 85 Metaquench 86 28 62 28 28 28 16 @100 C 16 @ 100 C 190 220 190 190 190 240 240 27.9 29.0 24.1 20.6 9.0 34.6 12.5
ROLLING OILS
and rolled
Cold Rolling : Where the metal is rolled at the ambient temperature
Reduction schedule.
Roll oil system-Recirculating or once used. Annealing equipment.
Quality requirements.
HP GRADES :
ROLMET 40 ROLMET 43 ROLMET 45
Appearance
Viscosity Kin. @ 40 0 C Flash Point COC 0 C
Clear
Clear
Clear
24
10
25
160
150
170
Pour Point 0C
Neutralisation No mgh KOH/gm 1
0 0.05
0 0.5
RUBBER OILS
ASTM Elastomer
Classification
NR
SBR IIR
Trade names
Natural
GR-S, BUNA S BUTYL
NRB
CR EPM BR
BUNA N
Neoprene EPR, EPN Polybutadiene PB
5.
6.
COMPOUNDING INGREDIENTS USED IN RUBBER GOODS MANUFACTURE Vulcanizing Agents Accelerators Activators Antioxidants Fillers Reinforcing Agents Softeners (Sulfur) (Sulfur Derivatives) (Stearic Acid) (Phenolic Derivatives) (Carbon Black) (Nylon, Rayon) (Easters, Resins, Veg. Oils)
Tackifiers
Pigments Retarders (Colouring materials)
To improve processibility of rubber in milling, mixing and extruding. To improve physical properties of valcanizites To reduce production costs 2.Extender Oils Used in extended SBR aromatic / naphthenic oil use for desired finish They contain 20 to 50% of oils per 100 parts of Rubber. 3.Reclaiming Oils Aromatic oils are widely used. 5% of oil on the wt. of rubber is generally used 4.Secondary Plasticizers Used in PVC cloth manufacture Di-Octyl Phathalate (DOP)
(Aromatic)2
Type 103 (Naphthenic)
0.1 - 35
12 Max.
0.5 Max.
35.1 - 65
6 Mix.
0.3 Max.
Type 104
(Napthenic & Paraffinic) 65.1 Min. 1 Max. 0.1 Max.
HP RUBBER OILS
Elasto 245
Elasto 215 Elasto 541 Elasto 590 Elasto 710 Elasto 715 Aromatic Naphthenic
Paraffinic
Low Solvency
Greatest use in butyl and EP DM rubbers Used for processing light coloured goods, white walled tyres, shoe soles, toys, sporting goods.
Naphthenic type
Good colour stability Solvency better than Elasto 245
Flash Points
Volatality Pour Point Aniline Point Neutralization Number
REFRACTIVITY INTERCEPT
The refractivity intercept of an oil is equal to refractive index @ 20 0 C density 2 0 C.
VISCOSITY GRAVITY CONSTANT
VGC =
Sp. Gravity @ 60 0 F
V1
SUS @ 210 0 F
0.79 - 0.82
0.82 - 0.90 0.90 and above
Paraffinic
Naphthenic Aromatic
ELASTO
Indicative of aromatic content. First digit multiplied by 10
Second and Third digits together show approx. SUS @ 100 OC When product viscosity is more than 100 @ 210 0F Last two digits Multiplied by 10 give products viscosity @ 100 OC.
RUBBER OILS
Properties Elasto
245 Viscosity cst @ 40 OC @ 100 0C Flash Point, COC OC Aniline Point, COC OC Pour Point OC Molecular Analysis ASTM D 2007 Asphltenes Wt % Polar Compounds wt % Aromatics wt % Saturates wt % Nil 0.6 20.3 79.1 Nil 1.3 47.5 51.2 Nil 17 73 10 33 190 96 0 541 21 160 75 0 710 23 220 48 15
Heat transfer fluids or heat carriers are defined as fluids which absorb thermal energy delivered from a source and then by cooling, or change of phase surrender to a place of utilization called a sink.
SELECTION CRITERIA 1.
Design Properties (Heat transfer and Transport properties). Density specific gravity expansion coefficient.
2.
Cost
3. Operation Properties (Handling Properties) Surface tension. Corrosion.
Flammability.
Physiological effects
PROPERTIES OF THERMIC FLUID Reasonably low pour point. Specific heat - heat transfer properties are reasonably well maintained.
Thermally stable.
Stability to oxidation. Not too viscous at ambient temperature (Cold start problem) Should not loose viscosity too much at high temperature - (High VI) Low vapour pressure - Fairly high Boiling Point Free from water & insoluble materials. Free from acidic reaction.
TYPICAL INSPECTION OF THERMIC FLUIDS CHARACTERISTICS Viscosity Kin. cSt.@ HYTHERM 500 HYTHERM600
40 0C
Flash Point, COC, 0 C Pour Point, 0 C Neut No, mg KOH/gm Specific heat @ 300 0 C Thermal Conductivity@ 300 0 C
30
200 0 0.1 0.665 97.2
33
205
DRAWING COMPOUNDS
SEVERITY OF DRAWING
AUTOMOTIVE SPECIALTIES
HP KOOLGARD
SHOCK ABSORBER OIL
SHOCK ABSORBER
BOTH THESE TYPES OF SHOCK ABSORBERS NEED TO BE OIL FILLED,SEALED FOR LIFE. SHOCK ABSORBER ASSEMBLY HAS RUBBER COMPONENTS TO SEAL OIL LEAKAGE WHICH COMES IN CONTACT WITH OIL. MINERAL OIL AFFECTS RUBBER.HENCE DUE IMPORTANCE IS GIVEN WHILE FORMULATING SHOCK ABSORBER OILS. THUS ANNILINE POINT SPECIFICATION BECOMES IMPORTANT.
IMPORTANT MANUFACTURERS OF SHOCK ABSORBERS STALLION SHOX HYDRAULICS LTD. INTERNATIONAL INSTRUMENTS GABRIEL INDIA LTD. D.H.WOODHEAD SACHS ARMSTRONG MUNJAL SHOVA(HERO HONDA- REAR) ESCORTS TELE
SPECIFICATIONS
CHARACTERISTIC HP SHOCK ABSORBER OIL TELE AW
KINEMATIC VISCOSITY CST @ 40 oC CST @ 100 oC POUR POINT, oC FLASH POINT, oC ANNILINE POINT, oC RUBBER SWELLING TEST CHANGE IN VOL%MAX.
SPECIFICATIONS
CHARACTERISTIC HP SHOCK ABSORBER OIL LIGHT HEAVY
18.1--21.3 3.3 MIN. -37 160 71--82 5.5--7.0 0/0/0 0.15
KINEMATIC VISCOSITY CST @ 40 oC 11.0--12.3 CST @ 100 oC 2.6 AVG. POUR POINT, oC -40 FLASH POINT, oC 145 ANNILINE POINT, oC 71--77 SAP VALUE,MG.KOH/gm. 5.5--7.0 COPPER STRIP CORROSION 3 HRS.@ 100 oC MAX. FOAM STABILITY 0/0/0 2 INC MIN. 0.15
BRAKE FLUIDS
ISI HAS WITHDRAWN IS:317-1970 FOR MODERATE DUTY BRAKE FLUID HP STANDARD BRAKE FLUID NO LONGER MARKETED.
WE MARKET TWO TYPES OF BRAKE FLUIDSHP HEAVY DUTY BRAKE FLUID MEETS IS:8654-1977 (AMENDMENT-1) SPECS. SUITABLE FOR USE IN MOST AUTOMOTIVE VEHICLES AND CARRIES THEIR APPROVAL. HP SUPER DUTY BRAKE FLUID (DOT 3) MEETS - FMVSS 16 DOT 3 OF USE\A
BRAKE FLUIDS
SPECIFICATION HP SUPER DUTY Dot-4 BRAKE FLUID Dot 3
SIGNIFICANCE OF TESTS: REFLUXE BOILING POINT - HIGH REFLUXE BOILING POINT AVOIDS VAPOUR LOCK AT HIGH SERVICE TEMPERATURE
MINERAL OIL AFFECTS ALL THESE TYPES OF RUBBER HENCE BRAKE FLUID IS NOT MADE WITH USE OF MINERAL OIL.
SIMILARLY VEGETABLE OILS DETERIORATE FASTER AT HIGH TEMPERATURE AND CAUSE SAFETY RISK. HENCE NOT USED IN MODERN VEHICLES. MIXTURE OF CASTOR OIL AND ALCOHOL, GLYCOLS AND POLYGLYCOLS ARE USED TO PRODUCE DIFFERENT TYPES OF BRAKE FLUIDS.
FREEZE PROTECTION
COOLING SYSTEM PROTECTION
HP KOOLGARD
33% IN WATER FOR AMBIENT TEMPERATURES UP TO (-) 15 OC 50% IN WATER FOR AMBIENT TEMPERATURES UP TO (-) 34 OC