Metalworking fluid risks addressed by CLP changes

Herwig Van Roey, a water-miscible metalworking fluids specialist at Shell Lubricants, looks at the issues affecting operators and how they can manage HSSE requirements and performance demands.

In January 2009, European regulations came into force introducing a new scheme for the classification, labelling and packaging (CLP) of potentially hazardous substances.

It was originally intended that from 1 June 2009, it would be mandatory for companies manufacturing, supplying and using chemical substances such as metalworking fluids (MWFs) to comply with the new regulations.

However, the date changed and is now set for 1 December 2010, when it will become a legal requirement for companies operating in European Union (EU) member states to comply with CLP regulation.

The regulations are designed to help improve personnel health and safety in the workplace.

For metalworking operators, this will lead to the reformulation of some MWFs as levels of certain additives will be minimised to reduce potential HSSE risks during processes such as cutting and forming.

This reformulation could compromise fluid performance, resulting in reduced fluid life, shorter maintenance intervals and lower levels of equipment efficiency.

Essentially, maintenance and fluid costs could increase, along with the risk of unscheduled stoppages.

With the right technical knowledge and understanding, MWFs can be developed that meet regulatory requirements, while also offering enhanced performance properties.

Shell Lubricants has reformulated part of its range of MWFs and continues to improve substance formulations in accordance with CLP regulation.

This is helping operators to promote better HSSE practices and maintain production capabilities well in advance of the mandatory compliance date in December 2010.

One of the components of water-miscible MWFs that has generated debate is boric acid.

It has been used extensively for a number of years in MWFs due to its corrosion protection, long life, pH and buffering properties.

However, there are concerns that it can potentially cause infertility in males and harm to unborn children in the long term.

To reduce these potential risks, CLP regulation will require MWFs to contain less than 5.5 per cent boric acid for them not to be labelled as containing boric acid.

As boric acid is soluble in water, it is difficult to remove from wastewater and remains active in biological treatments.

Therefore, it can pose a potential environmental risk in addition to a threat to personnel health.

To help operators improve personnel health and safety, and environmental compliance, expert MWF companies have developed fluid technology that contains less than 5.5 per cent boric acid as well as boron-free fluids that still offer optimal performance.

The secondary amines present in MWFs can react with nitrites and cause the formation of nitrosamines.

As some of these have proven carcinogenic properties, it is therefore preferable to choose a supplier offering secondary-amines-free technology.

The presence of contaminants can increase and speed-up the growth of bacteria and fungi in water-miscible MWFs.

There are growing concerns on the possible adverse health effects of microbial life by direct skin contact or inhalation.

Contaminants could include small particles of metal or alloys such as chips from the tool or machined part, tramp oils used to lubricate other parts of the equipment including hydraulics and gear boxes, and cleaning products used during finishing and general facilities management.

The contamination can degrade emulsions and change the properties of the MWFs, which can lead to the formation of potentially hazardous components.

Formaldehyde donor biocides are often used to control the growth of bacteria in MWFs.

The environmental impact of these substances is relatively low as it is rapidly broken down by sunlight or by bacteria present in soil or water and is quickly metabolised by normally-functioning cells.

Therefore, it does not often accumulate above extremely low, non-toxic levels.

However, laboratory tests have shown that the long-term inhalation of formaldehyde donor biocides could be responsible for producing malignant tumours in nasal cavities.

MWFs can pose a threat to personnel health through inhalation and direct skin contact.

High operating speeds, fluid pressures and MWF contamination can cause misting during machining.

This increases the risk of toxic vapours being inhaled by personnel and can lead to respiratory issues such as asthma and bronchitis.

Vapours can also be inhaled during improper MWF application, handling and storage.

Skin contact with MWFs can be caused by fluids flinging-off tools and parts due to high operating speeds, fluids splashing during manual application, leaks and drips from lubricant system hoses and during maintenance and cleaning practices.

Personnel may come into contact with MWFs when draining fluids, setting tools and changing work pieces.

Similarly, contact can occur through cloths and work clothes becoming soaked in MWFs during operation.

There are concerns that skin exposure could cause conditions such as dermatitis, acne, folliculitis and some cancers.

There are a number of solutions to reducing potential HSSE risks associated with the content of certain MWFs including ventilation and filtration systems, training, equipment guards, protective clothing and adding biocides to MWFs to reduce bacterial growth.

In addition, reducing equipment operating speeds and feed rates can also lessen the risk of misting and direct skin contact with MWFs.

While all of these can prove effective, one of the most practical and cost-effective solutions - opting for low-toxic MWFs - is often overlooked.

In the past, some low-toxic MWFs such as boron- and amine-free alternatives have not been able to meet all equipment performance requirements and operational demands.

This has led to issues such as reduced sump life and lower corrosion protection.

To overcome these challenges, Shell Lubricants is working in close partnership with customers to develop a comprehensive range of advanced MWFs.

Combining lubricants expertise with an in-depth understanding of everyday operating conditions is driving the development of fluids that help operators meet exacting operational demands and legislative requirements.

MWFs such as Shell Adrana, Shell Sitala and Shell Metalina have been formulated, resulting in low level, and in some formulations, no use of amines, boric acid, formaldehyde and other biocides.

As well as helping to reduce potential HSSE risks and complying with CLP regulation, the MWFs offer good performance properties including: high stability to promote long sump life and reduce the presence of tank-side additives and growth of bacteria, high corrosion protection, separation of tramp oils to reduce contamination, low foaming characteristics and high levels of detergency to promote effective cleaning and reduce degreasing requirements.

Furthermore, MWF technology including carefully selected base oils, anti-misting additives and esters reduces the potential risk of misting and associated risk of inhalation of vapours.

The MWFs have been developed for machining a wide range of materials and can be used in hard- and soft-water applications.

Metalworking operators are becoming increasingly concerned about personnel health and safety risks, and are looking for solutions to manage these risks.

MWF technology is now available that provides a practical and effective solution to enhancing HSSE, which in turn can help satisfy market demand and legislative requirements for better working practices.

As mentioned above, the CLP date for substances was postponed until 1 December 2010 to provide industries and companies using affected chemicals with the opportunity to efficiently prepare for the change in legislation.

Acting now and using the transitional period will not only help metalworking operators ensure compliance in time for the mandatory date, it could help them to better promote HSSE and prove advantageous in an increasingly competitive marketplace.

Investing in high-performance, low-toxic MWFs as a first step can also help to reduce the need for wider adaptation of production facilities, while enhancing overall efficiency and profitability through lower maintenance costs, longer equipment life and increased uptime.

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