Process for metalworking fluid from heavy alkylate

Abstract

The present invention relates to composition of metalworking fluid based on heavy alkyl benzenes having 20 to 22 alkyl carbon atoms and process for the preparation thereof. The heavy alkyl benzene based, less toxic, soluble metalworking fluid composition comprises heavy alkyl benzene, emulsifier, lubricity booster, antioxidant, fungicide, extreme pressure additive, antirust, co-surfactant, coupling agent and alkali component. The process comprises tailoring the heavy alkyl benzene, removing of insoluble matter from the heavy alkylate, addition of emulsifier, additives, coupling agent and co-surfactant, homogenizing the mixture at 20-120° C., followed by conditioning of the soluble metal working fluid concentrate which can be used as emulsion in water.

1 . A process for metalworking fluid from a heavy alkylate, concentrate composition comprising;
 (a) heavy alkylate having C20 to C22 alkyl carbon atoms on benzene ring, to replace mineral oil, in the concentration range of 40 to 85 weight percent of the metal working fluid concentrate,   (b) at least one sulfonate or oleate emulsifier in the range of 10 to 40 weight percent of the metalworking fluid concentrate,   (c) a synergetic combination of additives, (c1) at least one vegetable oil lubricity booster component in the concentration range of 2-10 percent of metal working fluid concentrate, (c2) an alkyl phenol or aromatic amine antioxidant component is in the concentration range of 50-500 mg/kg, (c3) a phenol fungicide component in the concentration range of 50-500 mg/kg, (c4) an organic sulfide or phosphosulfurized metal salt extreme pressure additive component in the concentration range of 50-500 mg/kg in the metal working fluid concentrate, (c5) a triazole or sulfonate antirust component in the concentration range of 50-500 mg/kg in the metal working fluid concentrate, (c6) an alcohol co-surfactant component in the range of 1-10 weight percent of metal working fluid concentrate, (c7) a sulfonate coupling agent in the range of 0.5 to 10 weight percent of metal working fluid concentrate, (c8) alkali or alkaline earth metal salt component in the range of 8-10 weight percent of metal working fluid concentrate, (d) said process comprises the steps of tailoring the heavy alkylate, removing of insoluble matter from the heavy alkylate followed by addition of emulsifier and vegetable oil to obtain the mixture; homogenising the resultant mixture at a temperature in the range of 30 to 100 degree Celsius; for about one hour with stirring; adding the antioxidant, fungicide, extreme pressure additives, anti trust component, co-surfactant, coupling agent, alkali, followed by addition of water to make up the quantity about 1 kg; homogenizing the mixture for about 30 minutes, adjusting the pH to 7-9 by addition of sodium carbonate; and cooling the resultant metal working fluid at room temperature, wherein the composition is suitable for use as soluble metalworking fluid as admixture or emulsion with water in concentration range from 20 to 80 weight percent.   
     
     
         2 . The composition as claimed in  claim 1 , wherein the heavy Alkylate is a non-toxic lube oil component having heavy alkyl benzene of C20-C22 alkyl carbon atom, a heavy fraction by-product separated from detergent class alkyl benzene during manufacture, wherein the Heavy alkyl benzene consists of a mixture of substituted benzenes, wherein the Benzene is substituted with alkyl chain wherein the Alkyl chains are straight-chain paraffin or branch-chain paraffin, and average of C20-C22 alkyl carbon atom, at single or two places of benzene ring, and no poly-aromatics or olefin compounds are present in the heavy alkylates. 
     
     
         3 . The composition as claimed in  claim 1 , wherein the emulsifier is selected from the group consisting of heavy alkylate sodium sulfonates, sodium carboxylate, sodium oleate, triethanolamine oleate, diethanolamine oleate or dodecyl toluene sodium sulfonate or mixtures thereof. 
     
     
         4 . The composition as claimed in  claim 1 , wherein the lubricity booster is a vegetable oil selected from the group consisting of karanja oil, neem oil, rice-bran oil, castor oil or mixtures thereof. 
     
     
         5 . The composition as claimed in  claim 1 , wherein the antioxidant component is selected from the group consisting of an alkyl phenol, aromatic amine, substituted tetrazole selected from 2,6-ditertiary butyl phenol, 2,6-ditertiary p-cresol, diphenylamine, Tertiary butyl phenol amino tetrazole and 2,6-dioctyl phenylene diamine or mixtures thereof. 
     
     
         6 . The composition as claimed in  claim 1 , wherein the fungicide component is a phenol or phenolic acid selected from the group consisting of o-cresol, phenol, m-cresol and cresylic acid or mixtures thereof. 
     
     
         7 . The composition as claimed in  claim 1 , wherein the extreme pressure additive component is an organic sulphide or phosphosulfurized metal salt selected from the group consisting of dibenzyl disulphide, sulfurized vegetable oil, phosphosulfurized decyl oleate molybdate and phosphothio pentadecyl phenol molybdate or mixtures thereof. 
     
     
         8 . The composition as claimed in  claim 1 , wherein the anti-rust component is a triazole or sulfonate selected from the group consisting of 1H-benzotriazole, ditertiary butylated 1H-Benzotriazole, calcium petroleum sulfonate and calcium heavy alkylate sulfonate or mixtures thereof. 
     
     
         9 . The composition as claimed in  claim 1 , wherein the co-surfactant component is a alcohol selected from the group consisting of isopropanol, n-butanol, iso-butanol, iso-amyl alcohol, 2-ethyl-1-hexanol, mono & poly glycol such as diethylene glycol and tri ethylene glycol or mixtures thereof. 
     
     
         10 . The composition as claimed in  claim 1 , wherein the coupling agent component is sulfonates (molecular weight less than 350) selected from the group consisting of ligno sulfonate, petroleum sulfonate, sodium dodecyl benzene sulfonate and sodium lauryl sulphate or mixtures thereof. 
     
     
         11 . The composition as claimed in  claim 1 , wherein the alkali component is an alkali and alkaline earth metal salt selected from the group consisting of sodium carbonate, sodium hydrogen carbonate, calcium carbonate and calcium oxide or mixtures thereof. 
     
     
         12 . The composition as claimed in  claim 1 , wherein the composition is suitable for use as soluble metal working fluid as emulsion or admixture with water in concentration range from 20 to 80 weight percent and useful for metal cutting, drilling, lathing, grinding or machining. 
     
     
         13 . Process for metalworking fluid from heavy alkylate, concentrate as claimed in  claim 1 , said process comprises the steps of;
 (a) tailoring the commercially available heavy alkylate, commercial heavy alkylates was fractionated by vacuum distillation, which should be done at 1 bar or 760 mm Hg vacuum and about 210° C., first 5 to 50 percent by weight cut and last 5 percent by weight cut should be left and middle cut of 55 to 90 percent by weight should be taken for formulation,   (b) removing of insoluble or oxidized matter from the heavy alkylate followed by addition of emulsifier and vegetable oil to obtain the solution;   (c) homogenising the resultant mixture at a temperature in the range of 30 to 100° C. for about one hour with stirring of force equivalent to 1300 RPM for 2 litre material;   (d) adding the antioxidant, fungicide, extreme pressure additives, anti trust component, co-surfactant, coupling agent, alkali;   (f) adjusting the pH of the solution to 7-9 by addition of sodium carbonate; and   (e) followed by addition of water to make up the quantity about 1 kg, and homogenising the mixture for about 30 minutes and cooling the resultant metal working fluid at room temperature.   
     
     
         14 . The process as claimed in  claim 13 , wherein the concentration of heavy alkyl benzene component is in the range of 40 to 85 weight percent of the metalworking fluid concentrate. 
     
     
         15 . The process as claimed in  claim 13 , wherein the concentration of emulsifier component is in the range of 10 to 40 weight percent of the metalworking fluid concentrate. 
     
     
         16 . The process as claimed in  claim 13 , wherein the concentration of vegetable oil component for lubricity boost is in the range of 2 to 10 weight percent of the metalworking fluid concentrate. 
     
     
         17 . The process as claimed in  claim 13 , wherein the concentration of antioxidant component is in the range of 50 to 500 mg/kg of the metalworking fluid concentrate. 
     
     
         18 . The process as claimed in  claim 13 , wherein the concentration of fungicide component is in the range of 50 to 500 mg/kg of the metalworking fluid concentrate. 
     
     
         19 . The process as claimed in  claim 13 , wherein the concentration of extreme pressure additive component is in the range of 50 to 500 mg/kg of the metalworking fluid concentrate. 
     
     
         20 . The process as claimed in  claim 13 , wherein the concentration of anti-rust component is in the range of 50 to 500 mg/kg of the metalworking fluid concentrate. 
     
     
         21 . The process as claimed in  claim 13 , wherein the concentration of co-surfactant component is in the range of 1 to 10 weight percent of the metalworking fluid concentrate. 
     
     
         22 . The process as claimed in  claim 13 , wherein the concentration of coupling agent component is in the range of 0.5 to 10 weight percent of the metalworking fluid concentrate. 
     
     
         23 . The process as claimed in  claim 13 , wherein the concentration of alkali component is in the range of 0.5 to 8 weight percent of the metalworking fluid concentrate.