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Anionic:
A negatively charged ion in water solution.
Bag Filter:
A pressure filter where fabric bags are installed inside
a cylindrical housing (pressure vessel) and the filtered
liquid is pumped through the bag walls. Liquid flow
is from the inside to the outside of the bag - dirt
is trapped inside the bag. These pressure vessels must
be ASME (American Society of Manufacturing Engineers)
coded.
Biocide:
A chemical agent used to kill microbiological organisms
(bacteria or fungi) in MRF. Biocides are registered
by the EPA under Federal Insecticide Fungicide and Rodenticide
Act (FIFRA) and are known officially as antimicrobial
pesticides.
Blind Off:
To plug or coat media pores to the point MRF will not
flow through.
Cartridge Filter:
A pressure filter where paper or fabric cartridges are
installed inside a cylindrical housing (pressure vessel)
and the filtered liquid is pumped through the cartridge
walls. Liquid flow is usually from the outside of the
cartridge wall through to the inside core - dirt is
deposited on the OD of the cartridge. These pressure
vessels must be ASME coded.
Central System:
A large MRF system for a transfer line or group of related
machines using a common MRF and usually machining the
same metal.
Centrifugal Separator:
A mechanical separator that uses centrifugal force to
remove aerosol particles from an air stream or uses
centrifugal force to separate liquids of different density,
e.g., separate tramp oil from water based MRF.
Chip Conveyor:
A mechanical system to move metal debris from the metal
removal process.
Clarifier:
Equipment used to remove contaminant from MRF.
Clarity:
Degree to which MRF is free of contaminant. Clarity
should include weight or volume of particulate in parts
per million (PPM). A description of particle count by
size may also be determined. A description or specification
of the test method is also required.
Close Capture Enclosure:
A device mounted near a contaminant source for the purpose
of containing or removing air contaminants. By design
it will have a high entrainment velocity and lower air
volume requirement. This is an effective method of enclosure.
Coalescence Separator:
A separator that collects fine particles and coalesces
them into a continuous phase that can drain from the
collector.
Compatibility:
"Compatibility" of MRF means that the fluid
does not chemically react with other materials in the
metal removal process.
Contaminants:
Substances contained in in-use metal removal fluids
that are not part of the original fluid formulation.
These can include abrasive particles, tramp oils, cleaners,
dirt, metal particles, dissolved metals, hard water
salts, bacteria, fungi, and microbiological byproducts.
Cyclone Filter:
A type of centrifugal separator.
Decant System:
System to separate light floating liquid (tramp oil)
from a heavier liquid (water-soluble MRF).
Denier:
As used here, the diameter of the fiber used in a disposable
filter medium.
Depth Filtration:
Filtering through a bed or cake of dirt (particulate)
removed from the MRF as it is established on the septum.
Dipstick: Slide prepared with appropriate
growth media, dipped into MRF, and incubated to measure
microbial growth in MRFs. Relatively inexpensive, easy
to use, and available commercially.
Disposable Medium: Usually a roll of
non-woven fabric through which the dirty MRF is passed.
This porous fabric filters the contaminant from the
MRF.
Dissolved Air Floatation System: A decant
system with a method of introducing compressed air into
the MRF air. The dissolved air bubbling up through the
MRF picks up fines and improves the clarity in the submicron
range.
Drag Conveyor:
A type of mechanical chip conveyor, often consists of
two roller chains with cross bars to move the metal
debris.
Drag Tank:
MRF tank with flight conveyor to scrape out chips that
have settled. Dirty liquid flows into tank and overflows
a relatively clear liquid to the next stage in the filtration
process.
DOP Filter:
A high efficiency air filter that has been tested using
the dioctylphthalate (DOP) challenge test.
Electrostatic Separator:
An air cleaner that charges aerosol particles and then
removes them from the airstream by passing the charged
particles between high voltage plates to cause electrical
migration to the surface.
Employee Exposure:
The exposure to metal removal fluids and contaminants
that would occur without protection provided by any
respirator or other personal protective equipment that
is in use.
Emulsion:
A mixture of liquids that do not dissolve in each other
to form a true solution, but have droplets of one liquid
dispersed throughout the other. For MRF it is generally
an oil and water mix.
Emulsifier:
A substance added to soluble oil MRF to aid in forming
an emulsion in the fluid.
Enclosure:
A mechanical device that creates a separation or barrier
between the process and the worker's environment. Enclosures
may be designed as close capture, total enclosure or
tunnel enclosures.
Endotoxin: A
component of the cell wall of gram-negative bacteria.
Filter:
A porous medium (disposable media, wedge-wire or mesh
screen) through which liquid is passed to separate and
trap particles held in suspension.
Filter Cake:
The buildup of particles on the surface of filter medium.
Filter cake can improve the removal performance of a
filter, but it also leads to increased pressure drop
and reduced fluid flow.
Flight Conveyor:
Conveyor consisting of a motorized drive, (2) sections
of heavy duty chain, and a series of bars or sections
of angle iron (flights) bolted between the chains at
regular intervals. As the conveyor moves, the flights
are dragged across the bottom of the tank carrying accumulated
contaminant out for disposal.
Flow-Through Conveyor: Similar to a
drag tank, having a flight conveyor, except that the
bottom is made of wedge-wire panels (.020 to .040 inch
slot width) and relatively clear liquid flows through
the wedge-wire. Used primarily on aluminum machining
jobs where aluminum chips float and would not settle
out in a drag tank. Flow-through conveyors are designed
to pass 75 to 100 GPM per square foot of wedge-wire
panel.
Head Pressure:
Discharge pressure of a pump in feet of liquid being
pumped.
HEAD x SG = psi discharge pressure
2.31
HEPA Filter:
High efficiency particulate air filter. Available in
different performance classifications ranging from 95
to 99.99% efficiency for 0.3 um DOP aerosol.
Hinge Pan Conveyor:
Conveyor consisting of a motorized drive, (2) sections
of heavy-duty chain, and a series of pans with pusher
bars mounted between the chains. Hinge pans are used
to remove bundles of stringy chips. Chips accumulate
on the hinge pan and are carried out for disposal while
the MRF overflows into the filter tank.
Hood:
A hood is a generic term for a device designed to capture
contaminated air and conduct it into an exhaust duct
system. The term may include enclosures, canopy hoods,
push-pull hoods, down draft hoods, side draft hoods
or others.
Impaction Separator:
A mechanical device that uses the inertial properties
of entrained aerosol particles to separate them from
an airstream and collect them on an "impaction
surface."
Impingement Separator:
Similar to the impaction separator except that the airstream
is directed toward a liquid surface instead of a solid
surface.
Index:
In automatic media filters (vacuum and flat bed), to
advance the media to remove a dirty and plugged section.
In automatic wedge-wire drum and wedge-wire septum filters,
to scrape the wedge-wire and remove a portion of the
dirt load that forms the filter cake.
In-Use MRF:
Metal removal fluid that is being used and continually
recycled for lubrication, cooling, chip transport, and
corrosion protection of a metal removal operation. These
fluids are distinguished from "as received"
metal removal fluids by the presence of contaminants
from the metal removal process, the machine tool, and
biological growth in water based fluids.
Magnetic Conveyor:
A chip or swarf conveyor for ferrous metals that uses
magnets below a chip plate to move the metal debris
without direct contact of the moving conveyor with the
waste material.
Media (Filter): That part of the filter
upon which the contaminant is actually trapped as the
fluid passes through. Usually disposable media, permanent
belt, wedge-wire, etc.
Medical Management:
The use of medical information to help control the health
risk posed by a contaminant in the workplace. The risk
management decisions may be directed toward the entire
workforce or they may be made for a single worker who
is not able to safely work in an area due to a temporary
or permanent medical condition.
Medical Monitoring:
The collection of medical information to screen for
health problems that may be related to work in a specific
work environment. The focus is on early detection of
health problems for the individual employee.
Medical Surveillance: Is the systematic
examination of medical monitoring data to determine
if there are unusual patterns of health problems in
the workplace. Statistical techniques may be used in
larger workplaces to improve this analysis.
Metal Removal Fluid (MRF): A fluid applied
to a tool and workpiece while cutting or removing metal.
This fluid may be water or oil-based. Its principal
functions are to cool the tool/workpiece interface,
to provide lubrication, and to flush chips or contaminants
generated in the metal cutting or removal process.
Metal Removal Process:
A manufacturing process that removes metal to produce
a finished part.
Metal Working Fluids:
A generic term to describe four categories of fluids
(straight oils, soluble oils, semi-synthetic and synthetic)
that facilitate a wide variety of operations involving
the working or modification of metals. Metal removal
fluids are used in machining, grinding and honing operations.
Metal forming fluids are used in stamping, forging,
drawing, coining, rolling, piercing, cold heading and
wire/bar/rod drawing operations. Metal protecting fluids
are used primarily for fingerprint displacing and indoor/outdoor
storage. Metal treating fluids are used primarily for
metal quenching operations. Drawing and forming fluids
are similar or identical in composition to MRFs but
are used in an entirely different way.
Micrometer (Micron):
One millionth of a meter.
1 m m = 1 meter ; 1 millimeter = 0.000039 In.
1,000,000 1,000 (39 millionths of an inch)
Mist:
Fine liquid droplets suspended in or falling through
a moving or stationary gas atmosphere.
MRF System:
Usually includes a clarifier, electrical controls, pumps
and a trench return for chips and spent MRF. May also
include water make-up, chiller for temperature control,
tramp oil skimmer, variable speed pump control, etc.
Neat Oil:
As it comes from the drum; not diluted. Usually refers
to soluble oil before mixing with water to form soluble
oil and water MRF mixtures. Sometimes used to describe
straight mineral oil.
Nominal Rating:
Rating for roll media, filter cartridges and filter
bags. Nominal rating is mean flow pore size of media:
half the flow is through pores smaller than the nominal
rating and half the flow is through pores greater than
the nominal rating. Not an explicit specification.
Nonionic:
A water soluble material, e.g., emulsifier, that does
not form charged molecules in solution. Not anionic
or cationic.
Occupational Exposure
Guideline: A guide for use in evaluating
worker exposures to particular workplace contaminants,
especially where there is a lack of definitive data
to establish a safe exposure level.
Particulate Matter:
Small dirt particles suspended in MRF or microscopic
particles suspended in air.
Plenum Duct System:
A portion of a ventilation system in which a section
of the duct is larger in cross sectional area resulting
in a much lower transport velocity. The advantage of
such a system is that ducts can be connected or removed
from the plenum section without causing dramatic changes
in the overall airflow balance of the system.
PPM: Parts
per million; must state test used and whether by weight
or by volume.
Pressure Filter:
A filter where the filtered liquid is pumped under pressure
through the media. Examples are automatic flat bed filters,
cartridge and bag filters.
Reverse Osmosis:
The use of semi-permeable membranes and pressure to
overcome osmotic pressure and produce high purity water.
Roller Filter Conveyor:
A system to use roll filter media with a mechanical
conveyor over a flat-bed filter to clean MRF.
Semi-synthetic MRF:
A water-based (reducible) MRF composed of both water-soluble
components and emulsifiable components. It may or may
not include performance-enhancing additives, and generally
contains 5 to 30% (by volume) of oil. In mixed form
semi-synthetic MRF may contain 5% or less of oil.
Soluble Oil MRF:
A water-based (reducible) MRF composed of an emulsion
of oil (or oil-like material) in water. It may or may
not include performance-enhancing additives.
Straight Oil:
Usually refers to an oil used as an MRF. Could be a
mineral seal oil (40 to 50 SSU) used for honing, a light
oil (90 to 100 SSU) used for aluminum machining (valve
bodies) or a heavy oil with high-pressure additives
used for broaching (250-450 SSU). Contains no water
and is not mixed with water in normal conditions.
Surfactant:
Surface active agent such as an emulsifier or detergent
that lowers the surface tension of water.
Swarf:
Fine particles of metal, graphite and carbide that result
from grinding operations.
Synthetic MRF:
A water-based (reducible) MRF composed of a true solution
of water-soluble organic and/or inorganic components.
It may or may not include performance-enhancing additives.
Tapered Main Duct System: An engineered
exhaust ventilation duct system that is balanced by
design rather than dampers or blast gates. The diameter
of the duct work increases as additional ventilation
air is added to the system.
Total Enclosure:
A box or housing around the machine or process. The
housing is not intended to be airtight. Openings are
limited to the minimum required to allow for part entry/egress,
maintenance or utility access.
Tramp Oil:
Petroleum contaminants of metal removal fluid that come
from hydraulic oil, gear oil, way oil, and other lubricants.
Tramp Oil Skimmer:
A device for removing floating tramp oil. Common types
are endless tube, disc, belt, and decant systems. All
tramp oil removal systems require regular maintenance
- systems remove fines as well as floating tramp oil
and tend to plug up. Must be installed in a still or
quiescent part of the filter dirty tank.
Tunnel Enclosure:
A continuous total enclosure over two or more connected
work stations or machining processes. The design principles
are similar to those applied for total enclosure.
Turnover Time or Retention
Time: Related to particulate settling
rate. The more viscous the MRF, the lower the settling
rate; thus the turnover time should be increased by
increasing the system tank volume.
-Flow rate gal x turnover time min = tank vol
gal
-min
-Turnover time min = tank vol gal
-flow rate gal
-min
-Soluble oil and water systems generally have 3 to 5
min. turnover time, while light oil systems have 7 to
10 min. turnover time.
Vacuum Filter:
A filter where a vacuum is created on one side of the
media, usually by means of the pump suction. Atmospheric
pressure then pushes the dirty liquid through the media.
Water-miscible:
Designed to be diluted with water.
Wedge-Wire Drum: Wedge-wire drums are
made by spirally wrapping wedge wire over a mandrel
with longitudinal support rods. The wedge wire is automatically
resistance welded to the support rods forming a drum.
As the wire is wrapped, a precise dimension is maintained
between each wrap to form precision slots. Slots are
usually in .007 to .010 range for vacuum filtration
applications.
Wedge-Wire:
Wire drawn to a wedge shape - used primarily for strainer
and filter applications. Standard materials are the
300 series stainless steels.
Wet Metal Removal Fluid
Environment: The workplace environment
in which wet metal removal operations occur. |
Applications
Automotive
Integrated Treatment Systems
