Machine tool evaluation (development of environmentally conscious machining fluids and systems). CRADA final report

The overall purpose of this CRADA is to select or develop as required a group of cutting fluids, for use with metals and/or ceramic materials, which are more environmentally benign and which will reduce or eliminate the environmental problems associated with management and disposal of these cutting fluids. This CRADA was initially funded by DOE/DP, and was expanded to include DOE/ER funding with an added focus on environmental issues related to synthetic cutting fluids. The specific objective of this DOE-ER funded project (one of ten technical tasks within the CRADA) is to determine and demonstrate chemical methods of degrading and/or improving the disposability of synthetic cutting fluids. Photochemical advanced oxidation processes were developed and demonstrated to successfully remove all carbon from new and used cutting fluids, and from surrogate solutions containing up to 15,000 ppm of total organic carbon in the initial solutions. Chemical and energy costs for the process were evaluated. Commercial providers of advanced oxidation process technologies were consulted concerning scale-up, and associated costs in industrial systems were estimated to be well represented by the laboratory bench-scale measured values. Engineering aspects and alternative oxidation methodologies were explored through consultation with an internationally recognized chemical engineer, and it was concluded that no clear alternatives were available for treating aqueous fluids with extremely high initial carbon content (i.e., 15,000 popm total organic carbon)