Alternatives for

Chlorinated

Paraffins in

Metalworking

Formulation

Dover Chemical Corporation

John Nussbaumer

Dover CP –Chlorinated Paraffins

Dover Chemical is the only CP producer in North

America.

CP is still the most popular EP-lubricant additive in

MWF formulation by far.

Long-chain, >C18, available

Medium-chain, C14-17, available

Short-chain, <C14, discontinued

Pamphlets on Dover CP upon request

More on Dover products, please visit http://www.doverchem.com/Products/MetalworkingFluidAdditives.aspx

CP-Advantages Disadvantages

Versatile, both oil and

water-based

Ease of formulation

Most cost effective

Stable in water

Active in wide range

of temperatures and

conditions

Physically pleasant, light-colored,

Uncertainty in future

regulation

Poor green image or

perception

CPA: Advantages Disadvantages

Free of stringent regulations

Readily biodegradable

Greener image

No chloride, corrosion issue

Ease of disposal

More-application specific

Requires formulating skill

Less cost effective

Some cases, less stable in water

More selective to base carrier

Limited in stainless applications

CP Alternatives (CPA) All Dover’s products used in this study

Chlorinated fatty esters and acid

Sulfurized hydrocarbons

Phosphate acid esters

P-containing blend

Boundary ester lubricants

Complex esters

Hydrogen phosphites

Nitrogen containing compound

Dover Chemical Additives:

Chlorinated Acids/Esters

DA 8506XS- Chlorinated methyl ester

DA 8527- Chlorinated stearic acid

Synchek 1203- Chlorinated PEG fatty

esters-Water dispersible

Dover Chemical Chlorine-Free

EP Additives

Doverlube NCEP- Nitrogen containing compound

Mayphos 45- Phosphate ester

Mayfree 133- Phosphate Amide

Doverlube NCL2- Phosphorous Containing Blend

Doverphos 253- Dioleyl Hydrogen Phosphite

Mayco Base 1351contains 10% sulfur

Mayco Base 1540 contains 38% with 27% of total sulfur

being active

Dover Chemical Boundary

Lubricants

Doverlube FL100: 2-Ethylhexanol Dimerate

Doverlube FL 296: 2-Ethylhexanol Oleate

Maylube E-112: Polyol Fatty Ester

Maylube E-101: Tridecyl Stearate

Lube Booster II: Complex Ester

Inversol 140: Inverse-emulsion complex ester

Klorfree 100: Complex polyol Dimerate

Additives Used as the

Standard for Comparison

Paroil 140: long chain chlorinated paraffin,

40% Cl.

Test Descriptions – Dover

Technical Service Capability

Used for internal developmental works

Assist customers in formulation

Assist customers in problem solving

Testing Methodology On steel and stainless

Metal removal -> tapping-> Microtap

Metal forming-> Drawing-> Draw-Bead & Falex EP

Formulae: Neat oil, soluble oil, semi-synthetic

Neat Oil: 5% CPA in 100 sec oil

Soluble oil: Formula = oil + emulsifier base + CPA,

5% emulsion in tap water, 0.0375% final CPA conc.

Semi-synthetic: 60/40 oil-water base, 0.15% final

CPA concentration.

TESTING CAPABILITIES

Falex EP (Pin & Vee)

Measures Torque Vs. Load

Better fluids yield lower Torque

per unit load

TESTING CAPABILITIES

Falex EP (Pin & Vee)

TESTING CAPABILITIES

Microtap Tap & Torque

Drill Press

Compares fluids by measuring

force required to thread a drilled

hole

Better fluids use less force to

thread a hole

+/- 3% margin of error

TESTING CAPABILITIES

Vertical Drawbead

Measures Force required for

drawing operation

Compares required forces

between fluids

There is a +/- 5% margin of

error associated with this test

Better fluids require less

force thus a lower efficiency

Laboratory Testing Data

Metal Forming,Falex EP,Water-

Based (WB)

Additives Soluble Oil Semi-

synthetic

Notes

Paroil 140

2500 lbs 4500 lbs Best, WB,

standard

FL-100 2250 lbs 4250 lbs Not quite

MF-133 2500 lbs 4500 lbs Very good

CPA, WB

DA8506XS 3000 lbs 2750 lbs More fortified,

hydrolytical

stability is

needed

Metal Removal, Microtap, Soluble

Oil, 0.0375% CPA final

Additives Tap % Eff Notes

Paroil 140 100% Standard

May Free133, 4%P 101% Equivalent

Maylube E-112, ester 101% Equivalent

Maylube E-101, ester 100% Equivalent

Klorfree100 Complex ester

101% Equivalent

Doverlube FL-100, dimerate 101% Equivalent

DA8506XS 104% Better

Metal Removal, Microtap, Semi-

Synthetic (WB),0.15%CPA final, 3%

Variance Additives Tap % Eff Notes

Paroil 140 100 standard

Doverlube FL-100 101 Equiv

May Free133 100 Equiv

DA8527 99 Equiv

Synchek1203 100 Equiv

Lube-booster II 103 Equiv

Inversol 140 106 Much better

Metal Removal, Microtap, Oil -Based

(OB), 5.0% CPA final, 3% Var

Additives Tap %

Eff

Notes

Paroil 140 100% Standard

Doverlube NCEP 97 Equiv

Doverphos 253 99 Equiv

Mayphos 45 101 Equiv

Mayco Base1351, 10%S 97 Equiv

Mayco Base 1540, 38%S 102 Equiv

90/10 1351/NCEP 99 Equiv

90/10 1540/NCEP 99 Equiv

Metal Forming, Draw-Bead, OB,

Smaller %Eff is better, 5% Var Additives Formula Type % Draw Eff Notes

Paroil 140 Neat, 5% Conc. 100 % Standard

Mayphos 45 Neat 103 Equivalent

NCL-2 Neat 100 Equivalent

NCEP Neat 96 Equivalent

MB1351 Neat 93 Better

DP-253 Neat 94 Better

MB1540 Neat 91 Much better

Metal Forming, Draw-Bead, Soluble

Oil, Smaller %Eff is better, 5% Var Additives % Draw Eff Notes

Paroil 140 100% Standard

Maylube E-101 98 Equivalent

Klor-Free100 94 Better

Doverlube FL-100 92 Much better

DA8506XS 93 Better

Maylube E-112 92 Much better

May Free 133 91 Best

Doverlube NCEP- Stainless

In Microtap, 5% in neat oil, NCEP yields

109% Tapping Eff when compared to

Paroil 140

NCEP: sulfurized blend demonstrates the

effective synergy at 10:90 ratio, yielding

comparable performance to Paroil 140 on

stainless.

NCEP synergy holds true also in drawing.

NCEP Synergy, Draw-Bead,

Steel, OB, 5% Conc, 5% Var.

Additives % Draw.

Eff.

Notes

Paroil 140 100% Standard

Doverlube NCEP 96 Equivalent

Mayco Base1351 94 Better

Mayco Base1540 91 Much better

90:10 1540:NCEP 87 Much better

90:10 1351:NCEP 77 Best by far

Conclusions Doverlube NCEP is the true CP alternative on

stainless and low-ferrous alloys.

Dover’s bench tests in general agree well with field

trials.

For steel, both metal removal and forming, Dover

offers many CP alternatives.

Dover Chemical still promotes CP as the most

versatile and cost effective additive, easiest to be

formulated.

Copy of this presentation on

Dover Homepage

Thank you!

Questions?