T6356 ZL 乳液使用手册.doc

Tandemol 6356ZL使用维护手册Manuals of Applications of Tandemol 6356ZL Emulsion 乳液维护控制指标Control Specification 添加剂说明 Information of on-site additives 乳液维护守则 Guildlines for maitainance. 问题和对策 Rolling Problems and Actions 有关乳液的技术服务事项After Sales Service TandemolSH671说明书 Data Sheet of Tandemol SH671 乳液检测方法 Test methods. 好富顿联系人员Contacts from Houghton好富顿（深圳）有限公司Houghton (China) Co.Ltd2004年12月 Tandemol 6356ZL的维护控制指标This document contains a series of actions to be taken to control the emulsion in using: T6356ZL.This targets are based on our observations during the trial time.However, since the trial time is limitedly long , thus accompanying the more experience accumulated in the later on rolling, these targets might be subject to change, But it must be practiced in a very cautious way.该资料中含有通常乳液应用和维护中经常可能碰到的问题以及所建议的措施。乳液中的参数设定是基于我们在调试期间的观察确定的，随着以后应用数据的积累，这些指标有可能进行必要的调整，但调整改变必须谨慎小心。 浓度Concentration浓度是乳液中的含油量，而润滑成分都是在存在于油相中。所以浓度，对润滑具有重要的影响，是润滑能力的基础，需要每天测量。浓度测量时的注意事项是：Concentration is the mesurment on the oil content in the emulsion, while lubricating contents remain in oil phase. Thus, the concentration would exert the great influence upon lubricity, needing being measured everyday. The following attention is needed for concentration control1）保持液位相对稳定。这样做的一个方法是定期补充水分或者取样是保持液位。定期多次补充水分的一个另外的优点是防止对系统造成较大浓度和温度变化的冲击，建议每次加水不超过20吨,20吨的添加增加约降低体系乳液温度5C，降低浓度约0.4%。Keep the emulsion level relatively stable when taking samples. A solution is to add water regularly. Regular addition of water gives another benifiit, preventing big flutuations of concentration and temperature of system. No more than 20 tons of water is added in one time, Each addition of water no more than 20 tons.According to the caculations, 20 tons of addition of water in one time, lower the temperature by 5C and lower the concerntration by 0.4%.2）在正常情况下，只要不出现打滑，可保持浓度在较高的范围内使用。If there is no refusals or slid, keep concentration in a relatively high.3）在目前这种测量方法情况下，0.2%的差异是很正常的，特别是在酸分离时在分离不彻底或者没有离心的情况下，底部可能会出现皂物质，建议，对皂高度按照一半读取，并一直按照这个标准做。如果使用硫酸分离效果将要稍好些。将来如有可能，可以考虑购买设备，进行较快速的测量。Based on current test methods, 0.2% error is quite normal due to the uncompleted split. The soap in the bottom side can be read by half, if using sulfuric acid , a better splitting can be expected, and in the future, a better equipment can be purchased for faster and more accurate measurement. 4）如果需要快速检测，可以考虑使用浓硫酸。If wanting fast test, sulfuric acid with high concentration can be used. 5）根据200吨的体积计算，1桶200升的添加提高浓度0.1%,10吨水约降低浓度0.20%.Based on 200 tons volume, 1 drum or 200 lts of T6356 can raise concentration by 0.1% and 10 tons of water lower concentration by about 0.2%.6) 如果粘度升高，这时可改加低粘度产品T6356LV。T6356LV 和T6356ZL的配方完全相同，差别只是在于粘度，所以浓度的计算方法也相同。If hydrophobic viscosity is high too, T6356LV, instead, can be used. T6356LV has exact same formula as 控制范围 Control Limits：最低 Minimum 3.5% v/v 正常 Normal 4.0% v/v最大 Maximum 4.5% v/v如果浓度太高 if too high：- 检查水位 check water level- 如果没有问题，继续轧制 if no problem， continue rolling - 不添加T6356ZL，只添加添加剂。No addition of T6356ZL, only additives.如果浓度太低：if too low泵前缓慢加入T6356ZL或者T6356LV（粘度高时）slowly add T6356ZL or T6356LV (When hydrophobic visicosity is high)pH一般而言，pH值对水基溶液体系具有重要的意义，它与乳液的松紧程度、防锈性能、抗菌性能等都有一定的关系。pH值较高时，乳液较紧，防锈性能较好，能抑制细菌生长,但pH值太高时，会降低乳液的润滑能力。 pH值的降低一半可能有如下原因：1)添加水质；2）外来泄漏；3）有机皂等成分减少；4）细菌滋生。因此，pH需要每天测量.Gernerally speaking, pH is a important indicator for emulsion tightness, anti-rust property and bacteria growth. Higher pH results in tighter emulsion, better anti-rust property and slow bacteria growth but poor lubricity. The causes for pH getting lower : 1）water qality；2) contamination and leakage; 3) Reduction of organic soap in emulsion; 4) Bacteria growth. Thus needing daily check.pH需要用pH计进行测量，并分别采用pH 7 and 10的两种标准溶液进行标定,而且要保持电极的清洁。另外，测量时发现温度和搅拌对批pH值测量的结果也有重要的影响，所以在测量时，如果没有温度补偿设置，应该等样品在室温下测量，所测量的样品应该进行充分搅拌以保证样品的均匀一致，但为防止搅拌对吸附电层的影响，应该在读数片刻停止搅拌。正常情况下，0.1的测量精度是正常的。pH reading can show large and significant deviations from the real values when equipment is used that is not appropriate. Firstly an electrode fit to measure emulsions must be used. Secondly, the electrode must be properly calibrated using at least 2 buffer solutions. In the present case, buffer of pH 7 and 10 are recommended. Lastly, the electrode cleanliness is of importance to yield good data. Sample temperature as well as circulation exert great influence to the readings too. The sample should be measure in the room temperature if there is no automatic temperature compensation settings. Stopping circulating in the reading-making moment while keep through circulation before making readings. Under these conditions, the accuracy would be kept within 0.1 pH units. 控制指标 Control limits 最小minimum7.5 正常Nominal8.0最大 Maximum8.3如果PH值太低，首先需要检查有机皂的含量，如果有机皂的含量也较低，可用S20去提高。200升的S20大致能够提高PH值0.2,一般每次添加不宜超过一桶,在下次添加前应该先再测量PH.If the pH reading is too low, the level of organic soap must be checked. If the latter is low, then additive S20 must be used to correct for it. 200lts of S20 would increase pH by 0.2. Quantities larger than 200 liters at the time should never be used. After each addition, the pH is checked again before a new addition is made. 如果有机皂(OS)的含量也较高 (9%),而PH的降低是由水质和泄漏带来的,可以用3542来调整. 40升的添加升高pH约0.2. 一次不宜超过40升,再次添加前,应该在检查PH.If soap levels are sufficiently high (9%l) and if the pH drop is caused by i.e. poor water quality or the leakage of tramp oil, then pH must be corrected via 3542 at quantities of 40 liters at the time. pH is checked after each addition.降低的另一个原因是由于细菌的滋生，因此在出现pH降低的情况下，在重复检测的基础上，还应该同时检测细菌滋生的情况,如果是由于细菌滋生引起的,首先应该加杀菌剂,杀死细菌,或者是将乳液升高到65C保持2-4小时.然后再提高PH 。杀菌剂可用TI6019,添加量是每次25lts. The another possible reason for pH drop would be bacteria growth. Thus when finding pH lower, bacteria should be checked too after the double check. If bacteria is a problem, firstly should add biocide or heat the emulsion to 65C for 2 or 4 hours, then raise pH. The biocide number is TI6019 at the quatity of each time 25 lts. 一般情况下PH值不会升高到8.2以上,除非是系统有清洗剂等外来碱性物质的泄漏.在这种情况下,通常要弄清楚是何种外来泄漏物,就采取措施而言,可能需要部分换液25%,然后补加产品到规定浓度,并要密切注意轧制过程是否正常.请先咨询好富顿工程师,然后再采取行动.Although it is unlikely, pH increases above 8.2 can occur as the result of i.e. leakage of alkaline cleaners into the emulsion or incorrect usage of additives. Unless it is clear what compound caused the increase (allowing more specific actions) a partial dump of 25% of the system is necessary ,followed by a top up and taking into account the target oil concentration. Eventually, after having checked the rolling performance at the present pH value, it can be decided to keep working with the emulsion allowing the pH to gradually go down until it reaches its window of operation. This can only be decided after consultation of the Houghton Technical staff. 电导率Conductivity实际上,没有There is no real minimum limit for conductivity. Under normal conditions, using DI water of acceptable quality, the start conductivity is in the range 200-300 S/cm. Metal build up, bacterial activity, biocide or other additive additions can significantly increase the conductivity. As a starting limit the maximum value is determined as:Maximum = 1000 S/cmThis limit must be carefully examined as the need for a lower maximum limit could be necessary.如果电导率超过了上述界限, 可以考虑采取以下手段:l 停机或者维修前,加入清净剂T6010添加剂2-3桶,循环2小时,然后撇油,T6010可以带出系统的脏污,从而降低系统的电导率.l 部分排放,例如排放10-20%l 深撇油.在撇油时,静止一段时间,让脏物充分上浮,然后将其撇掉.Hydrophobic viscosity疏水粘度数值对咬入、润滑（动力润滑）和冷却等都有一定的关系。从目前的使用情况看，使用相对较低的疏水粘度但较高的边界润滑，对保证咬入、冷却等有一定的帮助。The hydrophobic viscosity is in many cases influenced by tramp oil leakages. In the case of T6356ZL, viscosity increases are most likely and viscosity decreases are less obvious.The limits are established as:Minimum35 cst at 40 CNominal40 cst at 40 CMaximum 45 cst at 40 C现在的疏水粘度取值40-45cSt,但在现场备有同样配方的低粘度油品，既可以作为将来处理液压油泄漏的补偿，也可以用来进行降低粘度试验。In case that the viscosity exceeds the maximum limit, corrections are made with additive LV that at that moment replaces the regular neat oil. In critical conditions requiring quick action, a 25% partial dump followed by a top up with LV is necessary. In the rare event hat the viscosity would go beyond the minimum limit, daily additions of neat oil will automatically correct for it. If quick response is required (depending on the rolling behavior: under lubrication, poor surfaces) corrections with the HV additive are done. In case immediate action is necessary, a 25% full dump followed by a top up with regular neat oil or additive HV (depending on the actual value of the viscosity) are done.Back Back2Lubricating ester润滑酯润滑酯是重要的极压和边界润滑添加剂。特别是对轧制硬合金时相当关键。配方中已经有所提高，但具体的指标应该再进一步优化。目前建议的控制值是The lubricating ester level in T6356ZL is 7%. When using FTIR readings for additive analysis, and taking into account the experimental error, action is taken at the moment that the ester level has reached 80% of its target value: in this case 5.6%. It is almost impossible that ester levels would reach values above 100% unless an incorrect addition of additive 5594 has been done. Not more that 15% relative above the target level is allowed. The limits are:Minimum7.0 abs. %Nominal 8.0 abs. %Maximum9.0 abs. %If concentration too high:- No additions of Tandemol Additive 5594- Reduce concentrationIf concentration too low:- Make corrections to nominal value. - Use additive5581按照理论计算，每增加80升约升高1%，但润滑酯很难乳化，实际效果会大打折扣。如果要调整，可以按照30-40%有效程度来估算。如果事先能够和产品混合，加入效果会得到明显改善。Corrections are made using additive 5594. The available spreadsheet allows precise calculation of the quantity needed. The required quantity is 35 liters/100 m3 for an oil level of 3% in a 100 m3 system. Back Back2Additive 5594 is difficult to emulsify and a recovery of only 50% is realistic. Recovery can be increased by premixing the additive with neat oil (as pure compounds in absence of water). However a near to 100% recovery is very difficult to reach.In those cases where a too high ester level would cause a problem, a proportional partial dump is done. Back. Back 2Uncombined fatty acid#back2The uncombined fatty acid level is very low in the present formula and no reliable figures for the absolute level are given since the measuring signal in the FTIR spectrum at 1710 cm-1 is influenced by impurities in other raw materials. In the case of NEA, extra additions of additive 849 may be necessary (and are even likely) in order to ensure proper rolling of printing sheet. In this case the present FTIR-calibration curve may be insufficient and new standards will have to be made. In this case, at i.e. 3% uncombined fatty acid, more reliable absolute figures shall be used. The FTIR spectrum can however be used to correct for fatty acid depletion in the present formula. Taking into account uncertainty on the analytical figure, a corrective action is done at:Minimum = 50% relativeThis limit is expressed as a relative percentage of the FTIR-signal (peak height at 1710 cm-1). Corrections with additive 849 are done following the spreadsheet calculations or according to the rule: 20 liters of additive 849 per 100 m3 of emulsion at a concentration of 3%.It is unlikely that fatty acid levels would exceed 100% significantly. If this would be the case particular action should be taken after having investigated the cause of the increase in cooperation with the Houghton technical staff. Back Back2Organic soapIn T6356ZL 9% of organic soap is present, calculated according to the classic ratios of free TEA and fatty acid. Due to build up in the water phase, the organic soap levels tend to increase, resulting in levels above 100%. In practice, these high values are not seen as a problem and no corrective measurements are taken. Only in those cases that the soap level would be too high (150% relative) and indications for over lubricity are seen, a proportional partial dump followed by a top up with regular neat oil is considered. BackTramp oil leakages often cause preferential organic soap depletions in T6356ZL. From experience, this is seen as the most important cause for organic soap losses with this chemistry. The accepted minimum level is at 80% of its theoretical value:Minimum7.2 abs. %Nominal9.0 abs. %Maximum13.5 abs. %If concentration too high:- No additions of Tandemol Additive S20If concentration too low:- Make corrections to nominal value. - Use additive S20Minimum = 7.2 % (80% rel.)Additions are done according to the calculations in the spreadsheet. These correspond to 65 liters of additive S20. As said above, this quantity of additive is best split up into two separate portions.In some cases additive S20 is not well mixed into the emulsion resulting in poor recovery. In those cases the addition of additive R and additive 849 (separate) yield better results. As a rule of thumb, in order to add three percent of organic soap, two percent of additive 849 and one percent of additive R (in this order) are added to the system. Back Back2Emulsifier-1E1也是一个重要的润滑成分，一般的它不大可能很大的增加，除非有不正常的添加，在实际生产中设法保持不低于2.5%即可。有两个添加剂都可以使用来调整E1，一是P-5，另一个是5653，5653增加后效果较强，但对PH值可能会降低，而P-5是经过中和的，对PH值没有影响。The present formula contains 3% of emulsifier-1. This concentration is seen as the right starting concentration. It is however possible that this compound will be raised during the early trial days, as emulsions in use at some other mills based on this chemistry are at 6%. When using FTIR, corrections are made at the moment that the concentration reaches 80% of the theoretical concentration. In the present case, this is at 2.4%. It is unlikely that the concentration of this component will exceed 100% unless an incorrect addition of additive P-5 has been done. However, because of the low concentration of active ingredient in this additive (16%), this is unlikely. The minimum limit for correction is:Minimum = 2.5% (80% rel.)As mentioned, corrections are done with at 16% emulsifier-1 solution in water. Corrections can be calculated using the spreadsheet. When the 80% level is reached, the rule of thumb for correction is 100 liters of additive P5, calculated for a 100 m3 system at 3% of oil. BackStability Particle size controlParticle size, hence emulsion stability, can be influenced by the following parameters: Depletion of emulsifiers (organic soap, emulsifier-1, and PEG-ester) Incorrect additions Tramp oil leakages Bacterial activity Conductivity increases Other contaminations (i.e. alkaline cleaners)Only in a limited number of cases tightening of emulsion can occur. These are: additions of too high quantities of one of the emulsifiers, the contamination by a foreign compound that acts as a tightening agent like alkaline cleaners, or the formation of ionized soaps as the result of the reaction between organic soap and a foreign contaminant. In all those cases, only a partial dump of 25-50% of the system volume can restore the required emulsion stability. In case of increasing particle sizes, yielding a too instable emulsion, corrective actions should be taken depending on the cause of the problem:Additive depletion: If the particle size increase can be brought in relationship to depletion of organic soap or emulsifier-1 being the two most important emulsifiers, these components need to be brought within specification following the rules as mentioned in the paragraphs above covering these specific compounds. After correction, the evolution of the particle sizes in time will indicate if further corrective actions are required.Tramp oil leakage: This is the most likely cause for increasing the particle size in rolling mills of the type at NEA. When tramp oil leakages are observed. Rolling must be stopped immediately and extended skimming is required until all free floating oil is removed from the emulsion tanks. If this step is omitted, the risk of taking up larger quantities of this oil cannot be neglected.In those cases where a quantity of tramp oil has been emulsified this could result in depletion of some or all of the additives and important viscosity changes. When the tramp consists of heavy gear oil or grease, significant viscosity increases will also be observed. In those cases where it concerns hydraulic fluids, only minor changes will occur as the tramp oil and rolling oil viscosities are close to each other. In all cases additive depletion will occur. As for T6356ZL, from experience it is seen that a selective depletion of organic soap is most likely due to mixing of this compound with the tramp oil. In every case all depleted additives must be corrected as soon as possible according to the rules mentioned above.In those cases where, besides eventual additive depletions, important viscosity increases are seen, corrections are made using T6356ZL-LV instead of regular neat oil to make the daily oil additions. If the above mentioned actions are insufficient to correct for rolling problems and short term actions are required,