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Cutting Oil / Treated Oil Sterlization and Purification Unit
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Description
Cutting oil is used for cooling down the heat generated in metal product processing and improving lubricating operation. If it is used for a long time, decay is caused by propagation of bacillus and bacteria. If bad smell is generated and cutting capacity is reduced because of decay, the machine shall be abolished.
Main cause of cutting oil abolition
1) Decay of cutting oil caused by microbe (bad smell).
2) Change of color caused by growth of microbe (milk-white→blue-grey and yellowish red)
3) Separation of oil content and reduction of anti-corrosive content (microbe grows, using anti-corrosive content as nutritive substance)
4) Others (chip removal, tank cleaning, reduction of productivity caused by deterioration, etc.)
Like the above, the microbes such as bacillus and bacteria grow, using oil content of cutting oil as nutritive substance, destroys unique content of cutting oil, generates bad smell, causes bacterial dermatitis or headache and deteriorates working environment and work efficiency. Moreover, it requires tremendous cost for waste treatment and causes increase of prime cost of product.
The cutting oil sterilization system that the company developed and registered patent for solving the problem is a mild oxygen generation system using low temperature plasma discharge generated in high frequency and low voltage. It will enable your company to achieve eco-friendly company management by sterilizing bacteria of cutting oil with powerful oxidization and deodorization, extending the lifespan of cutting oil through perfect oxidization and deodorization of the material generating bad smell, reinforcing competitiveness of company through the effect of reducing prime cost and improving productivity and reducing the amount of waste material and recycling cutting oil.
The principle to generate mild oxygen(ozone)
The principle to generate mild oxygen(ozone).
When electric discharge occurs in atmosphere, molecular oxygen(O2) is dissolved to atomic oxygen(O) and ozone is generated by the reaction of other molecular oxygen(O2) and atomic oxygen(O) 
Function of ozone
One of the best advantages of ozone is an outstanding oxidization of material. The oxidization capacity of ozone is about several thousand times of that of chlorine and its sterilization capacity is 3~6 times of that of chlorine. Although too surplus ozone is a little dangerous, it is clear that it is effective material in the earth.
The third atom of ozone, which is unstable because of weak unifying force, has a nature to be detached from molecular ozone so it is attached to other material and dissolves or oxidizes the material. At the same time, original molecular ozone is transferred to molecular oxygen. As blaze changes one material to other material by oxidizing organic material, ozone destroys molecule through oxidization process. It is no doubt about ozone's oxidization of organic material, purification of air and removal of bacteria, algae, fungi and bad smell. If ozone is used properly for the sterilization of water-soluble cutting oil, it will be very helpful.
Expected effect of sterilization&purification system
1) It reduces the cost to treat waste material generated in the abolition of cutting oil.
2) It reduces the cost to purchase cutting oil after replacement.
3) It improves work efficiency and productivity by preventing bad smell.
4) It improves facility operation ratio by reducing facility shutdown for replacing cutting oil.
5) It prevents diseases caused by bacillus and virus.
6) It improves working environment by generating an anion.
Experiment on bad smell removal and sterilization
1) The Research Institute of Industrial Technology: Cutting oil sterilization unit performance test. The purpose of cutting oil sterilization system is to remove and inactivate microbe, which is a cause of decay of cutting oil. The main cause of deteriorating the capacity of cutting oil is microbe so it is determined that the cutting oil can be used for a long time without replacement if the propagation of microbe is controlled continuously.
※ Experiment result It is found that it has an outstanding sterilization capacity and effect on the removal of bad smell. The microbe growing in cutting oil can be perfectly handled by cutting oil sterilization system and it is effective for removing bad smell, thus, it is expected that it will contribute to the improvement of working environment. Moreover, because cutting oil is continuously used by circulation, it is expected that the sterilization effect will be enlarged by aerating cutting oil.
< Sterilization and removal capacity of fungi and decay smell by contact time >
Bacillus type | Before contact | Removal ratio(%) | Contact time | Density of sterilization gas | Remarks |
| Colon bacillus | 105 CELL | 100 | 5 sec | 0.35 ppm | Microbe |
| Influenza virus | 105 CELL | 100 | 5 sec | 0.35 ppm | Microbe |
| Mold | 106 CELL | 100 | 20 min | 0.5 mg/l | Bacillus |
| Salmonella | 107 CELL | 100 | 10 sec | 0.5 mg/l | Bacillus |
| Ammonia NH₃ |
| No olfactory detection | 10 min | 0.9 mg/l | Smell of rotten mean |
| Sulfureted hydrogen H₂S |
| No olfactory detection | 5 min | 0.9 mg/l | Cutting oil |
| Trimethylamine(CH₃)₃N |
| No olfactory detection | 7 min | 1.2 ppm | Smell of rotten fish |
| 개전성 hepatitis virus | 105 TCD | 100 | 10 sec | 2.0 ppm | Microbe |
| Bacillus cereus | 105 TCD | 99.99 | 10 min | 2.0 ppm | Spore of bacillus genus |
| Aspergillus usami | 105 TCD | 99.99 | 10 min | 0.3~0.5 ppm | Filamentous |
| Candida paracreus | 105 TCD | 99.99 | 10 min | 0.3~0.5 ppm | Yeast fungus |
2) National Institute of Environmental Research: Sterilization experiment
Receipt No. | Item | Number of general bacillus(CFU/ml) | Remarks |
Min 33 | Cutting oil (before treatment) | 6.5 X 105 |
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Min 33 | Cutting oil (after treatment) | Non | |
Min 33 | Painting water (before treatment) | 6.5 X 105 | |
Min 33 | Painting water (after treatment) | Non |
Experiment on capacity change of cutting oil when using sterilization&purification system
1) The Research Institute of Industrial Technology :
Although ozone has a good sterilization and smell removal effect, if the basic property of cutting oil is changed, it may cause another problem. Therefore, in order to check whether the property of cutting oil changes after ozone treatment, the experiment is performed.
Experiment method: After pouring 15L of 5% diluted solution to 20L vessels, one vessel is stationed and another vessel is aerated for 24 hours. After that, property changes of cutting oil were compared and analyzed.
Result: After aeration using sterilizer, there was no change in capacity and property of cutting oil. It was found that there was no change in property of cutting oil in the results of IR analysis and experiment.
Category | 정치액 | After aeration | |
External view | Milk-white emulsion | No change | |
pH | 9.6 | No change | |
| Number of alive bacillus | Bacteria | No creation | No change |
Fungi | No creation | No change | |
Density of cutting oil ( Brix % ) | 5 | No change | |
Density of chlorine ion ( ppm ) | 12 | No change | |
Capacity of anti-corrosion | 1 hour | No corrosion | No change |
2 hour | No corrosion | No change | |
3 hour | No corrosion | No change | |
6 hour | No corrosion | No change | |
12 hour | No corrosion | No change | |
2) Cutting oil manufacture company : B Chemical It showed good result in comparative experiment that sterilizes undiluted solution of cutting oil and decayed cutting oil with mild oxygen.
Experiment method: After pouring 15L of 5% diluted solution to 20L vessels, one vessel is stationed and another vessel is affected by ozone generator for 24 hours. After that, property changes of cutting oil were compared.
3) Cutting oil manufacture company : S Oil If the propagations of fungi and bacteria are suppressed in water-soluble cutting oil, the lifespan of cutting oil increases to the degree that it can be maintained just by adding oil.
Additives of water-sooluble cutting oil
Base oil : The oil for manufacture of cutting oil
Emulsifying agent : The additive for emulsifying base oil in water
Anticorrosive : The additive for preventing rust
Extreme pressure agent : The additive for endowing the property of extreme pressure.
Anti abrasive agent : The additive for endowing tool with the property of anti-abrasion .
Antifoaming agent : The additive for preventing foam of cutting oil .
Coupling agent : The additive for harmonizing other additives.
Sterilizer The additive for killing bacteria and fungi
Other additives
Category | ISFO - SI | ISFO - TW | ISFO - CF | ISFO - SM |
Rating | AC 220(440) V | AC 220(440) V | AC 220(440) V | AC 2209440) V |
Current | 0.2 A | 0.3 A | 0.2 A | 0.2 A |
Frequency | 60 Hz | 60 Hz | 60 Hz | 60 Hz |
Rating power consumption | 60 W | 100 W | 250 W | 60 W |
Generation | 0.4 g/hr | 0.4 g/hr x 2 EA | 0.4 g/hr | 0.4 g/hr |
Density of ozone | 0.02~0.03 ppm | 0.02~0.03* ppm | 0.02~0.03 ppm | 0.02~0.03 ppm |
Sterilization capacity |
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Size |
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| Weight | 60 kg | 70 kg | 80 kg | 5 kg |
① Sterilization capacity can be adjusted by installation condition.
② The size of mild oxygen generator can be adjusted by applied facility.
③ Warranty period: 1 year
When central cutting oil tank is installed
In the factory using a lot of cutting oil, contaminated cutting oil is collected one or several places in order to separate foreign matter and metal chip from cutting oil and it is stored in the tank for the supply to facility.
In this case, the cutting oil sterilized in tank is supplied to each working place.
The artificial ozone generated by ozone generator is injected to tank directly. Therefore, the facility is proper for large-sized factory.
When central cutting oil tank is not installed
In several factories, central tank is not installed or can't be installed because of the problem caused by insufficient space or various types of cutting oil.
In this case, ozone sterilizer is installed by the side of each metal processing machine
Contaminated cutting oil is adsorbed by adsorption pump installed in sterilizer and then it is supplied to small-sized sterilizing chamber Adsorbed cutting oil is sprayed with ozone in sterilizing chamber.
In the facility, adsorption pump, sterilizing chamber and ozone generator operates like the facility attached to machine tool.