YOUR VERSATILE PARTNER IN CHEMISTRY
High Performance Chemicals for Lubricants
Ketjenlube TM / POLYMERIC - SYNTHETIC AND NATURAL ESTERS Dapral TM / ASA - PIBSA - ASI - PIBSI Dapramid TM / FATTY ACID AMIDES Dapraphos TM / PHOSPHITES - PHOSPHONATES - PHOSPHATES Dapralube TM / OLEOCHEMICALS Rhodafac TM ASI / CORROSION INHIBITORS Dapraquest TM / SEQUESTERANTS
History of the Company
Italmatch Chemicals S.p.A is a global specialty chemicals company, leader in polymeric, natural, synthetic and complex esters and in its traditional sector of organic and inorganic phosphorus derivatives. Italmatch Chemicals Group has a strong international and global presence with more than 80% of production being exported. The company’s strategic and long term focus is mainly in the lube oil, water & oil and plastic additives markets, with six manufacturing sites in Europe (Spoleto, Naples and Arese in Italy, Zaragoza in Spain, Frankfurt in Germany and Newport in UK); two in US and four in Asia-Pacific. The Group is particularly committed to the Asian market growth, leveraging also on its historical access to China, with established local manufacturing and regional Asia Pacific marketing presence. The Arese lubricant product portfolio includes Ketjenlube Polymer Esters, Synthetic and Fatty Acid Esters, Amides, Fatty Acid Chlorides and ASA/PIBSA, as well as organic Phosphorus derivatives. In Spain the Group manufactures Oleochemicals. Water soluble Phosphonates are manufactured in UK and US. The Arese site is located near Milan, in northern Italy. Various reactors (glass lined and stainless steel) of different sizes allow highest flexibility in production planning with additional capacity for optimization and expansion. Core technologies/competences include, among others, polymerization, esterification, chlorination, amidation and “ene” thermal condensation. A consistent high product quality is ensured by a team of experienced and skilled people, with particular focus on joint product and technical development with Customers/Partners. Arese site has a fully equipped applicative laboratory to screen and test product performance. The Arese site is certified ISO 9001:2008 and ISO 14001:2004 and participates in the Responsible Care program. The plant maintains Halal and Kosher certifications for manufacturing of a range of food grade polymeric esters. The Zaragoza site has integrated acid raw materials and natural esters manufacturing (using renewable raw materials).
2
Chemicals for Lubricants Trade Name
Main Feedstocks
Chemistry
Chemical Name
Function(s)
Dapraphos TM
PCl3 / H3PO3
Esterification
Phosphite esters
Antiwear (AW)
Phosphate esters
AW/CI/Co-Emulsifier
Phosphonic acid
Corrosion Inhibitor
Phosphonates
Sequesterant
Di-esters
Synthetic Base stock
Rhodafac TM ASI Dapraquest
POCl3 / P2O5
TM
Ketjenlube TM
Alcohols
Dapralube TM
- renewable sources
Polyol Esters
- petrochemical sources
Complex Esters
Esterification
(Lubricity Additive) Synthetic Base stock (Lubricity Additive) Lubricity Boundary Additive Dapramid TM
Ammonia
Amidation
Amides
Friction Modifier (FM)
Ketjenlube TM
Olefins, Alcohols
Polymerization
Ester Copolymers
Synthetic Base stock
Unsaturated Diesters,
(Lubricity Additive)
Maleic Anhydride Dapral TM PA
Maleic Anhydride,
Condensation
ASA/PIBSA
Emulsifier
ASI/PIBSI
Dispersant
Olefins, reactive PIB Dapral TM Pl
Dapral PA, Amines
3
Ketjenlube Polymer Ester
GENERAL INFORMATION >> Ketjenlube Polymer Esters are unique, patented specialty components used in the formulation of synthetic and semi-synthetic high performance lubricants in both Automotive and Industrial fluids. They reduce wear much more efficiently than other conventional synthetic base fluids. This feature has made Ketjenlube Polymer Esters an important tool in the lubricating oil area during the last decade and even today are still finding new applicative uses due to their unique properties.
CHEMISTRY >> Ketjenlube Polymer Esters are ester copolymers. The product viscosities range from 15 cSt up to 3000 cSt at 100°C. As the average molecular weights (Mw) do not exceed 10,000 Dalton, even the highest viscous Ketjenlube Polymer Esters are very shear stable. Structurally Ketjenlube Polymer Esters can also be regarded as functionalized polyalphaolefins.
4
Properties >> Compatibility attributes: Ketjenlube Polymer esters are available in different polarities and are fully compatible with a wide variety of mineral base stocks Group I, II and III Base Oils, PAO both light and heavy grades. >> Outstanding inherent lubricity: Ketjenlube Polymer Esters exhibit one of the highest load carrying capacities compared to most other lube oil base fluids available in the market. >> High VI and shear stability: Ketjenlube Polymer Esters are able to perform consistently under high pressure and temperature regimes without losing their original properties. >> Very high oxidative stability and film strength: This makes Ketjenlube Polymer Esters the best choice as high performance additives for cutting oils enhancing lifetime and reducing corrosion potential of the product.
>> Powerful synergy with AW/EP Additives: This makes it possible to replace e.g. chloro-paraffins in metal working fluids by a combination of Ketjenlube Polymer Esters and sulfur/phosphorus additives without losing EP-performance. >> Superior hydrolytic stability: Ketjenlube Polymer Esters enhance/extend the lifetime of emulsions and are recognized as some of the most hydrolytically stable esters available for metal working fluids (soluble oils). >> Clean burning, clean evaporation and low volatily: Ketjenlube Polymer Esters burn or evaporate at high temperatures without giving rise to smoke, hazardous fumes and carbon residues. This allows the formulation of low smoke two-stroke engine oils or industrial oils for high temperature applications. >> Excellent Seal Compatibility: Ketjenlube polymer esters demonstrate neutrality to slight swelling character to the common seal materials when used as a base fluid which offers the advantage of no requirement for ester seal swelling agents when used together with PAO or Group III base oils.
Idealized structure of Ketjenlube Polymer Esters
5
Ketjenlube Polymer Ester Product Overview
Physical and chemical
Method
characteristics
KL
KL
KL
KL
KL
KL
115
135
165
1300
215
230
Medium/High Polar Products
Viscosity at 100°C (mm²/s)
ASTM D-445
15
34
65
260
16
30
Viscosity at 40°C (mm²/s)
ASTM D-445
115
340
770
4100
120
280
Viscosity index
ASTM D-2270
135
139
152
190
140
140
Pour point (°C)
ASTM D-97
-30
-39
-30
-21
-27
-33
Flash point (°C)
ASTM D-92
250
250
255
260
250
250
Acid Number (mgKOH/g)
ASTM D-974
0.4
0.2
0.3
<0.1
0.3
0.3
Density 20°C (g/cm³)
ASTM D-1217
0.93
0.96
0.98
0.99
0.92
0.94
Colour Gardner
ASTM D-1544
< 1
< 1
< 1
< 1
< 1
< 1
Oil phase
1.69
0.54
0.62
0.73
0.52
0.69
Water phase
0.75
0.27
0.45
1.1
0.54
0.24
Weight loss (%)
6.35
5.8
4.75
4.3
5.3
5.0
Viscosity Ratio
5.0
5.0
4.8
4.0
5.0
4.4
Pure Ketjenlube
30
31
20
20
35.6
33.7
10% KL in 150 N oil
89
88
89
90
96.1
90.2
Applicational DATA Volatility Noack (%)
ASTM D-5800
Hydrolytic Stability
ASTM D-2619
(Acid Number as mgKOH/g After 48 h)
Thermo-Oxidative Stability
IP 48
(200°C; 12h; 15 Liter Air/Hour)
Lubricity (% wear area; 150 N oil = 100%)
Seal Compatibility
6
Reichert
CEC-L-39-X-95
KL
KL
KL
KL
KL
KL
KL
240
2500
2700
3100
3300
3700
23000 305
KL
KL
KL
KL
445
445 VLP
522
KETJENLUBE POLYMER ESTERS LOW POLAR (PAO COMPATIBLE)
Water soluble/Emulsifiable Products
40
500
700
94
350
700
3000
5.5
-
-
-
400
7000
11000
990
5200
11000
43000
30
500
400
2200
160
230
250
174
220
250
300
140
-
-
-
-6
-9
-21
-21
-24
-9
n/a
-42
-24
-21
-18
260
270
270
260
>240
270
270
230
220
230
180
0.1
0.1
<0.1
0.5
<0.3
< 0.1
0.3
1.2
10
7
60
0.93
0.93
0.96
0.93
0.95
0.96
0.92
0.93
1.06
1.05
<1
< 1
< 1
< 1
<1
< 1
< 1
<1
6
4
2
1.2
1.4
1.4
1
-
-
-
-
-
-
-
0.44
0.2
0.28
0.21
0.4
0.18
0.12
-
-
-
0.46
0.33
0.18
0.17
0.52
0.14
0.25
-
-
-
4.15
2.6
3.45
3.15
3.5
3.7
3.50
-
-
-
4.0
2.8
1.6
3.2
2.16
1.5
0.72
-
-
-
28
6
12
17
6
5
11.0
19.4
19.7
17.2
93
87
90
92
89
90
-
-
-
-
NEUTRAL
SLIGHTLY SWELLING
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Ketjenlube Polymer Esters Applications
TWO-STROKE ENGINE OILS The high inherent lubricity together with their clean burning make the Ketjenlube Polymer Esters an ideal base fluid for two-stroke motor bike engine oils. The ISO-L-EGD results of four different formulation examples (semi-synthetic, synthetic, high solvent oils) containing Ketjenlube Polymer Esters as ester component are:
OIL
1
2
3
4
Type
Synthetic;
Synthetic
Semi
Semi
Synthetic
Synthetic
High Solvent Composition (wt %) Ad-pac A
/
/
5.2
/
Ad-pac B
9.3
/
/
5.2
Ad-pac C
/
5.2
/
/
Polyisobutylene
40.7
49.8
30
30
Ketjenlube 305
/
25
15
/
Ketjenlube 135
/
/
/
10
Ketjenlube 115
15
/
/
/
150 SN mineral oil
/
/
/
30
600 SN mineral oil
/
/
34.8
10
Solvent
35
20
15
14.8
8.8
9.6
9.5
9.5
Viscosity 100°C (mm /s) 2
ISO-L-EGD-Engine Test Results: - Exhaust smoke index
193
172
85
89
116
100
103
97
98
100
102
100
Not Determined
Not Determined
105
108
- Detergency index 3 Hours (GD limit: 125 min)
135
137
125
Not Determined
Exhaust port blocking index (FC limit: 90 min)
210
111
110
125
(FC limit: 85 min) - Lubricity index (FC limit: 95 min) - Torque index (FC limit: 98 min) - Detergency index 1 Hour (FC limit: 95 min)
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Ketjenlube Polymer Esters Applications
FOUR-STROKE ENGINE OILS Special performance needs for 4T Motor Cycle Engine Oil’s need to satisfy requirements of: Engine, Gear Box & Clutch. > > > > > >
High temperature piston cleanliness Thermal & Oxidative stability Higher HTHS viscosity Engine durability Superior clutch friction Strong gear Pitting/Wear performance.
Synthetic 10W-30 Oil with Ketjenlube 135 Formulation Details.
Meeting new JASO MA2 - 2011 Specification. Added value to customers: >> Fuel economy – 10W/30 & lower viscosity grades + low shear. >> Lower oil consumption due to low Noack volatility. >> Longer Oil Drain Intervals.
Test Results
COMPONENT
Wt%
Tests RESULTS
Method
Results
250 N Grp III (Ultra S8)
79.4
Viscosity @ 40°C, cSt
ASTM D 445
65.7
KETJENLUBE 135
9
Viscosity @ 100°C, cSt
ASTM D 445
10.2
Add Pack
10
Viscosity Index improver
1.3
Viscosity Index
ASTM D 2270
141
POUR POINT DEPRESSANT
0.3
HFRR (100C,50Hz,1000g,60 mins)
ASTM D 6079-M
Friction Coefficient
0.098
Wear Scar (mm)
0.46
Film Thickness (%)
84.9
Oxidation Stability (121°C, 312 h)
ASTM D 2893
KV@100°C Increase (%)
0
Acid number increase
0.38
(mgKOH/g) CCS -25°C, mPas (7000 max)
ASTM D 5293
5900
HTHS @ 150°C, cP (2.9 Min)
ASTM D 5481
3.25
JASO T 903 – 2011 Engine Test
MA2
PASS
DFI
2.08
≥1.85 & <2.5
SFI
1.87
≥1.7 & <2.5
STI
1.95
≥1.85 & <2.5
Results:
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Ketjenlube Polymer Esters Applications
AUTOMATIVE GEAR OILS The two high viscous Ketjenlube Polymer Esters Ketjenlube 23000 and Ketjenlube 2700 are tailor made for application in gear oils and are cost effective alternatives to higher viscosity polyalphaolefins. Besides their superior load carrying capacity they exhibit; >> >> >> >> >>
Excellent thermo-oxidative and hydrolytic stability. Shear stability. Compatibility with non-polar base stocks and polar additives. Excellent viscosity characteristics at low temperatures. Improved film strength enhancing micro-pitting performances
FORMULATION GUIDELINE
KL2700
Viscosity Grade
75W-140
Composition (wt %)
KL23000 75W-90
PAO 100 75W-90
PAO 40 75W-90
Ketjenlube 2700
50.5
Ketjenlube 23000
30
PA0 100
45
PA0 40
58
PA0 4
30
60
30
10
Di-Ester (Adipate)
9.5
15
15
10
10
10
17
Ad-Pac with Anti-Foam Performance Data
Viscosity 100°C (cSt)
24.3
14.8
15.1
14.9
Viscosity - 40°C (mPas)
125500
29400
57500
56800
Appearance (-15°C) Copper Corrosion ASTM D 130
HOMOGENEOUS, CLEAR 1a
1a
1a
1a
4.7
1
0.7
Shear loss After 20 h (%)
<1
CEC L-45-T93 GFC-Oxidation Test CEC L-48 -A-95 (160 DC, 192 h);
Acid Number After Test (mgKOH/g)
0.45
1.2
1
1.1
Viscosity Increase (%)
32
51
47
40
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Ketjenlube Polymer Esters Applications
INDUSTRIAL GEAR OIL
formulation GUIDELINE
Experimental Product Ketjenlube 2700/PAO 6
Commercial Product PAO/Ester based
Patented Product
Composition (wt %)
PA0 6
53.5
Proprietary
10.5
PA0 40
/
Proprietary
80
TMP-Ester
/
/
8
Ketjenlube 2700
45
34
/
Ad-Pack
1·5
Proprietary
1·5
Physical Properties
Viscosity 40°C (cSt)
219.6
218
221.1
Viscosity Index
172
175
149
Flash Point (°C)
265
265
260
Pour Point (°C)
-48
-46
-50
Performance Tests
Copper Corrosion Test ASTM D 130 (3 H, 100°C)
1B
1A
1B
Rust Preventing Characteristics ASTM D 665 Procedure A and B
Pass
Pass
Pass
Oxidation Test ASTM D-2893 (121°c, 312 H) -> Viscosity Increase (%)
3.54
3.80
3.80
Water Separation ASTM D1401 @T°
42-38-0 (45)
Not Determined
40-40-0 (30)
Foaming Characteristics ASTM D892
Sequence I: 0/0
Sequence I: 0/0
Sequence I: 30/0
Sequence II: 20/0
Sequence II: 60/0
Sequence II: 60/0
Sequence III: 0/0
Sequence III: 10/0
Sequence III: 30/0
Four-Ball Test ASTM 2783
LWI: 51,1 Weld Load: 250 Kg
LWI: 64,2 Weld Load: 250 Kg
LWI: 53,2 Weld Load: 250 Kg
Falex Pin&Vee Test ASTM D2670; Wear Teeth
1
3
1
11
Ketjenlube Polymer Esters
High Viscosity Ketjenlube IN WIND TURBINE OILS Proven alternative to PAO/ester based EP-gear Oils: >> Synergy with AW/EP-additives >> Lower peak temperatures under high load >> Long term stability: (Oxidative, hydrolytic, shear and thermal) >> Improved additive compatibility >> Improved micro pitting performance >> Higher durability. >> Use in Off-shore wind turbines. >> No need for ester solubilizers. Recommended grades: Ketjenlube 2700, 3100 and 3700 Various OEM approvals (e.g. Flender, wind turbine manufacturers) >> Cost competitive versus PAO 40/PAO 100
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Ketjenlube 2700 versus PAO 40 PERFORMANCE IN ISO VG 220 INDUSTRIAL GEAR OIL COMPOSITION (wt %)
Ketjenlube Fluid
Reference Fluid
Ketjenlube 2700
42
/
Polyalphaolefin 40
/
80.6
Polyalphaolefin 6
56.6
10.5
TMP C-8/10 Ester
/
7.5
Additive Package A (Plus Antifoam)
1.4
1.4
PERFORMANCE TESTS
Viscosity 40°C (cSt)
220
221
Oxidation Test ASTM D-2893 (121°C, 312h)
+ 3.5
+ 26
40-40-0 (45 min)
40-40-0 (45 min)
Viscosity Increase (%) Demulsibility Test ASTM D-1401 (121°C) Oil-Water Emulsion (ml) Demulsibility Test ASTM D-2711 (82°C) Water in Oil (ml)
0.4
0.3
Free Water (ml)
87
87
Emulsion (ml)
0
0
0
30-0
Foam Test ASTM D-892 Sequence I (ml)
Sequence II (ml)
50-0
60-0
Sequence III (ml)
0
30-0
4-Ball Test ASTM D-2783
Weld Load (Kg)
200
200
Load Wear Index
51.6
53.2
Copper Corrosion ASTM D 130
1A
1B
Rust Prevention ASTM D 665
PASS
PASS
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Ketjenlube Polymer Esters
Ketjenlube 240 in FOOD GRADE INDUSTRIAL GEAR OILS Provides: >> >> >> >> >>
Superior wear protection and stability (clearly exceeding DIN 51517-3) Low in colour even after ageing Complete elastomer compatibility Complete formulation with full proof of performance available All compounds of the formulation are NSF-approved as H-1 and HX-1
Ketjenlube 240 has been specially designed for the use in premium food-grade lubricant formulations (H1 lubricants) in combination with very low polar components like high viscosity Polyalphaolefins or Polyisobutenes. Ketjenlube 240 significantly improves the lubricity and friction characteristics in lubricants for food-grade applications such as:
• • •
Industrial gear oils; Chain lubricants (esp. for higher temperature applications); Greases
erformance of Ketjenlube 240 in a Food-Grade P Industrial Gear Oil (ISO 220 Grade; meeting DIN 51517-3) Formulation
Composition (wt %)
Ketjenlube 240 PAO 40 PAO 8 Additin RC 9330* Foam Ban 159*
13.5 64.5 20.5 1.5 0.0075
14
Foaming ASTM D 892 Sequence I (ml) Sequence II (ml) Sequence III (ml)
Copper corrosion ASTM D 130 (100°C, 3h) Steel corrosion ASTM D 665 (proc. A) max. load stage
FE 8 test E DIN 51819-3
wear loss bearing rollers (mg) wear loss bearing cage (mg)
Oxidation test A STM D-2893 (121°C, 312 h); Viscosity increase (%)
Elastomer compatibility (NBR, 168 h, 100 °C)
Analytical Results:
Viscosity 40°C (cSt) Viscosity 100°C (cSt) Viscosity index Pour point (°C) Flash point (°C) Water content (ppm)
Demulsibility ASTM D 1401 (82°C)
FZG-test (A/8.3/90);
*Additin and Foam Ban are registered trademarks of Rhein Chemie and Muenzing GmbH, resp.
Test method
Test method
Result
Limits according to DIN 51517-3
227 26.7 151 -33 274 100
198 - 242 90 -9 max. 200 min. 1000 max.
Volume change (%) Hardness change (shore A) Tensile strength change (%) Elongation break change (%)
Result
Limits according to DIN 51517-3
41-39-0 (10)
40-37-3 (30)
10/0 0/0 50/0
100/10 100/10 100/10
1a
1b max.
pass
pass
>12
12 min.
2.1 19.9
30 max -
3.4
6 max
0 -1 -3 -17
0/+10 max. -10/+5 max. -30 max. -40 max.
Ketjenlube High Performance Esters Metal Working Fluids
Ketjenlube Polymer Esters are used commercially in a wide range of metal working applications at treat levels of between 5% to 25% depending on the application and metal being machined: >> >> >> >>
In neat oils In water-miscible fluids (soluble oils) For metal cutting operations (e.g. broaching, tapping, milling) For metal forming operations (e.g. rolling, drawing, stamping)
The performance of Ketjenlube Polymer Ester containing fluids is further increased when combined with Anti-wear/EP agents, so enabling high performance formulations to be made which are characterized by: >> High film strength for good tool life and surface finish especially on hard metals; >> Reduction in mist generation especially in neat oil applications; >> Low carbon residues in post annealing operations in forming applications (stamping, drawing); >> Oxidative stabillity preventing corrosion, maintaining flash point and reducing shear in high pressure applications; >> Enhanced hydrolytic stability, improving long term stability of the product and maintaining cutting performance; >> Biological resistance reducing bacterial degradation of the ester component so enhancing the stability of an emulsion over extended periods thereby enhancing tool life and surface finish. Ketjenlube high performance esters have the added advantage of: >> Superior compatibility with Grp I, II, III and other highly refined base oils. >> Favourable toxicological profile. >> Versatility in a wide range of conditions and applications. Italmatch Chemicals has invested extensively in the capability to evaluate the performance characteristics of the Ketjenlube Polymer esters in both laboratory based and external customer orientated application tests. Within the Italmatch application laboratory the use of recognized performance test equipment such as Four-Ball, Reichert, Pin & Vee Block Falex, MICROTAP, CNOMO and Anton Paar Rheometer is creating a further detailed understanding of the application of the complete product range and differentiation of the existing and newly developed products.
15
Ketjenlube Polymer Esters
EXCELLENT
GOOD
NEUTRAL
Applications
CHEMISTRY
Ketjenlube Ketjenlube Ketjenlube Ketjenlube
115 135 165 1300
Polymeric Esters
LUBRICITY ENHANCER
EMULSIFIER
CORROSION INHIBITOR
EP/AW ADDITIVE
KEY CHARACTERISTICS - UNIQUE LUBRICITY PERFORMANCE; - VERY CLEAN BURNING; - HIGH ACTIVITY EVEN AT LOW TREAT RATES; - PROVEN SYNERGISTIC EFFECT WITH EP/AW ADDITIVES.
Superior Tool wear performances compared to Conventional Esters on steel
16
Ketjenlube Polymer Esters
EXCELLENT
GOOD
NEUTRAL
Applications
CHEMISTRY
Ketjenlube 445 Ketjenlube 445 VLP Ketjenlube 522
Ethoxylated Polymeric Esters
LUBRICITY ENHANCER
EMULSIFIER
CORROSION INHIBITOR
EP/AW ADDITIVE
KEY CHARACTERISTICS - WATER DISPERSIBLE/SOLUBLE; - SUPERIOR LUBRICITY PERFORMANCE; - WIDE TEMPERATURE RANGE STABILITY; - ALTERNATIVE OPTION TO PAG CHEMISTRY; - PROVIDES CO-EMULSIFYING PROPERTIES.
Proven tool wear performance on aluminium machining (KL 445)
17
Ketjenlube Polymer Esters
EXCELLENT
GOOD
NEUTRAL
CHEMISTRY
Ketjenlube Ketjenlube Ketjenlube Ketjenlube
9350 9360 9450 9505
Complex Esters
Applications LUBRICITY ENHANCER
EMULSIFIER
CORROSION INHIBITOR
EP/AW ADDITIVE
KEY CHARACTERISTICS - VERSATILE MULTIFUNCTION ADDITIVES; - LUBRICITY ENHANCERS WITH EMULSIFYING PROPERTIES; - ANTI RUST PROPERTIES IN BOTH NEAT AND WATERMIX FLUIDS; - LOW FOAMING; - ACIDIC FUNCTIONAL GROUPS REQUIRE NEUTRALISATION IN WATERMIX FLUIDS.
CHEMISTRY
Ketjenlube 2715 S
Sulphured Polymeric Ester
KEY CHARACTERISTICS - UNIQUE EXTREME PRESSURE PERFORMANCE; - ADEQUATE ALTERNATIVE TO CHLOROPARAFFIN CHEMISTRY; - LIGHT IN COLOUR AND EXHIBITS LOW ODOUR; - SULPHURIZED ADDITIVE ADAPTED FOR MULTI METAL APPLICATIONS.
THE TYPICAL “ACTIVE SULFUR” CONTENT IS 15%
18
Applications LUBRICITY ENHANCER
EMULSIFIER
CORROSION INHIBITOR
EP/AW ADDITIVE
Ketjenlube 2715 S Functionalised Ketjenlube
Niche functionalized polymeric esters using a sulphur source to combine the benefits of the Ketjenlube polymer esters, their compatibility with a wide variety of commonly available base oils. This offers formulators the added benefit of developing low mist and high load carrying performance neat oils. Pale in colour and low in odour this sulphured ester provides all the attributes of being oxidatively stable and shear resistant for use in modern high pressure/speed CNC machines found in to-days machine shops. Another advantage to be gained is the inactivity towards certain metals: stainless alloys, copper and other yellow metal alloys. CHARACTERISTICS
METHOD
KL 2715S
APPEARANCE
VISUAL
CLEAR YELLOW LIQUID
COLOUR
ASTM-D-1500
L 3.0
VISCOSITY. @ 40°C, cSt
ASTM-D-7042
665
SPECIFIC Gravity @ 29.5°C, g/cc ASTM-D-7042
0.988
SULPHUR, %
15
INTERNAL
PERFORMANCE TEST CU. CORROSION
ASTM-D-130-M @ 120°C, 3HRS
WELD LOAD, Kg
SOLUBILITY*
3% IN 150SN GR I
1b
3% IN 500N GR II
1b
3% IN 250N GR III
1b
ASTM-D-2783 5% IN 150N GR II
400
10% IN 150N GR II
500
INTERNAL 5% IN 150SN GR I
BRIGHT & CLEAR
5% IN 500N GR II
BRIGHT & CLEAR
5% IN 250N GR III
BRIGHT & CLEAR
* Base stock origin dependent
19
Dapral PIBSA Pibsa can be used in various emulsification systems and could be further reacted with alcohols, glycols, amines and alkanolamines to obtain further functionalities : Biostability, Emulsifying properties, Base oil / Diluent free, Chemical intermediate (PIBSI, PIBSE) All Dapral PA grades are produced via a Chlorine free process, diluent free and can be supplied in various molecular weights which allows formulator greater flexibility
EXCELLENT
GOOD
NEUTRAL
Applications
CHEMISTRY
DAPRAL PA 450 DAPRAL PA 750 DAPRAL PA 1000
PIBSA
LUBRICITY ENHANCER
EMULSIFIER
CORROSION INHIBITOR
EP/AW ADDITIVE
KEY CHARACTERISTICS - HIGH LEVELS OF EMULSIFYING PROPERTIES; - HARD WATER STABILITY IMPROVER; - SUITABLE ALTERNATIVE TO SULPHONATES; - CHLORINE FREE MANUFACTURING PROCESS.
TYPICAL PHYSICAL PROPERTIES
DAPRAL PA 450
DAPRAL PA 750
DAPRAL PA 1000
Item
Test-Method
Appearance
Visual
Clear Amber Liquid
Clear Amber Liquid
Typical Value Clear Amber Liquid
Viscosity 100°C (cSt)
ASTM D-445
75
340
520
Saponification
in-house
140
115
90
in-house
95
65
Number Acid Number
60
Sediments
in-house
< 0.05%
< 0.05%
< 0.05%
Colour Gardner
ASTM D-1544
15 MAX
10
10
Best Emulsification
Best Overall Properties
Best Defoaming Power
Performance Rating
Properties
PIBSA are increasingly used in Metalworking fluids (soluble oils), where they can be used together with other co-emulsifiers as an economic alternative to sulfonates. Separate detailed information related to the application of all of these additive groups within MWF formulations are available upon request
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Dapraquest Sequestering Agent
Italmatch Dapraquest® is offering a unique specialty additive to meet the needs of hard water soluble applications involved in water based MWF’s. This new product, Dapraquest® 1513 is a build on the well-known conventional sequestering products for example, Dequest® 2016 and Dequest® 2066.
Dapraquest® 1513 offers higher thermal stability and excellent calcium dispersing properties, preventing buildup of hard water soaps whilst not compromising other aspects such as foaming nature and/or corrosion. The mechanism of performance stems from the formation of soluble complexes there by limiting the formation of calcium and/or magnesium soaps, one of the prime reasons for break down in a soluble oil’s primary emulsifying system.
The Dapraquest® phosphonate here is basically used as chelating agent in the MWF formulation. A typical dosage of 0.2% to 0.5% to control particularly water hardness (Ca2+ and Mg2+). If the water hardness is high like 250-1000 ppm as CaCO3; then dosage of 0.5% - 1.0% would be recommended.
Italmatch is continuously developing new molecules in this area to fit customer needs and experimental grades can also be proposed if required.
Please contact our technical team for selection of the product that will best fit into your formulation.
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Ketjenlube Polymer Esters Applications
GREASE Ketjenlube Polymer Esters are used commercially in semi-synthetic and synthetic greases. They do significantly improve the AW/EP-properties without disturbing the grease texture. Four-ball endurance test of a lithium soap grease with and without Ketjenlube 135 (load 2000 Newton).
The synergistic AW/EP effect of Ketjenlube 135 helps to absorb the frictional forces, resulting in lower peak temperatures and a longer grease life
In Addition Greases formulated with Ketjenlube Polymer Esters show significantly increased ageing resistance even in the presence of iron. For more detailed information and test results about the use of Ketjenlube Polymer Esters please refer to the data-leaflet Ketjenlube Polymer Esters in Greases
22
MELAGARD Solid Lubricant
MELAGARD MELAGARD is a salt of melamine and cyanuric acid. It is a non-toxic additive during its life cycle. It is easy to handle, non-hazardous, recyclable and biodegradable. The use of MELAGARD in greases has been developed in Japan around 30 years ago, and there are known uses in Japan and the USA. A lubricant containing MELAGARD is effective for use in high-temperature, in high pressure atmospheres, or places where black-color producing contamination is not desired, or in metal working, cutting or grinding of metals. MELAGARD is not only a solid lubricant but also as an agent to thicken liquid lubricants.
MAJOR GREASE APPLICATIONS • • • •
NLGI grades from 0 to 2; High temperature greases; Greases used in moist environments; Metal soap, bentonite, polyurea or other synthetic base stock thickened greases
More details are available on request
23
Ketjenlube Conventional Esters
In addition its high quality Ketjenlube polymeric esters, Italmatch Chemicals is offering also other synthetic and natural esters under the Ketjenlube trade name
Trade Name
Description
Colour
Acid Value
KV@40°C
KV@100°C
Gardner
mgKOH/g
cSt
cSt
Viscosity Index
Pour Point
Flash Point
°C
°C
Reccomended Application
Ketjenlube 09
Dimer Ester
7
0.07
94
13
145
-57
280
Two-Stroke; MWF
Ketjenlube 10
Polyol Ester
2
0.07
22
4.4
-
-48
250
Automotive & Industrial Lubes
Ketjenlube 15
Dibasic Acid Ester
<1
0.05
27
5.35
138
-63
235
Ketjenlube 16
Dibasic Acid Ester
<1
0.08
14
3.7
149
-75
230
Ketjenlube 19
Dibasic Acid Ester
4
0.1
18
4.5
162
-75
240
Auto Gear Oils
Ketjenlube 63
PE Ester
300 (Apha)
0.05 Max
32
5.5
115
<-54
>210
Refrigeration
Ketjenlube 64
PE Ester
5
0.15 Max
67
9.5
>105
-42
>240
Refrigeration
Ketjenlube 66
PE Ester
500 (Apha)
0.15 Max
46
6
>110
<-48
>240
Refrigeration
Ketjenlube 67/100
PE Ester
<5
0.15 Max
150
15
>90
<-30
>250
Refrigeration
Ketjenlube 68
PE Ester
<5
0.15 Max
220
19
>100
<-20
>250
Refrigeration
Ketjenlube 72
Trimellitate Ester
50 (Apha)
0.1 Max
306
20.2
70
-20
270
Ketjenlube 73
Trimellitate Ester
50 (Apha)
0.1 Max
50
8
118
< -45
270
Ketjenlube 75
Trimellitate Ester
50 (Apha)
0.1 Max
88.5
9
88
< -40
>240
Ketjenlube 76
Trimellitate Ester
50 (Apha)
0.1 Max
45
7
117
< -40
> 241
Ketjenlube 77
Trimellitate Ester
50 (Apha)
0.1
143
13
83
-25
260
Ketjenlube 78
Trimellitate Ester
<150 (Apha)
0.1 Max
52
8
120
<-54
>230
Ketjenlube 83
Polyol Ester
5
0.1 Max
380
25
86
-21
280
Other viscosity available on request
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Biodegradable Hydraulic (Gear Oils)
High Temperature Lube Applications Chain Oils and greases
Ketjenlube Complex Esters
Italmatch offer a range of Complex Esters which can provide high viscosity range with • Excellent low temperature performance • Good thermal stability • Strong Thick Film
Trade Name
Colour
Acid Value
Gardner
Ketjenlube 39
8
Ketjenlube 9350
Viscosity Index
Pour Point °C
°C
140
-54
280
Reccomended Application
KV@40°C
KV@100°C
mgKOH/g
cSt
cSt
0,3 Max
135
18
8
50
1 000
100
180
-33
270
MWF
Ketjenlube 9360
6
46
1000
100
180
-30
270
MWF
Ketjenlube 9450
9
30
2200
180-220
210
-21
260
MWF
Ketjenlube 9501
7
0.5
380
39
150
-42
> 300
Industrial Lubes
Ketjenlube 9503
7
0.5
1650
125
170
-33
> 300
Ketjenlube 9505
5
0.5
45 000
2 000
250
/
> 300
MWF forming & engine oils
Flash Point
Two-Stroke, MWF
25
DAPRALUBE Natural Bases Esters
Italmatch offer under DAPRALUBE brand a full range of Natural based esters allowing formulations of high performance synthetic or semi-synthetic lubricants including biodegradable fluids.
Description Method of analysis
Colour
Unit
Acidity Value ASTM D974
Specific Gravity 20ºC ASTM D1298
Viscosity at 40ºC ASTM D445
Pour Point ASTM D97
Iodine value ASTM D5554
Gardner
mgKOH/g
Kg/dm3
cSt
ºC
gI2/100g
Dapralube BS
Butyl Stearate
1 max.
0.1 max.
0.83
5-9
<20
1 max.
Dapralube EO
2-ETHYL Hexyl Oleate
2 max.
0.5 max.
0.865
8-9
<-30
54-64
Dapralube GDO
Glycerol Di oleate
5 max.
4 max
0.92
40-50
5 max
100-115
Dapralube GMO
Glycerol mono oleate
6.5 max.
4 max.
0.92
90-100
10 max.
75-90
Dapralube IBS
Iso Butyl Stearate
1 max.
1 max.
0.86
4-10
<18
1 max.
Dapralube IPO
Isopropyl Oleate vegetable
5 max.
0.2 max.
0.86
4-10
<-20
76-88
Dapralube PET
Pentaerytritol Tetraoleate
6.5 max.
2 max.
0.92
58-65
<-19
85-95
Dapralube PGDO
Propylene Glycol Dioleate vegetable
5.5 max.
2 max.
0.90
15-22
<-15
84-92
Dapralube SMO
Sorbitan oleate
8 max
8 max.
0.98
380-400
na
65-75
Dapralube STO
Sorbitan trioleate
8 max.
0.96
124-145
na
75-85
Dapralube TO
Trimethylolpropane Trioleate
6 max.
2 max.
0.92
40-50
<-30
77-87
Dapralube TO-HP *
Trimethylolpropane Trioleate
<6
<2
0.9
44
-30
82
Dapralube 320 *
Trimethylolpropane Trioleate
< 10
< 1
0.93
320
-30
90
* LUsc listed for Biodegradable Hydraulic Fluids (Ecolabel) Some vegetable origin versions are available on request
26
Dapraphos Phosphorus Additives
Italmatch Chemicals is manufacturing series of highly pure and phenol free Di-and Tri-substituted phosphites used mainly as anti-wear and EP additives in industrial lube oils and ATF fluids
Di-Phosphites (Phosphorous acid, di-alkyl esters) Product
Description
Typical P%
Dapraphos DBHP
Di-Butyl Hydrogen Phosphite
15.8
Dapraphos P16
Di-n-Octyl Hydrogen Phosphite
11.5
Dapraphos DOHP
Di-Oleyl Hydrogen Phosphite
5.3
Tri-Phosphites (Phosphorous acid, tri-alkyl esters) Product
Description
Dapraphos P50
Tri-C12-C14 Phosphite
Typical P% 5.2
Phosphate esters
Dapraphos 260 and C4 are used in applications where acid value is sensitive. They act as Aluminium corrosion inhibitor and/or anti-wear additive Product
Description
Dapraphos 260
Short chain Phosphate ester
Dapral C4
Glycol Phosphate ester
Typical P%
Acid Value
12.9
330
2
65
Italmatch is open to further derivatization of Hydrogen Phosphites additives. Please contact your Italmatch representative for a technical discussion should you see a possible opportunity in a joint development.
27
Dapraphos Phosphorus Additives
Ethoxylated phosphate esters Dapraphos 065, 457 and 802 are multi-functional anionic co-emulsifiers. They are used as a co-emulsifiers with additional benefits like improved anti-wear properties and corrosion protection of white metals.
Product
Description
Typical P%
Acid Value
EO Num.
Dapraphos 065
Ethoxylated Phosphate
8.3
150
5
Dapraphos 457
Ethoxylated Phosphate
5.8
105
7
Dapraphos 802
Ethoxylated Phosphate
4.2
145
2
A number of options to formulate are available, balancing between Wear protection, Co-emulsifier and Corrosion performance of the lubricant.
28
Rhodafac ASI Phosphorus Additives
Phosphonic acid as corrosion inhibitor Rhodafac® ASI is an efficient corrosion inhibitor for: • Ferrous metals • Aluminum • Zinc • Magnesium and their alloys With high thermal stability up to 350°C Main applications are soluble oils, synthetic fluids and cleaners. Product
Description
pH in water
Rhodafac ASI 100
SOLUTION OF OCTYL PHOSPHONIC ACID in water
2.1 @ 1%
Rhodafac ASI 80
SOLUTION OF OCTYL PHOSPHONIC ACID in water and ethanol
2.3 @ 5%
Rhodafac ASI 80 BC
SOLUTION OF OCTYL PHOSPHONIC ACID IN GLYCOL
2.0 @ 5%
Rhodafac ASI are efficient corrosion inhibitors for ferrous metals (1% at pH = 9) TEST API 287 + 1% Rhodafac ASI-100
Rhodafac ASI are efficient staining inhibitors for aluminium (0,2 % at pH = 9)
Treat rate Weight uptake
0%
0,05%
0,1%
0,25%
0,5%
47,4 mg
- 0,3 mg
0,4 mg
0,6 mg
0,4 mg
29
DAPRAMID Fatty Acid Amides
The Italmatch Chemicals product range comprises of various long chain fatty acid amides. These amides are used among others as additives in automotive lubricants. Trade Name
Chemical Description
Appearance
Typical Use
Dapramid O
Oleylamide
Pellets or Molten Liquid
Lubricants
Dapramid HT
Stearylamide
Pellets
Greases
DAPRAMID O reduces the friction coefficient of the lubricant. In addition it improves the surface quality as shown on the graph:
0.3% Dapramid O
30
0.5% Dapramid O
Regulatory Information INVENTORY
• • •
All Italmatch products are REACH compliant The vast majority is listed worldwide. For some of them the registration is ongoing in certain inventories.
For more details and up to date information please call your local ITALMATCH representative
NSF registered for use in lubricants with incidental food contact (HX-1) KETJENLUBE 115
KETJENLUBE 135
KETJENLUBE 165
KETJENLUBE 1300
KETJENLUBE 215
KETJENLUBE 230
KETJENLUBE 240
KETJENLUBE 2500
Kosher Certification KETJENLUBE 115
KETJENLUBE 135
KETJENLUBE 165
KETJENLUBE 1300
KETJENLUBE 215
KETJENLUBE 230
KETJENLUBE 240
KETJENLUBE 2500
Please call your local ITALMATCH representative for specific demand
Halal Certification Ketjenlube, Dapraphos and Dapral series are certified. Please call your local ITALMATCH representative for more details or specific demand
LUsc Listed DAPRALUBE 320 DAPRALUBE TO-HP
31
Applicative Laboratory New Products Development Work Italmatch S.p.A have expanded the technology and quality facilities at the Arese site, through investment in a new Quality and analysis laboratory block. This is to keep pace with the changes also in the plant and its expansion as well as the global supply aspect of the business.
Wear/lubricity/Extreme pressure properties are key to the Ketjenlube polymeric ester performance and this is where Italmatch has invested extensively to prove these very aspects when developing the polymeric esters and other allied products.
32
Product commercialization
Italmatch has a very solid approach when working with its customers from concept to commercial delivery from a well-equipped synthesis laboratory leading to a 500 liters state of the art pilot plant prior to any large scale commercial production
33
Notes
34
Imprint The information presented herein is true and accurate to the best of our knowledge, but without any guarantee unless explicitly given. Since the conditions of use are beyond our control, we disclaim incurred in connection with the use of these product data or suggestions and accurate to the best. Published by: Italmatch Chemicals Group Via E. Vismara, 114 20020 Arese (Milano), ITALY. Version: December 2016
35
Geo Coverage
ltalmatch Chemicals Group Lubricant Sales Offices Headquarters & Sales Office: Via Magazzini del Cotone 17 16128 Genova – ITALY Phone: +39 010 642081 Telefax: +39 010 4695296 E-Mail:
[email protected] Web: www.italmatch.com
Italmatch Chemicals Shanghai Sales Office: Rm 703, Pine City, 8 Dong’an Road, Xuhui District, Shanghai 200032, P.R. CHINA Phone: +86 21 3469 1871 Telefax: +86 21 3469 1872 E-Mail:
[email protected]
Arese Manufacturing Plant & Sales Office: via E.Vismara 114 20020 Arese (MI) – ITALY Phone: +39 02 935251 Telefax: +39 02 93525496 E-Mail:
[email protected]
Italmatch Singapore Pte Ltd 1, Kim Seng Promenade #17-02 Great World City East Tower Singapore 237994 Phone: +65-62356483 Fax: +65-68364534 E-mail:
[email protected]
Frankfurt Office: Industriepark Höchst, Gebäude B 797 Brüningstraße 50 D-65926 Frankfurt am Main – GERMANY Mobile: +49 173 4124565 E-Mail:
[email protected]
Italmatch USA Corporation 5544 Oakdale Rd SE Smyrna, GA 30082 USA Phone: +81 3 52103812 Fax: +1 (404) 505-0671 E-Mail:
[email protected]
Barcelona Office Calle Comte d’Urgell 240 08036 Barcelona – España Phone: +34 93 6373537 Telefax: +34 93 6591902 E-mail:
[email protected]
Tokyo Office Burex Kojimachi 5F, 3-5-2 Kojimachi, Chiyoda-ku Tokyo 102-0083 Japan Phone: +81 3 52103812 Fax: +81 3 52103830 E-Mail:
[email protected]
dicembre 2016 - 329 cit - realizzazione grafica: www.silvestri.info
