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 Dequest TM / ANTISCALANTS
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 management and plastic additives markets, with five manufacturing sites in Europe (Spoleto and Arese in Italy, Zaragozza in Spain, Frankfurt in Germany and Newport in UK) and three in China. 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 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 Oleoesters. Water soluble Phosphonates are manufactured in UK. The Arese site is located near Milan, in northern Italy. Various reactors (glass lined and stainless steel) of different sizes allow high 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 it is also equipped with an 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 programme. The plant maintains Halal and Kosher certifications for manufacturing of a range of food grade polymeric esters. The Zaragozza site has integrated acids and natural esters manufacturing (using renewable raw materials).
2
Chemicals for Lubricants and Fuels Main
Chemistry
Chemical Name
Trade Name
Applications
Esterification
Phosphite esters
Dapraphos
Lubricant
Feedstocks PCL3 / H3PO3
POCl3 / P2O5
Alcohols
Esterification
TM
Phosphate esters
Intermediates
Phosphonates
EP additives
Di-esters
- renewable sources
Polyol Esters
- petrochemical sources
Complex Esters
Ketjenlube
TM
Lubricants
Lubricants
Ammonia
Amidation
Amides
Dapramid
Olefins, Alcohols
Polymerization
Ester Copolymers
Ketjenlube
Condensation
ASA/PIBSA
Dapral
TM
PA
Lubricants/Fuels
ASI/PIBSI
Dapral
TM
PI
Intermediates
TM
TM
Lubricants
Unsaturated Diesters, Maleic Anhydride
Maleic Anhydride Olefins, reactive PIB Amines
3
Ketjenlube Polymer Esters for Automotive and PHYSICAL AND CHEMICAL
Method
CHARACTERISTICS
KL
KL
KL
KL
KL
KL
KL
115
135
165
1300
215
230
240
Medium/High Polar Products
Viscosity at 100°C (mm²/s)
ASTM D-445
15
34
65
260
16
30
40
Viscosity at 40°C (mm²/s)
ASTM D 445
115
340
770
4100
120
280
400
Viscosity index
ASTM D-2270
135
139
152
190
140
140
160
Pour point (°C)
ASTM D-97
-30
-39
-30
-21
-27
-33
-6
Flash point (°C)
ASTM D-92
250
250
255
260
250
250
270
Acid Number (mgKOH/g)
ASTM D-974
0.4
0.2
0.3
<0.1
0.3
0.3
0.1
Density 20°C (g/cm³)
ASTM D-1217
0.93
0.96
0.98
0.99
0.92
0.94
0.93
Colour Gardner
ASTM D-1544
< 1
< 1
< 1
< 1
< 1
< 1
<1
Volatility Noack (%)
ASTM D-5800
4
3
3
1
4
3
3
Hydrolytic Stability
ASTM D-2619
Oil phase
0.29
0.29
0.25
0.10
0.22
0.36
0.11
Water phase
0.24
0.24
0.03
0.24
0.14
0.27
0.07
Weight loss (%)
6.35
5.8
4.75
4.3
5.3
5.0
4.15
Viscosity Ratio
5.0
5.0
4.8
4.0
5.0
4.4
4.0
APPLICATIONAL PROPERTIES
(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%)
Reichert
Pure Ketjenlube 10% KL in 150 N oil Seal Compatibility
4
CEC-L-39-X-95
30
31
20
20
32
26
28
89
88
89
90
78
74
93
NEU
d
Industrial Lubricants
L
KL
KL
KL
KL
KL
KL
KL
KL
30
240
2500
2700
3100
3300
3700
23000 305
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
-
-
-
0
400
7000
11000
990
5200
11000
43000
30
500
400
2200
0
160
230
250
174
220
250
300
140
-
-
-
3
-6
-9
-21
-24
-24
-18
n/a
-42
-24
-21
-18
0
270
270
270
260
>240
270
270
230
220
230
180
3
0.1
0.1
<0.1
0.5
<0.3
< 0.1
0.3
1.2
10
7
60
94
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
<1
6
4
2
3
1
< 1
1
1.4
< 1
1
-
-
-
-
-
-
-
36
0.11
0.12
0.26
0.18
0.16
0.26
0.16
-
-
-
27
0.07
0.08
0.17
0.12
0.3
0.17
0.13
-
-
-
0
4.15
2.6
3.45
3.15
3.5
3.7
3.50
-
-
-
4
4.0
2.8
1.6
3.2
2.16
1.5
0.72
-
-
-
28
6
12
17
6
5
11.0
-
-
-
93
87
90
92
89
90
-
40
43
60
NEUTRAL
SLIGHTLY SWELLING
5
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 mm2/s up to 3000 mm2/s 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.
6
Ketjenlube
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. chloroparaffins 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
7
Ketjenlube
Ketjenlube Polymer Esters IN 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
Viscosity 100°C (mm2/s)
8.8
9.6
9.5
9.5
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)
8
Ketjenlube Polymer Esters IN 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
(%)
Oxidation Stability (121°C, 312 h)
84.9 ASTM D 2893
KV@100°C Increase (%)
0
Acid number increase (mgKOH/g)
0.38
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:
9
Ketjenlube
Ketjenlube Polymer Esters IN GEAR OILS The two high viscous Ketjenlube Polymer Esters Ketjenlube 23,000 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
AUTOMOTIVE GEAR OILS / FORMULATION EXAMPLES
KL2700
KL23000
PAO 100
PAO 40
Viscosity Grade
75W-140
75W-90
75W-90
75W-90
COMPOSITION
Ketjenlube 2700
50.5
Ketjenlube 23,000
30
PA0 100
45
PA0 40
58 10
PA0 4
30
60
30
Di-Ester (Adipate)
9.5
15
15
Ad-Pac, Anti-Foam
10
10
10
17
PERFORMANCE DATA
Viscosity 100°C (mm2/sec)
24.3
14.8
15.1
14.9
Viscosity - 40°C (mPas)
125500
29400
57500
56800
Apperance (-15°C)
HOMOGENEOUS, CLEAR
Copper Corrosion ASTM D 130
1a
1a
1a
1a
Shear loss After 20 h (%)
<1
4.7
1
0.7
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
10
(%)
INDUSTRIAL GEAR OIL / FORMULATION EXAMPLE
Ketjenlube 2700/PAO 6
PAO/Ester
Experimental Product
Commercial Product
Commercial Product
COMPOSITION
PA0 6
53.5
Proprietory
10.5
PA0 40
/
Proprietory
80
TMP-Ester
/
/
8
Ketjenlube 2700
45
34
/
Ad-Pac
1·5
Proprietory
1·5
PHYSICAL PROPERTIES
Viscosity 40DC (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
Demulsibility ASTM D2711
Free Water: 87 ml
Free Water: 87 ml
Free Water: 87 ml
Emulsion: 0.0 ml
Emulsion: 0.0 ml
Emulsion: 0.0 ml
Water in OIL 0.4%
Water in OIL 0.8%
Water in OIL 0.3%
Water Separation ASTM D1401
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
Ketjenlube 2700 and 3700 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 >> Improved additive compatibility >> Improved micropitting performance >> Higher durability. >> Use in Off-shore wind turbines. >> No need for ester solubilizers.
thermal)
Various OEM approvals (e.g. Flender, wind turbine manufacturers) >> Competitively priced versus PAO 40/PAO 100
12
Ketjenlube 2700 versus PAO 40 PERFORMANCE IN ISO VG 220 INDUSTRIAL GEAR OIL COMPOSITION
"Ketjenlube2700"
"PAO 40"
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
PERFORMANCE TESTS Viscosity
40°C (mm2/s)
1.4
220
221
+ 3.5
+ 26
40-40-0 (45 min)
40-40-0 (45 min)
0.4
0.3
Free Water (ml)
87
87
Emulsion (ml)
0
Oxidation Test ASTM D-2893 (121°C, 312h) Viscosity Increase (%) Demulsibility Test ASTM D-1401 (121°C) Oil-Water Emulsion (ml) Demulsibility Test ASTM D-2711 (82°C) Water in Oil (ml)
Foam Test ASTM D-892
0
Sequence I (ml)
0
30-0
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
13
Ketjenlube
Ketjenlube 240 Use 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) Composition (wt%): Base fluids
PAO 40 PAO 8 Ketjenlube 240
64.5 20.5 13.5
Additives
Additin RC 9330* Foam Ban 159*
1.5 0.0075
*Additin and Foam Ban are registered trade marks of Rhein Chemie and Muenzing GmbH, resp. A nalytical Results: Test method
Viscosity 100°C (mm²/s) Viscosity 40°C (mm²/s) Viscosity index Pour point (°C) Flash point (°C) Water content (ppm)
14
Result
227 26.7 151 -33 274 100
Limits according to DIN 51517-3
198 - 242 90 min. -9 max. 200 min. 1000 max.
Test method
Result
Limits according to DIN 51517-3
41-39-0 (10)
40-37-3 (30)
Foaming ASTM D 892 Sequence I (ml) Sequence II (ml) Sequence III (ml)
10/0 0/0 50/0
100/10 100/10 100/10
Copper corrosion ASTM D 130 (100°C, 3h)
1a
1 max.
Steel corrosion ASTM D 665 (proc. A)
pass
pass
FZG-test (A/8.3/90); max. load stage
>12
12 min.
FE 8 test E DIN 51819-3 wear loss bearing rollers (mg) wear loss bearing cage (mg)
2.1 19.9
30 max -
Oxidation test ASTM D-2893 (121°C, 312 h); Viscosity increase (%)
3.4
41-39-0 (10)
Elastomer compatibility (NBR, 168 h, 100 °C) Volume change (%) Hardness change (shore A) Tensile strength change (%) Elongation break change (%)
0 -1 -3 -17
0/+10 max. -10/+5 max. -30 max. -40 max.
Demulsibility 1401 (82°C)
ASTM D
Functionalised Ketjenlube Esters KL2715S
Niche functionalized polymeric esters using a sulphur source to combine the benefits of the Ketjenlube polymer esters, their compatibility in Group I,II & III base oils to offer the 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.
PARAMETERS
METHOD
KL 2715S
APPEARANCE
VISUAL
CLEAR YELLOW LIQUID
COLOUR
ASTM-D-1500
L 3.0
VIS. @ 40°C, cSt
ASTM-D-7042
665
S.G. @ 29.5°C, g/cc
ASTM-D-7042
0.988
STABILITY
INTERNAL
STABLE
CU. CORROSION
ASTM-D-130-M
AT 120°C, 3HRS. 3% IN 150SN GR I
1b
3% IN 500N GR II
1b
3% IN 250N GR III WELD LOAD, Kg
1b ASTM-D-2783
5% IN 150N GR II
400
10% IN 150N GR II SOLUBILITY
500 INTERNAL
5% IN 150SN GR I
BRIGHT & CLEAR
5% IN 500N GR II
BRIGHT & CLEAR
5% IN 250N GR III SULPHUR, %
BRIGHT & CLEAR CALCULATED
15
15
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 Antiwear/EP agents, so enabling high performance formulations to be made which are characterised 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 enhanging tool life and surface finish. Ketjenlube high performance esters have the added advantage of: >> Superior compatibility with gp 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 new Italmatch application laboratory the use of recognized performance test equipment such as Four-Ball, Reichert, Pin & Vee Block Falex, MICROTAP and CNOMO is creating a further detailed understanding of the application of the complete product range and differentation of the existing and newly developed products.
16
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 WITH NO RESIDUE FORMATION; - HIGH ACTIVITY EVEN AT LOW TREAT RATES; - PROVEN SYNERGISTIC EFFECT WITH EP/AW ADDITIVES.
Superior Tool wear performances compared to Conventional Esters on steel
17
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)
18
CHEMISTRY
Ketjenlube 9350 Ketjenlube 9351 Ketjenlube 9450
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. PICTURE SEMISYNTHETIC FLUID.
CHEMISTRY
Ketjenlube 2715 S
Sulphured Polymeric Ester
APPLICATIONS LUBRICITY ENHANCER
EMULSIFIER
CORROSION INHIBITOR
EP/AW ADDITIVE
KEY CHARACTERISTICS - UNIQUE EXTREME PRESSURE PERFORMANCE; - COMPLETE ALTERNATIVE TO CHLOROPARAFFIN CHEMISTRY; - LIGHT IN COLOUR AND EXHIBITS LOW ODOUR; - SULPHURIZED ADDITVE ADAPTED FOR MULTI METAL APPLICATIONS. THE TYPICAL “ACTIVE SULFUR” CONTENT VALULES FOR THIS PRODUCTS IS: ~ 15%
19
Dapral PIBSA
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; EFFICIENT ALTERNATIVE TO SULPHONATES; CHLORINE FREE MANUFACTURING PROCESS.
SEPARATE DETAILED INFORMATION RELATED TO THE APPLICATION OF ALL OF THESE ADDITIVE GROUPS WITHIN MWF FORMULATIONS IS AVAILABLE ON REQUEST.
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Italmatch Dequest® is offering unique specialty additives to meet the needs of these industries involved in water management or deal with processes or applications where water plays a crucial role. More than 40 years ago Dequest® pioneered the development of phosphonates based antiscalants.
Dequest phosphonates basically are used as chelant in MWF at the dosage of 0.2% to 0.5% to control particularly water hardness (Ca2+ and Mg2+) so that to passivate these cation (by forming soluble complexes) and avoid them forming calcium or magnesium soap that depletes one of the primary emulsifying system.
Dequest® phosphonates have been the product of choice for scale prevention, dispersion, chelation and metal corrosion inhibition in many applications for years. Recently, Dequest® phosphonates have been successfully introduced in metal working fluids applications.
At the dosage of Dequest 0.2-0.5% as it is in the MWF system; Dequest phosphonates already can deliver the corrosion inhibition (for steel or carbon steel only) and antiscalant function as well. The corrosion inhibition function of Dequest phosphonates will be enhanced by combining with sodium metasilicates, sodium molybdates, amine carboxylates ... etc.
Dequest® phosphonates range is broad and products can be proposed in standard, pure or very pure grades depending on exact needs (low chloride levels, low metallic ions). On top of commercially available grades, ItalmatchDequest is also continuously developing new molecules fitting customer needs and experimental grades can also be proposed. Please contact our technical team for selection of the product that will best fit into your ormulation.
If the water hardness is high like 250-500ppm as CaCO3; then dosage of 0.5% - 1.0% would be recommended. In soluble oil is the incorporation of Dequest® SPE0520 improves the emulsion stability when hard water is used.
Product used are, for example, Dequest® 2016 and Dequest® 2066.
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Ketjenlube
Polymer Esters In Greases
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. Greases with Ketjenlube Polymer Esters also show significantly increased ageing resistance 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. 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
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MAJOR GREASE APPLICATIONS •NLGI grades from 0 to 2; •High temperature greases; •Greases for moist environments; •Metal soap, bentonite, or polyurea thickened greases.
MELAMINE CYANURATE Melamine Cyanurate is a salt of melamine and cyanuric acid. It is a non-toxic additive during its life cycle, including during fire situations, it is easy to handle, non-hazardous, recyclable and biodegradable. The use of Melamine Cyanurate (MC) in greases has been developed in Japan around 30 years ago, and there are known uses in Japan and the USA. A lubricant containing MC is effective for use in high-temperature, or high pressure atmospheres, or places where black-color producing contamination is not desired, or in metal working, cutting or grinding of metals. MC not only functions as a solid lubricant but also as an agent to thicken liquid lubricants such as mineral oil.
23
Regulatory Information
INVENTORY (COUN-
KL 115*
KL 165*
KL 3100
KL 445
TRY)
KL 135*
KL 305*
KL 3700
KL 445VLP
KL 215*
KL 1300*
KL 2700
KL 230*
KL 240*
KL 3300T
KL 2500*
KL 23000
EINECS (Europe)
**
**
**
**
**
TSCA (USA)
Yes
Yes
Yes
Yes
Yes
KL 522
DSL (Canada)
Yes
No
Yes
Yes
Yes
AICS (Australia)
Yes
Yes
Yes
Yes
No
MITI (Japan)
Yes
Yes
Yes
Yes
No
IECSC (China)
Yes
Yes
Yes
Yes
Yes
KECI (Korea)
Yes
No
Yes
Yes
No
NZIoC (New Zealand)
***
***
***
***
***
NECSI (Taiwan)
Yes
Yes
Yes
Yes
Yes
Thailand
**
**
**
**
**
* NSF registered for use in lubricants with incidental food contact (HX-1) ** Exempted - polymers *** Exempted – not hazardous substances
24
Saturated Complex Esters for use in Ecolabelled Lubricants
Biodegradable Hydraulic Fluids (Ecolabel) PHYSICAL PROPERTIES
KETJENLUBE
KETJENLUBE
KETJENLUBE
9200
9201
9202
Item
Test-Method
Typical Values
Appearance
Visual
Clear Liquid
Clear Liquid
Clear Liquid
Viscosity 40°C (mm s)
ASTM D-445
32
45
60
Viscosity 100°C (mm s)
ASTM D-445
6.8
8
9.2
Viscosity index
ASTM D-2270
170
150
130
Acid Number (mgKOH/g)
ASTM D-974
0.1
0.1
0.1
Pour Point
ASTM D-97
-52°C
-56°C
-40°C
Flash Point
ASTM D-92
230°C
230°C
230°C
Colour Gardner
ASTM D 1544
5
5
5
Iodine Number
in-house
<2
<2
<2
Biodegradability
OECD 301B
>70 %
>70 %
>70 %
% of Renewable
/
>78 %
>75 %
>72 %
2
2
(mgI2/100g)
Carbon
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Conventional
Esters
Apart from the patented Ketjenlube© Polymer Esters Italmatch Chemicals is offering also a wide range of various other synthetic and natural esters under the Ketjenlube trade name:
POLYOL ESTERS
-
DIBASIC ACID ESTERS
-
COMPLEX ESTERS
-
TRIMELLITATE ESTERS
A SELECTION OF THE ESTER TYPES CURRENTLY AVAILABLE IS GIVEN IN THE TABLE BELOW: Trade Name
Description
Acid Value
KV@40°C
KV@100°C
Viscosity Index
Colour
Pour Point
Flash Point
mgKOH/g
cSt
cSt
-
Gardner
°C
°C
Reccomended Application
Ketjenlube 09
Dimer Ester
0.07
94
13
145
7
-57
280
Two-Stroke; MWF
Ketjenlube 10
Polyol Ester
0.07
22
4.4
-
2
-48
250
Automotive & Industrial Lubes
Ketjenlube 15
Dibasic Acid Ester
0.05
27
5.35
138
<1
-63
235
Ketjenlube 16
Dibasic Acid Ester
0.08
14
3.7
149
<1
-75
230
Biodegradable Hydraulic Fluids (Gear Oils)
Ketjenlube 19
Dibasic Acid Ester
0.1
18
4.5
162
4
-75
240
Auto Gear Oils
Ketjenlube 9350
Complex Ester
50
1000
100
180
8
-33
270
MWF
Ketjenlube 9450
Complex Ester
30
2200
180-220
210
9
-21
260
MWF
Ketjenlube 39*
Complex Ester
0,3 Max
135
18
140
8
-54
280
Two-Stroke. MWF
Ketjenlube 9501*
Complex Ester
0.5
380
39
150
7
-42
> 300
Industrial lubes
Ketjenlube 9503
Complex Ester
0.5
1650
125
170
7
-33
> 300
Ketjenlube 9505
Complex Ester
0.5
45000
2000
250
5
/
> 300
Metalworking forming & engine oils
Ketjenlube 72
Trimellitate Ester
0,1 Max
306
20.2
-
50 (Apha)
-20
270
Ketjenlube 73
Trimellitate Ester
0,1 Max
50
8
-
50 (Apha)
< -45
270
High Temperature Lube Applications
Ketjenlube 75
Trimellitate Ester
0,1 Max
88.5
9
-
50 (Apha)
< -40
> 240
Chain Oils and greases
Ketjenlube 76
Trimellitate Ester
0,1 Max
45
7
117
50 (Apha)
< -40
> 241
* Saturated and unsaturated version available
26
Colour
Acidity Value
Saponification Value
Specific Gravity 20ºC
Viscosity at 40ºC
Pour Point
Hydroxyl value
Iodine value
Demulsivity test
Method of analysis
ASTM D974
ASTM D94
ASTM D1298
ASTM D445
ASTM D97
ASTM D1957
ASTM D5554
ASTM D1401
Units
Gardner
mgKOH/g
mgKOH/g
Kg/dm3
mm2/s
ºC
mgKOH/g
gI2/100g
Min-cc/ cc/cc
Dapralube EO
2 max.
0.5 max.
140-146
0.860-0.870
8-9
<-30
3 max.
54-64
Dapralube TO
6 max.
2 max.
180-200
0.913-0.928
40-50
<-30
17 max.
77-87
30min 46/37/3
Armotan MRD
10 max.
7 max.
145-165
190-215
Dapralube TO (vegetable based)
6 max.
2 max.
180-200
0.913-0.928
40-50
<-30
8 max.
30min 46/37/3
Dapralube PET
6.5 max.
2 max.
183-193
0.876-0.924
58-65
<-19
10 max.
85-95
Dapralube GMO
6.5 max.
4 max.
155-175
90-100
10 max.
75-90
Dapralube IBS
1 max.
1 max.
165-175
0.804-0.853
4-10
<18
1 max.
Dapralube IPO
5 max.
0.2 max.
170-180
0.860-0.920
4-10
<-20
1 max.
76-88
Dapralube PGDO
5.5 max.
2 max.
175-190
0.860-0.920
15-22
<-15
84-92
Dapralube SMO
8 max
8 max.
145-160
380-400
193-210
65-75
Dapralube STO
8 max.
170-190
124-145
55-75
75-85
Dapralube GDO
5 max.
4 max
170-185
40-50
5 max
Dapralube BS
1 max.
0.1 max.
165-175
0.804-0.853
5-9
<20
1 max.
1 max.
Dapralube PET (vegetable based)
6.5 max.
2 max.
183-193
0.876-0.924
58-65
<-19
10 max.
85-95
Others
Approved in Arese
100-115
Glicerine 5% max. Moisture 1.5% max.
Glicerine 1,5% Monoglycerides 15-20
27
Phosphites Dapraphos
Italmatch Chemicals is manufacturing a series of highly pure and phenol free Di-and Tri-substituted phosphites used mainly as chemical intermediates and finished additives in industrial lube oils and ATF fluids
Di-Phosphites (Phosphorous acid, di-alkyl esters) Typical P% DiMethyl Hydrogen Phosphite
#
DMHP
DiButyl Hydrogen Phosphite
Dapraphos DBHP
15.8
Di-n-Octyl Hydrogen Phosphite
Dapraphos P16
10.8
Di-2-Ethylhexyl Hydrogen Phosphite DiOleyl Hydrogen Phosphite
#
10 Dapraphos DOHP 7.4
DiLauryl Hydrogen Phosphite
#
5.3
# Under Development
Tri-Phosphites (Phosphorous acid, tri-alkyl esters) Typical P%
Typical S%
Tri-LaurylTriThiophosp hite
Dapraphos TLTTP
4.4
15.2
Tri-Lauryl Phosphite
Dapraphos TLP
5.2
-
Tri-C12-C14 Phosphite
Dapraphos P26
5.2
-
Tri-C12-C14 Phosphite
Dapraphos P50
5.2
-
Furthermore Italmatch starting from Dialkyl Hydrogen Phosphites is available to further derivatize such additives. Do not hesitate to contact your Italmatch representative for a technical discussion should you see a possible opportunity in a joint development.
28
Poly Iso-Butenyl Succinic Anhydrides PIBSA
Poly isobutenyl succinic anhydrides are a basic building block for dispersants in lubricating oils or detergents in fuels. They are increasingly used in Metalworking fluids (soluble oils), where PIBSA’s can be used together with other co-emulsifiers as an economic alternative to sulfonates. Italmatch Chemicals offers a PIBSA range of various molecular weights, chlorine free and low poly-dispersity index for improved emulsification properties.
PHYSICAL PROPERTIES
DAPRAL PA 450
DAPRAL PA 750
DAPRAL PA 1000
Item
Test-Method
Typical Values
Appearance
Visual
Clear Amber Liquid
Clear Amber Liquid
Clear Amber Liquid
Viscosity 100°C
ASTM D-445
70-75
400
540
in-house
140
110
85-90
Acid Number
in-house
80-85
70-75
55-60
Sediments
in-house
< 0.05%
< 0.05%
< 0.05%
Colour Gardner
ASTM D-1544
15 MAX
10
10
Best Emulsification
Best Overall
Best Foaming
Properties
Properties
Power
(mm2s) Saponification Number
Property Rating
PIBSA Derivatives Italmatch Chemicals manufacture also ASA derivatives like DDSA, HDSA and iso ODSA. Furthermore starting from PIBSA Italmatch is available to further derivatize succinic anhydrides to Succinimides, also on tolling arrangements, in order to produce dispersants, antifouling agents and fuel additives.
29
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. FATTY ACID AMIDE PRODUCT RANGE Trade Name
Chemical Description
Area of Use
Dapramid O
Oleylamide
Pellets or Molten Liquid Lubricants
Dapramid HT
Stearylamide
Pellets
Greases
Dapramid E
Erucamide
Pellets
Lubricants
Friction Reduction Performance
Friction Pattern of an Engine Oil with and without Dapramid O
30
Appearance
31
Applicative Laboratory New Products Development Work >> “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” >> “Key to a successful gear oil and especially Wind Turbine Oil is the ability to meet Flender OEM foam and filtration tests” >> “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 state of the art pilot plant prior to any large scale commercial production”
32
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. Responsible: Dr. Norberto Gatti Version: October 2013
35
Geo Coverage
ltalmatch Chemicals Group Headquarters & Sales Office: Via Pietro Chiesa 7/13 (8th floor) Torri Piane San Benigno 16149 Genova – ITALY Phone: +39 010 642081 Telefax: +39 010 4695296 E-Mail:
[email protected] Web: www.italmatch.it 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] Spoleto Manufacturing Plant: Via S. Tommaso 13 06049 Spoleto (PG) – ITALY Phone: +39 0743 20191 Telefax: +39 0743 45841 Barcelona Office (ex Union Derivan, S.A.) Avda. Generalitat 175-179 08840 Viladecans Barcelona – España Phone: +34 93 6373537 Telefax: +34 93 6591902 E-mail:
[email protected] Zaragozza Manufacturing Plant Poligono Industrial El Campillo Zuera Italmatch Japan Ltd Burex Kojimachi 5F, 3-5-2 Kojimachi, Chiyoda-ku, Tokyo, Japan Phone:+81 13 52103811 Mobile phone: +81 90 17390087 Email:
[email protected]
Nantong Italmatch Chemicals co. Ltd Manufacturing Plant & Sales Office: Bihne Road, Rugao Port Economic Development Zone Nantong, Jiangsu Province, 226532, P.R. CHINA Phone: +86 513 87688318 Telefax: +86 513 87586888 E-Mail:
[email protected] 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] Italmatch Singapore Pte Ltd 1, Kim Seng Promenade #17-02 Great World City East Tower Singapore 237994 Tel: + 65-62356483 Fax: +65-68364534 E-mail:
[email protected] Italmatch India Sales Office: No: 409, Paramount Residency Nagaram, Keesara Hyderabad - 500083 INDIA Phone: +91 40 65156999 Mobile Phone: +9160019710 E-Mail:
[email protected] Italmatch USA Corporation 21 East Front Street, Suite 500, Red Bank, NJ 07701 USA Phone: + 1 732 383 8309 Mobile phone: + 1 908 461 7960 E-Mail:
[email protected]
