your versatile partner in chemistry high … · high performance chemicals for lubricants your...

High Performance Chemicalsfor Lubricants

YOUR VERSATILE PARTNER IN CHEMISTRY

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

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).

Historyof the Company

2

Trade Name Main Feedstocks Chemistry Chemical Name Function(s)

Dapraphos TM

Rhodafac TM ASI Dapraquest TM

PCl3 / H3PO3 POCl3 / P2O5

Esterification Phosphite estersPhosphate estersPhosphonic acidPhosphonates

Antiwear (AW)AW/CI/Co-EmulsifierCorrosion InhibitorSequesterant

Ketjenlube TM

Dapralube TM

Alcohols - renewable sources - petrochemical sources

Esterification Di-esters

Polyol Esters

Complex Esters

Synthetic Base stock(Lubricity Additive)Synthetic Base stock(Lubricity Additive)Lubricity Boundary Additive

Dapramid TM Ammonia Amidation Amides Friction Modifier (FM)

Ketjenlube TM Olefins, Alcohols Unsaturated Diesters, Maleic Anhydride

Polymerization Ester Copolymers Synthetic Base stock (Lubricity Additive)

Dapral TM PA

Dapral TM Pl

Maleic Anhydride, Olefins, reactive PIB Dapral PA, Amines

Condensation ASA/PIBSA

ASI/PIBSI

Emulsifier

Dispersant

Chemicals for Lubricants

3

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.

KetjenlubePolymer Ester

4

>> 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.

Properties

Idealized structure of Ketjenlube Polymer Esters

5

KL 115

KL 135

KL 165

KL1300

KL215

KL 230

KL 240

KL 2500

KL 2700

KL3100

KL3300

KL 3700

KL 23000

KL 305

KL 445

KL 445 VLP

KL 522

KETJENLUBE POLYMER ESTERSPHYSICAL ANd CHEMICAL CHARACTERISTICS

Method Medium/High Polar Products

LOW POLAR (PAO COMPATIBLE) Water soluble/Emulsifiable Products

Viscosity at 100°C (mm²/s) ASTM D-445 15 34 65 260 16 30 40 500 700 94 350 700 3000 5.5 - - -Viscosity at 40°C (mm²/s) ASTM D-445 115 340 770 4100 120 280 400 7000 11000 990 5200 11000 43000 30 500 400 2200Viscosity index ASTM D-2270 135 139 152 190 140 140 160 230 250 174 220 250 300 140 - - -Pour point (°C) ASTM D-97 -30 -39 -30 -21 -27 -33 -6 -9 -21 -21 -24 -9 n/a -42 -24 -21 -18Flash point (°C) ASTM D-92 250 250 255 260 250 250 260 270 270 260 >240 270 270 230 220 230 180Acid Number (mgKOH/g) ASTM D-974 0.4 0.2 0.3 <0.1 0.3 0.3 0.1 0.1 <0.1 0.5 <0.3 < 0.1 0.3 1.2 10 7 60Density 20°C (g/cm³) ASTM D-1217 0.93 0.96 0.98 0.99 0.92 0.94 0.93 0.93 0.96 0.93 0.95 0.96 0.92 0.93 1.06 1.05 - Colour Gardner ASTM D-1544 < 1 < 1 < 1 < 1 < 1 < 1 <1 < 1 < 1 < 1 <1 < 1 < 1 <1 6 4 2APPLICATIONAL dATAVolatility Noack (%) ASTM D-5800 1.2 1.4 1.4 1 - - -Hydrolytic Stability (Acid Number as mgKOH/g After 48 h)

ASTM D-2619 - - -

Oil phase 1.69 0.54 0.62 0.73 0.52 0.69 0.44 0.2 0.28 0.21 0.4 0.18 0.12 - - -Water phase 0.75 0.27 0.45 1.1 0.54 0.24 0.46 0.33 0.18 0.17 0.52 0.14 0.25 - - -Thermo-Oxidative Stability(200°C; 12h; 15 Liter Air/Hour)

IP 48

Weight loss (%) 6.35 5.8 4.75 4.3 5.3 5.0 4.15 2.6 3.45 3.15 3.5 3.7 3.50 - - -Viscosity Ratio 5.0 5.0 4.8 4.0 5.0 4.4 4.0 2.8 1.6 3.2 2.16 1.5 0.72 - - -

Lubricity (% wear area; 150 N oil = 100%) ReichertPure Ketjenlube 30 31 20 20 35.6 33.7 28 6 12 17 6 5 11.0 19.4 19.7 17.210% KL in 150 N oil 89 88 89 90 96.1 90.2 93 87 90 92 89 90 - - - -

Seal Compatibility CEC-L-39-X-95 NEUTRAL SLIGHTLY SWELLING

Product Overview

Ketjenlube Polymer Ester

6

KL 115

KL 135

KL 165

KL1300

KL215

KL 230

KL 240

KL 2500

KL 2700

KL3100

KL3300

KL 3700

KL 23000

KL 305

KL 445

KL 445 VLP

KL 522

KETJENLUBE POLYMER ESTERSPHYSICAL ANd CHEMICAL CHARACTERISTICS

Method Medium/High Polar Products

LOW POLAR (PAO COMPATIBLE) Water soluble/Emulsifiable Products

Viscosity at 100°C (mm²/s) ASTM D-445 15 34 65 260 16 30 40 500 700 94 350 700 3000 5.5 - - -Viscosity at 40°C (mm²/s) ASTM D-445 115 340 770 4100 120 280 400 7000 11000 990 5200 11000 43000 30 500 400 2200Viscosity index ASTM D-2270 135 139 152 190 140 140 160 230 250 174 220 250 300 140 - - -Pour point (°C) ASTM D-97 -30 -39 -30 -21 -27 -33 -6 -9 -21 -21 -24 -9 n/a -42 -24 -21 -18Flash point (°C) ASTM D-92 250 250 255 260 250 250 260 270 270 260 >240 270 270 230 220 230 180Acid Number (mgKOH/g) ASTM D-974 0.4 0.2 0.3 <0.1 0.3 0.3 0.1 0.1 <0.1 0.5 <0.3 < 0.1 0.3 1.2 10 7 60Density 20°C (g/cm³) ASTM D-1217 0.93 0.96 0.98 0.99 0.92 0.94 0.93 0.93 0.96 0.93 0.95 0.96 0.92 0.93 1.06 1.05 - Colour Gardner ASTM D-1544 < 1 < 1 < 1 < 1 < 1 < 1 <1 < 1 < 1 < 1 <1 < 1 < 1 <1 6 4 2APPLICATIONAL dATAVolatility Noack (%) ASTM D-5800 1.2 1.4 1.4 1 - - -Hydrolytic Stability (Acid Number as mgKOH/g After 48 h)

ASTM D-2619 - - -

Oil phase 1.69 0.54 0.62 0.73 0.52 0.69 0.44 0.2 0.28 0.21 0.4 0.18 0.12 - - -Water phase 0.75 0.27 0.45 1.1 0.54 0.24 0.46 0.33 0.18 0.17 0.52 0.14 0.25 - - -Thermo-Oxidative Stability(200°C; 12h; 15 Liter Air/Hour)

IP 48

Weight loss (%) 6.35 5.8 4.75 4.3 5.3 5.0 4.15 2.6 3.45 3.15 3.5 3.7 3.50 - - -Viscosity Ratio 5.0 5.0 4.8 4.0 5.0 4.4 4.0 2.8 1.6 3.2 2.16 1.5 0.72 - - -

Lubricity (% wear area; 150 N oil = 100%) ReichertPure Ketjenlube 30 31 20 20 35.6 33.7 28 6 12 17 6 5 11.0 19.4 19.7 17.210% KL in 150 N oil 89 88 89 90 96.1 90.2 93 87 90 92 89 90 - - - -

Seal Compatibility CEC-L-39-X-95 NEUTRAL SLIGHTLY SWELLING

7

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:

Ketjenlube

TWO-STROKE ENGINE OILS

OIL 1 2 3 4Type Synthetic;

High Solvent

Synthetic Semi

Synthetic

Semi

Synthetic

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 / / / 10Ketjenlube 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

(FC limit: 85 min)

193 172 85 89

- Lubricity index

(FC limit: 95 min)

116 100 103 97

- Torque index

(FC limit: 98 min)

98 100 102 100

- Detergency index 1 Hour

(FC limit: 95 min)

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

Polymer Esters Applications

8

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.

FOUR-STROKE ENGINE OILS

Synthetic 10W-30 Oil with Ketjenlube 135 Formulation details.

Test Results

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.

COMPONENT Wt%

250 N Grp III (Ultra S8) 79.4

KETJENLUBE 135 9

Add Pack 10

Viscosity Index improver 1.3

POUR POINT DEPRESSANT 0.3

TESTS RESULTS METHOd RESULTS

Viscosity @ 40°C, cSt ASTM D 445 65.7

Viscosity @ 100°C, cSt ASTM D 445 10.2

Viscosity Index ASTM D 2270 141

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

(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

Results:

MA2 PASS

DFI 2.08 ≥1.85 & <2.5

SFI 1.87 ≥1.7 & <2.5

STI 1.95 ≥1.85 & <2.5

KetjenlubePolymer Esters Applications

9

Ketjenlube

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 KL23000 PAO 100 PAO 40

Viscosity Grade 75W-140 75W-90 75W-90 75W-90

COMPOSITION (wt %)

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

Ad-Pac with Anti-Foam 10 10 10 17

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) 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-T93GFC-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

AUTOMATIVE GEAR OILS

Polymer Esters Applications

10

INDUSTRIAL GEAR OIL

FORMULATION GUIdELINE Experimental ProductKetjenlube 2700/PAO 6

Commercial ProductPAO/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: 51,1Weld Load: 250 Kg

LWI: 64,2Weld Load: 250 Kg

LWI: 53,2Weld Load: 250 Kg

Falex Pin&Vee Test ASTM D2670; Wear Teeth

1 3 1


11

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

High Viscosity KetjenlubeIN WIND TURBINE OILS

KetjenlubePolymer Esters

12

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)

Viscosity Increase (%)

+ 3.5 + 26

demulsibility Test ASTM d-1401 (121°C)

Oil-Water Emulsion (ml)

40-40-0 (45 min) 40-40-0 (45 min)

demulsibility Test ASTM d-2711 (82°C) Water in Oil (ml) 0.4 0.3

Free Water (ml) 87 87

Emulsion (ml) 0 0

Foam Test ASTM d-892

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

Ketjenlube 2700 versus PAO 40PERFORMANCE IN ISO VG 220 INDUSTRIAL GEAR OIL

13

Ketjenlube 240 in FOOD GRADE INDUSTRIAL GEAR OILSProvides:

>> 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

Formulation Composition (wt %)

Ketjenlube 240PAO 40 PAO 8Additin RC 9330*Foam Ban 159*

13.564.520.51.5

0.0075

Test method ResultLimits

according to dIN 51517-3

Viscosity 40°C (cSt)Viscosity 100°C (cSt)Viscosity indexPour point (°C)Flash point (°C)Water content (ppm)

22726.7151-33274100

198 - 242-90

-9 max.200 min.1000 max.

Test method ResultLimits

according to dIN 51517-3

Demulsibility ASTM D 1401 (82°C) 41-39-0 (10) 40-37-3 (30)

Foaming ASTM D 892Sequence I (ml) Sequence II (ml) Sequence III (ml)

10/00/050/0

100/10100/10100/10

Copper corrosion ASTM D 130 (100°C, 3h) 1a 1b 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 51819-3wear loss bearing rollers (mg)wear loss bearing cage (mg)

2.119.9

30 max-

Oxidation test ASTM D-2893 (121°C, 312 h); Viscosity increase (%) 3.4 6 max

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.

*Additin and Foam Ban are registered trademarks of Rhein Chemie and Muenzing GmbH, resp.

Performance of Ketjenlube 240 in a Food-GradeIndustrial Gear Oil (ISO 220 Grade; meeting DIN 51517-3)

Analytical Results:

Polymer Esters

Ketjenlube

14

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

KetjenlubeHigh Performance EstersMetal 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 Ketjen-lube 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

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

GOOD NEUTRALEXCELLENT

Ketjenlube 115Ketjenlube 135Ketjenlube 165Ketjenlube 1300

Polymeric Esters

CHEMISTRY APPLICATIONS

LUBRICITY ENHANCER

EMULSIFIER CORROSION INHIBITOR

EP/AW ADDITIVE

Polymer Esters

Ketjenlube

16

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)

Ketjenlube 445Ketjenlube 445 VLPKetjenlube 522

Ethoxylated Polymeric Esters


LUBRICITY ENHANCER


EP/AW ADDITIVE

Polymer Esters

Ketjenlube

17

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.

THE TYPICAL “ACTIVE SULFUR” CONTENT IS 15%

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.

Ketjenlube 9350Ketjenlube 9360Ketjenlube 9450Ketjenlube 9505


LUBRICITY ENHANCER


EP/AW ADDITIVEComplex Esters


Ketjenlube 2715 S LUBRICITY ENHANCER


EP/AW ADDITIVESulphuredPolymeric Ester

KetjenlubePolymer Esters


18

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 be-ing 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.

Ketjenlube 2715 SFunctionalised Ketjenlube

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, % INTERNAL 15

PERFORMANCE TESTCU. CORROSION ASTM-D-130-M @

120°C, 3HRS

3% IN 150SN GR I 1b

3% IN 500N GR II 1b

3% IN 250N GR III 1b

WELD LOAD, Kg ASTM-D-2783

5% IN 150N GR II 400

10% IN 150N GR II 500

SOLUBILITY* 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

KEY CHARACTERISTICS

- HIGH LEVELS OF EMULSIFYING PROPERTIES;- HARD WATER STABILITY IMPROVER;- SUITABLE ALTERNATIVE TO SULPHONATES;- CHLORINE FREE MANUFACTURING PROCESS.

dAPRAL PA 450dAPRAL PA 750dAPRAL PA 1000


LUBRICITY ENHANCER


EP/AW ADDITIVEPIBSA

Separate detailed information related to the application of all of these additive groups within MWF formulations are avail-able upon request

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

PIBSA are increasingly used in Metalworking fluids (soluble oils), where they can be used together with other co-emulsifi-ers as an economic alternative to sulfonates.

TYPICAL PHYSICAL PROPERTIES dAPRAL PA 450 dAPRAL PA 750 dAPRAL PA 1000

Item Test-Method Typical Value

Appearance Visual Clear Amber Liquid Clear Amber Liquid Clear Amber Liquid

Viscosity 100°C (cSt) ASTM D-445 75 340 520

Saponification

Number

in-house 140 115 90

Acid Number in-house 95 65 60

Sediments in-house < 0.05% < 0.05% < 0.05%

Colour Gardner ASTM D-1544 15 MAX 10 10

Performance Rating Best Emulsification

Properties

Best Overall Properties Best Defoaming Power


DapralPIBSA

20

KEY CHARACTERISTICS

- HIGH LEVELS OF EMULSIFYING PROPERTIES;- HARD WATER STABILITY IMPROVER;- SUITABLE ALTERNATIVE TO SULPHONATES;- CHLORINE FREE MANUFACTURING PROCESS.

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.

DapraquestSequestering Agent

21

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).

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

The synergistic AW/EP effect of Ketjenlube 135 helps to absorb the frictional forces, resulting in lower peak temperatures and a longer grease life


GREASE

22

MELAGARDMELAGARD 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

Solid Lubricant

MELAGARD

23

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 Viscosity

IndexPour Point

Flash Point

Reccomended Application

Gardner mgKOH/g cSt cSt °C °C

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 250Automotive &

Industrial Lubes

Ketjenlube 15 Dibasic Acid Ester <1 0.05 27 5.35 138 -63 235 Biodegradable Hydraulic (Gear Oils)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

High Temperature Lube

Applications

Chain Oils and greases

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

KetjenlubeConventional Esters

24

In addition its high quality Ketjenlube polymeric esters, Italmatch Chemicals is offering also other synthetic and natural esters under the Ketjenlube trade name

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 KV@40°C KV@100°C Viscosity Index Pour Point Flash Point Reccomended

Application

Gardner mgKOH/g cSt cSt °C °C

Ketjenlube 39 8 0,3 Max 135 18 140 -54 280 Two-Stroke, MWF

Ketjenlube 9350 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 MWF forming & engine oilsKetjenlube 9505 5 0.5 45 000 2 000 250 / > 300

KetjenlubeComplex Esters

25

Description ColourAcidityValue

Specific Gravity 20ºC

Viscosity at 40ºC

Pour Point

Iodine value

Method of analysis ASTM D974 ASTM D1298 ASTM D445 ASTM D97 ASTM D5554

Unit 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

DAPRALUBENatural 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.

* LUsc listed for Biodegradable Hydraulic Fluids (Ecolabel)

Some vegetable origin versions are available on request

26

Dapraphos

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

Dapraphos 260 and C4 are used in applications where acid value is sensitive. They act as Aluminium corrosion inhibitor and/or anti-wear additive

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.

di-Phosphites (Phosphorous acid, di-alkyl esters)

Tri-Phosphites (Phosphorous acid, tri-alkyl esters)

Phosphate esters

Product description Typical P%Dapraphos DBHP Di-Butyl Hydrogen Phosphite 15.8Dapraphos P16 Di-n-Octyl Hydrogen Phosphite 11.5Dapraphos DOHP Di-Oleyl Hydrogen Phosphite 5.3

Product description Typical P%Dapraphos P50 Tri-C12-C14 Phosphite 5.2

Product description Typical P% Acid ValueDapraphos 260 Short chain Phosphate ester 12.9 330Dapral C4 Glycol Phosphate ester 2 65

Phosphorus Additives

27

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.

A number of options to formulate are available, balancing between Wear protection, Co-emulsifier and Corrosion performance of the lubricant.

DapraphosPhosphorus Additives

Ethoxylated phosphate esters

Product description Typical P% Acid Value EO Num.Dapraphos 065 Ethoxylated Phosphate 8.3 150 5Dapraphos 457 Ethoxylated Phosphate 5.8 105 7Dapraphos 802 Ethoxylated Phosphate 4.2 145 2

28

Rhodafac ASIPhosphorus Additives

Rhodafac® ASI is an efficient corrosion inhibitor for:• Ferrous metals• Aluminum• Zinc• Magnesium and their alloysWith high thermal stability up to 350°C

Main applications are soluble oils, synthetic fluids and cleaners.

Phosphonic acid as corrosion inhibitor

Product description pH in waterRhodafac 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

Rhodafac ASI are efficient staining inhibitors for aluminium (0,2 % at pH = 9)

+ 1% Rhodafac ASI-100

Treat rateWeight 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

The Italmatch Chemicals product range comprises of various long chain fatty acid amides.These amides are used among others as additives in automotive lubricants.

DAPRAMID O reduces the friction coefficient of the lubricant. In addition it improves the surface quality as shown on the graph:

Trade Name Chemical description Appearance Typical UseDapramid O Oleylamide Pellets or Molten Liquid LubricantsDapramid HT Stearylamide Pellets Greases

DAPRAMIDFatty Acid Amides

0.3% Dapramid O 0.5% Dapramid O

30

Regulatory

• 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

INVENTORY

NSF registered for use in lubricants with incidental food contact (HX-1)

Kosher Certification

Halal Certification

LUsc Listed

Information

KETJENLUBE 115 KETJENLUBE 135 KETJENLUBE 165


KETJENLUBE 240 KETJENLUBE 2500



KETJENLUBE 240 KETJENLUBE 2500

Ketjenlube, Dapraphos and Dapral series are certified.

Please call your local ITALMATCH representative for more details or specific demand

DAPRALUBE 320

DAPRALUBE TO-HP

Please call your local ITALMATCH representative for specific demand

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

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

Product commercialization

33

Notes

34

Imprint

Published by:

ITALMATCH CHEMICALS GroupVia E. Vismara, 11420020 Arese (Milano), ITALY.Version: December 2016

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.

35

ltalmatch Chemicals GroupLubricant Sales Offices

Headquarters & Sales Office:Via Magazzini del Cotone 1716128 Genova – ITALY Phone: +39 010 642081Telefax: +39 010 4695296E-Mail: [email protected]: www.italmatch.com

Arese Manufacturing Plant & Sales Office:via E.Vismara 11420020 Arese (MI) – ITALYPhone: +39 02 935251Telefax: +39 02 93525496E-Mail: [email protected]

Frankfurt Office:Industriepark Höchst, Gebäude B 797 Brüningstraße 50D-65926 Frankfurt am Main – GERMANYMobile: +49 173 4124565E-Mail: [email protected]

Barcelona OfficeCalle Comte d’Urgell 24008036 Barcelona – España Phone: +34 93 6373537Telefax: +34 93 6591902E-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 1871Telefax: +86 21 3469 1872E-Mail: [email protected]

Italmatch Singapore Pte Ltd1, Kim Seng Promenade#17-02 Great World City East TowerSingapore 237994Phone: +65-62356483 Fax: +65-68364534E-mail: [email protected]

Italmatch USA Corporation5544 Oakdale Rd SESmyrna, GA 30082 USAPhone: +81 3 52103812Fax: +1 (404) 505-0671E-Mail: [email protected]

Tokyo OfficeBurex Kojimachi 5F, 3-5-2 Kojimachi, Chiyoda-kuTokyo 102-0083 JapanPhone: +81 3 52103812Fax: +81 3 52103830E-Mail: [email protected]

dicembre 2016 - 329 cit - realizzazione grafica: www.silvestri.info

Geo Coverage

your versatile partner in chemistry high … · high performance chemicals for lubricants your...

Documents