Optimization of metalworking fluid microemulsion surfactant concentrations for microfiltration recycling

Microfiltration can be used as a recycling technology to increase metalworking fluid (MWF) life span, decrease procurement and disposal costs, and reduce occupational health risks and environmental impacts. The cost-effectiveness of the process can be increased by minimizing fouling interactions between MWFs and membranes. This paper reports on the development of a microfiltration model that establishes governing relationships between MWF surfactant system characteristics and microfiltration recycling performance. The model, which is based on surfactant adsorption/desorption kinetics, queueing theory, and coalescence kinetics of emulsion droplets, is verified experimentally. An analysis of the model and supporting experimental evidence indicates that the selection of surfactant systems minimally adsorb to membranes and lead to a high activation energy of coalescence results in a higher MWF flux through microfiltration membranes. The model also yields mathematical equations that express the optimal concentrations of anionic and nonionic surfactants with which microfiltration flux is maximized for a given combination of oil type, oil concentration, and surfactant types. Optimal MWF formulations are demonstrated for a petroleum oil MWF using a disulfonate/ ethoxylated alcohol surfactant package and for several vegetable oil MWFs using a disulfonate/ethoxylated glyceryl ester surfactant package. The optimization leads to flux increases ranging from 300 to 800% without impact on manufacturing performance. It is further shown that MWF reformulation efforts directed toward increasing microfiltration flux can have the beneficial effect of increasing MWF robustness to deterioration and flux decline in the presence of elevated concentrations of hardwater ions.