Document daE8B2L51x21R73ya9r8EwV2e

----------- /-------------- Monsanto Chemicals __ L < _ AROCLOR A NONFLAMMABLE HYDRAULIC FLUID FOR DIE-CASTING SYSTEMS Monsanto Technical Bulletin No. P-13T March 28, 1949 Monsanto Chemical Company St. Louie 4, Mo. Aroclor* 1248, chlorinated biphenyl, the safe and economical organic hydraulic fluid for metal die casting systems, eliminates the constant threat of serious fire hazard associated with the use of com bustible hydraulic fluldB In the dle-casting Industry. This safe and economical hydraulic fluid has been In continuous satisfactory use In Individualized dle-castlng units for about ten years and In central ized systems for the past two years. Registered in U. S. Patent Office II in ll.is l .iliri ii n band on nui rnj fiienre, ie[iifcris <iw beai judgmrni in ihf rostiri. and it L. In l| li.l.lmi < (ahiioc 'Miir ie*|K'OMl,,|n y (nr any less ot arndrnt that may mult from iia use. N **- MONS 06001A I. INTRODUCTION Aroclor 1248, chlorinated biphenyl, the safe and economical organic hydraulic fluid for metal dle-castlng systems, eliminates the constant threat of serious fire hazard associated with the use of combustible hydraulic fluids In the dle-castlng Industry. There are not many available noncombustible organic fluids and only very few possess the over-all physloal requirements of hydraulic fluids for dle-castlng systems. Notwithstanding the possibility of sustaining costly fire damage when using relatively Inexpensive petroleum oils, the economics Involved In replacing petroleum oils with the more expensive noncombuatlble organic hydraullo fluids Is an Important factor to the Industry. In this connection, It Is Important to emphasize that Aroclor 1248 appears to be substantially less expensive than the few other available noncombustible organic hydraulic fluids for this purpose. Aroolor 1248 has been used successfully in dle-castlng machines for many years and satisfactory continuous service records on Aroclor 1248 ex tend beyond ten years. It is used throughout the industry as widespread and leading dle-casters have installed Aroclor 1248 to replace combus tible oils and also to replace other nonoombustlble organic fluids, because of the demonstrated good performance obtainable with Aroclor 1248 and because of Its lower Initial cost and lower "make-up" require ments In the system. II. INDIVIDUALIZED DIE-CASTING SYSTEMS Aroclor 1248 has been used continuously for many years In Individualized dle-castlng units using machines built by Lester Engineering Company (13). The Hydraulic Press Mfg. Co. (ll), H. L. Harvill Mfg. Co. (9). and the Cleveland Automatic Machine Co. (4), as well as excellent "home built" units. Frequently, these machines are equipped with vane type oentrlfugal pumps such as the ones made by Vickers, Incorporated (21), but other types of centrifugals may also be used. The Watson-Stlllman Company's (22) dle-castlng machines are used as Individualized units equipped with Ollgear piston type pumps made by The Ollgear Company (15). Aroclor 1248 Is suggested as a nonoombustlble hydraulic fluid for Installations of this type. In most Instances, the normal operating temperature of the hydraulic fluid Is within the range of 80*-l2oF. and this temperature may or may not be controlled by Jaoketed water coolers, depending on the spe cific design of the dle-castlng machine. Most of these machines use 60-200 gallons of the hydraulic fluid and operate at pressures ranging as high as 1,000-3,000 p.s.l. 2. HONS 080015 III. CENTRALIZED DIE-CASTINO SYSTEMS Aroclor 1248 has been in continuous satisfactory use for a number of years In oentrallzed die-casting systems consisting of batteries of the machines connected to a central tank of the Aroclor hydraulic fluid. These systems are usually equipped with piston type pumps such as made by The Ollgear Company and have an accumulater In the line to maintain smooth operation. Such centralized systems may operate with 2,000 gallons, or even more, of Aroclor 1248. Systems of this type using Aroolor 1248 and Ollgear pumps have been In continuous service for a number of years with apparently satisfactory performance. IV. PHYSICAL PROPERTIES OF AROCLOR 1248 The physloal properties of Aroclor 1248 are listed below with similar constants for Aroclor 1254. The reason for including Aroclor 1254 Is that In some Instances, especially for viscosity considerations, It may be desirable to blend small portions of Aroclor 1254 with Aroclor 1248. For more complete data about the low vapor pressure of Aroclors, their low vaporization rates, their viscosity ranges, their noncorrosive properties, high order of stability to heat and corrosive Influences, as well as other pertinent qualities, please refer to Monsanto Techni cal Bulletin No. P-115 entitled, "The Aroclors" (14 bibliography reference). TABLE I. Outline of Physical Properties Aroclor 1248 Aroclor 1254 Form Yellow tinted mobile oil Light yellow viscous oil Color--APHA 100 Max. 100 Max. Acidity--Maximum (mgm. KOH/Om.) 0.015 0.015 Average Coefficient of Expansion - co/cc/'C. Density-Speoific Gravity (7257#V/2757'CF..) Pounds per Oallont% 25'C. t(7'T'7TF. 0.00070 (25*-65'C.) 1.447 to 1.457 12.08 0.00066 (25*-65'c.) 1.538 to 1.548 12.83 MUMS 080016 TABLE I. (continued) Aroclor 1248 Distillation Range--ASTM D- 20 (Mod.) Corr. C. 340-375 Vaporization Rate gms/cm hr/lOO'C. 0.000152 Flash Point--Cleveland Open Cup "C. 193-196 *F. 379-3840 Fire Point--Cleveland Open Cup C. None Pour Point--ASTM D-97 C. -7 f. 19.4 Viscosity--Saybolt Universal Sec. (ASTM D-88) 210F. (98.9 c.) 130F. (54.4,C.) 100f. (37.8c.) 36-37 60-78 185-240 Absolute Vlecoslty--Centi poises 212'F. (100"C.) 122F. ( 50*C.) 77F. ( 25C.) 4.2 25 208 Aroclor 12*54 3650-390* 0.000053 None None 10 50 44-48 260-340 1800-2500 8.5 146 777 V. NONCOMBUSTIBLE QUALITIES OP AROCLOR 1248 PLASH POINT. Limitations of thiB test for the prediction of the fire hazard of relatively nonvolatile organic fluids have been recognized by the ASTM committee (l). FIRE POINT is a more significant measurement. The National Board of Fire Underwriters Laboratories (20) concur that fire tests more truly reflect the (lack of) fire hazard of Aroclor. SPONTANEOUS IONITION TEMPERATURE. The combustion resisting qualities of Aroolor 1248 are indicated by its high spontaneous ignition tempera ture of 704*C. (l,299P.) determined by Sullivan, Wolfe and Zlsman (19). using the convenient apparatus described by Sortman, Beatty and Heron (18). Under industrial use conditions the spontaneous ignition temperature will be determined by factors including the nature of the hot surface, the amount of liquid lmplgnlng on it, the volume of enclosed space, and the ventilation. In this connection, we wish to refer to an 4. MOMS 060017 observation concerning the use of Aroclor 1248 as a noncombustible heattransfer medium In Aroclor heating systems. An accidental failure In one of our Aroclor heating systems demonstrated the nonflammability of Aroclor 1248 and Its freedom from the hazard of fire propagation. An operator's failure to start the circulation of the heat-transfer medium when the gas heater was on resulted In excessive coll tempera tures, causing the lower coll (steel) to soften and sag Into the fire chamber. A weld ruptured and Aroclor 1248 poured Into the red hot fire chamber in contact with the flame. Smoke arose from the heater but there was no Internal fire. After the gas flame was cut off, the smok ing stopped. SPRAY FLAMMABILITY. When a line ruptures In a dle-oasting system where the hydraulic fluid Is under relatively high pressure, a spray or mist prevails. The possible fire hazard of Aroclor 1248 under these con ditions requires considerations not covered by the foregoing discussions relative to the material in the liquid form. In their comprehensive study, "Flammability of Higher Bolling LlquldB and Their Mists", Sullivan, Wolfe and Zlsman determined the spray flammability limit of numerous materials In accordance with the percentage of oxygen required for com bustion. This value was then correlated with the results of incendiary firing tests of the fluid conducted at the Naval Proving Oround, Dahlgren, Virginia. The per cent oxygen requirement for Aroclor 1248 combustion in the spray flammability limit studies was established at 64#. It was observed that fluids requiring over 45*50# of oxygen in the spray test failed to cause a fire In the Incendiary test. These results firmly establish the nonflammable and noncombustible qualities of Aroclor 1248. Moreover, these results on spray flammability studies seem most pertinent since they reflect conditions prevailing in the case of pressurized systems such as used In metal dle-casting. There fore, we are taking the liberty of presenting the data in the following Table II as taken from the publication by Sullivan, Wolfe and Zlsman to compare this highly significant spray flammability rating given to selected chlorinated hydrocarbons, organic phosphates, etc. Benzene and a petroleum oil are Included for comparison purposes. 5MQNS oaooia Fluid TABLE IX. Flamro&blllty of Certain Higher Bolling Liquids and Their Mlata Viscosity Flash Pt. Fire Pt. Cs. at (COC) (1) (C0C^(1) S.I.T.(2) 100'F. 'F. F. Spray Plammablllty Limit % Oxygen Naval Ordnance hydraulic oil O.S. 1113 41.8 315 340 505 14 Benzene 0.58 12 - 1295 12 S:8Chlorobenzene o-Dlchlorobenzene 90 - 14 165 _ - 29 1,2,4-Trlchlorobenzene i.i 260 None >1000 44 Trlohlorodlphenyl (Aroelor 1242) 17.7 350 633 1230 45 AROCLOR 1248 (Tetraohlorodlphenyl) 45.4 14380 None 1300 Diphenyl ether 2.6 Ohlorodlphenyl ether 3.0 D1ohlorodlphenyl ether 4.9 Trlohlorodlphenyl ether Trlmethyl phosphate 8.7 - Trlbutyl phosphate 2.6 Trlootyl phosphate 8.1 Trloresyl phosphate 29 Hexamethyl tetra- phosphate Tetrabutyl pyro- 38.3 phosphate D1 octylphenyl 8.9 phosphonate 11.5 Diphenyl mono (p-tert- butyl phenyl) phos phate 40.3 Dl-(o-ohlorophenyl) monophenyl phosphate 34.3 265 260 300 325 225 285 380 500 >510 465 435 465 510 275 335 465 4901 245 370 465 685 None 720 480 720 >760 " 903 680 1170 920 845 630 1076 1296 11 27 33 42 47 27 13 19 31 14 21 12 21 (1) Cleveland Open Cup (2) Spontaneous Ignition temperature In light of the Importance of spray flammability as demonstrated to be the moat significant determination of the noncombustible qualities of higher boiling fluids and their mists. It Is Indeed interesting to note the laok of correlation between this value and other constants, such as, 6. HONS 080019 flash point, fire point and especially the spontaneous Ignition tempera ture . VI. RESISTANCE OP STRUCTURAL MATERIALS TO AROCLOR 1248 The nonoorroslve qualities of Aroolor 1248 and the strong resistance of structural materials to Aroclor 1248 are highly Important factors In the practical use of Aroclor as a hydraulic medium In dle-castlng sys tems. The following Table III Indicates the resistance of structural materials to Aroclors 1248 and 1254. TABLE III. Resistance of Structural Materials To Aroclors 1248 and 1254 Hgtplg 1248 1254 Wc1 T 1125C. 2oc5.n-^ 125"! Aluminum Copper Magnesium Nickel Sliver Tin Zinc Mild Steel Phosphor Bronze Red Brass Stainless Steel Yellow Brass RRRR R DRD RR R R R RR R R RR RRRR RRRR R R RR RR R RR RR R DRR DDR D RR RR RR RR R Re R De RR--Excellent resistance--less than 1.0 x 10^ cm/day penetration i 0.00014 ln/yr. ,, R --Oood resistance--has penetration between 1.0 x 10 and 10 x 10 em/day or between 0.00014 and 0.0014 ln/yr. r D --Doubtful reslstance--has penetration between 10 x 10 cm/day and 100 x 10 cm/day or between 0.0014 and 0.014 ln/yr. e --Following the letter Indicating resistance signifies material may be better than Indicated If totally Immersed Blnce weight loss Is believed to come from oxidation of the part of teBt strip exposed to air. 7- HONS 080020 VII. PACKINO MATERIALS AND GASKETS SUITABLE FOR USE WITH AROCLOR 1248 IN DIE-CASTINO SYSTEMS Results of accelerated laboratory tests show that Hycar P, Koroseal, Perbunan, Neoprene and various other "rubbers" are softened by Aroclors. especially at elevated temperatures. Accordingly, questions arise about the use of these materials for gaskets on die-casting machines using Aroclor. However, from practical experience In the operation of dle-oaritlng machines, It has been noted that fittings, such as the ball Joints made by Chlksan Tool Company (3). containing a small Neoprene gasket have given very good service under long continuous use when Installed In dle-castlng systems operated with Aroclor. Also, Neoprene lined, metallzed, flexible tubes used on the return lines of the dleoastlng machines appear to give good service with Aroclor. In some Instances It appears almost necessary to use flexible tubes, especially on the return lines of the dle-castlng machines. If possible to do so, It would seem desirable to use rigid lines fitted With ball Joints such as made by Chlksan or Barco Swivel Joints (2). For pipe connection, welded joints are not necessary but In the case of welded flange connections, these may be satisfactorily gasketed by the use of a thin sheet of aluminum. Various packing materials suitable for use with Aroolor at elevated temperatures Include Oarlock Packing Company's (8) #7021, 1/8 Inch asbestos fiber sheet for flange connec tions. Oarlock's #117 braided packing Is used In valves and Oarlock #234 packing Is used for pumps; also, Oarlock #431 and Chevron 7050-C materials are suitable packings. Likewise. Durametalllc (6) spiral asbestos fiber may be used. Doubtless, Johns-Manvllle Corp. (12) and others have comparable packing materials which would be suitable. In all Instances, when ordering packing, It should be Indicated to the supplier that the material Is Intended for use with Aroclor 1248. Teflon, duPont's (7) polytetrafluroethylene. Is not attacked by hot Aroclor (l30*C.) and Is to be recommended as a gasket material. Thlokol Is not attacked by Aroclors at ordinary temperaturfes and especially Thlokol 1605-A appears of Interest for use with Aroclors In dle-castlng systems. The maximum temperature ranges at which Thlokol Is suitable are Indicated as follows: Thlokol Type A - 150-200'F. max. Thlokol Type FA - 150"-200F. max. Thlokol Type ST - 250-300F. max. Dow Coming's (5) Silastic, Silicone 180 Is very resistant to hot Aroclor and use of this material Is suggested. The changes In proper ties of Silicone 180 when Immersed in hot Aroclor for 70 hours at 150C. are summarized as follows: 8. mons oaoozi 1. Lowering of the hardness by about 20 points. 2. Improvement in the elasticity by several points. 3. Practically no change In tensile strength. 4. An appreciable Increase In the ultimate elongation. Other types of packing materials recommended by the manufacturer for use In Aroclor installations Include the following Palmetto (16) pack ings: Hydraulic Service (Normal Temperatures^ Rod packing U Ring packing Flange packing Kup packing Sheet packing & gaskets - Palmetto Pyramid Packing #2510 - Palmetto U Ring Packing #2610 - Palmetto Flange Packing #2610 - Palmetto Kup Packing #2710 - Palmetto Hl-4 Sheet Packing #2910 Heat-Transfer Service Rod packing - Palmetto High Pressure Packing #2200 Sheet packing & gaskets - Palmetto Hl-4 Sheet Packing #2910 With reference to the manufacturer and also the user of die-easting equipment, It Is highly advantageous if the same packing materials generally used with oil can be used also with Aroclor 1248. In this connection, In the case of The Ollgear Company hydraulic equipment, It Is noted that suoh packings as Thlokol, whloh Is used for gaskets, and Oarlock #431, which Is used as ram packings on most Ollgear equip ment, oan be used either with oil or with Aroclor 1248. Vickers, Incorporated advise that all packing materials will have to be other than those normally used for petroleum base fluids to prevent rapid deterioration, and these are available through Vickers, Incorporated for their own equipment, or many of the suppliers of standard sealing elements. VIII. LUBRICATION Aroolor 1248 has lubricating properties and Is used In dle-castlng systems most frequently without the addition of added lubricants. However, In the case of piston type pumps where high lubricity is a requirement, sometimes the practice Is to add not more than 5% of a high lubricity oil to the Aroclor. Oils of this type In use are DTE medium heavy high lubricity oil and Pennsylvania Refining Company's (17) #90 VI light stock oil. Other similar oils are available for this purpose. 9. MONO 080022 Aroclor 1248 Is recognized In the Industry as an EP lubricant and Its heavy load carrying quality without Beizure is reflected by tests made with a hydraulic fluid containing a substantial proportion of Aroclor. The data pertains to results with an Almen test machine. During the standard test, the hydraullo fluid carried the full 30-pound load nor mally used as maximum on the Almen test. The torque at maximum load passed, average of 2 runs, was found to be 28.5 for the hydraulic fluid bull- on Aroclor as compared with a value of 14.0 for SAE 10 motor oil. IX. VISCOSITY The viscosity of Aroclor 1248 seems to be within the range required In the normal operation of many Industrial pumps and hydraulic equipment. As previously Indicated, the viscosity of Aroclor 1248 can be Increased by the addition of Aroclor 1254. In light of the Influence of tempera ture on the viscosity of Aroclor, this factor should be given considera tion with reference to the operation of the pumps or hydraulic system In which Aroclor Is used. As a general Indication of the viscosity requirements for different types of pumps, Vickers, Incorporated specifies the following for use with Its pumps: Industrial Machinery Installations (Ambient Temperature 50F. to 90*p7) Type of Installation Vane Type Pumps Machine tools operating at 150-225 S.S.U. pressures up to 1000 p.s.l. 100F. Presses and other heavy machinery 275-315 S.S.U. 9 100F. Piston Type Pumps All Industrial machinery 275-315 S.S.U. 9 100F. Piston Type and Ooar Type Fluid Motors All Industrial machinery 150-315 S.S.U. 9 100F. Vickers recommends that the oil temperatures in the hydraulic circuit should be maintained between 60 and 130F. If, for reasons of non operation for extended periods, the temperature drops below 60F., the fluid should be warmed to that temperature before starting operations. 10. MQNS 080023 Coolers should be provided to prevent temperatures In excess of 130*F., which will comply with the temperatures demanded by the Joint Industry Conference Hydraullo Standards, and Bhould also avoid the necessity of having to use vent ducks from any open or semi-open reservoir. Referring to the fact that the specific gravity of Aroclor 1248 is greater than the similar value of average petroleum base fluids used, inlet conditions to pumps should be carefully scrutinized to insure the absence of cavitation. X. FILTRATION It seems prudent to maintain clean oil regardless of the specific hydraulic fluid used in dle-castlng systems. Small particles of dirt, metal chips and sand from the castings seem to work their way into the hydraulic fluid whether the installation is a new one or one that has been in service for many years. Aroclor 1248 has a tendency to suspend auoh impurities. Although it is not always practiced, nevertheless, it seems important to provide adequate filtration so that abrasive particles are removed from the system and the Aroclor 1248 is kept clean. Many dle-castlng machines are equipped with internal fine mesh wire screens. These filters are suitable for removing the larger particles, but to keep the Aroclor in a satisfactorily clean condition, the recom mendation is to filter the Aroclor through a bed of suitably processed granular Fuller's earth. There are available a number of satisfactory filtering mechanisms or oil purifiers which may be used continuously or intermittently. Probably one of these filters available as a con venient portable model would be the most economical as it could be used to clean the oil in a number of dle-castlng machines. As one example of a supplier of Buch equipment, we wish to refer to the Honan-Crane Corporation (10). XI. DERMATOLOGY AND TOXICOLOGY Results of standard skin patch tests using over 100 individuals show that Aroclor 1254 is neither a skin irritant nor a skin sensitizer (14). We would expect that these results would serve to indicate that Aroclor 1248, which is only slightly lower in chlorine content than Aroclor 1254, is also neither a skin irritant nor a skin sensitizer. Although the vapor pressure of Aroclor 1248 is quite low and for all practical purposes the material is nonvolatile, nevertheless, when Aroclors are heated to elevated temperatures, vapors arise and these vapors bear a degree of toxicity and should not be breathed. This 11. NUNS 080024 consideration Is, of course, minimized in the case of using Aroclor 1248 in die-casting systems, which are necessarily thoroughly enclosed to prevent even the smallest kind of a leak, and the operating tempera ture is relatively low since practical operation never exceeds about 140F. Aroclor 1248 has been used for over ten years in individualized and centralized die-casting systems with 'omplete freedom from any trouble or fear of any toxic effects. If Aroclor 1248 comes in contact with the worker's skin, the skin should be washed in an ordinary manner with soap and water. If the Aroclor is sufficiently hot so as to cause a bum when in contact with the skin, the burn should be treated in the same manner as any ordinary burn. Aroclor adhering to the burned area need not be removed Immediately unless treatment of the burn demands it, in which case soap and water or repeated washings with a vegetable oil is recommended. # MONSANTO CHEMICAL COMPANY St. Louis 4, Mo. New York-Chleago-Boston-Blrmingham-Charlot tc-Cinclnnati-Clevcland Detroit-Philadelphia-Loo Angelco-San Francisco-Montreal PCh:MAG 2M BIBLIOGRAPHY (1) Am. Soo. Testing Materials, Proc. Am. Soc. Testing Materials, 34, 53 (1934). (2) Baroo Manufacturing Co., 1001-15 Wlnnemac Ave., Chicago, Illinois. (3) Chlksan Tool Company, Brea, California. (4) Cleveland Automatic Machine Co., 4900 Beech Street. Cincinnati 12, Ohio. (5) Dow Corning Corp., 392 Saginaw Road, Midland, Michigan. (6) Durametalllc Corp., 1936 Hall Street, Kalamazoo 24-P. Michigan. (7) E. I. duPont de Nemours ft Co., Inc., Wilmington 98, Delaware. (8) Oarlock Packing Company, 250 Main Street, Palmyra, New York. (9) H. L. Harvill Mfg. Co., Harvlll Building, Corona, California. (10) Konan-Crane Corporation, Lebanon, Indiana. (11) The Hydraulic Press Mfg. Co., 830 Marlon Road, Mount Gilead, Ohio. (12) Johns-Manvllle, 22 East 4oth Street, New York 16, New York. (13) Lester Engineering Co., 2711 Church Street, Cleveland 13, Ohio. (14) Monsanto Chemical Co. Technical Bulletin No. P-115, "The Aroolors." (15) The Ollgear Company, 1560 W. Pierce St., Milwaukee 4, Wisconsin. (16) Palmetto packings made by Oreene, Tweed ft Co., N. Wales, Penna. (17) Pennsylvania Refining Company, 2686 Lisbon Ave., Cleveland, Ohio. (18) Sortman, C., Beatty, H., and Heron, S., Ind. Eng. Chem., 33, 357 (1941). (19) Sullivan, M. V., Wolfe, J. K., and Zisman, W. A., Ind. Eng. Chem., 39, 1607 (1947). (20) Underwriters' Laboratories, "Miscellaneous Hazards No. 2498", Chicago, Illinois, 1934. (21) Vickers, Incorporated, 1402 Oakman Blvd., Detroit 32, Michigan. (22) The Watson-Stlllman Co., 109 Aldene Road, Roselle, New Jersey. 13. MUNS 080026