Using Jatropha Oil Based Metalworking Fluids in Machining Processes:

A Functional and Ecological Life Cycle Evaluation

1,2 1,2 1,2 1,3 1,3 1,2
Marius Winter , Gerlind hlschlger , Tina Dettmer , Suphunnika Ibbotson , Sami Kara , and Christoph Herrmann
1
Joint German-Australian Research Group Sustainable Manufacturing and Life Cycle Management
2
Institute of Machine Tools and Production Technology (IWF), Product- and Life-Cycle-Management Research Group,
Technische Universitt Braunschweig, Germany
3
School of Mechanical and Manufacturing Engineering, Life Cycle Engineering and Management Research Group,
The University of New South Wales, Sydney, Australia

Abstract
Metalworking fluids (MWFs) are used to ensure requirements in terms of component quality and process stability in metal
machining. A large proportion of MWFs are based on the non-renewable resource mineral oil. An alternative to mineral oil
are MWFs based on renewable resources. A possible substitute in this context is the oil of the jatropha curcas seeds. The
jatropha oil shows a suitable fatty acid pattern and is inedible for humans and animals. It can be grown under marginal
conditions which can avoid the direct competition for food and animal feed production. This paper describes and performs
a functional and an ecological evaluation of a jatropha oil based MWF life cycle.

Keywords:
Metalworking fluids; Jatropha oil; Functional evaluation; Ecological evaluation

1 INTRODUCTION
Metalworking fluids are used in various manufacturing processes to
reduce friction, to dissipate the heat and to transport metal chips or
swarf. The fulfilment of these tasks enhances the process stability,
leads to better work piece quality and prolongs the tool life [1]. A
wide range of different metalworking fluids can be used to improve
the process efficiency in relation to technological, economic and
ecological aspects. Metalworking fluids are of special importance e.g.
in the manufacturing process of grinding, due to the demanding
conditions of the relatively large contact area between the work piece
and the work tool, the high friction between the abrasive grits and the
work piece surface [1].
1.1 Metalworking Fluids for Machining Processes
Metalworking fluids consist of two major components, the basic fluid
and an additive package. Figure 1 presents how the base fluids are
distinguished, according to DIN 51385, in oil based and water based
types [2].
Oil-based MWF Water-based MWF
Basic oils: - Emulsions
Basic fluid
The base fluids of oil based metalworking fluids are not water-
miscible. They are based mostly on mineral oil, alternatively synthetic
or plant oils can also be used. The oil based metalworking fluids
normally consist of 80-95 % basic oil. The water based fluids can be
distinguished in two different compositions; namely solutions and
emulsions. The water based solutions are generally clear and
chemically stable fluids composed of water and non-organic and / or
organic substances. A water based emulsion is a milky and stable
disperse mixture of mineral oil and water. Alternatively plant oils can
be emulsified in water. The oil droplets are finely dispersed in the
water phase. The common oil concentrations in emulsions are
between 2 and 15 %. As mentioned before, beside the base fluid the
additives are another important component of metalworking fluids.
The additives are added to the base fluid to improve a specific fluid
characteristic. Therefore an optimal design and adaptation of the
metalworking fluid with regard to the particular production process is
possible. The additives can be divided into enhancer of physical and
/ or chemical fluid characteristics, furthermore into tribological active
additives [1], [2], [3], [4], [5].
1.2 Conventional Metalworking Fluids
Conventional lubricants are based on mineral oil. Approximately 5 %

- Mineral oil (concentrate:

- Hydrocrack oil basic oil + of the worldwide mineral oil consumption in 2010 was used to
- Polyalphaolefines emulsifier) formulate lubricants (based on [6], [7]). In the same year about
- Synthetic ester - Solution (organic 1 million tons of mineral oil was used for lubricants in Germany,
- Vegetable oil or inorganic) thereof about 7 % was used for the production of water-miscible and
non-water-miscible metalworking fluids [8].
- Anti-Wear-Additives The use of conventional mineral oil based lubricants has advantages
- Extreme-Pressure-Additives
and disadvantages. In the following, these points are discussed,
Additives

- Polar-Additives
- other Additives (Anti-Corrosion Additives, Anti-
Oxidant Additives, Anti-Mist Additives, Anti-
Foam Additives, etc.)
Metal working fluid
Figure 1: Components of metalworking fluids (according to [1], [2]).
beginning with the main advantages:
On the user side there is a high level of knowledge and
experience about the use and the behaviour of these lubricants
in machine tools. This fact is reflected for example in standards
or guidelines for the analysis (DIN 51834), handling (VDI 2897),
use and disposal of mineral oil based lubricants (VDI 3397).
Based on these standards manufacturers and users of lubricants
can communicate and carry out transactions.

19th CIRP International Conference on Life Cycle Engineering, Berkeley, 2012

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Machine tool manufacturers also have a high level of knowledge
and experience about the effects of mineral oil based lubricants.
Accordingly, machine tools are designed and optimized for use
with these lubricants. This is reflected in the use of appropriate
construction materials and guidelines (VDI 3035).
Due to the already mentioned standardization, lubricant
manufacturers can offer the required products on the market.
They are easily available on the market, and thus a safe supply
for the user.
Apart from these advantages there are also disadvantages arising
from the production, use and disposal of conventional mineral oil
based lubricants:
The extraction, processing, utilisation and disposal of mineral oil
based products have a negative impact on the environment [9],
[10]. Against this background, there are extensive national (e.g.
BGR 143: Handling of metalworking fluids) and international
(Regulation (EC) No 1907/2006 / REACH) regulations regarding
the handling of lubricants, so that risks for the environment are
minimized. To comply with these regulations, the mineral oil
based lubricants have to be tested and labelled.
Apart from the negative influences on the environment, lubricants
can have negative impacts on humans as well, if they are
exposed to it for a longer period. Through the machining process
fine mist of the metalworking fluid may arise, which can be
inhaled by the machine operator. These aerosols can cause a
variety of allergic respiratory diseases, for example asthma or
hypersensitivity pneumonitis [11]. Apart from allergic respiratory
diseases, occupational skin diseases can also occur such as
dermatitis through contact with metalworking fluid [12]. In
summary, contact dermatitis is a common occupational health
problem for metalworking machinists, whereas occupational
respiratory disease is rare [13].
Conventional lubricants are largely based on the finite resource
mineral oil. Figure 2 shows the development of Brent crude oil
price between 1990 and 2010 [6]. It turns out that in recent years
the crude oil price rose significantly. In summary, this price
increase of the main raw material leads to increasing lubricant
prices.
100
US-Dollar / Barrel
75
50
25
0 resource that can be cultivated in almost all tropical and subtropical
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Year
Figure 2: Brent crude oil spot market prices in US-Dollar per barrel
(1990 2010) [6].
1.3 JATROPHA Curcas Oil as a Basis for New Ecologically
Benign Metal Working Fluids
Jatropha curcas belongs to the family of Euphorbiaceae and is a
multipurpose, drought resistant, perennial small tree or large shrub.
The shape of the fruits is ellipsoid, inside the fruits are the physic
nuts called seeds with an oil content of up to 45 to 60% [14]. In
contrast to established plants such as rapeseed oil or palm oil,
jatropha can be grown on low-yielding soils that are unsuitable for
food production. The main growing area is in tropical and subtropical
M. Winter et al.
countries and is therefore considered as ideal plant for reforestation
due to drought or erosion of abandoned agricultural land. The oil is,
due to its concentration of phorbol ester content not usable as food.
The saturated fatty acids consist mainly of palmitic acids (16:0) with
a share of 15.6 % and stearic acids (18:0) with 9.7 %. The
unsaturated fatty acids consist of oleic acids (18:1) with 40.8 % and
linoleic acids (18:2) with 32.1 % [15]. The ratio in brackets describes
the number of carbon atoms to double bonds. Furthermore, Jatropha
oil contains approximately 25 % of crude protein, 47 % of crude fat,
and 5.5 % of moisture contents [16], [17]. The combination of these
properties offers a potential for the current problem of land-use
competition among food production and cultivation of renewable
resources for biofuel and material use.
When analysing the use competition in the context of jatropha oil
production, land use competition and direct competition for the
vegetable oil can be distinguished (see Table 1). The former can be
avoided if jatropha cultivation is limited to so called waste land. Given
the much higher yields under optimal conditions and the huge
interest of global biofuel companies this seems at least questionable.
Accordingly, a high share of the worldwide harvest on the
approximately 900,000 ha of jatropha plantations [18] currently goes
to biofuel production for road, air and maritime traffic. The use of
jatropha oil in the food sector is not possible due to the already
mentioned occurrence of phorbol esters. Use of jatropha oil in
sustainable boundaries seems most probable in the case of local
energy self-supply or of material use e.g. in lubricants (a later
cascading energetic use is just possible). These forms of utilisation
require far lower amounts of jatropha oil than the international biofuel
sector and therefore offer a chance for sustainable small scale
jatropha cultivation. Currently majority of jatropha plantations are
made up of wild plants, but not economically feasible cultivation
plants. Therefore, high improvements regarding yield as well as
regarding the occurrence of wanted or unwanted oil components can
be expected during the following years.
Kind of competition Competitors Example
Land use Natural ecosystems Forest,
Cultivation of food/fodder Cereals, grass,
competition
Cultivation of renewables Fibre/energy plants,
Vegetable oil (use as food)* (cooking/frying oil, )*
use competition Renewables material use Chem. industry, soap,
Renewable energy use Biofuel, light, cooking
Table 1: Use competition in the context of vegetable oils in general
and jatropha oil in specific (* jatropha oil is inedible).
The use of jatropha oil based metalworking fluids has advantages
and disadvantages. The main advantages are:
The Jatropha curcas plant, hence the jatropha oil is a renewable
countries on abandoned agricultural land under arid and semi-arid
conditions. Furthermore, the plant is inedible for humans and
animals and therefore is in no direct competition with aliment or
forage in the use of jatropha as a metalworking fluid.
2
The jatropha oil has a kinematic viscosity of 34 mm /s at 40 C
[19]. This has positive effects on the lubricating capacity of the
fluid and thus the later behaviour of the metalworking fluids. The
lubricating capacity is important for the friction between tool and
work piece and thus affects the wear behaviour of the tool and
the surface quality of the work piece.
Pure jatropha oil is a biocompatible, biodegradable and therefore
environmentally acceptable fluid. These properties are
maintained even after the conversion to a base fluid obtained for
a cooling lubricant. However, the used additives have a strong
influence on the biological properties.