Mill coolant system design
Tramp Oils. Tramp oils collect on the top of water-based coolants and must be removed or they will insulate the coolant and possibly promote bioactivity. Belt- and tube-type skimmers can be used to remove small volumes of oil; floating vacuum skimmers are used to remove larger volumes of oil that enter the system regularly. In addition, coolant flow can be used to direct tramp oils for more efficient isolation and separation.
Special Add-ons
A variety of implements can be added to enhance coolant performance further and eliminate manual processes involved in the use and maintenance of coolant systems. They are as follows:
1. Open-surface or closed-loop heat exchangers. These are used to lower coolant temperatures to proper levels if the process generates a lot of heat. Heat exchangers are used quite commonly with new mills, because maintaining coolants at proper temperatures improves their consistency and extends tool life.
2. Automatic coolant dilution meters and level controls. These units are available in a variety of shapes and sizes. Typical installations include floats to add a prediluted coolant as needed.
3. Monitors. Coolant pressure, temperature, and dilution all can be monitored automatically to identify problems before system failure.
Reduce System Load Where Possible
Your focus always should be to reduce and eliminate system load and contamination by ensuring that proper equipment is used for applying chemicals to the profile and machine and by providing setup procedures for operators and maintenance personnel.
You can reduce contamination further by providing documented initiatives for cleanliness and scheduled maintenance and repair of equipment. Using compatible chemicals that come in contact with the mill coolant also will make the process more predictable. Thorough system cleaning before charging also will benefit you.
Finally, a comprehensive system maintenance plan not only includes a review of existing situations but also implements necessary changes with follow-up. Flood coolant systems require ongoing maintenance and testing to ensure that proper coolant conditions are maintained at all times.
