K-Patents Applications in Metal Machining and Mining Industries

Metal Machining: Automotive Parts, Engines, Steel, Alumina, Tin Cans, Turbine Blades, Bearings etc.
Mining: Hydraulic Fluids
Metal Machining: Automotive Parts, Engines, Steel, Alumina, Tin Cans, Turbine Blades, Bearings etc.

Metal Machining Process: Water Based Hydraulic Fluids
K-Patents applications in metal machining industry are typically processes such as quenching (hardening), grinding, cooling, cutting, washing and coating, where water based hydraulic fluids or emulsions are used to make various metal products like engines, drill bits, beverage cans, steel coils, turbine blades, bearings etc. For instance, various protection layers often need to be applied on products to prevent corrosion. The protective layer is formed by a water-soluble oil that is applied on the surface by spraying or in a bath. This oil coating is especially critical for the goods that are stored for longer periods.

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Quenching: Quenchants
K-Patents process refractometer provides a concentration measurement for quenchants in the quenching/tempering process of metal parts. The liquid concentration of the quenchant is a critical parameter, which affects the quality of the heat-treated product. When the concentration is correct, the surface properties of the metal parts can be kept within specifications.

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Cooling/Cutting: Cooling Lubricants and Cutting Oils
K-Patents process refractometer is used for accurate concentration measurement of cooling lubricants both in centralized and local systems. The control task is to continuously monitor and provide instant feedback as to changes in the fluid and to precise dosing and mixing of the fresh fluid. The applications are in the feed line and in the recirculation line to the grinding tool.

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Washing: Protective Agents and Coating Fluids
K-Patents process refractometer provides a continuos concentration measurement for the wash liquid that is sprayed on the metal parts before they are sent to storage. Out of specs liquid means that the parts are improperly washed or have too much grease on them.

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Rinsing: Residue Solution
In case the metal parts are welded, the protective coating must be removed by rinsing. It is critical to wash off all the coating as any unwashed residue will affect the quality of the welds. K-Patents process refractometer monitors the concentration of the residue solution and notifies when it reaches a set point (typically 0.5 Brix) so that the used washing liquid can be replaced by a fresh one.

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Stamping Process of Tin Cans: Lubricating Oils
The cans are made from aluminum by a stamping process. Lubrication oils and emulsions are used to minimize tool wear and to prevent the metal from tearing during stamping. K-Patents process refractometer measures the concentrations of these emulsions, as they must be kept within tight tolerances to ensure their optimum lubricating properties.

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Mining: Hydraulic Fluids

Longwall Coal Mining: Hydraulic (Longwall) Emulsions
In the underground coal mines, so-called longwalls are use to support ceilings of the coal beds to allow safe mining of coal. The longwalls are operated by a hydraulic system. Due to losses through leakage, fresh oil emulsion is fed to the system regularly.

K-Patents process refractometer is used for keeping the concentration of hydraulic fluids constant while minimizing the use of fresh fluid. Fluid can be lost in the hydraulic circuit at extremely large rates. Too high concentrations can cause gasket failure in the hydraulic system resulting in oil spills, while too low concentrations reduce the rust prevention of the oil, which may thereafter cause huge damages and system failures. Unlike periodical sampling, continuous monitoring provides instant feedback as to changes in the fluid and to precise dosing and mixing of the fresh fluid.

Due to fire damp protection reasons, the whole refractometer system can be installed in an EX enclosure. In such case, the K-Patents remote panel and remote usability function allow for easy operation without having to access the transmitter.

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Alumina Refining: Caustic Soda, NaOH
Alumina mining and refining operations can also be improved by monitoring the concentration of caustic soda that is used to dissolve alumina.

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To find out how You can benefit from using a K-Patents Process Refractometer, please contact us or send us an Information request.