Chemicals used in the metalworking industry are often hazardous for workers’ health
and the environment. Managing chemicals is primarily associated with overcoming
health issues, since the primary cost of the chemicals is much lower than the cost of
possible health and security risks. Estimations of other costs including water, energy
and handling and disposal of chemicals demonstrate that the total cost of chemical
management may be ten times the initial purchase price (IAMS 1995). The process
fluids often contain hazardous substances including carcinogenic hydrocarbons and
eco-toxic substances. The fluids emit aerosols and vapour, which are the main reasons
for health concerns and emissions of volatile organic compounds (VOC) from metalworking
operations (Greaves et al. 1997). Contaminants in MWFs and lubricants
affect workers’ health, especially the respiratory system and the skin (Simpson et al.
2003; Gordon 2004), give rise to waste and emissions and reduce fluid system lifetime
(IAMS 1995). Also, more than 80% of the various corrosion inhibitors used in
the fluids are classified as having moderate or higher hazardousness (Pastovskaia
1990). Cleaning agents and surfactants are examples of other substances that are
dangerous to personnel. Process water contaminated with cleaning agents is the main
source of wastewater from metalworking plants. Besides health effects all the aforementioned
process fluids have a great negative impact on eco-efficiency. A majority
of the fluids are oil-based and thus require the use of scarce and expensive raw materials.
The production processes of these fluids are also energy-intensive, giving rise to
negative environmental and economic consequences. They also contribute to air and
water emissions and to generation of hazardous waste.
11.2.3