CN107287009A - 液压支架用乳化油及其生产工艺 - Google Patents
液压支架用乳化油及其生产工艺 Download PDFInfo
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Abstract
液压支架用乳化油及其生产工艺,液压支架用乳化油由以下物质组成:矿物基础油、油酸、三乙醇胺、石油磺酸钠、苯并三氮唑、甘油、S‑80、Op‑10、尿素、EDTA、氢氧化钠、余量为水;该乳化油性能稳定,乳化效果好,无油、皂等污物的析出,使用时间更长;具有良好的冻融性、抗磨抗极压性、防锈防腐蚀性,可满足液压支架在苛刻的工况下使用长期使用系统清洁干净,整个系统正常运行,液压支架无动作缓慢现象,作业安全准确,生产效率提高。
Description
技术领域
本发明涉及乳化油技术领域,更具体地说是一种液压支架用乳化油及其生产工艺。
背景技术
液压支架是一种利用液体压力产生支撑力并实现自动移设来进行顶板支护和管理的一种液压动力装置,是综合机械化采煤不可缺少的配套设备。液压支架主要用于水平面和小于等于10度的缓倾斜厚煤层沿底板一次放顶煤采全高开采的长壁综采工作面,也适用于急倾斜特厚煤层水平分层放顶煤综采工作面。采面矿压以外载的形式作用在液压支架上。在液压支架和采面围岩相互作用的力学系统中,若液压支架的各支承件合力与顶板作用在液压支架上的外载合力正好同一直线,则该液压支架对此采面围岩十分适应。它的支撑、升降、移动、推溜和过载保护都是借助乳化液在一定结构的管路和控制元件组成的系统中流动,来实现能量的传递和转化,因此用乳化油配制的乳化液被称作液压支架系统的“血液”,现有的乳化油,其冻融性、抗磨抗极压性、防锈防腐蚀性差,无法满足液压支架在井下苛刻环境的状况条件下使用,具体表现为:在使用过程中会出现污浊现象,有油、皂等污物的析出,这样不仅使得设备系统难以保持清洁、干净,而且增加了系统中过滤器、阀件的拆装次数,影响了系统的正常运行;在使用过程中会导致液压支架出现动作缓慢现象,影响了作业的效率及安全性。专利号为:201410166741.7,专利名称为:“一种矿山液压支架用乳化油”提供了一种性能较为优良的乳化油,在实用中、具有良好的润滑性能及对金属部件的防锈防腐蚀性能,低温条件下没有刺激性异味,对液压系统周围空气无污染;但是,矿山液压支架工作环境比较恶劣,作为活性剂的乙二醇受自身性能影响,在温度、静电达到一定条件时容易产生释放有毒气体、析出等问题。毫无疑问地,乳化油的质量是设备得以正常运行的关键,而活性剂的性能又影响了乳化油的质量。
当两个不同的物体相互接触时就会使得一个物体失去一些电荷如电子转移到另一个物体使其带正电,而另一个体得到一些剩余电子的物体而带负电。若在分离的过程中电荷难以中和,电荷就会积累使物体带上静电。所以物体与其他物体接触后分离就会带上静电。
目前了解到的静电现象在液压润滑系统中的具体表现形式主要有以下几种情况:能够在系统中(过滤器或油箱内)出现类似放电的“噼啪”声;系统过滤器滤芯寿命急剧下降;滤芯表面缠带甚至滤材破损;某些情况下在滤壳内壁、滤材上存在烧灼过的黑斑。静电现象还可能造成油液局部瞬间高温,从而引起油品变质,损坏系统中的重要元件,如伺服阀、比例阀。静电还可以使乳化油中产生一种很微小的(尺寸<1um)黄色或褐色粘性胶质类物质——油泥胶,这种油泥胶会吸附在系统管道、液压元件内壁或高精度控制阀的阀芯、阀套上,形成很薄的油泥胶层,造成系统工作故障。
可以看出,静电现象已经成为一种严重威胁液压系统正常运行、给用户带来极大经济损失、亟待解决的难题。
发明内容
为解决上述问题,克服现有技术的不足,本发明拟提供一种性能稳定、适用条件低、适应能力强的液压支架用乳化油及其生产工艺。
为实现上述目的,本发明提供的液压支架用乳化油,按照质量百分比包括以下物质:
矿物基础油:15.0%~20.0%、油酸:8.0%~10.0%、三乙醇胺:25.0%~30.0%、石油磺酸钠:10.0%~15.0%、苯并三氮唑:0.5%~0.8%、甘油:5.0%~10.5%、S-80:1.0%~2.5%、Op-10:3.0%~5.0%、尿素:5.0%~8.0%、EDTA:3.0%~5.0%、氢氧化钠:2.0%~3.5%、余量为水。
S-80全称硫磺预分散药胶S-80,价格低廉,具有更好的分散性;可以缩短混炼时间;与胶料的相容性更好;无粉尘飞扬,改善工作环境;操作方便,便于自动称量;加工过程中无损失,使批次之间品质更稳定;减少残次品和废品的产生,提高产品的合格率;Op-10成分是聚氧乙烯辛基苯酚醚-10,具有优良的匀染、乳化、防蜡、缓蚀、润湿、扩散、净洗,抗静电、耐酸、碱、硬水等特性,OP-10具有很好的乳化、润湿、匀染、扩散、等性能;作为亲水性乳化剂,乳液稳定、细腻,OP-10可与各类表面活性剂、染料初缩体混用。
一种液压支架用乳化油的生产工艺,其工艺步骤为:
步骤一:取油酸和三乙醇胺在氢氧化钠溶液的催化作用下进行皂化反应,反应温度70℃-90℃,反应时间2.5h,反应结束PH在8.0-8.5,皂化结束后待用。
步骤二:将石油磺酸钠加入1步骤制得的产物中,顺时针搅拌20分钟,然后将矿物基础油和S-80加入,继续顺时针搅拌20分钟。
步骤三:将甘油和水混和搅拌均匀后加入配方量的EDTA、尿素搅拌至完全溶解,加入苯并三氮唑溶解后,加入OP-10、环烷酸,搅拌10分钟。
步骤四:将步骤2中混合物转入具有乳化油专用搅拌装置的调和设备内,然后在开启搅拌装置的同时,缓慢加入步骤3中的水溶液,该过程控制温度在55℃-60℃,搅拌溶液至澄清透明后,加入消泡剂,搅拌10分钟。
本发明的有益效果是:该乳化油性能稳定,乳化效果好,无油、皂等污物的析出,使用时间更长;具有良好的冻融性、抗磨抗极压性、防锈防腐蚀性,可满足液压支架在苛刻的工况下使用长期使用系统清洁干净,整个系统正常运行,液压支架无动作缓慢现象,作业安全准确,生产效率提高。
具体实施方式:
为使本发明实施的目的、技术方案和优点更加清楚,下面对本发明进行更加详细的描述。
具体实施例1:
发明提供的液压支架用乳化油,按照质量百分比包括以下物质:
矿物基础油:15.0%、油酸:8.0%、三乙醇胺:25.0%、石油磺酸钠:10.0%、苯并三氮唑:0.5%、甘油:5.0%、S-80:1.0%、Op-10:3.0%、尿素:5.0%、EDTA:3.0%、氢氧化钠:2.0%、水:22.5%。
实施例2:
发明提供的液压支架用乳化油,按照质量百分比包括以下物质:
矿物基础油:17.0%、油酸:9.0%、三乙醇胺:28.0%、石油磺酸钠:11.0%、苯并三氮唑:0.6%、甘油:7.0%、S-80:1.3%、Op-10:4.0%、尿素:6.5%、EDTA:4.0%、氢氧化钠:2.5%、水:9.1%。
实施例3:
发明提供的液压支架用乳化油,按照质量百分比包括以下物质:
矿物基础油:20.0%、油酸:8.0%、三乙醇胺:26.0%、石油磺酸钠:11.2%、苯并三氮唑:0.8%、甘油:10.0%、S-80:2.5%、Op-10:5.0%、尿素:5.0%、EDTA:3.0%、氢氧化钠:3.5%、水:10.0%。
为验证使用不同活性剂的乳化油的抗静电性的差异,特做如下两组实验:
实验一:本产品:油酸:9.0%、三乙醇胺:28.0%、石油磺酸钠:11.0%、苯并三氮唑:0.6%、
甘油:7.0%、S-80:1.3%、Op-10:4.0%、尿素:6.5%、EDTA:4.0%、氢氧化钠:2.5%、水:9.1%;对比
1:其余组分相同,活性剂为乙二醇的产品;对比2:其余组分相同,活性剂为:油酸胺;各取等
量油液放置在容器中,外加1000V的电压60分钟;
分析项目 | 本产品 | 对比1 | 对比2 | 判定标准:MT76-2011 |
外观 | 透明均一流体 | 有析出 | 有析出 | 透明均一流体 |
气味 | 无刺激性气味 | 有气味 | 有气味 | 无刺激性气味 |
运动粘度(40℃),mm2/s | 10.22 | 60.06 | 70.10 | ≤100 |
闪点(开口),℃ | 无 | 无 | 无 | ≥110或无 |
PH值 | 9.1 | 8.5 | 8.7 | 7.5-10 |
稳定性 | 无析出物、无分层 | 有析出,形成油泥胶 | 有析出,形成油泥胶 | 液面析出物体积含量≤0.1%,无沉淀、无絮状物、无分层、无析水 |
润滑性 | 637N | 397N | 380N | PB值≥392N(40kgf) |
实验二:本产品:油酸:9.0%、三乙醇胺:28.0%、石油磺酸钠:11.0%、苯并三氮唑:0.6%、
甘油:7.0%、S-80:1.3%、Op-10:4.0%、尿素:6.5%、EDTA:4.0%、氢氧化钠:2.5%、水:9.1%;对比
3:和本产品组分相同,S-80含0.08%、Op-10含2.5%;对比4:和本产品组分相同,S-80含3.0%、
Op-10含6.0%。各取等量油液放置在容器中,外加1000V的电压60分钟;
分析项目 | 本产品 | 对比3 | 对比4 | 判定标准:MT76-2011 |
外观 | 透明均一流体 | 透明均一流体 | 透明均一流体 | 透明均一流体 |
气味 | 无刺激性气味 | 有微弱气味 | 有微弱气味 | 无刺激性气味 |
运动粘度(40℃),mm2/s | 10.22 | 25.15 | 27.30 | ≤100 |
闪点(开口),℃ | 无 | 无 | 无 | ≥110或无 |
PH值 | 9.1 | 8.9 | 9.2 | 7.5-10 |
稳定性 | 无析出物、无分层 | 有少量析出 | 有少量析出 | 液面析出物体积含量≤0.1%,无沉淀、无絮状物、无分层、无析水 |
润滑性 | 637N | 601N | 595N | PB值≥392N(40kgf) |
综上所述:在其余组分、其余条件均相同的情况下,以S-80、Op-10为活性剂的乳化油比以乙二醇、油酸胺为活性剂的乳化油更具抗静电性,更稳定,没有出现析出和形成油泥胶的现象;S-80、Op-10的最佳含量为:S-80:1.0%~2.5%、Op-10:3.0%~5.0%。
该乳化油性能稳定,乳化效果好,无油、皂等污物的析出,使用时间更长;具有良好的冻融性、抗磨抗极压性、防锈防腐蚀性,可满足液压支架在苛刻的工况下使用长期使用系统清洁干净,整个系统正常运行,液压支架无动作缓慢现象,作业安全准确,生产效率提高。
一种生产上述液压支架用乳化油的生产工艺,其工艺步骤为:
步骤一:取油酸和三乙醇胺在氢氧化钠溶液的催化作用下进行皂化反应,反应温度70℃-90℃,反应时间2.5h,反应结束PH在8.0-8.5,皂化结束后待用。
步骤二:将石油磺酸钠加入步骤一制得的产物中,顺时针搅拌20分钟,然后将矿物基础油和S-80加入,继续顺时针搅拌20分钟。
步骤三:将甘油和水混和搅拌均匀后加入配方量的EDTA、尿素搅拌至完全溶解,加入苯并三氮唑溶解后,加入OP-10、环烷酸,搅拌10分钟。
步骤四:将步骤二中混合物转入具有乳化油专用搅拌装置的调和设备内,然后在开启搅拌装置的同时,缓慢加入步骤三中的水溶液,该过程控制温度在55℃-60℃,搅拌溶液至澄清透明后,加入消泡剂,搅拌10分钟。
除说明书所述技术特征外,均为本专业技术人员已知技术。
Claims (5)
1.液压支架用乳化油,其特征在于按照质量百分比包括以下物质:
矿物基础油:15.0%~20.0%、油酸:8.0%~10.0%、三乙醇胺:25.0%~30.0%、石油磺酸钠:10.0%~15.0%、苯并三氮唑:0.5%~0.8%、甘油:5.0%~10.0%、S-80:1.0%~2.5%、Op-10:3.0%~5.0%、尿素:5.0%~8.0%、EDTA:3.0%~5.0%、氢氧化钠:2.0%~3.5%、余量为水。
2.如权利要求1所述的液压支架用乳化油,其特征在于按照质量百分比,各组成物的占比为:
矿物基础油:15.0%、油酸:8.0%、三乙醇胺:25.0%、石油磺酸钠:10.0%、苯并三氮唑:0.5%、甘油:5.0%、S-80:1.0%、Op-10:3.0%、尿素:5.0%、EDTA:3.0%、氢氧化钠:2.0%、水:22.5%。
3.如权利要求1所述的液压支架用乳化油,其特征在于按照质量百分比,各组成物的占比为:
油酸:9.0%、三乙醇胺:28.0%、石油磺酸钠:11.0%、苯并三氮唑:0.6%、甘油:7.0%、S-80:1.3%、Op-10:4.0%、尿素:6.5%、EDTA:4.0%、氢氧化钠:2.5%、水:9.1%。
4.如权利要求1所述的液压支架用乳化油,其特征在于按照质量百分比,各组成物的占比为:
矿物基础油:20.0%、油酸:8.0%、三乙醇胺:26.0%、石油磺酸钠:11.2%、苯并三氮唑:0.8%、甘油:10.0%、S-80:2.5%、Op-10:5.0%、尿素:5.0%、EDTA:3.0%、氢氧化钠:3.5%、水:10.0%。
5.一种生产权利要求1-4任一项所述液压支架用乳化油的生产工艺,其特征在于其工艺步骤为:
步骤一:取油酸和三乙醇胺在氢氧化钠溶液的催化作用下进行皂化反应,反应温度70℃-90℃,反应时间2.5h,反应结束PH在8.0-8.5,皂化结束后待用;
步骤二:将石油磺酸钠加入1步骤制得的产物中,顺时针搅拌20分钟,然后将矿物基础油和S-80加入,继续顺时针搅拌20分钟;
步骤三:将甘油和水混和搅拌均匀后加入配方量的EDTA、尿素搅拌至完全溶解,加入苯并三氮唑溶解后,加入OP-10、环烷酸,搅拌10分钟;
步骤四:将步骤2中混合物转入具有乳化油专用搅拌装置的调和设备内,然后在开启搅拌装置的同时,缓慢加入步骤3中的水溶液,该过程控制温度在55℃-60℃,搅拌溶液至澄清透明后,加入消泡剂,搅拌10分钟。
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CN112251278A (zh) * | 2020-10-30 | 2021-01-22 | 山东奥瑞特矿业科技股份有限公司 | 一种抗菌型液压支架用乳化油 |
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