Water-miscible metal working fluids with reduced aerosol inhalation toxicity

A process for producing a water-miscible metalworking fluid comprising combining:

• water;
• and
• one or more additives chosen from plasticizers, chelating agents, biocides, surfactants, dispersants, dyes, odorants, extreme pressure agents, anti-oxidants and corrosion inhibitors;
• with
• a polyether polyol produced by
• mixing an active hydrogen compound with a double metal cyanide (DMC) catalyst in a reactor vessel,
• charging to the reactor vessel a mixture containing two or more alkylene oxides to activate the catalyst, and
• continuously feeding one or more alkylene oxides to produce the polyether polyol,
• wherein a 1% solution in water of the polyether polyol has a cloud point of greater than about 32° C., the equivalent weight of the polyether polyol is greater than about 1,000 Da, and a four-hour aerosol inhalation exposure to the polyether polyol has a LC50 of greater than about 3 mg/L.

A process for producing a water-miscible metalworking fluid comprising combining:

• water;
• and
• one or more additives chosen from plasticizers, chelating agents, biocides, surfactants, dispersants, dyes, odorants, extreme pressure agents, anti-oxidants and corrosion inhibitors;
• with
• a polyether polyol produced by
• mixing an active hydrogen compound with a double metal cyanide (DMC) catalyst in a reactor vessel,
• charging to the reactor vessel a mixture containing two or more alkylene oxides to activate the catalyst, and
• continuously feeding one or more alkylene oxides to produce the polyether polyol,
• wherein a 1% solution in water of the polyether polyol has a cloud point of greater than about 32° C., the equivalent weight of the polyether polyol is greater than about 1,000 Da, and a four-hour aerosol inhalation exposure to the polyether polyol has a LC50 of greater than about 5 mg/L.

A process for producing a water-miscible metalworking fluid comprising combining:

• water;
• and
• one or more additives chosen from plasticizers, chelating agents, biocides, surfactants, dispersants, dyes, odorants, extreme pressure agents, anti-oxidants and corrosion inhibitors;
• with
• a polyether polyol produced by
• mixing with a double metal cyanide (DMC) catalyst in a reactor vessel an initiator chosen from one or more of a polyol from a prior preparation (heel) having an equivalent weight greater than about 300 Da, a lower molecular weight active hydrogen compound that does not deactivate the DMC catalyst and an inert solvent,
• charging to the reactor vessel a mixture containing two or more alkylene oxides to activate the catalyst, and
• continuously feeding one or more alkylene oxides and one or more starters to produce the polyether polyol,
• wherein a 1% solution in water of the polyether polyol has a cloud point of greater than about 32° C., the equivalent weight of the polyether polyol is greater than about 1,000 Da, and a four-hour aerosol inhalation exposure to the polyether polyol has a LC50 of greater than about 0.50 mg/L.

A process for producing a water-miscible metalworking fluid comprising combining:

• water;
• and
• one or more additives chosen from plasticizers, chelating agents, biocides, surfactants, dispersants, dyes, odorants, extreme pressure agents, anti-oxidants and corrosion inhibitors;
• with
• a polyether polyol produced by
• mixing with a double metal cyanide (DMC) catalyst in a reactor vessel an initiator chosen from one or more of a polyol from a prior preparation (heel) having an equivalent weight greater than about 300 Da, a lower molecular weight active hydrogen compound that does not deactivate the DMC catalyst and an inert solvent,
• charging to the reactor vessel a mixture containing two or more alkylene oxides to activate the catalyst, and
• continuously feeding one or more alkylene oxides and one or more starters to produce the polyether polyol,
• wherein a 1% solution in water of the polyether polyol has a cloud point of greater than about 32° C., the equivalent weight of the polyether polyol is greater than about 1,000 Da, and a four-hour aerosol inhalation exposure to the polyether polyol has a LC50 of greater than about 3 mg/L.

A process for producing a water-miscible metalworking fluid comprising combining:

• water;
• and
• one or more additives chosen from plasticizers, chelating agents, biocides, surfactants, dispersants, dyes, odorants, extreme pressure agents, anti-oxidants and corrosion inhibitors;
• with
• a polyether polyol produced by
• mixing with a double metal cyanide (DMC) catalyst in a reactor vessel an initiator chosen from one or more of a polyol from a prior preparation (heel) having an equivalent weight greater than about 300 Da, a lower molecular weight active hydrogen compound that does not deactivate the DMC catalyst and an inert solvent,
• charging to the reactor vessel a mixture containing two or more alkylene oxides to activate the catalyst, and
• continuously feeding one or more alkylene oxides and one or more starters to produce the polyether polyol,
• wherein a 1% solution in water of the polyether polyol has a cloud point of greater than about 32° C., the equivalent weight of the polyether polyol is greater than about 1,000 Da, and a four-hour aerosol inhalation exposure to the polyether polyol has a LC50 of greater than about 5 mg/L.