Method for the recovery of powder lubricants (SOAPS) used in the wire drawing process
Acid leaching and regeneration methods effectively separate and recover sodium- and calcium-based soaps from metals, addressing the limitations of existing recycling methods by providing sustainable and cost-effective lubricants for wire drawing.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2025-09-03
- Publication Date
- 2026-03-12
AI Technical Summary
Existing methods for recycling powder lubricants in the wire drawing process are limited by metal impurities, leading to reduced service life and increased costs, necessitating more efficient and cost-effective recovery and regeneration techniques.
Acid leaching and regeneration methods are employed to separate sodium- and calcium-based soaps from metals, using weak acids and salt solutions to recover and regenerate the soaps, followed by filtration and drying.
The recovered soaps are sustainable, long-lasting, and cost-effective, enhancing lubricant efficiency in wire drawing processes while ensuring waste recycling and reuse.
Abstract
Description
[0001] DESCRIPTION
[0002] METHOD FOR THE RECOVERY OF POWDER LUBRICANTS (SOAPS) USED IN THE WIRE DRAWING PROCESS
[0003] TECHNICAL FIELD
[0004] The invention relates to a method for the recovery and regeneration of powder lubricants (soaps) used in the wire drawing process in the metal processing industry. With this method, the efficiency of the lubricants used in wire drawing is increased, while waste recycling and reuse are ensured.
[0005] PRIOR ART
[0006] Wire drawing is a metalworking method in which thick-section steel wire rods with different carbon ratios are plastically deformed into thin wires by the drawing force applied by machine block motors towards the die exit, passing through conical dies called drawing dies. Drawing is also classified as wet and dry drawing. The basic principle of wet and dry drawing is the same and differs only depending on the lubricant used. In wet drawing, special liquid emulsions are used in the die boxes, while in dry drawing, aluminum-, calcium- or sodium-based powder lubricants (soaps) are used. Powder lubricants are produced with different chemical properties in order to provide suitable performance at different stages of the process. Powder lubricants are divided into three main groups: calcium-based soaps, sodium-based soaps, and aluminum-based soaps.
[0007] Calcium-based soaps are insoluble in water, with melting points ranging between 145°C and 165°C, and are mainly used in the initial boxes of the process where wire drawing speeds are low. Sodium-based soaps are soluble in water, with melting points between 140°C and 160°C. Aluminum-based soaps are insoluble in water, with melting points between 140°C and 160°C. While calcium- and sodium- based soaps are generally used in high-speed wire drawing processes and in cases where surface conditions are critical, aluminum-based soaps are mostly used in the processing of thick-section materials.
[0008] In studies related to soap recycling, waste lubricant crushed by a crusher and fed to a sieve is discharged through the mesh surrounding the sieve according to particle size. The discharged waste lubricant is fed from the inner surface of the cover to a magnetic element. The waste lubricant supplied to the magnetic element is separated into reusable lubricant and foreign iron particles by multiple magnets.
[0009] In the known technique, in another study, soap recovery was carried out by ion exchange in aqueous solutions, achieving 98% soap recycling. In another study, magnetic separation showed that 88% of soap in waste could be reused. However, soap materials may become mixed with metal impurities during wire drawing, which limits their service life. Therefore, new methods are required for the recovery and regeneration of soaps that are long-lasting, easily obtainable, and cost-effective.
[0010] BRIEF DESCRIPTION OF THE INVENTION
[0011] The invention relates to a method for the recovery and regeneration of powder lubricants (soaps) used in the wire drawing process. With this method, the efficiency of lubricants in wire drawing is increased, and recycling and reuse of waste are ensured. In our invention, acid leaching and regeneration methods are used for the recovery of Na- and Ca-based soaps by separating them from metals. Accordingly, the recovered soaps obtained through our invention are seen to be sustainable, long-lasting, easily obtainable, and cost-effective for use in the wire drawing industry.
[0012] DETAILED DESCRIPTION OF THE INVENTION
[0013] In our invention, metallic species present in used powder (solid) lubricants (sodium, potassium-, and calcium-based soaps) were leached into solution under a weak acid medium and recovered through soap regeneration. Accordingly, at least one of HNO3, H2SO4, and HCI acidic solutions at concentrations of at least 0.001 M (0.001 M - 10 M) and at least a 1 :1 volume ratio was prepared. Into this solution, solid lubricants (at least one of sodium-, potassium-, and calcium-based soaps) used in the wire drawing process were added at a solid-to-liquid ratio ranging from 1 :1 to 1 :1000. This mixture was stirred at a speed of at least 1 rpm (1-10,000 rpm), at a temperature of at least 20°C (20°C-200°C), and for at least 1 minute (1-2000 minutes). Then, the solid material was separated by filtration and dried at a temperature of at least 25°C (25°C-200°C).
[0014] To the dried solid material, at least two of NaCI, KCI, and CaCI2solutions were added at a concentration of at least 0.01 M (0.01 M-10 M) and at least a 1 / 1 mass ratio. After adding the salt solution, the mixture was stirred at a speed of at least 1 rpm (1-10,000 rpm), at a temperature of at least 20°C (20°C-200°C), and for at least 1 minute (1-2000 minutes). The solid material was then separated by filtration and dried at a temperature of at least 25°C (25°C-200°C).
[0015] The chemical structures of the used soaps and the regenerated soaps were examined using FT-IR and XRF methods. The morphological and thermal properties of the materials were analyzed using SEM and TG / DTA, respectively. The results showed that the regenerated soaps could be reused in the wire drawing process, thereby reducing the costs of the process.
Claims
CLAIMS1. A method for the recovery and regeneration of metallic species present in powder lubricants (sodium-, potassium-, and calcium-based soaps) used in the wire drawing process, characterized by;- adding the solid lubricants (at least one of sodium-, potassium-, and calcium-based soaps) used in the wire drawing process into at least one of HNO3, H2SO4Iand HCI acidic solutions at a concentration of at least 0.001 M and a volume ratio of at least 1 :1 , within a solid-to-liquid ratio range of 1 : 1 to 1 : 1000,- stirring the mixture at a speed of at least 1 rpm, at a temperature of at least 20°C, and for at least 1 minute,- separating the solid material by filtration,- drying the filtered solid material at a temperature of at least 25°C,- adding at least two of NaCI, KCI, and CaCI2solutions at a concentration of at least 0.01 M and at least a 1 / 1 mass ratio to the dried solid material,- stirring the mixture after salt addition at a speed of at least 1 rpm, at a temperature of at least 20°C, and for at least 1 minute,- separating the solid material by filtration and drying it at a temperature of at least 25° C.