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Lubricants For Cement Production PDF
Lubricants For Cement Production PDF
Lubricants For Cement Production PDF
Industrial sector
Speciality lubricants for the cement industry 3 Producing cement reliably and safely while reducing downtime Klüber Lubrication supports you by offering solutions
is a continual challenge faced every day. Machines in the particularly suited to these requirements of the cement
Optimally equipped with our speciality lubricants 4 cement industry are subject to extreme operating conditions industry.
like high contamination, temperatures, vibrations and shock
Lubricants for raw cement plant transport 6 loads. These conditions make maintenance and repair of your We offer a range of speciality lubricants tailored to the needs
machinery a very challenging task. of the cement industry that show their strengths particularly
Lubricants for crushing processes 8 in critical applications. We support you in selecting the right
In the extreme environment in which drives, bearings, conveyors lubricant and are with you as partner from changeover to
Lubricants used in clinker production 20 and other components have to function, the lubricant has to routine checks, from the lubricant sampling and the set-up of
meet the highest demands. First, the right lubricant has to lubrication systems to the optimisation of lubricant quantities.
Lubricants for open gear drives 26 be selected, as there is no standard solution for many of the Our long-standing experience of more than 80 years in the
applications in this industry. industrial lubrication and intense cooperation with well-known
Further applications in the cement industry 32 OEMs helps us develop just the right lubricant to ensure high
Depending on the mode of operation and the location of reliability, optimised consumption and achievement of the
Onsite services offered by Klüber Lubrication 36 use, you have to use different lubricants that are made up of design life.
different base oils, additives, viscosities and consistencies.
The right lubricant at the right place at the right time 37 Making the wrong decision can lead to premature component
failure or even production stoppages, resulting in high
maintenance costs and production losses. In addition, your
plant must run efficiently and cost-effectively with minimum
impact on the environment.
2 B142001002 / Edition 03.15 3
Cement plant applications:
Optimally equipped with our speciality lubricants
Raw material silo
Quarry Crusher Raw mill
Pre-heater tower
Kiln
Cooler
Pre-blending dome
Dispatching
Additions
Finishing mill
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Lubricants for raw cement plant transport
Apron feeders, belt & screw conveyers, bucket elevators, stackers & reclaimers
During the transport of raw material and additional materials, short lifetime of the loaded components. High-quality speciality
bearings and joints are mainly influenced by excessive lubricants help you prevent damage; the right lubricant protects
contamination from dust and water in combination with high your machines against temperatures and shock loads or
temperature fluctuations. The consequence: high wear and oscillating movements.
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Lubricants for crushing processes
Crushing processes are particularly demanding for bearings, as We make speciality lubricants to suit these requirements: they
vibrations, shocks and contamination are extremely high, and have the right viscosity and consistency combined with the right
temperatures fluctuate considerably. Speciality lubricants can additives and offer reliable lubricant pumpability. They are also
protect highly loaded bearings in these processes; they reduce chemically and physically stable, contributing to long bearing life.
wear, extend maintenance intervals and increase reliability.
Vibrating screens
Component Product Features Application notes and benefits
Bearings Klüberplex BEM 41-132 –– Temperature range -40 °C to 150 °C –– Longer service life
–– Grease based on mixture of synthetic hydrocarbon oil, mineral oil –– Less maintenance
and a special lithium soap –– Prolongs life of bearings subjected to vibration and shock loads
–– NLGI grade 2
–– Speed factor up to 1,000,000 mm/min
Klüberlub BVH 71-461 –– Temperature range -20 °C to 160 °C –– Efficient at increased temperatures, vibrations and shock loads
–– NLGI grade 1
–– Grease based on mineral oil, synthetic hydrocarbon oil and polyurea
Klüberlub BE 41-542 –– Temperature range -20 °C to 140 °C –– Protects highly loaded bearings running at slow to medium speeds
–– NLGI grade 2
–– Speed factor up to 500,000 mm/min
–– Extreme-pressure grease based on highly viscous mineral oil, special
lithium soap, antiwear, anti-oxidant and anticorrosion additives
Crushers
Component Product Features Application notes and benefits
Crusher main bearing Klüberlub BE 41-1501 –– Temperature range -10 °C to 150 °C –– Increased bearing life
–– NLGI grade 1 –– Improved pumpability
–– Grease consisting of highly viscous mineral hydrocarbon oil –– Increased productivity due to less downtime
(ISO VG 1500), special lithium soap and particularly effective extreme –– Recommended by leading OEMs
pressure / antiwear (EP / AW) additives
–– Contains solid lubricants (MoS2 and graphite)
Drive gearbox Klüberoil GEM 1 N –– Max. temperature: up to 100 °C –– Approved by leading gear drive manufacturers
–– Gear / multipurpose oils based on selected mineral oils –– Low maintenance cost
–– FZG scuffing test, A / 8.3 / 90, scuffing load stage ≥ 14 –– Protection even at peak loads, vibrations and oscillation
–– Excellent results in FAG FE8 rolling bearing test
Klübersynth GEM 4 N –– Max. temperature: up to 140 °C –– Approved by leading OEMs
–– Gear / multipurpose oils based on polyalphaolefin (PAO) and –– Reduces power losses and improves energy efficiency
synthetic hydrocarbon (SHC) oil –– Protection even at peak loads, vibrations and oscillation,
–– FZG scuffing test, A / 8.3 / 90, scuffing load stage ≥ 14 high temperatures
–– Excellent results in FAG FE8 rolling bearing test –– Extended service life of bearings, seals
–– Longer oil change intervals resulting in cost savings
Klübersynth GH 6 * –– Max. temperature: up to 160 °C –– Reduces power losses and improves energy efficiency
–– Polyglycol synthetic gear oil –– Approved by leading OEMs
–– Excellent results in FAG FE8 rolling bearing test –– Protection even at peak loads, vibrations and oscillation,
–– FZG scuffing test, A / 8.3 / 90, scuffing load stage ≥ 14 high temperatures
–– Excellent wear protection, ageing and oxidation resistance, good –– Prevents premature rolling bearing failure
viscosity-temperature behaviour and very good thermal stability –– Extended service life
–– Longer oil change intervals resulting in cost savings
* Check compatibility and follow the application notes in the product information sheet
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Lubricants for crushing processes
Vertical roller mills
Oil lubrication
Component Product Features Application notes and benefits
Main bearing / roller bearing Klübersynth GH 6 *-680, -1000, -1500 –– Max. temperature up to 160 °C (Klübersynth GH 6) –– Prevents premature rolling bearing failure
(CLP PG 680, -1000, -1500) –– Max. temperature up to 150 °C (SYNTHESO HT) –– Reduces power losses and improves energy efficiency
–– Polyglycol synthetic oil –– Extended service life
SYNTHESO HT 1000 –– Excellent results in FAG FE8 rolling bearing test –– Approved by leading OEMs
(CLP PG 1000) –– Excellent wear protection, ageing and oxidation resistance, good
viscosity-temperature behaviour and very good thermal stability
Grease lubrication
Component Product Features Application notes and benefits
Main bearing / rocker arm Klüberlub BE 41-1501 –– Temperature range -10 °C to 150 °C –– Increased bearing life
–– NLGI grade 1 –– Improved pumpability
–– Grease consisting of highly viscous mineral hydrocarbon oil –– Increased productivity due to less downtime
(ISO VG 1500), special lithium soap and particularly effective extreme –– Recommended by leading OEMs
pressure / antiwear (EP / AW) additives
–– Contains solid lubricants (MoS2 and graphite)
Klüberlub BE 41-1002 –– Temperature range -15 °C to 120 °C –– Good pumpability at low temperatures
–– NLGI grade 2 –– Less maintenance
–– Grease consisting of highly viscous mineral hydrocarbon oil
(ISO VG 1000), special lithium thickener
–– Contains solid lubricants
Elastomer seals of rollers SYNTHESO GLEP 1 –– Temperature range -50 °C to 150 °C –– Compatible with EPDM seals. No more leakages due to seal failures
–– Special lubricating grease with EP additives, compatible with EPDM
Klüberlub BE 41-1501 –– Compatible with elastomers 72 NBR 902 –– Increased component life
–– Temperature range -10 °C to 150 °C –– Improved pumpability
–– NLGI grade 1 –– Increased productivity due to less downtime
–– Grease consisting of highly viscous mineral hydrocarbon oil –– Recommended by leading OEMs
(ISO VG 1500), special lithium soap and particularly effective extreme
pressure / antiwear (EP / AW) additives
–– Contains solid lubricants (MoS2 and graphite)
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Lubricants for crushing processes
Separators
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Lubricants for crushing processes
Roller presses
In bearings subjected to high shock loads the lubricating film Klüberlub BE 41-1501 is a grease specially designed for such
has to ensure trouble-free operation, especially as lubrication heavily loaded roller press bearing lubrication. Even at 75 °C, it
starvation, contamination or the wrong lubricant can quickly ensures that no metal-to-metal contact occurs between rollers
contribute to bearing failure. Factors like long lead times for and bearing raceways.
delivery of expensive spares can have an adverse effect on
production and cost. Typical roller press bearings are cylindrical Please select viscosity and consistency according to your
roller bearings operating at maximum 75 °C. We need to ensure operating parameters, e.g. temperature, speed and load.
adequate lubricant film formation to prevent metal-to-metal Your Klüber Lubrication contact will be glad to help you.
contact between the rollers and bearing raceways.
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Lubricants for crushing processes
Tube mills / ball mills
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Lubricants for crushing processes
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Lubricants used in clinker production
Pre-heating
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Lubricants used in clinker production
Rotary kiln
The lamellar seal and the riding ring form one of the frequently Note: Mix the suspensions well before use to make sure the
lubricated friction points in kilns. It is important to ensure that carrier oil and the solid lubricants are homogenised. The oil
solid lubricants enter the contact area of these friction points to might ignite in the event of insufficient homogenisation.
prevent metal-metal wear.
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Lubricants used in clinker production
Rotary kiln
Coolers
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Lubricants for open gear drives
You expect your open gears to work reliably. We offer you a There are two basic types of lubricants for open gears: graphite- Benefits of Klüber Lubrication transparent open gear
comprehensive range of speciality lubricants to reach this goal based greases and Klüber fluids that are free of solid lubricants. lubricants: Profitability
and select the right viscosity lubricant for your open gear. We will Klüber fluids have been used successfully for more than 15 years –– Greater film thickness (higher lambda value) – even at higher –– Tooth flanks can be inspected during operation through the
be happy to support you on site during routine inspections, start- years and are an increasingly preferred alternative. These are oils operating temperatures resulting in better tooth flank protection transparent film
up, after repair, or with new gears. with additive packages tailored to the particular requirements of –– Intelligent additive package for protection under extreme –– Immediate identification of progressive damage in form of
open gears. The most important selection criterion is viscosity. pressure and mixed friction conditions material spalling or metal chips
The product must be selected based on the tooth flank condition, –– Good flow characteristics ensure clean gears –– No more “unpleasant surprises” at shutdowns – if required
load and temperature distribution, vibrations, mechanical –– No blocking of the spray nozzles results in enhanced life of corrective measures can be planned ahead
condition of gear and pinion and the surroundings. spray system and cost savings –– Reduced wear
–– Good vibration dampening –– Reduced lubricant consumption: up to 50 % less compared
–– Reduced tooth flank temperature to graphite based products
Type of lubrication system Spray lubrication, immersion, circulation, paddle Spray lubrication, immersion, paddle wheel Spray lubrication Spray lubrication, immersion, circulation, Spray lubrication, immersion, circulation,
wheel paddle wheel paddle wheel
Product Klüberfluid C-F 3 Ultra Klüberfluid C-F 3 M Ultra Klüberfluid C-F 3 S Ultra Klüberfluid C-F 4 Ultra Klüberfluid C-F 8 Ultra
Colour Transparent Transparent Transparent Transparent Transparent
Maximum peripheral speed in m/s 10 12 10 7 8
Temperature limits for spraying 15 °C to 120 °C 2 °C to 100 °C 0 °C to 80 °C 0 °C to 80 °C 10 °C to 80 °C
Temperature limits for immersion 15 °C to 120 °C / 15 °C to 80 °C Not applicable Not applicable 0 °C to 110 °C / 0 °C to 80 °C 10 °C to 120 °C / 10 °C to 80 °C
or circulation lubrication
Viscosity at 40 °C 16,500 mm2/sec 25,500 mm2/sec 4,000 mm2/sec 3,100 mm2/sec 8,000 mm2/sec
Application notes and benefits –– Long service life of open gears –– Long service life of open gears –– Long service life of open gears –– Long service life of open gears –– Long service life of open gears
–– Easy inspection during operation with UV lamp –– Easy inspection during operation with UV lamp –– Easy inspection during operation with UV lamp –– Easy inspection during operation with UV lamp –– Easy inspection during operation with UV lamp
–– Cost reduction due to less consumption –– Cost reduction due to less consumption –– Cost reduction due to less consumption –– Cost reduction due to less consumption –– Cost reduction due to less consumption
–– Excellent wear protection even at elevated –– Excellent wear protection even at elevated –– Excellent wear protection –– Excellent wear protection even at elevated –– Excellent wear protection
temperatures temperatures –– Tested and approved by OEMs temperatures –– Reduction in power consumption
–– Tested and approved by OEMs –– Tested and approved by OEMs –– Reduction in power consumption –– Tested and approved by OEMs –– Clean system: no accumulation of used
–– Reduction in power consumption –– Reduction in power consumption –– Clean system: no accumulation –– Reduction in power consumption grease in the cover
–– Clean system: no accumulation –– Clean system: no accumulation of used grease in the cover –– Clean system: no accumulation
of used grease in the cover of used grease in the cover of used grease in the cover
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Lubricants for open gear drives
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Lubricants for open gear drives
30 31
Further applications in the cement industry
Gearboxes in the cement industry are subjected to high Klüber Lubrication high-performance synthetic gear lubricants Application Product Features Application notes and
temperatures, high loads, vibration, dust and a corrosive demonstrate outstanding viscosity-temperature behaviour even benefits
environment, which adversely affect reliability, equipment life in extreme operating conditions. Cleaning of enclosed gears Klüber Summit Varnasolv –– Concentrated conditioner fluid –– Dissolves varnish and
containing synthetic ester oil carbon deposits, reducing
and energy efficiency. Selecting a high-performance gear oil will
and cleaning additives maintenance and cleaning
help you overcome these challenges and provide hassle-free, –– Miscible with mineral oils, costs
energy-efficient operation. synthetic hydrocarbons, ester –– No dismantling of systems
oils and polyglycols needed prior to cleaning
–– Neutral behaviour towards –– Used during operation,
seals no downtime of machines
Product Type of oil Application notes and benefits –– Designed for cleaning screw- for cleaning
Klüberoil GEM 1 N Mineral oil based –– Temperature range -15 °C to 100 °C (depends on viscosity grade selected) type compressors, hydraulic –– Reduced operating and
–– High-quality mineral oil approved by leading gear drive manufacturers systems, gears and other oil maintenance costs
–– Low maintenance cost circulating systems such as due to higher efficiency
–– Protection even at peak loads, vibrations and oscillation calenders (e.g. compressor) and longer
service life of the fresh oil fill
Klübersynth GEM 4 N Polyalphaolefin (PAO) and –– Temperature range -50 °C to 140 °C (depends on viscosity grade selected)
synthetic hydrocarbon (SHC) oil –– Reduces power losses and improves energy efficiency
–– Protection even at peak loads, vibrations and oscillation, high temperatures
–– Extended service life of bearings, seals
–– Longer oil change interval resulting in cost savings
Klübersynth GH 6 Polyglycol synthetic oil –– Temperature range -55 °C to 160 °C (depends on viscosity grade selected)
–– Reduces power losses and improves energy efficiency
–– Approved by leading OEMs
–– Protection even at peak loads, vibrations and oscillation, high temperatures
–– Prevents premature rolling bearing failure
–– Extended service life
–– Longer oil change interval resulting in cost savings
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Further applications in the cement industry
The efficiency of screw-type air compressors can increase Klüber Summit compressor oils can increase the oil life in the Component Product Features Application notes and benefits
considerably with the right compressor oil. It can also help compressor up to four-fold whilst decreasing the operating Gear coupling GRAFLOSCON –– Peripheral speed nmax / n < 1.6 –– Prevents failure at high pressure
decrease lubricant costs through reduced consumption. temperature by up to 10 %, increasing the lifetime of the (grease-lubricated) C-SG 500 PLUS –– Adhesive lubricant based on mineral oil –– Excellent adhesion
Mineral oil-based products with poor oxidation stability tend to compressor and reducing maintenance costs. Carry-over is also with aluminium complex thickener and –– Wear reduction
solid lubricant (fine graphite) –– Corrosion protection
form residues, resulting in frequent filter and oil changes and reduced leading to lower top-ups. –– Resistant to high pressure
consequently higher operating costs. –– Contains antiwear additives, adhesion
improvers and corrosion inhibitors
Klüberlub –– Peripheral speed nmax / n < 1.6 –– Wear reduction
Component Product Features Application notes and benefits BE 41-1501 –– Grease based on highly viscous mineral –– Corrosion protection
hydrocarbon oil (ISO VG 1500), special –– Prevents failure at high loads
Screw-type Klüber Summit SH –– Air compressor oils based on synthetic –– Achieve oil changeover interval of up to lithium soap, extreme pressure, antiwear
compressor hydrocarbon and additives 10,000 hours. additives and solid lubricants (MoS2 and
–– Suited for highly loaded, oil-injected –– Easy compressor oil conversion due to graphite)
screw-type compressors neutral behaviour of oils towards seals
–– Good oxidation stability –– No unnecessary cleaning or failure of Klüberplex GE 11-680 –– Peripheral speed nmax / n > 1.6 –– Prevents wear and prolongs component
–– High evaporation stability gummed pneumatic valves –– Adhesive lubricant with a mineral oil base life
–– Klüber Summit SH 32 is especially suitable –– Reduced operating costs due to extended and an aluminium complex soap thickener –– Adhesive lubricant
for centrifugal compressors and Klüber oil filter and separator life –– Particularly suitable for elevated –– Resistant to high pressures
Summit SH 100 for reciprocating piston component temperatures and wherever –– Anticorrosion properties
compressors lubricants containing solid lubricants –– Applicable through automatic lubrication
–– Temperature range: depends on viscosity should not be used systems
selected
Reciprocating piston Klüber Summit DSL –– Air compressor oils based on a synthetic –– Achieve oil changeover intervals of up to
compressor ester oil and additives 8,000 operating hours
–– Can be mixed with mineral oils, synthetic –– Easier compressor oil conversion
hydrocarbon oils and polyglycol oils –– Good soil dissolving capacity, clean oil
–– Suitable for oil-injected screw-type circuit due to the ester content in the oil,
compressors, centrifugal compressors, reduction of cleaning costs Assembly pastes
reciprocating piston compressors –– Low formation of oxidation residues in the
–– Neutral behaviour of oils towards seals oil circuit, reduced operating costs due to
Application Product Features Application notes and benefits
–– Temperature range: depends on viscosity extended oil filter and separator life
selected Screw compound WOLFRACOAT C –– Temperature range -30 °C to 1,200 °C –– Prevents seizing at high temperatures
–– Klüber Summit DSL 32, 46, and 68 are (screw connections) –– Grey colour, high-temperature lubricating –– Easy assembly and disassembly of power-
biodegradable paste containing metal solid lubricant locking connections
pigments
Cleaning agent Klüber Summit –– Concentrated conditioner fluid containing –– Dissolves varnish and carbon deposits,
Varnasolv synthetic ester oil and cleaning additives thus reducing maintenance and cleaning Screw paste Klüberpaste HEL –– Temperature range -40 °C to 1,000 °C –– Corrosion protection
–– Miscible with mineral oils, synthetic costs (in presence of 46-450 –– Black hot screw paste for high-alloy steels; –– Good water resistance
hydrocarbons, ester oils and polyglycols –– No dismantling of systems needed prior moisture) it contains fully synthetic polyalkylene –– Reliable screw connection ensured by
–– Neutral behaviour towards seals to cleaning glycol and ester base oils and a constant and sufficient preload force
–– Designed for cleaning screw-type –– Used during operation, no downtime of combination of inorganic solid lubricants
compressors, hydraulic systems, gears machines for cleaning
Rolling bearings ALTEMP QNB 50 –– Temperature range -15 °C to 150 °C –– Prevents failure in components subjected
and other oil circulating systems like –– Reduced operating and maintenance
and hub / shaft fits white / beige lubricating paste containing a to small to minimum motion under high
calenders costs due to higher efficiency
mineral base oil, a barium complex soap static and dynamic load
(e.g. compressor) and longer service life of
and inorganic solid lubricants –– High pressure absorption ensures
the fresh oil fill
–– Suitable for friction points subjected to constant clamping force
Check ageing T.A.N.-Kit –– Easy and quick test method to check the –– Rapid way of checking the condition of small motions under static and dynamic –– Corrosion protection
condition of ageing condition of compressor oils compressor oils on the spot loads
compressor oil –– Kit consists of a pipette (1 ml), a glass vial –– Determine compressor oil change intervals
Other sliding surfaces WOLFRACOAT C –– Temperature range -25 °C to 1,050 °C –– Corrosion protection
(neutralisation containing the test fluid and a cloth, all –– Easy to handle and portable
FLUID –– Viscous high-temperature release agent –– Lubricates surfaces subjected to thermal
number) packed in a plastic bag –– Can be used for all conventional mineral
and lubricating compound based on loads
and synthetic compressor oils
mineral and ester oil mixture
–– It contains solid lubricants, metal pigments
and an inorganic thickener
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The right lubricant at the
Onsite services offered by Klüber Lubrication right place at the right time
Klüber Lubrication offers KlüberEfficiencySupport, the professional For example: energy consumption, CO2 emissions, life cycle Systems for automatic lubrication
service program, not only for large girth gear and pinion drives cost reductions, etc. for all rotating equipment, from general
but for your entire machinery. Our systematic approach identifies conveyors to air compressors and “workshop” products. Millions We at Klüber Lubrication understand ourselves as a solution technology are available with standard, long-term or high-
and optimises the savings potential at your site and monitors are spent every year on corrective and remedial engineering and provider. We not only supply high-performance oils and greases, pressure greases, standard or high-temperature chain oils and
system condition providing plant engineers with trend analysis maintenance actions. These actions can be alleviated at source but also “intelligent packages” for automatic lubrication of your special oils and greases for the food-processing industry. We
and an “early warning” of potential failure. with proper consultation. Klüber Lubrication provides effective machines and components. Selected lubricants covering a wide are also able to supply other lubricants in automatic dispensers
solutions that are comprehensive yet simple to implement. range of typical applications are available in automatic lubricant on request and for higher order volumes, provided they have
Our trained and experienced lubrication engineers are equipped dispensers for single-point lubrication. These tried-and-tested been tested and approved for use – please contact your Klüber
with IR thermometer, vibrometer and stroboscope. Your machine KlüberRenew includes a running-in and repair service to increase systems based on electromechanical or electrochemical Lubrication consultant for details.
“health check” will be supported by a comprehensive report the useful service life of girth gears and pinions by controlling and
interpreted by specialists to determine any appropriate actions modifying tooth flank surface roughness, contact ratio, load
that may be required. These same engineers offer a plant-wide distribution, removal of surface pitting and ultimately a tooth Your benefits at a glance
service to support sustainability needs and strategies. flank repair where possible.
Profitability Reliability
Our cement industry experts are located worldwide and are
happy to support you on site. Continuous production processes and predictable maintenance Automatic lubrication systems from Klüber Lubrication ensure
intervals reduce production losses to a minimum. Consistently reliable, clean and precise lubrication around the clock. Plant
high lubricant quality ensures continuous, maintenance-free availability is ensured by continuous relubrication of the application.
long-term lubrication for high plant availability. Continuous supply
of fresh lubricant to the lubrication points keeps friction low and Lubrication with Klübermatic may help to prevent up to 55 %
reduces energy costs. of rolling bearing failures
1)
TPM: Total Productive Maintenance
Flexible use – and for For applications subject Precise and adjustable lubricant Externally controlled single-point
lubrication points with to wide temperature metering relubrication
high requirements fluctuations
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Klüber Lubrication München SE & Co. KG
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www.klueber.com