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Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
Presentation grease 2012
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Presentation grease 2012

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  • 1. Fluid SolutionsYour partner in planning and manufacturing latest state of the art grease plants www.fluid-solutions.de -2-
  • 2. LUBRICATING GREASE - DEFINITIONLUBRICATING GREASE *) IS A SOLID TO SEMI-FLUID PRODUCT OF DISPERSION OF A THICKENING AGENT IN A LIQUID LUBRICANT … OTHER INGREDIENTS IMPARTING SPECIAL PROPERTIES MAY BE PRESENT*) A.S.T.M. STANDARD DEFINITION OF TERMS OF PETROLEUM, 1959 www.fluid-solutions.de 3
  • 3. LUBRICATING GREASEGeneral composition: Base Oil + Thickener + Additives = GreaseConventional Oil Metallic Soaps (-salts) Surface active Grade of goods- Raffinate - Lithium soap - High pressure/abrasive - Multi purpose grease - Calcium soap protection - High temperature greaseUnconventional Oil - Sodium soap - Corrosion-/rust protection - Lubricating grease- Hydrocrack Oil - Aluminum soap - Solids - Semi-fluid grease (HC synthesis) - Lead soap - Gel grease- Synthetical Volatile - Barium soap Grease protective - Polyurea grease Organic Compounds - Age protection - Bentonite grease (VOC) Other thickeners- Synthetical Esters - Gels Performance classes - Polyurethane - Acc. to automotiveHerbal Oil - Bentonite regulations- Rape seed oil Identification - Acc. DIN 51502 Consistency classes - Acc. NLGI code www.fluid-solutions.de 4
  • 4. LUBRICATING GREASEClassification acc. to NLGI classes: classification applications Roller bearing Water pumps Slide bearing Block grease penetration NLGI-class lubricating (mm/10 Gear full- 000 445 – 475  00 400 – 430  0 355 – 385  1 310 – 340    2 265 – 295   3 220 – 250   4 175 – 205   5 130 – 160  6 85 – 115  www.fluid-solutions.de 5
  • 5. LUBRICATING GREASEClassification acc. DIN 51502: K PF 2 K - 30 Lower operating temperature (°C) Upper operating temperature, behavior in contact with water3 NLGI-class Additional letter(s) for base oil type and additive2 Lubricating grease for1 1)Lubricating grease for 3) Behavior Upper temperature Test temperature with water G Closed gears (DIN 51826) C 60°C 0 oder 1 40°C OG Open gears D 2 oder 3 K Ball bearing M Slide bearing and gaskets E 80°C 0 oder 1 40°C F 2 oder 3 2) G 100°C 0 oder 1 90°C Additional H 2 oder 3 G Closed gears (DIN 51826) OG Open gears K 120°C 0 oder 1 90°C K Ball bearing M 2 oder 3 M Slide bearing N 140°C P Additives P 160°C F Solids (e.g. MoS2) R 180°C By arrangement S 200°C 0 = no modification 1 = slight modification T 220°C 2 = moderate modification U > 220°C 3 = strong modification www.fluid-solutions.de 6
  • 6. LUBRICATING GREASEApplications: Industrial Lubricating Grease - Roller- and bush bearing lubrication - Central lube system - Strand casting systems, breaker and mill lubrication Roller Bearings Special- and Biodegradable Greases - Lubrication of high performance precision bearing - High speed bearings (railway wheels) Industrial Semi-Fluid Grease - Highly stressed roller bearings e.g. cylinder- and taper roller bearing - Gear motor, drives, couplings, chain drive systems - Gear semi-fluid grease Drill Rods Grease Wheel Bearing - Thread grease Automotive Lubricating Grease - Wheel bearing, ball joints, roller bearing - Bush and antifriction bearing - Steering linkage, wheel suspension Automotive Semi-Fluid Grease - Chassis lubrication - Central lubricating systems Drill Rod Lubrication www.fluid-solutions.de 7
  • 7. Grease Manufacturing ProcessCalculation of typical plant sizeRequired capacity: 2.000 to per yearWorking time: 250 days per year  8 to per day in total (1 shift, with 8 hrs batchtime)*With 2 Finishing vessels: 8 to per day in total  4 to per day (Batch) each  4,5 m³ per day in total (1 shift)  5 m³ working capacity of each finishing vessel*Process vessel:  half size of finishing kettle  3 m³ working capacity  2,7 to per Batch with batchtime 8 h (1 shift)* Key Equipment for grease plants Total required capacity Working capacity Working capacity of grease Process kettle* Finishing kettle* 2.000 to/year 3 m³ 2 x 5 m³ 4.000 to/year 6 m³ 2 x 10 m³ 8.000 to/year 2 x 6 m³ 4 x 10 m³ *depending on grease formulation www.fluid-solutions.de 8
  • 8. Grease Manufacturing Process Sketch Manufacturing Process www.fluid-solutions.de 9
  • 9. Grease Manufacturing ProcessProcess Flow Diagram www.fluid-solutions.de 10
  • 10. Grease Manufacturing ProcessKey Equipment – Mixing Equipment • Grease kettles are heated with hot oil to as much as 250°C or more • Kettle capacities generally range up to 10 tons • Kettles could be pressured up to 6bar as option if required • Kettles could have counter rotating paddles which force the grease in opposite directions to improve mixing efficiency and temperature transportation • Kettles also have a homogenization unit to provide additional (vertical) mixing & homogenization action and to transport the grease to other processing equipment such as a colloid mill. www.fluid-solutions.de 11
  • 11. Grease Manufacturing ProcessKey Equipment – Homogenization/Filtration/Dearation P&i diagram HFD unit HFD unit www.fluid-solutions.de 12
  • 12. Grease Manufacturing ProcessKey Equipment – Homogenization/Filtration/Dearation Mixing/Scraper EquipmentTank farm CIP elements Cooking vessel during assembly www.fluid-solutions.de 13
  • 13. Grease Manufacturing ProcessLayout Grease production unit as skid-mounted unit www.fluid-solutions.de 14
  • 14. Grease Manufacturing ProcessLayout Vertical grease production unit www.fluid-solutions.de 15
  • 15. Grease Manufacturing ProcessAutomation System Control the interactions between thickener and lubricant (Base Oil + Additive) together with the manufacturing process by process automation www.fluid-solutions.de 16
  • 16. Grease Manufacturing ProcessAutomation System Overview Tank farm Cooking kettle www.fluid-solutions.de 17
  • 17. Our expertise in Grease Production • High quality Engineering for the complete grease plant • Definition of working and delivery packages in the project • Available for a wide range of grease production applications • Pressurized processes possible • Available in a wide range of production sizes from pilot plants up to commercial plants www.fluid-solutions.de 18

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