Cement plant lubrication


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Cement plant lubrication

  1. 1. Cement Plant Lubrication A brief on Equipment and LubricantsHussam Adeni lube.specialist@gmail.com
  2. 2. Cement Plant LubricationA brief - on typical equipment and lubricantsCement is manufactured by either a Wet process or Dry process. In the wet process, water is addedand resultant slurry is transported through “closed conveyers” to the Kiln.Prior to a Lubrication survey, we can breakdown the lubrication at Cement Plants into 5 segments. i. Mines – Quarrying of limestone ii. Limestone processing - Crushing and grinding iii. Calcining – Rotary Furnace/Girth Gear iv. Clinker Grinding v. CPP – Captive Power Plant i. Mines Section:Hussam Adeni lube.specialist@gmail.com
  3. 3. Limestone is the single large raw material used in the manufacture of Portland Cement and mostCement Plants are located next to the limestone Quarries. Typically, open cast mining proceduresare adopted in India, which translates to a “dumper-dozer” operation; this consists of a series ofdrilling and blasting followed by haulage of the loosened rocks and boulders of limestone.Drilling and blasting: Holes are drilled on the limestone face and gelatine placed in it. The controlled explosion loosensthe limestone and Excavators and Back hoe’s (mini excavators) used to gather the limestone, this isthen transported by Dump trucks/lorries to the Limestone processing unit in the Cement Plant. Inbigger plants, the limestone may be hauled from mines to the plant by a conveyer system and a firststage rock breakdown may be taken up with use of Jaw crushers.Typical Equipment – Lubricants usedi. Compressors, Drilling Equipment (mounted on mobile rigs) - Hydraulic & Compressor Oil, Engine Oil, Air Line Lubricant (Pneumatic) , Greases- All Purpose, EP type and Graphited or Molybdenum grease for anti seize of threading in drilling rods.ii. Dumper, Lorries, Dozers, Excavators, Back hoe - Hydraulic Oils, Transmissions Fluids, Engine Oil, Automotive Gear Oils, Greases, All Purpose, Chassis, EP tyre Greases, Brake Fluids.iii. Auto motive Workshop – Lathes, drilling machines, welding machine, cranes, fork lift - Engine oil, Hydraulic oils, Gear oils, Greases ii. Limestone Processing Section:Crushing and grinding: Portland cement is manufactured by heating limestone (source of Calcium)with clay, Alumina (sand) and grinding this product after calcining (called clinker) with a source ofsulphate (most commonly gypsum). Gypsum is generally blended after calcining. The limestoneboulders/rocks are transported from the mines; are kept in the yard and after preliminarybreakdown/sizing in Crushers and Hammer Mills, to around 3 inches in diameter, it is then sent byconveyers towards the rotary kiln. Clay, Alumina and gypsum are introduced and blended in the line,in the required proportions. The blending is further complimented as the mixture goes through aseries of Ball mills for a process known as grinding. Once the blending of the raw materials iscomplete the product is ready to enter the rotary furnace or kiln.Typical Equipment – Lubricants usediv. Crushers, Hammer Mills, Ball mills, conveyers system, Gear box, Motors - Gear Oil, Greases- All Purpose, EP type.Hussam Adeni lube.specialist@gmail.com
  4. 4. iii. Calcining - Rotating furnace Section:Calcining: The conveyers transport the raw materials, towards the rotary furnace. A pre calciningunit may be installed as a part of energy optimisation programme. The rotary furnace (kiln), is theheart of the cement plant and is tilted slightly to ensure flow of material to the exit direction. Thekiln is supported on a massive Girth Gears, where a sophisticated lubrication dispensing system andSpeciality Lubricants are used. Calcining or sintering is a process where the raw material is heated toa temperature of 1450 to 1500 C (2700 F); at this temperature the mixture gets fused or partiallymolten and is often called, as clinker.Typical Equipment – Lubricants used:v. Conveyers, Coal Mill, Ball mill, Gear box, Rotating Furnace, Girth Gear, Specialty Grease dispenser - Gear Oil, Greases - All Purpose, EP type, High temperature Grease, Specialty Girth Gear Lubricant.iv Clinker Grinding Section:Grinding: The clinker is then cooled on- line and blended with Gypsum and “ground” to the desiredspecifications. The finished product is then conveyed to large holding tanks called Silos.Equipment – Lubricants used Ball mills, conveyers, ID Fans - Gear Oil, Greases- All Purpose, EP type, High temperature Grease.v Captive Power Plant - CPP Section:Process Plants like cement plants are power intensive and as grid power may be insufficient orerratic, many units have set up their own Captive Power Plants (CPP’s). Most of the CPP’s areDieseled Generators, which run on a variety of fuels, Low Sulfur Heavy Stock (LSHS), Heavy FurnaceOils (HFO) and smaller units depend on Light Diesel Oil (LDO) for their sub –one- MW generators.Some of the large units like the ACC, Birla Units have set up coal fired Thermal Power Plants.Equipment – Lubricants usedvi. Dieseled (LSHS,HFO ) Gensets -Wartsila, MAN etc - Very High (50 TBN) & High (40 TBN) Marine Engine Oils, Turbine Oils, Gear Oils, Greases- All Purpose, EP typevii. Dieseled below 1 MW units: Cummins, Skoda etc – Multi grade Engine Oils, Greases – All Purpose, EP Typeviii. Thermal Power Plants: Turbine Fluids, Greases, All Purpose, EP type Greases.Hussam Adeni lube.specialist@gmail.com
  5. 5. Lube consumption:  The highest lube consumption is in cements plants that have Dieseled CPP’s of 10 MW capacity or more. They have a typical Specific Lube Consumption (SLOC) between 0.5 to 0.8 g/kWH. This translates to more than 10,000 Lt of Marine Engine Oils per month during the peak season and likely to be higher if plant is located in States/locations that have power shortages and the CPP’s are run continuously.  Coal fired Thermal CPP’s have a much lower lube consumption.  Depending on the fleet size the Mines and Quarries are likely to have the second largest consumption of Lube oils.Objective: The objective of this note, is to highlight, in brief; typical equipment and lubricants used .It is not intended to be a detailed report on Cement Plant lubrication. Care has been taken to avoidrecommending any brands of equipment or lubricants, except where necessary (CPP’s).Hussam Adeni lube.specialist@gmail.com