Presentation grease 2012

6,812 views

Published on

Presentation grease 2012

  1. 1. Fluid SolutionsYour partner in planning and manufacturing latest state of the art grease plants www.fluid-solutions.de -2-
  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. 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. 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. 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. 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. 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. 8. Grease Manufacturing Process Sketch Manufacturing Process www.fluid-solutions.de 9
  9. 9. Grease Manufacturing ProcessProcess Flow Diagram www.fluid-solutions.de 10
  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. 11. Grease Manufacturing ProcessKey Equipment – Homogenization/Filtration/Dearation P&i diagram HFD unit HFD unit www.fluid-solutions.de 12
  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. 13. Grease Manufacturing ProcessLayout Grease production unit as skid-mounted unit www.fluid-solutions.de 14
  14. 14. Grease Manufacturing ProcessLayout Vertical grease production unit www.fluid-solutions.de 15
  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. 16. Grease Manufacturing ProcessAutomation System Overview Tank farm Cooking kettle www.fluid-solutions.de 17
  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

×