MINING & CEMENT INDUSTRY

Kra�tFluids

SPECIALTY LUBRICANTS

Large gear drives, the “heart” of the cement plant, are present in horizontal mills and in kilns. They are submitted to high load, vibrations, shocks and tem-perature. Changing and repairing gear drives is very expensive and time consuming, therefore it is critical to have the right lubrication to extend the life of the mechanism and reduce downtime.

LARGE PINION-GIRTH GEAR DRIVE’S LUBRICANTS

Running in

to achieve a Large Contact Area

to Work with a Low Contact Pressure

New Surface Roughness and Profile Imperfections

Small Contact Area On the Peaks

High Contact Pressure Risk of Seizing

Quicker Appearance of Pitting

Shorter life Longer life

Problem Purpose

The first step to have a long

life is to perform a proper

running in process when the

gears are new (or reversed).

There are different processes

to achieve good and smooth

matching surfaces. The

standard abrasion process

and the plastic deformation

process recommended by

KRAFFT.

Roughness andProfile Imperfections

Large Contact Area

Small Contact Area Large Contact Area

It is imperative to carry out an adequate running-in process assessed by experienced lubrication engi-neers to extend to the maximum the life of the me-chanism as well as to select the right lubricant for life service.

Kra�tFluids

Besides having a large experience in the field of more than 30 years, KRAFFT is also supported by different approvals and laboratory tests:

• The greases are homologated by the main OEM for cement equipment such as FLS.

• The FZG test has been performed by the German laboratory who originated the test with the best result: load higher than level 12 and wear less than 0.2 mg/kWh.

Traditional Way

by Grinding the Crests and Profile

by Plastic Deformation

Abrasive Particles in the Lubricant

Wear on the Spraying System: Pumps, Valves, Nozzles...

Micro-Scratches Could be the Start for Pitting

Krafft Solution

Plastic Deformation Below a Solid Lubricant Layer (Without Metal-Metal Contact)

No Abrasive Particles

This Solid Lubricant Layer (MoS2, Graphite) is Created First by the Priming Paste G Paste and Continuously Renovated by the Running in Grease KGP-2/P-E

Without Metal-Metal Contact

No micro-scratches but kind of roll milling

Why Graphite + MoS2?SYNERGIC EFFECT

Grap

hite

+M

oS2

Grap

hite

MoS

2

Abrasive Particles

Advantages

• The sprayability of the grease has been checked by the main spray system manufacturers, like DELIMON and LINCOLN.

This philosophy was developed and successfully tested from the forties when first the MoS2 (disulphide of molybdenum) was discovered and used as solid lubricant. This material was proven to be more resistant than steel. Based on this finding, the metallic surface can be protected with a layer of solid lubricant. Therefore with the high load of the contact between mating flanks, the crests (and other profile imperfections creating also a local high stress) will be deformed plastically till the contact surface is increased and the contact pressure decreased. For an optimum performance KRAFFT R&D team has achieved the right balance MoS2/Graphite to reach a synergistic effect.

In other words, KRAFFT performed running in process works by plastic deformation of the metal protected by a solid lubricant layer that avoids any seizing instead of creating wear with abrasive particles. This process is somewhere similar to a cold milling, so hardening the surface and providing it a higher resistance and consequently a better protection against the pitting formation.

Recommended process by KRAFFT

Increases the Superficial Resistance

Increases the Resistance To Fatigue

Delays the Appearance of Pitting

No Wear on the Spray System

No Forced Wear on the Gear

Running in Grease can be Used Many Months Without Risk of Excessive Wear

For Bath Lubrication, no Necessity to clean the Sump for the Service Grease

Based on grinding the surfaces to reach good smoothness and a good matching between teeth. This system implies the usage of abrasive particles into the lubricant, which leads to different disadvantages. A misuse or an excessive usage can cause undesired wear of the gear’s flanks. In addition to this, if the lubricant is applied by pulverization, these abrasives particles passing through the pump, distributor valves and nozzles may cause some damages.

Standard process:

Disadvantages

Priming paste for pre-treatment. This paste con-tains a high quantity of high purity graphite and MoS2.

This pre-treatment is to create a first protective layer on the surface to avoid seizing and to allow plastic deformation below the solid lubricant layer without damaging the surface. It is applied ma-nually during the gear assembly. It allows also to check the contact between the mating gears and to correct problems of assembly like alignment, axial run out, radial run out…

Recommended process by KRAFFT

1 G PasteRunning in

Priming paste

In order to avoid any

overload during the running

in process that will create

fatigue on the material

and eventually pitting, it is

also important to increase

the loads progressively,

according to the contact

surface.

Kra�tFluids

Running in grease to be used till a satisfactory fi-nish and contact surface between the mating teeth is achieved. It contains a high quantity of high purity graphite and MoS2. And it is free of abrasive parti-cles. This grease can be used with a spray system as it is sprayable and can be used also for dip lubri-cation. An additional advantage of KRAFFT running in grease without abrasive particles is that it is not necessary to perform a cleaning before using the service grease reducing then labor.

2 KGP-2 / P-E

Running in grease

SERVICE LUBRICANT

Fluid grease based on aluminum complex soap and high viscous oil, with 10% of ultra-pure graphite. It has been developed for dip lubrication. It is more fluid than the other service greases in order to come back easily into the sump.

ServiceLubricant

For service lubrication of the

open gear, there is a range of

lubricants depending on the

lubrication system and on the

preference between graphite

or graphite-free lubricant.

GRAPHITE LINE

KGP-2/F KGP-2/MFluid grease based on a special thickener and high viscous oil, with a high quantity of graphite. It has been developed for manual lubrication.

Fluid grease based on aluminum complex soap and high viscous oil, with 10% of ultra-pure graphite. Specially developed for spray lubrication. High performance service grease formulated to be used under extreme conditions: problem of pitting, vibra-tions... The base oil is an ISO VG 2500 to provide a higher adhesion and a thicker lubricant film. It de-creases or stops also the pitting growth. Compared also to a lower base oil viscosity in similar working conditions, it allows a decrease of consumption: bet-ween 10 to 20%.

KGP-2/PFluid grease based on aluminum complex soap and high viscous oil, with 10% of ultra-pure graphite. Specially developed for spray lubrication. High pit-ting and wear protection service grease. The base oil is an ISO VG 1000 to provide a high adhesion and a thick protective lubricant film.

KGP-2/PLEX 1500

High viscous transparent oil (around 16.000 cP at 40ºC), free of solid lubricants, to be used as a service lubricant. It is then a cleaner product and it allows seeing better the defects on the flank. It can be used with any lubrication system: for spray, dip or circula-tion lubrication. Its nature allows the oil to have ex-tremely high adhesion and it is easier to clean.

CLEAR LINE

KGP OIL 6

KGP-2P GREASE TYPICAL CONSUMPTION

2,7 gr/h.cm for Mill with 2 pimions2,0 gr/h.cm for Mill with 1 pimion or Kiln with 2 pinions1,3 gr/h.cm for Kiln with 1 pimion

Spray lubrication0

1

2

3

4

5

6

7

8

9

200 400 600 800 1000 1200

2,7 gr/cm.h

2 gr/cm.h

1,3 gr/cm.h

Kg/24 h

Kra�tFluids

These types of mechanisms have low speed bea-rings and are submitted to very high loads, to shocks and vibrations therefore high performance lubricant is required.

OTHER SPECIALTY LUBRICANTS

KILN’S LOOSE TYRES

KROIL SPECIAL RINGSWater based graphite suspension. KROIL SPECIAL RINGS is to be applied by pulverization. This KRAFFT eco-friendly lubricant offers a series of advantages with respect to oil based lubricants such as:

• Non flammable: due to high temperature the oils so-metimes take fire; this could be prevented by using KRAFFT water based product.

• No fumes formation: while KROIL SPECIAL RINGS will only generate clean steam, oils on hot surface cause fumes.

• Environmentally friendly and economic

• Easy viscosity adjustment: as easy as adding tap water, the viscosity can be adjusted to the pulverization system only if required.

• Metal free: graphite is environmentally friendly with respect to heavy metals used by other manufacturers.

The consumption should be adjusted in situ for each kiln and loose tyre because it could have an important variation in between each case. If there is no experience, a starting value could be around 5 litres per tyre, twice a week. If it is not enough, we recommend increasing the frequency and not the quantity; if it is too much, we recommend de-creasing the frequency and not the quantity. In case of any doubt always refer to our technical service.

Most of the kilns are using loose tyres. As there is a small differential speed in between the kiln and the tyres, it re-quires a lubricant to avoid seizing and blockage. Because of the high temperature on this area, only a solid lubricant can do the job.

GCG-3As a carrier for the graphite and to make it stay on its place, it is present into a grease-paste with a high consistency (NLGI 3). The ingredient of the grease-paste will disappear, leaving the graphite working as anti-stick.

The gate of the kiln has a seal and due to high tem-perature, it tends to stick making difficult to open it. To avoid this problem, a release product should be applied. In this case graphite is used.

KL COMPLEX 2000High adhesion grease based on aluminium com-plex soap and high viscous base oil (ISO VG 1000). In order to provide an extremely high load capacity, besides Extreme Pressure additives, it contains a synergistic combination of solid lubricants; graphite and MoS2 (molybdenum disulphide).

Easy to used in centralized system thanks to its con-sistency NLGI 1 (slightly softer than usual greases).

KL COMPLEX 2000Thanks to its high adhesion it stays on place and due to the optimum balance of solid additives, it gives very good protection against fretting. It provi-des spectacular results compared to standard MoS2 greases.

Couplings are exposed to high load. Standard lubri-cants get squeezed and are likely to abandon the contact surface. These gears are also submitted to constant small movements under load which lead to problems of fretting.

KILN’S GATE SEAL

KL COMPLEX 2000Same as for the roller press bearings.

Including in the quarry, there are many bearings and mechanisms with high load, low speed, vibrations and/or shocks, where KL COMPLEX 2000 will per-form to extend the life of the mechanism.

CRUSHER, VIBRATING SCREEN BEARINGS...

GEAR COUPLINGS

ROLLER PRESS BEARINGS

Our technical team provides

technical assistance to our

customers, particularly for the

lubrication of the pinions and

girth gears. Our team

performs

regular

inspection

of the gears

advising for

corrective actions if

needed. For that different

measurements are taken, using

stroboscope, vibrometer and

infra-red thermometer. Besides the

gears themselves, the team checks

also the spray system by taking the

spray pattern and measuring the

consumption.

Also our team can provide advices

for a good running-in process

and a correct repair of the gears

damaged by pitting.

Technical Assistance

SPECIAL LUBRICANTS

Lubricant ApplicationApplication

PointComposition Color

NLGI Consistency

Approx. Drop point

4-ball test (ASTM

D 2596), weld load

FZG test, load level

FZG test, wear rate

Lubekrafft® G Paste

Priming paste for open gear to apply before running in.

3, 4, 8, 9Paste with mineral oil, lithium soap, extremely pure graphite and MoS

2

Black 1-2 160ºC 5.300 N

KGP-2/P-ESprayable running in grease

for large open gears3, 4, 8, 9

Grease with mineral oil and PIB, aluminium complex soap, extremely pure graphite (10%) and MoS

2 (8%)

Black 00-0 170ºC > 6.000 N > 12< 0,2

mg/kW.h

KGP-2/PSprayable service grease

for large open gears3, 4

Grease with mineral oil and PIB (ISO VG 1000), aluminium complex soap,

extremely pure graphite (10%)Black 00-0 170ºC > 6.000 N > 12

< 0,2mg/kW.h

KGP-2/PLEX 1500

Sprayable service grease for large open gears

3, 4Grease with mineral oil and PIB (ISO VG 2500), aluminium complex soap,

extremely pure graphite (10%)Black 00-0 170ºC > 6.000 N > 12

< 0,2 mg/kW.h

KGP-2/FService grease for

dip lubrication for large open gears

3, 4Grease with mineral oil and PIB (ISO VG 2000), aluminium complex soap,

extremely pure graphite (10%)Black 000-00 170ºC > 6.000 N > 12

< 0,2 mg/kW.h

KGP-2/MService grease for

manual application for large open gears

3, 4Grease with mineral oil and PIB, special thickener, graphite (12%)

Black 00-0 6.000 N

KGP OIL 6Sprayable high viscosity

transparent oil for large open gears.

3, 4High viscous transparent oil (around 16.000 cP at 40ºC)

Yellow transparent

N.A. N.A. > 8.000 N > 13< 0,2

mg/kW.h

KROIL SPECIAL RING

Lubricant for kiln’s loose tyres

5 Graphite suspension in water Black N.A. N.A.

KL COMPLEX 2000

Grease for bearing under heavy loads, shocks,

vibrations and low speed1, 2, 6

Grease with mineral oil (ISO VG 1000), lithium complex soap, graphite and

MoS2, adhesion improver

Black 1 230ºC 4.000 N

GCG 3Grease for kiln’ gate

to avoid sticking7

Grease with calcium soap, mineral oil, graphite (20%)

Black 3 120ºC

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5

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8

9

7

3Kra�tFluids

KRAFFT S.L.U.Carretera de Urnieta s/n20140 AndoainTél.: (34)943 410 400 - Fax: (34)943 410 430Email: krafftfluids@krafft.eswww.krafft.es

CERTIFICADO Nº. 1937983/12 CERTIFICADO Nº. 1937983

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