High viscosity lubricants are commonly used, which means these critical components usually have insufficient, coarse mesh filters or -- worse yet-- no filtration at all. The standard maintenance routine can include frequent premature oil changes driven by a high contaminant load from the product getting into the lube oil. However, frequent oil changes won’t protect the equipment, as ingressed and internally generated wear debris will continue to damage the equipment since dirt makes more dirt. Each step is critical to the whole process in cement production, and if one link in the chain breaks, the whole unit can go down. And, whether the ambient temperature is subzero cold or equator-hot, Hy-Pro has the contamination solutions to ensure your critical equipment and lube oil last beyond rated life to avoid unnecessary oil consumption and the catastrophic failure of all cement mills dread.
Before the clinker enters the kiln dryer and after drying raw product is roughed, separated, and finally milled to size by cone, roller, hammer, or ball mills. The critical on-board bearings are often lubricated with expensive synthetics ISO VG220-460 and are vulnerable to shaft seal leaks resulting in high clinker and ambient contaminant ingression. Material is moved throughout the mill by an oil-lubricated impeller and rotary claw blowers that each requires a contamination solution. The kiln-dryer features a bull drive gear, usually unfiltered, that rotates the kiln and 2-4 lubricated tower bearings per kiln where extra-high viscosity lubricants ISO VG1000 are in service because of high kiln temperatures. In-service oil is often found to be operated at an ISO code of 24 for particles ≥ 4μ[c]. Hy-Pro’s extra-high-viscosity specific side loop solutions allow you to filter the oil with high-efficiency filters and achieve always-clean oil all the time.
The risk of unchecked contamination isn’t worth the reward. For less than 1% of the cost of a failure and unit down, you can have clean oil all the time, components that exceed rated life, and fewer oil changes. The reduced oil consumption pays for the upgrades.