Application
Maintenance, repair, and overhaul (MRO) operations are integral to the sliding runners and kiln seals within a cement operation.
Operational Parameters (LETS)
The operational parameters (LETS) encompass high loads with shock loads, an open-air and dusty environment, temperatures ranging from -40 to +130°C, and velocities up to 1.5 m/s. The process description involves a centralized lubrication system with a focus on the sliding surface.
Challenge
The rapid oxidation of grease, exposed to continuous heating up to +130°C and coke dust, has resulted in significant wear on the contacting plate. Consequently, the kiln seal has begun to fail, leading to the emission of coke into the atmosphere. The previously utilized lithium-based grease, equipped with EP additives, proved inadequate in withstanding the elevated temperatures and abrasive nature of the dust particles.
Solution
The MOLYKOTE® BR-2 Plus Multi-Purpose Grease has demonstrated commendable adhesion, wear and corrosion protection, along with long-term stability due to its solid lubricant content. Notably, it offers resistance to degradation under sustained heating conditions, making it ideal for prolonged lubrication applications. The inclusion of solid lubricants facilitates the formation of a thin film on contacting surfaces, effectively minimizing wear.
The utilization of this grease, enriched with solid lubricants, resulted in a notable extension of the seal replacement service life from six to 24 months. This achievement has significantly reduced maintenance requirements, downtime, and associated equipment costs.
