Cement Industry

Gear Shield meets OEM Viscosity Requirements, Lubricant Rupture Eliminated and Film Strength Restored – Extended Gears Operating Life

Below is a summary of Proof Of Performance from some of Cement factories those switched their Open Gear Lubricant (OGL) to Petron Gear Shield the best girth gear grease for lubrication of their mill & kiln girth gears.

The issues/areas of concern with earlier Open Gear Lubricant (OGL) were mitigated after changing over to Petron Gear Shield the high performance grease/lubricant for mill & kilns used in cement, steel, mining & coal power industry. To find details about Gear Shield Open Gear Lubricants, please visit.

Before using Gear Shield Lubricants for Best Girth Gear Grease After using Gear Shield Lubricants for Open Girth Gears
The lubricant did not meet OEM recommended viscosity for best girth gears lubricants.
High viscosity lubricant film strength restored on pinion and girth gear.
Insufficient lubricant film strength contributed to premature gear wear.
Lubricant film rupture eliminated.
Rupture of Lubricants Film
The Gear Shield exceeded the OEM recommended Lube Film minimum Thickness requirements.
Low lambda (lubricant film thickness) value between gear tooth mating surfaces.
Lubricant Lambda (lubricant film thickness) exceeds AGMA recommended standard of four (4) or greater.
Lack of adhesion to gear teeth / idler wheel transfer.
High viscosity film with higher thickness extends operating life of gear.
Excessive lubricant build-up on gears surfaces.
Reduced wear longer life of gears, lesser maintenance.
Lubricant build-up increased exposure of gear to air-borne contaminants.
Increased protection to gears due to superior film thickness (lambda value) of Gear Shield.
Reduced inventory and lesser warehousing space requirements
Reduced quantity of waste Oil.
Reduced cost of disposal.
In addition to above, Lubricant build-up eliminated through Gear Shield superior drainage capability.

Petron KL-300

Petron Kiln Lube Open Gear Lubricants are designed for slow-moving open gear drives on stationary rotating machinery operating at low or elevated temperatures. With its high viscosity, synthetic open gear lubricant is designed for use in spray, sump, or bath-type applications.

Its unique formulation provides high viscosity protection at elevated operating temperatures, yet stays fluid at cooler temperatures aiding in trouble-free start-ups.

A propriety blend of extreme pressure additives and friction modifiers contributes further to the separation of gear teeth during sliding motion encountered on slow-moving gears. Petron Kiln Lube has been designed with a special oxidation-resistance additive to provide extended drain intervals and can accommodate a wide range of ambient temperatures.

Reduction of Lubricant - Grease Consumption, Hard Cost Savings, Reduced cost for waste disposal

Below are some Proof Of Performance (POP) from the Cement factories that switched their mill or kiln Lubricant to Petron Gear Shield Open Girth Gears lubricant – Grease, below demonstrating the issues/concerns prior to changing and the benefits gained after switching over to Petron Lubricant

1. Gear Shield NC® In The Cement Industry | Best Girth Gear Grease

Industry Application Equipment Lubricant
Cement
Open Gear Lubrication
Finish Mills
Petron Gear Shield NC®

A) No Lubricant Build Up | Best Girth Gear Grease

Previous Condition

  • Customer used a grease type product to lubricate the open gears of two finish mills.
  • Lubricant build up evident on inspection door and inside gear guard.
  • Drainage of lubricant from gear guard not evident.
  • Previous timing of automatic lubrication was eight counts every twelve minutes.

Current Condition

  • Gear Shield NC® currently lubricates the open gears of both finish mills.
  • Lubricant build up eliminated.
  • Drainage of lubricant from guard of gear established.
  • Current timing of automatic lubrication system is four counts every twenty minutes.

B) Drainage Established - Proof of Performance

Gear Shield NC ® (Drainage Established)

Previous Product (No Drainage)

C) Automatic Lubrication System Count And Timing Comparison (Over Sixty Minutes)

Previous Product

Gear Shield NC®

70% Reduction In System Timing

D) Automatic Lubrication System Count And Timing Comparison (Over Sixty Minutes)

Previous Setting = 8 counts/12 minute cycle Current Setting = 4 counts/20 minute cycle
.15 cu. in. x 8 counts = 1.20 cu. in. per nozzle.
.15 cu. in. x 4 counts = .60 cu. in. per nozzle.
6 nozzles x 1.20 cu. in. = 7.2 cu. in. every 12 minutes.
6 nozzles x .60 cu. in. = 3.6 cu. in. every 20 minutes.
7.2 cu. in. x 5 cycles every 60 minutes = 36 cu. in. every 60 minutes
3.6 cu. in. x 3 cycles every 60 minutes = 10.8 cu. in. every 60 minutes.

70% Reduction In Rate of Application & Cost

2. Gear Shield NC® In The Cement Industry

Industry Application Equipment Lubricant
Cement
Open Gear Lubrication
Finish Mill/Kiln
Petron Gear Shield NC®

A) Drainage – Gear Shield NC® the best Girth Gear Grease

Before Gear Shield NC®:

  • The customer used a sprayable lubricant.
  • Lubricant applied via automatic lubrication system.
  • Lubricant did not meet OEM recommended viscosity for open gear lubricants.
  • Lubricant would not consistently drain from gear guard.

After Gear Shield NC®:

  • Gear Shield NC® exceeds OEM viscosity requirement for open gear lubricants.
  • Gear Shield NC® consistently drains from gear guard.
  • High viscosity film strength extends operating life of gear.
  • Consistent drainage eliminates lubricant build up inside of gear guard.

B) Gear Shield NC® Benefits

  • High viscosity film strength extends operating life of gear.
  • Consistent drainage eliminates lubricant build up inside of gear guard.
  • Consistent drainage flushes airborne contaminants from gear.

Consistent drainage eliminates lubricant build-up inside of gear guard and
flushes airborne contaminants from the best Girth Gear Grease.

3. Gear Shield NC® In The Cement Industry

Industry Application Equipment Lubricant
Cement
Open Gear Lubrication
Ball Mills
Petron Gear Shield NC®

A) Reduced Lubricant Consumption

Before Petron Gear Shield NC®: the best Open Gear Lubricant

  • Lubricant did not meet OEM recommended viscosity for open gear lubricants.
  • Automatic lubrication system applied 3.5 oz. of lubricant every 5 minutes.

Hourly

42.0 Ounces

Daily

1,008 Ounces

After Petron Gear Shield NC®:

  • Gear Shield NC® exceeds OEM viscosity requirement for open gear lubricants.
  • Automatic lubrication system applies 1.1 oz. of Gear Shield® every 20 minutes.

Hourly

3.20 Ounces

Daily

76.80

B) Reduced Weight of Transferred Open Gear Lubricant

Before Gear Shield NC® Open Gear Lubricant (OGL)

  • Lubricant - Grease would not consistently drain from gear guard.
  • Grease / lubricant consumption was approximately 63 pounds per day.

Hourly

63.0 pounds

Daily

22,050 pounds

Before Petron Gear Shield NC® best Open Gear Lubricant

  • Lubricant - Grease would not consistently drain from gear guard.
  • Open gear lubricant consumption was approximately 63 pounds per day.

Hourly

4.80 pounds

Daily

1,680 pounds

The benefits of using Petron engineered best open gear Lubricant for kiln & mill Open Gears; which resulted into reduced cost for lubricant/grease thus lower expenses for waste disposal. It also reduced stress on pump and lube lines.

Benefits

Extended gear operting life through higher viscosity film thickness.

Automatic lubrication system timing reduced 70%.

Cost for lubricant reduced 75% (timing reduction + lower cost per pound).

Engineered to withstand heat, pressure, and non-stop operations. Protect your equipment and boost efficiency.

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