In This Issue:

FEATURED PRODUCT: Pyroshield Syn Hvy and XHvy Open Gear Lubricants (9000 and 9011) 

TECHNI-TIP: Extreme Protection for Open Gears

CUSTOMER TESTIMONIAL: 9011 Pyroshield Open Gear Lubricant

MAR - APR 2014: PYROSHIELD SYNTHETIC OPEN GEAR LUBRICANT

FEATURED PRODUCT: Pyroshield Syn Hvy and XHvy Open Gear Lubricants (9000 and 9011)     



 

 

 

 

 

 

Pyroshield Syn Hvy and XHvy Open Gear Lubricants are heavy duty synthetic fluids designed to provide outstanding protection for high-load, heavy-shock applications, such as large shrouded open gears used in the mining, mineral processing and cement industries. Pyroshield Syn Open Gear Lubricants are non-asphaltic and are environmentally friendly, containing no heavy metals.

Pyroshield Open Gear Lubricants contain a synergistic mix of Almasol, LE's exclusive wear-reducing additive, and a unique combination of extreme pressure additives. They exhibit exceptionally high film strength that helps them to withstand heavy loads and cushion shock loading in applications where commercial grade lubricants would fail. They also prevent the metal-to-metal contact that can lead to high operating temperatures and destructive wear.

Longer Gear Life
- Superior extreme pressure and anti-wear properties
- High fluid viscosity (meets Falk viscosity specs)

Electrical Energy Savings
- Lower gear temperature (less friction)
- Reduction in amperage draw

Lower Lubricant Consumption
- Up to 50 to 80 percent less lubricant is required
- Lower waste disposal cost

Less Maintenance
- Pyroshield does not harden in the shroud and roots of the gear

Cleaner Environment
- Pyroshield is transparent and does not contain asphalt or graphite
- Pyroshield will not plug the lube system or shroud

Healthy Environment
- The diluent in 9011 Pyroshield is USDA H1 food grade
- 9011 is "non-controlled" under WHIMS

For more product information, please click here. For ordering information, please contact us at info@lubeng.com or 1-800-465-8237.

  

TECHNI-TIP: Extreme Protection for Open Gears

Introduction

Many electric generating, mineral mining and manufacturing facilities require materials to be ground or pulverized prior to fueling generator sets or prior to being used in final product processing. Much of this material is ground in ball, pebble, rod or breaker mills. Many of these mills have large open gear sets (bull or ring-and-pinion) as drive mechanisms. Large kilns, some as long as a football field, are also rotated by using open gear sets.

Lubricating these large open gears presents a unique challenge due to the heavy loads and harsh environmental conditions. Grinding or pulverizing mills are exposed to cement dust, silica or mineral dusts like limestone and coal dust. These conditions magnify the need for superior lubricating products. Empty grinding mills can weigh in excess of 400,000 pounds. Add product and a charge of grinding medium, and the gear system can be moving more than half a million pounds or more. Open gear systems on kilns face the additional difficulty of high operating temperatures

History

Traditionally, operators of open gear systems have relied upon asphaltic compounds to provide a cushioning effect. However, asphaltic lubricants create a major problem with housekeeping due to the large amount of product that must be used to provide a continuous coating to the gears. In addition, wherever asphaltic lubricants have been in use for an extended period, the eventual result is a buildup of hardened lubricant in the roots of the gears. This is difficult to eliminate and causes mechanical interference that can result in gear misalignment or stress on the pedestal mountings.

Many large open gear systems are lubricated using automatic spray systems manufactured by Farval, Trabon, Lincoln and others. These systems function by providing the lubricants to the gear teeth at set intervals in metered amounts. The solids in many of these asphaltic compounds have caused ...To continue reading and to view before and after photos please click here.


CUSTOMER TESTIMONIAL: 9011 Pyroshield Open Gear Lubricant

"
LE 9011 reduced pinion wear and saved significant pinion replacement cost"



HudBay Minerals Inc. Is a large Mining company with three operating mines in Northern Manitoba, Canada.

The open gear set on the Zinc Plant ball mill in Flin Flon has dimensions of 18.5' X 24". The gears are lubricated with an automatic air/oil spray system whereby a metered amount of lubricant is sprayed onto the gear at a set interval, usually every 15 to 30 minutes. HudBay Minerals has been applying Lubrication Engineers 9011 Pyroshield Syn XHvy Open Gear Lubricant to the gear set on this mill since 2008.

During a recent shutdown to replace the ball mill liners, the settings of the automatic lube system controller were changed. The lube interval, which is normally set in minutes, was mistakenly changed to hours, and as a result, for (6) six weeks the mill open gears were operated at a lube rate of only 2.5 percent of the AGMA recommendation for Open Gears.

LE 9011 Pyroshield Syn XHvy lubricant is formulated with high viscosity synthetic base stocks that enable Pyroshield to meet the Falk Viscosity specification for open gear lubricants at ambient temperatures between 50 degrees Fahrenheit and 125 degrees Fahrenheit

LE 9011 has excellent Extreme Pressure and anti-wear characteristics and contains Almasol, Lubrication Engineers exclusive solid-film lubricant. Almasol adds a third level of protection, and with five-times the load-carrying ability of graphite, it clings to the metal surfaces of the gears and reduces friction.

One of HudBay maintenance mechanics conducting a daily PM noticed the error and reported it. On examination of the gears after the incident, HudBay Zinc Plant NDE Technician commented "It looks like we are Ok, LE 9011 Pyroshield obviously helped to reduce wear on the pinion. Based on the results we saw even with limited spray lubrication, we will continue to use Pyroshield"

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