GREASES FOR METALLURGICAL INDUSTRY. solutions verified by equipment
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1 GREASES FOR METALLURGICAL INDUSTRY solutions verified by equipment
2 CONTENT SINTERING PLANT 4 CONTINUOUS CASTING MACHINE 6 ROLLING PLANT 8 PIPES PRODUCTION 10 GREASES CLASSIFICATION ACCORDING TO DIN GREASES CLASSIFICATION ACCORDING TO NLGI 13 GREASES DESCRIPTIONS 14 GLOSSARY 15
3 SINTERING PLANT At metallurgical plants the furnace charge is agglomerated in belt-type sinter machines, presented by a continuous chain of sintering trolleys with the bottom made of fire grates, further the sinter cake is supplied on the cooler band, then it is crushed in screens. PROBLEMS SOLVED AT OPERATION Protection of friction couples zone from dust ingress Stability of operation at high thermal loads OPERATING CONDITIONS Abrasive dust in drives and bearings of sintered trolleys High operating temperatures C Abrasive dust and high loads on the cooler chain links Continuous operation and complicated conditions of relubrication APPLICATION Sintering trolleys Elements of cooler chain Grate LUBRICATED UNIT Trolley bearings Sealing (beam) Driving gear clutch Rolling bearings Rolling bearings Plain bearings Rolling bearings Rolling bearings ENVIRONMENTAL TEMPERATURE, Ñ RECOMMENDED PRODUCT DIN PACKAGING BASIC PROPERTIES LUKOIL AQUAFLEX EP KP1R LUKOIL STEELFLEX KP1P LUKOIL CARBOFLEX OG HD OGF0N LUKOIL AQUAFLEX EP KP1P LUKOIL THERMOFLEX EP KP1P LUKOIL POLYFLEX PU KP1R LUKOIL THERMOFLEX EP HD KPF2Ð LUKOIL THERMOFLEX EP KP1P-30 Water-resistant high-temperature grease with high load carrying capacity High-temperature complex calcium grease, specially designed for centralized system Extremely high protection at boundary friction Water-resistant high-temperature grease with high load carrying capacity Universal high-temperature grease, resistant to water impact, has high adhesion Low wear at high temperatures Special grease with protection against shock loads Special high-temperature grease, resistant to water impact, has high adhesion
4 CONTINUOUS CASTING MACHINE Continuous casting is the moulding of metal into water-cooled mould, wherefrom partially hardened intermediate product is continuously rolled out. CCM Continuous Casting Machin or SPP Slab-Producing Plant. At present nearly 60% continuously casted intermediate products are moulded on slab CCM. Liquid steel is continuously moulded into water-cooled oscillating casting box, called mould. Downstream the mould a secondary cooling zone is situated. In this zone due to the forced surface cooling the intermediate product is hardened all over the cross section. Due to the continuity of the process a complete evenness of the melt all over its volume is achieved. Such process of metal casting is a way to receive melt of unlimited length. Lubrication via centralized system PROBLEMS SOLVED AT OPERATION Protection of friction zone against water ingress Long-life lubrication Protection against damages caused by shock loads Easy pumping via long lubrication pipes High humidity and water impact OPERATING CONDITIONS High thermal load on bearings Lack of time and difficulty in maintenance Shock loads CCM APPLICATION LUBRICATED UNIT Feeders, centralized lubrication system Secondary cooling zone bearings ENVIRONMENTAL TEMPERATURE, Ñ RECOMMENDED PRODUCT DIN PACKAGING BASIC PROPERTIES LUKOIL POLYFLEX PU KP1R LUKOIL AQUAFLEX EP KP1R LUKOIL THERMOFLEX EP KP1P LUKOIL STEELFLEX KP1P LUKOIL STEELFLEX KP1P LUKOIL AQUAFLEX EP KP1R-30 Low wear at high temperatures Water-resistant high-temperature grease with high load carrying capacity High-temperature complex lithium grease with high load carrying capacity, for centralized systems Special high-temperature grease, the best degree of pumping, anti-seize protection Special high-temperature grease, the best degree of pumping, anti-seize protection Water-resistant high-temperature grease with high load carrying capacity Pivoting valve Withdrawal and straightening units LUKOIL THERMOFLEX EP KP1P-20 High-temperature complex lithium grease with high load carrying capacity, for centralized systems Sliding surfaces and threading, for easy assembling LUKOIL PIPEFLEX 141C Bucket 30 kg Special pipe seal grease, lead-free formula
5 ROLLING PLANT Flat steel is one of the most cost-effective types of metal products. It is very convenient for producing of different pressed workpieces and light and strong constructions. Sheets of different types are widely used in transport machine building, in particular, in automobile industry, shipbuilding, production of agricultural machines, electrical industry and other branches of economy. PROBLEMS SOLVED AT OPERATION Protection of friction zone against water and steam ingress Protection against damages caused by shock loads Stability of operation at high thermal loads OPERATING CONDITIONS Cooling water ingress into the mill roll High thermal load on bearings Shock loads Hot rolling mil APPLICATION LUBRICATED UNIT Cardan joint Gears Roller conveyor bearings ENVIRONMENTAL TEMPERATURE, Ñ RECOMMENDED PRODUCT DIN PACKAGING BASIC PROPERTIES LUKOIL THERMOFLEX EP HD KPF1N LUKOIL POLYFLEX EP KP00K LUKOIL STEELFLEX K1P-20 Special grease for slow-speed units, subjected to shock loads Universal gear grease with protection from shock loads Special high-temperature grease, the best degree of pumping, anti-seize protection Cold rolling mill Cardan joint Gears LUKOIL THERMOFLEX EP HD KPF1N LUKOIL POLYFLEX EP KP00K-30 Special grease for slow-speed units, subjected to shock loads Semi-liquid gear grease on lithium base with EP additives Milling roller LUKOIL POLYFLEX EP LC KP2Ê-20 Water resistant grease with EP additives and protection against wear and shock loads Galvanizing Roller bearings in hot zone LUKOIL AQUAFLEX EP KP2P-30 Water-resistant high-temperature grease with high load carrying capacity
6 PIPES PRODUCTION For protection and preservation of threads of pump and compressor pipes and casing pipes and for sealing of thread joints and lock joints of pipelines the thread sealing lubricants are used. LUKOIL PIPEFLEX greases protect the metal from corrosion at operation in hydrogen sulphide and carbon dioxide media at oil, gas, gas condensate and highly flooded fields, secure protective properties during pipes storage and transportation even by sea transport. Specially designed composition secures excellent sealing of joints and thread protection against wear and corrosion, that allows to prevent most of short-circuitings and gas shows and to secure ecological compatibility and continuity of drilling. PROBLEMS SOLVED AT OPERATION Protection of pipes against corrosion during operation, storage and transportation Sealing of thread joints Operation in Extreme North conditions OPERATING CONDITIONS INTESMO LLC has designed a range of products, meeting the requirements of ISO (API-5A3) Protection against direct contact of metal thread joints and against tear at strong contact stresses and sliding of these surfaces over each other APPLICATION Drill pipes, casing pipes, pump and compressor pipes LUBRICATED UNIT Lock joints of drill pipes Thread joints of casing pipes and pump and compressor pipes ENVIRON- MENTAL TEMPERA- TURE, Ñ RECOMMENDED PRODUCT PACKAGING LUKOIL PIPEFLEX 111LT Bucket 30kg BASIC PROPERTIES Standard composition of grease LUKOIL PIPEFLEX 112C Bucket 30kg Lighter composition of grease LUKOIL PIPEFLEX 122S Bucket 30kg Copper-aluminium complex LUKOIL PIPEFLEX 141C Bucket 30kg Lead-free grease LUKOIL PIPEFLEX 141EG Bucket 30kg Lead-free grease LUKOIL PIPEFLEX 131HT Bucket 30kg Ecologically safe grease LUKOIL PIPEFLEX 223TF Bucket 30kg Lighter composition of grease Sealing of probable leakage outlines at high internal pressure Inhibiting properties of lubricants
7 GREASE CLASSIFICATION ACCORDING TO DIN The lubricant is assigned a code, which reflects the composition, field of application and some properties. KPF2K Designation of the lubricant 2. Base oils, additives and filters 3. Consistency (NLGI class) 4. Upper temperature limit, resistance to water washout 5. Minimum operating temperature, Ñ Code K G OG M Code E FK HC PH PG SI X Code P F 1. Designation For roller bearings, plain bearings and sliding faces For gears For open gears For plain bearings and seals 2. Synthetic base oil Polyether base oil Fluorhydrocarbon base oil Synthetic hydrocarbon base oil Phosphate ester based oil Polyglycol base oil Silicone base oil Other types of base oils 3. Addition agents Extreme pressure additives Solid lubricants (graphite, MoS 2, PTFE, etc.) Code 4. Upper operating temperature limit and resistance to water washout Upper temperature limit, Ñ Resistance to water washout at temperature ( Ñ) according to DIN C 60 0 or 1 at 40 Ñ D 60 2 or 3 at 40 Ñ E 80 0 or 1 at 40 Ñ F 80 2 or 3 at 40 Ñ G or 1 at 90 Ñ H or 3 at 90 Ñ K or 1 at 90 Ñ M or 3 at 90 Ñ N 140 P 160 R 180 S 200 T 220 U > 220
8 GREASE CLASSIFICATION TO N LG I The classification is based the worked penetration of the grease, expressed in 0.1 mm. The worked penetration is the depth of the standard cone penetration into the grease layer within 5 seconds at the temperature 25 Ñ after 60 double strokes. NLGI Class Worked penetration, 0,1 mm Body Liquid Soft Solid Application Centralized lubricating system, gear lubrication Plain bearings, roller bearings, pumps Sealing lubricants, locking lubricants
9 PRODUCT NAME COMPOSITION APPLICATION AQUAFLEX EP Mineral oil / Waterproof high-temperature grease with high load carrying calcium sulfonate soap capacity for centralized lubrication systems. AQUAFLEX EP Mineral oil / Waterproof high-temperature grease with high load carrying calcium sulfonate soap capacity for centralized lubrication systems. AQUAFLEX EP Mineral oil / Waterproof high-temperature grease with high load carrying calcium sulfonate soap capacity for centralized lubrication systems. AQUAFLEX EP Mineral oil / Waterproof high-temperature grease with high load carrying calcium sulfonate soap capacity for centralized lubrication systems. PIPEFLEX 111 LT Mineral oil / lithium soap / Waterproof low-temperature grease with high anticorrosion Pb / Zn / Cu / graphite properties, resistant to H2S and CO2. PIPEFLEX 112 C Mineral oil / lithium soap / Waterproof low-temperature grease with high anticorrosion Pb / Zn / Cu / graphite and sealing properties. PIPEFLEX 122 S Waterproof low-temperature grease with high anticorrosion, Mineral oil / lithium and sealing and anti-oxidant properties suitable for high aluminium soap / Cu / PTFE pressure operations. PIPEFLEX 131 HT PIPEFLEX 141 EG PIPEFLEX 141 C PIPEFLEX 223 TF POLYFLEX PU Mineral oil / lithium soap/ graphite/ PTFE Mineral oil / lithium soap / Zn / Cu / graphite Mineral oil / lithium and aluminium soap / Zn / Cu / graphite Mineral oil / calcium soap / fluoroplastic Mineral oil / polyurea Environmentally friendly / waterproof low-temperature grease with high anticorrosion and sealing properties. Waterproof low-temperature grease with high anticorrosion, sealing and antioxidant properties. Waterproof low-temperature grease with high anticorrosion, sealing and anti-oxidant properties. Waterproof grease with high anticorrosion properties. Special high-temperature grease based on polyurea for ultrahigh protection. POLYFLEX EP Mineral oil / lithium soap General purpose gearbox grease with protection from shock loads. POLYFLEX EP LC STEELFLEX THERMOFLEX EP HD THERMOFLEX EP THERMOFLEX EP THERMOFLEX EP HD CARBOFLEX OG HD Mineral oil / lithium and calcium soap Mineral oil / polyurea Mineral oil / lithium complex soap / MoS2 Mineral oil / lithium complex soap Mineral oil / lithium complex soap Mineral oil / lithium complex soap / MoS2 Mineral oil / aluminum complex soap / graphite General purpose grease with EP additives, used in high humidity conditions. Special high-temperature grease for centralized lubrication systems. Grease for slow-speed heavy loaded bearings. General-purpose high-temperature water-resistant grease with high adhesion properties. High-temperature complex lithium grease for centralized systems with high load carrying capacity. High-temperature grease for work at boundary friction. Special semiliquid lubricant for open gears, applied by spraying. High adhesion and water-resistance.
10 GLOSSARY Adhesion bonding of the surfaces of dissimilar materials, stickness. Boundary friction a mode arising in case when friction surfaces are separated by a thin layer of lubricant (less than 0.1 µm), not exceeding the height of the surface microroughness (unevenness). Causes to high wear. Operating temperature range the range of temperatures in which the grease meets technical requirements and an interval is maintained between the lubricant batches supply. Tribology a branch of physics dealing with research and description of the contact interaction of solid deformable bodies at their relative displacement. The subject matter of tribological researches is the processes of friction, wear and lubrication. The main tribological factors for lubricating greases are welding load, scar diameter and wear index. The tests are carried according to GOST , DIN 51350/4, ASTM D 2266, ASTM D 2596, ISO Welding load the minimum load at which the welding or conventional welding of the surfaces takes place (the torque on spindle exceeds the setting in GOST ). It characterizes the limit efficiency of the grease. Wear index dimensionless quantity which shows the ability of the lubricant to prevent the load wear (heavy wear caused by microwelding of the surfaces). Scar diameter the diameter of the wear scar after testing, measured in millimeters. Solid fillers solid materials which have the low friction coefficient. They are added into grease to reduce friction and wear, to prevent load wear, cold welding and fretting corrosion. Base oil dispersion media of different viscosities for manufacturing of greases NLGI National Lubricating Grease Institute; American National Institute of Greases. DIN Deutches Institut fur Norming e.v.; German Standards Institute. ASTM American Society for Testing and Materials.
11 INTESMO LLC Innovative Greases Technologies Tel/fax: +7 (8442) / info.intesmo@lukoil.com
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