Quakertek™ Cs Calcium Sulfonate Complex Greases

PERFORMANCE SHEET QUAKERTEK™ CS CALCIUM SULFONATE COMPLEX GREASES Background

Work Roll Bearings

hot strip mill in steel plants encounters some of • The the most severe conditions as far as lubrication is

concerned especially on the work roll and roller table bearings as mention in the tables to the right

greases used in the hot strip mill perform well • Standard under normal, dry conditions. However, performance

deteriorates quickly with water ingress, as these greases tend to soften with water

can lead to high grease consumption, bearing • This failures and increased workload for chock replacement

Benefits In the presence of water, QUAKERTEK™ CS has been formulated to:

• Maintain consistency – for lower grease consumption excellent extreme pressure and anti-wear • Sustain performance – for reduced bearing failures

CHALLENGES

REQUIRED GREASE PROPERTIES

• Heavy loads • Water ingress • Different speeds • Dirt

• Does not soften with water • Is shear stable anti-wear and • Has EP performance

corrosion protection • Excellent and sealing properties

Roller Table Bearings CHALLENGES

• Water ingress • Dirt • Medium loads

REQUIRED GREASE PROPERTIES

• Does not soften with water • Is shear stable excellent corrosion pro• Has tection and sealing properties anti-wear and • Has EP performance

reduced base oil viscosity • Has vs. work roll grease

•

Protect against corrosion

QUAKERTEK™ CS Calcium Sulfonate Complex Grease Key Applications For Hot Strip Mills QUAKERTEK™ CS 4015-EPE QUAKERTEK™ CS 2201-EPE

QUAKERTEK™ CS 4015-EPE

QUAKERTEK™ CS 4015-EPE

Heavy loads and low to medium speed lubricating grease Heavy loads and medium to high speed lubricating grease

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QUAKERTEK™ CS CALCIUM SULFONATE COMPLEX GREASES Mechanical Stability Tests Roll Test (ASTM D1831 modified)

Cone Penetration after 100,000 strokes (ASTM D217) In service, greases often become softer due to the mechanical shear of the thickener structure. Resistance of grease to mechanical shear can be evaluated by different tests:

• The pictures below show a comparison of the ability

of two greases to resist a change in consistency when worked by rolls (80ºC, with rolls at 165+/-15 rpm during 50h) with 20% water

chart below shows the results of the difference in • The • The QUAKERTEK™ CS 4015-EPE Calcium Sulfonate penetration after 100,000 strokes of the different grease types, both dry/neat and with 20% water added

QUAKERTEK™ CS 4015-EPE Calcium Sulfonate • The Complex grease doesn’t soften with the addition of 20%

Complex grease does not soften with the addition of water, whereas the Aluminum Complex grease softens and gives a slurry

120

Побышенная механическая стабильность Better Mechanical Stability

РАЗНИТЦА DIFFERENCE ЗНАЧЕНИЙ IN PENETRATION ПЕНЕТРАЦИИ AFTER ЧЕРЕЗ 100,000 100 000 STROKES ЦИКЛОВ

water, providing better mechanical stability, whereas other greases can be washed out of the bearing, leading to bearing failure, downtime, higher consumption and cost Сухая/чистая Dry/Neat С добавлением 20% Water added 20% воды

50

20

Aluminum Complex grease after Roll Test with 20% water

QUAKERTEK™ CS 4015-EPE after Roll Test with 20% water

-5

QUAKERTEK™ QUAKERTEK™ CS 4015-EPE 4015-EPE CS

Алюминиевый Aluminum Complex комплекс

Литиевый Lithium Complex комплекс

Полимочевинная Polyurea

Typical Properties of QUAKERTEK™ CS Greases NLGI

DROPPING POINT

BASE FLUID

BASE FLUID (MM2/S AT 40°C)

OPERATING TEMP. (°C)

AW/EP CHARACTER

CORROSION PROTECTION

WATER RESISTANCE

DIN 51.502

QUAKERTEK™ CS 2201-EPE

1

275

Mineral

220

-15 to 140

++/+++

+++

+++

KP 1 N-10

QUAKERTEK™ CS 4015-EPE

1/2

283

Mineral

400

-20 to 150

++/+++

+++

+++

KP 1/2 N-20

PRODUCT

Enables use in a centralized lubrication system (CLS)

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Lower base oil viscosity for higher speeds

Adequate formulation to hold up to extreme pressure and severe loads

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Does not soften in the presence of water protects against water ingress

QUAKERTEK™ CS CALCIUM SULFONATE COMPLEX GREASES Case Study A steel finishing mill was facing the following challenges: bearing failures a year on their finishing mill roller • 6bearings with a Lithium Complex grease

wanted to reduce bearing failures and grease • They consumption To provide solutions to the customer:

CS 4015-EPE was introduced to further • QUAKERTEK™ optimize the process

•

A trial was designed so the bearings would be greased one time, and then checked when 10.000tn, 15.000tn, and 20.000tn of steel was rolled

21.000tn/ rolled steel the picture below shows that • After the grease layer is thinner, but still remains in the space

With QUAKERTEK™ CS 4015-EPE, the mill:

• Reduced grease consumption, using 4 times less grease • Elimination of bearing failures • Reduced the amount of grease in inventory grease washout and residue - improving • Reduced workshop cleanliness and reducing the risk of slip and fall injuries

• Reduced hours for chock maintenance

Grease consumption reduction and no bearing failures resulted in a total annual savings of 51,110 €

between the rolling elements

The chart below shows a comparison of grease consumption for 21.000tn of rolled steel GREASE

g OF GREASE/tn OF STEEL

Lithium Complex Grease

14.72

QUAKERTEK™ CS 4015-EPE

3.67

Reduction in Consumption

11.05

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