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 • Standard well 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 • Protect against corrosion
CHALLENGES
• • Water ingress • Different speeds • Dirt
REQUIRED GREASE PROPERTIES
• Does not soften with water • Is shear stable anti-wear and • Has EP performance
Heavy loads
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
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
©2019 Quaker Houghton. All rights reserved.
quakerhoughton.com | info@quakerhoughton.com
QUAKERTEK™ CS CALCIUM SULFONATE COMPLEX GREASES Mechanical Stability Tests Roll Test (ASTM D1831 modified)
Cone Penetration after 100,000 strokes (ASTM D217)
• The pictures below show a comparison of the ability
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:
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 • The in penetration after 100,000 strokes of the different
• The QUAKERTEK™ CS 4015-EPE Calcium Sulfonate Complex grease does not soften with the addition of water, whereas the Aluminum Complex grease softens and gives a slurry
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
120
Dry/Neat 20% Water added
Aluminum Complex grease after Roll Test with 20% water
Better Mechanical Stability
DIFFERENCE IN PENETRATION AFTER 100,000 STROKES
20% water, providing better mechanical stability, whereas other greases can be washed out of the bearing, leading to bearing failure, downtime, higher consumption and cost
50
20
QUAKERTEK™ CS 4015-EPE after Roll Test with 20% water
-5
QUAKERTEK™ CS 4015-EPE
Aluminum Complex
Lithium Complex
Polyurea
Typical Properties of QUAKERTEK™ CS Greases PRODUCT
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
Enables use in a centralized lubrication system (CLS)
©2019 Quaker Houghton. All rights reserved.
Lower base oil viscosity for higher speeds
Adequate formulation to hold up to extreme pressure and severe loads
quakerhoughton.com | info@quakerhoughton.com
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:
With QUAKERTEK™ CS 4015-EPE, the mill:
wanted to reduce bearing failures and grease • They consumption
• 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
bearing failures a year on their finishing mill roller • 6bearings with a Lithium Complex grease
To provide solutions to the customer:
CS 4015-EPE was introduced to further • QUAKERTEK™ optimize the process
grease consumption, using 4 times less • Reduced grease
fall injuries
was designed so the bearings would be greased • Reduced hours for chock maintenance • Aonetrialtime, and then checked when 10.000tn, 15.000tn, and 20.000tn of steel was rolled
21.000tn/ rolled steel the picture below shows • After that the grease layer is thinner, but still remains in the
Grease consumption reduction and no bearing failures resulted in a total annual savings of 51,110 €
space 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
©2019 Quaker Houghton. All rights reserved.
quakerhoughton.com | info@quakerhoughton.com
V001.19.06.EN.GL