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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V001.19.06.EN.GL