The global spotlight on energy efficiency is especially focussed in South Africa where electricity production often cannot match demand and costs have the potential to increase dramatically in the short term.
Friction reduction is critical to maximising efficiency at all ends of the industrial scale – whether in a simple grease between two surfaces or in massive applications where proper lubrication can make tremendous differences to electricity consumption and costs.
Castrol Industrial offers a range of products to ensure that equipment is running smoothly and efficiently, and in some cases, a switch to the brand’s High-Performance Lubricants can save millions in running costs.
Last year a South African customer changed the lubrication product in two 4 MW SAG mills, with incredible results. A Measurement and Verification specialist first measured the baseline electricity demand from each of the mills’ two gear drives, and after a switch to Castrol Optigear Synthetic PD ES gear oil, the result showed a significant improvement in friction coefficient, and in turn immense monetary savings.
The Polyalphaolefin (PAO) based lubricant, with MFT PD Technology, meant electricity demand was reduced to a verified saving of R260,000 per month or more than R3-million per year. The savings in energy consumption is equivalent to that of roughly 250 homes for one year.
In conventional lubricants, additives are sacrificial and get used up over time. Even though they protect the equipment they still wear and breakdown can eventually happen.
Under a microscope, even the smoothest metals’ surfaces show peaks and troughs and a small portion of the surface area supports loads. This can create friction, and in turn, damage machinery. Gear oil additives protect these contact points by forming a protective layer.
Castrol’s Microflux-Trans (MFT) Plastic Deformation (PD) technology takes a different approach by smoothing surfaces without removing or depositing material, providing a protective layer with a hi-tech lubricating effect. As loads increase this layer is compressed and becomes even more pressure-resistant and in time improves friction coefficients.
As loads increase even further the MFT PD ES additive components migrate from the protective layer into the structure of the metal and initiate a micro-smoothing effect. This multiplies the load-bearing surface area, meaning less pressure, less friction and less wear.
These additives are also non-sacrificial so users will not need to replace lubricants as often. Castrol Optigear is proven to lower the coefficient of friction by up to 30% compared to standard gear oils, and actively lowers maintenance and energy costs while at the same time preventing unplanned downtime.
Optigear Synthetic PD ES is compatible with spur, bevel or planetary gear types and in heavily loaded gear units. It is also suitable for the lubrication of oil-lubricated rolling bearings.
Optigear Synthetic PD ES and other Castrol High-Performance Lubricants are available through the authorised importer and distributor Re-Eme Mining and Industrial (Pty) Ltd.
