Gaurav K Mathur, Director and Chief Executive, Global Technical Services, discusses how lubrication is the key to achieve sustainability in the cement industry.
Lubricants are one of the essential items for keeping machine running smoothly. Lubricants provides lubrication to reduce friction in the moving part of the machine. By reducing this friction machine runs for a much longer time and by good lubrication management the machine operation and reliability can be further achieved. By good lubrication and oil condition monitoring, machine can run uninterrupted for long time and provide reliability in manufacturing.
Industrial sector accounts for a fair amount of Green House Gases (GHG) emissions. In most of these Cement and Mining Industries, lubricants are used in large quantities. Lubrication can significantly impact the overall efficiency of a machine if the proper lubrication is being done. The lubricant also affects the energy efficiency of the equipment’s. In most cases, scientifically done lubrication has shown considerably reduced power consumption, besides machine reliability.
Why is lubrication key to sustainability?
The cement industry plays a pivotal role in infrastructure development, providing the foundation for buildings, roads and other critical infrastructure in nation building.
Cement manufacturing and mining are energy-intensive, with emissions contributing to carbon footprints. In the pursuit of sustainable practices, cement plants are increasingly turning their attention to good lubrication, as key elements in enhancing operational efficiency while minimising environmental impact.
As awareness of climate change grows, the cement and mining Industry is proactively looking towards adopting technology to decrease their carbon footprint and attention is being given to sustainability to ensure minimal impact to the environment. Efforts and resources are being pledged to optimise every aspect of production, including good lubrication practises by adopting to Total Lubrication Management (TLM).
Lubrication and its efficient management, by adopting TLM in the plant, have great potential
to reach their sustainability goal and at the same time improve operational excellence, with sustainability objectives.
Lubrication is the fulcrum of mechanical maintenance, thus playing a critical role towards sustainable and profitable operation in the limestone quarry or at plants. Traditionally, lubricants have been chosen based on their ability to reduce friction, wear and corrosion. However, the evolving landscape of sustainability demands a more comprehensive approach to lubrication, and Oil Condition Monitoring.
Through the careful selection of high-quality lubricants and optimized application practices, friction and wear within machinery are minimized, leading to increased energy efficiency. This results in lower energy consumption, reduced greenhouse gas emissions, and extended equipment lifespan. By incorporating advanced lubrication technologies and practices, cements and mining industry can contribute to the industry’s overall commitment to achieving more sustainable and environmentally friendly manufacturing.
Energy-efficient lubricants have been formulated by the Lubricant suppliers, typically cost more because they are made of tailored synthesised chemicals rather than straight hydrocarbon base oils. Generally, users are reluctant to purchase more expensive products unless there is demonstrable value.
Energy consumption is a significant concern in cement production, with a substantial portion of it attributed to the friction and heat generated by moving components in machinery. Lubrication management plays a pivotal role in optimising energy efficiency within all manufacturing plants. Advanced lubricants with superior friction-reducing properties contribute to lower energy consumption by minimising resistance in moving parts and ultimately play important role in machine reliability.
Moreover, lubricants can be tailored to specific applications within manufacturing plants, ensuring that each type of machinery receives optimal lubrication for its unique requirements. For example, synthetic lubricants achieve the most impressive energy savings where equipment slides or rolls. This targeted approach not only enhances energy efficiency but also extends the lifespan of critical equipment, reducing the need for frequent replacements and associated resource consumption.
Over a period of time, lubricants in machines gets contaminated by dust, dirt, wear metals and moisture. This oil has to be periodically tested at an Oil Testing Laboratory and cleaned to maintain its good condition.
Oil never dies – it just needs to be cleaned to its specification by removing contaminants and may be needing additives dosage required to keep it as per operating standard. All this activity can be done at plant itself, for continuous production and minimum downtime.
Since oil is contaminated, contaminants have to be removed. There are certain methods to remove contaminants and the simplest and best way is ‘oil filtration’ which can remove all suspected impurities along with moisture.
Required additives also be doped at the site to bring oil to its normal specification levels. Hence, besides oil re-cycling, there is a need for having an oil testing laboratory at the site as oil test report must be available within 36 to 48 hours. This will pay back maximum within six months in any cement or mining enterprise. This approach not only enhances the sustainability of operations but also aligns with the principles of the circular economy.
Save the environment with green manufacturing
While the adoption of sustainable lubricants and lubrication management holds great promise for driving sustainability in Industry, several challenges and considerations must be addressed. One significant consideration is the compatibility of new lubricants with existing equipment’s. Cement plants often have long lifecycles for their machinery, and transitioning to new lubricants must be carefully planned to avoid transition issues and ensure a seamless integration.
The cement industry’s journey toward sustainability involves a comprehensive approach that extends to every facet of production, including lubrication technology. By embracing sustainable processes, optimising energy efficiency, and leveraging advanced lubrication systems, cement plants can significantly reduce their environmental impact while enhancing operational performance, all aspects being covered by simply implementing TLM.
Significant efforts are being made by cement Industries for being sustainable, TLM is being implemented majorly by cement companies. Two roadblocks to widespread adoption of TLM include the challenge of quantifying measurable improvements and arriving at payback.
The transition to sustainable lubrication practices is a strategic imperative for cement manufacturers seeking to thrive in an era of increasing environmental awareness. As the industry continues to evolve, the integration of TLM plays a pivotal role in shaping a more sustainable future for cement production, where efficiency and environmental stewardship go hand in hand.
Lubricants must be kept clean and free from moisture while maintaining a healthy balance of additives to increase its lifespan, lubricants must be dealt with same sensitivity as blood in a human body.
We, at Global Technical Services, believe oil in the machine is like blood in the human body, and implementation of TLM is an important step towards sustainability. In fact, sustainable manufacturing is not possible without the implementation of TLM.
ABOUT THE AUTHOR:
Gaurav K Mathur, Director and Chief Executive, Global Technical Services, has been instrumental in developing advanced lubrication systems that ensure contamination-free maintenance across industries.
