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Tech Notes, Volume 2, Issue 1

January, 2011

POWERSPORTS DIVISION

Bel-Ray and Chad Reed Racing to Victory

New to the Bel-Ray family this season is professional motocross racer, Chad Reed. The former National Motocross and Supercross Champion has formed his own team and aligned himself with key partners in an attempt to win the Number 1 plate this year.

By creating his own race team, Reed has been given the flexibility to choose partners based on their performance, not the size of their checkbook, and Bel-Ray was the first to sign on. He will be racing a Honda CRF450 with motor and suspension modifications provided by industry giant, Pro Circuit. Reed will certainly be one of the favorites when the gate drops in Anaheim, California at Round 1 on January 8th. Other team sponsors are not yet mentioned, but Bel-Ray is thrilled for the excitement to come.

“I’m super excited to see Bel-Ray coming back into the sport and refocusing their goals and plans on racing at a top level,” said Reed and he added “I’m really proud to have them on board and to have a better understanding of their brand and where their brand has come from, what their brand has been about, and to be a part of their re-launch at the top level of racing.”

Bel-Ray Technical Services Manager, Bill Gay, has been working with the Team Manager, Dave Osterman, and Team Mechanic, Lars Lindstrom, to put together their product choices. In early season testing, the team has been excited with the results. They have specifically used the new Bel-Ray Friction Modified Thumper Racing 4T Engine Oil in the top end and the Bel-Ray Thumper Gear Saver Transmission Oil in the bottom end, and have already seen a substantial increase in clutch life and performance.

Be sure to look for Reed at the front of the pack this season when The Supercross Tour comes to town!

INDUSTRIAL DIVISION

Introducing New Anti-Wear, EP & No-Tox Products

Bel-Ray Anti-Wear Lube ISO VG series
Bel-Ray Raylene EP Lube ISO VG series
Bel-Ray Raylene Gear Oil SAE grade series

Bel-Ray is pleased to announce the introduction of these new products.

Bel-Ray Anti-Wear Lube ISO VG series is a high quality, anti-wear, general purpose lubricant.  The Bel-Ray Anti-Wear Lube product name includes the ISO viscosity grade.  It is available in 11 grades from ISO VG 15 to 680.  The formulas of new Bel-Ray Anti-Wear Lube ISO VG series are the same as the previous Bel-Ray Anti-Wear Lube AGMA number products.

Bel-Ray Anti-Wear Lube ISO VG series replaces the previous:

  • Bel-Ray Anti-Wear Lubricant (AGMA #1 to #8)
  • Bel-Ray Raylene Anti-Wear Hydraulic Fluid     (AGMA #00 to #3)
  • Bel-Ray Anti-Wear Compressor Oil (SAE 10 to 40)
  • Bel-Ray Raylene Anti-Wear Hydraulic Fluid (LT-85 and LT-300)

Bel-Ray Raylene EP Lube ISO VG series is a high performance, mineral oil-based lubricant for enclosed gears.  With a 100 pound Timken OK Load and a 12+ Stage FZG rating, the EP capabilities of the lubricant is unsurpassed.  Bel-Ray Raylene EP Lube ISO VG series product name includes the ISO viscosity grade.  It is available in 9 grades from ISO VG 68 to 1500. 

Bel-Ray Raylene EP Lube ISO VG series replaces the previous:

  • Bel-Ray Raylene EP Lubricant (AGMA #2 to #7)
  • Bel-Ray Belex Polar Gear Oil (SAE 75/80 to 140)

API GL-5 rated automotive gear oils are broadly used in industrial and mining gear lubrication.  The Bel-Ray Raylene Gear Oil SAE grade series is available in two grades and is API GL-5 and Mil-L-2105D compliant.

Bel-Ray Raylene Gear Oil SAE grade series (SAE 80W-90 and 85W-140) replaces the previous:

  • Bel-Ray ST Gear Oil (SAE 90 to 140)
  • Bel-Ray Polar Multi-Vis 30/90

For more information about these new products, please visit Bel-Ray’s website www.belray.com.  For product data sheets, call your Bel-Ray Representative or contact the     Bel-Ray Technical Services Department at 732-938–2421.

Bel-Ray No-Tox HD Oil ISO VG series
Bel-Ray No-Tox Syntra Oil ISO VG series

Bel-Ray is pleased to announce the introduction of these new products.

These new series of H1 food grade products are designed to give exceptional wear protection for hydraulic, gear, chain, compressor, bearing and other applications found in the “clean” industries such as food, beverage, pharmaceutical and personal care products.

Bel-Ray No-Tox HD Oil ISO VG series is a premium NSF registered H1 rated food grade, white mineral oil-based, heavy-duty oil.  Bel-Ray No-Tox HD Oil ISO VG series product name includes the ISO viscosity grade. It is available in 12 grades from ISO VG 15 to 1000.  Bel-Ray No-Tox HD Oils from ISO VG 150 to 1000 incorporate H1 food grade rated polyol esters.  This makes them suitable for other gear lubrication including worm gears.

Bel-Ray No-Tox HD Oil ISO VG series replaces the previous:

  • Bel-Ray No-Tox Anti-Wear Lubricant 
  • Bel-Ray No-Tox HD Hydraulic Oil 
  • Bel-Ray No-Tox Gear Oil
  • Bel-Ray No-Tox Seamer Oil D
  • Bel-Ray No-Tox Worm Gear Lube 
  • Bel-Ray No-Tox Chain Lubricant
  • Bel-Ray No-Tox Compressor Oil 20
  • Bel-Ray No-Tox Filler Oil 30
  • Bel-Ray No-Tox Oil 900
  • Bel-Ray No-Tox Steam Cylinder Oil

Bel-Ray No-Tox Syntra Oil ISO VG is a series of full synthetic PAO-based, premium NSF registered oils, H1 food grade polyol esters and high performance additives.  It has improved oxidation stability, lubricity, anti-wear properties and seal compatibility.  Bel-Ray No-Tox Syntra Oil is available in 11 grades from ISO VG 15 to 1000. The higher viscosity grades (ISO VG 320 to 1000) are suitable for other gear lubrication including worm gears.

Bel-Ray No-Tox Syntra Oil ISO VG series replaces the previous:

  • Bel-Ray No-Tox Synthetic Hydraulic Oil 
  • Bel-Ray No-Tox Synthetic Gear Oil 
  • Bel-Ray No-Tox Synthetic Worm Gear Lube 
  • Bel-Ray No-Tox HT Transfer Fluid
  • Bel-Ray No-Tox Chain Lubricant 65

For more information about these new products, please visit Bel-Ray’s website www.belray.com.  For product data sheets, call your Bel-Ray Representative or contact the     Bel-Ray Technical Services Department at 732-938–2421.

MINING DIVISION

Lubrication of Cement Plants – Pyroprocessing

In this second of four articles on the lubrication of cement plants, the topic is “cooking “ or pyroprocessing.

In the past, the cement raw materials were mixed with water, ground and cooked in a kiln. The kiln is a long rotating steel tube in which the cement raw materials are heated to about 1450°C or 2650°F. Considering this temperature, the first thing that happens to the raw material is dehydration and in the wet process all of the water added to the slurry must be evaporated. Once dehydration is complete, the actual cement cooking, in which the various reactions necessary to convert the raw material mixture to cement, begins. The wet process requires long kilns to allow enough time for dehydration of the materials. A wet process kiln can be up to 165 meters or nearly 550 feet long. This is a tremendous mass to heat and eliminating the water evaporation aspect of the process would result in a more efficient cement cooking process; this is the dry process.

The primary cement process used today is called the dry process. Water is not added to the raw materials in the dry process so dehydration of the materials is a simple and very efficient process. Dry materials are ground as described in the previous article using vertical or horizontal mills and carried as a dry powder into a preheater tower. In the tower the raw materials are heated to approximately 50% to 60% of their final temperature. Because there is no slurry water to evaporate and the raw materials are preheated, dry process kilns are much shorter than those used in the wet process. A typical dry process kiln is approximately 45 meters or about 150 feet long. Regardless of the process, the final temperatures in the kiln and the actual chemical reaction that the raw materials undergo are the same.

The reaction product of dehydrating and cooking the raw materials at the kiln temperature is called clinker. After the reaction takes place the process material is somewhat soft and adhesive. The materials bond forming a black nodular solid, this is clinker. After cooling, clinker is ground into cement.

In Figure 1 you can see the primary components of a kiln that require lubrication, the gear drive system and the riding rings or tires .

Rotation of the kiln is achieved through an open gear drive system. Electric motors drive intermediate enclosed gear cases that drive pinions that engage the large girth gear around the circumference of the kiln. The Bel-Ray mainline lubricants for the enclosed gearbox or speed reducer are Bel-Ray 100 Gear Oil or Raylene EP Lubricant. These are mineral oil-based high Extreme Pressure gear oils and they are excellent choices for the gearbox . However, Bel-Ray Synthetic Gear Oil is our primary recommendation. Bel-Ray Synthetic Gear Oil’s initial cost may be higher than mineral oil-based gear oils but it resists thermal breakdown better, it is highly filterable promoting extended lubricant life and it has superior wear and micropitting control.

Kiln rotation is very slow, typically 2 or 3 revolutions per minute, resulting in severe operating conditions for the actual girth gear and pinions. Girth gears are usually lubricated in one of two ways; immersion lubrication is a method in which the girth gear dips into a trough of lubricant and intermittent spray lubrication. Bel-Ray’s mainline immersion lubricant for kiln lubrication is Molylube MA1500 Special. This is a semi-fluid grease based on mineral oil and aluminum complex grease. High Extreme Pressure capabilities along with Molylube Solids ensure the formation of a dependable lubricating film. Our primary recommendation for immersion lubrication of a kiln girth gear and pinions is Bel-Ray ClearGear Lubricant. This product is a very high viscosity full synthetic fluid. It is chemically similar to Bel-Ray Synthetic Gear Oil and its users will benefit from all of the features of that product described earlier. Bel-Ray ClearGear Lubricant is a direct replacement for all competitor high viscosity synthetic fluid open gear lubricants.

Spray lubrication of a kiln gear is accomplished using a centralized lubrication system. This type of system includes a timer that can be used to set the lubrication interval, a pump, supply lines, a spray nozzle and a carefully selected lubricant. Selection of the lubricant is critical. Unlike the open gears and pinions of a grinding mill, kiln gears are hot and spraying a lubricant may present a fire concern. Kiln gear lubricants must be solvent-free. Bel-Ray’s mainline and preferred lubricant for kiln gears is Bel-Ray ClearGear Lubricant. Your Bel-Ray Technical Field Representative will assist you in grade selection which is based on using the highest viscosity grade that can be successfully sprayed at your ambient temperature. Grades selected for immersion may be more viscous than grades selected for intermittent spray.

Besides Bel-Ray ClearGear Lubricant’s preformance advantages as detailed earlier, the product also allows the operator to consolidate his lubricant inventory. Bel-Ray ClearGear Lubricant can be used to lubricate horizontal mills used to grind cement raw materials, coal or coke used to fire the kiln and for spray or immersion lubrication of the kiln gear. Bel-Ray ClearGear Lubricant improves housekeeping by eliminating black, tacky grease or residual open gear lubricants and replacing them with a straw colored fluid lubricant that is completely clear. During use, Bel-Ray ClearGear remains transparent allowing visual or stroboscopic inspections of operating gears without cleaning them. Bel-Ray ClearGear Lubricant does not accumulate in the gear tooth roots and, being fluid, it readily flows to drain points for collection and disposal.

At points along the length of the kiln are supports called riding rings or tires (see photo to right). These are large steel rings that surround the kiln and are supported by rollers. These are not driven. They are for support. Riding rings are not fixed to the kiln but they do have a system of support pads and retainer blocks that limit the movement of the kiln within. The flat surface of the ring and rollers is dry lubricated with graphite. However, special lubrication is required to properly lubricate all of the flat, sliding surfaces of the support system including the bore of the ring to protect the kiln skin. Molylube is a superior lubricant for this purpose. Molylube N is a blend of Molylube Solids in a water soluble resin and water. Molylube N is fire resistant. It will not catch fire and burn like many mineral oil-based and synthetic lubricants will when sprayed onto the hot kiln skin. A very important feature of Molylube N is that it can be applied once or twice a week using a manual spray system. It can be sprayed using a 3 or 4 meter pressurized spray wand keeping workers away from the hot kiln and the ring assembly, preventing burns and injuries.

The bearings of the rollers that cradle the riding ring are typically lubricated with a fluid lubricant that can withstand the radiant heat of the kiln. For this application, the mainline Bel-Ray products are Bel-Ray 100 Gear Oil or Raylene EP Lubricant. However, our primary recommendation for these bearings is Bel-Ray Synthetic Gear Oil for all of the reasons explained earlier.

Next Month: Cooling

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