Cement Industry

Rotterdam 2015
 Anglo International Mining B.V.

Company founded in 1980. Owner of the brand AIMOL.

AIMOL is a Dutch company producing a wide range of

lubricants:

- Automotive Lubricants
- Specialty Greases
- Hydraulic Fluids
- Chain Lubricants
- Food Grade Lubricants
- Metalworking Fluids
- Etc….
 Operating conditions in the Cement Industry

DUST
High Shock
Temperature loads
High
humidity

Machinery and equipment in the cement industry is subject

to extreme operating conditions!
 Basic lubricants for the cement industry

Greases Adhesive materials

Hydraulic fluid Special …Lubricants

Gear Oils Chain Oils

The correct choice of lubricant is an important factor in the reliability of the

equipment!

A wrong choice of lubrication leads to downtime, maintenance and repair. These

costs are much higher than the expenses for the lubricants.
Cement Manufacturing Process
Focus for AIMOL lubrication:

Coal
mill
Rotary
Kiln

Raw
mill

Cement
mill
 Mills and kiln in cement industry
In this presentation: focus on lubrication of mills and rotary kiln

Types of mills in cement plants:

• Raw mill: grinding the raw material into a dry rock powder: the ‘’raw mix’’

• Coal Mill: used to pulverize coal, for fuel of the kiln

• Cement Mill: grinding clinker to cement

Type of kiln in cement plants:

• Rotary Kiln: pyroprocessing stage to produce clinker

 Types of mills used for operations
Vertical Mill: A mill that is not very energy consuming, often
seen in cement plants for the following operations:
Raw mill (for dry processes), cement mill and coal mill

Ball Mill: For operations that need a uniform particle size.

Seen in cement plants for:
Raw mill (for wet and semi wet processes), cement mill (often) and
coal mill (rare)

Roller Press: more energy efficient than the ball mill, but the
particle size distribution is a disadvantage. In several cases the
roller press is used preliminary to the ball mill. The roller press
is used as:
Raw mill and cement mill
Vertical Mills – How it works
The material to be grinded (i.e. raw coal) enters the
mill via an feed screw and is discharged onto the
center of the rotating grinding table
The rotation of the table accelerates the flow of
material towards the grinding track, where the coal
is grounded between the table and the three rollers
The coal then continues over the dam ring and is
entrained in the hot drying gas that enters the mill
house through the nozzle ring
The gas lifts the coarser particles back onto the
grinding table and sweeps the finer particles up to
the separator.
The separator lets the final product proceed to the
mill outlet while returning the coarse fraction to the
table for further grinding
Having left the mill at the top, the final product
continues with the gas to a cy-clone or a bag filter,
where it is collected
Vertical Mill Manufacturers
MPS

DoRoll
Quadropol

VRM

ATOX
OK
FRM
Lubrication points of vertical mill

Grease for high

loads

Gear oils

Hydraulic oils

Gear oils
 Lubrication points of vertical mill
Bearings

Operational features:
Increased wear of the
friction unit under high loads.
Frequent replacement of
Hydraulic system lubricant.
Operational features: SPECIAL GREASES
Frequent changing of the
lubricant, need to be protected
from corrosion and cavitation, need
for high purity grade

HYDRAULIC OIL
Main gear box/ Gear Box

Operational features:
Burrs and high wear,
frequent oil changes

GEAR OIL
 AIMOL Gear Oils

MINERAL SYNTETIC

AIMOL GEARTECH CLP PAO

AIMOL INDO GEAR CLP
Fully synthetic oil-based (PAO)
The anti-wear test FSG=12 -
Very high viscosity index (about 160)
the highest level
Extends oil life 3 times!

AIMOL GEARLINE CLP F

AIMOL GEARTECH CLP PAG
Contains special additives to protect
equipment from micro-pitting Fully synthetic oil-based (PAG)
Very high viscosity index (more 200)
AIMOL GEARTECH CLP MOLY Extends oil life 5 times!
Very high anti-wear properties
Unique product! Significant increase equipment life
Contains organic molybdenum,
Significantly reduces friction
Reduce noise
 Benefits of synthetic Gear Oils
 Increased oil life
If you will use AIMOL
Geartech CLP PAO you can
increase the oil change
interval is three times
compared to mineral oils

If you will use AIMOL

Geartech CLP PAG you can
increase the oil change
interval is five times
compared to mineral oils
 Benefits of AIMOL synthetic Gear Oils
 Excellent thermal and improved flow
properties

 High viscosity index

 Excellent lubricating properties

 Increasing the efficiency of the gearbox by

reducing the friction loss of teeth

 Decreasing the temperature of the oil

 High oxidative stability

 Lubrication points of vertical mill
Bearings

Operational features:
Increased wear of the
friction unit under high loads.
Frequent replacement of
Hydraulic system lubricant.
Operational features: SPECIAL GREASES
Frequent changing of the
lubricant, need to be protected
from corrosion and cavitation, need
for high purity grade

HYDRAULIC OIL
Main gear box/ Gear Box

Operational features:
Burrs and high wear,
frequent oil changes

GEAR OIL
Cleanliness codes of Hydraulic Oil

ISO 22/19/17
Meets minimum requirement
of DIN 51524

Meets minimum requirement

ISO 19/17/14 of DIN 51524 and passed an
additional filtration

ISO 16/13/11 AIMOL Hydroline, produced

with high cleanliness class
 AIMOL Hydroline
With the naked eye you cannot see the level of
cleanliness. A microscope shows the following

ISO 22/19/17 ISO 16/13/11

Typical oil, meets minimum AIMOL Hydroline, very of
requirements of HLP cleanliness high level of cleanliness
 AIMOL Hydroline

The high level of cleanliness of AIMOL Hydroline

gives the following advantages :

• It preserves the equipment

• Minimum downtime of systems
• No extra filtration needed when using a ‘’fresh’’
oil (AIMOL Hydroline).
• Minimum filter contamination
• Saving money to change a filter
Hydraulic system of mills
AIMOL Hydroline HLP 46
 AIMOL Lubrication : Vertical mills
Centralized lubrication system
AIMOL Grease Lithium Calcium EP 2 LS Moly
with greases
Centralized lubrication system AIMOL Indo Gear CLP, Gearline CLP F,
with oils (EP type VG 320+) Geartech CLP PAG, Geartech CLP PAO
Main Bearings
Sump Lubrication grease
AIMOL Greasetech Special Graphite R Fluid
lubricated
Sump Lubrication oil lubricated
AIMOL Geartech CLP PAG
(EP type VG 320+)
Cleanness code (ISO 4406)
Hydraulic systems AIMOL Hydroline HVLP, Hydroline HLP
-/16/13
AIMOL Grease Lithium Calcium EP 2, AIMOL
Rocker Arm Bearings MDS Grease 2, AIMOL Grease Lithium
Calcium EP 2 LS Moly
AIMOL Indo Gear CLP, Gearline CLP F,
Main gear box Oil sump (EP type VG 320+) Geartech CLP Moly, Geartech CLP PAG,
Geartech CLP PAO
AIMOL Grease Lithium Calcium EP 2, AIMOL
Bearings
MDS Grease 2
Separator/Classifier
AIMOL Greasetech Special Graphite H-1000
Drive unit
/ H-1500
 MPS Mills

AIMOL Geartech CLP PAG

Fully synthetic oil-based (PAG)
Extends oil life 5 times!
Ideal for high loads and temperature

AIMOL Polyurea EP 2 LS
Special grease for high temperature
and shock loads
Due to the special organic thickeners,
grease has thermal stability and longlife

AIMOLIndo
AIMOL Indo Gear,
Gear CLP
AIMOL
AIMOL-M GearlineXP
Gearmax CLP F
(Flender)

*For more exact selection according to the manufacturer's instructions, please

contact technical support department
 VRM Mills

AIMOL Geartech CLP PAG

AIMOL Indo Gear CLP

23
*For more exact selection according to the manufacturer's instructions, please
contact technical support department
 DoRoll Mills

AIMOL Geartech CLP PAG

AIMOL Greasetech
Polyurea EP LS

AIMOL Indo Gear CLP

Quadropol mills

AIMOL Greasetech Polyurea EP LS

AIMOL Geartech CLP PAG

AIMOL Greaseline Lithium

Complex EP 2 LS Graphite

AIMOL Indo Gear CLP

 ATOX Mills

AIMOL Greaseline Lithium

Complex EP 2 LS Graphite

AIMOL Geartech CLP PAO 1000

AIMOL Indo Gear CLP

AIMOL Gearline CLP F

AIMOL Hydroline HVLP (all season)

AIMOL Hydroline HLP(summer)
FRM Mills

AIMOL Greaseline Lithium

Complex EP 2 LS Graphite

AIMOL Geartech CLP PAO

AIMOL Greasetech Polyurea EP LS

AIMOL Grease Lithium Calcium EP
2 LS Moly

AIMOL Indo Gear CLP

 ATOX Mills

AIMOL Greaseline Lithium

Complex EP 2 LS Graphite

AIMOL Geartech CLP PAO 1000

AIMOL Indo Gear CLP

AIMOL Gearline CLP F
Bearing between hydraulic cylinder and rocker arm
AIMOL Grease Lithium Calcium EP 2 LS Moly
 Ball Mill - How it works
• A type a grinder used to grind material in extremely fine powder

• A hollow cylinder rotating around its axis

• Usually it consists of two compartment:

- Coarse grinding compartment => crushing the coarsest particles
- Fine grinding compartment => small balls for optimal grinding

• Steel or rubber balls are inside the mill and size reduction occurs as the balls drop down
from the top of the shell
 Side Drive Ball Mill - How it works
1 2 3 4 5 6 3 7 8 9 10 11
1. Material inlet
2. Feeding Tube
3. Slide shoe bearings
4. Ball Mill
5. Pinion Gear
6. Open Gear
7. Drive Coupling
8. Outlet Casing
9. Main Gearbox
10. Turbo Coupling
11. Motor
 Central Drive Ball Mill: How it works
Grease for drive coupling: Oil Sump for turbo coupling:
AIMOL Polyurea EP 2 LS, AIMOL Hydroline HLP
MDS Grease, etc..
Oil for main gear
box: Oil Sump for auxilliary drive:
Central lubricated slide AIMOL Indogear AIMOL Hydroline HLP
shoe bearing: CLP, Geartech CLP Main motor:
AIMOL Indo Gear CLP Moly, Gearline AIMOL Turbo,
CLP F Turbo LD, etc.
 Ball Mill: AIMOL lubrication
Symetro Drive
Direct Meshing Gear Drive
Main Gear Box
Main Gear Drive
Open Gear Drive
High Speed Coupling
Slide Shoe Bearing Centralized Lubrication System AIMOL Indo Gear CLP
Gear Housing Seal oil lubricated drive
Auxiliary Gear Drive Oil Sump
Low Speed Coupling Oil Sump
AIMOL Indo Gear CLP
AIMOL Indo Gear CLP
AIMOL Gearline CLP F, Geartech CLP Moly
AIMOL Indo Gear CLP
AIMOL Gearline CLP F, Geartech CLP Moly
AIMOL Greasetech Special Graphite H-0/00
AIMOL Greasetech Special Graphite H-1000
AIMOL Greasetech Special Graphite H-3000
AIMOL Greasetech Polyurea EP 2 LS
AIMOL Grease Lithium Calcium EP 2 LS Moly
Greaseline Lithium Complex EP 2 LS Graphite
AIMOL Greasetech Special Graphite
AIMOL Greasetech Polyurea EP 2 LS
AIMOL Indo Gear CLP
AIMOL Gearline CLP F, Geartech CLP Moly
AIMOL Hydroline HLP or HVLP
 Roller Press – How it works
• The main parts of the roller press are: the press frame, the rollers with
bearings and bearing house, the drive and the feeder and associated
equipment like hydraulic pressurizing, lubrication and cooling systems.

• In the press frame, two rollers are installed. Usually one fixed and one
floating roller.

• Floating roller is supported by hydraulic cylinders, in this way the

pressing force can be adjusted by an hydraulic pressurizing system

• Both rollers are equiped with separate drives. To synchronous the

operation of the motor speeds, drive systems with planetary gears are
used

• Between the gearboxes and motors, there are cardan shafts which
ensure the movability of the floating rollers
 Roller Press – Lubrication
Lubricating oil for Grease for main frame sliding
planetary gearbox: Grease/oil for main roller bearing:
AIMOL Geartech CLP bearings: AIMOL Grease Lithium Calcium
Motor oil: PAG, AIMOL Geartech AIMOL Greaseline EP 2
AIMOL Turbo, CLP PAO, Indo Gear Lithium Complex EP 2 LS,
Turbo LD, etc. CLP Grease Lithium Calcium Hydraulic oil for floating
EP 2 LS Moly roller:
AIMOL Hydroline HLP,
Hydroline HVLP
 AIMOL: Lubrication Roller Press
Grease Lubricated Centralized Greaseline Lithium Complex EP LS Graphite
Lubrications System Greastech Lithium Calcium EP 2 LS Moly
Main Roller Bearings AIMOL Indo Gear CLP
Oil Lubricated Centralized
AIMOL Geartech CLP PAG
Lubrications System
AIMOL Geartech CLP PAO
AIMOL MDS Grease
Main Roller Bearing Seals if bearings are oil lubricated AIMOL Grease Lithium Calcium EP 2
AIMOL Greaseline Lithium Complex EP 2 Blue
AIMOL Hydroline HVLP
Hydraulic System
AIMOL Hydroline HLP
AIMOL Grease Lithium Calcium EP 2
Main Frame Bearing Centralized Lubrication System
AIMOL MDS Grease
AIMOL Indo Gear CLP
Planetary Reduction Gear Circulation System AIMOL Geartech CLP PAG
AIMOL Geartech CLP PAO
AIMOL Indo Gear CLP
AIMOL Geartech CLP Moly, AIMOL Gearline CLP F
Main Gear Box Oil Sump
AIMOL Geartech CLP PAG
AIMOL Geartech CLP PAO
AIMOL Grease Lithium Calcium EP 2
Seperator / Classifier Bearings
AIMOL MDS Grease
 Rotary Kiln – How it works
• The raw mix enters the cylinder in the upper end of the kiln.

• The kiln rotates around it is axis to stir/mix and also to shift the material to
the lower end

• The rotation of the kiln is driven by an open gear and supported by rollers

• In the kiln the pyroprocessing takes plakes where the materials are
subjected to very high temperatures (+- 1400°C)
Rotary Kiln Manufacturers
 Rotary Kiln – ThyssenKrupp

POLRO 2-support kiln 3-support kiln

 Rotary Kiln – Lubrication

Main gear drive

Grease for open gear drive:

AIMOL Greasetech Special Main gearbox:
Graphite AIMOL Geartech CLP
PAG, Gearline CLP F,
Indo Gear CLP
Grease for pinion bearings:
AIMOL Greaseline Calcium
Complex EP 2
Motor oil:
AIMOL Turbo, Turbo
LD, etc.
 Rotary Kiln – Lubrication

Support/Thrust Roller

Grease for open gear

drive:
Oil with solid lubricants AIMOL Greasetech
for tyre ring: Special Graphite
AIMOL Chaintech SHT
2000 Graphite

Grease/oil for roller

bearings of support roller:
AIMOL Greaseline
Complex EP 2 LS Graphite
,MDS Grease, Grease
Lithium Calcium EP 2 LS
Moly, etc..
 Rotary Kiln – Lubrication

Hydraulic Thrust device for rollers

AIMOL Hydroline HLP:
For heavy duty hydraulic installations.

AIMOL Hydroline HVLP:

Hydraulic oil with improved viscosity index
for operations under substantial
temperature variations.
 Rotary Kiln: AIMOL lubrication
AIMOL Indo Gear CLP
Gear Box AIMOL Gearline CLP F
Main Gear Drive AIMOL Geartech CLP PAG
Open Gear Drive AIMOL Greasetech Special Graphite 0/00
Pinion Bearings AIMOL Greaseline Calcium Complex EP 2
Gear Box AIMOL Gearline CLP F
Barring Device
Brake AIMOL Greaseline Calcium Complex EP 2
AIMOL Indo Gear CLP
Roller Bearings with oil AIMOL Gearline CLP F
AIMOL Geartech CLP PAG
AIMOL MDS Grease
Support/Thrust Rollers
Greaseline Lithium Complex EP LS Graphite
Greastech Lithium Calcium EP 2 LS Moly
AIMOL Hydroline HVLP
Hydraulic System
AIMOL Hydraulic Oil HLP
Inner tyre ring Roller AIMOL Chaintech SHT 2000 Graphite
Inlet/Outlet Seal if lubricated AIMOL Greasetech Special Graphite 0/00
Exhaust Gas Fans Roller Bearings AIMOL Grease Lithium Calcium EP 2
Cooling Fans Roller Bearings AIMOL Greasetech Polyurea 2 SLS
AIMOL Focus Products: Chaintech SHT 2000 Graphite
Lubrication of rollers in rotary kiln: AIMOL Chaintech SHT 2000 Graphite

AIMOL Chaintech SHT 2000 Graphite is a very suitable lubricating oil for
high temperatures.

At 250°C the oil starts to evaporate and leaves behind a thin dry graphite
film.

This lubricant film can whitstand temperatures up to 600°C.

AIMOL Focus Products: Chaintech SHT 2000 Graphite

AIMOL Chaintech SHT 2000 Graphite is applied in any industrial field to lubricate high
temperature operated mechanisms. Intended for conveyor chains, low speed roller and
ball bearings, threaded spindles, sliding bearings, bushings etc. In can be used in the
ceramic, steel , food (bread and pastry) or chemical (glass) industry.

Product Chaintech SHT 2000 Gr.

Appearance Grayish viscous fluid
Base oil type Synthetic ester
Density @ 20 ºC, gr/ml 0,950
Dynamic viscosity @ 25 ºC, cp. 2000-2500
Flash point, ºC >260
Welding load, kgs >240
Solids type Graphite
Solids content, % 10
AIMOL Focus Products: Chaintech SHT 2000 Graphite
• The graphite film left behind by AIMOL Chaintech SHT 2000 Graphite has a
lamella layer structure.

• The layered structure enables sliding movement of the parallel plates but is
very strong against vertical forces

• High protection with no metal-to-metal contact as well as low friction. Also It

does not leave behind a (carbon) residue

• Graphite can work as a lubricant with temperatures well above 500°C

• Graphite is very suitable for lubrication with air because adsorption of water
reduces the bonding between the plates
AIMOL Focus Products: Greasetech Special Graphite
AIMOL Greasetech Special Graphite is especially developed for the lubrication of
open gears.

The AIMOL Greasetech Special Graphite line of products exhibit very good
properties with respect to extreme pressure (EP), adhesion and antiwear.

AIMOL Greasetech Special Graphite contains graphite; providing a very stable,

lubricating and adherent film even at very high temperatures and high loads.
AIMOL Focus Products: Greasetech Special Graphite
Drive unit of separator in Vertical Mill
AIMOL Greasetech Special Grahpite H-1000
AIMOL Greasetech Special Grahpite H-1500
 Recent achievements

 Approved as supplier to Suchoi Aviation, Russia’s biggest

aerospace company.

 Received official approval of Volvo-Sweden for various motor

oils.

 Siemens approved AIMOL Turbine Oil A32 and A46 against

their industry specification TLV 901304.

 Startsupplying AIMOL lubricants to the Yemen Public

Electricity Corporation.
 Severstal

(largest mettallurgical company in Russia and the third largest in U.S.A.)

Reference List

Severstal: One of the largest

metallurgical companies worldwide

VSMPO Avisma: Largest titanium

producer in the world
 Reference List

Cummins: One of the largest producers of

diesel- and gas engines in the world

Pepsi Cola: Large softdrink producer with

subsidiaries in almost every country of the world
 Reference List

Danone: one of largest French dairy

producers, with factories in many countries

Nestle: largest food producing company in

the world
 Reference List

Yemen Public Electricity Corporation

Gazprom: world’s largest gas producer