SECTOR FOCUS: INDUSTRIAL GEAR OILS
Formulating Higher- Performing Synthetic Industrial Gear Oils
Dr. Paul Robinson, Commercial Manager for Industrial Gear Additives, Lubrizol
Industrial gearboxes continue to play a vital role in keeping the wheels of industry turning, whether directly as part of a production process, or indirectly by enabling a company’s valuable assets to operate smoothly and efficiently.
While the function of the industrial gearbox might appear straightforward, namely to change the speed of the input energy and increase the torque provided to the application required, the importance of ensuring it operates efficiently and tirelessly throughout its lifetime cannot be overstated. Effective operation enables increased production efficiencies and lower operating costs, while gearbox failure can lead to a total shutdown in production, lost output, lost revenues and even lost contracts.
Industrial gearboxes face a wide range of challenges such as particulate contaminant ingress in mining, cement and quarrying applications, or excessive water contamination and water ingress in paper or steel industries. In each case this can cause problems for the lubricant to function properly and in turn adversely affect the efficiency and durability of the industrial gearbox. Access to industrial gearboxes can also be a challenge in many applications; with the requirement for low maintenance and longevity of components and gear oils offering extended life being a main driver in the decision making process.
Today’s industrial gearboxes are not only smaller and lighter, but are delivering greater power densities than
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ever before. Higher gear teeth loading, higher bearing loads and increased oil temperatures are all impacting the requirements of a modern industrial gear oil (IGO). This is resulting in the need for IGOs to perform to the exacting standards demanded by the gearbox original equipment manufacturer (OEM).
Delivering IGOs that satisfy the performance requirements of the individual application requires the careful formulation of the base oil, additive package and compatibiliser. The use of synthetic base oils in IGOs continues to grow; their selection affected by both performance and total cost considerations. Mineral IGOs are often preferred in applications which have stable ambient temperatures, are easier to access and where initial cost may be a major consideration. From a performance perspective however, the lower thermal and oxidative stability of mineral oils mean they are less effective in applications with intermittent ambient temperatures and where long life and low maintenance are required. Providing improved thermal and oxidative stability, a correctly formulated synthetic IGO can address these limitations, while delivering around three times longer life performance over a mineral IGO.
Synthetic IGOs are typically formulated from either polyalphaolefin (PAO), polyalkylene glycol (PAG) or ester base oil. PAOs continue to account for the vast majority of synthetic IGOs available today, and are regarded by many as the synthetic base oil of choice. Continued on page 24
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