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Gearing Up for High-Performance Lubricants


Jonathan Brekan, Ph.D. – Elevance Renewable Sciences Introduction


The industrial gearbox is subjected to a wide range of conditions where factors such as lubrication, loads, stresses, vibrations and temperatures can continuously vary. In a review of the environmental benefits and impacts of gearbox lubrication, specifically, optimization of three lubricant parameters – friction reduction, wear reduction and lubricant stability – will lead to positive environmental impactsi


. Minimizing wear by efficient


lubrication prolongs the useful life of the equipment, thereby minimizing the consumption of non-renewable resources such as fossil energy and metal ores required for the manufacture and disposal of the machinery itself. In addition, wear of mechanical parts can cause the gears to operate less efficiently; thus wear reduction has a secondary possible benefit by reducing energy losses. Elevance Renewable Sciences utilises feedstocks from its biorefinery to generate novel materials that address the ongoing challenges in automotive and industrial lubrication while also addressing the needs to lower its overall carbon footprint.


Wind Turbine Challenges Wind turbine failure is an ongoing concern among some in the industry. One potential source of field-operating failures is a consequence of gearbox bearing failures. Potential sources of this type of failure include poor lubrication and improper routine maintenanceii


of $380,000 and that does not include labor and additional expensesii


require advanced lubrication to protect the metal components. As a result, formulators are taking a different approach toward meeting or exceeding these high-performance targets. The utilization of synthetic oils, for example polyalphaolefins (PAOs), and esters has become a widely adopted option for formulators to meet the demands of these extreme operating conditions. Elevance has recently introduced a new synthetic ester-olefin copolymer base oil designed to enable gearbox lubricant formulators to address the challenges associated with wind turbine applications.


Elevance Aria™ WTP 40


Elevance engineers have synthesised olefinic ester technology where PAO-type architecture is combined with covalently bonded ester functionality to create an ester functionalised PAO, Figure 1. A new material offering novel and differentiated performance from PAO, esters and PAO-ester blends, Elevance Aria™ WTP 40 is a novel synthetic base stock that is an ester-functionalised PAO. Its unique molecular architecture is devised by the use of Elevance Inherent™ renewable carbon- based building block C10 ME.


. The repair of one turbine can be upwards . In addition, the opportunity cost associated with the


loss of energy production due to windmill downtime must also be considered. For example, in Q2 of 2014, a major wind turbine producer reported a 54 percent decrease in profit from the prior year partially related to charges of €48 million, caused by a malfunction of bearings in some onshore wind turbinesiii


. Wind turbine gear boxes operate under extreme demands and Figure 1. Process: Catalytic oligomerisation of linear olefins and Inherent™ C10 Methyl Ester.


6


LUBE MAGAZINE NO.133 JUNE 2016


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