Preston Rubottom, Lubrication Engineers, shows how high quality lubrication practices can boost equipment reliability and plant sustainability in the cement industry.
The cement industry is one of the most energy-intensive and mechanically demanding sectors in the world. With heavy-duty equipment, such as kilns, crushers, mills, and conveyors operating under extreme conditions, machinery reliability is paramount to operational efficiency and plant sustainability. One of the most critical yet often overlooked aspects of equipment maintenance is lubrication.
Implementing world class lubrication practices can dramatically improve machinery reliability, reduce downtime, and extend the lifecycle of production assets, thereby contributing to sustainability by conserving resources. This article explores how adopting advanced lubrication strategies based on best practices can transform maintenance culture in the cement industry, leading to improved operational efficiency, reduced costs, and enhanced sustainability.
Role of lubrication in cement manufacturing
The study of tribology would say that lubricants are formulated to create a film between moving surfaces, minimising direct contact and, consequently, reducing friction. This reduction in friction lowers energy consumption and wear, extending the lifespan of machine components. While most lubricants will offer some level of protection, it is important to keep in mind that not all lubricants are made the same. In high-impact, heavily contaminated applications such as those found in cement plants, a high-performance specialised lubricant can have a significant impact on reducing operating and maintenance costs. An added benefit of lower energy use, longer lasting lubricants, and longer lasting equipment is a reduction in overall environmental impact.
Current challenges in lubrication practices
Although lubrication is a critical component of maintaining production equipment, it is frequently overlooked or treated as a secondary priority within many facilities. Proper lubrication is essential for reducing friction, preventing wear and tear, flushing contamination ingression, and ensuring reliable performance of machinery. However, several persistent challenges undermine a lubricant’s effectiveness, including over-lubrication and under-lubrication, both of which can lead to heat buildup, excessive wear, and insufficient lubrication resulting in increased metal-to-metal contact. The use of incorrect or poorly formulated commodity grade lubricants further compromises machinery by failing to provide adequate protection against friction and corrosion.
Given the harsh environments of the cement industry, the ongoing battle of contamination from dust and moisture makes its way into lubrication systems, leading to rust, corrosion, and accelerated component degradation. Additionally, with a significant shortage of skilled trades maintenance technicians, the mandatory lubrication routes simply do not get completed. Even when lube routes are completed, it is often the case that proper training has not been given to maintenance personnel, leading to inconsistent or incorrect procedures and improper application techniques.
Inadequate lubrication schedules, whether due to outdated planning or poor implementation, can cause either under-lubrication or over-lubrication, both of which stress equipment and reduce its lifespan. These issues across the cement industry contribute to premature equipment failure, increased maintenance costs, and unplanned downtime, ultimately hindering operational efficiency and profitability.
To mitigate these risks, it is imperative that cement plants prioritise comprehensive lubrication management strategies, emphasising proper training, precise scheduling, and the use of better formulated lubricants to extend equipment life, as well as enhance overall plant reliability, safety, and sustainability.
World-class lubrication programme
The primary goals of an effective lubrication programme include:
- Improving environmental health and safety (EHS) standards through the application of proper lubrication practices.
- Aiming for lubrication reliability excellence to ensure equipment performance.
- Increasing overall productivity by minimising equipment downtime and maximising efficiency.
- Maximising manpower efficiency through improving maintenance processes and reducing manual tasks.
A world-class lubrication programme encompasses several critical areas, and it is generally agreed upon that what gets measured gets improved; therefore, an audit is the recommended first step on the journey to lubrication excellence. A machinery lubrication audit involves a systematic review and evaluation of the lubrication practices within a facility to ensure optimal machinery performance, reliability, and lifespan.
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