Many high-load processing operations common in the primary metals industry require extraordinary force, generating extreme pressures, sometimes over 30 tons per square inch, heat surpassing 1,000 degrees, and intense friction at contact points. These conditions will rapidly deteriorate any type of equipment. Specialized lubricants can minimize this damage by dissipating heat, preventing corrosion, extending equipment lifespan, and ensuring product quality. By combining carefully selected base oils with specific additives, like extreme pressure agents, anti-wear compounds, and corrosion inhibitors, modern lubricant manufacturers now offer products that mitigate the effects of these high-load operations, protecting valuable machinery under the demanding conditions of the primary metals industry.
High-Load Operations
The primary metals industry employs several high-load processes, depending on the ore and the desired end product. Here are the most common:
Forging
In the pre-industrial age, village blacksmiths forged metal. They hammered heated metals into kitchen utensils and farming tools. Modern forging follows the same process, though on a much larger scale. Metals are heated to temperatures above 1,000 degrees, depending on the type of metal. Pressures ranging from 15 to 30 tons per square inch (tsi) are then applied to create the final shape.
Rolling
Workers place metal materials between rotating cylinders to reduce thickness and create uniform shapes. The high speed and heavy load of these rollers can strain equipment.
Extrusion
Metal is forced through a die requiring high-pressure machinery. This process creates long, uniformly shaped sections.
Die Casting
The die casting process can put considerable strain on machines and molds, especially when creating more complex products. The more complicated or intricate the final product, the more pressure is needed to force molten metal into a mold.
Why Use Specialized Lubricants?
Specialized lubricants for high-load operations are designed to dissipate heat, minimize corrosion, and optimize performance.
Heat Dissipation
Lubricants help transfer heat away from high-friction areas, preventing overheating and potential damage to equipment. Maintaining optimal operating temperatures can extend a machine’s lifespan by reducing the wear caused by direct contact between metal surfaces.
Contaminants and Corrosion
Lubricants protect metal surfaces from oxidation, which can lead to rust and chemical damage. These products form a barrier to prevent dirt, dust, and debris from interfering with operations.
Lifespan
Lubricants play a crucial role in extending the lifespan of equipment, which in turn decreases overall associated costs. This assurance of longer equipment lifespans helps ensure reliable operations with less downtime due to unexpected maintenance or the need for costly equipment replacements.
Surface Quality
By reducing friction and equipment wear, lubricants help produce consistent surface finishes, dimensional accuracy, and structural integrity. This benefit is crucial in precision metal processing operations where even the tiniest surface imperfections can result in product rejection or compromised performance in the end product.
Quality Control
By ensuring uniform metal flow and preventing defects that can compromise final products, lubricants contribute to achieving a consistent level of quality. Proper lubrication is more than just a checkbox on a maintenance schedule; it is a crucial component of reliable operations.
Key Components in Lubricant Manufacturing
Lubricant manufacturing involves blending essential additives, such as extreme pressure (EP) agents, anti-wear agents, and antioxidants, with base oils. Most base oils are derived from Groups I and II oils made from crude oil. Synthetic blends, such as polyalphaolefins (PAO), are also used as base oils for high-load applications. Each additive type has its own unique properties and use cases:
Extreme Pressure (EP) Additives
EP additives play a crucial role in high-load and high-temperature environments. They react with surfaces to create a protective layer that reduces wear and prevents seizure or catastrophic failure. When combined with sulfides, chlorides, and phosphides, EP additives form a thin film for protecting valuable machinery.
Anti-Wear Agents
These additives reduce friction by forming a protective layer on metal surfaces, but are designed for use in normal operating conditions. In contrast to EP additives, anti-wear agents build a protective film under normal temperatures and moderate loads. Not every application is considered high-load, and using the right tool for the right job is essential.
Corrosion Inhibitors
Antioxidants prevent oils from degrading due to oxidation, which can create sludge that slows down machine operations. Special inhibitors protect metal surfaces from moisture, ensuring they do not infiltrate the equipment.
Advances in Lubricant Manufacturing
Recent advancements in lubricant manufacturing focus on enhanced performance, sustainability, and efficiency. Emergent technologies in the lubrication space include:
- Nanolubricants: Nanoparticles such as graphene, MoS2, and carbon nanotubes are added to base oils to reduce friction, increase load capacity, and improve thermal stability.
- Bio-based Lubricants: Lubricants derived from renewable sources to offer enhanced biodegradability and reduced environmental impact.
- Smart Lubricants: Devices can now be integrated into machinery to monitor lubricant performance, enabling predictive maintenance.
Advances in quality control, driven by automation and artificial intelligence, are already in use, improving lubricant accuracy for even more performance reliability.
Moving Forward
Like many other business sectors, the primary metals industry faces uncertainty, with many forecasters constantly adjusting their projections. Regardless of current conditions, the industry needs to maximize its investment in maintaining proper equipment, including using the most effective lubricant for its operating environment. Maximizing the lifespan of mission-critical equipment means avoiding capital expenditures for equipment replacement and improving productivity by reducing and preventing downtime. Contact Allegheny Petroleum to discover how our toll blending capabilities can help your business achieve these goals.