Case | Lubrication improvement solution for high-pressure roller mill of iron ore plant, bearing’s temperature decreased by 7-8 ℃

铁矿厂高压辊磨机情况 

Iron ore plant high-pressure roller mill situation

该铁矿厂是某钢铁集团下属一家集采、选一体的国有中型露天开采矿山，生产规模超过200万吨/年，2021年实现产值6.4亿元。

The iron ore plant is a state-owned medium-sized open-pit mine under a steel group which integrates mining and selection, with a production scale of over 2 million tons/year and an output value of 640 million RMB in 2021.

优润团队通过前期沟通、现场调研，了解到该铁矿厂碎矿用的高压辊磨机生产设备，是中建材（合肥）院、辊径为1.5米的。润滑点位6个，动辊轴承2个点位、定辊轴承2个点位、滑轨2个点位。所用油脂是普通二硫化钼润滑脂，现用加油方式为单点电动泵，每个点位配备一台电动补油泵。目前存在一些问题：

Through the preliminary communication and on-site research, U.LUBE team learned that the 1.5-meter-high roller mill used for crushing ore in this iron ore plant is from CNBM (Hefei) Institute. It has 6 lubrication points: 2 points for dynamic roller bearing, 2 points for fixed roller bearing and 2 points for slide rail. The grease used is ordinary molybdenum disulfide grease, and current lubrication method is single-point electric pump, each point is equipped with an electric refill pump. At present, there are some problems:

1、设备管控工作量大 / High workload of equipment control.

每1个润滑点位配备了1台油脂补加泵，该设备共6个润滑点，现场一共配备6台油脂补加泵。润滑设备数量多、且经常堵塞，维护工作量大。

Each lubrication point is equipped with 1 grease refill pump, the equipment has a total of 6 lubrication points, the site is equipped with total 6 grease refill pumps. The number of lubrication equipment is large, which caused problems such as blockage and high maintenance workload.

2、岗位工人工作量大 / Heavy workload for workers

现场用油品补加泵容量小，每生产班次都需要人工加油，一天加注量约20个小桶，都是人工倾倒方式。

The capacity of the oil refill pump for the site is small, and manual refueling is required for each production shift, with a filling volume of about 20 small barrels a day, all by manual dumping.

3、现场环境无法改善 / Site environment can not be improved

补加泵数量多，分布不规范，输油管路杂乱无章。且因为没有粉尘隔离措施，油品管路经堵塞，油品跑冒滴漏现场无法避免。

The number of refill pumps is large, the distribution is not standardized, and the oil pipeline is disorganized. And because there is no dust isolation measures, the oil pipeline is blocked, and the oil leakage problems cannot be avoided.

4、油品使用费用高 / High cost of oil usage

从现场了解到，一台高压辊磨机设备，一个月用油量的费用就在15万元左右。

From the site, we know that a high-pressure roller mill equipment, the cost of oil consumption in a month is about 150,000 RMB.

5、设备轴承寿命短 / Short bearing life of equipment

从现场了解到，一台高压辊磨机的4盘轴承，每年都会更换至少2盘。

From the site, we know that a high-pressure roller mill has 4 plates of bearings, and at least 2 plates must be replaced every year.

高压辊磨机润滑改良建议 

U.LUBE’s lubrication improvement solutions for high pressure roller mill 

从现场调研，结合优润团队在重工行业服务30多年所具备的经验，为该铁矿厂提供润滑方式和润滑油品的改善，解决上述一些问题。

From the site research, combined with more than 30 years of heavy industry service , U.LUBE team provided solutions on lubrication methods and lubrication products to solve some of the above problems.

结合现代化生产节奏以及矿山车间的工况特点，优润团队建议使用VMAXX防护型辊压机集中润滑系统。

Combining the modern production rhythm and the working conditions of the mining plant, the U.LUBE team recommends to use the VMAXX protective roller press centralized lubrication system.

该系统以油桶本身为单位元，日常换油时只需要整桶更换，不需要重复倾倒。且一般企业用油量为一个月一桶，也就是一个月只需要更换一次油桶即可。配备了桶盖起重装置，换油时省时省力，还能保证油品干净，高智能控制器，能实现每个润滑点位的润滑油品需求量调节，精确到以克为单位。一个柜机主体，即可完成多所有润滑点位的供油需求。该设备将油桶、润滑泵、控制器等主要部件，集中在防护箱体内部，有效防止粉尘污染，增强设备可靠性。

The system allows replacing the whole drum during daily oil change instead of manually repeated dumping. Oil consumption is one drum per month, that means only replace once per month. Equipped with a barrel cover lifting device, it can not only save time and labour when changing oil, but also keeps the oil clean, with a highly intelligent controller, can realize the lubricating oil demand adjustment for each lubrication point, accurate to the unit of gram. One cabinet main body, can complete multiple lubrication points of the oil supply needs. The main parts of the equipment, such as oil drum, lubricating pump and controller, are all concentrated in the protective box, which effectively prevents dust pollution, enhances the reliability of the equipment.

油品则建议使用优润辊压机专用润滑脂ET RP 1500 ，具有优秀的抗挤压性能，且四球载荷至少400kg以上，能为高压辊磨机轴承提供良好的油膜，达到良好的润滑效果，从而延长设备轴承寿命，减少使用量，降低采购成本。

U.LUBE recommended the ET RP 1500 for roller press, which has excellent anti-extrusion performance and a four-ball load of at least 400kg, and can provide a good oil film for high-pressure roller mill bearings to achieve a good lubrication effect, thus extending the bearing life of the equipment, reducing the usage and lowering the procurement cost.

润滑改良的综合效果收益 

Comprehensive effect benefit of lubrication improvement solutions

以前高压辊磨机润滑系统手动加油，粉尘污染对油质造成很大影响，特别是夏季，轴承温度升高，工作现场33℃，严重影响设备作业效率。现在，将其改造为VMAXX高压辊防护型集中润滑自动加油装置，直接从油桶注油，无需人工加油，无粉尘等杂质，润滑油质好，轴承温度降低，延长了轴承使用寿命，提高了设备作业效率，工作现场温度也下降为25℃。

Previously, manual filing oil and dust pollution caused great impact on the oil quality, especially in summer, the bearing temperature was up to 33 ℃ at the work site, seriously affected the efficiency of equipment operations. Now, we introduced the VMAXX protective roller press centralized lubrication system, it can automatic fill oil instead of manual filling, which has advantages such as no dust and other impurities, good lubricating oil quality, bearing temperature reduction, extended bearing service life, improve equipment operating efficiency, the work site temperature also decreased to 25 ℃.

使用优润辊压机轴承专用脂，减少高压辊磨机油品的使用量，从而直接帮助企业节省油品采购额，每年可节省200万元。

Using the special grease for roller press bearings of U.LUBE can reduce oil usage in high-pressure roller mills, thus directly helping the enterprise to save the oil purchase amount, which can save 2 million RMB per year.

以往补油泵经常发生堵塞，导致油管崩裂、电机烧、油品跑漏等问题。采用防护型辊压机集中润滑系统搭配优润油品进行改良，每年设备维护至少节约20万元。

In the past, the oil replenishment pump was often blocked, leading to problems such as oil pipe collapse, motor burned, and oil leakage. With the adoption of the protective roller press centralized lubrication system with excellent lubrication oil products for improvement, the annual equipment maintenance saves at least 200,000 RMB.