Success Story: Cement manufacturing made profitable with cutting-edge lubrication solutions
India is the second largest producer of cement in the world, accounting for more than 7% of global installed capacity, India Brand Equity Foundation (IBEF) reports. While India’s rich quality and quantity of limestone deposits promise huge potential for the future of the cement industry – the sector also witnesses multiple operational challenges in enhancing equipment performance, reducing downtime, and improving profitability.
To achieve seamless operations, cement manufacturers are today reaching out to industry experts for assistance in choosing the correct products and services that can guarantee equipment health and longevity. Mobil™ Lubricants, with its continuous focus on ensuring customer satisfaction, has been partnering with top cement manufacturers to address their day-to-day challenges and ensure continuous performance. The company’s association with JK Cement is an instance of such industry engagement.
Challenge at JK Cement
JK Cement is one of India’s most prominent cement manufacturers with business units spread across the country. The company hosts a split grinding unit with a capacity of 1.5 MnTPA at Jharli, Jhajjar district, Haryana. The Jharli facility operates concentrator ball mills to crush ore for processing. The ball mills are primarily used for grinding the finished products and raw materials in cement plants, and are also suitable for grinding various ore and other materials in industrial and mining enterprises. This ball mill utilized a 2600 KW motor with average production of 180 T/hr.
JK Cement was facing a major challenge in its concentrator ball mill that was significantly denting productivity and profitability. The mill was being lubricated with a conventional ISO VG 320 oil, which however, was not performing as expected. The company began experiencing poor oil drain interval (ODI) of only one year, resulting in the loss of 420 liters of oil per annum. Simultaneously, the gear box showed efficiency of only about 92-93%. Seeking to reverse the situation and regain its operational efficiency, JK Cement reached out to Mobil for advice and expert insight.
Recommendation & Result
A team from Mobil visited the site in Haryana and conducted thorough studies of the equipment and its functioning. The team also examined the application of the conventional ISO VG 320 oil and, thereafter, completed an Energy Efficiency Documentation Study. The analysis included an in-depth examination of the machine and its various parts along with a study of its lubrication performance. The team from Mobil concluded that the efficiency of the gearbox could be increased by up to 1% and the ODI could be extended by up to four years. They recommended a shift to Mobil SHC™ 632, an advanced gear oil that would assist in achieving the twin outcomes of improved gearbox efficiency and extended gearbox ODI.
Following the recommendation, JK Cement began using Mobil SHC 632 in its concentrator ball mill. This resulted in extended oil drain interval of four years and improved gearbox efficiency by nearly 1%. Further, it contributed significantly to profitability by enabling cost savings of USD 18,764.