SHELL TECHNOLOGY SEMINAR for the Mining Industry Mobile and Fixed Plant Greases Ian Martin Lubricants Specialities Competence Development Manager Asia Michael Longbottom Global Mining Grease Business Development Manager

Copyright The Shell Company of Australia Limited

October 2011

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Copyright The Shell Company of Australia Limited

October 2011

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Presentation Scope 

Factors driving grease specification development (fixed & mobile)

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Key challenges facing grease formulation development

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Shell grease development: how the Global R&D team responds to these challenges

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Demonstrations of Shell grease technology in the marketplace

Trends

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Implications

Leadership

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Our Definitions - Fixed Plant Vs. Mobile Plant 

Fixed plant - that which rotates but does not relocate

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Mills, conveyors, crushers, kilns/dryers, etc

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Mobile plant - that which relocates frequently within the mine

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Draglines, shovels, excavators, haul trucks, loaders, dozers, etc

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October 2011

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1.0 Trends Lubricants trends within the mining sector

Copyright The Shell Company of Australia Date Limited 02/11/2011

October 2011

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Trends – Development of Thickeners

(1.0)

Thickener technology age (mineral oil based) Years since introduction Functional soaps Polyurea Calcium Sulfonate Complex Lithium complex Anhydrated calcium soap Calcium complex Aluminum complex

Lithium soap Clay Sodium complex Hydrated calcium soap 0

20

40

60

80

100

120

140

160

Things move slowly in the greases world... Copyright The Shell Company of Australia Limited

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Trends – Segmentation by Use (1.1) 

The global grease market in 2010 was 1,024,780 metric tonnes and was made up of different thickener technologies as follows:

1.48% 3.66% 3.99%

0.15% 3.08%5.23% 2.26% 1.82% 1.13%

LiX = 18.06%

Li12 = 59.15%

Lithium Conventional

59.15%

606,171,590

Lithium Complex

18.06%

185,025,355

Calcium Hydrated

3.99%

40,876,381

Calcium Anhydrous

3.66%

37,458,165

Calcium Sulfonate

1.48%

15,151,958

Calcium Complex

1.13%

11,559,963

Aluminum Conventional

0.15%

1,561,031

Aluminum Complex

3.08%

31,566,871

5.23% Polyurea (Including Complexes):

53,617,868

Other Non-soap Thickeners:2.26%

23,171,195

1.82% Organophilic Clay Thickeners:

18,620,401

Did you know that Shell is among the world’s largest manufacturers of grease? Copyright The Shell Company of Australia Limited

October 2011

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Trends – Thickeners – Main Properties (1.2)  Main jobs of the thickener  Provide thickening!  Stay thick!

 At high temperature (dropping point)  Under load and shear (mechanical stability)  Provide appropriate flow properties (rheology)

Mantra! Thickener can affect other properties Other components can affect the thickener properties Copyright The Shell Company of Australia Limited

October 2011

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Trends – Thickeners – Main Characteristics (1.3) Thickener

water resistance

mechanical stability

dropping point

corrosion resistance

Calcium

very good

fair

low

poor

Aluminium

good

poor

low

very good

Lithium

good

excellent

high

very good

very good

excellent

high

very good

Ca Complex

good

good

very high

good

Al Complex

good

good

very high

very good

Li Complex

good

excellent

very high

very good

Calcium Sulfonate Complex

fair

excellent

very high

excellent

Clay

fair

fair

very high

fair

Microgel

good

good

very high

good

Polyurea

very good

excellent

very high

very good

Li/Ca

Mantra! Thickener can affect other properties Other components can affect the thickener properties Copyright The Shell Company of Australia Limited

October 2011

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Trends – Thickeners – New entrant (1.4) Calcium Sulfonate Complex  Since circa 1980, a “new” thickener system has been introduced. There have been 3 “generations” of CaS to date  CaS offers inherently high EP (due to high sulfur content), stable oil bleed & high temperature resistance in a “sticky”

adhesive format

CaCO3 = Calcium Carbonate Main component in CaSx thickener matrix has a particle hardness of 3 – 4 Mohs depending on mineral source, mainly extracted from limestone or marble in the form of Calcite or Argonite.

 However, so far this thickener type also displays an abrasive characteristic that fails the industry standard SKF R2F wear test by a factor of; 

Up to 100 times for generation 1



Up to 3 times for generation 3

CaSO4 -2H2O = Calcium Sulphate Gypsum with typical particle hardness of 2 Mohs.

 The reaction of Calcium Sulfonate during manufacture results in the formation of Calcite particles, which are inherently hard and abrasive. These particles can produce point stress loads & induce abrasive wear in bearings

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Molybdenum disulphide with typical particle hardness of 1–1.5 Mohs

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Trends – Thickeners – New entrant (1.6) Calcium Sulfonate Complex  Most generation 1, 2 & 3 CaS greases fail the SKF R2F bearing wear tests  By the time you realise this, your equipment may have already failed When solid particles escape the lubricant film, they change the load dynamic, which can lead to wear within the bearing:

SKF R2F A 2010 Benchmarking Results COMBINED ROLLER WEAR 4000

3568 FAIL

3500

3162

FAIL

3000

PASS DIN 51806 spec =50mg/bearing SKF R2FA spec =25mg/bearing

FAIL 2500 2000

1592

FAIL

1500



1000

Load pressure reconfigured down to one point (at solid particle)

Surface Contact Point (rolling element and raceway) Outcome: pitting and bearing failure

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PASS

500

PASS

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

PASS 0

0 CaS A

CaS B

CaS C

Shell S2

Shell S3

V220 2

V1000A 2

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Trends – Thickeners – New entrant (1.7) So what is Shell’s position on CaS? 

Shell’s current portfolio covers applications that CaS suppliers are promoting and in many cases our existing products outperform CaS.



Shell is investigating suitable generation 4 CaS thickener systems, plus “Hybrid” Lithium/Calcium-Sulfonate alternatives

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Until the new candidates meet the SKF R2F bearing wear hurdle, we will not introduce this technology



Our position is to make haste slowly and get it right before incorporating within our

portfolio

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October 2011

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Trends – Base Fluids – Base Fluid Selection (1.8) Grease base fluids – almost anything can be a grease base fluid The vast majority of greases (>90%) are made with mineral oil. (MVI) 

Alkanes or Paraffins

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Cycloalkanes or Napthenics

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Aromatics

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Different viscosity base oils are blended to achieve the target viscosity.

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Referred to as GROUP I base oils

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October 2011

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Trends – Base Fluids – Base Fluid Selection (1.9) More demanding applications may require Synthetic Base Oil

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Synthetics are defined here as: “ Products containing base oil manufactured by chemical combination” 4 main types of base fluid:

Hydro cracked (HVI) = GROUP II  Severely Hydro processed Base Oil (XHVI) = GROUP III  Polyalphaolefins (PAO) = GROUP IV  Everything else! Esters, polyglycols, silicones, … = GROUP V  The viscosity temperature effect • E.g. A typical group 1 ISO 460 = 19 cSt @ 100oC • E.g. A typical group 5 ISO 460 = 37 cSt @ 100oC Sometimes “semi synthetic” blends of MVI plus synthetics are the best solution 

Mantra! Thickener can affect other properties Other components can affect the thickener properties Copyright The Shell Company of Australia Limited

October 2011

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Trends – Synthetic Applications - Where to Use Them? (1.10) More demanding applications may require Synthetic Base Oil  



Extreme (high or low) temperature – resist oxidation, higher VI High severity gears (temperature & or load) – higher fluid load carrying ability Low NVH applications (Noise/Vibration/Harshness) e.g. auto components applications like ball joints, steering systems, constant velocity joints

Benefits of synthetics 

Low viscosity change = improved start up torque = Better pump-ability at low temperatures



Better rheology

= longer component life = (3-6 times mineral oils) = Low traction coefficients = (increased efficiency & reduced energy) = Lowered frictional & fluid loss

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Excellent high temperature resistance = less carbon build up especially esters = Low evaporation = long grease life (3-5 times mineral)

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PAO/XHVI compatibility with mineral oils require no flushing

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October 2011

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Trends - What drives the mining equipment market

(1.11)

Trends 

Trend toward larger, more powerful & more efficient machinery increases the dependence on that equipment to operate continuously and reliably for as long as possible at the lowest cost Fewer Larger Equipment

Market Influence: Technology

Market Influence: Operated Cost

Market Drivers Increased Power Output

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Increased Reliability Dependence

Extended Service Intervals

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Trends - What drives the mining equipment market (1.12) Trends 

Equipment Examples

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Haul trucks capacity increases from 100 to 350 tonnes

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Dragline capacity increases from 60 to 120 cubic-metres

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Hydraulic excavator capacity increases from 20 to 50 cubic-metres

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Mill capacity increases from 50 to 600 tonnes/hour

EX1900 190 tonne

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EX8000 = 780 tonne

MT3000 110 tonne

W2000 2,000 tonne

MT5900AC 330 tonne

8950 = 5,800 tonne

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Trends - What drives the mining equipment market (1.13) Trends 

Increased global trend toward single, broader and more efficient OEM lubricant specifications to ensure equipment operates continuously & reliably at greatly varying environmental conditions

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Fixed plant Examples

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Clear open gear lubricant, fully synthetic, self-draining (driven by customers)

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Full open gear package including spray-able reconditioning lubricants (driven by OEM’s)

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Mobile plant Examples

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Bucyrus grease specifications - 1 grease for -40°C to +50°C

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Terex wheel bearing specification - 1 grease for -40°C to +40°C

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Komatsu/Caterpillar grease, solid additives 3-5%, 10 Million tones/year of coal & employs long term contract mining to remove overburden & coal.

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Shell designed, installed & maintains lubricants storage & dispensing equipment including high volume oil & grease on board filling to machines & workshops via a dedicated Shell lube truck operated by Shell staff. Shell’s Investment is recovered via a small cents per litre charge for all lubricants supplied for the term of the contract. The customer enjoys Shell’s experience in tank farm & lubricants dispensing equipment design, operation & maintenance. All operation of equipment & lubricants dispensing is provided by Shell staff.

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Savings / benefits to customer are in provision of AUD$1.7M equipment & contracted operation “off balance sheet” *

*Savings/benefits reported by one customer. Actual savings/benefits will vary

Shell Lubricants storage @ customer site Copyright The Shell Company of Australia Limited

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Q&A

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October 2011

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Copyright The Shell Company of Australia Limited

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