Please describe any strategy you implemented that resulted in significant energy savings for your customer.
TLT Sounding Board April 2011
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Conducting energy studies, creating new testing methods and switching oil grades and lubrication systems were among the top energy-saving ideas offered this month by readers. Not all the good ideas involved lubrication. One reader noted that changing a lighting system to motion activated instead of constantly on resulted in a $30,000/month savings. Many responders said that switching to synthetic oils increased energy efficiency, although that sentiment wasn’t unanimous. “I have not seen any significant data to show that synthetic oils save energy and money,” one reader stated.
We’ve developed systems to run with ultra-thin hydraulic oil (10 cst) as opposed to an ISO 46, by using special internal gear pumps. There is then less pressure loss in long hydraulic lines, resulting in greater use of available power.
Our organization conducts research on low-friction and wear materials and lubricants for the U.S. Department of Energy. It is part of our main mission. We have developed test methods, screened surface treatments, formulated new lubricants and presented the results to the industry.
We created equipment group studies, where all variables are eliminated or minimized except for variable fluids (i.e., mineral vs. synthetics). We measure temperatures, output and energy consumption.
Used a wide cross of oil grades to lower low-temperature viscosity while maintaining minimum film thickness at higher temperatures.
Using a PAO-based gear oil, we saved 8%-10% in energy savings for a coal pulverizer gearbox. The actual motor wattage was measured over time, so it was real. It did not take into account further savings from longer lives or using a lighter oil because the temperatures were lower.
Changing cutting fluids resulted in energy savings by reducing electricity consumption by electric motors of machining centers.
We changed from a mineral oil to a PAG with about a 2.5% energy savings. A different fuel delivery/monitoring system was installed on our boilers, which reduced fuel cost by 30%. The lighting over most of our 500,000-square foot building were changed from staying on constantly to being motion activated, resulting in a monthly savings of $30,000.
Used 1% canola biodiesel in city buses for 2%-4% savings in fuel cost due to enhanced lubricity.
We used a metalworking fluid that improved lubricity characteristics and achieved measurable reduction in amperage pulled.
We measured energy used per machine, switched to synthetic lube and re-measured. We also consolidated lubricants, organized and cleaned the lube room, labeled equipment for lube product, switched many lube products to synthetics, changed methods of lubricating and dispensers and provided training to maintenance and operations.
We have been working in the area of energy-efficient hydraulic fluids for about five years. We have measured double-digit efficiency gains in hydraulic motors.
We used an energy analyzer to document energy savings on feed mill mixer gearboxes. Two gearboxes both changed to a high-quality, moly-fortified oil and netted a 5% reduction in energy consumption.
Do you believe current industry tools can accurately measure the energy-savings potential of lubricants?
Yes
67%
No
33%
Based on responses from 1,000 TLT readers.
We have analyses showing an average of 8%-12% reduction in amp draw with a Primrose compressor and gear oils, as well as the hydraulic supplement. For one print shop with six compressors, the projected savings over the life of the oil is over $97,000 in energy alone.
We used a digital recorder on an amp meter to measure gearbox power consumption to justify use of a synthetic lube.
Made changes to a control-system that allowed technicians to more effectively control the operation of a high-pressure steam compressor.
Using 0W-30 oils in motor vehicles saves on engine wear during startup, as well as better fuel economy. Using engine block heaters with timers to come on 1.5 hours before morning startup saves on fuel use to warm up the vehicle.
We often are trying to reduce energy consumption in small mechanisms simply to get them to work. The main economic driver for that is the customer is able to use less powerful motors to do the same job. Energy conservation is a secondary advantage.
Developed and commercialized an energy-efficient hydraulic fluid.
Implemented condition-based maintenance.
Use of synthetic lubricants, which typically have less internal friction, thus saving on energy efficiency.
Recommended using synthetic lubricants.
Went to premium-efficiency motors.
We offered the customer a coolant that cost 50% more than their current coolant, but the change increased their tool life by over 500%. This saved the customer several thousands of dollars per month on not purchasing more tool parts, as well as less downtime for changing parts.
Worked with a customer in reducing suction temperature in high-pressure stages in reciprocating compressors, especially in wet-CO
2 service. Lubrication feed rates were either reduced or increased, depending on the gases being compressed.
Reduced power draw in heavy-loaded worm gears.
Through the use of friction-modified synthetic fluids, I have conducted several energy studies to calculate annual cost savings. Majority of studies have been done on industrial flooded rotary screw and some large reciprocating compressors, gearboxes and pumps utilizing an energy (electricity) analyzer. Have also conducted several dyno tests on over-the-road trucks along with a SAE J1321 Type 2 test.
Switching the customer from a mineral oil to a synthetic product.
Switched over to synthetic to reduce power consumption, as well as using calculated regreasing frequencies to reduce lubrication technicians’ energy use.
Extended use of Group III products.
Using a lighter grade of synthetic gear oil on paper machine gear drives resulted in a large decrease in energy required and also resulted in lower operating temperatures and extended drain life.
Working with the customers, we set up amperage-monitoring systems on high-speed, high-temperature, frame-oven chains. Shot-to-point (or spray) lubricators were set up to automatically discharge at a preset maximum amperage draw. The process was very successful and, therefore, also implemented on high-temperature fiberglass oven and gypsum wallboard oven chains.
We provide boric acid treatment of engine to reduce friction and wear to improve fuel efficiency.
The implementation of energy-efficiency labeling to allow consumers to make an informed choice when purchasing appliances and vehicles. Such empirically derived ordinal labeling also can be employed in lubricants.
Switching over to 0w-30 engine oil from 5w-30 yielded almost 10% fuel economy savings.
I promote energy savings by implementing centralized, automatic lubrication systems.
What level of energy-efficiency gains do you believe are possible for future lubricants?
Less than 1%
2%
1-2%
23%
3-4%
22%
More than 4%
53%
Based on responses from 1,000 TLT readers.
Editor’s Note: Sounding Board is based on an e-mail survey of 13,000 TLT readers. Views expressed are those of the respondents and do not reflect the opinions of the Society of Tribologists and Lubrication Engineers. STLE does not vouch for the technical accuracy of opinions expressed in Sounding Board, nor does inclusion of a comment represent an endorsement of the technology by STLE.