Paper 06yy

Biodegradable sugar mill lubricant.

What makes it suitable for a sweet but aggressive environment

Hocine Faci
Bob Cisler
BP/Castrol
and
Charles Barrett
BP Americas, Inc.

150 W. Warrenville Rd
Naperville, IL 60563

Presented at the 73rd NLGI annual meeting

Lake Buena Vista, Florida
October 29 - 31, 2006

NLGI Preprint: Subject to revision. Permission to publish this paper, in full

or in part, after its presentation and with credit to the author and the
Institute, may be obtained upon request. NLGI assumes no responsibility
for the statements and opinions advanced by contributions to its
publications. Views expressed are those of the authors and do not
necessarily represent the official position of the NLGI.
 Biodegradable sugar mill lubricant.
What makes it suitable for a sweet but aggressive environment

Abstract

Sugar mill journal bearings, commonly referred to as Top Roll Bearings, Receiving Roll
Bearings and Discharge Roll Bearings, are components operated in hostile
environments, under extreme loads, in the presence of high volumes of aggressive
water, steam, vegetable fibers, solid contaminants, etc. Most conventional mill lubricants
showed limitations in maintaining a continuous film of lubricant between the wear
components of these bearings. A vegetable oil based product has been developed to
address this situation. A tenacious continuous lubricating/sealing film has been obtained
leading to lower operating temperatures, reduced lubricant consumption and cleaner
waste water.
Introduction

The process of making raw sugar consists of separating the natural sugar present in the
cane stalk or beet root from the rest of the plant through a milling process. For cane
sugar, the process is carried out in the following steps: the harvested cane enters the
mill and is chopped into the optimum size for crushing; the chopped cane passes
through a series of rolls in what is typically referred to as a tandem mill where it is
crushed and pressed to extract the sugar rich juice; (see figure 1) the juice is heated
under pressure and lime is added; the heated juice passes through a clarifier where the
impurities precipitate and settle to the bottom and the clarified juice is drawn from the
top; the clarified juice is concentrated into syrup by boiling off excess water in a series of
connected evaporator vessels; the syrup from the evaporator continues to be heated in
vacuum pans where small seed crystals are introduced to the concentrating syrup, the
seeded crystals grow in size to the required size; the mixture of crystals and syrup is
separated in centrifugal machines; the moist raw sugar from the centrifugal machines is
tumble dried in a stream of air and transferred to bulk storage bins. [1, 2, 3, 4, 5]
The raw sugar is typically further processed in a refinery that can be an integral section
of the mill or an independent facility. At the refinery the sugar can undergo several
washing, filtering and re-crystalizing processes before it is packaged and distributed to
the consumer market. Beet sugar processing is similar except for the absence of the
machinery required to chop and crush cane. Sugar beets enter the mill where they are
washed, sliced and soaked in hot water to separate the sugar containing juice from the
beet fiber. After the sugar rich juice is separated from the beet fiber the concentrating,
crystallizing, separation, drying and refining steps are similar to cane sugar processing.
Cane crushing mills are equipment designed to shred, crush and press the sugar cane
between rollers in a series of mill stands [6]. The extraction (Figure 1) is actually
conducted as a counter-current process using fresh hot water at one end being pumped
in the opposite direction to the cane. The more water that is used, the more sugar is
extracted but the more dilute the mixed juice is and hence the more energy that is
required to evaporate the juice. The more accurately that the mills are adjusted, the
drier is the residual fiber, and hence the less sugar remaining in the fiber.
The journal bearings supporting these rollers, commonly referred to as Top Roll
Bearings, Receiving Roll Bearings and Discharge Roll Bearings are components that
operate in an extremely hostile environment that includes heavy loads and shock loading
in addition to mechanical misalignment, contamination with hot water, acidic sugar cane

2
juice, and other debris such as cane fibers, dirt, etc. These adverse conditions
constitute a major challenge to the effective lubrication of these bearings and typically
require the use of application specific high performance lubricants. This paper will
discuss the performance displayed by a non-conventional product in comparison with
polymer based products that traditionally have provided adequate lubrication. The
physical properties as well as the performance characteristics of this product will be
covered along with the product consumption and its impact on the sugar mill rolling
process.
Background

Traditionally, the criteria of lubricant selection for this type of application relied mainly on
the tackiness/adhesion properties as well as extreme pressure characteristics. High
viscosity polymeric type products fortified with solid or sulfurized compounds may
provide both adequate film thickness and proper load carrying capacity. The field
experience, however, showed that lubricant performance wouldn’t categorically improve
with the viscosity increase or with the introduction of solids or sulfur content in the
finished product. Many high molecular weight (high viscosity) polymers have a tendency
to shear down under service stress leading to reduced viscosity base oils under
continued operation, and thus lower film thickness and reduced adhesion. Several
technologies of sulfurized compounds are available in the market, however some display
extreme aggressiveness toward cupric metals. In conclusion, the ideal product for this
application would be a product that displays the following characteristics:
 Ability to form a strong film that is resistant to shear and squeeze out under
pressure
 Sufficient tackiness/adhesion to make the product strongly adhere to the journal
and bearing surfaces
 Sufficient flow to continuously carry away debris from the loaded journal and
bearing surfaces
 Sufficient resistance to washout to maintain a consistent lubricant film between
the journal and bearing surfaces in the presence of high volumes of hot water
 High base oil Viscosity Index (VI) to assure continuous protection at high
temperatures (see Figure 2)
 Protection of ferrous and cupric metal surfaces from corrosion in presence of
strong acidic sugar cane juice
 Extreme pressure and anti wear protection against wear and damage from
continuous high and severe and shock loads
 A light color would be desirable to minimize discoloring of the processed product
 Preferably bio-based or biodegradable, heavy-metal free and therefore less
environmentally harmful than traditional sugar mill lubricants

Laboratory evaluation

Two samples of conventional commercially available sugar mill lubricants were

evaluated in order to determine their performance properties under laboratory test
conditions. Standard test methods were used for evaluation of wear and extreme

3
pressure characteristics, corrosion inhibition, water resistance and mechanical stability.
Friction properties were also taken into consideration for performance during low startup
operating temperatures, and reduced bearing noise under extreme operating load
conditions. The following summarizes the laboratory test methods determined to be
appropriate evaluating and comparing sugar mill lubricants [7]:
Water resistance
In grease lubrication applications water contamination may cause the structure of the
grease to change. It may become softer or harder. It may adsorb water or reject it, and
in some instances, it may lose its adhesiveness or sealing capabilities. The use of fresh
samples of process water from the actual application(s) for which a lubricant is intended
to be used is known to be critical in determining the operating properties of lubricants.
The differences in chemical composition, contaminants, pH, and adsorbed gases in
process waters versus the standard distilled water or synthetic seawater specified in test
methods can have a significant influence on the water resistance and corrosion
protection test results. The effect of process water on lubricant resistance in this
situation was determined to best evaluated through the use of the following test
methods:
Water Spray-off (ASTM D4049)
This method consists of subjecting an evenly distributed layer of lubricant spread at a
given thickness on a stainless steel panel to water spray-off. The lubricant is sprayed
with water at a given temperature for 5 minutes at a prescribed pressure. The panel
is then air dried and weighed. Spray-off resistance is reported as the mass percent
of lubricant removed by the water spray. (see figure 3)
Wet Roll Stability (ASTM D1831)
This method consists of running the standard ASTM D1831 roll stability test with the
addition of the presence of water. Process water such as that containing sugar cane
juice may be used instead of specified standard water. Visual inspection of the
lubricant and its penetration change after being subjected to roll shear, along with the
presence of free water and its quantity, are determining factors for the water
resistance characteristics of the lubricant.
Shear stability
Shear stability is the ability of a lubricant to resist changes in consistency when
subjected to mechanical work. The most common laboratory test used to evaluate shear
stability is the roll stability test.
Shear stability (ASTM D1831)
In the Roll Stability Test, a small sample (50 grams) of lubricant is rolled at 165 rpm
for 1 hour under a given temperature. The difference in worked penetrations
(measured with ¼ scale penetrometer) before and after roll is reported.
Corrosion Resistance
In wet applications, such as those in sugar mill environments, lubricants are expected to
assure protection against steel rusting and the corrosion of cupric metals.
Steel Rust (ASTM D665 modified)
This method consists of the complete immersion of a cylindrical steel test rod in a
lubricant sample, removing it and placing it directly into a beaker containing process

4
 water from the application for which the lubricant is to be used. The test rod remains
in the beaker of process water at ambient temperature for one week. The test rod is
routinely visually examined for signs of rusting during and at the conclusion of the
test period. At the conclusion of the test the rod may also be inspected and
measured for the degree of rusting.
Copper corrosion (ASTM D 4048)
This method consists of the immersion of a clean polished strip of copper in a
lubricant sample at 100°C for 24 hours. If desired, the test temperature and time
may be varied from the standard conditions. At the end of the test, the strip is
removed and cooled. The strip is then cleaned and inspected for staining. Corrosion
may be qualitatively described or rated numerically.
Extreme Pressure / Anti wear
Equipment such as the Four Ball EP and Four Ball Wear tester, to name only two, have
played and continue to play a critical role in the development, testing and selection of
lubricants.
Four Ball EP (ASTM D2596)
This method consists of 4 balls arranged in the form of an equilateral tetrahedron.
The basic elements of the tetrahedron are 3 balls held stationary in a pot to form a
cradle in which the fourth (upper) ball is rotated on a vertical axis under pre-
determined conditions of loads. The rotating speed is 1770 +/- 60 rpm. A series of
10-second runs are made at successively higher loads until the 4th ball seizes/welds
to the 3 stationary balls.
Four Ball Wear (ASTM D2266)
This method uses the same principle as above. The test is run at a specified
rotational speed under a prescribed load at a controlled temperature. The test
standard duration is 1 hour. The diameter of the wear scars on the stationary balls is
measured after completion of the test.
Friction
Multiple test apparatus and numerous methods are employed to measure friction at the
contacting surfaces of various shapes and sizes of test specimens. Apparatus includes
Four Ball, Pin and Vee, Ring on Block, Block on Ring, Disk on Disk, and Ball on Disk
Testers. The SRV test machine was selected for measuring the coefficient of friction in
this project because it can be adjusted and programmed to closely simulate the line
contact configuration of journal bearings
Friction (ASTM D 5707 modified).
Test specimens consisting of a steel cylinder representing a mill bearing journal and
a bronze disk representing a mill bearing shell were used. A detailed description of
the SRV test machine can be found in references [8] and [9]. (see Figures 4 and 5)
Biodegradability
Measuring the biodegradable property of lubricants remains a work in process at both
national and international standards level. ASTM D-5864, EPA Shake Flask, CEC-L-33-
A-93, ISO 9439, OECD 301 A to F, and OECD 302 are a few of tests currently used to
measure the biodegradability of lubricants.

5
 Biodegradability (OECD 301B)
The OECD 301B test method has been found to be suitable for determining the
ready biodegradability of soluble and insoluble organic chemicals under aerobic
conditions. It is the basis for ISO 9439. This method is only applicable to those test
materials which, at the concentration used in the test, have negligible vapor
pressure, are not inhibitory to bacteria and do not significantly adsorb to glass
surfaces. In general, bio-based greases fit this category of substances.
Percentage biodegradation is calculated by dividing the Biological Oxygen Demand
(BOD) by the Theoretical Oxygen Demand (ThOD). The calculation of ThOD is
based on the percentage composition of the elements C, H, Na, Cl, P, and S. A
sample with high water content and/or low carbon content will have a
correspondingly high oxygen value (this being calculated by difference). This will
result in a low estimation of the ThOD, and as a consequence, an overestimation of
the percentage biodegradability. The elemental analysis for aqueous samples may
also be harder to achieve. Due to these difficulties, Chemical Oxygen Demand
(COD) values can be used as an alternative to ThOD

Laboratory Test Results:

Laboratory test results are summarized in Table 1 and Figures 2, 3, 4 and 5

Discussion

Test results displayed in Table 1 indicate the following:

Although the polymeric based products (PBP1 and PBP2) have a kinematic viscosity at
40°C approximately twice as high as that of Biodegradable Sugar Mill Lubricant (BSML),
the gap between these viscosities becomes less and less significant at higher
temperatures. At 100°C, the viscosity of PBP1 is only 10% higher than the viscosity of
BSML, and at 102°C and above, the viscosity of BSML becomes higher than the
viscosity of PBP1 (Figure 2). This is due to the higher VI of the BSML base oils. This
suggests that the viscosity of the base fluids, and thus the film thickness, is less
sensitive to variations in operating temperature.
Also, when qualitatively evaluating the tackiness/adhesion in the presence of water or in
the presence of hydrocarbon solvents, BSML showed outstanding resistance to wiping
even while in an extremely thin film. Even though it’s recognized that polymeric
compounds, because of their non-polar characteristic, play a key role in repelling water
away from lubricants, it appears that the biodegradable systems produced with
vegetable oil provide much better water resistance than the products built with polymeric
compounds without thickening systems (Figure 3). The mechanical stability test results
obtained in the presence or absence of water are also more favorable in case of the bio-
based product. Less shearing and less viscosity change was observed with BSML.
The results of the rust resistance testing (modified ASTM D665) applied to the three
lubricants were not surprising. All products tested in this program passed the test with
excellent results. However, when tested against cupric metals in the copper corrosion
test (ASTM D 4048) only the BSML passed the test with outstanding results.

6
On the wear and extreme pressure side, when BSML was tested with steel against steel
configurations, it showed equivalent to slightly better wear characteristics in Four Ball
Wear, but much better results in Four Ball EP compared to the polymer based products.
In SRV tests using a steel-bronze configuration (Figures 4 and 5), the friction was
significantly lower with BSML than PBP1 and PBP2. This trend was maintained when
the load was increased. PBP2 failed the SRV test after 13 minutes of run time. These
SRV results confirmed the results obtained on the Four Ball EP test discussed earlier.
Finally, BSML is a compound with a light amber color and displays no adverse effects on
the housekeeping or surrounding environment. It is also a biodegradable compound that
presents reduced environmental risk.
Field Testing

Description
Field testing was conducted in a cane sugar mill in South Eastern Louisiana. The
equipment involved in the evaluation was a Tandem mill stand with three operator’s side
bearings isolated from the drive side bearings. [10]. Nomenclature for bearings was Top
Roll, Receiving Roll and Discharge Roll. These were half-shell, removable bronze
segments with water-cooled
chocks. Ambient temperatures
during the evaluation period
ranged between 50°F and 90°F,
and component temperatures
ranged between 60°F and 120°F.
Pitch line speeds of the bearings
were <250 fpm and the loads
ranged from very high to
extremely high depending on
throughput of the sugar cane.
Environmental conditions included
a wet atmosphere with water wash
potential, and the presence of
steam. There was the continuous
potential for severe contamination
Typical Conditions at Receiving Roll Bearings
by dirt, as well as cane fibers and
dust (bagasse). The process
water was primarily supplied from wells. As a result its physical and chemical properties
varied from moderately to very aggressive with groundwater conditions.
Testing of BSML
Several weeks prior to commencing the lubricant evaluation the ambient temperatures in
close proximity to and the operating temperatures of the tandem mill stand bearings, mill
loads, mill throughputs, and process water flow rates and temperatures were monitored
and recorded. A special log sheet was developed and used to record these and all
future mill readings and comments. This base line data also was used to produce
reliable, repeatable plots of the relationship of mill loading, and mill throughput to the
delta between the near proximity ambient and operating temperatures of the tandem mill
bearings. (see Figure 6)
At the commencement of the evaluation the lubricant feed lines for the tree journal
bearings on the operator’s side were isolated from the main centralized lubrication

7
system. These lubricant lines were connected to an independently controlled portable
dual line system centralized lubrication system. After purging the independent lubricant
delivery system and bearings of the existing product (PBP1), the individual metering
valves were adjusted and the controller was set to a 15 minute cycle. These settings
replicated 130% of the previous PBP1 lubricant feed rates to the three evaluation
bearings. There was a measurable decrease in bearing temperatures within a few hours
after the conversion from PBP1 to BMSL (See Tables 2 and 3 and Figure 6).
The following morning, bearing temperatures continued to remain stable and it was
agreed on by the mill and on-site Castrol personnel to reduce the output lubricant
metering valves from 100% to 70%. At this setting the lubricant delivered was equivalent
to that of the PBP1. It was also
agreed to stop the flow of
external cooling water onto the
bearing chocks. Water was is
limited in availability in this area
of the mill so eliminating its use
as an additional bearing coolant
provided associated benefits as
well as cost savings. The
ongoing monitoring of the mill
confirmed that the elimination of
external cooling water on the
bearing chocks was
accomplished with no adverse
impact on bearing temperatures.
Discharge Roll Bearing External Cooling Water Hose During the remaining two months
of the mill lubrication evaluation
the consumption of BMSL as compared to the PBP1 was reduced by 15% on the
receiving and discharge rolls. The use of external cooling water on the bearing chocks
became sporadic during this portion of the evaluation as a result of the mechanical
condition of the roll journals and bearing shells. This particular stand was selected by
the mill owner because it was both
one of the highest loaded in the
mill and was in its last season of
service prior to being
reconditioned. Deep grooving of
the journal and bearing surfaces
produced during previous grinding
seasons produced localized hot
spots under the severe mill loading
conditions incurred towards the
end of this year’s grinding season
and required compensation from
time to time by the use of external
cooling water.
The evaluation concluded with the
grinding season. Based on visual Typical Condition of Bearing Journals at Evaluation
observations, data collection, and Start
input from the plant maintenance

8
and engineering personnel, it was generally believed both mill and Castrol personnel
that the BSML not only met but exceeded initial performance expectations [11].
Conclusions

Based on both the laboratory testing and field evaluation data of BSML, it is believed
that its superior tackiness/adhesion characteristics, its high resistance to water washout,
its outstanding extreme pressure and anti wear properties in slow and heavily loaded
applications, its excellent steel and copper corrosion resistance in the presence of
extremely acidic and aggressive fluids, makes this bio-based product a cost effective
excellent lubricant in severe applications such as those present cane sugar mills. Its low
friction property intimately contributed to decreased bearing temperatures, the
elimination of the use of external cooling water, and certainly to a cleaner and safer
environment.
Acknowledgements

The authors wish to express their gratitude to E. Hubner, E. Chamberlin, J. Haspert, M.

Pourciau and M. Dennison for the support they provided during the development and
both the laboratory testing and this field evaluation of BSML.
References

[1] Sugar Cane: Past and Present, http://www.siu.edu

[2] Sugar Cane, http://en.wikipedia.org
[3] Steam Equipment in Javan Sugar Mills, http://internationalsteam.co.uk
[4] Sugar Processing, http://www.suedzucker.de
[5] Sugar history, http://www.sugar.ca
[6] How cane sugar is made – the basic story, http://www.sucrose.com
[7] H. Faci, B. Cisler, A. Medrano, M. Inns, “When Performance and Biodegradability
Converge: A Superior Product in a Demanding Environment”, NLGI Spokesman, Vol.
70, Nr 1. April 2006
[8] H. Faci, I. Bjel, A. Medrano, B. Cisler “Frictionless Open Gear Lubricant” , NLGI
Spokesman, Vol. 66, Nr 6, September 2002
[9] H. Faci, A. Medrano, B. Cisler “Biodegradable Open Gear Lubricant”, NLGI
Spokesman, Vol. 67, Nr 12, March 2004
[10] C. Barrett, “Product Testing & Evaluation -Sugar Mill Grease”, PT&E report, Castrol,
Engineering Department, December 1999 (internal publication)
[11] E. Hubner, “PT&E Summary For the Sugar Mill Lubricant”, Castrol Industrial,
Downers Grove, IL, April 2000 (internal publication)

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Table 1: Laboratory test results

Characteristic Test Method PBP1(*) PBP2 BSML(**)

Thickener type -- NA NA Proprietary

NLGI Grade -- NA NA 00-000

Worked Penetration, D 217 NA NA 440

Appearance -- Black Dark grey Light amber

Tackiness/adhesion -- Tacky Tacky Extremely

tacky/adhesive

Base oil viscosity, cSt

@ 40°C D 445 7900 6500 3700
@ 100°C 250 225 235

Base oil Viscosity Index D 2270 134 136 190

Water Sprayoff, % loss D 4049

10 Psi @ 80°F 2.2 0.6 0.6
10 Psi @ 100°F 39.0 22.0 1.9
10 Psi @ 120°F 67.9 51.5 18.0

Resistance (in thin film) to solvent -- Moderate Moderate Excellent

washout

Resistance (in thin film) to water -- Moderate Moderate Excellent

washout

Shell Roll Stability, penetration D 1831

points change, 1/10 mm
Dry
+ 28 +38 +11
With 10% water
+28 +29 +4

Steel Corrosion D665(mod) Pass Pass Pass

Copper Corrosion D 4048 Fail (2c) Fail (1c) Pass (1a)

Four Ball EP, kg weld D 2596 250 250 500

Four Ball Wear, mm D 2266 0.62 0.57 0.54

SRV Test, COF after 1 hr run D 5707

(modified)
Steel Cylinder on Bronze Disk
50N, 50°C, 50Hz, 1.0mm, 1hr 0.169 0.108 0.090
100N, 50°C, 50Hz, 1.0mm, 1hr 0.193 Failed @ 800 sec 0.098

Specific Gravity D 1475 0.912 0.912 1.004

Biodegradability, % OECD 301B NA NA 91

(*) PBP: Polymeric Based Product
(**) BSML: Biodegradable Sugar Mill Lubricant

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Table 2: Temperature readings

Day Time Product Ambient Top Roll Bearing Receiving Roll Discharge Roll
Temp.°F Temperature, °F Bearing Temp. Bearing Temp.
°F °F

T1 T2 T3 t1 t2 t3 Θ1 Θ2 Θ3

1 17:52 PBP1 72 86 120 120 88 86 83 110 94 89

1 19:50 BSML 73 94 91 103 74 77 80 91 83 86

2 8:30 BSML 56 75 74 80 60 62 64 77 70 73

2 10:00 BSML 58 83 79 87 63 66 69 76 76 75

2 17:00 BSML 70 91 82 90 67 69 73 87 81 85

2 21:00 BMSL 61 85 74 84 63 64 69 81 72 78

2 23:00 BMSL 57 83 71 85 60 63 67 79 71 74

3 3:00 BMSL -- 83 73 85 58 61 66 79 73 75

3 8:25 BMSL 55 81 78 84 65 75 79 79 75 77

3 9:55 BMSL 56 82 82 83 70 79 78 78 74 77

Table 3: Impact on product consumption and cooling water usage

Day Time Product Cons Top Roll Bearing Receiving Roll Discharge Roll
umpti Bearing Bearing
on, %

1 17:52 PBP1 100 One water line on No water 2 water lines on

1 19:50 BSML 100 One water line on No water 2 water lines on

2 8:30 BSML 100 One water line on No water 2 water lines on

2 10:00 BSML 100 One water line on No water 2 water lines on

2 17:00 BSML 100 No water No water No water

2 21:00 BMSL 70 No water No water No water

2 23:00 BMSL 70 No water No water No water

3 3:00 BMSL 70 No water No water No water

3 8:25 BMSL 70 No water No water No water

3 9:55 BMSL 70 No water No water No water

11
Figure 1: Sugar cane crushing/extraction section

Figure 2: Effect of temperature on base oil viscosity

12
Figure 3: Effect of pressure and temperature on water sprayoff

Figure 4: Coefficient Of Friction by SRV test machine (50 Newtons)

COF per SRV, Steel cylinder on Bronze Disk, 50N, 50°C, 50Hz, 1.00mm, 1 hr
0.30
Testnr
PBP1
BSML
PBP2 0.25

0.20

0.15

0.10
ci
tn
o

0.05
r
Fi

0
0 600 1200 1800 2400 3000 3600
Time, sec

13
Figure 5: Coefficient Of Friction by SRV test machine (100 Newtons)

COF per SRV, Steel Cylinder on Bronze Disk, 100N, 50°C, 50Hz, 1.00mm, 1 hr
0.30
Testnr
PBP1
BSML
PBP2 0.25

0.20

0.15

0.10
ci
tn
o

0.05
r
Fi

0
0 600 1200 1800 2400 3000 3600
Time, sec

Figure 6: Variation of the bearing temperatures throughout the BSML field testing

14