CN105969488A - 一种回转窑托轮大瓦润滑油组合物及其制备方法 - Google Patents
一种回转窑托轮大瓦润滑油组合物及其制备方法 Download PDFInfo
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Abstract
与现有技术相比，本发明提供了一种回转窑托轮大瓦润滑油组合物，包括如下质量百分数的成分：聚α‑烯烃5～10％；光亮油65～79％；稠化剂15～25％；抗氧剂0.1～5.0％；金属钝化剂0.01～0.5％；腐蚀抑制剂0.1～5.0％；极压抗磨剂0.5～5.0％；抗泡剂0.0005～0.05％。本发明提供的回转窑托轮大瓦润滑油组合物具有很好的抗磨损、抗氧化、抗乳化、抗腐蚀、抗极压、耐高温等性能。而且具备较高的黏度系数指标，确保托轮轴瓦正常工作时能形成一定厚度的油膜，避免托轮轴与瓦之间直接接触摩擦，有效地保护托轮轴及衬瓦，能降低托轮轴瓦发热的概率。
Description
技术领域
本发明属于润滑油技术领域，具体涉及一种回转窑托轮大瓦润滑油组合物及其制备方法。
背景技术
回转窑设备是水泥企业生产过程中的关键设备有水泥厂“心脏”之称。托轮作为回转窑的运动支撑点，承受着热负荷、物料负荷和窑自重三大载荷。由于回转窑托轮轴瓦的工况比较差，如环境温度高，负载大，容易混人粉尘和水分。回转窑的托轮轴瓦如果润滑不良，会造成轴瓦发热、拉丝(拉丝是轴表面严重损伤形成纹丝)、抱瓦、甚至翻瓦现象，影响了正常生产。因此，性能优异的回转窑托轮轴瓦专用油可以降低托轮轴瓦发热，减少因润滑对生产产生的影响。托轮的稳定运行是回转窑安全运行的保证，也直接影响到水泥厂的产量和运转率。
新型干法窑采用的是液压挡轮，托轮纵向中心线与回转窑纵向中心线应该平行，在垂直于回转窑纵向中心线的垂直面内，每档内两个托轮中心点与轮带中心点应构成正三角形，相互夹角为60°，具体见图1，图1为拖轮中心点与轮带中心点的构成示意图。只有在此状况下，才能确保各托瓦的受力合理均衡，有效避免托轮因受到纵向力而使托轮轴端的止推圈和衬瓦端面之间产生不合理的摩擦，见图2，图2为拖轮轴端止推圆和衬瓦端面结构示意图。产生热量聚集，最终导致衬瓦温度升高、刚度降低、拉伤变形而失效的严重后果。
由此可见，在运行过程中托轮轴瓦应该属于弹性流体动力润滑。所谓弹性流体动力润滑是指流体进入在两个相互运动的固体摩擦接触表面后，受到接触表面产生的巨大接触压力而发生的性状改变，以分割固体摩擦接触表面，减少摩擦。其原理是利用流体的弹性随压力变化而变化的特性，来实现分割量高压表面而达到润滑的目的。
目前，国内外专用于水泥厂回转窑托轮轴瓦润滑的油品不多，许多水泥厂采用沥青质重油或气缸油进行润滑。但这种油品黏温性能较差，当托轮轴发生偏离时，轴温上升，产生大量热量，此时黏温性能差的油品运动黏度及油膜厚度均急剧下降，如果润滑效果不良，热量无法带走，则容易造成烧瓦。同时这种油品氧化性能差，积炭严重。此外，气温较低时，这种油品容易发硬变脆，甚至从齿轮表面脱落，不利于润滑。
因此，油品的黏度、黏温性能、极压性能及黏附性能等是不可忽略的。首先，黏度选择要合适：油品黏度提高，易形成油膜，但油品黏度过高，增加能耗，不利于散热，同时易使轴瓦温度上升；油品极压性能提高，轴瓦承载能力加大。如能合理选用回转窑托轮轴瓦润滑油，通过提高油品质量有效地改善轴瓦的润滑状况，可延长大瓦使用寿命，节约能源，减少维修，提高效益。
发明内容
有鉴于此，本发明要解决的技术问题在于提供一种回转窑托轮大瓦润滑油组合物及其制备方法，本发明提供的润滑油具有良好的黏度、黏温性能、极压性能及黏附性能。
本发明提供了一种回转窑托轮大瓦润滑油组合物，包括如下质量百分数的成分：
优选的，所述抗氧剂选自有机酚类抗氧剂、硫氮型复合物抗氧剂和有机硒化物抗氧剂中的一种或几种。
优选的，所述金属钝化剂选自苯三唑衍生物类金属钝化剂、噻二唑衍生物金属钝化剂、有机胺类金属钝化剂中的一种或几种。
优选的，所述腐蚀抑制剂选自磺酸盐类腐蚀抑制剂、脂肪酸及其衍生化合物和复合磷酸酯类化合物中的一种或几种。
优选的，所述抗泡剂选自硅型抗泡剂或非硅型抗泡剂。
优选的，所述稠化剂优选为PMA、OCP和PIB中的一种或多种。
优选的，所述聚α-烯烃在100℃的运动粘度为18～22mm2/s，所述光亮油在100℃的运动粘度为22～28mm2/s，所述稠化剂在100℃的运动粘度为4500～4900mm2/s。
本发明还提供了一种回转窑托轮大瓦润滑油组合物的制备方法，包括以下步骤：
将稠化剂、抗氧剂、金属钝化剂、腐蚀抑制剂和抗泡剂依次加入基础油聚α-烯烃和光亮油中，在真空条件下加热搅拌均匀，得到回转窑托轮大瓦用润滑油组合物。
优选的，所述加热的温度为45℃～130℃。
优选的，所述真空条件的真空度为52Pa～400Pa。
与现有技术相比，本发明提供了一种回转窑托轮大瓦润滑油组合物，包括如下质量百分数的成分：聚α-烯烃5～10％；光亮油65～80％；稠化剂15～25％；抗氧剂0.1～5.0％；金属钝化剂0.01～0.5％；腐蚀抑制剂0.1～5.0％；极压抗磨剂0.5～5.0％；抗泡剂0.0005～0.05％；上述组分之和为100wt％。本发明提供的回转窑托轮大瓦润滑油组合物具有很好的抗磨损、抗氧化、抗乳化、抗腐蚀、抗极压、耐高温等性能。而且具备较高的黏度系数指标，确保托轮轴瓦正常工作时能形成一定厚度的油膜，避免托轮轴与瓦之间直接接触摩擦，有效地保护托轮轴及衬瓦，能降低托轮轴瓦发热的概率。
附图说明
图1为拖轮中心点与轮带中心点的构成示意图；
图2为拖轮轴端止推圆和衬瓦端面结构示意图。
具体实施方式
回转窑托轮大瓦(也称回转窑托轮轴瓦)专用油工作条件苛刻，因而对油品的要求很高。由于负载很大，油品应具有优异的极压抗磨性能；油品还应具有抗高负荷、抗水淋、抗氧化、成膜迅速持久等特点，能有效地避免拉丝、愈合拉丝，降低大瓦温度，能使经常发烧到60℃以上的大轴瓦降温至接近大瓦所处的环境温度。因此，要求回转窑托轮轴瓦专用油具有良好的粘温性能、抗氧化安定性能、极压性能、黏附性能等。
根据回转窑托轮轴瓦工况及对润滑油性能的要求，结合对市场需求的了解，初步确定研制的产品，具体指标如表1。
表1研制托轮轴瓦油的暂定质量指标
根据上述问题，本发明提供了一种回转窑托轮大瓦润滑油组合物，包括如下质量百分数的成分：
由于应用的特殊性，回转窑托轮轴瓦油100℃运动黏度要求≥70mm2/s，在用的基础油无法达到这一指标，因此，在本发明中，所述基础油选用光亮油以及聚α-烯烃合成油配合使用，同时加入稠化剂。
优选的，所述光亮油在100℃的运动粘度为22～28mm2/s，更优选的，采用型号为120BS或者150BS的高黏度的光亮油。在本发明中，所述光亮油的添加量为65wt％～79wt％，优选为70wt％～75wt％，更优选为72wt％～74wt％。
轴瓦有时发烧时的极端温度可高达160℃左右，如果基础油的抗氧化性能不佳，则会积炭严重，影响对轴瓦的润滑，在本发明中，所述聚α-烯烃在100℃的运动粘度为18～22mm2/s。所述聚α-烯烃优选采用型号为PAO20或PAO40的聚α-烯烃合成油。所述聚α-烯烃的添加量为5wt％～10wt％，优选为6wt％～9wt％，更优选为7wt％～8wt％。
对于回转窑托轮轴瓦专用油来说，油品对低温流动性能没有太苛刻的要求，稠化剂的选择主要取决于单位黏度增加和剪切稳定性。在本发明中，所述稠化剂在100℃的运动粘度为4500～4900mm2/s。优选为PMA(聚甲基丙烯酸酯)、OCP(乙丙共聚物)和PIB(聚异丁烯)中的一种或多种。优选为PIB，更优选为型号为JX6240、JX6130或JX6240的稠化剂。其添加量为15wt％～25wt％，更优选为17wt％～23wt％，更优选为19wt％～21wt％。
本发明提供的回转窑托轮大瓦润滑油组合物还包括抗氧剂，所述抗氧剂的添加量为0.1wt％～5.0wt％，优选为0.5wt％～4.0wt％，更优选为1.0wt％～3.0wt％。在本发明中，所述抗氧剂优选为有机酚类抗氧剂、硫氮型复合物抗氧剂和有机硒化物抗氧剂中的一种或几种。
本发明提供的回转窑托轮大瓦润滑油组合物还包括金属钝化剂，所述金属钝化剂的添加量为0.01wt％～0.5wt％，优选为0.05wt％～0.4wt％，更优选为0.1wt％～0.3wt％。所述金属钝化剂优选为苯三唑衍生物类金属钝化剂、噻二唑衍生物金属钝化剂、有机胺类金属钝化剂中的一种或几种。
本发明提供的回转窑托轮大瓦润滑油组合物还包括腐蚀抑制剂，所述腐蚀抑制剂的添加量为0.1wt％～5.0wt％，优选为0.5wt％～4.0wt％，更优选为1.0wt％～3.0wt％。在本发明中，所述腐蚀抑制剂选自磺酸盐类腐蚀抑制剂、脂肪酸及其衍生化合物和复合磷酸酯类化合物中的一种或几种。
在本发明中，可以单独的添加上述单一的添加剂，例如抗氧剂、金属钝化剂以及腐蚀抑制剂，也可以添加成品的复合添加剂，即复合剂。所述复合剂具有成品油要求的多种功能，只要在指定性质的基础油中加入适当的剂量，就可以生产某一质量级别的油品。在本发明中，所述复合剂的添加量优选为0.5wt％～2wt％，更优选为0.8wt％～1.5wt％，最优选为1.0wt％～1.2wt％。
由于托轮球面瓦采用的是循环水强制冷却，在工作时，有大量水蒸气。停工时，水蒸气冷却，凝结在油面上。所以，优选在有水气状态下不会失效的复剂。在本发明中，所述复合剂优选型号为H317或LZ5060的复合剂，所述复合剂的添加量优选为0.5wt％～2wt％，更优选为0.8wt％～1.5wt％，最优选为1.0wt％～1.2wt％。
在本发明中，所述回转窑托轮大瓦润滑油组合物中还包括抗泡剂，所述抗泡剂的添加量为0.0005wt％～0.05wt％，优选为0.001wt％～0.045wt％，更优选为0.01wt％～0.03wt％。所述抗泡剂优选硅型抗泡剂或非硅型抗泡剂，更优选为硅型抗泡剂，最优选为型号为5000#的甲基硅油。
冬季温度降低，特别是北方地区，会达到零度以下，优选在所述回转窑托轮大瓦润滑油组合物中加入降凝剂，所述降凝剂的添加量优选为0.5wt％～1wt％，更优选为0.6wt％～0.9wt％，所述降凝剂优选采用型号为VX1-248的降凝剂。
本发明还提供了一种回转窑托轮大瓦润滑油组合物的制备方法，包括以下步骤：
将稠化剂、抗氧剂、金属钝化剂、腐蚀抑制剂和抗泡剂依次加入基础油聚α-烯烃和光亮油中，在真空条件下加热搅拌均匀，得到回转窑托轮大瓦用润滑油组合物。
当添加剂选用复合剂时，所述制备方法如下：
将复合剂和抗泡剂依次加入基础油聚α-烯烃、光亮油以及稠化剂形成的组合物中，在真空条件下加热搅拌均匀，得到回转窑托轮大瓦用润滑油组合物。
在本发明中，所述加热的温度优选为45℃～130℃，更优选为50℃～100℃。所述真空条件的真空度为52Pa～400Pa，更优选为60～380Pa。
本发明提供的回转窑托轮大瓦润滑油组合物具有很好的抗磨损、抗氧化、抗乳化、抗腐蚀、抗极压、耐高温等性能。而且具备较高的黏度系数指标，确保托轮轴瓦正常工作时能形成一定厚度的油膜，避免托轮轴与瓦之间直接接触摩擦，有效地保护托轮轴及衬瓦，能降低托轮轴瓦发热的概率。
为了进一步理解本发明，下面结合实施例对本发明提供的回转窑托轮大瓦润滑油组合物及其制备方法进行说明，本发明的保护范围不受以下实施例的限制。
实施例1～4
按照表2的配比进行回转窑托轮大瓦润滑油组合物的配置，具体方法如下：
将复合剂和抗泡剂依次加入基础油聚α-烯烃、光亮油以及稠化剂形成的混合物中，在100～350Pa的真空条件下45～65℃加热搅拌均匀，得到回转窑托轮大瓦用润滑油组合物。
将得到的润滑油组合物进行性能测定，结果见表3，表3为本发明实施例1～4以及对比例1的润滑油组合物的性能比较。
对比例1
选用洛阳正本的HF拖轮油作为对比例1。
表2回转窑托轮大瓦润滑油组合物配方
表3本发明实施例1～4以及对比例1的润滑油组合物的性能比较
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种回转窑托轮大瓦润滑油组合物，其特征在于，包括如下质量百分数的成分：
2.根据权利要求1所述的润滑油组合物，其特征在于，所述抗氧剂选自有机酚类抗氧剂、硫氮型复合物抗氧剂和有机硒化物抗氧剂中的一种或几种。
3.根据权利要求1所述的润滑油组合物，其特征在于，所述金属钝化剂选自苯三唑衍生物类金属钝化剂、噻二唑衍生物金属钝化剂、有机胺类金属钝化剂中的一种或几种。
4.根据权利要求1所述的润滑油组合物，其特征在于，所述腐蚀抑制剂选自磺酸盐类腐蚀抑制剂、脂肪酸及其衍生化合物和复合磷酸酯类化合物中的一种或几种。
5.根据权利要求1所述的润滑油组合物，其特征在于，所述抗泡剂选自硅型抗泡剂或非硅型抗泡剂。
6.根据权利要求1所述的润滑油组合物，其特征在于，所述稠化剂优选为PMA、OCP和PIB中的一种或多种。
7.根据权利要求1所述的润滑油组合物，其特征在于，所述聚α-烯烃在100℃的运动粘度为18～22mm2/s，所述光亮油在100℃的运动粘度为22～28mm2/s，所述稠化剂在100℃的运动粘度为4500～4900mm2/s。
8.一种回转窑托轮大瓦润滑油组合物的制备方法，其特征在于，包括以下步骤：
将稠化剂、抗氧剂、金属钝化剂、腐蚀抑制剂和抗泡剂依次加入基础油聚α-烯烃和光亮油中，在真空条件下加热搅拌均匀，得到回转窑托轮大瓦用润滑油组合物。
9.根据权利要求8所述的制备方法，其特征在于，所述加热的温度为45℃～130℃。
10.根据权利要求8所述的制备方法，其特征在于，所述真空条件的真空度为52Pa～400Pa。
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