Calcium Sulfonate Complex Grease Deployment for Heavy Mining Crushers & Slurry Systems
Supply Bottlenecks & Exposure
Primary jaw crushers, vibrating sizing screens, and wet slurry pump bearings were failing prematurely due to constant water spray and heavy shock loading (>550 kg). The previously used standard lithium complex grease suffered severe water washout (<48 hours) and oil bleed-out, resulting in recurring bearing overheating, unplanned mill shutdowns, and excessive grease re-lubrication consumption.
Direct Sourcing & Bonded Buffer Staging
Zabion engineered and supplied heavy-duty Calcium Sulfonate Complex Grease (NLGI 2, 460 cSt base oil viscosity, >620 kg Four-Ball Weld Load, drop point >300°C). Unlike conventional lithium soap thickeners, the calcium sulfonate complex matrix delivers inherent extreme-pressure load capacity, superior rust inhibition, and near-zero water washout (<1.5% at 79°C). Zabion maintained local buffer stocks in 180 kg steel drums at Takoradi for guaranteed 48-hour site replenishment.
Production Impact
Eliminated grease washout across all wet screens and slurry pumps. Extended bearing regreasing intervals from 7 days to 28 days, reduced operating bearing temperatures by 11°C under peak loads, and reduced annual bearing replacement costs by 65% across the crushing and milling circuits.
"Zabion’s calcium sulfonate complex grease solved our water washout problems overnight. Our crusher and vibrating screen bearings now run cooler and last through the rainy season without failure."