CEMENT & AGGREGATESWHITMORE OVERVIEW AND

PRODUCTS

OVERVIEW1. The productivity challenge

2. Value proposition

3. Whitmore experience

4. The Solution

5. Whitmore Savings

6. Lubrication Principals

7. Target Applications

8. Case Studies

Cement companies continue to be challenged to improve productivity in operations:

• Reduction of downtime• Lost production• Lower labor costs• Less wear on assets• Parts replacement• Reduced capital expenditures

In demanding environments such as cement production the challenges are significant.

THE PRODUCTIVITY CHALLENGE

For more than 120 years, Whitmore has provided high performance lubrication and reliability products to industries around the world. We provide Ball Mill Lubrication products specifically engineered for Cement and Aggregate operations.

While most Ball Mills spray every 5 to 10 minutes for 30 seconds, our lubrication reduces spray cycles to 15 to 20 minutes reducing consumption by up to 75%.

Our team is dedicated to your large assets are well maintained to ensure they are more productive with less downtime, extended life and reduced total costs.

VALUE PROPOSITION

With over 120 years of experience, our company has provided lubrication solutions for some of the most demanding applications in the world.

WHITMORE EXPERIENCE

PANAMA CANALLubricated 48 miles (77km) of lock gates.

NASA Lubricated Crawler-transporter with payloads over 18,000,000 lbs (8,164,000 kg).

BIG MUSKIELubricated biggest dragline in the world, weighing over 13,500 tons and standing 22 stories tall.

For cement plants, Whitmore has exceptional products that help keep assets operating at peak performance. We offer a range of reliability products in three areas.

THE SOLUTION

High Performance Lubricants

Lubrication Management Systems

Desiccant Breathers

WHITMORE SAVINGS

Parts replacement

Inventory costs

Labor costs

Short termMaint. sol.

Enviro.Solutions

Energy costs Downtime

Partsreplacement Savings $$$

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Inventory costs

Labor costs

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LUBRICATION PRINCIPLES

REDUCED FRICTION

Reduced Wear

Reduced Temperature

- Extended Parts Life- Reduced Downtime- Increased Production- Reduced Energy Usage

- Extended Lube Cycles- Reduced Inventory- Reduced Clean-Up- Reduced Waste Disposal

PROFITIMPROVEMENT

TARGET APPLICATIONS

• Ball Mills And Kilns – Open Gear Lubricants• Kilns Trunnion Bearings – Gear Oils• Quarry Drills – Greases and Anti-Seizes• Quarry Shovels – Greases and Gear Oils• Quarry Haul Trucks – Bearing Greases and Gear Oils• Conveyor Systems – General Purpose Grease• Crushers – Greases and Gear Oils• Gearboxes - Desiccant Breathers• Reliability – Lubrication Management Systems

TARGET APPLICATIONS

BALL MILLS AND KILNSOPEN GEARS ENVIROLUBE® XE EXTREME • Wear Protection- extends gear life and reduces operating expenses. The need for

special running-in compounds is eliminated. • Gear Inspection - The brown coating is visible on the gear, but is transparent enough

to allow for gear inspection using a strobe light. • Easy Cleanup - The non-asphaltic base remains soft. It flows readily from the gear

guard and is easily removed. • Savings – The lower friction and better lubricated gears can help to reduce the cost

of Open gear lubricants up to 54%, can help to reach savings of 4% in energy and 50% reduction in operating temperatures.

ASTM # GRADE NAME Medium Heavy

D-445 Kinematic Viscosity cSt @ 100°C 1,100 1,100

D-2783 Four Ball EP Weld Point, kg Passes 800 Passes 800

D-4172 Four Ball Wear (standard settings) Scar Width, mm 0.51 0.45

Low Temperature Pumpability Lincoln Ventmeter @ 400 psi, °F (°C) 5 (-15) 20 (-7)

Coefficient of friction -- 0.0551

KILNS

BALL MILLS

ENVIROLUBE® XE EXTREME – FZG testGears showing FZG testing results. Both of the FZG gears have been used to test lubricants that passed 12 stages and then been through the 30-hour Extended Wear Test.

• The Gear on the right is more typical, as the Giving this test the net result is that Envirolube® XE Extreme helps to reduce wear in the machinery.

• Lower downtime.

This test often shows scuffing but in this case, the damage has been done by a form of wear called polishing. WHITMORE

The original crosshatch patternon the gear is still clearly visible.

COMPETITORThe original crosshatch has been partially worn off.

KILNSTIRESWBL-52

Water-based gel with super-fine synthetic graphite in suspension. To reduce wear, graphite is also applied to the contact area between Tire, Trunnions, and Slipper Pads. Cracking and kiln shutdowns will result if the tires are not lubricated.

• Excellent Wetting Ability - on metal surfaces.• Graphite Particle Size - 1-2 microns. Does not interfere with surface of material

being produced.• Economical – dilute 10:1 with water.• Stable Concentrate - minimal separation before dilution. After dilution, moderate

agitation is beneficial.• Easy Application - can be sprayed, brushed, or dipped.

KILNSTRUNNION BEARINGSDECATHLON™ PAG 1000• Decathlon™ PAG is specifically formulated for non water-cooled trunnion

bearings. It is particularly useful in extreme temperature conditions. Kiln trunnion bearings are subjected to extremely high load and fluctuating temperatures. They challenge both equipment designers and lubricant chemists. Decathlon™ PAG is designed to protect this expensive equipment.

PARAGON™ ISO 680• Paragon™ is specifically formulated for water-cooled trunnion bearings. It is

particularly useful in extreme temperature conditions. Kiln trunnion bearings are subjected to extremely high load and fluctuating temperatures. They challenge both equipment designers and lubricant chemists. Decathlon™ PAG is designed to protect this expensive equipment.

QUARRY SHOVELSOPEN GEARS, HOUSE ROLLERS, DIPPER STICKSURSTIK ® 800 • Is an aluminum complex high performance extreme pressure lubricant designed for use

on open gears and other highly loaded components under the most punishing conditions and hostile environments!

GEARMATE ® 1000 ICT • Whitmore's toughest lithium based grease and specially formulated for use on open

gears and other severe applications on draglines, mining shovels, ball mills and kilns where automatic lubrication is required, provides superior load-carrying ability and wear resistance while remaining environmentally friendly. Gearmate ® extends the lubrication frequency up to 30% using less lubricant giving a protecting barrier between metal to metal improving the gears life up to 50%.

QUARRY SHOVELSENCLOSED GEARBOXESPARAGON™ GOLD • High performance extreme pressure gear oil, use where conventional gear oils fail

extending the gears life up to 35%, where long component life is essential or where long intervals between oil changes are unavoidable.

SHOVEL BEARINGSCALIBER™ M • Lithium complex grease containing molybdenum disulfide.

MATRIX ®

• Industry proven high performance calcium sulfonate complex grease, highly recommended for difficult applications such as extreme pressure, water, heat, or chemical attack. Extending the lubrication frequency using less grease protecting from premature wear of components. HYDRAULIC

QUARRY HAUL TRUCKSWHEEL BEARINGS AND CHASSIS LUBRICATION

CALIBER™ M • Is a series of extreme pressure lithium complex greases that contain molybdenum. The

series is designed primarily for use in draglines, shovels, drills, earthmoving equipmentand other heavy-duty rolling stock applications. Caliber™ M has the extreme pressurecapability to prevent wear in heavily loaded bushings and bearings. Caliber™ 3Mcontains 3% solid lubricants and 5M contains 5%.

MATRIX ®

• Calcium Sulfonate complex grease.

QUARRY DRILLSBEARINGS, PINS, AND CHASSIS LUBRICATIONKOPPER PLATE• High performance anti-seize and hydraulic hammer lubricant containing micro-size

copper flakes and graphite. Kopper Plate contains a patented EP additive to provide extra protection no other compound can offer, providing a shield against metal-to-metal contact, thus preventing seizure and corrosion.

WHEEL BEARINGS, PINS, AND CHASSIS LUBRICATIONCALIBER™ M • Lithium complex grease containing molybdenum disulfide.

MATRIX ®

• Calcium Sulfonate complex grease.

CONVEYORSBEARINGS

CALIBER™ M • Lithium complex grease containing molybdenum disulfide.

MATRIX ®

• Calcium Sulfonate complex grease.

CRUSHERSBEARINGS

MATRIX ®

• Calcium Sulfonate complex grease.

CALIBER™ M • Lithium complex grease containing molybdenum disulfide.

ENCLOSED GEARS

PARAGON™ GOLD • High performance extreme pressure gear oil.

BACKING COMPOUND CRUSH-BAC™•2-part epoxy backing compound that maximizes efficiency, extends equipment life, eliminates wear liner gaps and remediates alignment errors.

DESICCANT BREATHERS Air Sentry ®

Air Sentry® set the industry standard for contamination control particulate and moisture contamination. This innovative breather line is the first to integrate check valve technology and desiccant/filter cartridges, significantly reducing maintenance costs.

THE GOLD STANDARD IN CONTAMINATION CONTROL

FLUID PROTECTION

Catalog

OILSAFE ®

Think how much better your systems would work with a Lubrication Management System like this.

With modular bulk storage and built-in filtration to prevent contamination, precise-pour transfer containers to eliminate spills and slowdowns, integrated color-coding and customized labeling to avoid mix-ups, your facility is organized and safe every step of the way.

LUBRICATION MANAGEMENT MADE EASY.

LUBRICATION MANAGEMENT SYSTEMS

• Filthy• Disorganized• Unsafe• Wasteful

DESTRUCTIVE

• Clean• Organized• Safe• Efficient

RELIABLECatalog

CASE STUDIES

PARAGON ®

A Cement manufacturing company located in the Southwestern United States utilizing ball mills driven by Falk Gear Reducers.

PROBLEMS• Falk reducers were operating at temperatures high enough to promote severe oxidation. • The oxidation was causing carbonaceous build-up on the inside walls of the units. • The oil oxidized at such a rate that the maintenance department would require more frequent change-out of the

oil. • The oil being used was a major oil company brand.

SOLUTION

The Whitmore distributor used a non-foaming detergent additive to remove the buildup and also recommended PARAGON® enclosed gear oil. In addition, a routine oil analysis-sampling program was established for the units.

Number of oil change intervals were immediately cut in half. The average operating temperature was reduced by 30~F.

Cement Plant - USA

AngloGold – South AfricaENVIROLUBE® XE EXTREME - Open Gear Lubricant

AngloGold – South AfricaENVIROLUBE® XE EXTREME - Open Gear Lubricant

OGLConsumption

Saving$ 75,759

Hazardous Waste Disposal Saving

81 Drums @ $ 14,569

Production Cost Saving

@68c/kWh$ 526,673

$ 659,183

Energy Saving

4%

Lubricant Cost / Year

$ 185, 756Additional Spend

12L Tax Rebate @ 95c/kWh$735,740

Slime Ingress Downtime at 2/Year/mill $571,837

EXPENSEINCOME

TOTAL SAVINGS

Thank You