Advantages of SMB:
- Kettles are not required. However, addition of kettles imparts flexibility to the blending process.
- Large production capacity batch blending.
- The output is transferred to storage tanks, equipped with mixers for final homogenization after charging all components into the tank.
- Mass flow measurement ensures accurate raw material control for on target specifications.
- Efficient for any blend size – limited only by the size of destination tank
- Minimum cross contamination ensures finished product integrity.
- Accuracy is not limited by batch size
- Minimum contamination, pigging and flushing
There are 2 VI solubilizing kettles to ensure adequate VII availability at all times. Heating is provided for the VII kettles, tanks and blending systems by a BONO hot oil system.
To efficiently use the SMB, the plant is also equipped with 2 nos. drum heating ovens and 1 nos. DDU (Drum Decanting Unit). There are 2 nos. additive premixing tanks and 3 nos. finishing agitator kettles along-with 1 buffer kettle. It also has 14 nos. intermediate holding tanks to store finished products.
The manufacturing facility has 1 nos. Stratco contactor, 1 no. pressurized autoclave, 5 nos. finishing kettles and 1 extra finishing kettle for black greases. It is supplemented by 2 sets of deaerators and colloid mills. Heating is provided by 2 nos. BONO heaters and cooling through 1 no. chiller.
The Base Oil tanks are common with the Lubricant Plant. There are 2 nos. drum filling lines, 1 nos. metal filling line plus 1 no. small plastic pack filling line giving the plant an ability to fill any desired packaging for its client base.
The Grease plant can manufacture Lithium, Lithium-Calcium, Calcium and Clay based greases including variants i.e. EP, Complex, Moly/Graphite infused.
After manufacturing the product is finished in deaerators and colloid mill prior to filling through micron filters. The plant is capable of filling various packs like 400 gm cartridge, ½ Kg, 1 Kg, 3 Kg, 5 Kg, 15 Kg and 175/180/182 Kg.
The high shear rate gives a more uniform dispersion of thickener into the oil, resulting in a product which yields more grease per unit weight of thickener.
REDUCED PRODUCTION TIME
High internal circulation rate and large heat transfer surface (triple that of a conventional kettle) allow rapid heating and saponification. This cuts processing time in half.
Enhanced heat transfer and mixing characteristics maximize process efficiency and result in utility savings for both electrical and heating fuel.
Controlled pressure reaction conditions inhibit undesirable “foaming” and result in a more complete reaction of thickener components.
All standard calcium, sodium, lithium, compound and complex soap greases including polyurea, can be produced in a single Contactor reactor. Cleaning between batches of dissimilar greases is simple and very effective.
CONSISTENCY AND UNIFORMITY
High heat transfer coefficient and high internal circulation results in tight time-temperature control and highly uniform dispersion of thickeners, allowing a high level of repeatability and consistent product quality between batches..
Savings of up to 17% of manufacturing costs are typical if used effectively.