SHELL RELIABILITY ENHANCEMENT SOLUTIONS FOR SUGAR INDUSTRY Junaid

SHELL RELIABILITY ENHANCEMENT SOLUTIONS FOR SUGAR INDUSTRY Junaid Khan- Technical Manager Central PSSTSeminar Karachi, October 1 st-2 nd 2018

AGENDA Copyright of Shell Lubricants 1 Shell Technology Leadership 2 Lubrication Requirements of Sugar Industry 3 Shell Product Range for Sugar Industry 4 Premium Product: Gadus S 2 U 1000 5 Collaboration with Shahtaj Sugar Mill & Al Moiz DI Khan 6 Shell Technical Support and Services

NUMBER ONE GLOBAL LUBRICANTS SUPPLIER FOR CONSECUTIVE 11 YEARS* WE’VE BEEN THE FIRST TO INTRODUCE NUMEROUS BREAKTHROUGH TECHNOLOGIES TO THE MARKET: n Invented a lithium 12 hydroxystearate grease, making up the largest share of the world’s grease volumes from all manufacturers up to today. n Commercialised GTL base oils, through: n the building of Pearl GTL in Qatar, the world’s largest plant to turn natural gas into cleaner burning fuels and lubricants. n the introduction of Pure. Plus Technology in our Shell Helix Ultra range. n the launch of a new generation transformer oil – Shell Diala S 4 ZX-I that offers significant performance advantages over conventional mineral-based products * based on Kline Research n Formulated and commercialised a Low-SAPS extended drain Heavy Duty Diesel Engine Oil. n Developed an energy efficient hydraulic oil. n Actively promoted cross-industry co-engineering as the fastest route towards optimising fuel efficiency, in part through our on-going collaboration with numerous OEMs. n One of first companies to invest in R&D for advanced biofuels.

“ We use our world class lubricants technology to offer our customers innovative solutions designed to meet their most demanding challenges. Going forward, we will maintain our focus on technology leadership so we can continue to meet and exceed our customer’s expectations. Mark Gainsborough, Executive Vice President - Global Commercial n Investment - US$ 1. 3 billion on research & technology. n Top Technologies - 158 patent series for lubricants, base oils and greases. n Top Scientists - More than 500 Research & Development scientists ”

LUBRICANT REQUIREMENTS OF A SUGAR PLANT Applications Lubricant Requirements Lubricants for Open Gears & Mill Bearings Turbine Oils Gear Oils Industrial Hydraulic Oils Greases Geared coupling Turbineo r Electric motor. Turbine Oils Primary reduction Secondary reduction Enclosed gearbox Industrial Gear Oils ~65 -70% ~10 -15% ~5 -10% ~5 -8% ~1% Tertiary reduction Open gears Open Gear Lubricant (Bituminous Oils currently Used) Lubrication solutions for win Tandem open gears in small baths Bituminous Oil Sugar cane crushing rolls plain bearings Bituminous Oils (currently used)

COMPREHENSIVE LUBRICANT PORTFOLIO FOR SUGAR PLANTS

GADUS S 1 OG RANGE FOR MILL BEARING APPLICATION Produced by using asphalt only from Shell approved sources, virgin base oils and proprietary additive technology. Manufactured at Shell Lubricating Oil Blending Plantunder stringent supervision utilizing world-class manufacturing practices and quality control. Especially formulated sugar mill lubricant purpose-designed for multiple applications i. e. Open Gears and Mill Bearings. Only sugar mill lubricant in the country which contains anti-wear and anti-oxidant technology to minimize wear in sugar mill bearings while preventing formation of acidic products which lead to corrosion.

KEY PRODUCT: SHELL GADUS S 2 U 1000 D 2 One of our key greases for Sugar Mill bearing lubrication with Bentonite Clay thickener and Mo. S 2 as a solid lubricant. Main Features are: Central lubrication system High Temperatures Low Speed Equipment Very high load carrying capacity (Resistance against shock loading) High base oil viscosity (Superior lubrication of bearing surfaces) Contains solid lubricant Mo. S 2 (Very low co-efficient of friction). Good corrosion protection (Superior protection to surfaces against degradation) Excellent pumpability due to clay based thickener (Easy to reach lubrication points) Can operate up to 200 o. C (Good thermal stability) Good water washout (Protection against water ingress)

SHELL GADUS S 2 U - (PROMINENT CUSTOMERS) — Pakistan Shahtaj Sugar Mill, Al Moiz DI Khan. — Philippines Universal Robina Corporation – Carsumco, Central Azucareta De Tarlac, Davao Sugar Central Company, Busco Sugar Milling Co. , Cotabato Sugar Central Company, Universal Robina Corporation – URSUMCO, SONEDCO, Hawaiian – Phillipines Company, Victorias Milling Company. — India Vishwaraj Sugars, Satish Sugars, EID Parry, Shahu Sakhar, Shiv Shakti Sugars, Ryatar sahakar sakkar, GEM sugar, Shree Renuka Sugar, Bilage Sugar — Australia & Thailand Macknade Sugar Mill, Victoria Sugar Mill, Invicta Sugar Mill, Pioneer Sugar Mill, Kalamia Sugar Mill, Inkerman Sugar Mill, Proserpine Sugar Mill, Plane Creek Sugar Mill, Thai Sugar Mills, Thai Multiplication Sugar, Mitr Phol Sugar, Mitr Kasetr Sugar Mill etc.

GADUS S 2 U PERFORMANCE DEMONSTRATION – IN A GLIMPSE Copyright of Shell International

GADUS S 2 U 1000 D 2 – SUGAR MILL LUBRICATION (OVERVIEW) Background Info Country Pakistan Sector / Application / Product Sugar / Sugar Cane crushing mill bearings / Gadus S 2 U 1000 D 2 For further information please contact Faisal Azhar, Junaid Khan What was the Situation & Challenge? Customer Name: Shahtaj Sugar Mills & Al Moiz DI Khan. • • • High lubricant consumption of Gadus S 1 O G. High temperatures of mill shaft & bearings during operation. Reduced life of mill bearings and shaft. High handling and storage costs. Excessive waste product resulting in fresh water contamination and environmental implications. Copyright of Shell International The Solution implemented A comprehensive lube audit of the sugar mills was carried out. Details of oil/grease supply system and mill design were analyzed. Average daily consumption of grease was calculated using Graco-Trabon engineering calculations. Gadus S 2 U 1000 D 2 product performance demonstration was initiated. Outcome / Benefit / Learning • Reduction in lubricant consumption approx. 5 to 7 times. • Reduced storage, handling and dispensing resulting in labor cost savings. • 73 % reduction in Energy Consumption (Operating time of Grease transfer pump reduced from 24 hours to 6 hours and 40 minutes). • Significant reduction in water usage for maintaining bearing temperatures. • Elimination of lubricant contaminating process water due to adhesive properties of grease. • Less waste product resulting in more environment friendly conditions.

JOURNAL BEARING TEMPERATURE PROFILES SHAHTAJ

JOURNAL BEARING TEMPERATURE PROFILE AL MOIZ : MILL HOUSE # 1 Top Drive Top Off Discharge Off Feed Drive Feed Off 26. 1 21. 4 27 21. 2 27. 4 23. 3 28. 8 24. 1 34. 2 26. 4 23. 3 29. 3 28. 8 40. 6 53. 1 79. 9 Gadus OG 100 (Before) Gadus S 2 U 1000 D 2 (After) Force Feeder Drive Off

PERFORMANCE OUTCOMES: JOURNAL BEARING CONDITION Copyright of Shell Lubricants 14

SHELL TECHNICAL SERVICES Expert technical advice and value improvement Lubrication surveys and product recommendations Oil and equipment condition monitoring Onsite Videoscopy services Lubrication training Copyright of Shell Lubricants Lubrication solutions for wind turbines 14 September 2017 15