1591 Big Shanty Dr.

Kennesaw, GA 30144
Tele: 770-424-4093 Fax: 770-426-4167 Toll Free: 877-402-1670
Email: sales@easybarlube.com website: www.easybarlube.com

MAINTENANCEISSUESFORROTARYKILNS

KILN TIRE SYSTEM: REQUIRES ACCURATE ALIGNMENT OF SHELL AND TIRE.

Tire Bore (Inside Diameter):

As the Kiln Shell rotates inside the tire, there are rolling and sliding frictions on the mating
surfaces of the Chair Pads and the inside diameter (ID) of the Kiln Tire.
EASY BAR LUBRICATION IS CRITICAL TO MINIMIZE ANY SCORING OR GOUGING OF
THE TIRE BORE.

Wear Pads:

When too much wear pad wear has taken place, the shell alignment and support system is
compromised. The steel shell will flatten at the top of the rotation resulting in ovality. As this
condition continues the results may become catastrophic, resulting in damage or loss of the
insulating refractory inside the kiln shell. This will result in hot spots on the shell, prompting Kiln
shut down with loss of production and costly repair.
EASY BAR LUBRICATION IS CRITICAL TO MINIMIZE THE WEAR OF THE WEAR PADS.

Stop Blocks:

Stop Blocks limit the movement of the tire as it travels back and forth on the trunnion rollers. As
the tire rubs against the stop blocks wear occurs. A tire that is thrusting against the stop blocks
will wear and cause damage. Without attention, the stop blocks will break and/or require
replacing.
EASY BAR LUBRICATION IS CRITICAL TO MINIMIZE THE WEAR OF THE STOP BLOCKS.

Weld Fractures:

Weld Fractures occur due to friction of the tire I.D and the surface of the chair pads. Wear
Fractures are detrimental to the chair pad system and will need to be repaired. Lubricants with
poor lubricating qualities will not protect against weld fractures.
EASY BAR LUBRICATION IS CRITICAL TO MINIMIZE WELD FRACTURES.

Creep:

Creep is the difference in distance travelled between the shell and the tire. Creep increases as
wear occurs. Creep of greater than 25mm require immediate attention.
EASY BAR LUBRICATION IS CRITICAL TO MAINTAIN CREEP AND MINIMIZE CHANGES
OR VARIATIONS.

THIS EQUIPMENT DEMANDS A LUBRICANT THAT (1) FUNCTIONS AT TEMPERATURES GREATER

THAN 750 DEGREES FAHRENHEIT (2) DELIVERS THE OPTIMUM AMOUNT OF WEAR REDUCING SOLIDS
(3) LEAVES NO TACKY RESIDUE BEHIND AND (4) IS 100% LUBRICANT COMPOSITION (NO FILLERS.
NO WAX. NO WASTE).

EASY BAR IS THE ONLY LUBRICANT BAR THAT MEETS THESE REQUIREMENTS
WHILE PROLONGING THE LIFE OF THESE KILN COMPONENTS!

EASYBARRotaryKilnTireBoreLubricant
Perfect for Cement, Lime, Pulp & Paper,
Mineral and Chemical Industries
Easy Bar is utilized by all major kiln manufacturers including
Andritz, Metso, Polysius, Humbolt Wedag, Fuller FLSmidth
Easy Bar is a patented formula of premium grade lubricants encased within a
solid organic carrying agent. When placed between the tire and the kiln shell, the
carrying agent melts and releases the lubricants. The rotation of the kiln
distributes the lubricants over the filler bars and inside the tire bore.

100% Lubricant Composition: Every ounce of Easy Bar is

utilized for maximum lubrication. No fillers. No waxes. No waste.
Extend Kiln Life by 50%. Protects the kiln and stop blocks while
eliminating breakage of filler bar welds.
Save Money on Maintenance! Reduces the wear that results from
scoring of the inside bore of riding ring.
No Flame Ups! Auto-ignition point +1000F and 538C.
Highest Quality for Fewer Applications: Highest graphite content
of any other tire bore lubricant.
Environmentally Safe! Easy Bar completely evaporates leaving
no sticky residue, no waste and no harmful chemicals traces.
Quick and Simple! No mixing or preparation time needed.
Easy To Apply! Easy Bar installs in one kiln revolution
which increases employee productivity while reducing their
exposure to hazardous environments.
Over 15 Years of Proven Field-Performance! Make sure your
lube bars say Easy Bar Kiln Tire Lube to ensure optimal
performance.

EASYBAR
CrescentKTL100RotaryKilnLubricant
PRODUCT DESCRIPTION:
Crescent KTL-100 Rotary Kiln Lube consists of a special high auto-ignition point
synthetic thickener with organic and metallic solid film-forming components.
Crescent KTL-100 Rotary Kiln Lube deposits its solid film forming components into
the surface of the filler bars and ring bore to assure maximum protection from cold
welding or galling in an easy to apply form for this severe high temperature
application.
APPLICATIONS:
This product is specifically designed for application on the Stop Block, Riding Ring
and Filler Bars of Horizontal Calciners, Rotary Kilns and Dryers. Crescent KTL-100
is easily inserted between the filler bars where it melts and releases the high
temperature solid lubricants. The product's high solids content fills the surface
imperfections resulting in a smoother bore surface, lower friction and less wear.
The improved lubrication between filler bars and riding rings reduces weld fractures
at filler bars and kiln shell interface, contributing to extend shell and refractory
service.

TYPICAL PROPERTIES
Solids Content
Melting Point
Auto-Ignition Point
Texture
Color

40% Typical
115-125F
>1,000F
Smooth Hard
Bronze

TEST PARAMETERS
Cone Penetration for Base @ 77F
Corrosion 24 hrs @212F
Steel
Rust Inhibitor
Flash Point (COC)
Viscosity @ 100C

13 Max
Pass
Yes
400F
5.4 cSt

These are typical specifications and are subject to manufacturing tolerances.

EasyBarTestimonials
Titan - Maintenance Manager
"Your product has perfect fit, it is much more resistant to heat and fire than the
previous product that they were using, and does a really good job (as it seems
from Monday that they first applied it). Moreover, it has a nice and well-shaped
appearance and doesn't leave dirt on hands as the previous one. Generally, the
quality of the product is obvious in many ways and very satisfying in its
lubrication cause."

Lafarge North America - Improvement Engineer

"This is an excellent opportunity to see the bars in action. I will work to see if we
can have these entered into the budget for 2010 for a couple of tires on each kiln.
With the prospect of building a new kiln in a couple years we are VERY
interested in using correct lubrication for the new installation and building the
habit and culture of not using kerosene as a mixing agent (current practice). We
are very impressed with the product and were able to use it on all piers. (Many of
our piers have different pad / retaining ring configurations)."

R&D Manager at ZMP Industry Machine Engineering

"I can recommend this product with confidence. This is an indispensable tool for
modern maintenance of the rotary kilns. Safe and easy to use, if you want to
extend life of your kiln's tyres try it."

Managing Partner - Mareche Distribucion, S.L.

"Easy Bar is the best melting bar available in the market. Easy Bar has changed
the way Rotary Kilns Tyres are lubricated. The highest performance: safe, quick,
environmentally safe, and simple to help reduce maintenance cost."

Graymont Lime Engineer

"I received the lube bars this morning and have placed them in our #4 kiln. At first
glance, they appear to be a good quality product and I was glad to see they didnt
flame up on our firing end of the kiln. I think this is something that will work very
well in our application."

Carbo Ceramics Engineer

"They have allowed our kiln and coolers to float freely on the tires which is a
great improvement due to the fact that the tires were binding on axial float in the
past, likewise, I havent witnessed an acceleration in radial creep"

CEMEX Plant Engineer

"We've had a good experience with the Easy Bars. Our oiler likes them since
they are easy to carry and place in the kiln tire."

EASYBARvs.OTHERMETHODS
Easy Bar

Melting
Lube Bars

Water + Graphite
Spray

Percent (%) Lubricant

Composition

100%

10-15%

1-5%

Graphite Composition

30-35%

1-9%

1-5%

Mixing / Prep Time Required

NONE

NONE

YES

Auto-Ignition Point
Blow-Back Hazard or
Fire Hazard
Tacky or Sticky Residue
After Application

+1000 degrees F ~500-750 degrees F ~500 degrees F

+ 538 Celsius
~ 260-399 Celsius
~ 260 Celsius
NONE

YES

YES

NONE

YES

YES

Applications per Week

One

Multiple

Every Other Day

Time Required per

Application per Tire

< 1 Minute

>2+ Minutes

20-30 Minutes

Bars Needed per Week (avg)

2 to 4

8 to 16

NA

Disadvantages of other melting lube bars:

Wax and Non-Lubricant Binders:

Unlike Easy Bar which is 100% lubricant, other melting lube bars consist
of 40-60% wax and non-lubricants. These components create a tacky
grease which will:
o Build up a sticky residue on the tires.
o Collect dirt and debris which will cause additional wear.

Low Auto-Ignition Point Flame-Ups

Other melting lube bars have a much lower auto-ignition point, unlike
Easy Bar whose auto-ignition point is above 1000F or 536C

Other lube bars from time to time auto-ignite which is an enormous safety
hazard for workers and is detrimental to the tire and wear pads.

CHOOSINGTHEBESTEASYBAR

PRODUCT CODES

PRODUCT DIMENSIONS

25-A/50

CASE OF 50 EASY BARS

12" long , 5/8th" thick , 2.5" wide

304.8 mm long , 15.9 mm thick , 63.5 mm wide

25-C/50

CASE OF 50 EASY BARS

12" long, 3/8th" thick, 2.5" wide

304.8 mm long , 9.5 mm thick , 63.5 mm wide

25-F/50

CASE OF 50 EASY BARS

10" long, 5/8th" thick, 2.0" wide

254 mm long , 15.9 mm thick , 50.4 mm wide

Based on the measurements of the Filler Bar Thickness, the Spacing Between
Wear Pad or Filler Bars and the Tire Face Width, the most appropriate Easy Bar
can be determined for your superior rotary kiln tire lubrication.
Space between Inside Tire Bore
and Outside Kiln Shell
(Filler Bar Thickness)

Tire Face Width

Spacing Between Wear Pad or

Filler Bars

WhyEASYBARforRotaryKilnTires?
1. Cost savings are realized immediately in extending replacement part life
greater than 50% and higher while reducing maintenance costs. Filler
Bars & Wear Pads last significantly longer.
2. Labor costs are lowered by reducing lubricant application time down to
less than 1 minute a week for each tire.
3. Longer equipment life means savings to repair filler bar weld fractures and
replacement of filler bars. Typically $20,000 to $60,000 per tire section.
4. Easy Bar prevents against unscheduled downtime which ultimately can
shut down a plant and halt production.
5. 100% Lubricant for 100% Effectiveness!
No Flame-ups, No Messy Residues, No Fillers, No Waste.
6. Applies easily by hand or with an EZ-Reacher Pro applicator.