EverZinc Belgium (Zolder)

EverZinc Belgium (Zolder) (formerly SA Umicore Zinc Alloying) is the world’s largest recycler of sintered zinc oxide. Their plant in Heusden-Zolder, Belgium, has the capacity to process up to 30,000 tons of sintered zinc oxide, which is used in their sister plant in Eijsden, the Netherlands, for the production of high-purity zinc oxide for animal feed products.

The sintering process requires processing residues in a rotary calcining oven at temperatures of 500°C. A lift moves 80 kg trays of residue through the oven. The pivot shaft is recessed into the floor, causing it to rotate in the sintered ashes.
The bronze bushings supporting the lift shafts had to be replaced every six months due to insufficient lubrication and excessive wear. The costs of parts and downtime were a major concern.
These bushings were lubricated with food-grade grease from various suppliers (SKF, Texaco, Promanté), but due to the high shaft temperatures (500°C, with bearing contact temperatures reaching up to 200°C), these greases evaporated quickly. As a result, the bronze bushings had to be replaced approximately every six months.

SWEPCO Field Service Representative Frank Kleijn suggested switching to SWEPCO 115 Food Machinery Grease due to its superior thermal stability and excellent wear control.

• After switching to SWEPCO, the following results were reported:
  The bronze bushings were replaced preventively after 5.5 years, as the chain needed replacement, making it convenient to replace the bushings at the same time.
• Wear was reduced by more than 90%. The exact reduction was not determined since they were replaced preventively.
• Grease consumption decreased by over 70%.
• Oxidized grease in the open space around the bushings is no longer an issue.
• Annual savings of more than €2,500 in parts and downtime.
• Since 2017, they have also been using SWEPCO 222 Sprayable EP Open Gear Lube to achieve better protection for open gears. The initial results have been overwhelmingly positive.

“Over the years, we have tested various greases for this application, but the results were always more or less the same. Since we started using SWEPCO 115 Food Machinery Grease, wear has been reduced by at least 90% (previously six months of wear compared to a minimum of 5.5 years now). Grease consumption has decreased significantly, as has downtime due to maintenance work. All of this has greatly contributed to the desired reduction in maintenance costs and the reliability of the installation. We are very satisfied and more than positively surprised by SWEPCO 115.” – Mr. R. Belemans, Maintenance Technician, Work Planner, SA Umicore Zinc Alloying Heusden-Zolder.

EverZinc Belgium (Zolder) has been using SWEPCO lubricants since 2012.