While rising energy costs affect all manufacturers, they can be incredibly daunting if you are in energy-intensive sectors such as steel, cement, plastic, and paper production. According to ExxonMobil’s latest ‘Outlook for Energy’ report, the industrial sector currently represents 50% of global energy use. It also predicts that by 2050 there will be a 15% increase in industrial energy demand.

These same sectors also generate Green House Gas (GHG) emissions that are hard to reduce with conventional means. If you are operating in heavy industrial sectors, you will need to consider several options to reduce GHG emissions to help meet the United Nations Intergovernmental Panel on Climate Change’s (IPCC) Lower 2°C target.

The “first fuel” of the energy transition

According to the International Energy Agency (IEA), energy efficiency is the “first fuel” in the clean energy transition as it provides some of the fastest and most cost-effective reductions in CO2 emissions.

To stay competitive and advance sustainability ambitions, industries need to make a substantial and unparalleled transition towards more efficient industrial processes. A key component of this transition could be your choice of lubricants. This simple ingredient can have a significant impact on your overall energy efficiency, equipment lifespan, and greenhouse gas emissions.

Lubricants: A small yet powerful solution

Our experts will work with you to identify the best lubricant solutions for your needs and help ensure a smooth transition towards a lower-emission future.

For example, our Mobil DTE 10 Excel™ Series of hydraulic oils can improve energy efficiency. These lubricants were found to increase hydraulic pump efficiency by up to 6% in a controlled laboratory test compared with Mobil standard hydraulic fluids when operating in standard hydraulic applications.*

For some applications, a synthetic lubricant formulation may be beneficial. Synthetic lubricants can offer high performance under extreme temperatures and pressures due to their high viscosity index, which helps retain viscosity when temperatures change. An oil with a more stable viscosity over the operating temperature range of the equipment helps ensure greater efficiency, which lowers energy consumption.*

Another key benefit of synthetic lubricants is their lower traction coefficient. Their uniform molecular size creates lower internal fluid friction, which leads to lower temperatures and higher viscosities in the contact zone, resulting in thicker Elastohyrdodynamic (ELH) films and improved mechanical efficiency. This, in turn, reduces energy consumption. Their chemical structure helps maintain fluid film protection at high temperatures, whilst their wax-free formulation helps ensure greater fluidity at low temperatures, which can minimise energy loss, especially at start-up.*

*Results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.

Demonstrating cross-sector success

At Mobil, we witness the benefits of the correct lubricant solutions, day in, day out. And we’ve plenty of customer case studies to prove the efficacy of our Mobil-branded oils and greases. These are especially effective when combined with Mobil Serv℠ Lubricant Analysis, our high-performance oil analysis service.

For instance, a Turkish ceramics mill tested Mobil SHC Gear™ 320 synthetic gear oil to reduce lubricant-related failures in selected gearboxes. This resulted in a total cessation of this issue and an overall reduction in energy consumption of 2.3%. The total annual saving was $304,000.*

*The proof of performance presented above is based on the experience of a single customer. Actual results can vary.

A German tissue paper manufacturer had a dryer roll suffering from roller bearing damage due to strong vibrations from its shaft-mounted Flender gearbox. ExxonMobil Field Engineers recommended switching to Mobil SHC™ Gear 220 synthetic gear oil, which halted vibration-related bearing failures and reduced maintenance costs. The customer also reported a 7% energy savingfrom using synthetic gear oil. The total saving was €138,000.*

*The proof of performance presented above is based on the experience of a single customer. Actual results can vary.

Top tips for supercharging energy efficiency

By following the top tips below and investing in suitable oils and lubricants, you can help reduce your energy bills by as much as 30% across your operations:

• Always turn off motors and services that aren’t contributing to production
• Peripherals and services can account for 25% of a plant’s energy use so require effective management
• Use isolating material to avoid thermal energy dispersion in your operations
• More efficient lighting and insulation can pay dividends Look beyond the hardware – engaging staff in energy saving is critical
• You can also gain valuable insights into energy efficiency with a comprehensive study led by one of our Mobil Serv™ expert engineers. Our engineers can guide you through the following steps: Determine objectives, expectations, focus and scope
• Coordinate and oversee pre-test, test and post-test work
• Involve and coordinate with appropriate plant personnel
• Develop detailed test protocol
• Respect all safety and labour rules and ensure complete confidentiality
• Document results and recommendations

It’s time to take action

By selecting high-performance lubricants, you can significantly reduce energy loss, which can help lower energy bills and associated greenhouse gas emissions.* Additionally, optimising equipment performance with these lubricants can lead to reduced maintenance costs and improved reliability, ultimately resulting in a better bottom line for your operation. With the guidance provided in this article, you're well-equipped to begin implementing energy-saving measures*. Contact your local Mobil representative today to get started.

*Results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.