Wind Turbine Gear Oil Market: Overview
Wind turbines have been used in one form or another since the
last 7,000 years. The primary function of the gear oil for rolling bearings in
a wind turbine is to prevent or reduce contact between rolling and sliding
surfaces. As a result, friction and wear are kept to a low level. Gear oil has
the following functions: corrosion protection, heat dissipation from the
bearing, flushing out of wear particles and contaminants (recirculating oil
lubrication with filtration of the oil), and support for the sealing effect of
bearing seals (grease collar and pneumatic oil lubrication). Surfaces moving
relative to each other are separated completely or almost completely by a
lubricant film. This film is called gear oil.
Hydrodynamic lubrication gear oil is preferred for wind turbines
with power rating of 0.75 MW to 2.5 MW. This lubricant is conveyed into the
narrowing lubrication gap by the motion of the contact surfaces relative to
each other. Due to the extremely high pressure in the immediate contact zone,
the lubricant here has extremely high viscosity for a short period and
facilitates separation of the contact surfaces.
Development of advanced wind turbines in the 4 MW to 5 MW
capacity range is under testing phase. The gear box and drive systems of these
prototypes demand use of Elastohydrodynamic (EHD) lubrication.
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Wind Turbine Gear Oil: Market Dynamics
and Trends
Most manufacturers of wind turbine gearbox have compiled or are
in the process of compiling new lubrication specifications. These
specifications are more stringent than those for industrial gear applications,
and more accurately reflect true operating conditions, including
low-temperature conditions. Performance expectations for lubricants used in
offshore wind turbines are higher due to the demand for extended life.
New trends include FAG FE 8 bearing test (Fatigue test) which is
required by all gear box manufacturers, move toward synthetic formulations
(PAO/ester based – Poly Alfa Olefin and PAG-based – Polyalkylene Glycol), new
oil compatibility specifications for paints-lacquers-sealants and bearing
materials, and new extended lifecycle seal tests for static and dynamic seals.
The SKF EMCOR rust test, for example, is being evaluated to
include testing with salt water. With the latest trend of offshore wind turbine
parks, accessibility is even more difficult than on land. Therefore, proactive
prediction of the useful life of lubricants becomes the new maintenance
strategy rather than the reactive strategy based on measuring acid number and
viscosity.
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Another collaborative effort has produced a monitoring system
for in-service wind turbine lubricants that detects the remaining concentration
of antioxidants. As a quick check for fluid condition, at a minimum, the
turbine operators should be measuring cleanliness (contamination by ISO class),
oxidation, water, and viscosity.
Wind Turbine Gear Oil Market: Market
Segmentation
The wind
turbine gear oil market has been segmented by major turbine components
(gear box and generator), by oil replacement cycle (6-12 months and 12 months
above) and by type of gear oil (semi synthetic industrial gear oil, fully
synthetic industrial gear oil, and polyalphaolefin based gear oils).
Wind Turbine Gear Oil Market:
Region-wise Outlook
Wind power is a high-growth, rapidly evolving industry with a
direct proportion to the lubricant usage (gear oil). Currently, North America
is the leading region for the manufacture and usage of gear oils. Europe
follows North America in terms of consumption and manufacture of gear oils for
wind turbines. With new developments and rising focus on renewable energies,
Asia and Latin America are poised to surpass North America and Europe in terms
of consumption of gear oils in the near future.
Wind Turbine Gear Oil Market: Key
Players
Key players operating in the global wind turbine gear oil market
are Lubrizol, Exxon Mobil Corporation, Klüber Lubrication, Shaeffler Group, OKS
Spezialschmierstoffe GmbH, Castrol, Evonik Industries, PETRONAS, CNOOC, Petro
China, Amsoil Inc., and Suzlon.
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