A Smooth Ride: Friction Management Solutions

Loram Technologies specializes in offering several friction management solutions, including biodegradable, synthetic, and water-based lubricants for both gauge face and top-of-rail.

Courtesy of Loram Technologies

ATLANTA - From the December 2024 issue of Railway Track & Structures, here is a lineup of friction management solutions from suppliers across the industry.

Rail friction management affects the safety and efficiency of all rail operations, passenger and freight. With the growth of rail networks and the subsequent increase in finding necessary friction management solutions, RT&S has tasked itself with finding some of the best the industry has to offer. The strategies and products employed by railroads nationwide can be found among the following.  

L.B. Foster is excited to launch KELTRACK® On-Board (KOB), a new on-board, top-of-rail, Friction Management delivery system. This technology promises a fresh approach to managing the wheel-rail interface, giving railways the chance to deliver safer, more effective and more precise friction management. The technology integrates directly with the vehicle, applying product intelligently based on parameters such as speed and location. System designs are fully customizable to suit operator needs.  

To complement this hardware launch, a new formulation of the established KELTRACK friction modifier has been developed – optimized for on-board applications. KELTRACK AP EX is an all-season fluid with a wide operating temperature range, negating the requirement for heated tanks, hoses, and nozzles in an on-board spray system. It is a water-based engineered composite of inorganic solids, polymers, and friction modifying additives that provides excellent protection in the wheel/rail interface without the use of oils. 

Loram Technologies specializes in friction management solutions that enhance the performance and lifespan of rail and rolling assets. It offers biodegradable, synthetic, and water-based lubricants for both gauge face and top-of-rail applications, designed to reduce wear and improve overall efficiency. Its products include EcoCurve Heavy Haul, a high-performance curve lubricant for freight applications, and Rail King HL, an inherently biodegradable alternative that provides the same benefits at a lower cost. Additionally, EcoCurve Trackside is widely used in transit markets. These lubricants are effective across varying temperatures and are environmentally friendly, breaking down naturally and being suitable for use near bodies of water. 

For top-of-rail friction management, Loram Technologies offers TOR-Extend, a clean synthetic friction modifier that minimizes evaporation and extends carry distance. It also offers ClareShield-WS, a water-based friction product developed in partnership with RS Clare, which has shown improved stability and shelf life compared to competitors. Its modular tank systems, ranging from 25-gallon to 200-gallon sizes, provide flexible, easy-to-install solutions for different rail needs, with remote monitoring options becoming increasingly popular. 

A case study of a rail operator’s two-year friction management study highlights the significant benefits of ClareTech EcoCurve Heavy Haul. The operator, struggling with inconsistent lubricant performance, varying climatic conditions, and logistical complexities, trialed the lubricant across several locations. Results showed a 75% reduction in curve flange wear, leading to a fourfold increase in rail life. EcoCurve Heavy Haul was praised for its consistent performance, environmental credentials, and low maintenance requirements. Composed of 75% renewable sources and readily biodegradable, it aligns with the operator’s sustainability goals. Following the successful trials, EcoCurve Heavy Haul is now being rolled out network-wide, focusing on high-wear areas to maximize ROI and improve overall performance. 

NatureBlend, an eco-friendly solid stick polymer friction modifier from MPL Innovations, offers significant benefits for railroads, especially in reducing energy consumption and GHG emissions. This biodegradable formulation, applied as a wheel flange lubricant, effectively minimizes friction between locomotive wheels and rail. A study conducted by TTCI (now known as MxV Rail) at the Federal Railroad Administration’s Transportation Technology Center in Pueblo, Colorado, highlights NatureBlend’s impact.

The tests involved extensive data collection across different track conditions, comparing laps with and without NatureBlend application. In both a 3.5-mile curvier track and a 9.1-mile mostly straight track, NatureBlend demonstrated a measurable reduction in energy use, estimated at 3.2%. By enabling locomotives to operate at lower throttle levels, particularly less time in throttle notch 8, where fuel use peaks, NatureBlend solid stick lubrication helps conserve fuel and reduce emissions. 

Statistical analyses performed by First Analytics verified these results at a 99% confidence level, solidifying NatureBlend’s role in rail sustainability initiatives. The projection model developed allows rail operators to estimate potential savings across their own unique rail profiles, from straight tangents to challenging curved tracks, considering average train length and horsepower per trailing ton parameters. 

In addition to fuel efficiency, NatureBlend offers ancillary safety benefits. Reduced flange friction decreases the likelihood of “wheel climb” derailments, an issue particularly relevant on curves. Also, by lubricating the otherwise dry wheel flange to rail interface, incidence of “wheel squeal” is also greatly reduced helping to alleviate noise pollution in high population areas near railroad yard switching facilities. The study supports NatureBlend as a critical solution for energy savings, safety, and environmental goals in the rail industry. 

The rail industry continues to evolve, and therefore, the importance of friction management cannot be understated. Solutions like L.B. Foster’s KELTRACK® On-Board system, Loram Technologies’ EcoCurve and TOR-Extend products, and MPL Innovations’s NatureBlend are not only advancing operational efficiency, but they drive sustainability.

As rail networks expand, innovative friction management solutions offer not only sustainability but cost-effectiveness as well. As such, the industry needs to continuously adapt to meet the increasing demands of railroads. These products provide the necessary solutions to ensure safer and more efficient operations.