Molykote Application - Rolling Mills by Project Sales Corp

Smart Lubrication™

Molykote® Applications for Steel Plants and some success stories

Lubrication Solution CapabilitiesMolykote(®) group worldwide –

cost reduction by managing friction in each application we work !!

© 2005 Dow Corning, All rights reserved

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Collated by Project Sales Corp, Authorised Distributors for Molykote products in Visakhapatnam

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Steel Plant Equipment LubricationChallenges and Success

Applications for the Steel Industry



Rolling Mills• Primary Mills

– Blooming and Billet Mill

– Slabbing Mill




Rolling Mills– Secondary Mills

• Rolling Mills- Long– Light Medium Merchant

Mills– Medium Merchant Mills– Wire Rod Mills

• Rolling Mills - Flats– Hot Strip Mill– Cold Rolling Mill




Primary Mills• Conditions

– High temperatures– Mill Scales– Cooling Water– Shock and heavy loads

• Application Areas– Reheating furnace/ soaking

pits– Table Rollers and chains– Spindles of cardan shafts– Roll Neck Bearings– Edging and Guide Rollers




Rolling Mills - Longs• Conditions

– High speeds– Cooling water– Mill scales– High temperatures

• Application Areas– Furnace discharge tables– Furnace door chains– Cooling bed conveyors– Chain drives– Guide Rods– Compactors




Why the customer chose to go for Molykote Products

• Enhancing productivity- both man and machine.

• Scheduled Downtime had to be reduced

• Unscheduled stoppages had to be avoided

• Lubrication related failure costs to be minimized.

• Manpower costs had gone up due to wage increases.

• System Reliability has to increase because of competition.

• Molykote products have a proven and reliable performance Hence, more products were allowed in when new applications were found.




Success Stories atVisakhapatnam Steel Plant

India




Hammer Crushers• Conditions – Heavy Shock Loads, Dust,

Vibrations and high loads

• Concerns – Daily relubrication schedule increases chances of human errors

• Desired – Weekly Lubrication Schedule.

• Product Recommended – Molykote Long-term 2+.

• Results – Relubrication period extended to weekly within 3 months of application.

• Volume – 4 x 180 kg drums/ year




Blender Reclaimer• Spherical Roller Bearings

• Concern – Bearings go through a phase of abrasive wear followed by failure.

• Relubrication Schedule – Daily

• Product Used- Conventional EP Grease

• Product Recommended – Molykote Longterm 2+

• Current Relubrication Schedule – Once in 5 days without bearing failures. Extension to 7 days lead to bearing failures. So now schedule in once in 5 days.

• Used since 2002. 2 x 180 kgs drums /year.




Vibratory Screens• Conditions – Continuous operation, weekly

shutdowns, vibrations, shock loads.

• Concern – Failure can result in lot of downtime in the entire plant process

• Desired – More reliable lubrication without extending relubrication schedule

• Product Tried – Molykote Longterm 2+

• Result – Schedule can be extended to 12 days.

• Expected Volume - 720 kgs/year Many screens have extended their schedule from one week to 45 days. This particular screen in the picture is the most critical in the plant’s Sintering Zone.




Continuous Caster• Area – Secondary Cassette Cooling

Zone

• Component – Bush Rollers

• Concerns – High temperature with cooling water washed out grease and bush sticking with corrosion

• Molykote Product Recommended – P 40 Paste

• Results – After 220 heats and six months of trials, product’s performance good. Formal orders awaited.

Bush Bearings were lubricatedwith Molykote P40. With steel mill environment of high temperatures and cooling water, P 40 Paste is an ideal product for many applications.




Torpedo Ladle (SMS - Demag)• Torpedo Ladle Spherical Sheet (Ladle

carries the hot metal from the BF to the Converter for Lancing)

• Various products tried by customer with poor results

• Product Suggested – Molykote Cu 7439 Paste

• Results – Good. In use for last 5 years.

• Volume: 20 kgs/year

Spherical sheets subjectedto oscillation and high temperatureslubricated now with Molykote Cu 7439for last 5 years, once during overhaul.




Other Molykote Products Supplied• Molykote D Paste

• Roll Shop Roll Assembly– WRM Compactor Rails– Water Management for Valve

Assembly

• Molykote GN + Paste– Various assembly

applications at Area Repair Shops

• Molykote Z Powder– Various dry lubrication

applications in utility plants, converters and coke ovens.

• Molykote M 30 Chain Oil– Furnace Area Chains– Rolling Mill Conveyor Bed

Chains

• Molykote 1000 Paste– Anti-seize applications

• Molykote 111 Compound– O ring assembly

• DC 4 Compound– Electrical Repair Shop




New Products in 2005

Molykote G-0106 Sitela 1 :900 kgs (Will be used for lubrication of high temperature bearings in SMS, blast furnace mudguns and slag wrecking machines).




One application in Steel Plant




The case study with Customers voice..




Equipments Lubricated with Molykote at Vizag Steel

• Hammer Crushers• Blender Reclaimers• ID/FD Fans• Motors• Pumps• Vibratory Screens• Chains• Hydraulic Cylinders• Conveyor Bearings• And, many many more

A Bird Eye View of Visakhapatnam Steel Plantwith the Thermal Power Plant in the Foreground




Success in Ispat Industries- Mumbai

• Continuous Caster SMS –

• G-0106 Sitela1 in thin slab continuous casting machine

• to lubricate from Ladle Turret to on line Pendulum shear with 17 heats average per day

• by centralized lube system




P-37 Success in Turkey

• Magnesium Lancing tube threaded connection

• P37 reduce lance tube seizing increasing productivity recognized Molykote contribution.

• P37 is a standard solution and appears in the plant approved Lube manual.


Port crane in Steel Plant application- Turkey

• Cleaned Gear Lubricated by Molykote G 4700


Wire Rope application- Port cranes in Turkey


Arcelor Meditéranée, France

• Ladle Trunion Bushes of Tilting Mechanism is Lubricated by Molykote P-40 to prevent seizure




FAMAK S.A., PolandContinuous steel moulding

line for a plate rolling mill• G-0102 used for

– very high load– slow movements– high temperatures –

continuos over 130°C; up to +200°C in short periods

– humidity (housings of bearings additionaly water -cooling)




Haynes Steel, USA• Single stand reversing sheet

rolling.

• Roll neck bearings 71 inch diameter

• Molykote G-0102

• Used grease tested from mill shows little change in properties

• Bearing Life is increased.




Thank you for your attention



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Molykote Application - Rolling Mills by Project Sales Corp