Date post: | 28-May-2015 |
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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
Smart Lubrication™
Steel Plant Equipment LubricationChallenges and Success
Applications for the Steel Industry
© 2005 Dow Corning, All rights reserved
Smart Lubrication™
Rolling Mills• Primary Mills
– Blooming and Billet Mill
– Slabbing Mill
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
Success Stories atVisakhapatnam Steel Plant
India
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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).
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
One application in Steel Plant
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
The case study with Customers voice..
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
Smart Lubrication™
Port crane in Steel Plant application- Turkey
• Cleaned Gear Lubricated by Molykote G 4700
Smart Lubrication™
Wire Rope application- Port cranes in Turkey
Smart Lubrication™
Arcelor Meditéranée, France
• Ladle Trunion Bushes of Tilting Mechanism is Lubricated by Molykote P-40 to prevent seizure
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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)
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
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.
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry
Smart Lubrication™
Thank you for your attention
© 2005 Dow Corning, All rights reserved
Applications for the Steel Industry