Your SlideShare is downloading. ×
0
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Dow Corning® Molykote Team Welcomes Bhushan Delegates
Upcoming SlideShare
Loading in...5
×

Thanks for flagging this SlideShare!

Oops! An error has occurred.

×
Saving this for later? Get the SlideShare app to save on your phone or tablet. Read anywhere, anytime – even offline.
Text the download link to your phone
Standard text messaging rates apply

Dow Corning® Molykote Team Welcomes Bhushan Delegates

1,483

Published on

Published in: Business
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total Views
1,483
On Slideshare
0
From Embeds
0
Number of Embeds
0
Actions
Shares
0
Downloads
61
Comments
0
Likes
0
Embeds 0
No embeds

Report content
Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
No notes for slide

Transcript

  • 1. Dow Corning® Molykote Team Welcomes all Delegates this evening Completion of One Year of Providing Lubrication Management Solutions At Bhushan Power & Steel Smart Lubrication Solutions
  • 2. Presentation • Agenda – RP Mukherjee – Molykote Application in Sponge Iron Plants – Anil Tiwari – Success Story – Vizag Steel Smart Lubrication Solutions
  • 3. Presentation Purpose today is to: 1. Illustrate some application areas of Molykote in Sponge Iron Plants 2. Share success stories of Molykote Products in the Steel Industry 3. Gain your commitment to explore options to further reduce maintenance costs by utilizing products & services from Molykote® 4. Get to know each other better and celebrate together Smart Lubrication Solutions
  • 4. Dow Corning Molykote • Molykote® & Dow Corning have been in industrial lubrication for 60+ years • Dow Corning is a Joint venture between Dow Chemicals and Corning Glass in the US. Molykote is a brand of Dow Corning. • Dow Corning is 4 Billion US$ (18,000 Crores INR) company. Dow Corning India Pvt. Limited is a 100% subsidiary of Dow Corning Corporation, USA • Specialty greases, compounds, pastes, dry film lubes, sprays, etc. • Recently added complete line of Molykote® industrial oils to product offering: Gearbox, hydraulic, air compressor, chain, bearing, vacuum pumps NOW, THE MOST COMPLETE LINE OF INDUSTRIAL LUBRICANTS! Smart Lubrication Solutions
  • 5. Sponge Iron Industry R.P. Mukherjee, Technical Sales Specialist Molykote in Sponge Iron Industry
  • 6. Key Application Areas • Slip Seal Mechanisms • Segmented Liner & Fasteners • Motor Bearings & Blower Fan Bearings • Support Roller Bearings • Open Gear Drives • Conveyor Head Pulley & Tail Pulley Bearings • Coal Impactors, Crushers & Screen Bearing • Assembly And Disassembly Applications Molykote in Sponge Iron Industry
  • 7. Molykote ® Application Areas in the Kiln Slip Seal Mechanisms • Lubrication Characteristics Desired - Good Sealing effect - Very High Temperature withstand capacity - Good Pumpability - A / W additive to minimizes wear Molykote G-0103 designed for slip seal application has a high drop point, with high base oil viscosity to provide lubricity and sealing effect, and easily pumped through centralized systems. Low grease consumption, better wear protection of Slip Seal segments, and environmental friendly thickeners are some of the key benefits. Pre-treatment is recommended on Slip Seal segments & bolts with Molykote P-74 Paste prior to installation. Molykote in Sponge Iron Industry
  • 8. Motor, Fan And Pump Bearings … Lubrication Requirements … - Good channeling characteristics - NLGI grades 2-3 - High dropping point, 204 0C - Excellent resistance to high temperature oxidation. - Good AW performance but not EP (causes corrosion in windings) Molykote ® G-0100 is a mineral oil in poly-urea thickener high temperature resistance designed for motors operating in continuous high temperature. This grease is fully water resistance, long-term lubrication for high speed bearing also, avoid costly downtime due to bearing failures. Molykote in Sponge Iron Industry
  • 9. Support Roller Bearing Lubrication Requirements - Mixed lubrication film is necessary due to high load and slow speed. - High viscosity base oil grease with solid lubricants film, which will work as a emergency lubrication. Molykote ® Long Term 2 Plus with a high viscous base oil & high load carrying capacity, contains MoS2, which can make a boundary lubrication film in slow speed bearings, can work in dusty environment and will extended re-lubrication period. Molykote in Sponge Iron Industry
  • 10. Open Gear Drives Lubrication Requirements … - Semi-fluid 0 to 00 consistency Grease - Tackiness - High load-carrying capability - Higher base-oil viscosity - FZG test > 12 stage passed - Rust and corrosion protection - Contains Solid lubricant Molykote ® Molykote KGP- 2/P is the spray-able service grease. Its outstanding features are : - Formulated with highly refined mineral oil ,1000 Cst. viscosity - very high load bearing capacity - Solid lubricants ( Graphite ) with a purity of 99.5 to 99.9 percent The product contains Aluminum Complex thickeners, solid lubricants and chemical reaction additives that provide a separating film under the highest stresses, provides longer re-lubrication intervals, reduces maintenance cost, and increases with resultant higher economy. Molykote in Sponge Iron Industry
  • 11. Impactors, Crushers, Screens and Conveyors Lubrication Requirements … - extreme resistance to high pressures - ability to withstand high shock-loads - good mechanical stability - excellent resistance to water wash-out - outstanding anti-corrosion properties - ability to work in dusty atmosphere Molykote ® Longterm 2 Plus is an extreme pressure grease designed for the highest bearing loads and long-term lubrication. It contains the optimum blend of (MoS2) solid lubricants, which provides : - reduction of wear - longer life of components - longer re-lubrication intervals - less maintenance - increased reliability & reduce cost Molykote in Sponge Iron Industry
  • 12. General Assembly & Maintenance Products Product for Application Areas: Chains Wire Ropes Oil Seals Fasteners Press-fits Disasssembly Valves, etc Molykote in Sponge Iron Industry
  • 13. Stock Codes at Bhushan for Some Molykote Products Product Name Stock Code Current Application Area Molykote G-0103 59585 Slip Seals in Kiln 3&4 Molykote KGP-2P 59586 Kiln Open Gear Drives Molykote G-0106 06531 Caster Bearing Lubrication in SMS1 &2 Molykote Longterm 2+ 54586 RMHP – Crushers, Screens, Conveyors, etc – Trials over Molykote G-0100 63966 Electric Motor Bearings at Power Plant Molykote 1122 Grease 65205 Ladle Turrets Open Gears SMS 1 & 2 Molykote P74 Paste 65203 Slide Gate Mechanism SMS 1 & 2 Molykote 111 Compound 65206 Oil Seals and O Rings SMS 1 Molykote M Gear Guard 65204 Gear Box Additive – SMS1 Molykote in Sponge Iron Industry
  • 14. Success Stories at Visakhapatnam Steel Plant Anil Tiwari – Application Engineer, Project Sales Corp, Molykote Distributors for this Region Molykote in the Steel Industry
  • 15. 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 Plant with the Thermal Power Plant in the Foreground Molykote in the Steel Industry
  • 16. 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 Molykote in the Steel Industry
  • 17. 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. Molykote in the Steel Industry
  • 18. 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 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. Molykote in the Steel Industry
  • 19. 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 Bush Bearings were lubricated • Results – After 220 heats and six with Molykote P40. With steel mill months of trials, product’s performance environment of high temperatures and cooling water, P 40 Paste is an ideal good. Formal orders awaited. product for many applications. Molykote in the Steel Industry
  • 20. 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. Spherical sheets subjected to oscillation and high temperatures lubricated now with Molykote Cu 7439 • Volume: 20 kgs/year for last 5 years, once during overhaul. Molykote in the Steel Industry
  • 21. Other Molykote Products Supplied • Molykote D Paste • Molykote M 30 Chain Oil – Roll Shop Roll Assembly – Furnace Area Chains – WRM Compactor Rails – Rolling Mill Conveyor Bed – Water Management for Valve Chains Assembly • Molykote 1000 Paste • Molykote GN + Paste – Anti-seize applications – Various assembly applications at • Molykote 111 Compound Area Repair Shops – O ring assembly • Molykote Z Powder • DC 4 Compound – Various dry lubrication – Electrical Repair Shop applications in utility plants, • DC Sylgard 170 A&B Elastomer converters and coke ovens. – Potting of electro-magnets Molykote in the Steel Industry
  • 22. New Product in 2006 Molykote G-0106 Sitela 1 : used for lubrication of high temperature bearings in SMS, blast furnace mudguns and slag wrecking machines). Molykote in the Steel Industry
  • 23. Techno-Economics Molykote in the Steel Industry
  • 24. The case study with Customers voice.. Molykote in the Steel Industry
  • 25. Concluding Remarks Typical Maintenance Budget Breakdown Lubricants 3% REPLACEMENT PARTS 40% MISC. SUPPLIES/ EQUIP. 12% MAINTENANCE LABOR 45% The smallest part of your maintenance budget budget can greatest The smallest part of your maintenance can have the have the greatest impact on labor and parts cost impact on labor and parts cost
  • 26. Concluding Remarks Molykote Products help in: • 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. Key Benefits of Molykote Products
  • 27. Concluding Remarks • As we complete one year of supply status at Bhushan, we take this opportunity to thank the team at • Kiln # 3&4, SMS 1&2, Power Plant • Materials Management Department, Stores, Accounts • and each of you for your support during last year and look forward to your continued support in the coming years Thank you
  • 28. Any Questions ? Smart Lubrication Solutions
  • 29. Thank you for your attention Molykote Team - Your reliable lubrication partners

×