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p                        Collated by Project Sales Corp, Authorised Distributors for Molykote products in Visakhapatnam   ...
Steel Plant Equipment Lubrication                             Challenges and SuccessApplications for the Steel Industry   ...
Rolling Mills • Primary Mills         – Blooming and Billet           Mill         – Slabbing MillApplications for the Ste...
Rolling Mills         – Secondary Mills                 • Rolling Mills- Long                         – Light Medium Merch...
Primary Mills • Conditions         –    High temperatures         –    Mill Scales         –    Cooling Water         –   ...
Rolling Mills - Longs • Conditions         –    High speeds         –    Cooling water         –    Mill scales         – ...
Why the customer chose to go for Molykote Products •     Enhancing productivity- both man and machine. •      Scheduled Do...
Success Stories at                     Visakhapatnam Steel Plant                               IndiaApplications for the S...
Hammer Crushers •     Conditions – Heavy Shock Loads, Dust,       Vibrations and high loads •     Concerns – Daily relubri...
Blender Reclaimer •     Spherical Roller Bearings •     Concern – Bearings go through a phase of       abrasive wear follo...
Vibratory Screens •     Conditions – Continuous operation, weekly       shutdowns, vibrations, shock loads. •     Concern ...
Continuous Caster •     Area – Secondary Cassette Cooling       Zone •     Component – Bush Rollers •     Concerns – High ...
Torpedo Ladle (SMS - Demag) •     Torpedo Ladle Spherical Sheet (Ladle       carries the hot metal from the BF to the     ...
Other Molykote Products Supplied •     Molykote D Paste • Roll Shop Roll Assembly                  •   Molykote M 30 Chain...
New Products in 2005         Molykote G-0106 Sitela 1 :                   900 kgs (Will be used for lubrication of high   ...
One application in Steel PlantApplications for the Steel Industry                                            Smart Lubrica...
The case study with Customers voice..Applications for the Steel Industry                                            Smart ...
Equipments Lubricated with Molykote                at Vizag Steel •     Hammer Crushers •     Blender Reclaimers •     ID/...
Success in Ispat Industries- Mumbai •     Continuous Caster SMS – •     G-0106 Sitela1 in thin slab       continuous casti...
P-37 Success in Turkey•   Magnesium Lancing tube    threaded connection•   P37 reduce lance tube seizing    increasing pro...
Port crane in Steel Plant application- Turkey• Cleaned Gear  Lubricated by  Molykote G 4700                               ...
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  seizu...
FAMAK S.A., Poland Continuous steel moulding   line for a plate rolling mill • G-0102 used for         – very high load   ...
Haynes Steel, USA •     Single stand reversing sheet       rolling. •     Roll neck bearings 71 inch       diameter •     ...
Thank you for your attentionApplications for the Steel Industry                                            Smart Lubricati...
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Molykote Application - Rolling Mills by Project Sales Corp

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Transcript of "Molykote Application - Rolling Mills by Project Sales Corp"

  1. 1. p Collated by Project Sales Corp, Authorised Distributors for Molykote products in Visakhapatnam Molykote® Applications for Steel Plants and some success stories Lubrication Solution Capabilities Molykote(®) group worldwide – cost reduction by managing friction in each application we work !! Smart Lubrication™© 2005 Dow Corning, All rights reserved
  2. 2. Steel Plant Equipment Lubrication Challenges and SuccessApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  3. 3. Rolling Mills • Primary Mills – Blooming and Billet Mill – Slabbing MillApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  4. 4. 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 MillApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  5. 5. 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 RollersApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  6. 6. 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 – CompactorsApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  7. 7. 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.Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  8. 8. Success Stories at Visakhapatnam Steel Plant IndiaApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  9. 9. 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/ yearApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  10. 10. 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.Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  11. 11. 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. Many screens have extended their • Expected Volume - 720 kgs/year schedule from one week to 45 days. This particular screen in the picture is the most critical in the plant’s Sintering Zone.Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  12. 12. 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.Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  13. 13. 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 Spherical sheets subjected • Results – Good. In use for last 5 years. to oscillation and high temperatures lubricated now with Molykote Cu 7439 for last 5 years, once during overhaul. • Volume: 20 kgs/yearApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  14. 14. Other Molykote Products Supplied • Molykote D Paste • Roll Shop Roll Assembly • Molykote M 30 Chain Oil – WRM Compactor Rails – Furnace Area Chains – Water Management for Valve – Rolling Mill Conveyor Bed Assembly Chains • Molykote GN + Paste • Molykote 1000 Paste – Various assembly – Anti-seize applications applications at Area Repair • Molykote 111 Compound Shops – O ring assembly • Molykote Z Powder • DC 4 Compound – Various dry lubrication – Electrical Repair Shop applications in utility plants, converters and coke ovens.Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  15. 15. 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).Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  16. 16. One application in Steel PlantApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  17. 17. The case study with Customers voice..Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  18. 18. 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 ForegroundApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  19. 19. 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 systemApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  20. 20. 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™
  21. 21. Port crane in Steel Plant application- Turkey• Cleaned Gear Lubricated by Molykote G 4700 Smart Lubrication™
  22. 22. Wire Rope application- Port cranes in Turkey Smart Lubrication™
  23. 23. Arcelor Meditéranée, France• Ladle Trunion Bushes of Tilting Mechanism is Lubricated by Molykote P-40 to prevent seizureApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  24. 24. FAMAK S.A., Poland Continuous 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)Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  25. 25. 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.Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  26. 26. Thank you for your attentionApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
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