Molykote Application - Rolling Mills by Project Sales Corp
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Molykote Application - Rolling Mills by Project Sales Corp

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Molykote Application - Rolling Mills by Project Sales Corp Molykote Application - Rolling Mills by Project Sales Corp Presentation Transcript

  • 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
  • Steel Plant Equipment Lubrication Challenges and SuccessApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  • Rolling Mills • Primary Mills – Blooming and Billet Mill – Slabbing MillApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  • 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
  • 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
  • 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
  • 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
  • Success Stories at Visakhapatnam Steel Plant IndiaApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  • 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
  • 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
  • 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
  • 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
  • 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
  • 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
  • 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
  • One application in Steel PlantApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  • The case study with Customers voice..Applications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  • 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
  • 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
  • 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 seizureApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved
  • 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
  • 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
  • Thank you for your attentionApplications for the Steel Industry Smart Lubrication™ © 2005 Dow Corning, All rights reserved