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Specialty Chemicals Guide to Automotive, Appliance and Assembly Applications
1. Specialty Chemicals Business
Major Market Business Units
Automotive, Appliance,
Assembly & Maintenance
Advanced Interface Markets
Construction
Electronics
Life Sciences
Solar
Reference Number: 80-3477-01 1
14. Solutions
Confirm operating parameters
– speed, load, temperature
Do not use mixed lubricants
Use proper Flushing Techniques and procedure
Use the most suitable, cost effective lubricant
Consult with lubricant supplier for benefits on longer
oil/grease drain cycles
Review lubrication program and budgets
15. Corrosion
Corrosion results from the chemical attack on
the metal by hostile fluids or atmospheres.
Ball path
Ball Path
Red/brown
stains or
deposits on rings
19. Solutions
Reduce load
Re design using a bearing with higher load
carrying capacity
Use High Performance Lubricants to increase
surface area
Increase surface area with solids and extend
life
21. Contamination
Clean work areas, tools, fixtures and hands will
reduce bearing contamination failures.
Irregular dents or
material embedded in
raceways
Balls will be
similarly dented,
dull, or scratched
22. Solutions
• Clean work areas
• Keep grinding operations away from assembly
areas
• Keep bearings in original packing
• Keep seals in good shape
• Use of high performance lubricants will be
helpful
23. Portfolio of Steel Plant Lubricants
Heavy duty greases (ISO Vg- 680-1000)
Roll neck greases (ISO Vg- 320-460)
High temperature greases (Drop point 260+)
Gear oils synthetics (PG/PAO –680/460)
High temperature chain oils
Open gear lubricants- non drip type.
Future trend
– Calcium complex greases as MPG for steel mills with or without SOLIDS
24. Bearing in Steel Plant environment
Conditions
– High temperatures
– High pressure cooling water
– Mill scales
– Shock loads
– Emulsions
– Acid Fumes
Application Areas
– Roll Neck Bearing
– Chock Liners
– Table Roll Bearings
– Blower Fans
– Motors
– Coilers and decoilers
25. Summary of Environment of Lubricants in
steel plant
Temperature Water/humidity Speed
Contamination Shocks Loads
27. Equipments Lubricated with Molykote
at Vizag Steel
Hammer Crushers
Blender Reclaimers
ID/FD Fans
Motors
Pumps
Vibratory Screens
Chains
Stelmore and Fan bearings in
New Wire Rod Mill
Conveyor Bearings
And, many many more
A Bird Eye View of Visakhapatnam Steel Plant
with the Thermal Power Plant in the Foreground
28. Why the customer chose to go for
Molykote Products
Increasing demands on enhancing production without capacity expansion
Downtime had to be avoided
Unscheduled stoppages had to be avoided
Reliability had to be increased. Chances for human errors to be minimized.
Manpower costs as a %age of total lubrication costs had gone up due to
wage increases.
Molykote products have a pedigree of proven performance and had shown
excellent results in wherever they were used. Hence, more products were
allowed in when new applications were found.
29. 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
30. 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.
31. 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.
32. 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 subjected
to oscillation and high temperatures
lubricated now with Molykote Cu 7439
for last 5 years, once during overhaul.
34. 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
37. Molykote Products in caster
bearing Lubrication
Molykote G0102
Molykote G6000
Molykote P40
Performance Parameters
– Resistance to steam and
water wash outs
– shear Stable
– Good corrosion protection
– Good load carrying capability
– Aging resistant in presence
of water and steam
38. Approvals and referrals
Approvals
SMS Demag
– G0102
– P40
– HP 870
Danielli
– G 6000
User Referrals
P40
– Durgapur Steel Plant
G0102
– Hadeed Steel – Saudi
Arabia , Places in India
Molykote 41 Grease
– Emirates Steel – Abudhabi
– Vizag Steel Plant India
Applications for the Steel Industry
39. Fettarten nach der Spezifikation nach DIN 51502
K2N-30
Reference Number: 80-3477-01 39
DOW CORNING
www.dowcorning.com
High Performance
Grease
Molykote G-0102
High Load Bearing Grease
MOLYKOTE HP-870
Grease
Juni 2007
Betriebsmittel
Schmierstoff: Fett
Auswahl
SN 180
Teil 1Betriebsmittel
Schmierstoff: Fett
Auswahl
40. Approvals and Referrals
From: ccmmechanical [mailto:ccm.mechanical@siscol.com]
Sent: Thursday, October 04, 2007 4:50 PM
To: Premier Bearings
Subject: Offer -Reg
Importance: High
SISCOL/CCM/SM/171
04/10/2007
Dear Sir,
With refence to your mail Dt:04/09/07 regarding synthetic greases requirement for our Bloom caster
project, Further we have forwarded your technical data sheet to our Principles M/s. Danieli Centromet Italy
for their approval, and we have received the approval for Molykote G-6000 grease for our centralized
lubrication system as well as manual lub systems.
Kindly give your best offer for one unit based on that we will place order for our required qty.
With Regards,
M.RAVI,
SR.MANAGER/MECH.
Mob:+919994895131
SISCOL.
Juni 2007
Betriebsmittel Schmierstoff:
Fett Auswahl
SN 180 Teil 1
42. 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 lubricated
with Molykote P40. With steel mill
environment of high temperatures and
cooling water, P 40 Paste is an ideal
product for many applications.