Dow corning® molykote team welcomes bhushan delegates
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
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
