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Molykote Application - Rolling Mills by Project Sales Corp
- 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. Steel Plant Equipment Lubrication
Challenges and Success
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 3. Rolling Mills
• Primary Mills
– Blooming and Billet
Mill
– Slabbing Mill
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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 Mill
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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 Rollers
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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
– Compactors
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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. Success Stories at
Visakhapatnam Steel Plant
India
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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/ year
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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. 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. 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. 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/year
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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. 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. One application in Steel Plant
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 17. The case study with Customers voice..
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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 Foreground
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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 system
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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. Port crane in Steel Plant application- Turkey
• Cleaned Gear
Lubricated by
Molykote G 4700
Smart Lubrication™
- 23. Arcelor Meditéranée, France
• Ladle Trunion Bushes
of Tilting Mechanism is
Lubricated by Molykote
P-40 to prevent
seizure
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved
- 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. 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. Thank you for your attention
Applications for the Steel Industry
Smart Lubrication™
© 2005 Dow Corning, All rights reserved