Molykote Application - Rolling Mills by Project Sales Corp

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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 Success

Applications for the Steel Industry


Rolling Mills
• Primary Mills

– Blooming and Billet
Mill

– Slabbing Mill



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



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


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



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.



Success Stories at
Visakhapatnam Steel Plant
India


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



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.



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.



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.



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



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.


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).



One application in Steel Plant



The case study with Customers voice..



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



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



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.


Port crane in Steel Plant application- Turkey

• Cleaned Gear
Lubricated by
Molykote G 4700


Wire Rope application- Port cranes in Turkey


Arcelor Meditéranée, France

• Ladle Trunion Bushes
of Tilting Mechanism is
Lubricated by Molykote
P-40 to prevent
seizure



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)



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.



Thank you for your attention



Molykote Application - Rolling Mills by Project Sales Corp

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