LUBRICANTS FOR STEEL PLANT
Continuous research for deploying efficient, reliable and environmentally safe technology has led to the deployment of special lubricants in steel manufacturing process. While break down costs are exponential, conditions in steel manufacturing process pose tribological challenges such as high process temperatures, corrosive cooling liquids, abrasive dust, devastating shock-loads etc. In such a scenario, the lubricant is primarily desired to act as protective film with high separation power, be inert to entraining process fluids, resist tribo-corrosion and maintain lubrication during high operating temperatures.
Some critical machinery in a steel processing unit where special lubricants play a pivotal role in functioning of the systems are the continuous caster unit, hot strip mill, thermo mechanically treated (TMT) bar mill and the run on table (ROT). Whilst work environment of these machine systems are almost similar with high temperatures, dusty environment and high water ingress, the lubrication technology to be employed requires careful consideration.
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Established in the year 1834 in Germany, BECHEM pioneered the concept of specialty lubricants. As one of the earliest lubricant firms, BECHEM focused on constant product innovation and thorough application engineering. This guiding principle helped BECHEM evolve as a niche supplier of high performance specialty lubricants. Based on research and development of advanced formulations, the BECHEM Group today offers specialized products for critical industrial applications and metal working processes across the world.
BECHEM believes in the philosophy of delivering exceptional value to customers through high quality products and outstanding service. BECHEM’s business and manufacturing processes are IATF 16949 : 2016 certified, a validation of it’s commitment to deliver quality product and service consistently.
BECHEM for Integrated Steel Plant
Conditions in steel manufacturing process pose tribological challenges due to extreme process temperatures, presence of corrosive cooling liquids, abrasive dust, shock-loads etc. Therefore the operational environment on a lubricant is very demanding and severe. The lubricant is primarily desired to provide a strong protective film with high degree of separation, be inert to entraining process fluids, resist tribo-corrosion and withstand high operating temperatures.
While operational breakdown costs are exponential, the lubrication technology to be employed requires careful consideration. BECHEM’s Berutox, Highlub and Beruplex range of specialty lubricants have been developed in order to surpass the demands in virtually all critical applications of an integrated steel plant.
BECHEM’s customised solutions complemented with unparalleled service help customers achieve higher productivity levels by mitigating machine downtime and extending equipment life.
- Excellent consistency/temperature properties
- High corrosion protection
- Very good water resistance
- Very good wear protection
- Excellent pumpability
- Minimising of friction and wear
- Wide service temperature range
- Increased base oil viscosity
- Extreme pressure properties
- Bearings of guide rollers of continuous casters
- Hot slab transportation systems in metallurgical plants
- Bearings of furnaces such as annealing and drying furnaces subjected to extreme temperatures
- Slide tracks of travelling grate furnaces and sinter machines
- Rotary kilns
- Roller and plain bearings
- Cooling beds
- Conveyor systems
- Hot air fans
- Electric motors
- Waste gas fans for aggressive media
- Gate valves in bulk material container systems
Frequently Asked Questions
Short bytes for queries on lubricants that always bothered you
Greases are made by mixing a solid material, called a thickener, with a base oil and property enhancing additives; but it’s the oil that forms the lubrication film. For better understanding, grease thickener can be thought of as a sponge saturated with oil. Moving parts squeeze the oil out of the sponge like thickener for forming the lubrication film. Typically, the base oil constitutes the largest proportion of grease weight at about 80-90%, followed by thickener at 10 to 20% and additives under 10%.
Dropping point of a lubricating grease is an indicator of the heat resistance of the grease. and is the temperature at which the grease is no more a thickened lubricating medium. The dropping point indicates the upper temperature limit at which a grease retains its structure, not the maximum temperature at which a grease may be used.
Few greases have the ability to regain their original structure after cooling down from the dropping point.
The most important feature of a grease is its consistency. A grease that is too stiff may not get pumped into areas requiring lubrication. While a grease that is too fluid may leak out. Grease consistency depends on the type and amount of thickener used and the viscosity of its base oil. A grease consistency is its resistance to deformation by an applied force.
The measure of consistency is called penetration. Penetration depends on whether the consistency has been altered by working. Standard test procedures established by American Society for Testing and Materials International (ASTM) and accepted by industry are ASTM D 217 and D 1403, measure penetration of unworked and worked greases.
The NLGI has established consistency numbers ranging from 000 to 6, corresponding to specified ranges of penetration distance of the standard cone into the test grease. Table below lists the NLGI grease classifications along with a description of the consistency of each classification.
Viscosity: It is a measure of resistance to flow of a lubricating oil.
Viscosity index: It is defined as rate of change of viscosity with respect to temperature.
- It is the most important property which determines the performance of lubricating oils under the influence of temperature
- A lubricating oil should have sufficient viscosity to retain a lubricating film on the surface
- On machine part moving at slow speeds under high pressures, a high viscous oil should be used as it better resists being squeezed out from between the rubbing parts. Light oils can be used for lower pressures and high speeds.
- It is not possible to maintain a liquid oil film between two moving or sliding surfaces if the viscosity is too low and hence excessive wear will occur.
The pour point of an oil is the minimum temperature at which the oil turns into semi solid and almost losses its flow characteristic. At low temperatures, the viscosity of the oil will be very high, causing the oil to resist flow. This is important in equipment that operates in a cold environment or handles cold fluids.
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