ALUMINUM

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From the start of the trial, QUAKEROL® CCR 109 SW provided excellent lubrication on the mill. The first bar transitioned through the mill to the coiler without difficulty, no slip, no refusals and no evidence of quality problems. After six months, the customer happily reported that QUAKEROL® CCR 109 SW had:

» Decreased the scrap rate by 25% » Improved the aluminum rod production/gallon of oil

from 8,000 to 14,000 lbs » The overall cleanliness in the rolling mill has

improved

Here is a direct excerpt from an e-mail Quaker received from the Operations Manager at the mill.

“ The Quaker product has performed well and has held up well during operating conditions. Technical support has been top notch through the process of startup and continued production over time. Several questions have been answered and solutions given to problems that we have dealt with for some time. We have been very pleased with the ease of the transition to the Quaker product and its functionality. ”

THE PRODUCT

QUAKEROL® CCR 109 SW represents the latest generation of aluminum rod rolling oils developed by Quaker. The formulation couples outstanding emulsion stability with superior boundary and hydrodynamic lubricity without relying on fatty acids, often used in other rod mill rolling chemistries.

QUAKEROL® CCR 109 SW was specifically formulated for this mill after Quaker completed an extensive mill survey and in-depth conversations with operations, maintenance and plant management.

THE EXPERTISE

Rolling lubricants represent a very minor part of the costs of aluminum rolling operations, typically considerably less than 1%. This case illustrates the importance of using the leverage of advanced lubricant technology to achieve substantial productivity increases while at the same time reducing total applied cost. That is why Quaker focuses on developing products with the highest performance without compromise, products that sharpen your competitive edge.

ALUMINUM ROD ROLLINGQUAKEROL® CCR 109 SW

THE SOLUTION Quaker earned an opportunity to conduct a trial on this mill following the successful conversion of four rod to strip mills in the same facility. The customer was appreciative of Quaker’s technical service and analytical support during the strip mill conversions and understood that these benefits would transition nicely to the aluminum rod production operations. The customer converted their aluminum rod mill to QUAKEROL® CCR 109 SW which offers the following benefits:

CHALLENGES

» An 8-stand Southwire type aluminum rod mill producing 3xxx, 4xxx, 5xxx, 6xxx and 8xxx series alloys, and has a caster that operates at 4.5 tons/hour, with a bar size of roughly 1,900 mm2

» This mill process only 3/8” or 9.5 mm rod, and the coolant system is < 7,000 gallons

The customer uses well water to prepare and maintain the emulsion: » Very little effort was given to

emulsion control, with almost no on site testing

» Oil and make-up water were added sporadically and often in large slugs, as a result of poor rod quality

The customer wanted to convert to a new rolling oil so they could » Benefit from the supplier’s

technical expertise in aluminum rod production

» Improve control of emulsion parameters and maintain consistent throughput

» Reduce total rolling oil usage

» Outstanding boundary and hydrodynamic lubricity performance

» Superior emulsification performance for emulsion stability and consistency

» Excellent corrosion inhibition performance » Low consumption rates » Low metallic soap formation tendency

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