dow corning® molykote team welcomes bhushan delegates

Dow Corning® Molykote Team

Welcomes all Delegates

this evening

Smart Lubrication Solutions

Completion of One Year

of Providing Lubrication Management Solutions

At Bhushan Power & Steel

Presentation

• Agenda

– RP Mukherjee – Molykote Application in

Sponge Iron Plants

– Anil Tiwari – Success Story – Vizag Steel


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


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!


Sponge Iron Industry

R.P. Mukherjee, Technical Sales Specialist

Molykote in Sponge Iron Industry

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 ® 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.


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.

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.

Open Gear Drives



- 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.

Impactors, Crushers, Screens and

Conveyors



- 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

General Assembly & Maintenance

Products


Product for

Application Areas:

Chains

Wire Ropes

Oil Seals

Fasteners

Press-fits

Disasssembly

Valves, etc

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

Success Stories at

Visakhapatnam Steel Plant

Anil Tiwari – Application Engineer, Project Sales

Corp, Molykote Distributors for this Region

Molykote in the Steel Industry

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 moreA Bird Eye View of Visakhapatnam Steel Plant

with the Thermal Power Plant in the Foreground


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 extended to 12 days.

• Expected Volume - 720 kgs/yearMany screens have extended theirschedule from one week to 45 days.This particular screen in the picture isthe most critical in the plant’sSintering 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

• Results – After 220 heats and six

months of trials, product’s performance

good. Formal orders awaited.

Bush Bearings were lubricated

with Molykote P40. With steel mill

environment of high temperatures and

cooling water, P 40 Paste is an ideal

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

• Results – Good. In use for last 5 years.

• Volume: 20 kgs/year

Spherical sheets subjected

to oscillation and high temperatures

lubricated now with Molykote Cu 7439

for last 5 years, once during overhaul.


Other Molykote Products Supplied

• Molykote D Paste

– Roll Shop Roll Assembly

– WRM Compactor Rails

– Water Management for Valve

Assembly

• Molykote GN + Paste

– Various assembly applications at

Area Repair Shops

• Molykote Z Powder

– Various dry lubrication

applications in utility plants,

converters and coke ovens.

• Molykote M 30 Chain Oil

– Furnace Area Chains

– Rolling Mill Conveyor Bed Chains

• Molykote 1000 Paste

– Anti-seize applications

• Molykote 111 Compound

– O ring assembly

• DC 4 Compound

– Electrical Repair Shop

• DC Sylgard 170 A&B Elastomer

– Potting of electro-magnets


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).


Techno-Economics


The case study with Customers voice..


Typical Maintenance Budget Breakdown

The smallest part of your maintenance budget can have

the greatest impact on labor and parts cost

Lubricants

3%

REPLACEMENT PARTS

40%

MAINTENANCE LABOR

45%

MISC. SUPPLIES/

EQUIP. 12%

Concluding Remarks

The smallest part of your maintenance budget can have the greatest

impact on labor and parts cost

Concluding RemarksMolykote 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

• 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

Concluding Remarks

Thank you

Any Questions ?


Thank you for your attention

Molykote Team - Your reliable lubrication partners

dow corning® molykote team welcomes bhushan delegates

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