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CASE STUDY 2 - Steel

This document summarizes information about lubrication for no twist wire rod mills. It discusses how no twist mills have high-speed rolling stands that require special oils for both the roll bearings and bevel gears. Failure of this lubrication can cause breakdowns costing millions per day. The document promotes a new wire rod mill lubricant, MAK Steel EP 100, that exceeds specifications and provides better oxidation stability and demulsibility than existing options. It has been successfully trialled in several Indian wire rod mills and the goal is to expand its use in more mills nationwide.

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Ankit Ujjwal
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403 views19 pages

CASE STUDY 2 - Steel

This document summarizes information about lubrication for no twist wire rod mills. It discusses how no twist mills have high-speed rolling stands that require special oils for both the roll bearings and bevel gears. Failure of this lubrication can cause breakdowns costing millions per day. The document promotes a new wire rod mill lubricant, MAK Steel EP 100, that exceeds specifications and provides better oxidation stability and demulsibility than existing options. It has been successfully trialled in several Indian wire rod mills and the goal is to expand its use in more mills nationwide.

Uploaded by

Ankit Ujjwal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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No Twist Block lubrication in Wire Rod Mills

Broken the monopoly of Mobil and moving forward


Why Wire-Rod Mills are important
No Twist Mill ( NTM ) for Wire Rods

• NTM Blocks for better finish and


maximum precision.
• Very high speeds of 60 to 120
m/s.
• Series of closely packed high
speed rolling stands
• Both the roll bearings
and the bevel gears
lubricated with same
very special kind of oil.
Criticality for Oil

Same oil for Very High


bearings and Speeds Seal failure
gears upto 120 m/s

Large Oil
Expensive
Water Ingress Sumps upto
components
40 KL

Breakdown Longer oil life


loss risk desired
Huge Cost of Failure

Critical Components Oil Cost Production


•Bearings •Oil Replacement loss
` 70,000 X 12 ` 140/litre X 14000 •3 days down time
•Rolls •Flushing ` 90 lakhs X 3 X 3
` 1,20,000 X 12 ` 140/litre X 10000

1.15 3.36 8.1


Crores Crores Crores
Balancing of performance

Oxidation
Protection
Business cycle for 1 system
Approx Profit
retention of 10 %
Initial Fill
14 KL

Approx Profit
retention of 15 %
60 KL in 20 KL High
5 years
Sump top up

High Top-ups
due to heavy water
ingress

5 barrels
per
month
Top up rate of 7-8 %
per month
Segments

GREEN ORANGE BLUE PURPLE RED


Newly planned Out of warranty Upcoming new Out of warranty Unorganized
blocks of Indian blocks at projects with blocks at Major rerolling mills
OEMS small/medium blocks of Integrated steel working as
rerolling mills International plants subcontractors for
(Indian OEMS) OEMS (International big steel plants
OEMS)
Total business High Moderate Very High High Low
from all lubricants
Influence of OEM High Moderate Very High Moderate Low
Operation speed High High Very High Very High Low
Willingness to try Low Moderate Very Low Low High
alternatives
Sensitivity to price Very High High Moderate Low Vey High
Maintenance level Moderate Low Outstanding Good Very Low
Need for technical Moderate High Very low low Moderate
support and
Services
What's special about our
MAK Steel EP 100 ?

 Specially developed for Morgan No twist mill specifications


from our own premium Group II Plus Base oil

 Not only it meets the OE specifications, it exceeds in critical


parameters

 Tested and proven for Dynamic Demulsibility by CLARK


Laboratories, LCC , USA

 Better Oxidation Stability and demulsibility compared to


Mobil Vacuoline 525

 Fully Compatible to Mobil Vacuoline 525

 IOCL has tried to introduce this product in past and failed in


the past.
Minimum MLP MAK Steel EP 100
Requirement

Viscosity Index 95 99 115

Oxidation stability
( RPVOT) 140 170 750

Demulsibility
40-37-3 40-37-3 40-40-0
25 minutes 15 minutes 5 minutes

Higher Viscosity Index Facilitates better film strength at high temperatures .


This means that the bearings and gears have an extra protection at operating
temperature

Higher oxidation stability translates directly into lower sludge formation and hence cleaner
systems.
This also Reflects on life of oil against any degradation.
Quicker water removal means reduction in possibility of additive depletetion.

This is the most critical requirement for this application and for oil life.
MAK 1234 OIL CARE PROGRAM

1
1
Story of NTM Oil
FY2015-16 FY2016-17* Cumulative since 2011
123.81 MT 119.14 MT 433.72 MT

8 New Blocks on MAK Steel EP 100 added in last 2 years

18 Newfield Engineers systems are today


running on MAK Steel EP 100

M/s. Supersmelters ,Jamuria ( Kolkata Direct


Territory), First breakthrough in Armech
Engineers (P) Ltd. Make NTM Block
FY2015-16 FY2016-17* Cumulative since 2011
123.81 MT 119.14 MT 433.72 MT

8 New Blocks on MAK Steel EP 100 added in last 2 years

1. M/s Shakumbhari Ispat , 5. M/s. Supersmelters ,Jamuria


Durgapur 6. M/s. KD Iron & Steel ,
2. M/s RR Ispat, Raipur Guwahati
3. M/s Rathi Steels ,Ghaziabad 7. M/s Vandana Global,Raipur
4. M/s N N Ispat Durgapur 8. M/s Real Ispat ,Raipur
– what is different
and what is same

 Different  Same
 Common tank  Oil Specifications
 Severe filtration  OEM expectations
 Using the blocks for on oil care
TMT as well  Water ingress
 Higher speed s for
wire rods
Blocks

 Existing
 Super Smelters Ltd., Jamuria
 Super Smelters Ltd., Durgapur
 Ankit Metals & Power Ltd. Kolkata
 Jai Balaji Steels Ltd., Durgapur
 Global Smelters Ltd., Kanpur
 Binju Saria Metal Box Co. Ltd, Hyderabad
 Sunflag Iron & Steel Co.Ltd , Nagpur

 Future
 Shyam steel Durgapur
 Nandan Steel Raipur
 Anjani Steel Raigarh
What Next

First trial at
Morgardshammer
GREEN ORANGE BLUE PURPLE RED
Newly planned Out of warranty Upcoming new Out of warranty Unorganized
blocks of Indian blocks at projects with blocks at Major rerolling mills
OEMS small/medium blocks of Integrated steel working as
rerolling mills International plants subcontractors for
(Indian OEMS) OEMS (International big steel plants
OEMS)
Total business High Moderate Very High High Low
from all lubricants
Influence of OEM High Moderate Very High Moderate Low
Operation speed High High Very High Very High Low
Willingness to try Low Moderate Very Low Low High
alternatives
Sensitivity to price Very High High Moderate Low Vey High
Maintenance level Moderate Low Outstanding Good Very Low
Need for technical Moderate High Very low low Moderate
support and
Services
 Rashtiya Ispat Nigam Ltd.
 Tata Steel Jamshedpur
 Bhilai Steel Plant
 ISSCO Steel Plant
 Bhushan Power and Steel , Chandigarh
 Mittal Steels ,Indore
 Usha Martin , Jamshedpur
 Jaisawal Neco , Raipur
 Viraj Profiles Limited ,Tarapur
Thankyou

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