Steel and Aluminium
The metal production process poses significant challenges for lubricants due to a combination of factors such as extreme temperatures, heavy loads, corrosion, abrasive particles, caustic substances, and acids.
Iron and Steel Mills
Machinery in iron and steel mills are required to operate consistently under harsh conditions, including high temperatures, heavy loads, exposure to water, steam, and corrosive chemicals, which collectively contribute to the deterioration of lubricants, unexpected downtime, and heightened maintenance expenses.
Casting operations take place in a highly corrosive and hot environment, often contaminated with substantial particulates and water. The gearbox drive serves as a critical oil-lubricated component, and a failure in this system can lead to a halt in casting operations, causing production losses and potential safety risks.
The mill rolling process occurs in hot, corrosive, and wet environments, often affected by significant particulate and water contamination. The gearboxes and hydraulic systems serve as the primary oil-lubricated components in this setting. The gearboxes drive various machine components and power conveyors responsible for transporting the metal to other locations. Simultaneously, the hydraulic units play a crucial role in shaping the metal to precise dimensions, weight, and thickness.
Any failure in these systems can impact safety, production quality, and overall output.
Sinter plants incorporate numerous rotating components crucial for producing a product suitable for blast furnace use. Crushers, situated in confined spaces, are exposed to significant particulate and moderate water contamination. The gearbox and hydraulic system are the primary oil-lubricated components in this setup. The gearbox drives the crusher’s counter shaft, while the hydraulic system maintains a specific gap between the bowl and mantle.
The failure of either component can result in production loss or a decline in product quality. Although these systems may have OEM-specified filtration, additional protective measures will be necessary.
Operating within an intensely hot environment with substantial particulate contamination, an Electric Arc Furnace (EAF) relies heavily on its hydraulic system as the major oil-lubricated component. This system powers nearly all movements within the EAF, including roof operations (lowering, raising, and swinging), electrode arm adjustments, furnace tilting, slag door control, and the movement of auxiliary systems like the burner lance.
Challenges such as low fluid levels, decreased accumulator pressure, system leaks, fluid degradation from overheating, valve or hydraulic line blockages, and mechanical component wear can significantly impact system performance and lead to operational failure.
Mill rolling operations occur in hot, corrosive, and wet environments, often contaminated with heavy particulates and water. The major oil-lubricated components in this setting are the gearboxes and hydraulic systems. Gearboxes drive various components in the milling machines and power conveyors that transport the metal to different locations, while hydraulic units are essential for shaping the metal to precise dimensions, weight, and thickness. Should these components fail, it could have a significant impact on safety, production quality, and overall output.
Mill rolling operations take place in environments that are hot, corrosive, and wet, often experiencing significant particulate and water contamination. The gearboxes and hydraulic systems serve as the primary oil-lubricated components in this setup.
Gearboxes are responsible for driving various components in the milling machines and powering conveyors that transport the metal to different locations, while hydraulic units play a crucial role in shaping the metal to precise dimensions, weight, and thickness. Any failure in these components can have adverse effects on safety, production quality, and overall output.
Mobile equipment operates in a harsh environment characterized by dirt, moisture, and rugged terrain, often facing heavy particulate and water contamination. The engine, final drives, and hydraulic components are the major oil-lubricated parts in this setup.
The engine provides power to the equipment, the final drives facilitate the movement of large wheels, and the hydraulic components are responsible for transporting substantial amounts of material from one location to another. A failure in any of these components could lead to a substantial production loss due to the absence of redundancy. Despite potential OEM specified filtration, additional protection will be necessary for these systems.
Every industrial plant should be equipped with a designated lube room, ideally located in an area with minimal particle and dirt contamination and capable of maintaining a constant temperature.
The central function of the lube room is the storage of new oil. This necessitates the inclusion of storage drums and drum racks. New oil should undergo filtration before use, achieved through the utilization of storage units with built-in filtration or by employing a filter cart to purify oil in drums. Additionally, these units should be equipped with desiccant breathers.
In addition to oil storage, the lube room serves as the designated area for housing transfer pumps, valves, filter carts, portable storage containers, and various other lubrication-related supplies such as grease guns, oil cans, unused filters, cleaning materials, and spill absorbents. The organization of these supplies is a crucial aspect of lube room management.
The lube room serves a dual purpose: not only as a site for oil dispersal and transfer, but also as a platform for a company to instil and uphold a culture of effective, meticulous oil handling standards.