Success Stories at

Visakhapatnam Steel Plant

India
 Equipments Lubricated with
Molykote at Vizag Steel
• Hammer Crushers
• Blender Reclaimers
• ID/FD Fans
• Motors
• Pumps
• Vibratory Screens
• Chains
• Hydraulic Cylinders
A Bird Eye View of Visakhapatnam Steel Plant
• Conveyor Bearings with the Thermal Power Plant in the Foreground

• And, many many more

 Why the customer chose to go for
Molykote Products
• Increasing demands on enhancing production without capacity
expansion

• Downtime had to be avoided

• Unscheduled stoppages had to be avoided

• Reliability had to be increased. Chances for human errors to be

minimized.

• Manpower costs as a %age of total lubrication costs had gone up

due to wage increases.

• Molykote products have a pedigree of proven performance and had

shown excellent results in wherever they were used. Hence, more
products were allowed in when new applications were found.
 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 can be extended to 12 Many screens have extended their
schedule from one week to 45 days.
days. This particular screen in the picture is
the most critical in the plant’s
Sintering Zone.
• Expected Volume - 720 kgs/year
 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.
Spherical sheets subjected
to oscillation and high temperatures
lubricated now with Molykote Cu 7439
for last 5 years, once during overhaul.

• Volume: 20 kgs/year
 Other Molykote Products Supplied
• Molykote D Paste
• Molykote M 30 Chain Oil
– Roll Shop Roll Assembly
– Furnace Area Chains
– WRM Compactor Rails
– Rolling Mill Conveyor Bed
– Water Management for Valve
Chains
Assembly
• Molykote 1000 Paste
• Molykote GN + Paste
– Anti-seize applications
– Various assembly
applications at Area Repair • Molykote 111 Compound
Shops
– O ring assembly
• Molykote Z Powder
• DC 4 Compound
– Various dry lubrication
– Electrical Repair Shop
applications in utility plants,
converters and coke ovens.