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I would like feed back as to what grease is being used around the world to lubricate the segment rolling bearings, I'm looking for brand names.

Thank you all
Original Post
In India TATA STEEL have been successfully using MATRIX POLY HT PLUS 2 -POLY UREA GREASE for castor roller bearings for the past 2 years .

For more info please contact frankyxavier@yahoo.co.uk
We are using a calcium sulfonate grease with a 460 cSt base oil, in an NLGI 1 grade. We experience the avoidance of bearing breakages especially in sections 1-6, and the low volumes used makes this a special grease.
Hi

Both the greases mentioned will perform well, the Calcium Sulfonate would be our chaoice as is Over based preventing corrosion and will continue to provide good lubrication with 50-60% water inter mixed with the grease, The calcium Sulfonates are not suitable for high speed, we are a lot warmer here in Australia so look for a ISO 460 Base Oil @ an NLGI 2 rather than a #1.
SKF, Anglomoil, Mainlube carry calcium Sulfonates, here, the Mobil Exxon Grease has CaCO3 Solids, usually a light brown opaque grease.

Regards

Rob S

rttech.com.au
So far we have:
Calcium sulfonate
Aluminium complex
Polyurea
All appear to work satisfactorely.
No trend so far

I would like technical data for all products mentioned, please email them to Frank.Cabello@bluescopesteel.com
Hi Frank

Long time no chat nice the see you are still at the wheel

I'm inclined to steer you towards the Calcium Sulfonates as they were designed for steel mill type applications,

Polyureas will perform OK in these applications but I think the calcium sulfonate will be the superior product.
Polyureas are excellent grease for hot no regreasing application as the thickener will not solidify significantly in over temp situations.

The calcium Sulfonate can "lock up" if not relubricated in hot applications but most of your applications are lubricated via auto lubricator so would work OK,
The main advantage of the calcium Sulfonate is the thickener is over based providing very good corrosion control in addition to the ability to lubricate well when mixed with water.

I think the importers all utilise the Mobil Exxon calcium Sulfonate (Was Witco), the 400 cSt base oil version would suit,
The opaque light Brown Grease Uses CaCO3 as the boundary additive so no chemical EP and no reactivity from water being mixed.

Hope this assists.

Best regards


Rob S

rttech.com.au
Rob
I agree with you and GREASESPEC that a 460 cSt calcium sulfonate is the best lube for the lubrication of segment bearings in a continuous caster, the next question is who out there is using a similar grease in a Demag/SMS continuous caster ?
Kluber STABUTHERM GH 461/462 for central lubrication.
Contact your local Kluber company!
We have extensive experience in this application.

Regards,

Ciprian
We tried some polyureas and calcium sulfonate. It's really a question of more or lesse re-lubrication or more or less corrosion protection.

Many brands available, almost everyone has this products.
Ciprian and pedrofamado
You mind telling me is your caster a continuous caster?
What make? SMS, Demag, Vost Alpine, Danielly
hi,

I'm not sure whether u would rather choose grease to meet the demand, but I can introduce a brand called Huifeng. www.huifengco.com ,their vacuum quenching oil maybe can meet ur need.

jenniehu1987@hotmail.com
quote:
Originally posted by macabf:
I would like feed back as to what grease is being used around the world to lubricate the segment rolling bearings, I'm looking for brand names.

Thank you all
Macabf,

Most casters around the world are still using 1940 lithium grease technology due to the misconception that low unit cost is equivalent with a low cost to serve. This is basically the same reason for the domination of aluminum complex greases in some parts of the world.

The operating conditions can vary greatly between a billet or rail caster and a slab caster and if or not the shafts in the spray chamber has thru shaft cooling or just spray cooling. Most modern slab casters with thru shaft cooling run pretty cool with bearing temperatures in the spray chamber and straightener of 60-80C peaking at 100-110C whereas billet casters often only have spray cooling and thus run much hotter, sometimes as high as 160-180C. This means that the grease technology required can vary with the type of caster.

For billet casters I would normally recommend lithium complex and polyurea such as Albida HD, Albida WR, Limona LX and Stamina 0511. For slab casters you can achieve excellent results with state-of-the-art lithium-calcium technology and I've seen reduced grease consumption to <5g/casted tonne using products such as Steelrol EPH1. With lithium complex greases consumption rates are often ranging from 35-65g/tonne and for aluminum complex greases I've seen consumption rates in excess of 160g/tonne. Thus unit cost can be misleading.

Calcium sulphonates has interesting EP performance but lacking in lubricity, often failing lubricity tests such as SKF R2F A and also lacking in water sprayoff resistance.

If you use high temperature grease formulations when operating temperatures are low you sacrifice washout resistance and rust inhibition as well as possibility to minimize consumption and waste handling i.e. scale pit reclaim costs.

If you use a temp logger and insert some probes thru the lube grooves and monitor over some time you can determine what the requirements of your caster is and make a better choice than going on references alone.

You may get the best result by using one type of product in spray chamber and straigthener and a different type of product on runout table and cooling bed.

You may also find it beneficial to look at theoretical bearing life and optimize viscosity and load carrying capacity to your casting speed. You may be able to significantly extend bearing life and reduce segment rebuild cost by chosing the right product.

Grease is not just grease it is an engineering component.

Cheers,
GG
I got a question, would a ISOVG 150 base oil viscosity of a grease can be used instead of ISOVG 460 in segment bearings of continuous casting machine?
Can we ressuracte this discussion - Coming back after a long time to Noria Bulletin Board
So is the globe getting Inclined to Ca Sulfonates rather than poly urea in casting Machines?
Hi
Has anyone faced solidification issues with calcium sulfonate grease as they have deposit forming tendencies which tend to block the lube lines?
Ok to be honest with you, you need to look at a Calcium Sulfonate grease. Look at the specs for they all are not the same, for example. ACT has one that has 800KG weld, less than 1% water washout and has a dropping point of 550F. The working temp is 500F. On the other hand Mobil has a product that is 450 KG weld, 3.5% water washout. This makes a difference in the steel industry. I know that Bob McKimm is placing this product in every application in a steel mill, because it works. You get a better product over the Polyurea that everyone is talking about. You might pay a little more but it is well worth it. If you need any further information let me know or call me.

Why do we need a grease with 800 kg Weld Load?

Has anyone measured the bearing load at the worse location?

Is there correlation between Weld load at 1200 rpm and bearing speed 4 rpm

All good questions, any answers?

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