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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.


Rob S
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

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

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.

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.

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