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  • Dr S Paul, DGM & Dr Pankaj Bhatnagar, GM Indian Oil Corporation Ltd

    Research & Development Centre

    Faridabad, Haryana

    52nd Rolling Mill Operating Committee (RMOC) Meeting

    Feb 14-15, 2019

    1

  • Contents

    o General

    o Servo Hot Rolling Oil Portfolio

    o Composition and Commercialization

    o Portfolio of Other Rolling Oils

    o Rust Preventive and Cutting Oils

    o Summary

    2

  • Role of Rolling Oil at Hot Strip Mill

    Optimizing Friction at Roll Bite

    Overall Lubrication and Cooling

    Reduction of Roll Wear and Surface Peel Off

    Increased Campaign Length / Production

    Lower Power Consumption

    3

  • Servo Hot Rolling Oils Diversified Product Portfolio

    S.N Product Application Characteristics

    1. Servosteerol H2 Flat Slab/Sheet Rolling  Dispersion type Rolling Oil

     Quick separation of oil for

    optimum lubrication

     Excellent spreading

    characteristics on the roll

    surface

     Improved wear properties

    and lubricity on the roll

    surface

     Safe-High Flash Point

     Easy to handle-Low Pour

    Point

     Good burn-off characteristics

     Environmentally safe

    2. Servosteerol H3 Flat Slab/Sheet Rolling

    3. Servosteerol H4 Structural Rolling like Rail

    Mill etc.

    4. Servosteerol H5

    Edger Rolling

    5. Servosteerol H6

    Flat Slab/Sheet Rolling

    6. Servosteerol H7

    Structural Rolling like

    Channels, Angles etc

    Roll Bite Lubrication (RBL) / Edger Roll Lubrication

    Systems also provided by IndianOil 4

  • Servo Hot Rolling Oils

    Mineral Base Oil

    Vegetable Ester

    EP Additive

    Antiwear Additive

    Others

    Each rolling oil is

    customized

    for

    customer specific

    requirement

    as per plant parameters

    and

    operational requirements

    Provides optimum plate out and tribological

    performance at roll bite

    Synergistic Composition

    5

  • Introduction of Servo Hot Rolling Oils

    Rourkela Steel Plant(RBL)

    Bokaro Steel Plant

    ( RBL)

    Bhilai Steel Plant (RBL)

    Rourkela Steel Plant

    (RBL)

    Jindal Stainless(RBL)

    2012

    2013

    2014

    2015

    2016

    2017 2018

    JSW Steel

    (ERL)

    Bokaro Steel Plant

    (ERL)

    Servosteerol

    H2

    Servosteerol

    H4

    Servosteerol

    H3

    Servosteerol

    H2

    Servosteerol

    H5

    Latest Developments: Servosteerol H6 & Servosteerol H7 as per

    specific requirement of two Steel Plants

    6

  •  Product introduced initially at F1 Stand of HSM

     Following benefits obtained:

     Reduction in roll force by ~10%

     Reduction in power consumption by ~ 7 %

     Reduction in work roll wear

     Lower roll surface peel off

     Commercial Supply at RSP

     All the Six finishing stands

     Roll Bite Lubrication System(RBL) provided by IOCL

    On BOO (Build-Own-Operate) basis.

     Provided Total Fluid Management (TFM)

    Case Study -1 Introduction and use of Servosteerol H2 at Rourkela Steel Plant

    IOC provided Oil, RBL & TFM 7

  • Following benefits obtained:

     Increase in campaign size by ~15%

     Reduction in specific consumption of rolls

    by >15%

     Decrease in power consumption by 5-10%

     Ease in rolling of value added steels

     Significantly lower Specific Oil

    consumption (~25 ml/t )

    8

    Case Study - 2 Introduction and use of Servosteerol H2 at Bokaro Steel Plant

    IOC provided Oil as well as TFM

  • Introduction of Servosteerol H3 at Jindal Stainless Ltd, Jajpur

    Application : Roughing Mill : Work Roll & Back up Roll

    Finishing Mill : Back up Roll

    Benefits Obtained : Improvement of Roll life

    Reduction of Surface defects

    Case Study -3

    9

  • Trial at 4th and 6th pass of the 2nd intermediate stand

    Material : Bloom of 70 m

    Trial Parameters Results

    Physical properties of Oil

    -Odour, Fumes/Smokes

    -Pour ability

    -Mist Formation

    -Mix ability with water

    No bad smell or fumes

    Excellent at room temperature

    Good Spray Quality

    Excellent at room temperature

    Roll Wear & Grinding Less wear marks & lower grinding

    requirement compared to commercial

    product

    Specific oil consumption

  • As per MOM trial condition

    Referance Commercial

    sample

    IOCL Oil 1st campaign

    IOCL Oil 2nd campaign

    As per MOM trial condition

    IOCL Oil 1st campaign

    IOCL Oil 2nd campaign

    Lower Avg. Roll wear

    As per MOM trial condition

    Referance Commercial

    sample

    IOCL Oil 1st campaign

    IOCL Oil 2nd campaign

    Successful completion of extensive field trial for 5 months

    Case Study - 5 Introduction of Servosteerol H5 for Edger Rolling at JSW Steel

    Key Highlights

    Smooth plant operation without

    any slippage

    Overall higher production

    Relatively low er roll wear

    Lower oil consumption and

    Better overall economics

    T ri

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    O il

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    O il

    Production

    Oil Consumption

    11

  • Approval by JSW Steel

     Oil, ERL System and TFM by IOC

    Commercial Supply Started

    Case Study - 5 Introduction of Servosteerol H5 for Edger Rolling at JSW Steel

    12

  • Servo Rolling Oils for Other Applications

    S.N Grades Application as Rolling Metals

    1. Servosteerol 22 (J)L Neat Oil Stainless Steel

    2. Servocuprol 10 Neat Oil Copper & Bronze

    3. Servoarol 76 Emulsion Aluminum

    4. Servosteerol C5

    Servosteerol SS C6

    Servosteerol C28

    Servosteerol C32

    Metastable

    Emulsion

    Mild Steel

    5. Servocuprol S Water Solution Copper

    Diversified Rolling Oil Portfolio 13

  • Servo Rust Preventive(RP) and Cutting Oils

    RP Oils

    (Servo RP Series Oils)

    Wide portfolio/range of Solvent and Mineral oil based RP

    Oils for different Industrial applications

    Oil suitable for the protection of Cold Rolled(CR) Sheet

    OEM approved oils for electrostatic spraying

    Cutting Oils

    (Servo Cut, Servo Synth Cut and Servo Grind Series Oils)

     A range of Soluble and synthetic cutting oils portfolio

     Specifically for grinding and cutting applications

    Customized Products for Steel Plant Application

    14

  • Summary

    IOC has developed and successfully commercialized different grades of hot rolling oils for various steel plants and different

    type of applications including structural & edger rolling.

    Servo Steerol H series Hot Rolling Oils provides optimized lubrication, lower roll friction and wear and lower power

    consumption enhancing the productivity

    Servo range of oils for diversified applications including rolling, rust

    prevention and cutting/grinding of a variety of metals like mild steel, stainless steel, aluminum

    and copper available

    IOCL is capable of providing/developing

    customized oils / solutions including RBL/ERL and TFM

    for steel and other plants suiting their specific

    requirements.

    Customized solutions for optimum lubrication 15

  • Steel Plant Plants IndianOil

    16

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