dr s paul, dgm & dr pankaj bhatnagar, gmrmoc.tksranchi.in/rmoc52/presentations/iocl.pdf · dr s...
TRANSCRIPT
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
<50 ml/T
Case Study -4 Introduction of Servosteerol H4 at Bhilai Steel Plant
Application : Rail Mill
10
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
Tri
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Tri
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Tri
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mm
erci
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Oil
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Oil
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Oil
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