CASE STUDY Finishing Mill Roll Bearings : Reduced Consumption and Improved Lubrication QUAKERTEK™ CS 4015-EP The Challenge
large steel mill, was currently using a grease in the roll • Abearings on their finishing mill, that was causing them to have 24 bearing failures a year
mill wanted to make a change that would extend • The the lubrication periods, reduce grease consumption and even further reduce bearing failures
Verkol Lubricants, a Quaker Houghton Company, assessed the mill’s situation, and introduced QUAKERTEK™ LX 4602EPE, a lithium complex grease, reducing bearing failures to 5-6 a year. After 8 years of using QUAKERTEK™ LX 4602-EPE, the mill wanted to run a trial with the main purpose of optimizing grease consumption without causing wear problems, and also to:
• • Avoid grease spillage and residue • Reduce the number of bearing failures Extend grease lubrication cycles
steel. At this point the trial was considered a success and ended
by using QUAKERTEK™ CS 4015-EP the • Additionally, mill was able to extend lubrication cycles and reduce
The chart below shows the comparison of grease consumption for 21.000tn of rolled steel GREASE
g OF GREASE/ tn OF STEEL
QUAKERTEK™ LX 4602-EPE
14.72
QUAKERTEK™ CS 4015-EP
3.67
Reduction in consumption
11.05
reduced grease consumption, also allowed • The the mill to reduce the amount of grease in stock,
The trial was designed so the bearings would be greased one time with QUAKERTEK™ CS 4015-EP, calcium sulfonate complex grease, and then checked when 10.000tn, 15.000tn, and 20.000tn of steel was rolled. The chart and pictures below shows how the bearings looked at the evaluation points. At each point the grease layer becomes thinner, but grease still remains in the space between the rolling elements.
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CS 4015-EP was able to remain in • QUAKERTEK™ place and lubricate the bearing for 22.078tn of rolled
grease consumption, using 4 times less grease in their finishing mill operation
The Solution
BEARINGS
The Benefits
TARGET (tn)
REACHED (tn)
10.000
9.007
15.000
15.928
20.000
22.078
improving the cleanliness of the workshop and reducing the risk of slip and fall injuries
benefits realized with the conversion to • Additional QUAKERTEK™ CS 4015-EP were:
• Reduced hours for chock maintenance bearing life, reduced bearing stock and • Increased bearing failures to 0-3 a year
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