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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

Dr S Paul, DGM & Dr Pankaj Bhatnagar, GMrmoc.tksranchi.in/rmoc52/Presentations/IOCL.pdf · Dr S Paul, DGM & Dr Pankaj Bhatnagar, GM Indian Oil Corporation Ltd Research & Development

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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

<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

al

Co

nd

itio

n

Tri

al

Co

nd

itio

n

Tri

al

Co

nd

itio

n

Co

mm

erci

al

Oil

Co

mm

erci

al

Oil

Co

mm

erci

al

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

Steel Plant Plants IndianOil

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