Blue Star XH 9655/200-1/3M Case Study

Manufacturing

Case Studies:

Blue Star XH 9655/200-1/3M Improves Bearing Reclaim Rates and Load Wear While Withstanding Low Temperatures and Water Exposure

BACKGROUND:

Driving sustainable process improvements within the caster operation of a steel mill is very challenging. The severe environment requires careful planning and control of any operational change to avoid production risks. When this steel manufacturer began experiencing a significant reduction in their average bearing life and reclaim rates, a large increase in maintenance costs was incurred. Bearings have typically been able to be reclaimed seven times before requiring replacement.

OPPORTUNITY:

• Improve bearing life and reclamation frequency.
• Extend the segment tonnage between rebuilds.
• Reduce the volume of grease used.

CHALLENGES:

• Determining optimal grease thickener and base oil.
• Ensuring that the grease will pump in below zero environment.
• Implementing the grease transition without impeding production.

THE DUBOIS SOLUTION:

A DuBois team of technical experts partnered with the manufacturer to determine what factors contributed to the reclaim reduction and determine an ideal high-performance lubricant that would protect the bearings and significantly reduce their bearing expenditures. Blue Star XH 9655/220-1/3M was deemed a suitable option through a series of laboratory evaluations. This innovative technology has drastically increased the level of lubrication and water resistance. Compatibility with the existing grease allowed for a seamless transition throughout the caster.

RESULTS AND BENEFITS:

• Doubled the load wear and weld load performance for improved bearing protection.
• 87% reduction in water wash out improves the grease’s sealing ability and extends lubrication cycles to reduce usage.
• Improved grease performance achieved without sacrificing pumpability during freezing weather conditions.
• Compatible grease technologies for seamless transition in grease lubrication system.

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