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Environmentally and operationally unacceptable products such as borax have been used in lubricating the inner bore of pierced shells in the production of seamless pipe. Borax represents significant threat to workers and also leads to significant maintenance costs (electrical equipment) and disposal costs to the steel mill. This paper discusses the development of water based lubricants replacing borax decreasing occupational health and safety risks, and lowering maintenance and disposal costs without compromising shell quality and production. The development of the application system, to reduce waste and optimize operations had a significant influence on project success. In particular, de-oxidising technology developments learnt from seamless pipe rolling are being applied to scale reduction in other hot rolling operations such as long products, Steckel mill, plate mill and hot strip mills. Key engineering developments in application system technology and spray application have been needed to meet many process challenges. All stakeholders in developing this new technology bundle of chemical and application systems needed to track and quantify benefits obtained in a systematic manner. This systematic approach ensures that all change processes necessary in achieving a successful replacement of borax are identified, fine-tuned, and embedded into standard seamless pipe mill operations.