Use our 3D guide to get closer to how we are improving energy efficiency and enhancing equipment
protection through lubrication.
Welcome to our virtual steel mill: Maintaining productive mill operations.
Explore our interactive virtual steel mill tool to see how effective lubrication keeps three critical
pieces of equipment running smoothly, safely, and reliably – even in the most extreme environments.
Disclaimer: Please note, this tool is for illustrative purposes only. The size, layout and detail of the
equipment, machinery and processes displayed may not show a 100% accurate representation relative to each
mill’s specific operating set-up.
Concaster: Improving performance and safety
Click the hotspots to discover how Shell lubricants can help to improve
productivity, efficiency and worker safety in concaster operations.
Strand guide roller bearings – centralised grease distribution system: Extending roller bearing life with
centralised grease distribution
With ineffective lubrication, moisture ingress and high temperatures can lead to incipient corrosion and
shortened bearing life – as well as increased downtime and maintenance expense. This means that grease
selection can have a positive impact on reliability and operating efficiency. Important performance
characteristics to consider during selection include centralised system mobility, water resistance,
corrosion inhibition, load carrying capacity, and mechanical stability – all of which are covered by the
Shell Gadus range.
Recommended products: Shell Gadus S3 V460; Shell Gadus S3 T460 and Shell Gadus S5 T460
For roller bearings using the oil air system, operators need to maintain the nozzle regularly to ensure a
constant spray and check for contamination from dirt and water. High-quality oils (such as Shell Omala S4
GXV) help to protect the bearings at high temperatures, extend equipment life and reduce lubricant costs
with less product needed.
Concaster hydraulic system: Improving hydraulic performance and worker safety
Facing extreme temperatures and possible contact with ignition sources, conventional mineral oils can be a
hazardous lubrication choice for the concaster hydraulic system. Selecting fire-resistant hydraulic fluids
for high-performance hydraulic systems (such as Shell Water Glycol ranges) significantly reduces the risk of
fire and helps to maintain the safety of metal workers.
Recommended products: Shell Water Glycol S2 CX 46
Some manufacturers prefer to lubricate their servo valves in the concaster hydraulic system with
mineral-based hydraulic oils, such as Shell Tellus S2 MX. Shell Tellus S2 MX fluids are high performance
hydraulic fluids based on Group II base oils that use Shell’s unique patented technology to provide
outstanding protection and performance in most manufacturing and industry equipment. They resist breakdown
under heat or mechanical stress, provide outstanding wear protection with long fluid life and help prevent
damaging deposit formation that can decrease the efficiency of your hydraulic system.
Hot rolling mill: Protecting bearings and mill workers
Click the hotspots to discover how Shell’s greases, and fire-resistant hydraulic fluids can help to
protect and extend the lifetime of rolling mill bearings – while also improving worker safety.
Back-up roll application: Providing greater protection and lower Morgoil consumption
Where previous designs had two tanks (to include a standby), OEMs have moved towards single tanks of
smaller size. This increases lubricant efficiency and reduces operator costs but requires a higher-quality
product – one that releases air and delivers water separation. Shell Morlina S3 BA provides superior air
release and water separation properties, extending bearing life while reducing oil consumption.
Work roll bearings: Extending equipment life with superior water resistance
Corrosion and water contamination are a challenge for rolling mill bearings, reducing the component life
and increasing the need for replacement, increasing inventory costs. To prevent this and improve
productivity, it is important to use high-performance greases (such as the Shell Gadus range) formulated
with appropriate base oil viscosities – alongside a combination of water resistance, mechanical stability,
anti-wear performance, and corrosion protection.
Recommended products: Shell Gadus S2 V220 AC; Shell Gadus S3 V460
Automatic gauge control Hydraulic System: Reducing safety risks with fire-resistant hydraulic fluids
Gauge control, roll balancing and coiling systems face a significant fire hazard – and the use of
conventional mineral oils in the hydraulic system can increase the risk of fluid ignition. Fire-resistant
fluids, such as the Shell HFDU range, significantly reduce this risk, maintaining mill safety while helping
to drive productivity.
Recommended products: Shell Fire Resistant Hydraulic Fluid S3 DU; Shell Fire Resistant Hydraulic Fluid S1
DU
Run out table: Improving efficiency and bearing life
Click the hotspots to discover how Shell’s high-performance greases can overcome lubrication mobility
challenges to help extend bearing life and improve mill productivity.
Run out table: Extending bearing life with high performance greases
Run out tables require effective lubrication to insure smooth, continuous operation. However, many grease
technologies struggle with mobility when faced with different system designs or even a drop in ambient
temperature. High-performance greases for these applications (such as Shell Gadus) overcome these
challenges, providing effective lubrication to drive productivity, increase re-greasing intervals and extend
bearing life.
Recommended products: Shell Gadus S2 V220; Shell Gadus S2 V220 AC; Shell Gadus S3 V460