Shell Metals

3D sector guide

Lubricants for Metals

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.

Recommended product: Shell Morlina S3 BA

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