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January 9, 2026Prevent Bearing Failures and reduce Lubricant consumption in TMT Bar Mills
TMT bar production involves a series of continuous processes including billet heating, rolling, quenching, and cooling to manufacture high-strength steel bars. Mechanical elements used in these operations are exposed to extreme conditions such as radiation heat, shock loads, high-speeds and continuous exposure to cooling water. From high-temperature zones (1200 °C) like casting moulds and induction furnaces to high load, high-friction areas such as rolling mills and cutting units, use of appropriate lubricants that can withstand these extreme conditions and ensure consistent lubrication of friction partners of bearings, chains, gears and other mechanical elements is crucial in ensuring reliable operations.
In the rolling section, work roll bearings support the roll shafts that mold and shape billets into desired diameter. These bearings are subjected to high radial loads with certain axial thrust and endure intense shear rates. Additionally, the bearings also experience radiation heat while also being exposed to contaminants such as high-pressure water, scale, and metal particles. Effective lubrication protects these bearings from wear, ensures smooth rotation and maintains consistent dimensional accuracy throughout the operation
Customer : A leading manufacturer of high-quality TMT bars, with a legacy spanning over two decades. With an annual production capacity of more than 500 metric tonnes, the company has been delivering durable, high-strength and flexible steel solutions tailored to the needs of the construction industry.
Application details:
Concern in ‘Finishing Section’
At the finishing section operating conditions include impact loads, heavy water exposure, corrosive conditions, radiation heat and high-speed. A centralized lubrication system is critical in maintaining equipment integrity under these demanding conditions.
The customer was using a mineral oil-based calcium sulfonate thickened grease of Brand ‘X’.
Issues Faced
BECHEM’s recommendation
Having observed the operational parameters and based on vast expertise in manufacturing and supply of speciality greases to top steel mills, the BECHEM team recommended, high performance water resistant grease, BECHEM High-Lub FA 67-400. This heavy-duty grease with excellent water resistance characteristics ensures good protection against corrosion and smooth pumpability in challenging operational environments.
Did you know : BECHEM India is one the largest speciality grease manufacturers and suppliers for industrial applications in the country with its own manufacturing plant at Bidadi Works.
Having previously encountered tube choking issues with NLGI 2 greases, the maintenance team was initially reluctant to approve a trial in the centralized lubrication system. However, the BECHEM team, addressed these concerns by presenting proven performance data and success stories from similar applications in other steel plants. This evidence convinced the customer to proceed with a controlled trial.
Trial Procedures:
Key observations:
Result :
As the trial progressed, the customer observed a steady improvement in grease flow and distribution, with no issues of distributors choking. Satisfied with the consistent performance and a drastic reduction in bearing-failures, the customer, switched over to BECHEM High-Lub FA 67-400.
