Alexandria National Iron and Steel Company (ANSDK) is an Egyptian-Japanese joint venture, owned 87% by 11 Egyptian public-sector companies, 10% by a Japanese consortium, and 3% by International Finance Corporation. It produces and distributes reinforced bars, billets of all international standards, and hot rolled flat steels. ANSDK was established in 1982, being regarded as one of the most prominent economic development projects in Egypt, exported to Saudi Arabia, Yemen, the United States of America, Canada, Spain, Sudan and China. Reinforcing bars sales contributed to over 90% of revenues. In 1998, the company was ISO 14000 accredited recognizing its achievements in environmental protection.
ANSDK, having an annual capacity of 800,000 tonnes of direct-reduced iron (DRI) and 160,000 tonnes of flat steel products was strategically located at El-Dikheila on the Mediterranean, 15 km west of Alexandria City. Import of raw materials was deemed possible through the newly constructed expansion of Alexandria. A more cost effective energy – natural gas was readily available at East and West of Alexandria city, Egypt.
The Hot Job
There were many lubrication and greasing needs in a full-fledged steel plant like ANSDK. An ordinary grease would somehow meet the basic needs of common equipment with limited range of operating temperatures. However, the real hot and most demanding greasing job was in the “hot strip mill” which operated at the highest temperature with the lowest machinery speed in a steel plant. These ultra demanding operating conditions emulsify the ordinary grease with the coolant. The needed grease characteristics and performance for the hot strip mill had been sub-optimal.
More frequent top ups and monthly re-application of grease were seemingly the only way out, though understandably undesirable. Excessive man-hours and grease costs were incurred at the disadvantage of ANSDK.
Toughest Challenges Embraced by Omega
In industrial maintenance, it is only through the toughest job one may differentiate the best from the ordinary. With the joint effort of Mr. Amr Hafez, General Manager of Scientific Center for Industrial Services (SCIS), distributor of Omega Lubricants, Greases & Additives in Egypt, Mr. Walid Guindi, Senior Marketing Consultant and Mr. Wagih Eldeeb, Marketing Consultant of Magna Industrial Co. Limited, (supplier of Omega) Omega 57 – Super Bearing Grease was recommended.
Omega 57 grease withstood all the thorough tests and extreme application conditions at ANSDK. With the professional service of the Omega experts and the specially designed grease pump offered by Scientific Center as a complimentary tool, ANSDK had enjoyed a truly hassle-free solution.
Omega Means Cost-Savings
Very detailed cost saving analyses were conducted by ANSDK and Omega experts to justify and illustrate the cost-saving capabilities of Omega. From the following table, you may identify 12% saving was concluded for Stands F1 and F4 of the hot strip mill; while 35% saving was derived from application of Omega 57 in Stands F5 and F6. The total annual saving in all stands amounted to 22%.
Omega 57 Super Bearing Grease
Omega 57 is truly an “All-Purpose Lubricant” designed to give optimum lubrication results. It is quality engineered for use in a wide variety of high impact, extreme pressure and temperature conditions. Omega contains super supplements and Omega’s exclusive “Megalite” additives that form a wear-resistant film on metal surfaces to minimize metal-to-metal contact. It is formulated for excellent resistance to water and protection to working surfaces against corrosion and oxidation.
Omega 57 features high fiber strength paraffinic base oils to provide unprecedented built-in toughness. Omega 57 is triple milled for rapid penetration into even close-fitting, tight tolerance bearings and fitting. It is also suitable for outdoor applications, thanks to its excellent sealing action.
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