STEEL MILL GEARBOXES RUN COOLER, CLEANER, AND LONGER WITH EUROTEC GEARLUX CLP 220

Industry: Iron & Steel

Location: Algeria

Client: Private Rolling Mill Producing Long Products with 18 Gearbox Systems

Related Product: Eurotec GearLux CLP 220

Client Background

This Algerian steel mill operates a continuous bar and wire rod production line with integrated roughing,

intermediate, and finishing stands. The facility relies on 18 high-load enclosed gearboxes, including

horizontal reduction gearboxes, pinion stands, and auxiliary conveyors. Operating conditions includeambient temperatures exceeding 40°C and heavy shock loading during production shifts, creating extreme demands on the lubricant’s film strength and thermal stability.

Operational Challenge

Over a 12-month period, the plant experienced frequent oil-related issues in their gearbox systems:

• Operating temperatures consistently above 95°C, triggering alarms and derating

• Visible sludge and dark deposits inside gear cases during inspection

• Frequent foaming, especially during extended shifts, leading to lubricant starvation

• Gear wear and pitting confirmed through endoscopic inspection

• Oil replacement every 3 months, disrupting production and driving up costs

The existing lubricant, a conventional EP gear oil with minimal thermal conditioning, failed to meet the demands of continuous steel rolling under variable loads.

Solution

Eurotec proposed replacing the incumbent oil with Eurotec GearLux CLP 220, formulated with:

• A high-quality mineral base enhanced with a thermally stable sulfur-phosphorus EP additive system
• Strong demulsifying properties to protect against water ingress from mill operations
• Advanced oxidation inhibitors to resist thermal degradation over extended drain intervals
• Foam suppressants to maintain consistent film thickness and circulation under stress

A detailed implementation plan included a two-phase deployment: initial flushing and testing on 6 critical gearboxes, followed by full conversion if results met operational KPIs.

Implementation Process

• Gearboxes were flushed using Eurotec’s system cleaning protocol to remove sludge and varnish
• New filters and desiccant breathers installed to minimize contamination
• Infrared thermography and vibration monitoring conducted pre- and post-transition
• Oil analysis scheduled every 2 months to evaluate TAN, viscosity, ISO cleanliness code, and oxidation

Eurotec provided training for the mill's reliability engineers on proper gear oil condition monitoring and early failure detection.

Measured Results

• Gearbox temperatures dropped by 6–8°C, improving lubrication film strength and reducing metal-to-metal contact
• Sludge formation eliminated, with gear cases remaining clean during quarterly inspections
• Oil drain interval doubled from 3 to 6 months without degradation or additive depletion• Maintenance labor hours reduced by 22%, allowing reallocation of staff to other critical tasks
• No new wear or pitting observed via borescope inspections after 9 months of service

Customer Statement

The switch Eurotec GearLux CLP 220gave us exactly what we needed - consistent thermal performance,

clean gearboxes, and fewer shutdowns. It's a long-term win for operational efficiency and asset life extension.