LUBRICANT MANAGEMENT

Rolling oils are formulated with many components like lubricity agents, synthetic esters,
anti-wear additive, extreme pressure additive, emulsifier, anti oxidants, anti-carbon
additive, anti-corrosion additive, biocide, etc. The oils are also designed to have varying
properties including some special properties like ion rejection properties, tramp oil
rejection properties, hydrolytic stability, thermal stability, detergency, etc. There is
usually more than one choice for each additive in the oil. Thus formulation of candidate
oil for a given mill is not simple. Oil formulators select the types and doses of these
additives based on rolling conditions like type of material to be rolled, geometry of roll
bite (draft, reduction, roll diameter), mode of application (direct or re-circulation), mill
speed, surface finish to be given to the strip, possible chemical reactions with the strip,
further processing of the rolled strips, make-up water type, type and level of
contaminants, etc.

Considering the number of variables involved in designing an oil formulation, the

product so developed may not be a perfectly suitable for the target mill. It is therefore
important for mill operators to have their own methodology for selecting a suitable oil for
their mill. The purpose is not fulfilled only with selecting an oil for the given mill. To
achieve the desired results, the oil should also be properly applied and maintained. Thus,
in any mill, lube management has three vital components:
(a) Selection of suitable rolling oil,
(b) Effective application of rolling oil, and
(c) Proper maintenance of emulsion quality.

5.1 Selection of Cold Rolling Oil

Earlier, there was no scientific approach for selection of rolling oil for a given mill.
Normally oil vendors approached users and selection was based on the wisdom of the
users. In this case, performance of the oil was evaluated directly at the industrial mill.
However, in case of failure of the oil, this exercise was uneconomic owing to
Flat Rolling Lubrication

interruptions in production, product damage, system breakdown, etc. This method of

evaluation also had one more disadvantage that, often, unrecognised variables crept into
the evaluation. This is why laboratory evaluation of lubricants was preferred before going
in for full-scale industrial trials. In the laboratory too, there is no universal test by which
industrial applicability of a lubricant can be evaluated. Therefore each important aspect of
the system is simulated scientifically through different tests in the laboratory.

Selection of candidate rolling oil based on its performance can be divided in four groups:
(a) Evaluation of physico-chemical properties of the oil,
(b) Evaluation of tribological characteristics of the oil at laboratory rigs,
(c) Evaluation of rolling performance of the oil at laboratory mill, and
(d) Evaluation of actual performance of the oil at industrial mill.

Based on the laboratory performance of the candidate oil, its formulation can be
optimised. The optimised formulation can be re-evaluated in the laboratory and if found
suitable, it may be recommended for field trial at the industrial mill.

5.1.1 Evaluation of Physico-Chemical Properties

It was mentioned in the previous chapter, that physico-chemical properties of rolling oils
are important in the sense that they give prior information about the nature and behaviour
of the oil. Although it has not been possible to directly correlate performance of the oil in
industrial condition with regards to its properties, these properties nonetheless are
necessary for making oil specifications. Some of the important physico-chemical
properties of the oil are viscosity, pour point, saponification value, free fatty acid value,
iodine value, emulsion stability index (ESI), surface tension, pH value, ash content,
carbon residue value, chemical corrosiveness, and thermal and chemical stability.
Annexure II gives a list of ASTM standard test methods for evaluating various physico-
chemical properties. Methodologies for the evaluation of some of these properties are
briefly discussed below. Typical properties of some of the successful cold rolling oils are
given in Table 5.1.
Chapter V Lubricant Management

Table 5.1 Typical physico-chemical properties of cold rolling oil

Properties Value
Kinematic viscosity, cSt at 40 oC 30-60
Saponification value, mg KOH/g 90-200
Free fatty acid, mg KOH/g (% Oleic) 5-20
Iodine value, g I2/g 20-55
pH in distilled/demineralised water 5-8
Emulsion stability index (ESI) 0.80-0.95
Mean oil particle size, m 2-12
Ash content, weight % 0.00-0.10
Carbon residue (CCR), weight % 0.10-0.50
Pour point, oC 0-20
Flash point, oC, (COC) 200-250

(a) Viscosity: It is measured by a standard viscometer. Since viscosity is a temperature

related parameter, so a viscosity index is measured which gives relationship of viscosity
with temperature. The viscosity of the rolling oil varies greatly with the pressure. Thus
for calculating oil film thickness at roll bite, it is essential to measure the viscosity at
rolling pressure using a high-pressure viscometer.

(b) Saponification Value: Sap value may be determined by method of titration as per
ASTM D94 standard. It denotes the weight of potassium hydroxide, expressed in
milligrams, required to saponify one gram of the oil or fat to produce soap and glycerine.
Higher the sap value is preferred for better lubricity, however, it may adversely affect
cleanliness performance of the oil.

(c) Free Fatty Acid (FFA) Value: The organic acidity of an oil or fat is usually
expressed in either of two ways: (a) As weight % of free fatty acid present (molecular
weight of which is arbitrarily assumed to be 282, 256 or 200 corresponding to oleic,
palmitic or lauric acid), and (b) As the total acid number. The total acid value is measured
by the method of titration where it is the number of milligrams of potassium hydroxide
required to neutralise the acidity of one gram of the oil or fat. The free fatty acid value of
the oil is approximately taken as half the value of total acid number.
Flat Rolling Lubrication

Total acid value = 5.61*A/F

Free fatty acid, as % oleic = 2.82 A/F.
Where, A = volume in cc of 0.1N alkali used and F = mass of fat or oil sample in gram.

(d) Iodine Value: Iodine value gives the degree of unsaturation of fatty materials and is
measured by titration method involving reaction with pyridine bromide solution.

(e) Emulsification Characteristics: The emulsification characteristics of an oil and

effect of various factors on it can be studied in the laboratory by different methods. But
the principle remains the same, i.e., the rate at which the oil particles separate is
determined by measuring the oil content of emulsions after specified time interval.

In all the methods, a heated sample of the oil is mixed with a specified quantity of water
in a specially designed container to make an emulsion. Mixing rate/speed, time and
temperature vary from experiment to experiment. The emulsion is then sampled at
specified times and then poured into specified flasks and treated with specified acid split
solution. Each flask is then placed in either an oven or boiling water bath in order to
promote oil separation. The volume of separated oil can then be read off using the scale
on the flask. Finally plotting oil content against the time generates a demulsification
curve. An emulsion stability index (ESI) is also calculated in either of the following two
ways:
Oil2 OilBottom
ESI  Or, ESI 
Oil1 OilTop

Where, Oil1 is initial oil concentration and Oil2 is oil concentration after a specified time.
Similarly, OilTop and OilBottom are oil concentrations in respectively top and bottom layers
of emulsion after a specified time.

The effect of emulsion age, contamination and/or shear rate on the emulsification
characteristics or oil particle size can be studied by re-circulating the emulsion in the
specified rig. Different rigs are available for study of emulsification characteristics of the
Chapter V Lubricant Management

oil. Some of them are: Ultraturrax Mixer, Tempunit, Braun Mixer, Oil Breakout Set-up,
etc.

(f) Oil Particle Size: There are some dedicated equipments for measuring oil particle size
in emulsions. For example: Coulter laser particle size analyser, Malvern particle size
analyser, etc. Normal optical microscope can also be used to measure oil particle size on
a slide of emulsion. Using sophisticated equipment, study can be made on the
dependency of oil particle size on various parameters like agitation or shear stress,
temperature, time, etc. as well as type and dose of additives.

Shear stability of the oil is measured in terms of change in oil particle size with applied
shear force. A stable rolling oil exhibits practically no change in its particle size with
application of shear force. On the other hand, unstable oil exhibits maximum change
(reduction) in particle size under such condition. The optimum stability may be designed
in metastable oil.

(f) Ash Content: It is measured by burning/evaporating the oil under controlled condition
furnace.

(g) Carbon Residue: There are few test methods in which level of carbon residue is
measured after breaking the oil under controlled condition. Condradson Carbon Residue
(CCR) Test is one such methods, in which carbon-forming tendency of rolling oil is
studied under specified pyrolysis condition.

5.1.2 Evaluation of Tribological Characteristics at Rigs

Over the times, various types of laboratory rigs have been developed for evaluation of
rolling oil. Test procedures at some of these rigs have been made standard and are given
in books of ASTM or IP standards. The advantages with using test rigs are that these are
simple to use, require small quantity of oil sample and can be used to evaluate a specific
property of the candidate oil. However, the main disadvantage or rather limitation with
most of them is their inability to simulate proper roll bite condition.
Flat Rolling Lubrication

Evaluation of Lubricity: There are various test rigs available today for evaluating
lubricity of the rolling oils. Some of these rigs are Soda Pendulum Lubricity Test Rig,
SRV Test Rig, Falex Pin and V Block machine, LFW-1 Test Rig, and Plint Tribometer.
Details of contact configuration of these test rigs have been given in Table 5.2. In these
tests, lubricity of oil is measured in terms of friction coefficient, critical load/torque, and
wear rate/scar. Some of typical results achieved with successful rolling oils are shown in
Table 5.3.

Table 5.2 Rigs for performance evaluation of rolling oils

Test Equipment Contact Configuration Type of Contact

Soda Pendulum Pin on two pairs of balls Point Contact
Amsler Wear Tester 4 pair of crowned discs Line Contact
SRV Test Rig Ball or Roller on disc Point / Line Contact
LFW-1 Rig Ring on block Line Contact
Ring Compression Test Ring on platen Surface Contact
Plint Tribometer Pin on sheet Line Contact

In all the above tests, specimens are not deformed plastically to a level normally achieved
in rolling operation. Therefore, some additional tests have been developed to evaluate
lubricity of oil under deforming workpiece condition. The two commonly known tests
under this category are Forming Test and Ring Compression Test. Some of these lubricity
tests are discussed below.

Table 5.3 Typical Performance of cold rolling oil at tribological rigs

Test rig Test parameter Value

4 Ball EP Tester Wear scar diameter (at 40 kg, 1 hr), mm 0.40-0.70
Friction coefficient 0.04-0.06
Soda Pendulum Test Rig Friction coefficient 0.08-0.15
SRV Test Rig Wear scar, mm 0.3-0.6
Chapter V Lubricant Management

Friction coefficient 0.04-0.09

Falex Pin & V Machine Load, lb 2900-7500
Torque, lb-in 30-60
Falex Tapping Torque Test Efficiency, % 95-110
LFW-1 Friction Machine Friction force, lb 0.25-0.35
Friction coefficient 0.06-0.08
Amsler wear tester Friction coefficient 0.07-0.11

(a) Plint Tribometer Test: A reciprocating tribometer is used primarily for evaluation of
lubrication characteristics of the oil. It is a computerised friction and wear test apparatus.
A test panel (hot band) is dipped in the oil and a standard pin slides (line contact) over the
panel under a given load and at a predefined frequency. The variables under the
experiments could be speed, load, stroke, and oil temperature. Lubricity is assessed
automatically by the computer in terms of friction coefficient and can be plotted against
Friction coefficient

0.20

0.15 Oil-B
0.10

0.05 Oil-A
0.00
100 150 200 250
Temperature, oC

Figure 5.1 Typical friction curve generated at Plint tribometer

the emulsion temperature. Figure 5.1 depicts friction curve generated for comparison of
two rolling oils A and B.

Results achieved at Plint Tribometer are truly representative of the industrial performance
and can be used to study thermal stability of the oil. It is also used to study the wear
debris and chemical interactions between oil and metal surface.
Flat Rolling Lubrication

(b) Forming Test: The forming test consists of deforming a perforated steel washer held
on the load cell mounted test table of Falex Tapping Torque machine. The average
forming torque of the lubricant is an index of its performance. The test specimen is a 1.13
mm thick steel washer of precisely controlled dimensions and metallurgy. The forming
tool is ball-ended and is made of die steel. For each test lubricant, a new forming tool is
used.

The test procedure used for evaluating a lubricant consists in determining the average
forming torque of a test fluid and that of a reference fluid using same forming tool. The
forming efficiency is then calculated as given below.
Forming Efficiency (%) = (A / B) x 100
Where, A is average forming torque of the reference lubricant, and B is average forming
torque for the test lubricant.

(c) Ring Compression Test: It is basically a plain strain compression test to measure the
friction between platens and ring surfaces during compression with different lubricants.
The ring used for this purpose is made of mild steel, which is ground and polished. The
ratio of outer diameter, inner diameter and thickness of the ring is maintained at 6:3:2.
The candidate oil is applied over the ring in neat form at a temperature of about 50-60 oC.
Reduction is imparted to the ring in steps from 10% to 60% by pressing it on a universal
testing machine. In each step, the change in the internal diameter is plotted against the %
reduction in height or thickness of the ring. The curves so obtained are compared with the
standard coefficient of friction curves to obtain the average friction coefficient between
the platen and the ring specimen.
(d) Evaluation of Oil Film Strength: The measurement of oil film strength is done
through an Optical
Incident light Detection
Rig Interferometer. 1 2
The schematic
diagram of the
method is shown in Glass disk

Figure 5.2. In this Semi-reflective

Steel
coating
Ball
Oil
film
Figure 5.2 Schematic of optical rig interferometer
Chapter V Lubricant Management

method, an oil film is generated between a steel ball and a glass disc having semi-
reflective coating. Film thickness is measured under different loads and speeds by
detecting the refracted/reflected light.

It has been observed that the 4 Ball EP Tester also gives a fairly good result with respect
to load bearing capacity of the oil. The critical load at which scar generates on three
stationary balls along with scar diameter gives the maximum load bearing capacity of the
oil. Weld load is also evaluated to measure the EP property of the oil.
Flat Rolling Lubrication

(e) Evaluation of Burn-off Characteristic: Cold rolling oils are designed for clean
burn-off during annealing process. The carried over oil from the mill should get

evaporated from the coil at lower temperature, say at about 400 oC without leaving any

100
75
Weight of Oil, %
50

25
0
0 200 300 400 500
Temperature, oC

Figure 5.3 Typical TGA curve

residue. At the same time it should have sufficient thermal stability to sustain the roll bite
conditions. This property of the oil is studied through thermogravimetric analysis (TGA).
In this a known quantity of the oil is heated under controlled atmosphere and weight loss
is noted at increasing temperature (Figure 5.3). Since this test is conducted at atmospheric
pressure, it does not evaluate thermal stability of the oil at roll bite conditions. Even if

onset point for the distillation curve is between 200-250 oC, this does not mean that the
oil will decompose at roll bite. During the rolling process, the oil composition may be
unaffected by component loss due to the roll bite pressure being sufficiently higher than
the vapour pressure of even the most volatile components. In addition, chemical integrity
is maintained by selection of thermally and biologically hard raw material in conjunction
with a selected blend of antioxidants.

TGA can also be used to study the compatibility of general mill lubricants (morgoil,
hydraulic oil etc.) with the rolling oil. If a lubricant shows inferior burn-off characteristics
than the rolling oil, it may contaminate the annealed strip surface.
Chapter V Lubricant Management

(f) Evaluation of Rust Prevention Property: Rust prevention property of rolling oil is
studied in a humidity cabinet test. The samples of steel panels coated with 5% emulsion

are kept in humidity cabinet, with 100% humidity at 49 oC, for 48 hours. The samples are
examined before and after the test for any rust formation.

(g) Evaluation of Corrosiveness of Oil: The fatty acids present in rolling oil may cause
corrosion on mill equipment. The corrosiveness of the oil is evaluated in chemical attack
test, where test specimens of 1"x2" AISI 52100 chrome ball bearing steel are kept in neat

oil at 150oC for 24 hours. The surface of the balls is examined optically before and after
the test. The oil is rated according to the severity of the attack.

(h) Evaluation of Stability of Neat oil: Rolling oil is kept for seven days at 0 oC and is
examined for any defects in the oil upon cooling to room temperature. Again oil is kept

for 3 days at 80oC and is examined for any instability at 80oC or when it returns to room
temperature.

(i) Plate-Out Characteristics: It indicates the ability of the oil to come out of the
emulsion and properly spread in the roll bite. To evaluate this, steel samples are cleaned

and polished and dipped in emulsion of 3 and 5% oil concentration at 50 oC and then
dried and submerges in 1% copper sulphate solution for 5 seconds. Any copper adhering
to steel would indicate failure of the oil to spread evenly over the steel surface.

5.1.3 Evaluation of Rolling Oil at Laboratory Mill

The Experimental Rolling Mill has been a good tool to simulate industrial condition in
the laboratory. Here, the effect of different parameters like reduction, speed, roughness,
emulsion concentration, emulsion temperature, agitation, etc. on the rolling process and
lubricant behaviour can be studied. Performance of the lubricant-in-use is selected as a
reference base that serves as the link between experimental and industrial processes.
However, unfortunately, there is no standard test method suggested for evaluating
performance of rolling oil at laboratory rolling mill. The authors have developed a
Flat Rolling Lubrication

methodology which has been used to evaluate industrial applicability of various rolling
oils. The results obtained at the laboratory mill have been validated at industrial mill.
This methodology has been useful in developing large number of successful cold rolling
oils. Details of the laboratory rolling mill, the authors have extensively used for
development of these oils, are given in Annexure III.

At this mill, emulsion is prepared in a tank with varying oil concentration (1-5 % v/v) and

is agitated at 100-200 rpm. Emulsion at temperature in the range of 50-60 oC is sprayed

over sheet and rolls close to the roll bite. With this emulsion, hot rolled pickled
sheets/coils are rolled in successive passes down to a minimum thickness generally rolled
in the industrial mill. Performance of the oil is normally evaluated in terms of the
following: (a) Lubrication Characteristics, (b) Cooling Characteristics, (c) Emulsion
Behaviour, (d) Cleanliness Characteristics and (e) Ageing Behaviour.

(a) Lubrication Characteristics: Lubricity of the candidate oil is evaluated in terms of

reduction level achieved,
minimum thickness of the 0.14
0.12 Candidate Oil
Friction Coefficient

rolled sheets and friction

Upper Friction Curve
0.10
coefficient at the roll bite. Lower Friction Curve
0.08
The rolling parameters,
0.06
such as reduction, rolling 0.04
load and rolling speed, 0.02
are used as input data for 0.00
a computer model, which 10 20 30 40 50 60 70 80 90
calculates the friction Cumulative Reduction, %
coefficient and the Figure 5.4 Lubrication characteristics of
specific rolling pressure. oil at laboratory mill
The model uses equation
3.14 to compute the friction coefficient. A typical friction curve is shown in figure 5.4,
where lubrication characteristic of the candidate oil is compared with the two reference
curves.
Chapter V Lubricant Management

(b) Cooling Characteristics: Sheet temperature after rolling is a function of lubricity of

oil as well as its
cooling ability. 120

Temperature, oC
Cooling efficiency 100
of the oil is 80
measured in terms
60 Oil-A Oil-B
of emulsion and
40
sheet temperature
30 40 50 60 70 80 90
after rolling.
Cumulative Reduction, %
Cooling efficiencies
of two oils have Figure 5.5 Cooling characteristic of oil at
laboratory mill
been compared in
figure 5.5.

(c) Emulsification Characteristics: Although emulsion stability index gives an idea of

stability of emulsion, the measurement of oil separation in emulsion recirculation system
of the experimental mill simulates the industrial condition in a better way. Here emulsion
samples are collected from emulsion tank as well as from the spray header and oil % in
these samples are measured. The difference in oil % in the two samples indicates the
level of oil separation. The emulsion stability index is calculated as ratio of the oil% at
spray header to that in the emulsion tank.

(d) Cleanliness Behaviour: Cleanliness of the mill and strip can be visibly observed
during rolling in the experimental mill. Surface reflectance of the rolled sheets, measured
in a tape test with the help of a reflectometer, is however a better way of quantifying
surface cleanliness of rolling oil. In this method first of all an adhesive scotch tape is
pasted over a white paper. Its reflectance is measured with the reflectometer and set at
100. This is considered as reference for the quantification of cleanliness of rolled sheets.
Subsequently, the tape is pasted over the rolled sheets and after removing from the sheet
it is again pasted over the white paper. During removal of the tape from the rolled sheet it
Flat Rolling Lubrication

carries with it all the loose deposits over the sheet. Reflectance of this tape is measured
and compared with that of the above reference.

The amount of carboneous deposit over rolled sheets before and after annealing can also
be measured using a surface carbon analyser. For this, a sample of the stained rolled sheet
is cut and placed in the sample boat inside the furnace of analyser. Temperature of the
furnace is set at 600 oC. Oxygen gas at controlled flow rate is then passed through the
furnace, which converts the surface carbon into carbon dioxide. Infrared cells present in
the analyser measures the quantity of carbon dioxide. From this the amount of carbon is
calculated and the result is displayed as milligram of carbon per unit area of the sample.

(e) Ageing Behaviour: The chemical ageing of rolling oil emulsion in the steel plant is
mainly due to tramp oil mixing, iron fine generation, impurity level in industry water and
bacterial growth. The same is generated in the experimental mill by mixing these
impurities in the emulsion tank. This impure form of emulsion is heated, agitated and
circulated for few weeks in the mill and then again a similar set of rolling is conducted as
is conducted with fresh emulsion. The difference in rolling parameters and emulsion
behaviour gives the idea of how particular oil deteriorates after a certain chemical ageing.

5.1.4 Industrial Evaluation of Cold Rolling Oil

Performance of the candidate rolling oil in industrial condition is studied in terms of
following characteristics: (a) Lubrication Characteristics, (b) Cooling Efficiency, (c)
Cleanliness Characteristics, (d) Emulsion Ageing Behaviour, and (e) Economic Potential.
In case of new developments, performance of the candidate rolling oil is compared with
that of the oil-in-use. When analysing the performance of existing oil in aged condition,
its performances are compared with that of the fresh oil.

(a) Lubrication Characteristics: Lubricity of the oil is evaluated in terms of rolling

parameters (load, speed, tension and reduction), friction coefficient, and maximum
achievable reduction and speed. The friction coefficient is computed with the help of a
mathematical model utilising different rolling parameters.
Chapter V Lubricant Management

(b) Cooling Efficiency: The cooling potential of the oil is evaluated in terms of strip
temperature and work roll temperature. Roll thermal profile is also studied by measuring
work roll temperature along its barrel length.

(c) Surface Cleanliness: Reflectance of the cold rolled strips, iron fine deposit on the
strip, carbon and ash residues and thermal stability of the neat oil are selected as
parameters for evaluating the cleanliness properties of the candidate oil. The method of
measuring strip surface reflectance is the same as explained in case of laboratory
evaluation. It is generally studied at three locations, i.e. after rolling, after annealing, and
after skin pass rolling.

(d) Emulsion Quality: It is studied in terms of variation of emulsion concentration, iron

fines, pH, conductivity, bacterial count, tramp level, etc. For successful oil, there should
not be large variation in these parameters and contaminant level should not exceed
beyond critical limits. Performance of the oil should also not deteriorate with the age of
emulsion.

(e) Techno-economic Performance: The ultimate suitability of the candidate oil depends
on the techno-economics of its use and therefore it is evaluated in terms of rolling rate,
specific oil consumption, specific roll consumption, roll spalling, occurrence of strip
breakage, power consumption, etc.

5.2 Application of Cold Rolling Oil

The roll bite lubrication at cold rolling mills is mainly achieved by spray of oil-in-water
emulsion over the work-rolls as close to the bite as possible. The emulsion concentration
in this type of systems generally varies from 1 to 5% primarily to achieve higher cooling
of work rolls. However, in case the lower concentration emulsion is not able to cater the
need of higher lubrication, a separate strip lubrication system is also provided to spray
emulsion of rich concentration. The emulsion system of a mill must be designed to
Flat Rolling Lubrication

provide a constant flow, temperature, pressure, particle size, pH and hardness of the
rolling solution.

The lubricant application systems have direct effect on cold rolling lubrication. For a
given mill and rolling oil, optimum design parameters may lead to improvement in its
effectiveness. The coolant flow rate and its distribution along the roll barrel length should
be properly calculated considering the requirements of both cooling and lubrication. The
total quantity of emulsion flow regulates the lubricity and the thermal condition at roll
bite. It varies from mill to mill and from stand to stand in a tandem mill depending upon
the softness of metal. The flow rate should be designed in such a way that the strip

temperature in no case exceeds 150 oC and there is no occurrence of frictional pick up.

The impact pressure of spray over the rolls affects the heat transfer coefficient; it
increases with increasing pressure to an optimum level after that it becomes constant. At
very high pressure, the spray bounces over the roll making it ineffective. The pattern of
flow along the work roll axis is also important because it may required to be varied
depending upon the differential deformation along the width of strip. The headers are
usually divided in different zones to facilitate control over emulsion flow. It helps in
controlling the shape of the rolled strip.

The rheology and film formation at roll bite very much depend on the temperature and
initial concentration of emulsion. Temperature control is important as its fluctuations
change the lubrication properties of the oil and lead to inconsistency in the rolling
process. The application system is designed with the possibility of changing the volume
fraction of oil.

The emulsions are mechanically sheared by agitator, pump and nozzles to achieve the
required particle size. The level of agitation depends on the type of emulsion oil. A stable
type emulsion requires less agitation to favour the self-cleaning action. However, higher
agitation is required for dispersion type oil to control its uniformity and the system must
be designed to avoid idle or dead spots within the system.
Chapter V Lubricant Management

5.3 Application of Hot Rolling Oil

There are three basic methods of applying hot rolling oil to roll surfaces: (a) direct
method, (b) injection method and (c) dispersion method. In the direct method, undiluted
oil is sprayed directly over the rolls through pneumatically or hydraulically operated
valves. This is considered as the best method of applying oil so far lubrication
performance is concerned. However, it has a major drawback that it requires intricately
engineered application system. Actually, hot rolling lubrication requires only very low oil
flow rate, which can be achieved through very small nozzle orifices and finely adjustable
control system. Maintaining these systems in an arduous environment of hot rolling mill
is difficult.

In the injection method, rolling oil is injected into the existing roll cooling water sprays.
This method can be suitable for a new mill, which is designed with this feature. In an
existing mill, this method may not be practical as it increases the complexity of pipe-
work. Since all the rolling oil mixed with large volume of cooling water may not be
effectively utilised for lubrication purpose, this method has a big disadvantage of higher
oil consumption requirement.
Flat Rolling Lubrication

L
G
C F H

E L

B D
M

A: Oil tank & heater E: Flow meter J: Water supply

B: Oil pump F: Solenoid valve K: Oil-water mixer
C: Pressure control G: Indicator switch L: Spray header
D: Flow control H: Non-return valve M: Load cell signal

Figure 5.6 Typical hot rolling oil application system

In the dispersion method, a dispersion/emulsion of oil-in-water is made in a separate

emulsion system and this emulsion is applied over the backup rolls through a
supplementary spray system (Figure 5.6). As soon as emulsion comes in contact with the
rolls it breaks down in oil and water phases and the oil phase plates out over the rolls. The
contact between the backup roll and the work roll forms a lubricant reservoir and spreads
an even film of lubricant over the work roll surface before it contacts the strip. The film
so formed has a firmly secured molecular layer due to presence of extreme pressure and
other additives.

The dispersion method is considered as the most satisfactory method as it requires

nozzles of larger orifice size and relatively less sophisticated flow control system. Since
the spray nozzles are placed in the vicinity of the backup rolls, it is less liable to
accidental damage. In this method, the oil consumption can easily be controlled by
varying the emulsion concentration.
Chapter V Lubricant Management

In a hot strip mill, roll wear is more pronounced at the early stands of finishing train. This
is why roll lubrication is provided at these stands (usually first three or four stands of a
six-stand finishing mill). This also ensures that any excess oil left over the rolled strip is
completely burnt off before the strip is cooled and coiled.

An important aspect of oil application is timing of emulsion spray at a particular stand. It

is required that there should not be any oil over the work rolls at the time strip enters that
particular stand. Otherwise there could be insufficient friction to draw the metal through
the roll bite. Therefore spray of emulsion should be put on only when strip has already
entered that stand. Also, it should be put off sufficiently before the tail end is rolled at that
stand, so that the oil over the rolls is completely burnt off before the next coil is fed. This
feature of the oil application system is achieved through a solenoid valve. The solenoid
valve in energised for spraying the emulsion by signal of load cell of that particular stand.
It is de-energised by load-off signal of first or second previous stand.

As shown in figure 5.6, mixing of oil and water is achieved in a simple device consisting
of a pipe elbow in the water line with the oil pipe attached so as to feed the oil axially
into the exit limb of the elbow. Water is flowing continuously and the oil is injected only
when a strip is being rolled. A non-return valve is provided in the oil line to keep it
primed. Generally alternate spray headers are provided for narrow and wider coils so that
unnecessary oiling of unused barrel length is avoided during rolling of narrow coils.

5.4 Emulsion Management in Cold Rolling Mills

Maintenance of proper emulsion quality is basically a must for two reasons: first for
ensuring improved and consistent performance of the rolling lubricant and second for
achieving longer emulsion life. The important emulsion parameters that should be
controlled within a specified narrow range are emulsion concentration (oil % in
emulsion), emulsion temperature, pH of emulsion, oil particle size and emulsion
contaminants. The major contaminants in the emulsion include chlorides, pickling oil,
hard water, microbiological species, tramp oil, iron fines, mill sludge, and detergent.
Flat Rolling Lubrication

Desired values of some of these parameters are given in Table 5.4. These parameters are
measured either with the available equipment or by chemical methods.

(a) Emulsion concentration: In an actual production line, large variations in emulsion

concentration may be observed due to disproportionate addition of oil in emulsion,
evaporation of water, change in emulsification characteristics of the oil, skimming of
tramp oil, etc. Online emulsion concentration measuring instruments are advantageous in
this respect to give timely feedback to the operators for carrying out correction if
required. If not controlled, changing emulsion concentration may lead to varying
lubrication condition from coil to coil or even in the same coil. Optimum emulsion
concentration depends on the type of rolling oil, grade of steel, reduction level, mill
speed, etc.

(b) Emulsion Temperature: Similar to oil concentration, the temperature of emulsion

has a relation with lubrication and cooling characteristics of the oil. At higher emulsion
temperature, the oil film thickness may get reduced due to lower viscosity of the oil.
Cooling efficiency will also be adversely affected. Normally, emulsion temp is controlled
within 50-60oC.

(c) Emulsion pH: Emulsifier system of the rolling oil is normally pH sensitive. It is
therefore desirable that pH of the emulsion be controlled within a narrow specified range.
Acid carryover from the pickling line, inferior quality of feed water and mixing of tramp
oil are prime sources of pH deviation in the emulsion. In case, pH of the emulsion is not
controlled properly, it will lead to destabilised emulsification characteristics of the oil.
The preferred pH could range between 5.0 and 7.0; at pH values below this range, the
particle size distribution will increase as demonstrated by increased instability. Corrosion
problems and erratic rolling performance can be symptomatic of this condition. At pH
values above 7.0, the formation of metallic soaps is encouraged and also a reduction in
particle size is possible.
Chapter V Lubricant Management

Table 5.4 Desired values of some important emulsion parameters

Parameters Desired Value

Chloride in pickling rinse water < 60 ppm
Chloride on pickled strips < 0.03mg/sq ft
Emulsion conductivity < 500 mS/cm2
Hardness of water < 250 ppm
Bacteria < 5x106 counts/ml
Yeast < 200 counts/ml
Tramp oil < 20% of rolling oil
Iron in emulsion < 200 ppm
pH variation + 0.5-1.0
Iron on CR strip < 100 mg/m2
Oil on CR strip < 100 mg/m2
Carbon on annealed strip < 7 mg/m2 (Ford spec for autobody)

(d) Conductivity: The conductivity of an emulsion is measured using a conductivity

meter, which is basically a modified Whetstone bridge. The conductivity is a measure of
the ionic activity of an emulsion. The major common contributors to the conductivity are

the ions of low mass or high charge, e.g. H +, OH-, Cl-, and SO42-. Minor contributors

are Ca2+, Mg2+, Na+, and K+.

The conductivity is dependent on the make up water. Good quality deionised water will
have a conductivity of less than 10 mho, while poor quality industrial water can have
conductivity even above 500 mho. An increasing concentration of salt from the hard
water decreases the emulsion stability. Another source of salt (e.g. chloride) is carryover
from pickling line. The chloride level in the final rinse of pickling line should be
controlled within 60 ppm. Carryover of chloride should not be allowed to exceed 0.03
mg/sq.ft of pickled strip. Conductivity of rolling oil emulsion is normally checked within
200 S/cm and in no case it should exceed 500 S/cm.
Flat Rolling Lubrication

(e) Oil particle size: The most important emulsion parameter that controls both lubricity
and emulsification characteristics is oil particle size. A typical distribution of oil particle
size in an emulsion is shown in figure 5.7 and its typical range observed with some
successful cold rolling oils is given in Table 5.5. The oil particle size depends upon many
factors. The type and dose of emulsifier is the major controlling element of oil particle
size. Apart from this, there are several other external factors that affect the particle size.
Important among them are - type of filtration, size of system, retention time, emulsion
temperature, type of water used, system configuration, spray pressure, types of
contaminants, and type of material being rolled. For its control, however, adequate
agitation should be applied on the emulsion depending upon the type of rolling oil
(unstable, metastable, stable). In absence of particle size analyser, emulsion stability
index (ESI) should be measured periodically.

10
8
Volume, %

6
4
2
0
0 2 4 6 8 10 12 14 16 18
Droplet size, micron
Figure 5.7 Oil Droplet size in emulsions of rolling oils

(f) Tramp Oil: The tramp oil must be removed from the rolling oil solution periodically
to improve its health. The modern oils are having tramp rejecting characteristics and
therefore it is easy to remove the tramp oils by skimming it off. In no case it should be
allowed to increase over 20-30% level. It is calculated by measuring sap value of
extracted oil.

Table 5.5 Typical oil particle size and other related parameters
Chapter V Lubricant Management

Parameters Sheet Rolling Oil Tinplate Rolling Oil

Mean Particle Size, micron 2-5 3.5-10
ESI, % 80-98 50-95
Oil Plateout, mg/m2 350-600 500-1100
Iron Content, ppm 0-300 100-700

(g) Iron in Emulsion: Iron content in the solution should be maintained less than 200
PPM with the use of magnetic separator. Other foreign bodies should also be removed
from the solution with the use of filtration system to avoid any strip surface
contamination.

(h) Bacterial Count: The bacterial attack on the emulsion can lead to build-up of acidic
materials, enhanced corrosiveness (a fall in pH), destruction of additives, foul odour, loss
of stability in emulsions (increase in oil particle size), increase in free oil and oil
consumption, and/or excessive foaming. The alarming levels of bacteria and yeasts

reported are 5x106 counts/ml and 200 counts/ml, respectively.

(i) Analysis of Extracted Oil: The emulsion quality of a rolling oil in use at an industrial
mill can be assessed at different interval of time by extracting the oil phase from the
emulsion and determining some of its properties. These properties include free fatty acid,
acid number, and saponification value. Oil extraction is done not chemically but with the
help of mechanical equipment such as rotary evaporator so that dry and unreacted oil is
obtained for further analysis.

The acid value of the extracted oil will usually be lower than that of the fresh oil. Free
fatty acids (FFA) are lost due to soap formation with iron and water hardness salts. Any
mineral oil contamination of the emulsion will also reduce the % of FFA present. If the
acid value increases suddenly this could be caused by excessive bacterial activity
resulting in the formation of short chain degradation products o hydrolysis of ester due to
live steam leak, etc.
Flat Rolling Lubrication

The drop in Sap value usually indicates contamination of emulsion with the tramp oils. It
is used to calculate the presence of active oil in the emulsion.
Active Oil (%) = [(Sap of extracted oil) / (Sap of fresh oil)] x 100
Although the % active oil varies from mill to mill, as a general rule, it is not allowed to
fall below 70%. The level of tramp oil is calculated from active oil as,
Tramp oil = Total oil – Active oil

Infrared analysis of the extracted oil is also done to predict its ester content and fatty acid
concentration. It also finds its application in identification of contamination in emulsion
and monitoring changes in oil composition during storage as well as in use.

5.5
Troubleshooting in Cold Rolling Mills
The cold rolling process is complex and it is often difficult to establish the cause of
problem. It is suggested that regular monitoring of process and emulsion parameters
should be conducted to establish a set of reference results. Upper and lower control limits
should also be set for these parameters to trigger corrective actions and thus limit the
number of problems. Some of the condition-monitoring methods are suggested in Table
5.6 for different troubleshooting purposes.

Table 5.6 Recommended condition-monitoring methods for troubleshooting

Cause Effect Check & Correct

Lesser reduction Lubricity
Chapter V Lubricant Management
Inferior Lower mill speed
lubrication
High mill load
Heat scratch/friction mark
Shape defects
Mill vibration
High roll consumption
High oil consumption
Inferior Carbon soot on strip
Iron soot on strip
cleanliness
Stain mark/black patch on strip
Strip rustiness/corrosion
Inferior Inability to achieve desired oil%
emulsification at header/large variation
High emulsion temperature
High iron fine
Large variation in pH
High conductivity
High tramp level
High bacterial growth
High oil consumption
Film strength
EP/Anti-wear property
Oil particle size/ESI
Emulsion concentration
Emulsion flow and pressure
Nozzle, header & filter chocking
Tramp oil level
Carryover from pickling line
Temperature rise at roll bite
Iron fine generation in mill
Thermal stability of oil
Burn-off characteristics of oil
Saponification value
Tramp oil level
Bacterial level
Oil & iron carryover with strip
Water quality
Demulsification curve
Oil particle size/ESI
Lubricity/cooling efficiency of oil
Functioning of filters/agitators
Carryovers from pickling, water
contamination, bacterial growth
Leakage of hydraulic/ morgue oil
Emulsion stagnation, emulsion
temp, water contamination