Steel Belt Gearboxes:
Why Clean Oil is the Best Insurance Policy

Overview

Steel belt gearboxes are complex, mission-critical components in sinter plants.

They endure high thermal stress, mechanical loads, and the constant threat of contamination from the surrounding environment. These gearboxes are not only expensive to replace but also vital for ensuring consistent sinter quality and throughput.

Protecting them is less about waiting for issues and more about preventing them—and that starts with CLEAN OIL.

The Hidden Costs of Contamination

While contamination may begin at the microscopic level, its consequences ripple throughout the plant.

The fine sinter dust, especially chromium particles common in ferrochrome operations, acts like sandpaper in the system.

• Gear damage:

Abrasive particles trigger surface pitting, scoring, and three-body abrasion, drastically reducing the life of gear teeth.

• Seal degradation:

Continuous particle exposure compromises seals, allowing more contaminants to enter and worsening internal wear.

• Unplanned maintenance:

Frequent oil changes, bearing replacements, and system cleanouts become routine, increasing costs and labor needs.

• Downtime losses:

Every gearbox shutdown—even for scheduled maintenance—risks interrupting the sintering process and creating production bottlenecks.

These hidden costs accumulate rapidly, often surpassing the price of preventive maintenance many times over.

The FMS Approach

FMS Africa tackled these challenges head-on by deploying an Offline Filtration System (OLUHS) paired with a range of contamination monitoring and exclusion technologies.

The goal? Implement a proactive, always-on system that protects gearboxes from the inside out.

Key components included:

• Glass fiber filtration units: Designed to capture even the finest wear-causing particles.
• Desiccant breathers (ACM61 & IsoLogic®): Prevent moisture and airborne debris from entering the lubrication system.
• Oil Quality Sensors (OQS) and Contamination Monitoring Sensors (CMS): Offered real-time data on fluid health and particulate levels.
• 3D Bullseye® oil viewing tools: Enabled visual inspections of lubricant clarity and levels.

This setup created a closed-loop system that continuously filtered oil, excluded new contaminants, and provided data-driven insights for maintenance teams.

Visual Impact

The transformation was dramatic. A visual comparison of ISO cleanliness levels before and after implementation showed a drop from 23/22/19 to 15/13/10. This shift placed the gearboxes well below industry contamination thresholds, greatly enhancing their lifespan.

• Pre-implementation: High contamination levels risked frequent failures and repair cycles.
• Post-implementation: Cleanliness levels not only met but exceeded ISO targets, indicating a healthy and stable lubrication environment.

The reduction in wear rates and improved lubricant quality translated into fewer breakdowns, less maintenance, and higher operating efficiency.

Takeaway

Clean oil is more than just a maintenance goal—it’s an operational strategy.

For steel operations, investing in advanced filtration systems like those deployed by FMS Africa is a cost-effective, high-return method to:

• Extend gearbox life
• Lower total cost of ownership
• Enhance worker safety
• Preserve product quality
• Ensure continuous production

For modern sinter plants, clean oil isn’t optional. It’s the best insurance policy your critical equipment can have.

• 👉 Get in touch now to schedule a consultation.

  Let’s keep your machinery running cleaner, longer, and stronger