calcium sulfonate grease making processes
The calcium sulfonate thickener system protects against water washout and bearing corrosion under challenging conditions: Exceptional mechanical stability: Resists softening under mechanical shear in the presence of process water contamination. A method for making an overbased calcium sulfonate grease comprising the steps of: a. blending from about 22.5 to about 32.5 weight percent solvent neutral oil, from about 36 to about 47.4 weight percent calcium sulfonate, from about 5 to about 15 weight percent calcium carbonate in an open kettle while heating to a temperature range of from about 150.degree. An article in NLGI Spokesman, July 20022, supports that the calcite particles, inherent in calcium sulfonate greases, make them a good choice for high-temperature applications. general process for making gelled calcium sulfonate grease has remained largely unchanged since these types of greases were first developed in the 1960s. On the other hand, the right grease can allow equipment to run for years without a maintenance problem. While they offer both water and heat resistance, they can be sensitive to water-becoming firmer or softer under different conditions-and, if … acid). Jeff St. Aubin. Multipurpose Calcium Sulfonate Complex Grease. Calcite particles have been described as forming a wafer- or scale-like structure which creates shear planes that trap between the metal surfaces. Heavy-duty diesel applications require an approximate treat level of five percent. Calcite particles are the business end of making the product work, but reaching that point can be expensive. Chemtool Inc. W. Mackwood, Crompton Co., and K. J. Author Info: Richard Denis, Matthew Sivik: Presented On: 2008: Document: Click Here to Preview First Page of PDF : Add to Cart Checkout. If the right grease is not being used in equipment, you could be paying too much for replacement parts. Habot H - CSXM 460 Grease has been carefully formulated using high viscosity base oil and over based calcium sulfonate complex thickener system fortifi ed with Moly and special additives providing this grease outstanding Extreme Pressure properties, exhibiting excellent water repellent, oxidation resistance, and a wide operating temperature range. The grease Water-resistant calcium sulfonate complex grease A grease that is suitable for the lubrication of all kinds of components that are subject to high loads, shocks or working in conditions where the grease is in frequent contact with water (including seawater). Not new to the grease scene, calcium sulfonate thickeners have been around for almost 50 years. In-process corrosion protection for ferrous metals: View All K-Syn. A descrip-tion of the manufacturing process can be found in Denis and Sivak (11)Fish and (12). COMPLEX AND SIMPLE CALCIUM SULFONATE GREASE MANUFACTURING The neutral calcium sulfonate process involves mineral oil, solvent, sulfonic acid, water and calcium hydroxide. With respect to calcium sulfonate greases, the art involves the process used to convert the detergent to grease. C. water binding the oil and soap is lost so they separate and lubrication property is lost. general process for making gelled calcium sulfonate grease has remained largely unchanged since these types of greases were first developed in the 1960s. An overbased calcium sulfonate grease comprising neutral oil, calcium sulfonate, calcium carbonate, dodecyl benzyl sulfonic acid, isopropyl alcohol, water, calcium hydroxide, 12-hydroxy stearic acid, phosphoric acid and an antioxidant. There are a number of grease thickeners available, each with its own strengths and weaknesses. Briefly, typical lithium-based greases (the most common) are made from a fatty acid, usually 12-hydroxystearic acid, and a lithium base to produce a simple soap which acts as the grease thickener. 118 N Conistor Lane, Suite B-281 | … Another downside is their performance with respect to pumpability and water sprayoff. 17. Applications that fit this category include marine environments, suspension bridges, automotive or other applications exposed to salt conditions. Calcium grease became commercially available in the late 1940s. Type Of Grease Calcium Base: Used for simple bearings, general purpose machinery and chassis lubrication for normal temperature applications. The total global market size of lubricating greases is about 2.38 billion pounds and consists of lithium/lithium complex, calcium, sodium, aluminum/aluminum complex, calcium sulfonate, clay based, polyurea, etc. Unfortunately, the answer is not that simple, because there are many types of greases. Obviously we offer products which resist the high temperatures seen in the production of glass. (1) The first step in the manufacturing process is to add an overbased calcium sulfonate with a total base number (TBN) of 300 to 500 mg KOH / g eq. Pumpability is a concern that can be alleviated through proper base oil selection. These properties, combined with the fact that it can be formulated for use in H-1 (food-grade) applications, make it an attractive alternative to other greases. However, making a grease is not simply a matter of mixing a set of ingredients together. Calcium sulfonate greases are also used in motor-operated steam valves to control high-pressure steam. General applications for calcium sulfonate greases include automotive, agricultural, construction, food, industry, mining, paper manufacturing and steel mills. Plants are operating at capacity, and grease is not the only bidder. After the test is completed, the percent of grease lost is calculated. Specific automotive applications include chassis, ball joints, universal joints and wheel bearings. At about 80 deg. In the first stage, Newtonian ultrabasic calcium sulfonate is changed to non-New-tonian ultrabasic calcium sulfonate. Components are then added to give it EP and other desirable properties that allow equipment to run at peak performance. Grease formulation is a com-plex process that takes into account the multiple interactions among base oils, thickeners, ... Calcium Sulfonate 2.83 2.20 0.92 Lithium 54.51 57.36 56.16 It needs the free play of the mind in as great a degree as any other creative art.” Making a grease is no exception. Soda Base: Grease is grease, right? In addition, calcium sulfonate supply is limited, while costs are escalating. Although the thickener can affect oxidation, it is often based on the oil’s quality. Therefore, art also plays a role in the manufacturing process. Calcium sulfonates are used in engine oil, metalworking, automatic transmission fluid, industrial and automotive gear oil additives as well as other applications. Calcium sulfonate greases have outstandingly been used in mining and construction industry since this class of greases has a high tolerance to dirt, dust, and a humid environment. Because of the calcite particles’ lubricating properties, performance additives containing sulfur, phosphorous or zinc may not be needed. to a grease kettle. In the grease-making process, the amorphous carbonate is converted into a crystalline carbonate (mostly calcite). By far the most popular greases worldwide are lithium-based greases wit… $20.00/member and $75.00/non-member: NLGI. This is why some calcium sulfonate-based greases are attractive to the food industry. In the ASTM D4049 sprayoff test, a thin layer of grease is placed on a panel and sprayed with water. Since then, the basic principle of making gelled overbased calcium sulfonate greases using liquid over based calcium sulfonate with total base number (TBN) ranging from 300 to 500 remains practically unchanged . to Calcium Sulfonate-based Greases. This grease excels in EP performance, as demonstrated in the ASTM D2596 four-ball EP test, and in the ASTM D2509 Timken test. In summary, if the application requires H-1 approval, heat resistance or water tolerance, a properly manufactured calcium sulfonate grease that meets your needs may be worth the price. Calcium greases were the first, followed shortly after by the lithium and barium greases. Calcium sulfonate-based greases have a higher dropping point, making them attractive for some high-temperature applications. The key is learning which grease is right for your needs. The lack of a closed system in these kettles allows the volatile promoters used in the calcium sulfonate grease production process to escape. Calcium sulfonate greases are generally beneficial for rust performance, with oxidation stability considered good or excellent. In grease applications, the treat levels spike to between 20 and 50 percent. SUPERIOR MECHANICAL STABILITY These steam valves are typically found in nuclear plants and thermal-generating stations. Whatever your formulating requirement, Kimes Technologies offers a wide variety of both components and packages to meet the exacting demands of the Rust Preventive & Coatings industry. Brown, Utility Service Associates. process for calcium sulfonate complex grease can be divided into two stages. ASTM D2266 — ANTI-WEAR PERFORMANCE Measures the greases ability to protect against wear. ã§ã³ï¼®ï½ï½ ï¼£ï½ï½ï½ï½ï½ï½, ТоÑÐ°Ð»Ñ ÐаÑкеÑин СеÑвиÑ, NCH CORPORATION, 2727 CHEMSEARCH BLVD., IRVING, TE, ASSIGNMENT OF ASSIGNORS INTEREST. A method for making an overbased calcium sulfonate grease comprising the steps of: a. blending from about 22.5 to about 32.5 weight percent solvent neutral oil, from about 36 to about 47.4 weight percent calcium sulfonate, from about 5 to about 15 weight percent calcium carbonate in an open kettle while heating to a temperature range of from about 150.degree. 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Our packages allow for the ease of formulating This forms a sacrificial layer on the metal that is constantly sheared away. It produces very small micelle particles that are 0.5-10 nm in diameter and es-sentially neutral once they have been removed from the solvent. • The QUAKERTEK™ CS 4015-EPE Calcium Sulfonate Complex grease does not soften with the addition of water, whereas the Aluminum Complex grease softens and gives a slurry grease … Although greases represent only about 2% by weight of this category (2.48 billion pounds per year worldwide), they provide lubrication in high-pressure, high-load situations where oils are not effective. hbspt.cta.load(3951034, '0185d019-b885-48b3-81bb-598c6269bb64', {}); How one executes this can affect the EP performance and dropping point. This particular type of grease has inherent extreme pressure (EP) properties that stand out from the rest. 17. ... DDBSA-type promoter in grease or gelled calcium sulfonate production: View All Sulfon. To complicate the situation, let’s compare the treat rates. Some formulas also excel in salt fog performance. •For some sets of greases, %(wt) OCS was re-calculated to a specific worked 60 stroke penetration value to make yield comparisons easier. Industrial applications include continuous casters, conveyors, ball mills, crushers, off-shore and underwater applications.1. Worldwide, the demand for lubricating greases has risen from 1.64 billion pounds in 2002 to 2.48 billion pounds in 2015. Although calcium sulfonate greases have desirable properties, an inhibiting factor is the cost. Calcium Sulfonate Grease Calcium sulfonates also reffered to as overbased calcium sulfonate complex are the most versatile of the calcium greases. Table 1. Calcium sulfonate based greases are conventionally prepared in atmospheric “open” kettles. (1) The first step in the manufacturing process is to add an overbased calcium sulfonate with a total base number (TBN) of 300 to 500 mg KOH / g eq. How we choose grease and how you can evaluate which grease actually stands up to extreme environments. There is a range of manufacturers, and sometimes the process used for one manufacturer’s equipment must be modified for another. Multipurpose Calcium Sulfonate Complex Grease. Additionally, calcium sulfonate greases are more compatible with lithium/lithium complex greases than other greases. This type of mixed soap structure has special properties that enable the grease to be heated to a higher temperature without losing its structure or oil separating from the thickener. •For some sets of greases, %(wt) OCS was re-calculated to a specific worked 60 stroke penetration value to make yield comparisons easier. A method of making the composition comprising the steps of mixing the overbased calcium sulfonate and base oil, adding the calcium carbonate, adding one or more converting agents, and adding one or more complexing acids. Rust inhibitors are surfactants that neutralize acids on the surface of metal. According to the 2014 NLGI global annual grease production survey, the production of calcium sulfonate complex grease in 2014 increased almost twice compared to that in 2010 (Mackwood (4)). When would you want to use calcium sulfonate grease? Test Results Comparing Lithium Complex Grease
When the benefit outweighs the cost. This type of production vessel is limited by the basic design in its mixing and heating effectiveness. If an application has specific requirements that only this type of grease can meet, then it is worth the price. Before 1985, calcium sulfonate greases were niche and only produced in small quantities. Many calcium sulfonate greases typically show significant sprayoff. Lithium, Polyurea & Calcium Sulfonate Based Greases - Quaker Houghton Author: Quaker Houghton Subject: Shows an overview of available products from our Grease … The calcium carbonate may be used to react with complexing acids when making a complex grease, such that the addition of calcium oxide or calcium hydroxide is not required. To make a lithium-based complex grease, part of the fatty acid is replaced with another acid (usually a diacid), which makes the complex soap. The grease Lubricants can be divided into oils (liquid) and greases (semi-solid). A descrip-tion of the manufacturing process can be found in Denis and Sivak (11)Fish and (12). •Thickener yield was determined by relative comparison of %(wt) overbased calcium sulfonate (OCS) in final grease. The increasing cost of lithium hydroxide has brought price parity close to each other, therefore making calcium sulfonate greases more commercially viable. Calcium Sulfonate Complex Greases -- CERAN MS: Multi-purpose, heavy-duty, extreme pressure, calcium sulfonate complex grease designed for all types of industrial components subject to high loads, shocks, and where the grease is in frequent contact with water. Sept-Oct 2009 - Calcium Sulfonate Grease-Making Processes. There’s more to the art of making grease. Calcium sulfonate greases are made by converting a fluid detergent that contains amorphous calcium carbonate to a grease containing calcite particles. That’s a big difference and a major reason for the high cost. OVERBASED CALCIUM SULFONATE LUBRICATING GREASE OBCS GREASE PERFORMANCE TESTS EXTREME PRESSURE AND ANTI-WEAR ASTM D2596 — EXTREME PRESSURE Determines if grease can carry heavy loads at consistent speeds and pressure. Unmatched for consistency in both appearance and performance and is compatible with a wide range of oils, solvents, emulsifiers, coupling agents, bactericides, antioxidants and corrosion inhibitors. These properties, combined with the fact that it can be formulated for use in H-1 (food-grade) applications, make it an attractive alternative to other greases. •It is understood that the OCS is chemically changed during the grease making process. manufacturing process. hbspt.cta.load(3951034, 'c99217f3-09e7-4751-bc3a-7739dac44a0e', {}); Product Unboxing - Simalube Single-Point Automatic Lubricators, How to Calculate Grease Quantity and Frequency for Bearings, 7 Steps to Trouble-free Grease Lubrication, Unboxing: Luneta Column Sight Glass in Tritan™, Unboxing: Mystik® JT-9™ LeakShield® AW Hydraulic Oil, Product Unboxing: Hy-Pro Compact Offline Filter, The Cost Effective Benefits of a High Performance Kidney Loop System, 8 Steps to Successfully Implement a Preventive Maintenance Program. Type Of Grease Calcium Base: Used for simple bearings, general purpose machinery and chassis lubrication for normal temperature applications. They can also make an oily surface, or barrier, to stop rust on the surface. Soda Base: 100,000 strokes of the different grease types, both dry/neat and with 20% water added » The QUAKERTEK™ CS 4015-EPE Calcium Sulfonate Complex grease doesn’t soften with the addition of 20% water, providing better mechanical stability, whereas other greases can be washed out of the C. water binding the oil and soap is lost so they separate and lubrication property is lost. Lubricating greases basically are composed of a thickener (10 to 15 percent), base oil (80 to 90 percent) and performance additives (5 to 10 percent). In the case of the four-ball weld test, a weld of 315 kg, 400 kg or even higher is common with a calcium sulfonate grease. After all, it is better to shear the calcite particles than the metal on the equipment. Sulfonic Acids. •Thickener yield was determined by relative comparison of %(wt) overbased calcium sulfonate (OCS) in final grease. This particular type of grease has inherent extreme pressure (EP) properties that stand out from the rest. •It is understood that the OCS is chemically changed during the grease making process. In the grease-making process, the amorphous carbonate is converted into a crystalline carbonate (mostly calcite). The dropping point is critical because it is the point at which the grease reverts back to a liquid (the oil separates from the thickener). In a general process, highly overbased Proper Grease Selection Reduces Steam Valve Maintenance. This maximum temperature is referred to as the dropping point. The calcium sulfonate thickener system protects against water washout and bearing corrosion under challenging conditions: Exceptional mechanical stability: Resists softening under mechanical shear in the presence of process water contamination. Before 1985, calcium sulfonate greases were niche and only produced in small quantities. Much of this rise in demand comes from rapidly developing countries like China, whose grease demand rose from 199 milli… Matrix offers solutions for both the glass making process (Glassmax) and the maintenance of the equipment. Calcium Sulfonate Grease. Our componentry encompasses an extensive range of corrosion inhibitors for use in various rust preventive and coatings applications. Calcium Sulfonate is a high temperature grease with many excellent properties such as shear stability, corrosion inhibition, water resistance and an inherent high load carrying capability. Max Born, a German mathematician and physicist, once said, “Science is not formal logic. Thixotropic Calcium Sulfonates. McMillen in 1960’s patented calcium sulfonate greases having dropping point over 500 0F (260 0C). Calcium based greases are water resistant and are low in cost. The only limiting factor with calcium sulfonates greases is their inferior pump ability and cost; however, recent advancement in the calcium sulfonate thickener chemistry enabled them to be similar to lithium greases. These complex greases are typically produced by adding a strong calcium-containing base, such as calcium hydroxide or calcium oxide, to the simple calcium sulfonate grease produced by either the two-step or one-step process, and reacting with stoichiometrically equivalent amounts of complexing acids such as 12-hydroxystearic acid (12-HSA), boric acid, acetic acid, or phosphoric acid. acid). At about 80 deg. Not new to the grease scene, calcium sulfonate thickeners have been around for almost 50 years. to a grease kettle. Calcium based greases are water resistant and are low in cost.