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Calcium Sulphonate Complex Grease
Calcium Sulphonate Complex Grease: General Overview, Composition and Formulation
Calcium sulphonate complex grease is developed for wet, corrosive, high-load and elevated-temperature service. Its overbased calcium sulphonate thickener can contribute inherent corrosion protection and load-carrying performance.
Formulation balance and the conversion process affect consistency, pumpability, water resistance, oil release and EP behaviour. The process must be adjusted to the chemistry of the available overbased sulphonate.
General Composition of Calcium Sulphonate Complex Grease
- COMPONENT | PURPOSE
Overbased calcium sulphonate
Primary thickener precursor with inherent detergency, corrosion protection and load-carrying characteristics.
Base oil
Mineral or synthetic oil selected for speed, load and temperature.
Conversion components
Promote conversion to the required grease structure.
Complexing components
Support formation and stability of the complex thickener.
Water-control chemistry
Used during conversion and subsequently controlled or removed.
Antioxidant and supplementary additives
Added where additional oxidation, wear or corrosion performance is required.
Final composition depends on sulphonate chemistry and the selected process.
Production Process and Lubechem Technical Support
- TYPICAL MANUFACTURING SEQUENCE
1. Charge the overbased sulphonate and selected oil.
2. Introduce conversion components in the validated sequence.
3. Control water, temperature, mixing and conversion.
4. Add complexing components and complete thickener formation.
5. Add finishing oil to achieve the required consistency.
6. Cool under controlled agitation.
7. Add compatible finishing additives.
8. Homogenise, deaerate and test.
LUBECHEM SUPPORT
• Raw-material and sulphonate evaluation
• Conversion-process development
• Formula, SOP and batch sheet
• Water-resistant and EP optimisation
• Laboratory, pilot and plant-scale support
• Operator training and troubleshooting
• Steel, mining and marine application development
Typical Specifications, Testing and Applications
- TYPICAL DEVELOPMENT TARGETS
NLGI grade: application-dependent
Worked penetration: ASTM D217
Dropping point: often above 260°C; ASTM D2265
Four-ball weld load: ASTM D2596
Four-ball wear: ASTM D2266
Water washout: ASTM D1264
Water spray-off: ASTM D4049 where required
Rust prevention: ASTM D1743
Copper corrosion: ASTM D4048
Pumpability and oil separation: application-specific limits
COMMON APPLICATIONS
• Steel mills and continuous casters
• Mining and construction equipment
• Marine and submerged service
• Paper mills
• Wet, dirty and high-load bearings
Final limits depend on base oil, thickener concentration and conversion quality.
Calcium Sulphonate Complex Grease: Frequently Asked Questions
- Why is it suitable for wet applications?
The thickener system can provide excellent water resistance and corrosion protection.
Does it require an EP additive?
The thickener has inherent load-carrying characteristics, but final requirements depend on testing.
Is it suitable for high-speed bearings?
Suitability depends on base-oil viscosity, oil release, consistency and bearing design.
Can food-compatible versions be developed?
Potentially, but every ingredient and manufacturing control must meet the intended requirement.
Why is the production process important?
Conversion quality strongly affects consistency, performance and batch repeatability.
Get in Touch with Us
If you found this information useful and would like to discuss further, please contact us. We are committed to providing high-quality solutions tailored to your specific needs.
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