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Agenda
Grease Definition
How Greases Function
Reasons for Using A Grease
Grease Composition
Manufacturing Process
Evaluation of Greases
Recommended Practices
Grease Selection Tree
Feature & Benefits of PC Grease Line
Grease Definition
& Structure
A grease is a semi-solid formed as a result of
dispersing a thickener in a liquid lubricant.
In this colloidal dispersion, the oil is held in the 3-D
structure by:
Capillary action
Grease Definition
& Structure
As a result:
Fibres are the best structure because they have the largest
surface to volume ratio.
Softer greases bleed more (more oil in the 3-D voids)
Soap particles held together by Van der Waals forces
Impact on manufacturing via concentrate approach:
Warm grease concentrate absorbs the oil easier
Dilution oil has to be added gradually to avoid flooding
which leads to a higher oil bleed
4
Grease Structure
GREASE IS
A THICKENED OIL
NOT
A THICK OIL
1997 NLGI
Production Survey
ALL COUNTRIES
Straight lithium/lithium complex greases still dominate at
10
12
Grease Composition
Grease = Oil + Thickener + Additives
Base Oil (75-90%)
Thickener (5-25%)
Additives (0-5% or higher)
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Base Oils
Viscosity Selection
SERVICE
Temperature:
High
Medium
Medium
Low
15
Viscosity Selection
SERVICE
Centralized system
(normal temperature)
Medium
Centralized system
(low temperature)
16
Viscosity Selection
SERVICE
Equipment
High
Loaded
High
High speed
Medium
Electric motor
Medium
Open gears
High
17
Viscosity Selection
SERVICE
Grease
Minimum loss
Low separation
High
Water resistance
High
Maximum sealing
High
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Thickeners
19
Inorganic
Lithium
Clay
Aluminum
Silica
Calcium
Barium
Organic
Polyurea
20
Thickeners
POPULARITY OF THICKENERS
Soap based greases represent about 80% of the
total market.
Lithium soap products are the most dominant.
POPULARITY TRENDS
Soaps showing growth: complexes of lithium and
to some extent aluminum.
Another thickener showing growth: polyurea.
Decrease in popularity: calcium greases and
(already low) for sodium greases.
21
Additives
Additives are added to greases to improve their properties.
The most commonly used additives are:
Additives
Other additives are also used but are less important and
additives.
23
Manufacturing Process
The most popular greases, those based on metal soaps are
normally manufactured in three stages:
Typical
Manufacturing Process
Oil + Thickener
Ingredients
Additives
To Customers
Contactor
Packaging
Kettle
Transfer
Pump
Mill
(homogenizer)
Transfer
Pump
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HEATING OR COOLING
MEDIUM OUT
SOLIDS FEED
LIQUID
OR SLURRY
FEEDS
INNER JACKET
OUTER JACKET
HEATING OR
COOLING
MEDIUM IN
PRODUCT
OUT
26
Jacketed Vessel
for
Open-Kettle
Saponification
27
Evaluation
IMPORTANT TESTS
Penetration
Mobility
Dropping Point
Water Washout
Timken OK
4-Ball EP
Compatibility
28
Penetration
ASTM 217
Determine
Grease Consistency
Shear Resistance
29
Penetration
NLGI Grade
6
5
4
3
2 very common
1 common
0
00
000
Penetration (1/10mm)
Analog
85-115
Cheddar Cheese Spread
130-160
Smooth Pate
175-205
Frozen Yogurt
220-250
Vegetable Shortening
265-295
Peanut Butter
310-340
Tomato Paste
355-385
Brown Mustard
400-430
Applesauce
445-475
(Soft) Ketchup
30
Dropping Point
ASTM D2265
The temperature at which the grease becomes soft enough to
form a drop and fall from the orifice of the test apparatus.
Evaluation of dropping points
Not recommended
Acceptable
Very good
Excellent
< 100C
100-200C
200-250C
> 300C
temperature.
31
Mobility
U.S. Steel DM 43
Determines the ease of pumpability
Results
Resultsobtained
obtainedfor
for
commercial
commercialproducts:
products:
Mobility
Mobilityg/s
g/sat
at -18C
-18C
in
indecreasing
decreasingorder:
order:
Aluminum
AluminumComplex
Complexno.1
no.1
Lithium
Lithiumno.1
no.1
Lithium
Lithiumno.2
no.2
Lithium
LithiumComplex
Complexno.1
no.1
Calcium
CalciumComplex
Complexno.2
no.2
32
Water Washout
Results
Resultsobtained
obtained for
for
commercial
commercialproducts.
products.
Resistance of the grease in a bearing A good resistance
A good resistance
to washout when subjected to a jet
results
results in
inlower
lowerlosses.
losses.
of water.
%
grease
loss
after
the
%
grease
loss
after
the
Results varies as a function of: 1test
testin
in decreasing
decreasing
soap, 2- base oil, 3- additives.
order:
order:
Acceptable results: (10% or less for
Lithium
Lithiumno.1
no.1
#1 grade, 5% or less for #2 grade)
Lithium
no.2
Lithium
no.2
Pertinent to paper and pulp
Lithium
LithiumComplex
Complex
industries.
ASTM D1264
Calcium
CalciumComplex
Complex
Aluminum
AluminumComplex
Complex
33
Timken OK Load
ASTM D2509
Gives a measure of the extreme pressure properties of the
grease.
The higher the Timken OK load (kg or lb.) the better the
EP properties.
The results obtained are dependent on the EP additive.
34
4-Ball EP
ASTM D2596
Determines the EP properties of a grease
The higher the weld load the better the EP properties.
Results obtained depend on the EP additive used.
Good results: 250 kg and higher
35
Compatibility
Compatibility is a chemical effect but dilution is a physical
effect.
The two greases are mixed at 50/50 wt% and the penetration is
determined. This is repeated with other ratios / percentages
and the results plotted.
Observe that the consistency of the mixture increases versus
the consistency of the individual greases. Such a grease
mixture is considered incompatible.
Some manufacturers point out that >20% change is an
indication of incompatibility. Note that the greases become
less compatible with increasing temperatures.
36
Compatibility of Mixtures
Grease
Mixture
Al
Li 12-HOSA
Polyurea
Li Complex
Ba
Si
Clay
Supreme
EP2
Multipurpose
EP2
Chevron
SRI 2
Precision
EP2
Barimol
Heavy
Thermex
Bentone
RM2
Li 12-HOSA
Multipurpose
EP2
Yes
Polyurea
Chevron
SRI 2
Yes
Yes
130
145
Li Complex
Precision
EP2
Yes
Yes
Yes
150
170
158
Ba
Barimol
Heavy
Yes
Yes
Yes
Yes
168
153
173
160
Si
Thermex
Yes
No
No
No
Yes
115
80
173
Clay
Bentone
RM2
No
No
No
Yes
Yes
No
58
95
183
173
75
Ca
Sulphonate
Grease
OG-2
No
Yes
No
Yes
Yes
No
No
98
125
95
125
140
95
140
37
38
Recommended Practices
Select grease characteristics to match equipment
requirements
Plan changes to take account of potential grease
incompatibility
Inform operators about selected greases and
equipment requirements
Apply the grease by the most efficient method,
Recommended Practices
Ensure that the ultimate goal is met: lubrication
capacity
Open the relief plug or fitting if available
40
Recommended Practices
Monitor bearing temperatures during operation
requirements
Review greasing frequency, if operating
conditions change
41
Grease:
Service Categories
Regular
Premium
Specialty
42
Colour
Price
Package
Colour
Light
Can be a customer requirement
Dyed
Desirable for many applications
Grey / black
Solid lubricants
Package
Price
Availability
Price
Low
For regular greases
Higher
For premium greases
High to V. High
For specialty greases
44
Temperature
Oil type
Environment
Load
Special applications
Speed
OEM specific requirements / specifications
45
High:
Low:
Temperature
High:
Low:
Environment
Open / dusty:
Wet:
47
49
P
R
E
M
I
U
M
50
S
P
E
C
I
A
L
T
Y
PRECISION GOLD
Lithium Complex Soap
Synthetic (hydrocarbon) oil
Wide temp range (-40C to 170 C)
Eliminates or reduces need to switch grades by season
Oil viscosity: 98 cSt @ 40C
Meets NLGI GC-LB for wheel bearing and chassis lubrication
PRECISION GOLD MOLY
As for Precision Gold, but with Molybdenum Disulfide added for vibration protection
All-season grease for equipment which demands Moly
Oil viscosity: 98 cSt @ 40C
PRECISION GOLD HEAVY & GOLD HEAVY EP00
Lithium Complex Soap
Synthetic Oil
High oil viscosity of 492 cSt @ 40C for heavily-loaded applications and wider temperature range
Enhanced antioxidant package for longer service life at higher temperatures
51
52
53
VULCAN
GEARSHIELD NC
Asphalt-based, for open gear systems on mills
GEARSHIELD P
Semi-synthetic asphalt-free product designed for Mill open gears
GEAR DRESSING EP
High resistance to heat and water
Forms a tenacious film to protect gears against abnormally heavy loads and pressures
SEMI-FLUID GREASE EP
Designed for use in poorly sealed gear boxes and chain cases
Particularly suited for the lubrication of continuous miners in the Potash Industry
ARDEE EP000
Designed for the lubrication of air-operated rock drills
Applied through the same lubricator used for the rock drill oil
CAM COMPOUND
Designed for the lubrication of the Rolling (Monighan) Cam mechanism of Bucyrus-Erie (B-E) draglines
54
B
A
R
I
U
M
G
R
E
A
S
E
S
55
N
O
N
G
R
E
A
M S
E E
L
T
BENTONE RM2
Bentonite Clay thickened for non melt performance
Contains solid Molybdenum Disulfide for shock-load protection
Does not melt and has non drip properties
High temp bearing grease (150C)
Oil viscosity: 162 cSt @ 40C
THERMEX
Silica gel thickened, synthetic oil, NLGI 2 grade
56
D
R
I
L
L
I
N
G
L
U
B
R
I
C
A
N
T
S
Non-toxic and environmentally safe for use as a wire rope top dressing
Solvent-free
Gives excellent low temperature performance and exceptional load-carrying capability
Excellent rust protection
C
O
Meets the API Bulletin 5A2 specifications
M
Protects the threads against galling for casings, tubings and line pipes
P
Provides a positive seal against drilling fluids
D
Protects pipe joints against galling
S
Provides a positive seal against drilling mud pressure
57
58
Agenda
Multipurpose Greases
Multiflex Greases
Precision Greases
Supreme Greases
Grease OGs
Peerless LLG
}
}
}
Regular
Premium
Food Industry
Fleet/Construction Industry
Forestry Industry
Mining Industry
59
Multipurpose Greases
Multipurpose EP2, EP1, EP00, LoTemp EP
Multipurpose Greases
Better pumpability @ low temps. relative
to some complexes
Upsell to ....Precision line.....
61
Multipurpose Greases
Competitive Products:
Exxon.........Lidok EP
Texaco...................Multiflak EP, Marfak
Shell.......................Alvania EP
Mobil......................Mobilux EP
Sun.........................Prestige
Fiske.......................Lubriplate 630 Series
62
Exxon.................
Lidok EP Moly
Texaco................
Molytex
Shell....................
Retinax
Sun......................
Prestige Moly
Fiske....................
Lubriplate 3000
Tribol...................
Precision EP Greases
Grades: EP2, EP1, EP00, EMB
Premium performance, multipurpose lithium-complex:
66
Retinax
Competitive Assessment:
Precision has a little better EP properties, better low temp
pumpability and a much higher temperature capability than
most of the competitive products
67
Albida SLC
Mobil.............
Exxon....
69
for EP00
Designed for heavy duty applications and long life at higher
temperatures
Specifically for dryer felt-roll bearings in paper machines,
70
71
Supreme Greases
Supreme Greases
73
Supreme Greases
Competitive Products:
Texaco.........................
Sun...............................
Brooks Technology.......
Fiske.............................
Elf-Atochem..................
Summit
Sunaplex
Plexalene 725
Lubriplate 730 series
Keystone Zeniplex
74
Grease OG
75
Grease OG
Competitive Products:
Mobil..............
Mobilplex 46, 47
76
greases
Recommended for sealed-for-life applications, e.g. CV-
77
78
Grey
Grey
Cream
Multiflex Moly
Grey
Brown
Burgundy
Green
Grey
Gold
Gold
Grey
Brown
Grey
Red
Black
Temperature
-18 to 120C
<-18 to >120C
< -18C
Speed
Load
High
High (Vibration/Shock)
X
X
Low/Moderate
Environment
Low Moisture
High moisture
Durability
Normal
Long Life
X
X
This matrix displays only the major distinguishing features of each grease / grease family
This matrix is intended as a general guideline only. Please refer to the Lubricant Handbook or Tech Data sheets for more information.
79
80
81
82
(GB/LA)
(GC/LB)
(GC/LB)
84
Fifth wheels:
Precision Moly - Grease OG-2 (also effective)
85
Woodlands:
For general purpose greasing of off-highway, woodlands
machinery:
Multiflex Moly EP or upsell to Precision Moly/Gold
Moly EP
Precision Gold for all-round, wide temp. use
Supreme G-124 offers excellent resistance to water and
has a good temp range
For trucks used in woodlands operation:
Precision EP for wheel bearings & chassis
Precision Moly for 5th wheels
86
consolidation
Peerless LLG for fans in dryer section (high heat, hard-
to-reach area)
87
88
89
90
94
ALS Premium
ALS Moly
96
97
Greases - Summary
Petro-Canada has a comprehensive grease line to meet
98