High-load bearing lubricant for Morgan rolling mill and preparation method of high-load bearing lubricant

Abstract

The invention discloses a high-load bearing lubricant for a Morgan rolling mill and a preparation method of the high-load bearing lubricant. The lubricant comprises synthetic base oil, modified titanium-silicon composite particles, slow-release antioxidant microcapsules, an organic molybdenum anti-wear agent, an extreme pressure additive, an environment-friendly ternary antirust agent and a viscosity index improver. Modified nanoparticles are prepared through atomization melting and solvent heat treatment, antioxidant microcapsules are prepared through a polyethylene glycol coating technology, and then the composite lubricating system is formed through high-temperature and high-shear mixing. The lubricant disclosed by the invention has excellent extreme pressure anti-wear performance, thermal oxidation stability, anti-rust and anti-corrosion capability and good oil-water separation performance, and is suitable for a rolling mill bearing lubricating system under severe working conditions of high load, high temperature, high humidity and the like. The lubricant can effectively prolong the service life of the bearing and reduce the operation and maintenance cost of equipment, and has a good industrial application prospect.

Description

Technical Field

[0001] The invention relates to a high-load bearing lubricant for a Morgan rolling mill and a preparation method thereof. Background Art

[0002] As the metallurgical industry continues to demand high-speed, high-precision, and high-continuity wire rod rolling processes, the bearing systems of Morgan mills, as critical rolling equipment, are constantly operating under the demanding conditions of high loads, high speeds, high temperatures, and high humidity. To ensure operational stability and equipment life, the lubricant system must not only provide basic lubrication protection but also meet the coordinated requirements of load-bearing capacity, anti-wear, anti-oxidation, rust prevention, and water separation.

[0003] However, the bearing lubricants currently used in the industry generally face the following technical bottlenecks:

[0004] First, the lubricating film has insufficient load-bearing capacity. Under high-speed shear and heavy-load conditions, the lubricating film formed by traditional lubricants is prone to fracture or instability, resulting in direct contact between the friction pairs and increased wear on the bearing surface. In severe cases, this can cause equipment shutdown or burnout.

[0005] Secondly, achieving both extreme pressure and anti-wear properties is difficult. Although extreme pressure additives can improve load-bearing capacity, they are susceptible to degradation at high temperatures and compete with other functional additives for adsorption, making it difficult to continuously form a stable boundary lubrication film, resulting in a decrease in anti-wear capabilities.

[0006] Third, the antioxidant life is short and oil changes are frequent. During continuous operation, the bearing temperature of the Morgan mill can reach over 120°C. Oil oxidizes rapidly at high temperatures, making it difficult for traditional antioxidant systems to effectively maintain oil stability over long periods of time. Frequent oil changes lead to high operating and maintenance costs.

[0007] Fourth, they are prone to emulsification and corrosion in humid, water-containing environments. The proximity or partial integration of the lubrication and cooling systems makes it extremely easy for water to mix into the oil. Conventional lubricants demulsify slowly, and their rust-preventing capabilities rapidly decline after emulsification. This significantly increases the risk of corrosion in high-humidity, high-salt environments.

[0008] Finally, multifunctional lubricants are difficult to prepare stably. Traditional additive systems suffer from poor solubility, uneven dispersion, and poor shear stability, leading to stratification, particle settling, and insufficient storage stability. These factors make it difficult to meet the batch consistency and long-term application requirements of industrial-grade lubrication systems.

[0009] In summary, the market urgently needs a composite lubricant system capable of long-term stable operation under high-load, high-shear, and high-humidity conditions. This system must possess excellent lubrication load-bearing capacity, wear resistance, oxidation stability, rust prevention, and water separation capabilities, while also being well-suited for industrial production. This invention addresses these technical bottlenecks and possesses outstanding comprehensive technical advantages and engineering application value. Summary of the Invention

[0010] The purpose of the present invention is to solve the above deficiencies in the prior art and to provide a high-load bearing lubricant for a Morgan rolling mill and a preparation method thereof.

[0011] A high-load bearing lubricant for a Morgan rolling mill, suitable for use in high-load equipment operating environments, comprises the following components (in percentage by mass):

[0012] Base oil 60% to 75%, granular composite friction reducer 5% to 8%, slow-release antioxidant additive 3% to 6%, anti-wear additive 4% to 7%, extreme pressure additive 3% to 5%, functional additive 4% to 6%, viscosity improver 1% to 2%.

[0013] Furthermore, the granular composite friction reducer is titanium silicon particles that have been subjected to atomization melting and solvent thermal composite modification, and is used to form a dynamic rolling lubrication film.

[0014] Furthermore, the sustained-release antioxidant additive is a microcapsule structure formed by the antioxidant being loaded on a porous carrier and coated with polyethylene glycol.

[0015] Furthermore, the anti-rust functional additive includes an organic compound system that does not contain barium, specifically: quaternary ammonium salt ionic liquid, phosphate amine salt and alkylbenzene sulfonate calcium, and the mass ratio thereof is 1.0-3.0:1.0-3.0:3.0-9.0.

[0016] Furthermore, the four-ball sintering load under the ASTM D2783 standard is not less than 160 kg, the wear scar diameter under the ASTM D4172 standard is less than 0.5 mm, and the oxidation life under the ASTM D2272 standard is greater than 180 min.

[0017] A method for preparing a high-load bearing lubricant for a Morgan rolling mill comprises the following steps:

[0018] Titanium-silicon composite particles were synthesized by vacuum atomization and solvothermal reaction;

[0019] The antioxidant is loaded on a porous carrier and coated with polyethylene glycol to form a sustained-release microcapsule;

[0020] The base oil, composite particles, microcapsules, anti-wear agent, extreme pressure agent, rust inhibitor and improver are mixed in proportion under high shear at 160 DEG C to prepare the lubricant.

[0021] Furthermore, in the preparation of the composite particles, the atomization temperature is 550-650°C, and the solvent thermal reaction temperature is 120-140°C.

[0022] Furthermore, the microcapsules are prepared by a single coacervation method, and the inducers are 5-10 wt% sodium hydroxide and 6-10 wt% sodium chloride.

[0023] Furthermore, in the mixing step, the shear temperature is controlled at 150-165° C., and the shear time is 1-3 hours.

[0024] Furthermore, the obtained lubricant is centrifuged at 3000 rpm to remove bubbles and is filtered to form a clear and transparent finished product.

[0025] Beneficial effects: Compared with the prior art, the present invention has the following advantages:

[0026] In terms of extreme pressure and anti-wear performance, the lubricant incorporates modified titanium silicon particles produced through atomization smelting and solvent heat treatment, forming a dynamic rolling support film between the friction pairs, effectively reducing interfacial friction and wear. In a four-ball test, the lubricant achieved a sintering load of 165 kg and reduced the wear scar diameter to 0.45 mm, significantly outperforming existing commercially available products and greatly improving the equipment's operational reliability under high loads.

[0027] Secondly, in terms of antioxidant stability, the use of slow-release antioxidant microcapsules ensures controlled release of antioxidants during the lubricant's high-temperature aging process, effectively extending the lubricant's useful life. In actual measurements, the lubricant's oxygen bomb life reached 182 minutes, approximately 76% longer than conventional lubricants. This helps reduce maintenance, replacement frequency, and the risk of system failure.

[0028] In terms of rust protection, this invention innovatively utilizes a ternary compounded rust inhibitor system, replacing traditional barium salt additives. This system is environmentally friendly and non-toxic, while also forming a highly stable anti-corrosion film on metal surfaces. Salt spray testing has proven that the product exhibits no corrosion after 96 hours in a highly corrosive environment, far surpassing the 48-hour durability of conventional products and meeting the requirements of equipment such as rolling mills operating under long-term, hot and humid conditions.

[0029] This lubricant also demonstrates excellent system stability and adaptability. Its demulsification time is only 18 minutes, demonstrating excellent oil-water separation capabilities and making it suitable for use in water-containing or humid environments. The high-shear mixing process ensures uniform distribution of particles and additives, resulting in a clear and transparent system that is less prone to stratification or precipitation, making it easy to promote and use in industrial settings.

[0030] In summary, the present invention achieves the systematic technical effects of "strong lubrication, high antioxidant capacity, excellent rust prevention, and wide adaptability" through the integrated innovation of lubricating particle engineering, additive controlled-release technology, rust inhibitor synergistic formula and efficient preparation process. It is particularly suitable for high-load, high-speed, and high-humidity operation scenarios of metallurgical rolling equipment such as Morgan rolling mills, and has broad market application prospects and industrial promotion value. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a flow chart of the lubricating oil preparation method. DETAILED DESCRIPTION

[0032] In order to deepen the understanding of the present invention, the present invention will be further described in detail below with reference to embodiments and drawings. The embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0033] Example 1:

[0034] A composite lubricant suitable for high-load equipment such as Morgan rolling mills, comprising the following components in percentage by mass:

[0035] Synthetic base oil (PAO and synthetic ester mixture): 70%;

[0036] Modified titanium-silicon composite particles: 6%, which are titanium-silicon nanoparticles that have undergone atomization melting and solvent thermal composite treatment and are used to form a dynamic rolling lubricating film at the lubrication interface;

[0037] Sustained-release antioxidant microcapsules: 5%, which are microcapsule structures coated with zinc dialkyl dithiophosphate antioxidants to prolong the antioxidant time;

[0038] Organic molybdenum anti-wear agent: 6%, using organic molybdenum additives such as di(2-ethylhexyl) dithiophosphate molybdenum to improve boundary lubrication performance;

[0039] Extreme pressure additive: 4%, a compound of phosphate ester and sulfurized fatty acid ester, which improves extreme pressure and anti-wear capabilities;

[0040] Environmentally friendly ternary anti-rust additive: 5%, containing quaternary ammonium salt ionic liquid, dioctyl phosphate octadecylamine salt and low-base alkylbenzene sulfonate calcium, does not contain barium element, and has excellent corrosion resistance;

[0041] Viscosity index improver: 1%, used to improve high temperature operating viscosity stability.

[0042] The lubricant has a sintering load of up to 165kg in the ASTM D2783 four-ball test, a wear scar diameter of less than 0.5mm, and an RPVOT oxidation life of more than 180min. It has the ability to be used stably for a long time in high temperature and high load environments.

[0043] Example 2:

[0044] Step 1: Synthesis of modified titanium silicate particles

[0045] Titanium dioxide and sodium silicate were mixed in a mass ratio of 2:1 and spray-melted at 650°C using argon atomization technology;

[0046] The obtained spherical particles are placed in a solvent thermal reactor and reacted with an imidazoline ligand and zinc sulfate. The temperature is controlled at 120° C. and the reaction time is 20 hours to obtain composite friction-reducing particles.

[0047] Step 2: Preparation of sustained-release antioxidant microcapsules

[0048] The antioxidant is dissolved in base oil and ultrasonically dispersed, and then mixed with the modified porous carrier for adsorption;

[0049] Add 5 wt% sodium hydroxide solution dropwise at 72°C and react for 20 minutes;

[0050] Then, 6 wt % sodium chloride solution was added dropwise to form microcapsule wall material, and the sustained-release microcapsule powder was obtained after filtration, washing and drying.

[0051] Step 3: Lubricant mixing and finished product processing

[0052] Weigh synthetic base oil, composite particles, antioxidant microcapsules, organic molybdenum, extreme pressure agent, rust inhibitor, and viscosity improver according to the proportions in Example A1;

[0053] Stir and mix in a high shear emulsifier at 160°C for 1.5 hours;

[0054] The mixed liquid was centrifuged at 3000 rpm for 10 minutes for degassing, and then filtered through a 200-mesh filter to remove impurities to obtain the finished lubricating oil.

[0055] Principle: First, the modified titanium-silicon nanoparticles introduced into the lubricant are produced through a vacuum atomization and solvent thermal reaction process, resulting in a spherical, smooth surface morphology. These particles form a "rolling support layer" at the lubricated contact interface, analogous to micro-ball bearings. Under high load and high-speed shear conditions, they effectively reduce shear stress and contact wear between the friction pairs, thereby improving the load-bearing capacity and stability of the lubricating film. This is demonstrated by the four-ball test, which achieved a sintering load of up to 165 kg and a wear scar diameter reduced to 0.45 mm.

[0056] Secondly, the antioxidant system adopts a slow-release microcapsule structure. The antioxidant is adsorbed on a porous carrier and then coated with polyethylene glycol to form microcapsules. The active components are gradually released under the temperature rise and shear conditions during the operation of the oil product. This structure realizes the "two-stage release" of antioxidant ingredients, preventing oxidation-induced reactions in the early stage of operation and continuously releasing them in the middle and late stages to maintain an antioxidant environment, thereby significantly extending the service life of the lubricant. Its oxygen bomb oxidation life (RPVOT) can reach 182 minutes, which is more than 70% higher than that of ordinary lubricants.

[0057] Thirdly, regarding the rust prevention system, the present invention utilizes a ternary, environmentally friendly rust inhibitor composed of a quaternary ammonium ionic liquid, a phosphate amine salt, and a low-base calcium alkylbenzene sulfonate. This system is barium-free, environmentally friendly, non-toxic, and exhibits excellent metal affinity and film-forming properties. The components work together through physical and chemical adsorption to rapidly form a multilayer protective film on the metal surface, enhancing the lubricant's long-term corrosion protection in humid, saline environments. In practical applications, the salt spray test can achieve 96 hours of rust-free results.

[0058] Furthermore, all ingredients are homogenously mixed at 160°C under high shear conditions, effectively preventing particle agglomeration and phase separation, ensuring system stability and uniformity. The entire formulation balances lubricity, protection, environmental adaptability, and industrial feasibility, resulting in a composite lubrication system with four key mechanisms: rolling friction reduction, controlled-release antioxidants, synergistic rust prevention, and shear homogenization. This system is suitable for long-term, stable lubrication under high-load conditions, such as Morgan rolling mills.

[0059] Experimental data:

[0060]

[0061]

[0062] Table 1

[0063] As can be seen from the table above, in terms of extreme pressure performance, the four-ball sintered load is increased to 165kg, a 37.5% increase compared to the 120kg load of traditional lubricants. This demonstrates superior resistance to extreme pressures and effectively prevents lubricant film failure during heavy-load rolling. Furthermore, in terms of wear resistance, the wear scar diameter is reduced to 0.45mm, a 40% reduction compared to the control sample, significantly reducing wear on the friction pair surface and extending the bearing's service life.

[0064] In terms of oxidation stability, the lubricant achieved a lifespan of 182 minutes in an oxygen bomb test, a 76.7% improvement. This effectively slows lubricant aging in high-temperature, high-load environments, helping to extend oil change intervals. In terms of emulsification and separation capabilities, the demulsification time is only 18 minutes, 60% shorter than existing products. This demonstrates its ability to rapidly separate water in water-contaminated conditions, making it more suitable for the high-humidity environment of Morgan rolling mills.

[0065] In addition, the lubricant performed excellently in the anti-rust performance test, and no rust occurred after 96 hours in a salt spray environment, and the anti-rust effect was significantly better than the traditional formula. In terms of viscosity performance, its kinematic viscosity at 40°C remained stable at 68.2mm 2 / s, with a viscosity index of 142 (a 23.5% increase), it exhibits excellent thermal stability and viscosity-temperature consistency, ensuring continuous and stable lubrication of equipment under conditions of severe temperature fluctuations. The coefficient of friction is reduced to 0.071, a 34% decrease compared to the control product, significantly reducing operating frictional resistance. Scanning electron microscope (SEM) images show that the lubricating film structure is intact and wear marks on the metal surface are minimal, further confirming the reliability of its lubricating and protective effects.

[0066] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A high-load bearing lubricant for Morgan rolling mill, suitable for high-load equipment operating environment, characterized by: The lubricant comprises the following components (in percentage by mass): Base oil 60% to 75%, granular composite friction reducer 5% to 8%, slow-release antioxidant additive 3% to 6%, anti-wear additive 4% to 7%, extreme pressure additive 3% to 5%, functional additive 4% to 6%, viscosity improver 1% to 2%.

2. The lubricant according to claim 1, characterized in that The granular composite friction reducer is titanium silicon particles that have been subjected to atomization smelting and solvent thermal composite modification, and is used to form a dynamic rolling lubricating film.

3. The lubricant according to claim 1, characterized in that The slow-release antioxidant additive is a microcapsule structure formed by an antioxidant loaded on a porous carrier and coated with polyethylene glycol.

4. The lubricant according to claim 1, characterized in that The anti-rust functional additive comprises an organic compound system that does not contain barium, specifically: quaternary ammonium salt ionic liquid, phosphate amine salt and alkylbenzene sulfonate calcium, and the mass ratio thereof is 1.0-3.0:1.0-3.0:3.0-9.

0.

5. The lubricant according to claim 1, characterized in that The four-ball sintering load under ASTM D2783 standard is not less than 160kg, the wear scar diameter under ASTM D4172 is less than 0.5mm, and the oxidation life under ASTM D2272 is greater than 180min.

6. A method for preparing a high-load bearing lubricant for a Morgan rolling mill, characterized in that: The following steps are involved: Titanium-silicon composite particles were synthesized by vacuum atomization and solvothermal reaction; The antioxidant is loaded on a porous carrier and coated with polyethylene glycol to form a sustained-release microcapsule; The base oil, composite particles, microcapsules, anti-wear agent, extreme pressure agent, rust inhibitor and improver are mixed in proportion under high shear at 160 DEG C to prepare the lubricant.

7. The preparation method according to claim 1, characterized in that In the preparation of the composite particles, the atomization temperature is 550-650°C, and the solvent thermal reaction temperature is 120-140°C.

8. The preparation method according to claim 1, characterized in that The microcapsule is prepared by a single coagulation method, and the inducing agents are 5-10 wt% of sodium hydroxide and 6-10 wt% of sodium chloride.

9. The method according to claim 1, characterized in that The shearing temperature in the mixing step is controlled at 150-165° C., and the shearing time is 1-3 hours.

10. The preparation method according to claim 1, characterized in that The obtained lubricant was centrifuged at 3000 rpm to remove bubbles and filtered to form a clear and transparent finished product.

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