Extreme pressure antiwear gear oil composite additive and processing method thereof

Abstract

The invention discloses an extreme pressure anti-wear gear oil composite additive and a processing method thereof, and relates to the technical field of gear oil composite additives, and the extreme pressure anti-wear gear oil composite additive comprises the following components: 15-25% of sulfurized isobutylene, 10-20% of zinc dialkyl dithiophosphate, 8-15% of polyisobutylene succinimide, 5-12% of mahogany petroleum sulfonate, 5-12% of 2, 3, 5-trimethyl-1, 3-pentanediol monoisobutyrate, 5-12% of 2, 3, 5-trimethyl-1, 3- According to the invention, through scientific compounding of core functional components, synergistic interaction of extreme pressure and anti-wear performance is realized, the defect that performance of a single additive is poor is effectively overcome, the anti-wear performance of the lubricating oil is greatly improved, the service life of the lubricating oil is prolonged, and the service life of the lubricating oil is prolonged. The product can be precisely adapted to different application scenes such as heavy-load engineering machinery, high-speed precise gear transmission systems and mining machinery, can form a stable lubricating protective film under harsh working conditions, resists the failure problems such as abrasion, scratch and sintering of a gear contact surface, is high in adaptability, does not need to additionally adjust a formula according to the working conditions, and is low in cost. The lubricating protection requirements of various gear transmission devices can be met, and the application range is wide.

Description

Technical Field

[0001] This invention relates to the field of gear oil composite additives, and in particular to an extreme pressure anti-wear gear oil composite additive and its processing method. Background Technology

[0002] Gear transmission, as a core and widely used transmission method in mechanical equipment, is widely used in automobiles, construction machinery, industrial equipment, mining machinery and other fields. Its operating status directly affects the working efficiency and service life of the entire equipment. During gear transmission, especially under harsh conditions such as high speed, heavy load and high temperature, the gear contact surface is prone to boundary lubrication or even extreme pressure, which can easily lead to failures such as wear, scratches and sintering. In severe cases, it can cause equipment shutdown failure. Therefore, stringent requirements are placed on the extreme pressure anti-wear performance of gear oil.

[0003] Gear oil additives are a key component in improving gear oil performance, and their performance directly determines the lubrication and protection effect of the gear oil. In existing technologies, gear oil additives are mostly based on single extreme pressure agents or anti-wear agents. These single-component additives cannot simultaneously meet the dual requirements of extreme pressure and anti-wear, exhibiting poor synergistic effects and significant performance shortcomings. While some composite additives attempt to combine multiple functional components, unreasonable component ratios lead to poor compatibility, resulting in limited improvement in extreme pressure and anti-wear performance and a tendency for stratification and precipitation with the gear oil base oil, severely impacting stability and effectiveness. Furthermore, existing composite additives generally suffer from single-function limitations, mostly focusing only on extreme pressure and anti-wear performance, lacking consideration for comprehensive properties such as anti-oxidation, rust prevention, and anti-foaming. This fails to fully meet the long-term use requirements of gear oil under complex operating conditions, leading to rapid gear oil aging and increased equipment maintenance frequency and costs. Summary of the Invention

[0004] (a) Technical problems to be solved

[0005] To address the problems existing in the prior art, the present invention provides an extreme pressure anti-wear gear oil composite additive and its processing method.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, the present invention provides the following technical solution: an extreme pressure anti-wear gear oil composite additive and its processing method, comprising the following components: 15-25% isobutylene sulfide, 10-20% zinc dialkyl dithiophosphate, 8-15% polyisobutylene succinimide, 5-12% petroleum sulfonate, 3-8% 2,6-di-tert-butyl-p-cresol, 2-6% benzotriazole derivative, 3-7% ammonium molybdate, 20-40% base oil, and 0.01-0.1% antifoaming agent.

[0008] As a preferred embodiment of the extreme pressure anti-wear gear oil composite additive of the present invention, the sulfur content of the sulfurized isobutylene is 30-40 wt%, and the molecular weight is 300-500.

[0009] As a preferred embodiment of the extreme pressure anti-wear gear oil composite additive of the present invention, the dialkyl dithiophosphate zinc is a primary alkyl or secondary alkyl type with a zinc content of 8-12wt%.

[0010] As a preferred embodiment of the extreme pressure anti-wear gear oil composite additive of the present invention, the amount of the composite additive added to the gear oil is 3-8%, and after addition, the gear oil has a PB value ≥1000N, a PD value ≥3000N, and a wear scar diameter ≤0.4mm (392N, 60min).

[0011] As a preferred embodiment of the extreme pressure anti-wear gear oil composite additive of the present invention, the antifoaming agent is methyl silicone oil or polyether modified silicone oil.

[0012] As a preferred embodiment of the extreme pressure anti-wear gear oil composite additive and its processing method described in this invention, the base oil is an API Group II or Group III mineral base oil with a kinematic viscosity of 10-20 mm² / s at 40°C.

[0013] The processing method of the extreme pressure anti-wear gear oil composite additive of the present invention includes the following steps: (1) raw material pretreatment; (2) ingredient mixing; (3) heating reaction; (4) cooling maturation; (5) filtration purification; and (6) testing and packaging.

[0014] As a processing method for the extreme pressure anti-wear gear oil composite additive of the present invention, in step (1), the solid component is crushed to a particle size ≤100μm, and the liquid component is dehydrated to a moisture content ≤0.1wt%.

[0015] As a processing method for the extreme pressure anti-wear gear oil composite additive of the present invention, in step (3), the temperature of the heating reaction is 80-120℃, the holding time is 1.5-3h, and the stirring speed is 300-500r / min.

[0016] As a processing method for the extreme pressure anti-wear gear oil composite additive of the present invention, in step (4), the cooling and maturation temperature is 40-60℃, the maturation time is 1-2h, and the stirring speed is 150-250r / min.

[0017] (III) Beneficial Effects

[0018] This invention provides an extreme pressure anti-wear composite additive for gear oil and its processing method. It has the following beneficial effects:

[0019] 1. Through the scientific compounding of core functional components, the product achieves a synergistic effect of extreme pressure and anti-wear properties, effectively compensating for the shortcomings of single additives. It can be precisely adapted to different application scenarios such as heavy-duty engineering machinery, high-speed precision gear transmission systems, and mining machinery. Under harsh working conditions, it can form a stable lubricating protective film to resist wear, scratches, and sintering failures on gear contact surfaces. Its strong adaptability eliminates the need for additional formula adjustments based on working conditions, meeting the lubrication and protection needs of various gear transmission equipment and making it widely applicable.

[0020] 2. By rationally combining dispersing and cleaning components with standardized raw material pretreatment processes, the product ensures stability across a wide temperature range, minimizing issues such as stratification and sedimentation. Simultaneously, the product integrates multiple functions including anti-oxidation, rust prevention, and anti-foaming, comprehensively enhancing the overall performance of gear oils, slowing down oil aging and deterioration, extending gear oil lifespan and equipment maintenance cycles, reducing downtime losses due to equipment failures, and lowering overall operating costs.

[0021] 3. Mass production can be achieved using conventional production equipment. Key process parameters such as heating, stirring, and maturation are easy to control precisely, and operation is convenient, ensuring batch-to-batch product consistency. Compared to traditional technologies, its production process is simple and efficient, with strong raw material adaptability. It eliminates the need for complex purification steps, effectively improving production efficiency and reducing energy and raw material consumption during production. It possesses significant advantages for industrial production, helping companies control costs and enhance market competitiveness. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a flowchart of the processing method of the present invention. Detailed Implementation

[0024] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0025] Example 1

[0026] I. Raw material formula:

[0027] An extreme pressure anti-wear gear oil composite additive comprises the following raw materials by weight percentage: 20% isobutylene sulfide, 15% zinc dialkyl dithiophosphate, 12% polyisobutylene succinimide, 8% petroleum sulfonate, 5% 2,6-di-tert-butyl-p-cresol, 4% benzotriazole derivative, 5% ammonium molybdate, 30% base oil, and 0.1% polyether-modified silicone oil.

[0028] II. Processing Method:

[0029] Raw material pretreatment stage

[0030] Solid component treatment: Ammonium molybdate and benzotriazole derivatives are fed into a high-speed pulverizer, the pulverizing speed is set to 8000 r / min, the pulverizing time is 15 min, until the material particle size reaches 80 μm, and then screened through a 100 mesh sieve to ensure that there are no large particle impurities.

[0031] Liquid component processing: Sulfated isobutylene, zinc dialkyl dithiophosphate, base oil and other liquid components are injected into a vacuum dehydration kettle, the vacuum degree is set to -0.09MPa, the temperature is 80℃, and the dehydration is carried out for 2 hours. Finally, the moisture content of each liquid component is controlled to be ≤0.08wt%. After dehydration, the kettle is sealed for later use.

[0032] Ingredient mixing stage

[0033] Start the 500L stainless steel reactor and check the equipment's sealing and the operating status of the stirring system to ensure there are no leaks or abnormal noises.

[0034] First, pump the dehydrated base oil into the reactor, turn on the stirring device, set the stirring speed to 250 r / min and the temperature to 30℃.

[0035] Add polyisobutylene succinimide and petroleum sulfonate slowly in sequence, with a 10-minute interval between each addition, and continue stirring for 35 minutes until a homogeneous and transparent mixture is formed, with no visible particles or stratification.

[0036] Heating reaction stage

[0037] The system temperature was raised to 100℃ by heating the reactor jacket at a rate of 5℃ / min.

[0038] Keep the temperature stable, and add isobutylene sulfide, zinc dialkyl dithiophosphate, and ammonium molybdate in sequence. During the feeding process, increase the stirring speed to 400 r / min to avoid excessively high local concentrations.

[0039] The reaction was carried out at a constant temperature of 100℃ for 2 hours. During the reaction, samples were taken every 30 minutes to observe the state of the system and ensure that there was no precipitation or gelation.

[0040] Cooling and ripening stage

[0041] After the reaction is complete, the heating system is turned off, and cooling water is introduced through the jacket to cool down the system at a rate of 8℃ / min until the system temperature drops to 50℃.

[0042] Add 2,6-di-tert-butyl-p-cresol, benzotriazole derivative, and polyether-modified silicone oil, adjust the stirring speed to 200 r / min, and cure at a constant temperature for 1.5 h to promote full integration of the components.

[0043] Filtration and purification stage

[0044] Start the high-precision plate and frame filter press, install the 5μm filter membrane, and check the sealing of the filtration system.

[0045] The matured material is pumped into the filter through a conveying pump. The filtration pressure is controlled at 0.3 MPa and the filtration flow rate is 50 L / h. The filtered clear liquid is collected. After filtration, the filter membrane is backwashed to recover the small amount of retained effective components.

[0046] The filtered liquid was sampled a second time to ensure that the mechanical impurity content was ≤0.005wt%, thus guaranteeing the purification effect.

[0047] Testing and packaging stage

[0048] Sampling and testing of core performance indicators: Using a four-ball milling machine according to GB / T 3142-2019, the PB value is 1120N, the PD value is 3200N, and the wear scar diameter is 0.35mm; according to SH / T 0193-2008, the oxidation resistance is tested, and the acid value increases by 0.15mgKOH / g after 100h at 150℃; according to GB / T 11143-2008, the rust prevention is tested, and there is no rust after immersion in salt water for 72h.

[0049] After passing the inspection, the finished product is injected into a vacuum packaging machine and packaged in sealed iron drums weighing 20kg each. Each drum is labeled with the production date, batch number, and quality certificate. The product is then stored in a warehouse (at an ambient temperature of 5-35℃, away from light and in a well-ventilated area).

[0050] III. Implementation Results:

[0051] When the product of this embodiment is added to gear oil at a concentration of 5%, the gear oil can reach the GL-5+ standard, which is suitable for the gear transmission system of heavy-duty engineering machinery. Under high temperature (120℃) and heavy load (load ≥2500N) conditions, it can run continuously for 1000 hours with gear wear ≤0.02mm and service life extended by more than 50% compared with ordinary gear oil.

[0052] Example 2

[0053] I. Raw material formula:

[0054] An extreme pressure anti-wear gear oil composite additive comprises the following raw materials by weight percentage: 18% isobutylene sulfide, 18% zinc dialkyl dithiophosphate, 10% polyisobutylene succinimide, 11% petroleum sulfonate, 6% 2,6-di-tert-butyl-p-cresol, 3% benzotriazole derivative, 6% ammonium molybdate, 32% base oil, and 0.08% polyether-modified silicone oil.

[0055] II. Processing Method:

[0056] Raw material pretreatment stage

[0057] Solid component treatment: Ammonium molybdate and benzotriazole derivatives were fed into a high-speed pulverizer, the pulverization speed was set to 9000 r / min, the pulverization time was 12 min, the particle size of the material reached 70 μm, and the material was screened through a 120 mesh sieve to ensure uniform particle size.

[0058] Liquid component processing: Inject each liquid component into a vacuum dehydration kettle, set the vacuum degree to -0.095MPa, the temperature to 85℃, and dehydrate for 1.5h, controlling the moisture content to ≤0.07wt%. After dehydration, seal and store.

[0059] Ingredient mixing stage

[0060] Start the 500L reactor, check that the equipment is normal, pump in base oil, start stirring, set the speed to 280r / min and the temperature to 32℃.

[0061] Add polyisobutylene succinimide and petroleum sulfonate sequentially, with a 12-minute interval between additions, and continue stirring for 32 minutes until the system forms a homogeneous viscous liquid without stratification.

[0062] Heating reaction stage

[0063] The jacket is heated at a rate of 6℃ / min until the system temperature reaches 110℃.

[0064] Add isobutylene sulfide, zinc dialkyl dithiophosphate, and ammonium molybdate, and increase the stirring speed to 450 r / min to prevent material agglomeration.

[0065] The reaction was carried out at a constant temperature of 110℃ for 1.8 hours, with samples taken every 25 minutes to ensure the system was stable and free of abnormalities.

[0066] Cooling and ripening stage

[0067] Turn off the heating and introduce cooling water at a rate of 7℃ / min to lower the temperature to 55℃.

[0068] Add 2,6-di-tert-butyl-p-cresol, benzotriazole derivative, and antifoaming agent. Adjust the stirring speed to 220 r / min and mature for 1.2 h to ensure that the additives are fully dispersed.

[0069] Filtration and purification stage

[0070] A 5μm precision filter with a filtration pressure of 0.35MPa and a flow rate of 45L / h is used to filter the material.

[0071] Collect the filtered liquid and test for mechanical impurities content ≤0.004wt%. If the content does not meet the standard, perform secondary filtration.

[0072] Testing and packaging stage

[0073] Performance test results: PB value 1080N, PD value 3100N, wear scar diameter 0.37mm; oxidation resistance 0.22mgKOH / g increase in acid value after 100h at 150℃; rust prevention no rust after 72h immersion in salt water.

[0074] After passing the inspection, the product is sealed in 20kg drums, labeled with relevant information, and then stored in the warehouse. It has a storage period of 18 months without any stratification or sedimentation.

[0075] III. Implementation Results:

[0076] The product in this embodiment has outstanding anti-wear properties. When added at a rate of 6%, it is suitable for high-speed precision gear transmission systems. Under operating conditions of 3000 r / min and 2000 N load, the gear wear failure cycle is extended by 60%. It also has excellent compatibility with synthetic gear oil base oils and no adverse reactions.

[0077] Example 3

[0078] I. Raw material formula:

[0079] An extreme pressure anti-wear gear oil composite additive comprises the following raw materials by weight percentage: 23% isobutylene sulfide, 12% zinc dialkyl dithiophosphate, 14% polyisobutylene succinimide, 6% petroleum sulfonate, 4% 2,6-di-tert-butyl-p-cresol, 5% benzotriazole derivative, 4% ammonium molybdate, 31% base oil, and 0.09% polyether-modified silicone oil.

[0080] II. Processing Method:

[0081] Raw material pretreatment stage

[0082] Solid component treatment: Ammonium molybdate and benzotriazole derivatives were fed into a high-speed pulverizer at a speed of 7500 r / min for 18 min until the particle size reached 90 μm. The particles were then screened through an 80-mesh sieve to remove impurities.

[0083] Liquid component processing: The liquid component is injected into a vacuum dehydration kettle, with a vacuum degree of -0.085MPa and a temperature of 75℃. It is kept at this temperature for 2.5h to dehydrate, and the moisture content is controlled to be ≤0.09wt%. After dehydration, it is sealed for later use.

[0084] Ingredient mixing stage

[0085] Start the 500L reactor, pump in base oil, turn on the agitator at a speed of 220r / min and a temperature of 28℃.

[0086] Add polyisobutylene succinimide and petroleum sulfonate sequentially, with an 8-minute interval between additions, and continue stirring for 38 minutes until the system is homogeneous and transparent with no suspended particles.

[0087] Heating reaction stage

[0088] The jacket is heated at a rate of 4℃ / min until it reaches 90℃.

[0089] Add isobutylene sulfide, zinc dialkyl dithiophosphate (12.0 kg), and ammonium molybdate (4.0 kg), and increase the stirring speed to 380 r / min to prevent local overheating.

[0090] The reaction was carried out at a constant temperature of 90℃ for 2.2 hours, with samples taken every 35 minutes to ensure a complete reaction.

[0091] Cooling and ripening stage

[0092] Heating is turned off, and cooling water is used to lower the temperature at a rate of 6℃ / min until it reaches 45℃.

[0093] Add 2,6-di-tert-butyl-p-cresol, benzotriazole derivative, and antifoaming agent, adjust the stirring speed to 180 r / min, and mature for 1.8 h to promote the fusion and stability of the components.

[0094] Filtration and purification stage

[0095] It uses a 5μm precision filter with a filtration pressure of 0.28MPa and a flow rate of 55L / h to filter materials.

[0096] Collect the clear liquid and test for mechanical impurities, ensuring the product purity is ≤0.006wt%.

[0097] Testing and packaging stage

[0098] Performance test results: PB value 1150N, PD value 3300N, wear scar diameter 0.34mm; oxidation resistance 0.18mgKOH / g increase in acid value after 100h at 150℃; rust prevention no rust after 72h immersion in salt water.

[0099] After passing inspection, the product is sealed in 20kg drums, labeled with information, and stored in the warehouse. When the storage environment meets the requirements, its performance remains stable for 18 months.

[0100] III. Implementation Results:

[0101] The product in this embodiment has excellent extreme pressure performance. When added at a dosage of 4%, it is suitable for heavy-duty mining machinery gear systems. Under operating conditions of 3000N load and 130℃ high temperature, it can effectively prevent gear sintering and scratches, extend equipment maintenance cycle by 40%, and reduce operating costs.

[0102] It should be noted that in this paper, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

Claims

1. A gear oil complex additive for extreme pressure and wear resistance, characterized by, By weight percentage, including the following components: sulfurized isobutylene 15-25%, zinc dialkyldithiophosphate 10-20%, polyisobutylene succinimide 8-15%, petroleum sulfonate 5-12%, 2,6-di-tert-butyl-p-cresol 3-8%, benzotriazole derivative 2-6%, ammonium molybdate 3-7%, base oil 20-40%, antifoaming agent 0.01-0.1%.

2. The extreme pressure anti-wear gear oil complex additive as claimed in claim 1, wherein, The sulfur content of the sulfurized isobutylene is 30-40wt%, and the molecular weight is 300-500.

3. The extreme pressure and anti-wear gear oil additive composition as claimed in claim 1, wherein, The zinc dialkyldithiophosphate is a primary alkyl type or a secondary alkyl type with a zinc content of 8-12wt%.

4. The extreme pressure and anti-wear gear oil additive composition as claimed in claim 1, wherein, The addition amount of the composite additive in the gear oil is 3-8%, and after adding, the PB value of the gear oil is ≥1000N, the PD value is ≥3000N, and the wear scar diameter is ≤0.4mm (392N, 60min).

5. The extreme pressure and anti-wear gear oil additive composition as claimed in claim 1, wherein, ###0002### The antifoaming agent is methyl silicone oil or polyether modified silicone oil.

6. The extreme pressure and anti-wear gear oil additive composition as claimed in claim 1, wherein, The base oil is API II or III mineral base oil, and the kinematic viscosity at 40℃ is 10-20mm² / s.

7. A process for the manufacture of the extreme pressure antiwear gear oil additive combination of claim 1, characterized by, It includes the following steps: (1) raw material pretreatment; (2) batching and mixing; (3) temperature rising reaction; (4) temperature reduction curing; (5) filtration and purification; (6) detection and packaging.

8. The process for manufacturing of the extreme pressure anti-wear gear oil additive composition as claimed in claim 7, wherein the process is characterized by, In step (1), the solid components are crushed to a particle size of ≤100μm, and the liquid components are dehydrated to a moisture content of ≤0.1wt%.

9. The process for manufacturing of the extreme pressure anti-wear gear oil additive composition as claimed in claim 7 wherein, In step (3), the temperature rising reaction temperature is 80-120℃, the holding time is 1.5-3h, and the stirring speed is 300-500r / min. ​ 10. The process for manufacturing of a multi-additive extreme pressure anti-wear gear oil as claimed in claim 7, wherein the process is characterized by, In step (4), the temperature reduction curing temperature is 40-60℃, the curing time is 1-2h, and the stirring speed is 150-250r / min.

Images