Renewable Base Oil Calcium Sulfonate Grease With Calcite Conversion
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Solution Overview
Problem
Existing formulations of overbased calcium sulfonate greases in renewable base oils face challenges in achieving desired consistency and performance characteristics due to the reactants reacting with vegetable oils or esters during gelation, leading to inadequate conversion of amorphous calcium carbonate to crystalline calcite, and lack of high-temperature, extreme-pressure, and anti-wear properties.
Innovation Solution
A two-step process involving promotion and conversion using renewable base oils, such as SynNova 9, to form a non-Newtonian overbased calcium sulfonate complex grease without performance additives, utilizing specific hydrocarbon mixtures with controlled branching and polarity to facilitate the conversion of amorphous calcium carbonate to crystalline calcite.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If overbased calcium sulfonate is used as thickener in renewable base oils, then environment friendliness is improved, but consistency and performance characteristics deteriorate due to reactants reacting with vegetable oils or esters during gelation
Solution Approach 1:
The patent uses a two-step process with an intermediary conversion step. First, overbased calcium sulfonate is prepared in a promotion step, then converted in a separate conversion step using converting agents (water, alcohols, or acids) to transform amorphous calcium carbonate to crystalline calcite. This intermediary conversion process resolves the contradiction by preventing direct reaction with renewable base oils while achieving proper gelation and consistency.
Solution Approach 2:
The patent changes the physical and chemical parameters of the system by controlling the conversion process. By adjusting parameters such as temperature (100-200°C), adding converting agents (water, alcohols, or acids), and controlling the gelation time, the patent transforms the system from a reactive state (amorphous calcium carbonate) to a stable state (crystalline calcite), thereby achieving desired consistency without harmful reactions with renewable base oils.
2Reliability
If conventional mineral or synthetic base oils are used, then performance characteristics are improved, but environment friendliness deteriorates
Solution Approach 1:
The patent changes the base oil parameter from conventional mineral or synthetic oils to renewable base oils (vegetable oils or esters). By controlling other parameters (two-step process, converting agents, temperature), the patent maintains performance characteristics while improving environment friendliness.
Solution Approach 2:
The patent introduces an intermediary conversion step that acts as a bridge between the thickener preparation and the final grease formulation. This intermediary process ensures that the overbased calcium sulfonate is properly converted before contact with renewable base oils, thereby maintaining performance characteristics equivalent to conventional oils while using environment-friendly renewable base oils.
3Device complexity
If amorphous calcium carbonate is not converted to crystalline calcite, then gelation process is simplified, but high-temperature and extreme-pressure properties deteriorate
Solution Approach 1:
The patent performs preliminary conversion of amorphous calcium carbonate to crystalline calcite in a dedicated conversion step before final grease formulation. By preparing the crystalline structure in advance (preliminary action), the patent ensures high-temperature and extreme-pressure properties are achieved while maintaining a manageable gelation process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting grease exhibits superior performance in lifespan, anti-wear, anti-friction, oxidation resistance, and high-temperature characteristics, outperforming mineral and synthetic oil-based counterparts, with reduced thickener content and improved stability under heavy loads and humid conditions.
Implementation Method 1
conversion of amorphous calcium carbonate to crystalline calcite
Implementation Method 2
form a non-Newtonian overbased calcium sulfonate complex grease
Implementation Method 3
utilizing specific hydrocarbon mixtures with controlled branching and polarity to facilitate the conversion
Implementation Method 4
superior performance in lifespan, anti-wear, anti-friction, oxidation resistance, and high-temperature characteristics
Implementation Method 5
superior performance in lifespan, anti-wear, anti-friction, oxidation resistance, and high-temperature characteristics
Data Source
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AI summary
The present invention is directed to high-performance grease compositions based on renewal base oils. The compositions disclosed in this invention with or without performance additives delineate superior anti-wear, anti-friction, thermal & oxidation stability, high temperature long life, low noise, low thickener content, better dispersion in renewable base oil compared to identical grease compositions prepared with conventional mineral and synthetic base oils. The grease compositions formed from renewable base oils may be utilized in bearings and gears in automotive, industrial and marine applications.