Production Method and Raw Materials for Lubricating Oils and Greases

1. Production of Lubricating Oil (Engine Oil, Gear Oil, Hydraulic Oil, etc.)

Raw Materials:

1. Base Oil (70-90%)
   • Mineral Base Oil: Derived from crude oil refining. (Group I, II, III)
   • Synthetic Base Oil: PAO (Polyalphaolefin), Ester, GTL (Gas-to-Liquid), etc.
   • Bio-based Oils: Derived from plant oils (e.g., vegetable oil-based lubricants).
2. Additives (10-30%)
   • Detergents: Calcium, magnesium, and sodium sulfonates to neutralize acids.
   • Dispersants: PIBSA (Polyisobutylene Succinimide) to prevent sludge formation.
   • Anti-Wear Agents: ZDDP (Zinc Dialkyldithiophosphate) to reduce friction and wear.
   • Viscosity Index Improvers: Polymethacrylates (PMA), Olefin Copolymers (OCP).
   • Friction Modifiers: Molybdenum compounds, Organic Esters.
   • Anti-oxidants: Phenols, Amines to prevent oil degradation.
   • Pour Point Depressants (PPD): PMA, Alkylated Naphthalenes.
   • Foam Inhibitors: Silicone-based compounds.
   • Rust Inhibitors: Succinic Acid Derivatives.

Production Method:

1. Base Oil Selection & Pretreatment
   • The selected base oil is filtered and preheated (50-70°C) to remove any impurities.
2. Blending of Additives
   • Pre-calculated amounts of additives are added step-by-step into the base oil.
   • Continuous agitation ensures homogeneous mixing.
   • The temperature is maintained between 60-80°C during blending.
3. Mixing & Homogenization
   • The blend is continuously mixed in a high-speed mixer or blending tank.
   • Additives like viscosity modifiers require shear force to dissolve completely.
4. Quality Control Testing
   • The mixture is tested for viscosity, flash point, pour point, foaming tendency, and oxidation stability.
5. Filtration & Degassing
   • The blended oil is passed through fine filters (5-10 microns) to remove solid particles.
   • Degassing is done under vacuum to remove trapped air bubbles.
6. Packaging & Storage
   • The finished lubricating oil is stored in bulk tanks or filled into drums, pails, or bottles.

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2. Production of Grease

Raw Materials:

1. Base Oil (60-80%)
   • Similar to lubricating oil (Mineral, Synthetic, Bio-based).
2. Thickening Agent (10-25%)
   • Soap-based: Lithium, Calcium, Aluminum, Sodium soaps.
   • Non-soap-based: Polyurea, Clay-based, PTFE.
3. Additives (5-15%)
   • Extreme Pressure (EP) Additives: Sulfurized compounds, Molybdenum Disulfide (MoS₂).
   • Anti-Wear Agents: ZDDP, Borate Esters.
   • Anti-Oxidants: Phenolic or Aminic additives.
   • Corrosion Inhibitors: Barium or Calcium sulfonates.

Production Method:

1. Soap Preparation (For Soap-Based Greases)
   • The thickener (soap) is prepared separately by reacting a metal hydroxide (e.g., lithium hydroxide) with a fatty acid (stearic acid, 12-hydroxy stearic acid).
   • The mixture is heated to 200-220°C to ensure a complete reaction.
2. Base Oil & Thickener Blending
   • The base oil is heated to around 100-120°C in a grease kettle.
   • The prepared thickener (soap mixture) is added slowly while stirring.
   • Continuous mixing and shearing action ensure uniform dispersion.
3. Cooling & Additive Incorporation
   • The mixture is cooled to 80-100°C, and additives are introduced.
   • Extreme pressure (EP) additives, antioxidants, and anti-corrosion agents are blended in.
4. Homogenization & Milling
   • The grease is milled through a homogenizer or a three-roll mill to achieve a fine, uniform consistency.
5. Quality Testing
   • Penetration (NLGI Grade), Drop Point, Oxidation Stability, Water Resistance are tested.
6. Packaging & Storage
   • The final product is stored in drums, pails, or cartridges for distribution.

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3. Simple Production Line Setup

Basic Equipment Needed:

1. Storage Tanks – For holding base oils and additives.
2. Mixing Tanks (Blenders) – For blending oils and additives.
3. Heating System – For temperature control.
4. Homogenizer/Milling Machine – For uniform blending of grease.
5. Filtration Unit – To remove impurities.
6. Filling Machine – For packaging into bottles, drums, or cartridges.
7. Quality Control Lab – For testing viscosity, stability, and other properties.

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The production of lubricating oils and greases follows a structured process that involves base oil selection, additive blending, homogenization, quality testing, and packaging. A simple production line with mixing tanks, filtration units, and heating systems can efficiently produce high-quality lubricants for automotive, industrial, and specialty applications.