QLK5-2000-00611 Environmentally friendly multifunctional grease based on regrowing resources and advanced thickener technology to apply in loss lubrication of earth moving equipment

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Bulk Chemicals : Crops for Bulk Chemicals : Quality of Life - 5.2 Non-Food Development

Contract No:	QLK5-2000-00611
Source	Progress Report - March 2002 - Abstract
	Progress Report - March 2003 - Abstract
	Progress Report - March 2004 - Abstract

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Progress Report - March 2004 - Abstract

Introduction

The project continued to study the following components of the articulated arm of the earth-moving machines:

• he shaftlbearing bushing/pin) and,
• the internal teeth of the swing ring

At present two different conventional greases are used to lubricate these. These are an extreme pressure performance grease(crown/gear) and another with anti-wear characteristics (bushing/pin).

A proper selection and modification of the base oil is critical. For a successful result in low-temperate storage, it is obvious that the composition of the blend is of great importance. The imitations for the blend lay with the properties of the High Oleic Sunflower Oil (HOSO), which is a mixture of fatty acids. The main motive for choosing an oil with C18:1 (oleic acid) as main component is that this presents an acceptable compromise between low and high temperature demands.

Results

It has been found that in order to further enhance the low-temperature properties of the grease other components had to included in the blend: polymethylacrylate, styrene-butadiene-copolymer and Di-ester. It was found that if necessary the high oleic sunflower oil may be replaced by rapeseed oil of a similar type. Using rapeseed oil matched and exceeded the performance HOSO at low temperatures.

A new polypropylene thickener that has been incorporated in the product gives the grease the desired properties. It has been shown to be compatible with the base oil blend that has been developed and has given good results in all tests of properties, mainly reflecting the characteristics of the thickener itself. These properties are: consistency, mechanical stability, thermal stability, water resistance and low temperature behaviour.

An intensive optimisation process has been followed in order to achieve the proper tribological properties of the biogrease. Many solid and liquid EP/AW additives have been tested. Finally, the best anti-wear properties have been achieved with a low consistency biogrease based in high oleic sunflower oil DIDA and polypropylene thickener. Rhein Chemie new additive package along with a thiadiazol ER-booster have been used in this formulation.

This final full formulated biogrease showed good antiwear and extreme-pressure properties, comparable with the reference greases. In addition, this final bio-lubricant has been tested in bench tests simulating real working conditions in both systems: gear/crown and bushing/pin.

Tests have been carried out with the different materials employed in those elements and also using sand as abrasive in order to simulate the aggressive environment of a quarrie.

An extensive laboratory study has been carried out analysing the reference grease, and different new formulations. The testing procedures were designed to obtain information about friction, wear, corrosion, compatibility with seals, biodegradability, ecotoxicity, low temperature performance, oxidation stability, etc, etc

The bio-grease has been formulated at a laboratory level and the first trials in earth moving machines have been carried out. The grease is effective at low temperatures despite being formulated with an significant content of sunflower oil.

The final stages of the project includes production of the biogrease in industrial quantities and validation of its performance under real working conditions.

Benefits and Beneficiaries:

The first benefit is the increase of use of agricultural products such as vegetable oils in industrial (non-food applications) increasing the agricultural land use and work.

The second benefit is the improvement of the environment by the introduction of an environmentally friendly lubricant in industrial application working in sensitive environments. More benefits would arise from the utilisation of biogreases in total loss lubrication systems, as those applied in earth moving equipments and agricultural machinery.

The third benefit concerns the decrease of need of mineral oil based lubricants coming from petroleum sources.

Future Actions:

Actions for the final period of the project are related to the industrial validation of the final product developed so far at laboratory scale:

• Development of additive package in a industrial scale
• Development of the final full formulated biogrease in a industrial scale
• Checking the basic tribologicaf properties of final biogrease
• Verifying performance of final biogrease in bench testing
• Testing the biodegradability and toxicity behaviour of the final biogrease
• Checking phisico-chemical properties of the final biogrease
• Testing the final biogrease in an excavator in real working conditions

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Progress Report - March 2003 - Abstract

Introduction

Oils and greases used in total loss dry lubrication systems, as applied in earth moving equipment and agricultural machinery, are some of the products in which the utilisation of raw materials derived from natural sources show significant environmental benefits. The main aim of this project is to increase the utilisation of vegetable oils in non-food applications by using them as the bases for formulating environmentally friendly greases to be used in earth moving equipment. The project aims to introduce into the market new bio-based lubricants that are biodegradable and non-toxic, providing diverse products to end users and consumers that will benefit the environment. At the same time the work will promote agricultural production systems resulting in the modification of sunflower oil to increase oleic acid and palmitoleic content. Once formulated opportunities to extend the use of these greases to other applications will be explored, resulting in savings in maintenance costs and lubricant consumption.

Activities

It is hoped to develop a multi-functional environmentally friendly grease thatmeets the specifications required for earth-moving machines and similar equipment. The project milestones relate to the production of the required modified base oil, development of suitable thickener technology, production of an additive package and to measure the performance of the grease on the laboratory scale, in bench systems and in the field tests.

Results

The main machine components of the earth-moving machines to be studied in this project are the following;

• the articulated components of the articulated arm, which is the support of the bucket (shaft bearing, bushing pin)
• the internal teeth of the swing ring (crown/reduction gear).

Nowadays two different conventional greases are used to lubricate these parts: one with high EP (Extreme Pressure) performance (crown/gear) and another with more AW (anti-wear) characteristics (bushing/pin).

A proper selection and modification of base oil is critical. For a successful result in low-temperature storage, it is obvious that the composition of the blend is of great importance. The limitations for the blend were set by the properties of the high oleic sunflower oil, which depends on the mixture of fatty acids. The reason for choosing an oil with C18:1 (oleic acid) as the main component is that a mono unsaturated fatty acid represents an acceptable compromise between low and high temperature demands.

In order to further enhance the low-temperature behaviour and adjust other properties to the required specifications level, additional components were required. Introducing a low-viscous ester and two different kinds of polymers gave the required increase in performance. During the investigations it was found that if necessary the high oleic sunflower oil could be replaced by rapeseed oil of a similar type. Using rapeseed oil the product matched and some ways exceeded the performance for the high oleic sunflower oil based product at low temperatures.

A new polypropylene thickener that has been incorporated into the product appears to give the grease the desired properties. It has not exhibited any compatibility problems with the developed base oil blend and has shown good results in all properties that are mainly determined by the characteristics of the thickener itself. These properties are: consistency, mechanical stability, thermal stability, water resistance and low temperature behaviour.

Nevertheless investigations have shown that both EP and AW properties are difficult to adjust to the desired level at the same time. It is clear that the new thickener does not respond to additives in the same manner as the conventional thickener used in petroleum greases does. Many additives tried have been found to have little if any effect. For example these results ruled out the intended use of calcium-complex soap as the main EP provider.

An extensive laboratory study has been carried out analysing the reference grease and various new formulations. Testing has been used to acquire further information concerning friction, wear, corrosion, compatibility with seals, biodegradability! ecotoxicity, low temperature performance, oxidation stability, etc, etc....

The bio-grease has been formulated at a laboratory level and the first trials using it in earth-moving machines have been carried out. The formulation needs to be further improved in order to enhance the friction and wear properties, especially when applyied at the bushing/pin contact of the earth-moving machine. The grease is able to stand low temperatures even when formulated with a significant content of sunflower oil.

Benefits and Beneficiaries

The first benefit is the increase of use of agricultural products such as vegetable oils in industrial (non-food) applications increasing the agricultural land use and work.

The second benefit is the improvement of the environment by the introduction of an environmentally friendly lubricant in industrial application. More benefits would arise from the utilisation of biogrease in total loss lubrication systems, as those applied in earth-moving equipments and agricultural machinery

The third benefit concerns the decrease of need of mineral oil lubricants coming from petroleum sources.

Future Actions

Three different routes are being further investigated in order to optimise the formulated biogrease improving anti-wear properties:

• Selection of new additives Modification of the thickener

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Progress Report - March 2002 - Abstract

Objectives

The general aim of the project is to increase the utilisation of natural re-growing oils in non-food applications by using them as the base for new formulations of environmentally friendly lubricants to be used in earth moving equipments. It continues similar work supported under FAIR-CT96-2025. The main aims will be met through a number of more specific objectives:

• introduction in the market of a new bio-based environmentally friendly product, which will offer diversified products to lubricants and grease end users and consumers and which will contribute to the care of the environment
• to promote agricultural production systems related to the modification of sunflower oil to increase proportions of oleic acid and palmitoleic acid.
• to extend the utilisation of these greases to other applications, and
• to save in maintenance cost and consumption of lubricants.

Results and Milestones

The expected achievement is the development of a multi-function environmentally friendly grease which meets the specifications required for earth moving machines and related equipment.

The milestones are related to:

• The achievement of the proper modified base oil
• The development of the proper thickener technology
• The development of an additive package
• Demonstration of the performance of the grease at laboratory scale, in bench systems and in the field.

Benefits and Beneficiaries

The first benefit is the increase of use of agricultural products such as vegetable oils in industrial (non-food applications) increasing the agricultural land use and rural employment. The second benefit is in the improvement of the environment by the introduction of an environmentally friendly lubricant in industrial application. The third benefit concerns the decrease in need for mineral oil lubricants coming from petroleum sources.

Future Actions

To extend the use of the vegetable oils to other industrial applications.