Chetan Pagare

Dy. Manager Technical & QA

NANDAN PETROCHEM LIMITED
J-26, Taloja MIDC, Dist.:- Raigad
[Link]@[Link]
8433972574
 About Me…….!
Education Info
1. M. Tech in Chemical Engineering from Dr. B. A. T. U. Lonere in 2016
2. B. Tech in Petrochemical Engineering from Dr. B. A. T. U. Lonere in 2013.
Work Experience
1. Dy. Manager Technical & QA at Nandan Petrochem Limited, Taloja. (Currently working)
2. Asst. Manager R&D at GP Petroleums Ltd (IPOL LUBRICANTS), Vasai.
3. Senior Chemist R&D at MOSIL Lubricants Pvt Ltd, Navi Mumbai.
4. Senior Executive R&D at Standard Greases and Specialities Pvt Ltd, Silvassa.
Skills
1. Formulation Development
2. Cost Optimization
3. Process optimization
4. Training and Testing Of FG
Achievements
1. Development of GC-LB Greases and conducting their field trials
2. Developed greases for automobile, cement, steel, pharma and food industries.
3. Development of synthetic greases, silicone pastes, thread compounds and different metal pastes
Summary
Lubricants Design Engineer with 8 years of experience in Research & Development of Greases and other lubricants
 Contents

1. Lubricants (History & Significance)

2. Grease (Definition, Thickener, Base oils & Additives)
3. Grease manufacturing
4. Benefits of Grease over oils
5. Classification of Greases
6. Evaluation of grease (Quality Control Tests, Performance tests,
Tribotesting)
 Glimpses On Lubricants History
When mankind invented wheel
Probably, at same time they
realized need for lubricant

• Lubricants scrapped from Hubs & Axles of carts & chariots used in 1450 BC in Egypt.
• Analysis indicated olive oil & lime: Ca Grease.
 Significance of Lubricants

❖Wherever there is movement/motion between two mechanical parts, there will be a

friction
❖Friction is unavoidable
❖Friction causes wear and tear and damage of machine or mechanical parts.
❖To reduce/minimize friction we need lubricants
 Lubricating Grease
ASTM D 88

“ A solid to semi solid product of

dispersion of thickener in liquid
lubricant. Other ingredients
imparting special characteristics
may be included ”

Thickener = Soap Liquid Lubricant = Base Oil

Other ingredients = Performance Additives 4
 Grease
Grease = Thickener + Oil + Additives
• Performance Thickener
Additives 0 -10 % 5-10 %

Base Oil
70 -90 %
 Thickener

An oil Reservoir release the oil when squeezed out under pressure and becomes a
source of an oil to form lubrication film.

Thickeners are the water insoluble soaps on which greases performance are depends

Fatty Acid + Alkali Metal Hydroxide + Water

Thickener (Soap)

Thickeners are characterized by the alkali metal hydroxide used in formation of thicker structure
Influencing parameter - Thickeners
Classification Of Thickeners
 Under Microscope

SOAP Lithium Grease

Lithium Complex Grease Structures

Calcium Sulfonate Grease

Calcium Grease
Base Oil Categories
 Effect of Base Oil on the performance of GREASES

Base oil Yield Drop Point Shear Water Oxidation

Group Stability washout Stability
Group I

Group II

Group III

Group IV

Group V

Worst For VELVEX Greases, we carefully choose our base oils with respects
Good to the application and parameters as base oils have impacts on the
performance.
Better
 Additive System for Greases
Extreme
Pressure
Antiwear

Antioxidant
Structural
modifiers
With tons of experience in technicality and
formulation WE at VELVEX defines our own
additive chemistry rather than some else choose it
for us, gives us cost effective performance
oriented products Rust
inhibiter Additives are
Metal Base oils are
lubricants with utilized to fill in
deactivator missing the missing
performance
Tackifiers performance
pieces
attributes
Friction
Modifiers
 Benefits of Grease over Oils

Grease Oil
Grease is semisolid made from thickener Oil is a low viscosity liquid
dispersed in a oil 90% of
Stay put at application Requires reservoir bearings
are grease
lubricated
Sealant and avoid leakages Cant avoid leakages

Provides lubrication for long time Frequent relubrication is required.

Carrier for solid lubricants Unable to carry Solid Lubricants

 When to use Grease & when oil

▪Dm = Mean Dia. of bearing in mm Greases/ base oil viscosities and their effect on speed factor
▪N= RPM of bearing Grease Type KV@ 40 Deg. Speed Factor
(Dm.N)
❑ Dm.N value for Greases < 600000 Mineral Oil/ 1000-1500 50000
Lithium/MoS2
❑Dm.N value for Oil > 600000 Mineral Oil/Lithium 400-500 200000
Complex
Mineral Oil/Lithium 100-200 400000
Complex
Ester/Lithium 15-30 1000000
Complex
Ester/ Polyurea 70-100 700000

Mineral /Polyurea 400-500 250000

Dm.N Factor & Base Oil Viscosity

DmN Factor Viscosity at 40 °C (cst)

Below 100000 460
100000 320
200000 220
300000 150
500000 100
600000 68
800000 32
1000000 and above 10/15
Grease Manufacturing Process Flow Chart
 VELVEX Grease Manufacturing Facility
1. 15 TPD state of the art plant with advanced kettle design

2. Dedicated kettles (Total 9 Kettles) for different thickener to avoid

contaminations

3. Plants has both open kettles and pressure kettle

4. 2 high pressure homogenizers and 2 milling machines.

5. 2 barrel filling lines 2 small pack filling lines

6. State of the art Quality Control lab and R&D Facility, to support Production
department and troubleshooting of their problems

7. Abundantly huge base oil storage facility and RM storage

Classification Of Greases
Based on NLGI Grade

NLGI WORKED VISUAL APPLICATION

GRADE PENETRATION ASSESMENT
000 445-475 Very Soft Gears
00 400-430 Very Soft Gears
0 355-385 Soft Gears/Bearing
1 310-340 Soft Bearing
2 265-295 Creamy Bearing
3 220-250 Creamy Bearing
4 175-205 Hard Water Pump
5 130-160 Very Hard Block Grease
6 85-115 As Soap Block Grease
 Types Of Greases

• CALCIUM /CALCIUM COMPLEX GREASES

• SODIUM BASE GREASES
• ALUMINIUM/ ALUMINUM COMPLEX
GREASE
• LITHIUM / LITHIUM COMPLEX GREASE
• MIXED BASE GREASES
• CLAY BASE GREASES
• CALCIUM SULFONATE /COMPLEX GREASE
• SYNTHETIC GREASES
• POLYUREA GREASES
 Evaluation Of Greases
• PENETRATION ASTM D 217, D 1403
• DROP POINT ASTM D 566, D 2265
• SHEAR STABILITY ASTM D 1831
• OXIDATION STABILITY ASTM D 942
• OIL SEPARATION ASTM D 1742
• THERMAL STABILITY IS:1448 P 89
• RUST PREVENTION ASTM D 1743
• EMCOR RUST TEST IP 220
• WATER WASHOUT ASTM D 1264
• DELETERIOUS PARTICLE ASTM D 1404
• WB LEAKAGE TEST ASTM D 1263
• LIFE PERFORMANCE (WB) ASTM D 3527
• WB (ACCELERATED) ASTM D 4290
• LOW TEMP. TORQUE IP 186
• EVAPORATION LOSS ASTM D 972
• COPPER CORROSION ASTM D 4048
• TIMKEN OK LOAD ASTM D 2509
• FOUR BALL EP IP 239, ASTM 2596
QUALITY CONTROL TEST

23/26
 Penetration (ASTM D 217)
Significance :-
Penetration is the depth, in dmm, to which a standard cone
sinks into grease. It decides the consistency of greases base
on how much deep that cone sinks, and reading is noted
which decides the NLGI No. greases.

Testing Parameters
Temperature 25̊ C
Duration 5 Sec
Unworked Fresh Grease
Worked 60 Stroke
Prolong Penetration 10k , 100K
24/26
stroke
(Performance test)
 VELVEX Greases As Per The NLGI Grades
NLGI Grades Worked VELVEX Greases
Penetration
000 445-475 EP000

00 400-430 EP00

0 355-385 EP0

1 310-340 EP1

2 265-295 EP2, LICOM BLUE 222,

CS 2
3 220-250 MP3, EP3, RR3,
LICOM3, CS COMPLEX
BLUE 3
4 175-205 -

5 130-160 -

6 85-115 - 25/26
 Dropping Point ( ASTM D 2265/ 566)
Significance : Temperature at which a grease passes from
solid/semi-solid state to liquid state. It Defines the Service
Temperature of the Greases. Higher the Drop Point Higher the
Service Temperature it will sustain.

ASTM D 566 :-
Used For lower dropping point grease.
Temperature increases with pre defined ramp
rate. Ex. – Crushing grease, MP3, EP3

ASTM D 2265:-
Aluminum block as heating element. Used for
higher temperature Grease, No specific ramp
rate. Ex.- LICOM3, 2, CS 2,…etc. ASTM D 566 ASTM D 2265

26/26
PERFORMANCE TEST

11/26
 Roll Stability (ASTM D 1831)
Significance :-

❖ Provides an indication of shear stability of grease under

heavily loaded churning action.
❖ Provides the information about directional change in
consistency of greases in service. Creating the Scenario of
EHD lubrication.
❖ Higher Shear Resistance Lower the Percentage Increase in
Consistency.

For Greases
Used in Motor Testing Parameters
Bearing, Journal
Bearings and RPM 160
Sliding Duration 2 to 96 Hrs
Applications Weight Of Rods 5 Kg
Temperature Ambient28/26
to 80 ̊C
 Oil Separation During Storage ( ASTM D 1742)
Significance :-
It represents the oil bleeds under static conditions in
fully and partially filled container. It is indicative test
that represents stability of fibrous structure of grease
under extensive pressure. It also decides the shelf life
of greases

Testing Parameters
Duration 24 Hrs
Temperature 25̊C
Pressure 1.72
29/26kPa
 Cone Bleed ( ASTM D 6184)
Significance :-
Effect of heat on oil separation of Grease. Indicative
test for heat stability of soap structure to hold oil
within fibrous network even when exposing to heat.

Greases Used in
High Speed
Rolling and
Steady state Testing Parameters
Operation
conditions Duration 30 Hrs
Temperature 100 ̊C
Cone Mesh 60 Micron
15/26
 Copper Corrosion ( ASTM D 4048)
Significance :-
Certain Components in greases causes the detoriation of yellow
Greases Having EP Properties
metals. An Indicative method to measure the ability of greases by
providing protection against corrosion at an elevated temperature.

Testing Parameters
Duration 24 Hrs
Temperature 100 ̊C
31/26
 Oxidation Stability (ASTM D 942)
Significance :-
✓ Shelf life of grease
✓ Determine the oxidation stability
✓ Resistance to oxidation
✓ Indicates the useful life of the grease
✓ Better the oxidative property longer the life

High
Performance
Greases and Testing Parameters
Automotive Duration 100,200 hrs
Greases
LICOM3, MP3 Temperature 99 ̊C
Pressure inside 110 Psi
the Bomb 32/26
 Wheel Bearing Leakage Tendency (ASTM 1263)

Significance :- Leakage of Oil through grease moiety

under dynamic conditions/ in roller bearing
application Indicative test for hub greases and
automotive bearing greases

High
Performance
Greases and
Automotive
Greases Testing Parameters
CS2, MP3 Duration 6 Hrs
RPM 660
Temperature 10533/26
̊C
 Water Wash- Out ( ASTM D 1264)
Significance :-
Resistance of greases to the water inclusing during
certain application. It decides up to extent grease posses
the water rejection property

For Greases
made to
withstand Testing Parameters
water
washing Off Bearing RPM 600 RPM
EP2, MP2 Duration 1 hr. Watering
16 Hrs Drying
Water Flow Rate 5Ml/Sec
Temperature 7934/26
C
̊
 Water Spray Off ( ASTM D 4049)
Significance : Adherence property of greases to the
substrate while under continuous spraying of pressurized
water.

For Marine and Steel Plant Greases. CS2, LICOM2

Testing Parameters
Duration 5min Watering
1 Hrs Drying
Water Pressure 40 Psi
Temperature 38 35/26
̊C
 Rust Prevention Property (ASTM D 1743)
Significance:-
This test method covers the determination of the corrosion
preventive properties of greases using grease-lubricated
tapered roller bearings stored under wet conditions.

Greases
Used In
Testing Parameters
Acidic and
Bearing RPM 1750 RPM
Humid
Duration 60 Sec Run Time
Conditions 48 Hrs under Humid
Atmosphere
Temperature 52 ̊C to maintain
100% humid
conditions
36/26
 Emcor Rust Test ( IP 220/ ASTM D 6138)
Significance : Determine the corrosion protection of a
grease in the presence of water and sea water
approximating typical service conditions.

Greases
Used For
Marine,
Textile,
Chemical Testing Parameters
Plants Bearing 1306K with steel cage
Duration 8 h run 16 h stop;
8 h run 16 h stop;
8 h run;
108 h + 2 h stop
Water 20 + 1 ml 37/26
TRIBO TESTING

38/26
 Extreme Pressure / Anti-Wear Properties ASTM D 2596 &
ASTM D 2266

Significance:-
The 4 Ball EP test machine operates in a sliding or rolling
motion. A single stainless steel ball rotates onto three stainless
balls, all of which are completely coated with a lubricant film, or
“boundary”, held stationary in the form of a cradle. The load is
then increased until the lubricant film no longer exists and there
is metal to metal contact.

EP Greases
Testing Parameters for EP Heavy Duty
Testing Parameters for AW
Duration 10 Sec Greases are Duration 1 hour
Tested RPM 1200
RPM 1770 CS2, EP2,
Incremental load until LICOMOL Load 40 Kg
seizure occurs Temperature 75̊ 39/26
C
 Extreme Pressure / Anti-Wear Properties ASTM D 2596 &
ASTM D 2265

Weld Load

Wear Scar

40/26
VELVEX Grease Portfolio
Name of Thickener Product Name
MP3 & 2
EP 3, 2, 1, 0, 00 & 000
Lithium Grease
EPL2
RR3

LICOM 3 & 2
LICOM BLUE 222
Lithium Complex
LICOM Special 2
LICOMOL 2 & 000

Crushing grease
Calcium Hydrous
Chassis Grease

Calcium Anhydrous Graphite Grease

Calcium Sulfonate CS HT 2 Blue

CS HT 2

Clay Base HITEMP

HITEMP E

Soda Base WB grease

Calcium Base Grease

• First Grease known to mankind

• Smooth Texture
• Cheapest
Properties • Water Resistant

• Operating Temperature is 50° C

• Automotive Chassis
Application • Water Pump
• Stone crusher

VELVEX
Grade
• Crushing Grease, Chassis Grease
Sodium Base Grease

▪ Heat Resistance grease in early years

▪ Fairly good drop point (170 Deg.)
▪ Visible Fibrous structure
Properties
▪ Good rust and corrosion resistance
▪ Water Soluble

▪ Automotive wheel bearing grease

▪ Hard Loco grease
Application ▪ Sliding Grease

VELVEX
▪ Wheel Bearing.
Grade
 Lithium Base Grease • Highest consumable till date
• Good mechanical /shear stability
• High drop point
Properties
• Good water resistance
• Excellent additive response
• Good EP /AW properties

Application • Used for antifriction and plain bearing

• Fulfil the IS 7623 and IPSS 1-06-009
• Widely used in steel plants , textile mill,
petrochemical industry

VELVEX • VELVEX MP 3/2

Grade

Lithium EP Grease
• Possess extreme pressure properties and
prevent welding and seizure of moving
Properties
parts under shock loads.
• Meets the requirements of IS 7623 and
IPSS 1-09-005

• Most sought after grease used in

Application
earth moving equipments , Gear
coupling, mining equipments and
many other industrial application

VELVEX
Grade • VELVEX EP Series (NLGI 1,2,3,0,00,000)
Lithium Complex Grease

▪ Widely Popular as High temp. grease

▪ Drop point is 260- 290 deg.
▪ Highly shear stable, corrosion resistance,
better resistance to water
Properties ▪ Good Pump ability
▪ Adaptive to central Lubrication system
▪ Operating Temp. range -20 to 200 deg.

▪ Minimum oil separation under pressure

hence useful in centralized lubrication
systems
Application ▪ Widely popular in steel industry till date,
used in automotive and in other engineering
industries
▪ New chemistry of lithium complex greases
can withstand in long life traction motor

VELVEX
Grades

▪ LICOM3/2, LICOM BLUE 222, LICOMOL

Clay Base Grease

▪ Manufactured with naturally occurring

bentonite / smectonite clays
Properties ▪ Smooth texture
▪ Non melt grease
▪ Can absorb shocks

Application ▪ Used in open gears, rotary kilns, furnace

clutches.

VELVEX
Grades VELVEX HITEMP and HITEMP E Grease
 Calcium Sulfonate Grease

▪ Novel chemistry based on over based Sulfonate chemistry

▪ Grease with Highest dropping point
▪ Most sought after grease by steel plants and allied industries
Properties ▪ Good shear stability in presence of water
▪ Weld load 315 kg without any EP additive

▪ Steel plant hot contact zone

Application ▪ Marine grease
▪ Slip Seal Grease for rotary klins
▪ Automotive grease for heavily loaded trucks

VELVEX
▪ VELVEX CS HT 2, CS HT 2 Blue
Grades

Typical Properties

Drop Point Weld Load Water Wash Out Copper Corrosion

• >300°C • 315 kg • Less than 1% • Negative

 Grease Compatibility Chart

❑ Mixture of greases –
25:75,50:50, 75:25 & tested for:
❖ Penetration
❖ Drop point

Incompatibility may lead to

catastrophic failure