Calcium hydroxyapatite based calcium sulfonate grease compositions and method of manufacture
An overbased calcium sulfonate grease composition comprising a reduced amount of overbased calcium sulfonate, calcium hydroxyapatite, base oil, one or more converting agents, and one or more complexing acids if a complex grease is desired. The calcium sulfonate grease composition improves thickener yield and expected high temperature utility as demonstrated by dropping point. A method of making the composition comprising the steps of mixing the calcium sulfonate and base oil, adding the calcium carbonate either before or after conversion, adding one or more converting agents, and adding one or more complexing acids. All or a portion of one or more of the complexing acids may be added with or prior to the one or more converting agents.
1. A calcium sulfonate grease composition comprising the following ingredients:
overbased oil-soluble calcium sulfonate in an amount greater than 0% but not exceeding 36% by weight of a final grease product made with the composition; and
calcium hydroxyapatite having a formula of Ca5(PO4)3OH or mathematically equivalent formula with a melting point of around 1100° C. and wherein such mathematically equivalent formula is not a mixture of tricalcium phosphate and calcium hydroxide.
2. The calcium sulfonate grease composition according to claim 1 wherein the final grease product is an NGLI grade no. 000 grease.
3. The calcium sulfonate grease composition according to claim 1 wherein the final grease product is an NGLI grade no. 00 grease.
4. The calcium sulfonate grease composition according to claim 1 wherein the final grease product is an NGLI grade no. 0 grease.
5. The calcium sulfonate grease composition according to claim 1 wherein the final grease product is an NGLI grade no. 1 grease.
6. The calcium sulfonate grease composition according to claim 1 wherein the final grease product is an NGLI grade no. 2 grease.
7. The calcium sulfonate grease composition according to claim 1 wherein the final grease product is an NGLI grade no. 3 grease.
8. The calcium sulfonate grease composition according to claim 1 wherein the grease has dropping point of 575 F or higher.
9. The calcium sulfonate grease composition according to claim 1 further comprising the following ingredients: at least one converting agent and at least one complexing acid.
10. The calcium sulfonate grease composition according to claim 9 wherein the amount of calcium hydroxyapatite is stoichiometrically insufficient to neutralize all of the complexing acid or acids.
11. The calcium sulfonate grease composition according to claim 10 further comprising the following ingredients: one or more other basic calcium compounds.
12. The calcium sulfonate grease composition according to claim 11 wherein the total amount of the one or more other basic calcium compounds is stoichiometrically sufficient to neutralize the complexing acid not neutralized by the calcium hydroxyapatite.
13. The calcium sulfonate grease composition according to claim 11 wherein the total amount of the one or more other basic calcium compounds is stoichiometrically insufficient to neutralize the complexing acid not neutralized by the calcium hydroxyapatite.
14. The calcium sulfonate grease composition according to claim 11 wherein the other basic calcium compounds are calcium hydroxide, calcium oxide, added calcium carbonate or any combination thereof.
15. The calcium sulfonate complex grease composition according to claim 1 wherein calcium oxide and calcium hydroxide are not ingredients.
16. The calcium sulfonate grease composition according to claim 1 wherein the overbased oil-soluble calcium sulfonate is a poor quality calcium sulfonate.
17. A calcium sulfonate grease composition comprising the following ingredients:
overbased oil-soluble calcium sulfonate;
calcium hydroxyapatite having a formula of Ca5(PO4)3OH or mathematically equivalent formula with a melting point of around 1100° C. and wherein such mathematically equivalent formula is not a mixture of tricalcium phosphate and calcium hydroxide.
18. The calcium sulfonate grease composition according to claim 17 wherein the final grease product is an NGLI grade no. 000 grease.
19. The calcium sulfonate grease composition according to claim 17 wherein the final grease product is an NGLI grade no. 00 grease.
20. The calcium sulfonate grease composition according to claim 17 wherein the final grease product is an NGLI grade no. 0 grease.
21. The calcium sulfonate grease composition according to claim 17 wherein the final grease product is an NGLI grade no. 1 grease.
22. The calcium sulfonate grease composition according to claim 17 wherein the final grease product is an NGLI grade no. 2 grease.
23. The calcium sulfonate grease composition according to claim 17 wherein the final grease product is an NGLI grade no. 3 grease.