The search for alternatives
In light of these challenges in lithium supply and availability, the industrial grease community at large has been focusing on identifying and applying alternative thickening chemistries.
For the past three years, Lubrizol has devoted extensive work and testing to develop real solutions for this need. Two alternative candidates to lithium- thickened greases have emerged with significant potential.
Novel dicalcium hybrid greases Novel dicalcium hybrid greases which combine overbased calcium sulphonate with anhydrous calcium grease manufacturing, offer a competitive alternative to lithium complex and conventional lithium greases. These greases are cost-comparable to conventional lithium greases. These new dicalcium greases can fulfill the basic performance requirements of the NLGI’s (formerly National Lubricating Grease Institute) new High-Performance Multipurpose (HPM) grease certification for North American lubricating greases.
Aspect of the concentrated PU grease after and before processing (without grading).
Further changes on the horizon It is anticipated that dicalcium hybrid greases and polyurea concentrate greases will begin to penetrate the industrial grease market in the coming years, helping to reshape an industry once defined by its dependence on lithium. But these are not the only impacts on the world of grease manufacturing and design, nor are they the end of the story. Further headwinds are on their way, and they will necessitate further innovative solutions from our industry. Some of the most widely used antioxidant technologies based on aromatic amine chemistry are under heavy scrutiny and may impose unacceptable labelling to a myriad of grease formulations containing them.
From left to right: Anhydrous Calcium; Dicalium; and Calcium sulfonate Complex.
Concentrated diurea greases Concentrated diurea greases which in their pourable liquid form can produce NLGI 3 consistency and softer, enable grease manufacturers to enter this arena with a novel thickening chemistry. Manufacturers then will be able to finish this concentrate to the desired consistency and include performance additives that help them differentiate its formulation.
The grease market is still promoting and growing calcium sulphonate complex greases. However, these formulations are not perceived as a direct competition to conventional lithium and lithium complex greases. Instead, they are viewed as a high-tier lubricant where EP/AW under high pressure and temperature of process are required.
Additionally, along with the PFTEs and PFOAs, new regulations will require alternatives for formulators. Furthermore, new electric vehicle motors demand greases that are capable of higher speeds above 12,000 rpm and will perform under higher temperature environments above 150 °C and under heavy electrical discharges. Demand also continues to grow for more renewable lubricants by end users and producers in pursuit of carbon dioxide reduction targets.
Indeed, it is a time of unprecedented change in the industrial grease market. At Lubrizol, we are applying all of our resources to help our customers in this space navigate these changes and provide continuous support for grease manufacturers with high-performance lithium alternatives. Continued collaboration will be required among all stakeholders to find continued success in this changing marketplace.
https://go.lubrizol.com/LubrizolGrease
LUBE MAGAZINE NO.180 APRIL 2024
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