Tuesday, June 10
2024 Grease Production Survey
The NLGI Grease Production Survey continues to be the single most comprehensive global report on lubricating grease production. It tabulates the global production of grease providing a snapshot of growth by thickener type and base oil type, organized by geographic region of the world. This presentation will provide a summary overview of the key results and trends from the completed 2024 production survey.
Gary Dudley is the President of GKD Consulting & Services in Spring, Texas, with over 27 years of experience in the Grease and Lubricants industry. He holds a Bachelor’s degree in Chemistry from the College of Wooster and a PhD in Chemistry from Pennsylvania State University. Before retiring from ExxonMobil, Gary held various research and management roles in Synthetic Base Oils, Aviation Lubes, Industrial Oils, Planning, and Greases. He is a member of both STLE and NLGI. Gary has received the NLGI SOPUS Products Award for Excellence and the NLGI Golden Grease Gun Award, and he is a former NLGI Board Member.
Tuesday, June 10
New Developments in Emulsion Greases
Contrary to the traditional saying, water and oil do mix. More than twenty years ago, the concept of emulsion greases was introduced. High internal phase water-in-oil emulsions with grease-like properties were proposed as alternates for mineral oil greases used in total loss applications, that can end up in the environment and pose a threat to water cleanliness. The lubricant has up to 60 wt% water and a biodegradable vegetable oil base as the hydrophilic phase, so a lower environmental impact could be achieved.
After a ten-year hiatus, work on emulsion greases resumed and several patents were filed for this type of technology. More recently, due to concerns with the sustainability of mineral oil-based lubricants this concept was again revisited. The original formulations that had been proposed were again manufactured. One of the things missing from earlier work was storage stability. Basic testing and storage stability evaluations showed the vegetable oil-based products had a tendency to breakdown and as is well known in the metal working fluid arena, suffer form microbial degradation. Changing from vegetable oil to mineral oil, reduced the microbial attack but did not eliminate it.
From these learnings a new generation of high-performance emulsion greases were developed and tested. Under room temperature storage conditions, the new products showed significant improvements in stability. Bench testing showed that the products had good grease like lubricant properties. This paper will review the historic work and outline the latest developments on emulsion greases and their behavior in industry standard tests.
Dr Gareth Fish is a Technical Fellow at the Lubrizol Corporation, Wickliffe, Ohio. He holds a PhD in tribology from Imperial College, London, and has more than 35 years grease industry experience. He is an internationally recognized, multiple (x20) award-winning author of more than 90 technical papers including 19 NLGI papers. He has taught more than 90 public classes on tribology and lubricating greases. He is a member of the NLGI Board of Directors and chair of the NLGI Basic Grease Course. He was 2020 recipient of the NLGI Award for Achievement. He is an NLGI Certified Lubricating Grease Specialist (CLGS), a Chartered Scientist, STLE Fellow and Certified Lubrication Specialist (CLS). He is active within ASTM sitting or chairing multiple Committees related to grease and tribology. Previously worked at UK Ministry of Defence and GKN Automotive in UK and USA.
Dr. Chris Hsu received a Ph.D. in Chemical Engineering from Penn State University. He started his grease career with Dow Corning as a Senior Engineer specializing in their Molykote specialty lubricants and grease brand. In 2010, Chris joined The Lubrizol Corporation, where he is the Senior Research Chemist for Lubricating Greases.
Dr. Robert Dura received his B.S. in Chemistry from Cleveland State University. He then worked at Curragh Chemistries in Cleveland, OH, synthesizing small pre-drug intermediates for the pharmaceutical industry. He was accepted into graduate school at The Ohio State University for chemistry, working for Prof. Leo Paquette. He graduated with his Ph.D. which focused primarily on natural product synthesis. He then carried out post-doctoral work at the University of Pittsburgh for Prof. Scott Nelson on iridium and rhodium mediated enantioselective catalysis of cyclic and acyclic conjugated systems. Following his post-doc, he returned to Cleveland to work for Ben Venue Labs, a subsidiary of Boehringer Ingelheim. At Ben Venue, Robert was responsible for new product development, product lifecycle management, manufacturing support, and analytical method development and validation.
Since 2014, he has been with The Lubrizol Corporation, Wickliffe, OH, initially as Technology Manager for Grease Development within Industrial products and in 2023 was promoted to Director of Grease and Metalworking.
In 2022, Robert passed the NLGI Certification examination to become an NLGI Certified Lubricating Grease Specialist.
Tuesday, June 10
No Free Lithium
This paper investigates how lithium grease can be manufactured with <0.1% ‘free lithium’ using a pre-formed thickener (soap) in order to comply with potential EU and US regulatory requirements. A review of the reasons behind the concern over the presence of lithium and the status of the potential regulatory changes will be covered. A comparison of the manufacturing methods for lithium grease using the standard in-situ process and the pre-formed soap process will be made. As well, the basic manufacturing process for the pre-formed lithium soap will be shown. This study investigates the test methodologies used to calculate free alkalinity (lithium hydroxide), which allows the detection of free lithium content in a pre-formed thickener, and therefore, the prediction of how much ‘free lithium’ is present in the grease. Chemical analysis completed via FTIR, DSC and ICP measuring the free fatty acid (FFA), free alkalinity, free lithium hydroxide and total lithium content will be shown. A review of approximately 30 years of data will show that the pre-formed lithium thickener has typical FFA at 0.15%; free lithium hydroxide at 0.07%; total lithium content at 2.25% and moisture content at 0.28%. The conclusion will be made that if a pre-formed soap used to make grease at a level of 10%, the amount of ‘free lithium will be approximately 0.007% which is far below the 0.3% or 0.1% potential regulatory limits.
Howard Kennedy has B.SC and MBA degrees from Guelph and York Universities in Canada. He has spent the last 30 years of his career developing products and business in various areas of the chemical world including coatings, plastics, pigments and lubricants.
Dr. Steven Lu obtained a Bachelor Degree in Chemical Engineering at Zhengzhou University, China, and his PhD at Loughborough University, UK. He has worked in China, UK and Canada for over 40 years in Research and Development and at HL Blachford since 2007 as a formulator in the area of metallic stearic product development and process optimization. The metal stearates include Lithium, Lithium 12OH, Calcium, Calcium 12OH, Zinc, Manganese, Aluminum, Sodium and Potassium as well as aqueous stearate dispersions. Applications include lubricants, mold release agents and stabilizers in plastics, rubber, grease and powdered metals.
Victoria Dameski earned her Bachelor of Science degree in Chemistry from Trent University in Canada. There she focused on various areas of chemistry such as spectroscopy, mass spectroscopy, chromatography, organic chemistry, inorganic chemistry, physical chemistry, and environmental chemistry. For the last 4 years, Victoria has been working for H.L. Blachford doing research and process optimization of various stearate chemistries including Lithium, Calcium, Zinc, Manganese and Sodium.
Tuesday, June 10
Re - thi(n)ck: Design and Application of a Novel Circular Model Concept That Explores the Sustainable Recycling Potential of Lubricating Greases
The economy is gradually transitioning to a circular model that extends resources, reduces waste, and requires a great deal of creative thinking. Both established and emerging global economies view waste as a bioresource for our next generation energy, chemicals, or platform molecules and materials. Waste minimization can be achieved in an efficient way by focusing primarily on the first of the 3Rs, “reduce -reuse-recycle.” In the past it has been demonstrated that the use of renewable raw materials as well as the reduction of the energy consumption in the grease production can contribute to an increasing sustainable profile of lubricating greases. In order to move forward the utilization of waste materials and the re-use/recycling of end-of life components in the production of greases, can promote further the sustainable performance within a circular model.
In this paper a first attempt is made to evaluate the potential of recycling and reusing the thickener content of used greases at the End-of-Life stage. A series of used greases were collected, analyzed and subjected to extraction or separation process in order to recover the contained thickener and separated it from the base oil phase. The properties of the recovered thickener were examined, and the latter was further processed and assessed as a pre-formed thickening agent in new grease preparations. The ability of the recycled thickener to produce mechanically and thermally stable grease formulations was examined, and a comparative assessment was carried out against conventional virgin formulations. The recovered oily phase was also evaluated in terms of its re-refining/reuse potential. This approach has the ability to increase the sustainable performance of certain greases and it can have a positive impact on the overall LCA by reducing the depletion of resources and by promoting the transformation of the lubricating greases value chain from linear to circular.
Dr. George S. Dodos has a Diploma and a PhD degree in Chemical Engineering from the National Technical University of Athens in Greece. He is working with ELDON’S S.A. in research and development of new innovative products and sustainable lubrication solutions. He also holds a Research Associate position in the Laboratory of Fuel Technology and Lubricants in the National Technical University of Athens with his research activities focusing on sustainable and biobased fuels and lubricants. He has more than 100 publications in international peer-reviewed journals and conference proceedings on topics related to conventional and biobased lubricants and fuels. George has received the ELGI AGM Best Paper Award three times as well as the NLGI Author Award-Application. He is also an active member in the SAE Fuels and Lubricants Committee, and he acts as session organizer in the “Driveline Lubricants” session and lead session organizer in the recently formed “Lubricating Greases for Conventional and Electric Propulsion Systems” technical session (FFL 390). He is affiliated to several international organizations including ELGI, STLE, ASTM, SAE, ACS and IBBS. He chairs the joint ELGI/NLGI Biobased Greases WG and the End-of-Life TF in the ELGI STC.
2529
Tuesday,
June 10
High-Performance Biodegradable EAL Grease: A Fully LuSC-Compliant Formulation
The demand for environmentally acceptable lubricants (EAL) is rising as industries navigate stricter regulations requiring sustainable solutions and compliance with the Vessel General Permit (VGP) for marine, mining, and forestry applications. This paper presents a novel high-performance biodegradable EAL grease formulation that meets Lubricant Substance Classification (LuSC) requirements and achieves biodegradability per OECD 301B standards. By carefully selecting a LuSC-listed and hydrolytically stable ester base oil, biodegradable thickener, and environmentally compliant additives, this formulation delivers superior lubrication performance while ensuring compliance with global environmental regulations.
This innovative grease composition offers exceptional thermal stability, oxidation resistance, and extreme pressure (EP) performance, making it ideal for demanding and high temperature applications. Unlike conventional biodegradable greases, which often face challenges related to hydrolytic stability and long-term durability, this formulation leverages advanced chemistry to enhance operational lifespan and mechanical integrity. By integrating sustainable components without compromising performance, this development represents a significant advancement in the field of biodegradable lubricants. The findings underscore the feasibility of producing high-performance EAL greases that meet stringent regulatory and industrial standards while contributing to environmental sustainability.
Dr Liwen Wei is a highly experienced professional with over 30 years in the lubricant and grease industries, holding 15 patents. His expertise spans both technical and commercial aspects of the field. In 2015, he embarked on an entrepreneurial venture, launching a specialty sales business and establishing himself in the innovation and manufacturing of performance grease thickeners. Building on this, since 2016, he has also provided consulting services to companies in the chemical manufacturing, grease, and lube segments.
Noura Smaili Iderkou joined Novitas Chem Solutions in 2021 and has been deeply involved in the company’s commitment to innovation within the grease and lubricants sector. Participating in multiple R&D projects, contributed to the creation of new product concepts and the development of advanced lubrication technologies. Main focus is on generating innovative ideas that address key industry challenges and meet the evolving needs of customers, particularly in the development of next-generation biodegradable lubricants and high-performance greases.
Tuesday, June 10
Development of New 4-Ball Load Ramp Test for Tribological Analysis of Lubricating Greases and Comparison to ASTM D2596
In this study, a tribological analysis for lubricants is evaluated utilizing a programmable, variable load 4-ball machine. In the lubricants industry, the 4-ball tribological techniques are employed to evaluate lubricants ability to protect against wear and extreme pressure. Recently, issues related to varied acceleration rate across machines have called into question the use of tests like ASTM D2596. Here a method for evaluation of the scuffing and seizure load of lubricants is presented. First, reference greases are developed for consistent behavior in testing. Second, each material is evaluated: test specimens are run-in at 40kg normal load for 1 minute followed by a fixed rate ramping normal load until failure or the maximum is reached. Finally, these data are compared to data from legacy 4-ball test machines in ASTM D2596. These data suggest this method may provide a comparable rapid tribological analysis, giving critical first guidance on lubricant material properties.
Jacob Bonta has more than 10 years of experience in designing and testing new chemical products for various industrial sectors. Hired by Valvoline in 2018, he leads lubricating grease and industrial fluid research and development in North America and supports grease related operations for Valvoline globally. His graduate research is focused on lubricating grease fundamental material properties. He has multiple patents issued or pending for chemical products with five being specific to lubricating greases. He is a member of SAE, STLE, and NLGI and holds the NLGI CLGS certification.
Dr. Dirk Drees has a Materials Engineering PhD from The University of Leuven, Belgium and proceeded to establish Falex Tribology in Belgium in 2000. This joint-venture with Falex Corporation USA provides testing and consulting services to the European industry, with more than 20 European R&D projects, 950 individual customers, and over 4000 commercial projects in the past 25 years. Dirk Drees is the CEO of Falex Tribology and responsible for all R&I of the Falex Group of companies. This includes development of new methods, bilateral application oriented tribology test programs with industrial clients, and cooperative European research projects. The focus of activities lies on providing know-how and quality information regarding tribological issues in all industries, with the sincere motivation to contribute to the United Nations Sustainable Development Goals and the European Green Deal. After all, tribology is all about saving energy and resources.
Lais Lopes is Mechanical Engineer with experience in design and construction of test benches and automotive constructions. After a successful internship at Falex Tribology in 2019 and working as project engineer at Librelato S.A., Brasil, she rejoined Falex Tribology in 2021, where she is now the project manager. Her work focuses on delivering expertise on tribological issues across various industries. She is also the main contact point for technical services, calibrations and repairs on Falex machines.
Pedro Baião has a Master’s in Micro and Nanotechnology Engineering from NOVA School of Science and Technology, Lisbon, Portugal. After working as postgraduate researcher at the University of Warwick in the field of battery materials, and at CET UK in an organizational role, he returned to materials testing by joining Falex in 2022 as project engineer. He is responsible for the timely execution of many parallel testing projects in the Falex Tribology lab and of lab organization.
