MANUFACTURER & EXPORTER OF GREASE (LUBRICANT) FROM DUBAI UAE

Grease (Lubricant)

GREASE (LUBRICANT)

RAHA Oil Co stands at the forefront of Grease (Lubricant) manufacturing, with a global reach extending to Europe, Africa, and Asia. Grease, a crucial lubricating agent, essentially comprises a suspension of oil in a thickening agent, complemented by specific additives. Typically, the oil constitutes between 75% and 90% of the grease’s weight, securely held in place by the thickener’s gel structure, allowing it to effectively fulfill its lubricating role. Grease (Lubricant), characterized as a semisolid Grease (Lubricant), is predominantly a blend of soap emulsified with mineral or vegetable oil. Notably, greases exhibit a distinctive high initial viscosity that, when subjected to shear, diminishes, creating an oil-lubricated bearing effect with a viscosity similar to the base oil used. This viscosity alteration is known as shear thinning. While the term “grease” is sometimes loosely applied to describe soft solids or high-viscosity liquids, true greases, such as those manufactured by RAHA Oil Co, demonstrate shear-thinning properties. Unlike classic greases, materials like petroleum jellies, including Vaseline, are not typically classified as greases.

Greases play a pivotal role in lubricating mechanisms that require infrequent maintenance and in situations where traditional lubricating oils might not adhere. Additionally, they serve as effective sealants, preventing the ingress of water and incompressible materials. It’s worth noting that grease-lubricated bearings may exhibit higher friction characteristics due to their elevated viscosity. Grease is a semisolid liquid that consists of a liquid lubricant mixed with a thickener. The oil does the lubricating while the thickener holds the oil and provides a resistance to flow. Soaps (a metallic element such as lithium, calcium, sodium, or aluminum reacted with a fatty acid) or fine particles of a lubricating additive, such as polytetrafluoroethylene (PTFE) or lead are used as thickeners in the grease . The consistency of grease is such that it can be cut using a knife and also can flow under low pressure. Similar to oil lubricants the additives are added to grease to improve load-carrying ability, oxidation resistance, and corrosion control. Grease has complex rheology hence it is a special lubricant. It has a multiphase formulation which includes the presence of both fluids and solids. Also, the rheological properties of the grease are dependent on both the shear rate and the duration of shearing. Grease can be defined, on the basis of its rheological characteristics, as a ‘lubricant which under the action of small loads at ordinary temperatures exhibits properties of a solid, and when the load is applied and at critical value it starts deforming to act like a liquid vice versa’ .

WHAT MAKES GREASE?

At its core, grease is a semi-fluid to solid substance that emerges from the combination of a liquid lubricant and a thickening agent. This amalgamation results in a product that stays in place, providing consistent lubrication to machinery parts, unlike its more fluid counterpart, oil.

THE COMPONENTS OF GREASE

Base Oil (70-90%): This is the primary lubricating element. Most greases utilize mineral oil due to its satisfactory performance across various applications. However, in environments with extreme temperatures, synthetic base oils are preferred for their enhanced stability.

Additives (1-10%): These are crucial in enhancing the grease’s inherent properties. Common additives include oxidation and rust inhibitors, extreme pressure agents, anti-wear, and friction-reducing compounds. They ensure the grease can withstand demanding industrial conditions.

Thickeners (5-20%): Thickeners give grease its distinctive consistency. They are typically metallic soaps like lithium, calcium, or complex agents like polyurea. The thickener acts like a sponge, holding the base oil and additives together, thereby determining the grease’s overall performance and suitability for specific applications.

GREASE (LUBRICANT) APPLICATIONS

The decision to employ grease or oil lubrication hinges on specific factors, guiding the choice based on distinct requirements. Grease is preferred in applications characterized by the following conditions:

• Streamlined maintenance processes
•  Enhanced cleanliness, resulting in fewer leaks
•  Improved protection against contaminants

On the other hand, oil lubrication finds its suitability in applications where elevated operating temperatures stem from external heat sources or excessive heat generated by the machine or its high-speed bearings.

Grease and oil serve distinct purposes and are not interchangeable. The decision to use grease is driven by practicality and convenience when oil application is not feasible. Selecting the appropriate lubricant for a particular application involves aligning machinery design and operating conditions with desired lubricant characteristics.

APPLICATIONS OF DIFFRENT GREAT TYPES

• Lithium Grease: Popular for its versatility and good water resistance. Used in automotive and general industrial applications.
• Calcium Grease: Known for excellent water resistance, making it suitable for marine and agricultural use.
• Polyurea Grease: Commonly used in electric motor bearings due to its long life and good thermal resistance.
• Synthetic Greases: Designed for extreme temperature conditions, either very high or very low, and are often used in aerospace and high-temperature industrial applications.

GREASE IS TYPICALLY EMPLOYED IN THE FOLLOWING SCENARIOS:

1. Machinery with intermittent operation or prolonged storage, benefiting from grease’s ability to stay in place over extended periods.
2. Machinery that is challenging to access for frequent lubrication. High-quality greases excel in lubricating isolated or less accessible components, making them ideal for applications like sealed-for-life systems in electrical motors and gearboxes.
3. Machinery subjected to extreme conditions such as high temperatures, pressures, shock loads, or slow speed under heavy loads. Grease (Lubricant), with its ability to provide thicker film cushions, becomes crucial for effective lubrication and protection in such challenging environments where oil films might be too thin and susceptible to rupture.
4. Worn components, where grease maintains thicker films in enlarged clearances due to wear, extending the life of previously oil-lubricated parts. Additionally, the thicker grease films offer noise insulation.

GREASE VS OIL: KEY DIFFERENCES AND APPLICATIONS

The debate between using grease vs oil for lubrication in industrial settings hinges on understanding their fundamental differences and specific applications. While both serve the primary purpose of reducing friction between moving parts, their composition, behavior, and suitability vary significantly.

APPLICATIONS IN INDUSTRIAL MACHINERY

Grease Applications: Ideal for machinery that operates intermittently or is in storage for extended periods, as it remains in place, ready to lubricate once the machinery is in motion. It’s also favored in machinery that is not easily accessible for frequent lubrication and in components operating under extreme conditions (high temperatures, pressures, shock loads, or slow speed under heavy load).

Oil Applications: Best suited for continuous-operation machinery where a thin, steady lubricant layer is needed. Oil’s fluidity makes it preferable for systems with complex circulation and cooling requirements.
The choice between grease vs oil in industrial applications depends on various factors, including machinery design, operating conditions, and maintenance practices. Understanding these nuances allows maintenance professionals to make informed decisions, ensuring optimal machinery performance and longevity.

THE ROLE OF GREASE IN VARIOUS INDUSTRIES

Grease lubrication plays a critical role in various industries by ensuring the smooth operation and longevity of machinery. Its unique properties make it suitable for a wide range of applications beyond the typical uses in automotive and manufacturing sectors.

Automotive Industry: Chassis and Wheel Bearings: Grease oil is extensively used for lubricating chassis components and wheel bearings in vehicles. Its ability to withstand heavy loads and resist water contamination makes it ideal for these applications.
Suspension Systems: High-performance greases are used in suspension systems, where they endure varying temperatures and pressures.

Manufacturing Sector: Conveyor Belts and Motor Bearings: Grease is essential in lubricating conveyor belt systems and electric motor bearings, reducing wear and tear and prolonging equipment life.
Heavy Machinery: In heavy manufacturing machinery, grease provides lubrication under high pressure and load, ensuring smooth operation and protection against breakdown.

Aerospace Industry: Aircraft Components: Specialized synthetic greases are used for aircraft components, including bearings, gears, and control systems, where they must perform reliably under extreme temperature variations and pressures.

Marine Industry: Ship Machinery: Marine-grade grease lubricants is used to protect ship machinery from saltwater corrosion and extreme weather conditions. It’s crucial for equipment like winches, pulleys, and rudders.

Construction Industry: Heavy Construction Equipment: Grease is vital for lubricating moving parts in construction equipment like bulldozers, cranes, and excavators, especially in outdoor environments where dust and water resistance is necessary.

In each of these industries, grease serves not only as a lubricant but also as a protector against wear, corrosion, and environmental challenges. Its selection and application are based on specific industry needs and environmental conditions, highlighting its versatility and indispensability in the industrial world.

FUNCTIONAL BENEFITS OF GREASE LUBRICATION IN INDUSTRIAL APPLICATIONS

Grease offers several functional benefits that make it an essential choice for lubrication in various industrial applications. Its unique properties address specific challenges and operational requirements encountered in different industrial settings.

Pumpability: Grease’s pumpability, or the ease with which it can be moved through a lubrication system, is crucial for ensuring consistent lubrication across complex machinery parts. This property allows grease to be effectively applied in hard-to-reach areas and maintained within systems with minimal leakage.

Water Resistance: Grease’s resistance to water is particularly important in environments where moisture or direct water exposure is common. This resistance helps maintain its lubricating properties even when exposed to water, preventing rust and corrosion in machinery.
Consistency and Stability: The consistency of grease, determined by its thickener and base oil composition, ensures that it stays in place and provides a continuous lubricating film. This stability is vital for machinery that experiences high vibrations or varying operational speeds.

Temperature Tolerance: High-temperature tolerance is a key feature of many greases, allowing them to maintain their consistency and lubricating properties in environments with elevated temperatures. Conversely, certain greases are formulated to remain effective at extremely low temperatures, ensuring reliable performance in cold conditions.

Sealing Properties: Grease acts as a sealant to prevent the ingress of contaminants such as dust, dirt, and water. This sealing ability extends the life of machinery components by protecting them from harmful elements.

Versatility: Grease lubricants is available in a range of formulations to meet the specific requirements of various applications. This versatility allows for targeted lubrication solutions across different industries, from automotive to aerospace and manufacturing.

The functional benefits of grease oil make it an invaluable component in industrial lubrication. Its ability to adapt to different environmental conditions and operational demands ensures the effective and efficient functioning of machinery, ultimately contributing to the longevity and reliability of industrial equipment.

PHYSICAL AND FUNCTIONAL DIFFERENCES

Consistency and Application: Grease oil has a thicker consistency compared to oil. This thickness allows grease to stay put and maintain a lubricating film over a longer period and under higher pressures. Oil, being more fluid, flows more easily but may require more frequent application.

Temperature Resistance: Grease generally handles extreme temperatures better than oil, especially when the correct thickener and base oil are chosen. In contrast, oils are more prone to viscosity changes with temperature fluctuations.

Sealing Properties: Grease oil acts as a sealant to minimize leakage and prevent contaminants’ entry, a trait not inherent in oils.

GREASE PROPERTIES

Lubricating grease consists of 65-95% base oil, 3-30% thickener and 0-10% additives. All these constituents provide the grease with a semi-solid structure. The interaction between the oil and thickener system determines the flow properties, or rheology, of the grease.

Viscosity: The flow of lubricating grease is strongly non-linear due to the decrease in viscosity with increasing shear rate, called shear thinning. In general, the viscosity reaches a maximum plateau at low shear rates and a minimum plateau at high shear rates.

Shear stress: At very low stresses, no fluid behavior can be observed in greases within a reasonable time. Under these conditions, the fiber contacts are able to restrict the grease flow by mechanical obstruction. It is said that greases display apparent yield behavior, i.e. they only experience irreversible flow after minimum stress or strain has been applied, called ‘yield stress’ . The yield stress is important for a number of practical reasons, since, for example, it prevents grease leakage and determines its sealing capability in a bearing.

FUNCTION OF GREASE

• The main function of the grease is to remain intact on the surface to provide the lubrication for that surface without leaking under the affect of the gravity.
• Grease should not lose its shear properties in presence of varying temperature.
• Grease must flow through bearing through the grease gun, however it should not add as an additional agent to consume more power.

FUNCTIONAL PROPERRTIES OF GREASE

1. It acts as a sealant and prevents leakage.
2. It has more advantages compared to oil.
3. It acts as a solid lubricant.
4. The fluid levels are not to be controlled or measured.

ASTM COMMON TESTS FOR GREASE CHARACTERISTICS INCULDE

• Apparent viscosity
• Bleeding, migration, synergesis
• Consistency, penetration, and National Lubricating Grease
• Institute (NLGI) numbers Corrosion and rust resistance
• Dropping point
• Fretting wear and false brinelling
• Oxidation stability
• Pumpability and slumpability
• Shear stability
• High and low temperature effects

DISTINGUISHING GREASE FROM OIL

In the realm of bearing lubrication, both grease and oil play essential roles. The key disparity lies in their compositions. Grease is a combination of oil and a thickening agent, with the thickener acting akin to a sponge that retains the oil. Beyond this, greases can incorporate various additives such as rust inhibitors, EP (extreme pressure) additives, and oxidation preventatives. Typically exhibiting a semi-solid to solid consistency, grease possesses the unique ability to maintain its place over an extended duration. This longevity is attributed to its thicker composition, granting grease an advantage in numerous applications where the capacity to stay in position and gradually release oil surpasses that of oil alone.

TYPES OF GREASE

Grease falls into two primary categories: soap-based and non-soap-based, each distinguished by the type of thickener employed.

Soap-Based Grease:

1. Simple Soap Grease: Comprising base oil and a metal soap resulting from the reaction and neutralization of a fatty acid with a metal hydroxide (e.g., aluminum, sodium, calcium, lithium, or barium).
2. Mixed Soap Grease: Formulated with base oil and a blend of two distinct metal soaps, such as lithium and calcium soaps.
3. Complex Soap Grease: Engineered to enhance heat resistance, this grease mirrors standard soap grease but incorporates a thickener composed of two dissimilar acids—one fatty and one organic. Notable complex soap greases include aluminum, lithium, calcium, and barium variants.

Non-Soap-Based Grease:

1. Mineral-Based Grease: Consists of base oil and a mineral thickener like bentonite, modified mineral silicate, or graphite.
2. Polymer-Based Grease: Another non-soap variant with distinct properties.

ADVANTAGES OF GREASE

• Better stop-start performance: When the system shuts down, oil drains away while grease remains in the component.
• Contamination – the risk of contamination products such as food and pharmaceutical type products is reduced with the use of grease due to its resistance to flow into the products.
• Greases decrease dripping, splattering and leakage.
• Greases reduce noise.
• Greased machinery tends to need less power

DISADVANTAGES OF GREASE

• Reduced cooling/heating transfer – the flow of oil removes heat from the point of generation where it can be removed or dissipate. Grease tends to hold heat in place.
• Poorer storage ability – too long storage can lead to separation of base oil and thickener and may also result in altered properties.
• Greases may not reach all places in need of lubrication.
• Greases cannot be used at the high speeds that liquids are well suited for

FAQs

A: What are the main components that make up grease?
B: Grease consists of base oil (70-90%), additives (1-10%), and thickeners (5-20%).

A: In what situations is grease preferred over oil in industrial machinery?
B: Grease is preferred for intermittent operation, inaccessible lubrication points, extreme conditions, and where sealing out contaminants is important.

A: Is grease and oil the same thing?
B: No, grease and oil are not the same, although they share the primary function of lubrication. Their differences lie in their composition, physical state, and application methods. Grease, being semi-solid, is better suited for applications where it’s challenging to contain liquid oils or where components cannot be frequently lubricated.

A: Can different types of grease be mixed in machinery?
B: Mixing different types of grease is generally not recommended as it can lead to reduced lubrication performance and potential incompatibility issues.

A: How often should grease be applied in industrial machinery?
B: The frequency of greasing depends on the machinery type, operating conditions, and the grease’s performance characteristics. Regular maintenance schedules should be followed as per manufacturer guidelines.