A sulfonate-based grease composition and method of manufacture comprising (1) addition of both overbased calcium sulfonate and overbased magnesium sulfonate in a ratio range of 60:40 to 100:1, with the magnesium sulfonate added all at once, a portion prior to conversion and another portion after conversion, and/or one more delay periods between the addition of water or other reactive ingredient and the addition of magnesium sulfonate; (2) one or more delay periods between the addition of at least a portion of a facilitating acid and at least a portion of the next subsequently added ingredient; (3) no conventional non-aqueous converting agents added prior to conversion; or (4) a combination thereof. The grease has a high dropping point and reduced thickener yield.

A sulfonate-based grease composition and method of manufacture comprising (1) addition of both overbased calcium sulfonate and overbased magnesium sulfonate in a ratio range of 60:40 to 100:1, with the magnesium sulfonate added all at once, a portion prior to conversion and another portion after conversion, and/or one more delay periods between the addition of water or other reactive ingredient and the addition of magnesium sulfonate; (2) one or more delay periods between the addition of at least a portion of a facilitating acid and at least a portion of the next subsequently added ingredient; (3) no conventional non-aqueous converting agents added prior to conversion; or (4) a combination thereof. The grease has a high dropping point and reduced thickener yield.

Effects of Oxygen on grease or another organic paste product can be evaluated with a modified version of the ASTM D942 test methodology for oxidation stability of lubricating greases or other organic paste products by employment of an oxidation pressure vessel, in which at least one of (A) a very small sample of the grease or other organic paste product is deployed for testing within the oxidation pressure vessel such that the sample has an enhanced surface area to mass ratio, and (B) a temperature other than about 99° C. is employed during the testing. In general, the testing is carried out under oxidation pressure conditions. The sample may be evaluated with respect to Oxygen uptake. Additional technique(s) directed to oxidation and/or other properties of the sample may be carried out before to after any Oxygen uptake evaluation, for example, FTIR analysis and/or ATR-FTIR analysis.

Effects of Oxygen on grease or another organic paste product can be evaluated with a modified version of the ASTM D942 test methodology for oxidation stability of lubricating greases or other organic paste products by employment of an oxidation pressure vessel, in which at least one of (A) a very small sample of the grease or other organic paste product is deployed for testing within the oxidation pressure vessel such that the sample has an enhanced surface area to mass ratio, and (B) a temperature other than about 99° C. is employed during the testing. In general, the testing is carried out under oxidation pressure conditions. The sample may be evaluated with respect to Oxygen uptake. Additional technique(s) directed to oxidation and/or other properties of the sample may be carried out before to after any Oxygen uptake evaluation, for example, FTIR analysis and/or ATR-FTIR analysis.

Zinc complex greases with different complexing acids having dropping points comparable to lithium greases and tailor-made dropping points can be made by processing at low temperature in open as well as close kettle process. The present invention discloses a process of manufacturing Zinc complex greases—through reaction of fatty acid and complexing acid with zinc oxide in mineral oil to obtain zinc complex greases having high dropping points of 180 to 280° C.

A sulfonate-based grease composition and method of manufacture comprising (1) addition of both overbased calcium sulfonate and overbased magnesium sulfonate in a ratio range of 60:40 to 100:1, with the magnesium sulfonate added all at once, a portion prior to conversion and another portion after conversion, and/or one more delay periods between the addition of water or other reactive ingredient and the addition of magnesium sulfonate; (2) one or more delay periods between the addition of at least a portion of a facilitating acid and at least a portion of the next subsequently added ingredient; (3) no conventional non-aqueous converting agents added prior to conversion; or (4) a combination thereof. The grease has a high dropping point and reduced thickener yield.

A sulfonate-based grease composition and method of manufacture comprising (1) addition of both overbased calcium sulfonate and overbased magnesium sulfonate in a ratio range of 60:40 to 100:1, with the magnesium sulfonate added all at once, a portion prior to conversion and another portion after conversion, and/or one more delay periods between the addition of water or other reactive ingredient and the addition of magnesium sulfonate; (2) one or more delay periods between the addition of at least a portion of a facilitating acid and at least a portion of the next subsequently added ingredient; (3) no conventional non-aqueous converting agents added prior to conversion; or (4) a combination thereof. The grease has a high dropping point and reduced thickener yield.

Zinc complex greases with different complexing acids having dropping points comparable to lithium greases and tailor-made dropping points can be made by processing at low temperature in open as well as close kettle process. The present invention discloses a process of manufacturing Zinc complex greasesthrough reaction of fatty acid and complexing acid with zinc oxide in mineral oil to obtain zinc complex greases having high dropping points of 180 to 280 C.

A sulfonate-based grease composition and method of manufacture comprising (1) addition of both overbased calcium sulfonate and overbased magnesium sulfonate in a ratio range of 60:40 to 100:1, with the magnesium sulfonate added all at once, a portion prior to conversion and another portion after conversion, and/or one more delay periods between the addition of water or other reactive ingredient and the addition of magnesium sulfonate; (2) one or more delay periods between the addition of at least a portion of a facilitating acid and at least a portion of the next subsequently added ingredient; (3) no conventional non-aqueous converting agents added prior to conversion; or (4) a combination thereof. The grease has a high dropping point and reduced thickener yield.

A sulfonate-based grease composition and method of manufacture comprising (1) addition of both overbased calcium sulfonate and overbased magnesium sulfonate in a ratio range of 60:40 to 100:1, with the magnesium sulfonate added all at once, a portion prior to conversion and another portion after conversion, and/or one more delay periods between the addition of water or other reactive ingredient and the addition of magnesium sulfonate; (2) one or more delay periods between the addition of at least a portion of a facilitating acid and at least a portion of the next subsequently added ingredient; (3) no conventional non-aqueous converting agents added prior to conversion; or (4) a combination thereof. The grease has a high dropping point and reduced thickener yield.