Grease production plants

Pishgam Palayesh Force  offers state of the art plants for the manufacture of a wide range of greases such as Lithium, Calcium, Soda, Aluminum complex, Polyurea, Synthetic and Specialty greases. We employ highly experienced Partners and Grease technologists who have hands on plant experience for manufacturing quality greases based on NLGI
specifications.
Grease is the most widely used lubricant in the world (about four percent) after oils. It can be said that without the use of this lubricant, the wheels of the economy of any country would not turn. The formulation, manufacture, reactions and application of grease occupy a complete set of diverse technologies including broad areas of physics, chemistry and chemical engineering.
Grease is a semi-solid to solid lubricant that is formed by combining a liquid lubricant (such as mineral or vegetable oil) with a thickening agent (often soap-based) and additives. This combination allows the grease to stay in place and, unlike liquid lubricants such as oil, provides continuous lubrication and protection against wear and corrosion in machinery parts.
Grease components:
Base oil: This is the primary lubricating component, which usually makes up 70 to 90 percent of the grease. Depending on the application, it can be mineral or synthetic oil.
Thickener: Common thickeners include soaps (e.g., lithium, calcium) and non-soap materials such as polyurea or organophilic clays. The thickener traps the oil and gives the grease its semi-solid consistency.
Additives: These materials enhance the performance of the grease by improving properties such as oxidation resistance, load-carrying capacity, and corrosion control.
Grease properties:
Shear thinning: The grease initially exhibits high viscosity but becomes more viscous under shear stress, allowing it to act as a fluid when needed.
Sealant properties: The grease can act as a sealant, preventing lubricant leakage and displacing contaminants.
Adhesion: The grease adheres well to surfaces and forms a protective layer that reduces friction and wear.
Grease Uses: Grease is widely used in industrial and mechanical applications, including automotive parts, bearings, and machinery, due to its ability to provide lasting protection and lubrication in high-temperature and harsh environments.
Process Steps:
Metering and Addition of Reactants: Fatty acids, base oils, water, alkali, and metal hydroxides are added to the reactor.
Saponification: The mixture is heated in a reactor to convert fatty acids and alkali into soap.
Water Elimination: Excess water is removed.
Cooling and Homogenization: Base oil is added for cooling, and the mixture is homogenized to achieve the desired consistency.
Degassing and Filling: Air is removed, and the grease is packaged.
Advantages: Flexible production, suitable for small batches and various grease types.
 
Types of Greases Produced
Lithium Grease: Uses lithium soap as a thickener.
Calcium Grease: Uses calcium soap.
Aluminum Grease: Uses aluminum soap.
Complex Soap Greases: Include lithium complex and calcium complex greases.

The image below shows the grease production line plant implemented for the Takran Kaveh project: