Calcium Soap Greases:
Tallow (animal fat) based calcium greases were the earliest lubricants developed during 1845. As a result, calcium greases were relatively inexpensive to manufacture and are still in use since then.[3]. While there are three types of calcium greases but anhydrous calcium grease is the most economical multipurpose grease. Besides, the other two greases are hydrated calcium and calcium complex. In addition to multipurpose anhydrous calcium, hydrated calcium or lime grease is one of the most economical greases for general-purpose wet applications.
Three common types of calcium greases:
- Hydrated calcium grease (lime grease)
- Anhydrous calcium Grease
- Calcium complex
Hydrated calcium soap grease
Hydrated calcium grease has mineral oil, animal fat (tallow), and lime in its composition. Grease has a 90°C (194°F) dropping point, whereas the useable temperature is around 65°C (149°F). Still being manufactured on a large scale, it is one of the most economical greases. Due to the chemical reaction of hydrated lime with tallow, lime greases need water to retain their grease structure. A small amount of water acts as a stabilizer. Lime greases have limited use because of lower useable temperatures and the need for water to stay as grease.
Uses (applications) of hydrated calcium grease
- Machines in a wet environment
- Agricultural and farming machinery exposed to water
- Water pumps
- Non-bearing axles
- Chassis lubrication
Advantages of hydrated calcium (lime) grease
- Smooth structure
- Good low-temperature properties (depending upon the base oil)
- Excellent water resistance (don’t form an emulsion with water)
- Good adhesion (adhere to surface applications)
- Pumpable
Disadvantages of hydrated calcium lime grease
- Low drop point 90-100°C (195-210°F)
- The maximum working temperature is 65°C (149°F).
- Not suitable for high-speed application (bearings)
- Grease structure breaks without water
- Poor storage stability
- Poor shear/mechanical stability
Anhydrous calcium soap grease
Anhydrous calcium grease is an economical multipurpose grease. Calcium 12-Hydroxy Stearate, or anhydrous calcium grease has 12HSA (12-hydroxystearic acid) instead of animal fat (tallow/stearic acid) as a thickener. As a result, 12HSA eliminates the need for water in calcium greases. In the same way, it is also possible to use blend of 12HSA and HCO (hydrogenated castor oil) or stearic acid with an 85:15 ratio. The grease has a 150°C (300°F) dropping point, good thermal stability, excellent water resistance, and good mechanical stability. Therefore, it is the best multipurpose grease for applications where equipment running at the ambient temperature or up to 90°C (194°F) max. Theoretically, it is okay for up to 110°C (230°F) because of 150°C (300°F) dropping point, but as layman selection criteria use it for non-powered machinery.
Composition/formulations of anhydrous calcium grease
Learn More:
- Lithium Grease: Composition, Formulations, and Applications
Lithium grease is widely regarded as one of the most versatile greases ever made. It was first created back… Read more: Lithium Grease: Composition, Formulations, and Applications - Calcium Grease: Composition, Formulations, and Applications
Calcium Soap Greases: Tallow (animal fat) based calcium greases were the earliest lubricants developed during 1845. As a result,… Read more: Calcium Grease: Composition, Formulations, and Applications - NLGI Grease Consistency, Classifications and Applications
Lubricating grease consistency A grease consistency or penetration score indicates grease consistency or stiffness to help predict how it… Read more: NLGI Grease Consistency, Classifications and Applications
| Components | Percent Wt |
|---|---|
| Base Oil (Group I SN600) | 75% |
| Bright Stock | 5% |
| 12-Hydroxystearic Acid | 11.9% |
| Hydrogenated Castor Oil | 2.1% |
| Calcium Hydroxide | 2% |
| Additives | 4% |
| Components | Percent Wt |
|---|---|
| Base Oil (Group I SN600) | 41% |
| Bright Stock | 39% |
| 12-Hydroxystearic Acid | 11.9% |
| Hydrogenated Castor Oil | 2.1% |
| Calcium Hydroxide | 2% |
| Additives | 4% |
How to make grease:
The process to make anhydrous calcium soap grease. See the above example for composition or formulation.
1. Charged 15% of the total base oil to an open kettle.
2. Heat is applied to reach 50-60°C (122-140°F) with stirring.
3. 12-hydroxy stearic acid and hydrogenated castor oil added (the preferred ratio is 85:15 up to 50:50).
4. Reached 80°C (176°F) with continuous stirring to melt the acids.
5. At 80-90°C (194°F), the slurry of calcium hydroxide is added slowly to the kettle over 20 minutes.
6. Added the calcium hydroxide slurry; 30 minutes further mix time is completed, maintained below 100°C (194°F) temperature to avoid foaming.
7. Following the 30 minutes mixing time, the temperature increased stepwise to complete the reaction and water removal.
8. At 110°C (230°F), the heat increased to initiate the temperature ramp to the 140°C (284°F) process maximum. A portion of the base oil is added multiple times during this process.
9. At 140-145°C (284°F) temperature stage, cooling oil is applied at a slow, controlled rate.
10. Cooling started, below 90°C (194°F), antioxidants, EP, and other additives added. The grease is milled, and the penetration and dropping point tested.
11. Final adjustment base oil added to achieve the desired grade.
| Description | Hydrated Calcium Grease | Anhydrous Calcium Grease |
|---|---|---|
| Dropping Point | 90°C (194°F) | 150°C (300°F) |
| Useable Temp °C Max | 65°C (149°F) | 110°C (230°F) |
| Appearance | Fibrous | Buttery |
| Good for Use as | Economical General-Purpose | Economical Multi-Purpose |
| Water Resistance | Good to Excellent | Excellent |
| Work Stability | Fair to Good | Good to Excellent |
| Oxidation Stability | Poor to Excellent | Fair to Excellent |
| Rust Protection | Poor to Excellent | Poor to Excellent |
| Oil Separation | Poor to Good | Good |
Uses (applications) of calcium 12-hydroxystearate grease
- Multipurpose grease for wet environment
- Wet industrial machinery
- Sewage plant and machinery
- Agricultural, farming machinery exposed to water, tractors, mine cars, and textile machinery
- Water pumps and bearings
- Slow-moving axle grease
- Chassis lubrication
Advantages of calcium 12-hydroxystearate grease
- Smooth translucent structure
- Good low-temperature properties (base oil-dependent)
- Available in EP (extreme pressure)
- Excellent water resistance (don’t form an emulsion with water)
- Good adhesion (good for adhere-to-surface applications)
- Excellent shear stability
- Pumpable
Disadvantages of calcium 12-hydroxystearate grease
- Low drop point of 150°C (302°F)
- The low continuous use temperature of 52 to 66°C (125 to 150°F) up to 90°C(194°F). The absolute max is 110°C (230°F)
- Fair storage stability
References:
[1] Dropping Point of Lubricating Grease
[2] ASTM grease definition
[3] History of Automotive Lubrication SAE Technical Paper 961949 By SQA Rizvi
[4] NLGI Grease Guide
How to make calcium sulfonate grease
We will publish in the coming days.
I need Calcium Sulfonate making formula & proces, plz
Calcium sulfonate complex greases are made by converting a fluid detergent (Overbased Calcium Sulfonate) to a grease containing calcite particles. While Calcium Sulfonate Complex grease offers excellent lubrication properties, formulating and manufacturing it involves a complex process that utilizes flammable components. It requires specialized equipment, in-depth knowledge of grease manufacturing, and an experienced person to monitor the first few batches. Please reply if you have manufacturing infrastructure in place.
very informative discussion and formulations I will try in my unit.
Hi, I am studying on calcium complex grease synthesis. I have a problem I was wondering you would help me.
My final compound is grainy and this is my procedure: addition of calcium hydroxide, acetic acid and dibacic acid first, at bellow 60°C, and then 12OH stearic acid. So what do you think is making it grainy?
thank you in advance
Please send complete process and formulations. You can use our contact-us form also.
thank you, I sent my message through that form.
No message till today.
Dear Admin,
How to increase Shinning and transparency in Calcium grease?
I’ve tried multiple small batches with different base oil ratios, but there are two problems I’m facing, first one is that the transparency and shining of the final grease is not up to the mark (even after milling), and the second problem is that the final grease is so much grainy, and after milling the grease with colloid mill, the grains got dispersed but when we rub it between two fingers precisely, there is some powdery feeling, I’ve also tried plunger pump but the result is same, very minute but powdery feeling, even after milling the same grease three times the results aren’t different, kindly guide me, is there a manufacturing process problem or something else, and how can I solve this issue,
regards,
Umer
To better understand the grainy texture of grease, I need more information about the specific details of your manufacturing process and the properties of the final product. Few reasons are listed:
1- Incomplete reaction: If the calcium hydroxide and fatty acid have not fully reacted, unreacted particles can contribute to a grainy texture. Test free alkali in final grease to check for unreacted calcium hydroxide.
2- Contamination: The presence of foreign particles in the grease can also contribute to a grainy texture. Try to filter slurry or use quality calcium hydroxide.
3- Check sample after 10-15 days of production. Is it still the same or improved.
Hello Sir
Greetings of the Day!
Thank you for providing such a useful formulations.
I have a Query sir,
1. what will be Ca(OH)2: Water ratio to make slurry?
2.Which chemical is used for making thread inside grease?
It depends but in open kettle up to 1:1
Thank You Very Much Sir for this formulations.
But I have one Query Sir
Sir what will be Ca(OH)2: Water ratio to make slurry?
In Open Kettle 1:1
HOW CAN I MILL THE GREASE IN LAB
You can purchase small milling for lab.
hi is it possible to use recycled oil (destilation oil) to manufacture anhydrous calcium base grease
without using bright stock???
Yes, It is possible.
Yes, you can use recycled oil and remove bright stock but you have to use more fat to bring desired consistency.
I am facing some issues in manufacturing Anhydrous Calcium Grease from the above given method and want some guidance:
Does using Recycled oil (Reclaim Oil) for reaction affects the process? I reacted in recycled oil with exact same ratios given above but after completing the reaction and evaporating the water, when I added the bright stock (base oil), the bright stock didn’t blend in the soap and kept moving separately, I heated and melted the whole soap manually on stove and mixed it to about 220°C to make the material uniform, It became one homogeneous liquid but after putting back it and mixing it in the kettle, when the temperature got down to around 140°C or below, the material and Oil I added after the reaction, got separated again, I also added the recycled oil but nothing changed, I’ve putted a lot of effort and investment in making the kettle and now it’s not going how I thought it should be, can you please guide us, we can provide you videos of our kettle and issues, we are already experienced manufacturer in synthetic base greases but now want to manufacture Anhydrous Calcium Grease,
waiting for the reply from experts,
Regards,
Umer.
Just read again, Did we ask to heat the grease to 220°C? Follow the instructions to make grease. Recycled oil is fine. Maximum process temperature is 140-145°C.
Sir, please explain mechanical stability for anhydrous calcium grease.
For most general purpose application it is perfect.
10. Cooling started, below 90°C (194°F), antioxidants, EP, and other additives added. The grease is milled, and the penetration and dropping point tested.
Proces of milling is not getting clear.
From Cooking to Cooling —- Then from cooling, grease will be milled and through deaerator the final outcome.
Please suggest
Would like to know more about the corrosion resistant property of Calcium Grease.
Sir, thanks for great information on “Anhydrous Calcium Grease” and sharing its formulation. But its costing is on higher side in comparison with hydrated Calcium Grease (lime Grease). It would be great if you suggest us low cost formulation for Anhydrous Calcium Grease or any fillers those can reduce its cost without disturbing its Dropping point and advantage mentioned.
Awaiting your valuable response in the matter.
Thanks & regards
Akshay
So many non Lithium grease(veedol mp-3) calcium base coming in market having drop point is above 200 c if u have any idea about their formulation please tell me
I am really obliged after getting so much support.
Will try this formalution tomm itself.
Please provide us your contact detail in case we require some help.
Thanks,
Sir what will be Ca(OH)2: Water ratio to make slurry
How can i make grease at home with used cooking oil.
Thank you for ur help
In step 6 you mention adding a “calcium hydroxide slurry”. Is this slurry water and Ca(OH)2 or oil and Ca(OH)2. What percent Ca(OH)2 was used?
It is water and Ca(OH)2.
i am making Grease with HL, RB Fatty acid , HCO and NaOH. But Question is what happened more or less of fatty acid.
Hello Sir
I am trying to make calcium complex grease using stearic acid, phosphoric acid, and acetic acid.
The problem is that the soup becomes soft when the temp increases to 160 C. When the temp reaches 220 C, it gets thick. After quenching and adding oil, it gets soft again and I should add water to thicken it. The final grease loses its consistency by mixing after some time.
Could you please help me with this problem?
Thanks
you used rice brain fattey acid tallow n calcium
can we use Hydrated Lime with 12HSA and HCO ?
Yes, it is the most common.
Do I need any other chemicals to make Anhydrous Calcium grease besides 12HSA/HCO and Calcium Hydroxide (LIME) and off course the additives?
Is there any way (altering the proportions of soap etc) to enhance the dropping point?
Can you please share Lithium Complex grease making process
Hello sir,
We make grease by using tallow, rbd oil, base oil and hlp.
This grease is losing its transparency. Can you help me with getting optimal transparency
Hi
Interested for formulatilns
Hi sir
I have some question.
1. what should be the highest temperature for making tallow base grease …?
2. when should i stop heating i mean does grease become tight when its water evaporates ..?
plz assist me step by step about mfg process of tallow base calcium grease.
Need to know what role does caustic soda play in the formation of Lime based grease. We use caustic soda (lye) for forming the Calcium Greases.
You can adjust the free acid/base of the grease with caustic soda at the end.
Hi sir I m prabhat
I liked your information and I am working in grease department Even I am developing in lab
I need your help sir
To develop more
If I get this chance to work with you
Really I am feeling I am very lucky I want to work with you on some formula and development.
Hi prabhat
are you working on grease mfg..?
can you assist me regarding calcium base grease manufacturing if you have grease production knowledge.
Hlo sir
Can I get any video of anhydrous calcium grease or hydrated calcium grease manufacturing process.
We will try to post a video in future.
I made calcium complex grease
Can share how…?
please guide me also for calcium complex
You can share with us.
Please share formulation for calcium & lithium complex if possible. need to start production in my plant.
HOW CAN YOU PLEASE SHARE
HEY RAHUL I NEED YOUR ASIST
Sir，How Anhydrous Calcium Grease Prevents Hardening Problems？
Anhydrous Calcium is a perfect MP grease. The only problem is low drop point for some applications.
At 110°C (230°F), the heat increased to initiate the temperature ramp to the 140°C (284°F) process maximum. A portion of the base oil is added multiple times during this process. — This is process —my problem soap not smooth / It lime+12HSA gathered into small lumps
There are 3 main reasons to have lumps:
1- Mixing
2- Mixing
3- Mixing
Check your grease cooking kettle.
Thanks
hi when will you post formulation and manufacture process for calcium & lithium complex greases??please
Hello!
Have some questions about formulation and blending process.
-How is shaft speed affect yield.
-What is the difference between 2-HSA and HCO? And why use both in grease blending as raw
materials?
-Any required ratio of LiOH:12 HSA:HCO to get maximum yield.
-How is intermediate and final temperature & ramp time during grease blending affect yield and grease properties?
-How hold time for final temp before addition base oil for cooling affect yield and grease properties?
-How does start quantity base oil affect yield and grease properties?
-How does cooling rate affect grease properties?
If you provide more services, kindly contact me via the mentioned e-mail.
Thanks.
Thank you sir
Hi sir
Is it possible to make calcium grease only with animal fat?
Yes, To manufacture calcium soap grease, hydrated lime (calcium hydroxide) and water are added to a stirring mixture of fat (animal fat), and oil. For making hydrated calcium grease (lime grease), the usual fatty component is tallow. In case of an open kettle, the temperature must be below 100°C, the boiling point of water. If animal fat alone is used as the starting material, the addition of a certain amount of water is necessary to facilitate saponification. Animal fat base calcium grease required the presence of at least 1–2 % water to maintain grease structure.
Thank you sir
can we use Hydrated Lime with 12HSA and HCO ?
Hi Admin, Can we have your contact details of whatsapp number so that while preparing sample of Complex Grease. We can get guidance pertains to some problem.
Rgds,
Saranjeet
+91 9810153213
It must have reached its maximum temperature.
Thank you sir
Can i get the percentage
Hi sir, is it possible to make calcium grease only with animal fat?
Yes, use animal fat, oil, and lime with 10% of water. Keep temperature below 100°C.
Hello,
I tried to make fat based on calcium, stearic acid, hydrogenated castrol oil, and an improver, but the final texture was very very soft, so, what’s the matter please.
Please share your formulation including base oil and type of improver. There are many factors that can lead to low yield or loose grease.
Try to make grease with hydrogenated caster oil only, no stearic acid. With stearic acid you may need 16-22% fat to make NLGI 3 grease.
Is anhydrous calcium grease made in pressure vessel?
Pressure vessel is better but open kettle is completely fine too. Most manufacturers use open kettle for anhydrous grease manufacturing.
Thanks .
Very useful formulation of anhydrous calcium grease.
If we add 5% sebacic acid with 12HSA then its drop point would not increase 150c to 150c.
PLEASE SUGGEST ME.
Thanks and Regards
D .Ghosh.
Commercial calcium complex greases contain complex soap of three acids.
1- Soap of a higher fatty acid
2- Soap of lower fatty acid,
3- Soap of aromatic fatty acid.
Preferred higher fatty acids are (12-HSA) 12-Hydroxystearic acid, and hydrogenated castor oil (HCO). similarly, benzoic acid is a choice for aromatic fatty acids. Highly preferred lower fatty acid is acetic acid. You can use alternatives, but 12-HSA, benzoic acid, and acetic acids are economical.
Calcium complex greases can replace lithium and lithium complex greases in many applications but are inferior to lithium greases in terms of dropping point, mechanical stability, and heat resistance. Calcium complex greases tend to harden during long-term storage and are not recommended in some bearings. Surface hardening is a problem in many calcium complex greases.
Calcium sulfonate complex grease is a superior alternative to lithium and lithium complex grease. Due to the record high price of lithium hydroxide, Calcium sulfonate greases are gaining popularity.
How can we avail formulation of Calcium sulfonate greases
I can contact you if you provide your business e-mail. Please use our contact us form.
Hi
I am from chennai, India.
We make both lithium and calcium grease.
Looking for calcium sulphonate grease formulation.
Thanks
Bajnath Singh
hi is it possible to use recycled oil (destilation oil) to manufacture anhydrous calcium base grease
without using bright stock???
Yes, you can make anhydrous calcium grease with recycled oil.
Dear Sir,
I want to Make calcium base Grease.
I Have Palmitic Fatty acid, ca(oh)2 and mineral Oil.
Please Help me make calcium base Grease.
Thanks,
Wimalasena
The complete process for the manufacturing of anhydrous calcium grease is given in the above article. If you still have issues please provide details so I can give you a solution.
Manufacturing calcium sulfonate complex greases is not easy and requires special grease-making equipment. We will publish articles for calcium sulfonate complex greases very soon. Stay updated for the latest articles at this website.
Hello sir
How to make calcium complex grease. What raw material we need. Pls tell me
Hello,
We will publish articles for both calcium complex and lithium complex greases very soon.
Waiting for published article.
Rgds
Sir, please publish the calcium complex grease manufacturing process.
Are these soaps same when we make lithium complex grease like benzoic acid and acetic acid???
For Lithium complex grease use Azelaic acid and 12-HSA combination.
can i use hco & lithium and Azelaic acid only, and when should i use Azelaic acid means addition temperature etc??
Sir 12hsa how much percentage to be used
Dear brother how can I manufacture calcium sulfonate grease please benefit and what do you think about using stearic acid with palm oil