This paper documents the recent development of several new process methods for making calcium sulfonate complex greases. These new process techniques included: (1) the delayed addition of the primary non-aqueous converting agent relative to the addition of water; (2) the use of trace levels of alkali metal hydroxide; and (3) a delay after the addition of the facilitating acid and before the addition of the next reactive raw material. By judicious use of one or more of these process methods, the overbased calcium sulfonate content of an NLGI No. 2 grade grease was reduced to between 15 and 22 wt% without the use of pressurized manufacturing equipment.
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