Lubes em Foco Magazine – issue 93
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Technologies and challenges for the grease market in Brazil
Anyone who thinks the challenges of the grease market are limited to developing new formulations or meeting sustainability demands is mistaken. During the second day of the 4th International Meeting with the Lubricants Market, it became clear that it is also necessary to pay attention to the growth of other markets that may emerge as competitors in the use of certain raw materials.
The opening panel of the event covered many important topics for the sector, including raw materials such as palm fatty acid. With 90% of global production concentrated in Indonesia and Malaysia, access to the product has been quite complex, explains Felipe Camargo, Commercial Manager at ABIOSSA.
To make matters worse, national production, which is already low, is expected to suffer a significant impact due to the drought in Pará. With a reduced supply and a strong presence in the animal feed market, fatty acid is beginning to be used as a raw material for second-generation advanced biofuels.
“As the volume of fatty acid is limited in Brazil, an additional competitor has a huge impact. Due to the drought in Pará, there is little oil to refine, and a lot of refined palm oil is already entering Brazil. This is complicated for those working with derivatives. It has always been difficult, but this year is worse,” he states.
Thus, Camargo points to storage as a solution. “Those who have storage capacity will be able to make strategic purchases.” He also suggests importing from Peru, Colombia, and Ecuador—three major producers in Latin America—as well as Argentina. “Unlike Brazil, Argentinians use animal fat as food, which generates a lot of tallow fatty acid.”
Another important raw material is 12HSA, derived from castor oil, with India as its largest producer. In Brazil, the crop has lost ground, mainly due to corn, which has been used for ethanol production.
There are multinational efforts to introduce a hybrid seed that would allow mechanical harvesting instead of manual. However, Camargo explains, the competition is very tough.
Once again, imports appear as an alternative, particularly due to an NCM (Mercosur Common Nomenclature) that enables a zero tax rate. Due to India’s low labor costs, the product can arrive in Brazil at a price similar to type I oil, he emphasizes.
Price was also one of the topics discussed in the panel. After the surge in lithium prices due to electric vehicle batteries, the situation is now stable. Consultant Manoel Honorato, from Honorato Assessoria, believes that importing is still advantageous since prices are not expected to rise significantly. “Another price drop of around 3% is expected by the end of the year. Even though the moment may not be ideal, there are no longer import restrictions, and the price is certainly fluctuating abroad and in Brazil, but trending downward.”
The issue of lithium import restrictions, as well as the correct NCM classifications for determining taxes, was addressed by Giancarlo Passalacqua, Lubricants Manager at the Downstream Executive Directorate of the Brazilian Institute of Petroleum and Gas (IBP).
He outlined a timeline of the entire TIPI table issue and presented the proposals that IBP submitted to the government, highlighting that this is a modification that must be made by the Executive, as it is a Decree.
The IBP manager pointed out that this confusion has caused legal uncertainty for importers. It is important to emphasize that the approval of lithium grease imports resulted from IBP’s strong efforts. Since the country only had one local supplier, prices were very high, which affected the competitiveness of Brazilian greases for export to South America.
For panel moderator Pedro Nelson Belmiro, from Lubes em Foco magazine, resolving the TIPI table issue is essential so that all importers can bring products under the same code and pay the same taxes. “However, this proposal does not have a set deadline. In the meantime, imports depend on this Decree for equalization.”
The panel concluded with a discussion on Technical Standards. Specialist Maurício Prado Alves spoke about ABNT Standard 17505, highlighting its impact mainly on older installations and noting that it is being debated at ANP.
Installations with a storage capacity exceeding 60,000 liters assess not only the volume of individual tanks but the total site installation. In other words, the sum of all tanks in the facility. Thus, if an installation has a total volume exceeding 60,000 liters, the distance between the external wall of the containment area and ground level must not be less than three meters from any property boundary.
For installations with a storage capacity of up to 60,000 liters, this distance can be reduced to 1.5 meters. “This was discussed to meet market demand, regulatory requirements, and fire department standards. The topic has been debated in working groups and is currently in public consultation.”
The discussion is a proposed amendment specifically addressing Class 3, for installations with a storage capacity of up to 120,000 liters. “Practically speaking, if you have an installation adjacent to another property and its capacity is up to 120,000 liters, it can remain in place, provided at least two sides have a 1.5-meter separation. Even if this spacing is internal, there is no issue.”
The public consultation is ongoing, and considerations are expected to be assessed by the end of November, according to the specialist. The publication of the final amendments is anticipated within 60 days.
The Future
Thinking about greases also means assessing what lies ahead: more sustainable technologies, special applications, raw material compatibility, and many other factors.
This future vision depends on knowledge. Promoting research groups and providing a framework for technical discussions on lubricating greases is part of the mission of the National Lubricating Grease Institute (N.L.G.I.).
ICONIC’s R&D Manager and N.L.G.I. member, Daiane Spadari, discussed the Institute’s work, introduced the benefits of membership, and explained the certifications the Institute offers, such as GC-LB and HPM.
In the search for products with higher added value, calcium sulfonate greases are gaining market share compared to lithium greases. In Brazil, their market share remains small, but between 2022 and 2023, they registered a significant increase in production volume, notes ICONIC researcher Paulo Felipe Berto.
Calcium sulfonates are divided into simple ones, used with thickeners, and complex ones, which can receive additives to improve certain properties. Borates can be used to enhance thermal and wear resistance; phosphates improve wear resistance; and 12HSA acid enhances water washout resistance, exudation, and oil separation.
Calcium sulfonate greases have a high dropping point, significantly better water resistance compared to lithium grease, excellent mechanical stability, strong intermolecular interaction, and effective corrosion and wear protection.
Their disadvantages include pumpability issues. Due to the higher thickener content, performance at low temperatures may be affected, and there may be some incompatibility when replacing systems that have used lithium grease for a long time.
Berto states that producing calcium sulfonate greases is a highly technical process that requires precision and deep expertise.
Knowledge is also crucial when it comes to compatibility. Often, tables present different information depending on the source, emphasizes Zica Consultoria consultant Bernardo Zica Viana.
He notes that all grease contains oil, so it’s important to consider the oil type, as well as the compatibility of the grease’s additives and thickeners. The biggest issue with incompatibility is that the grease softens and leaks, which can be a serious problem. “In extreme cases, if the grease leaks entirely, it can lead to catastrophic failure.”
The complexity of oil compatibility increases when using synthetic or high-end greases. Some esters cause greater seal swelling than hydrocarbons, so caution is needed when using PAOs and esters in applications where they may contact elastomers designed for mineral oils.
Solubility is another important factor. When changing the base oil, solubility may vary. “When mixing very different materials, the additives in the lubricant inside the grease can also result in altered characteristics.”
The most referenced ABNT standard for testing is D6185, which states that greases can be considered compatible if the dropping point of the mixture is lower than the average of the individual greases.
Mechanical stability must remain within the consistency range. “If two greases are grade 2, mixing them should not result in a grade 1 grease. The storage test must also be considered, as greases tend to settle over time.”
The consultant advises conducting tests in stages. “If the dropping point test already indicates incompatibility, there’s no need to proceed with further steps.” He also emphasizes the importance of evaluating graphs and understanding the acceptable limits of NLGI and companies like CRC. “Greases may be compatible in one test and incompatible in another. Additional tests should be performed depending on the severity of the application. The recommendation is to be conservative—unless the test results are highly favorable, assume incompatibility.”
When discussing the future, sustainability is the key concept. To meet this market demand, Lubrizol developed an emulsion technology that could allow the use of an eco-friendly grease-like lubricant instead of standard mineral-based grease.
However, the process was not simple and involved multiple development phases. Senior Manager of Greases and Metalworking, Robert Dura, presented the stages leading up to a solution that met the proposed goals.
According to Dura, the initial concept was to help reduce the cost of manufacturing goods and introduce a more environmentally friendly product. The technology consisted of a continuous oil emulsion typically composed of water, vegetable or mineral oil, and performance additives.
The original objective was to meet the performance targets of a cotton harvester grease, which currently uses a conventional lithium grease NLGI 00 to 0 with additives.
The initial goals were achieved; however, field performance did not meet expectations. Additional tests demonstrated that shear stability and maintaining an intact emulsion were challenges for the emulsified grease product.
Water was easily lost if storage exceeded room temperature and the container was not properly sealed. Changes in composition negatively impacted its appearance and performance.
New approaches were undertaken, and a revised scope was defined. Initially, the product was aimed at a grease with a high water content. “However, recent studies led us to take a more conservative approach with a lower water content.”
The target hydrated grease product was intended to be NLGI 2, with the possibility of being NLGI 2, 1, or even 0, depending on the amount of water or organic component contained in it.
Extended bench tests and unconventional stress tests confirmed that the product is a more stable candidate for analysis compared to the HIPE or GEN1 products.
The results of the bench tests were very promising for a groundbreaking product of this kind, using a substance—water—that is typically harmful in most lubricant grease applications and tests.
Free from MOSH and MOAH, PAGs (polyalkylene glycols) stand out due to their structural versatility and non-hazardous nature, which is a key differentiator, especially in the European market, where mineral oil percentages can be taxed.
PAGs are Group V synthetic lubricants, polymers of ethylene oxide (EO) and/or propylene oxide (PO). Their properties, explains Muriel Ecormier, Technical Sales Manager at GEO Specialty Chemicals, can be adjusted by varying the initial alcohol, EO/PO ratio, final coating, and polymerization degree.
PAGs are used in various industrial applications, including greases, gear lubricants, hydraulic fluids, fire-resistant hydraulic fluids (HFC type), compressor lubricants, and refrigeration lubricants. Their primary characteristics are lubricity, stability, and compatibility.
Beyond selecting the right lubricant grease, understanding the application conditions is crucial. This warning comes from Emerson Pedrozo, head of SKF’s lubricant analysis laboratory, lubrication engineering, and reliability engineering.
Presenting a case study on a large-size bearing, Pedrozo highlighted that SKF data shows 50% of bearing failures are linked to lubrication: 36% due to inadequate lubrication and 14% due to contamination.
Liquid contamination is a critical concern in bearings, both when stationary and at extremely low rotation speeds, as these conditions promote accelerated corrosion.
Pedrozo explains that corrosion can develop into a severe failure, and the higher the water concentration, the shorter the bearing’s lifespan. Therefore, selecting the right grease requires knowing the bearing type, load, rotation, and temperature. “These parameters cover most standard applications. If the application is uncommon, greater caution is required.”
The case study involved a 249/800 bearing (800 mm bore diameter), rotating at 1.3 mm, with a temperature of 55ºC, lithium/calcium grease with a mineral oil base of 400 cSt, automatic lubrication at 5g/day, a speed factor of 2418 mm/min, and high liquid contamination.
The specialist cautions that the grease for this application must provide corrosion protection, excellent water resistance, mechanical stability, excellent EP properties, pumpability, good base oil separation, a viscosity limit of 460 cSt to prevent kinematic exhaustion, and must be free of solids.
The proposed grease was complex calcium sulfonate, replacing lithium/calcium grease, ensuring good mechanical stability and corrosion protection. Its superior EP, intrinsic to the thickener type, provides additional load protection, and Emcor testing indicated 0/0 across all concentrations.
After the first year of implementation, the new bearings showed no corrosion marks, the used bearings had no further progression of humidity-induced corrosion, grease adhesion improved, and there was no need to modify the load zone.
The new era of sustainable lubrication involves searching for differentiated raw materials and processes while fostering client partnerships. This is how CONDAT Brazil has been driving the development of the Lubriscore system.
The company designs products based on market sustainability requirements and regulations. “Our challenge is to create an ecologically viable product for every application. Achieving this is complex, as numerous specifications must be met.”
Guaratto explains that even within sustainability standards, efficient products can be developed by sourcing renewable raw materials with superior biodegradability and reduced pollutant emissions.
Among these raw materials are vegetable oils such as soybean, palm, castor, and sunflower, as well as synthetic esters with high biodegradability. “These products offer a broad range of available viscosities, additive solubility for easier formulation, and, as synthetic products, they provide extensive flexibility to meet specific needs.”
