Method of producing plastic and liquid lubricants

A method for producing plastic and liquid lubricants characterized by conducting a dispersion of the starting components, such as thickeners or reagents for the formation thereof, additives and fillers and base liquids into a vortical bed of ferromagnetic particles formed under the action of a rotating magnetic field. The proposed method makes it possible to reduce the duration of chemical reactions between the dispersed components of lubricants by thousands of times as compared to the known batch processes and by dozens of times as compared to the known continuous processes. The method provides continuous conduction of technological processes with high productivity, reduces by 10-20% specific consumption of expensive components, by 2-3 times the consumption of energy, and allows the process to be conducted at lower temperatures and pressures.

The present invention relates to methods of producing plastic and liquid 
lubricants widely used in transport, machine engineering, instrument 
making, and metal working for reducing the wear and enhancing service life 
of engines, mechanisms, and devices, for reducing friction in various 
units, for corrosion-protective coatings, and for intensifying the 
processes of metal working. 
The main types of lubricants used for the above-cited purposes are plastic 
(consistent) and liquid lubricants obtained by dispersing various types of 
thickeners, fillers, and additives in base liquids which are mineral 
(petroleum) or synthetic oils. 
Plastic lubricants fall into the following main types depending on the 
thickener used: 
SOAP LUBRICANTS, USED, MAINLY, AS ANTIFRICTION ONES, IN WHICH THICKENERS 
ARE SOAPS, VIZ. SALTS OF HIGHER FATTY ACIDS OBTAINED BY NEUTRALIZATION OF 
FATTY STOCK MATERIALS WITH HYDROXIDES OF METALS; MOST WIDELY USED ARE 
LUBRICANTS BASED ON CALCIUM, LITHIUM, BARIUM, OR ALUMINUM SOAPS, AS WELL 
AS ON MIXED SOAPS, FOR EXAMPLE, CALCIUM-LEAD, OR BARIUM-ALUMINUM ONES; 
HYDROCARBON LUBRICANTS, USED MAINLY, AS ANTICORROSION ONES IN WHICH 
THICKENERS ARE HIGH-MOLECULAR HYDROCARBONS OF NORMAL STRUCTURE 
(AFFINS), NAPHTHENIC, OR NAPHTHENO-AROMATIC HYDROCARBONS WITH LONG SIDE 
CHAINS (CERESINS), THEIR MIXTURES, AND SIDE PRODUCTS OF DEAFFINIZATION 
(PETROLATUMS); 
INORGANIC LUBRICANTS, OFTEN USED INSTEAD OF SOAP AND HYDROCARBONS, ARE 
OBTAINED BY THICKENING OILS WITH THE HELP OF INORGANIC COMPOUNDS: CLAYS 
(FOR EXAMPLE, BENTONITE), SILICA GEL, ASBESTOS, MICA, GRAPHITE, CARBON 
BLACK, SULPHIDES, SULPHITES, OXIDES AND HYDROXIDES OF VARIOUS METALS; AND 
BY DISPERSION OF PURE METALS; MOST WIDELY USED ARE SILICA GEL, BENTONITE, 
GRAPHITE, AND DISULPHIDE-MOLYBDENUM LUBRICANTS; 
ORGANIC LUBRICANTS, HIGH TEMPERATURE ONES, IN WHICH FOR THICKENING OILS USE 
IS MADE OF ORGANIC COMPOUNDS, VIZ. PIGMENTS (PIGMENT LUBRICANTS), UREA 
DERIVATIVES (UREATE LUBRICANTS); AS WELL AS LUBRICANTS FOR OPERATING IN 
AGRESSIVE MEDIA, IN WHICH THICKENERS ARE SOLID HIGH-MOLECULAR POLYMERS, 
VIZ. POLYETHYLENE, POLYVINYL CHLORIDE, POLYPROPYLENE, AND 
FLUORINE-CONTAINING POLYMERS; AS BASE LIQUIDS IN SUCH LUBRICANTS USE IS 
MADE OF POLYMERIC LIQUIDS, VIZ. POLYSILOXANE, POLYFLUOROCARBON, ETC. 
(POLYMER LUBRICANTS). 
Various additives (stabilizing, antiscuff, antiwear, anticorrosion, 
antioxidizing, antiradiation) and solid fillers (antifriction, sealing, 
loading) are introduced into many plastic lubricants to improve their 
properties. 
Liquid lubricants are of the following types: 
lubricating oils used in internal-combustion engines, steam engines, 
turbines, compressors, etc.; they are obtained by dispersion of various 
additives in base liquids (petroleum oils and their mixtures); 
lubricating compositions used in metal working either directly, or in the 
form of concentrates for preparing lubricating and cooling emulsions 
(liquids); these compositions are obtained either by simple dispersion of 
the components (additives, emulsifiers, etc.) in mineral oils, or by 
dispersion of the components entering into reaction (for example, 
saponification), the reaction products being used as additives, 
emulsifiers, etc. 
At present, two main processes of producing lubricants are known, namely, 
batch and continuous ones. Their combinations as various semi-continuous 
processes also find application. 
Plastic lubricants are produced mainly by batch processes (see, for example 
a book by Velikovsky D. S., Poddubny V. N., Vainshtok V. V., and Gotovkin 
B. D. "Konsistentnye Smazki" (Consistent Lubricants) in Russian, "Khimiya" 
Publishers, M., 1966). The initial components batched in weight or in 
volume are put into a boiling reactor with a capacity of up to 10 m.sup.3 
fitted with a device for mechanical stirring. Saponification reaction (for 
soap lubricants) is conducted up to 100.degree. C. for several hours 
(sometimes for dozens of hours), then water is evaporated, the soap formed 
or other thickeners in oils are dispersed and thermally treated. The 
thermal treatment resides in heating up to 100.degree.-250.degree. C. to 
obtain melts of thickeners in oils and cooling at a given rate down to 
30.degree.-70.degree. C. to establish required crystallization conditions. 
Cooling of the product is performed either in the boiling reactor or in a 
special cooler in which simultaneous deaeration of lubricants can be 
accomplished. In the process of preparing plastic lubricants various 
additives and solid fillers can be added for the purposes mentioned above. 
After discharging from the reactor or cooler, some types of lubricants are 
additionally subjected to mechanical treatment to improve their 
rheological (volume-mechanical) properties: grinding on rolling machines, 
treating in slotted, disk, or other homogenizers, colloid mills, etc. Then 
the finished product is prepacked and wrapped for delivering to consumers. 
The total duration of the technological cycle of producing plastic 
lubricants by batch process is from several hours to several days. All the 
stages, except for deaeration, are usually conducted at atmospheric 
pressure in unsealed reactors. Sometimes, for intensifying the processes, 
the saponification reaction is run in autoclaves under a pressure of up to 
6 kgf/cm.sup.2 and at a temperature of up to 150.degree. C. Deaeration is 
performed in vacuum apparatus. 
The known method of producing plastic lubricants has some essential 
disadvantages: 
the processes are multi-step and time-consuming, which limits the equipment 
capacity; the processes are power-consuming with nonuniform energy 
consumption at separate steps; large size and weight of technological 
equipment; large working areas occupied by technological units involving, 
usually, several large-sized reactors; poor quality of dispersion, calling 
for increased specific consumption of expensive components; thickeners, 
fillers, and additives; high labor consumption; complexity and 
inefficiency of process automation; arduous conditions for the attending 
personnel (high temperatures, carcinogenic vapors of oils and of other 
components, high noise level, possible ejection of hot reaction mass from 
boiling reactors, etc.). 
Many of the above-cited disadvantages are eliminated when lubricants are 
obtained by continuous processes. Known in the art is one of most advanced 
continuous technological processes developed by "Texaco", U.S.A. (see, for 
example, the article by Rosenzweig M. D. "Continuous production of 
consistent lubricants on compact installations", Chemical Engineering, 
1971, v. 78, No. 10, p. 67). The known process resides in that the initial 
components of a thickener and a portion of base liquid are fed into a 
reactor at a given ratio. In the reactor 170.degree. C. and 7 kgf/cm.sup.2 
are maintained. As a reactor, a coil is used heated with steam or hot oil. 
Continuous circulation of the components through the coil favors their 
adequate intermixing. The treatment of the components in such a reactor 
takes 5 minutes. The product discharged from the recirculation cycle goes 
to a heat exchanger and then, through a valve regulating the pressure in 
the reactor and heat exchanger, to an evaporation chamber where 
rarefaction of about 250 mm Hg is sustained. Water vapors are removed from 
the evaporation chamber through the vacuum line and condensed. The 
condensate is discharged into the system of waste water treatment. 
Dehydrated mass is treated in the evaporation chamber for 30 minutes by 
recirculation through a dispersion valve under a pressure of about 4 
kgf/cm.sup.2. The mass withdrawn from the evaporation chamber is mixed at 
a definite temperature with the remaining amount of oil and with 
additives. To obtain a homogeneous product, the latter is finally 
dispersed in a third recirculation cycle with a dispersion valve at 
105.degree.-107.degree. C. under 7 kgf/cm.sup.2. The final product is 
delivered into reservoirs for storage and then for packing and 
transportation. This method of producing plastic lubricants also has 
serious disadvantages: 
multiple and time-consuming recirculation of the product with exposure to 
intensive mechanical effects is not suitable for all types of plastic 
lubricants: some calcium, lithium, sodium and other lubricants are 
weakened under such conditions, the ultimate strength is considerably 
decreased without further thixotropic reduction; the use of a coil as a 
reactor requires recirculation for obtaining a turbulent flow in which 
mixing and dispersion of the components is ensured, but recirculation 
cannot provide complete treatment since part of the product discharged 
from the recirculation cycle is always mixed with a certain amount of 
undersaponified (for soap lubricants) and underdispersed components; 
considerable time of treating the components in the reactor (up to 5 
minutes) limits the productivity of the process; insufficient dispersion 
of thickeners, fillers, and additives in a base liquid makes it impossible 
to improve lubricant properties and decrease consumption of expensive 
components as compared to batch process; saponification reactions are 
performed at elevated temperatures (up to 170.degree. C.) and pressures 
(up to 7 kgf/cm.sup.2); the automatic control of the saponification 
reaction and, consequently, of the product quality presents difficulty 
because of elevated temperatures and pressures, and non-steady state 
processes in the reactor. 
Known in the art are semi-continuous processes, the most interesting being 
that of producing plastic lubricants from dry soaps (see, for example, 
theses of report by Afanas'ev I. D. Vorob'eva V. A., et al. "Method 
nepreryvnogo proizvodstva smazok na sukhom myle" (Method of continuous 
producing lubricants on dry soaps), Proceedings of scientific and 
technical conference, TsNIITENeftekhim, M., 1970, pp. 35-45). The method 
consists in that dry soap, obtained by following special technology, and a 
base liquid are charged together with additives into an apparatus fitted 
with a mechanical stirrer where dispersion is performed for several hours. 
This part of the process is a batch one. Then, the dispersion obtained is 
treated by a continuous method: with the help of a metering pump said 
dispersion is pumped through a heated unit where it melts, through a 
cooler where the lubricant crystallizes, and after that through a filter 
and a homogenizing head ensuring the required rheological properties of 
the product. 
The following disadvantages are inherent in the known semi-continuous 
process. 
the necessity of preliminarily preparing dry soap by a batch method with 
the help of large-sized reactors and centrifugal sprayers by complex 
technology with a good deal of manual labor; difficulties in introducing 
automatic control of the process and of quality of the soap obtained; a 
great duration of the process of preparing the soap-oil dispersion in the 
apparatus with the mechanical stirrer; insufficient dispersion, which, as 
in the previous cases, makes it impossible to decrease consumption of 
expensive components and improve the quality of the lubricant obtained. 
Liquid lubricants are also prepared both by periodic and continuous 
processes. From the technological standpoint, the preparation of liquid 
lubricating compositions for metal working is the most complicated process 
(see, for example, a book by Kurchik N. N., Vainshtok V. V., and Shekhter, 
Yu. N. "Smazochnye materialy dlya obrabotki metallov rezaniem" (Lubricants 
for treating metals by cutting) in Russian, "Khimiya" Publishers, M., 
1972). Lubricants for these purposes are mainly prepared by batch process. 
But, due to much higher volume of production, reservoirs of a capacity 
from 100 to 1,000 m.sup.3 are usually used as boiling apparatus. Mixing 
and dispersion of the components in such reservoirs are performed either 
by the recirculation method or by bubbling compressed air through the 
whole bed of the product. Working temperatures do not exceed 100.degree. 
C.; pressure is atmospheric; cycle duration is from several hours to 
several days. 
All the above-cited disadvantages of batch processes are inherent in this 
method. 
It is an object of the invention to provide a method of producing plastic 
and liquid lubricants, which will make the process of producing these 
materials cheaper. 
Another object of the invention is to provide a method of producing plastic 
and liquid lubricants, which will accelerate the process of producing 
these materials. 
A further object of the invention is to provide a method of producing 
plastic and liquid lubricants which will reduce the consumption of 
expensive components. 
The objects of the invention are accomplished by producing plastic and 
liquid lubricants by dispersing starting components: a thickener or 
reagents for the formation thereof, fillers, additives and base liquids, 
etc. According to the present invention, the dispersion is accomplished in 
a vortical bed of ferromagnetic particles formed under the action of a 
rotating magnetic field. Subsequent steps of melting the dispersion, 
moisture removal, cooling, deaeration and homogenization can also be 
included. 
The proposed method of producing plastic and liquid lubricants makes it 
possible to reduce by several thousands of times, as compared to the known 
batch processes, and by several dozens of times, as compared to the known 
continuous processes, the duration of chemical reactions between the 
components of lubricants and duration of dispersing these components. The 
method ensures continuous run of technological processes with high 
productivity decreases by 10-20% specific consumption of expensive 
components and by 2-3 times consumption of energy; lowers operating 
temperatures and pressures. 
For a better understanding of the further objects and advantages of the 
present invention the following detailed description of the method of 
producing plastic and liquid lubricants and the examples of realizing the 
method are given hereinbelow by way of illustration. 
The proposed method is accomplished in a reactor representing a length of a 
non-magnetic pipeline around which a system of windings is arranged 
creating a rotating magnetic field. Non-equiaxial ferromagnetic particles 
are placed in the reactor; said particles under the effect of the rotating 
magnetic field are set in a compound motion: each particle travels in the 
direction of field rotation and, simultaneously rotates precessionally 
about its smallest axis at a speed of 10,000 r.p.m. Ferromagnetic 
particles, operating as elementary mechanical stirrers, create a vortical 
layer filling the whole operating volume of the reactor, and, at the same 
time, emit acoustic and ultrasonic oscillations of a wide frequency 
spectrum. In addition, under the action of an alternating magnetic field, 
ferromagnetic particles emit magnetostrictive oscillations. Eddy currents, 
arising in the particles as in electric conductors, give rise to rapidly 
alternating magnetic and electric fields. Due to the combined action of 
all the above-cited factors, an intensive stirring and dispersion of the 
components takes place in the working zone of the reactor, at the same 
time the components are fed into the reactor continuously and at a given 
ratio. The duration of treating the components in the reactor, even when 
the saponification reaction (for soap lubricants) takes place, does not 
exceed several seconds at temperatures no more than 70.degree.-90.degree. 
C. under atmospheric pressure. The product obtained in the reactor is 
discharged continuously and delivered to the subsequent stages of 
treatment, if necessary. Thus, for example, when preparing soap- sodium, 
lithium lubricants, the dispersion obtained is heated at a temperature of 
about 160.degree.-250.degree. C. for producing a melt of thickeners in 
oils with a regular structure; then water is evaporated, deaeration 
performed, and the product is cooled at a rate ensuring prescribed 
crystalline structure of the lubricant. After that the lubricants are 
subjected to homogenation to improve their rheological properties. The 
ferromagnetic particles are retained by the magnetic field in the working 
zone of the reactor and do not contaminate the product. 
The best effect can be obtained when using non-equiaxial ferromagnetic 
particles with the ratio between their large and small size within the 
range from 6 to 20. Various ferromagnetic metals and alloys both 
magnetically soft and hard, such as carbonaceous steel, nickel, 
cobalt-nickel alloys, and the like, can be used for preparing particles. 
When it is necessary to exclude interaction of aggressive components of the 
product being treated with the material of the ferromagnetic particles and 
contamination of the flow with corrosion products and with the materials 
of the particles, the surface of said particles can be coated with a layer 
of a polymer insoluble in oils or of other material stable to acids, 
alkalies, and other aggressive components entering into the composition of 
the lubricants being produced. As coatings use can be made of 
polyethylene, polyamide, polyvinyl chloride, fluorinated plastic, and 
other materials, depending on the required stability of the coating and on 
the working temperatures. Thus, polyvinyl chloride coatings can be used at 
temperatures no more than 60.degree.-70.degree. C. At 
70.degree.-90.degree. C. satisfactory results are obtained with 
polyethylene or polyamide; at higher temperatures fluorinated plastic is 
suitable. Fluorinated plastic coatings are very stable to aggressive 
components present in the product flow. 
To produce a magnetic rotating field, inductors of simplest designs may be 
used supplied from three-phase alternating current mains of industrial 
frequency (50 Hz). This allows maximum speed of rotation of the magnetic 
field to be obtained equal to 3,000 r.p.m. (for the U.S.A. it is possible 
to use frequency of 60 Hz and speed of rotation 3,600 r.p.m.). The active 
power consumed does not exceed 4 kW per liter of the working zone of the 
reactor; a capacity up to 1,000 kg/hr for plastic lubricants and up to 
2,000 kg/hr for liquid lubricants can be obtained when one-liter reactor 
is used. In practice, the working zone of the reactors with the rotating 
magnetic field may be from half a liter to dozens of liters, depending on 
the required capacity. 
High degree of dispersing the components makes it possible to reduce the 
amount of thickeners, fillers, and additives by 10-20% as compared to the 
known methods, the properties of the lubricants obtained being the same or 
even better. 
The characteristics of the initial products which can be used for producing 
plastic and liquid lubricants by the method proposed in the present 
invention are given hereinbelow. 
Fatty stock material is used in the production of soap lubricants for 
preparing soaps: stearic acid, 12-oxystearic acid, hydrogenated castor 
oil, cotton seed oil, talloil, gossypol oil, acidol, vegetable oil, animal 
fats, hydrogenated fats of fish and sea animals, technical and goudroun 
fat, synthetic fatty acids, and the like; and hydroxides of metals: 
lithium, sodium, potassium, magnesium, calcium, zinc, strontium, barium, 
aluminum, lead, silver, and the like. 
Soaps are prepared by neutralization of higher fatty acids with metal 
hydroxides (alkalies): 
##STR1## 
for example, 
______________________________________ 
C.sub.17 H.sub.35 COOH + LiOH = 
C.sub.17 H.sub.35 COOL; + H.sub.2 O 
stearic acid lithium soap of 
stearic acid 
______________________________________ 
or by saponification of higher fatty acid glycerides with alkalies: 
##STR2## 
where R is an aliphatic radical [(CH.sub.3 -(CH.sub.2).sub.n ] 
Me is a cation of metal. 
Paraffin, ceresin, and their mixtures are used as thickeners for 
hydrocarbon lubricants. 
For inorganic lubricants the following thickeners are used: bentonite clay, 
silica gel, asbestos, mica, graphite, carbon black, oxides, hydroxides, 
carbonates, sulphites, sulphides, disulphides, and nitrides of various 
metals, fiberglass and the like, as well as fine powders of pure metals: 
aluminum, copper, iron, zinc, tin, lead, and of various alloys which are 
dispersed in oils containing surfactants. 
For organic lubricants the following thickeners are applied: pigments 
(copper indanthrene, copper phthalocyanine, oxazole, isoviolanthrone, 
etc.; 
arylureates (urea derivatives); 
alkyl and acyl derivatives of urea, tetraureates; 
aminophenols, alcoholates of metals, cellulose, calcium acetate, chelates 
of cobalt and zinc dithiooxamides, triazine derivatives, copolymers of 
vinylacetate and ethylene, titanium and zirconium tetraphenylphosphinates. 
However, only lubricants thickened with the following thickeners have 
found practical application: phthalocyanine, indanthrene, and other 
pigments, arylureates, and some polymers: polyethylene, polypropylene, 
polytetrafluoroethylene, polytrifluorochloroethylene, polyvinyl chloride, 
and polyamide. 
The following additives are introduced into lubricants: 
antioxidizing: diphenylamine; tetrabenzylamide of 
ethylenediaminetetraacetic acid; 2,4-diaminodiphenyl ester; 
1-alkylbenzyl-3-phenylureate; acenapht-1,2-.alpha.-acenaphthylene; 
di-tert-butyl-n-cresol; lead and zinc diamyldithiocarbamates; 
phenothiazine, dilaurylselenide; trisodiumphosphate; 
metal deactivators (inhibiting catalytic action of metals on oxidizing 
processes in lubricants): 
(1) passivators forming films on metal surfaces: 
.beta.-dicyclohexylaminoethylsulphide, triarylalkylphosphate, 
trialkylphosphate, and the like; 
(2) deactivators entering into the reaction with ions of metals with the 
formation of catalytically inactive compounds: 
disalicylindeneethylenediamine (trade name Nonoxol CD) imides of oxalic 
acid, soaps of some metals (chromium, tin, or nickel oleates). 
Concentration of deactivators does not exceed 0.001-0.5%. In lithium 
lubricants free lithium hydroxide acts as a deactivator; anticorrosion 
additives used in anticorrosion and antifriction lubricants; they must be 
present in inorganic lubricants: lead, magnesium, or zinc naphthenate, a 
mixture of barium naphthenates and sulphonates, manganese oleate, amides 
of benzenepolycarboxylic acids; alkylene-bis(alkylsuccinimide); products 
of the reaction of organic amines with polymers of unsaturated acids, 
chromates and bichromates of alkaline and alkaline earth metals and of 
zinc, sodium nitrite, 1,2,4-triazol in a mixture with 
3-amine-1,2,4-triazol, butylstearate, sorbitol monooleate, salts of 
phosphoric, nitric, and naphthenic acids, derivatives of phenols, wool 
fat, and products of petrolatum oxidation; 
antiscuff and antiwear additives used, mainly in lubricants for 
heavy-loaded mechanisms. More often use is made of compounds of sulphur, 
chlorine, phosphorus, salts of molybdic or tungstic acids, cadmium salts 
of acetic and oxalic acids, lead naphthenates, carbonates of some metals, 
and the like. Concentration of these additives in lubricants varies from 
0.1 to 10%. Among the additives are: sulphurated spermacetic oil; 
bis-butylxantogenate, resorsinol sulphides, .gamma.-isomers of 
hexachlorobenzene, telomers of trifluorochloroethylene, 
tricresylphosphate, thiobisdichlorophenol, 3,2-chloroethylphosphate, lead 
naphthenate, antimony diamyldithiocarbamate; 
a mixture of calcium sulphonate and bismuth sulphide; 
tungsten carbonyl; 
sulphonated oxymolybdenum dithiocarbamates; 
dicyclohexylamine; 
esters of boric acid. 
Solid fillers are materials insoluble in oils and incapable of forming a 
structure; fillers improve properties of plastic lubricants: 
antifriction--molybdenum disulphide (MoS.sub.2), graphite, polymers 
(polyethylene, polypropylene, polytetrafluoroethylene), etc.; 
sealing (for threaded and gland joints)--powders of soft metals (lead, 
zinc, copper, and the like); 
loading (for increasing density of the lubricants operating, for example, 
under water in immersible pumps)--lead filings, etc. 
Dispersion medium or base liquid constitutes no less than 50-60% of 
lubricants. Therefore, in spite of the fact that the most important 
characteristics of lubricants are determined by the type of the thickener, 
such parameters as viscosity, solidification point, and colloidal 
stability depend on the oil base used. Petroleum and synthetic oils are 
usually applied. The great majority of lubricants (99.9%) are prepared 
with petroleum oils: 
______________________________________ 
velocite viscosity 
4-5 cSt 
instrument oil 6-8 " 
transformer oil 8-9 " 
spindle oil 12-14 " 
industrial oil 10-58 " 
axle oil 22-25 " 
perfumery oil 16-24 " 
cylinder oil 9-13, 32-44 " 
base oil 9-13 " 
machine oil 42-58 " 
aviation oil 80-200 " 
transmission il 350-450 " 
______________________________________ 
(the names of the oils are for the USSR only, viscosity values are given 
for +50.degree. C.) 
Synthetic oils are used for producing lubricants operating under especially 
arduous conditions. Such lubricants are produced in small amounts (dozens 
of tons per year); the lubricants are produced either with pure synthetic 
oils, or with mixtures of synthetic and petroleum oils. Most widely used 
synthetic oils are polysiloxanes, esters, synthetic hydrocarbons, 
polyphenyl esters, polyalkyleneglycols, and halogen derivatives of 
hydrocarbons. 
Polysiloxanes (polymer compounds of silicon and oxygen) are the main type 
of synthetic oils for high-temperature lubricants operable up to 
250.degree.-300.degree. C. Use is made of polydimethyl and 
polydiethylsiloxanes, polyphenylmethylsiloxanes, and polyfluorosiloxanes. 
Also applied are: 
esters of dibasic acids, 
polyphenyl esters, polyalkyleneglycols, polymers of fluorine-containing 
hydrocarbons, perfluorotrialkylamines, perfluroalkyl polyesters, etc. 
Emulsifiers are introduced into compositions of lubricants used as 
lubricating and cooling liquids in metal working; among these are ethyl 
alcohol, water, and polyglycols. 
Application of the proposed method of producing plastic and liquid 
lubricants offers the following advantages: 
duration of saponification and dispersion of the components is reduced by 
several thousands of times as compared to batch processes and by dozens of 
times as compared to the known continuous processes; 
duration of action on the product during treatment in the reactor does not 
exceed several seconds; 
continuous performance of the processes with a high capacity; 
technological flow sheet is simplified; size and weight of the equipment 
and, consequently, working floor areas occupied by it are reduced; 
specific power consumption per unit of the produced products is decreased 
by 2-3 times; 
the quality of the dispersion process is increased; a possibility arises of 
reducing by 10 to 20% specific consumption of expensive components; 
thickeners, fillers, and additives; 
working pressures and temperatures are reduced, which makes it possible to 
decrease power consumption and increase safety of the processes; 
complex automation of the technological processes of producing lubriants 
becomes possible, including automatic control and regulation of 
characteristics of the product; 
labor conditions are improved and labor productivity is increased.

EXAMPLE 1 
To obtain plastic soap lithium lubricant, non-equiaxial ferromagnetic 
particles, from magnetically soft carbonaceous steel, with a ratio between 
large and small size equal to 9-11 and with a surface covered by a 
polyethylene layer are placed into a 0.5-lit. reactor fitted with an 
electric inductor having an active power of 1.7 kW and supplied from 
three-phase alternating-current mains at 380/220 V and 50 Hz. The inductor 
is switched on and a magnetic field is established inside the reactor, 
said magnetic field rotating at a speed of 3,000 r.p.m. The components are 
fed into the reactor with the help of a metering device at 76.degree. C., 
the flow rates of the components being as follows: 
______________________________________ 
technical-grade stearin 44.8 kg/hr; 
10% aqueous solution of lithium 
hydroxide 36.2 kg/hr; 
mineral oil with a viscosity of 
7 eSt at +50.degree. C. 392.0 kg/hr; 
5% solution of diphenylamine in the 
same mineral oil 27.0 kg/hr. 
______________________________________ 
The soap-oil dispersion formed at a flow rate of 500 kg/hr, from the 
reactor with the rotating magnetic field, is delivered with the help of a 
metering pump into a thermal unit. The soap-oil dispersion is melted in 
the thermal unit at +220.degree. C. under 15 kgf/cm.sup.2. The product 
leaving the thermal unit goes to an evaporator where a rarefaction of 
150-220 mm Hg is maintained. Due to a sharp pressure drop, the moisture 
from the product is completely removed. The product temperature falls down 
to +150.degree. C. After the evaporator, the product with the help of a 
second measuring device is fed into a scraper cooler where it is cooled 
down to +40.degree. C., and then the product passes through a filter and a 
slotted homogenizer where it is treated under 100-120 kgf/cm.sup.2. After 
that the product is discharged. 
The lubricants obtained (465 kg/hr) have the following characteristics: 
______________________________________ 
ultimate strength at +50.degree. C. 
4gf/cm.sup.2 ; 
viscosity at -50.degree. C. and de- 
6,450 poises 
formation rate 10 s.sup.-1 
free alkali content as calculated 
for NaOH 0.08%; 
drop point 178.degree. C.; 
oxidability (in mg of KOH) 
0.13; 
colloidal stability 24.2%; 
evaporativity 18.8%; 
mechanical impurities none 
water content none 
corrosive action on copper plates 
at +100.degree. C. for 3 hours 
none 
______________________________________ 
EXAMPLE 2 
To obtain plastic soap lithium lubricant, similar to that described in 
Example 1, a 2-lit. reactor fitted with an inductor having an active power 
of 7.5 kW and the same type of ferromagnetic particles are used. The flow 
rates of the components are as follows: 
______________________________________ 
technical-grade stearin 
190 kg/hr 
10% aqueous solution of lithium 
hydroxide 153 kg/hr 
mineral oil with a viscosity 
7 cSt at 50.degree. C. 1,660 kg/hr; 
5% solution of diphenylamine 
in the same mineral oil 
120 kg/hr. 
______________________________________ 
The soap-oil dispersion (2,123 kg/hr) formed in the reactor is treated by 
following the procedure described in Example 1; lubricant is obtained 
(1,980 kg/hr) with characteristics close to those given in Example 1. 
EXAMPLE 3 
To obtain plastic soap calcium lubricant, non-equiaxial ferromagnetic 
nickel particles (with open surface) having a ratio between large and 
small size equal to 10-12 are placed into a 0.5-lit. reactor fitted with 
an inductor having an active power of 1.7 kW. The components are fed into 
the reactor at -80.degree. C. with the following flow rates: 
______________________________________ 
synthetic fatty acids C.sub.20 and higher 
50 kg/hr 
synthetic fatty acids C.sub.5 -C.sub.6 
20 kg/hr 
water 5 kg/hr 
lime-oil suspension with lime content of 
3 wt. % prepared on petroleum oil 
with viscosity 20 cSt at +50.degree. C. 
450 kg/hr. 
______________________________________ 
The final lubricant discharged from the reactor (525 kg/hr) has the 
following parameters: 
______________________________________ 
ultimate strength at +50.degree. C. 
3.4 gf/cm.sup.2 ; 
viscosity at 0.degree. C. and deformation 
rate 10 s.sup.-1 1,640 poises 
free alkali content as calculated 
for NaOH 0.1%; 
water content 2% 
mechanical impurities none 
corrosive action on steel plates 
for 3 hours none 
______________________________________ 
EXAMPLE 4 
To obtain liquid lubricating composition which represents a concentrate for 
preparing coolant-lubricant emulsions used in metal cutting, unprotected 
ferromagnetic particles from a magnetically hard alloy with a ratio 
between large and small size equal to 6-10 are charged into a 0.5-lit. 
reactor fitted with a 1.7 kW inductor. The components are fed into the 
reactor at +25.degree. C. with the following flow rates: 
______________________________________ 
acidol 42.5 kg/hr; 
talloil 42.5 kg/hr; 
polyglycols 8.0 kg/hr; 
caustic soda 5.0 kg/hr; 
water 15.0 kg/hr; 
petroleum oil with viscosity 
21 cSt at +50.degree. C. 
432 kg/hr. 
______________________________________ 
The final product discharged from the reactor (545 kg/hr) has the following 
parameters: 
______________________________________ 
total content of organic acids 
9.4%; 
water and alcohol content 4.1%; 
acid number (in mg of KOH per 
gram of product) 2.9 mg; 
stability: separation of oil 
for 3 hours 0.1%; -corrosive action 
of 5% water emulsion of product on grey iron 
for 3 hours none 
______________________________________ 
EXAMPLE 5 
To obtain liquid lubricating composition which is a concentrate for 
preparing coolant-lubricant emulsions used in metal cutting, ferromagnetic 
particles similar to those described in Example 4 are charged into a 
2-lit. reactor fitted with a 7.5 kW inductor. The components are fed into 
the reactor at +45.degree.-50.degree. C. with the following flow rates: 
______________________________________ 
gossypol resin 175 kg/hr; 
talloil 175 kg/hr; 
caustic soda 25 kg/hr; 
polyglycols 38 kg/hr; 
water 75 kg/hr; 
petroleum oil with viscosity 
21 cSt at +50.degree. C. 
2,012 kg/hr. 
______________________________________ 
The final product discharged from the reactor (2,500 kg/hr) has the 
following parameters: 
______________________________________ 
total content of organic acids 
8.8%; 
water content 5%; 
acid number (in mg of KOH per gram of 
the product) 4.25; 
stability: separation of oil for 
3 hours 0.1%; 
corrosive action of 5% water emul- 
sion of product on gray iron for 
3 hours none 
______________________________________ 
EXAMPLE 6 
To obtain lubricating-cooling liquid which does not require the 
saponification reaction to be performed, non-protected ferromagnetic 
particles with a ratio of large size to small equal to 9-11 are put into a 
2-lit reactor with a 7.5 kW inductor. 
The components are fed into the reactor at +90.degree. C. with the 
following flow rates: 
______________________________________ 
petroleum oil with viscosity 
12 cSt at +50.degree. C. 
1,900 kg/hr; 
petroleum oil with viscosity 
160 cSt at +50.degree. C. 
200 kg/hr; 
phosphatite food concentrate 
20 kg/hr; 
chlorinated paraffin 125 kg/hr; 
50% solution of zinc dialkyl- 
dithiophosphate 250 kg/hr; 
natural technical-grade sulphur 
(ground) 12.5 kg/hr; 
polymethylsiloxane 0.14 kg/hr; 
______________________________________ 
The final product discharged from the reactor (2.5 ton/hr) has the 
following parameters: 
______________________________________ 
kinematic viscosity at +50.degree. C. 
18 cSt; 
chlorine content 2.1%; 
mechanical impurities 0.01%; 
flash point 182.degree. C.; 
basicity (as calculated per NaOH) 
1.04%; 
phosphorus content 0.4% 
water content no 
corrosive action on steel and pig 
iron for 3 hours none 
______________________________________ 
EXAMPLE 7 
To obtain acidic synthetic emulsions by simple dispersion of synthetic 
fatty acids in oil, non-protected ferromagnetic particles from 
magnetically soft steel with a ratio of large size to small equal to 10-20 
are put into a 25-lit. reactor with a 110 kW inductor. 
The components are fed into the reactor at 90.degree. C. at the following 
flow rates: 
synthetic fatty acids C.sub.20 and higher: 3 ton/hr; 
petroleum oil with viscosity 20 cSt at +50.degree. C.: 27 ton/hr. 
The final product discharged (30 ton/hr) has the following parameters: 
______________________________________ 
acid number (in mg of KOH per gram of 
the product) 9.6; 
stability: separation of oil for 3 hours 
0.2%; 
water content 1%; 
mechanical impurities none 
______________________________________