We have tried calcium sulphonate for slip seal (seewww.projectsalescorp.com for a picture of the slip seals) applications in sponge iron plants. Traditionally they were lubricated with aluminium complex greases with 460 cst.

Key Characteristics of Desired Lubrication
1. High quality base oil with high viscosity. 2. Good Pumpability through centralized lubrication systems.
3. High drop point to address high temperature requirements.
4. High load carrying capacity to resist extreme pressures, minimize friction and minimize wear.
5. Good film forming capacity to provide a sealing effect in the seal segments.
6. Environmental friendly, should not emit toxic fumes into the atmosphere.

We tried a calcium sulphonate grease with VG460 and found that we could cut down on the consumption by over 25% in one plant. The product, commercialised and sold by Molykote as G-0103 allows reliable operation of slip seals at high temperatures.

Indian Oil's Servogrease SI 0 (SI-Sponge iron, 0- NLGI-0 grade) will have all desired characteristics which you have mentioned and it performs better than Li-complex soap or Al-complex soap based greases.
This product is claimed to have >400 KG weld point, high drop point (>200 deg C) and good film forming capacity (EHD data supports) and good pumpability/sprayability characteristics.

Dear Satish

You made a good choice by selecting calcium sulphonate grease in this application. People worldwide now shifted to sulphonate base grease specialy from sponge iron steel plants.

Apart from Molykote there are couple of reputed brands in india manufacture this product in India. They are much faster in service than imported brands. If you are interested can mail me at romesh_sawant@yahoo.com or contact me on 09370149793.

Romesh Sawant