FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
[See section 10, Rule 13]
TITLE OF THE INVENTION A LUBRICANT COMPOSITION AND A PROCESS THEREOF
HINDALCO INDUSTRIES LIMITED
having address at 21st Floor, One Unity Center (Formerly called as One International Center), Tower 4, Prabhadevi, Near Prabhadevi Railway Station, Senapati Bapat Marg, Mumbai 400013,
Maharashtra, India
Preamble to the description:
The following specification particularly describes the invention and the manner in which it is to be performed:

FIELD OF THE INVENTION:
The present invention relates to a lubricant composition and a process to prepare the same. In particular the present invention relates to aluminum forging lubricant composition applied for hot rolling operation (Roughing Mill) of aluminum ingot and process to prepare the same.
BACKGROUND OF THE INVENTION:
Aluminium rolled products are produced in two ways, one with Continuous Casting (CC) route and the other with Direct Chilling (DC) route.
In CC route, the molten aluminium alloy is casted continuously into 6-8 mm thickness directly. Cast sheet from continuous caster is further rolled in cold rolling mills to get desired thickness. Aluminium sheet produced by continuous cast route has limited application due to presence of high smut level on surface of aluminium sheet. Smut level generation is due to high oxidation of aluminium during casting, lubricant applied etc., further metallographic properties limit its application.
In DC route, casting of aluminium alloy ingot is done with desired width, thickness and length. Surface preparation of Rolling Ingot (RI) is done through scalping operation. This is done to remove oxide layer present on the surface of Aluminium RI.
RI is then soaked in Soaking Pits at 500-600°C. Soaking is done to achieve recrystallization temperature of aluminum alloys. Once that is achieved, ingot is rolled in hot rolling mill to desired thickness normally 2-8 mm thickness. Hot rolled coils, thus produced, are further rolled in cold rolling mills to produce aluminum coil or sheet of various thickness ranging from 1 mm to 0.040 mm.
Aluminium sheets produced from this route have applications in various industrial sectors like lithography, lamp stock, bottle closure, automotive fin, bus bars, food foil, pharma-foil, blister foil, etc.

Conventionally, the metalworking fluids (Soluble oils) are used as lubricants for roughing hot rolling mill application. Usually, the lubricant is mixed in water to concentration of 2-10% depending upon the type of metal, amount of heat generation and type of hot rolling mill. However, they are not appropriate as they cause uneven oxide coating on rolled aluminum sheet, bands on aluminum surface in rolling direction, patchy surface and many more defects.
For the increased productivity in all these applications, the surface of the aluminum sheets is critical. One of the most important parameters that contributes substantially towards a better surface finish of said aluminum sheets at hot mill, is the lubricant used for rolling said sheets. Usually, the aluminum sheet surface which is generated in hot rolling application continues in cold rolling mill as well. Hence, it is important that the aluminum sheet produced during hot rolling should have a very good surface finish.
Use of a specialized hot rolling lubricant for roughing tandem mill for aluminum rolling is important to improve the overall quality of the finished product along with increasing the overall productivity. The better and specialized lubricant composition further provides cooling to the working rolls and cools the aluminum sheets along with cleaning the surface from aluminum fines and aluminum oxide fines generated during trimming. It further provides corrosion protection to the final product. The conventionally used lubricants fails to provide the same and hence an improved lubricant composition that provides better product and which can be utilized in hot rolling operation (Roughing Mill) of aluminum ingot is required.
CN102746924B relates to aluminium hot-rolling oil, comprising 51-70 wt% of mineral oil, 1-15 wt% of non-ionic surfactant, 1-8 wt% of phosphorous extreme pressure agent, 1-5 wt% of antirust agent, 1-3 wt% of mixed alcohol amine, 1-3 wt% of oleic acid, 2-15 wt% of polyol ester, and 0.1-0.5 wt% of antifoaming agent, measured as the total weight of the hot-rolling oil.
US 5437802 recites a lubricant composition for hot rolling of metal comprising (1) a base oil or base grease having a combination of heat-insulating agents (A) and (B), in which the heat-insulating agent (A) is an inorganic compound, and the heat-insulating

agent (B) is an inorganic powder (2) an extreme pressure additive; and (3) a solid lubricant.
US3855136 recites a non-staining neat oil composition for hot rolling aluminum products suitable for dispersion in water consisting essentially of about 5 to 50% by weight of at least one fatty alcohol selected from the group consisting of monohydric, saturated primary fatty alcohols having from 8 to 20 carbon atoms, about 20 to 60% by weight polybutene having an average molecular weight greater than about 500 and a viscosity from about 2400 to about 10,000 SSU at 100°F, and about 20 to 75% by weight of an additional hydrocarbon lubricating oil having a distillation range from about 500° to 725°F at one atmosphere, which distillation range is below that of the polybutene wherein at least 90% of said hydrocarbon oil is distilled within said temperature range.
Lubricants widely used in the industry are expensive and maintenance of the lubricant is not adequate. Therefore, there is a need to develop lubricants for roughing tandem mill operations which overcome the aforesaid disadvantages.
OBJECTS OF THE INVENTION:
It is therefore an object of the invention to provide a lubricant composition applied for hot rolling operation (Roughing Mill) of aluminum ingot that overcomes the undesirable effects of the prior art lubricants.
In an object, the lubricant composition of the present invention provides cooling to the aluminum sheet and the work rolls during the hot rolling operation (Roughing Mill) of aluminum ingot process. In another object, the present invention provides a lubricant composition that enables cleaning of the aluminum surface of aluminum fines and aluminum oxide fines generated during trimming process.
In another object, the present invention provides a lubricant composition that facilitates production of a corrosion resistant aluminum sheet. In an object, it provides a lubricant composition that facilitates removal of oxide coating on rolled aluminum sheets,

eliminates bands, patchy surface and many more defects on the aluminum surface in rolling direction substantially improving the quality of aluminum sheet in terms of surface finish.
In another object, the present invention provides a lubricant composition, with improved lubricity. In an object it provides a user friendly and economical lubricant composition that requires low maintenance.
An object of the present invention is to provide a process for preparation of a lubricant composition for application in hot rolling operation (Roughing Mill) of aluminum ingot.
SUMMARY OF THE INVENTION:
In a general aspect of the present invention there is provided a lubricant composition for application in hot rolling operation (Roughing Mill).
In an aspect, a lubricant composition achieving the foregoing objects is disclosed. In one aspect the lubricant composition is disclosed wherein the composition comprises; a mixture of at least two base oils, at least one organic soap, at least a lubricating ester, at least a phosphate ester, at least an anti-wear additive, at least a particle size controller, and at least a nonionic emulsifier. The viscosity of said composition is in the range of 55-75 mm2/sec.
In an embodiment said composition optionally comprises, at least one vegetable oil based fatty acid in an amount of 5.0-7.0 wt.%, at least one biocide in an amount of 0.05-0.1wt. %, at least one defoamer in an amount of 0.05-0.1wt.%, at least one antioxidant in an amount of 0.5-0.1wt% or combinations thereof.
In a preferred embodiment said composition comprises a mixture of at least two base oils preferably in the range of 70-80wt%, at least a lubricating ester preferably in the range of 12-13wt%, at least a phosphate ester preferably in the range of 3-4wt%, at least a particle size controller preferably in the range of 2-3wt%, and at least a nonionic emulsifier preferably in the range of 4-5wt%.

In an alternative embodiment said composition comprises a mixture of at least two base oils in more preferably in the range of 70-70.5wt% , at least a lubricating ester more preferably in the range of 12-12.5wt%, at least a phosphate ester more preferably in the range of 3-3.5wt%, at least a particle size controller more preferably in the range of 2-2.5wt%, and at least a nonionic emulsifier more preferably in the range of 4- 4.5wt%.
In another aspect of the present invention, a process to prepare said lubricant composition is disclosed. The process comprises, (a) preparing and heating a mixture of organic soap; (b) Stirring and sequentially adding of a mixture of two or more base oils, lubricating ester, phosphate ester, non-ionic emulsifier, anti-wear additive, and additives such as defoamer and antioxidant to the heated mixture of step (a) and stirring the mixture for 1-2 hours to obtain the present lubricant composition.
DESCRIPTION OF THE INVENTION
In describing and claiming the invention, the following terminology will be used in accordance with the definitions set forth below. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein. As used herein, each of the following terms has the meaning associated with it in this section. Specific and preferred values listed below for individual process parameters, substituents, and ranges are for illustration only; they do not exclude other defined values or other values falling within the preferred defined ranges.
As used herein, the singular forms "a," "an," and "the" include plural reference unless the context clearly dictates otherwise.
The terms “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of

one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the invention.
As used herein, the terms “comprising” “including,” “having,” “containing,” “involving,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to.
The term “lubricant” as used herein refers to substance that helps to reduce friction between surfaces in mutual contact, which ultimately reduces the heat generated when the surfaces move. It may also have the function of transmitting forces, transporting foreign particles, or heating or cooling the surfaces.
The term “Hot roughing tandem mill rolling” as used herein refers to an operation which is conducted after soaking of scalped ingots. Rolling is done at recrystallisation temperature with help of lubricant in form of oil in water emulsion in multiple stands. Quality of lubricant decides the quality of rolled sheet at hot mill. Quality of rolled sheet is very critical in further rolling process as surface created at hot mill can’t be corrected further in cold rolling operation.
The invention relates to a lubricant composition having substantially improved lubricity. The present lubricant finds application in roughing tandem mill of aluminum ingots amongst others. The present lubricant composition increases the productivity of the finished product along with improving the quality of the finished product.
Accordingly, in an embodiment the invention discloses a lubricant composition for application in hot rolling operation (Roughing Mill). The composition comprises a mixture of at least two base oils, at least one organic soap, at least one lubricating ester, at least one phosphate ester, at least one anti-wear additive, at least one particle size controller, and at least one non-ionic emulsifier.
In a preferred embodiment, the lubricant composition further comprises at least one vegetable oil based fatty acid, at least one biocide, at least one defoamer, at least one antioxidant or combinations thereof.

In an aspect of the invention, the mixture of at least two base oils, with appropriate viscosity as for example with viscosity VG-20 and VG-100 may be used in an amount ranging from 50.0-80.0 wt.% in the present composition. The base oils are selected from petroleum having less than 10 wt. % aromatic content, 35-50 wt. % naphthenic content, and 40-60 wt. % paraffinic content. Preferably the first and the second base oil is selected from a group comprising of Nynas T-22, Nynas T110, or combinations thereof. The concentration of the base oil in the present composition is such that the viscosity of the lubricant composition ranges from 55-75 mm/sec2. The selected mixture of base oils as per the invention, helps in achieving the desired viscosity for lubrication during hot rolling.
In an aspect of the invention, organic soap in the present composition, in the range of 5.0-7.0 wt.% based on its molecular weight. The preferred organic soap in the present composition is, but not limited to, triethanolamine salt of fatty acid, triethanolamine oleate, ethanol amine oleate, diethanol amine oleate, amongst others.
In another aspect, said composition comprises a lubricating ester, having viscosity in a range of 300- 400 mm/sec2. The concentration of the lubricating ester in the composition is in a range of 11.0-13.0 wt.% based on the type of roughing mill and type of alloys to be rolled. The lubricating ester is selected from but is not limited to sorbitol ester, Peta ester, TMP ester, and combination thereof.
In yet another aspect of the invention, the concentration of phosphate ester is in the range of 0.0- 4.0wt.%. The phosphate ester is preferably selected from a group comprising polyoxyethylene alkyl ether phosphate amongst others.
In yet another aspect of the invention, the anti-wear additive is preferably amine neutralized phosphoric acid esters of fatty alcohols or Additin RC3770, Additin RC 3740, Additin RC 3760 in an amount of 0.0-2.0 wt.% based on load in the roughing mill.
In yet another aspect of the invention, at least one particle size controller is present in

the amount of 0.5-3.0wt.%. The particle size controller is preferably a complex high molecular weight non-ionic surfactant having hydrophilic lipophilic balance (HLB) in the range of 5-7 .The preferred surfactant can be selected from Hypermer A70 or Emulsogen 5781.
In yet another aspect of the invention, the non-ionic emulsifiers is preferably a mixture of ethoxylated alcohol or alkoxylates and castor oil ethoxylate with one of the emulsifier having hydrophilic lipophilic balance (HLB) in the range of 4-3, whereas the other emulsifier has hydrophilic lipophilic balance (HLB) in the range of 2-5.
In a preferred embodiment said composition comprises a mixture of at least two base oils preferably in the range of 70-80wt%, at least a lubricating ester preferably in the range of 12-13wt%, at least a phosphate ester preferably in the range of 3-4wt%, at least a particle size controller preferably in the range of 2-3wt%, and at least a nonionic emulsifier preferably in the range of 4-5wt%.
In an alternative embodiment said composition comprises a mixture of at least two base oils in more preferably in the range of 70-70.5wt% , at least a lubricating ester more preferably in the range of 12-12.5wt%, at least a phosphate ester more preferably in the range of 3-3.5wt%, at least a particle size controller more preferably in the range of 2-2.5wt%, and at least a nonionic emulsifier more preferably in the range of 4- 4.5wt%.
Another embodiment of the invention further optionally comprises at least one vegetable oil fatty acid with a preferable molecular weight of 270-300 kDa and more preferably has one carboxylic acid group. The preferred concentration of said vegetable oil fatty acid in the present composition may be 5.0-7.0 wt.% based on the type of mill and type of alloys to roll.
Another embodiment of the invention further optionally comprises at least one defoamer. The said defoamer may be present in an amount ranging from 0.05-0.1 wt.%. The defoamer is preferably a blend of 3-dimensional siloxane and water or alkyl polyacrylates defoamers, EO/PO (ethylene oxide/propylene oxide) based defoamers. The ratio for EO/PO (ethylene oxide/propylene oxide) is preferably between 1:4 to 1:6

In an aspect of the invention, said antioxidant is present in an amount ranging from 0.05-0.1 wt.%. The antioxidant is selected preferably from butylated hydroxyl toluene or butylated hydroxyl anisole, tert-butylhydroquinone.
In an aspect of the invention, said biocide is present in an amount ranging from the 0.05-0.1 wt.%. The biocide is preferably selected from a blend of 1,2-Benzisothiazol-3-one in Sodium Hydroxide, Mono Propylene Glycol and Glycerin. It has low toxicity & it is effective against a wide range of microorganisms including gram positive and gram-negative bacteria, yeast, and fungi.
The combination of the components in specific proportions as disclosed herein are in synergy to provide a lubricant composition having superior benefits in terms of the desired lubricity. Metal pickup on the rolls due to insufficient lubrication is avoided. Rejection in the roll bite due to over lubrication is also avoided.
In an aspect, the invention provides a process to prepare said lubricant composition. The process comprising the steps of:
(a) Preparing and heating a mixture of organic soap:
The organic soap in the concentration range of 5.0-7.0 wt.% is taken and is heated at a temperature ranging from 50°C-70°C, preferably for 1-2 hours to obtain a homogenous mixture.
(b) Stirring and sequentially adding of other component:
The base oils, lubricating ester, phosphate ester, non-ionic emulsifier, anti-wear additive, and particle size controller and optionally, additives such as defoamer and antioxidant are added sequentially to the heated homogenous mixture of step (a) under stirring condition. The resultant mixture is further stirred preferably for 1-2 hours at a temperature in the range of 50°C-70°C to obtain the present lubricant composition.
The lubricant composition obtained in step (b) can be further used in roughing tandem hot rolling mill to obtain an improved aluminum sheet with improved surface.

In an aspect the present composition is an emulsion comprising water and the lubricant in a weight ratio of 95:05. The concentration of water in said emulsion is in the range of 90-97 wt.%. This is optimum for the desired lubricity of the present composition and further resists bacterial growth. Said emulsion can be applied to the roughing tandem hot rolling mill to provide sufficient lubrication.
EXAMPLES:
Examples and implementations are provided herein below for the illustration of the invention. Variations, modifications, and enhancements to the described examples and implementations and other implementations can be made based on what is disclosed.
The below table 1 illustrates the varied alternatives (C1-C11) prepared using the mixture of components in the claimed ranges along with the final composition of the present lubricant composition.
Table 1: Present Inventive Compositions

Sr. no
1 2
3 4
5 Components (wt.% of
total
composition
) C-1 C-2 C-3
5.0 6.0
12.4 0.0
0.0 C-4
5.1 6.1
12.1 0.0
0.0 C -5
5.0 6.1
6.1 0.0
6.0 C -6
5.0 6.0
0.0 12.5
0.0 C -7
5.1 6.1
12.1 0.0
0.0 C -8
5.1 6.0
12.0 0.0
0.0 C -9
5.2 6.1
12.2 0.0
0.0 C-10
5.0 6.2
12.2 0.0
0.0 C-11

Organic soap 5.1 5.0







6.7

Vegetable oil based fatty acid 6.1 6.1







4.15

Lubricating Ester 12.0 12.0







12.0

Lubricating Ester-Complex ester 0.0 0.0







0.0

Lubricating Ester (Priolube 1808) 0.0 0.0







0.0

6
7
8
9
10
11
12
13
14 Particle Size Controller
(Hypermer A70) 2.0 2.0 2.1
3.0
0.0
2.1
0.0
45.7
24.6
0.1
0.1 1.1
3.0
0.0
2.1
0.0
45.7
24.7
0.0
0.1 1.0
3.0
0.0
2.1
0.0
45.7
24.5
0.1
0.1 1.0
0.0
3.2
2.2
0.0
45.8
24.7
0.1
0.1 1.0
0.0
3.0
2.1
0.0
45.7
24.5
0.1
0.1 2.1
0.0
3.0
4.0
0.0
45.5
24.6
0.1
0.1 2.0
0.0
3.0
4.2
0.0
38.9
32.2
0.1
0.1 2.0
0.0
3.0
4.2
0.0
35.2
35.2
0.1
0.1 2.0

Extreme Pressure anti wear Additive 3.0 3.0







0.0

Phosphate ester 0.0 0.0







3.0

Non-ionic Emulsifier 0.0 4.2







4.05

Lubricating Ester (Tween 80) 4.1 0.0







0.0

First Base oil 45.7 45.5







37.5

Second Base oil 24.7 24.6







32.5

Biocide 0.1 0.1







0.05

Antioxidant 0.1 0.1







0.07 5
The inventive example composition (C1-C11) as disclosed in table 1 were subjected to distribution of particle size parameter test. For a composition to be used as a better lubricant the particle size distribution should be optimum. Higher particle size results in higher lubrication and difficulty in rolling whereas lower particle size means lower lubrication and difficulty in rolling because of metal sticking. Hence the optimum particle size is necessary for enhanced lubricity, which the present invention provides. Results of the same is herein illustrated in Table 2:
TABLE 2: RESULTING PROPERTIES OF PRESENT COMPOSITION (C1- C11)

Sr.no Parameter C-1 C-2
10.1 C-3
11.8 C-4
12.0 C-5
10.2 C-6
12.5 C-7
12.4 C-8
10.4 C-9
7.6 C-10 C-11
Parameter (Distribution of Particle size) (µm)

1 D 0.5 (5 Min) 2.1







8.3 7.63

2
D 0.5 (10 min) 2.2 9.6 7.3 2.4 1.5 9.9 9.3 7.3 4.8 1.8
68.7 8.4 7.9
142 11.3 8.0 2.4 1.5
11.6
11.0 8.1 4.9 1.8
69.7 8.5 8.2
155 10.9 7.8 2.4 1.7
11.9
10.6 7.9 4.8 2.1
65.8 8.1 8.1
167 9.2 3.6 2.2 1.5 9.9 8.9 5.5 4.3 1.7
55.0 7.8 8.3
178 11.3 9.4 3.0 1.9
12.7
11.4 9.2 5.8 4.4
54.1 7.8 7.6
186 10.3 8.3 7.3 2.5
11.9
10.4 8.1 7.3 4.9
59.5 8.1 7.7
167 10.1 8.0 6.1 2.5
10.2
10.3 8.3 6.5 4.7
63.9 8.2 7.9
156 7.9 7.9 7.5 2.4 7.3 8.2 8.2 7.8 4.8
69.5 8.5 8.1
187 8.3 7.87
3 D 0.5 (30 min) 1.8







8.3 7.93
4 D 0.5 (1Hrs) 1.6







8.1 7.51
5 D 0.5 (2 Hrs) 1.5







2.4 2.41
6 D (4,3) (5 Min) 4.7







8.3 7.27
7 D (4,3) (10 Min) 4.5







8.4 8.19
8 D (4,3) (30 Min) 3.1







8.3 8.22
9 D (4,3) (1 Hrs) 2.2







8.0 7.81
10 D (4,3) (2 Hrs) 1.8







4.7 4.81
11 Kinematic Viscosity at 40 ºC, mm2/S 69.0







71.6 69.5
12 Kinematic Viscosity at 100 ºC, mm2/S 8.4







8.5 8.488
13 pH at 25 ºC 7.8







7.8 7.8
14 Conductivity at 25 ºC 138







168 <50
The inventive example composition (C1-C11) as disclosed in table 2, evaluates the performance in terms of kinematic viscosity, conductivity, particle size distribution of the inventive composition. It is evident that the kinematic viscosity is increased with the present inventive composition, hence better lubricity. Table 2 further provides analysis of the particle size distribution data of the lubricant composition under shear 10000 RPM in a homogenizer. For an ideal lubricity, the particle size distribution in an emulsion should generally be at a lower side. The optimum particle size distribution (between 3-5) is obtained for compositions C8-C10, where for D 0.5 (2 Hrs), it is observed to be 2.5, 2.4, 2.4, 2.41respectively, whereas for D (4,3) (2 Hrs), it is observed to be 4.7, 4.8,4.7, 4.81.
WORKING EXAMPLES
The formulation provided below were tested for hot rolling roughing mill operations. The observations are provided in table 3 & typical properties are provided in table 4.
Example 1

5.1 Wt/Wt of Organic soap is heated at a temperature in the range of 50°C-70°C for 1-2 hours. To the heated mixture, 45.5 Wt/Wt of Nynas T-22 base oil & 24.6 Wt/Wt of Nynas T110 base oil (naphthenic oil), 6.1 Wt/Wt oleic acid, 12.2 Wt/Wt of priolube3953 & 2.1 Wt/Wt of hypermer A70 lubricating and complex esters, 3.0 Wt/Wt of Crodaphos OD4A, 4.0 Wt/Wt of Span80, 0.05 Wt/Wt biocide, 0.05 Wt/Wt Foamban-MS575 defoamer and 0.05 Wt/Wt antioxidant was added in a sequential manner. Subsequently the mixture stirred for a duration of 2 hours to obtain a lubricant with consistent viscosity.
Table 3:

Formulations Particle Size d 0.5 pH at 25 0c Conductivity at 25 0C Viscosity at 40 0C
Working Formulation 2.53 7.9 156 63.9
[1] The working formulation of Table 3 was tested for hot rolling operations. The observations are provided below in table 4.
Table 4: Property evaluation of the roughing oil composition

SL. No.
1 2 3 4 5 6
7
8 Test Parameters Test Method Unit Working formulation 1

Appearance Visual Dark Brown Liquid

Colour ASTM D1500 2.0

Density@29.5 0 C ASTM D4052 g/ml 0.946

Kinematic Viscosity @ 400C ASTM D445 mm2/S 62-67

Kinematic Viscosity @ 100 0C ASTM D445 mm2/S 7.5-8.5

Viscosity Index ASTM D2270 150-160

Copper Strip Corrosion @ 100 0C for 3 hours ASTM D130 1a

Four Ball Weld Load ASTM D2783 Kgs 160-200
Example 2:
In an embodiment the present composition comprises of the components as described in table 5, wherein the properties and the viscosity as achieved by the present composition and the prior art is compared in table 6 below.
Table 5: shows the ingredients of the composition in claimed range as working example.

Sr.no Ingredient/Formulations Range (wt% based on the entire composition) Inventive
example C-11
(Wt%)
1 Component A (Base Oil -1) 38-45 37.5
2 Component A (Base Oil -2) 24-33 32.5
3 Component C (Fatty acid) 5-7 4.15
4 Component D (Organic Soap) 5-7 6.7
5 Component E (Ester) 11-13 12.0
6 Component F (Phosphate Ester) 0-4 3.00
7 Component G (AW Additive) 0-2 0
8 Component H (Particle Size controller) 0.5-3 1.95
9 Component I (Emulsifier) 2-5 4.05
10 Component J (Biocide) 0.05-0.1 0.05
11 Component K (Defoamer) 0.05-0.1 0
12 Component L(Antioxidant) 0.05-0.1 0.075
Comparative Data
Table 6: Shows the Comparison between present composition and conventional composition establishing better lubricity of the present composition.

Sr.no Properties Commercially available product Claimed Patent formulation (C-11)
Particle Size Distribution
1 D 0.5 (5 Min) 7.235 7.634
2 D 0.5 (10 min) 6.839 7.875
3 D 0.5 (30 min) 5.837 7.936
4 D 0.5 (1Hrs) 5.078 7.515
5 D 0.5 (2 Hrs) 2.613 2.41
6 D (4,3) 5 Min 7.695 7.27
7 D (4,3) 10Min 7.258 8.197
8 D (4,3) 30 Min 6.461 8.222
9 D (4,3) 1Hrs 5.867 7.812
10 D (4,3) 2 Hrs 4.317 4.813
11 Kinematic Viscosity at 40 ºC mm2/S 68.41 69.5
12 Kinematic Viscosity at 100 ºC mm2/S 8.783 8.488
13 pH at 25 ºC 7-8.5 7.8
14 Conductivity at 25 ºC <150 <50
15 Wear scar diameter in micron 852 733

16 EP Pass Load 100 126
17 EP weld Load 126 160
As shown in table 6 the present composition shows the increased lubricity. Higher EP pass load, Weld load and lower wear scar diameter indicates better lubricity. As per the standards, the higher the EP weld load, the pass load is better resulting in better lubricant film, hence better the lubricant. Furthermore, the lower wear scar diameter, better the lubricant.
The foregoing description of the invention has been set merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to a person skilled in the art, the invention should be construed to include everything within the scope of the disclosure.

We Claim:
1) A lubricant composition, wherein the composition comprises:
at least an organic soap,
a mixture of at least two base oils,
at least one lubricating ester,
at least one phosphate ester,
at least one anti-wear additive,
at least one particle size controller, and
at least one nonionic emulsifier.
wherein, the viscosity of the composition is 55-75 mm2/sec.
2) The lubricant as claimed in claim 1, wherein the total amount of the mixture of base oils is in the range of 50.0-80.0 wt.% and is selected from a group comprising of Nynas T-22, Nynas T110, or combinations thereof.
3) The lubricant as claimed in claim 1, wherein the base oil is petroleum having less than 10wt.% aromatic content, 35-50wt.% naphthenic content, and 40-60wt.% paraffinic content.
4) The lubricant as claimed in claim 1, wherein the lubricating ester is in an amount of 11.0-13.0 wt.% and is selected from a group comprising of sorbitol ester, peta ester, TMP ester or combination thereof.
5) The lubricant as claimed in claim 1 and 4, wherein the lubricating ester has a viscosity of 300-400 mm2/sec.
6) The lubricant as claimed in claim 1, wherein the phosphate ester is Polyoxyethylene alkyl ether phosphate in an amount of 0.0-4.0 wt.%.
7) The lubricant as claimed in claim 1, wherein the anti-wear additive is in an amount of 0.0-2.0 wt.% and is selected from amine neutralized phosphoric acid esters of fatty acid.

8) The lubricant as claimed in claim 1, wherein the particle size controller is in an amount of 0.5-3.0wt. % and is a high molecular weight non-ionic surfactant having hydrophilic lipophilic balance (HLB) in the range 5-7.
9) The lubricant as claimed in claim 1, wherein the nonionic emulsifier is in an amount of 2.0-5.0 wt.% and is a mixture of ethoxylated alcohol or alkoxylates and castor oil ethoxylate, wherein the hydrophilic lipophilic balance (HLB) of one emulsifier is 4-3 and the other is 8-18.
10) The lubricant as claimed in claim 1, wherein the organic soap is amine based in the concentration of 5.0 -7.0wt% and is selected from a group comprising of triethanolamine, ethanol amine, diethanol amine or combination thereof.
11) The lubricant as claimed in claim 1, comprises additives selected from a group
comprising at least one vegetable oil based fatty acid, at least one defoamer, at least one
biocide, at least one antioxidant or combinations thereof.
12) The lubricant as claimed in claim 11, wherein the vegetable oil based fatty acid is in concentration of 5.0 - 7.0wt%, the biocide is in concentration of 0.05-1% wt.%, the defoamer is in concentration of 0.05-0.1 wt.% and the antioxidant is in concentration of 0.05-0.1 wt.% .
13) The lubricant as claimed in claim 11, wherein the defoamer is a mixture of 3-dimensional siloxane and water, alkyl polyacrylates defoamers, EO/PO based defoamers.
14) The lubricant as claimed in claim 11 and 13, wherein the ratio for EO/PO is 1:4 to 1:6.
15) The lubricant as claimed in claim 11, comprising an anti-oxidant selected from a group
consisting of butylated hydroxyl toluene, butylated hydroxyl anisole, tert-
butylhydroquinone or combination thereof.
16) The lubricant as claimed in claim 1, wherein said lubricant is an emulsion comprising

said composition and water in concentration of 4wt%-8wt%.
17) The lubricant as claimed in claim 10, wherein said fatty acid is an industrial grade Oleic acid.
18) The lubricant as claimed in claim 11, wherein said biocide is a solution of 1,2-Benzisothiazol-3-one in Sodium Hydroxide, Mono Propylene Glycol and Glycerin.
19) The lubricant as claimed in claim 1, wherein the process of preparing the lubricant composition comprising the steps of:
(a) Preparing and heating a mixture of organic soap of organic soap at a temperature in
the range of 50°C-70°C for 1-2 hours;
(b) Stirring and sequentially adding of the two or more base oils, lubricating ester,
phosphate ester, non-ionic emulsifier, particle size controller, and anti-wear additive, to
the heated mixture of step (a) and stirring the mixture for 1-2 hours, at a temperature in
the range of 50°C-70°C to obtain the lubricant composition.