FORM 2
THE PATENT ACT 1970
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION:
"Bio-based Wire Rope Dressing Grease / Lubricant and Process of Preparation Thereof
2. APPLICANT
(a) NAME : Mint Agri Research & Development Pvt Ltd
(b) NATIONALITY: Indian Company
(c) ADDRESS : S. No. 1073/1-2-3 Mutha road, Pirangut
Taluka - Mulshi, District-Pune Pin -412 111
3. PREAMBLE TO THE DESCRIPTION
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

Bio-based Wire Rope Dressing Grease/Lubricant and Process of Preparation
Thereof
Field of the invention
The present invention relates to a penetrating and dressing multipurpose lubricant, and more particularly, to a highly lubricating, polar, biodegradable, non-toxic and bio-based wire rope dressing grease / lubricant and a process for the preparation thereof.
Background of the invention
Wire ropes comprise continuous wire strands that are wound with each other and also around a central core and are made up of special steel or even plastics. Wire ropes are high strength flexible means for lifting, pulling or carrying load from one place to another and thus form an important part of material handling machines such as cranes. JCB's construction machinery for use in places like ports, harbors, mines, cement plants, coal carriers or even for rope ways.
Wire ropes are manufactured with grease/lubricant to protect the rope while in transit, storage and during initial operations. For various reasons, the originally applied lubricant becomes depleted or contaminated over a period of time and field lubrication becomes essential. Lubricity of wire lubricants is a major factor in proper operations of the wire ropes and also for their life. All strands move over each other as well as over the central core during operations. The lubricant reduces the friction and wear of the strands. Thus the high lubricity is essential for such lubricants. Moreover, during field lubrication of wire ropes, it is essential that, the lubricant is provided not only for outer surface coating but also between the strands and the core with thin strong film around them as protection. This requires penetration and thin film forming property. Additionally the lubricant should provide corrosion protection and prevention of dust layer.

The lubricants of the prior art suffer from following drawbacks:
1. Petroleum based greases or even synthetic based greases do not have good lubricity. Hence, the wire ropes with such lubricants have limited life and their status need to be checked frequently to avoid any risk. Moreover, they require extra power to overcome internal friction between strands and core and friction between wire rope and driving and guiding pulley's and mechanisms. This friction increases bending fatigue due to increased resistance to movement between strands and wire.
2. Many dressing greases are not penetrating due to high viscosity and hard layer formation on outside the rope for environmental protection. All tar based coatings have this limitation. This increases friction between strands and core during operations as the lubricant provided during manufacturing gets depleted.
3. The synthetic or petroleum based penetrating lubricants are not polar. Hence they cannot form thin film with good adhesion around the wires and the core. Hence, there are increased chances of wire rope coming in contact with water or earth as the applied lubricant falls on the floor.
4. It is difficult task to apply such hard coatings on assembled wire rope during operations which are many times carried out manually. Their penetration cannot be ensured in such cases.
5. Existing wire rope greases are not biodegradable and are toxic posing safety and contaminations concerns. Hence, their contact with water or earth is hazardous for environmental conditions. There are regulations being imposed in many countries against using such greases when the wire ropes are likely to come in contact with water.
Accordingly, there is a need of a highly lubricating, multipurpose, bio-based wire rope dressing grease/ lubricant that overcomes the drawbacks of the prior art.

Objects of the invention
An object of the present invention is to provide a highly lubricating, polar, multipurpose, biodegradable, non-toxic, bio-based grease having penetrating and dressing/coating ability that provides enhanced lubrication of a wire rope.
Another object of the present invention is to provide penetration and thin strong film around individual strands and core having good adhesion with substrate thereby resulting in reduced friction, saving energy and longer life of the wire
rope.
Still another object of the present invention is to provide a process for the preparation of biodegradable, non-toxic, bio-based grease having penetrating and
dressing/coating ability.
Yet another object of the present invention is to provide risk free use/clean manual handling/application on the wire rope and disposal even if the wire rope comes in contact with water and earth thereby avoiding environmental pollution.
Further object of the present invention is to prevent rust formation in individual strands and core and to provide protection against environmental conditions.
Summary of the invention
Accordingly, the present invention provides a bio-based wire rope dressing grease/lubricant formulations 1, 2 and 3 having penetrating and coating ability.
The bio-based wire rope dressing grease/lubricant formulation 1 comprises bio-based grease in a range of 18 % by weight to 20 % by weight. Further, the grease/lubricant formulation 1 comprises degummed vegetable oil in a range of 56 % by weight to 58 % by weight. Furthermore, the grease/lubricant formulation 1 comprises vegetable oil based diesel in a range of 18 % by weight to 20 % by

weight. Moreover, the grease/lubricant formulation 1 comprises triethanolamine in a range of 4 % by weight to 6 % by weight.
The bio-based wire rope dressing grease/lubricant formulation 2 comprises bio-based grease in a range of 18 % by weight to 22 % by weight. Further, the grease/lubricant formulation 2 comprises polyol of vegetable oil in a range of 8 % by weight to 12 % by weight. Furthermore, the grease/lubricant formulation 2 comprises degummed vegetable oil in a range of 48 % by weight to 52 % by weight. Moreover, the grease/lubricant formulation 2 comprises vegetable based diesel in a range of 18 % by weight to 22 % by weight. Further, the grease/lubricant formulation 2 comprises triethanolamine in a range of 6 % by weight to 8 % by weight.
The bio-based wire rope dressing grease/lubricant formulation 3 comprises palmolein oil in a range of 10 % by weight to 25 % by weight. Further, the grease/lubricant formulation 3 comprises 12-Hydroxy lithium stearate soap in a range of 3 % by weight to 8 % by weight. Furthermore, the grease/lubricant formulation 3 comprises polyalphaolefins in a range of 0.5 % by weight to 2 % by weight. Moreover, the grease/lubricant formulation 3 comprises a first degummed vegetable oil in a range of 10 % by weight to 30 % by weight. The first degummed vegetable oil is selected having free fatty acid content less than 2%. Further, the grease/lubricant formulation 3 comprises second degummed vegetable oil in a range of 30 % by weight to 50 % by weight. The second degummed vegetable oil is selected having low free fatty acids. Furthermore, the grease/lubricant formulation 3 comprises degummed vegetable based diesel in a range of 10% by weight to 30% by weight. Moreover, the grease/lubricant formulation 3 comprises triethanolamine in a range of 2 % by weight to 10% by weight. In addition, the grease/lubricant formulation 3 comprises antioxidant for example, di-tert-butyl-p-cresol up to 0.6% by weight.

Typically, the vegetable oil used in the grease/lubricant formulations 1, 2 and 3 is derived from any one of Karanj (also known as Pongamia pinnata), palm oil and combinations thereof.
In another aspect, the present invention discloses a process for the preparation of the grease/lubricant formulations 1, 2 and 3 having penetrating and coating ability.
Brief description of the drawings
Figure 1 shows a flowchart for a process for preparation of a wire rope dressing grease/lubricant formulation 1, in accordance with the present invention;
Figure 2 shows a flowchart for a process for preparation of a wire rope dressing grease/lubricant formulation 2, in accordance with the present invention; and
Figure 3 shows a flowchart for a process for preparation of a wire rope dressing grease/lubricant formulation 3, in accordance with the present invention.
Detailed description of the invention
The foregoing objects of the present invention are accomplished and the problems and shortcomings associated with the prior art, techniques and approaches are overcome by the present invention as described below in the preferred embodiments.
The present invention provides a highly lubricant, polar, multipurpose, and bio-based wire rope dressing grease/lubricant formulation having penetrating and coating/dressing ability. The bio-based wire rope dressing grease/lubricant formulation is made from vegetable oil based lithium complex grease and is biodegradable and non-toxic. In another aspect, the present invention discloses a process for preparation of the bio-based wire rope grease/lubricant formulation.

The present invention provides a highly lubricant polar, multipurpose and bio-based wire rope dressing grease/lubricant formulation 1, 2 and 3 (herein after "the grease/lubricant formulation 1", "the grease/lubricant formulation 2", and "the grease/lubricant formulation 3"). In an embodiment, the grease/lubricant formulations 1, 2 and 3 comprises vegetable oil. The vegetable oil is derived from Karanj (also known as Pongamia pinnata).
In the context of the present invention, the grease/lubricant formulation 1 comprises bio-based grease in a range of 18 % by weight to 20 % by weight. Further, the grease/lubricant formulation 1 comprises degummed karanj oil in a range of 56 % by weight to 58 % by weight. Furthermore, the grease/lubricant formulation 1 comprises karanj biodiesel in a range of 18 % by weight to 20 % by weight. Moreover, the grease/lubricant formulation 1 comprises triethanolamine in a range of 4 % by weight to 6 % by weight.
In an embodiment, the grease/lubricant formulation 1 is prepared by a cold process (100) (herein after referred to as "the process (100)") as illustrated in figure 1. The process (100) starts at (10).
At step (20), the process (100) includes adding bio-based grease/lubricant to degummed karanj oil to form a mixture.
At step (30), the process (100) includes adding and mixing karanj biodiesel to the mixture for 30 minutes under high shear agitation.
At step (40), the process (100) includes adding triethanolamine to the mixture and continuing mixing till the mixture becomes yellow hazy thick suspension.
At step (50). the process (100) includes milling the suspension to get uniform particle size and thick suspension. The above steps (20-50) of the process (100)

are carried out at ambient temperature and pressure conditions. The process (100) ends at step (60).
In the context of the present invention, the grease/lubricant formulation 2 comprises bio-based grease in a range of 18 % by weight to 22 % by weight. Further, the grease/lubricant formulation 2 comprises karanj polyol in a range of 8 % by weight to 12 % by weight. Furthermore, the grease/lubricant formulation 2 comprises degummed karanj oil in a range of 48 % by weight to 52 % by weight. Moreover, the grease/lubricant formulation 2 comprises karanj biodiesel in a range of 18 % by weight to 22 % by weight. Further, the grease/lubricant formulation 2 comprises triethanolamine in a range of 6 % by weight to 8 % by weight.
In an embodiment, the grease/lubricant formulation 2 is prepared by a hot process (200) (hereinafter referred to as "the process (200)") as illustrated in figure 2. The process (200) starts at step (110).
At step (120), the process (200) includes adding bio-based grease/lubricant to karanj polyol to form a mixture.
At step (130), the process (200) includes heating the mixture at a temperature ranging between 118° -122° C for a duration of 10-20 minutes to get thick homogeneous paste.
At step (140), the process (200) includes adding degummed karanj oil to the mixture over a predefined period of time with constant stirring. The addition of the degummed karanj oil results in a temperature drop up to 78° -80° C.
At step (150), the process (200) includes adding karanj biodiesel to the mixture with stirring and maintaining the temperature in the range of 78° -80° C.

At step (160), the process (200) includes adding triethanolamine to the mixture. Further, the step (160) involves stirring the mixture at 80° C and maintaining the temperature at 80° C for a duration ranging between 25-35 minutes till a clear brownish solution is formed.
At step (170), the process (200) includes cooling the clear brownish solution to room temperature to get thick viscous hazy suspension. The process (200) ends at step (180).
In the context of the present invention, the grease/lubricant formulation 3 comprises palmolein oil in a range of 10 % by weight to 25 % by weight. Further, the grease/lubricant formulation 3 comprises 12-hydroxy lithium stearate soap in a range of 3 % by weight to 8 % by weight. Furthermore, the grease/lubricant formulation 3 comprises polyalphaolefins (herein after referred as "PAO") in a range of 0.5 % by weight to 2 % by weight. In an embodiment, the polyalfaolefins is of 100 grade. However, it is, understood that other grades of polyalfaolefins can be used for alternative embodiments of the grease/lubricant formulation 3. Moreover, the grease/lubricant formulation 3 comprises a first degummed vegetable oil in a range of 10 % by weight to 30 % by weight. The first degummed vegetable oil is selected having free fatty acid (herein after referred to as "FFA") content less than 2% that is required for structure stabilization. Further, the grease/lubricant formulation 3 comprises a second degummed vegetable oil in a range of 30 % by weight to 50 % by weight. The second degummed vegetable oil is selected having low FFAs required for quenching. Furthermore, the grease/iubricant formulation 3 comprises degummed vegetable based diesel in a range of 10% by weight to 30% by weight. Moreover, the grease/lubricant formulation 3 comprises triethanolamine in a range of 2 % by weight to 10% by weight. In addition, the grease/lubricant formulation 3 comprises antioxidant for example, di-tert-butyl-p-cresol up to 0.6% by weight.

In an embodiment, the grease/lubricant formulation 3 is prepared by a process (300) that is a combination of the cold and hot processes (hereinafter referred to as "the process (300)") as illustrated in figure 3. The process (300) starts at step (210).
At step (220), the process (300) includes preparing grease by mixing palmolein oil, 12-Hydroxy lithium stearate soap, PAO and first degummed Karanj oil (FFA<2.0%) at room temperature to form a mixture. The mixture is stirred for about 30 minutes. In an embodiment, the polyalfaolefins is of 100 grade. However, it is, understood that other grades of polyalfaolefins can be used for alternative embodiments of the grease/lubricant formulation 3.
At step (230), the process (300) includes structure stabilization of the mixture by heating at a temperature up to 200 °C and maintaining the temperature at about 200 °C for about 1 hour.
At step (240), the process (300) includes quenching, wherein second degummed Karanj oil and Karanj biodiesel are added all at once to the stabilized mixture. In an embodiment, the second degummed karanj oil has low FFA content.
At step (250), the process (300) includes charging, wherein triethanolamine as a buffer is added at ambient temperature and the resulting mixture is stirred for about 1 hour.
At step (260), the process (300) includes additive dosing, wherein antioxidant is added and the resulting mixture is stirred for about 15 minutes at ambient temperature. In an embodiment, the antioxidant is di-tert-butyl-p-cresol.
At step (270), the process (300) includes milling and filling the mixture to get a thick suspension of uniform particle size. The process (300) ends at step (280).

In the processes 100, 200 and 300 for preparing the grease/lubricant formulations 1, 2, and 3 respectively, the grease is made from lithium soap to provide good lubrication and having extreme pressure capabilities. The degummed karanj oil is a good lubricator and serves as base oil for preparing the grease formulation. The karanj biodiesel is used for providing deep penetration of the lubricant. Furthermore, triethanolamine acts as buffer and holds soap particles in suspension form. The lubricity and coating properties are augmented by providing triethanolamine suspension.
Advantages of the invention
1. The wire rope dressing grease/lubricant of the present invention is a multipurpose grease and is used as penetrating grease for all types of industrial wire rope applications.
2. The wire rope dressing grease/lubricant of the present invention is a petroleum solvent free, semi-fluid lubricant that is designed to penetrate to the core of the rope to provide excellent lubrication between individual strands, wires as well as to the core.
3. The wire rope dressing grease/lubricant of the present invention has at least 3-4 times higher lubricity than petroleum and at least 2 times higher lubricity than synthetic oils. High lubricity naturally reduces the friction between strands and core as well as between the wire rope and the driving mechanism having pulleys, guides, drum etc. Due to less friction, the wire rope has longer life and longer servicing period thus saving at least 10 to 15% energy or power of the drive.
4. The wire rope dressing grease/lubricant uses an advanced load carrying system based on sub-micron complex soap solid particles in suspended form. The result is a finished product that is both clean to handle and

transparent in use without compromising the load carrying or anti-wear properties.
5. The wire rope dressing grease/lubricant of the present invention is highly resistant to water wash-off. This property is important for use on ports and harbours that involve contact of the wire ropes with water during under water operation or tug dragging operation.
6. The wire rope dressing grease/lubricant of the present invention is polar in nature and thus offers non-tacky thin film on each strand and on wire ropes that prevents build up of dust and dirt and provides outstanding corrosion protection. The thin strong film provides adhesion with the substrate i.e. wire steel, and core steel. This improves the protection layer and reduces the frequency of re-lubrication.
7. The high lubricity and polar nature of the wire rope dressing grease/lubricant of the present invention increases the life of strands and of the core thereby reducing the inspection frequency for safety.
8. The wire rope dressing grease/lubricant is manufactured from biodegradable and renewable raw materials and hence, is non toxic, non hazardous to water or environment as well as to the aquatic organisms and very much safe for use. In case of an accidental release to the environment, the lubricant is broken down into harmless substances by the action of micro-organisms.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above

teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the present invention.

We Claim:
1. A bio-based wire rope dressing grease/lubricant formulation having
penetrating and coating, ability, the grease/lubricant formulation comprising
bio-based grease in a range of 18 % by weight to 20 % by weight;
degummed karanj oil in a range of 56 % by weight to 58 % by weight;
karanj biodiesel in a range of 18 % by weight to 20 % by weight; and
triethanolamine in a range of 4 % by weight to 6 % by weight.
2. A process for preparation of the grease/lubricant formulation of
claim 1, the process comprising the steps of:
a) adding bio-based grease in degummed karanj oil to form a mixture;
b) adding karanj biodiesel to the mixture of step a and mixing for 30 minutes with high shear agitation;
c) adding triethanolamine to the mixture of step b and mixing to form a yellow hazy thick suspension; and
d) milling the suspension of step c to get uniform particle size and thick suspension.

3. The process as claimed in claim 2, wherein the steps a, b, c and d are adapted to be carried out at ambient temperature and pressure conditions.
4. A wire rope dressing grease/lubricant formulation having penetrating and coating ability, the grease/lubricant formulation comprising:
bio-based grease in a range of 18 % by weight to 22 % by weight; karanj polyol in a range of 8 % by weight to 12 % by weight; degummed karanj oil in a range of 48 % by weight to 52 % by weight;

karanj biodiesel in a range of 18 % by weight to 22 % by weight;
and
triethanolamine in a range of 6 % by weight to 8 % by weight.
5. A process for preparation of the grease/lubricant formulation of
claim 4, the process comprising the steps of:
a) adding bio-based grease in karanj polyol to form a mixture;
b) heating the mixture of step a till a thick homogeneous paste is formed;
c) adding degummed karanj oil to the mixture of step b over a predefined period of time with constant stirring;
d) adding karanj biodiesel to the mixture of step c with stirring and maintaining the temperature of the mixture at 78° -80° C;
e) adding triethanolamine to the mixture of step d with stirring at 80° C for a duration of 25 minutes to 35 minutes to form a clear brownish solution; and
f) cooling the mixture of step e to room temperature to form a thick viscous hazy suspension.

6. The process as claimed in claim 5, wherein the step b is adapted to be carried out at a temperature ranging between 118° C to 122° C for a duration ranging between 10-20 minutes.
7. A bio-based wire rope dressing grease/lubricant formulation having penetrating and coating ability, the grease/lubricant formulation comprising:
palmolein oil in a range of 10 % by weight to 25 % by weight;
12-hydroxy lithium stearate soap in a range of 3 % by weight to 8 % by weight;
polyalphaolefins in a range of 0.5 % by weight to 2 % by weight;

first degummed karanj oil in a range of ] 0 % by weight to 30 % by weight;
second degummed karanj oil in a range of 30 % by weight to 50 % by weight;
degummed karanj biodiesel in a range of 10 % by weight to 30 % by weight;
triethanolamine in a range of 2 % by weight to 10 % by weight; and
antioxidant in a range of 0 % by weight to 0.6 % by weight, wherein the antioxidant is di-tert-butyl-p-cresol.
8. A process for preparation of the grease/lubricant formulation of claim 8, the process comprising the steps of:
a) preparing grease/lubricant by mixing palmolein oil, 12-hydroxy
lithium
stearate soap, polyalphaolefins and first degummed Karanj oil at room temperature with stirring for a duration of 30 minutes to form a mixture;
b) structure stabilizing the mixture of step a by heating at a temperature up to 200° C and maintaining the temperature at 200° C for a duration of 1 hour:
c) quenching by adding second degummed Karanj oil and Karanj biodiesel all at once to the mixture of step b;
d) charging the mixture by adding triethanolamine to the mixture of c at ambient temperature and stirring the mixture for a duration of 1 hour;
e) additive dosing by adding antioxidant to the mixture of step d and stirring the mixture for a duration of 15 minutes at ambient temperature, wherein the antioxidant is di-tert-butyl-p-cresol; and

f) milling and filling the mixture of step e to form a thick suspension of uniform particle size.
9. The grease/lubricant formulation as claimed in claims I, 3 and 8 is a vegetable oil based grease formulation, wherein the vegetable oil is selected from any one of Karanj oil, palm oil and combinations thereof.