In the mining industry, as in many other sectors, the identification and management of operational suffering or pain points is crucial for maintaining efficiency and minimising downtime. These problems often manifest as machinery failures, leading to costly repairs or replacements, and can significantly disrupt mining operations, as well as being a potential safety hazard.
To mitigate these issues, it is essential to implement a well-organised and efficient maintenance programme that includes regular assessments and adjustments of equipment, such as bearings. By asking targeted questions about the frequency and nature of these adjustments, mining operators can proactively address potential problems before they escalate, creating smoother and cost-effective operations*.
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Below, mining machinery lubrication specialists, Mobil™, have collated a list of the eight most common ‘suffering’ points as told by their customers, miners and mining machine operators from around the globe. (All figures supplied by Mobil™)
Eight most common suffering points of mining machinery
1. High fuel consumption
The mining industry is increasingly recognising the pivotal role of energy efficiency and equipment reliability in driving operational success. In fact, higher quality synthetic lubricants can contribute to savings on fuel and power, making them an essential component of modern mining operations*.
Field testing has also demonstrated that synthetic lubricants not only help optimise fuel economy but also contribute to the longevity of critical equipment, such as haul trucks and engines. For instance, the implementation of Mobil Delvac 1™ ESP has shown promising results in extending engine life while maintaining peak performance[i].
2. Dirt/dust contamination leading to premature wear
Oil reservoirs contaminated with dirt, water or cutting fluids are bad news. Miners must be able to detect any sources of contamination, such as vents, breathers and holes where pipes go through the top or sides of the reservoir. It is important to conduct regular inspection and monitoring of the filtration/seal and oil condition to prevent premature machine failure. To further improve machine life and oil drain interval, it is recommended to develop a robust filtration strategy.
3. Inefficient oil maintenance intervals
Optimising oil drain intervals is a critical strategy in the mining industry, particularly for enhancing equipment uptime. Taking a truck out of service for oil drains can cost mine operators a huge amount of money over the lifetime of the truck. Even gaining just a few additional hours of uptime, per truck, could translate into millions of dollars in increased revenue for mining companies*.
By leveraging Mobil Lubricant Analysis (MLA), mining operations can help extend oil drain intervals*, which can lead to significant benefits, including increased equipment availability, reduced oil consumption, and higher productivity. Extending oil drain intervals also contributes to enhanced safety, with less frequent human interaction required for maintenance.
4. Hydraulic shovel performance
Hydraulic shovels are seen as critical components in the mining industry, particularly for their ability to enhance operational efficiency and productivity. However, if not properly maintained, the complexity of hydraulic systems can lead to unplanned downtime that disrupts operations.
Additionally, as hydraulic shovels are typically diesel-powered, they can incur high fuel costs, especially in large-scale operations. The efficiency of fuel usage can significantly impact overall operational costs, making it a critical pain point for mining companies.
With the use of high-performance lubricants such as Mobil DTE 10 Excel and Mobiltrans AST, oil life in hydraulic shovels can be increased from around 2,000 hours to over 6,000 hours*. Extended oil life not only reduces the frequency of oil changes but also contributes to lower maintenance costs and increased uptime for operations.[ii]
Enhanced lubricants can also help to improve pumpability and lower the pour point of oils, which is essential for maintaining optimal operating temperatures in hydraulic systems.
5. Time-based oil changes leading to lubricant overconsumption and lost productivity
Oil reclamation is a critical process aimed at extending the useful life of oil products, reducing waste. Often, maintenance schedules dictate that oil is replaced based on a set timeline or due to contamination concerns, even when the oil may still be functional. This practice leads to unnecessary disposal of potentially usable oil, contributing to environmental waste.
Implementing oil reclamation strategies allows companies to recover and refine oil that would otherwise be discarded. This process not only conserves resources but also aligns with modern environmental standards. By optimising oil drain intervals and conducting thorough equipment inspections, companies can better manage oil quality and reduce the frequency of oil replacements.
6. Lubricant cross-contamination due to a high number of SKUs
If the stockroom is filled to the brim with unused lubricants and oils, not only is this wasted inventory, but the chance of accidental spillage or contamination is high. Lubricant consolidation refers to the strategic approach of simplifying the maintenance and inventory processes by unifying various lubricant types used in machinery and equipment. This practice not only streamlines operations but also enhances overall efficiency and helps reduce costs associated with purchasing and managing multiple lubricant products.
Consolidation also helps avoid seasonal oil changes, while extended oil drain intervals can contribute to improved operational efficiency and reliability.
7. Varnish-related pump failures
The shovel main pump failure rate, which currently stands at 15 failures per year, incurs significant financial losses amounting to approximately $810,000 annually[iii]. One of the primary causes of these failures is varnish accumulation, which can lead to pump inefficiencies and ultimately, breakdowns.
However, switching to Mobil DTE 10 Excel 46 can yield substantial benefits, including the reduction of oil-related pump failures, which directly contributes to enhanced operational reliability. Other benefits include the potential for reduced fuel consumption and cost savings, highlighting the importance of proactive measures in maintenance and operational practices[iv].
8. Lack of workforce knowledge
Finally, a well-trained workforce is invaluable for ensuring both mining machines and workers are well looked after. Through training services, Mobil Field Engineers aim to empower its strategic relationships with the knowledge and skills necessary to optimise their operations and achieve greater efficiency and reliability in mining activities. Training includes:
- Product training
- Fundamentals of lubrication
- Contamination control
- Oil analysis best practices and interpretation
Mobil Services
To help alleviate these suffering points and to achieve productivity, Mobil offers a broad range of synthetic oils and greases for all kinds of machines, vehicles and equipment.
Mobil Services is a full suite of solutions designed to help miners minimise unscheduled downtime, maintenance costs, and equipment issues. Mobil offers services tailored specifically to the mining industry, including shovel optimisation, advanced energy efficiency documentation, and grinding mill gear inspection. Mobil provides invaluable hands-on direction and application expertise to help miners monitor lubricant and equipment condition.
Discover how expert lubrication solutions can help to enhance your operation’s efficiency by downloading the free paper below.
*Actual results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.
[i] Compared to an SAE 15W-40 engine oil. Actual savings are dependent on vehicle engine type, outside temperature, driving conditions, and your current engine oil viscosity. https://www.mobil.co.uk/en-gb/product/mobil-delvac-1-esp-5w40
[ii] This success story is based on the experience of a single customer. Actual results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.[iii] Ibid [iv] Ibid
