Mining Case Studies

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Engine Oil and Fuel


Newcrest Mining : Symons Cone Crusher

Problem:

Ferrous Metal contamination in the engine of a Symons 4 ¼” Cone crusher was causing premature wear and frequent PM periods for operations at Cracow Gold mine.

Results After OEI Filtration:

After 64 hours, a substantial amount of ferrous metal was extracted and trapped on the OEI Magnetic Filter. The OEM was unable to collect these contaminants ranging in size from under 10 microns to above 40 microns. Newcrest ’s view is that without the One Eye filter, a proportion of this material would have found its way back to the bearings, gears and lubrication pump. This could have lead to premature failures and costly unplanned maintenance. As part of the continuous improvement program at this site, Newcrest has identified other pieces of critical plant equipment that will benefit from the advantages of OEI Magnetic Filters.

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Mount Polley Mining: Pinion Gear Lube

Problem:

Ferrous metal contamination in Pinion Gear Lube oil, was causing premature wear on pinion bearings and gears. This resulted in frequent PM periods and premature failure.

Results After OEI Filtration:

After 7 days, a substantial amount of ferrous metal was extracted and trapped on the OEI ADD -Vantage 9000 Magnetic Filter Rod. Andrew Nairn, Mill Maintenance Planner for Mount Polley Mining, stated, “That without the One Eye filter a significant proportion of this fine metal would have found its way back to the pinion bearings, gears and lubrication pump. This could have lead to premature failures and costly unplanned maintenance. ”

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Surface Lignite Mine: Diesel Tank Flushing

Problem:

The presence of contamination in the diesel fuel tank causes damage to fuel system components including the circulation pump. Traditional filtration is unable to remove the most damaging contamination (below 10 microns) effectively causing premature wear of the injectors, actuators, and camshaft.

Results After OEI Filtration:

By removing the ferrous contamination to submicron levels the diesel fuel is cleaned to a much lower ISO level than the standard (18/16/13) and the life of the pump and the fuel system components are increased. The higher level of cleanliness of the fuel results in a more efficient burn and reduced emissions.

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Gearbox


Australian Mining Company fits Dozers with Magnetic Plugs to stay operational

Problem:

High metal counts, brought on with a change of lubricant that was not compatible with the final drives.

Results After OEI Filtration:

The Final Drives were fitted with One Eye Magnetic Plugs as they did not have spares and they needed the Dozer to keep going until the spares arrived. These are the results after 11,420 hrs (click read more to see photo). “Alan stated that the OEM plug would not have been able to do what the One Eye Magnetic Plug did and in fact the One Eye Magnetic Plugs played a major part in getting the final drive to keep operating until the spares arrived.”

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Anglo American: Reticulating Lube System

Problem:

High levels of ferrous metal contamination present in the Talcor-1300 Molybdenum-Disulfide lube oil as a result of inadequate filtration to the submicron level.

Results After OEI Filtration:

There were initial challenges that had to be overcome during installation due to the original flexible hose being replaced with a rigid scrubber and ball-valve arrangement that had to match up to the existing 1-7/8” JIC Male Hose Fittings. However, the 2” Ball-Valves & Elbows fitted in such a way that the axis of the outlet aligned to the inlet of the OEI Scrubber. “Due to recent correspondence, we feel content that the OEI product will soon pay for itself and increase reliability with or without monitoring oil samples.”

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7-figure savings achieved through 32% extension in maintenance intervals

Problem:

The final drives in their dozer fleet were keeping the mine from achieving maintenance interval targets of 330 hours.

Results After OEI Filtration:

By replacing OEM ceramic magnetic plugs with OEI rare earth magnetic plugs, targets were achieved and cost savings realized.

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Teck: Wheel Motor Magnetic Plugs

Problem:

High levels of ferrous metal contamination were present in the wheel motor of one of Teck’s Komatsu 930E trucks. The OEM ceramic magnetic plugs were not acting as efficient predictive maintenance tools, as they were too weak in magnetic power to remove the contamination in the oil and identify a premature wear problem.

Results After OEI Filtration:

Before the test was completed, the wheel motor had a catastrophic failure. The magnetic plugs were all removed at the rebuild shop, and the contamination collected by the OEI Magnetic plug was significantly higher than all 7 other OEM plugs combined. A bolt head had broken off and was caused severe damage in the wheel motor.

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South Africa Cement Mine Gear Lube Filtration

Problem:

A cement mine consumed 6 drums/year of Molub-Alloy 8031-3000 open gear high viscosity oil base gel >78,000 cPs at a cost of $12,000 USD/year. Traditional filtration is unable to sufficiently filter this highly viscous oil gel at the necessary flow rate, also insufficient filtration results in a one time product life. The gel was disposed of as a waste grease which has a significant environmental footprint.

Results After OEI Filtration:

Three OEM’s approved the addition of the OEI Magnetic Scrubber. When the oil gel cycled through the OEI filter, ferrous and nonferrous contamination was captured down to submicron level. Oil consumption was reduced by 3.75 drums/year saving over $7500 USD. OEI filtration increases component life, lowers consumption and reduces disposal costs and the company’s carbon footprint.

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Hydraulic and Pneumatic


Mosaic: Potash Mine Hydraulic Oil FIltration

Problem:
Dean Stephens A.Sc.T., CMRP Underground PdM Supervisor was concerned with the ISO cleanliness level of new hydraulic fluid.

Results After OEI Filtration:

The Magnetic Scrubber Filter extracted a substantial amount of ferrous metal. Mine supervisors, were amazed just how much ferrous metal there is in new hydraulic oil. The Underground PDM Supervisor stated, “Had this metal been introduced to our equipment, it would definitely have caused premature wear to the seals and gears.”

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Company X: Hydraulic Shovel Filtration at a Diamond Mine

Problem:

Dirty hydraulic fluid with an ISO of 25/24/16. Traditional filtration was unable to meet a minimum ISO standard of 18/16/13 with a limited kidney loop filtration interval of three hours.

Results After OEI Filtration: 

Results showed that not only had OEI met the anticipated standards but exceeded them retaining a cleanliness level of 17/14/10. The diamond mine maintenance manager has since incorporated other OEI filtration solutions.

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Consol Energy: Longwell Emulsion System Filtration

Problem:

Ferrous contamination prematurely wearing Emulsion System components, and traditional filtration is unable to filter below 10 microns. The ferrous metal contamination is also compromising the existing media filtration integrity, by cutting holes in it (referred to as worm-holing and channeling the fluid).

Results After OEI Filtration: 

A significant amount of ferrous and non-ferrous contamination was collected by the OEI Magnetic Filter, after only 4 days in operation. Removal of this submircon ferrous contamination will extend component life, reduce emulsion loss and increase uptime.

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