Mining Industry
1. 595NC Open Gear Lubricant at Dexing Copper Mine on a TZ-WK35 Shovel
A) Jiangxi Dexing Copper Mine
Before 595 NC OGL
- TZ WK-35 Shovel was continually exposed to heavy dust, high moisture and abrasive overburden resulting in a “sandblasting effect” to the dipper handles and crowd pinions.
- The product in use had to be applied every 10 minutes to ensure an adequate lubricant film on the gearing and also to prevent balling up from the severe moisture and dusty conditions.
After OGL 595 NC
- Petron’s OGL 595NC provided complete coverage of the applications on the dipper handles, pinions & swing gears.
- Lubricant film of OGL 595NC was strong and smooth without build up and also showed a good dustproof performance.
- The hourly consumption on the same type of shovel was a 33% reduction compared to the competitor.
B) Benefits to Dexing by using Petron OGL 595NC
Petron OGL 595NC showed the following benefits to Dexing Copper Mine,
- Smooth tenacious lubricant coverage and film/ protection to top and mesh sides of gearing, rack and pinions under heavy dust and moisture conditions.
- Reduction in lubricant consumption.
- Reduction in lubricant handling costs.
- Extended component life.
- Regular field support from Petron.
2) 595NC Open Gear Lubricant in the Mining Industry (P&H 4100 Shovel)
A) 595NC’s superior performance
Before 595 NC OGL
- P&H 4100A Shovel was continually exposed to harsh winds, blowing dust and abrasive overburden resulting in a “sandblasting effect” to the dipper handles and crowd pinions.
- The lubricant had to be applied every 7 minutes to prevent balling up from the severe dusty conditions.
- Protection provided to the exposed areas of the dipper handles and pinions was inadequate.
After 595 NC OGL
- Petron’s 595NC OGL provided complete coverage of all open gear applications using 186% less lubricant while providing superior parts protection
- The lubricant had to be applied every 7 minutes to prevent balling up from the severe dusty conditions. Protection provided to the exposed areas of the dipper handles and pinions was inadequate.
B) Cost Savings Analysis
Upon completion of the 90 day test, the following benefits of 595NC OGL were realized:
- Complete stick lubricant coverage/protection to top, sides, racking and pinions under harsh, dusty, windy conditions.
- Reduction in lubricant consumption.
- Reduction in lubricant handling costs.
- Extended component life.
- Regular field support from Petron.
3. Gear Shield Synthetic
| Industry | Application | Equipment | Lubricant |
|---|---|---|---|
|
Mining |
Open Gear Lubrication |
Ball Mills |
Petron Gear Shield Synthetic®
|
A) Lower Lubrication Cost By Using Gear Shield Synthetic
Previous Condition
- Customer was using a low viscosity clear synthetic product to lubricate the girth gears on two raw mills.
- Calculated previous consumption of open gear lubricant for both mills was approximately 10,483 pounds per year.
- Current Condition: The lubricant was changed to Gear Shield Synthetic® both mills.
- Calculated current consumption of Gear Shield Synthetic® estimated at 5,896 pounds per year.
Benefits
- Less wear due to thicker lubricant film spanning wear particles and reducing metal to metal contact.
- Annual open gear lubricant consumption for both mills reduced by 44% (4,587 lbs).
- Reduced consumption leads to an estimated annual cost reduction greater than $5,000.
B) Benefits Of Using Gear Shield Synthetic
- Less wear due to thicker lubricant film spanning wear particles and reducing metal to metal contact.
- Annual open gear lubricant consumption for both mills reduced by 44% (4,587 lbs).
- Reduced consumption leads to an estimated annual cost reduction greater than $5,000.
C) Lubricant Consumption Comparison
| Previous Consumption | Current Consumption |
|---|---|
|
Per Mill |
Per Mill |
|
1. 3.0 ounces every fifteen minutes |
1. 2.25 ounces every twenty minutes |
|
2. 12.0 ounces per hour |
2. 6.75 ounces per hour |
|
3. 288 ounces per day |
3. 162 ounces per day |
|
4. 126 lbs per week |
4. 70.8 lbs per week |
|
5. 5,241.6 lbs per year (based on 80% mill run time) |
5. 2,948.40 lbs per year (based on 80% mill runtime) |
|
Two Mills |
Two Mills |
|
1. 5,241.6 lbs x 2 = 10,483.2 lbs per year |
2. 2,948.40 lbs x 2 mills = 5,896.8 lbs per year |