Mining engineers and procurement teams face equipment wear, contamination, tight oil-drain schedules and high overall maintenance costs. In fact, the majority of mechanical failures are caused by poor lubrication. So, what are the common challenges in the mining sector, and how can they be overcome with the right lubrication?
In this blog, we’ll discuss issues you may be facing and how using the right heavy-duty Gulf lubricant for the right equipment can make a big difference to your overall maintenance costs and mitigate these challenges.
Common lubrication challenges in mining and how to overcome them
Because mining equipment typically operates in remote locations that are difficult to reach, maintaining a proper lubrication schedule can be a challenge. However, it is essential to the safe and smooth running of your equipment. Using the right lubricants at the right time can help your equipment operate efficiently while prolonging its lifespan.
Here are some of the common challenges with each piece of mining equipment and the recommended lubricants for essential maintenance:
How lubrication affects each type of mining equipment
Specialist machinery requires specialist lubrication, so you must use the right lubrication for each piece of machinery and each specialist part. We’ll break down common mining equipment and suitable lubricants below.
Excavators
Built for handling extreme conditions, mining excavators have a large bucket capacity for moving immense loads of earth, rock and ore. This puts a lot of pressure on the powerful hydraulic system, so it needs to be correctly maintained.
Pain points: High-pressure hydraulics, variable operating temperatures, contamination from dust and water.
Recommended product: High-performance hydraulic fluid
Product benefits: Excavator hydraulic oil exhibits excellent anti-wear properties, while its high viscosity index ensures optimal performance in both hot and cold conditions. With an ability to ‘stay-in-grade’ under shear and rapid demulsibility to handle moisture, high-performance excavator hydraulic oil supports consistent performance under variable loads.
Crushers
Used for breaking down the size of large rocks, ore and other solids into smaller pieces that are easier to use, crushers create a lot of dust and gravel from compression. Although it’s an essential process, the dust can damage components of the machinery if it is not correctly lubricated and protected.
Pain points: Crushers are subject to open-gear wear, heavy loads, dust damage and vibration that can lead to wear on moving parts.
Recommended product: Adhesive open-gear lubricant
Product benefits: Adhesive open-gear lubricant is ideal for heavily loaded open gears in crushers. It is free from asphalt and heavy metals while resisting corrosion and oxidation to extend equipment life in dusty, high-load conditions.
Draglines and electric rope shovels
Used to excavate and move high volumes of materials like overburden, rock and ore, draglines and electric rope shovels require similar lubrication due to their high-pressure hydraulic systems. They handle immense loads for high production rates and are exposed to extreme operating conditions.
Pain points: Hydraulic wear, oxidation, water contamination, and requiring extended stability.
Recommended product: High-performance hydraulic fluid
Product benefits: High-performance hydraulic fluids deliver excellent wear protection, oxidation resistance and corrosion resistance. This ensures reliable performance and the potential to extend electric rope shovel and dragline maintenance intervals.
Dump Trucks
Designed to withstand the harsh environments of mining sites, dump trucks load and transport large quantities of minerals like rock and coal. That’s why dump truck maintenance is essential to ensure they are properly lubricated and protected against heavy loads.
Pain points: Heavy-duty hydraulics (steering, suspension), extreme cycles, and long drain intervals to reduce downtime.
Recommended product: High-performance anti-wear hydraulic fluid
Product benefits: High-performance hydraulic fluid has a strong anti-wear resistance and oxidation stability to extend component and oil life. Through rapid air release, compatibility and foam control, it ensures smooth, reliable operation.
Additional mining lubricants & tips
While each piece of equipment has varying lubrication needs, some universal components on most machinery require frequent lubrication. Meanwhile, there are some additional tips you can follow to improve the lifespan and performance of your equipment, too.
Bearings, pins & bushes require a heavy-duty off-highway or high-adhesion lithium complex grease with wear, corrosion and shock-loading protection and up to a 200 °C drop point. These can protect components against friction, contaminants and corrosion and prolong the life of bearings, pins and bushes while optimising performance under extreme conditions.
Engines benefit from advanced oil formulations that reduce wear, manage soot and protect against deposits. They lubricate critical components in the engine that are under continuous strain and exposed to friction, and minimise the risk of oxidation and corrosion by cooling the system.
Hydraulic lubricants that resist oxidation and maintain system cleanliness are essential for preventing critical failures. They also reduce wear, transmit power, reduce heat and protect against corrosion, ensuring smooth and efficient operation to improve the equipment lifespan.
Gears and final drives need high-load protection to minimise scuffing, pitting and corrosion. They require high-performance gear and final drive oil to lubricate gears, bearings and other components by forming a thick protective film between heavy-duty components.
Prevent contamination by storing lubricants in a safe, secure and dry place and make sure they are stored at the correct temperature.
With preventive maintenance, you can take a proactive approach to maintaining your equipment with regular service intervals and oil analysis to identify minor issues before they become serious problems.
A lubrication partner, like Gulf Care, can help you select the right high-performance lubricants for your mining fleet and plan service and maintenance intervals.
Futureproof your mining fleet
Using the right lubricants for your mining equipment can lead to reduced wear, contamination resilience, optimised drain intervals and greater uptime. By partnering with a lubrication specialist that offers oil analysis programmes, like Gulf Care, we can match the right heavy-duty lubricants to your fleet and support with maintenance schedules to reduce downtime and improve efficiency.
Learn more about our industrial lubricants now.