Advanced lubricants play a crucial role in modern industrial operations, particularly in helping to address the complex challenges posed by high-temperature and demanding environments such as mining. As the industry evolves, conditions under which mining machinery and equipment operate are becoming increasingly complex, necessitating the development of specialized lubricants designed to withstand these challenges.
The development and use of synthetic lubricants, meanwhile, has been highlighted as crucial to improving fuel efficiency, wear resistance and durability. Products that can withstand extreme conditions, such as high temperatures and pressures, are able to help reduce equipment damage and maintenance costs. They can also help enhance safety by lowering friction and wear, preventing machinery failures that could pose safety risks to workers.
By leveraging such innovations, miners can improve equipment performance and extend the service life of machinery, ultimately leading to reduced operational costs and improved productivity*.
The challenges of high-temperature environments
The global demand for critical minerals is increasing, leading to the opening of more mines. The World Bank predicts that the production of minerals, such as graphite, lithium and cobalt, could increase by nearly 500% by 2050.
With heightened mining activities, equipment breakdown becomes even more critical. Increased usage can lead to more frequent failures, necessitating proactive maintenance strategies, and the use of advanced lubrication systems plays an important part in the strategy. Understanding equipment condition is crucial for mining companies to anticipate component failures and replace parts before they cause larger issues, reducing downtime and maintaining productivity.
Manu Bhargava is Chief Engineer of Field Engineering Services at Mobil™, based in Bengaluru (Bangalore), India. Bhargava uses his many years of experience to provide his customers with insights into how to enhance their machine performance, reduce energy consumption, and implement cutting-edge lubrication strategies across various industries, including mining.
“We actively collaborate with our customers to pinpoint and resolve issues, ensuring they achieve maximum output with seamless, trouble-free operations through our proactive troubleshooting approach,” says Bhargava. “For example, we have many customers in process industries, like mining, where they face the challenge of high temperature issues during peak summer, where traditional mineral lubricants may not be able to offer the required protection because of the increase in both the machine temperature and in the ambient temperature.”
The solution is synthetic oils, says Bhargava, which have a wider operating temperature range. Bhargava explains that this is where synthetic oils come into their own, as they are engineered to perform where conventional lubricants would break down, offering critical protection in challenging high-temperature, industrial environments: “Synthetic oils offer the required film strength, better anti-wear and extreme pressure properties, which not only enhances lubricant life, but also enhances machine life as well.”
Bhargava also emphasises the significance of having effective maintenance control for mining machinery, highlighting monitoring and training programs, and having in-depth discussions with stakeholders.
“We start by asking, what is the requirement and current equipment setup? Are they able to achieve maximum productivity from equipment, if not, how these are impacting overall productivity? What are their goals?” explains Bhargava. “To understand this, we run an application survey. We do a ‘walk-through’ audit on site, so that we can understand that the best practices are being followed and how the machine is performing. Once we evaluate that, we ask what tools are available to enhance the availability or the upkeep of the machines by using next-gen lubricants. We determine this by looking at the application, reviewing the operating parameters, or monitoring the operating conditions. Then we ask – what is the productivity goal?
“For example, if we have a machine where the customer requires very high availability, they may not be in a position to opt for frequent shutdowns to perform the maintenance. Instead, they need to have a duplicate that offers them long life. We need to consider how monitoring tools can help them monitor that application, within parameters, without compromising the application. We also offer them a duplication solution, including what product to use and how to monitor.”
“When customers require machines with very high availability, frequent shutdowns for maintenance are not feasible,” Bhargava continues. “We must consider how monitoring tools can help them oversee the application within set parameters, without compromising its performance and deliver production goals. To support that, we provide advance solutions, this includes detailed lubrication recommendations considering application demand and operational challenges. We also guide customers on how to effectively monitor and maintain equipment health and running parameters e.g. giving recommendations on offline filtration, effective breathing system, modifying greasing systems, using state of the art Mobil Lubrication, Mobil Grease analysis program and Mobil Advance Analysis System.”
Bhargava also explains that they extend training beyond just supervisors to all users of lubrication on-site, helping customers understand how lubrication solutions address application demands, enhance machine performance, and meet changing industry needs. Bhargava highlighted that as machines become smarter and more robust, traditional lubrication technologies may not work, but Mobil™ lubricants can address these evolving demands.
Engineers: experts in their field
Mobil’s™ expertise, proactive maintenance, and productivity improvement approaches can help, Bhargava says, as well as understanding customer maintenance practices based on industry standards. The equipment team has recommendations from leading global equipment builders and industry associations, and this serves as an initial guide for users to select appropriate lubricants for specific applications and equipment.
However, Bhargava and his team of engineers also draw on their own experience and Mobil’s vast knowledge base to best serve their customers, as he explains:
“As engineers, we do certain calculations when it comes to what kind of viscosities are required based on the temperature band and application use, to determine what kind of products require a high viscosity index. For instance, when it comes to grease, if they are looking for an enhanced regressing interval, we consider what kind of grease offers them the best enhanced regressing interval taking into account the application demands, whether it is water exposed, the temperature, dust or high impact protection requirements, and high load services, etc.”
Mobil™ provides innovative, tailored solutions to enhance industrial equipment performance and productivity, including adjusting lubrication, the transition to predictive maintenance, specialized lubricants, and comprehensive engineering services, all to enhance machine efficiency, energy consumption, and equipment life for its customers.
To discover how your mining operation can benefit from lubrication solutions from the experts, download the free paper below.
* Results are 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.
