OILS & LUBRICANTS
He concludes : “ Certainly the lubrication industry as a whole has made tremendous progress in ash reduction over the past decade . The CK-4 standard represented a huge leap over previous generations . Now , the introduction of ULA technology is a game-changing breakthrough , achieved without compromising any of the protective benefits you expect from a CK-4 oil . Simply stated , if you really want to minimise DPF ash accumulation and avoid unpredictable maintenance and downtime , then you are better off with an oil specifically designed for that purpose . And at the time of this posting , there is only one on the market .”
HollyFrontier on the hidden impact of engine idling
Gord Susinski , Senior Technical Adviser at HollyFrontier Lubricants & Specialties , which includes the Petro-Canada Lubricants brand – told IM about the significant negative effects of idling in mining and the role of oils to mitigate problems .
“ Heavy-duty equipment in the mining industry operates in some of the world ’ s most extreme environments and weather conditions . In an industry where any unplanned downtime can have a negative impact on a business ’ bottom line , mining fleets are expected to run reliably , efficiently and safely on sites that are active 24 hours a day , seven days a week . For mining fleet managers looking to improve equipment performance , marginal gains in reliability and efficiency can have a significant impact . It is therefore important to consider the effect that prolonged engine idling can have on equipment .”
Susinski adds that mining fleet vehicles often spend a large proportion of their time idling , with Komatsu estimating that the average idle time for heavy equipment is 40 %. Given the nature of the mining industry , it is safe to assume that this figure could be even higher . “ It is estimated that a large diesel engine can consume up to four litres of fuel for each hour it is left idling , meaning there are significant environmental and financial benefits to be gained if idling time can be reduced . When engines idle extensively , oil consumption and the side effects can damage engines . Volatility is an important characteristic when choosing an oil for engines in this operating environment . Engine oils with poor volatility can cause engine oil consumption and fouling within the exhaust gas recirculation ( EGR ) systems . When an oil has poor volatility characteristics , the oil turns to a vapour which can be seen as oil consumption and buildup of deposits and sludge within the engine .”
Idling can have hidden and significant impacts on the equipment engine . The detrimental impact on engine wear increases as engine loading is reduced , which can in turn alter the combustion process . This can result in fuel dilution and the accumulation of moisture and soot , which can lead to an increased risk of acid formation , in addition to possibly reducing oil viscosity . Regular and prolonged idling can therefore accelerate engine wear and shorten oil drain intervals , even though the vehicle ’ s hour meter or maintenance schedule might state differently .
“ Using a quality lubricant can improve an engine ’ s pumping and cranking efficiencies while minimising metal-to-metal contact between moving components . This protects the engine ’ s vital components , which enhances its performance and may help improve fuel economy , so the choice of lubricant and suitable viscosity grade should not be overlooked . For those within heavy-duty off-highway industries such as mining , the benefits of API CK-4 oils are particularly applicable . Oils that meet this specification protect against oxidisation and aeration , as well as offering increased shear stability . Mining equipment engines can be more heavily loaded at the bearings , which require an oil film to ensure protection , and can benefit from improved aeration control .”
Susinski argues that is also important to consider that mining equipment operates in some of the coldest conditions , so it is essential to select an oil that benefits from cold weather performance characteristics . A low temperature viscosity oil enables easier cold starts and provides added protection against frequent stop and starts , which supports the ability of the engine to be turned off to reduce idling . In these colder conditions , a high viscosity oil can resist pumping and cranking and delay lubrication to critical engine components , which can impact the protection of the engine and increase wear . Industry standard tests such as ‘ Cold Crank Viscosity ’ ( ASTM D5293 ) and ‘ Borderline Pumping Viscosity ’ ( ASTM D4684 ) should be reviewed when choosing a lubricant that will protect critical components in the coldest of operating conditions .
“ To monitor the impact of engine idling , operators should incorporate used oil analysis into their maintenance routine . This can highlight maintenance issues caused by regular and prolonged idling before they become too serious or expensive to repair . Oil analysis and robust maintenance programs are key components in tackling and monitoring the impact of idling in harsh conditions . A superior lubricant can also offer essential protection for engine components , protecting them from the hidden impacts of engine idling such as fuel dilution and soot loading .”
He concludes : “ The impact of engine idling can be significant for off-highway engines , especially those in the mining industry where equipment is under pressure to operate reliably in extreme conditions . However , there are proactive measures that can be taken to reduce the negative effects of idling on fuel economy and engine wear . Regular oil analysis , a proactive maintenance program and , above all , a quality lubricant can reduce the impact of idling and help avoid unplanned downtime .”
Advanced filtration systems for oils and lubricants
In the mining industry , “ time is money ,” is meant quite literally . To make sure you stay in the black , you need to get the most out of every minute . And that means getting the most out of every piece of equipment .
Nate Zambon , Director of Filter Minder at Donaldson told IM : “ Making sure that everything is running as it should , when it should , is vital to keeping your entire operation running smoothly . In the harsh environments of mining , there ’ s no way to completely avoid unexpected downtime on a job site . But what if you could better control what is in your control ? If you knew more about your equipment ’ s systems - notably the filters and engine oil - you could know what to expect and plan for it .”
Zambon says it ’ s widely accepted that it ’ s best to change your filters at a predetermined time of year or at a set interval . “ But if the filter has sufficient life remaining to hit the next interval , you can maximise consumption and get more productivity out of your fleet . Using advanced telematics and sensors integrated into the fluid and filtration systems , we ’ re now able to generate real-time data to create more efficient service scheduling , including optimal filter replacement timing . This wireless sensing
JULY 2021 | International Mining