MINING LUBRICANTS
Leveraging lubricants
Lubricants play an important role in mining in terms of machine uptime and efficiency relative to their cost and volume . Paul Moore looks at key developments and products
Miners today face a perfect storm . Their outputs have never been more critical , with materials like copper pivotal to supporting the transition to a low carbon future . Yet the sector is facing some of its biggest challenges , with the pressure to meet growing demand and maintain profitability , whilst decarbonising operations . And these pressures are coming at a time of rising consumable costs and talent shortages .
So , how can miners address the seemingly impossible challenge of producing more , while emitting less , and staying competitive ? In this challenging landscape , total cost of ownership ( TCO ) has become more critical than ever . According to Shell ’ s ‘ Breaking New Ground : Shaping a Successful Future for Mining ’ report , a third ( 33 %) of site managers say that rising consumable costs will significantly impact their operations in the next three to five years .
Making any investment at a time when cost is so clearly king might seem counter-intuitive . But , Shell argues , investing in high performing lubricants and lubrication programmes could provide the answer to meeting productivity , cost , and sustainability challenges all at once .
Shell says adopting an ‘ invest to save ’ approach and working with experienced technical suppliers to put in place a tailored lubrication programme can not only aid component reliability , but can also reduce maintenance budgets . “ At a time when equipment downtime costs can run between $ 30,000 to $ 100,000 an hour , careful lubrication selection can protect machinery , avoid costly downtime and upgrades , and help reduce maintenance budgets by up to 30 % each year .”
But Shell adds that addressing TCO is just the start . Careful lubricant selection can also help reduce emissions . For example , high performance biodegradable lubricants can help protect mining equipment as well as the environment miners operate in , by reducing their impact on the soil and water .
“ With lubricants holding a tangible answer to efficiency , productivity , and sustainability wins , it ’ s no surprise that 41 % of miners are already using high performing lubricants , with a further third ( 33 %) planning to adopt them over the next one to two years .”
Then there are expert lubrication programmes which Shell says help reduce TCO and support miners in meeting sustainability goals . “ However , digitalising your operations and working with suppliers who have the expertise to leverage digital technologies , is fundamental to modernising lubricant strategies . As mining operations generate a wealth of data , harnessing and maximising this data can help businesses make informed decisions , and drive operational efficiencies .”
For instance , Shell argues incorporating real time sensors may enable predictive maintenance
programmes that can extend component lifetime
by up to 50 %, delivering sought after costefficiencies and even reductions in CO 2 emissions . “ In fact , lubricant management , enabled by real time oil monitoring , can reduce
Shell argues that investing in high performing lubricants and lubrication programmes could provide the answer to meeting productivity , cost , and sustainability challenges all at once
emissions by up to 20 %. In short , the humble lubricant – so often the first consumable cut when pressure is on – could provide a lever to answering mining ’ s seemingly impossible paradox of producing more , while emitting less , and achieving tangible results today .”
In key mining regions , Shell recently announced its plan to build its first grease manufacturing plant ( GMP ) in Indonesia . The plant is a new addition that will compliment Shell ’ s existing Marunda Lubricants Oil Blending Plant ( LOBP ) in Bekasi , Indonesia .
Upon completion , Shell ’ s new GMP in Indonesia will be capable of producing up to 12 kilotonnes of grease per year , helping to meet the growing demand for premium grease products in the country . The plant will be built with the latest technology , including a contact reactor , to enhance agility and efficiency .
Jason Wong , Global Executive Vice President of Shell Lubricants , said , “ Shell ’ s success has always been built upon our ability to meet and anticipate our customers ’ ever-changing needs . This investment by Shell in Indonesia is yet another example of our commitment to this philosophy of putting customer demand at the heart of our business . Indonesia ’ s economy has grown rapidly in recent years and lubricant products , including grease , are essential enablers for the country ’ s growth ambitions in almost every sector . By bringing our supply closer to end users in a reliable , efficient , and sustainable manner , this project will ensure we can be there for our customers for years to come .”
International Mining | JULY 2024