Global Mining Operator Saves $4.6M in Oil Costs
A Tier-1 global mining operator faced escalating maintenance costs due to extreme environmental dust and moisture contamination. High-viscosity gear oils and hydraulic fluids in critical machinery required frequent, costly replacements.
Component wear rates were increasing, threatening costly unscheduled downtime across processing assets.
Problem
Operating in a very remote, high-dust and fluctuating thermal environments, the client’s machinery was highly vulnerable to sub-micron particle ingress and emulsified water.
- Accelerated Component Wear: Fine silica dust particles bypassed standard OEM filtration, acting as an abrasive paste inside high-value gearboxes.
- Premature Fluid Degradation: Moisture contamination triggered rapid additive depletion and oil oxidation, forcing short drain intervals.
- Escalating Operational Costs: The operation was purchasing hundreds of thousands of litres of replacement oil annually, alongside soaring hazardous waste disposal fees.
Engineering Solution
The Lubemaster Approach
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On-Line Conditioning: Lubemaster systems were connected directly to live reservoirs, cleaning high-viscosity gear oils at full flow rates without stopping production.
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Submicron & Total Water Removal: The equipment simultaneously extracted fine wear debris and all phases of water (free, emulsified, and homogenised) down to trace levels.
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Zero-Element Filtration: By using Lubemaster’s wash-and-reuse system, the site avoided the ongoing procurement and disposal costs of traditional replacement filter elements.
It was determined that standard element-based filters were inadequate and cost-prohibitive due to constant clogging. The mining company installed customised Lubemaster units capable of continuous, high-volume conditioning.
Following a comprehensive engineering assessment by our experts, the client deployed an $880,000 targeted installation of Lubemaster filtration systems and oil analysis laboratory equipment.
The Impact
By installing a state-of-the-art laboratory and implementing online lubricant conditioning and restoring fluid cleanliness to levels exceeding those of new oil, the operator successfully eliminated premature oil replacement.
Over the first 12 months, savings from lubricant purchases alone totalled $4.6 million, with the investment paying for itself in under 10 weeks. Additional benefits included substantial reductions in waste disposal costs and improved equipment reliability through extended component service life – all results were laboratory supported.
The Financial Impact: Annual Savings $4.6m in Oil Costs
| Financial Metric | Before Lubemaster | With Lubemaster |
|---|---|---|
| Lubricant Purchases | High Volume/ Frequent | Drastically Reduced |
| Waste Oil Disposal | Continuous Dumps | Minimal Waste Streams |
| Component Replacement | Premature Failures | Extended Lifecycle |
| Replacement Filters | Less than monthly replacement | More than 1 year service life |
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- Oil Cleanliness Exceeded New Oil Standards: Lubemaster systems successfully brought the fluid contamination levels significantly lower than those of fresh, unconditioned drum oil.
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- Additive Protection: Because the filtration process is mechanical and non-chemical, vital anti-wear and extreme-pressure additives remained fully intact.
From the Client’s Engineeering Team
Achieve Similar ROI for Your Operation
The $4.6M annual savings are verified, but the peace of mind regarding plant reliability is worth even more.”
Get a Technical Evaluation on Your Lubrication Data
Don’t let contamination dictate your maintenance budget. Speak directly with our technical sales engineers to review your current oil analysis data or to scope a custom Lubemaster configuration for your site.
Call our Technical Expert: +61 7 4728 7777