Masana Energy Solutions Mining Brochure

MAJOR EFFICIENCY ADVANTAGES: THE HIGH PERFORMANCE OF CASTROL’S DEDICATED LUBRICANTS FOR THE MINING INDUSTRY OFFERS THE POTENTIAL OF REAL COMPETITIVE ADVANTAGE. 6. LONGER EQUIPMENT LIFE Castrol’s high performance products can help to provide protection against component wear, enhancing equipment life and helping to reduce repair and replacement costs. INCREASED PRODUCTIVITY High performance lubrication can lead to reduced failure risk, which can help keep equipment operating longer to deliver increased reliability and production output. EXTENDED MAINTENANCE INTERVALS High performance lubricants can help to extend equipment life, resulting in less downtime, reduced labour cost and higher productivity, reliability and production output. LOWER OVERALL LUBRICANT CONSUMPTION AND WASTE High performance lubricants specifically engineered and optimised for your applications can result in lower lubricant consumption, reducing your lubricant costs and helping to deliver an overall reduction in handling and disposal costs. CASE STUDY: Lubrication Survey & Product Rationalisation CASE STUDY: Pin & Bush Lubrication CASE STUDY: Reducing Mill Operating Costs CASE STUDY: Oil Cleanliness The following benefits were derived by a large smelter from the lubrication survey and rationalising of products: • Year 1 – 45 products used (Masana takes over lubricants supply contract) • Year 2 – 26 products used • Year 3 – 24 products used • Overall, 47% reduction in the number of products used • Currently, there are 53 material codes for various products and pack sizes used, loaded in SAP, which is a 65% reduction • Overall, 21% reduction in annual lubricants consumption By implementing a high performance grease in the bucket pin & bush application on a Komatsu PC 5500 hydraulic shovel in open cast mining, the following benefits were realised: • After 70,000 hrs negligible signs of pin wear • Bucket changes takes 3 to 4 hrs vs previous 1.5 days • Operating cost achieved was R0.01/ton • Machine availability increased from 85% to 95% • Cost avoidance on pin replacement and line boring costs was > R10mil over 10 year period Implementation of new technology open gear lubricant to lubricate large mill gears reduced temperatures and elimination of waste grease disposal, resulting in an annual operating cost reduction of R 2mil per annum on two mills. By implementing energy efficient gear oil in mill gearboxes, the solution reduced electrical consumption on two 4MG Auto Mills with resultant savings of R3.12mil in direct electrical cost. The saving was enough to power 250 homes for one year. Masana offers an option to manage the bulk oil cleanliness requirement to the point of dispensing, e.g. at the workshop, lube top-up bays and into the lube trucks. Actual new oil cleanliness achieved at the point of dispensing in a mine HME workshop: Engine oil: 15/13/7 Hydraulic oil: 13/12/8 Transmission oil: 14/13/10 ISO 22/21/18 ISO 16/14/11 ISO 18/16/13 ISO 14/13/11