Modern mining pushes equipment performance limits like few other industries. Gigantic excavators scoop rock all day in dusty deserts. Massive ore crushers grind chunks into powder a mile underground. Diesel trucks lug colossal payloads along steep inclines. Throughout this heavy-duty work, mining grease serves as a vital protective shield.
Specially formulated greases allow bearings, joints and moving parts to function reliably despite the tremendously difficult operating environments. Here’s a look at how advanced thickener, oil and additive technology empowers greases to conquer three common harsh conditions faced in mines:
Extreme Temperatures
Mines situated in Queensland’s tropical north or Canada’s frigid north face scorching heat or subzero cold. In low temperatures, ordinary greases solidify and resist flow. But synthetic polyalphaolefin (PAO) oils used in greases like Rhenus STARBIO PAO 100 resist thickening even at -50°C. This ensures smooth pumpability for cold start-up and running.
At the other extreme, high temperatures degrade cheaper greases quickly. But Klüberplex BEM 41-132 utilizes thermally stable polyurea thickener technology. It provides outstanding resistance for peak temperatures up to 140°C encountered near smelters or refractory kilns. Advanced greases optimize mining productivity in extreme climate zones.
Constant Moisture Exposure
Mines pump out gallons of groundwater every minute during operations. Conveyors and equipment get continually doused leading to lubricant washout. But highly adhesive water-resistant greases like Rhenus RBWX Complex retain their consistency. They utilize calcium sulfonate complex soap that does not dissolve easily when wet. Sodium additives enhance protection against corrosion. Such formulations withstand wet mines far longer before requiring re-grease.
High Load Conditions
Colossal compressive and shear forces are constantly exerted on bearings and pins during ore extraction and crushing. Under such extreme pressure conditions, ordinary greases get squeezed out from frictional surfaces causing wear and seizure. Sinopec noted that special EP additives in greases like Klüberplex BEM 34-132 react under pressure to form protective films on metal. These prevent direct metal contact even under 350,000 psi loads. This load withstanding ability is indispensable for smooth operation of high-impact mining equipment.
Apart from combating temperature, moisture and pressure stresses, advanced greases also provide benefits like –
- Resistance to acid and alkali extremes arising from mineral ores
- Protection against wear by solid contaminants like metal fragments or coal dust
- Stability under prolonged and intense vibration in crushers and screens
- Preventing electric current flow that sparks fires in coal mining
- Extended life through oxidation inhibitors that prevent oil thickening over time
Grease Fit for the Digital Age
In addition to harsh physical conditions, modern mines also present complex technological challenges. Sophisticated sensors and automation govern processes, requiring greases fit for the digital age.
Electrically Conductive Greases
Automated mining machinery like self-driving trucks or remote control LHD loaders contain sensitive electronics. Ordinary greases can cause current leakage or static buildup that damages circuits. But conductive greases like Klüber quiet BEM 34-132 contain carbon micro fillers that dissipate static charges. Their stable electrical resistance prevents malfunctioning of digital controls. They also resist stray radiofrequency signals that could corrupt control modules. Special conductive greases prevent downtime in automated mines.
High-Frequency Vibration Resistance
Mines utilize ultrasonic analysers, weigh feeders and metal detectors with inbuilt high-frequency transducers. But common greases inhibit effective signal transfer causing reliability issues. Fluorocarbon filler greases like Dow Corning 33 Extreme low temperature grease allow unimpeded transmission of high-frequency vibrations across lubricated parts. This maintains sensitivity of ultrasonic instruments that optimize ore processing and metal purity.
Non-Magnetic Composition
Magnetized greases interfere with magnetic sensors for monitoring vehicle position, drill depth or robotic arm articulation in automated mines. Klüberplex BEM 34-132 utilizes non-magnetic soap thickeners and is certified for magnetic particle inspections. Such neutral magnetism characteristics make the grease fully compatible with magnetic field-based instrumentation. This prevents sensor disruptions.
Low Noise Properties
Hydraulic excavators and drilling rigs rely on precise acoustic control mechanisms. Noisy grease formulations hamper the performance of acoustic valves and other sound-based error detectors. To enable flawless functioning, low-noise greases like Klüberquiet BQH 72-102 are formulated using ester oils that minimize friction-induced vibrations. The result is reliable equipment with advanced acoustics that enhances automated mining.
Overall, greases have to evolve technologically alongside the mines they serve. With automation and instrumentation permeating extraction processes, advanced electrical, magnetic, acoustic and frequency traits allow next-gen greases to deliver silent high-tech lubrication. They empower smooth functioning of the futuristic mine.
Specialized Greases for Innovative Mining Methods
Apart from harsh environments and digital tech, greases also enable newer sustainable mining techniques that reduce environmental footprint:
Tungsten Disulfide Greases for Vibration Dampening
Mines utilize high-frequency vibrating screens for dry mineral sieving as an eco-friendly alternative to water-based processing. But constant high-speed vibration strains bearings and joints. WS2 powder in greases like Klüberlub BE 41-542 absorbs vibration to protect equipment. This enables sustainable, dry sieving.
PFPE Greases for Leak-Free Marine Mining
For deep sea mining, leak-proof greases are a must to prevent aquatic pollution. Klüberbio LR 9-3 uses perfluoropolyether (PFPE) oil which doesn’t disperse if released into water. Its environmental safety enables greasing of dredgers, pumps and crawlers used in responsible marine excavation.
Methane Compatible Greases
Coal mines utilize methane drainage pipelines to capture fugitive emissions for power generation. To avoid pipe corrosion, greases like Kenlube USS2 utilize non-aromatic oils that prevent reactions with methane. Such chemically inert greases enable green methane capture initiatives underground.
Thus, from extreme climate resilience to digital-age conductivity, advanced mining greases equip equipment with multifaceted lubrication. By confronting diverse challenges, they enable smooth excavation, crushing and mineral processing. Grease technology innovations will continue playing a pivotal role as mining processes become heavier, automated, and more sustainable.
Final words
By using the latest thickener, base oil and additive chemistry, cutting-edge greases empower mining machinery to conquer the most difficult operating environments on earth. Based on the application, you may think about using the most appropriate to get work done.
