Open gears in mining operations run under extreme loads, high temperatures and dusty conditions, making them vulnerable to wear, unplanned downtime and reduced equipment life. Advanced lubrication and technical inspections are essential to maintaining reliability. However, a recent range of lubricants has provided greater levels of protection for open gears.
The Shell Gadus OG grease range is designed to protect open gears under shock loads, reduce wear and provide emergency lubrication through optimal graphite levels. The greases are REACH compliant, free from harmful chemicals and easy to apply.
By adopting Shell Gadus and working with the Shell LubeExpert team, Maaden Barrick Copper Company (MBCC) reportedly saved nearly $1.8 million.
MBCC integrates advanced technologies such as geophysical surveys, AI and data modelling to improve mineral exploration while supporting sustainability initiatives. During a review of its open gear equipment, MBCC identified inadequate lubrication that risked premature failure and downtime. A Shell LubeExpert audit found the existing grease underperformed in extreme temperatures, while a poorly positioned spray bar wasted lubricant and increased consumption by 25%. Limited monitoring and support further threatened the pinion gear’s expected service life.
Shell recommended trialling Shell Gadus S4 OG Clear Oil 2000 for improved viscosity and protection, redesigning and relocating the spray bar, installing larger grease containers and planning improvements for the next shutdown. After a two-month trial, the new grease demonstrated stronger film performance above 100°C and better pumpability below 10°C. The spray bar redesign reduced excess grease use and improved protection, extending pinion life, lowering maintenance costs and preventing downtime.
The takeaway? High-quality lubricants combined with expert audits and digital monitoring can significantly improve reliability and total cost of ownership in mining operations. For more detail of this impressive turnaround that saved $1.8 million see the full article here.