Reduced oil consumption and downtime on gyratory crusher
Severe contamination ingress caused frequent oil changes and production shutdowns on a gyratory crusher. Installing a CJC® Oil Filter significantly reduced oil consumption, downtime, and operating costs.
Application Snapshot
Industry:
Mining
Country:
Chile
Oil type:
Lubrication oil, ISO VG 320
Executive summary
A gyratory crusher operating at Minera Escondida experienced heavy dirt ingress into the lubrication oil system. Despite almost daily in-line filter changes, oil changes were required every two months, each resulting in an eight-hour production shutdown.
A CJC® Oil Filter with high dirt holding capacity was installed to continuously remove contamination from the lubrication oil.
After installation, oil contamination was effectively controlled. Oil changes were reduced to one planned annual shutdown of six hours, resulting in major oil savings, reduced downtime, and significant financial benefits.
High dirt ingress controlled
The CJC® Filter removes up to 150 kg of dirt every two months, keeping lubrication oil clean despite harsh operating conditions.
Significant operational cost savings
Reduced oil consumption, waste oil handling, shutdown costs, and spare parts usage delivered substantial financial savings.
Fewer production shutdowns
Shutdowns were reduced from six events per year to one planned shutdown.
Lower oil consumption and waste generation
Oil consumption was reduced from 24,000 litres to 4,000 litres per year, significantly lowering waste oil handling.
Controlling heavy contamination in crusher lubrication oil
Before filtration, oil changes were required every two months due to severe contamination ingress. The system consumed approximately 24,000 litres of oil annually and required frequent shutdowns and spare parts replacement.
After installation of the CJC® Oil Filter, contamination was effectively controlled. The filter removed up to 150 kg of dirt every two months, allowing the oil to remain in service for extended periods.
As a result, oil changes were reduced to one planned annual shutdown lasting six hours.
Measurable results and operational impact
Annual oil consumption was reduced from 24,000 litres to 4,000 litres, saving 20,000 litres of oil. Waste oil handling costs were reduced from USD 19,200 to USD 4,800.
Production shutdowns were reduced from six eight-hour shutdowns per year to one six-hour shutdown, corresponding to shutdown cost savings of approximately USD 445,200. Spare parts usage was reduced from six components to two.
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