In the heart of Ghana, nestled within the bustling activity of the Chirano Goldmine, a silent revolution was underway. The mine, operated by Kinross, was home to a fleet of 40 robust Volvo FMX 440 mining trucks. These vehicles were the lifeblood of the operation, tirelessly transporting materials across the mine’s rugged terrain. However, beneath their sturdy exteriors, a significant challenge was brewing. Can offline filter be of help?
The Challenge: Battling the Elements
The harsh, dusty environment of the Chirano Goldmine placed enormous strain on the engines of these trucks. The engine lube oil, crucial for smooth operation, was quickly degraded by the conditions, necessitating changes every 500 hours. This frequent maintenance was not only costly but also resulted in high wear rates on the engines. With each truck clocking in 6,000 hours annually, the maintenance schedule was grueling: endless service intervals and repeated engine overhauls.
The Solution: A Leap Forward with CJC™ Offline Filter
Enter CJC™ Heavy Duty HD HDU 15/12 offline filters with CJC™ Filter Inserts BG 15/12. These sophisticated filters were installed in a kidney loop system, designed to keep the oil clean and extend its life. The initial test was conducted on a single truck, and the results were nothing short of remarkable. The oil change interval was extended from a mere 500 hours to over 1,500 hours. Engine wear was significantly reduced, showcasing the effectiveness of maintaining clean oil during operation. This innovative solution promised not only to revolutionize the maintenance schedule but also to bring substantial financial and environmental benefits.
Financial and Environmental Transformation
The impact of full implementation across the fleet was profound. Kinross realized annual savings of $681,800, a combination of reduced engine running costs ($594,000), lower labor costs ($27,000), and decreased oil costs ($60,800). This financial boon was accompanied by an impressive reduction in oil consumption. The mine’s annual oil usage plummeted from 36,480 liters to just 6,080 liters—a reduction of 30,400 liters.
The Broader Impact: Efficiency and Sustainability
With the new filtration system in place, the service intervals were drastically reduced. Instead of performing 480 services annually, the number dropped to 160, slashing downtime significantly. Moreover, the major engine overhauls, previously required every 10,000 hours, could now be extended to 18,000 hours. For Kinross, this meant reducing overhauls from 24 per year to just 13, saving considerable costs and labor.
Conclusion: A Model for Industry-Wide Adoption
The success story of Kinross at the Chirano Goldmine is a testament to the power of innovation in overcoming operational challenges. By adopting CJC™ oil filtration technology, the mine not only optimized its maintenance processes but also achieved substantial cost savings and environmental benefits. This case study serves as an inspiring example for the mining industry, illustrating how targeted technological interventions can lead to remarkable improvements in efficiency and sustainability.
As the trucks at Chirano Goldmine continue their relentless journey across the mine, they do so with a newfound resilience and efficiency, driving Kinross toward a brighter, more sustainable future.
