19th of February 2004Gregory Crinum Mine1

Gregory Crinum Mine – Rotary Breakers

Gregory Rotary Breaker - Old Lubrication System

Crinum Rotary Breaker - New Lubrication System

19th of February 2004Gregory Crinum Mine2

Rotary Breaker – Lubrication System Improvements

PROBLEMS

• Lubricant being splashed on the Rotary Breaker chain and surrounding structures

• Lubricant spillage causing an imminent workplace and safety issues

• Unnecessary waste of lubricant• Environmental impact (Penetration into the soil,

costly and unsafe disposal)

19th of February 2004Gregory Crinum Mine3

Rotary Breaker – Lubrication System Improvements

Lubricant spillage

• Chain splashing lubricant over surrounding structures

• Pools of lubricant laying underneath Rotary Breaker

•Lubricant deteriorating floor plate and dripping into the ground

19th of February 2004Gregory Crinum Mine4

Rotary Breaker – Lubrication System Improvements

OBJECTIVES

• Improvements to current Automated Lubrication System

• Addition of air operated pump to agitate lubricant prior to pumping

• Addition of brushes for lubricant application• Ensure that lubricant reaches critical points on the

chain

19th of February 2004Gregory Crinum Mine5

Rotary Breaker – Lubrication System ImprovementsCOMPARISON

Previous System Automated Lubrication System: Lubricant

application for 10 seconds every 40 minutes Consumption: 205 Litre Drum of Mobil 630 or BP GR

– XP 220 per month. (Not including down time due to shutdowns or other maintenance factors)

 Cost: 205 Litre Drum - $351.35

19th of February 2004Gregory Crinum Mine6

Rotary Breaker – Lubrication System ImprovementsImproved System Automated Lubrication System: 300mL of

Lanotec Heavy Duty Lanolin (HD) applied during 10 seconds every 8 hours (3 applications daily).

 Consumption: 205 Litre Drum of Lanotec Heavy Duty

Lanolin (HD) will allow for 683 applications, which is equivalent in time to 7.5 months. (Not including down time due to shutdowns or other maintenance factors).

 Cost: 205 Litre Drum – Price on application

19th of February 2004Gregory Crinum Mine7

Rotary Breaker – Lubrication System Improvements

New System Installation

• New Lanotec Lanolin drum

• Air pump installed

• Lubrication lines installed

• Brushes installed

19th of February 2004Gregory Crinum Mine8

Rotary Breaker – Lubrication System Improvements

 3-MONTH TRIAL (Started November 2003) Results Improved Automated Lubrication System

• Controlled and efficient application of lubricant• Lubricant application in critical areas• Excessive presence of lubricant in chain and

surrounding structures eliminated• Lubricant waste factor eliminated

19th of February 2004Gregory Crinum Mine9

Rotary Breaker – Lubrication System Improvements

Equipment Life

• Chain life was approx. 4-5mths• Chain life currently 3 years and still going!• Sprockets wear reduced• Deterioration of surrounding structures reduced

19th of February 2004Gregory Crinum Mine10

Rotary Breaker – Lubrication System Improvements

Performance & Costs

• Improved equipment efficiency• Reduced maintenance costs• Increased maintenance intervals• Increased equipment life• Reduction of lubricant drums in stock• Down time and loss of production reduced• Workplace health and safety impact reduced• Disposal costs eliminated

19th of February 2004Gregory Crinum Mine11

Rotary Breaker – Lubrication System Improvements

Environmental

• Lubricant is bio-degradable• Non toxic• Non carcinogenic• Ozone friendly• Safer to dispose

19th of February 2004Gregory Crinum Mine12

Rotary Breaker – Lubrication System Improvements

Results

• No lubricant spillage

• System performing efficiently

• Chain properly lubricated

• Cleaner work area

19th of February 2004Gregory Crinum Mine13

Rotary Breaker – Lubrication System Improvements

COST EFFECTIVE RESULTS 12 Months Expectations

• Savings of $604.19 in lubricant purchase per year• Maintenance costs reduced (equipment, parts and

labour)• Lubricant usage reduced from 2460 Litres (12

drums) to 328 Litres (1.6 drums) per year• Delivery and storage costs reduced• Handling and disposal costs reduced

19th of February 2004Gregory Crinum Mine14

BMA Savings (over 2 yrs) usingthe Lanotec Lubrication System

Old System Lanotec System

Lube System N/A $3,000

Lubricant Cost $9,200 $7,500

Chain replacement(5) $30,000 NIL

Labour on above $3,000 NIL

Lost Production (30hrs) $3,000,000 NIL

TOTAL = $3,042,000 $10,500

SAVINGS (2yrs) = $3,031,500

19th of February 2004Gregory Crinum Mine15

Rotary Breaker – Lubrication System Improvements

INITIAL INVESTMENT

• Chain Lube Pump/Spray unit• Installation

TOTAL COST:  Price on application

19th of February 2004Gregory Crinum Mine16

Rotary Breaker – Lubrication System Improvements

CONTACT INFORMATION

MARK PEATEYCHPP MAINTENANCE PLANNERGREGORY CRINUM MINEBHP Billiton Mitsubishi AlliancePO Box 1526Emerald, QLD 4720Phone (+61) 07 4982 8237Fax (+61) 07 4982 8274Email mark.m.peatey@bmacoal.com

 

STEVE GREENWESTERN AUSTRALIAN BUSINESS DEVELOPMENT MANAGERLANOTEC AUSTRALIA PTY LTD

Phone (+61) 07 3373 3700Mobile (+61)417 638 004Email sgreen@lanotec.com.au