Liquid Tungsten cuts iron wear by 70% in North Asia mine fleet

Jul 29, 2021 | engine wear, liquid tungsten

Liquid Tungsten cuts iron wear by 70% in North Asia mine fleet

Case study by Techenomics demonstrates capabilities of nanotechnology to optimise operations
Freezing cold or boiling hot, in dusty or icy conditions, the Liquid Tungsten nanotechnology distributed by Techenomics reduces friction and lowers operating temperatures, which leads to a reduction in the impacts of excessive iron in lubricants.

Even in an area where temperature extremes prevail year-round, the nanotechnology has demonstrated its effectiveness in improving the function of lubricants in a range of operating conditions, including at mines.

Laboratory testing and trials in the field by Techenomics have shown the value to equipment operators of adding Liquid Tungsten to oil and other lubricants.

Concerned with high iron levels and wear being generated in a mine mobile fleet comprising dump trucks, excavators, dozers and graders, operators approached Techenomics Mongolia in a bid to find a solution.

Due to the remoteness of the hard rock mine site, poor quality gear oil was initially used in the final drives of mobile equipment and high levels of iron wear were being experienced. This was as high as 0.97 grams per oil hour or a massive 19 kilograms of iron over a 20,000 hour operating life.

Site management decided that in an attempt to reduce the gear lubricant coefficient of friction, they would trial the Liquid Tungsten supplied by Techenomics, which is exclusive global distributor of the product to the mining industry.

The dosage was 3% and this was mixed into a 1,000-litre tank on-site for supply to five final drives.

In the differential, the result was a 77% reduction in wear – before adding the Liquid Tungsten the wear rate was 0.22ppm per hour while after putting the additive in the oil, the wear rate was just 0.05ppm/hour.

Owing to Techenomics’ long-term involvement with the operation a complete history of oil analysis was available and the iron generated per oil hour at each oil change was calculated and plotted. Overall, the iron generated per oil hour decreased by 70% while this also enabled the intervals between oil changes to be increased.

The results for the three final drives on a dozer are included in this release but for all five compartments iron generation was reduced to less than half a kilogram over a 20,000-hour component life.

Techenomics CEO Chris Adsett says that while other factors may come into play with respect to ultimate failure, it is believed that failure is likely to occur at any levels greater than one kilogram and reducing the iron generation to 0.03 grams per hour or less than one kilogram will greatly increase the life of these final drives – with a resulting considerable decrease in costs.

He says that this case study in North Asia is another example how Liquid Tungsten reduces friction and lowers operating temperatures, thereby reducing mechanical wear, increasing the life of lubricants, lowering fuel consumption, limiting maintenance and cutting emissions in the operating components of engines and other mechanical equipment.