Mining Machine Health Solutions

Screens & Shakers

Screens and shakers are essential equipment for keeping mining operations running, yet the average facility suffers up to 30 failures per year for this asset type.

• Up to $20,000/hour downtime cost
• 4-20 hours of downtime, on average
• Long replacement lead times

Industrial Pumps

Pumps are the key to maintaining throughput in a mining operation, but they frequently fail due to the harsh conditions in which they operate and the difficulty of monitoring their health.

• Up to $30,000/hour downtime cost
• 4-24 hours downtime, on average
• Long replacement lead times 

Baghouse Fans

Baghouse fans keep production areas free of airborne fine particulate matter that can threaten the health and safety of your employees. The average baghouse fan fails up to 10 times per year.

• Up to $100,000/hour downtime cost
• 2-24 hours downtime, on average
• Long replacement lead times

Rotating Kiln Dryer

Frac sand mining operations rely on drying kilns to complete the critical final step in the production of sands used in paving. The trunnion bearings that keep them moving have to work constantly, increasing their rate of failure.

• $4,600/hour downtime cost
• Failing bearings can catch fire, causing safety issues
• 2-4 week lead time for new parts

Mills & Crushers

Jaw crushers and mills are used to break mine products into standard discharge sizes. Naturally, crushing ore causes high levels of wear and tear on these assets, and they’re difficult and often unsafe to monitor.

• Up to $100,000/hour downtime cost
• 4-30 hours of downtime, on average
• Long replacement lead times

Belt Conveyors

Bearing defects, clutch failures, and bent pulleys all contribute to conveyor system failures which can bring production to a standstill. Belt conveyor failures can also threaten worker health and safety.

• 12-24 hours downtime, on average
• Significant quality control issues
• Elevated risk of injuries

ID Fans

Induced draft fans are crucial to the mining industry. Failures on these assets can be costly as it can take a considerable amount of manpower to replace. Unexpected downtime from an induced draft air fan can get expensive, very fast.

• $250,000 per failure event in equipment costs
• Up to $20,000 per hour of unplanned downtime

Gearboxes

Gearbox failure is one of the most common reasons for malfunctions and production loss. In the mining industry, gearbox failures can lead to unplanned downtime, lost production and costly damage to connected equipment.

• $15,000/hour downtime cost
• 6-8 hours of downtime, on average
• Up to $100,000 per incident (secondary damage)

Reduce Operating Costs

Equipment and maintenance costs account for up to half of a typical mine’s operational expenditures, so any efficiency gains in the area of machine health represent a significant boost to your bottom line. Knowing when downtime should be scheduled to keep assets running at their best—rather than constantly reacting to disruptive equipment failures—keeps throughput high and makes better use of labor resources.

Keep Workers Safe

Equipment failures don’t just impact productivity. Mining equipment can fail catastrophically, posing a threat to the health and safety of your workers. Even routine monitoring and maintenance can lead to workplace injuries, since mining assets are often difficult to reach and operate in hostile environments. Continuous remote monitoring keeps your maintenance team safer and gives them more time to focus on reliability. Plus, the ability to forecast machine failure ensures that no one will be in the wrong place at the wrong time.