CJC™ in The Mining Sector

Rough Environment - Smooth Filtration

C l e a n O i l - B r i g h t I d e a s

Mining Applications

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We all depend upon our machinery performing well- and performance improves with clean oil

Crushers

Lube oil,hydraulic oil

Extreme contamination of the oil systems with

particles and water causescritical downtime and

high replacement costs for these cost-intensive

components.

Mills

Lube oil, gear oil

Huge loads on bearings and gears lead to wear.Dirt and water ingress

damage the system components. Depending

on the process, increasedtemperatures can also

accelerate the oil ageing.

DrillingEquipment

Hydraulic oil

Dirt and water in the oil systems cause wear, corrosion and erosion on

pumps, cylinders and bea-rings. Oil degrada-

tion products result in malfunction of critical

components.

Dump Trucks & Excavators

Hydraulic oil, gear oil,lube oil, diesel

Changing operation conditions and rough

environments entail dirtand condensate in the oil.

Vibrations and impactload cause additionalwear and abrasion.

Baltzer Grafik • Mining Segment • UK • 05.2010

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Have Your Oil Systems ever Experienced...?Extreme dust ingress?

Unforeseen breakdowns?

Excessive wear on components?

Frequent oil changes?

- All can be avoided by using CJC™ Offline Oil Filtration!

MineralProcessing

Hydraulic oil

In every stage of mineral processing, maintenance of the fluid systems can enhance process

stability and efficiency.

Storage Tanks

Lube oil, hydraulic oiland diesel

Oil and fuel are already contaminated with particlesand condensate by trans-portation and transferring.

During storage, diesel can additionally be polluted with microbes.

Conveyor Belts

Gear oil, hydraulic oil

In addition to the dirt ingress from the

environment, gear and hyd-raulic oil systems

in conveyor belts are contaminated with

wear particles and oil degradation products.

Truck Shop Service

Vehicle fleet, oil systems

With a specially designed mobile filtra-

tion unit, cleaning of the vehicles’ oil systems canalso be carried out during

general and planned maintenance.

The Most Common Types of Wear

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80% of all machinery repair and maintenance costs arerelated to contaminated oil

Particles

Water

Varnish/resin

“Sandblasting” When particles are transported with the oil flow, the particles col-lide with metal parts, destroyingthe metal surface and formingnew particles.

GrindingWhen clearance sized hard particles are wedged betweenmovable metal parts, they destroy the metal surface further and can result in additional wear.

CavitationCavitation occurs in areas where water is present and oil iscompressed. The water implodesand blows particles off the metalsurface, which then cracks.

CorrosionWater or chemical contaminantsin the oil cause rust or chemicalreactions, which deteriorate thecomponent surfaces.

Oil DegradationOxygen, water and high tempe-ratures lead to oil degradationwhich is the precursor of var-nish/resin deposits.The result of these deposits is a “sandpaper-like” surface onmachine parts.

Oil care is a must, especially in dirty environments like mining applications,because up to 80% of all machinery repair and maintenance costs can betraced back to contaminated system oils and fluids. This has been substan-tiated by several independent analyses. The main cause is wear induced bycontamination through solid particles, water, and oil degradation products,which are not retained effectively by most inline filters.

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Particles

Water

Varnish/resin

Removal of ParticlesParticles down to 0.8 μmare retained in the uniqueCJC™ Filter Insert mass.

Removal of WaterThe CJC™ Filters can either absorb or separate the water according to oil system requirements.

Removal of Degradation ProductsResin in the oil will be attracted to the polar fibres in the CJC™ Filter Inserts.

One Filter - Three SolutionsCJC™ Offline Filters remove particles, absorb waterand retain oil degradation products round-the-clock

CJC™ Offline Filters do not only remove solid particles and water. They alsoretain oil degradation products - “soft contaminants” - which are the pre-cursors to the sticky varnish that deposits on metal surfaces. Varnish cannotbe removed by traditional filtration, but with the CJC™ Filter Insert, it can.

Traditional Inline Filtration

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In most applications the inline filter alone, cannot keepan oil system clean

Inline filters are usually of very compact design but must still cope with highflow rates. This affects their minimum pore size, and consequently, the opti-mum oil cleanliness can rarely be achieved. Oil degradation products, waterand microparticles will accumulate in the oil.

Millipore membrane

Sample taken before installation of offline filtration

External EnvironmentWater from the external environ-ment enters the system via theelements, high-pressure water bla-sting, washing etc.

Wear & Tear Particles Wear particles are generated inside the oil system.

Air VentParticles and water ingressthrough the air vent.

Internal EnvironmentWater condensation in the oil reservoir, due to temperature variations.

Acid Produced by OxidationHigh temperature + contaminatedoil = acid and resin.

Rust /CorrosionWater initiates the formation of rust particles which are very hard and abrasive particles.

Cooler Leaking WaterA leaking cooler results in wateringress to the oil reservoir.

Varnish/ResinOil degradation products,microparticles and water are accumulated in the bottom of the oil reservoir.

Contamination Sources:

Oil systemHydraulic, gear,lube, etc.

Inline filter

System pump

InlineFiltration

Principle drawing of inline filtration

Round-the-clock removal of particles, water, and oildegradation products all in the same operation

The CJC™ Offline Solution

CJC™ Offline Filters are easy to install and the depth filter insert has a verylarge dirt holding capacity. CJC™ Filters have low operation costs and arealmost maintenance free. All CJC™ Fine Filter Inserts have a 3 μm absolutefiltration ratio and will remove particles, water, and oil degradation pro-ducts, all in the same operation.

External EnvironmentWater ingress from the environmentis continuously removed from thesystem with CJC™ Filters.

Wear & Tear Particles Wear and tear particles are stillbeing created, but are removed by the CJC™ Filter.

Air VentContamination can be reduced byadding an airborne silica gel filter.

Internal EnvironmentWater still condensates in the oilreservoir, but with the CJC™ Filtersinstalled, the water is removed before it reaches the oil system.

Acid Produced by OxidationThe risk of developing acids and oxidation by-products has been considerably reduced.

Rust /CorrosionContamination is still being createdbut is removed by the CJC™ Filter.

Cooler Leaking WaterThe leaking cooler can be repaired at scheduled overhauls as the CJC™ Filters continuously removewater in large volumes.

Varnish/ResinOil degradation products and micro particles have now practically disap-peared from the bottom of the oilreservoir.

Contamination Sourcesare now under Control:

Oil systemHydraulic, gear,lube, etc.

Inline filter

System pump

OfflineFiltration

The CJC™ Filter

Clean oilis returned

to the oilreservoir

Clean oil

CJC™ Filter Insert after use 7

Principle drawing

of offline filtration

Millipore membrane

Sample taken afterinstallation of offline filtration

CJC™ Filter Insert before use

Rough Environment - Smooth Filtration

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Each application performs specific tasks - as do CJC™Offline Filters in order to ensure high oil cleanliness

The most effective and economical way to maintain oil in the many systemsfound in mines, is to use CJC™ Filters. Equipment reliability and lifetime canbe dramatically increased by introducing an offline oil filtration system.

CrushersThe key equipment for effective production in amine are the Primary, Secondary and TertiaryCrushers. They operate under extreme environmentalconditions which can lead to badly contami-nated system ISO cleanliness levels as highas 27/25.The recommended level should be 16/14 (100times lower) if the crushers are to operate reli-ably and efficiently.

Seal failures cause water and particle conta-mination and oil degradation.The combination of all contaminants resultsin wear of system parts and component failu-re. These failures lead to unscheduled stoppa-ges and unbudgeted replacement of parts.This is particularly relevant for sensitive com-ponents such as bushings, socket liners andbevel gears.

Most importantly, the effect of contamina-ted oil is down-time and lost production.

MillsMills in mines operate under extremely roughenvironmental conditions leading to very con-taminated oil that results in high ISO classes.The recommended ISO cleanliness level of theoil is 19/16/13, if the mills are to work reli-ably and effectively, and thereby add to aprofitable production. Typically, the CJC™ FineFilters, Filter Separators, and Desorbers areinstalled on the lube oil systems containing400 - 10,000 L of oil.

The lube oil system is most often contamina-ted by oil degradation products, silica dust,and water. The result of this contaminationcan be extremely expensive repair anddowntime. The most sensitive componentsare bearings and bronze bushings found inthe system.

The most important effect of contamina-ted oil is lost production.

CJC™ HDU 2x27/108

CJC™ PTU3 27/81

CJC™ HDU 27/108

CJC™ HDU 27/54

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CJC™ Offline Filters for Mining Applications

Dump Trucks & ExcavatorsEarth moving equipment operates underextreme operating conditions. The exposureto extreme weather, a dusty environment andhigh vibration can severely stress the sensi-tive system components.The particle contamination in the oil is oftenvery high. Problems also occur with moisturedue to frequent start/stops. Furthermore, theharsh operation conditions cause oil degra-dation, leading to reliability issues and lostproduction.

By installing CJC™ Filters these problems willbe reduced to a minimum. Sensitive compo-nents such as hydraulic pumps, motors, trans-mission gears, steering systems and injectorpumps will operate more efficiently and forlonger hours, thus increasing reliability andequipment lifetime.

For all systems, it is possible to reduce oilchanges and maintenance costs, therebyachieving fast pay back on investment.

Storage TanksOil delivered to storage tanks is generally con-taminated with particles, water and sludge. Oilcleanliness levels of ISO 23/21/19 are com-mon.

Installation of a CJC™ Offline Filtration Systemwill clean the oil in the tanks to the cleanlinesslevel required by the machine manufacturers(trucks, dozers, excavators). The recommen-ded ISO cleanliness level is 19/16/13, whichenhances the performance of the machineryimmediately.

The above mentioned is also applicable to die-sel oil storage, where the diesel bugs (microbi-al contamination) are a major problem.

The key to reliable machinery and effec-tive production is clean oil and diesel.

CJC™ HDU 27/27

CJC™ HDU 15/25

CJC™ HD HDU 15/25 Heavy Duty Filter

CJC™ HDU 427/108

CJC™ PTU3 2x27/108

HDUSeries

CJC™ Series of Solutions

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All CJC™ Series are of uncomplicated design, easy toinstall and almost maintenance free

Using CJC™ Offline Filters will have a positive effect on your maintenancebudget as well as increase your productivity and reduce your energy con-sumption - all advantages in terms of total economy!

C l e a n O i l - B r i g h t I d e a s

PTUSeries

CJC™ HDU SeriesThe CJC™ Fine Filters remove particles, water, and oil degradation products fromhydraulic and lubricating oils and have flow rates from 45 to 20,000 L/h.

CJC™ Filter Inserts before use and after use, showing thelarge dirt holding capacity.

CJC™ PTU SeriesThe CJC™ Filter Separatorscombine depth filtration withwater separation and are usedfor water contaminated diesel,hydraulic and lubricating oils.

The CJC™ PTU Series continuously removes water from oil in large volumes.

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Optimal Oil Performance WithCJC™ Offline Filters

DesorberSeries

CJC™ DesorbersThe CJC™ Desorbers providesolutions for removal of water in mineral, synthetic and high viscosity oils.

The Desorbers remove watereven from stable emulsions andfrom oils with a density above 1.

FilterInserts

The CJC™ Filter Insert SystemThe unique modular build-up of the CJC™ Filter Inserts means thata CJC™ Filter can be sized to fitany applications and requirements.

Furthermore, they can be equippedwith a neutralizing media for removal of acids from oil.

CASESProblem solving and preventive maintenance are key-words in the mining industry

A CJC™ Filter Separator installed on one

of the crushers atKumba Iron Ore’s

Sishen Mine in the Northern Cape,

South Africa

Cases and Statements from Our Customers in Mining

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C l e a n O i l - B r i g h t I d e a s

Kumba Iron Ore’s Sishen Mine Application:Crushers

Savings of EUR 35,000 per crusher!

SolutionA CJC™ Filter Separator was installed with 4 x CJC™Filter Inserts, capable of retaining up to 16 kg of particles.

The CJC™ Filter removed 13 L of water in the first 24hours, continuing to remove water for another 2 weeks.Within 3 months, the ISO level was brought down from24/22 to an astounding 16/11.

The installation of the CJC™ Filter provided numerousbenefits in wear reduction. Replacement of bronze bus-hings for each crusher alone costs around EUR 35,000,and are replaced up to twice a year. A reduction of 50% in wear reduces the cost by EUR 35,000 per crusher - and Kumba Iron Ore’s Sishen Minehas 19 of these machines in their production.

Senior tribologist at Anglo American, Mr. Dave J. Gamble:

“The CJC™ Filter will give benefits such as redu-ced downtime for maintenance, greatly reducedwear and consequent failures, increased availa-bility, utilisation, and production. Together thisresults in extended oil lifetime”

ProblemSignificant ingress of contaminated particles into thelube oil system through a water flow seal under thecrusher head, also causing significant water ingress intothe lube oil system. The particle and water contaminationof the oil in turn significantly contributed to componentwear and subsequently large volumes of metallic partic-les being suspended in the lube oil as a result.

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ProblemThe main lubricating system of 6,000 litres of oil was highly conta-minated with pulp (ore-silica-water). The contamination causednumerous production stoppages.

SolutionA CJC™ Fine Filter with a dirt holding capacity of 8 kg was instal-led. The oil was passed through the filter only once. After seeingthe instant visual improvements of the oil, CMD authorised pay-ment for two additional CJC™ Filters.

After 5 days, the oil and storage tank was clean, avoiding any pro-duction stoppages, costing in the region of USD 90,000 per stop.

CMD's investment costs including spares were USD 10,000.

Mr. Fernando Cavassa C,Grinding Maintenance Chief - CMD L.B.

“The equipment was installed just to cleanthe oil periodically. However, due to the out-standing results, it has been installed to ope-rate continously.”

ProblemThe Minera El Tesoro has four tanks for storage of new oil, with acapacity of 10,000 litres each. Every 15 days, the tanks are topped-up with 5,000 litres of new oil.When the oil arrives in trucks it is highly contaminated from thetransportation process. Caterpillar and other manufacturers ofearth moving equipment recommend a cleanliness level of ISO19/16/13, with the purpose of maintaining reliability and economicaloperation of their equipment, i.e. drilling machines, dumpers etc.

SolutionA CJC™ Fine Filter was installed on each tank, operating with afiltration of 3 μm absolute and 0.8 μm nominal. Each CJC™ FilterInsert has a dirt holding capacity of 4 kg and a water absorptioncapacity of 2 litres. The CJC™ Fine Filters absorb resin, and oildegradation products as well.

ESSO Chile

“Benefits of a filter system maintaining cleanoil can be seen in the extended life time ofmechanical components of earth movingequipment. This is partially due to the sub-stantial reduction of particles greater than 6micron”.

ProblemGeneral repair needs, erosion in pumps and cylinders. Frequent oilchanges and downtime.

SolutionAfter installation of CJC™ Offline Filters, the benefits of impro-ved cleanliness levels are a noticeable reduction in repairs and redu-ced erosion of pumps and cylinders. As a result, the expense of oilchanges and service intervals is reduced.

The filter inserts are generally changed twice a year, at the sametime as when other service is needed. The pressure gauge on thefilter makes it easy to supervise the dirt holding capacity.

The CJC™ Filters do not need any service other than, the changeof the filter inserts.

Mr. Ari-Pekka Jormanainen, Project Manager, E. Hartikainen Oy

“We have used CJC™ Offline Filters for manyyears. We now have 20-30 Filters in operation.We take oil samples after installation of a fil-ter and follow up with random samples - andthe oil is always very clean.

SAG Mill,Disputada de Las Condes CMD,Mining Company, Chile

CJC™ Filtersinstalled in Minera El Tesoro,Chile

E. Hartikainen Oy,Talvivaara Mine,Finland

Downtime no longer under-mines Operational Liability

Disputada de Las Condes CMD

Minera El Tesoro

Talvivaara Mine

Application:Ball Mill SAG

Application:Storage Tanks

Application:Atlas Copco Drill Rig

Clean Oil Clean Oil - Bright Ideas

At C.C.JENSEN, our mission is unmistakable - CO2 emissions must be redu-ced to help the global environment.

The company contributes to this goal through the development of BRIGHTIDEAS and by making them accessible to the rest of the world.

We are fully aware of the importance of CLEAN OIL, both for the environ-ment and the economy. Offering our customers CLEAN OIL is the aim of allinitiatives and development programmes within the company.

C.C.JENSEN is respected as a company that offers values such as quality,traditions, reliability, credibility and stability. C.C.JENSEN is actively workingtogether with customers, promoting "green" solutions to benefit the globalenvironment.

At C.C.JENSEN, we are firmly committed to assisting in the global goal toreduce emissions, and this is why we believe that CLEAN OIL - BRIGHTIDEAS makes sense.

C l e a n O i l - B r i g h t I d e a s14

- Bright Ideas

CJC™ Filter Inserts are made of 100%

organic material

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Removal of by-products before they have time to reactfurther and form insoluble sludge and varnish deposits

Oil degradation by-products cannot be removed with conventional mechani-cal filters because they are submicron particles. It is a fluid in a fluid - likewhen sugar is dissolved in coffee.

These by-products can be removed by CJCTM Fine Filters and CJCTM FilterSeparators through a combination of adsorption and absorption processes.

Adsorption is the physical or chemical binding of molecules to a surface (likegetting a cake thrown into your face). In contrast with absorption, in whichmolecules are absorbed into the media. See illustrations.

CJCTM Filter Inserts, made of cellulose fibres, have a high surface area andcan be effective as adsorbents and absorbents. In addition, due to theirchemical nature, they are highly suited to pick-up oxygenated organicmolecules, such as oil degrading products.

C.C.JENSEN All Over the WorldThe CJC™ Offline Filters are distributed by our own inter-national sales organisations and designated distributors

Your Local CJCTM Distributor We are represented all over the world by distributors.

Find your nearest distributor on our website: www.cjc.dk

- or give us a call.

C l e a n O i l - B r i g h t I d e a s

Manufacturer & Headquarters

C.C.JENSEN A/SLøvholmen 13 • DK 5700 Svendborg • Denmark Tel. +45 6321 2014 • Fax: +45 6222 4615filter@cjc.dk • www.cjc.dk

Benelux C.C.JENSEN Benelux B.V.Tel.: +31 182 37 90 29ccjensen.nl@cjc.dkwww.ccjensen.nl

Chile C.C.JENSEN S.L. LimitadaTel.: +56 2 739 2910 ccjensen.cl@cjc.dk www.ccjensen.cl

ChinaC.C.JENSEN A/S ChinaTel: +86 10 6436 4838ccjensen.cn@cjc.dkwww.ccjensen.cn

DenmarkC.C.JENSEN DanmarkTel: +45 72 28 22 22ccjensen.dk@cjc.dkwww.cjc.dk

FranceC.C.JENSEN FranceTel: +33 3 59 56 16 58ccjensen.fr@cjc.dkwww.ccjensen.fr

GermanyKARBERG & HENNEMANN GmbH & Co. KGTel: +49 (0)40 855 04 79 0kontakt@cjc.dewww.cjc.de

Greece C.C.JENSEN Greece LTD.Tel.: +30 210 42 81 260ccjensen.gr@cjc.dkwww.ccjensen.gr

Ireland C.C.JENSEN IrelandTel.: +353 61 374 943ccjensen.ie@cjc.dkwww.ccjensen.ie

ItalyKARBERG & HENNEMANN srlTel: +39 059 29 29 498info@cjc.itwww.cjc.it

Poland C.C.JENSEN Polska Sp. z o.o.Tel.: +48 22 648 83 43ccjensen@ccjensen.com.plwww.ccjensen.pl

Spain C.C.JENSEN Ibérica, S. L.Tel.: +34 93 590 63 31ccjensen.es@cjc.dkwww.cjc.dk

United Arab Emirates C.C.JENSEN Middle EastTel: +971 4 447 2886ccjensen.uae@cjc.dkwww.cjc.ae

United Kingdom C.C.JENSEN LTD.Tel.: +44 1 388 420 721filtration@cjcuk.co.ukwww.ccjensen.co.uk

USA C.C.JENSEN INC.Tel.: +1 770 692 6001ccjensen@ccjensen.comwww.ccjensen.com