Don’t let mining operations come to a halt due to equipment failure.
One unscheduled downtime event during a single shift can cost millions in lost productivity (Mining Weekly). In mining operations, downtime comes in two forms:
- Scheduled downtime for maintenance
- Unscheduled downtime from unexpected equipment failures
While no one wants downtime, planned maintenance is far less costly than the alternative. Without a solid preventative maintenance program, especially for critical systems like your compressors, you’re gambling with productivity, safety, and profit.
MCE Rotating Equipment Solutions have techs with expertise in the mining industry and can assist in selecting equipment for the needed application along with maintenance programs to keep that equipment running efficiently.
Let’s break down why compressor system maintenance matters more than you might think:
Mining’s Overlooked Fourth Utility: Air Compressors
Compressed air plays a vital role in both surface and underground coal mining, serving as a primary source of power for pneumatic tools, ventilation, and material handling.
Some air compressors run continuously to keep adequate system pressure in and outside of mines, making them among the most energy-consuming systems. These units power:
- Pneumatic tools
- Drilling pickers
- Pumps
- Fans
- Turbine lights
- Cranes, conveyors
- Loaders, excavators
- Ventilation & process air systems
Also known as the fourth utility, compressed air works alongside water, electricity, and natural gas but is largely overlooked when considering regular service and maintenance. That’s a big problem when failure strikes across any of these systems.
MCE delivers high-quality compressed air solutions to keep your mining operations efficient, safe, and cost-effective.
Compressed Air in Harsh Mining Conditions
Coal mining operations are notoriously harsh and demanding, placing extreme stress on both workers and machinery. The environment is often characterized by constant exposure to contaminants, abrasive dust, high humidity, fluctuating temperatures, mechanical strain, and confined underground conditions. These factors can severely impact the performance and longevity of air compressors and their associated tools.
In these environments, without proper maintenance and rugged design, compressors are prone to accelerated wear, corrosion, and failure, which can lead to significant safety and operational risks.
For this reason, smart coal mining operations keep backup compressors on standby, just in case.
In an industry where failure is the difference between life and death or millions in lost productivity, equipment reliability is everything.
The Cost of Compressed Air Leaks in Mining
Air leaks are another hidden drain on system efficiency. Typical compressed air systems lose between 30% and 50% of their volume to air compressor leaks, with poorly maintained systems running as high as 80%. That’s not just air; it’s wasted energy and money.
In mining, one uncontrolled airline leak can impact critical air pressures, degrade tool performance, and destroy operational timelines.
Downtime costs add up fast: on average, a mining machine failure can cost $180,000 per incident, and some operations report losses of $130,000 per hour during critical downtime.
Air Compressor Maintenance Tips for Mining Operations
An air leak audit is the first step in a proper air compressor maintenance program. The trouble is that air audits are not always feasible in mining operations due to safety and certification concerns.
However, mining operators can cut operational costs, improve safety, boost productivity, and meet environmental standards by investing in strong maintenance programs and rapid service response.
MCE recommends the following:
1. Watch for Pressure Drops
Significant pressure drops often signal air leaks, especially common at hose fittings and connectors. In mining, flexible hoses are used out of necessity (due to mobility and terrain), but they’re less efficient than smooth-walled pipe and more prone to leaks.
2. Inspect Fittings Regularly
Always check hose joints and threaded connections. Even silent leaks can cost you, and those small leaks make your compressor work harder, increasing energy use and wear.
3. Prioritize Durable Piping
Where possible, replace hose with aluminum air lines or smooth-wall pipe to reduce flow resistance and leaks. Complete replacement may not be feasible in mining, but any strategic upgrade can help performance.
4. Perform Site Inspections
The compressed air division can perform fitting inspections to identify high-loss areas above ground. Underground inspections may be limited due to site-access restrictions, but surface systems can still benefit from proactive maintenance.
Additional maintenance tips from our manufacturer partner, Kaishan USA:
- Implement annual preventive maintenance
- Replace filters and desiccant regularly
- Pair compressors with desiccant dryers to ensure air purity
- Use infrared/ultrasonic leak detection tools to find and fix leaks early
- Monitor system performance using flow and pressure sensors
- Establish a leak management program with ongoing tracking and repairs
Containerized Compressor Units
There’s another way you can protect your air compressor systems. Many mining operations use containerized systems to protect equipment and gain added floor space.
What is a containerized air compressor unit?
Containerized compressor systems are smart, turnkey solutions for harsh above-ground mining environments. The units are completely packaged systems that include all the needed equipment - piping, wiring, and heating. They are ready to Plug-and-Play. All you have to do is connect incoming power and discharge the airline. This reduces costs of additional infrastructure and permits for typical installations.
Using a containerized compressor system provides benefits from easy deployment, cost savings, added environmental protection, and improved serviceability.
Why consider a containerized compressed air unit?
Containerized units reclaim valuable indoor space and allow on-site serviceability, even during operation. Other benefits include:
- Climate resistant from the worst weather conditions (-40°F to 130°F)
- Protects compressors, dryers, receivers, and plumbing against dirt, debris, dust, and moisture
- Technicians can work on the unit while it remains operational
- Frees up interior space in existing buildings
- Avoids the cost and hassle of building fees and permits needed for a permanent compressor room
- Sound dampening insulation for quieter operation
- Basic heating for winter conditions
- Locked doors for added security
- Options for complex fire suppression
MCE also provides emergency services and rental compressors when units fail.
Choosing the Right Compressed Air Solution for Mining
MCE solutions carry the world’s best air compressor systems and support all your repair, preventative maintenance, and spare parts management. We also pair compressors with desiccant dryers, essential in humid mining environments to ensure clean dry air.
The key to optimal air performance is to right-size your system, especially when using a rotary screw air compressor. Choosing a system with too much capacity is as bad as choosing one with not enough. But don’t worry. Our team of experts can help you size your system appropriately.
Learn more about our Air Compressor Experts.
Why Choose MCE for Compressed Air Systems
Your air compressor system’s success rests on four pillars: the compressor unit, the manufacturer of the unit, your compressor’s system design, and a trusted service provider. We understand your entire system, not just the compressor. This includes proper sizing, integration with existing infrastructure, and long-term compatibility across components and control systems.
We prioritize energy efficiency and total cost of ownership.
We focus on lifecycle costs and compare energy consumption, maintenance expenses, and operational efficiency over the system’s lifespan. Additionally, we supply clear data on anticipated savings and payback timelines.
We offer expert service capabilities and support.
We’re there with you for the long haul. We understand the complex needs of the coal mining industry and have decades of expertise to support your specific operational needs. All our service techs are MSHA-certified, and some are electrically certified for work in mining environments. We provide ongoing support, including preventative maintenance, troubleshooting, rebuilds, and critical spare parts management.
MCE recommends Kaishan USA’s large rotary screw compressors for their durability, availability of parts, customer service, and strong warranties. MCE is a Kaishan USA Authorized Distributor.
Don’t wait for a breakdown. Optimize your compressed air system today.
Contact us to discuss your needs.
Clean, dry, and compressed air goes a long way in ensuring your operation’s quality, safety, compliance, and profitability. We can help with system design and consultation, preventative maintenance, emergency services, and routine inspections.