In ancient times, mining was genuinely a hectic task to perform. Workers get on their wits end after making some effort for the whole day. Extracting minerals and ores from deep down the Earth is not a piece of cake. Besides minerals and ores being rare, it requires excellent craftsmanship; maybe that is why mining is so expensive. 

Not only difficult, but extracting natural resources is quite dangerous for the workers. They need to work underground to reach the deepest layers of Earth to find those valuable ores. There is a risk of flood coming out or exposure to toxins that may damage the workers’ lungs. 

With the advent of technology, air compressors came as a blessing to mining industries, which took the responsibility of craftsmanship and removed the dangers faced by miners. Air compressors, when maintained properly, are safe to use in the mining industry. In this article, we will discuss common mining applications, energy usage, and the cost of air compressors.

Compressed air systems are used worldwide in the mining industries for several reasons. Here we have mentioned some of them:

Safety

Mining comes with significant risk; that is why it is ranked as the second most dangerous industry concerning fatality. In the previous decades, it was relatively more dangerous than now. Extraction from deep down the Earth was a risk for workers. 

Previously, the workers were directly contacting the toxins and air-borne particles underground. They used to develop lung diseases like silicosis, pneumoconiosis, and allergies. Now, as their work is on the air compressors, they are less in contact with the toxins.

Since air compressors have reduced the hazards and improved the environment in which the workers work, it has dramatically increased the safety of the workers. Moreover, the safety of equipment has also improved nowadays. Air compressors can survive harsh environments, and there is lesser risk of mileage.

Energy source

Besides offering safety in the mining industry, Air compressors also provide energy to the equipment. Mining industries prefer to use compressed air over electricity or diesel to power their tools such as pneumatic tools, wrenches, saws, tools used for drilling, etc. 

Another advantage of air compressors when used as an energy source is that they can reduce the chances of leakages and ultimately lessen the energy cost. Hence, it is a cost-effective and safer choice for mining industries. 

Cuts the need for several equipments

The mining industry previously used several types of equipment to extract metals and alloys, which were not even reliable and durable. Air compressors, a long-lasting and reliable product, have cut the need to use unreliable equipment. 

Underground air compressors also provide the function of pipelines and cut their need as well. Otherwise, complex pipeline systems were used previously for proper functioning. 

Here are some common areas where air compressors are used in the mining industries.

Drilling

Air compressors power a rotating drill bit inserted into the rock to crush it. It works on the exact mechanism as a jackhammer. The hole is typically made till the bottom of the rock. It takes approximately a day to complete an extensive drilling process. 

Smelting

Smelting is the process combined of heating and extracting. Air compressors heat the ores and decompose them to extract metal from them. 

This process is followed by refining, increasing the purity of the metal. Compressed air oxidizes the base metals to remove further impurities and make the product pure and natural. 

Pneumatic tools

Pneumatic tools such as wrenches, saws, and drills are driven by air. So mining industries need compressed air systems to power them. 

Blasting

Rock blasting is often dangerous and leads to several risks. However, it is safely performed by compressed air systems. A high velocity of air is provided by air compressors to explode the rock and continue the mining process.

Cleaning

Mining procedures make a lot of mess during extraction and other processes. After that, a thorough cleaning is required to guarantee the durability of the gear. It also cleans the impurities from the filters.

Material handling

Compressed air helps in handling and conveying the material. Some materials have fine particles that are difficult to handle but mixing compressed air makes it more accessible. Moreover, it converts the particles into liquid through fluidization. 

Ventilation 

The quality of air is relatively poor in the deepest layers, which makes it difficult to breathe for the miners. Here is where again, compressed air comes to the rescue. Besides ensuring a breathable environment, air compressors purify and remove impurities.

Methane Gas Extraction 

Explosions are common in coal mines due to methane gas buildup. What happens is that methane and a byproduct of coal come in contact with the heat source, and an explosion occurs. Moreover, methane gas is toxic to breathe in for the miners. So its extraction is carried out by a compressed system.

A compressed air system is a little expensive. However, it is cheaper than electricity and diesel. Here is a brief of allover costs of compressed air in mining.

• 40 percent of the overall cost depends upon compressed air usage.
• 70 percent of the compressed air usage cost depends upon the leakages.
• 20 percent of the total power is actually used by the compressed air system, while 80 percent is lost in any form like heat.