Powering mining operations with Low Emissions Solutions
Project Overview
Given their history of successful collaborations and the positive outcomes of previous projects, it was only natural for the mining operator to turn to Fuelfix for their fuel facility extension project.
The client required two new fuel storage and dispensing facilities to be strategically set-up in 2 different locations on the mine site. The mining operator needed one independent stand-alone 30,000L self-bunded fuel tank at each location to facilitate the refuelling of heavy vehicles and machinery directly in the mine work areas.
Before partnering with Fuelfix, the mining company depended on a fuel truck that travelled in a cycle from the fuel farm to various work sites four times within each 24-hour period. The truck followed a fixed schedule, stopping at designated refuelling points. This approach limited the amount of time and fuel available to each piece of machinery and often led to downtime, as vehicles were unable to refuel when necessary. In addition, some of the mobile plant equipment had to travel to the primary refuelling facility increasing downtime.
Given the 24/7 nature of the operation, minimising downtime was critical to decrease inefficiencies and unproductivity.
The client faced several challenges with the long and costly process of refuelling machinery and mining fleet using the fuel service truck. The key to the success of this project was the ability to supply an efficient refuelling station, strategically located on site to avoid unnecessary downtime related to fuel supply.
The remoteness of the site was another challenge, the client needed a fuel storage solution capable of operating completely off-grid, providing optimal performance and requiring very low maintenance.
To avoid the added cost, noise, maintenance and refuelling requirements that a diesel-powered generator would have introduced, Fuelfix & Tanks2Go determined the best solution would be the installation of a hybrid-powered fuel storage and refuelling solution. addressed these operational challenges through an innovative approach.
Fuelfix offered one of its new innovative hybrid powered fuel tank solutions consisting of 30,000L Self-Bunded Fuel Tanks with heavy vehicle Dispensing solution and two Hybrid Power Systems (3-phase hybrid generators).
Fuelfix’s solution was provided in accordance with the client’s specifications, with the two tanks strategically positioned on the mines northern and southern work sites. Fuelfix proposed integrating its hybrid generators to power the refuelling stations, offering significant operational and environmental advantages over traditional diesel generator-powered solutions.
Traditional refuelling stations rely on diesel generators operating 24/7. Fuelfix’s hybrid power solution ensures the main power source is derived from the battery energy storage with the small diesel generator operates only when necessary, reducing fuel consumption and maintenance by up to 75%. This hybrid system ensures continuous power supply to remote sites no matter the operating conditions.
As hybrid power systems are relatively new and not widely adopted in the mining industry, Fuelfix worked closely with the mining operator to drive the implementation of the hybrid technology and provided training to service personnel on how to operate the new equipment, with a strong emphasis on ensuring the equipment and installation met stringent safety standards.
The outcomes:
The system enables the operator to refuel machinery directly on the mine site when needed, minimising fuel truck trips.
The hybrid power system provides an energy-independent solution, ideal for the remote location, and eliminates the need for regular servicing and refuelling.
- Cost Benefits: Lower fuel consumption, reduced maintenance costs, extended equipment lifespan.
- Operational Benefits: Significant reduction in maintenance and daily servicing requirements through reduced generators hours of operations.
- Environmental Benefits: Reduced emissions due to lower fuel consumption.
- Safety Benefit: Reduced truck and personnel movements around the site.
Based on the performance to date, annualised results indicate this set-up will enable the client to:
- Save 46,000L of fuel by reducing generator runtime by 86%
- Reduce fuel and maintenance costs by 88%
- Cut their operational CO2 emissions by 120 tonnes
- Significantly decrease operational downtime
The solution provided by Fuelfix helped the client achieve their business goals by increasing operational efficiency and productivity. The hybrid power systems ensured a reliable power source for the refuelling stations, delivering substantial benefits compared to traditional diesel generator options.
“We are very happy with the refuelling solution installed by Fuelfix as well as the service and support provided by the team. This auto refuelling system paired with new technology is enabling significant reduction in fuel costs, maintenance of the power unit, and CO2 emissions. This system led the reduction of downtime which ultimately increased the site productivity and energy efficiency as well as safety with fewer service truck movements on site.” said the Operational Manager at the mine site.
Fuelfix’s innovative approach has proven instrumental in reducing downtime and operational costs, extending equipment life, and minimising emissions, setting a new standard for sustainable operations in the mining industry.
Fuelfix Pathway to a clean energy future
Fuelfix remains committed to delivering high-performance energy solutions, tailored to meet the unique needs of Australia’s mining sector. The success of this project underscores our dedication to helping clients achieve their business goals through efficiency, innovation, and sustainability.
This project is in line with our Two Pathways, One Goal Strategy and involves creating and implementing solutions that offer opportunities to lower carbon emissions while ensuring efficient operations and achieving better environmental results.
Contact us today for flexible energy and emissions solutions to manage current fuel consumption and transition to green energy solutions.
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