HIGH PROFILE
Macmahon-operated Volvo A60H fitted with FuelActive technology at gold mine in Indonesia
Simplicity in innovation
The FuelActive ® floating fuel pickup unit offers a simple yet low maintenance and highly effective solution to the problem of fuel contamination that is rife in mining around the world due to a combination of particulates from dust and / or use of biodiesel or lower quality diesel . IM Editorial Director Paul Moore talked to the company
Sometimes the simplest ideas in mining can have a huge impact when measured across the scale of an equipment fleet . In some cases , they may have not been thought of before or in others the idea may have been put forward but not implemented correctly or supported – often it just needs a champion onsite to get it installed so the data can speak for itself . A great example of this type of innovation is found in Cardiff , UK-headquartered FuelActive Ltd .
Approximately 80 % of machine downtime or premature maintenance is caused by fuel contamination . This is a global problem affecting the mining sector . Fuel contamination drives up operating costs by unduly increasing repair and maintenance budgets , reducing productivity and eroding capital efficiency . With the engine operating at lower thermal efficiency , it can lead to increased harmful emissions and reduced fuel economy . The operator also runs a serious risk of causing a catastrophic engine failure on the jobsite . There are multiple aftermarket solutions for fuel contamination , but all require regular servicing and replacement parts . FuelActive says it has the only in-tank , fit-and-forget product on the market today .
The patented FuelActive fuel pickup unit is a unique , innovative solution to the problem of fuel contamination in diesel engines . Unlike a standard fuel pickup pipe , the unit uses a floating pickup pipe that draws clean fuel from the top of the fuel level , thus avoiding the harmful contaminants that settle at the bottom . Contaminants like solid particles and water can hamper or ruin the efficiency of even the finest fuel-injection systems . And contamination starts with the first fill . Having the most effective
filtration , which starts with a clean pickup method
inside the tank , is vital to ensuring that all dieselpowered engines operate at the highest level of efficiency .
FuelActive states : “ By supplying the fuel lines with the highest quality fuel available , FuelActive protects the fuel system and significantly reduces problems associated with contaminated fuel . Most contamination is water borne and is approximately 15 % heavier than diesel , sinking to the bottom of the fuel tank as a result . By drawing fuel from the upper level of fuel , the FuelActive unit avoids the settled contamination at the bottom of the tank .”
Max Lytle , Chief Commercial Officer told IM : “ Contamination in diesel tanks typically consist of sediments ( dirt , metal & rust ), water and microorganisms , all of which separate very rapidly and settle at the bottom of the fuel tank . Standard diesel engines place the fuel pick up point exactly where these contaminants are located , at the bottom of the tank . These contaminants create numerous problems for operators ; early blocking of filters , damaging lift pumps and degrading the performance of sensitive engine injectors . The patented FuelActive unit is a unique , innovative solution to tackle this problem .”
The introduction of the high-pressure common rail with injection pressures of > 2,500 bar has further exacerbated the need to operate with clean fuel . Qualified technicians can install the FuelActive unit in less than an hour , in nearly all applications . FuelActive goes to work immediately , protecting the engine from the effects of diesel fuel contamination . It works in virtually all environments , in temperatures ranging from -40 ° C to 50 ° C . FuelActive is also manufactured using high-grade materials designed specifically for working with hydrocarbon fuels . It is backed by a five-year warranty on all standard products .
Proven in Indonesian contract mining
Mining is a highly conservative industry – operators want to see data and preferably comparative data showing the effect with and without the technology – and they want lots of it . They also want data that shows consistent performance and a proven benefit to the bottom line . FuelActive has already achieved this on a number of mining and quarrying related sites . However , one of the most impressive has been a rollout with global contract mining major Macmahon Holdings at a client ’ s gold mine in Sumatra , Indonesia . Macmahon ’ s extensive experience in surface and underground mining has established the company as the mining contractor of choice for global resources projects across various commodity sectors .
50 International Mining | MARCH 2022