Coal miner sees AUD$4.3m cut in fuel costs after boosting fuel management software workload

Problem

Site Improvement and Reliability Engineering teams at a large metallurgical coal mine needed to upgrade VERIDAPT’s fuel management software, AdaptIQ, to improve control and better monitor fuel usage and delivery to substantially reduce fuel costs.

Solution

The AdaptIQ Fuel Management software was already controlling the dispensing of fuel for mining equipment and light / medium vehicles on-site. 

However, the client agreed with the VERIDAPT Success Team that the fuel management system could be maximised by incorporating the following processes:

Monitoring fuel dispensed to all mining equipment to identify machines with faulty fuel systems;

1. Deactivate all decommissioned equipment from the AdaptIQ system;
2. Implement dual identification process for all vehicles refuelling onsite through radio frequency identification tags (RFID) and personnel TAMS cards;
3. Program fuel tank capacities for all light vehicles used onsite
4. Review Contract Management System contracts and review proposed fuel issued for contractor vehicles, limiting fuel for site use only; and
5. Install RFID tags in all vehicles for automatic authentication at refuelling bays. 

Benefit

The client recorded direct annual savings on fuel of AUD$4.3m, AUD$14m in fuel tax credits (applied to non-roadworthy equipment), reduced fuel usage, lower emissions and greater accountability and social consciousness around consumption.

The client also identified an opportunity to replicate the results at its other coal mines, noting the FMS is also effective in oils and coolant dispensing management.