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International Mining magazine visited the Kaltim Prima Coal mining complex in Indonesia in late 2015, to see how such a large operation manages its huge fleet of machines over an extensive area. Kaltim Prima Coal (KPC) is the world’s largest single producer and exporter of thermal coal, as well as largest single coal mining complex in Asia. ‘Back in 2008 the fuel accounting system at KPC was still highly manual, yet local teams were expected to manage inwards deliveries of some 3 million litres of diesel, which were arriving by barge every couple of days. This product was being hauled 16 km by tanker trucks and pipeline to the ROM storage area. From the ROM area, the diesel was used to fill haul trucks and large service trucks which would operate at refuelling locations within the pit. Pretty much everything was hand written, while contractors on the site also had to acquire the fuel they needed via a paper-based system. These factors caused significant difficulty in terms of reconciling around 1.6 million litres per day.
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Banlaw has spent three decades refining the functionality of the refuelling area. We understand the particular challenges you face with scale, speed and harsh environments. We have outlined the top ten issues our customers come up against with their fuel and hydrocarbon storage, management and use, and how Banlaw can help you to swiftly overcome these issues with tried-and-tested methods and proven cost-effective services.
Choose Banlaw for your next project, and rest-assured that every drop will be delivered where you need it, when you need it. Brief summaries have been included of jobs in various categories. These range from the supply of a single loading arm, to fuel/lubricant management technologies on tank farms and fleets, all the way up to full turn-key fuel facilities with automated stock management and safety solutions.
Grease transfer couplings. Dry break quick couplings. Fluid evacuation products. Fuel skids. PLC/MCC automated fuel stock management.
9 x Fuel Management Controller Upgrades. Service Truck Mobile Fuel Management Controller.
Fortescue Metals Group
Fortescue Metals Group (FMG) is the world’s fourth largest iron ore producer and is still growing. In FY 2014 FMG mined, railed and shipped 124 million tonnes of iron ore. Fortescue examined several fuel management systems before selecting Banlaw to implement its Enterprise Fuel Management System.
In a multi tank environment, without fuel stock rotation, most fuel or other hydrocarbons are drawn from or dispensed into those tanks closer to the pumps. The tank content farthest away from the pumps stays unused for long periods of time, leading to it becoming stale and causing potential microbial build-up in the tank. This can be detrimental to engines and overall equipment performance, impacting on efficient operations and maintenance costs.
Banlaw’s fuel management system easily integrates with any Enterprise Resource Planning (ERP) software. Banlaw ResTrack™ interfaces through a file system as a CSV (flat) file. With over 20 standard fuel management reports, it is likely that Banlaw have already thought of every possible output your site might want. If not, speak to our dedicated system IT engineers who can provide a customised report.
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If you want to stay on top of your fuel management without employing your own fuel champions, Banlaw’s expert staff can be an efficient and cost effective alternative. Our staff can be based on-site or visit periodically to conduct inspections and calibrations. There is often a benefit in having an independent third party, separate from your fuel supply company and your staff, perform this work.
An effective partnership between Banlaw, mining giant KPC and its distributor Atlas Copco Nusantara has been central to the highly successful implementation of an integrated fuel management system at one of the world’s largest open pit mining operations in Sangatta, Indonesia. Five years on, Banlaw’s fuel management system is performing extremely well, saving KPC time and money. The good news is there are still more benefits being realised.
Banlaw utilises the Elaflex ZVA Slimline 2 Nozzle for its splash fill refuelling installations. For Banlaw FuelTrackTM managed applications, automatic vehicle identification auxiliary equipment is mounted on the nozzle. When identification tags are sensed by the modified nozzle, it will allow the fuel management system to log the vehicle, the amount of fuel, the location and the time of the transaction.
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We all know how expensive fuel can be. It’s one of the largest expenses for any business in mining, rail, fleet and port operations. With the quantities that your industry stores fuel, would anyone notice if a few hundred litres went missing? Probably not. But collectively it can be a very costly area to overlook.