Battery-Powered Temporary Fuel Facility
Project Overview
Fuelfix was engaged by a major EPCM company, following their appointment as principal contractor to deliver the bulk earthworks project at the Iron Ore Mine. The project required the design and supply of a compliant, temporary fuel infrastructure solution to support construction activities at the remote site for an estimated duration of 12 to 18 months.
As part of its scope of works, the contractor was responsible for installing a temporary fuel facility at the site. To meet the Mine’s operational, safety, and environmental standards, they sought an experienced subcontractor capable of supplying temporary fuel storage and dispensing infrastructure suitable for a remote Pilbara mining environment. Fuelfix was selected based on its proven capability in fuel storage, fuel management systems, and mobile and temporary mining infrastructure.
The project involved establishing a new fuel facility, with no pre‑existing infrastructure on site. Traditionally, temporary fuel facilities, and many permanent ones, are powered by diesel generators operating continuously, regardless of dispensing demand. While proven, this approach introduces operational inefficiencies in remote mining applications.
Continuous generator operation typically results in:
- Higher fuel consumption,
- Frequent refuelling,
- Increased maintenance requirements,
- Accelerated equipment wear
In a 24/7 mining operation, generators can quickly reach service intervals, increasing operational cost and maintenance coordination requirements.
In addition, the solution needed to meet strict mining operator specifications while remaining adaptable to a temporary project environment. Multiple stakeholders were involved, requiring careful coordination to ensure compliance, safety assurance, and timely delivery without disruption to the broader construction program.
Fuelfix delivered a temporary fuel infrastructure solution aligned with the client’s construction requirements and the mine operator’s site standards, while introducing a battery‑powered approach to reduce reliance on continuous diesel generation.
The solution included the following core infrastructure:
- Fuel Storage: Three 110,000L Fuelfix Self‑Bunded Fuel Tanks supplied on a hire basis, configured in a multi‑tank arrangement with actuated valve control to allow controlled fuel transfer and efficient tanker unloading.
- Fuel Dispensing & Transfer: An integrated pumping skid supporting both light and heavy vehicles, including low‑flow and high‑flow dispensing capabilities and a dedicated high‑capacity road tanker unloading pump.
- Fuel Management & Monitoring: Fuelfix Gen 3 Fuel Management System (FMS) with fob keys access control, Automatic Tank Gauging (ATG), and remote data upload, designed for accurate fuel accountability and operation in harsh Pilbara conditions.
- Power Supply: An ESU50 Battery Energy Storage System (BESS), providing an intelligent, modular power source and significantly reducing the need for continuous diesel generator operation.
- Safety & Environmental Controls: Integrated overfill protection, high‑ and low‑level alarms, fail‑close valves, and heavy‑duty bunded spill grates rated to a 240‑tonne safe working load were incorporated to minimise spill risk and protect the surrounding environment.
- Safety Equipment: Solar‑powered emergency eyewash and safety shower system, constructed to AS 4775–2007, were installed to provide immediate emergency response capability. The self‑contained units ensure reliable access to critical safety infrastructure without reliance on mains power, making it well suited to remote mining environments.
Fuelfix Expertise
This configuration delivered a robust, site‑compliant temporary fuel facility while improving efficiency and reducing operational complexity.
Given that safety is paramount on a mine site and a core value of Fuelfix, significant emphasis was placed on ensuring that the equipment and installation was smooth and met the deadline and stringent standards required by the customer.
The integration of a Battery Energy Storage System enabled a significant reduction in diesel generator runtime compared to traditional temporary fuel facilities. This results in lower fuel consumption, reduced maintenance requirements, and improved reliability of the fuel infrastructure.
- Operationally, the solution reduces refuelling logistics and routine servicing demands, supporting uninterrupted activities throughout the project duration.
- From an environmental perspective, reduced diesel usage contributes to lower emissions, aligning with broader sustainability objectives without compromising operational performance.
The solution was delivered, installed, and commissioned in line with project schedules, meeting stringent safety and compliance requirements.
In just a week (7-days), the generator ran 10 hours (less than 1 hr a day) instead of a 168 hrs. The system enabled savings of 581L of fuel and reduced CO2 emissions by 1.56T.
Based on the performance to date, annualised results indicate this set-up could enable the client to:
- Save 30,212L of fuel by reducing generator runtime by 94%
- Significantly reduce fuel and maintenance costs with only one annual service required for the diesel genset and minimal refuelling operations
- Reduce risks associated with personal safety with less movement on site
- Cut their operational CO2 emissions by 80.7 tonnes
Fuelfix’s battery‑powered temporary fuel infrastructure enabled our customer to support the mine expansion project with a reliable, efficient, and compliant solution tailored to a defined project timeframe.
By combining high‑capacity Self‑Bunded Fuel Tanks, advanced Fuel Management Systems, and an ESU50 Battery Energy Storage System, Fuelfix delivered a future‑ready temporary fuel facility that reduced operating costs and maintenance burden.
With safety as a core value for both Fuelfix and the mine operator, the solution was executed with a strong focus on compliant design, controlled installation, and smooth commissioning, making it well suited for large‑scale mining projects in remote and demanding environments.
Fuelfix Pathway to energy efficiency
This project supports Fuelfix and Tanks2Go’s Two Pathways, One Goal Strategy, which focuses on delivering fuel and energy solutions that enable efficient operations today while creating practical opportunities to reduce emissions over time.
By integrating battery energy storage with temporary fuel infrastructure, Fuelfix helps customers improve fuel efficiency, reduce operational risk, and achieve better environmental outcomes without compromising site performance.
Through this solution, the client is able to access fuel safely and efficiently, reducing environmental, personal, and operational risks associated with refuelling, while supporting a lower‑emissions operating model suited to remote mine sites.
Contact us today for flexible energy and emissions solutions to manage current fuel consumption and transition to green energy solutions.
Transition Partner Contact Us
