Uncovering hidden potential: How combining premium fuel and lubrication could be an efficient solution to an evolving sector
Mining businesses need to maximise equipment utilisation, boost their output and decrease costs – all while advancing their decarbonisation efforts. Offering improved productivity and reduced operational costs, premium fuels and lubricants are solutions that operators cannot afford to overlook as they work to meet shifting global demand and disruption to supply chains.
Global disruption shapes mining output
With the mining industry facing extreme global disruption, operational efficiency has become even more vital than ever. Current geopolitical events mean that some nations are swiftly switching to alternative sources for commodities1. And, where this hasn’t been possible, it is causing a slowdown in production across many industries and sectors.
While rising energy costs have been front and centre in the minds of most people, the disruption has also led to sharp price increases in metals such as gold, nickel and palladium due to fears of a shortage1. In fact, nickel prices more than doubled in the two weeks following the beginning of the war in Ukraine2.
In the short term, these price rises will likely drive growth in the mining industry. However, businesses will still need to address the challenges facing them as they look to meet the shifting demands of countries trying to maintain the fluidity of their supply chains. This makes it essential to enhance productivity across every area of operations by reducing equipment downtime and increasing system efficiency as much as possible.
What’s driving industry change?
Maximising equipment utilisation in the demanding mining environment is a difficult job at the best of times, but with the impact of COVID-19 and geopolitical pressures resulting in further cost pressures and tighter margins, there is now a much greater need for mining site managers to unlock efficiencies wherever possible.
That is in addition to some important emerging trends that are shaping approaches to operations across the sector:
Alternative fuels
As mining looks to transition towards a net-zero future, alternative fuels are a means of maintaining operational efficiency while meeting sustainability targets. However, they will place different demands on equipment and require effective management to reach their potential.
Changing equipment designs
To meet output needs, mining equipment is becoming bigger, which means unplanned downtime can have an increasingly detrimental impact. New OEM designs also mean higher loads, increased temperatures and smaller oil sumps, raising the pressure even further on maintenance programmes to keep machines running smoothly.
Tightening regulation
Equipment emissions standards increased with the advent of Tier 4 diesel engine requirements, and more recently, industry-wide targets have emerged. For example, the International Council on Mining and Metal has committed its members to net-zero Scope 1 and Scope 2 greenhouse gas emissions by 2050.
Driving efficiency with premium consumables
Improving efficiency and profitability while adapting to changing trends and global disruption might seem like a near impossible task, but it can be achieved by going back to basics and focusing on the variables that are in your control, such as your consumables.
It is vital that your business does not lose sight of some of the most significant inputs (such as fuel and lubrication) when it comes to protecting operational fundamentals. Because ultimately, it is these fundamentals – equipment health, uptime and efficiency – that will dictate the strength of your bottom line for years to come.
After all, the fuels and lubricants you select can have a big impact on equipment and, in turn, business performance, with studies showing better fuel economy and improved fuel system technology can deliver up to a 5.5% reduction in fuel consumption3.
The right combination of fuels and lubricants has the power to drive efficiency across your equipment operations and help you to reduce your running costs. And this has been demonstrated by professional experts putting consumables to the test under real-world conditions – making sure they can meet evolving industry requirements.
For example, Shell collaborated with Deutsche Landwirtschafts-Gesellschaft (DLG) to measure the total cost of ownership (TCO) savings and efficiency gains that can be achieved when using premium fuel and lubricants together.
Shell and DLG: A case study in product testing
Situated in Gross-Umstadt, Germany, DLG has a rich history of promoting the technical and scientific progress of off-highway equipment. Engaging a facility at the standard of DLG allows precise testing and close monitoring of test conditions.
“The project has been a good opportunity for the DLG Test Centre,” explains Stefano Mastrogiovanni, Managing Director, DLG Test Service GmbH. “We’ve tested thousands of test cycles of vehicles using our PowerMix, but now we’ve also tested for fuels and lubricants as well.”
Over the course of more than four months, and across nearly 600 hours, the DLG team tested Shell FuelSave Diesel (known as Shell Diesel Extra in some countries) in combined use with Premium Shell Rimula Lubricants, against regular diesel and standard lubricants. The premium consumables were first put through DLG’s PowerMix test procedure using test frames and parameters designed by an independent expert commission, a format regularly used by leading global manufacturers to assess the quality of their machines.
Next, the two companies designed a new Power Take Off (PTO) testing programme which combines a series of assessments to verify the quality of premium fuels versus standard ones. The result was a real-world measurement of how the tested fuels can impact the overall performance of an engine.
While there is a growing awareness across the mining sector of the benefits that either a premium fuel or a premium lubricant can have on equipment performance, the DLG test demonstrates the additional efficiencies that can be unlocked by combining the two.
The testing showed that, when used together, Shell’s premium diesel and premium lubricants can deliver up to 472 more operating hours as a combined efficiency benefit4, a figure that could have significant cost-saving potential for the 24/7 schedules that are not uncommon for mining projects.
The results also highlight the increased productivity that these fuels can offer, with DLG measuring up to 2.7% better fuel economy5 and 5.6% more load-pulling power when compared with regular diesel6.
Why fuel is an investment, not a cost
Turning back to fuel, this idea of an interlinked value chain is in full view, since fuel represents an important share of operating costs for mining businesses, with the average large mine hauling truck using 900,000 litres of diesel each year 10. Therefore, any improvement in fuel economy can have a significant impact on the bottom line, releasing savings that can be redirected to other parts of the business or used to protect financial health during periods of extended uncertainty.
A key factor in this is the ability to maintain engine efficiency while operating with heavy loads or on uneven terrain, especially with equipment that is consistently running at high capacity. And much of this comes down to the health of your injection system, particularly injector cleanliness. Shell and DLG’s test, for instance, showed that Shell FuelSave Diesel was able to achieve clean-up of up to 100% of performance-robbing deposits (linked to power) in less than three working days, which can significantly reduce downtime and maintenance costs 6.
As more solutions become available to operators, being able to rely on products with performance proven under real-life conditions by independent test experts such as DLG, will be key to ramping up operations. After all, the efficiency gains that once offered a competitive edge, may now be essential for survival as mining businesses shake off the lasting effects of the pandemic.
New Shell FuelSave Diesel
Shell’s new and innovative diesel formulation Shell FuelSave Diesel, which is the result of extensive development and testing, has been designed to help address a number of key challenges that operators face. Prioritising engine cleanliness for efficient and effective operation, our new deeper cleaning formula takes our fuel technology to the next level.
The pressure is on to find a solution to sustainable growth
Another important element for your business is the ability to not only drive efficiency and growth in your business, but also to do it sustainably. This is especially important given that mining currently accounts for 4% of total global energy consumption7 and is responsible for up to 7% of greenhouse gas emissions worldwide8.
What’s more, these factors are not just useful for contributing to the sector’s decarbonisation but can also help bring external stakeholders along on the journey too – something that holds its own significant value considering how important an operation’s license to operate (LTO) can be to the wider business.
And this hasn’t gone unnoticed by mining executives either, with six out of ten citing their LTO as the biggest risk facing their business9. Why? Because ultimately, they know that strengthening their LTO transcends societal and environmental factors, becoming critical for renewing existing business and winning new contracts as well.
In this context, any potential improvements around fuel efficiency or fuel consumption could be a massive driver of responsible growth. Even before you think about the transition to alternative fuels, you can make a significant difference by using the right combination of premium fuels and lubricants. The more efficient your operations are and the less fuel you consume, the fewer emissions you generate – helping you to take an important step towards the decarbonisation of your business (while showing new and existing customers that you can deliver in this area).
How to connect people, purpose and performance
Given the disruption facing global supply chains, operational efficiency is more important than ever. Which is why operators are looking across the board for opportunities to claw back marginal gains, be it through their consumables, digital technologies or stronger collaboration.
Closing this gap will take time and investment, but once businesses are equipped with the right solutions, and staff given the correct skillsets, the potential benefits are clear. The important thing to remember, however, is that – just as the DLG testing shows – it’s not always enough to have the right product, service or equipment on its own.
Rather, to deliver consistent performance when it’s needed most, mining operators must connect the various dots from around their business, whether that’s through: combining digital technology with staff upskilling; understanding that an LTO is a societal and business imperative; or unlocking efficiency potential by using premium fuel and lubricant in tandem.
Shell Commercial Fuels and Lubricants Joint Testing
Read the transcript
Read the transcript
Shell FuelSave Diesel and Premium Fuels are put to the Ultimate Test:
Duration: 3:26 minutes
Description:
We put our latest Shell Fuelsave Diesel and Premium Lubricants to the test at Greenmot, an independent test centre.
See how using our incredible replaced with Shell technology innovative products can help make your fleet more efficient. Listen to our experts describe the process of the rigorous testing and the incredible results.
Shell FuelSave Diesel and Premium Fuels are put to the Ultimate Test Transcript
[Background music plays]
Bright, uplifting music is playing in the background
[B-roll footage]
A Truck driving down a road
[Voiceover]
The choices you make can have a big impact
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A close up of the wheel of a truck driving on a wet road
[Voiceover]
On your efficiency
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A side on shot of a truck driving down a desert terrain road.
[Voiceover]
On your profits
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An angled head on shot of a truck driving down a road.
[Voiceover]
And all you need, is one amazing fuel
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[B-roll footage]
An arial view of a truck driving in highway traffic that transitions into a shot showing bottles of multiple Shell Fuel oils on a table.
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A gloved hand holding up a bottle of Shell FuelSave Diesel
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[B-roll footage]
Three women in a lab holding and inspecting tubes of oil
[Voiceover]
and incredible lubricants
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[B-roll footage]
Oil being poured into a metallic container
[Voiceover]
Shell has spent five years developing
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A shot showing a Shell worker pouring oil into a metallic container
[Voiceover]
Shell FuelSave Diesel
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[B-roll footage]
A woman in a Shell lab coat inspecting a component in a laboratory office
[Voiceover]
making sure that you get Shell's best performance.
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[B-roll footage]
A side shot of a man working in a lab
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[B-roll footage]
Oil being poured in a tube
[Text displays]
Our Best Performance For Less
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[Voiceover]
The innovative formulation is designed
[Text displays]
Our Best Performance For Less
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[B-roll footage]
Side shot of a truck driving down the right-hand side of an empty motorway
[Text displays]
Designed To Clean More Thoroughly
[Voiceover]
Is designed to clean more thoroughly than ever before
[Voiceover]
So that even the most demanding modern engines
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[B-roll footage]
Side shot of a truck driving towards a tunnel at night
[Voiceover]
as well as older ones can benefit from it
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Front view of a white truck in a depot
[Voiceover]
But we didn't stop there.
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A mechanic using a tool on an engine
[Voiceover]
We wanted to test how Shell's exclusive
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[B-roll footage]
A forward pan shot of a warehouse isle containing a storage of barrels that transitions into a person opening a component then to a scene with a lot of people in lab coats assessing cables.
[Voiceover]
fuel formulation and premium lubricants technology
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[B-roll footage]
Three people with hard hats standing outside of a plant which then transitions into a scene of two people walking and conversing outside of a plant. Then transitions into a scene with three people looking at screens and finally transitions to a scene with four people standing wearing hard hats and green high visibility vests.
[Voiceover]
can work together to give our customers the best results.
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[B-roll footage]
Ariel shot of two trucks turning onto a road that transitions into a shot of Jo Thomson, Diesel Fuel Development Lead at Shell speaking
[speech]
Jo Thomson, Diesel Fuel Development Lead at Shell
{Jo Thomson}
We've conducted a wide range of internal tests
to optimise each of our product formulations
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A device mixing oil
{Jo Thomson}
and we are very pleased with the results.
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A close up of the front left wheel of a truck rotating that transitions into a mechanic in a garage working on a trucks wheel
{Jo Thomson}
However, we wanted to put our best fuel and lubricants
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A man in a lab working transitioning to a mechanic in a lab using a wrench
{Jo Thomson}
through further rigorous testing by “external industry experts”
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A front view shot of a mechanic working on a truck wheel transitioning into a shot of Jo Thomson speaking
{Jo Thomson}
to impartially assess combined product performance.
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A shot from behind showing Jo Thomson and a man walking into a room
{Jo Thomson}
That's why we've worked with Greenmot,
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[B-roll footage]
A shot showing the “Greenmot” logo at the top of a door, that transitions into a shot panning forward in a room then out to show the Greenmot building outside
{Jo Thomson}
an independent, innovative and renowned test center located in France.
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[B-roll footage]
A black truck driving into a Greenmot test depot transitioning into a shot of Jo and a man looking at a screen in an office. The scene then transitions into a side shot of Jo and the man next to a machine.
{Jo Thomson}
They have state-of-the-art equipment and highly skilled engineers
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[B-roll footage]
A group of 3 Greenmot workers on a table looking at a screen. The scene then transitions into a shot of a black truck in a depot
{Jo Thomson}
able to carry out the precision tests we need
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[B-roll footage]
A machine rapidly turning the wheels on the truck. The scene then transitions into a shot of a hand holding a fuel pump.
{Jo Thomson}
to demonstrate that the combination of Shell FuelSave Diesel
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[B-roll footage]
A shot showing a hand tightening a Shell oil barrel
{Jo Thomson}
and our premium lubricants
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Side shot of a white truck driving down a road with blades of grass covering the bottom of the shot
{Jo Thomson}
can really make a difference to vehicle performance,
compared to regular products...
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A hand carrying a metal container of Diesel
{Jo Thomson}
which, by the way, included
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A close up shot of a measured jug full of oil
{Jo Thomson}
some of our mainstream grades.
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A shot of a man pouring the metal container full of diesel into a tube.
{Jo Thomson}
Because we don't like to make life easy for ourselves.
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[B-roll footage]
A shot of a hand removing a lid and placing a filter into the opening, this then transitions into a man pouring oil into the opening
[Speech]
Vincent Castaignede, Senior Test Engineer at GreenMot
{Vincent Castaignede}
We are glad that Shell entrusted us
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[B-roll footage]
A shot of Vincent Castaignede standing and talking to the camera
{Vincent Castaignede}
to test their latest fuel formulation
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[B-roll footage]
A shot of diesel being poured into a red filter that transitions into a gloved hand pouring fluid into a machine
{Vincent Castaignede}
together with premium engine, gearbox and transmission oil.
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[B-roll footage]
Workers toggling with components
{Vincent Castaignede}
We set out to independently determine the fuel economy,
[Text displays]
Fuel Economy Power Acceleration Benefits
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[B-roll footage]
A man looking at a screen showing data that transitions into a man standing looking at data
{Vincent Castaignede}
power and acceleration benefits of Shell FuelSave Diesel
and Shell's high-performance lubricants.
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[B-roll footage]
A shot of a man placing a device inside the drivers side of a truck, which transitions into the man working on the truck with the device
{Vincent Castaignede}
To do this, we employ the latest technology
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[B-roll footage]
A shot of a device with a blue, red and green light flashing that transitions to a shide shot of the front of a black truck
{Vincent Castaignede}
heavy duty truck featuring a turbo-charged engine
[Text displays]
Turbo-charged HD Engine Emissions Class Euro VI
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A wheel being spun rapidly
{Vincent Castaignede}
with the newest Emissions Class Euro VI.
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[B-roll footage]
Three men in an office looking at screens which transitions into a front shot of a black truck
[Text displays]
20 Tonnes
{Vincent Castaignede}
And we loaded it with 20 tonnes
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[B-roll footage]
A finger pointing at a graph on a screen
[Text displays]
200 Hours
{Vincent Castaignede}
and ran it for approximately 200 hours
under a range of conditions to emulate real life usage.
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[B-roll footage]
A vertical three split screen showing a truck in traffic, a truck on a country road and a truck driving through a tunnel. Then transitions in to a horizontal split screen that shows a truck driving in traffic on both sides.
{Vincent Castaignede}
To make sure our measurements were representative of real-world-driving
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[B-roll footage]
A shot of a rotating device that changes into a screen displaying data and a graph
[Text displays]
World Harmonized Vehicle Cycles
{Vincent Castaignede}
we used an industry test cycle to determine the truck’s fuel economy
during urban, rural and highway driving conditions.
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[B-roll footage]
A three split screen of trucks that transitions in to one shot of a truck driving down a highway
{Vincent Castaignede}
And we pushed the truck to its limits
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[B-roll footage]
The front of a black truck that transitions into a device rotating the trucks wheel rapidly
{Vincent Castaignede}
to measure power and acceleration performance under the conditions
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[B-roll footage]
A man fitting a device into the front seat of a truck. Transitions into a shot of a man looking at two monitors displaying data, then back to the device rotating the wheel rapidly. Lastly a hand turning a page.
{Vincent Castaignede}
where you need those benefits most.
We made multiple measurements
to ensure the accuracy of the results.
[Text displays]
The Results
{Vincent Castaignede}
We measured improvements in the truck's
performance in all of our tests
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[B-roll footage]
A shot from behind show Jo and Vincent conversing next to a Greenmot machine. This then transitions into a shot of a device rotating the trucks wheel rapidly.
[Voiceover]
When using Shell FuelSave Diesel and Shell premium lubricants
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[B-roll footage]
A shot of the front of a black truck
[Text displays]
Greater Fuel Efficiency, helping to reduce total cost of ownership
[Voiceover]
in World Harmonised Vehicle Cycle fuel economy tests,
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[B-roll footage]
Fuel bubbling in a glass container
[Text displays]
Average 0.94L/100km up to 1.6L/100km saved
[Voiceover]
the truck used less fuel under all conditions,
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[B-roll footage]
A birds eye view shot of a truck driving in a depot which transitions into a shot inside a truck showing the wing mirror as it is being driven.
[Voiceover]
delivering the best savings under urban driving conditions,
which could help fleet owners reduce their total cost of ownership.
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[B-roll footage]
A truck driving on a road in a field
[Text displays]
Improved vehicle performance over a wide range of driving conditions
Help to reduce fuel consumptions and therefore total cost of ownership
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[B-roll footage]
A shot showing the windscreen wiper in a truck that transitions into a red truck driving down a road.
[Text displays]
1.4% quicker acceleration
1.2% more power during acceleration
[Voiceover]
And the improved power and responsiveness measured could help drivers
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[B-roll footage]
A shot of a truck driving down a highway that transitions into a birds eye view shot of a truck driving down a highway
[Voiceover]
to get on to highways and haul loads uphill more easily.
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[B-roll footage]
A shot showing a person walking into a Shell service station
[Voiceover]
Help to get more out of your fleet
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[B-roll footage]
Multiple shots of people shaking hands, giving high fives and fist bumping.
[Voiceover]
with Shell FuelSave Diesel and Shell premium lubricants.
[Animated sequence]
Shell Pecten animation
[Background music plays]
Shell Jingle plays at the end
Disclaimers
1 Mining Technology. “Russian invasion of Ukraine: Potential impact on supply chains of mineral commodities.” mining-technology.com. 2022.
2 Center on Global Energy Policy. “Supply of Critical Minerals Amid the Russia-Ukraine War and Possible Sanctions.” Energypolicy.columbia.edu. 2022.
3 Aytek Yuksel. “Digging Deeper: Increasing Mining Equipment’s Efficiency.” Cummins Newsroom. 2021
4 For the same amount of fuel compared to regular diesel without fuel economy formula and to standard lubricant. Baseline of 1,00,000 lt and 50 lt/hr fuel consumption per equipment. Based on demonstration tests with off-highway heavy-duty Tier 4 engines in collaboration with DLG Germany.
5 Shell FuelSave Diesel is designed to help provide by up to 3% fuel economy, compared to regular diesel without fuel economy formula. Actual savings may vary according to vehicle, driving conditions and driving style. Internal Shell tests and with customers have shown a range of fuel savings depending on age of vehicle and type of operations.
6 Compared to regular diesel without fuel economy formula. Based on demonstration tests with off-highway heavy-duty Tier 4 engines in collaboration with DLG Germany. Achieved within 50 hours of engine operations and 4 tankfuls.
7 IEA. “Largest end-uses of energy by sector in selected IEA countries.” IEA.org. 2021.
8 Lindsay Delevingne, Will Glazener, Liesbet Grégoir and Kimberly Henderson. “Climate risk and decarbonization: What every mining CEO needs to know.” McKinsey & Company. 2020.
9 EY. “Top 10 business risks and opportunities for mining and metals in 2022 (PDF).” EY.com. 2021.
10 Raghav Muralidharan, Thomas Kirk and Thomas Koch Blank. “Pulling the weight of heavy truck decarbonization: Exploring pathways to decarbonize bulk material hauling in mining.” Rocky Mountain Institute. 2019.
