Author: Naisha Ramlal

The Mining Indaba 2025 was a pivotal event for the global mining industry. It brought together key stakeholders, innovators, and decision-makers to discuss the future of sustainable mining.

Energy and Combustion Services (ECS) was proud to be represented by Peter Meyer, the company’s Marketing and Sales Director. Peter attended the prestigious conference in partnership with TotalEnergies to present on the Optimizer Solution Suite.

Strategic collaboration with TotalEnergies

ECS’s ongoing collaboration with TotalEnergies marks a significant step in advancing energy efficiency and sustainability in the mining sector. This partnership underscores a shared vision of optimising energy consumption while maintaining operational excellence.

By working together, ECS and TotalEnergies are delivering innovative solutions that help mining and industrial clients improve energy performance and reduce carbon footprints.

Presenting the Optimizer Solution Suite

At the event, Peter showcased the capabilities of the Optimizer Solution Suite – a cutting-edge solution designed to enhance energy efficiency and streamline operations for mining and industrial companies.

The suite leverages advanced data analytics and automation to optimise energy use, reduce waste, and improve overall system performance.

During his presentation, Peter highlighted the key benefits of the Optimizer Solution Suite, including:

• Real-time energy monitoring for improved decision-making
• Automated efficiency enhancements that drive cost savings
• Sustainability-driven solutions that align with industry decarbonisation goals
• Seamless integration with existing operations to maximise return on investment

Growing focus on energy efficiency & carbon reduction

The Mining Indaba provided a valuable platform for ECS to engage with industry leaders, potential clients, and technology partners.

Peter’s participation further reinforced ECS’s commitment to innovation in energy optimisation, positioning TotalEnergies as a trusted partner in the mining sector.

The event also emphasised the growing importance of energy efficiency and carbon reduction in mining operations.

With increasing pressure to meet environmental regulations and sustainability targets, solutions like the Optimizer Product Suite are becoming essential for companies looking to stay ahead in a competitive and evolving landscape.

ECS, in partnership with TotalEnergies, remains dedicated to pushing the boundaries of energy efficiency through its strategic partnerships and groundbreaking solutions.

• Contact us to find out more about the Optimizer Product Suite

In today’s rapidly evolving industrial landscape, managing operational costs is a top priority. Fuel consumption, a significant yet often overlooked expense, has become a critical focus for businesses.

Rising fuel prices, incidents of fuel theft, and growing environmental concerns make optimising fuel usage essential for industries like mining, agriculture, transportation and manufacturing.

Fuel inventory and allocation control provide a strategic solution to these challenges. By implementing a robust system, organisations can enhance operational efficiency, reduce wastage, and improve cost management.

What Is Fuel Inventory Control?

Fuel facilities inventory management refers to the systematic process of monitoring, controlling, and optimising fuel stocks at storage and dispensing facilities. This is critical for ensuring adequate fuel supply, minimising losses, and maintaining operational efficiency.

Effective inventory management involves tracking fuel levels, usage patterns, and storage conditions, as well as ensuring compliance with regulatory standards. Key aspects include:

Inventory Monitoring

• Regular measurement of fuel levels in storage tanks using manual or automated systems (e.g., dipsticks, electronic gauges, or sensors).
• Monitoring for temperature changes, leaks, or contamination.

Record Keeping

• Maintaining accurate records of incoming deliveries, consumption, and current stock levels.
• Using automated hydrocarbon management and control systems to log and analyse data.

Loss Prevention

• Detecting and mitigating losses caused by evaporation, leaks, theft, or improper handling.
• Conducting continues audits and reconciliation of inventory records against physical counts.

Demand Planning

• Forecasting future fuel needs based on historical consumption patterns, seasonality, or specific project requirements.
• Avoiding overstocking (leading to spoilage) or understocking (leading to operational delays).

Technology Integration

• Utilising Automatic Tank Gauging (ATG) systems for real-time monitoring.
• Employing fuel management software for data analysis and decision-making.
• Implementing Internet of Things (IoT) devices for remote tracking.

Compliance and Safety

• Ensuring that fuel storage complies with environmental and safety regulations.
• Regular maintenance of storage tanks to prevent leaks and ensure structural integrity.

Cost Control

• Optimising purchasing schedules to benefit from price fluctuations.
• Reducing waste and ensuring efficient usage of fuel.

Effective inventory management ensures operational continuity, reduces environmental risks, and supports cost efficiency. Advanced systems like ECS’s SmartFEMS can streamline these processes by integrating electronic monitoring and reporting tools.

What Is Hydrocarbon Allocation Control?

Fuel allocation control is a systematic approach to monitoring, tracking, and optimising fuel consumption. It ensures that fuel is precisely allocated to specific vehicles, equipment, or projects, promoting accountability and preventing misuse.

Key Features of an Effective Fuel Allocation System

An effective fuel allocation system incorporates several essential components:

• Dispensing authentication control system: Automates the dispensing process, ensuring only authorised personnel can access fuel.
• Real-time monitoring: Tracks fuel usage across vehicles and equipment, providing insights into consumption patterns.
• Allocation limits and thresholds: Defines usage limits and sends alerts when thresholds are exceeded, identifying anomalies early.
• Integration with Fleet Management Systems (FMS): Centralises control by syncing with fleet management tools for seamless operations.
• Alerts and reporting: Issues notifications for unauthorised usage or exceeded limits and generates detailed usage reports for analysis.
• Data analytics: Provides actionable insights, helping organisations identify trends, optimise fuel strategies, and reduce costs.

Common Challenges in Fuel Allocation

Managing fuel allocation involves addressing several logistical, operational, and technical hurdles:

• Preventing misallocation or theft: Ensuring fuel is used only for authorised purposes.
• Tracking transactions accurately: Capturing data across diverse vehicles and equipment without gaps.
• Data synchronisation: Integrating multiple data sources to create actionable insights.

Addressing Key Challenges

Fuel and Lube Management System (FLMS)

A robust FLMS centralises fuel usage data, enabling better monitoring, misuse prevention, and cost optimisation. It includes automated transaction logging, detailed reporting, and real-time tracking of fuel and lubricant levels.

• Unaccounted for fuel and lubricants: Unaccounted fuel transactions occur when dispensing activation tags are overridden, preventing the capture of information about the vehicle or equipment receiving the fuel.
• Misallocation of fuel transactions: Misallocated transactions occur due to errors or fraud. Using RFID tags, vehicle-specific authorisation, and automated reconciliation can minimise these risks.
• Missing fuelling transactions: Unrecorded fuelling events disrupt data accuracy. Automated tank gauging and telemetry systems ensure all transactions are captured in real-time.
• Miscellaneous fuelling transactions: Off-system transactions, such as emergency or offsite refuelling, can distort reporting. Portable terminals or mobile apps that sync with the main system can address this issue.

Matching critical transactional datasets

Synchronising run hour meter data, vehicle location, and operational activity with fuelling transactions helps detect inefficiencies and anomalies. IoT integration and advanced analytics tools make this process seamless.

Checking system health

Monitoring the health of the fuel management system ensures reliability.

• Fuel meter and tank gauging serviceability: Regular calibration and serviceability checks, supported by automated notifications, ensure accuracy.
• FMS equipment maintenance: Maintenance notifications for FMS components prevent unexpected downtime and ensure smooth operations.

Benefits of Fuel Allocation Control

A well-implemented fuel allocation system delivers numerous advantages:

• Cost savings: Reduces fuel wastage and enforces budget control.
• Improved accountability: Assigns Fuel to specific vehicles or projects, ensuring transparency and preventing misuse.
• Operational efficiency: Maintains optimal fuel levels, reduces shortages, and boosts productivity.
• Regulatory compliance: Helps meet industry regulations for fuel management and emissions.
• Sustainability: Optimises fuel use and minimises environmental impact, supporting corporate sustainability goals.

Challenges with Implementation

Despite its benefits, implementing a fuel allocation system can present challenges:

• Integration with existing systems: Requires careful planning to connect with ERP or fleet management tools.
• Training and adoption: Ensuring staff are proficient with the system demands adequate training.
• Data accuracy: Maintaining consistent and reliable data is vital for effective decision-making.

Best Practices for Fuel Allocation Control

To maximise the benefits of fuel allocation control:

• Conduct a Needs Assessment: Identify specific requirements and tailor the system accordingly.
• Choose the Right Technology: Select scalable and reliable solutions that align with organisational goals.
• Perform Regular System Audits: Ensure ongoing accuracy and effectiveness.
• Engage Stakeholders: Involve operators, managers, and finance teams in the implementation process to encourage adoption.

The Role of Emerging Technology

Fuel allocation control is further enhanced through the application of technologies like:

• IoT integration: Enables automated tracking and real-time monitoring.
• AI and predictive analytics: Optimises fuel consumption and detects anomalies.
• Sustainability innovations: Supports reduced emissions and environmentally friendly practices.

Conclusion

Implementing an effective fuel allocation control system requires addressing challenges with advanced technology, proactive maintenance, and integrated data management.

Energy and Combustion Services’ Productivity and Energy Management Services, along with its Fuel Energy Management Control System, incorporates advanced practices and technologies to enhance transparency, reduce waste, and optimise operational efficiency for businesses.

• Contact us for more information about our fuel management system

Climate change is no longer a distant threat; it’s a present-day reality. The consequences of unchecked carbon emissions are far-reaching, impacting economies, societies and ecosystems worldwide. As businesses grapple with the challenges of a changing climate, decarbonisation has emerged as a critical imperative.

According to the Intergovernmental Panel on Climate Change, decarbonisation is defined as “human actions to reduce carbon dioxide emissions from human activities.” Decarbonisation refers to the process of reducing carbon emissions. It involves transitioning from fossil fuels such as coal, oil and natural gas, to cleaner, low-carbon energy sources.

The urgency of decarbonisation is undeniable. Climate change poses significant risks to businesses, from regulatory and physical risks to reputational and financial challenges.

Benefits of Decarbonisation

The benefits of decarbonisation extend beyond environmental responsibility, offering significant advantages for businesses:

Regulatory compliance: Governments worldwide are enforcing stricter environmental regulations to combat climate change, including implementing carbon taxes to penalise excessive emissions. In South Africa, for example, environmental regulations are increasingly stringent as the country advances its climate commitments, notably through mechanisms such as the carbon tax, as noted by KPMG.

By proactively adopting decarbonisation strategies, businesses not only ensure compliance with these regulations but also significantly reduce their carbon tax liabilities. This dual benefit of mitigating penalties and lowering operating costs makes decarbonisation a financially savvy and environmentally responsible approach.

Enhanced reputation: Consumers and investors increasingly prioritise sustainability. A strong commitment to decarbonisation can enhance a company’s brand reputation and attract environmentally conscious stakeholders, as this article by Oren demonstrates.

Cost savings: Decarbonisation makes business sense, as integrating energy efficiency measures, adopting renewable energy, and utilising innovative technologies can result in substantial cost savings.

Innovation and competitive advantage: Decarbonisation can drive innovation, leading to the development of new products, services and business models.

Risk mitigation: Businesses can enhance their long-term resilience by reducing reliance on fossil fuels and mitigating climate-related risks.

What is a Decarbonisation Strategy?

A decarbonisation strategy is a comprehensive plan that outlines how an organisation will reduce its greenhouse gas emissions. It involves setting targets, identifying emission hotspots, and implementing measures to reduce carbon footprint.

By implementing a robust decarbonisation strategy, businesses can contribute to a more sustainable future while reaping the benefits of reduced costs and enhanced reputation.

Starting early on decarbonisation offers businesses a strategic advantage in navigating evolving regulatory, market, and operational challenges.

Governments are tightening emissions standards, and early action ensures companies have time to adapt, avoiding fines or costly retrofitting while aligning effectively with policies. This proactive approach also enhances brand reputation, attracts eco-conscious customers, and appeals to sustainability-focused investors.

Additionally, many businesses now require their suppliers to demonstrate emissions reduction efforts, making early decarbonisation critical for maintaining partnerships and staying competitive in the value chain. This article by McKinsey outlines how Scope 3 emissions can be tackled through supplier collaboration.

Beyond compliance, early decarbonisation delivers financial and operational benefits. Upfront investments in cleaner technologies and efficient processes can yield long-term cost savings through reduced energy use and minimised waste.

It also strengthens resilience against climate-related risks like resource scarcity and supply chain disruptions. Companies acting early can access grants and incentives for sustainability initiatives and stand out as employers of choice, attracting talent that values environmental responsibility.

By taking the initiative now, businesses position themselves for sustainable growth and mitigate the risks of delayed or reactive strategies.

Core components of a decarbonisation strategy

• Setting ambitious targets: Establish clear and measurable goals for reducing emissions, such as net-zero targets.
• Conducting a carbon footprint assessment: Identify the sources and quantities of greenhouse gas emissions across the organisation’s operations.
• Prioritising decarbonisation levers: Focus on the most impactful actions, such as energy efficiency improvements, renewable energy adoption and switching to low-carbon fuels.
• Developing a roadmap: Create a detailed plan outlining the steps to achieve decarbonisation goals, including timelines and resource allocation.
• Investing in low-carbon technologies: Explore and adopt innovative technologies that can reduce emissions.
• Engaging employees and stakeholders: Foster a culture of sustainability within the organisation and communicate progress to stakeholders.
• Monitoring and reporting: Track progress towards decarbonisation goals and report transparently on emissions reductions.

Developing Your Decarbonisation Roadmap

Assessment: Analysing Current Carbon Footprint

A comprehensive assessment of an organisation’s carbon footprint is crucial for identifying emission hotspots and prioritising decarbonisation efforts. This involves:

• Data collection: Gathering data on energy consumption, fuel usage, and other relevant activities across the organisation’s value chain.
• Carbon accounting: Using standardised methodologies to calculate greenhouse gas emissions associated with these activities.
• Identifying emission hotspots: Pinpointing the areas with the highest carbon emissions, such as energy-intensive processes or transportation.

Goal Setting: Establishing Emission Reduction Targets

Setting clear and ambitious emission reduction targets is essential for driving decarbonisation efforts. These targets should be:

• Measurable: Quantifiable and trackable to monitor progress.
• Achievable: Realistic and feasible within the organisation’s capabilities and constraints.
• Time-Bound: Defined with specific deadlines to create a sense of urgency.
• Aligned with Business Strategy: Integrated into the overall business plan to ensure consistency and long-term commitment.

Exploring Different Ways to Reduce Carbon Emissions

There are various pathways to reduce carbon emissions, including:

• Renewable energy: Transitioning to renewable energy sources such as solar, wind, and hydropower to reduce reliance on fossil fuels.
• Energy efficiency: Implementing energy-efficient technologies and practices to minimise energy consumption and waste.
• Low-carbon fuels: Adopting low-carbon fuels like biofuels or hydrogen to reduce emissions from transportation and industrial processes.
• Circular economy: Adopting circular economy principles to minimise waste and maximise resource efficiency.

By carefully considering these pathways and their potential synergies, organisations can develop a tailored decarbonisation roadmap that aligns with their specific needs and priorities.

Choosing the Right Decarbonisation Pathway

Tailoring a decarbonisation pathway to your specific industry and needs is crucial for achieving effective and efficient results.

For instance, the McKinsey report highlights sector-specific strategies such as transitioning heavy industries to hydrogen and carbon capture to mitigate emissions.

According to Deloitte, each industry has unique challenges, opportunities and technological capabilities, Each industry has its unique challenges, opportunities, and technological capabilities, necessitating a customised approach.

Here’s why tailoring is essential:

• Industry-specific challenges: Industries like manufacturing, transportation, and agriculture have distinct carbon emission sources and operational constraints. A one-size-fits-all approach may not address these specific needs.
• Resource constraints: Businesses have varying levels of financial, technological, and human resources. A tailored approach ensures the decarbonisation strategy aligns with the organisation’s capabilities and priorities.
• Regulatory landscape: Different industries face different regulatory requirements and incentives. A tailored strategy can help businesses comply with regulations and leverage available support.
• Customer and market demands: Consumer preferences and market trends are evolving towards sustainability. A tailored approach can help businesses capitalise on these opportunities and build a competitive advantage.

By carefully considering these factors, businesses can develop a decarbonisation strategy that maximises impact, minimises costs and positions them as leaders in the transition to a low-carbon economy.

Optimise Carbon Efficiency with ECS

Energy and Combustion Services (ECS) is a leading provider of energy management solutions, specialising in optimising carbon efficiency, reducing greenhouse gas emissions, and supporting businesses in their transition to net-zero carbon operations.

With a deep understanding of energy systems, ECS offers a range of services and expertise to help organisations achieve their decarbonisation goals.

ECS offers a comprehensive approach through its SmartEPS™ and SmartOSR™ services.

SmartEPS™ simulates the impact of proposed energy and carbon reduction projects to evaluate which projects will yield the most sustainable benefits.

SmartOSR™ helps businesses develop a roadmap for the complete elimination of greenhouse gas emissions through a combination of internal reduction strategies and potential future carbon removal technologies.

This two-pronged approach caters to businesses at various stages of their sustainability journey, allowing them to either achieve carbon neutrality quickly or embark on a strategic path towards complete decarbonisation.

• If your business is committed to reducing its carbon footprint and building a more sustainable future, Energy Combustion Services (ECS) is here to help. Contact us for more information

The design, construction, and maintenance of roads heavily impact safety, productivity, energy, and costs. That’s why the management of road functionality plays a pivotal role in the total cost and safe operation of roads, as well as ensuring legal compliance.

In the current business operating environment where there is a sustained focus on improving safety, productivity, and energy efficiency, ensuring that equipment and people operate in good road conditions has become more important than ever before.

Mining operations can manage their haul roads effectively only if they are equipped with relevant and actionable information. That is why they need to use digital systems to support effective management of road functionality.

However, ‘traditional’ road inspection and reporting methods fall short of enabling mining operations to meet this objective. Thus, this calls for modern digital methods that have been tried and tested in challenging conditions to be explored.

This is the sage advice of Dr Mark Rawlins Pr Eng, Executive Chairperson and Chief Engineer at Energy & Combustion Services Group (ECS), to mining companies through an interview with Mining Business Africa.

The ECS Group has built a reputation for providing smart road condition monitoring solutions to companies in mining and other sectors.

Rawlins recommends adopting digital systems such as SmartRoad™, enhanced by Machine Learning and advanced analytics, to manage road functionality. This is based on it being successfully used at different operational sites.

‘Traditional’ road inspection and reporting

The strong business case for adopting SmartRoad™ in the effective management of roads becomes clear when the challenges of ‘traditional’ inspection and reporting methods are examined.

‘Traditional’ inspection and reporting methods may include:

• A competent person driving on the roads making mental or written notes of road conditions and then giving written or verbal feedback to others;
• Taking photographs of road conditions or taking notes and then sending a report via WhatsApp or email;
• Dispatch controllers getting feedback from vehicle operators as they identify issues, mainly dusty or wet conditions; and
• Truck vibration monitoring systems reporting excessive vibration but without any situational context on road conditions, which still require an inspection.

Challenges of ‘traditional’ methods

‘Traditional’ inspection methods are too time and labour-intensive, making it difficult to report, review and schedule maintenance and repair.

The key challenges with inspecting mining haul roads for functional condition assessment are related to frequency, completeness, and repeatability.

• Frequency: how often inspections can be done for the same section of road
• Completeness: the percentage of the total road network inspected in a period
• Repeatability: how an inspector scores the road condition from one period to the next.

Moreover, once a defect has been identified, there’s no effective way of reporting, reviewing, and scheduling maintenance and repair.

Unfortunately, manual systems can’t provide geospatial images or visual location-based information for reporting and improved insight and transfer of information for maintenance scheduling. In addition, keeping track of maintenance or compliance-related workflows or job cards is cumbersome and error-prone.

So, mining operations find that applying the standard practice of condition monitoring and predictive maintenance on mining roads, as they do on their plant and machines, is difficult and mostly ineffective. This is because they need a readily accessible and complete history of road functional condition and repair.

Rawlins underlines the importance of accurate information to allow reliable conditions and predictive maintenance of roads.

“Road conditions can change rapidly due to weather changes, resulting in rain-damaged or slippery roads or dusty conditions,” he says.

“So, being able to readily assess the condition of the roads before resuming production is important, and ensuring historical evidence of legal compliance is essential.”

In the long run, ‘traditional’ inspection and monitoring greatly undermines mining operations.

Improvement in safety and productivity, as well as reduced costs (fuel and tyres), can only be achieved with effective management of road quality. This is attainable through the integration of monitoring and reporting of road conditions with the production, engineering, road construction and maintenance teams.

How SmartRoad™ addresses shortcomings of ‘traditional’ methods

A modern digital road management platform, ECS’s SmartRoad™ has proved effective in integrating key aspects of road management.

It facilitates both a readily accessible and complete history of road functional and safety conditions and repair.

When deployed in challenging conditions that require road inspections and functional quality management, SmartRoad™ excels. This is thanks to features that directly address the shortcomings of traditional methods. These include:

• SmartRoad ARID™ (Autonomous Road Inspection Device) mobile units for autonomous visual and dynamic inspection of the roads
• Cloud databases for managing the data
• User portal for managing the system, reviewing, and reporting on road conditions

SmartRoad ARID™ performs autonomous road inspections, eliminating the specialist labour needed for inspection. It also inspects many kilometres of road in a short time.

Road inspections are supported by AI and Machine Learning algorithms with autonomous defect and condition assessment with visual and vibration data. This enables repeatability in condition assessment for the entire road network.

Job review, scheduling, assignment, and close-out are standard features of SmartRoad™. There is also a feature that can navigate the maintenance team to a specified defect needing repair.

Moreover, SmartRoad ARID™ enhances safety in three areas:

• Autonomous and rapid inspections ensure inspection safety
• The inspection units can be used in low-light and night-time operations
• They can also be used in applications for dust monitoring in specific mining locations (load and dump areas)

Road performance dashboards and portals

SmartRoad ™ has Road Performance Dashboards and portals that enable easy identification of the problem areas via geospatially pinned information on maps of the roads.

These Dashboards have powerful analytics and ways of showing the road condition – from detailed defect information to overall condition and road quality via heat maps.

This enables retrieval of the inspection records, analytics, and reports, with photographs, and services for digitally managing the corrective action workflows or escalations needed.

The Dashboards provide a complete history of the road inspections for all states, including acceptable and compliant conditions, together with unacceptable and non-compliant conditions.

This enables trending of road performance and comparisons between periods. An important aspect of this history is the ability to review the road life performance and make design and construction changes over time.

The convenience of SmartRoad™ is that it is set up to accommodate the specifics of each mine road network, with the setup of bespoke road maps and operational zones.

SmartRoad™ reporting is layered in detail, whereby the analysis is designed such that not only are the important information and trends reported, but it also allows for deep diving into the details when needed.

Conclusion

For mining companies, there are massive benefits to switching from their conventional approach to road condition monitoring to SmartRoad™.

Modernising road condition monitoring and management by exploiting advances in 4IR, IIoT, Machine Learning, and AI enables significant savings in energy usage and related carbon emissions, tyre consumption, and water usage.

SmartRoad™ ensures that complete and actionable information is provided to the right person at the right time.

“Ultimately, miners want safe and compliant roads with the least cost of ownership, and SmartRoad™ is a key enabler for this,” says Rawlins.

• This is an edited version of the original feature published in the September-October 2022 edition of Mining Business Africa