FuelActive

Floating Fuel Pickups

92% cleaner fuel than standard pickups

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Reduce fuel consumption & CO₂ by ~6.94%*

60 437 L fuel, 206t GHG*

Supercharged efficiency

Boost your ﬁlter performance by up to 5X

Pure performance

Reduced contaminants = cleaner power, superior injector performance

Less downtime & operating costs

Haul truck studies have proven FuelActive's remarkable capabilities

Protect your mobile mine assets from fuel contaminants.

Improve your fuel quality and filter life
Prolong the lifespan of your injectors and fuel pumps
5 year standard warranty

Applications

Trucks

Loaders

Excavators

Dozers

Run Clean, Drive Savings

Slash CO₂ Emissions

By improving fuel efficiency, FuelActive helps in reducing CO₂ emissions by about 5%, contributing to a lower carbon footprint and your environmental sustainability efforts.

Quick ROI, Long Service Life, Zero Maintenance

The payback period for installing FuelActive systems is remarkably short, ranging from 2 to 3 months, depending on the fleet's size and usage patterns. This quick ROI makes it a financially viable solution for fleet management.

Protect your engine and filters from contaminants

Protecting sensitive components like injectors

Free ROI Assessment

Less Maintenance, More Performance

Water, particles, and microbial growth are common fuel contaminants. These contaminants can clog fuel filters, cause fuel pump failures, and degrade injectors, leading to significant engine issues.

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FuelActive is 4x More Effective than Standard Pickup Pipes*

Water Separation

At 3.5 mm water: Standard pipe hits just 24.4% efficiency, while FuelActive soars to 98.6%.
At 5 mm water: FuelActive maintains 94.2% efficiency, but the standard pipe can't keep up and the engine stops

*Results from Independent laboratory testing by Sogefi Filtration Ltd.

Filter Contamination Reduction

FuelActive reduces filter contamination by 82.5% in pre-filters and 66.8% in secondary filters compared to conventional pick-ups. Across the entire filtration system, FuelActive cuts contamination by 1.727 g or 82.2%.

DPM, the 'silent killer,' reduced by 17%.
NOx reduced by an average of 10%.
CO₂ reduced by 1.5%.
NOx measured at both load and idle conditions.

FuelActive’s float design with built-in diffuser reduces localized pressure minimizing the disturbance of contamination within the tank. The conventional fuel pick-up design creates a high-velocity disturbance in and around where contaminants settle (see red area).

Fluid Dynamics CFD Computer Simulation

Reduces Harmful Emissions

FuelActive's pilot with an international mining company achieved significant reductions in underground mining emissions.

Case Studies

“Diesel is one of our biggest costs on the mine and our mobile equipment is the largest consumer of diesel. Therefore to find a product which assists in the reduction is great financially. However, more importantly, it’s great to support Mafube’s continued pledge to reduce energy consumption.”

- Tshepiso Mapule, Digital Innovation Lead, Mafube Colliery

Superior results

The FuelActive outperformed similar control groups and historical data every month.

Validated results

Hypothesis testing validated a 95%+ chance of at least 3% in fuel savings.

6.94% in fuel savings

Data point averages showed over 6.94% in fuel savings - double the expected minimum of 3%.

Positive fuel sampling

Mafube carried out additional fuel sampling, further validating the field trial results.

"For Komatsu Chile and our clients, the installation of FuelActive has proven to be an effective way of combating the global issue of fuel contamination in diesel powered machinery."

Jeffrey J. Dawes, President & CEO, Komatsu Cummins Chile

"The difference in filter costs is obvious but the real advantage is in reduced downtime, improved reliability and improved production levels."

Steve Woods, VP Product Support, Komatsu Cummins Chile

"When the market is down, the miners look for cost savings; when it is up, they look for asset availability. You have the perfect product because you can contribute irrespective of cycle."

Juan Pablo Bustos, Project Manager of the ESTRS Project, Escondida Mine, Chile

Trucks fitted with FuelActive were the only machines to continue operating when a batch of contaminated fuel was delivered to the mine site."

Andrew Warren, Product Support Manager, Komatsu, South America

"FuelActive is a terrific solution that can add to your portfolio of products as a complement to your fuel filtration ones."

Dario Andres Nancupil Paredes, Mining Group Director, Cummins Chile

"We ran a trial in Escondida with 2 Komatsu 980 and our largest mining engine. The results were very good, we were able to move from 500 hours to 1000 hours without impact on the performance of engine. We don't lose the power, we don't lose differential pressure between stage 2 and the stage 1. FuelActive was a big collaborate to keep the system clean, without FuelActive we saw the engine turn from good condition to bad condition, we loss power, we have several fault calls and when we check the fuel line it is full of contamination. FuelActive cares for the fuel system, reduces the TCO for the customer and is very good for Cummins because at the end of engine lifecycle it reduced our costs in filters and repairs to the fuel system."

Juan Pablo Bustos, Project Manager of the ESTRS Project, Escondida Mine, Chile

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Specifications

Parameters	Description
Operational Temperature	-30°C to +50°C
Fuel Flow / Engine Power	330 l/hr (450 kW / 600 hp)*

Warranty	Period
FuelActive® Unit	5 years

Components	Material
Gasket	Klingersi
Gasket	BS Nitrile
Flexible Fuel Line FA10	Plastic hydrocarbon resistant, remains pliable when immersed in fuel.
Dynamic Float FA10	Plastic hydrocarbon resistant
Baffle	Stainless Steel 304
Toplate	Stainless Steel 304

Shield your equipment from fuel contaminants

FA10 FuelActive Unit

Flow Rate / Hour

Pressure Drop (bar)

US Gal	Litre	400mm	900mm
32	32	0.02	0.05
40	150	0.03	0.07
47	180	0.04	0.09
55	210	0.05	0.11
63	240	0.06	0.13
71	270	0.07	0.16
79	300	0.08	0.18
87	330	0.09	0.21

FuelActive FA10: - 110kW-450kW

(150 - 600hp)

FuelActive Unit	Unit Height (mm)	Weight (kg)
FA010B12H350	350	3.25
FA010B12H400	400	3.4
FA010B12H475	475	3.53
FA010B12H550	550	3.83
FA010B12H625	625	4.02
FA010B12H700	700	4.12
FA010B12H775	775	4.48
FA010B12H850	850	4.61
FA010B12H900	900	4.73