Reducing diesel and increasing dump truck fuel efficiency

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Bi-fuel Solution for a Dump Truck Fleet

ComAp Russia has set up a long-term partnership with an opencast mine owner from the city of Novokuzněck in Central Siberia, Russia. The cost of rock mass transportation is the largest part of the total opencast mining costs. So, in order to increase the economic efficiency of the mine and reduce transportation costs, the dual fuel solution was ideal for a fleet of BELAZ 7513 dump trucks with a carrying capacity of 130 tons and Cummins diesel KTA50 engines.

Watch a case study video here.

With Kamms, an engine service provider, and TechnoEco, ComAp´s local service and commissioning partner, we have implemented ComAp´s bi-fuel solution that converts a conventional diesel engine to run primarily on gas, without compromising the engine´s power, durability, orlongevity. “If we are thinking about the economic effects of our bi-fuel solution, on average, we are saving 35% of diesel by replacing it with gas,” says Roman Slavik, Business Development Director, Russian Federation and CIS. The bi-fuel solution has been applied on more than 30 dump trucks in Novokuzněck, with more to follow.

The solution reduces diesel fuel consumption and lowers diesel-based emissions (NOx, PM, SOx, CO2).

The biggest challenge of this project was to deliver our solution and prove its seamless operation in extreme weather conditions where temperatures varied from – 40° C up to + 40° C.
This project has shown that ComAp’s bi-fuel technology can be used in extreme environments and provides beneficial fuel efficiency improvements for a wide variety of industries, including mining.


The system consists of:

- InteliBifuel control system (InteliBifuel Mobile and InteliBifuel Denox)
- A high-pressure gas train that prepares the gas before it is fed to the engine
- High-pressure gas injectors controlling the quantity of gas fed to the engine cylinders
- Sensors monitor all vital engine parameters to always ensure safe operation 

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