Additized Diesel: Turning Cost into Investment for Mining Operations in Asia Pacific

The Changing Fuel Reality for Mining

On a rainy morning deep in Kalimantan, Indonesia, a fleet of massive haul trucks rumbles into the pit. Each truck burns through hundreds of liters of diesel a day, powering the backbone of one of Asia Pacific’s most vital industries: mining.

But operators have been noticing something troubling. Engines lose power more often than expected. Fuel filters need replacement more often. And fuel efficiency seems inconsistent despite strict maintenance schedules. The culprit is not faulty machinery—it’s the fuel itself.

Across Asia Pacific (AP), governments are mandating higher biodiesel blends to reduce reliance on crude imports and cut carbon emissions. Indonesia, for example, has introduced B40 with ambitions to move toward B50. While this policy supports national sustainability goals, it also introduces new challenges for mining operations that rely on consistent, reliable fuel.

This is where additized diesel enters the conversation.

From Commodity to Competitive Advantage

For years, many fuel buyers and users have viewed additives as an unnecessary cost. Yet global experience tells a different story: fuel additives are a performance investment.

Mining is uniquely demanding. A single breakdown of a haul truck or excavator can cost thousands of dollars per hour in lost productivity. Additives help operators avoid such losses by keeping engines clean, protecting fuel filters, and ensuring combustion efficiency.

Why Now? Pressures Shaping Mining’s Fuel Future

Mining in Asia Pacific has always been defined by extremes—remote locations, heavy loads, and unforgiving climates. But today, operators face new pressures that make the adoption of additized diesel more urgent than ever.

Market Pressures

Coal Price Declines: Global coal prices in 2025 are generally lower than in 2024, with further declines expected as demand softens in Asia and supply remains steady worldwide. For miners, weaker revenue magnifies the need to control costs across every part of operations—including fuel.
Tightening Margins: Demand in key markets like China and India is slowing, while operational costs remain high. Margins are under strain, leaving no room for inefficiency or unplanned downtime.

Natural & Operational Challenges

Weather-Driven Disruptions: The La Niña weather pattern has disrupted production in key mining regions, creating uncertainty in supply chains and heightening operational risk. Reliability of mining fleets is more critical than ever to maintain steady output.

Government & Policy Mandates

Biodiesel Requirements: Governments across AP are mandating higher biodiesel blends. Indonesia implemented B40 in January 2025, with plans to move to B50 by 2026. While these policies support energy resilience and emissions goals, they also introduce technical risks—such as filter plugging, microbial contamination, and injector fouling—that directly impact mining fleets.

Economic & Cost Efficiency

Fuel’s Share of Mining Costs: According to the SRK Report (Oct 2024), diesel haulage and fuel-related activities account for up to 56% of mining operational costs. With such a high share of total cost of operation (TCO), even small gains in fuel efficiency can create significant savings, while fuel problems can erode margins quickly.

With falling revenues, weather volatility, rising biodiesel mandates, and fuel making up more than half of mining operational costs, additized diesel is no longer optional—it’s a critical investment in resilience and profitability.

The Hidden Risks of High-Biodiesel Blends

High biodiesel blends, while environmentally forward-looking, create fuel system issues that operators may not fully anticipate:

Filter Blocking – Biodiesel contains natural impurities that can clog filters faster, leading to power loss and costly downtime.
Injector Deposits – Fouling disrupts spray patterns, reducing combustion efficiency, power, and fuel economy.
Incomplete Combustion – Poor fuel atomization increases fuel consumption and raises emissions.
Accelerated Engine Wear – Deposits and blocked filters force engines to work harder, shortening component life.

The result is a cascade of inefficiencies: more frequent downtime, higher maintenance costs, reduced reliability, and increased fuel consumption—all of which directly hit a mine’s bottom line.

Greenclean™ 4: A Proven Solution for Mining Fuels

Recognizing this challenge, Afton Chemical developed Greenclean™ 4 technology, an advanced additive package tailored to modern diesel and high-biodiesel blends.

How Greenclean™ 4 Works in Mining Applications:

Keeps Engines Clean: Prevents deposit formation on injectors, ensuring optimal spray and combustion.
Protects Filters: Reduces plugging risk, extending filter life even in biodiesel-rich fuels.
Boosts Reliability: Provides consistent performance across extreme load conditions.
Delivers Efficiency: Improves fuel efficiency by ensuring complete combustion.
Supports Compliance: Helps fleets meet tightening emissions standards.

Backed by field data , Greenclean™ 4 has demonstrated measurable improvements in mining fleets—lower emissions, longer equipment life, and reduced unplanned downtime.

Story from the Field

At a large coal mine in Indonesia, operators running on B35 noticed frequent filter replacements and injector issues, leading to unexpected downtime. After adopting additized diesel with Greenclean™ 4 , the site reported:

A 3% improvement in fuel efficiency, with estimated savings of up to US$580,000 per year
Doubled filter life, contributing to estimated savings of up to US$100,000 per year
Noticeable improvement in engine responsiveness under heavy load.
Reduced unplanned downtime, keeping trucks hauling longer and harder.

Overall, the trial demonstrated that using additized diesel with Greenclean™ 4, which costs less than 0.1% of total cost of operation (TCO), can deliver annual savings of up to US$680,000. This is equivalent to approximately a 2% reduction in TCO. The shift reframed the site manager’s view of additives: from “extra expense” to a direct enabler of productivity.

Shifting Mindsets: From Cost to Investment

In the high-pressure environment of mining, where every hour of uptime counts, the conversation around fuel must change. Additives should no longer be seen as an optional premium, but as a strategic investment in productivity, compliance, and sustainability.

Mining operators and diesel producers in AP markets who take the lead on additized diesel will not only protect their equipment but also position themselves ahead of tightening regulatory landscapes.

Mining is a cornerstone industry for Asia Pacific, fueling economies and development. But as fuels evolve, so too must the strategies to keep operations running smoothly. Additized diesel—powered by technologies like Greenclean™ 4—offers mining operations a clear path to greater reliability, efficiency, and compliance.

In the end, the message is simple: mining is already challenging enough. Your fuel shouldn’t make it harder.