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Modular vs. Permanent Fuel Farm: Which Is Right for Your Mine?
Every new mine needs fuel and lube on day one. The big question is whether you pour concrete for a permanent fuel farm or bring in a modular system you can move later.
9 min read
Modular vs. Permanent Fuel Farm: Which Is Right for Your Mine?
Table of Contents
Every new mine needs fuel and lube on day one. The big question is whether you pour concrete for a permanent fuel farm or bring in a modular system you can move later.
The short answer: if your pit will move, your mine life isn't locked in, or you need fuel on site fast, a modular, skid-mounted system usually makes more sense. A permanent fuel farm makes sense when the site, the layout and the fleet will stay put for decades.
Side by side
A permanent fuel farm is built in place: foundations, poured containment, custom piping and a pump house. A modular fuel system is built and tested in a shop, then shipped to site on skids and connected together.
| Permanent fuel farm | Modular fuel system | |
|---|---|---|
| Site prep | Heavy civil work: foundations, berms, trenching | Much less civil work; modules set on a prepared pad |
| Time to first fuel | Long build on site | Mostly setting and connecting modules |
| When the pit moves | Stays behind, or gets torn down | Taken apart and moved to the new pad |
| Adding capacity | New design and new construction | Plug in another module |
| New fluids (DEF, renewable diesel) | Hard to retrofit | Add a separate module for each fluid |
| Best for | Long-life sites with a fixed layout | New mines, moving pits, uncertain mine life |
When permanent still makes sense
Modular isn't always the answer. If your mine has a long, proven life, the fuel bay will sit in the same central spot for decades, and your volumes are huge, a permanent farm can be the right call. You pay more up front, but you build it once.
Four questions to ask before you pour concrete
- How long will the pit stay where it is? If the answer is "not sure," don't bury your capital in the ground.
- What will your fleet look like in five years? Modular lets you start small and add capacity as trucks arrive.
- How soon do you need fuel? Pre-built modules cut most of the construction time on site.
- Will your fluid mix change? More DEF, renewable diesel or new lubes are easier to add when each fluid has its own module.
If you answered "not sure" to two or more, modular is probably the safer bet.
Where the iGrid fits
The Innoflo iGrid is a modular fuel, lube and DEF system built for Canadian mine sites. Fuel modules hold 60,000 to 120,000 litres each, and you can chain up to ten together. Lube and DEF modules sit in heated buildings that are winter-rated to -40°C. When the mine plan changes, the whole system moves with it.
Frequently asked questions
Is a modular fuel system cheaper than a permanent fuel farm?
Usually up front, because it needs much less civil work. Over the life of the mine, the bigger saving comes from moving and reusing the equipment instead of building a new farm every time the pit shifts.
Can a modular fuel system handle a large mining fleet?
Yes. The iGrid fuel module is designed to dispense at 850 litres per minute for haul trucks, and each module holds 60,000 to 120,000 litres. You can link up to ten modules together, giving you a maximum total capacity of 1.2 million litres.
This means you can start small and scale your fuel storage and throughput as your fleet grows without having to rebuild your infrastructure.
Do modular fuel and lube systems work in Canadian winters?
They can, if they're built for it. The iGrid is winter-rated to -40°C, with lube and DEF kept inside heated, insulated buildings.
Can I switch from a modular system to a permanent one later?
Yes. Many sites start modular during construction and early production, then decide on permanent infrastructure once the mine plan is proven. The modules can then move to the next pad or project.
Not sure which way to go?
Tell us about your fleet, your mine plan and your timeline. We'll help you figure out whether modular, permanent or a mix of both makes sense for your site.
Explore the iGrid or reach the team at info@innoflo.com or 780-944-4819.
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