MINING ENERGY
The rise of
renewables
John Chadwick considers traditional power systems for
mine sites and also notes the expected growth in the use
of and great potential for renewable energy sources and
power storage
nanth Parameswaran, Director of Power
Systems and Global Marketing at
Cummins Power Generation, says “only
generators robust enough to operate at high
reliability under extremes of ambient
temperature or at high altitude can be
considered for applications at mining sites. For
this reason, diesel engines already proven in
large mining equipment are the preferred choice
for onsite power generation installations, as
they offer a proven performance.”
“This engine commonality greatly simplifies
the diesel engine servicing required on the mine
site, contributing to easier and lower cost of
service.
“Generator sets and installations are typically
rated according to the number of hours and the
related duty cycle they operate, ranging from
emergency standby power (ESP) to limited-time
running power (LTP), prime power (PRP) and
continuous (COP). Each of these applications
place increasingly higher running time and load
hours on the generator set, with a
corresponding reduction in rated output to
ensure reliable operation. Generator frequency
may be either 60 Hz or 50 Hz, depending on
which area of the world the mine site is located,
adding a further influence on the rated output of
the generator set.”
A popular generator used on mines, such as
the DQK Series from Cummins Power Generation
using a Cummins QSK60 diesel engine, will be
rated 2,250 kW at 60 Hz for emergency standby
use, while for continuous use will be rated lower
at 1,600 kW for unlimited hours use. Mines
requiring 50 Hz frequency operation will use the
A
In Madagascar, the Ambatovy operation
purchased 30 Cummins Power Generation
generator sets – 30 1,000 kW C1250 D2R
generator sets using KTA50-G3 engines and
STAMFORD P7 alternators. The rental-spec
generator sets suit the harsh conditions
70 International Mining | SEPTEMBER 2016
same generator with a lower 2,000 kW rating at
standby and 1,230 kW for continuous
applications.
Onsite power systems are typically installed
as a connected series of containerised generator
sets with associated power control and
switchgear systems. In other examples,
customised enclosures or even a dedicated
power station facility is constructed to
accommodate larger, open generator sets.
There is a power choice mines can make
between using a larger number of lower rated
generators, or a smaller number of higher rated
generators. Depending on the specific power
requirements, economies of scale can be
achieved by using a fewer number of higher
output generators to reduce the requirement for
paralleling switchgear and automatic transfer
switches.
Apart from the generator sets themselves,
mine power projects will often require
transformers, paralleling systems, switchgear,
containerization or acoustic enclosures, cooling
and remote monitoring.
Parameswaran notes that the power load
demand of an off-grid mine is dependent upon
the size of the infrastructure supported, the
commodity being extracted and if the mine is
open pit or underground. Metals mining may
undertake processing onsite with crushing,
concentration and even smelting, accounting for
Raglan Mine wind turbine is well situated to
take advantage of the power of wind, courtesy
of Tugliq
a high power demand.
“Underground mines can use double the
amount of electrical power per tonne of mined
material compared to open pits. Shafts and
lifts require power, as do extractor fans, lights
and dewatering pumps. Deep mines require
air conditioning, while mines in cold climates
may require heating. This equipment can
impose load ups of typically 5 MW demand,
with additional power requirements for
standby generators in place for emergency
situations.”
Of course, if a mine is close enough to a gas
pipeline to make tapping in a feasible option,
natural gas fuelled generators can offer an
attractive option in place of diesel-powered
generators for base load prime power and can
help mine operators to significantly reduce their
cost of energy.
“While the rebound in commodity prices will
improve the viability of new and existing sites
throughout Africa, reliable power supply remains
a significant challenge facing new mines,
especially in areas that are not connected to the
grid,” says Clayton Marsland, Regional Sales
Director at APR Energy – a leading provider of
fast-track mobile turbine power.
This is of course true of projects in many
other parts of the world, especially as the trend
recently has been to develop more mines in
remote areas, far removed from existing power
infrastructure. “In some cases, it can take five to
six years for mines in these areas to be
connected to the grid,” Marsland says. “As a
MINING ENERGY
result, a new mining operation has to consider alternative power options to
expedite and facilitate its evolution through the exploration, development
and operational stages.”
Presently, he explains, mines are investing in capital-intensive
permanent generating capacity to meet their power needs. “Some mining
companies are even in negotiations with local governments to take over
closed hydropower plants. Both of these solutions require heavy financial
outlay at a time when savings and cost-reductions are crucial for a mine’s
success.”
Mobile fast-track power is a solution that offers mining operations a
unique value proposition: fast, flexible and full-service.
“Mobile power modules and turbines are the size of a trailer, and can
easily be transported to remote areas via air, road or sea. Once on-site,
they can be up and running within 30 to 90 days,” Marsland said. “These
solutions also are easily scalable, and can be ramped up or down according
to production requirements. The fact that they are located on site is
particularly beneficial as the power does not have to travel long distances,
reducing issues related to grid stability and aging transmission
infrastructure,” Marsland says.
“Power is another non-core process that mines should consider
outsourcing until a reliable connection to the grid is available. This also
allows the mine to focus on its core business,” he says.
“By outsourcing mobile fast-track power, the supplier brings in its own
staff to operate and maintain the plant, leaving the mine with no
responsibilities when it comes to power generation other than paying the
monthly bill,” Marsland concludes.
APR Energy is a world leading provider of fast-track mobile turbine
power. It offers fast, flexible and full-service power solutions to provide
customers with rapid access to reliable electricity when and where they
need it, for as long as they need it. Combining state-of-the-art, fuelefficient technology with industry-leading expertise, its scalable turnkey
plants help run industries around the world, in both developed and
developing markets.
One recent example is the award of two five-year projects valued at more
than $450 million by the Ministry of Energy and Mining of Argentina to
provide a total 350 MW of generating capacity for South America’s secondlargest country. The generating capacity will be split between two sites,
using 14 of the company’s state-of-the-art dual-fuel mobile gas turbines.
“This is the largest single award in the history of APR Energy, and it is
the result of having the best people and the best technology in our
industry. I couldn’t be prouder of our team,” said Chairman and Chief
Executive Officer John Campion.
APR Energy has had a continuous presence in Argentina since 2008 and
currently generates a combined 75 MW of power at three sites: Formosa,
Magdalena and Sáenz Peña.
“Our Argentina award further demonstrates that turbines have a key
place in the fast-track power market. They are the preferred technology of
utilities and a solution that integrates well into their existing infrastructure,”
Campion said.
APR Energy’s mobile turbine fleet features the GE TM2500+™, one of the
world’s most widely used, reliable gas turbine solutions for fast-track
applications. The highly mobile aero derivative turbine is capable of
w w w. b u s b a r- s y s t e m s . c o m
Serving as the sole source of electricity to Minera San Rafael’s Escobal
silver mine in Guatemala, APR Energy’s local team received the 2015
Safety Recognition Award from the customer
S T R O M S C H I E N E N
A G
B U S B A R
S Y S T E M S
SEPTEMBER 2016 | International Mining 71
MINING ENERGY
TM2500+ technical data
producing up to 30 MW of power and is quick to
dispatch, achieving full power in less than 10
minutes.
The high power density and reliability of these
units allows APR Energy to deliver scalable
solutions of 400 MW or more that can integrate
into existing infrastructure and operate on a
NORDIC LIGHTS
72 International Mining | SEPTEMBER 2016
semi-permanent basis.
Developed specifically for delivering fast-track
and mobile power, the TM2500+ is packaged on a
two-trailer system with a top-mounted air inlet
filter and exhaust assemblies. It offers a spaceconscious design with a 24 m x 6.5 m footprint,
and can be shipped by land, air, or sea to
anywhere in the world for quick installation.
A key advantage of
turbines over
reciprocating technology
is the fuel flexibility they
bring. The TM2500+ has
the ability to operate on,
and switch seamlessly
between, diesel and
liquid distillate fuels. It
is also dual frequency,
with the ability to easily
convert from 50 to 60Hz.
Mobile turbines
produce significantly
less emissions than
reciprocating engine
solutions. The TM2500+
offers the option of
water injection for NOx
suppression down to 25
ppm.
At the beginning of
the year, GE was
awarded a landmark
contract valued at nearly
$1 billion for the
engineering,
construction and
provision of gas turbine
services for the Waad Al
Shamal 1,390 MW combined cycle power plant of
Saudi Electricity Co (SEC). Scheduled for
completion in 48 months, the plant will support
the phosphate mining operations in the locality,
in turn driving industrialisation and job creation.
GE will deliver the turnkey power plant, supplying
four advanced GE 7F.05 heavy duty gas turbines
and a GE steam turbine, and featuring solar
innovation technology. One of the gas turbines
will be assembled fully at the GE Manufacturing
Technology Center in Dammam, underlining GE’s
commitment to localisation. The remaining gas
turbines will be produced at GE’s manufacturing
plant in Greenville, South Carolina, USA, and the
steam turbine will be produced at GE’s
manufacturing plant in Schenectady, New York.
GE’s 7F.05 heavy duty gas turbine technology
brings industry-leading flexibility to the Waad Al
Shamal plant with a 10-minute startup to an 80%
load. It can accommodate a wide range of fuels
lending greater flexibility to the operations while
providing customers with lower fuel costs
compared to previous GE technology. GE Power
will also extend its long-term service support to
the plant to ensure seamless operations.
Caterpillar recently launched of Cat® Microgrid
technology, "an innovative suite of power
systems that adds environmentally friendly solar
panels, state-of-the-art energy storage, and
advanced monitoring and control systems to
Caterpillar’s traditional line of reliable power
generation equipment, including Cat generator
sets, switchgear, uninterruptible power supplies
and automatic transfer switches."
Described as ideal for a broad range of
applications including mining installations, the
Cat Microgrid technology suite is designed to
reduce fuel expenses, lower utility bills, decrease
emissions, and reduce the total cost of
ownership while increasing energy efficiency in
even the most challenging environments.
Available worldwide through the Cat dealer
network, Cat Microgrid technologies can be
purchased as turnkey installations or design-toorder solutions. Ranging from 10 kW to 100 MW,
units can be added in a modular fashion to create
systems customised for a variety of power needs.
Caterpillar says it has proven the real-world
value of its microgrid technology by
commissioning a system at its Tucson Proving
Ground in Arizona. In March 2016, facility
managers installed 500 kW of photovoltaic solar
power along with 500 kW of short-term energy
storage in the form of batteries and
ultracapacitors to supplement power that
previously had been supplied solely by three C15
410-kW diesel generator sets. The integrated
system is expected to reduce fuel consumption
by approximately 33%.
“With the declining cost of renewable energy
sources and rapid advances in energy storage
MINING ENERGY
n The Cat Microgrid Master Controller to
monitor and optimise power usage in the
microgrid.
To support the development of the Cat
Microgrid technologies over the past year,
Caterpillar has invested in Fluidic Energy for
energy storage and signed a strategic alliance
with First Solar for an integrated photovoltaic
(PV) solar solution.
Caterpillar has made an equity investment in
Powerhive, an energy solutions provider for
emerging markets
Renewable energy
technology, the time is right to provide an
integrated application for remote power,” said
Rick Rathe, General Manager of new ventures for
Caterpillar’s Electric Power business. “Cat
Microgrid technologies deliver an innovative,
financially viable way to incorporate sustainable
sources of energy into our existing portfolio of
traditional power generation offerings.”
In a hybrid microgrid, renewable sources of
energy can account for any percentage of the
load depending on conditions. Excess energy
produced by renewables is stored for
stabilisation as well as for use during
unfavourable conditions, such as cloudy days
and night time. Generator sets supplement the
system by powering the microgrid when energy
from other sources is unavailable.
Cat Microgrid applications can include any
combination of the following elements:
n Thin-film solar modules, which capture more
energy, especially in high-temperature, highhumidity, desert, and coastal climates
n Energy storage such as ultracapacitors,
lithium-ion, or rechargeable metal-air storage
that provides the most economical and
advanced energy storage with controls and
monitoring down to the cell level
n Cat generator sets powered by diesel, heavy
fuel oil (HFO), natural gas, biogas, or dual
fuel, offering high power density, high-part
load efficiencies, and excellent capability to
follow loads
In her paper New Energy Paradigms in Resource
Extraction at the SME Annual Conference in
Phoenix in February 23, Resa Furey, Market
Analyst with MWH (now part of Stantec) noted
that “many mining companies set goals for GHG
reductions rather than renewable energy
production.
“IAMGOLD,” for instance, “is committed to a
goal of 15% of energy generation coming from
renewables in the next three to five years.” Gold
Fields, she reported has made a commitment to
have 20% renewable energy generation on
average in all new mine developments. And Gold
Fields’ corporate office is to go 50% off-grid
using solar PV.
Industry experts estimate, she reports that “by
2020:
n At least 5% of the energy used by the mining
industry will come from renewable sources.
Currently less than 0.1% of the industry’s
INGETEAM
SEPTEMBER 2016 | International Mining 73
MINING ENERGY
energy consumption is from renewable
sources
n Wind power will become the most important
renewable energy technology to the mining
industry, making up over half of the industry’s
renewable energy
n Solar power will come next in popularity,
supplying a bit less than half of the industry’s
renewable energy
n Mine owners will invest $20 billion in new
renewable energy facilities.”
Wind power
Raglan Mine, part of the Glencore group, is
located at the northernmost limit of Québec,
where it operates one of the richest base-metal
mines in the world. The property stretches 70 km
from east to west, and encompasses a series of
high-grade nickel and copper ore deposits. The
site includes four underground mines currently in
operation, a concentrator, an accommodation
complex and administrative buildings. It has all
the infrastructures of a small municipality.
Since its facilities are not connected to the
hydro network nor to the natural gas grid, the
mine has to produce its own electricity; this is
why it is recognized as the Arctic’s largest
consumer of diesel and its largest emitter of
greenhouse gas (GHG).
Sitting on a plateau 600 m high on the Ungava
Peninsula in northern Quebec, it is well situated
to take advantage of the power of wind. In 2014,
Raglan partnered with Tugliq and Hatch to
complete the construction of a 120-m high
Enercon wind turbine and storage facility. TUGLIQ
is the promoter, owner and operator of the
project.
Like most other northern mines, Raglan was
heavily dependent on diesel to fuel its
operations. With climate change considerations,
commitments to limit environmental impacts and
rising diesel costs, there was a strong business
case for the company to explore alternative
energy solutions.
The project aimed to design, install, and
operate an industrial-scale wind turbine (one of
Quebec's largest). Raglan set out to diversify its
energy mix with wind as a means of improving
sustainability, reducing emissions and cutting
costs. The system was installed at a mine in
severe arctic climate conditions in order to
demonstrate; at an industrial scale that such
configuration can achieve significant reductions
in the energy cost and in diesel consumption
compared to diesel-only or to pure wind-diesel
alternatives. Importantly, the project was sized
and designed to bear relevance to Aboriginal and
remote communities in the North.
The project was a private-public partnership
between Raglan mine, TUGLIQ Energy and the
federal and provincial governments. Hatch
74 International Mining | SEPTEMBER 2016
completed the feasibility study for the project
and managed its implementation and the
integration of wind power into the mine's energy
mix in such a way that grid power quality
and stability is maintained. The project
involved overcoming Arctic conditions and
severe wind power variability.
The project evaluates three
technologies: flywheel, lithium-ion
battery, and electrolyser with fuel cell and
hydrogen tanks. Hatch designed and
implemented the Hatch Microgrid (HμGrid),
which monitors demand for wind power and
supply variations, and economically dispatches
the charger and discharge from energy storage
units to smooth out wind power variations and
displace diesel generation.
The engineering and construction by Hatch
and TUGLIQ Energy was fast-tracked to be
completed within the short Arctic summer
construction window; the project was completed
within budget and schedule, with zero accidents
Since its implementation in August 2014, the
3-MW wind turbine and storage facility has
already saved over 4 million litres of diesel and
reduced GHG emissions by 11,000 t, equivalent to
removing 2,400 cars off Canadian roads. Based
on these results, Glencore estimates that it will
save more than $40 million in fuel-related costs
over the projected 20-year life of the wind
turbine. This successful pilot project could have
transformative impacts across northern Canada,
helping to pave the way for the more widespread
adoption of greener energy alternatives. It is a
fully-developed and tested wind power and
storage system that could be duplicated into
Aboriginal communities and other northern
mining operations in the future. Raglan Mine is
currently evaluating the possibility to install a
second wind turbine at the site.
Similarly, lying on an island in a remote subarctic
lake about 300 km northeast of Yellowknife, the 9.2
MW Diavik wind farm is the first large-scale wind
energy facility in Canada’s Northwest Territories.
The project was developed by Diavik Diamond
Mines to help diversify the energy supply at its
mining operation at Lac de Gras.
The four Enercon wind turbines are integrated
into the mine’s existing diesel-powered system
and offset diesel use when the wind is blowing,
saving the company an estimated $5-6 million a
year in fuel costs. Diavik expects the $33 million
project to reduce its reliance on diesel by around
10% and lower the mine’s carbon footprint by
about 6%.
The 33-m long turbine blades were the longest
loads ever to take the 19-hour, 353-km trip along
the road to Diavik, and custom-designed trailers
had to be used so the trucks could manoeuvre
steep land portages between the lakes. In total,
it took 60 truck loads to get the turbine
components to the site. Rotor diameter for each
of the four wind turbines is 71 m and hub height
64 m.
The wind turbines have been designed to
operate in temperatures as low as -40°C,
exceeding the industry standard of -30°C and
building on Canadian expertise in cold-climate
wind technology.
“Although projects like this are very
challenging technically, and require as many
resources as much larger projects, the impact is
huge. This project will save more than one million
litres of diesel per turbine per year. That is a big
gain. And economically, it just makes sense. I
think now we’ve showcased a clear alignment of
economic and environmental benefits,” said
Marc-Antoine Renaud, Business Development
Manager, Enercon Canada.
This diesel fuel saving also means a reduction
in the annual winter road haul of 100 tanker
trucks a year.
Solar
Last year’s article by Paul Moore, Extractive
power, noted the Degrussa mine solar project
and it was June this year when Sandfire
Resources announced that it had been
commissioned and was now in steady-state
operating mode. The project involved the
installation of 34,080 solar PV panels and
associated site electrical work, allowing
incorporation of the 10MW facility and the 6 MW
on-site battery storage with the existing dieselfired power station at the DeGrussa copper-gold
mine.
The solar array covers a total area of over 20
ha at the site, which is located immediately
adjacent to the DeGrussa underground mine and
processing plant.
The innovative A$40 million project is the
largest integrated off-grid solar and battery
storage facility in Australia and reportedly, in the
world. It comprises 34,080 solar PV panels with a
single-axis tracking system mounted on 4,700
steel posts. This enables the panels to track the
sun during the day, improving the plant’s overall
performance. Electrical infrastructure installed
includes inverters to change the
The panels are connected via an extensive
network of low-voltage, high-voltage and
communication cables to a 6 MW lithium-ion
battery storage facility and the existing 19 MW
diesel-fired power station at DeGrussa.
The project is owned by leading French
renewable energy firm Neoen, with juwi
Renewable Energy responsible for the project
development, EPC and O&M. Project financing
was provided by the Clean Energy Finance Corp
(CEFC) and recoupable grant funding support of
A$20.9 million from the Australian Renewable
Energy Agency (ARENA).
MINING ENERGY
DeGrussa’s Solar Project is the largest
integrated off-grid solar and battery storage
facility in Australia and reportedly, in the world.
The project comprises 34,080 solar PV panels
with a single-axis tracking system mounted on
4,700 steel posts. This enables the panels to
track the sun during the day, improving the
plant’s overall performance
Sandfire’s Managing Director, Karl Simich:
“This is the largest integrated off-grid solar and
battery storage facility in Australia and draws
together a number of technologies which are
widely expected to have a transformational
impact on the global economy over the next
decade. These include solar power combined
with a state-of-the-art lithium-ion battery storage
facility, which has been used for the first time in a
remote location at the DeGrussa mine.
“This project has already attracted a
significant amount of interest from within the
mining industry in Australia with Sandfire
receiving inquiries from several of our peers
interested in adopting this technology at their
mine sites. I would not be surprised to see more
facilities like this built over the next few years, as
the benefits and potential of solar power become
increasingly recognised across the resource sector.
“The DeGrussa Solar Project is expected to
reduce our annual diesel consumption and cut
our carbon emissions by more than 12,000 t of
CO2 annually – a reduction of more than 15%
based on our reported emissions for the 2016
financial year.”
The juwi Group is one of the world’s leading
renewable energy companies specialising in the
EPC of utility-scale projects. juwi has been
involved in the development, design,
construction and operation of more than 1,500
solar PV projects and the installation of more
than 700 wind turbines with a cumulated
capacity of over 3,300 MW.
Franck Woitiez, Managing Director of Neoen
Australia: “Neoen is thrilled with this major
success and recognises that Australia is a
Three SolarMax 2000s installed by IM2 Energía
Solar at Chuquicamata mine in Chile in June 2014
with a capacity of 6 kW
76 International Mining | SEPTEMBER 2016
tremendous place for the development of such
innovative projects.”
Neoen has a portfolio of more than 1,000MW
of projects across Australia and aims at owning
and operating 600 MW by 2020 in the country. It
is an independent power producer, generating
electricity from renewable sources (solar, wind or
biomass). Neoen develops, finances, builds and
operates plants and is active in France, Portugal,
Australia, Mexico, Egypt, Mozambique, Jamaica,
Zambia, Jordan and El Salvador. With a current
operating base of 759 MW, Neoen seeks to
achieve installed power of over 1,000 MW by
2017.
Just over a year ago, Hanwha SolarOne, a
global photovoltaic manufacturer of high-quality,
cost-effective solar modules, completed its 2
MWp delivery to the Ozkoyuncu Solar Enerji
power plant in the Turkish province of Kayseri,
Cappadocia. Else Enerji, a leading Turkish EPC
contractor, was responsible for the turnkey
completion on behalf of Turkish mining company
Ozkoyuncu Mining Co. Based on the positive
outcome of quality assessments conducted by
the German testing institute, TÜV Rheinland,
Hanwha SolarOne qualified as the solar module
supplier for the project. The solar park was
connected to the grid in July.
As part of the quality audit, HSL solar module
samples were randomly selected by the project
owners and sent to TÜV Rheinland for third-party
testing.
“The PV modules from Hanwha Solar have
already demonstrated their high performance
and reliable output in existing solar parks
realised by Else Enerji in Turkey,” says Mustafa
Herdem, General Manager of Else Enerji. “As
expected, our positive experience in the field was
confirmed by the stringent third-party quality
assessment performed in Germany by TÜV
Rheinland. The combination of high-quality
products and a financially strong parent company
represent an attractive package.
The positive outcome of the quality tests
meant that the delivery of the HSL modules was
able to commence. It is estimated that it will
generate around 3.4 million kWh/y of electricity.
“The approach taken by Else Enerji and
Ozkoyuncu Mining confirms a very positive
market trend – namely an increasing sensibility
regarding the quality of solar products,” says
Winfried Wahl, Senior Director Products and
Marketing at Hanwha SolarOne GmbH. “Our
company is continuously expanding its
cooperation with renowned testing institutes in
order to verify our processes and products to the
benefit of our customers.”
With approximately 2 Mt of annual production,
Özkoyuncu Mining is the largest iron ore
producer in Turkey.
Furey notes that mine tailings facilities can be
good sites for solar power installations. At
Molycorp’s abandoned Questa, New Mexico,
mine, a 1- MW concentrated photovoltaic (CPV)
solar facility sits on 20 acres of mine tailings. It
has been operational since February 2011 and is
the largest of its kind in the US. A local energy
MINING ENERGY
cooperative purchases the energy through a 20year agreement.
She also points out the solar thermal plant at
Codelco's Gaby Mine in the Antofagasta region,
Chile. Opened in October 2013, this plant
transforms solar radiation into thermal energy to
generate hot water to heat the copper extraction
process. The “process uses flat-plate solar
collectors that gather heat by absorbing sunlight.
Collectors are 99% recyclable and have capacity
to generate around 4,000 m3 of hot water.” At full
capacity the plant generates an average of 54
GWh/y, replacing 85% of the diesel that is
normally used to heat the copper extraction
process.
Erwin Spolders, CEO of Redavia, highlighted
the significance of reliable energy for mining and
noted specific concerns regarding the use of
reliable energy in the industry. “Mining investors
and executives are asking themselves how these
new reliable energy options could improve their
concerns”, said Spolders. “They want to know
what prospects solar energy as a new remote
energy technology option brings to them, and
whether this technology provides a reliable, lowcost energy supply to remote minerals
operations”.
“We at Redavia, have proven that solar
hybridisation of diesel or HFO power plants at
remote mine sites represents a clear and proven
opportunity for the industry to reduce energy
IDS
78 International Mining | SEPTEMBER 2016
SunSHI FT is a modular and moveable solar farm solution for large-scale on-grid and off-grid
electricity generation. Its pre-engineered and pre-fabricated container-sized modules minimise the
risk, time, and site resources required to deploy a solar farm. Unlike traditional solar farms,
SunSHIFT systems can be easily moved, allowing future expansion, rearrangement, or removal.
These turn-key solutions scale from 50 kW arrays to multiple 1 MW blocks, and can incorporate
energy storage for increased solar penetration. Stand-alone systems or turn-key integration with
fossil-fuelled generators are available
cost, build shareholder value and enhance its
reputation of being a societally beneficial,
environmentally responsible and technologically
innovative industry” said Spolders. “Our tried
and tested, patented containerised, modular
solar system allows our clients to become
environmentally responsible cost-leaders,
without distracting our customers from their core
mining operations”.
Redavia rents out redeployable, containerised
solar farms, which means that companies avoid
upfront costs or long-term financial commitments,
while still enjoying the benefits of cost savings
from reduced diesel fuel use. This makes the
solution very attractive because it addresses key
concerns. The solar farms include smart
integration of solar power into existing or new
on-site diesel generation power systems and are
MINING ENERGY
First Solar is cost competitive with conventional energy sources today. It provides a LCOE of between
$0.07-0.15/kWh, depending on irradiance levels, interest rates, and other factors such as
development costs
monitored and controlled to ensure optimal
operation and savings throughout the entire system.
A mining client in western Tanzania which had
high power costs in off-grid is a case in point.
This is a mine in Western Tanzania producing
some 80,000 oz/y of gold. Without access to a
reliable grid power source, the mine relies
exclusively on a rented 6 MW HFO power station.
It turned to Redavia Rental Solar Power’s flexible
solar power service to reduce diesel fuel cost.
In the first phase, Redavia deployed a 63 kWp
rental solar power plant at the client site,
converting the client’s power source into a hybrid
system. The solar plant is financed by Redavia
and rented to the client on a high flexible 24-
month rental contract. The client started making
cash cost savings immediately, and the small
scale farm is predicted to produce 100,000
kWh/y, saving 28,000 litres of diesel.
In the second phase, the client intends to
increase the installed solar capacity to MW scale.
Phase 1 has already provided valuable sitespecific data and experience, while cementing
relationships with local operations and maintenance
service providers. Once operational, the full-scale
rental solar farm will generate six figure savings
during the anticipated rental period.
Redavia says it has “unique capabilities to
satisfy mining’s need for flexible, low cost, and
reliable energy in even the most remote
locations:
n Containerised, re-deployable rental solar
plants gives clients unrivalled flexibility in
rental contract duration
n Innovative rental solar financing structure a
clients to access savings from solar energy
without up-front investment.
Caterpillar’s strategic alliance with First Solar
was noted earlier. First Solar’s advanced Series 5
solar modules provide the next generation of thin
film solar technology. These thin film solar
modules deliver “faster installation, extensive
compatibility and a higher return on investment
for long-term owners,” the company says.
“Series 5 PV modules have a demonstrated
performance advantage over conventional
crystalline silicon solar of up to 10% more energy
each year.
n Outperforms conventional crystalline silicon
solar modules with equal power rating
n Proven energy yield advantage in humid
climates due to superior spectral response
and in hot climates due to superior
temperature coefficient (-0.28%/°C)
n Robust against shading in landscape
orientation
n Extended reliability in harsh environments
n More watts per connection than the 72-cell
multicrystalline modules
n New design increases compatibility to
eliminate BOS costs
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SEPTEMBER 2016 | International Mining 79
MINING ENERGY
n Compatible with newer 1,500V system
architecture for operational and capital
benefits
n Anti-reflective coated glass (Series 5A™)
enhances energy production.
“At temperatures above 25°C, First Solar
modules produce more energy than competing
solar modules due to a superior temperature
coefficient. This proven performance advantage
provides stronger plant performance in high
temperature climates, where more than 90% of a
plant’s generation will occur when module
temperatures are above 25°C and First Solar
modules have a proven performance advantage.”
Solar panels on tailings ponds
An innovative and energy-smart concept to
harness clean solar power for multiple
applications is being tested in the
Mediterranean, off the island of Malta. Conceived
and developed by researchers at MIRARCO and
Laurentian University in Sudbury, Canada, the
Offshore Passive Photo-voltaic (OPPV) project is
using thin solar panels (photo-voltaic cells)
floating on the water’s surface to generate energy.
The array of panels, measuring about 20 m by 20
m, is expected to have a peak output of 8 kW.
MIRARCO researcher Kim Trapani: “We believe
our system is a substantial improvement on other
forms of marine renewable energy, such as
offshore wind, rigid offshore photo-voltaic
structures, wave and tidal energy. The floating PV
panels do not pose a collision risk, and should
require very low maintenance.”
Dr Dean Millar, Professor in the Bharti School
of Engineering and the MIRARCO Research Chair
of Energy in Mining is particularly interested in
the potential applications of the OPPV project in
mining.
“Wherever they are located, mines tend to
consume appreciable amounts of energy to
support mineral production,” said Millar. “The
Maltese demonstration project is a world first
that aims to prove thin-film PV technology in the
saltwater marine environment, but it has also
been developed as an electricity generating
system for mines.”
The flexible laminated panels will float on the
surface of the water of tailings ponds, said Millar.
“The panels could form a barrier to isolate
wildlife from the tailings waters, while the panels
generate electricity for the mine.”
Trapani and Millar have published research
suggesting that for remote mines, the cost per
kilowatt-hour produced with the PV systems is
lower than the cost of installing and running
diesel-powered generators. “Our OPPV
technology could have game-changing
implications for the mining industry, especially
with remote mine sites, by providing clean and
cheap energy that can be set up where needed
82 International Mining | SEPTEMBER 2016
with relatively little infrastructure. These
demonstration projects aim to prove longer term
reliability,” said Millar.
Power management
In May, Schneider Electric announced Premset,
its innovative range of solid insulated medium
voltage switchgear for power distribution
management. Premset is the first global product
to use solid and shielded insulation. The earth
shielded system offers unprecedented safety,
efficiency and ease of use. The main circuit
components are insulated by a layer of solid
material covered by an external conductive coating
with ground potential. There is no electric field in
the ambient air, because live conductors and the
ground is confined within the switchgear enclosure.
“Premset is a breakthrough innovation that
combines the Schneider Electric expertise in airinsulated switchgear and gas-insulated
switchgear to deliver the innovation of a Shielded
Solid Insulation System (2SIS) that reduces
internal arcing risk for increased safety,” said Juan
Macias, Senior Vice President-Energy, Schneider
Electric. “Premset represents the future of medium
voltage distribution, embracing intelligent
connectivity to bring a new level of efficiency to
help meet the growing demand for power.
With embedded smart technology, Premset
includes:
n Shielded Solid Insulation System (2SIS) and
screening of all live parts, ensuring improved
safety and reliability
n Simple, flexible, modular design makes it
easy to install, upgrade and maintain, thanks
to (2SIS) technology
n Advanced protection, control and monitoring
technology is fully integrated for higher
reliability and energy efficiency.
Premset enables simplified network upgrades,
with the ability to leverage the same accessories
and monitoring devices across the entire range.
The ‘plug and play’ design allows for on-site
additions that do not require special training,
tools or adjustments. Designed with
standardised dimensions, a reduced footprint
and simple front accessible power connections,
Premset reduces installation time and cost and
can minimise future downtime delays when used
with Schneider Electric services. Additionally,
through advanced monitoring and control,
Premset switchgear helps ensure the network is
at its peak performance, enabling:
n Automated Redundancy (Auto Source
Transfer) with pre-engineered, easily applied
solutions
n Load management with integrated, smart
metering
n Asset management with advanced switchgear
and transformer monitoring
n VIP self-powered protection and communication
relay for higher MV network availability
In addition to standard electrical, mechanical
and visual equipment inspections, Schneider
Electric also offers optional start up and
commissioning services for all Premset
purchases, to ensure equipment and components
are functioning properly. This service includes:
n Confirmation the system has been installed
properly and the equipment is operating as
specified
n Gathering and evaluation of initial operational
data to check insulation, current path,
functionality and sequencing to minimize
future downtime and expenditures
n Verification of correct operation of interfaces
between new and existing equipment.
WEG Transformers Africa (WTA), a division of
Zest WEG Manufacturing, is determined to
continue growing its share in both the African
transformer market. Louis Meiring, chief
executive officer at Zest WEG Group Africa, says
the acquisition last year of Heidelberg-based TSS
Transformers facilitated immediate access to
MINING ENERGY
Colombia, Brazil and Mexico. These operations
produce the same or similar products which
meant that the manufacturing processes are the
same and similar. These facilities already
complied with WEG best practices, and Juliano
Vargas, Zest WEG Group Logistics and Operations
Director, says that some had done so for more
than 20 years.
Energy storage
redT took its first step into Africa recently with
A suite of structured transformer maintenance
programs that allow customers to protect these
assets from degradation is an important valueadded service offering from WTA
additional facilities as well as best-in-class
technical skills. “Upskilling ourselves in this
critical market sector and increasing our local
manufacturing base was a strategic move that
will see greater involvement from Zest WEG in
this industry,” Meiring says.
Zest WEG Group is owned by Brazil-based WEG
and this significant investment in local
manufacturing highlights WEG’s financial
commitment to its local operations. Meiring says
the acquisition was in line with the international
player’s intention to expand its global network of
businesses and manufacturing plants. The WEG
Group aims to increase its sales year-on-year by a
minimum of 17% until it reaches an annual
turnover of $10 billion in 2020.
WTA operates two major facilities and is
poised to reinforce its position as a leading
African manufacturer of electrical equipment.
WTA Wadeville produces standard distribution,
power and special application transformers
ranging from 50 kVA to 10 MVA in voltages up to
66 kV with off-load tap switch or on-load tapchangers. The facility also has the engineering
expertise and capability to manufacture special
transformers for mining, industrial, rectifier/
traction, converter and thyristor drive applications.
WTA also manufactures a range of mini substations.
The Heidelberg facility is capable of locally
manufacturing power transformers up to 40 MVA
in voltages up to 132 kV as well as mini
substations and moulded circuit breakers.
The most recent investment has been in best
practice production control programs that will
allow the Zest WEG Group manufacturing
84 International Mining | SEPTEMBER 2016
operations to improve processes thereby
accelerating production and meeting shortened
lead times.
In November 2015, a team of skilled
practitioners from WEG Brazil visited the South
African facilities to assess these operations and
establish the status compared to WEG global
best practices in manufacturing. This took place
over a three week period to ensure in-depth
assessment of all four facilities.
Comparisons were done with WEG facilities in
The BKS in-house laboratory has been
accredited by LOVAG. BKS is now able to carry
out authorised tests for lifting, ability to
withstand mechanical loads, clearances and
creepage distances, dielectric properties,
temperature rise limits and electromagnetic
compatibility. This, it says, puts BKS ahead of its
competition in the ability to provide testing for
projects and enhance R&D efforts. BKS offers
cast resin busbar systems for low and medium
voltage. It has expanded its portfolio and in the
future will deliver coloured busducts by request
the arrival of two 5kW, 40kWh energy storage
systems at a customer’s site in Johannesburg,
South Africa. On this continent business owners
and operators are now looking to safeguard their
supply and provide firm power through the use of
industrial-scale energy storage machines such as
redT’s.
redT has spent 15 years developing its
patented Vanadium Redox Flow Battery (VRFB)
technology which is ideal for use in weakgrid/off-grid applications. Unlike technologies
such as lead-acid or lithium, it does not degrade
when fully discharged and is suited to long
duration (three hours plus) storage. This means it
can handle the high volatility, high-cycling
characteristics of solar PV and diesel generators.
For these reasons, the system is highly robust
and can be monitored remotely – reducing
operating expenditure.
For these reasons, Africa is a key market for
the company and the applications for redT's
technology are wide ranging, from working
alongside grid-connected solar to coupling with
diesel gensets within the mining and extractives
industry.
For renewable assets such as solar, the
fundamental issue surrounds the mismatch
between generation availability and demand.
Both solar and wind energy are highly dependent
on external conditions but energy demand is
independent of these factors. redT’s energy
storage machines solve this issue by allowing
operators to store excess energy when
generation capacity is available for use at
another time, for example, at night. Using energy
storage in this manner creates firm power from
an intermittent, renewable energy source,
providing operators with the ability to maximise
their generation capacity, make savings through
arbitrage activities and secure their own,
independent power supply.
Energy storage such as this can also be used
alongside diesel gensets or a combination of
renewable and diesel assets. Storage allows
operators to run gensets at optimal loads to
charge the system, increasing efficiency and
reducing wear on the engine – base load demand
can then be met by the system, with the
generator being used for ramping during demand
spikes.
MINING ENERGY
For these reasons, Africa is a key market for
the company and the applications for redT's
technology are wide ranging, from working
alongside grid-connected solar to coupling with
diesel gensets within the mining and extractives
industries.
Vionx Energy further explains that the VRFB is
a pure redox flow battery, which stores energy by
employing vanadium redox couples (V2+/V3+ in
the negative and V4+/V5+ in the positive halfcells). Like other vanadium redox flow batteries,
the power and energy ratings of VRFBs are
independent of each other and each may be
optimised separately for a specific application.
That means the volume of storage and the output
of storage are scaled separately. All the other
benefits and distinctions of pure redox flow
batteries compared to other energy storage
NORMET
86 International Mining | SEPTEMBER 2016
systems are realised by VRFB’s. VRFB’s are time
tested—it’s the same chemistry that powered the
batteries on the Apollo moon missions.
VNX1000 Series has a rated system power of
1MW and energy storage capacity: 6-10 MWh.
The usable depth-of-discharge is 100% and AC
efficiency: 68% @PCC. The design lifetime is 20
years with a performance warranty of 10 years.
Vionx batteries employ vanadium flow
chemistry, with a breakthrough optimisation
invented by partner, United Technologies Corp
(UTC) that provides twice the power at lower cost.
Vionx says “traditional vanadium flow batteries
employ a range of components that include tanks
of anolyte and catholyte fluids and a power cell
at the centre of the system. How these fluids
‘flow through’ and ‘flow by’ each other in the
power cell is at the heart of system performance.
“Our breakthrough was a new process
improvement within the cell called
the ‘Interdigitated Flow Field’, by
which the most efficient flow-through
and flow-by processes are integrated
to generate a much higher power
density (2X) at lower pressure. This
increased power output combined
with lower material costs now makes
our VRFB energy storage system
extremely competitive when
compared with other long-term grid
storage options.
Vionx’s energy storage system earns its
durability from its roots in rechargeable polymer
electrolyte membrane (PEM) fuel cells leveraged
from decades of UTC fuel cell engineering to
reliably forecast a multi-decade expected life.
UTC’s battery stack architecture is based on
this fuel cell experience, on a vanadium
chemistry for which there is over 20 years of
actual operational experience, and on low
pressure electrolyte flow that virtually eliminates
any propensity for pressure related leakage. This
durable design is scalable and relies on global
leaders for components (3M) and assembly
(JABIL).
The Vionx design uses chemical and
pharmaceutical industry standard piping, pumps,
and supply for all wetted surfaces and procures
equipment from premier chemical industry
suppliers adhering to best industry practices.
MINING ENERGY
Vionx’s preventative maintenance program
(PM), provided under our long-term service
agreement, is based on constant, real-time
systems monitoring and fault isolation.
Caterpillar has invested in Fluidic Energy,
which designs, manufactures and markets
proprietary energy storage solutions. It says it “is
the first and only company to commercialise and
deliver rechargeable metal-air battery technology
in high production volumes for commercial loadshifting applications. Metal-air battery
technology has long been considered the lowest
cost way to store an electron. Fluidic is also the
only company to develop integrated controls
intelligence at the cell level taking the system's
sophistication and ability to reduce energy costs
to a whole new level. The net result is a technology
suite that delivers the lowest total energy cost
solution and optimal performance metrics for many
grid scale and peak shaving markets.”
“Entering into global commercialisation in
mid-2011 with over 35,000 batteries in operation
by mid-2014, the technology is proven to increase
reliability and outperform in terms of cost, longevity
and functionality. In addition to proven capabilities
of managing both long and short partial cycles at
the lowest cost, other key fundamental advantages
include repeated ultra-long discharge time
capability, higher energy density, environmentally
friendliness, no theft value and increased safety (i.e.
no chance of thermal runaway).” IM
Marthinusen & Coutts recently repaired two large mill motors for leading uranium producer, Rössing
Uranium; celebrating 40 years of production this year. Two brush mill motors were inspected on site.
It was found that the starting cage winding on one of the motors had moved and rubbed against the
stator winding, while an insulation test conducted on the second motor indicated that the stator
winding was down to earth. This necessitated having both motors repaired at Marthinusen & Coutts’
facility in Johannesburg. As no spare motor would be available to the mine in the event of a further
breakdown while the two spare motors were being attended to, the first of the two brush motors to
be repaired was treated with the greatest urgency to ensure that it was returned as quickly as
possible. “The repairs were completed within three months and the motor was returned to the
mine,” Craig Megannon, Marthinusen & Coutts’ General Manager, explains. The repairs consisted of
rewinding the stators incorporating use of a resin-rich winding system, overhaul of the rotors and
complete replacement of the rotors’ electronic diode and synchronising hub. This picture shows
Alpheus Mtshali, Marthinusen & Coutts, with one of the 1,586 kW 187.5 rpm, 3,300 V, 278 A stator
FLOWROX
SEPTEMBER 2016 | International Mining 87