Industry Solution
Mining Power Distribution Solutions
Rugged, dust-protected power distribution equipment for open-pit and underground mining operations — from mine intake substation to processing plant distribution.
Mining operations present the most demanding electrical environment in industry: 24/7 operation, extreme dust, vibration from blasting and heavy machinery, wide temperature swings, and remote locations with limited grid infrastructure. Electrical equipment must survive these conditions while delivering uninterrupted power — a single transformer or switchgear failure can stop production worth millions per day.
Ziyao Power supplies purpose-engineered power distribution solutions for mines: heavy-duty oil-immersed transformers with reinforced tanks and enhanced cooling, dust-protected (IP54+) LV and MV switchgear, motor control centers for crusher/conveyor/host drives up to megawatt ratings, and containerized mobile substations for rapid deployment at remote mine sites.
Our mining packages are designed for open-pit copper/gold mines, underground coal operations, aggregate quarries, and mineral processing plants. We configure equipment for common mine voltages (6.6kV, 11kV, 13.8kV, 33kV), incorporate redundancy for critical loads (ventilation, dewatering pumps), and provide comprehensive protection against arc flash, earth faults, and voltage dips from large motor starts.
Mega-Motor Starting Loads
Mine crushers, ball mills, and hoists draw 5–8× full load current during starting. Transformers must be oversized and switchgear rated for high inrush — typically 150–200% of running load capacity.
Extreme Environmental Conditions
Open-pit mines at 4000m+ altitude need altitude-derated equipment. Underground coal mines require flameproof (Ex-d) certification. Desert mines need 55°C+ ambient rating with de-rated cooling calculations.
Remote Site Logistics
Mines are often 500km+ from the nearest port or major city. Equipment must be robust for rough-road transport, simple to install with minimal site infrastructure, and supplied with comprehensive spares and documentation.
Power Quality & Harmonics
VFD-driven mills, hoists, and conveyors generate significant harmonics. Mines need active front-end (AFE) drives, harmonic filters, and dynamic reactive compensation to maintain power quality and avoid utility penalties.
Safety Critical Systems
Underground ventilation fans, dewatering pumps, and personnel hoists are safety-critical loads. They require redundant power supplies, automatic transfer schemes (ATS), and UPS-backed control power — failure is not an option.
Grid Connectivity Challenges
Many mines operate at the end of weak transmission lines or with captive power generation. Equipment must handle wide voltage fluctuations (±15%), frequency variations, and load shedding schemes.
Heavy-Duty Main Transformers
S22-MReinforced oil-immersed S22-M transformers with oversized tanks, additional cooling radiators for high-altitude/high-temperature derating, and seismic-rated construction.
Oversized for motor starting to handle crusher/hoist inrush currents.
View S22-M Series →MV Metal-Clad Switchgear
KYN28KYN28/KYN61 arc-proof MV switchgear with vacuum or SF6 CB. Designed for dusty environments with IP54 enclosure, filtered ventilation, and anti-condensation heaters.
Heavy-Duty MCC & VFD Panels
MCCMining-grade Motor Control Centers with withdrawable starters up to 1000kW. Integrated VFD panels for crusher/conveyor/hoist drives. IP54 rated, dust-filtered ventilation.
Containerized Mobile Substation
YBSelf-contained mining substation in a 20ft/40ft container: transformer + MV switchgear + LV switchboard + MCC + PFC. Fully pre-wired and factory-tested for rapid deployment.
Mobile substation reduces site civil works. Move as mine expands. Ideal for remote/expansion projects.
View YB Series →Open-Pit Copper/Gold Mine
Main intake substation, crusher/conveyor power, SAG/ball mill drives, and processing plant distribution.
Underground Coal Mining
Flameproof (Ex-d) transformers and switchgear. Redundant ventilation/dewatering supply. Personnel hoist drives.
Aggregate & Quarry
Crusher motor control, conveyor belt VFD drives, screening plant power, and wash plant electrical.
Mineral Processing Plant
Flotation cells, thickeners, filter presses, and tailings pumps. Chemical-resistant equipment for process areas.
Remote Exploration Camp
Containerized diesel/gas generator + transformer + distribution package for exploration drilling and camp power.
Underground Ventilation
Redundant (2N) fan motor supplies with ATS. Soft-start/VFD for large axial fans up to 5MW. UPS-backed controls.
Reference: 20MW Open-Pit Mine Electrical System
Typical electrical configuration for an open-pit copper/gold mine with crushing, conveying, milling, and processing. Reference design based on mining industry standards — not a specific customer project.
| Equipment | Qty | Specification |
|---|---|---|
| Main Intake Transformers | 2 | S22-M 12.5/16MVA, 33/6.6kV, ONAN/ONAF, reinforced tank |
| MV Main Switchgear | 1 set | KYN61-40.5, 33kV line bay + transformer protection, 31.5kA |
| MV Distribution Switchgear | 1 set | KYN28-12, 6.6kV, 2000A, 31.5kA, multiple feeders |
| Crusher Transformer | 1 | S22-M 4000kVA, 6.6/0.69kV, oversized for starting, Dyn11 |
| Crusher MCC + VFD | 1 set | 690V, 2× 800kW VFD (primary + secondary crusher) |
| Mill Transformer | 1 | S22-M 5000kVA, 6.6/0.69kV, 2× winding for 12-pulse drive |
| SAG/Ball Mill VFD | 1 system | 690V, liquid-cooled MV VFD, 2× 3000kW, active front end |
| Process Plant Transformer | 2 | S22-M 2500kVA each, 6.6/0.4kV, Dyn11, IP54 enclosure |
| LV Switchboard + MCC | 2 sets | GCS, 400V, 3200A, pumps/flotation/conveyor starters |
| Reactive/Harmonic Compensation | 2 sets | Active harmonic filter 500A + PFC 1000kVAR per plant |
Q: How do you size transformers for mine crusher loads?
Crusher motors draw 6–8× rated current on DOL starting. We size the transformer at 200–250% of running load to ensure voltage drop during starting stays below 15%. For very large crushers (>500kW), we recommend soft starters or VFDs to reduce transformer size and network disturbance.
Q: Do you provide explosion-proof equipment for underground coal mines?
We supply equipment suitable for underground mining environments, including enhanced safety features and robust enclosures. For coal mines requiring IEC 60079 (Ex) certification, we can supply certified Ex-d flameproof transformers and switchgear through our partner network. Please specify Ex requirements during inquiry.
Q: Can you supply mobile containerized substations for mines?
Yes, our YB Series containerized (mobile) substation is ideal for mining: pre-wired, factory-tested, delivered as a single 20ft or 40ft container. Includes transformer, MV switchgear, LV distribution, and optional MCC. Reduces site civil works and can be relocated as the mine expands.
Q: What altitude de-rating do your transformers have?
Standard transformers are rated for <1000m altitude. For high-altitude mines (Andes, Tibet, etc.), we de-rate per IEC 60076: approximately 1% per 100m above 1000m for air-cooled. We also factor in reduced air density for switchgear insulation and cooling. Altitude tests available on request.
Q: What about harmonics from mine VFD drives?
VFD-driven mills and hoists are major harmonic sources. We recommend: (1) active front end (AFE) VFDs with <5% THD, (2) multi-pulse transformer configurations (12-pulse, 24-pulse) for large drives, and (3) active harmonic filters at the PCC. We provide harmonic study and filter sizing as part of our engineering package.
Q: What spares and after-sales support do you provide?
We supply a recommended spares list with every mining package: fuses, contactors, relays, gaskets, bushings, and consumables sufficient for 2 years of operation. We also offer on-site commissioning, remote diagnostics, and emergency spare dispatch via air freight. Critical spares can reach most mine sites within 5–7 days.
Power Your Mining Operation with Rugged Equipment
Tell us about your mine — location, altitude, major loads (crusher/mill ratings), and timeline. We'll engineer a complete power distribution package that survives your harshest conditions.