BESS MW solar design for mining plants

Customer Design Case
1.
Usage Scenarios:
The system will be operating continuously in a mining industry setting, providing full-time power.
2.
Load Details:
1.Total Load: Approximately 4 MVA
2.Largest Load: A ball mill rated at 400 kW
3.Load Startup: All loads are started in a staggered manner to manage inrush currents and power surges.

Operating Hours and Schedule:
1.Ball Mill: Operates 24 hours/day
2.Compressors: Operate 24 hours/day, though not all run simultaneously
3.Crushing Plant: Operates 16 hours/day
All equipment runs 7 days a week, ensuring continuous mining operations.

Solar Panel Installation Site:
The solar panels will be installed on a prepared 6-hectare land area (solar farm), rather than on a rooftop.

Existing Backup Power:
There is an existing diesel generator providing backup power, rated at 2 MVA. The generator is currently on-site and available as needed.

Energy Consumption & Diesel Usage:
The diesel generator currently runs less than 60 hours per month. Under full load, it consumes approximately 320 liters/hour.

1.Conversion: 320L of diesel = approximately 1,280 kWh
2.Daily Consumption at Full Load: 320L/h × 24h = 7,680L/day
7,680L/day × (1,280 kWh/320L) = 30,720 kWh/day
Given about 6 hours of effective daily sunshine, a solar system sized at approximately 5 MW (5,120 kW) is suitable to meet these energy demands and significantly reduce diesel dependency.

This design case highlights the operational requirements of a mining facility, its continuous load demands, and the optimal solar system sizing (around 5 MW) to offset the current diesel consumption and provide a more sustainable energy solution.