Diesel Generator for Mining Applications | Hosem Power

In metal mines, aggregate quarries, open-pit mines, and underground mining operations, power supply stability directly determines production safety, operational efficiency, and cost control. Most mining sites are located far from public utility grids, operating under high load, heavy shock, harsh environments, and strict safety requirements.
As a result, independent diesel power stations have become a critical infrastructure for modern mining operations.

Backed by proven engineering systems and extensive global mining project experience, Hosem Power provides high-power, scalable diesel generator solutions specifically designed for mining applications—ensuring uninterrupted 24/7 operation and supporting safe, efficient, and sustainable production.

Core Power Challenges in Mining Operations

1. Off-Grid “Island Power” Is the Norm

Mining sites are commonly located in mountains, plateaus, deserts, or remote regions, where grid access is limited or unavailable. Power stations must independently support:

• Crushing, mining, and conveying systems

• Auxiliary loads such as offices, camps, ventilation, and drainage

• 24/7 continuous operation

• Zero tolerance for power outages

This places extreme demands on generator reliability and redundancy.

2. Concentrated High-Impact Loads Require Strong Transient Performance

Mining equipment such as crushers, ball mills, air compressors, and pumps generates high starting currents and large shock loads.

Mining diesel generators must deliver:

• Fast transient response

• Rapid voltage and frequency recovery

• Controlled voltage and frequency dips within equipment tolerance limits

Without proper transient capability, power instability can damage critical equipment and disrupt production.

3. Extreme Environments Demand Industrial Durability

Mining environments are among the harshest for power equipment:

• Heavy dust → reinforced air filtration systems

• High ambient temperatures → enhanced cooling systems

• Corrosive gases or salt mist → anti-corrosion and anti-salt spray coatings

• Ground vibration → reinforced base frames and vibration-resistant structures

Generator sets must be purpose-built, not standard industrial models.

4. High Safety Standards Are Non-Negotiable

As the heart of mining operations, power stations must meet strict safety and compliance standards:

• Complete electrical protections (overcurrent, short circuit, over/under voltage)

• Explosion-proof equipment selection where required

• Proper fuel storage management and fire isolation zoning

• Reliable automatic transfer and emergency shutdown logic

In mining sites, diesel power stations are both production engines and safety guardians.

Hosem Power Mining Diesel Generator Solutions

1. Industrial-Grade High-Power Engine Platforms

Hosem Power mining generator sets are built on world-class engine platforms including MTU, Cummins, Mitsubishi Heavy Industries, and Volvo, offering:

• Strong continuous power reserve for heavy-duty mining loads

• High fuel efficiency to reduce long-term operating costs

• Global service networks and reliable spare parts availability

These engines are designed for continuous heavy-load mining operations.

2. Multi-Generator Paralleling Systems (3MW–20MW)

Hosem Power factory-level synchronizing systems support large-scale mining power stations:

• Stable load sharing across multiple generator sets

• Segmented power supply for multiple production lines

• Scalable expansion as mining capacity grows

• N+1 / N+2 redundancy to eliminate critical downtime risks

This ensures maximum reliability and operational flexibility.

3. Mining-Specific Enhanced Configurations

To address harsh mining conditions, Hosem Power offers customized enhancements:

• Dual-stage air filtration for extreme dust environments

• 50°C high-temperature radiators for hot climates

• High-altitude configurations (above 1500 m)

• Anti-corrosion and anti-salt spray coatings for containers, canopies, frames, and control panels

These upgrades significantly extend equipment service life.

4. Comprehensive Operation & Maintenance Support

Hosem Power provides full lifecycle service solutions:

• 24/7 remote monitoring and diagnostics

• Scheduled inspections and preventive maintenance

• Fast supply of critical spare parts

• Optional turnkey power station O&M services

This minimizes downtime and protects mining investments.

Key Principles for Selecting Mining Diesel Generators

1. Power Selection Based on Load Characteristics

Start by defining core mining loads:

• Crushing lines (high shock loads)

• Grinding lines (continuous heavy loads)

• Conveying systems (intermittent loads)

• Drainage, ventilation, dust collection (essential safety loads)

Selection logic:

• Size generators for maximum stable load

• Reserve 10–20% power margin

• Use staged loading to reduce starting impact

2. Starting Method Impacts Generator Capacity

• DOL (Direct-On-Line): high impact, larger generator required

• Soft Starter: moderate impact, optimized sizing

• VFD (Variable Frequency Drive): minimal impact, most economical configuration

3. Environmental & Altitude Conditions Must Be Confirmed Early

• Ambient temperature >45°C → high-temperature radiator

• Altitude >1500 m → power derating or altitude-adapted engines

• High dust → upgraded air filtration systems

• Corrosive or salt mist environments → enhanced surface protection

4. Electrical Design & Paralleling Requirements

Mining power stations typically require:

• Multi-generator paralleling

• Segmented power supply by production line

• Expansion-ready system architecture

Key configurations to confirm:

• Synchronizing panel compatibility

• Load priority management logic

• Remote monitoring and intelligent dispatch systems

5. Lifecycle Cost & Maintenance Considerations

Decision-making should include:

• Fuel consumption rates

• Consumables replacement cycles (air, fuel, oil filters)

• Brand service accessibility

• Spare parts availability and delivery speed

Hosem Power Core Advantages

1. Flexible Engine Platform Coverage

• A-M Series (Mitsubishi engines): ultra-reliable for continuous heavy-duty mining loads

• A-P Series (Perkins engines): efficient and economical for cyclic operations

• A-C Series (Cummins engines): cost-effective for standard mining and backup power

Solutions are tailored to load profiles, runtime, and budget.

2. Factory-Level Paralleling Technology

Designed specifically for continuous mining operations, supporting N+1 / N+2 redundancy, ensuring zero production interruption even during single-unit failures.

3. Mining-Grade Structural & Environmental Reinforcement

From filtration and cooling to vibration resistance and corrosion protection, all systems meet mining operational standards without secondary modification.

4. Full Lifecycle Service Assurance

• Professional on-site commissioning

• Customized operator training

• Ready stock of common spare parts

• Preventive maintenance and full power station O&M services

Recommended Mining Generator Models

• A-C1100

• A-C1650

• A-M2000

Project Case Study: Large Iron Mine in Nigeria

Configuration

• 6 × A-C1100 diesel generator sets

• Cummins KTA38-G5 engines

• Hosem Power ASF 404E alternators

• Prime power: 1000 kVA per unit

Project Background
The mine operates both open-pit and underground facilities under extreme temperature variation and heavy sandstorms, with exceptionally high reliability requirements.

Solution
Hosem Power engineered a 6 MW synchronized power station with full-weather protection and redundancy, delivering stable, continuous power to support uninterrupted mining operations.