Mozambique Coal Mine Prefabricated Power Substation
Mozambique Coalfield Phase II Expansion — Prefabricated E-House Substation Procurement Project
KeRun provides Coal Mine Prefabricated Power Substation solutions in Mozambique, featuring mobile, explosion-proof, and cost-effective E-Houses.
Project Overview
The photovoltaic power plant is located near the capital of Papua New Guinea , an area with a weak power grid infrastructure and extremely high requirements for power supply stability. To address the intermittent fluctuations in photovoltaic power generation, the owner initiated an expansion project, adding a battery energy storage system with a total capacity of 5MW/10MWh .
This project aims to procure key equipment connecting energy storage battery stacks to the local 11kV power grid. KeRun Intelligent Control Co., Ltd. will serve as the core supplier, providing YB-1000 prefabricated substations (Huabian) and supporting high and low voltage switchgear to ensure the efficient and stable transmission of green energy to the PNG national power grid.
Project Introduction and Supply Scope
We provide a complete solution, not just individual components, based on the “mobile substation” concept to meet the needs of the open-pit coal mine. Our supply scope is carefully calculated and divided into four independent power islands:
-
Core Carrier: Four 40-foot high-cabinet special container-type prefabricated cabins.
-
Logic: We use reinforced corrugated steel structures. All high and low-voltage equipment, HVAC systems, and fire protection systems are integrated inside.
-
-
Transformer System: Eight 2500kVA 33kV/0.4kV epoxy resin cast dry-type transformers (installed inside the cabin).
-
Quantity Logic: Each prefabricated cabin has two transformers, operating in a “single busbar section” mode. Normally, both transformers run in parallel. If one transformer undergoes maintenance, the other continues to power critical loads via a bus tie switch to ensure uninterrupted operation of the mine’s drainage pumps and ventilation fans.
-
-
Medium Voltage Switchgear: 24 units of KYN61-40.5 (33kV) armored, withdrawable switchgear.
-
Logic: These units receive the 33kV power from the mine’s main substation.
-
-
Low Voltage Motor Control Center (MCC): Forty-eight MNS low-voltage withdrawable units.
-
Logic: These units directly control crushers and conveyor belt motors, equipped with soft start functions.
-
Design Logic and Principles
Power supply design for Mozambique’s coal mines must address three main challenges: “dust explosion risk,” “high temperatures,” and “construction delays.” We apply strict design principles to solve these issues:
Positive Pressure Explosion-proof Logic:
-
-
Challenge: Coal dust is conductive and highly explosive. If coal ash enters the switchgear, it could cause short circuits and destroy the equipment.
-
Solution: We designed the prefabricated cabins with positive pressure ventilation. The air conditioning system constantly blows air into the cabin, raising the internal pressure slightly above the outside. This ensures that any gap in the door will expel air, preventing coal dust from entering the cabin and physically avoiding insulation faults.
-
-
-
Thermal Shielding Temperature Control Logic:
-
Challenge: Summer temperatures can reach 45°C, and containers under direct sunlight act like ovens.
-
Solution: We filled the cabin walls with 80mm thick rock wool insulation and applied high-reflectivity white marine paint to the outer surfaces. Combined with industrial-grade explosion-proof air conditioners, the cabin maintains a constant internal temperature of 25°C to ensure the longevity of electronic components.
-
-
Factory Pre-Commissioning Delivery Logic:
-
Challenge: Mozambique lacks skilled high-voltage electricians, and civil construction work is extremely slow.
-
Solution: We pre-installed the transformers, switchgear, and secondary wiring in our factory in China and completed the system integration testing. After shipping to the mine, the customer only needs to connect the 33kV incoming cables. No further internal wiring is required, greatly shortening the installation time.
-
-
Mozambique Market Research and Insights
KeRun’s team conducted in-depth research on the local conditions in Mozambique before designing the project:
-
Influence of South African Standards:
-
Research: Mozambique’s power facilities are heavily influenced by neighboring South Africa.
-
KeRun’s Solution: We adopted the bottom cable entry method, which is standard in South Africa, and included oversized terminals to accommodate locally common large aluminum core cables.
-
-
Voltage Level Specificity:
-
Research: The mine uses 33kV as its main distribution voltage, which differs from the common 10kV or 35kV used in China.
-
KeRun’s Solution: We designed all insulating components to meet the 40.5kV maximum voltage level. We doubled the clearance distances to fully align with the local grid architecture.
-
-
Language Barrier:
-
Research: Portuguese is the official language, and local workers do not understand English.
-
KeRun’s Solution: We customized all warning labels (e.g., “High Voltage Danger,” “Do Not Enter”), operation buttons, and HMI screen interfaces in Portuguese.
-
Product Advantages and Selling Points
-
IP54 Rated “Mining Armor”: Our container bodies are reinforced to withstand ground vibrations caused by mining explosions. They also have an IP54 dust- and water-proof rating, unlike regular containers.
-
Skid-Mounted Base: The prefabricated E-Houses feature heavy-duty sled bases and drag hooks. As the mine excavation advances, bulldozers can directly tow the entire substation to a new location without dismantling, achieving true mobile power supply.
-
Lowest Lifecycle Cost: By avoiding expensive labor and material costs for building a brick-and-mortar substation in Mozambique, our total cost is 40% lower than traditional solutions.
Procurement of Transformers/Prefabricated Cabins – Key Considerations
Mozambique has strict foreign exchange controls and a complex logistics chain. To mitigate risks, we implement the most stringent business terms:
-
Trade Terms: Only EXW or FOB.
Reason: The road conditions from Beira Port to the coal mine are poor, and the customs process is unpredictable. We are responsible for loading high-quality products onto the ship. The buyer takes control of the remaining risks. -
Payment Terms: 100% payment before shipment.
Process:-
Pay 30% of the total amount as a deposit within 10 days of signing the contract (for purchasing steel and copper materials).
-
After the product is manufactured, customers or third parties are welcome to conduct FAT (Factory Acceptance Test).
-
After passing the FAT, pay the remaining 70% balance upon shipment notification. Shipment will be made after payment is completed.
Note: Since prefabricated cabins are customized and cannot be resold, we insist on full payment before shipment.
-
Why Mozambique Coal Mine Project Chose KeRun?
-
Speed: South African suppliers need 8 months for delivery, and European suppliers have high costs. KeRun guarantees a 3-month delivery time, perfectly meeting the coal mine’s urgent production needs.
-
System Integration: Most competitors only sell transformers or switchgear. KeRun integrates transformers, switchgear, air conditioning, fire protection, and lighting into one unit, making the customer’s job easier.
Value-added Services: Technical Empowerment and Spare Parts Guarantee
We don’t just sell equipment; we provide peace of mind:
-
Spare Parts “Black Box”: Considering the difficulty of procurement in the mining area, we reserve a “5-year spare parts kit” in each prefabricated cabin. This includes circuit breaker contacts, indicator lights, fuses, etc., ensuring small failures are fixed promptly.