The historic Kipushi zinc/copper mine in the Democratic Republic of Congo (DRC) is undergoing a refurbishment process led by Ivanhoe Mines.

Zest WEG  is supplying electrical and energy infrastructure which includes a 14 MW power plant, motor control centres (MCCs), medium voltage (MV) variable speed drives (VSDs) and a 1 200 kW MV medium voltage motor. The company is also the preferred supplier of low voltage (LV) motors, and will supply these to a range of mechanical original equipment manufacturers (OEMs) servicing the mine.

“Our diesel-powered plant, which will provide the mine with backup energy, has been designed to comprise 12 generator sets – each rated at 1 587 kVA and 400 V,” says Zest WEG business development external sales engineer: mining and industrial Luveshen Naidoo. “Assembled at Zest WEG’s specialised Cape Town facility, the plant includes MV switchgear, six 3 150 kVA ONAN type 400 V / 6.6 kV step-up transformers, a 40 000 litre fuel tank and an automated fuel system.”

He explains that splitting the plant design into smaller generating units ensured engines and alternators were readily available, securing a quicker delivery time. The configuration of the plant in this way also gives the mine greater energy security in case of maintenance or breakdown. The gensets can also be transported to site using conventional trucking, without the need for abnormal load vehicles.

The MCCs are being supplied for use in an established substation on the Kipushi zinc/copper mine, as well as for a containerised substation elsewhere on the site. The units are designed for a back-to-back configuration with a compact bucket size, to accommodate space constraints.

For the mine’s semi-autogenous grinding, or SAG, mill, Zest WEG is providing its W60 MV motor rated at 1 200 kW – a robust unit for the demanding applications and aggressive environments found in the mining sector, says Naidoo. The motor is mounted onto a compact base plate, or plinth, making it lighter in weight and lowering installation costs. The motor is IP55 rated, indicating reliable protection from dust or water ingress.

In order for the MV VSD to drive the ball mill motor, WEG is supplying its MVW3000 unit which features a compact design with an integral dry-type transformer. In addition, a ducting system has been specially designed for the 1 200 kW VSD, to help dissipate heat and reduce the need for cooling of the substation.  

Zest WEG says that its equipment will be supported by Panaco, the company’s value added reseller in the DRC.

“Our partners at Panaco can generate technical reports to share with Zest WEG to ensure we can provide accurate and necessary specialist support,” notes Naidoo. “We have an after-sales team who can deliver support and solutions remotely or by travelling to site.”