Diesel Generator for Mining — 2.5MW Prime Power
Southern Africa — 2.5 MW Prime Power
Project Overview
Remote mine sites frequently operate with no grid connection, making on-site generation the sole source of power for crushers, conveyors, ventilation, lighting, and camp facilities. This mine required a diesel generator for mining that could run continuously at prime rating, sustaining production around the clock in a hot, dust-heavy environment.
H&C supplied a 2.5 MW prime-rated generator built around an MTU 20V4000 engine and Leroy-Somer alternator, mounted on a heavy-duty skid for remote deployment. The unit is engineered for continuous duty, low fuel consumption per kilowatt-hour, and straightforward field servicing by the mine's maintenance team.
Challenge & Requirements
The diesel generator for mining had to deliver continuous prime power, not just emergency standby, which demanded sustained full-load capability, high fuel efficiency, and robust cooling. The remote, dusty site required heavy-duty air filtration and packaging that could withstand transport over rough terrain, plus simple, maintainable systems that did not depend on a stable grid for starting or control power.
Technical Specifications
| Parameter | Specification |
|---|---|
| Generator Model | HC-2500GF (Skid-Mounted) |
| Rated Power (Standby) | 2,750 kW / 3,438 kVA |
| Rated Power (Prime) | 2,500 kW / 3,125 kVA |
| Engine | MTU 20V4000G63 |
| Alternator | Leroy-Somer LSA 53 M8 |
| Controller | ComAp InteliGen NT |
| Voltage / Frequency | 400V / 50Hz (6.6kV available) |
| Rated Speed | 1500 RPM |
| Cooling Method | Water-Cooled Radiator (Heavy-Duty) |
| Starting Method | 24V DC Electric Start |
| Fuel Tank | 8,000L Skid Tank + Bulk Storage |
| Enclosure / Noise Level | Containerized — ≤85 dBA @ 1m |
| Dimensions (L×W×H) | 7,200 × 2,440 × 2,590 mm |
| Dry Weight | 23,500 kg |
| Compliance | ISO 8528-5, ISO 3046-1 |
Solution & Implementation
H&C selected an MTU 20V4000G63 engine matched to a Leroy-Somer LSA 53 alternator for 2.5 MW prime output. A ComAp InteliGen controller provides load management, automatic start, and remote monitoring, while heavy-duty filtration and a high-capacity cooling system were specified for continuous operation in a mining environment.
The generator was built on a galvanized skid with an integral fuel tank and containerized enclosure, allowing rapid deployment at the mine site. Full-load testing at the factory confirmed rated output, fuel consumption, and temperature performance under sustained load before export.
H&C coordinated ocean freight and inland transport to the remote site, and provided commissioning support and documentation. A complete spare-parts kit and operator training enabled the mine's crew to perform routine service in the field without external support.
Project Gallery
Robotic welding of the generator base frame in the H&C factory
CNC press brake forming enclosure panels in the H&C factory
Full-load factory testing before shipment
Project Results
The diesel generator for mining has provided reliable prime power for the mine's operations, sustaining production through extended continuous-run periods with no major unplanned downtime reported.
The operator reported strong fuel efficiency and low maintenance burden, and the successful deployment led to repeat enquiries for additional off-grid power units for other mine sites.
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