Portable power generation is often an essential component of many sites as Patrick Smith reports.
Chicago Pneumatic skid-mounted air compressors are playing a vital role in new blast hole drilling machines being used for overburden removal in the coal fields of central India. BGR Mining and Infra, one of the biggest mining contractors in Hyderabad, with a fleet of 1,600 dumpers, 200 excavators and 200 supporting vehicles, has placed an order for ten CPS 1100/300 high-pressure compressors, with each forming part of a special machine suitable for blast hole drilling.
The new machines are industry-first conceptualised units in which the compressor is mounted on a crawler excavator, where usually conventional blast hole drills rigs or truck-mounted compressor units connected to drills are used.
They are mounted on excavators with the counterweight eliminated and the drill mast mounted onto the boom, enabling the machine to reach areas with difficult or limited accessibility. A swivelling arrangement also provides greater versatility than truck-mounted rigs, thus minimising drilling time.
With a higher cfm and higher pressure, the rate of drilling with the CPS 1100/300 will be approximately 100m/hour for overburden drilling compared with conventional water well drilling rigs, which typically deliver around 72m/hour.
“Chicago Pneumatic air compressors are the preferred choice for us because of the product performance and the fact it is an international brand with proven quality,” says K.A. Udaya Kumar, general manager of BGR Mining and Infra.
“With the increased performance of the supplied equipment, we may see further opportunities open up in the mining industry.”
Chicago Pneumatic has also extended its range of CPDG mobile diesel generators, bolstering the original five models (from 9-40kVA) with the addition of six new models from 60-200kVA.
“As a result of this expansion, we are now able to offer our customers a complete range of small to medium-sized mobile generators, which all provide a combination of exceptional toughness, reliability and easy operation,” says Tony Calippe, spokesperson for generator equipment at Chicago Pneumatic.
Using proven technology, which draws on Chicago Pneumatic’s history of making generators since the mid-1930s, the generators are all fully CE compliant for use in Europe.
To provide operators with the option of extended run times, CPDG generators can now be equipped with higher capacity fuel tanks. This, says Chicago Pneumatic, coupled with 500-hour service intervals, means CPDG generators are especially suited for applications where a generator is required run to reliably for a high number of hours with reduced attention from the operator.
Meanwhile, Atlas Copco’s XATS 900E, an electric portable compressor, is said to have the versatility to suit a wide range of demanding applications, and is equipped with a 160kW motor.
“As an energy-efficient alternative to traditional diesel-driven compressors, the XATS 900E delivers compressed air from seven to 10 bar with a flow of up to 25m³/min, while offering users the advantages of reduced running costs and reduced requirement for maintenance,” says Atlas Copco. Suitable for sites with a ready supply of power, the XATS 900E is easy to install on any surface as it requires no additional foundations.
It has a power-flex frame that supports ease of movement, higher safety and protection from spillage, while the corrosion-resistant canopy of the compressor is designed for use in all weather conditions, without the need for additional rooms and enclosures. The electrically-powered unit is enclosed in a silenced acoustic canopy, with sound levels of 73db(A) at 7m. This conforms to ISO9614-2 standards and makes the unit suitable for working in urbanised areas and confined spaces.
The company says that the XATS 900E is designed to provide quality air solutions with an inbuilt after-cooler and water separator and can be fitted with optional downstream filtration to further enhance the air quality. Also, the new electric portable compressor features large door panels for easy access and single side service procedures.
“The launch of the XATS 900E opens up new options for our customers to harness the power of electric. It combines smart engineering, proven technology and quality components. The XATS 900E, is an outstanding choice when it comes to setting up an efficient job site”, says Ben Van Hove, vice-president of marketing in Atlas Copco’s Portable Energy division.
At Doosan Portable Power, its comprehensive range has been increased and now includes an enhanced selection of small high ambient models, complementing the standard range of compressors from the company.
The high ambient range includes the 7/26E HA; 7/31E HA; 7/41 HA, and 7/53 HA models, with free air deliveries from 2.5-5m³/minute and a rated operating pressure of 7bar.
These small compressors are aimed at a very wide range of applications in plant hire, construction and general industry, including standard pressure applications such as powering breakers and tools in road repair, demolition and refurbishment.
They can also be equipped with a bunded base option for environmental safety, providing a fully contained base to ensure that all operating fluids (fuel, oil and water) stay within the compressor.
The 7/26E HA, 7/31E HA, 7/41 HA and 7/53 HA models offer a number of important options, including an integral 6kVA generator, which increases compressor flexibility by supplying electrical output in addition to compressed air. As a result, electric tools or other electrical equipment such as lights and fusion welding systems can be run in parallel with pneumatic equipment.
The new 7/53 HA portable compressor is the latest addition to the range, replacing the previous 7/51 HA model, and it has been redesigned by Doosan so that it remains in the Stage IIIA category, avoiding the need to transition to meet Stage IIIB regulations.
The compressor supplies 5m³/min of compressed air and is powered by the four-cylinder mechanical turbo-charged Yanmar liquid-cooled 4TNV84T-BMDP engine, producing 36kW of power at 2,600rpm.
Like all the other models in the small compressor range, it can be supplied with a range of running gear options to meet local market requirements, and this gear can also be replaced with a permanent metal support, typically ordered when the compressor is to be truck-mounted.
The new 7/53 HA compressor offers a reduced size, with a length of 3,389mm in the fixed height, running gear version, and a minimum/maximum height of 3,520/3,770mm with adjustable height running gear.
“The serviceability of all Doosan small compressors is excellent with easy access to all maintenance points,” says the company.
“All areas have been carefully designed for ease of inspection, maintenance and repair. Service intervals for several components have been extended to increase uptime and reduce maintenance costs. The 7/53 HA compressor incorporates a new spin-on separation element that further reduces service time.”
Energy Power Systems Australia (EPSA) was contracted to supply temporary power generation to a purpose-built port facility, which required continuous and reliable power up to a maximum demand of 35MW.
The company supplied a fully operational power station incorporating 30 Cat XQ2000 power modules each containing a Cat 3516B diesel generator set installed in a 40foot container.
This was required at the Roy Hill iron ore mining facility in the Chichester Range in the Pilbara region of Western Australia, which has a life of more than 20 years, and the potential to produce 55 million tonnes/year.
The project includes a mine; a mine process plant; a heavy haul railway system from mine to port, and port facilities, and under a fully-integrated Build, Own and Operate (BOO) agreement, EPSA was contracted to supply the temporary power generation.
“Under the contract, we designed, constructed, connected and commissioned the temporary power generation facility. We will also own, operate and maintain it for a minimum two-year period, with options to extend thereafter up to ten years,” says Bill Thomson, EPSA’s general manager, Project Services.
“The power station currently supplies the entire power needs for the port facility. It is termed temporary because the long-term planning intention was to establish a grid connection.”
Generators were built in the US, shipped to Fremantle, and then transported to the site over 1,200km away.
EPSA extended its relationship with Roy Hill through the negotiation of a separate contract to design and build the enabling infrastructure for a stand-by power station at the mine site capable of deploying up to 80MW of power through 56 stand-by generator bays ready and able to take Cat XQ2000 power modules.
