Vietnam · Mining / Crushing Plant

800 kVA Open-Frame Prime Power for a Northern Vietnam Nickel Mine

Two 800 kVA open sets running 14 hours a day as main power to a remote nickel-ore crushing plant, with dual-stage air filtration for dust.

This page describes a project we scoped and quoted. It is a scenario and a solution, not a delivered reference - we do not publish a client name, a site photograph or a commissioning record we cannot show you.

Project overview

A nickel-mining operation in northern Vietnam runs a crushing and screening plant at a remote site where grid power is either unavailable or unreliable. The plant needs two parallel 800 kVA generator sets as the main power supply, running roughly 14 hours per day through the dry season. The air carries fine ore dust, temperatures reach 40°C in summer, and the nearest service town is a multi-hour drive.

What the site had to solve

• ›No reliable grid at the mine site — the gensets must be the prime (continuous) power source, not standby.
• ›High ore-dust atmosphere clogs standard air filters within hours, causing power loss and premature engine wear.
• ›Summer ambient hits 40°C; a standard radiator will derate or overheat under continuous load.
• ›Continuous 14-hour duty means fuel consumption and oil service intervals directly affect operating cost.
• ›The site is remote — any maintenance callout takes half a day, so the design must favour reliability and local-serviceable parts.

Technical requirements

How we configured it

1. 01Selected a Yuchai YC6MK series engine rated for prime continuous duty — a six-cylinder turbocharged/aftercooled unit built for long-hour mining operation.
2. 02Fitted a dual-stage air intake: a heavy-duty cyclonic pre-cleaner on top of the standard safety air filter, so coarse ore dust is ejected before it reaches the engine filter.
3. 03Upgraded to a heavy tropical radiator with over-sized cooling core and oil-to-oil cooler, derated safely at 40°C ambient under continuous load.
4. 04Specified a mechanical fuel transfer pump with primary and secondary fuel filters and a water-separator bowl, so fuel-water contamination does not interrupt the shift.
5. 05Built the two sets on a common skid with a synchronising and load-sharing panel, so they can run in parallel or drop one set for service without stopping the crushing line.

Product configuration

All specifications subject to confirmation per order. Spectrum table is the internal reference; final data per technical agreement.

What this configuration is designed to deliver

• ›This solution effectively solves the no-grid problem by providing two parallel prime-rated sets sized for the crusher inrush.
• ›The dual-stage air intake is expected to dramatically extend air-filter life in ore-dust conditions and protect the engine cylinders.
• ›The heavy tropical radiator holds rated power at 40°C ambient without the derating that would cut crushing throughput in summer.
• ›The synchronising panel allows one set to run while the other is serviced, keeping the plant running through the 14-hour shift.
• ›Standard, field-serviceable wear parts keep long-term maintenance cost low even at a remote site.

These are the effects the design targets, described as expectations rather than measured field results.

Keep reading

• Full duty guide: Mining / Crushing Plant →
• Buyer guide behind this design →
• Browse every generator set in the catalogue →
• 250 kVA Silent Backup Power for a Metro Manila Hospital →

Power ratings follow ISO 8528-1:2018 (Prime PRP / Standby ESP), and the fuel figures are stated at ISO 3046-1:2002 standard reference conditions. Both are confirmed unit by unit on our load bank, and the test record ships with the set. Standby figures are the engine's factory standby rating from the model spectrum table — never a computed 110% of the rated output. Noise figures are typical open-type reference values, not a guaranteed sound-power level.