HIGH PROFILE
Cummins powers up energy generation plans
Mining operations are embracing the opportunities
created by new technology, from automation and electric
vehicles to renewable energy, but what can traditional
fossil fuel power generation contribute to this technology-
led evolution? Craig Wilkins, Director Prime Power at
Cummins, explains how natural gas is key to meeting the
industry’s power needs in the coming decades
mg/Nm3 for diesel). Also, lean burn particulate
levels are almost zero, so meeting location-
specific emissions regulations can be far easier
across a global perspective.
Power generation fuel flexibility
Technological advances in design, running in
tandem with market change, will result in gensets
that can use fuel efficiently in varying qualities.
This innovation is demonstrated by our new
HSK78G, which delivers high electrical efficiency
of up to 44.2% (50 Hz) and 43.5% (60 Hz) on a
range of pipeline natural gas down to 70 MN
without impacting power output and efficiency.
Ultimately this fuel flexibility empowers
operators to derive clean power from what would
otherwise be regarded as waste products, at
worst emissions. The technology for smarter and
cleaner power solutions is speeding up and
adoption will continue to grow as more mines
embrace its capital expenditure (capex) and
operational expenditure (opex) advantages.
Engineered to extremes
The Cummins HSK78G gas-powered generator
delivers high electrical efficiency of up to
44.2% (50 Hz) and 43.5% (60 Hz) on a range
of pipeline natural gas down to 70 MN,
according to Cummins
any mining operations take place in
remote parts of the world where access
to large electric utility feeds is either
unavailable or requires significant investments in
electrical transmission and distribution. These
same sites may also have little or no access to
pipeline gas, or experience a variation of natural
gas supply. In addition, they are operating in the
most extreme climates imaginable, faced with
blistering heat, the wettest humidity and high
altitudes.
Therefore, the need to secure a reliable prime
and peaking power supply to keep production up
and running 24/7 is paramount.
Cummins has responded to this challenge with
a significant investment into the natural gas arena
with the launch of its HSK78G gas-powered
generator, a flexible prime power solution for
heavy-industry installations in the most extreme
environments. Its extreme engineering is
designed to push the boundaries of performance
and challenge the perceived limitations of natural
gas generators for mining operations. It has
barrier-breaking fuel flexibility, is able to burn
pipeline natural gas, flare gas and biogas, even
the lowest BTU methane down to 40 Methane
Number (MN), and free fuel sources, with high
efficiency and low emissions.
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68 International Mining | AUGUST 2019
Gas vs diesel A further challenge for the mining operation is the
environment in which the generator set operates.
As engines operate, they produce heat and tend
to be more sensitive to the ambient temperature
levels. A generator’s ambient capability is defined
as the maximum temperature at which it can
operate without experiencing a loss of efficiency
and it is an essential factor for customers
operating in such extreme environments.
Without an engine capable of meeting high
ambient temperatures, customers risk having to
derate their engine, which can lead to reduced
Miners continuously look for ways to lower their
cost of production. One of the major sources of
cost for an open-pit mine site is fuel. Some mines
have access to an un-interruptible supply of
natural gas that offers them a lower total cost
when compared to diesel.
Although technological advancements in
natural gas storage and filling have yet to yield an
economical replacement to diesel engines in
mobile mining equipment, prime power generator
sets are quickly moving towards lean burn,
natural gas technologies. Lean burn gas powered
generator sets use twice as much air in the
fuel/air mix than required for total burn, which
lowers burn temperature and NOx output,
ensuring compliance with emission regulations.
Due to increasing emissions limits being
adopted for generator sets, diesel generators
sometimes are limited in their use. Lean burn,
natural gas generator sets typically have 10 times
lower NOx than diesel equivalents (250-500
mg/Nm3 for natural gas compared to 2,500-3,000 Cummins’ Craig Wilkins says, in the future, most
power systems will require a mix of technologies
that are specifically suited to their environment,
emissions zone and location
The investment on the HSK78G comes as the
power market across the globe is changing.
Technological advances in renewable energy, and
its application with batteries as part of modular
power networks, tend to dominate the future of
power generation. The concept is flexible,
scalable and able to power entire cities as well as
remote off-grid installations – such as mines. So
why invest in traditional natural gas power?