Copper Mine Power Distribution Solution – Zambia
Project Name: Konkola Copper Mine Power Supply Expansion
Country: Zambia
Supplied Products:
220/66kV 100MVA Oil-Immersed Power Transformers (2 units)
66/11kV 31.5MVA Step-down Transformers (3 units)
KYN61-40.5 Medium Voltage Switchgear Panels (24 panels, 40.5kV)
KYN28-12 Medium Voltage Switchgear Panels (76 panels, 11kV)
VS1-12 Indoor Vacuum Circuit Breakers (withdrawable type)
ZW32-12 Outdoor Vacuum Circuit Breakers (18 units)
11/0.4kV Prefabricated Substations (20 units)
GCS/MNS Type Low Voltage Switchgear Panels (120 panels)
High-Capacity Motor Control Centers (MCCs) for >2MW Motors
Client: Konkola Copper Mines PLC (via EPC Contractor – China Nonferrous Metal Mining Group)
Delivery Time: August 2024
Application: Reliable power distribution for open-pit and underground mining operations, concentrator, smelter, water pumping stations, and staff residential areas.
Project Overview:
QZ Switchgear supplied a turnkey power distribution package for Zambia’s Konkola Copper Mine expansion, one of Africa’s largest copper producers. The project included high-voltage substations, medium-voltage feeders, low-voltage motor control, and remote monitoring systems, ensuring reliable supply for ore crushers, hoists, conveyors, smelting furnaces, and dewatering pumps.
Technical Highlights:
High Voltage Backbone (220/66kV)
Two 100MVA transformers connected to Zambia national grid
220kV double busbar substation design with full relay protection
Ensures redundant and stable supply for mining operations
Medium Voltage Distribution (66/11kV & 11kV)
KYN61-40.5 switchgear for main step-down substations (66/11kV)
KYN28-12 switchgear feeding concentrator, crushers, and underground mine loads
Dedicated 11kV feeders for 2–4MW mill drives, ventilation fans, hoists, and pumps
Low Voltage & MCC Systems
Prefabricated substations deployed near crushers, conveyors, and workshops
MCCs designed for large induction motors (>2MW), with soft-starter and VFD integration
GCS/MNS switchgear powering lighting, workshops, and residential facilities
Power Quality & Monitoring
Harmonic filtering to stabilize load from large VFD-driven motors
Reactive compensation improved PF to >0.96, reducing system losses
SCADA integration enabled remote monitoring of underground substations and feeders
Client Benefits:
Uninterrupted mining operations: Dual-source supply ensured continuous ore production
Improved efficiency: Power factor correction and harmonic filtering reduced downtime and saved ~10% on annual energy bills
Environmental adaptation: Equipment designed with IP54 enclosures for dust, humidity, and high-temperature resistance
