5 MW Mining Power System Cost Breakdown (Q3 2026 China Supplier Pricing)
5 MW Mining Power System Cost Breakdown (Q3 2026 China Supplier Pricing) — itemized bill of materials and FOB pricing for a typical configuration.
Estimated total (FOB): $805,825 · 5000 kVA transformer
Bill of materials
| Item | Specification | Qty | Price (USD) |
|---|---|---|---|
| HV incoming panel (KYN28A-12-630-315) | 630 A / 31.5 kA · vacuum | 1 | $2,448 |
| Main transformer (S13-M-5000/10) | 5000 kVA · Oil-Immersed · Copper · S13 | 1 | $51,399 |
| LV incoming panel (MNS (drawer type)) | 4000 A busbar · In 7217 A | 1 | $13,273 |
| LV feeder panel (×4) (MNS (drawer type)) | distributes 19 circuits | 4 | $53,092 |
| Cable branch box (LV) (DFW-0.4) | 1-in / 4-out · 0.4 kV · 630 A | 4 | $2,520 |
| Main feeder cable (TX→LV) (YJV 0.6/1kV 300 mm² ×16) | 16× 300 mm² Cu · ΔU 1.76% @ 120 m · $154.0/m | 16 | $295,680 |
| Main feeder (custom/dual busway) (Busway > 6300 A) | LV current 7217 A exceeds the largest standard busway (6300 A) — custom busway or dual-run busway required; shown as parallel cables below | 1 | POA |
| Feeder cable — Crusher 1 (×19) (YJV 150 mm²) | 150 mm² Cu · 285 A · ΔU 2.2% · $86.0/m | 19 | $196,080 |
| Branch trunk cable (LV → branch box 1) (YJV 240 mm² ×3) | 3× 240 mm² Cu · 1140 A · ΔU 1.9% · $123.0/m | 3 | $44,280 |
| Branch trunk cable (LV → branch box 2) (YJV 240 mm² ×3) | 3× 240 mm² Cu · 1140 A · ΔU 1.9% · $123.0/m | 3 | $44,280 |
| Branch trunk cable (LV → branch box 3) (YJV 240 mm² ×3) | 3× 240 mm² Cu · 1140 A · ΔU 1.9% · $123.0/m | 3 | $44,280 |
| Branch trunk cable (LV → branch box 4) (YJV 300 mm² ×2) | 2× 300 mm² Cu · 855 A · ΔU 1.7% · $154.0/m | 2 | $36,960 |
| Main busbar (Cu) (Cu 125×10) | 125×10 · 2500 A rating · ref $147.8/m | included | POA |
| Grounding electrode (Φ20mm × 2.5m rod) | R₁ 39.6 Ω → 13 rod(s) ≤ 4 Ω | 13 | $125 |
| Soft starter cabinet (largest motor) (1500 kW) | Soft starter (3.0× In) · start dip 5.6% | 1 | $6,600 |
| Detuned PFC capacitor bank (1421 kvar) | automatic · 7% detuned · 0.4 kV | 1 | $10,800 |
| Series detuning reactor (7%) (99.5 kvar) | 189 Hz tuning · below 5th harmonic | 1 | $4,009 |
| Active harmonic filter (APF) (547 A) | VFD harmonic mitigation (40% VFD load) · GB/T 14549 | 1 | POA |
Single-line diagram
How it was calculated
- Crushers: 4 × 250 kW = 1,000 kW
- Hoists: 1 × 1,500 kW = 1,500 kW
- Ventilation fans: 6 × 160 kW = 960 kW
- Conveyors: 8 × 90 kW = 720 kW
- Connected load = 4,180 kW → demand = 4,180 × 0.7 = 2,926 kW
- Altitude derating: 1500 m → factor 0.97 → effective load = 2,926 ÷ 0.97 = 3,001 kW
- Largest motor start (motor-starting): 1500 kW ÷ (0.90×0.85) × 3.0 = 5,882 kVA → dip = 5.6% vs limit 15%
- Reactive compensation: Qc = 3,001 × (tanφ₁ − tanφ₂) = 1,421 kvar
- VFD harmonics: 40% VFD load → Ih = 547 A (30% THDi) · 7% detuned reactor
- Loads: P=3,001 kW, PF 0.80, 19 circuits
- Demand: 3,001 × 1 = 3,001 kW
- Transformer: S = 3,001 ÷ 0.95 = 3158.9 kVA → 5,000 kVA standard
What drives the cost
- Equipment — the transformer/switchgear/inverter is the largest single line item.
- Storage (where applicable) — batteries are the biggest swing factor.
- Copper & freight — copper-linked cabling and freight shift landed cost ±5–10%.
Frequently asked questions
How does altitude affect transformer and switchgear rating?
Above 1000 m, thinner air reduces cooling and dielectric strength. Transformers derate about 0.5% per 100 m above 1000 m, and switchgear derates similarly. A 1500 m site needs roughly 2.5% derating; a 3000 m site about 10%. The calculator applies altitude derating to the selected transformer and panels per IEC 60076 and IEC 62271.
What is the typical voltage for underground mining power?
Underground mining uses 10 kV or 6 kV distribution into the mine, stepping down to 1.14 kV or 0.66 kV for crushers, hoists and conveyors, and 0.4 kV for auxiliaries. Long cable runs and motor starting favour the higher LV levels. The calculator models a 10/0.4 kV surface plant with motor-starting dip checks for the hoist and crusher.
Why do mine hoists need special starting consideration?
A mine hoist motor (often 500 kW-3 MW) draws 5-7 times rated current on DOL start, which can dip the mine bus below 85% and trip other drives. Soft-start or VFD limits the inrush, and the transformer must be sized for the starting kVA. The calculator checks the voltage dip of the largest motor and sizes supply accordingly.
How are VFD harmonics handled in a mining plant?
With 40% of load on VFDs, THDi can exceed 20%, so a detuned capacitor bank (7% reactor) or APF is needed to meet IEEE 519 (5% THD at PCC). The calculator sizes reactive compensation and detuning based on the VFD share; heavy-dust duty also calls for IP54 or higher enclosures.
What demand factor applies to a mining plant?
Crushers, hoists, fans and conveyors do not peak together; a demand factor of 0.6-0.75 is typical. A plant with 250 kW crushers, a 500 kW hoist, 160 kW fans and 90 kW conveyors rarely exceeds 60-70% of the 1,600+ kW nameplate simultaneously. The calculator applies kd before selecting transformer kVA.
What enclosure and protection does mining switchgear need?
Mining switchgear must resist dust and moisture: IP54 or IP55 for surface plants, flameproof Ex d for underground gassy mines (IEC 60079). Heavy-dust environments shorten creepage distances, so wider clearances and anti-tracking insulation are standard. The calculator flags dust level and applies the corresponding enclosure grade in the BOM.
Size your own configuration
Run the calculator for your exact load and get a full BOM + FOB price.
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