Background
Redpath Australia (Redpath) and Energy Power Systems Australia (EPSA) have redefined innovation in decarbonisation in mining with a groundbreaking, Australian-first innovation. Together, we successfully integrated Caterpillar’s BESS Power Grid Stabilisation (PGS1260) system with regenerative hoist technology, delivering a reliable, energy-efficient power solution for one of Australia’s most remote goldmines.
This cutting-edge hybrid system, combining gas grid, diesel generators, and battery storage, significantly reduces diesel reliance while optimising energy efficiency. The regenerative hoist technology plays a critical role, capturing energy from the hoist’s descent and storing it for future use.
This not only lowers emissions but also ensures uninterrupted power – essential in an environment where every minute of downtime carries significant financial consequences.
Energy Power System Australia’s hybrid power systems have helped us cut diesel usage and emissions, while also supporting our client’s decarbonisation goals and improving the operational performance of our equipment”
Greg Bell, Electrical Manager, Redpath Group
To learn more about how our power solutions can benefit your business, contact us today.
- Client Redpath
- Completion Date 2023
- Industry Mining
- Location Northern Territory
About Redpath Group
Requirement
Redpath requires a reliable power system to move materials through a 1,460-meter-deep vertical shaft in one of Australia’s most remote gold mines. The goal is to deliver uninterrupted, energy-efficient power for the hoist system, which will later replace traditional decline truck haulage to transport ore from the mine to the mill.
Efficient material movement is essential in mining, where any power disruption can lead to costly downtime and inefficiencies. Redpath needs a flexible, energy-efficient power solution to ensure continuous operations, reduce reliance on diesel, and align with sustainability targets.
The key challenges of this project include:
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The mine is located 3,500 km from the nearest service location, posing logistical challenges.
- The site requires a power system capable of handling highly variable energy loads from the vertical hoist without fail.
- With growing regulatory pressure, the mine must demonstrate measurable reductions in carbon emissions, or risk environmental penalties of up to $55 per tonne of CO2.
To meet these challenges, Redpath requires a power system that ensures a continuous energy supply for the hoist while accommodating fluctuating energy demands.
The system needs to integrate renewable technologies and battery storage, provide reliable backup power, and reduce diesel dependence. It must support long-term operations while minimising environmental impact in a remote mining site.
Solution
The project spans 2.5 years, beginning with the design and manufacturing of the BESS unit, Caterpillar’s Battery Energy Storage (BESS) Power Grid Stabilisation (PGS1260) system, followed by careful planning of logistics, procurement, and installation.
EPSA coordinates the engineers and technicians to tackle the logistical challenges posed by the mine’s remote location. After successful testing, we ship and integrate the system into the mine’s operations.
The solution brings together several key innovations:
- A hybrid power solution that combines the gas grid, diesel generators, and BESS ensuring consistent and flexible power delivery.
- A regenerative hoist system that captures energy during descent and stores it in the BESS for future use; energy that would otherwise go to waste.
- An ultra-fast BESS response time with a 20-millisecond response time, allowing stable operations even during power fluctuations or grid outages.
- Optimised load with the system finely tuned to synchronise energy generation, storage, and use based on real-time demand from the hoist.
Deploying and integrating such a complex system in an isolated environment isn’t without its challenges. From restrictive AC drive parameters causing nuisance trips to the logistical hurdles of remote-site deployment, the project team faces numerous technical and operational roadblocks.
Through collaboration, agile problem-solving, and technical precision, Redpath, EPSA, and their partners overcome every obstacle; delivering a high-performance solution that meets the mine’s power needs today and sets the stage for future sustainable mining operations.
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Hybrid Power Solution
Combines the gas grid, diesel generators, and BESS ensuring consistent and flexible power delivery.
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Regenerative Hoist System
A regenerative hoist system that captures energy during descent and stores it in the BESS for future use; energy that would otherwise go to waste.
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Advanced Technology
Ultra-fast BESS response time with a 20-millisecond response time, allowing stable operations even during power fluctuations or grid outages.
Results
The hybrid Cat solution not only meets expectations but redefines them. We significantly reduce diesel reliance by up to 98% and lower emissions with a hybrid power system that delivers reliable, uninterrupted power for material movement, even during grid shutdowns.
Other results include:
- Fuel costs are cut by up to 69%, thanks to reductions in fuel consumption, equipment wear, and maintenance demands.
- The hoist completes 20 uninterrupted cycles on stored energy, proving the system’s reliability.
- Real-time monitoring data confirms a significant 58% in energy efficiency savings and continuous operation despite power interruptions.
- Carbon emissions are significantly reduced, helping the Tanami Gold Mine advance its decarbonisation targets and environmental commitments.
- When compared with a traditional equivalent sized hoist powered by a diesel generator set and load bank, the system is expected to decrease diesel consumption by nearly 380,000 gallons (more than 1.4 million liters) over a two-year trial period, saving an estimated $1.3 million ($2 million Australian) in fuel costs and reducing CO2 by nearly 4,200 tons (more than 3,800 metric tons).*
The project sets a new benchmark for sustainable mining operations, especially in remote regions, proving that sustainability and productivity can work together. Stakeholders praise the achievement, reinforcing EPSA’s reputation as a leader in sustainable energy solutions and Redpath’s commitment to mining innovation.
“With EPSA and Caterpillar contributing to the early success of this trial, we’re exploring pathways for deploying our regenerative hoisting solution throughout our projects globally.”
Greg Bell, Electrical Manager, Redpath
*For the temporary power station requirement and the initial traditional design configuration for this project included three generator sets and a load bank.
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Cut Fuel Costs by up to 69%
Daily operating costs fall by 69% reductions in fuel consumption, equipment wear, and maintenance demands.
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Reduce Diesel Reliance by up to 98%
Diesel consumption drops by up to 98%, significantly lowering fuel use and associated costs.
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Improve Energy Efficiency by 58%
Real-time monitoring data confirms significant energy efficiency savings and continuous operation despite power interruptions.
Powering the Future of Mining
Today, Redpath and EPSA demonstrate that the future of mining lies in smart, sustainable energy systems. Through bold thinking and collaborative engineering, they deliver a power solution that not only ensures continuous operations in a remote location but also redefines what is possible in environmentally responsible mining.
To see how Redpath Group continues to lead the way in mining, click here.