Modern Mining July 2025

Modular substations from Trafo Power Solutions simplify logistics, reduce civil works and enable rapid deployment in remote mining locations.

High ambient temperatures and direct sunlight on mine sites demand robust thermal management in electrical equipment design.

Trafo Power Solutions leverages modular design and preassembly to deliver high performance electrical systems with faster turnaround times and reduced onsite complexity.

Underground mining environments require compact, modular electrical systems that can be transported through constrained access points like shaft cages.

spaces and easily reassembled on site.” Further strengthening the company’s underground expertise is the experience of its Italian technology partner, TMC Transformers, which has a long history of serving the marine sector. Claassen notes that TMC’s work in designing transformers for marine vessels has provided valuable insights into optimising performance in confined spaces - a capability that translates well into the underground mining environment. “Taking all these factors into account, we often find that a modular design is the most effective way to meet customer specifications,” he explains. “Manufacturing and assembly can be completed under controlled workshop conditions, ensuring quality and consistency. Our modular substations typically incorporate medium and low voltage switchgear, transformers and uninterruptible power supply (UPS) systems with all configured for efficient road or sea transport and straightforward connection and commissioning on site.” This approach is especially effective for remote sites where access to specialised electrical personnel is limited. By eliminating the need for traditional brick-and-mortar structures, it also reduces on-site civil construction requirements, shortens project timelines and cuts down on travel costs for skilled labour. “These solutions have been well received in fast developing mining regions like the DRC, where project timelines are often tight,” says Claassen. “The modular approach also helps .reduce project risk, as all testing and certification are completed before the substation leaves the workshop.” n

ventilation or forced-air cooling systems to effectively manage heat dissipation.” However, in space-constrained environments, water is also employed as a cooling medium, either through direct contact to extract heat from the transformer or via a water-to-air heat exchanger, where water cools the air which in turn cools the equipment. In addition to high temperatures, many African mine sites contend with excessive dust levels, requiring transformers and substations to be equipped with robust ingress protection. This must be carefully balanced with the cooling design as higher ingress protection typically limits the natural airflow needed for effective cooling. In addition to its strong track record in South Africa, Trafo Power Solutions has extensive experience in the Copperbelt region of Zambia and the Democratic Republic of Congo (DRC) as well as in countries like Mozambique and Sierra Leone. The company has worked across both surface and underground mining operations, where design considerations vary significantly with surface applications requiring resistance to sunlight and dust while underground environments demand solutions tailored to limited space. “Space constraints in underground mines affect not only the areas where electrical equipment is installed but also the pathways and conveyances used to transport that equipment,” says Claassen. “Shaft cages - particularly in South Africa’s deep level gold mines - are often compact and space efficient so we have developed specialised solutions that can be transported in these confined

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