Exploration drilling programs face a unique power challenge – camps that need reliable electricity for weeks or months, then relocate to the next prospect. Traditional diesel generators deliver power but burn through fuel budgets at remote sites where every litre costs three times the Perth price. Temporary solar for exploration camps offers an alternative that moves with the program whilst cutting fuel consumption by 50-70%.
Why Exploration Camps Need Relocatable Power Systems
Mineral exploration operates on tight budgets with uncertain timelines. A diamond drilling program might spend six weeks at one prospect, then move 200 kilometres to test the next target. Power requirements remain constant – lighting, communications, core processing, accommodation – but the location changes every campaign.
The Diesel Cost Problem
Diesel generators handle mobility well. Load them on a truck, relocate, restart. But fuel logistics dominate operating costs at remote sites. A 50kVA genset running 16 hours daily consumes roughly 200 litres per day. At remote exploration sites in the Goldfields or Northern Territory, delivered diesel costs reach $3-4 per litre. That equates to $600-$800 daily in fuel alone, or $18,000-$24,000 per month for a single generator.
How Hybrid Solar Reduces Fuel Consumption
Temporary solar for exploration camps reduces this fuel consumption significantly. A hybrid configuration combining photovoltaic modules, battery storage, and diesel backup typically cuts fuel use by 50-70% depending on solar resource and load profile. The same 50kVA load might drop to 60-100 litres daily – saving $300-$420 per day in fuel costs. For exploration companies managing multiple drill programs across Western Australia, these savings compound across every campaign.
Technical Requirements for Relocatable Solar-Battery Systems
Exploration camp power systems need specific design features to support frequent relocation and rapid deployment.
Skid-Mounted or Containerised Configuration
Equipment must mount on transportable frames suitable for truck or trailer movement. Skid-mounted systems use structural steel bases that lift with a crane or forklift. Containerised systems integrate all components inside modified shipping containers – typically 20-foot or 40-foot ISO containers with internal racking and thermal management.
The hybrid solar skid approach combines solar inverters, battery storage, and diesel genset control in a single transportable unit. This consolidation reduces installation time at each new site to hours rather than days, making it the preferred configuration for temporary solar for exploration camps that relocate frequently.
Modular Solar Arrays for Rapid Deployment
Fixed ground-mount solar arrays work well for permanent installations but create problems for temporary sites. Each relocation requires dismantling, transport, and reinstallation – labour-intensive work that delays drilling operations.
The RSM Rapid Solar Module system addresses this with pre-assembled solar arrays on transportable frames. Arrays from 10kW to 100kW ship as complete units, deploy in hours, and relocate without disassembly. Ground anchors or ballasted mounts eliminate concrete foundations, perfectly suiting drill rig solar power applications where speed of deployment directly impacts program productivity.
Lithium-Ion Battery Storage for Harsh Conditions
Exploration camps need battery systems that tolerate frequent transport and temperature extremes. Lithium iron phosphate (LFP) chemistry delivers the necessary durability with 6,000+ cycles at 80% depth of discharge and stable performance from -20°C to +50°C.
Battery capacity sizing depends on overnight loads and desired diesel-free operation hours. A typical exploration camp drawing 20-30kW overnight requires 150-250kWh of usable battery capacity to run 8-10 hours without diesel backup. The Li-ion Hub battery energy storage system offers containerised configurations from 100kWh to 5MWh with integrated thermal management and transport-rated enclosures designed for the rigours of remote exploration operations.
System Sizing for Typical Exploration Camp Loads
Exploration camps vary in size from small drilling operations with 5-10 personnel to larger programs supporting 30-50 workers. Power requirements scale accordingly.
Small Drilling Camp (5-10 Personnel)
Accommodation lighting and power draw 3-5kW, communications and IT equipment require 1-2kW, core processing and sample preparation consume 5-8kW, water pumping needs 2-3kW, and kitchen and amenities add 3-5kW. Peak load reaches 15-25kW with an average 24-hour load of 8-12kW, producing daily energy consumption of 200-300kWh.
The recommended system comprises a 30-40kW solar array, 150-200kWh battery storage, and 50kVA diesel backup. This configuration provides 60-70% diesel displacement with battery covering overnight loads and solar recharging during daylight hours. Even at this smaller scale, drill rig solar power configurations deliver meaningful fuel savings that improve exploration program economics.
Medium Exploration Camp (15-25 Personnel)
Expanded accommodation requires 8-12kW, larger kitchen and cold storage consume 6-8kW, workshop and maintenance facilities need 4-6kW, and additional core processing adds 8-12kW. Peak load reaches 35-50kW with an average 24-hour load of 18-25kW and daily energy consumption of 450-600kWh.
The recommended system specifies a 60-80kW solar array, 250-350kWh battery storage, and 100kVA diesel backup. Diesel displacement reaches 65-75% with proper load management.
Large Exploration Program (30-50 Personnel)
Multiple accommodation units draw 15-20kW, full kitchen and mess facilities require 10-15kW, core processing and assay preparation consume 15-25kW, workshop with welding and fabrication needs 8-12kW, and water treatment and pumping adds 5-8kW. Peak load reaches 60-90kW with an average 24-hour load of 35-45kW and daily energy consumption of 850-1,100kWh.
The recommended system includes a 100-150kW solar array, 400-600kWh battery storage, and 150-200kVA diesel backup with parallel gensets for redundancy. At this scale, temporary solar for exploration camps delivers substantial operational savings that can fund additional drilling metres.
Deployment and Relocation Logistics
The practical value of temporary solar systems depends on deployment speed and relocation efficiency.
Initial Site Setup
Rapid deployment systems install in 1-3 days depending on capacity. The process includes site preparation with levelling for solar arrays and equipment (4-8 hours), solar array positioning and anchoring (6-12 hours for 50-80kW), battery container or skid placement (2-4 hours), and electrical interconnection and commissioning (4-8 hours). Pre-commissioned systems with factory-tested components reduce on-site installation time, and plug-and-play connections between solar arrays, battery storage, and diesel backup eliminate custom electrical work.
Relocation Process
Moving to the next exploration target requires systematic shutdown and transport. Battery discharge to 30-40% state of charge for transport safety takes 2-4 hours, system shutdown and electrical disconnection requires 2-3 hours, solar array securing for transport needs 3-6 hours, equipment loading and transport varies by distance, and reinstallation at the new site takes 1-3 days.
Total downtime between sites is 2-5 days depending on distance and site preparation requirements. This compares favourably with diesel-only systems whilst delivering ongoing fuel savings that accumulate across every relocation.
Operating Modes for Exploration Camp Hybrid Systems
Hybrid solar-battery-diesel systems operate in multiple modes to match power availability with camp loads.
Solar-Priority Mode
During daylight hours with adequate solar irradiance, photovoltaic arrays supply camp loads directly whilst simultaneously charging batteries. Diesel gensets remain on standby. This mode maximises fuel savings and operates silently – a significant benefit for exploration camps where noise management supports worker wellbeing.
Solar output varies with time of day, season, and weather conditions. A 60kW solar array in the Pilbara might produce 50-55kW at midday in summer but only 15-20kW in winter or during cloudy conditions. The system controller continuously balances solar generation, battery charging, and load requirements.
Battery-Priority Mode
During evening and overnight hours, battery storage supplies camp loads without diesel operation. A properly sized battery system handles typical overnight loads for 8-12 hours, allowing complete diesel shutdown during low-load periods. Battery depth of discharge affects cycle life and long-term system economics. Operating between 20-80% state of charge maximises battery lifespan whilst providing adequate energy storage. A 200kWh battery system delivers 120kWh of usable energy within this range – sufficient for overnight operation of small to medium exploration camps.
Diesel-Backup Mode
When solar generation is insufficient and battery state of charge reaches minimum thresholds (typically 20-30%), diesel gensets start automatically. This ensures continuous power regardless of weather conditions or unexpected load increases. Modern hybrid controllers optimise diesel operation by running gensets at 70-85% rated capacity – the most fuel-efficient loading range. Excess generation charges batteries rapidly, then the genset shuts down once batteries reach 80-90% charge.
Fuel Savings Analysis for Exploration Applications
Actual fuel savings depend on solar resource, load profile, and system sizing. Real-world performance data from Australian exploration camps demonstrates typical results.
Goldfields Exploration Site – Six-Month Program
Location: 180km northeast of Kalgoorlie. System: 60kW solar, 250kWh battery, 100kVA diesel backup. Average daily load: 450kWh (20kW average, 45kW peak).
Baseline diesel consumption (generator-only) was 180 litres per day. The hybrid system reduced diesel consumption to 55 litres per day – a fuel saving of 125 litres per day representing a 69% reduction. Daily savings reached $437.50, monthly savings $13,125, and six-month program savings totalled $78,750. System cost was approximately $185,000 installed, with a payback period of 2.4 years across multiple exploration programs.
Northern Territory Diamond Drilling Program
Location: 340km south of Darwin. System: 40kW solar, 180kWh battery, 75kVA diesel backup. Average daily load: 280kWh (12kW average, 28kW peak).
Baseline diesel consumption was 115 litres per day. The hybrid system reduced consumption to 40 litres per day – a saving of 75 litres per day representing a 65% reduction. Daily savings reached $315, monthly savings $9,450, and eight-week program savings totalled $17,640. These savings accumulate across multiple deployments as the system relocates to successive exploration targets throughout the year. Drill rig solar power configurations consistently deliver these returns regardless of whether the program operates in the Goldfields, Pilbara, or Northern Territory.
Maintenance Requirements for Mobile Solar Systems
Temporary systems require minimal maintenance but benefit from regular inspection between relocations.
Solar Array and Battery Monitoring
Photovoltaic modules tolerate dust and light soiling but perform best when clean. In dusty exploration environments, quarterly cleaning improves output by 8-15%. Inspection during relocation identifies any transport damage to modules, frames, or connections. Module mounting hardware requires periodic torque checking, particularly after transport over rough tracks, as loose connections create resistance heating and potential fire hazards.
Lithium-ion battery systems include built-in monitoring that tracks cell voltages, temperatures, and state of charge. Remote monitoring via satellite or cellular connection allows early detection of performance issues before they cause failures. Battery thermal management systems require monthly filter cleaning in dusty environments, as blocked filters reduce cooling capacity and accelerate battery degradation in hot conditions.
Diesel Generator Service in Hybrid Operation
Hybrid systems reduce diesel runtime by 50-70%, which extends service intervals proportionally. A generator requiring 250-hour oil changes in continuous operation might run 1,000 hours between services in a hybrid system – reducing maintenance costs and downtime.
However, infrequent operation creates its own challenges. Diesel engines benefit from regular exercise under load to prevent fuel system issues and maintain reliability. Weekly test runs of 30-60 minutes at 50-70% load keep gensets ready for backup operation.
Regulatory and Safety Considerations
Temporary power systems at exploration sites must comply with relevant electrical safety standards and mining regulations.
Electrical Standards Compliance
Portable and relocatable electrical installations fall under AS/NZS 3000 and AS/NZS 3012 requirements for temporary installations. Key requirements include residual current protection for all socket outlets, equipotential bonding and earthing systems, overcurrent protection and isolation devices, and IP-rated enclosures suitable for outdoor conditions.
CDI Energy designs temporary solar for exploration camps to AS/NZS 5139 requirements for battery safety and AS/NZS 4777 for grid-interactive inverters where applicable. UL9540 certification provides additional assurance for battery energy storage system safety.
Transport and Handling Safety
Lithium-ion batteries require proper transport procedures to comply with dangerous goods regulations. Batteries must be secured against movement during transport, maintained at 30-50% state of charge during long-distance transport, protected from short-circuit and physical damage, and accompanied by appropriate safety documentation. Battery containers include lifting points rated for loaded weight and designed for crane or forklift handling.
Economic Comparison: Temporary Solar vs Diesel-Only
The economics of temporary solar systems depend on program duration, fuel costs, and number of relocations.
Break-Even Analysis
A typical 60kW solar + 250kWh battery system costs approximately $180,000-$220,000 installed, compared with $35,000-$45,000 for equivalent diesel generator capacity. The capital cost difference of $140,000-$180,000 must be recovered through fuel savings. At $400-$500 daily fuel savings typical for medium exploration camps, payback occurs in 280-450 operating days.
For exploration companies running continuous programs across multiple sites, this payback period represents 12-18 months of field operations. The system then delivers ongoing savings for its 15-20 year operational life.
Five-Year Total Cost of Ownership
A five-year total cost comparison for a medium exploration camp consuming 450kWh daily reveals significant differences. Diesel-only operation costs $40,000 in capital, $1,149,750 in fuel (1,825 days at $630), and $45,000 in maintenance – totalling $1,234,750. A hybrid solar-battery system costs $195,000 in capital, $355,875 in fuel (1,825 days at $195), and $28,000 in maintenance – totalling $578,875.
Five-year savings reach $655,875 representing a 53% reduction in total cost of ownership. These calculations assume continuous operation across multiple exploration programs with periodic relocation. Reviewing CDI Energy’s completed projects demonstrates this economic performance across diverse Australian exploration environments.
Conclusion
Exploration drilling programs need power systems that match their operational reality – temporary installations that relocate every few weeks whilst delivering reliable electricity in remote locations. Temporary solar for exploration camps built on skid-mounted or containerised platforms provides this mobility whilst cutting fuel consumption by 50-70% compared with diesel-only generation.
The technology has matured beyond experimental status. Lithium iron phosphate battery systems deliver 6,000+ cycles with stable performance in harsh environments. Modular solar arrays deploy in hours and relocate without disassembly. Hybrid controllers manage the transition between solar, battery, and diesel operation automatically. Drill rig solar power configurations consistently deliver returns that justify the initial investment, particularly for companies running continuous programs across multiple sites.
Economics favour hybrid systems for exploration companies running continuous programs across multiple sites. Fuel savings of $400-$600 daily recover the capital premium within 12-18 months of field operation, then deliver ongoing cost reduction for 15-20 years of system life.
For exploration programs seeking to reduce fuel costs whilst maintaining operational flexibility, consult our hybrid solar engineers or email us on info@cdienergy.com.au to discuss system sizing and deployment strategies for your specific drilling program requirements.