Temporary mining operations face a persistent challenge – delivering reliable power to sites that may relocate within months. Traditional diesel generators burn through fuel budgets whilst containerised systems prove too permanent for short-term deployments. Relocatable hybrid solar skids solve this problem by combining solar PV generation, battery storage, and diesel backup in transportable configurations designed for rapid deployment and frequent moves.
These skid-mounted systems deliver 20kW to 200kW power capacity with integrated solar arrays, lithium-ion battery banks, and control systems mounted on structural steel frames. The entire power plant relocates via forklift, crane, or truck without disassembly, making them ideal for exploration drilling, temporary camps, construction sites, and progressive mining operations that advance across lease areas.
CDI Energy manufactures relocatable hybrid solar skids engineered for Australian mining conditions – dust, heat, and rough transport across remote sites. The systems operate from -20°C to +50°C with IP65-rated enclosures protecting power electronics from Pilbara dust storms and Goldfields temperature extremes.
Why Temporary Mining Projects Need Relocatable Power Solutions
Exploration drilling programs typically run 3-12 months before moving to new target areas. Construction phases for mine expansions last 6-18 months before permanent infrastructure comes online. Progressive mining operations advance haul roads, ventilation raises, and support facilities as ore bodies extend. Each scenario demands reliable power without the capital expense or installation time of permanent systems.
The Diesel Cost Burden
Diesel-only generators deliver power but consume 15-25 litres per hour at typical mining loads. A 100kW genset running 12 hours daily burns approximately 65,700 litres annually at AU$1.80 per litre in remote locations – that equates to $118,260 in fuel costs alone. Add maintenance, oil changes, and filter replacements, and operating expenses exceed $140,000 per year for a single temporary site.
Containerised battery systems reduce fuel consumption but require crane installation, concrete pads, and electrical infrastructure that becomes stranded assets when projects relocate. The installation costs $80,000-$150,000 depending on site preparation requirements – economically questionable for deployments under 24 months.
Advantages of Skid-Mounted Hybrid Systems
Relocatable hybrid solar skids eliminate these compromises. The complete system mounts on a structural steel skid measuring 6m x 2.4m x 2.6m high – standard flatbed truck dimensions. Solar arrays deploy on tilt frames or ground mounts that assemble without concrete footings. Battery cabinets, inverters, and diesel gensets integrate into the skid structure. When the project moves, a crane lifts the entire assembly onto a truck for transport to the next location.
Fuel consumption drops 40-70% compared to diesel-only operation depending on solar resource and load profile. A typical 100kW hybrid skid with 50kW solar capacity and 200kWh battery storage reduces annual diesel consumption from 65,700 litres to 20,000-30,000 litres – saving $65,000-$82,000 in fuel costs annually whilst eliminating 120-150 tonnes of CO2 emissions.
Technical Architecture of Relocatable Hybrid Solar Skids
The hybrid solar skid integrates four primary subsystems into a single relocatable platform: solar PV generation, battery energy storage, diesel backup generation, and hybrid control systems. Each component mounts to the structural steel skid frame with vibration isolation for transport and quick-disconnect electrical connections for rapid commissioning.
Solar PV Integration
Photovoltaic arrays mount on separate ground frames or tilt structures positioned adjacent to the main skid. Typical configurations include 30kW to 100kW solar capacity using 400W monocrystalline modules with MPPT charge controllers. The RSM Rapid Solar Module system provides pre-wired solar arrays on transportable frames that deploy in 4-6 hours without specialised tools or concrete foundations.
Solar arrays connect to the main skid via weatherproof DC cabling rated for outdoor mining environments. Quick-disconnect MC4 connectors allow complete system separation for transport in under 2 hours. Tilt angles optimise for site latitude – typically 20-25 degrees in Western Australia and Northern Territory mining regions.
Battery Energy Storage
Lithium-ion battery banks provide 100kWh to 500kWh storage capacity using LFP (LiFePO4) chemistry selected for thermal stability and 6,000+ cycle life at 80% depth of discharge. Battery cabinets mount within the skid structure with thermal management systems maintaining 15-35°C operating temperatures regardless of ambient conditions.
Relocatable battery energy storage technology adapts to skid-mounted configurations with vibration-resistant battery racks and transport-rated electrical connections. Battery management systems monitor cell voltages, temperatures, and state of charge whilst protecting against overcharge, over-discharge, and thermal runaway conditions per IEC 62619 safety standards.
Diesel Backup Generation
Integrated diesel gensets provide 50kW to 150kW backup capacity for extended cloudy periods or high-demand operations. Modern Tier 3 or Tier 4 Final engines meet emissions requirements whilst operating efficiently at partial loads when solar and battery resources handle base demand. The hybrid controller starts diesel generation only when battery state of charge drops below programmed thresholds – typically 30-40% SOC.
Fuel tanks mount within the skid structure or on auxiliary skids, providing 1,000-2,000 litre capacity for 3-7 days autonomous operation without refuelling. This reduces fuel delivery frequency compared to diesel-only systems whilst maintaining energy security during consecutive overcast days.
Hybrid Control Systems
Programmable logic controllers manage power flow between solar PV, battery storage, diesel generation, and site loads. The control strategy prioritises solar generation during daylight hours, charges batteries with excess solar capacity, discharges batteries during evening and morning peak loads, and starts diesel generation only when battery reserves deplete.
SCADA monitoring provides real-time visibility of generation sources, battery state of charge, fuel consumption, and load profiles via cellular or satellite connectivity. Remote monitoring allows operations teams to track system performance, identify maintenance requirements, and optimise hybrid control parameters without site visits.
Deployment Speed and Relocation Process
Relocatable hybrid solar skids deliver operational power within 24-48 hours of site arrival – a critical advantage for exploration programs and construction schedules constrained by weather windows or regulatory timeframes. The rapid deployment process eliminates concrete foundations, building enclosures, and extensive electrical infrastructure required for permanent installations.
24-48 Hour Commissioning Process
Initial site preparation involves levelling the skid location using compacted gravel or crushed rock – no concrete pad required. The solar array area is cleared of vegetation and graded to within 5 degrees of level, and temporary site load cabling runs from the distribution board to equipment locations. Total site preparation takes 4-8 hours depending on terrain conditions.
System installation includes positioning the main skid using mobile crane or forklift, deploying solar array frames and installing PV modules with pre-wired harnesses connecting to MPPT controllers on the main skid, connecting DC cabling between solar arrays and battery system, filling the diesel fuel tank and connecting the exhaust system, and commissioning the hybrid controller to verify system operation. Total installation time is 16-24 hours with a 2-person crew.
Systematic Relocation
When the project moves, the solar array DC cabling is disconnected and tilt frames are folded or disassembled. Diesel fuel drains into transport containers or pumps to receiving tanks. Battery cabinets and power electronics are secured for transport, and the main skid lifts onto a flatbed truck using a crane. Solar frames transport separately or on a second truck. Total decommissioning time is 8-12 hours.
The system recommissions at the new location following the same 24-48 hour installation process. Battery systems retain charge during transport, allowing immediate operation upon reconnection. Solar arrays redeploy on the same frames without rewiring. This mobility supports progressive mining operations where power requirements advance with ore extraction.
Fuel Savings and Operating Cost Analysis
Relocatable hybrid solar skids deliver measurable fuel savings compared to diesel-only temporary power – the economic justification for exploration and construction projects evaluating power options.
Baseline vs Hybrid Performance
A 100kW diesel generator supplying 50kW average load (50% capacity factor) consumes approximately 18 litres per hour or 216 litres per 12-hour operating day. Annual consumption reaches 78,840 litres assuming 365-day operation. At AU$1.80 per litre delivered to remote sites, annual fuel costs total $141,912.
A 100kW hybrid skid with 50kW solar capacity and 200kWh battery storage reduces diesel runtime to 3-5 hours daily in locations receiving 5-6 kWh/m²/day solar irradiance – typical for Pilbara and Goldfields regions. Daily diesel consumption drops to 54-90 litres depending on seasonal variation and load patterns. Annual diesel consumption reaches 20,000-33,000 litres at $36,000-$59,400 in fuel costs, delivering annual fuel savings of $82,500-$105,900 and diesel displacement of 58-75%.
Maintenance Cost Reduction
Diesel generators operating 12 hours daily require oil changes every 21 days, air filter replacements every 42 days, and major services every 1,000 hours (83 days). Annual maintenance costs including labour, filters, oil, and consumables total $18,000-$25,000 for remote site operations.
Hybrid systems reduce diesel runtime 60-75%, extending maintenance intervals proportionally. Oil changes occur every 50-70 days, air filters last 100-140 days, and major services extend to 200-250 days. Annual diesel maintenance costs drop to $6,000-$9,000 whilst battery systems require only quarterly inspections and annual thermal system checks totalling $2,000-$3,000 annually.
Total Operating Cost Comparison
Annual comparison reveals the economic advantage clearly. Diesel-only operation costs $141,912 in fuel plus $21,500 in maintenance, totalling $163,412. A hybrid solar skid costs $47,700 in fuel plus $8,000 in maintenance, totalling $55,700. Annual savings reach $107,712 with a payback period of 18-24 months depending on system capacity. These savings accumulate across temporary project durations, making the investment increasingly attractive for companies managing multiple concurrent operations.
Applications Across Temporary Mining Operations
Relocatable battery energy storage paired with solar generation serves multiple temporary mining applications where power requirements last 6-36 months before relocating or decommissioning. The mobility advantage justifies hybrid investment for projects where permanent infrastructure proves economically inefficient.
Exploration Drilling Programs
Diamond drilling and RC drilling operations require 50-150kW power for drill rigs, water pumps, core processing, and camp facilities. Programs typically run 3-12 months per target area before moving to new prospects. Relocatable power systems move with drilling crews, eliminating generator rentals and fuel logistics for each new drill pad. A typical configuration comprises an 80kW hybrid skid with 40kW solar, 150kWh battery, and 80kW diesel backup, supporting two drill rigs plus camp facilities with 55-70% diesel displacement.
Mine Construction and Expansion
Construction phases for processing plants, tailings facilities, and infrastructure require temporary power for 12-24 months before permanent systems commission. Concrete batching, welding equipment, dewatering pumps, and construction lighting demand reliable power across large site areas. Relocatable skids position near active construction zones and relocate as work progresses – supporting progressive concrete pours, structural steel erection sequences, and mechanical installation phases without extending permanent electrical distribution. A typical configuration uses a 150kW hybrid skid with 75kW solar, 300kWh battery, and 150kW diesel backup, supporting construction equipment and site facilities with 45-60% diesel displacement.
Progressive Mining Operations
Underground development, open pit expansions, and satellite ore bodies require mobile power for ventilation fans, dewatering systems, lighting, and mobile equipment charging. Power requirements advance with mining faces, making relocatable systems more practical than extending permanent electrical infrastructure. Skid-mounted systems reposition every 6-18 months as mining advances. A typical configuration features a 100kW hybrid skid with 50kW solar, 200kWh battery, and 100kW diesel backup, supporting ventilation, pumping, and auxiliary loads with 50-65% diesel displacement.
Remote Camps and Facilities
Temporary accommodation camps, first aid stations, and maintenance workshops require 24/7 power for HVAC, refrigeration, lighting, and communications. Camps supporting 20-50 personnel consume 30-60kW average load with morning and evening peaks for cooking and hot water. Hybrid skids optimise for camp load profiles – charging batteries during high solar production hours and discharging during evening peak demand. A typical configuration includes a 60kW hybrid skid with 30kW solar, 150kWh battery, and 60kW diesel backup, supporting camp facilities with 60-75% diesel displacement due to predictable load patterns matching solar availability.
Australian Mining Environment Considerations
Perth-based engineering teams must design relocatable hybrid solar skids specifically for Australian mining conditions – addressing dust ingress, extreme temperatures, transport vibration, and remote maintenance challenges that differentiate outback deployments from grid-connected installations.
Dust and Particulate Protection
Pilbara iron ore operations, Goldfields gold mines, and coal regions generate airborne dust concentrations exceeding 10 mg/m³ during dry seasons. Standard IP54-rated enclosures fail within months as dust infiltrates cooling systems, electrical connections, and battery compartments.
Relocatable skids specify IP65-rated enclosures for all power electronics, battery cabinets, and control systems. Sealed cable glands prevent dust ingress at penetration points. HVAC systems incorporate pre-filters rated for mining environments with quarterly replacement schedules. Inverters and charge controllers mount in sealed cabinets with heat exchangers rather than ventilation fans that draw contaminated air across electronics.
Thermal Management for Extreme Conditions
Summer temperatures in Northern Territory and Western Australia mining regions exceed 45°C ambient whilst equipment enclosures reach 60-70°C in direct sunlight. Lithium-ion batteries require 15-35°C operating temperatures to maintain cycle life and prevent thermal degradation.
Active thermal management systems incorporate refrigerant-based cooling for battery cabinets and forced-air heat exchangers for power electronics. Insulated enclosures with reflective white coatings reduce solar heat gain. Temperature monitoring triggers cooling systems before battery temperatures exceed safe thresholds, protecting the investment in relocatable battery energy storage assets.
Winter temperatures in central Australian mining regions drop to -5°C to -10°C, requiring battery heating to maintain discharge capacity and prevent electrolyte freezing in auxiliary lead-acid starter batteries. Integrated heating elements activate automatically when temperatures drop below 5°C.
Transport Vibration Resistance
Relocatable systems endure transport across unsealed haul roads, exploration tracks, and rough terrain between deployment sites. Battery racks, inverter mounts, and electrical connections must withstand vibration and shock loads exceeding AS/NZS 60068 transport testing standards.
Battery modules mount in spring-isolated racks with compression restraints preventing movement during transport. Electrical connections use vibration-resistant terminals and flexible conduit at equipment interfaces. Solar array frames incorporate transport locks securing panels during movement. Diesel gensets mount on vibration isolators designed for mobile applications rather than stationary installations.
Remote Maintenance Access
Temporary mining sites operate 200-800km from major service centres with limited access to specialised battery technicians or solar installers. Relocatable systems are designed for field maintenance by mine electricians and mechanical fitters rather than requiring factory-trained specialists for routine service.
Modular battery cabinets allow individual module replacement without specialised tools. SCADA systems provide remote diagnostics identifying failing components before complete system shutdown. Spare parts kits include common failure items – contactors, fuses, sensors, and cooling fans. Annual service visits perform detailed inspections, thermal imaging, and battery capacity testing whilst training site personnel on routine maintenance procedures. Reviewing CDI Energy’s delivered projects provides evidence of proven performance across diverse Australian mining environments.
System Sizing and Configuration Selection
Selecting appropriate hybrid skid capacity requires analysing load profiles, solar resource data, and operational patterns to optimise diesel displacement whilst maintaining energy security during extended cloudy periods.
Load Profile Analysis
Documenting hourly power consumption across typical operating days – including equipment startup surges, base loads, and peak demand periods – forms the foundation of system design. Mining operations exhibit distinct patterns: drilling programs show daytime peaks matching solar availability whilst camp facilities peak during evening hours when solar generation ceases. Daily energy consumption (kWh/day) and peak power demand (kW) determine hybrid skid sizing, with the system needing to supply peak loads from battery discharge or combined solar-battery-diesel operation.
Solar Resource Assessment
Bureau of Meteorology solar irradiance data provides the basis for array sizing. Western Australian mining areas receive 5.5-6.5 kWh/m²/day annual average with seasonal variation from 4.0 kWh/m²/day in winter to 7.5 kWh/m²/day in summer. Northern Territory sites receive 5.8-6.8 kWh/m²/day with less seasonal variation. Solar array capacity should generate 1.2-1.5 times daily energy consumption during average irradiance conditions, allowing battery charging whilst simultaneously supplying daytime loads.
Battery Capacity and Diesel Backup Sizing
Lithium-ion battery banks should store 1.5-2.5 times average overnight energy consumption to cover evening peak loads and morning startup demand before solar generation resumes. Operating batteries at 30-80% state of charge (50% usable capacity) maximises cycle life. A 200kWh battery bank provides 100kWh usable energy – sufficient for 8-12 hours operation at 8-12kW average overnight load. The Li-ion Hub battery energy storage system scales from 100kWh to 5MWh, supporting configurations from small exploration camps through to large construction phase installations.
Diesel gensets should match or exceed peak site loads to provide backup during battery depletion or maintenance periods. Modern hybrid controllers operate diesel generators at 60-80% rated capacity for optimal fuel efficiency rather than the 30-50% loading typical of diesel-only configurations. The Modulus utility-grade stand-alone power system provides a comprehensive off-grid architecture for operations requiring complete power autonomy with integrated protection and control systems.
Conclusion
Relocatable hybrid solar skids deliver the operational flexibility temporary mining projects demand – 24-48 hour deployment, 40-70% diesel displacement, and seamless relocation between sites without stranding capital in permanent infrastructure. These systems are purpose-engineered for Australian mining conditions, with IP65-rated enclosures, active thermal management, and vibration-resistant construction that ensures reliable performance across Pilbara heat, Goldfields dust, and the rough transport conditions of remote operations.
Relocatable battery energy storage paired with rapid-deploy solar arrays transforms temporary power from a recurring expense into a reusable asset that delivers compounding fuel savings across multiple projects. With 18-24 month payback periods and annual operating cost reductions exceeding $100,000, the economic case is clear for exploration companies, mine developers, and construction contractors operating across Western Australia and remote Australia.
To assess the right hybrid skid configuration for your temporary mining operation, talk to our hybrid power engineers or email us on info@cdienergy.com.au to discuss load requirements, deployment timelines, and system sizing.