Dumarey deployed a Peak Power 200 flywheel system on a hybrid jaw crusher to enable generator downsizing and load levelling, reducing fuel consumption, emissions, and equipment stress.
Clients:
Keestrack
Industries:
Applications:
Generator downsizing from 330 kVA to 250 kVA, delivering approximately 6,000 litres annual fuel savings and around 17 tonnes of CO₂ reduction, while improving generator stability and reliability.
The Keestrack B7e is a heavy-duty hybrid jaw crusher that can operate using either:
Rock crushers exhibit highly dynamic load profiles, characterised by:
This results in:
Additionally, starting the crusher presents a major challenge due to high reactive power demand, even with soft-start systems in place.
The deployment demonstrated both generator downsizing and effective load levelling:
Key benefits include:
Additional operational insights showed:
Dumarey deployed the Peak Power 200 flywheel system in two phases:
Phase 1: Generator Downsizing
An initial test attempted to start the crusher using a 250 kVA generator alone:
The Peak Power 200 was then introduced:
This demonstrated that generator downsizing was achievable when supported by the flywheel system.
Phase 2: Load Levelling on Site
At a live operating site, the Peak Power 200 was connected to:
The flywheel system was configured to:
Optimal system tuning identified a load levelling setpoint of 175 kW.
The Peak Power 200:
Provides instant real and reactive power for highly dynamic industrial loads
Enables smaller generators without compromising performance
Stabilises generator output and improves efficiency
Reduces reactive power demand and improves system performance
Reduces stress on alternators and extends service intervals
litres of fuel saved per year
tonnes of CO₂ avoided per year
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kVA
Generator downsized
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