MV Soft Starter System for Sylvinite Mining in Spain

This project highlights the implementation of the DriveStart medium voltage soft starter system in an underground mining facility located in Súria, near Barcelona. The site is engaged in the extraction of sylvinite, a potassium-rich mineral widely used in fertilizer production.

A critical component of the operation is the main ventilation fan, responsible for maintaining safe air quality conditions throughout the underground mine.

Application Overview

The system was designed to control a:

• Motor rating: 3200 kW
• Voltage: 5 kV
• Current: 449 A
• Application: Underground ventilation fan

The installation site was located approximately 840 meters below ground, followed by an additional 190 meters of underground transport, creating significant logistical and operational constraints.

Engineering Challenges

Underground Installation Constraints

Transporting and installing medium voltage equipment at this depth required detailed logistical planning and strict adherence to safety procedures.

Harsh Environmental Conditions

The operating environment included:

• High humidity
• Dust exposure
• Temperature variations

These conditions required a solution capable of maintaining reliable performance under continuous industrial duty.

Electrical Integration

Ensuring compatibility between the soft starter, motor, and associated systems was essential to achieve stable and controlled motor acceleration without introducing electrical disturbances.

Solution

The DriveStart medium voltage soft starter was selected due to its robust design and suitability for high-power motor applications in demanding environments.

The system provides controlled motor acceleration and deceleration, reducing both mechanical stress and electrical transients during startup.

Implementation Process

Factory Pre-Testing
The system was fully tested above ground to verify electrical compatibility and performance with the 3200 kW motor.

Logistics and Transport
All components were prepared for safe transport and delivered to the underground site using coordinated lifting and transport procedures.

Installation
A specialized team of engineers supervised the installation, ensuring compliance with all operational and safety requirements.

System Integration
The soft starter was integrated with the motor and ventilation system to ensure stable operation and coordinated control.

Commissioning
Comprehensive testing and monitoring were conducted under real operating conditions to validate system performance.

Results and Performance

The deployment of the DriveStart system delivered measurable operational improvements:

• Controlled motor starting
  Smooth acceleration reduced mechanical stress on the motor and fan assembly
• Reduced electrical stress
  Lower inrush current minimized impact on the electrical network
• Improved equipment lifespan
  Reduced wear contributed to extended motor and system longevity
• Lower maintenance requirements
  Stable operation decreased the frequency of service interventions
• Enhanced operational safety
  Reliable fan performance ensured consistent ventilation in deep underground conditions

Engineering Significance

This project demonstrates the importance of controlled motor starting in high-power underground applications, where both environmental conditions and system accessibility impose strict reliability requirements.

The DriveStart solution enabled stable and repeatable operation of a critical ventilation system, supporting both safety and productivity in a challenging mining environment.

Positioning Statement

With proven performance in demanding applications such as underground mining, Solcon-IGEL’s medium voltage soft starters provide reliable motor control solutions for high-power systems operating under extreme conditions.