Ganfeng Lithium Sierra Leone Bombali Mine 2M TPA Solar-Storage-Diesel Hybrid Power Station EPC
Project Background
The Ganfeng Lithium Sierra Leone Bombali Lithium Mine 2 Million TPA Mining & Processing Plant Solar-Storage-Diesel Hybrid Power Station EPC Project is a critical energy infrastructure project supporting Ganfeng Lithium's strategic lithium resource development in West Africa. Located in Bombali District, Northern Province of Sierra Leone, the mining area spans over 80 km² with granted mining licenses and environmental permits.
As of end of 2025, the Bombali lithium deposit contains approximately 39.15 million tonnes of measured + indicated + inferred ore with 483,600 tonnes of Li₂O content (average grade 1.24%). The initial phase is designed for 2 million tonnes of ore processing per year, targeting approximately 500,000 tonnes of lithium concentrate annually, with production ramp-up expected in 2027. The hybrid power station is being procured by China Energy Engineering Group Guangdong Electric Power Design Institute Co., Ltd. New Energy Engineering Company, with a milestone of diesel generation system readiness by August 31, 2026.
Challenges Faced
Remote Off-Grid Location
The Bombali mining district in Sierra Leone's Northern Province has minimal grid infrastructure. The entire power supply must be self-contained — a completely independent, island-mode microgrid with no utility backup. All equipment, fuel, and spares must be self-sufficient for the mine's operational lifespan.
No grid connection available within 50 km of the mine site
Complete dependence on self-generated power for 24/7 mining and processing operations
Tropical West African climate: high temperature (30–35°C), high humidity, and heavy rainfall during monsoon season
Equipment must withstand tropical conditions — salt corrosion, UV exposure, and vermin protection
Multi-Energy Hybrid Integration Complexity
The power station integrates three distinct energy sources — solar PV (96.915 MWp DC), battery energy storage (80 MW / 320 MWh), and diesel generators (25.6 MW) — requiring sophisticated energy management and seamless switching between sources:
PV output fluctuates with weather; battery must absorb and release at megawatt scale to smooth the supply curve
Diesel generators must start, synchronize, and load-share automatically when solar/storage cannot meet demand
Energy Management System (EMS) must optimize fuel consumption vs. battery cycle life vs. PV availability in real time
Protection coordination across three energy sources with different fault current characteristics
Aggressive Procurement & Deployment Timeline
The project has a binding milestone of August 31, 2026 for diesel generation system readiness — a compressed timeline considering international procurement, ocean freight to West Africa, and civil works in a remote location:
Equipment design, manufacturing, and factory testing within tight windows to meet shipping deadlines
Ocean freight from Chinese ports to Sierra Leone (transit time: 30–45 days) adds non-negotiable schedule lead time
Inland transport from Freetown port to Bombali mining area over roads with limited heavy-haul capacity
On-site installation must proceed in parallel with civil works, requiring precise logistics coordination
Customized Solution Highlights – 110kV Switchgear & Hybrid Power Distribution System
Pushen Electric provided a comprehensive medium-voltage power distribution and protection solution tailored to the unique demands of this West African hybrid power station project:
110kV Switchgear Package: A complete high-voltage switchgear solution for the main step-up substation, including SF6 gas-insulated switchgear (GIS), protection relays, and control system. The GIS design significantly reduces footprint compared to air-insulated alternatives — a critical advantage given the restricted substation area within the mine layout. Factory-assembled modules minimize on-site assembly time in Sierra Leone's tropical conditions.
Medium-Voltage Switchgear Array: Metal-clad switchgear units configured for the hybrid power station's specific voltage requirements, architected with separate incomer sections for PV, battery storage, and diesel generator feeders. Intelligent monitoring and remote operation capabilities enable centralized control from the mine's control room — essential for the off-grid location where on-site technical staff availability is limited.
Protection & Control System: Engineered protection coordination across the microgrid's three energy sources, accounting for the differing fault current contributions from inverter-based sources (PV, battery) and rotating machines (diesel generators). Includes anti-islanding protection for PV inverters, battery management system (BMS) integration, and automatic load-shedding schemes for critical mine loads during supply-demand imbalances.
Project Outcomes
Reliable Off-Grid Power for Critical Mining Operations
The hybrid power station ensures 24/7 continuous power supply for the Bombali lithium mine's entire processing chain — from crushing and grinding to flotation and drying — without any dependency on the weak local grid. The solar-storage-diesel multi-energy complementary design delivers stable power quality even during Sierra Leone's extended monsoon season.
Optimized Operating Costs vs. Pure Diesel Generation
The solar PV + battery storage combination significantly reduces diesel fuel consumption compared to a conventional diesel-only solution. During daylight hours with sufficient solar irradiance, the mine can operate predominantly on solar power, with batteries absorbing surplus PV output and discharging during cloud transients or evening peak load periods. The 25.6 MW diesel generators serve as reliable backup — running only when solar and storage cannot meet demand.
Strategic Contribution to Ganfeng Lithium's Global Supply Chain
By enabling the Bombali lithium mine to achieve its production ramp-up target of 500,000 tonnes of lithium concentrate per year, the power station plays a direct role in Ganfeng Lithium's global battery material supply chain strategy. The project strengthens China-Africa cooperation in critical mineral resources while demonstrating the viability of hybrid renewable power systems for large-scale off-grid mining operations in West Africa.
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