Technology in the Potash IndustryTechnology in the Potash Industry
Presented to:Presented to:
U of S Mechanical EngineeringU of S Mechanical Engineering
October 10, 2002October 10, 2002
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryPresentation OutlinePresentation Outline
?? PotashPotashCorpCorp
?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
?? ProcessProcess
?? Products Products
?? EnvironmentEnvironment
Technology in the Potash IndustryTechnology in the Potash Industry
PotashPotashCorpCorp ProfileProfileTechnology and Corporate GoalsTechnology and Corporate Goals
Customers for PCS Potash
5.7 billion people1.42 Gha arable land
• Technology leader
• Best products
• Low cost producer
• Safe operations
• 2500 m2/person
Technology in the Potash IndustryTechnology in the Potash Industry
PotashPotashCorpCorpBusiness ProfileBusiness Profile
?? Produce, market and transport N, P and K products:Produce, market and transport N, P and K products:
•• Plants in USA (N+P), Canada (K), Trinidad (N) Plants in USA (N+P), Canada (K), Trinidad (N)
•• PCS operates 5 potash mines in SK and 1 in NB PCS operates 5 potash mines in SK and 1 in NB
•• 2001 Sales: 16.6 million 2001 Sales: 16.6 million tonnestonnes of N, P and K productsof N, P and K products
?? Financial 2001: Financial 2001:
•• Assets: $4.6 billion US Assets: $4.6 billion US
•• Net Sales Revenues: $2.07 billion USNet Sales Revenues: $2.07 billion US
•• Employees: 4997Employees: 4997
Technology in the Potash IndustryTechnology in the Potash Industry
PCS Nitrogen and PCS PhosphatePCS Nitrogen and PCS PhosphateAmmonia, Urea, Phosphoric acid, Solutions, FeedsAmmonia, Urea, Phosphoric acid, Solutions, Feeds
PCS Phosphate at Aurora, North Carolina
Technology in the Potash IndustryTechnology in the Potash Industry
PCS PotashPCS PotashMines in Saskatchewan and New BrunswickMines in Saskatchewan and New Brunswick
Rocanville, SK
Sussex, NB
Technology in the Potash IndustryTechnology in the Potash Industry
Impacts on Revenues, Costs and RisksImpacts on Revenues, Costs and RisksTechnology in BusinessTechnology in Business
Profit = Revenue Profit = Revenue -- Cost Cost -- RiskRisk•• Revenue:Revenue:
–– Sales of products: MarketplaceSales of products: Marketplace
–– Investment incomeInvestment income
•• Cost:Cost:–– OperationsOperations
–– MaintenanceMaintenance
–– TransportationTransportation
•• Risk:Risk:–– Probability x ConsequenceProbability x Consequence
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryPresentation OutlinePresentation Outline
?? PotashPotashCorpCorp
?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
?? ProcessProcess
?? Products Products
?? EnvironmentEnvironment
Technology in the Potash IndustryTechnology in the Potash Industry
Potash Deposits in SaskatchewanPotash Deposits in SaskatchewanDevonian Period, Devonian Period, --350 Ma350 Ma
• Seas covered continent
• Mountain uplift, then cutoff
• Solar evaporation concentrated brine
• Sea water concentrated
• Chloride salts crystallized in sequence
• Now buried by 1000 m of sediments
Technology in the Potash IndustryTechnology in the Potash Industry
Profits= RevenuesProfits= Revenues--CostsCosts--RisksRisksMining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
• Mining at -1000 m
• Multi-pass room and pillar
• Stress relief chevron method
• Continuous, mechanized system
• High Productivity
• Automated, 3-D control of miners
• Safe operations
Technology in the Potash IndustryTechnology in the Potash Industry
Continuous Mining SystemsContinuous Mining SystemsPlan View of Mining PanelsPlan View of Mining Panels
?? Room and Pillar MiningRoom and Pillar Mining•• Needs stable, flat ore bodyNeeds stable, flat ore body
•• MultiMulti--pass cutting of roomspass cutting of rooms
•• Can use automated minersCan use automated miners
•• Ore extraction in panels: 42%Ore extraction in panels: 42%
?? Stress Relief MiningStress Relief Mining•• Used in clayUsed in clay--banded orebanded ore
•• Complex cutting patternComplex cutting pattern
•• Some automationSome automation
•• Ore extraction in panel: 65%, Ore extraction in panel: 65%, (42% overall)(42% overall)
Technology in the Potash IndustryTechnology in the Potash Industry
Continuous Mining SystemsContinuous Mining SystemsMechanization andMechanization and AutomationAutomation
Lanigan Division 4-Pass Systemwith moveable extensible panel conveyor
Fixed mainline conveyor moves ore to the mine shaft
14.6 m
4.9 m
Technology in the Potash IndustryTechnology in the Potash Industry
Continuous Mining SystemsContinuous Mining SystemsTriTri--axial Control of a Mining Machine in the Ore Horizonaxial Control of a Mining Machine in the Ore Horizon
X: Laser beam guidance system for 1st pass miningAdvance rate sensor
Y: Ultrasonic sensors for 2nd and 3rd pass mining
Z: Vertical array of K-40 gamma radiation sensors for optimum ore gradeClay seam sensor
Z
X
Y
Technology in the Potash IndustryTechnology in the Potash Industry
Mining Machine PerformanceMining Machine PerformanceBit and Pattern Design for Best Cutting EfficiencyBit and Pattern Design for Best Cutting Efficiency
Bit Design:
Reduce bit wear and frequency of replacementIncrease machine availabilityReduce fines and dust from primary rock fragmentation
Tooling Pattern:
Improve energy efficiencyIncrease average particle size of broken ore
Technology in the Potash IndustryTechnology in the Potash Industry
Mining Machine PerformanceMining Machine PerformanceDesign for Elimination of the Trim ChainDesign for Elimination of the Trim Chain
Cutting Profile Goals:
Rectangular opening
No cusps
Reduce dust and fines
Principle:
Cam-following cutting arm extensions
SK Design:
Prairie MachinePrototype at IMC Colonsay
Technology in the Potash IndustryTechnology in the Potash Industry
Ore Body Geology Ore Body Geology Technologies to Detect Geological Disturbances Technologies to Detect Geological Disturbances
Stratigraphy
Aquifers above and below the highly soluble ore body
are potential sources of inflow water, particularly near
collapse structures
Dep
th, m
etres
Ore
Technology in the Potash IndustryTechnology in the Potash Industry
GeoscienceGeoscience Helps to Prevent Mine FloodingHelps to Prevent Mine Flooding33--D Seismic Surveys to Detect and Avoid Major Anomalies D Seismic Surveys to Detect and Avoid Major Anomalies
Seismic Data Collection:
1-D geophone string yields information on structures in 2-D plane
2-D Geophone surface array yields 3-Dinformation
Rocanville Division Collapse Structure:
Image shows elevations of the top of the Dawson Bay formation that lies above the evaporite salts
First application of 3-D seismic method by PCS to confirm a collapse anomaly
High
Low
1600 m
Technology in the Potash IndustryTechnology in the Potash Industry
Managing Potash Mine FloodsManaging Potash Mine FloodsSuccessful Plug Installed at the Successful Plug Installed at the RocanvilleRocanville Division Division
Location of mined rooms in panel
Technology in the Potash IndustryTechnology in the Potash Industry
Rock MechanicsRock MechanicsMaterials Properties Measurement in the LaboratoryMaterials Properties Measurement in the Laboratory
Instrumented Tri-axial Test Cells 15 cm diameter core of potash ore shows strain after testing
Technology in the Potash IndustryTechnology in the Potash Industry
Rock MechanicsRock MechanicsMine Monitoring and Modeling Mine Monitoring and Modeling
Rock mechanics monitoring station.Deformation of rock is measured.
Data logged underground are transmitted to the surface for analysis
2-D and 3-D numerical modeling of the displacement and stress distribution around mine openings in viscoelastic rock helps to ensure stability and safety
Effect of stress relief slot cut in roof
High
Low
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryPresentation OutlinePresentation Outline
?? PotashPotashCorpCorp
?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
?? ProcessProcess
?? Products Products
?? EnvironmentEnvironment
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreMineral SeparationMineral Separation and Particle Sizing Unit Operationsand Particle Sizing Unit OperationsProfits= Profits= RevenuesRevenues--CostsCosts--RisksRisks
?? Crushing and SizingCrushing and Sizing
?? DeslimingDesliming
?? FlotationFlotation
?? CrystallizationCrystallization
?? DryingDrying
?? Compaction and ScreeningCompaction and Screening
?? Product HandlingProduct Handling
?? Tailings ManagementTailings Management
Mill Feed Rates are up to 1400 tonnes/hour
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreOre MineralogyOre Mineralogy
?? Composition:Composition:•• NaCl: NaCl: 55%55%
•• KCl:KCl: 3535--40%40%
•• KMgClKMgCl33.6H.6H22OO:: 11--5%5%
•• InsolublesInsolubles: : 11--8%8%
?? Size Range of Natural Crystals Size Range of Natural Crystals in Ore:in Ore:•• 11--10 mm10 mm
3 mm
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreParticle Size Distributions of Potash ProductsParticle Size Distributions of Potash Products
Particle Size Distributions of Selected Grades of Potash Examples of Standard, Coarse and Granular Products
0
10
20
30
40
50
60
70
80
90
100
0.0 1.0 2.0 3.0 4.0
Particle Size, mm
Fine Standard
Pink Standard
Red Standard
White Standard
Pink Coarse
Red Coarse
White Coarse
Pink Granular
Red Granular
White Granular
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreOre Preparation for Flotation by DeOre Preparation for Flotation by De--slimingsliming
PCS Lanigan Flotation Summary
Fines conditioning
Desliming
Primary scrubbers
Brine
Raw Ore RecrushingDesliming screens
Wet Sizing
Primary Cyclones
Secondary scrubbers
Secondary Cyclones
Tertiary Cyclones
Coarse conditioning
Hydros
To scavenger flotation
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreOre Preparation for Flotation by DeOre Preparation for Flotation by De--slimingsliming
De-sliming cyclones separate -150 micron particles from
coarse slurries of potash ore
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreMineral Separation by FlotationMineral Separation by Flotation
Parallel Banks of Flotation Cellunits operating in series
KCl-rich slurry is removed as Concentrate
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OrePrinciple of Separation by FlotationPrinciple of Separation by Flotation
?? Feed slurry:Feed slurry:
•• NaCl + KCl + NaCl + KCl + InsolsInsols
•• CoCo--saturated brinesaturated brine
•• ReagentsReagents
–– DepressantDepressant
–– CollectorCollector
?? Concentrate:Concentrate:
•• Mainly KCl slurryMainly KCl slurry
?? Tailings:Tailings:
•• Mainly NaCl slurryMainly NaCl slurry
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreFlotation Process Flotation Process FlowsheetFlowsheet
PCS Lanigan Flotation Summary
Frother (MIBC)Brine
DepressantFlocculant
Starch
Starch
Extender
Amine
Amine
Brine
Starch
Amine
Extender
Frother
Tails
Tails
XLR CycloneU/F
Dryers
Rougher & Regrind Flotation
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreMechanical Cell Banks Separate Particles by Size
Rougher Flotation Particle Size Distribution
0
5
0.0 1.0 2.0 3.0 4.0
Particle Size (mm)
KC
l Mas
s Fl
ow, %
T
C1
C2
C3
C4
C5
C6
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreRate of Flotation Depends on Particle Size
KCl Grade vs Recovery Flotation Data
0
10
20
30
40
50
60
70
80
90
100
40 50 60 70 80 90 100
Grade (%KCl)
KC
l Rec
ove
ry (
%)
+6
+8
+10
+14
+20
+28
+35
+48
+65
-65
Fines: high recovery, low grade
• Coarse: low recovery, high grade
Mesh Size
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OrePrinciple of KCl Recovery from Brine by CrystallizationPrinciple of KCl Recovery from Brine by Crystallization
3 Stage Crystallization at the Cory Division
1012
14
16
182022
2426
2830
60 70 80 90 100
Temperature, oC
NaC
l and
KC
l, W
t % Supersaturated KCl
NaCl
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreCrystallizer Vessel and ComponentsCrystallizer Vessel and Components
3.65 m
0.46 m
1.37 m
2.89 m
5.85 m
5.49 m
2.99 m
0.76 m
Hot Brine Feed KCl Slurry
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreMass Flows of Solids and BrineMass Flows of Solids and Brine
Water Evaporation, 4.4 kg/s
Overflow Brine404 kg/s
4550 kg/s Density=Quiet (10 x Feed) Quiet 1.24 kg/LZone Zone
84 oC
Feed Brine Product 30% Solids Outat 96 oC 46.9 kg/s
455 kg/s Density=Density= 1.47 kg/L1.24 kg/L
Draft Tube Top and Bottom Views
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreTypical Crystal Size Distribution of KClTypical Crystal Size Distribution of KCl
Particle Size Distribution
0.1 1 10 100 1000 3000
Particle Size (µm)
0
2
4
6
8
10
12
14
Vol
ume
(%)
PPxlr M-108-6b, 21 Dec 1999 11:38:51
Maximize Growth
Rate = f (S*)
Minimize Nucleation
Rate = f (S*)3
Technology in the Potash IndustryTechnology in the Potash Industry
Crystallizer Product CharacteristicsCrystallizer Product CharacteristicsProcessing Potash OreProcessing Potash Ore
?? 600600--1200 micron particles1200 micron particles•• rounded by abrasionrounded by abrasion
•• compositescomposites
?? 300300--425 micron particles425 micron particles•• complex microstructurescomplex microstructures
•• agglomeratesagglomerates
?? 150150--212 micron particles212 micron particles•• primary KCl cubesprimary KCl cubes
•• some agglomerates some agglomerates
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreMineral Separation and Mineral Separation and Particle Sizing Unit OperationsParticle Sizing Unit OperationsProfits= Profits= RevenuesRevenues--CostsCosts--RisksRisks
?? Crushing and SizingCrushing and Sizing
?? DeslimingDesliming
?? FlotationFlotation
?? CrystallizationCrystallization
?? DryingDrying
?? Compaction and ScreeningCompaction and Screening
?? Product HandlingProduct Handling
?? Tailings ManagementTailings Management
Mill Feed Rates are up to 1400 tonnes/hour
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreCompaction and ScreeningCompaction and Screening
Compactors compress fine particles into sheets before crushing and screening into marketable products. Important variables are feeder design, roll dimensions, speed, surface contour and materials of construction.
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreCompaction Circuit Compaction Circuit FlowsheetFlowsheet SimulationSimulation
Compactor
Crushers
Screens
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreProduct Storage and TransportationProduct Storage and Transportation
Technology in the Potash IndustryTechnology in the Potash Industry
Processing Potash OreProcessing Potash OreProfits= Profits= RevenuesRevenues--CostsCosts--RisksRisks
?? Crushing and SizingCrushing and Sizing
?? DeslimingDesliming
?? FlotationFlotation
?? CrystallizationCrystallization
?? DryingDrying
?? Compaction and ScreeningCompaction and Screening
?? Product HandlingProduct Handling
?? Tailings ManagementTailings Management
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryOutline of the PresentationOutline of the Presentation
?? PotashPotashCorpCorp
?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
?? ProcessProcess
?? ProductsProducts
?? EnvironmentEnvironment
Technology in the Potash IndustryTechnology in the Potash Industry
Potash Product Quality ManagementPotash Product Quality ManagementMaterials Science FundamentalsMaterials Science Fundamentals
Moisture uptake and release from packed
beds of stored potash can occur rapidly,
depending on RH, temperature, particle
size and type.
Brine films on the surface of the potash
particles are controlled by minerals deposited
from brine during the drying process. KCl, NaCl
and MgCl2 minerals affect moisture dynamics.
SEM image shows cluster of Mg-rich solid.
Technology in the Potash IndustryTechnology in the Potash Industry
Potash Product Quality ManagementPotash Product Quality ManagementMaterials Science FundamentalsMaterials Science Fundamentals
Compacted Granular potash
products creep under applied
stress at high RH typical of
tropical and coastal climates
for fertilizer storage
Technology in the Potash IndustryTechnology in the Potash Industry
Potash Product Quality ManagementPotash Product Quality ManagementModeling Moisture Transport in Hygroscopic FertilizersModeling Moisture Transport in Hygroscopic Fertilizers
U of S-PCS-NSERC Research Program
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryPresentation OutlinePresentation Outline
?? PotashPotashCorpCorp
?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
?? ProcessProcess
?? ProductsProducts
?? EnvironmentEnvironment
Technology in the Potash IndustryTechnology in the Potash Industry
Environmental ManagementEnvironmental ManagementProfits = RevenuesProfits = Revenues--CostsCosts--RisksRisks
Aerial photo of a potash mine
site showing tailings pile and
brine pond
About 2 tonnes of salt and insolubles waste solids is
separated for each tonne of potash produced
Technology in the Potash IndustryTechnology in the Potash Industry
Environmental ManagementEnvironmental ManagementRisk ProfileRisk Profile
Salt piles are expected to grow during the
lifetime of potash mines in Saskatchewan.Decommissioning plans assume that slowdisappearance of salt will occur by dissolution in precipitation.
Risk of contamination of groundwater in
aquifers by brine seepage is low because
of low gradients, low permeability tills, and
effective containment systems.
Technology in the Potash IndustryTechnology in the Potash Industry
Environmental ManagementEnvironmental ManagementAlternative Technologies for Tailings DisposalAlternative Technologies for Tailings Disposal
Stabilize
Surface
Cover/Cap
Dissolve SaltsInject Brine
Underground
Backfill Mine
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryThe PresentationThe Presentation
?? PotashPotashCorpCorp
?? Mining, Geophysics and Rock MechanicsMining, Geophysics and Rock Mechanics
?? ProcessProcess
?? Products Products
?? EnvironmentEnvironment
Technology in the Potash IndustryTechnology in the Potash Industry
Technology in the Potash IndustryTechnology in the Potash IndustryThe PresentationThe Presentation
Customers for PCS Potash
5.7 billion people1.42 Gha arable land
Profits = RevenuesProfits = Revenues--CostsCosts--RisksRisks