Mosaic Facility Tour: Expanded Opportunities

Mosaic Facility Tour Belle Plaine Conveyor

While driving west from Regina, Sas­katchewan, along Pro­vincial Route 1 for 30 minutes or so, motorists will notice an impressive-looking facility looming off in the distance. This is the Mosaic Co.‘s Belle Plaine potash processing facility, which sits on approximately 200 acres of land surrounded by some of the world’s largest potash reserves. When it was first built in 1962, the facility represented the largest solution mining operation in the world, producing more than 800,000 short tons of potash per year.

But today’s Belle Plaine operation is much bigger than it was 48 years ago. Pulling into the facility, visitors will notice hundreds of steel girders being mounted, dozens of front-end loaders moving earth and more than 500 construction workers scurrying across the site. The plant is in the midst of a major expansion of its operations — an effort that sometimes confuses even seasoned Mosaic employees.

“This parking lot wasn’t here the last time I visited,” says Sarah Fedorchuk, internal communications specialist, looking for a visitors parking place. “Things here in Belle Plaine are moving pretty fast.”

In reality, the speed of Belle Plaine’s expansion is something of an optical illusion. According to Sam Farris, Belle Plaine expansion manager, potash mining developments at Mosaic tend to be planned out five to six years in advance as a general practice. “Right now, the Belle Plaine expansion is expected to involve three separate stages,” says Farris. “We received the first stage approval in October 2007.”

A Different World

Of course, the world of potash was in a much different place three years ago then it is today. At that time, the agricultural and global economies were booming. Grain prices were at record highs, thanks in part to the growth of corn-based ethanol, and growers were spending plenty of money on crop nutrients such as potash to keep their yields (and profits) high.

But as any agricultural follower knows, these good times all came to a screeching halt during late 2008. Grain prices fell and financially-stung growers virtually halted crop nutrient application work for the remainder of the year.

In 2009, says Norm Beug, senior vice president, potash operations for Mosaic, conditions weren’t much better for crop nutrient suppliers. “There was a major pull-back in crop nutrient use last year,” says Beug. “If I had to characterize how things are for crop nutrients in 2010, I would say we are in recovery, but not fully recovered just yet.” For example, as of March 2010, U.S. potash inventories were reportedly 21% below their five-year average.

Despite this fact — and persistent fears that the general economy could experience a double-digit recession by year’s end — Beug is confident that the future for crop nutrients is bright. “Food demand is still on an upward trend line,” he says. “The world’s population continues to grow, adding some 75 million people per year, and food consumption did not drop off — even during the height of the recession. So from our perspective, the fundamentals of this business are still the same as they were.”

As proof of this view, Beug says all an observer needs to do is look what’s currently happening with potash demand. “Grain prices are going up and this is typically the signal that growers need to make important input decisions,” he says. “Also, China hasn’t upped its potash purchases just yet, but I think that’s going to happen. By 2011, our industry should be back to its normal growth trend line.”

Expansion Plans

To service this expected demand, Mo­saic is in the process of adding capacity to its Belle Plaine operation. As Peter Jackson, general manager, operations at the facility, explains, potash solution mining is a production-intensive process. “In solution mining, you drill bore holes down approximately one mile and pump hot water into the hole to form a cavity,” says Jackson. “This creates a brine which is pumped out of the cavity through a second bore hole and processed in one of two ways to remove the potash from other materials.”

In the first method of extraction, the brine is sent through an evaporation and crystallization process to create the potash crystals from the mined solution. These then leave a crystallizer and are de-watered. They then go to a dryer and compactor before being sent for storage in a warehouse. In the second method, the brine is pumped into a cooling pond just outside the plant. Here, the materials are crystallized naturally and the potash crystals are recovered using a dredge.

For its first stage expansion, the Belle Plaine operation has added a second drilling rig to make bore holes and is constructing an expanded water injection system to produce the heated water at 1,000 psi the plant uses to inject into the mining cavities. There are also four new compactors and a conveyor system for product transportation being built.

“When we are done with this first stage of expansion, the Belle Plaine plant will have significantly more potash production capacity then it currently does,” says Farris. “We will be going from producing 2.55 million short tons today to 3.5 million short tons by 2017.”

The White Stuff

A key characteristic of Belle Plaine’s potash is its color. Unlike traditional potash which is red because of iron impurities, the plant’s production process completely separates the potash crystals from the iron present in the ore body. This results in potash that is white and contains 98% potassium chloride (compared with 95% for red potash).

In 2010, Mosaic began branding this white potash under the tradename Pegasus K62. “Because of its purity level, Pegasus K62 gives users an estimated two more units of potassium per ton than other potash types,” says Beug. “This represents a win-win for our customers because it allows them to do more with less.”

For Belle Plaine’s second stage of expansion, the plant hopes to add to the crystallization process of its operations. “This would help grow our production capacity substantially,” says Farris. “We would be moving from producing 3.5 million short tons of potash to approximately 5 million short tons by 2020.”

Leave a Reply

Fertilizer Stories

Potash Corp Agrium
Crop InputsAgrium, Potash Corp To Merge To Create $36 Billion Company
September 12, 2016
Canada’s Agrium Inc. and Potash Corp of Saskatchewan Inc. have agreed to combine in a deal that would create a Read More
FertilizerBRANDT Specialty Fertilizers Help Grower Set Soybean Yield Record
September 12, 2016
BRANDT, a leading agriculture retailer and manufacturer of specialty Ag products, has announced that its new proprietary nutrition products were Read More
Corn Field
FertilizerBridging Crop Nutrition Science And Technology
September 7, 2016
The future seemed to draw nearer for the 1,600-plus attendees of the co-located InfoAg and International Precision Agriculture conferences in St. Read More
Fertilizer Bin
FertilizerState Of The Fertilizer Industry Report Highlights Environmental, Social Contributions
September 6, 2016
As consumers, we live in a world with access to more data than we could ever hope to mine through. Read More
Trending Articles
Bayer Monsanto
Crop InputsBayer-Monsanto Mega-Merger: 6 Things You Need To Know
September 14, 2016
Mega mergers have become almost routine in the agricultural industry. Right on the heels of Monday’s news that fertilizer giants Potash Read More
Potash Corp Agrium
Crop InputsAgrium, Potash Corp To Merge To Create $36 Billion Company
September 12, 2016
Canada’s Agrium Inc. and Potash Corp of Saskatchewan Inc. have agreed to combine in a deal that would create a Read More
Osage Co-op Elevator Osage, IA Finished Building
OpinionAre We Crazy?
September 8, 2016
At some point in the first few months of my employment here at CropLife® magazine, I started getting curious about Read More
ManagementMAGIE 2016 Highlights and Deere Anti-Trust
September 1, 2016
CropLife Editor Eric Sfiligoj discusses the recent Midwest AG Industries Exposition and the Department of Justice’s objection to John Deere Read More
ASMARK 2016 Retailers Live! Tour - CPS
CropLife 100CPS Acquires Texas Retail Operation
August 23, 2016
Crop Production Services (CPS) has acquired the assets of Larry’s Chemical and Spray, Inc., for an undisclosed amount in an Read More
Key Cooperative Marcus Construction Steel Building
Retail FacilitiesMarcus Construction Builds High-Speed Agronomy Center For Key Cooperative
July 7, 2016
Key Cooperative in Grinnell, IA, wanted a state-of-the-art Agronomy Center to better serve its customers. Marcus Construction delivered exactly that. Read More
Latest News
Syngenta Seedcare Institute
Seed/BiotechSyngenta Opens New North America Seedcare Institute In …
September 23, 2016
Syngenta unveiled its new Seedcare Institute in Stanton, MN, during a recent grand opening celebration. More than 150 industry leaders, Read More
StewardshipMonsanto Invests $1.6 Million In System To Quantify Gre…
September 23, 2016
The USDA – Natural Resources Conservation Service (USDA-NRCS) recently awarded the National Corn Growers Association (NCGA) and its Soil Health Read More
Pipe rack
LegislationCourt Sides With Ag Retailers On PSM
September 23, 2016
The D.C. Court of Appeals has ruled the Occupational Safety and Health Administration violated the Occupational Safety and Health Act when Read More
ManagementPacific Coast Fertilizer Announces Interest In Longview…
September 22, 2016
Pacific Coast Fertilizer LP (PCF) announced at the Cowlitz Economic Development Council board of directors meeting its interest in developing Read More
Young corn plants in soil
UncategorizedCool Planet Raises Additional $9 Million To Commerciali…
September 22, 2016
Cool Planet has announced the first close of a new financing round to commercialize the company’s Cool Terra Engineered Biocarbon Read More
Crop InputsJim Loar Promoted To President And CEO Of Cool Planet
September 22, 2016
In a move that reflects and reinforces the company’s commitment to the agricultural market, the Cool Planet board of directors Read More
BlendersNorth Dakota Coop Debuts Dry Fertilizer Plant
September 22, 2016
North Central Grain Cooperative has begun operations at a new dry fertilizer plant at its Rolla, ND, site. It is Read More
Crop InputsMonsanto, Bayer Officials Defend Proposed $66 Billion M…
September 21, 2016
Top officials for Monsanto and Bayer defended their proposed $66 billion merger before skeptical senators on Tuesday, insisting that the Read More
ManagementUpcoming Shows & Recent Events
September 19, 2016
Editors Paul Schrimpf and Eric Sfiligoj talk about upcoming trade shows and events and review the Mid America CropLife Association Read More
Industry NewsVerdesian Life Sciences Appoints New CEO
September 19, 2016
Verdesian Life Sciences, a plant health and nutrition company, today announced that its board of directors has named Kenneth M. Avery Read More
Corn
Crop InputsEPA Settles With Syngenta For Alleged Multi-Regional Pe…
September 19, 2016
The U.S. EPA has announced a multi-region settlement with Syngenta Crop Protection, LLC (Syngenta) in Greensboro, NC, for alleged violations of Read More
ManagementMerger Mania
September 16, 2016
Editors Paul Schrimpf and Eric Sfiligoj discuss this week’s mega-ag mergers of Bayer and Monsanto and Potash and Agrium. Read More
Monsanto sign
Crop InputsMonsanto Ends Up Being A Bargain For Bayer
September 16, 2016
History will say Bayer got a bargain in its $66 billion purchase of Monsanto, writes David Nicklaus, St. Louis Post-Dispatch. The Read More
Greg Musson, Gar Tootelian
CropLife 100California Ag Retailer Steps Up To Feed Families Affect…
September 16, 2016
GAR Tootelian, Inc. (GAR) in Reedley, CA, is challenging the Central Valley to help raise enough money and provide 525,000 meals Read More
Crop InputsBayer, Monsanto CEOs Discuss Merger
September 15, 2016
Werner Baumann, Bayer CEO, and Hugh Grant, Monsanto CEO, discuss why they decided to merge their companies. Read More
Corn close up
Crop InputsNY Times: Bayer-Monsanto a Bad Deal for Farmers
September 15, 2016
Via NY Times: Don Halcomb, a 63-year-old farmer in Adairville, KY, is expecting his profit to vanish this year, largely Read More
Werner Baumann, Bayer AG, and Hugh Grant, Monsanto
Crop InputsBayer-Monsanto Merger Creates New Global Ag Giant
September 14, 2016
During the whole of 2016, many of the companies that do business in the agricultural industry have concluded the best Read More
Bayer Monsanto
Crop InputsBayer-Monsanto Mega-Merger: 6 Things You Need To Know
September 14, 2016
Mega mergers have become almost routine in the agricultural industry. Right on the heels of Monday’s news that fertilizer giants Potash Read More