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

Sulfur Deficiency In Corn
Crop InputsManaging Sulfur Deficiency In Corn
January 6, 2017
Corn sulfur (S) deficiency is a growing problem in and across North Dakota, according to an article on the NDSU Read More
AFS Seed Retailer and Grower
Crop InputsThis Is Not Your Father’s World Of Nitrogen Management
January 6, 2017
Many of us older citizens can remember times when our fathers toiled day and night, to coax meager crop yields Read More
Young Corn Field
FertilizerPotassium Needs More Attention In Crop Nutrition
January 6, 2017
It’s well understood that plants require the right combination of the 14 essential mineral nutrients to sustain their growth, writes Read More
FertilizerSulfur: The 4th Major Nutrient
January 6, 2017
Sulfur is an essential nutrient in crop production. It is classified as a secondary element, along with Mg and Ca, Read More
Trending Articles
AgriSync
Matt Hopkins17 Agriculture Apps That Will Help You Farm Smarter In 2017
December 9, 2016
Ag professionals are working smarter, not harder, than ever before. Smart farming technologies have enabled them to reduce costs, maximize Read More
R4023 Sprayer, John Deere
CropLife 100Ag Retail Equipment Report: The Green Party Continues
December 7, 2016
In the annual race for sales in the ag retail equipment marketplace, the color schemes for participants are a little Read More
Mike Stern
Precision AgClimate Corp. CEO Talks Retailer Support For Digital Ag
December 1, 2016
CropLife Magazine’s sister publication, AgriBusiness Global, recently sat down with Mike Stern, CEO of The Climate Corp., following the Monsanto subsidiary’s Read More
Precision AgTrimble Debuts End-to-End FMIS Platform
November 28, 2016
October’s inaugural PrecisionAg Vision Conference left this author with many thoughts and things to ponder in the coming months. Probably Read More
CHS Primeland
CropLife 100The 2016 CropLife 100 Report: Reviewing The Many Bulls And Bears Impacting This Year’s Marketplace
November 28, 2016
For virtually all of 2016, the nation was wholly focused on the big Presidential election. Some folks aligned themselves with Read More
Monsanto sign
Crop InputsMissouri Governor Meets With Bayer CEO To Discuss Monsanto Merger
November 21, 2016
Missouri Gov. Jay Nixon visited Bayer AG global headquarters in Leverkusen, Germany, on November 18 to discuss the proposed Bayer-Monsanto Read More
Latest News
Young Corn Plants
ManagementTimac Agro USA Acquires Michigan Ag Retailer
January 20, 2017
Timac Agro USA, an agriculture supply company specializing in high-efficiency plant and animal nutrition products, has acquired St. Louis,MI-based A&E Ag, Read More
Soybean field
Crop InputsNufarm Teams Up With John Deere Financial
January 19, 2017
Nufarm and John Deere Financial have teamed up to help farmers grow a better tomorrow. This program helps make purchases Read More
Sonny Perdue
LegislationTrump Formally Picks Perdue As Agriculture Secretary
January 19, 2017
U.S. President-elect Donald Trump officially announced Sonny Perdue as his choice for secretary of agriculture on Thursday, selecting a former Read More
ManagementPresident Trump, Wisconsin Review, and a Dow-DuPont Upd…
January 18, 2017
Editors Paul Schrimpf and Eric Sfiligoj reflect on a new administration, a recent winter show, and crop protection company mergers. Read More
Industry NewsBayer, MS Technologies Get China Approval For Balance G…
January 18, 2017
MS Technologies and Bayer have received import approval from China for Balance GT soybeans. The new Balance GT Soybean Performance Read More
Werner Baumann, Bayer AG, and Hugh Grant, Monsanto
Industry NewsReport: Monsanto, Bayer CEOs Among Latest to Make Trump…
January 18, 2017
The chief executive officers of German chemical giant Bayer AG and U.S. seed behemoth Monsanto, Werner Baumann and Hugh Grant, Read More
Giant Ragweed
HerbicidesStudy: Focusing On Weed Seedbank Can Help Manage Herbic…
January 18, 2017
Researchers writing in the latest issue of the journal Weed Science provide important insights on the control of herbicide-resistant giant Read More
Management3 Financial Trends To Watch In Agriculture
January 17, 2017
I recently had the opportunity to attend a meeting of credit managers for Midwest ag supply and input companies, in part Read More
Andersons Retail Store
CropLife 100The Andersons To Close All Retail Stores; Shutdown Does…
January 16, 2017
In a stunning announcement to the Toledo area, The Andersons Inc. said on Sunday that it would close its two Read More
Trimble TMX-2050 In-Cab Display
Eric SfiligojPrecision To Lead Agriculture In 2017?
January 16, 2017
Another new year is upon us! And I’m certain I speak for many in the agricultural world when I say Read More
Corn
Eric SfiligojThe Mood From Madison? In A Holding Pattern
January 16, 2017
Last week, I had the chance to attend the annual Wisconsin AgriBusiness Classic show in Madison, WI. It’s been a Read More
Syngenta Sign
Crop InputsAccenture Helps Syngenta Transform Its Global Logistics
January 13, 2017
Syngenta, a leading agriculture company, has collaborated with Accenture to design and implement a new digital logistics operating model across Read More
Fall Creek Seth Harden The Nature Conservancy
StewardshipLocal Farmers’ Watershed Initiative: Continuous Improve…
January 13, 2017
The goal in the Big Pine Watershed Project is to more intentionally do what local farmers and responsible ag retailers Read More
HerbicidesEPA Expands Enlist Duo Herbicide Registration To 34 Sta…
January 13, 2017
The U.S. EPA has expanded the geography for application of Enlist Duo herbicide from 15 to 34 states. This means Read More
Olson Ag Enterprise
CropLife 100Wilbur-Ellis Acquires Nebraska Seed Retailer
January 13, 2017
Wilbur-Ellis’ Agribusiness, a recognized leader in precision agriculture technology and the distribution and marketing of plant protection, seed and nutritional Read More
ManagementDeere-Precision Planting Update and the Ag Secretary Wa…
January 12, 2017
Editors Paul Schrimpf and Eric Sfiligoj provide the latest on the court date for John Deere/Precision Planting and the quest Read More
Monsanto sign
Seed/BiotechMonsanto, NRGene Form Agreement For Big Data Genomic An…
January 12, 2017
Monsanto Co. and NRGene have announced that the companies have reached a non-exclusive, multi-year global licensing agreement on NRGene’s genome-analysis Read More
AGCO Custom applicator
SprayersAGCO, Asmark Institute To Offer Training For Beginning …
January 11, 2017
AGCO Corp. and the Asmark Institute are collaborating to offer a new training program dedicated to educating and developing custom Read More