CWA performed the detailed design of an expansion project to increase the handling capacity of an existing potash facility from six million tonnes per year to ten million tonnes per year. The project included a new 600-tonne capacity surge bin, modifications to an existing conveyor to create a shuttling head end, a new 6,000 t/h conveyor, a conveyor tunnel, and a vehicle overpass.
The expansion was constrained by the size of the existing surge bin and the existing infrastructure on site. The construction and installation of the new equipment and infrastructure took place within a limited site footprint and needed to accommodate ongoing terminal operations.
Using state-of-the-art technology, CWA designed a new “expanded flow” surge bin that doubled the bin capacity while maintaining the same height as the existing surge bin. The surge bin, with two new infeed conveyors and two new outfeed conveyors, was completely constructed beside its final position to allow the existing surge bin to continue operating during construction, then seamlessly moved into place and commissioned during a brief shutdown period.
This project also created an alternative path for potash handling, which provided the flexibility and potential for a future expansion to further increase the facility’s capacity.