Neptune Bulk Terminals Capacity Upgrade

6,000 metric tons per hour in rate capacity

30% increase in potash production capacity annually

Challenges

The Canadian province of Saskatchewan meets 35% of the demand for globally traded potash.
Much of this mineral fertilizer passes through Neptune Terminals, one of the largest multiproduct bulk terminals in North America.
Expansion was definitely needed, but efforts were challenged by the site, which is physically constrained.

Solutions

This design-bid-build project saw rail car dumper # 1 and conveyor belt replaced, increasing the rated capacity to 6,000 metric tons (MT) per hour.
The conveyor system was upgraded, modifying five conveyors and replacing one.
A surge bin was replaced with a new 620 MT stainless steel bin and support tower.
Two tunnels were constructed, one reaching 35 feet below grade, and a new roadway overpass was built that spanned two conveyors.

Highlights

As a result of the expansion, rail tracks can now accommodate two potash trains, or 340 railcars, at one time.
Two enclosed gravity-fed dumper pits can handle four railcars each. Two large storage sheds can store approximately 210,000 metric tons of potash and deliver it to two different berths.
Separate cascade chutes are used for red and white potash, and the chutes “gently” deposit potash into the holds of vessels, minimizing breakage and dust.
In 2011, Neptune Terminals handled a record 12.85 million metric tons of cargo and an estimated 7.2 million metric tons of potash.

“We surpassed our previous handling record by 12% while undergoing construction, which is a credit to the efforts of our operations, maintenance, and construction teams. Through strategic investments in our terminal, we have delivered a reliable supply chain for our shareholders and their customers, and these investments are paying off.”
Jim Belsheim | President and CEO, Neptune Terminals