Source: Buffalo Potash Corporation (2026)
Website: https://www.buffalopotash.ca/
Critical Data
| Parameter | Value | Unit | Notes |
|---|---|---|---|
| Processing Capacity (IPM) | 125,000 | t/a | Initial Production Module |
| Processing Capacity (Full-Scale) | 500,000 | t/a | Per HLD mine (West and East) |
| Operating Days | 330 | days/year | Annual plant operation; includes shutdowns for maintenance |
| Head Grade (Ore) | 33.66 | % KCl | Average ore grade used in mass balance for full-scale plant |
| Brine Injection Temperature | 50+ | °C | Heated from ~28°C; IPM uses boiler, full-scale uses natural gas heaters |
| Crystallizer Feed Temperature | 45 | °C | Recovery brine temperature at plant inlet |
| Crystallizer Discharge Temperature | 13 | °C | Second stage crystallizer temperature after cooling |
| Centrifuge Cake Moisture | <5 | % | Target moisture after screen bowl centrifuge |
| Dryer Product Moisture | <0.2 | % | Rotary dryer final moisture content |
Overview
Buffalo Potash Corporation (BPC) is advancing the Disley Project in Saskatchewan, Canada, with a staged development plan that begins with an Initial Production Module (IPM) producing 125,000 t/a of soluble muriate of potash (MOP) before scaling to full-scale HLD mines capable of 500,000 t/a each. The recovery methods used are based on solution mining: KCl-rich brine is produced from horizontal drill (HLD) wells, cooled in crystallizers to precipitate high-grade potassium chloride, then dewatered, dried, and either shipped as soluble product or compacted into granular MOP. The IPM, sited on Section 10-20-23W2 for proximity to roads, power, and natural gas, serves as a proof-of-concept to optimize mining and processing parameters. The full-scale plants (Disley West and Disley East) will incorporate compaction and glazing circuits to produce premium granular product. The process is designed to operate 330 days per year, with scheduled maintenance shutdowns. The recovery method relies on injecting heated brine (above 50°C) into underground caverns, dissolving potash ore, and recovering the saturated brine at 45°C. Two-stage crystallization drops the temperature from 45°C to 13°C, using barometric condensers and chillers, followed by centrifugation and rotary drying to achieve <0.2% moisture. This comprehensive potash recovery approach balances energy efficiency, product quality, and scalability, positioning BPC to meet growing global fertilizer demand.
Key Process Stages
- Stage 1: Brine Recovery and Injection – KCl-rich brine from production wells is received in tank T1100 with dilution water to prevent crystallization. Spent mother liquor from crystallizers, along with make-up water from the Mannville source well, is heated to over 50°C in brine injection tank T100 using a natural gas-fired boiler (BP001) and injected back into the cavern via pumps P001 and P002. This closed-loop circulation maintains cavern pressure and dissolves additional ore.
- Stage 2: Two-Stage Crystallization – Recovery brine at 45°C enters first-stage crystallizer X100, cooled to 32.5°C via barometric condenser BC100. The mother liquor then flows to second-stage crystallizer X101, where a chiller package CH100 and heat exchanger HE100 further cool the circulating brine to 13°C, inducing KCl crystallization. The slurry from both stages is combined and sent to centrifuge feed tank T105. The two-stage design allows heat recovery through the barometric condenser, reducing brine heating requirements.
- Stage 3: Centrifuging and Drying – Product slurry from crystallizer X101 is fed to screen bowl centrifuge C200 (IPM) or C1200/C1201 (full-scale) to dewater the KCl crystals to <5% moisture. The centrifuge cake drops into dryer feed screw SC200/SC1200 and enters a rotary dryer D200/D1200, which reduces moisture to <0.2%. Dryer exhaust is filtered through baghouse BH200/BH1200, with recovered dust returned to the product stream via screw and drag conveyors.
- Stage 4: Compaction and Glazing (Full-Scale) – For granular MOP production, dried product is sent to compactor feed bin T1401. Two compactors (CC1401/CC1402) produce flakes, which are broken by flake breakers FB1401/FB1402 and further crushed by CagePaktors (CR1401/CR1402). Oversize material is recycled via screens and bucket elevators. The granular product passes through a glazing water addition screw (1.5% w/w water) and a fluid bed dryer cooler to dry and cool to 80°C. Polishing screens remove oversize and fines, and dedust solution is applied before storage.
- Stage 5: Product Storage and Loading – Granular and soluble products are conveyed to dedicated storage buildings via belt conveyors and tripper systems. Reclaim is done by loader to a reclaim belt, screened to remove lumps, and weighed before loading into railcars or trucks. Soluble product is treated with 10% amine solution in screw conveyor SC301 (or SC1601 for full-scale) and bagged in 2 t bags or shipped as KCl brine. The loading weigh bin system ensures accurate dispatch.
Additional Interesting Data and Summary
The mass balance development for the Disley Project’s potash recovery methods is based on the KCl-NaCl-MgCl2-H2O system saturation data, using D’Ans solubility equilibria to determine component behavior at various temperatures. The IPM mass balance (Table 17.1) was used to size equipment for 125,000 t/a, detailing injection brine flow, recovery brine composition, and expected cavern dynamics including undissolved ore and brine losses to mining plane enlargement. The full-scale wet end mass balance (Table 17.2) for 500,000 t/a uses an average ore grade of 33.66% KCl, 0.55% carnallite, 6.64% insolubles, and remainder NaCl. The two-stage crystallizer system enables heat recovery via barometric condensers, reducing overall energy consumption for brine heating. Equipment sizing and performance are validated against established potash plants and original supplier data. Notably, BPC is evaluating a Vortex Crystallizer for low-temperature crystallization, which could reduce CAPEX and OPEX; pilot testing is anticipated during IPM operation. Environmental considerations include brine disposal wells for purge streams and a baghouse dust collection system for particulate control. The full-scale plants will have dedicated dust collection baghouses for compaction and glazing circuits. Product treatment involves amine solutions for soluble product (10% concentration at 60°C) and dedust oil for granular product, both requiring heated storage and mixing. The project’s economic impact is tied to its staged approach: the IPM de-risks technology and market entry, followed by simultaneous construction of two 500,000 t/a HLD mines (West and East) to capture economies of scale. Future outlook includes potential deployment of the Vortex Crystallizer and optimization of brine circulation. The Disley Project’s recovery methods demonstrate a robust, scalable solution mining process designed to produce high-purity MOP with flexible product forms (soluble and granular) to serve agricultural markets. The plant’s 330-day operating schedule with planned maintenance ensures high availability, while the closed-loop brine system minimizes freshwater consumption.
Key Processes: Crushing
Target Commodities: N/A
Consolidated report summaries
The following former standalone pages about this operation were consolidated here on October 25, 2026. They are retained for source traceability; dates and figures reflect each report’s own effective date and may be superseded by the current information above.
Optimizing Potash Recovery: Crystallization, Compaction & HLD Mine Methods
Optimizing Potash Recovery: Crystallization, Compaction & HLD Mine Methods
Source: Buffalo Potash Corporation (2026)
Website: https://www.buffalopotash.ca/
Critical Data
| Parameter | Value | Unit | Notes |
|---|---|---|---|
| Throughput | 125,000 (IPM) / 500,000 (HLD West/East each) | t/a | Annual production capacity; IPM for soluble MOP, HLD for granular MOP |
| Operating Days | 330 | days/year | 14-day annual shutdown for major maintenance plus two 8-hour shutdowns per month |
| Brine Temperature In | 45 | °C | Recovery brine from production wells enters crystallizer |
| Injection Temperature | >50 | °C | Brine heated from ~28°C to >50°C before injection |
| Crystallizer Stage 1 Outlet | 32.5 | °C | First stage crystallizer cools brine via barometric condenser |
| Crystallizer Stage 2 Outlet | 13 | °C | Second stage crystallizer uses chiller package for further cooling |
| Centrifuge Cake Moisture | <5 | % | Moisture content after screen bowl centrifuge |
| Dried Product Moisture | <0.2 | % | Rotary dryer reduces moisture to <0.2% |
| Head Grade (Ore) | 33.66 | % KCl | Average ore grade for HLD Mine wet end mass balance |
Overview
Buffalo Potash Corporation (BPC) is advancing potash recovery at the Disley Project in Saskatchewan, Canada, with a staged development plan that begins with an Initial Production Module (IPM) and scales to full High Legacy Deposit (HLD) mines. The IPM, situated on Section 10-20-23W2, leverages proximity to roads, power, and natural gas to produce 125,000 tonnes per year of soluble muriate of potash (MOP). This facility allows BPC to optimize mining and processing before commissioning two 500,000 t/a HLD mines at Disley West and Disley East. The recovery process relies on hot brine injection into underground caverns to dissolve KCl-rich ore, followed by two-stage crystallization, centrifuging, drying, and compaction to produce granular potash. The two-stage crystallizer system cools recovery brine from 45°C to 13°C, using a barometric condenser and chiller package for heat recovery. Mother liquor is recycled to injection wells, minimizing waste. The full-scale HLD plants include compaction circuits to convert crystallized potash into durable granular products, with glazing and screening to meet market specifications. BPC’s method emphasizes energy efficiency through heat recovery and reduced reagent consumption, aligning with sustainable mining practices. The Disley Project represents a significant step in Canadian potash production, with the IPM serving as a testbed for innovative technologies like the Vortex Crystallizer, which promises lower capital and operating costs.
Key Process Stages
- Stage 1: Brine Recovery and Injection – KCl-rich brine from production wells at 45°C is received in tank T1100, with dilution water added to prevent crystallization. Mother liquor and make-up water are heated to over 50°C using natural gas-fired heaters (50 psia steam for IPM; three heaters for HLD) and injected into the cavern via pumps P001/P002 (IPM) or multiple injection pumps (HLD).
- Stage 2: Two-Stage Crystallization – First stage crystallizer X100/X1100 cools brine from 45°C to 32.5°C via barometric condenser BC100/BC1100. Second stage crystallizer X101/X1101 further cools mother liquor to 13°C using a chiller package (CH100/CH1100) and heat exchanger, producing high-grade KCl crystal slurry.
- Stage 3: Centrifuging and Drying – Product slurry from crystallizer X101/X1101 is fed to screen bowl centrifuge C200/C1200-C1201, delivering a cake with <5% moisture. Rotary dryer D200/D1200 reduces moisture to <0.2%. Exhaust gases are treated in baghouse BH200/BH1200 for dust collection.
- Stage 4: Compaction and Glazing (Full-Scale HLD Only) – Dried product is compacted via compactors CC1401-CC1402 and flake breakers, then screened. Oversize is gently crushed in CagePaktors. Granular product receives 1.5% w/w water in glazing screw SC1501, then cooled to 80°C in a fluid bed dryer-cooler. Polishing screens ensure final product size.
- Stage 5: Product Storage and Loading – Granular and soluble products are conveyed to storage via tripper belt conveyors. Reclaim uses loaders and bucket elevators, with a loading weigh bin system for railcar or truck loading. Dedust and amine treatment are applied to meet quality specifications.
Additional Interesting Data and Summary
The Disley Project’s recovery methods are underpinned by comprehensive mass balances developed for both the IPM and full-scale HLD plants. The IPM mass balance sizes equipment for 125,000 t/a while the HLD wet-end mass balance supports 500,000 t/a per plant, based on an average ore grade of 33.66% KCl, 0.55% Carnallite, 6.64% insolubles, and remainder NaCl. The two-stage crystallization system incorporates heat recovery via a barometric condenser, reducing the heating load for brine injection – a key energy efficiency measure. Utility systems include instrument and plant air dried to -40°C dew point, fresh water from a potable well, and amine/dedust oil treatment at 60°C for product conditioning. The full-scale HLD plants produce 100% granular MOP with a compaction circuit that includes flake breakers, CagePaktors, and glazing at 1.5% water addition, followed by fluid bed drying to 80°C. Dust collection is managed by baghouses (BH1501, BH1502) with exhaust stacks. Environmental considerations are evident in the closed-loop brine recycling: mother liquor is returned to injection wells, and purge brine is sent to disposal wells only when necessary. BPC plans to test the Vortex Crystallizer during IPM operation, which could reduce CAPEX and OPEX significantly. Economically, the staged approach minimizes risk and allows process optimization before full-scale development. The project also benefits from existing rail infrastructure (Figure 18.2) and proximity to markets. Looking ahead, the dual HLD mines (West and East) will double capacity, positioning Buffalo Potash Corporation as a significant producer in the Saskatchewan potash basin. The commitment to energy recovery, reduced water usage, and innovative crystallization aligns with industry sustainability trends. With a 330-day operating schedule and robust equipment sizing based on proven supplier data, the Disley Project is poised for reliable, high-efficiency potash recovery.
Key Processes: Crushing
Target Commodities: N/A
