PotashCorp

PotashCorp Gets Larger Capacity, Smaller Footprint and BIG Results From Rotex Mineral Separator™

Manufacturers aren’t usually enlisted to assist in designing the equipment that goes on their plant floors. But in an unusual turn of events, the PotashCorp of Rocanville, Saskatchewan became an important contributor of ideas that helped shape the new ROTEX Mineral Separator™ they eventually bought. At the same time the PotashCorp was looking for a mineral separating screener that delivered more than their current machine, Rotex, Inc. was enlisting input from its customers in the design of a new, state-of-the-art separator for minerals markets. The two came together in a cooperative venture that benefited them both. “This was a situation where Rotex was the home team in the bottom of the ninth and needed one run to win,” says Terry Daniels, PotashCorp of Rocanville Mill General Foreman. “And with two strikes and two outs, they hit a home run to win the game.”

PotashCorp of Rocanville, which is located in Saskatchewan, Canada, is the largest single producer of agriculture fertilizer.

In an effort to respond to changes in the market, Rotex had launched a campaign to build a new minerals separator. “We knew that to stay competitive in the minerals industry, we had to upgrade our product offerings with newer technology,” says Scott Haley of Rotex. “So rather than guess what best suited our customers’ needs, we decided to ask them.” In a program called Voice of the Customer, Rotex engineers enlisted feedback from manufacturers across the industry. It was a tedious, time-consuming process, but it gleaned valuable information that Rotex used to begin developing initial designs. It was also good timing for the PotashCorp of Rocanville, because they were actively exploring new mineral separation technology. And like many other stories involving opportunity—timing was everything.

When Motivation & Minds Work Together

PotashCorp of Rocanville, which is located in Saskatchewan, Canada, is a division of PotashCorp the largest single producer of agriculture fertilizer. The Rocanville plant employs approximately 360 people and is a preferential supplier of Potash to North America. The division manufactures two primary products—granular and standard potash.

PotashCorp of Rocanville was also a valued Rotex customer and the two enjoyed a close working relationship. At the time, the plant was using Rotex 522 screeners in its production operations—a longstanding industry workhorse. They trusted Rotex quality and commitment to customer service and the mineral separator project that Rotex was working on held great potential for improving Rocanville’s production capabilities. The fact that Rotex was seeking its input on the design of a new machine made it even more attractive. “They pretty much asked us to give them a wish list of everything we wanted a minerals separator to include,” says Daniels. “And this gained our interest because they were addressing important issues that we felt would help us achieve our objectives. Their success would advance our efforts and further our success.”

Those efforts involved gearing up for an expansion program. And it included exploring new technology their current machines lacked. “Our expansion plans centered around two important needs,” says Daniels, “a higher capacity screener, but in a compact footprint that maximized the use of our floor space. Rotex seemed sincerely interested in designing a machine that addressed those needs along with several other ones too. But whether or not they could meet our timetable was another thing.”

	The Rocanville plant manufactures two primary products — granular and standard potash.

A Separator Success for Potash Producers

Although Rotex enlisted feedback from manufacturers across the minerals industry, Rocanville’s expansion plans increased motivation from both sides and encouraged a closer working relationship on the project. Representatives from Rocanville visited Rotex to examine and provide feedback on initial designs and Rotex made the project a priority and placed it on a fast track in order to meet Rocanville’s schedule. As a result, the new Rotex Mineral Separator™ was built in record time and incorporates many new made-to-order features that are a result of Rotex’s Voice of the Customer campaign.

Specifically designed to meet the demanding screening requirements of mineral applications, the Rotex Minerals Separator™ provides unsurpassed screening performance when sharp separations and high efficiencies are required. Its multiple, stacked deck provides higher capacity in a smaller footprint and new, easy screen access permits a single screen change in minutes. The external drive is easily accessible and has been redesigned with fewer moving parts for less maintenance. Furthermore, the unique elliptical-linear motion provides superior screening performance. The Rotex Minerals Separator™ maximizes product recoveries at material temperatures up to 400 degrees F. “The Rotex Minerals Separator™ delivers high performance in a design that is easy to maintain,” says Daniels. “That’s a great combination for any production facility.”

After successful beta testing, PotashCorp of Rocanville ordered a fleet of new Rotex Mineral Separators™.

Coming Through in the Clutch

Of course, in any competition, the measure of a true champion is coming through in the clutch. It was at this big moment that Rotex delivered a game-winning stroke. “We had explored other equipment and advanced to the point of selecting another supplier and were just short of issuing a purchase order number,” says Daniels. “But a delay on our end and a final push forward on Rotex’s end made the final outcome on this project a win for both of us.”

After successfully testing a Rotex Beta model in its facility, PotashCorp of Rocanville ordered a fleet of new Rotex Mineral Separators™ for its operation. In doing so, they increased their production capacity from an ability to produce 40% granular to a plant that could product 60% granular at 23% higher through-put, and still conserve floor space. “The Rotex Minerals Separator™ has performed above our expectations,” says Daniels. “And Rotex has continued to stand behind and support their product in a way that not only enhances our business, but says that we are an important customer.”