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K+S Potash site, Saskatchewan

Delivering Bethune - Saskatchewan's first potash mine in over 40 years

Amec Foster Wheeler is currently delivering the Bethune Mine Project (formerly known as the Legacy Project), Saskatchewan’s first new potash mine in more than 40 years. As KSPC’s design and project management partner, we are responsible for leading an integrated execution team tasked with delivering all aspects of engineering, procurement, construction and commissioning for this solution mine and processing facility. Our work has included the management of complex third-party design-supply technology packages for key components of the plant.

Safety is Amec Foster Wheeler’s top priority. In collaboration with KSPC, we have successfully managed health, safety, security and environmental aspects of the project as it has evolved from a pure green-field site to a fully operational production facility. With a site workforce that peaked above 3,000 people in a complex and changing work environment, it was paramount that every individual contribute to a safe and sustainable workplace. As a result, the project team achieved more than 10 million hours without a lost-time injury, a clear demonstration of what can be accomplished through collective and resolute commitment to HSSE performance.

By applying our innovative capital efficiency principles at the preliminary design stage, significant cost reductions were achieved. We densified the mill’s layout to reduce the building’s footprint and volume by 45%, thereby reducing the installed cost of concrete by roughly $100M. We also implemented modular design principles to maximise opportunities for pre-assembly, including 42 conveyor galleries, 71 pipe rack modules and 27 E‑room modules. Benefits to the project included a smaller construction workforce, reduced construction costs and a shorter timeline to first production.

Location:Saskatchewan, Canada
Client:K+S Potash Canada (KSPC)
Value:Capital cost: 3.1 billion EUR (>4 billion CAD)
Scope:EPCM
Date:2011 to date