Case Study: Potash Development Project in Turkmenistan

Addressing Challenges in Mine Development and Production

Overview

This case study highlights the strategic interventions undertaken to address significant challenges faced by a potash mine in Turkmenistan. The site, initially designed to operate at full nameplate capacity of >1 million tonnes finished product, was producing only 20%, resulting in reduced efficiency and profitability. The client faced multiple issues, including incomplete construction and mine development, insufficient geological knowledge, declining mineral reserves, and inconsistent grades of raw minerals supplied to the processing facility.

Challenges

• Incomplete construction and mine development project delivery.

• Site operating at only 20% of its nameplate capacity.

• Low geological knowledge and understanding of the underlying issues.

• Decreasing availability of mineral reserves.

• Significant variation and lower-than-expected grade of raw mineral supplied to the processing facility.

• Engagement of various EPM contractors without definitive solutions, leaving the client uncertain of the optimal path forward.

Actions Taken

A systematic approach was adopted to address the identified challenges:

• Conducted a comprehensive site audit and gap analysis to pinpoint issues and inefficiencies.

• Presented findings to the client and emphasized realistic timelines for a turnaround.

• Highlighted the importance of geological exploration and modelling to better understand the mineral reserves and mitigate variability.

• Calculated and emphasized the need for underground mine development to access new reserves.

• Reviewed and re-drafted contracts with service providers to ensure alignment with project goals.

• Acted as the engineering representative, providing technical and strategic oversight.

• Designed a simplified turnaround and project redevelopment plan to propose a feasible path forward.

Outcomes

While the project is still ongoing, the client is now equipped with a clearer understanding of the issues and actionable steps for improvement. The foundation has been laid for a potential increase in production capacity, improved reserve management, and greater operational efficiency.

Conclusion

This case study demonstrates the value of proactive and data-driven decision-making in overcoming complex industrial challenges. By emphasising geological exploration, streamlined processes, and clear contract management, our team has positioned the client for greater certainty in their future.