Good luck down the mine!

The Zielitz potash works in Saxony-Anhalt is the largest individual facility operated by K+S, and extracts potassium-bearing crude salts for the production of fertilisers as well as products for both industrial applications and the food and animal feedstuff industry. In terms of annual output, the plant is one of the world's largest and most modern potash mines.

K+S and HANSA‑FLEX can look back on many years of cooperation, which has intensified over the years and finally culminated in the first HANSA‑FLEX underground service container. In the beginning, hose lines for the mine were produced at the nearest branch. Each order had to be transported individually, which repeatedly led to unavoidable waiting times due to the strictly timed schedules for the transport of people and materials into the mine – especially in the event of unforeseen repairs. On the basis of a technical study Yves Hummelt, who coordinates external contractors in the mining operations at the K+S plant in Zielitz, investigated how this process could be optimised. He hit on the possibility of producing hydraulic hose lines underground, and entrusted HANSA‑FLEX with the practical implementation of the project. The aim from the outset was to exploit synergies and to recoup the costs, which were mainly incurred by HANSA‑FLEX, as quickly as possible. 

“You can't get any closer to the customer than with an underground service container,” explains Christian Josef Falkner, Service Manager in the Service Container department at HANSA‑FLEX. The hydraulic specialist's service containers are used all over the world wherever mines or tunnel construction sites are difficult to access and an immediate supply of spare parts is essential. At a depth of 600 m in the potash-salt mine, a location was found that had the necessary infrastructure (electricity, compressed air, internet) and fast access to the extraction zone. Setting up a 37 m² service branch in the mine was new territory for everyone involved. The limiting factor here was the size of the shaft through which the entire transportation of people and materials takes place. The branch consists of three containers, each of which had to be shortened by one metre for transport purposes. HANSA‑FLEX carried out the assembly of the containers in the mine and their complete outfitting itself - right down to the typical illuminated sign and the HANSA‑FLEX banners. “Meticulous preparation was essential, because if a screw is missing, you can't just make a quick trip to the nearest DIY store,” jokes Eduard Hecht, specialist consultant for service containers at HANSA‑FLEX.

The technical equipment with tools and machines as well as the stock of hydraulic hose lines and fittings to be stored there were customised precisely to the requirements of the customer K+S. “Over the years, every branch specialises in its customers. For the initial equipment of the service branch in the potash salt mine, we took into account the customer’s orders in recent years as well as our experience from other projects in mines,” reports Tobias Gold, the HANSA‑FLEX sales representative responsible for the plant. The online connection to the SAP merchandise management system ensures that used materials can be re-ordered in good time.

The focus of our deepest service branch is on the preventive maintenance of the colossal vehicles used to extract the potash salt in Zielitz. Three-shift operation, lots of dust, salt and temperatures of up to 45 °C impose the highest demands on the hydraulics - and on the HANSA‑FLEX technicians. The massive mining machines, including wheel loaders with a bucket capacity of up to 21 tonnes and an operating weight of almost 60 tonnes, have their own maintenance areas with a pit and crane near the service branch. “The HANSA‑FLEX technicians do a very good job underground. The maintenance requirements are planned by K+S. HANSA‑FLEX is then entrusted with the work projects within the framework of a service contract. Efficient communication is the key to success here, and this works extremely well at all levels,” says Hummelt with satisfaction. 

When it comes to repairs at short notice, the service branch can really show what it is capable of. The HANSA‑FLEX technicians drive directly to the site in their pick-up truck, remove the defective hose line, produce a new one and install it on the spot. “If a mobile production machine is out of action this can cause serious downtime costs, as it can affect the entire process both above and below ground. Thanks to HANSA‑FLEX's on-site service, we can minimise downtimes,” comments Hummelt. The distances covered are sometimes considerable: the network of tunnels in the potash salt mine is roughly equivalent to that of a nearby city. As the routes in the mine follow the salt seam, gradients of up to 28% are commonplace, and an off-road vehicle is essential. Speaking of driving, before our colleagues were allowed to get behind the wheel themselves, they had to undergo extensive instruction in an underground driving school vehicle - including a theory and practical test.

“With this branch at a depth of 600 metres, HANSA‑FLEX has taken the concept of service to a new level. We are seeing the benefits of this project day by day and are planning to improve the efficiency step by step, for example by extending it to other shifts,” summarises Hummelt. In the opinion of HANSA‑FLEX Project Manager Tobias Gold, team spirit has been the key to the success of this unique project. “We formed a really powerful team with experts from various locations, and were able to draw on the extensive expertise of the international HANSA‑FLEX network. The partnership-based cooperation with our customer K+S has also made a significant contribution towards turning this idea into reality.”