The project is designed as a solution mining operation using a proven dual-well process developed in Germany. As illustrated in Karnalyte’s solution mining reference diagram, two boreholes are drilled to the base of the potash deposit, an oil control blanket is established to support horizontal dissolution, and water is injected below the target layer until the boreholes interconnect. The oil blanket is then raised to allow mining of the potash-bearing zone, where hot water preferentially dissolves carnallite at a materially faster rate than salt.
This process is important because it supports modular development, staged capital deployment, a smaller surface-based workforce, shorter timelines to production and a lower environmental footprint relative to conventional underground mining. Phase 1 requires approximately 18 active caverns, with additional caverns prepared as production expands through Phases 2 and 3. The mine plan is designed to maintain a sylvinite-to-carnallitite brine ratio between 25:75 and 10:90 to support consistent plant operation and product quality.
Figure: Karnalyte Dual-Well Solution Mining Process