Cleveland Potash
Case Study: Cleveland Potash — Lithium Battery Storage at Boulby Mine (UK)
This case study documents a deployment of Phoenix battery safes at a UK mining operation. Phoenix Safe Company is Battery Safes Australia’s manufacturer and supply partner. The same product range is available to Australian mining and resources operators through Battery Safes Australia.
Background
Boulby Mine, operated by ICL Group as ICL UK, is one of the UK’s most significant potash and salt mining operations. Located in East Cleveland, the mine covers approximately 8,200 hectares and has been continuously operational since the late 1960s.
In mid-2023, the team at Cleveland Potash identified a growing operational risk: lithium-ion batteries were becoming central to their mining activities, but their existing storage arrangements weren’t built to manage the hazards those batteries introduced. Thermal runaway, toxic gas release in a confined underground environment, and the physical demands of a working mine site all pointed to the need for a purpose-built solution. Phoenix Safe was engaged to assess the requirement and propose a fit-for-purpose approach.
THE CHALLENGE –
Safety and Reliability Concerns
Cleveland Potash’s existing storage methods were inadequate for lithium battery management at scale. The specific concerns included thermal runaway risk leading to uncontrolled fire, toxic gas release in the event of a battery incident, and the need for units robust enough to withstand the physical demands of an active mine environment — including forklift handling and rough operational conditions.
They required a solution that combined secure containment, advanced fire suppression, and practical durability for a demanding industrial site.
The Solution
Phoenix Safe supplied their Battery Commander lithium-ion storage cabinets, configured for high-volume industrial battery storage. The deployment included an automatic fire suppression system using potassium nitrate and potassium carbonate — effective in oxygen-depleted environments and specifically suited to enclosed underground facilities. Units were engineered to withstand the physical demands of forklift handling and high-traffic operational zones.
The Outcome
Cleveland Potash successfully transitioned their battery storage to a certified, purpose-built solution. The deployment gave their safety team a defensible, documented approach to lithium battery risk management — critical for a site operating under strict UK health and safety obligations.
Relevance for Australian Mining Operations
Australian mining and resources operators face identical challenges. Lithium battery use across underground and surface mining operations is growing rapidly — from cordless equipment and survey tools to communications systems and UAVs. WorkSafe obligations under Australian WHS legislation require organisations to manage battery storage as a formal hazard.
Battery Safes Australia supplies the same Phoenix battery safe range to Australian mining operators. We can provide specification sheets, compliance documentation, and site-specific advice for operations across WA, QLD, NSW, and nationally.
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