The Phosphate ore is extracted by surface miners or by bulldozers and excavators. Overburden is being removed by scrapers to mined out pads for reclamation. Extracted ore is placed into articulated dump trucks and hauled to the beneficiation site.
Phosphate ore is being beneficiated in a mobile processing unit to increase the average level of P2O5 content to approximately 17%. Beneficiation is done by crushing phosphate ore and passing it through a series of screens.
Sulphuric Acid Plant
- Sulphuric acid is produced from elemental sulphur using a conventional technology.
- Electricity generation facilities and steam distribution facilities will utilise waste heat from the production of sulphuric acid and convert it to electricity that will be used by the Project.
- The Company intends to adopt a modular approach and plans to construct two 4,100tpd Monsanto-type sulphuric acid plants that will have a combined annual design capacity of approximately 2.7 million tonnes of sulphuric acid (H2SO4) sufficient to produce 824,900 tonnes of phosphoric acid in P2O5 equivalent per annum.
Phosphoric Acid Plant
The phosphoric acid plant uses sulphuric acid digestion of phosphate rock to produce phosphoric acid. The sulphuric acid reacts with 17% P2O5 concentrate to produce weak phosphoric acid. Direct acid leaching of low-grade 17% concentrate avoids conventional froth flotation what results in cost reductions for the Project when compared to other producers.
In order to produce DAP and MAP, the content of metal oxides equivalents (Fe2O3 + Al2O3 + MgO) in produced phosphoric acid (MER) should not exceed a certain level. The phosphoric acid must have MER no more that 0.09 to be able to be converted into DAP and no more that 0.12 to produce MAP.
Diammonium / Monoammonium Phosphate Granulation Plant
To produce DAP or MAP, phosphate liquid ammonia and phosphoric acid are reacted. Received wet DAP/MAP is then granulated.
The DAP/MAP phosphate granulation plant will have an annual capacity of 1.76 million tonnes of diammonium phosphate.
At full capacity, the plant would consume approximately 400,000 tonnes of liquid anhydrous ammonia per year, which is currently assumed will be imported from Russia, Uzbekistan, or other sources and not produced on site.