Phosphates can present a number of challenges to processors. From its abrasive nature, to the variance throughout the phosphate rock deposit, phosphate processors need to be prepared for the issues they may face. This presentation looks at many of the problems that can come up when processing phosphates, as well as how to combat those issues.

1. Processing Phosphates
Experts in process design and material
processing for over 65 years.
Challenges in

2. Phosphorus is essential to all life on Earth. Its
life-giving properties are key to a variety of
cellular and biological processes that allow
plants, animals, and even humans to grow
strong and healthy.

3. Just as with any mineral, phosphates can
present challenges during processing,
requiring careful planning and preparation
to ensure process efficiency and prolong
equipment life.

4. Just as with any mineral, phosphates can
present challenges during processing,
requiring careful planning and preparation
to ensure process efficiency and prolong
equipment life.
The following covers some of the key issues
processors face when working with
phosphates.

5. Material
Characteristics

6. Abrasiveness
Depending on what form they’re in,
phosphates can be anywhere from
mildly to extremely abrasive.

7. Abrasiveness
Depending on what form they’re in,
phosphates can be anywhere from
mildly to extremely abrasive.
Abrasiveness can pose problems to
unprotected equipment. Equipment
should be designed with this in mind.

8. Dusty
Phosphate products can also be
dusty, making for difficult handling.
This is especially true of phosphate
rock upon drying.

9. Dusty
Phosphate products can also be
dusty, making for difficult handling.
This is especially true of phosphate
rock upon drying.
These fines are commonly collected in
a baghouse. And while difficult to
handle, the agglomeration of fines
offers opportunity to more easily
reintroduce fines to the process.

10. Corrosiveness
Corrosive agents are commonly added
during the production of phosphate
products.

11. Corrosiveness
Corrosive agents are commonly added
during the production of phosphate
products.
Phosphoric acid, the base of many
phosphate products, is highly corrosive.

12. Corrosiveness
Corrosive agents are commonly added
during the production of phosphate
products.
Phosphoric acid, the base of many
phosphate products, is highly corrosive.
Specialty alloys and linings on equipment
are often necessary to protect against
corrosion.

13. Clumping
Phosphate products can also be prone
to clumping and causing buildup, which
can clog equipment.

14. Clumping
Phosphate products can also be prone
to clumping and causing buildup, which
can clog equipment.
Modifications can be made to
counteract clumping, such as the
addition of knocking systems to
rotary dryers.

15. Variability
Phosphate deposits are extremely
diverse. From one deposit to the next,
and even within the same deposit,
phosphate ore differs greatly in makeup.

16. Variability
Phosphate deposits are extremely
diverse. From one deposit to the next,
and even within the same deposit,
phosphate ore differs greatly in makeup.
This means that a one-size-fits-all
approach to processing often does not fit
within the phosphates industry.

17. Contamination
Phosphate rock is sometimes found in the
presence of organics, rendering it
contaminated. As-is, the phosphate rock
is low value and not usable for many
applications.

18. Contamination
Phosphate rock is sometimes found in the
presence of organics, rendering it
contaminated. As-is, the phosphate rock
is low value and not usable for many
applications.
However, the phosphate ore can be
“upgraded” through calcination in a
rotary kiln.

19. Combatting Phosphate
Challenges

20. While challenges in phosphate processing
do exist, there are ways to combat them…

21. Testing
Feasibility/Pilot testing procedures are
often both necessary and desirable
when working with phosphates.
Testing helps to work out process
variables, providing a recipe for process
scale-up and equipment design.

22. From troubleshooting or improving an
existing process, to developing a new
process or product, testing is valuable in
all applications.

23. From troubleshooting or improving an
existing process, to developing a new
process or product, testing is valuable in
all applications.
Testing helps to minimize surprises after
scale-up by gathering important data
and gaining a familiarity with the unique
sample at hand.

24. This is especially true when upgrading
phosphate ore through calcination.

25. This is especially true when upgrading
phosphate ore through calcination.
Because phosphate deposits vary so
significantly, the time and temperature
profiles required to remove the organic
components often differ as well.

26. This is especially true when upgrading
phosphate ore through calcination.
Because phosphate deposits vary so
significantly, the time and temperature
profiles required to remove the organic
components often differ as well.
Testing in batch and pilot kilns allows for
these profiles to be developed in a test
environment.

27. High Quality Equipment
It may sound simple, but high quality
equipment is essential in maintaining
process efficiency and prolonging
equipment life.

28. High Quality Equipment
It may sound simple, but high quality
equipment is essential in maintaining
process efficiency and prolonging
equipment life.
For best results, equipment should be
designed around the unique
characteristics of the specific phosphate
material to be processed.

29. Conclusion
Although phosphates can present a number
of challenges to processors, they can be
overcome through careful planning and
preparation, including thorough testing, and
high quality equipment designed around
the sample at hand.

30. has been working with phosphates for over 65
years, providing testing services, process
design and development, and custom
phosphate processing equipment.

31. Want to learn more?
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Phosphates Processing
Handbook.
Phosphates Processing Handbook
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