Phosphate Rock

Formula for rock is CaF2.3Ca3 (P04)2 or Ca10F2(P04)6 Tri calcium phosphate. Its chemical name is Fluorapatite This compound is totally insoluble in water. Its trading is done by the name of Bone phosphate of lime (BPL) Grounded rock is directly applied on acidic soil, but out -put is not good. The rock is made water soluble by treatment of acid. Rock is used for manufacture of, i. Fertilizers, ii.Phosphoric acid, iii. Super phosphates, iv. Phosphorus, and phosphorus compounds.

Phosphatic Fertilizers
Phosphate Fertilizers The best use of phosphate rock is in the manufacture of single and triple super phosphates and other phosphate derivatives including phosphoric acid. The acidulation of phosphate rock to produce super phosphates has been the most important method to make phosphate available for fertilizer purposes The phosphate rock formula is CaF2.3Ca3 (P04)2 and overall reaction is as follows, Ca F2.3Ca3 (P04)2+7H2S04+3H20 -- 3CaH4(P04)2. H2O + 2HF + 7CaS04 (mono calcium phosphate)

Phosphate Rock

Grinded Phosphate Rock

Phosphate rock Reserves

Transportation of rock

Phosphorus Rock
A good phosphate rock must have following properties, 1. P205 content above 33%, 2. less CaC03 & Gypsum and Silica, 3. Nil toxic elements, 4. Less other chemical impurities, 5. must be soft , and 6. less than 1% moisture and impurities

Phosphatic Fertilizers

Single supper phosphate

The product produced contains 16 to 20% available P205 and it contain 50% active CaSO4, which is good for reclamination of soil. The manufacture of SSP involves the following four steps. 1. preparation of rock, 2. Mixing rock with acid, 3.Curing and drying of original slurry by completing the reaction, 4.Excavation, milling and bagging of the product. All plants, first pulverize rock. The rock is grounded to an average of 70 to 80% through 200 mesh screen, with the following benefit. 1. reaction rate become faster, 2. More efficient use of acid (less use). 3. A higher grade of product is achieved.

Single super phosphate

The rock is acidulated with acid (H2SO4) to produce SSP. Insoluble phosphorus is made soluble in water for plant . The stage wise reactions are; i. Ca3(PO4)2 +H2SO4 + 4H2O CaH4(PO4)2 + 2(CaSO4 . 2H2O) ii. CaF2+H2SO4+H2O CaSO4.2H2O + 2HF iii. 4HF + SiO2 SiF4 + 2H2O iv. 3Si F4 + 2H2O SiO2 + 2H2SiF6 i. An excess of H2S04 is used by the impurities present in the phosphate rock like CaC03, Fe203,Al203 and CaF2.& SiO2

Super Phosphate
Following is a more probable expression of the main reaction. CaF2.3Ca3(PO4)2 + 7H2SO4 + 3H2O (Phosphate rock) 3Ca H4(PO4)2.H2O + 2HF (gas) + 7CaSO4. (Monocalcium Phosphate)

Flow sheet for SSP

SSP plant

Single supper phosphate plant

TSP
Triple Super phosphate. (TSP) This fertilizer is three times more concentrated than SSP, containing 45 to 46% P205, which is available to plant. TSP is made by the action of H3P04 on phosphate rock. No CaS04 (Gypsum) is formed in this process.

TSP
The reaction for the manufacture of TSP is, CaF2.3Ca3(P04)2 +14 H3P04 10Ca(H2P04)2 + 2HF Process - The pulverized rock is mixed with H3P04 in a reactor. The resultant slurry is sprayed into the granulator along with recycled fines from the process. The products from the granulator, is dried, screened, over sizes are crushed and cooled.
THE FINISHED PRODUCT IS CONVEYED TO THE

STORAGE, where the product is cured for 4 to 6 week , before packing and dispatched to market.

TSP
During this time, which is four to six weeks in the storage, the reaction between rock and acid is completed and P205 availability is increased Exhaust gases from the process are scrubbed with water to remove SiF4. Non-granulated TSP is also available, which is prepared by using cone- mixer and conveyer belt only. The setting time for TSP is only 14 to 20 minutes.

Flow sheet of Non-granulated TSP

Powder TSP Production Plant

TSP Manufacturing Process

Grounded rock is mixed with H3PO4 acid. The resultant slurry is sprayed into granulator along with recycled fines. The product from granulator is dried , screened, the over sizes crushed and cooled. The final product is conveyed to store for curing for 4 to 6 weeks. During this period the reaction is completed. The exhaust gases are scrubbed in a scrubber to remove SiF4.

TSP is an acidic fertilizer having 46% P2O5

TSP manufacturing Plant

Di ammonium phosphate (DAP)

DAP is a concentrated fertilizer containing 18% N2 and 46% phosphorus in the form of P205. Vapors or anhydrous liquid NH3 and H3P04 acid (40 to 50%) are continuously fed to an agitated tank, called preneutralizer vessel. The heat of reaction heats up the mass, evaporating app. 100Kg of water per ton of product. The reaction ratio is maintained at 1.5 moles of NH3 per mole of H3P04 acid. This ratio is optimum for maintaining fluidity of the slurry.

DAP Manufacturing Plant.

DAP Processing Diagram

Flow sheet for DAP

DAP
The slurry formed in the preneutralizer flows into a ammoniator Granulator at 120c, where it is distributed evenly over the bed of solid materials and is made to react with additional NH3, which is supplied under the bed from a distributor to complete the reaction. Dried recycled material from product screening is used to control the moisture. The ammomitor combined the function of chemical reactor, mixing and proper size and shape of granular particles.

DAP
The dryer reduce the moisture content of the product to 1.0%. After cooling the product, in a counter current air flow rate, the product is stored in bulk storage. The exhaust gases are scrubbed by incoming H3P04 acid This complete the process of manufacturing of a concentrated fertilizer called DAP. Di ammonium phosphate

Rock crushing

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Hammer Crushers

Hammer Crushers

Ball Mill

Rock Crushers

Roll Mill

Granulation/prilling

Moderate Cost Easy to Operate Hard Granules Less Dusty-no Caking Normal Size 2-4mm Less Corrosion Problems More Common Nowa-Days Can be Used for Making NPK Graduals Good for Blending with Other Fertilizers

Low Cost Easy to Operate Hard Graduals Less Dusty-no Caking Graduals Sizes 411mm Less Pollution Problems Can be Used for Blending with Other Fertilizers Limited Use

High Cost Expensive to Operate Hollow Prills Dusty-More Caking Prills 1-2mm Big Pollution Problems Not Good for Blending Cannot be Used for Making NPK