General discussion, page-12176

Using data from the WA1 Metallurgical Results andcommodity indexes, this analysis presents what the phosphate by-product wouldlook like for a 2 million tonnes per annum (MTPA) plant.

The only estimate madeis for the OPEX, as the phosphate concentrate is treated as a"by-product." Consequently, no OPEX is attributed to the stepsleading up to beneficiation

Step 1: Ore Feed Parameters (Excluding from OPEX)

• Ore Input: 2,000,000 tonnes
• Feed Grade: 24.9% P₂O₅

Step 2: Beneficiation Process (Excluding from OPEX)

Objective: To concentrate the phosphate content from the ore, increasing the P₂O₅ percentage.

Key Parameters:

• Phosphate Recovery Rate (after beneficiation): 65.2%
• Concentrate Grade: 37.6% P₂O₅

Outcome:

1. Total P₂O₅ in Ore: 498,000 tonnes
2. Recovered P₂O₅ (after beneficiation): 324,696 tonnes
3. Phosphate Concentrate Output: 863,026 tonnes

Step 3: Conversion of Phosphate Concentrate to PhosphoricAcid (H₃PO₄)

Objective: To convert the concentrated phosphate into phosphoric acid, which is the precursor to DAP.

Chemical Reaction:

P₂O₅ + 3 H₂O → 2 H₃PO₄\text{P₂O₅ + 3 H₂O → 2 H₃PO₄}P₂O₅ + 3 H₂O → 2 H₃PO₄

Outcome:

1. Phosphoric Acid (H₃PO₄) Produced: 446,332 tonnes

Step 4: Ammoniation to Produce DAP

Objective: To react the produced phosphoric acid with ammonia (NH₃) to form Diammonium Phosphate (DAP).

Chemical Reaction:

H₃PO₄ + 2 NH₃ → (NH₄)₂HPO₄ (DAP)\text{H₃PO₄ + 2 NH₃ → (NH₄)₂HPO₄ (DAP)}H₃PO₄ + 2 NH₃ → (NH₄)₂HPO₄ (DAP)

Outcome:

1. Ammonia (NH₃) Needed: 155,828 tonnes
2. DAP Produced: 601,454 tonnes

Step 5: Sulfuric Acid Requirement

Objective: To determine the amount of sulfuric acid (H₂SO₄) needed to produce phosphoric acid.

Chemical Reaction:

Ca₅(PO₄)₃F + 5 H₂SO₄ + 10 H₂O → 3 H₃PO₄ + 5 CaSO₄\cdotp2H₂O + HF\text{Ca₅(PO₄)₃F + 5 H₂SO₄ + 10 H₂O → 3 H₃PO₄ + 5 CaSO₄·2H₂O + HF}Ca₅(PO₄)₃F + 5 H₂SO₄ + 10 H₂O → 3 H₃PO₄ + 5 CaSO₄\cdotp2H₂O + HF

Outcome:

1. Sulfuric Acid (H₂SO₄) Needed: 744,732 tonnes

Step 6: Cost Calculations

Market Prices:

• Price of Ammonia (NH₃): AUD$600 per tonne
• Price of Sulfuric Acid (H₂SO₄): AUD$60 per tonne
• DAP Sale Price: AUD$825 per tonne

Step 7: OPEX Breakdown (Post-Beneficiation)

1. Raw Materials Costs (Ammonia and Sulfuric Acid)

• Ammonia Cost:
  • 155,828 tonnes × AUD$600 = AUD$93,496,800
• Sulfuric Acid Cost:
  • 744,732 tonnes × AUD$60 = AUD$44,683,920
• Total Raw Materials Cost: AUD$138,180,720

2. Energy Costs:

• Estimated Cost: AUD$27.6 million to AUD$34.5 million

3. Labor Costs:

• Estimated Cost: AUD$13.8 million to AUD$20.7 million

4. Maintenance and Repairs:

• Estimated Cost: AUD$6.9 million to AUD$13.8 million

5. Consumables:

• Estimated Cost: AUD$4.1 million to AUD$6.9 million

6. Environmental Compliance:

• Estimated Cost: AUD$6.9 million to AUD$13.8 million

7. Logistics and Transportation:

• Estimated Cost: AUD$6.9 million to AUD$13.8 million

8. Insurance and Miscellaneous:

• Estimated Cost: AUD$2.8 million to AUD$5.5 million

Step 8: Total OPEX (Post-Beneficiation)

OPEX Range:

• Lower Estimate: AUD$206.2 million
• Upper Estimate: AUD$246.2 million

Step 9: Revenue and Profit Calculation

Total Revenue from DAP:

• 601,454 tonnes × AUD$825 = AUD$496,199,550

Total Profit:

• Total Profit Range:
  • Lower Estimate: AUD$496,199,550 - AUD$246.2 million = AUD$250 million
  • Upper Estimate: AUD$496,199,550 - AUD$206.2 million = AUD$290 million

Summary:

Process Overview (Post-Beneficiation)

• Phosphoric Acid Produced: 446,332 tonnes
• Ammonia Needed: 155,828 tonnes
• Sulfuric Acid Needed: 744,732 tonnes
• DAP Produced: 601,454 tonnes

Financial Summary in AUD:

• Total OPEX: AUD$206.2 million to AUD$246.2 million
• Total Revenue from DAP Sales: AUD$496,199,550
• Total Profit: AUD$250 million to AUD$290 million

First time looking into a fertilizer plant, happy for anyone to sift through and point out any errors I have made.

Enjoy