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% Pâ‚‚Oâ‚…
Step 2: Beneficiation Process (Excluding from OPEX)
Objective: To concentrate the phosphate content from the ore, increasing the Pâ‚‚Oâ‚… percentage.
Key Parameters:
- Phosphate Recovery Rate (after beneficiation): 65.2%
- Concentrate Grade: 37.6% Pâ‚‚Oâ‚…
Outcome:
- Total Pâ‚‚Oâ‚… in Ore: 498,000 tonnes
- Recovered Pâ‚‚Oâ‚… (after beneficiation): 324,696 tonnes
- 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:
- 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:
- Ammonia (NH₃) Needed: 155,828 tonnes
- DAP Produced: 601,454 tonnes
Step 5: Sulfuric Acid Requirement
Objective: To determine the amount of sulfuric acid (Hâ‚‚SOâ‚„) 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:
- Sulfuric Acid (Hâ‚‚SOâ‚„) Needed: 744,732 tonnes
Step 6: Cost Calculations
Market Prices:
- Price of Ammonia (NH₃): AUD$600 per tonne
- Price of Sulfuric Acid (Hâ‚‚SOâ‚„): 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
(20min delay)