REPROCESSING AND RETREATMENT
technology, it is possible to process materials of
very different types and consistencies without
any problems; for example in order to produce
granulates from slurries under the addition of dry
materials.
“In the process, agglomerates are
disintegrated in the best possible way so that the
end product offers an excellent quality of mix,
even if auxiliary substances such as chemicals
are added in the ppm range. The good self-
cleaning effects and the system-related low wear
of the mixer are often important aspects.”
In addition to mixers that operate on a batch
basis, EIRICH sees the advantage of using
“continuous” mixers.
“For example, it has been shown in the
processing of tailing mounds from magnesite
production that these mixers offer significant
process and cost advantages. One of the
advantages here is that – unlike in batch mode –
there is no time needed for filling and emptying.
In addition, smaller mixers with lower input
power can be used,” the company said.
EIRICH’s mixing technology also brings
advantages to other recycling tasks, including
waste processing, landfill engineering and the
reprocessing of contaminated sites.
“Examples include the agglomeration of dust
from steelworks for recirculation to the sintering
“The super-phosphoric acid also contained
toxic phosphogypsum waste during continuous
operation of its new demonstration plant in the
US.
The Improved Hard Process – or IHP – for
producing phosphoric acid for agricultural and
industrial use, the company says, “is one of the about 2 ppm of cadmium, with about 80-90% of
cadmium in the phosphate feed being eliminated
during the process and captured in pollution
control scrubbing systems. The process also
significantly reduces levels of other trace heavy
most significant advancements in many decades
for the phosphate industry”.
The technology is a kiln-based process that metals, such as lead and arsenic,” the company
said.
Timothy Cotton, CEO of JDCPhosphate, said
avoids direct acidulation of phosphate rock,
minimising the amount of waste and “completely
avoiding” phosphogypsum production,” JDC this process development was a major milestone
for JDC and its technology, “showcasing IHP’s
value as a cost-efficient and scalable new
said. “Instead, IHP co-produces a commercially
useful aggregate for construction and road
building called J-Rox.”
During recent operations at its demonstration
plant in Fort Meade, Florida, JDC was able to process”.
He said: “Given the limited phosphate rock
reserves in the world, it will be critical for future
generations that we waste as little as possible of
operate its entire process continuously –
including feed preparation and agglomeration,
induration, reduction, oxidation, and acid
production – to produce the product using
phosphate rock waste tailings from local mining
operations.
The company said: “The phosphate raw
material contained an average of about 14%
phosphate as P 2 O 5 , with high levels of silica and
other impurities, including magnesium oxide. The
company combined this low-quality phosphate
material with clay and petroleum coke to make
these vital resources. At the same time, we need
to minimise the production of toxic
phosphogypsum wastes and reduce the level of
harmful impurities in phosphate products. The
IHP technology will become a critical part of the
global phosphate production chain.”
JDC is now further upgrading its commercial
demonstration plant for on-demand and
sustained operations. By early 2019, the
company planned for the Fort Meade plant to be
capable of testing various qualities of phosphate
ore raw material, allowing potential licensees to
validate the process for the phosphate ore and
silica sources they have available. JDC will then
complete its process design engineering for
conveyor or for addition to reduction processes,
or for the agglomeration of converter dusts
containing zinc for input into the Waelz process,”
EIRICH said. “Special mixer designs are used for its kiln feed.”
The feed was then processed in the kilns and
acid plant at the demonstration plant to produce
super-phosphoric acid at a concentration of 68% the processing of contaminated soil or – in the
form of so-called vacuum mixers – for the drying
of paint/enamel sludge with explosion P 2 O 5 with less than 2.5% impurities, including
less than 0.3% CaO, 0.2% MgO, 0.3% SO 4 , 1.0% commercial-scale applications of the IHP
technology.
The company also is exploring optimal routes
to commercialisation of IHP, including expanding
Fe 2 O 3 , 0.1% F and 0.1% Al 2 O 3 . its operations in Florida. IM
protection.”
In addition, heated mixers are
available for special applications
(up to 250°C), EIRICH said.
EIRICH concluded: “Every mixer
is specially designed for the
relevant purpose. The company’s
internal test centres are available
all around the world for the
performance of customer trials so
that process parameters can be
defined. EIRICH can also supply
suitable rental mixers for
subsequent upscaling tests,
allowing the cost-effectiveness of
the preparation process to be
tested at a larger scale.”
Building your digital ecosystem
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Rock retreatment
JDCPhosphate recently used its
patented Improved Hard Process
technology to produce high-
quality super-phosphoric acid
(SPA) from low-quality phosphate
rock tailings without creating
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MAY 2019 | International Mining 13