The 16th Annual Regional Phosphate Conference

Florida Phosphate: Moving Ahead

Thursday Oct. 18 and Friday Oct. 19, 2001

Sponsored by

Society for Mining, Metallurgy and Exploration (SME)
American Institute of Chemical Engineers (AIChE)
American Institute of Professional Geologists (AIPG)
Association of Fertilizer and Phosphate Chemists (AFPC)
Florida Institute of Phosphate Research (FIPR)

Program Advertisements

Power & Pumps Inc.
Florida Engineering and Design, Inc.
LPG Environmental & Permitting Services, Inc.
Streamline Environmental
Florida Environmental Compliance Corp.
KEMWorks Technology, Inc.
Arroyo
FFE Group Companies
GIW Industries, Inc.
Jacobs Engineering
IWT


Thursday, October 18, 2001

9:00 – 5:00 Registration

 

GENERAL SESSION

 

Chairperson Hassan El-Shall, 
The Engineering Research Center for Particle Science and Technology, University of Florida

 

FLORIDA PHOSPHATE – MOVING AHEAD
PANEL DISCUSSION

The Panel will be discussing ( S.P.O.T.)  (S)trengths, (P)otentials, (O)pportunities, and (T)hreats Facing the Florida Phosphate Industry as it moves ahead.

9:30 A.M. -
11:30 A.M.
Ms. Mary Lou Rajchel
President/CEO Florida Phosphate Council
Mr. Jim Williams
President, BETE, Inc. Industrial Consultants
Mr. Joe Bakker  
Chief, Bureau of Mine Reclamation, DEP
11:30 – 12:00 Break – Opportunity to Visit Vendor Exhibits and Displays

 

12:00 – 1:30 Lunch

HERO OF THE INDUSTRY AWARDS
SME, AIChE, AIPG

KEYNOTE ADDRESS

"SME and Industry Trade Organizations: A Necessary Relationship to Build Professional Pride and Positive Public Opinion"
Presented by: Paul A. Scheidig, Executive Director, Society for Mining, Metallurgy and Exploration (SME)


 CONCURRENT TECHNICAL SESSIONS

Thursday, October 18, 2001

1:30 – 5:00

Geology

Reclamation

5:00 – 7:00 Social Hour

 

Friday, October 19, 2001

 

8:00 – 9:00 Opportunity to Visit Booths and Displays
9:00 – 12:00

Environmental
Chemical Processing

12:00– 1:30 Lunch
1:30 – 4:00

Mining and Mineral Processing
Interactive Session: Analytical and Regulatory

4:30 Door Prize Drawing
Must Be Present to Win!

 

Thursday
October 18, 2001

AFTERNOON TECHNICAL PROGRAM

 

GEOLOGY

Thursday, October 18, 2001

Session Chair:

Wink Winkler, BCI

 

1:30 P.M. A Hydrogeochemical Model For the Contemporary Formation of Hard Rock Phosphate Deposits in Florida

Sam B. Upchurch, SDII Global Corporation

The first great boom in phosphate mining in Florida involved exploitation of carbonate- hydroxylapatite deposits in central and north Florida.  These deposits consist of secondary accumulations of phosphate minerals in karst features along the flanks of escarpments developed on Hawthorn Group strata.  These “hard-rock” phosphate deposits have been characterized as lining sinkholes and replacing karstic limestone, and they are associated with siliciclastic sediments and chert, much of which has been transported into these relict karst features.  The known deposits were largely exhausted by the mid-1960s, and the mines are now abandoned. 

Research on regional ground-water quality near the flanks of the Brooksville Ridge and Cody Scarp in north Florida indicates that the hard-rock phosphate deposits continue to form as a result of scarp retreat.  Carbonate-fluorapatite contained in the Hawthorn Group strata that characterize the uplands behind the scarps is dissolved in acidic surface water and shallow ground water.  This unbuffered phosphate-rich water is transported to the escarpments in streams, the surficial aquifer system, and within siliciclastic aquifers of the Hawthorn Group (the intermediate aquifer).  Upon reaching the scarps, the water recharges the underlying carbonate-rich Floridan aquifer through sinkholes and other karst features.  Upon coming in contact with the limestone of the Floridan aquifer, the recharge water becomes alkaline and the phosphate is redeposited as carbonate-hydroxylapatite.  

 

2:00 P.M. Late Tertiary Siliciclastics in Southern Florida: New Perspectives From Seismic and Borehole Data in the Caloosahatchee River Basin

Stanley D. Locker, College of Marine Science, University of South Florida

Kevin J. Cunningham, USGS

Albert C. Hine, College of Marine Science, University of South Florida

Recent high-resolution seismic-reflection data collected along the length of the Caloosahatchee River provide significant new insight into the Late Tertiary phase of siliciclastic accumulation in South Florida. The data acquisition focused on defining structural and stratigraphic characteristics of the surficial and intermediate aquifer systems (Tamiami, Peace River, and Arcadia Formations), with some imaging reaching over 200 m (>650 ft) deep to within the Upper Floridan Aquifer (Lower Arcadia and Suwannee Formations). Six continuously-cored boreholes were drilled to verify seismic interpretations and to provide chronostratigraphic control.  

East of La Belle, FL (eastern Caloosahatchee River), an erosional unconformity, cut into the Lower Peace River Formation to near the top of the Arcadia Formation, is located at a subbottom depth of approximately –120 m (400 ft). This is overlain by a major late Miocene(?)-to-early Pliocene sand-rich fluvial-deltaic system that prograded southward across the Florida Platform. This system contains steeply inclined prograding clinoforms, over 100 m in thickness, that extend from the downlap termination on the Lower Peace River unconformity, to the surface where these clinoforms crop out at the river bottom. This fluvial-deltaic system likely continued prograding southward, forming the late Miocene-Pliocene siliciclastic foundation of the middle-to-upper Florida Keys.

This period of siliciclastic deposition reflects the importance of antecedent paleotopography and accommodation space, in response to late Tertiary sea-level highstands, in controlling siliciclastic accumulation patterns within the mostly carbonate Florida Platform.

 

2:30 P.M. Water Sustainability in Florida - Research, Policy and Geologists’ Responsibilities 

Dr. Thomas Scott, P.G., Assistant State Geologist, Florida Geological Survey

Florida is a water-rich state.  Florida relies heavily on groundwater from the Floridan aquifer system (FAS), although the intermediate and surficial aquifer systems are utilized in limited areas.  It is estimated that more than two quadrillion gallons of fresh water are in the FAS.  Approximately four trillion gallons of water recharge the FAS each year, which is approximately 0.2% of the total fresh water in the FAS.  Three trillion gallons are naturally discharged annually, mostly via Florida’s more than 600 springs (0.15%).  One trillion gallons per year are withdrawn by pumping (0.05%).  However, available fresh groundwater is not evenly distributed throughout the state.  In order to provide adequate supplies of fresh water, alternative supplies from mineralized waters and subsurface storage of excess surface water are being used. 

Geologists are currently challenged to better define the state’s aquifer systems in order to supply fresh water, facilitate subsurface storage and recovery of fresh water (ASR), dispose wastewater and use mineralized waters.  Among the issues facing our profession are: 1) the continuity of confinement within the FAS; 2) the continuity of the intermediate confining unit; 3) how will the FAS be affected by the injection of billions of gallons of fresh water per day; 4) how does fresh surface water react with aquifer materials to affect water quality; 5) if untreated to partially treated surface water is placed in the FAS, what is the fate of bacteria, algae and other organisms.  These questions and others must be answered in order to protect the environment and aquifer systems while providing the necessary water supply for Florida’s burgeoning population.  Geologists have an important opportunity to provide input into the policies being developed in relation to the use and protection of Florida’s water resources.  

 

3:00 P.M. Break

 

3:30 P.M. A Geological Assessment of the Miami Circle Site

Guy H. Means and Thomas M. Scott, Florida Geological Survey

A routine archaeological investigation of a proposed construction site located on the southern bank of the Miami River in downtown Miami, Florida revealed a circular pattern of some twenty-four primary rectangular holes cut down into the limestone bedrock.  Numerous secondary smaller rounded holes, along with irregular shaped holes, were also associated with the site.  The site had previously been occupied in the 1950's by six low-rise apartment complexes.  A septic tank, which serviced the apartments, was also uncovered at the site, and is coincident with the southern edge of the circular feature.  The location of the septic tank raised questions regarding the Circle's antiquity.  In May of 1999, geologists from the Florida Geological Survey were asked to visit the site and assess any geological evidence for the site's antiquity.

 

4:00 P.M. Use of a Proprietary Geophysical Technique to Locate Valuable Ferrophosphorus Material at Abandoned Elemental Phosphorus Plants

Ronald A. Crowson, Geo Solutions Ltd.

Geo Solutions has developed a proprietary geophysical technique to locate ferrophosphorus material associated with the production of elemental phosphorus.  This technique involves the use of a multifrequency electromagnetic profiler geophysical tool and a rapid field analysis technique.

Two primary waste slag components are produced during the production of elemental phosphorus in an electric furnace.  A light-colored calcium silicate slag and a much dark colored and heavier ferrophosphorus slag are generally drawn off as separate molten liquids from the furnace.   The calcium silicate slag is generally used as roadbed material, and more recently as a nutrient in soils deficient in calcium silicate.  The ferrophosphorus is presently utilized in the steel industry as an additive to improve the ductility of iron/steel.

When elemental phosphorus production was common, the availability of ferrophosphorus exceeded demand and the market value was relatively low.  As such, all of the ferrophosphorus produced was not sold.  As elemental phosphorus plants closed operations, the value of ferrophosphorus increased reaching a spot market value of more than $400 per ton.  Current market value has declined to a little more than $200 per ton due to low cost imports from operating plants in China.  Geo Solutions has completed geophysical surveys at two abandoned elemental phosphorus facilities and has located substantial quantities of high-grade ferrophosphorus using our propriety technique.

 

RECLAMATION

Thursday, October 18, 2001

Session Chair:

Bryant Grant, IMC

 

1:30 P.M.

Use of Recycled Yard Waste to Enhance Reclamation of Pine Flatwoods Habitat

M.J. Chanen, Cargill Fertilizer Inc.

J.V. Ragsdale, City of St. Petersburg FL

M.L. Stratton, Manatee Community College

Florida's 1975 Mandatory Mine Reclamation Act requires phosphate companies restore the land they disturb.  Mandatory Phosphate Reclamation Rules also require reclamation, through initial revegetation, be completed within 2 years of completion of mining operations. 

Unamended mine soils typically exhibit poor soil structure, are prone to compaction, has low organic matter content and lacks microbial activity needed to initiate nutrient cycling.  Use of harvested wetland topsoil has been adopted by the phosphate industry and regulatory agencies to enhance mine soils and accelerate the succession process of created wetlands. Upland topsoiling is also recommended by the FDEP-Bureau of Mine Reclamation, especially for creation of pine flatwood habitats. Upland topsoil can be a source of organic matter, nutrients, soil microbes/mycorrhizae, native groundcover seeds and native shrub seeds.  However, topsoiling for upland revegetation is more limited relative to wetlands, primarily due to the large acreages involved, lack of donor sites and associated high costs. The cost of topsoiling is a function of hauling distance, soil volume spread and stockpiling requirement. 

In this paper results of a State-funded Innovative Recycling Grant Project will be presented.  In this study, the benefit of using ground urban yard debris (yard waste) to extend/enhance available pine flatwoods topsoil at Cargill Fertilizer's South Ft. Meade Mine is evaluated.

 

2:00 P.M. The Establishment of a Native Plant Nursery at the BMR’s Homeland Field Office and its Relevance to Land Reclamation Activities in the State

Bill Hawkins, Manager, Bureau of Mine Reclamation Homeland Office

Kevin Claridge, Bureau of Mine Reclamation

For many years, regulatory agencies, including the Florida Department of Environmental Protection (FDEP) Bureau of Mine Reclamation (BMR) have been advocating the use of native plants in the establishment of groundcover on reclaimed land. Field implementation of this practice has been hindered by the lack of commercially available sources of seed and planting material for native groundcover.  The dearth of planting material is particularly acute for native grasses.  To date, many of the attempts to establish native groundcover have proven to be either cost-prohibitive or technically infeasible. 

The BMR recently obtained funding for the reclamation of a 107-acre nonmandatory program adjacent to the Homeland Field Office.  The reclamation plan for this program calls for native groundcover, including grasses, to be used in the revegetation of this program, to the greatest extent practical.  The need for field quantities of native grass planting material for this project was the driving force behind the establishment of the BMR’s nursery at Homeland.  The BMR has worked cooperatively with both the National Resource Conservation Service Plant Materials Center in Brooksville and the Range Cattle Research and Education Center at Ona.  Native grass plant material has been obtained from both of these sources as well as some field locations in the area.  The BMR’s goal is to work towards developing practical and economically feasible methods of propagating native groundcover. The presentation will summarize the BMR’s experience to date.  

2:30 P.M. Preliminary Assessment of Fire and Climatic Stresses on Wetland Reclamation

Rosemarie Garcia, Cargill Fertilizer Inc.

The year 2001 has been marked with the extremes of drought and wildfires. An attempt will be made to  gauge the impact of fire and drought on a range of new and old reclamation projects. An emphasis will be placed on the role of fire following drought on the sawgrass wetlands at Cargill's Hookers Prairie and Ft. Meade Mines. Both the sustainability of these projects and their shifts in vegetation will be noted. Also, the results of direct seeding experiments conducted during this same time frame will be discussed.

 

3:00 P.M.

Break

 

3:30 P.M.

Green World Science Innovative Environmental Solutions

Al Pollock, Florida Engineering and Design Inc.

Green World Science Inc. (GWS) specializes in providing innovative environmental solutions utilizing its patented proprietary technology, in a variety of industries ranging from Mining to Food and Chemicals. During its five-year history, GWS has earned a reputation of employing advanced technologies offering significant savings over conventional treatment methods. GWS headquarters is in Boise, Idaho. The technology was originally developed and tested by J.R. Simplot Company at the wet acid plant gypsum disposal stacks at the Don Plant in Pocatello, Idaho. The initial development proved to be a success by treatment of the Gyp Stack Plume, a contaminated body of water below the stacks and in the surrounding area, that was near to causing a forced shutdown of the subject gyp stacks by Idaho environmental regulators. 

GWS owns three patents and has four additional patents pending relative to in-situ use of nutrients in earthen materials such as heap leaches in the mining industry, waste and spoils in coal, precious metals, copper, uranium and phosphate industry wastes. The technology is also used for wastewater treatment with additives fed to wetlands, drainage areas, ponds and lakes. The treatment applies to both surface and groundwater. Cyanide, nitrate, sulfate, ammonia (ammonium ion), as well as a suite of solubilized metals are removed or immobilized in-situ by microorganisms able to perform certain transformations. 

Florida Engineering and Design Inc. (FED) has an agreement for marketing GWS technology in Canada, Eastern USA, Central & South America and the Caribbean. We are currently offering the technology to the Florida Phosphate Industry with a pending application for Environmental Protection Agency (EPA) funding of a demonstration project. 

The two measures of success in metal containment and stabilization are a lowered concentration of metal in the exiting solutions and a decrease in the rate of metal peak movement and elution from the soil column. Metals of interest to this technology include arsenic, barium, cadmium, chromium, copper, iron, lead, mercury, selenium and uranium. The reduction of these metals in an industrial effluent has been achieved to the level of the National Drinking Water Standard (NDWS). Significant reductions of nitrate and sulfate anions have also been achieved by the addition of nutrients to enhance bacterial growth in soils underlying a stack. The nitrate ion is biologically reduced and eliminated from the system prior to the initiation of sulfate bioreduction. Ammonia (ammonium ion) is also reduced by bacteria activity with the necessary addition of organic carbon supply and an extended reaction zone. 

GWS has successfully treated multiple rock heaps, totaling over 70 million tons, as well as 1.35 billion gallons of water in ponds, lakes, and drainages associated with mining operations. Proper nutrient addition to these systems promotes the formation of anaerobic conditions resulting in the removal of metals resulting in clean water from the drainage. The nutrients include proprietary mixtures of agricultural commodities and therefore provide an economical solution for the client.

GWS technology offers an exciting alternative for mine operators and other potential users who up to this point has been limited to chemical treatments for waste dumps / stacks, ponds and groundwater contamination. It is a proven technology that offers substantial savings, particularly when compared to the cost of liners for ponds and stacks that are currently required to provide groundwater protection.

4:00 P.M.   Talk To Be Announced

 

Friday

October 20, 2000

TECHNICAL SESSIONS

 

ENVIRONMENTAL SESSION

Friday, October 19, 2001

Session Chair:

Gary Blitch, CF Industries, Inc.

 

9:00 A.M. BBTC Extra Measures to Ensure Sulfur Rule Compliance

Edward Newberg, Sulfur Project Coordinator, Big Bend Transfer Company (BBTC)  

Big Bend Transfer Company is a joint venture of Cargill Fertilizer, CF Industries, and IMC Global to build the world’s most technically advanced solid sulfur-handling facility.

Sulfur is a key raw material used to make phosphate fertilizer.  Over 80 percent of the world sulfur trade is in the solid form.  BBTC will import an approved standard solid sulfur pellet, then melt it for transport to the members’ facilities.  This will allow for a more reliable, diversified sulfur supply and improved competitiveness in the marketplace.

BBBTC will take full advantage of the existing port facilities, including the existing dock and support infrastructures on the 210-acre site.  New facilities will include an enclosed ship unloader, pipe conveyors, storage building, melter, liquid storage tanks and truck loadout. 

The Big Bend Transfer Company project will protect the environment by investing $49 million in facility construction that will include sophisticated environmental technology that will exceed the high standards set by the state of Florida for sulfur handling facilities.

Including:

  •  Proven scrubber technology will be used to reduce air emissions and eliminate odors.

  • Technically advanced unloading and transport systems will prevent  material spillage, control dust, and protect the environment.

  •  Enclosed transfer equipment and water spays with wetting agents used to control dust. 

  • Storage areas will be completely enclosed.

  • Water will be recycled.  No water will be discharged into the bay.

 

9:30 A.M.

The Impact of Phosphate Mining on Water Resources in the Peace River Basin

 Dr. John E. Garlanger, P.E., Ardaman and Associates, Inc.

There is substantial public interest in the impact of phosphate mining on water resources in the Peace River Basin.  This study analyzed Basin rainfall, streamflow, hydrogeologic data, pumping records, and mined and reclaimed acreage to assess the impacts of mining on streamflow, groundwater outflow, aquifer recharge, baseflow and direct surface runoff.  Mining impacts are quantified and compared with other hydrological impacts in the Basin.  

10:00 A.M. Simulated Dam Breach and Routing Analysis 

Mark Schwartz, P.E., Sr. Water Resources Engineer, BCI Engineers& Scientists Inc.

The Florida Administrative Code 62-672.550 requires that an emergency action plan be prepared for clay (and sand/clay mix) settling areas.  The plans have two parts: a map showing the potential area of inundation and a plan for notifying state and local officials in the event of dam failure. This presentation describes some factors affecting the estimated discharge from a dam breach, downstream flow routing, and flow depths.  These factors include soils, berm physical dimensions, downstream conveyance, and models used in analysis.

 

10:30 A.M. Break

 

11:00 A.M. NELAC – A New Perspective on Laboratory Requirements

Silky S, Labie, Environmental Administrator, Environmental Assessment Section, Florida Department of Environmental Protection

The National Environmental Laboratory Accreditation Conference (NELAC) and the associated program, National Environmental Laboratory Accreditation Program (NELAP), are beginning to have an impact on how laboratories across the nation are accredited. 

The Department of Environmental Protection, through Chapter 62-160, F.A.C., proposes to require that laboratories supporting DEP programs (compliance, clean-up, etc.) be certified by the Florida Department of Health Environmental Certification Program.  The DoH ELCP is a recognized NELAP accrediting authority. 

Florida Laboratories will feel very little impact in how business is conducted if they have been following their DEP approved Comprehensive Quality Assurance Plans.  A summary of the similarities and difference between a NELAP-compliant laboratory and a “DEP-approved” laboratory will be presented.  A brief overview of the certification process will also be presented. 

Once certified by the DoH ELCP, laboratories can expect that the focus of DEP’s audits will change to project specific data, and determining if the data are useable for its intended purpose.  Many DEP programs are considering using electronic data formats so that laboratory and field data can be reviewed quickly and more efficiently.

 

11:30 A.M.

Upper Respiratory Tract Disease in Gopher Tortoises:  Research and Regulation

Joan E. Berish, Florida Fish and Wildlife Conservation Commission 

Within the last decade, research has revealed an upper respiratory tract disease (URTD) in wild gopher tortoises (Gopherus polyphemus) in Florida.  URTD is a highly contagious disease; clinical signs include nasal discharge, ocular discharge, and swollen eyelids.  One causal agent of URTD is Mycoplasma agassizii.  A blood test has been developed to detect antibodies to this bacterium.  Blood samples collected at various Florida sites have indicated that exposure to mycoplasma is widely distributed but apparently not pervasive.  In 1998, the Florida Fish and Wildlife Conservation Commission (FWC) initiated a radio telemetry study to investigate the effects of URTD on tortoise populations on public lands.  Because the current blood test only indicates exposure to mycoplasma, nasal lavages were also taken to detect presence of mycoplasma.  To date, three different mycoplasmas have been detected on the four study sites:  Mycoplasma agassizii, a genetically distinct but unnamed mycoplasma, and an undescribed mycoplasma.  The latter mycoplasma was detected on a study site where more than 100 dead tortoises were found during 1998-99.  Of the 15 tortoises radio-instrumented on that study site, two died outside their burrows, and a third, severely symptomatic tortoise was euthanized, necropsied, and found to have nasal lesions associated with mycoplasma infection.  Five of 15 radioed tortoises have been found dead at a second study site.  In 2001, concern over tortoise mortality and the potential for disease transmission during relocations prompted FWC to mandate testing for exposure to URTD prior to moving tortoises off-site.

 

CHEMICAL PROCESSING

Friday, October 19, 2001

Session Chair:

Tino Prado, Prado & Associates

 

9:00 A.M. The Science and Application of Technologies of Lime

John L. Thompson, Chemical Lime Company

Lime is a common industrial chemical, which, by its nature, and by its close association with limestone, is a much-misunderstood chemical.  The presentation of "The Science and Application Technologies of Lime" will clarify the origin and properties of lime, list the various types of lime that are available, and outline the physical and chemical characteristics of each type.  Principal lime handling and application technologies will be discussed, as well as traditional and emerging industrial and environmental uses.

 

9:30 A.M.

Corrosion Resistant Materials for Acid Storage in the Phosphoric Acid Industry

John Grocki, Advantage Resources Consulting, LLC

The production of phosphoric acid using either the hemi-hydrate or di-hydrate process requires many tanks. These tanks may be subjected to corrosion by sulfuric or phosphoric acids or to erosion-corrosion by phosphoric acid slurries. 

Carbon steel has been used for decades to handle concentrated sulfuric acid, but this material is not resistant in phosphoric acid solutions unless it is efficiently protected. As a consequence of this, plant storage tanks are often made of carbon steel or cement, and then protected by a combination of rubber and bricks. This technology is time consuming for both the erection of new plants and the revamping of old ones. In countries where labor costs are expensive, the initial investment cost may be very high. In addition, leak detection is quite difficult as a result of the multilayer construction and repairs are difficult and expensive. 

Investigations, carried out over several years, have demonstrated that tanks made of solid duplex UNS S31803 and super-duplex UNS S32520 grades may be a very competitive alternative to traditional construction. The super duplex grade UNS S32520 may be used as a versatile tank able to handle either phosphoric acid or sulfuric acid as it is resistant to both. 

Corrosion tests carried out in various acids, including concentrated sulfuric acid and industrial phosphoric acid solutions (30% and 54% P2O5) are discussed. A proposal for the selection of materials for intermediate storage of hot phosphoric acid in production plants and final storage and transportation of 54% P2O5 at lower temperatures is presented. Finally, a cost comparison between the traditional construction and solid duplex stainless steels is provided.  

10:00 A.M.

A Guide to Troubleshooting in H2SO4 Plants+

Bernard Kalis, Technical Director, Amistco Separation Products Inc.

It is not unusual for a combination of factors to camouflage the real cause of an apparent emission problem. An in-depth review of operating data, visual evidence during operation and inspection of the candles themselves can narrow down the probable cause of the emission failure. Often a process problem gives the filters an abnormal duty, causing the filters to fail. We will review a detailed checklist of cause-effect-result-corrective action.

 

10:30 A.M.

Break

 

 

11:00 A.M.

Waterless Seals in Phosphoric Acid Manufacturing: Economics, Challenges and Experience

Ernie Gudath, Thornton and Company

The use of waterless mechanical seals in the manufacture of wet process phosphoric acid will be discussed, with particular reference to ANSI horizontal centrifugal pumps, and evaporator circulation pumps. Although this technology has enormous economic potential, its acceptance has been slow, for reasons that will be discussed.  

11:30 A.M.

Metallic Heaters for Phosphoric Acid Evaporation

Curt Nicolio

The corrosiveness of phosphoric acid during the wet-process concentration is quite complex and dependent on several influencing factors.  The factor, which has the most significant impact, is the presence of impurities.  For example, at a given concentration, the presence of fluorine, calcium oxide, sodium and chlorine in the process will decrease the corrosivity of phosphoric acid whereas iron, alumina and magnesium will have the opposite affect.  This paper discusses the general aspects of the corrosiveness of phosphoric acid produced via the wet-process method. Additionally, information exploiting the benefits of stainless steel metallic heaters versus graphite will be detailed. Finally, several case references are documented describing twenty years of successful application experience of Sandvik Steel's Sanicro 28 used as a material of construction for metallic heaters for phosphoric acid evaporation.  

 

MINING AND MINERAL PROCESSING

Friday, October 19, 2001

Session Chair: David R. Gossett, CF Industries, Inc.

 

 1:30 P.M. Electrical Energy Management: A Practical Approach to Controlling Cost & Consumption

Henry C. Lilly, Jr., Chief Engineer, E & I, Hardee Phosphate Complex, CF Industries, Inc.

Electrical energy management is often approached from the perspective of reducing cost and consumption by retrofitting with more efficient devices, and using electrical power savings to pay for the additional capital expenditures.  Although this is certainly a valid approach to reducing long-term electrical cost, often larger and more immediate savings are overlooked. 

This presentation will employ a practical approach of examining existing systems and methods, and then using the discoveries for modifying schedules and operations to achieve the ultimate goal of reducing electrical energy cost. Highlights from eighteen years of electrical energy management at CF Industries, Inc. Hardee Phosphate Complex mining operations will be emphasized.

 

2:00 P.M. Design Optimization of Hydraulic Classifiers

Dr. J. N. Kohmuench and Dr. M. J. Mankosa, Eriez

Dr. G.H. Luttrell, Department of Mining & Minerals Engineering, Virginia Tech

Hydraulic classification is used extensively in the minerals industry.  Hydraulic, or teeter-bed, separators provide efficient classification at high unit capacities for particles generally greater than 200 mesh.  Unfortunately, over the past decades, the basic design concept of these separators has not changed.  This presentation provides a review of hydraulic classifier design based on fundamental engineering design principles.  Using this approach, a spreadsheet-based process model was developed to evaluate different design configurations.  The findings from this study have resulted in a new, more efficient teeter-bed design concept.   Data from laboratory-, pilot- and full-scale testing of this design for phosphate and other industry mineral applications will be presented in comparison with the model results.

 

2:30 P.M. Improved Efficiency Through Control

Bernard J. Scheiner, President, BCD Technologies

Charles L. Karr, Department of Aerospace Engineering and Mechanics, The University of Alabama

Operating data from the Swift Creek Mine was obtained for a month of operation. The data was analyzed and a relationship involving the amount of incoming BPL and fatty acid was developed. This relationship was used to develop a series of control curves. These control curves were used to develop a process control system for manipulating a rougher flotation circuit. In simulations the controller consistently reduced the amount of fatty acid required to obtain approximately 90% recovery from the rougher flotation circuit. At present the controller is being tested at the Swift Creek Mine and final results should be obtained late in the fall, 2001.  

 

3:00 P.M. Break

 

3:30 P.M. Western Phosphate Producers: Featuring SF Phosphates Vernal Utah Mine

James M. Williams, former Vice President of Operations

Miles Weaver, Mine Manager

Merrill Allen, Senior Metallurgical Engineer

An overview of active phosphate mining operations in Idaho and Utah will be presented. Ore types, mining methods, production estimates and rock uses will be discussed. 

SF Phosphates LLC operations at the Vernal mine will be the main topic of discussion. This open-pit mine is located on the southern slope of the Uinta Mountains about 15 miles north of Vernal Utah. Shovel and truck operations strip and mine the moderately dipping sedimentary phosphate ore that averages about 20% P2O5 and 2-3% MgO. 

Beneficiation consists of size reduction, desliming, and flotation. The flotation process is complex with a unique carbonate rejection circuit that allows processing of unweathered high carbonate ore to produce a concentrate suitable for phosphoric acid production. 

Concentrate is pumped at about 68% solids 98 miles to the SF Phosphates chemical plant at Rock Springs Wyoming. MAP and superphosphoric acid are the products manufactured.

 

4:00 P.M. Challenging the “Double Float” Process III - Introducing the FIPR/SAPR Process  

Dr. Patrick Zhang, Robert Snow, and Yingxue Yu  
Florida Institute of Phosphate Research

The FIPR/SAPR process is FIPR’s third approach to develop a viable alternative to the Crago “Double Float” process for phosphate flotation. SAPR stands for Single-collector, All-anionic Phosphate Recovery. The FIPR/SAPR process offers a universal flowsheet for any anionic reagent system and flotation feed of varying sizes.  For an unsized or fine flotation feed, the FIPR/SAPR process consists of the following steps: 1) high-solids conditioning with an anionic collector; 2) anionic rougher flotation, with the rougher concentrate sized at 48 (or 65) mesh and the +48 mesh recovered as a final product; and 3) cleaning flotation of the –48 mesh fraction from step 2.  In a variation of step 2, the rougher concentrate from the first two cells may be collected as a final product, and the rougher concentrate from the last two cells sized at 48 or 65 mesh.  The new process was tested with two different reagent systems, achieving single-digit insol at 90+% recoveries.

 

INTERACTIVE SESSION: ANALYTICAL AND REGULATORY

Friday, October 19, 2001

Session Chair:

Sanford Siegel

 

 1:30 P.M. A Product Defense Story:  Perchlorate in Fertilizers?

Linda Weber, Environmental Laboratory Director, IMC-Global

The history and development of events surrounding the perchlorate in fertilizer controversy are reviewed. The reaction to, and proactive steps taken by, industry the scientific community, and regulators to address the issue are covered. These steps resulted in: involvement of stakeholders, improved methodology, greater understanding of the issues, and development of a large database of product information. Specific analytical methodology will be reviewed.  Data will include analysis of a wide range of fertilizer materials and finished products that were analyzed independently of the EPA sampling efforts. This data will be reviewed in the context of historical likelihood of contamination as well as the likelihood of future contamination events. Additionally, the need and implications of future monitoring programs will be discussed.

 

 2:00 P.M. Florida’s Adoption of the National Environmental Laboratory Accreditation Program and How This Will Affect the Phosphate Industry

Susanne Allen, Chief Chemist, Quality Control, U.S. Agri Chemicals

The National Environmental Laboratory Accreditation Conference (NELAC) is an organization formed to promote a consistent laboratory certification program in the United States.  The National Environmental Laboratory Accreditation Program (NELAP) is the certification that uses the standards developed by NELAC.  The Florida DEP will require all laboratories generating environmental data for submittal to DEP (except the Clean Air Act) to be accredited under NELAP.  These new requirement will place a financial and man power burden on the phosphate environmental laboratories.  We will compare the differences between the old accreditation program and the new accreditation program.  We will discuss the states that have adopted NELAP, and how successful these states have been in the implementation of NELAP.  We will end our discussion on where the future is leading the environmental accreditation program and how to make sure your laboratory is ready for these changes.

 

2:30 P.M. Which Trace Metals Analytical Technique is Right for You?

Kerry Besecker, PerkinElmer Instruments

Trace metals analysis can be accomplished by several techniques.  How do you determine which analytical technique is right for you?  There are many factors to determine when choosing a technique.  These factors include: detection limits, potential interferences, speed of analysis, sample load, initial cost, ownership costs, accuracy, precision, and regulatory considerations.  This presentation attempts to compare the techniques of flame atomic absorption, graphite furnace atomic absorption, inductively-coupled plasma optical emission spectrometry, and inductively-coupled plasma mass spectrometry.  The aforementioned factors will be discussed to help the user determine which analytical technique should be chosen.

 

3:00 P.M. Break

 

3:30 P.M. Comparative Methods for Metals in Fertilizer and “Some” Pitfalls to Avoid

Harold Falls, Chief Chemist, Plant City Phosphate Complex, CF Industries, Inc.

Sanford Siegel, John Longest and Barton Boggs, CF Industries, Inc  

The Association of Fertilizer and Phosphate Chemists (AFPC) has developed analytical methods to analyze state-regulated metals and other metals in fertilizers. These metals include Fe, Al, Mg, Ca, Na, K, Cd, As, Cu, Zn, Hg, Pb, Mn, Cr, Co, Mo, Ni, and Se.  Fertilizers analyzed are diammonium phosphate (DAP), monoammonium phosphate (MAP) and granular triple superphosphate (GTSP), which are the three major phosphate fertilizers used in the United States.  The study includes two different Inductive Coupled Plasma analytical methods developed by the AFPC and compares them with the EPA’s method for analyzing metals in sludge (Solid Waste 846 Guidelines).   The Association of Fertilizer and Phosphate Chemists has established a monthly check program for metals in fertilizer and has published the results on their web page http://afpc.net.  

There are some pitfalls to avoid in the analyses of metals using either atomic absorption or inductive coupled plasma.  Examples of the pitfalls to avoid with ways to correct the analytical values will be presented.  

The discussion will include how we came to this point in regulation of metals in fertilizers by the State Agencies, such as State of Washington, State of California and others.

 

4:00 P.M. Nuclear Magnetic Resonance and Raman Spectroscopy – Novel Analytical Techniques

Vaughn E. Davis, Vice-President, Oxford Instruments Process Systems

Over the last 10 years nuclear magnetic resonance (NMR) and raman spectroscopy have occupied unique analytical niches, but are now gaining broader market acceptance as the technologies have evolved. NMR is a valuable technique for evaluating hydrogen, fluorine, and phosphorus nuclei in a variety of industries and the technology is equally at home in the laboratory or in the process plant. Due to its ability to evaluate nuclei in a range of physical environments and under harsh environmental conditions, NMR can be a valuable tool in the process environment.

Raman spectroscopy can also be a valuable process analytical tool and can be utilized for such tasks as monitoring BTU content of natural gas feed and sulfates in phosphoric acid slurries. Remote optic probes can be placed in-process with the spectrometer itself placed hundreds of feet away and combined with the low cost of operation makes raman spectroscopy an attractive analytical option. 

Data from the phosphate chemical industry will be utilized to show the benefits of the technology.


Hero of the Industry Awards

SME/AIME* AIPG AIChE
2000 15th John Paugh John R Walter David Leyshon
1999 14th Roy Duval  Henry Lamb  Randy Charlot
1998 13th   Lee Thurner  Leonard Burnett  Regis Stana
1997 12th Tom Leto  Jon Courtney  William Cook
1996 11th    Ron Wiegel Eric Norman Don Clark
1995 10th   Maywood Chesson  Walter Schmidt  Frank Arroyo, Sr.
1994 9th   Clint Hollingsworth  Lonnie Engel Gerald Rubin
1993 8th   Selwyn Presnell  Don Crissinger  Gordon Palm
1992 7th    Fred Myers Tom Scott Edward Newburg
1991 6th    Dan Lynch Rick Powers Les Bromwell
1990 5th    Richard Hunter Richard Fountain Jim Williams
1989 4th   A. L. Holmes Tom Patterson  Don Chamberlain
1988 3rd    Don Morrow John Paugh Arthur Hansen
1987 2nd   Colin Campbell  James Cathcart Ray Garcia

1986 1st Dave Raden – General Chairman

* AIME – 1986-1995


THANKS

 

Our sincere thanks to the companies who have supported the Regional Phosphate Conference as exhibitors or sponsors for a decade or more.  We certainly appreciate your help in making the conferences a success. 

American Compliance Technologies, Inc. 
BCI Engineers & Scientists, Inc.
Jacobs Engineering Group
P.E. LaMoreaux & Associates, Inc.
Thornton Laboratories, Inc.


 REFRESHMENT SPONSORS 

 GOLD 

Ardaman & Associates
Cargill Fertilizer, Inc.
Central Maintenance & Welding Inc.
Chastain Skillman
Jacobs Engineering Group
PhosChem Supply Co.
Terra Environmental
  

SILVER

Custom Chemicals
Penn Pro, Inc.
 

BRONZE 

Bird Machine Company
CCC Group, Inc./Florida Division
Power and Pumps, Inc.

 


EXHIBITORS

 AB Sandvik Steel
American Compliance Technologies, Inc.
BCI Engineers & Scientists, Inc.
Beneficiation Technologies, LLC
Chastain Skillman

Comanco Environmental Corp.
DCR Business Solutions, Inc.
FFE Minerals
Florida Environmental
Florida Environmental Compliance Corporation
Florida Institute of Phosphate Research
Geosyntec Consultants, Inc.

GIW Industries, Inc.
Heartland Supplies, Inc.

Hudson Pump & Equipment Assoc., Inc.
IF Rooks & Associates, Inc.
Jacobs Engineering Group
Midwest Industrial Supply, Inc.
Mustang Tampa, Inc.
Oxford Instruments Process Systems
P.E. LaMoreaux & Associates, Inc.
Pembroke Laboratories, Inc.

Perkin Elmer Instruments
Rad Elec, Inc.

R.H. Moore & Associates, Inc.
Roberts & Schaefer Company

Severn Trent  Services
SGS Commercial Testing & Engineering Co.

SIMS Crane & Equipment Co.
Sherba Analytical Lab Products, Inc.
Streamline Environmental, Inc.
Surpac Software International
Tampa Armature Works, Inc.
Terra Environmental Services, Inc.

Thermo Elemental

Thornton Laboratories, Inc.
University of Florida

URS Corporation Southern


2001 Phosphate Conference Committee

 

Conference Chairman.........................................................Karen Lulf, Cargill Fertilizer Inc.

General Session Chairman.........................................Hassan El-Shall, University of Florida

Technical Session Chairman............................................Dave Spedden,  Cargill Fertilizer, Inc.

Environmental.....................................................................Gary Blitch, CF Industries, Inc.

Chemical Processing............................................................Tino Prado, Prado & Associates

Mining & Mineral Processing..........................................David Gossett, CF Industries, Inc.

Reclamation.....................................................................Bryant Grant,  IMC

Geology............................................................................Wink Winkler, BCI

Analytical/Regulatory..................................................Sanford Siegel, CF Industries, Inc.

Arrangements....................................................................Deborah Ray, Custom Chemicals Corp.

Registration.............................................Anna Dunn, Shannon Medley, Florida Institute of Phosphate Research

Exhibits...........................................................................Karen H. Mort, PE LaMoreaux & Associates

Attendance.....................................................................William Wyllie, Florida Institute of Phosphate Research

Finance..........................................................................Carey Stafford, Cargill Fertilizer, Inc.

Publicity/Web.Site.......................Mary Ellen Murphy, Gary Albarelli, Florida Institute of Phosphate Research

Past Conference Chair.....................................................John Powers, GIW Industries, Inc.

SME Representative.......................................................Jeff  Beriswill, Ardaman & Associates

AIPG Representatives.....................Duke Clem, Hardee County Mining, Henry Lamb, Mineral Resource Assoc.

AIChE Representative.........................................................Tino Prado, Prado & Associates

AFPC Representative....................................................Sanford Siegel, CF Industries, Inc.

FIPR Representative...........................................................Brian Birky, Florida Institute of Phosphate Research

Audio Visual Coordinators........................Jon Harris,  Aaron Medley, Florida Institute of Phosphate Research

 


RETURN TO FIPR LIBRARY HOMEPAGE | RETURN TO FIPR HOMEPAGE

Last Updated: Oct. 12, 2001
Copyright© 2001 Florida Institute of Phosphate Research