Our Technologies

Our Technologies

Novaphos is ready to change how phosphates are made with innovative, sustainable process technologies.

Novaphos Phosphoric Acid Process

Novaphos phosphoric acid technology applies several proprietary innovations to well known carbo-thermal reduction and oxidation reactions in a continuous process that:

Uses low quality rock

Consumes low-quality rock with high silica and other impurities.
P2O5 as low as 10-15% vs ~30% for wet-acid process.
Impurities, e.g. iron, aluminum and magnesium can be much higher than for wet-acid process.
No need for expensive beneficiation steps, like flotation: can unlock value of uneconomic reserves.

Produces higher-quality phosphoric acid

Makes high-quality phosphoric acid that can be used throughout the phosphate chain:
- MGA for solid fertilizer
- DFA for animal feed
- SPA for liquid fertilizer
- PPA tech grade
Most rock metallic impurities, e.g. radium, cadmium and arsenic, are left encapsulated in the J-Rox with resulting low levels in our phosphoric acid.

Leaves no gypsum

Produces no large volume waste streams, such as phosphogypsum.
Processed feed balls can be used as construction aggregate where economic, leading to additional revenues.
Alternative use in mine reclamation. Makes phosphoric acid production possible where gypsum stacks are not permitted.

Lowers cost significantly

Operating costs less than conventional phosphoric acid:
- Mining cost of P2O5 in phos rock is reduced—can even use mine tailings
- Pet coke instead of sulfur
- No gypsum disposal costs
- Avoid downstream processing to upgrade acid
Novaphos capital cost per unit of P2O5 expected to decrease over time with economies of scale.

The Novaphos Phosphoric Acid Process uses well know carbo-thermal reduction reactions to liberate phosphorus from phosphate rock with proprietary process conditions and techniques. The result is an efficient process that can use phosphate rock material containing 10-20% P2O5 and high levels of impurities. Our product acid is high-quality and low in impurities, and we avoid the production of large volume wastes like phosphogypsum.

Our phosphoric acid process starts by combining phosphate rock and, if needed for process chemistry, silica, together with a source of carbon, like pet coke and a binder. Phosphate raw materials can be ore, concentrates or tailings streams. These raw materials are ground, mixed and formed into a feed ball or briquette, which is then processed at high temperature to trigger a reduction reaction in which phosphorus gas evolves. Following the reduction reactions, phosphorus is oxidized into phosphate gas and absorbed into water to make phosphoric acid. Following reduction, the processed solids are cooled and can be sold as J-Rox.

Novaphos Phosphogypsum Reprocessing

The Novaphos phosphogypsum process uses similar reactions and processes to efficiently transform waste gypsum into sulfur gases and J-Rox. The process combines gypsum, silica and a binder. These raw materials are ground, mixed and formed into a feed ball or briquette, which is then processed at high temperature to trigger a reduction reaction in which sulfur gases evolve. The sulfur gases can be used to make useful commercial products, such as sulfuric acid, ammonium sulfate or clean, industrial gypsum. The processed, cooled solids are the same J-Rox as produced in our phosphoric acid process.

Sustainability and Circularity

Phosphate producers are under pressure from stakeholders— customers, investors, employees and regulators—to improve ESG measurement, reporting and performance. As an industry focused on extracting and processing minerals, our greatest focus must be on the efficient use of limited natural resources that are essential for life.

Novaphos technologies can help the phosphate industry to become more sustainable and more circular.

WATCH OUR VIDEO ON WHY NOVAPHOS IS 'MORE CIRCULAR'

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+1 863. 285. 8607

+1 863. 285. 8607