Our Technology

A Disruptive and Sustainable Technology

Novaphos technology applies several prorietary 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 impurities, e.g. radium, cadmium and arsenic, are removed in the process.
  

Leaves no gypsum

• Produces no large volume waste streams, such as phospho-gypsum.
• 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 Process

The Novaphos 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 10-15% 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 phospho-gypsum.

Our 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, 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 balls are cooled and can be sold for use as construction aggregate as J-Rox.

ABOUT NOVAPHOS

OUR TECHNOLOGY

OUR LEADERSHIP

WHY PHOSPHATES