The Production Facility

Land Size

An area of around 11.25 hectares is sufficient to accommodate the production plant and associated infrastructure. The potential to secure an additional 6 hectares exists to accommodate future expansion, particularly if/when the fertilizer plant option is exercised.

The plant will produce two essential animal feed supplement ingredients: Dicalcium Phosphate (DCP) and Monocalcium Phosphate (MCP). These Calcium Phosphate extracts constitute an essential supplementary additive in animal feeds adding the essential elements Phosphorous and Calcium, and can be chemically produced by using naturally occurring Phosphate Rock in a reaction with Sulphuric Acid.


Production Capacity

The proposed production facility is divided into three stages of development and the outputs are estimated as:
Stage 1 - 30,000 tonnes expected mid to late 2016
Stage 2 - 60,000 tonnes expected late 2017
Stage 3 - 90,000 tonnes or more subject to both local and export market demands


Raw Material Requirements for 30,000 Tonnes Output (Excluding By-Products)

Rock Phosphate - 45,000 tonnes delivered from Phosphate Hill or Mount Isa via rail
Sulphuric Acid - 30,000 tonnes delivered from Sun metals or from the Townsville Port via rail
Calcium Carbonate - 10,000 tonnes via road or rail
Calcium Hydroxide - 35,000 tonnes via road or rail


Utility Requirements

Water on Startup: Operational Consumption = 14 Cubic meters per hour
Water post Startup: Standard Operational Consumption = 7 Cubic meters per hour
Recycled Water = 7 Cubic meters per hour
Electricity = 160 Kilowatt hour
Natural Gas = 165 Cubic meters per hour


Input Material and Associated Output Material


INPUT (Tonnes per Year) OUTPUT (Tonnes)
Rock Phosphate 45,000 DCP 30,000 Annually
Calcium Chloride (CaCl2) 2,000 Gypsum 61,500 Annually
Calcium Carbonate (CaCO3) 10,000 Residue Cake 16,500 Annually
Calcium Hydroxide (Ca(OH)2) 35,000 Off Gas 1.05 per hour
Sulphuric Acid (H2SO4) 30,000 Vapour 1.95 per hour

Producing DCP from MCP has the advantages of:

  • Producing pure Gypsum as a by-product
  • High quality DCP with very low impurity content
  • Less rock pretreatment required so no grinding or calcination (heating)
  • Lower percentage of Rock Phosphate (P2O5) rock can be processed
  • Better filterability due to reaction with a low concentration of Hydrochloric Acid (HCl)
  • Lower operating temperature of the process
  • Lower corrosion of plant and equipment due to the low HCl concentration and low temperature
  • High overall yield of P2O5


Environmental Impact - Emissions & Consumption

Off Gas - Scrubbers and filters will remove any noxious and problematic emissions
Acid Vapour - The reaction of the dilute HCl on Rock Phosphate results in a relatively small vapour yield. However, this will be captured and returned to the process cycle.
Water - Waste water will be fully recycled for the production process.
Water Consumption - Rainwater tanks will be installed and water collected from the plant roofing (if it ever rains again around Charters Towers).


Plant Construction

Labour, building materials and plant equipment will be sourced locally wherever local and Australian products/personnel are available.