Subhashis Ghosh, Metso, analyses strategies that can be used to optimise fertilizer mining and processing.
Fertilizers have become a cornerstone of global food security. Since the 1960s, their increased usage has enabled modern agriculture to meet the nutritional demands of a rapidly growing population. Despite projections indicating a slowdown in population growth over the coming decades, the world is still projected to surpass 9 billion people by 2050, driving continued demand for efficient fertilizer production.
This demand exists alongside new challenges. The fertilizer manufacturing industry now faces evolving sustainability requirements, stricter regulations, fluctuating raw material costs, and shifting market dynamics. Meeting these challenges requires reliable, energy-efficient processes and technologies that enhance productivity whilst minimising impact.
From mine to market: the growing demand for phosphoric acid and potash
The three essential macronutrients in fertilizers are nitrogen, phosphorus, and potassium. While nitrogen is derived from air and does not require mining, phosphorus and potassium come from mineral deposits and require extraction and processing. Phosphate rock, a primary source of phosphorus, is typically mined using open-pit methods. Potash, which provides potassium, is extracted from deep-shaft mines or, at times, strip mines.
Global demand for phosphoric acid and potash continues to grow steadily. According to industry forecasts, global phosphoric acid supply capacity is expected to grow at approximately 4.2% annually from 2025 through the early 2030s, while demand is also projected to increase at around 4.2% per year.
Similarly, potash demand for agricultural applications is projected to increase approximately 4.5 - 5.3% per year. There are two common forms of potash – muriate of potash (MOP) and sulfate of potash (SOP). Unlike MOP, SOP is free of chloride, which is harmful to plants. As a result, SOP commands a premium price of approximately 50% as it is used primarily on high-value crops, such as leafy plants, fruits, and vegetables.
Integrated solutions
From ore extraction and beneficiation, to granulation and waste management, fertilizer production involves multiple stages, each of which presents opportunities for efficiency gains and sustainability improvements. Metso supports fertilizer producers through an integrated portfolio of equipment, plant, automation, and life cycle services across the entire processing flowsheet, including mining, comminution, beneficiation, filtration and tailings management.
Mining and comminution
The exploration and extraction of phosphate and potash ores are the first critical steps in fertilizer manufacturing. It is important for operations to achieve the required particle size for downstream processing, thus high throughput and energy efficiency are essential for maintaining competitiveness.
Metso’s portfolio includes the MPTM cone crushers and HRCTM high-pressure grinding rolls, which are capable of in delivering high throughput whilst maximising crushing performance at the lowest possible cost per ton. These technologies can help operators in reducing their energy consumption and improve downstream process performance, enabling better recovery in beneficiation.
To further optimise operations, Metso’s Process Optimisation (PRO) services provide consulting, laboratory analysis, and advanced digital tools for process improvement.
Beneficiation and filtration
Once the ore is reduced in size during comminution steps, phosphate and potash ores undergo beneficiation to separate valuable minerals from waste. Here, froth flotation remains a key technology for phosphate recovery. Metso’s portfolio includes advanced flotation equipment that is designed to maximise recovery and concentrate quality, as well as minimise reagent consumption. For example, with Metso’s ColumnCellTM technology, operations can increase phosphate recovery compared to conventional sparger systems. The ConcordeCellTM technology utilises high intensity pneumatic flotation by recovering unachievable fine and ultra-fine particles. These technologies complement Metso’s TankCell® technology.
The company’s automation portfolio, including samplers, online analysers, and plant control systems, ensure plant optimisation and maximisation of metallurgical benefits to customers. For example, Metso Courier® 8X SL enhances plant efficiency by enabling measurement of light elements, while improving recovery and reducing impurity content in flotation circuits. This addresses the need for phosphate concentrators as an application.
Filtration is another critical step in fertilizer processing. One example is Metso’s Larox® RT vacuum filter – which can handle the high tonnages common with fertilizer plants – enables multi-step counter-current washing to achieve high product purity with minimal water use. This is a key factor for sustainability in water-stressed regions.
These products and technologies can be offered as a fully integrated solution if so desired. This approach is enabled by seamless integration of functional design available in Metso plant units for each process area. The company can also assist with early stage offerings, such as end-to-end flowsheet development testwork, scoping and feasibility studies to mitigate techno-economic risks, and selecting the most sustainable flowsheet for a customer’s projects.
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