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The Process Water Problem
Florida Institute of Phosphate Research
Florida Institute of Phosphate Research
• An Independent State Research Agency• Governed By a Board of Directors Appointed by
the Governor• Funded by the Severance Tax on Phosphate Rock
FIPR’s Mission
• Environment and Public Health Research
• Technology Research
• Education and Public Information
Florida Institute of Phosphate Research
Washerand
FlotationPlants
ChemicalPlant
Sand
Spoil
Clay
FertilizerGypsum
Overburden
Matrix
Phosphate
FIPR Research Priorities
• Technology– Mining and Rock Processing– Phosphogypsum and Process Water– Waste Clay Ponds
• Environment and Public Health– Environment– Restoration/Reclamation– Public Health
Florida Institute of Phosphate Research
• ~800 Million to 1 Billion Tons in Stacks in Florida
• ~30 Million Tons Being Added Each Year
Phosphogypsum Problem
Florida Institute of Phosphate Research
Concentrates ManufacturingConcentrates Manufacturing
Sulfur
Phos. Rock
Anhydrous Ammonia
Sulfuric Acid Plant
Air
SulfuricAcid
HeatHeat
Phosphate Rock Storage
PhosphoricAcid Plant
Phosphoric AcidPhosphoric Acid
Merchant GradeMerchant GradePhosphoric AcidPhosphoric Acid
GypsumStack
GranulationPlant
NH3 Storage
GranularGranularCrop NutrientsCrop Nutrients
Animal FeedIngredientsPlant
Defluorinated Feed Phosphates
ExportedElectricPower
Cogen-erationPlant
Concentrates ManufacturingConcentrates Manufacturing
Sulfuric Acid Plant
Phosphoric Acid Plant
Granulation Plant
Product Warehouses
Gypsum Stack
Animal FeedIngredientsPlant
Gypsum Production, 1997
Production(Mt/yr)
RelativeAmount
PG in Florida 30 1
Gypsum in US 20 0.67
Gypsum in World 114 3.80
Florida Institute of Phosphate Research
Process Water Problem
• Each stack has 1 to 3 billion gallons of process water
• pH is about 1 to 2
• Dilute mixture of– Phosphoric, sulfuric, fluorsilicic acids– Saturated with calcium sulfate– Contains numerous other ions and ammonia
Florida Institute of Phosphate Research
Process Water Problem
• Piney Point
• Other Gypsacks
Florida Institute of Phosphate Research
Piney Point Problem
• Approximately 1 billion gallons of low pH, high conductivity water
• Water near the top of the stack– Threatening to spill into Bishop’s Harbor
Florida Institute of Phosphate Research
• Trucking
• Lime treatment and removal
• Reverse osmosis with no pretreatment (US Filter)
• Ocean Dumping
• Pretreatment/reverse osmosis project (IMC/FIPR)-in negotiation
Piney Point Water Inventory Reduction
Florida Institute of Phosphate Research
Problems with Other Stacks
• There are approximately 20 other stacks which will eventually have to be closed
• The water in these stacks has a pH of 1 to 2
• The conductivity of the water is greater than at Piney Point
Florida Institute of Phosphate Research
An Example of Quality of Water at Other Stacks
Parameter Untreated Process Water
pH 2.1Conductivity (umhos/cm) 22,100Calcium mg/l 538Magnesium (mg/l) 223Sodium (mg/l) 2260Potassium (mg/l) 210Fluoride (mg/l) 4120Sulfate (mg/l) 6200Total Phosphorus (mg/l) 6600Ammonia Nitrogen (mg/l) 1240
Florida Institute of Phosphate Research
Possible Solutions
• Reduce the accumulation of phosphogypsum
• Reduce the amount of water on the stacks
• Improve the quality of the water on the stacks
Florida Institute of Phosphate Research
Potential Uses for Phosphogypsum
• Road building
• Agriculture
• Landfills
• Oyster Culch
• Roofing Tile
Florida Institute of Phosphate Research
Radioactivity of Phosphogypsum
Phosphogypsum pCi/g
Northern Florida 5 to 10
West Central Florida 20 to 35
Florida Institute of Phosphate Research
Activity Relative RiskLiving Near the Road 1Building the Road 2Driving on the Road (Radioactivity) 72Airplane Crash 65240K Decay in Your Body 1304Dying in a Fire 1957Drowning 4565
Relative Risks
Florida Institute of Phosphate Research
• Regulatory agencies
• Public fear of the word radioactivity
Florida Institute of Phosphate Research
Barriers to Phosphogypsum Use
Florida Institute of Phosphate Research
• Preproposal
• Proposal
• Reviewers
• Technical Advisory Committee (TAC)
• Staff Review
• Board Decision
Proposal Review Process
Keys to Success (Cont.)
• Listen to the advise of the research directors and the TAC
• Have demonstrated industry support
• Have co-funding
Florida Institute of Phosphate Research
How to Contact Us
Florida Institute of Phosphate Research
• Phone Number: 863-534-7160
• Web Page: www.fipr.state.fl.us
Who to Contact
• Mining and Beneficiation: Patrick Zhang, Ph.D.
• Chemical Processing, Phosphogypsum and Process Water: Mike Lloyd, B.S. Ch.E.
• Environment and Reclamation: Steve Richardson, Ph.D.
• Public Health: Brian Birky, Ph.D.
Florida Institute of Phosphate Research
