^Sa^^k- '^;l'>^-:>i^^:SiHi;-^-^ ■■■■ cy * cy t-^ V-^' ;• ../\. -J . /.'^,:..'\ .**.c:^.\. /.'J^>."\ .*^.c;^'. > 4 o ' » o S ^ V ^ av -fj '^b >*" '^^^r^^ '^'^ r,'^ c^ffl^^^^'" **:- •^ .7* ,0^ „,..'/\;-^^,^ ^- V^»<^^^>'' ^%:^^m\^^^' ^%-'X<^^^>"^ "v-^^^^^^ .. ,/.'^;:>- ./\v;^A. co^.^v% ./\c^.X >°/^;:.^o ./\^i ^ "% -,^ ^>, O^ 6 o " * "^o a'5^ . " « * ^ ^^ -% ^ .'l°.^ -^ V ^^1'°' "c^ ^0* .si^^lnL'*. '^■^ . .V .^1*°' "cu aP .*i.!;nL'* -i^ v* .^I'f' ^^^ \ \/ ^^ •C*^ tit. <* .^ V %/ *^^ - ? iP-T!,, •I o • « .V* -^-^^ --f^ ^"-^^^^ -':, --t. /..^^>>o ./\v:;i;cvV .d^.^^'^'^% ./^yJJ^^\. ^ ^^^' ';^o^ f" .. ^^Z*""''' 1^"^ q,. **i^.^*' aO .s'^^* ♦'^>. v^^ .•b'V.^ ^^-v. V ■/ .<.^' "^^ --^ t: J^' ^. . . 5 * />■ "■=v.** :'^~ r. "e.. A^ /^ ♦" ; ^^ n • f " " . V o'V "^^ '-V-..^V^ ..j> ^*l9^ ^/ :}^^' h''^^ \/ :Mm^ \.^ » ;'?^'* »*f«>i>t'. ^. IC 8989 Bureau of Mines Information Circular/1984 V Phosphate Rock Availability— World A Minerals Availability Program Appraisal By R. J. Fantei, T. F. Anstett, G. R. Peterson, K. E. Porter, and D. E. Sullivan UNITED STATES DEPARTMENT OF THE INTERIOR ^^^{l^^JiJMJir ■ ^UAJUM. rf¥^^ Information Circular 8989 Phosphate Rock Availability— World A Minerals Availability Program Appraisal By R. J. Fantel, T. F. Anstett, G. R. Peterson, K. E. Porter, and D. E. Sullivan UNITED STATES DEPARTMENT OF THE INTERIOR William P. Clark, Secretary BUREAU OF MINES Robert C. Horton. Director Library of Congress Cataloging in Publication Data: Phosphate rock availability— world. (Bureau of Mines information circular ; 8989) Bibliography: p. 55-56. Supt. of Docs, no.: I 28.27:8989. 1. Phosphate industry. 2. Phosphate mines and mining. I. Fan- tel, R. J. (Richard J.), II. Series: Information circular (United States. Bureau of Mines) ; 8989. TN295,U4 [HD9585.P482] 622s [333.8'5] 84-600128 ^ PREFACE k) ^ The Bureau of Mines Minerals Availability Program is assessing the Ji' worldwide availability of nonfuel minerals. The program identifies, iV, collects, compiles, and evaluates Information on active and developing mines, explored deposits, and mineral processing plants worldwide. Ob- jectives are to classify domestic and foreign' resources; to identify by k cost evaluation, resources that are reserves; and to prepare analyses of mineral availabilities. This report is part of a continuing series of Division of Minerals Availability reports to analyze the availability of minerals from do- mestic and foreign sources and those factors affecting availability. Analyses of other minerals are in progress. Questions about the Miner- als Availability Program should be addressed to Chief, Division of Min- erals Availability, Bureau of Mines, 2401 E St., NW. , Washington, DC 20241. iii CONTENTS Page Preface 1 Abstract 1 Introduction 2 Acknowledgments 2 World phosphate industry 3 Production 3 Exports 5 Objective 6 Evaluation methodology 7 Geology and resources 10 North America 12 United States 12 Canada 13 Mexico 14 North Africa 14 Morocco '. 14 Western Sahara 16 Algeria 16 Tunisia 16 Middle East 17 Egypt 17 Iraq 17 Israel 18 Jordan 18 Saudi Arabia 18 Syria 18 Turkey 18 Oceania 18 Australia and Christmas Island 18 Nauru 20 South America 20 Brazil 20 Colombia, Peru, and Venezuela 21 West Africa 22 Senegal 22 Togo 22 Southern Africa 23 Asia 23 Europe 24 Centrally planned economy countries 25 U.S.S.R 25 China 26 Mining and processing of phosphate 28 Mining methods 28 Surface 28 Strip level 29 Open pit 29 Dredging 29 Underground 29 Room and pillar 29 Overhand stoping 30 Longwall caving 30 XV CONTENTS — Continued Page Benef Iclatlon methods 30 Sizing 31 Washing 31 Flotation 32 Calcining 33 Drying 33 Byproducts 33 Phosphate deposit costs 34 Costing methodology 34 Production costs 35 Capital costs 38 Comparison of Florida and Moroccan costs 38 Phosphate rock availability 40 Economic evaluation methodology 40 Total availability 41 Market economy countries 42 Centrally planned economy countries 43 Annual availability 44 Effect of transportation 50 Conclusions 32 References 55 Appendix A. — Phosphoric acid production and costs 57 Appendix B. — World phosphate deposit information of those deposits included in the study 60 Appendix C, — Present research in phosphate 65 ILLUSTRATIONS 1. 1981 world production of phosphate rock, by region 3 2. Share of world phosphate rock production in 1961, 1971, and 1981: United States, Morocco, and U.S.S.R 3 3. Principal 1981 world exports of phosphate rock 5 4 . Flow chart of evaluation procedure 8 5. Mineral resource classification categories 9 6. Demonstrated phosphate rock resources, by region and geologic type 12 7 . Location map , North American deposits 13 8. Location map, north African deposits 15 9 . Location map , Moroccan deposits 15 10. Location map. Middle Eastern deposits 17 11. Location map, Nauru and Christmas Island deposits 19 12. Location map, Australian (Georgina Basin) deposits 19 13. Location map. South American deposits 21 14. Location map, west African deposits 22 1 5 . Location map , southern African deposits 23 16. Location map, U.S.S.R. and Finland deposits 24 17. Location map, Chinese deposits 27 18. Typical Florida phosphate washing circuit 31 19. Typical process flowsheet. Southeastern United States, incorporating f lotation process 32 20. Typical process flowsheet. Western United States, incorporating calcining process 33 ILLUSTRATIONS — Continued Page 21. Production costs for selected world phosphate surface mines and deposits. 37 22. Production costs for selected world phosphate underground mines and deposits 38 23. Phosphate rock potentially recoverable from all mines and deposits in market economy countries 42 24. Phosphate rock potentially recoverable from producing mines and nonpro- ducing deposits in market economy countries 44 25. Potential annual production from producing mines in market economy coun- tries at various cost levels 45 26. Potential annual production from developing mines and explored deposits in market economy countries at various cost levels 48 27. Phosphate rock potentially recoverable from all mines and deposits in market economy countries 50 A-1 . Wet-process phosphoric acid 58 TABLES 1. World production of phosphate rock, by region and country 4 2. International trade in phosphate rock, 1981 6 3. Summary of world demonstrated phosphate resources as of January 1981 11 4. Phosphate mill plant operating parameters, by region 31 5. Production costs for selected world phosphate surface mines and deposits. 36 6. Production costs for selected world phosphate underground mines and deposits 38 7. Capital costs to develop nonproducing surface phosphate mines in selected world countries 39 8. Comparison of nonproducing Florida and Morocco surface phosphate deposit costs 39 9. Estimated potential annual production capacities in market economy coun- tries by 1983 46 10. Estimated potential annual production capacities in market economy coun- tries by 1995 47 11. Estimated potential annual production capacities for undeveloped deposits at an average total production cost of less than $100 per ton of phos- phate rock in the year A^+IO, by country 49 12. Assumed destinations for phosphate rock, by country 51 13. Comparison of average total costs per metric ton of phosphate rock, f.o.b. mill and f.o.b. port or acid plant, by major producing region.... 52 14. World phosphate rock shipping charges 53 A-1. Phosphoric acid production costs, by region 59 UNIT OF MEASURE ABBREVIATIONS USED IN THIS REPORT in inch m meter km kilometer m^ cubic meter km2 square kilometer wt ' % weight percent PHOSPHATE ROCK AVAILABILITY— WORLD A Minerals Availability Program Appraisal By R. J. Fantel, ^ T. F, Anstett, ^ G. R. Peterson,^ K. E, Porter,-^ and D, E. Sullivan'* ABSTRACT The Bureau of Mines investigated the resource potential of 201 mines and deposits in 28 market economy countries and 17 mines and deposits in the U.S.S.R. and China. The 201 mines and deposits evaluated from market economy countries contain an estimated 34.2 billion metric tons of recoverable phosphate rock (at the demonstrated resource level) , with Morocco and Western Sahara accounting for 61% (21 billion tons), followed by the United States with 19% (6.4 billion tons). The 17 mines and deposits evaluated in the U.S.S.R. and China contain approxi- mately 1.5 billion tons of potentially recoverable phosphate rock. Potential annual capacity from low-cost, high-grade producing mines in the United States is estimated to decline significantly during the latter half of the next decade, and the United States will have to de- velop new, higher cost, lower grade mines in order to satisfy demand into the next century. Of the world's new production capacity which could likely be developed over the next decade, slightly over one-third could be produced at an estimated 1981 cost of $40 per ton or less, and about two-thirds would cost in the $40 to $50 range (including a 15% rate of return) . In comparison, most of the competing phosphate rock from producing mines in Morocco could be produced for under $40 per ton. The United States has sufficient demonstrated resources of phosphate rock (plus huge quantities at the identified and hypothetical resource levels) to satisfy domestic consumption for many years to come, but its future ability to compete in the major export markets against low-cost competitors is much more uncertain. ^ Geologist. ^Mineral economist. ^Mining engineer. ^Economist. Minerals Availability Field Office, Bureau of Mines, Denver, CO. INTRODUCTION Phosphate rock, the only significant commercial source of the element phospho- rus, is of vital importance to an expand- ing agricultural sector worldwide. Phos- phorus, nitrogen, and potassium are the three primary nutrients necessary for plant growth. When these elements are either lacking or depleted from the soil, their addition is necessary to rees- tablish high agricultural yields. The growth of world agricultural production partially depends on the availability of phosphate fertilizers. Phosphate rock consists of the calcium phosphate mineral apatite, with quartz, calcite, dolomite, clay, and iron oxide as the gangue constituents. Following industry practice, the term "phosphate rock" is defined in this paper as the beneficiated product of phosphate ore rather than the in situ material. After benef iciation, phosphate rock ranges from 26% to about 34% P2O5 (phosphorus pent- oxide) . Phosphate rock can be converted to phosphoric acid by the wet process, converted to elemental phosphorus in an electric furnace, or applied directly to acidic soils as direct-application ferti- lizer. The acceptability of phosphate rock for wet-process acid production is affected by the amounts of aluminum, iron, magnesium, and chloride in the con- centrates. Phosphate rock containing more than 1% magnesium oxide (MgO) , more than 3.5% iron oxide plus aluminum oxide, or more than 0.2% chlorine can cause problems in the manufacture of wet- process phosphoric acid. Most of the phosphate rock produced in the world is used to manufacture wet-process phosphoric acid. Phosphoric acid is produced by digesting the apatite mineral, i.e., phosphate rock, in sulfu- ric acid. Diammonium phosphate (DAP), a common bulk blending-grade fertilizer chemical, is produced by reacting phos- phoric acid with ammonia. If the phos- phate rock is reacted with phosphoric acid, triple superphosphate (TSP) is pro- duced. When wet-process phosphoric acid is subjected to evaporation, a higher concentration of phosphoric acid is pro- duced, which when reacted with ammonia produces a liquid ammonium phosphate fertilizer (j_).^ Phosphate animal feed supplements are produced by the def luorinization of ei- ther phosphate rock or phosphoric acid. Lime is reacted with def luorinated phos- phoric acid to produce dicalcium phos- phate. Phosphate rock at proper condi- tions and compaction is def luorinated in kilns at high temperature. These phos- phate animal feeds are necessary supple- ments to assure nutritional quality of livestock diets (J^) . Elemental phosphorus is produced by re- ducing phosphoric rock in electric fur- naces and is marketed as is , or oxidized to produce anhydrous derivations and phosphoric acid. Phosphoric acid pro- duced from elemental phosphorus is com- monly used to manufacture sodium tripoly- phosphate, a detergent builder. In countries with acidic soils , such as Brazil, phosphate rock can be ground, sold, and distributed for direct appli- cation with limited improvements in soil productivity compared with applica- tions of high-analysis soluble phosphate fertilizers. ACKNOWLEDGMENTS Data for the foreign mines and de- posits in the evaluation were provided by Zellars-Williams , Inc., under con- tract J0100122. Data for mines and de- posits in the Southeastern United States were developed by the former Bureau of Mines Eastern Field Operations Center in Pittsburgh, PA, in conjunction with Zellars-Williams, Inc. Data for the Western United States were developed by Bureau of Mines Field Operations Centers in Denver, CO, and Spokane, WA. ^Underlined numbers in parentheses re- fer to items in the list of references preceding the appendixes. WORLD PHOSPHATE INDUSTRY PRODUCTION Phosphate rock, was produced in 29 coun- tries during 1981 (table 1 and figure 1). The three main producers, the United States, the U.S.S.R., and Morocco, produced 104 million tons,^ which was 72% of total world production. World produc- tion during 1981 was over 145 million tons — over 73% more than in 1971, and more than three times as much as in 1961. Production from market economy coun- tries^ was just over 100 million tons ^Unless otherwise noted, "tons" in this report refer to metric tons. 'Market economy countries are defined by the Bureau of Mines as all countries that are not centrally planned economy countries. Centrally planned economy countries compries the following: Albania Bulgaria China Cuba Czechoslovakia German Democratic Republic Hungary Kampuchea Korea, North Laos Mongolia Poland Romania U.S.S.R. Vietnam during 1981, which was 70% of world pro- duction. During 1961 and 1971, produc- tion from countries with market economies was approximately 78% and 74% of world production, respectively. This shows a decline in the share of world production from market economy countries during the 20 years preceding 1981. Figure 2 illus- trates the share of world phosphate rock production from the three major producing nations for the years 1961, 1971, and 1981. South Amenco 2% Australia, Oceonio, and Far East 2% Other market economy countries 1% Total = 145,540,000 metric tons FIGURE 1, - 1981 world production of phosphate rock, by region. 1961 1971 1981 / United States X / United States X / \ United States \ ^\^ 42% \ A^^ 42 7o \ L / Morocco \ 37 % \ Morocco ^s^ \ Morocco ^\^^ / 14% ^ \ ] 1 8 %, y\ 1 1 4 /o ^^.,>'^ \ X \ U.S.S.R. 1 Y^^^^"^ \ U.S.S.R. i \ \ U.S.S.R. / ^ Other \ 19°/° / \ Other \ 23% / \ Other \ 28%> \ 2 1 % / \ 21%, \ / \ 21% \ y \ \ / Total = 45,299,000 naetric tons Total = 83,860,000 metric tons Total =145,540,000 nnetric tons FIGURE 2* - Shore of world phosphate rock production in 1961, 1971, and 1981: United States, Morocco, and U.S.S.R. TABLE 1. - World production of phosphate rock, by region and country' (2-5) (Thousand metric tons) Region and country' 1961 1971 1981 Market economy countries: North America: Mexico Netherlands Antilles (Curacao), United States Total^ , South America: Brazil Chile Colombia Venezuela Total^ , North Africa: Algeria Morocco and Western Sahara. ... Tunisia Total^ Other African countries: Senegal South Africa, Republic of Togo. Uganda Zimbabwe Total5 Middle East: Egypt Israel Jordan Syria Turkey , Total^ , Oceania and Far East: Australia Christmas Island Indones ia Kiribati (Banaba Island, formerly Ocean Island), Makatea Island (French Oceania) Nauru , Philippines , Total 5 , Miscellaneous countries: Belgium Finland France , Germany, Federal Republic of India Sweden^ , Total^ , Total market economy countries^ , Centrally planned economy countries: Chinae , Korea, Norths. Poland U.S.S.R.e Vietnam^ Total centrally planned economy countries^. Total world ^ 29 143 18,856 19,029 659 14 674 440 7,949 1,981 10,370 574 297 118 961 627 226 423 1,275 5 705 10 343 381 1,303 2,747 14 81 20 116 35,172 508 152 47 8,799 622 10,127 ^Estimated. 'Purely guano deposits not included on this table. ^Some producing countries may not be listed because of small quantities. ^Data may not add to totals shown because of independent rounding. ^Swedish material is byproduct apatite concentrate derived from iron ore 45,299 58 156 35,270 35,484 200 10 25 235 495 12,006 3,161 15,662 1,545 1,233 1,715 16 105 4,614 713 765 569 6 2,053 6 990 619 1,867 5 3,487 19 60 243 322 61,856 2,177 272 19,002 553 22,004 83,860 355 53,624 53,979 2,637 9 2,646 858 19,696 4,596 25,150 2,017 2,910 2,244 125 7,296 700 2,373 4,244 1,321 43 8,681 15 1,422 5 2,000 16 3,458 130 25 550 75 780 101,990 11,500 550 30,950 550 43,550 145,540 Phosphate production from North Ameri- ca, primarily the United States, was about 54 million tons in 1981. This was over 52% of the total production from market economy countries. During 1961, North America produced about 54% of the market economy total and during 19 71 over 57%. Production from South America was less than 3 million tons during 1981, less than 2% of total market economy production. Phosphate rock production from north Africa, over three-fourths of which was from Morocco, was 25 million tons dur- ing 1981. This was almost 25% of market economy production, nearly the same per- cent as 10 years ago. Twenty years ago, the north African share was almost 30%. Other African countries produced over 7 million tons during 1981, which was more than 5% of market economy output. These countries produced 7% 10 years ago, while 20 years ago they produced less than 3% of market economy production. Phosphate rock production from coun- tries in the Middle Eastern area, includ- ing Egypt and Turkey, was over 8 million tons during 1981, over 8% of market econ- omy production. This share of market economy production is double that of 10 and 20 years ago. Phosphate rock from Australia and Oce- ania during 1981 was over 3 million tons, which was over 3% of market economy pro- duction. The share of phosphate rock production from this area has declined from almost 6% during 19 71 and almost 8% during 1961. Production from other market economy countries historically totals less than 1% of total market economy production. Phosphate rock production from central- ly planned economy countries was over 43 million tons during 1981. This was 30% of world production, up from 26% during 1971 and 22% during 1961. The U.S.S.R. produced almost 31 million tons during 1981, over 71% of production from cen- trally planned economy countries. China produced over 11 millions tons, which is over 26% of centrally planned economy production. Production from centrally planned economy countries increased at a faster rate than production from the world as a whole between 1961 and 1981. EXPORTS World trade in phosphate rock during 1981 is shown in table 2 (2) and illus- trated in figure 3. The table shows the destination of phosphate rock from eight major exporting areas to the major im- porting area of each. It must be noted that this table only shows exports of phosphate rock and not phosphoric acid or other processed products, and that these are to major importing areas and may omit small-volume exports to other areas. The phosphate rock that is not exported di- rectly by a country is either consumed domestically or exported after further processing. The table shows that during 1981, prin- cipal exports of the United States to- taled nearly 9 million tons of phosphate rock, almost 17% of 1981 production. Morocco exported almost 15 million tons of phosphate rock, which was over 76% of its 1981 production. Algeria and Tunisia together exported 1.6 million tons, more than 29% of their combined domestic Total expofts= 41,400,000 metrictons FIGURE 3. - Principal 1981 world exports of phos- phate rock. TABLE 2. - International trade In phosphate rock, 1981 (2) (Includes only principal exporting sources and destinations) Exporting source and destination of exports United States: Western Europe Canada Asia South America Eastern Europe Total Morocco: Western Europe Eastern Europe South America Asia Total Algeria and Tunisia: Eastern Europe Western Europe Total Israel and Jordan: Asia Eastern Europe Western Europe Total Quantity, 10^ metric tons 3,525 3,200 1,486 481 254 8,946 10,181 2,848 1,103 859 14,991 807 794 1,601 1,962 1,438 1,431 4,831 production, Israel and Jordan together exported almost 5 million tons, which is 83% of their combined production, Sene- gal exported 1 million tons, almost 52% of production. Togo exported over 2 mil- lion tons, almost 95% of production. The U.S.S.R, exported over 5 million tons, about 16% of production. The Pacific Is- lands exported almost 3 million tons, 100% of production. The United States exported significant quantities of chemical phosphate products Exporting source and destination of exports Senegal: Western Europe Asia Total Togo: Western Europe Eastern Europe Total U,S.S,R,: Eastern Europe Western Europe Total Pacific Islands: Australia New Zealand Indonesia, Republic of Korea, Malaysia, Singa- pore , and Japan Total Quantity, 10^ metric tons 826 215 1,041 1,393 712 2,105 4,067 948 5,015 1,767 853 231 2,851 during 1981, These included 1,5 million tons of greater than 40% superphosphates, 2,000 tons of less than 40% superphos- phates, 3,9 million tons of dianmionium phosphates, 1 million tons of less than 65% P2O5 phosphoric acid, 500,000 tons of more than 65% P2O5 phosphoric acid, and 28,000 tons of elemental phosphorus (_3 ) , Morocco, which now exports mostly un- processed phosphate rock, has plans to develop acid plants to increase the value of the phosphate rock before export. OBJECTIVE The United States has traditionally been the world's largest producer and net exporter of phosphate rock and re- lated products. However, the U,S, pro- ducers are facing the challenge of for- eign competition for export markets (primarily from Morocco) , and rising pro- duction costs for Florida phosphate will make it more difficult to meet foreign competition in future years. This study was undertaken to assess the worldwide availability of phosphate rock, rec- ognizing the critical importance of phosphorus to maintain agricultural pro- duction; and to compare the cost of pro- ducing phosphate rock in the United States with costs in other phosphate- producing nations. A detailed study of the availability of phosphate from the United States, "Phosphate Availability — Domestic, A Min- erals Availability Program Appraisal," was recently published (6^) . The data concerning U.S. mines and deposits in this world report are all from that study. EVALUATION METHODOLOGY For this study, a total of 201 mines and deposits were evaluated (130 domestic and 71 foreign). These deposits include resources of phosphate rock, at the demon- strated level which can be mined and milled using current technology. An ad- ditional 17 mines and deposits in the U.S.S.R. and China, although not included in the evaluation, are discussed in this report. They were not included in the availability analysis owing to uncertain- ty as to the accuracy of the cost data. Typically, beneficiated phosphate rock contains 7% to 20% moisture. Currently many processes to convert phosphate rock into its numerous end uses will accept wet rock feed, although less than 3% moisture is desirable. The final product in this study is defined as dry phosphate rock. For this study, the term "phos- phate rock" refers to the beneficiated product, and "phosphate ore" refers to the minable material in the ground. For purposes of consistency, it was as- sumed in the evaluation that all rock produced at a mine was transported to a local port for export unless that rock was being used for internal domestic con- sumption. If internally consumed, the rock was transported to a nearby acid plant or market. Typical world phosphate rock shipping charges are listed in the availability section later in this re- port. Additional costs for further pro- cessing of phosphate rock into its many end products were not included in the evaluation, although appendix A does dis- cuss phosphoric acid production and re- lated costs throughout the world. The analysis methodology of this study follows: 1. The quantity and grade of phosphate ore resources were evaluated in relation to physical and technological conditions that affect production from each deposit as of the study date, January 1981. 2. The capital investments and operat- ing costs for appropriate mining, concen- trating, and processing methods were es- timated for each mine or deposit. 3. An economic analysis of each opera- tion determined its average total produc- tion cost over its entire producing life and the associated total demonstrated tonnage of phosphate rock that could po- tentially be recovered at specific pro- duction levels. 4. Upon completion of the individual property analyses, all properties in- cluded in the study were simultaneously analyzed and aggregated onto phosphate rock availability curves. These curves are aggregates of total potential phos- phate rock that could be produced over the life of each operation, ordered from the lowest cost deposits to the highest. The curves illustrate the comparative costs associated with any given level of potential total output and provide an es- timate of what the average long-run phos- phate rock price (in January 1981 dol- lars) would have to be in order for a given tonnage to be potentially avail- able. The long-run price that each oper- ation would require to cover its average total cost of phosphate rock production would provide revenues sufficient to cover the average total cost of produc- tion, including a return on investment high enough to attract new capital. The rate of return used in this study is a 15% discounted cash flow rate of return (DCFROR) on the total investments of each operation. The data collected for this report are stored, retrieved, and analyzed in a com- puterized component of the Bureau of Mines Minerals Availability Program. After a deposit was selected for the analysis, an evaluation of the operation was begun. The flow of the Minerals Availability evaluation process from de- posit identification to analysis of availability information is illustrated in figure 4, measured plus indicated tonnages (fig. 5). Generally, reserve and resource ton- nage and grade calculations presented in this paper were computed from specific measurements, samples, or production data, and from estimations made on geo- logic evidence. Selection of deposits was limited to known deposits that have significant dem- onstrated reserves or resources. Re- serves are material that can be mined, processed, and marketed at a profit under prevailing economic and technological conditions. Resources are concentrations of naturally occurring solid, liquid, or gaseous materials in the Earth's crust in such form that economic extraction of a commodity is currently or potentially feasible (_7 ) . Information on the indi- vidual phosphate mines and deposits in- cluded in this study (such as ownership, status, deposit type, grade, and capac- ity) is in appendix B. For the deposits analyzed, tonnage es- timates were made at the demonstrated resource level based on the mineral resource-reserve classification system developed jointly by the Bureau of Mines and the U.S. Geological Survey (_7 ) . The demonstrated resource category Includes To be included in the analysis, U.S. phosphate deposits had to meet technolog- ical criteria representing current ac- ceptable U.S. industry standards at the time of the analysis. The criteria shown below for the southeastern deposits should be viewed as guidelines rather than an absolute lower limit (8^) . Al- though not used in this study, a new set of criteria for classifying phosphate rock resources has recently been com- pleted (9^). In the current criteria, an exception is made to the deposit size requirement if the deposit is adjacent to larger identified deposits or is in a hardrock area. In the first three cases below the stipulated radius equates to the resource ore body covering one-half of the area of the deposit, at an average of 2,500 tons per acre (.6), 1. Deposit size must be more than 5 million tons of recoverable phosphate rock, and this rock must be within an dentif ication and [" Mineral ^ Indust r ies 1 Location 1 ' System 1 1 (MILS) 1 1 data J « MAS compu ter dota base se lection of deposits To n n g e and grade dete rmination P ^ Engineering and cost eva 1 u at ion i ' ^ Deposit report pr epora tion ^ MAS per mane n t de posit fi Ies r 1 f Data selection and va I idatlon Taxes, royalties, cost indexes, prices, etc. Economic analysis Dato Availability r curves Analytical reports Variable ond parameter adjustments Sensitivity analysis {y DotQ Availability curves Analyticol reports FIGURE 4. - Flow chart of evaluation procedure. Cumulative production IDENTIFIED RESOURCES UNDISCOVERED RESOURCES Demonstrated Inferred Probability range Measured Ind icaled (Or I Hypothetical Speculative ECONOMIC -f - MARGINALLY ECONOMIC SUB- ECONOMIC Other occurrences Includes nonconventional and low-grade materials FIGURE 5. - Mineral resource classification categories. average radius of 1.5 miles from the cen- ter of the ore body. 2. Deposit size must be more than 10 million tons of recoverable phosphate rock if the average overburden thickness is more than 6 m, and this rock must be within an average radius of 2,5 miles of the ore body centroid, 3. Deposit size must be greater than 15 million tons of recoverable phosphate rock if the overburden average thickness is more than 9 m, and this rock must be within an average radius of 2.5 miles from the center of the ore body. 4. The flotation feed grade must be more than 4.6% P2O5. 5. The concentrate grade must be more than 27.5% P2O5. 6. The phosphate concentration must be 1 ton of recoverable product per 8 m^ of ore. 7. The ore zone must be more than 2 ra thick. 8. Phosphate rock product must contain less than 1,5% magnesium oxide (MgO). (Resources of high-MgO phosphate deposits were quantified in this report and tech- nological developments are discussed, but deposits containing greater than 1% MgO were not evaluated in this study.) The following criteria for developing resource estimates of Tennessee phosphate represent a range that the central Ten- nessee phosphate companies recognize as those representing acceptable minable deposits (_6) : 1, A minimum cutoff grade range of 16% to 17,2% P2O5. 2, Minimum ore thickness range of 0.6 to 1.2 m. 3. Maximum overburden-to-ore range of 3:1 to 4:1. ratio 4. A minimum ore body size of 22,675 dry tons of phosphate rock. The average ore body is small — 150,000 to 1.2 million tons — which means that 10 deposits at a number of separate loca- tions may have to be mined to satisfy one company's annual requirement. The study criteria for explored depos- its in Utah and Wyoming include a minimum ore thickness of 0.91 m and a minimum average grade of 18% P2O5. For economic classification, minable resources were further subdivided by depth, thickness, dip, grade, and probability of occur- rence. Resources above adit entry level^ were estimated and economically evaluated after site-specific corrections were ap- plied. The quantity of resources occur- ring below adit entry level was not costed or economically evaluated in this study because of its extremely high re- covery cost. The foreign deposits included in the analysis had to meet the following criteria: 1. Producing properties accounting for at least 85% of the phosphate rock pro- duction from each significant world pro- ducing country. 2. Developing and explored deposits where the demonstrated phosphate rock reserve-resource quantity was equivalent to at least the lower limits of the reserve-resource quantity of the produc- ing deposits. 3. Past producing deposits where the remaining demonstrated phosphate rock reserve-resource quantity was equivalent to at least the lower limits of the reserve-resource quantity of the produc- ing deposits. Evaluation of each phosphate prop- erty included determining phosphate re- sources, deposit development, technolo- gies, and costs. Information on the average grades, ore tonnages, and differ- ent physical characteristics affecting production from domestic phosphate depos- its was obtained from numerous sources , including Bureau of Mines and Geological Survey publications, professional jour- nals. State and industry publications, annual reports, company lOK reports, prospectuses filed with the Securities and Exchange Commission, data made avail- able to the Bureau of Mines by private companies (domestic and foreign) or via contract, and estimates made by Bureau personnel based on personal knowledge and judgments. GEOLOGY AND RESOURCES Following is a discussion of the depos- its evaluated as part of this study. For nearly every country, a brief discussion is included for each deposit evaluated; however, for certain countries such as Morocco and the U.S.S.R., where it is impractical to mention each deposit indi- vidually, the geology and resources of the regions containing several deposits are discussed. Demonstrated resources used in the analysis are listed in table 3 and shown graphically on figure 6. Not all numbers in table 3 agree precisely with those contained in the text, as text numbers ^The adit entry level is defined as the nearly horizontal access to the minable resource. The adit level also serves as a conduit for natural mine water drainage. were obtained directly from published sources , whereas the table shows numbers derived from data obtained for this anal- ysis, some of which are confidential. Confidential figures, however, are in- cluded within aggregated numbers in the table. Morocco has an enormous phosphate re- source, accounting for over 56% of the total demonstrated resource included in this analysis and for nearly 59% of total demonstrated resources in market economy countries. The United States is a dis- tant second, with approximately 19% of total market economy countries' demon- strated resources. Based on Bureau of Mines estimates of long-term world demand for phosphate rock, which is projected to grow at an average annual rate of 3.2% through the end of the century to a cumu- lative total of approximately 3.7 billion 11 TABLE 3. - Summary of world demonstrated phosphate resources as of January 1981 In situ ore In situ Recoverable Rock product Region and county tonnage, 10^ grade. rock product. grade, wt % metric ton wt % P2O5 10^ metric ton P2O5 Market economy countries: North America: Canada 120 1,127 27,462 20 5 10 35 121 6,382 39 Mexico 31 United States 30 Total NAp NAp 6,538 NAp North Africa: Morocco and Western Sahara.... 38,143 30 20,920 32 Tunisia and Algeria 741 26 375 31 Total NAp NAp 21,295 NAp Middle East: Egypt 1,757 26 1,026 28 Israel 179 26 91- 33 Jordan 1,194 27 525 33 Syria, Iraq, Saudi Arabia, and Turkey 1,167 23 492 32 Total NAp NAp 2,134 NAp Australia (including Christmas 1,516 18 551 34 Nauru 26 38 16 39 Total NAp NAp 567 NAp South America: Brazil: Igneous 2,130 531 9 13 270 136 36 Sedimentary 35 Colombia, Peru, and Venezuela 2,612 7 248 30 Total NAp NAp 654 NAp West Africa: Senegal and Togo... 640 29 183 34 Southern Africa: Angola and Zimbabwe 50 14 11 35 Republic of South Africa 21,496 6 2,638 37 Total NAp NAp 2,832 NAp Other market economy countries: (') (') 158 36 Total market economy NAp NAp 34,178 NAp Centrally planned economy China 337 26 208 28 U.S.S.R. Igneous 2,699 2,354 14 14 654 679 39 28 Total centrally planned economy countries NAp NAp 1,541 NAp Total world NAp NAp 35,719 NAp NAp Not applicable. In situ tonnage and grades not geologic types. averaged because of combining deposits of different 12 Centrally planned economy countries 4.37c Other market economy countries 3.9% Other African countries 7.9% Middle East 6.0% Total = 35.7 billion metric tons FIGURE 6t - Demonstrated phosphate rock resources, by region and geologic type. tons (2^) , Morocco alone has sufficient resources to provide for world demand far into the future. On the basis of geologic type, sedimen- tary deposits contain nearly 90% of the total demonstrated resource of 35,7 bil- lion tons. Significant igneous deposits, which account for the remaining demon- strated resources, are located in Canada, Brazil, South Africa, Finland, and the Soviet Union, U,S. demand is expected to grow at an average annual rate of 2% in the future (2^), Given the necessary productive ca- pacity, the United States can meet its needs into the next century. The United States has inferred re- sources estimated on the order of 7 bil- lion tons, while the total for all mar- ket economy countries is over 20 billion tons. In addition to the demonstrated and inferred resources evaluated as part of this study, the Bureau of Mines and U,S, Geological Survey have reported that there is a total of about 95 billion tons of phosphate rock resources in the world (10) , These include inferred, hypothe- tical, and speculative resources. NORTH AMERICA United States The United States is the world's largest producer of phosphate rock, ac- counting for nearly 54 million tons in 1981. The geology and resources of U.S. phosphate have been treated in a recent Bureau publication (6) and are not ad- dressed in detail here. However, a brief summary is warranted to provide a compar- ison of geology and resources of U,S, phosphate with those of the rest of the world. U.S. phosphate resources are concen- trated in two geographical areas: the Southeast (especially Florida and North Carolina) and the West (Idaho, Montana, Utah, and Wyoming) (fig, 7), Phosphates in Florida, Georgia, and South Carolina are in the Hawthorn Formation of middle Miocene age, and in the Bone Valley For- mation and younger formations that con- sist of reworked Hawthorn sediments. The 13 important commercial deposits consist of pebble- and sand-size grains of carbonate fluorapatite and quartz in a clay- and silt-size matrix. Deposits in North Carolina are in the middle Miocene Pungo River Formation and consist of carbonate fluorapatite pel- lets, quartz sand, and minor clay and carbonate. The central land-pebble district in central Florida has been the largest pro- ducer of phosphate in the world for many years. The deposits there have an ore zone ranging in thickness from 3 to 8 m, with overburden of 3 to 10 m. Total dem- onstrated in situ resources for the Southeastern United States are 23 billion tons at an average grade of 7% P2O5 , re- sulting in approximately 4 billion tons of recoverable product. There are esti- mated to be an additional 6 billion tons of product at the inferred level {6), The phosphate deposits of the Western United States occur in the Permian Phos- phoria Formation, with phosphate rock composed primarily of carbonate fluorapa- tite pellets, oolites, pisolites, nod- ules, and bioclasts. Ore is mined prin- cipally from the upper and lower zones of the Mead Peak Member. The two zones range in thickness from 9 to 18 m and are separated by the sandstone, shale, and carbonate of the middle zone, which typi- cally is 30 m thick. Overburden is com- monly 5 to 10 m thick. Only the altered rock portion of the total resources was evaluated as part of this study because unaltered phosphate-bearing rock contains high amounts of impurities (magnesium and iron) and is presently uneconomic. Total demonstrated in situ resources for the deposits evaluated are 4.9 billion tons averaging 21.3% P2O5 , resulting in 2.5 billion tons of product. There is an ad- ditional 1 billion tons of recoverable product at the inferred level, most of which is unaltered (6). Canada Phosphate in Canada occurs mainly as accessory apatite in carbonatlte in northern Ontario and western Quebec, The Ontario Carbonatite Province contains some 50 known carbonatite complexes over an area of 1.3 million km^. All carbona- tite complexes that have been examined for their mineral potential contain apa- tite grading from 5% to 25% P2O5. Some have been enriched in apatite by removal of carbonate by leaching. Only the Car- gill deposit (fig. 7) was evaluated for this study because it is the only deposit that has been studied in sufficient de- tail to allow for a complete analysis and is the most promising in terms of its potential as a future phosphate producer. The Cargill deposit, located 640 km northwest of Toronto, was discovered in 19 75. It is a high-grade residual phos- phate on a karst topography. The deposit is covered by a layer of glacial lake clay averaging 7m in thickness, and sand, clay, gravel, and silt from to 130 m thick. The residual phosphate deposit reaches up to 170 m thick in troughs and sinks but is missing or very thin on topographic highs. In situ re- sources, assumed to be demonstrated for this study, are about 120 million tons. >hS / ^ HUDSO N BAY\, ^ ^&\6 CANADA ^- ^ r^ N \\ i a' /^^^ " 1 1 ^ i s j UNITED STATES ^ paciric >-.._ ATLANTIC OCEAN \^ '~\^^ .^r— #' OCEAN MO l/DpO MEXICoM '—^BELIZE CO «=- 5 17 ^HONDURAS dominican , /republic f-4 PUERTO i<--^ '='HICO ^HAITI • StoH.lr-' GUATEMALA-—^ z-X-^,^ T — NICARAGUA ■> LEGEND A Discrete individual deposits (.,_,/ Several deposits within a district FIGURE 7. - Location mop, North American depos- its, ], Cargill; .-, San Hilario (inferred only); 3, San Juan de la Costa; //, Santo Domingo; f), Florida; 6, North Carolina; 7, Tennessee; 8, Western United States (Idaho, Montana, Utah, Wyoming), 14 Grade has been reported to average 19.6% P2O5 m). Mexico Mexico has several phosphate deposits. Those that were evaluated are located on the Baja California peninsula. The most significant deposits, San Juan de la Costa (producer) and Santo Domingo (under development) , were evaluated at the dem- onstrated level. Together they contain 121 million tons of recoverable phosphate rock. San Hilario, a nonproducer, has only inferred resources at this time. Locations of the three deposits are shown in figure 7. The La Negra property, lo- cated in Hidalgo State at Zimapau, al- though accounting for a portion of Mexi- co's annual production, was not included in this study because of its insignifi- cance on a world scale, San Juan de la Costa is 100 km north of La Paz on the eastern coast of Baja Cali- fornia Sur. It was discovered in 1976, and production began in January 1981, The phosphorite is in the lower Miocene Monterrey Formation, which consists of alternating beds of sandstone, clayey sandstone, sandy shale, shale, and silt- stone. The formation's two members at- tain a combined maximum thickness of 110 m. The lower member is 70 m thick and contains some phosphatic oolite beds that grade 1% to 9% P205* The upper member contains the economic phosphate beds. The phosphatic zone consists of five hor- izontal beds which range in thickness from 0,8 to 1,5 m; the thickest and most economical bed is referred to as the Hum- boldt Superior, with a thickness of 1,5 m and an average P2O5 content of 19%, The deposit is reported to contain 50 million tons of in situ reserves averaging 18% to 20% P2O5 (JJ^), The Santo Domingo deposit, 110 km north-northwest of La Paz along the Pa- cific coast of Baja California Sur, con- sists of phosphate pellets in recent beach sands. The pellets were derived from Miocene sediments. In situ reserves are estimated to be more than 1 billion tons averaging about 5% P2O5 (13) , Only about 4% of the total l,500-km2 phosphate-bearing area had been explored in detail by 1979, and there are presumed to be substantially more resources in the deposit. San Hilario is situated in the center of the Baja California peninsula, 80 km west-northwest of La Paz. The phosphatic zones occur within the Monterrey Forma- tion and consist of two well-defined beds, each of which is about 0.5 to 1.2 m thick. Inferred in situ resources at San Hilario total 760 million tons averaging 14% P2O5 (14). The deposit was discov- ered in 1974, but its unfavorable loca- tion and problems in benef iciation and mining have resulted in a decision to forego development, NORTH AFRICA Morocco Morocco is the world's largest exporter and third largest producer of phosphate rock, with a 1981 production of 19.7 mil- lion tons. It has enormous resources, with over 20 million tons of recoverable phosphate rock at the demonstrated re- source level, or 56% of the total con- tained in deposits evaluated for this study. Inferred resources in Morocco to- tal about 5 billion tons of recoverable product, part of which cannot be benef i- ciated at the present time. Moroccan deposits are located in three regions: the Oulad Abdoun Plateau, the Ganntour Plateau, and the Meskala district (figs. 8-9) . Production of phosphate began in 1921 near the town of Khouribga on the Oulad Abdoun Plateau, where the country's richest and most extensive deposits oc- cur. Production from the Ganntour Pla- teau began in 1932 at Youssoufia, while the Meskala phosphates, although discov- ered in 1908, have yet to be exploited. Morocco plans to begin production there by the late 1980' s. All three phosphate-bearing regions lie within a northeast-southwest-trending belt of Upper Cretaceous and Eocene sedi- ments, about 350 km long. The main phos- phatic suite on the Oulad Abdoun Plateau 15 S s=>i s y... -ffff-NfJS 5fJ _v*-^~~7^ VO . . . \^^ /^"'"^ ^ ' " /N^_ / -X ^5; ^ 1 ^^^' y \ ^TUNISIA T , — ' s / ^IBYA y \ ALGERIA \ r" ~ k. r /^^^ ^^\ V •esTERH r— ^ SikHAR* \. /■" MAURITANIA UAUI ^ / X^ y^mazR LEGEND A Discrete individual deposits !, / Several deposits within a district FIGURE 8. - Location map, north African depositst 1, Djebel Onk; J, Ganntour Plateau; J, Meskala Dis- trict; -l, Oulad Abdoun Plateau; 5, South Basin (Kef Eschfair, M'Dilla, Metlaui, M'Rata, Moulares, Red- eyef, and Sehib); 6, Kalaa Khasba; 7, Bou Craa, 1 ^^^^"•COJOOI ..c= i 1 / /^ « B C C Ai Borogi;;/^ »<- Ourod- Abdo»*t Ploteoj yWEsMOwn 90 KB 190 IaM.» LEGEND Discrete individual deposits Several deposits wittiin a district FIGURE 9, - Location map, Moroccan deposits. 1, Ben Guerir (BenGuerir, El Outa, Nzala, Tessaout); 2, Youssoufia Black Rock; 3, Youssoufia Open Cast; 4? Youssoufia White Rock; 5, Meskala District (Chicha- ouc and Imi N'Tonoute); fj, Dooui Nord; 7, Daoui-Re- cette 4; 8, Khouribga Underground; 9, Meraa El Arech; ]0, Sidi Hajjaj; 11, Southern Khouribga Region, consists of sandy oolitic beds alternat- ing with marl, clay, phosphatic lime- stone, and some chert. The ore zone ranges in thickness from 50 m in the south at Al Borouj , where 10 distinct beds are present, to about 25 m at Khour- ibga in the north. Total demonstrated in situ resources on the Oulad Abdoun Pla- teau are about 7 billion tons at an aver- age grade of 30% P2O5. The Ganntour Plateau is southwest of the Oulad Abdoun Plateau (fig. 9). Al- though the phosphatic section thins from west to east, there is an increase in the number of beds of high enough grade and thickness to warrant exploitation; thus, the average ore zone thickness at Yous- soufia (west end) , where mining is confined to one bed, is less than 3 m, whereas at Ben Guerir, several kilometers east of Youssoufia, the ore zone reaches a maximum of 50 m (average, 12 m) , and there are 23 beds in the section. Over- burden thickness ranges from an average of 6 m at Ben Guerir to an average of 50 m at Youssoufia, where underground mining has proceeded to the south into an area of increased overburden thickness. Total demonstrated in situ resources in the Ganntour Plateau region are about 11 bil- lion tons averaging about 30% P2O5. Phosphate resources in the Meskala dis- trict occur on the northern slope of the High Atlas range, near Imi N'Tanoute, and farther north near Chichaoua. The main phosphate beds contain a total of 18 billion tons of demonstrated in situ re- sources averaging nearly 32% P2O5. Near Imi N'Tanoute, the beds have been folded and faulted. This situation will render mining a difficult undertaking relative to the other Moroccan deposits, which are essentially flat-lying. Morocco is pursuing a policy of expand- ing phosphate production and constructing facilities to convert phosphate rock to phosphoric acid. A new port and acid plant complex, Jorf Lasfar located at El Jadida, is expected to accommodate pro- duction increases from areas currently 16 exploited, while a new port will probably be built at Essaouira to handle future production from the Meskala district. In addition, Morocco plans to begin extrac- tion of uranium from acid produced at Safi, where the first such plant is to be built. Western Sahara The Bou Craa deposit is in the El Aaiun Basin, 100 km inland from the port of Aaiun (fig. 8). It was discovered in 1947, production began in 1972 but was severely curtailed in 1976 following sab- otage of the 100-km-long conveyor system used to transport rock from the deposit to Aaiun. The operation was completely inactive in 1980 and 1981, but was re- started late 1982. The Bou Craa deposit is in Upper Creta- ceous and Paleocene sediments in the northern end of the Aaiun Basin. At Bou Craa Wadi, where the richest phosphates occur, the grade averages 32% P2O5 > and the ore zone is 5 to 6 m thick. Total in situ resources, assumed to be demon- strated for this study, are 1.6 billion tons (15) . Overburden consists mainly of quartz sand and silt, with some calcare- ous conglomerate and limestone. Thick- ness varies from to 40 m, averaging 18 m. Algeria The most important phosphate resources in Algeria are at Djebel Onk, 320 km south of the port of Annaba (fig. 8). Phosphate has been mined in Algeria since its discovery in the late 1800' s, but mining at Djebel Onk, which accounts for over 90% of the country's production, be- gan in 1967. The other Algerian mine, Djebel Koif , has a long history of pro- duction, but is nearly exhausted. Only Djebel Onk was evaluated as part of this 8 tudy . Phosphate beds at Djebel Onk, upper Pa- leocene in age, are exposed in two anti- clinal structures, where the ore zone averages about 30 m thick. Overburden thickness ranges from to 120 m, averag- ing 25 m. In situ reserves have been conservatively estimated to be about 500 million tons (15) at an average grade of nearly 25% P2O5 . Algeria plans to nearly double produc- tion at Djebel Onk by 1986 to provide phosphate rock for expanded acid plant facilities at Annaba and Tebessa; how- ever, expansion plans were temporarily shelved in 1982. Water used to process the ore must be piped 90 km to Djebel Onk, and availability of water could lim- it further production. Tunisia Phosphate was first produced in Tuni- sia in the late 1800' s. There are eight active mines , seven of which are in the Gafsa area: Kef Eschfair, M'Dilla, Metlaui, M'Rata, Moulares , Redeyef , and Sehib (fig. 8). The eighth mine, Kalaa Khasba, is in the Tebessa-Thala area. Total demonstrated recoverable phosphate rock resource for the eight deposits studied is 126 million tons. The seven Gafsa mines are in the South Basin, an area of 129 km by 40 km with an east-west axis. Phosphates are contained in upper Paleocene to lower Eocene lime- stone and marl within an east-west- trending series of anticlines and syn- clines with average dips of 20°. There are nine phosphate-bearing beds , not all of which are present everywhere in the basin. Individual beds range from 1 to 10 m in thickness; ore zone thickness ranges from 2 m at Redeyef and Sehib to 10 m at Kef Eschfair. All but Kef Esch- fair are underground operations, with overburden thicknesses averaging from 100 to 200 m. Overburden thickness averages 25 m at Kef Eschfair. In addition to the operations listed above, Tunisia plans to begin operations at four other areas (with a total of 393 million tons of inferred in situ re- sources) by 1990. The four areas are Djellabia, Kef Eddour, Oum el Kecheb, and Sra Ouertane ( 16 ) . All but Sra Ouertane are located in the Gafsa area. They were not evaluated because of insufficient data at the time of this study. 17 MIDDLE EAST Twenty-two deposits in seven Middle Eastern countries were considered for this study. Those that contain only in- ferred resources were only quantified, not evaluated with respect to cost. Countries containing deposits and number of deposits evaluated follow: Egypt (7), Iraq (1), Israel (4), Jordan (4), Saudi Arabia (2), Syria (3), and Turkey (1). All deposits studied lie within a belt of Upper Cretaceous sediments that stretches from Turkey to Morocco (fig. 10). Total recoverable phosphate rock resources in Middle East deposits evaluated are 2,135 million tons at the demonstrated level. Egypt Phosphate in Egypt is contained in three areas: the Nile Valley, the Red Sea area, and the Western Desert. Eval- uated deposits that contain resources at the demonstrated level include Abu Tar- tur, Hamrawein, Quseir, Safaga, and Sabaiya East and West. Also included in the study is the Qena deposit, with re- sources only at the inferred level. All but Abu Tartur and Qena are producing. Sabaiya West is a surface operation. All other producing deposits are underground operations owing to the thickness of overburden, which averages in excess of 100 m. The bulk of Egyptian production comes from Safaga and Quseir, near the Red Sea. Phosphate has been known in the Western Desert of Egypt since the late 1800' s, but because of the remote loca- tion, Abu Tartur, a potential producer, may be the first mine in that area. Min- ing in the Nile Valley, where the Sabaiya properties are located, began in 1908. Ore zone thicknesses range from an aver- age of less than 2 m at Hamrawein and Quseir to over 14 m at Safaga. The aver- age thickness at Abu Tartur is 9 m; at Sabaiya it is 8 m. Total demonstrated in situ resources in the deposits studied are 1,757 million tons at an average grade of 26% P2O5. Including Qena, Egypt contains an additional 221 million tons of recoverable product at the inferred ^^ TURKEY A2o___^y-' c^P I x~— -^^X 00 1 ^ ...^ SYRIA 1 ^3=^ MEDITERRANEAN SEA '^^^r LEBANON CYPRUS ISRAEL-jL Ashdod/ \ Vlartus ^y J / AI7 / IRAQ ■7^ y^ \ •Rutbo 14 JORDAN^^4^|5 ^--^ r^ v K' \ ( Coiro« v\ / Aqabo ,^^ h.\i, 1 EGYPT I2. \J^ A SAUDI ARABIA 1 N- 1 ▲ ' 100 200 500 / \RED SEA \ \A4 \ < ScaU.km LEGEND A Discrete individual deposits FIGURE 10, » Location map, Middle Eastern depos- its, i, Abu Tartur; 2, Hamrawein; 5, Quseir; yj, Sabaiya West and East; 5, Safaga; Q, Qena (inferred only); 7, Akashat; 8, Arad; 9, Ein Yahav ^inferred only); 10, Nahal Zin; 11, Oron; 12, EI Hasa-EI Abiad; 13, Esh Shidiya; lip, Ruseifa; 15, Turayf (inferred only); IQ, West Thaniyat; 11, Kneifess; 18, Sharkya; 19, Tarag El Hbari (inferred only); 20, Mardin-Mazidag. level. A special problem regarding most Egyptian deposits is the high level of contaminants such as iron, aluminum, mag- nesium, and chlorine. Iraq Akashat is the first mine to exploit the vast deposits of the Western Desert of Iraq, where phosphates were discovered in 1955. It was the only Iraqi deposit evaluated for this study. It is north of Rutba, where phosphates occur in Upper Cretaceous and lower Eocene sediments of the Tayarat and Um-er-Radkuma Formations. Ore zone thickness averages 10.5 m, with 5.5 m of overburden. There are reported to be 450 million tons of proven in situ reserves averaging 21% P2O5 (17) . 18 Israel Four Israeli deposits were evaluated, three of which (Arad, Nahal Zin, and Oron) are producing. The fourth, Ein Yahav, is a nonproducer with resources known only at the inferred level. The nearly depleted Makhtesh deposit, which provides phosphate rock for superphos- phate production, was also not evaluated for this study. Total demonstrated in situ resources for the producing deposits are 179 million tons averaging 26% P2O5. Including resources at Ein Yahav, there is an additional 126 million tons of re- coverable product at the inferred level. All deposits are Upper Cretaceous in age and are exposed in a series of anticlines and synclines that traverse the Negev Desert. Deposits of commercial size are preserved within the synclinal basins. All production is by surface methods, as overburden thicknesses do not exceed 30 m. Ore zone thickness ranges from an average of 5.7 m at Oron to about 10 m at Arad. The high carbonate and organic content of the Oron deposit dictates that the ore must be calcined if used to pro- duce wet-process phosphoric acid. Jordan The important phosphate deposits of Jordan occur in the marine Belqa Series that ranges from Upper Cretaceous to Eocene in age. There are three producing deposits (El Abiad, El Hasa, and Ruseifa) and one developing deposit (Esh Shidiya) in the country. Demonstrated in situ re- sources for deposits evaluated in this study total nearly 1.2 billion tons aver- aging 27% P2O5 (533 million tons of re- coverable product) . Maximum overburden depth does not exceed 40 m; thus all de- posits are mined using strip level meth- ods. Ore zone thicknesses range from an average of 5 m at El Hasa and El Abiad to 8 m at Esh Shidaya. All Jordanian depos- its contain substantial amounts of chlo- rine, which can be removed by washing the ore. Saudi Arabia Only one deposit in Saudi Arabia was evaluated at the demonstrated level. West Thaniyat contains in situ resources totaling 225 million tons of 22% P2O5. The West Thaniyat phosphate and that at Turayf (inferred only) are contained in the phosphatic sediments of the Hibr (Paleocene-Eocene) and Aruma (Cretaceous) Formations. Syria Syria has two producing deposits, Kneifess and Sharkya, which contain dem- onstrated in situ resources totaling 412 million tons at 25% P2O5. Production of Syrian phosphate begain in 1971 with de- velopment of the Kneifess deposits. Ge- ology of the deposits is similar to that of those in neighboring Jordan and Iraq, with economic phosphates contained in Upper Cretaceous and Eocene sediments. In addition to Kneifess and Sharkya, the Tarag El Hbari deposit was evaluated, al- though only at the inferred level. The deposit is located in the area of the Rutbeh Uplift, 250 km northwest of Damas- cus. It contains over 150 million tons of inferred recoverable phosphate rock resources (15) . Turkey The only Turkish deposit included in this analysis is Mardin-Mazidag, where there are three main phosphate beds to- taling 1.8 m in thickness. Overburden thickness averages 15 m. Production is from oolitic limestones of the Kasrik Formation of Upper Cretaceous age. Esti- mated in situ resources in the Mardin- Mazidag area were reported to total 258 million tons at 10% P2O5 (15); about 80 million tons, averaging 18% P2O5, was considered to be demonstrated for pur- poses of this study. OCEANIA Australia and Christmas Island Australia has two major sources of phosphate resources, Christmas Island and the Georgina Basin in Queensland and Northern Territory (figs. 11-12). Total demonstrated recoverable resources of phosphate rock are 551 million tons, less 19 -H- 1 X> V^EPV^SLIC OF THE VS^ PHILIPPINES aZQ CAROLINE MARSHALL ••• • ISLANDS . •• • • (K'RNEOr' r^*V .NAURU ■ — -~i^«=> ^CMSISTfclAS ISLAND / Geo'girx)V~v_. ., \ NCW Cj^ HEBRIOeS ( AUSTRALIA PACIFIC ^ J OCEAN L ^-->1 NEW y^ ZEALAND **^ I i^ ^y\. US .jj )^' ,y^ Guonqxl 3 2: r 'THAILAMO LEGEND A Dltcr«t« individual deposits FIGURE 17, • Location map, Chinese deposits. /, Emei (inferred only); 2, Fanshan (inferred only); 2, Fu- chuan and Gaiyang; 4/ Kunming and Jinning; 5, Jing- bing (inferred only); 6, Jingshan; 7, Jin He (inferred only); 8, Shandong; -9, Zhongxiong, Eighty kilometers east of Gaiyang is the Fuchuan deposit, discovered in 1976 and presently in a developing stage. It is probably within the Doushanto Forma- tion, Fuchuan resources are apparently very extensive, possibly 800 to 900 mil- lion in situ tons at 25% to 30% P2O5. Other major producing deposits located within the Doushanto Formation occur at Jingshan and Zhongxiang, in Hubei Prov- ince, 110 km northwest and 175 km west- northwest, respectively, of Wuhan. Ex- ploitation began at both in the 1960's. Production is from the lowest of four phosphatic horizons occurring within a sequence of interbedded dolomites and dolomitic marls. The minable bed is 1 to 2 m thick, and the Doushanto Formation here reaches a total thickness of 300 m. Assuming a 14-year life remaining and present production levels, there are assumed to be at least 4,2 million tons of demonstrated rock resources at Jing- shan and 5.8 million tons at Zhongxiang. Grade has been reported at 28% to 35% P2O5 (L5), Other important Chinese production occurs at Jinning in central Yunnan Province, 40 km south-southeast of the city of Kunming, Exploitation began there about 1966 from two massive beds within the Lower Cambrian Meisuchen For- mation, a member of the Lei-Bo suite which contains phosphatic units in other areas of China, The beds are exposed on the south side of an east-west anticline and dip to the south at 15°, Ten kilome- ters north of the Jinning Mine, on the north limb of the anticline, is the Kun- ming deposit. Beds on the north limb dip at 3° to 8° . At both Kunming and Jin- ning, there are two ore beds, the lower of which is 3 to 6 m thick, separated from the upper by 10 m of dolomite. The upper bed averages between 8 and 10 m in thickness and is of slightly higher grade than the lower. Average grade of total proven ore is 25% P2O5. Fluorapatite is the ore mineral, with minor amounts of magnesium oxide and greater than 2% flu- orine. Measured reserves at each deposit are 65 million tons in situ (9), but 28 apparently there are several hundred mil- lion tons of additional resources in the area that have yet to be defined. Li and Wang (30) stated that the two deposits could account for 70% of China's rock production for the foreseeable future. Shandong Province in northeastern China contains deposits of igneous apatite. Little is known about the deposits, except that a grade of 28% P2O5 sug- gests that enrichment through weathering has occurred and the ore lies near the surface. The deposits, containing an estimated 150 million tons in situ demonstrated resources (15) , are ex- ploited by as many as 400 individual min- ing operations. The only other known igneous apatite deposit occurs 36 km southwest of Bei- jing. It is believed to be of Precam- brian age, was discovered in 1977, and is referred to as the Fanshan deposit. It has been described as the largest deposit in northern China (31) , but no resource data are given. Development of the de- posit would provide a local source of phosphate, which would preclude having to transport rock from Yunnan and Guizhou, over 1,800 km to the southwest. The Jingbing, Jin He, and Emei deposits in Sichuan Province comprise an extensive phosphate resource, but figures are un- available. Jingbing is located 340 km southwest of Chongqing in the southeast- ern part of the Province, while Jin He and Emei are 180 km south-southwest and 275 km west, respectively, of Chonqing, in central Sichuan. All are believed to occur within the Lower Cambrian Lei-Bo suite, which contains the phosphate cur- rently mined at Kunyang, several hundred kilometers to the south in Yunnan Prov- ince. The suite is 30 to 50 m thick at Emei, where it is exposed. The phos- phatic horizon is 5m thick and occurs within interbedded dolomites and cherts. MINING AND PROCESSING OF PHOSPHATE MINING METHODS Nearly 88% of the phosphate rock prod- uct produced in market economy countries today is recovered by surface mining methods. The remaining 12% is recovered by underground mining techniques , predom- inantly in Morocco and Tunisia. In the U.S.S.R. and China, approximately 30% and 23%, respectively, of the phosphate rock product is recovered by underground min- ing methods. Appendix B shows specific deposit data such as mining and milling methods, status, capacities, grades, de- posit type, ownership, and initial year of production for the deposits and mines included in this study. Surface The two major surface-mining methods used in the phosphate industry are strip mining and open pit mining, A third method, dredging, is used in special sit- uations. Strip mining accounts for 90% of U.S. and 57% of total world phosphate rock production. Market economy country production by this method is almost 72%. Strip mining is predominantly used be- cause of the tabular, bedded, sedimen- tary nature of most phosphate deposits. Most deposits in the Southeastern United States and North Africa use this method. Nearly 16% of current market economy country phosphate rock production is supplied by the open pit mining meth- od. Open pit mining is extensively em- ployed to exploit the massive igneous phosphate carbonatites , which in them- selves contribute approximately 5% to current market economy country produc- tion of phosphate rock. The U.S.S.R. and China derive 69% and 32% of their respec- tive production from igneous sources. Dredging is employed at a few deposits throughout the world, particularly at the Wingate Creek operation in Florida (U.S.), and will be employed at the pro- posed Santo Domingo operation in Mexico. It is also used to strip off overburden at Texasgulf 's Lee Creek Mine in North Carolina (U.S.). 29 Strip Level An estimated 75% of the mines producing at the time of this study are using the strip level mining method. Approximately 82% of those not producing would probably use this method of mining. In this method the overburden is stripped from an initial cut and stock- piled. The phosphate ore is excavated while a second parallel cut is being stripped of overburden. The waste from the second cut is side-cast into the first cut. This cycle is repeated as the mining proceeds. In the larger operations, overburden is stripped by draglines or bucket-wheel excavators and cast into the adjacent mlned-out strip. In smaller operations, or where selective mining is critical, scrapers and bulldozers with rippers working in tandem are used, with the waste material being dumped into the pre- vious strip. Some strip mine opera- tions utilize dredges to remove a por- tion of the overburden. An example of this is the Lee Creek operation in North Carolina. Ore removal is accomplished by a drag- line, scraper, or shovel-truck operation. In Florida, draglines dump the ore into a slurry pit where the phosphate material is slurried and pumped through pipes to the benef iciation plant. Most phosphate ore or overburden requires little or no drilling or blasting prior to excavation. The strip level method is used extensive- ly in the Southeastern United States and North Africa; blasting is frequently re- quired to mine Moroccan deposits. Open Pit Open pit mining is employed to recover hard igneous carbonatite rock. The meth- od differs from strip mining in that the waste is stored separately instead of be- ing dumped into mlned-out areas. Bench- ing of the waste and ore is often neces- sary owing to the thickness or depth of the ore. Overburden removal is accomplished by shovel, front-end loader, or dragline in conjunction with trucks. In some cases, scrapers and bulldozers working in tandem are used to excavate and transport the waste to the dump. The same equipment and methods are used to mine the ore as are used for overbur- den removal. Drilling and blasting are more common in open pit mining than in strip mining. This is due to the harder nature of the carbonatite deposits that this method is suited for. Dredging This method is used in special hydro- logic situations for which the overburden and phosphate horizon are unconsolidated clay and sand. Salardina Bay in South Africa mines phosphate using dredges. Texasgulf Chemicals Co., North Carolina, uses a dredge to remove overburden. Pumps dewater the pit , and draglines mine the ore from a bench. Underground The relatively low unit value of phos- phate rock makes underground mining meth- ods generally unprofitable. However, steeply dipping phosphate beds or high stripping ratios sometimes make the use of underground mining techniques prefer- able. In such cases, highly mechanized room-and-pillar , longwall caving, and overhand-s toping methods have been used successfully. While only 12% of present phosphate rock production capacity in market economy countries is from under- ground methods, this study estimates that 18% of the capacity of deposits not pro- ducing at the time of the study could be from underground mines. The majority of producing underground phosphate mines are located in north Africa. Room and Pillar A horizontal- to shallow-dipping phos- phate bed, with fairly competent strata overlying the ore zone is necessary for successful room-and-pillar mining. This 30 method consists of interconnecting open- ings with pillars left for roof support. Access is usually from, the outcrop or pit wall but may be by incline or vertical shaft. Continuous mining machines simi- lar to those used in coal and potash min- ing are used to excavate the phosphate ore. Sometimes drilling and blasting are required, with slushers or front-end loaders used to load the broken ore. Trucks or conveyors transport the ore to the surface. Approximately 9% of current market economy country phosphate rock product capacity is supplied by room-and-pillar mining operations. Morocco and Tunisia contribute over 90% of this room-and- pillar capacity. Future projections in- dicate nearly 8% of the capacity from nonproducing deposits in market econon^^ countries could be from room-and-pillar operations. Overhand Stoping Steeply dipping beds or massive ore bodies, such as the igneous carbonatites , can be mined by overhand-stoping methods. Various methods fall under the category of overhand stoping, such as cut-and-fill and shrinkage stoping. The material is first drilled and blasted, then loaded with slushers or load-haul-dump machines. Transportation to the surface is by ei- ther rail, truck, or load-haul-dump. Loading in the shrinkage-s toping method is usually from ore chutes that draw broken ore from the stope into trucks or rail cars. Overhand stoping is not being used in any of the producing properties in market economy countries included in the study. The U.S.S.R. and China use overhand-stoping methods for all current underground mining. This represents 37% of the phosphate rock production capacity in these countries. Nearly 10% of the estimated new capacity in the United States from developing and explored de- posits could be supplied by this method. Wyoming is the principal location for the proposed application of overhand stoping in this country. Longwall Caving Longwall caving is a highly productive but capital intensive mining method used in flat-lying bedded deposits of coal, potash, and phosphate. The ore is cut from a long face, usually greater than 50 m in length, by a cutting drum, also called a face shear. The broken ore drops onto a conveyor belt that runs par- allel to the face and is transported to the surface. Roof support chocks keep the roof from caving in at the face to allow working room for the men and equip- ment. As the face advances, the roof support chocks and conveyor are advanced, allowing the roof to cave in behind. Only two producing mines, Recette No. 7 (Youssoufia Black Rock) in Morocco and the Sehib Mine in Tunisia, use this meth- od. This represents 3% of market economy countries' existing capacity, or almost 20% of existing phosphate rock production capacity in north Africa. BENEFICIATION METHODS In almost all cases the run-of-mine phosphate material has to be benefici- ated. The basic benef iciation methods employed in the phosphate industry are sizing, washing, flotation, calcining, and calcining with leaching. A phosphate benef iciation plant may use one or more of these methods to produce a marketable product. The milling method assigned to proper- ties in this study indicates the most significant method used to beneficiate the phosphate material. An example would be a property that screens and washes before sending the phosphate material through a flotation circuit. The milling method for this property would be listed as flotation, even though sizing and washing were used. In the United States, 87% of current phosphate rock product capacity is bene- ficiated through flotation, followed by calcining and washing at 9% and 4%, 31 TABLE 4. - Phosphate mill plant operating parameters, by region' Pro ducing mi nes Nonpro ducing de posits Region Feed grade, % P2O5 Product grade, % P2O5 Recov- ery, % Feed grade, % P2O5 Product grade, % P2O5 Recov- ery, % United States: Southeast 8.4 25.2 10.3 29.5 26.4 36.1 31.7 30.6 35.2 31.5 32.3 37.2 89.6 80.1 61.7 62.3 66.7 83.7 5.7 21.9 10.8 29.6 24.5 17.3 30.7 28.4 32.3 33.2 31.4 34.1 85.1 West 79.2 South America 68.7 North Africa 65.8 Middle East and Asia. ..••• 67.9 Oceania, including Australia 83.4 Feed grade, product grade, in each region. and recovery are weighted average for all the deposits respectively. An estimated 48% of cur- rent world production is beneficiated through flotation, followed by washing — 34%, siz-ing — 14%, and calcining — 6%. Average feed grade, average product grade, and average mill recovery are shown in table 4 for the various market economy country regions. Feed grade is here defined as the recoverable grade of the ore that feeds the mill. As shown in this table, the Southeastern United States has the lowest average feed grade but the highest average recovery (at 8.4% P2O5 and 89.6%, respectively). North Africa, on the other hand, has an average feed grade of 29.5% P2O5 but a mill re- covery of only 62.3% owing to losses of fine material during washing. Sizing Sizing is primarily used on direct- shipping material that already meets acid plant chemical specifications. Oversized waste material, such as limestone and dolomite, is removed by screening, and the phosphate ore is crushed and some- times ground to meet acid plant size specifications. Washing The purpose of washing is to remove the minus 150-mesh clay-sized slimes fraction from the run-of-mine material. The clay-sized fraction contains impuri- ties such as aluminum which cause high reagent consumption in the flotation circuit and acid consumption in the phos- phoric acid plant. The largest loss of phosphate occurs in the washing process. Screening is typically used to remove the larger limestone and dolomite gangue material prior to desliming. In Florida the screen oversize (plus 14 mesh) is washed to remove clay particles and re- screened at 0.75 in to reject limestone Phosphate ore Overflow Minus 14 mesh Overflow Minus 14 mesh DISTRIBUTOR TROMMEL SCREENS FLAT SCREENS Plus 3/4 in I To waste Minus 14 mesh PRIMARY VIBRATING SCREENS To desliming (debris) Minus 14 mesh PRIMARY LOG WASHERS SFCONDAPY VIBRATING SCREENS SECONDARY LOG UASHEP' FINISHING SCREENS Pebble product (3/4 In by 14 mesh) FIGURE 18, • Typical Florida phosphate washing circuit. 32 gangue. The Intermediate minus 0.75-in, plus 14-mesh pebble fraction is shipped directly to the acid plant (fig. 18). In the des liming section of the washing plant, the clay-sized particles are re- moved from the screen undersize fraction with cyclones. The minus 150-mesh slimes are pumped or flow to the waste clay pond. The deslimed material is either dried and shipped as a final product or sent to further processing for upgrading. Flotation The primary function of flotation is to separate the phosphate minerals from the associated quartz sand or carbonate. The phosphate grade is increased to market- able levels , and the silica and carbonate are reduced to acceptable levels for acid plant feed specifications (fig. 19). Anionic froth flotation is used in the rougher circuit to float fine phosphate (minus 35 mesh) . The cationic froth flo- tation is used in the cleaner circuit to remove quartz from the phosphate. The anionic collectors used for phos- phate flotation are fatty acids which include crude tall oil, blends of fatty acids, and soap skimmings. The cationic collectors used for silica flotation include tallow amines and condensed amines . Slurried phosphate ore Wells MINING AREA > WASHER Ground water. WATER RESERVOIR Overflow Return water Pebble Clay waste Flotation feed FLOTATION STORAGE 1 Concentrated phosphate DRYING Sand tailings Clear decanted water WASTE STORAGE AREA SHIPPING WASTE STORAGE AREA FIGURE 19. - Typical process flowsheet, Southeastern United States, incorporating flotation processt 33 In some cases, the coarser phosphate (plus 35, minus 14 mesh) requires the use of skin flotation. Calcining High levels of organic matter in phos- phate rock feed to an acid plant cause excess foaming and darken the acid color. Even after washing and desliming, unac- ceptable levels of organics may still re- main. Calcining is used to remove the organic matter by heating the ore in a f luidized-bed calciner to 800° C or higher (fig. 20). Drying To reduce long distance transportation costs, it is important to remove as much water as possible from the phosphate rock by drying. Phosphate rock also must be dried if the grinding circuit is designed for dry rock. Many grinding and phos- phoric acid plants will now accept wet rock. Either rotary dyers or fluidized- bed dryers are used to dry the rock. The -*■ To vasce duaps ac mine site lau-CtJOz. SHALES -» To stockpiles at nine site KEDrjH-CRASE ORE — i HICB-CSA2>£ 0K£ 1 iJ ELECTRIC FURNACE I ; I FEED 1 cd'santc 1/t la CBDSHIHC ' 1/t In CLASSIFTUC plus 32 S aes Tailings (alnus 325 acsh) ' to ponds at Bill site 'J^CIIIWC cHoaciu. puurr fees FIGURE 20, • Typicol process flowsheet, Western United States, incorporating calcining process. dry rock is stored in silos or bins until shipped. BYPRODUCTS Phosphate rock contains several materi- als that, in most cases, are either very expensive to extract as marketable by- products or are considered a waste prod- uct with little or no market value. The most significant of these potential by- products are uranium (U3O8), recovered from phosphoric acid, vanadium (V2O5), removed from f errophosphorus , and fluo- rine (F). Gypsum (CaS04*2H20) is a waste product from the production of phosphoric acid. Few world operations are recover- ing any byproducts from phosphate rock. This study only considered byproducts at operations in which the recovery of that commodity significantly impacted upon the economics. The following is a discussion of each byproduct's present extraction process, the potential uses for the by- product, and the constraints presently inhibiting their recovery. Uranium is the most important byproduct (or potential byproduct) of phosphate. Most phosphate rock contains uranium, al- though not in quantities high enough for economic extraction. On the average, ap- proximately 1 ton of 100% P2O5 phosphoric acid will produce 1 lb of recoverable U3O8 (p. The extraction of uranium from phos- phoric acid is technologically very com- plex and is not fully comparable to the extraction of uranium from other kinds of ores. There are three basic steps in the recovery of uranium from phosphoric acid. First, the uranium compounds are dissolved with sulfuric acid at the same time that the phosphate rock is digested. Next, the uranium is removed from the phosphoric acid through a new and techni- cally complex solvent extraction process. An important key to the solvent extrac- tion process is the removal of both im- purities and organic materials from the acid before solvent extraction of the U3O3. These contaminants affect the ef- ficiency and subsequently the economics of the solvent extraction process. The 34 final step in the recovery of uranium is concentrating the separated uranium by precipitating it out of solution to its most common form, the hydrated peroxide salt known as "yellow cake." At this point, the uranium product is in a form suitable for further upgrading through standard uranium refining techniques so that it can be used as fuel for nuclear reactors as well as other uses (_1_) . Although some phosphoric acid producers are presently recovering the uranium (particularly in the Southeastern United States) , extensive research is present- ly underway to make this process more economical, Ferrophosphorus is produced as a by- product in the production of elemental phosphorus, Ferrophosphorus collected in the electric furnace contains vanadium as well as other metal impurities. It is often sold for the purpose of extracting vanadium pentoxide. The supply of ferro- phosphorus is greater than the demand from vanadium recovery plants (I)* The fluorine content in phosphate rock averages between 3% and 4%, No concen- tration of fluorine occurs during produc- tion of phosphoric acid. Some fluorine is retained in the gypsum waste, some es- capes as a gas, and some remains in the acid. The fluorine gas fraction that is recovered as fluosilicic acid represents only about 35% of that which was in the rock prior to phosphoric acid production. The process to recover the fluosilicic acid consists of scrubbing the fluorine gas released when phosphate rock is di- gested and weak phosphoric acid is heated and concentrated to a higher phosphate content. The principal uses for fluosi- licic acid are for water fluoridation and the production of cryolite. This process to recover fluosilicic acid is presently being used by a number of U.S, phosphoric acid producers (1) » Phosphogypsum is a waste byproduct from the wet phosphoric acid process. It is precipitated when the phosphate rock is digested with sulfuric acid. Gypsum is normally stockpiled at the acid plants, with a small percentage used as fertili- zer or as a soil conditioner (land plas- ter). In the United States, phosphogyp- sum is not presently competitive for use in construction material nor is it an economical source for sulfur (_1^) . There are a number of other less sig- nificant byproducts presently or poten- tially recoverable from phosphate de- posits. These include copper, zircon, precious metals, and vermiculite at the Foskor operation in South Africa, tita- nium, columbium, rare earths, and venni- culite from Brazilian operations, and montmorillonite from the Thies Mine in Senegal. PHOSPHATE DEPOSIT COSTS COSTING METHODOLOGY The costs used in this study were col- lected or developed using various method- ologies. Costs for the deposits in the Southeastern United States (including Florida, North Carolina, and Tennessee) were developed by the former Bureau of Mines Eastern Field Operations Center in Pittsburgh, PA, in conjunction with Zellars-Williams , Inc. A more detailed discussion and breakdown of these costs and the models used to develop them are available in a Bureau of Mines report entitled "Phosphate Rock Availability — Domestic, A Minerals Availability Program Appraisal" (6), Costs for the deposits in the Western United States (Idaho, Mon- tana, Utah, and Wyoming) were developed by Bureau of Mines Field Operations Cen- ters in Denver, CO, and Spokane, WA, us- ing various methodologies such as scaling from known values, the MAS Cost Estimat- ing System (CES) (32), and actual re- ported company data. The costs from all the other world countries were collected or developed by Zellars-Williams, Inc., under a contract with the Bureau of 35 Mines. Some of the foreign deposit costs are actual company reported data, al- though in most cases they were developed using the contractor's computerized cost model. This cost model uses data on la- bor, equipment, and supplies that are site specific for each deposit. An esti- mate was made for the input quantities for these variables, and then a unit cost was assigned for each variable. The unit costs were based on local rates at that deposit converted to 1981 U.S. dollars. The final product of this model is a unit cost for each portion of the mining- milling operation. Capital expenditures were calculated for exploration, acquisition, develop- ment, mine plant and equipment, and con- structing and equipping the mill plant, all in U.S. dollars. Capital expendi- tures for mining and processing facili- ties include the costs of mobile and stationary equipment, construction, engi- neering, facilities and utilities, and working capital. A broad category, fa- cilities and utilities (infrastructure) , includes the cost of access and haulage facilities, water facilities, power sup- ply, and personnel accommodations. Work- ing capital is a revolving cash fund re- quired for such operating expenses as labor, supplies, taxes, and insurance. Mine and mill operating costs were also calculated for each deposit, in U.S. dol- lars. The total operating cost is a com- bination of direct and indirect costs. Direct operating costs include materials, utilities, direct and maintenance labor, and payroll overhead. Indirect operating costs include technical and clerical labor, administrative costs, facilities maintenance and supplies, and research. Fixed charges , which mainly include local taxes and insurance, are also included in the mine and mill operating costs. PRODUCTION COSTS Table 5 and figure 21 illustrate the average costs for selected surface oper- ations included in this study (ex- pressed in January 1981 U.S. dollars per ton of product). In most cases, the mine operating cost for surface deposits is $7 to $13 and mill operating costs is $8 to $14. A few areas in the world deviate from these ranges, particularly the mill operating cost in Morocco, where benefi- ciation merely consists of screening and drying the ore, and in South America, where the mill operating cost reflects the high cost of benef iciating the car- bonatite ore of Brazil. Mining and mill- ing costs for nonproducers are generally greater than those for producers; this is due to the fact for most of the nonpro- ducing deposits, grades are lower and stripping ratios tend to be higher, caus- ing greater costs. The column labeled "Other" primarily includes estimated tax payments. These costs are also greater for nonproducers, because in most cases the overall total costs and revenues nec- essary to cover them are greater. Trans- portation costs from mine to plant or port are in most cases small except in the Western United States where the rock in Utah and Wyoming is assumed to go to Idaho and in Australia where the deposits are in the middle of Queensland and the rock must be transported to the coast. Table 6 and figure 22 illustrate pro- duction costs for underground mines and deposits, mainly representing the pro- ducers in north Africa and the nonpro- ducers in the United States (Utah and Wyoming) . When comparing this table to the previous one on surface mines, it is apparent, as would be expected, that the underground mines are much more expensive to operate. In the case of the north African underground mines , even though they are more expensive to operate than the surface mines, they are near enough to a market that they would still be eco- nomical. The underground deposits in the Western United States (particularly the nonproducers in Utah and Wyoming) have costs much higher than any of the other evaluated phosphate deposits in the world. This is largely due to the char- acteristics of the ore, coupled with the higher costs of underground mining. These highly uneconomical deposits are not likely to be developed in the near future. 36 TABLE 5. - Production costs for selected world phosphate surface mines and deposits (All costs are expressed as January 1981 U.S. dollars per metric ton product on a weight-averaged basis) Total Transpor- Total Average opera- tation operating cost^ Region and country Mine Mill Other' ting cost to cost total cost plant or including at plant (f .o.b. port^ transpor- or port mill) tation North America: United States: Southeast:^ Producers ........•• $8.60 9.10 $12.30 13.80 $1.80 7.30 $22.70 30.20 $3.50 4.20 $26.20 34.40 $28.90 Nonproducers West:^ 50.30 Producers ...••..... 11.20 17.90 16.70 13.40 1.20 6.60 29.10 37.90 11.70 10.20 40.80 48.10 43.00 Nonproducers 63.90 North Africa: Morocco and Western Sahara: Producers. ......... 10.60 9.10 5.70 7.50 7.70 14.30 24.00 30.90 2.10 2.40 26.10 33.30 32.40 Nonproducers 46.60 Middle East: Israel, Egypt, and Jordan: Producers .......... 10.20 W 13.00 W 3.10 W 26.30 W 6.00 W 32.30 W 44.80 Nonproducers W Syria, Iraq, and Turkey: Producers .......... 10.00 W 9.60 W 9.00 W 28.60 W 14.20 W 43.30 W 55.20 Nonproducers W Oceania: Christmas Island and Nauru : Produce rs . . . 6.90 8.60 8.80 24.30 0.00 24.30 27.30 Australia: Producers W 7.60 W 12.40 W 6.40 W 26.40 W 12.30 W 38.70 W Nonproducers 53.50 South America: Brazil, Peru, and Venezuela: Producers ••.....•.. 10.50 13.50 26.90 22.90 8.80 19.30 46.20 55.70 3.40 2.40 49.60 58.10 66.80 Nonproducers 84.20 West Africa: Senegal and Togo: Producers.. 10.10 12.30 1.60 24.00 2.00 26.00 30.80 W Withheld to avoid dis closinj ; indivi dual de] posit dat :a. 'includes all property, State, Federal , and S( 2ve ranee taxes plus any royalty ', ^Transportation costs tc ► select :ed port s or ac Ld plants 5 that have been assume d as the product destination points for this study. (See table 12.) 3lncludes a 15% DCFROR on all capital investments over the life of the property, '^ Includes Florida, North Carolina, and Tennessee. ^Includes Idaho, Utah, and Wyoming 100 37 90 80 o T3 tn O < O KEY QI57o rate of return on all investments over the life of the property [ 1 Transportation cost j — I Prof>erty, State, Federal, and severance ' — ' taxes plus royalty ^ Mill operating cost ■ Mine operating cost < o UJ 4 PRODUCERS -NONPRODUCERS FIGURE 21t • Production costs for selected world phosphate surface mines and depositst 38 TABLE 6. - Production costs for selected world phosphate underground mines and deposits (All costs are expressed as January 1981 U.S. dollars per metric ton product on a weight-averaged basis) Total Transpor- Total Average operating tation operat- total Region and Mine Mill Other' cost cost to ing cost cost^ at country (f .o.b. plant or including plant mill) port^ transpor- tation or port North America: United States^ and Mexico: Producers W $44.00 W $30.30 W $13.80 W $88.10 W $11.40 W $99.50 W Nonproducers $130.80 North Africa: Morocco: Producers. 11.90 9.20 6.30 27.40 1.50 28.90 34.10 Tunisia: Producers, 15.50 12.10 5.60 33.20 10.10 43.30 58.80 Middle East: Egypt: Producers 15.60 W 20.00 W 7.00 W 42.60 W 0.90 w 43.50 W 68.30 Nonproducers W W Withheld to avoid disclosing individual 'includes all property, State, Federal, and ^Transportation costs to selected ports or product destination points for this study. ( ^Includes a 15% DCFROR on all capital inves ^Includes Montana, Utah, and Wyoming. deposit data, severance taxes plus any royalty, acid plants that have been assumed as See table 12.) tments over the life of the property. CAPITAL COSTS KEY 77;^ 15% rote of return on all investments ■^ over the life of the property j:;:::| Transportation cost □ Property, State, Federal, and severance taxes plus royalty fj%J Mill operating cost ^1 Mine operating cost I I -PRODUCERS- L, NONPRODUCERS' A FIGURE 22. * Production costs for selected world phosphate underground mines and depositsi Table 7 shows the average capital costs estimated for this study to develop non- producing surface deposits. These costs represent the costs to acquire, explore, develop, and equip a new mine site, along with construction of any mine and mill plants and buildings necessary. The ta- ble shows that in most cases the capital cost for the mill (plant and equipment) is the largest cost in developing a phos- phate deposit (40% to 60% of total capi- tal investment) . Not shown on the table are infrastructure costs, which in coun- tries like Australia or Brazil can be very large and can make the difference between developing and not developing. COMPARISON OF FLORIDA AND MOROCCAN COSTS A comparison was made between costs at nonproducing surface deposits in Florida and Morocco (table 8) . The operating costs shown are f.o.b. mill; transporta- tion charges have not been included. The capital cost shown is the cost required to bring the operation into production; 39 TABLE 7. - Capital costs to develop nonproducing surface phosphate mines in selected countries, January 1981 dollars Thousand metric Capital cost. million doll ars Cost, per tons per year Exploration acquisition. Mine Mill Total 1 annual ton Ore Product Ore Product and development United States (Southeast) : Small 2,500 450 $9.6 $8.9 $21.3 $39.8 $15.90 $88.40 Medium 5,600 1,000 32.2 16.1 38.3 86.6 15.50 86.60 Large 15,600 2,400 74.6 34.5 71.4 180.5 11.60 75.20 Brazil 3,200 530 11.8 9.1 54.7 75.6 23.60 142.60 Morocco 6,200 3.300 45.7 75.1 74.4 195.2 31.50 59.20 Australia. . . . 8,700 3,700 5.1 26.4 42.0 73.5 8.50 19.90 Excludes any infrastructure. TABLE 8. - Comparison of nonproducing Florida and Morocco surface phosphate deposit costs (All costs are in U.S. January 1981 dollars, f.o.b. mill) Mine or mill operating cost, dollars per metric ton product: Labor Electricity Diesel. Supplies Drying fuel , General and administrative (G&A) Total Capital cost, million dollars: Acquisition , Exploration , Development Mill plant , Mine equipment , Infrastructure , Working capital , Total , Florida No. 1^ $3.10 3.90 .10 4.70 1.90 4.10 17.80 44 4 11 83 33 I 17 NAp 192 Florida No. 2^ $4.50 5.80 .10 7.20 2.90 6.10 26.60 44 6 17 121 50 I 17 NAp 255 Morocco-' $3.50 1.60 1.90 4.60 3.40 4.90 19.90 1 47 49 53 28 19 216 NAp Not applicable. 'Deposit that will probably be developed during the next 10 yr. ^Deposit that will probably be developed in 20 to 40 yr. ^Deposit that will probably be developed during the next 5 to 10 yr, ^This cost may not be applicable from the standpoint of the Govern- ment of Morocco. reinvestments and costs of planned expan- sions are not included. The costs repre- sent a typical mine that would produce between 2.5 and 3 million tons of rock, product per year. The Florida No. 1 deposit is an example of a mine that would be developed in the next 10 years, while the No. 2 deposit would not be mined for 20 to 40 years. The Moroccan deposit is an example of one to be mined 40 in the next 5 to 10 years. The Florida deposits have lower grade reserves typi- cal of the areas immediately south of the active mining district in central Florida (the southern extension) , with magnesium oxide content of these deposits accept- able for conventional processing. The Florida No. 2 deposit has a feed grade and mill recovery value significantly lower than the Florida No. 1 deposit, al- though both produce a rock product con- taining approximately 30% P2O5 • As shown in the table, the Florida No. 1 deposit has only slightly lower total operating costs than the Moroccan depos- it, while costs at Florida No. 2 are one- third greater, which in part reflects the lower grade and recovery at No. 2. The table shows that fuel costs are greater in Morocco, but electricity costs are greater in the Florida deposits. In reality, the fuel costs per unit do not differ greatly between the Moroccan and Florida operations, although the cost per ton is greater at the Moroccan operation because most of the equipment is diesel fuel operated (the draglines, shovels, etc.). Most Florida mining equipment is electrically powered (draglines, flota- tion units, etc.), and therefore electri- cal costs per ton of product are greater. Since much of the Moroccan rock is dried for export, drying costs are an addition- al factor. It is important to note that the Moroc- can mine has a much larger resource at a higher ore grade than either of the Flor- ida deposits; at the production rates used in this comparison (2.5 to 3 million tons of rock per year) the Moroccan mine would produce for over 300 years while Florida No. 1 and No. 2 would last for only 20 and 40 years, respectively. PHOSPHATE ROCK AVAILABILITY ECONOMIC EVALUATION METHODOLOGY After capital and operating costs were determined, the data were entered into the MAS Supply Analysis Model (SAM). The Bureau of Mines developed the SAM to per- form discounted cash flow rate of return (DCFROR) analyses to determine the price of the primary commodity required for each operation to obtain a specified rate of return on its investments (33) . This determined value for the phosphate rock price is equivalent to the average total cost of production for the operation over its producing life under the set of as- sumptions and conditions (e.g., mine plan, full capacity production, and a market for all output) that is necessary in order to make an evaluation. The DCFROR is most commonly defined as the rate of return that makes the present worth of cash flow from an investment equal to the present worth of all after- tax investments (34). For this study, a 15% DCFROR was considered the necessary rate of return to cover the opportunity cost of capital plus risk. Based on the MAS methodology, all capi- tal investments incurred 15 years before the initial year of the analysis (January 1981) are treated as sunk costs. Capital investments incurred less than 15 years before January 1981 have the undepreci- ated balances carried forward to January 1981, with all subsequent investments re- ported in constant January 1981 dollar terms. This computation means that for producing operations, the undepreciated capital investment remaining in 1981 was calculated. All reinvestment, operating, and transportation costs are expressed in January 1981 dollars. No escalation of either costs or prices was included be- cause, assumedly, any increase in costs would be offset by an increase in price. A separate tax-records file, maintained for each State and/or nation, contains the relevant fiscal parameters under which the mining firm would operate. This file includes corporate income taxes, property taxes, and any royalties, severance taxes, or other taxes that per- tain to phosphate rock production. These 41 tax parameters are applied to each min- eral deposit under evaluation, with the implicit assumption that each deposit represents a separate corporate entity. The system also contains an additional file of economic indices to allow for continuous updating of all cost estimates to a base date (January 1981 for this s tudy ) . Beginning with 1981, the first year of the analysis, detailed cash flow analyses were generated for each preproduction and production year of an operation. Upon completion of the individual property analyses, all properties included in the study were simultaneously analyzed and aggregated onto resource availability curves. The total resource availability curve is a tonnage-cost relationship that shows the total quantity of recoverable product potentially available at each operation's average total cost of produc- tion over the life of the mine, deter- mined at the stipulated (15%) DCFROR. Thus, the curve is an aggregation of the total potential phosphate rock that could be produced over the entire producing life of each operation, ordered from operations with the lowest average total cost of production to those with the highest. The curve provides a concise, easy-to-read, graphic analysis of the comparative costs associated with any given level of potential output and pro- vides an estimate of what the average long-run phosphate rock price (in January 1981 dollars) would likely have to be in order for a given tonnage to be po- tentially available to the marketplace. Two types of curves have been generated for this study: (1) total availability curves and (2) annual curves at selected production costs. Annual curves are sim- ply a disaggregation of the total curve to show annual phosphate rock availabil- ity at varying costs of production. Certain assumptions are inherent in the curves. First, all deposits produce at full operating capacity throughout the productive life of the deposit. Second, each operation is able to sell all of its output at a price equal to or greater than its average total production cost. Third, development of each nonproducing deposit began in the same base year (N) (unless the property was developing at the time of the evaluation). Since it is difficult, if not impossible, to predict when the explored deposits are going to be developed, this assumption was neces- sary. Also, the preproduction period al- lows for only the minimum engineering and construction period necessary to initiate production under the proposed development plan. Consequently, the additional time lags and potential costs involved in fil- ing environmental impact statements, receiving required permits, financing, etc. , have not been included in the indi- vidual deposit analyses. The potential tonnage and the estimated average total cost over the life of the mine for each of the 201 mines and depos- its evaluated have been aggregated onto phosphate rock availability curves, which illustrate the comparative costs associ- ated with any given level of potential total output. Costs reflect not only capital and operating costs, but also all pertinent taxation and the cost of trans- porting the rock product to the nearest port or acid plant. A comparison of costs on an f.o.b. mill basis and a dis- cussion of ocean freight charges appear later in this section. Potential avail- ability of phosphate rock from China and the U.S.S.R. is described in the text but is not included on curves owing to the difficulty in gathering accurate cost data and developing U.S. dollar equivalents. TOTAL AVAILABILITY At the demonstrated resource level, ap- proximately 34.2 billion tons of phos- phate rock is potentially recoverable from the 201 mines and deposits in market economy countries, with Morocco and West- ern Sahara (21 billion tons) accounting for 61% of the total, followed by the United States (6.4 billion tons) at 19%. In addition, the 17 deposits evaluated in the U.S.S.R. and China contain approxi- mately 1.5 billion tons of potentially recoverable phosphate rock. 42 Market Economy Countries The tonnage of phosphate rock poten- tially available from the deposits ana- lyzed in market economy countries is shown in figure 23. A total of 32.9 bil- lion tons of phosphate rock is potential- ly recoverable at total production costs ranging from $17 to $100 per ton (in Jan- uary 1981 dollars) from 175 mines and de- posits. Approximately 1.6 billion tons is potentially recoverable at costs rang- ing up to $30 per ton (55% from the United States), 10.6 billion tons at costs ranging up to $40 (13% from the United States), and 15.7 billion tons at costs up to $50 (21% from the United States). An additional 1.3 billion tons could potentially be produced at a cost of over $100 per ton from 26 deposits which are not shown on the curves . The curve for north Africa includes po- tential production from Algeria, Morocco, Tunisia, and Western Sahara. Approxi- mately 21.3 billion tons of phosphate rock (94% from Morocco) is potentially recoverable from the 20 north African 100 80 60 40- 20 / MARKET ECONOMY COUNTRIES 10 20 25 30 35 H o o < o 6.0 uu I 1 1 1 I 1 ' 1 J ' 80 - f - 60 - r 40 - 20 1 1 1 MIDDLE EAST 1 1 1 1 ._ 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 TOTAL RECOVERABLE PHOSPHATE ROCK, billion metric tons FIGURE 23. * Phosphate rock potentially recoverable from all mines and deposits in market economy countries. Note that curves are drawn at different scales. 43 mines and deposits evaluated, or 62% of the market economy country total. At costs ranging from $24 to $30 per ton, 612 million tons of phosphate rock is potentially recoverable, 7.8 billion tons is potentially recoverable at costs up to $40 per ton, and 8.1 billion tons is po- tentially recoverable at costs up to $50 per ton. The curve for the United States shows 5.6 billion tons of phosphate rock poten- tially recoverable from 110 mines and de- posits at costs ranging from $17.50 to $96.50 per ton. Approximately 8 75 mil- lion tons of phosphate rock is potential- ly recoverable at costs ranging up to $30 per ton, 1.4 billion tons at costs up to $40 per ton, and 3.3 billion tons at costs up to $50 per ton. Another 822 million tons potentially recoverable from 20 deposits (mostly in Wyoming and Utah) at costs greater than $100 per ton is not shown on the curve. The curve for the Middle East illus- trates potential production of 1.9 bil- lion tons at costs ranging from $30 to $96 per ton from 16 mines and deposits in Egypt, Iraq, Israel, Jordan, Saudi Ara- bia, Syria, and Turkey. An additional 234 million tons of estimated potential production from one deposit in Egypt is not shown on the curve because its esti- mated cost of production is over $100 per ton. Potential recoverable phosphate from the Middle East amounts to 6% of the market economy country total. The three regions highlighted in figure 23 account for 8 7% of the recoverable demonstrated phosphate rock resources of market economy countries. Other regions included in the total availability curve for market economy countries but not shown on separate curves are South Ameri- ca, Oceania (which includes Australia and Nauru), Mexico, Senegal, the Republic of South Africa, and Zimbabwe. South Amer- ica has an estimated production potential of 654 million tons of phosphate rock from 14 mines and deposits in Brazil (11 mines and deposits), Peru, Colombia, and Venezuela (1 deposit each). Oceania has an estimated production potential of 567 million tons from six mines and deposits in Australia and one mine in Nauru. The combined potential tonnage from Senegal (two mines), the Republic of South Afri- ca, Togo, and Zimbabwe (one mine each) amounts to 2.8 billion tons. Figure 24 presents availability curves for all market economy countries, north Africa, the United States, and the Middle East, comparing potentially recoverable phosphate rock from producing mines with that from developing mines and explored deposits. Of the 34.2 billion tons of phosphate rock estimated to be potential- ly available from market economy coun- tries, 39% is from producing mines and 61% is from undeveloped deposits. The curve for north Africa shows that produc- ing mines account for 7.1 billion tons of potential recoverable phosphate rock (34% of the total potential for north Africa of 21.3 billion tons) and that developing mines and explored deposits account for 14.2 billion tons (67% of the north Afri- ca total). For the United Staes, out of a potential total of 6.4 billion tons of phosphate rock, 1.3 billion tons is from producing mines (21%), and undeveloped deposits account for slightly over 5 bil- lion tons (79%). Of the 2.1 billion tons of phosphate rock potentially available from the Middle East, 1.4 billion is from producing mines (66%) and 773 million (36%) is from undeveloped deposits. Centrally Planned Economy Countries The 7 mines in China (6 producing and 1 developing) investigated at the demon- strated level for this study contain 208 million tons of potentially recoverable phosphate rock, and the 11 mines in the U.S.S.R. (10 producing and 1 developing) contain 1.3 billion tons. Estimated costs of production range from $11.50 to $86.50 per ton of phosphate rock product. Generally, the Chinese mines have lower total production costs than those of the U.S.S.R., with the exception of the de- veloping Kunming deposit, which ranks with the higher cost Soviet mines. Re- sources of phosphate rock in both China and the U.S.S.R. are relatively small compared with those of the United States 44 100 80 60 40 ^ 20 E T 1 1 r — Producers 1 r 1 — TT Nonproducers , I ; J I J ._/' ^ MARKET ECONOMY COUNTRIES J L O 1^ 1 1 1 1 1 ^ ' .^-^ I-" ^_i w rl o 1 O 80 _1 ~ J J ? / o ^ 60 — y ~ / „r— ' 40 ;./""7"' ' ^ _ 20 r UNITED STATES 1 1 1 i J 1 1 1 5 2 4 6 8 10 12 14 16 18 20 22 100 80 60 ■ r- 1 1 1 1 r _ 1 ! 1 1 ' - 40 1 J 1 ' . __J ^ 20 ^ NORTH AFRICA 1 1 I _1, 1 25 5.0 7.5 10.0 12.5 15.0 0.5 1.5 2.0 2.5 3.0 3.5 4.0 4.5 0.2 0.4 0.6 TOTAL RECOVERABLE PHOSPHATE ROCK, billion metric tons FIGURE 24. * Phosphate rock potentially recoverable from producing mines and nonproducing deposits in economy countries. Note that curves are drawn at different scales. 1.4 market and Morocco. The U.S.S.R. is the domi- nant factor in supplying the Eastern European market. It is doubtful that ei- ther China or the U.S.S.R. will become a major supplier in the world market for phosphate rock and related fertilizers; more likely, these countries represent potential export markets for Western phosphate producers. ANNUAL AVAILABILITY Another way of illustrating phosphate availability is to disaggregate the total resource availability curve and show po- tential availability on an annual basis. For analysis, separate annual availabil- ity curves have been constructed for pro- ducing and proposed operations in mar- ket economy countries. Separate annual availability curves have been constructed for all producing mines in market econ- omy countries, north Africa, the United States, and the Middle East. For unde- veloped deposits, only one curve for the market economy countries was constructed. Since no realistic development schedule can be proposed for all of the undevel- oped deposits, the emphasis of this curve is to indicate capacity and cost levels of potential future deposits. Potential annual production of phos- phate from producing mines in market economy countries, north Africa, the United States , and the Middle East from 1981 to 1995 is shown in figure 25. The curves reflect the production capacity of existing mines , including planned expan- sions when known. It was assumed that all operations produce at full (100-pct) capacity over the life of the mine. 45 140 120 100- o 80- o _ • 60- ic 20 u o q: ^ 50 I Q. o J 40 UJ _i (D 2 30 > o u it; 20 \. ^ — ^ $50 MARKET ECONOMY COUNTRIES 60 50 40- - 30- 20- 10 1 T- T- 1 1 1 "^ ~'~"~'-v ■^.., \ \ - -^ \ \\ V^ ^ \^ ^~ ^^^-s$50 - -— ^^^4(^^ ^s - UNITED STATES 1 1 1. 1 ' $30 1 ^ 10- \ \ . \ ■. \ $75 /$50 \ / NORTH AFRICA $30 _L 1981 1983 1985 1987 1989 1991 1993 1995 198! 1983 1985 1987 1989 1991 1993 1995 FIGURE 25, - Potential annual production from producing mines in market economy countries at various cost level s« Note that curves are drawn at different scales. Since actual production may be at less than capacity levels, the curves shown in this section would not actually decline as rapidly as shown. The curves shown in figure 25 illustrate the fact that poten- tial production from producing mines in the United States will likely decline dramatically after 1986, while production from north Africa, in particular, will continue to increase through 1987. The U.S. phosphate industry has been produc- ing at much less than full capacity since mid-1981, however, so the decline in po- tential U.S. production shown on the curve will actually be delayed for sev- eral more years and the eventual decline will be more gradual than shown. Al- though potential annual capacity in north Africa will decrease between 1987 and 1993, additional capacity expansions are schedulaed after 1993. The estimated annual production capac- ities for each producing country at different cost levels in 1983 and 1995 are shown in tables 9 and 10. The pro- duction capacities listed for each cost level were used to construct the annual curves. As shown in table 9, the esti- mated capacity for mines in market econ- omy countries in 1983 is 122.7 million tons of phosphate rock at production costs ranging up to $75 per ton. This compares with actual production of 101.1 million tons of phosphate rock in 1981. The estimated capacity for the United States in 1983 of 55.3 million tons is slightly higher than the 1981 production of 54 million tons. Although not shown on the curves , an additional 1.6 million tons of phosphate rock could be produced at production costs over $75 per ton from mines in Bra- zil, Egypt, and Finland. These high-cost producers either are subsidized or com- pete against high-cost phosphate rock im- ports (such as in Brazil) . 46 TABLE 9. - Estimated potential annual production capacities in market economy countries by 1983, for mines that produced in 1981 (Thousand metric tons) Region and Cost per ton Total country $17-$30 $30.01-$40 $40.01-$50 $50.01-$60 $60.01-$75 North America: United States.... Mexico 44,842 16,434 3,001 1,400 2,491 3,986 8,919 1,830 100 1,000 5,819 5,956 141 2,005 3,031 3,261 129 770 2,135 159 1,204 1,998 849 1,701 2,501 329 801 2,425 468 1,901 179 230 250 475 55,272 801 South America: Brazil 3,629 Colombia 141 Venezuela North Africa: Algeria 468 2,005 Morocco 27,351 Tunisia 5,781 Other African countries: Seneffal .......... 1,830 South Africa Togo Zimbabwe 3,261 3,001 179 Middle East: Egypt Iraq Israel 459 1,701 3,501 Jordan. .......... 6,589 Syria 2,135 Oceania: Australia Nauru 1,650 2,491 Other: India 475 Total 68,168 21,654 17,428 8,412 7,058 122,720 NOTE. — Dashes indicate that the cost range contains no tonnage. Table 10 shows potential production of 88.5 million tons of phosphate rock in 1995 at production costs ranging up to $75 per ton. The interesting comparison between tables 9 and 10 is the decline in potential production capacity for the United States compared to the increase for Morocco. The United States shows a decline from 55.2 million tons in 1983 to 16.4 million tons in 1995 as the demon- strated resources of producing mines be- come exhausted. Morocco, on the other hand, shows an increase from 27.3 mil- lion tons in 1983 to 31.3 million tons in 1995. Potential production of phosphate rock in 1995 at costs of under $30 per ton would decline to 21.1 million tons com- pared with 68.2 million tons in 1983. The U.S. share of this production would decline to 51.5%, while Morocco's share would be 29.3%. Of the 33.4 million tons of phosphate that could be produced in 1995 at costs between $30 and $40 per ton, the United States would account for only 4.1% and Morocco would account for over 69%. At estimated production costs between $40 and $50, 15.9 million tons of phosphate rock could be produced in 1995, with the United States accounting for 47 TABLE 10. - Estimated potential annual production capacities in market economy countries by 1995, for mines that produced in 1981 (Thousand metric tons) Region and country Cost per ton Total $I8-$30 $30.01-$40 $40.01-$50 $50.01-$60 $60.01-$75 North America: United States Mexico 10,850 6,172 4,065 1,360 23,127 1,979 100 1,000 5,819 3,746 564 2,005 1,547 5,608 129 770 1,492 159 2,208 1,998 1,701 2,501 329 801 3,427 468 1,401 270 1,000 1,103 16,444 801 South America: Brazil 5,635 Colombia. ......... 564 Venezuela. ........ 468 North Africa: Algeria. •••....... 2,005 Morocco. ••••.....• 31,297 Tunisia. .......... 3,79 7 Other African countries: Sene2al. .......... 1,979 South Africa To so 5,608 4,065 Middle East: Egypt 499 "6/ i**-. ...... ...... Iraq ,,, 1,701 Is rael. 3,501 Jordan. ........... 6,589 Syria 1,492 Oceania: Australia. Other: India 1,000 1,103 Total 21,087 33,385 15,861 9,416 8,799 88,548 NOTE. — Dashes indicate that the cost range contains no tonnage, 23.6% and Morocco having zero potential production in this cost range. Brazil would dominate production in the $50 to $75 cost range with 30.9% of the poten- tial 1995 production. If the market permitted it, some of the estimated decline of production by pro- ducing mines in the United States could be counteracted by an expansion of production capacities of the remaining producers that have large resources, al- though such an expansion would effective- ly shorten their producing lives. Future U.S. needs will have to be met through the development of new mines, which in most cases will have higher total costs, or possibly through importation. The potential annual availability curve for all of the undeveloped deposits in market economy countries is shown in fig- ure 26. Since no definite startup is known or available for most of these de- posits, it was assumed that preproduction began in a base year (N) of the analysis which cannot be connected with an actual year since production from many of these deposits is not expected in the near fu- ture. However, the annual curves for un- developed deposits do show the required lead times before production can begin and therefore are important in that they show the potential production costs and potential annual capacities of the mines of the future. In these curves, all un- developed deposits (with the exception of 48 /V+6 ^+8 YEAR ^+10 FIGURE 26. - Potential annual production from de- veloping mines and explored deposits in market econ- omy countries at various cost levels. the mines that are currently under devel- opment) assumedly begin preproduction development at the same time; consequent- ly the tonnage available in a given year is overstated since not all of the non- producers will begin preproduction devel- opment simultaneously. Mines that are currently developing appear in the first couple of years, and then potential annul production increases dramatically as the other nonproducers begin to come on- stream in the year 717+4. The key factor that this curve highlights is the tonnage differential at the different cost lev- els. Under the assumption that all of the nonproducing deposits began prepro- duction development in year N, all would be producing at full capacity by the year ^+10 (although some capacity expansions would continue to occur beyond that time). In this case, 136.9 million tons of phosphate rock could be produced in the year N+IO at production costs ranging up to $100 per ton. (An additional 21.2 million tons at estimated production costs greater than $100 is not shown on the curve.) Of this amount, 15.3 million tons could be produced at costs under $35 per ton: 67% from the United States, 31% from Morocco, and 2% from Australia. At production costs between $35 and $45 per ton, 28.8 million tons of phosphate rock could be produced: 76% from the United States, 14% from Jordan, and 10% from the Western Sahara. From $45.01 to $60 per ton, 49.3 million tons of phosphate rock could be produced: 71% from the United States, 22% from Australia, and 6% from Morocco. From $60.01 to $75 per ton, an additional 24 million- tons of phosphate could be produced: 8% from the United States, 14% from Peru, and the remaining 18% from Saudi Arabia, Mexico, and Pakis- tan. Of the 19.5 million tons that could be produced from $75 to $100 per ton, 82% would be from the United States , mainly from deposits in the West. The data un- derlying figure 26 are shown in tabular form in table 11. The United States pre- dominates in the potential production of phosphate rock at costs under $50. Po- tential U.S. production in the year 27+10 at $50 or less is slightly over 49 mil- lion tons, which is 81% of the total for all of the market economy countries at that cost level. Based on the data presented in tables 9 and 10, the United States will have to invest in the development of new mines within the next few years in order to maintain or increase current production. Assuming fixed capacities for existing mines, if U.S. production in 1995 re- mained the same as in 1981 (at 54 million tons of phosphate rock) , almost 70% of the production in 1995 would come from mines that have yet to be developed. Obviously, much of the potential ton- nage shown in figure 26 for the year N+10 will not actually be produced for a very long time, especually from the high-cost deposits. If we can assume, however, that most of the deposits that could pro- duce for under $50 per ton will actually be developed over the next 20 years or so, it appears that the undeveloped de- posits in the United States have a future cost advantage over the undeveloped de- posits in other countries, at least when measuring production costs f.o.b. port or acid plant. However, based on the fore- going analyses, the U.S. phosphate indus- try in Florida will have to invest in the next few years to develop new deposits if it intends to maintain or expand upon current production levels, while Morocco 49 TABLE 11. - Estimated potential annual production capacities for undeveloped deposits at an average total production cost of less than $100 per ton of phosphate rock in the year N+10, by country (Thousand metric tons) Region and country Cost per ton Total $27-$35 $35.01-$45 $45.01-$60 $60.01-$75 $75.01-$100 North America: United States. . . . Canada 10,311 4,677 300 21,831 2,929 4,000 34,998 3,070 228 11,000 16,342 1,204 3,435 2,500 556 16,048 702 498 2,094 130 99,530 702 Mexico 1,204 South America: Brazil 498 Peru. 3,435 North Africa: Morocco. • 9,841 Western Sahara. . . Other African countries: Angola. Middle East: Jordan. .......... 2,929 228 4,000 Saudi Arabia Turkey. 2,500 130 Other Middle East: Pakistan. , . Oceania: Australia 556 11,300 Total 15,288 28,760 49,296 24,037 19,472 136,853 NOTE. — Dashes indicate that the cost range contains no tonnage. may need to invest primarily to expand production of existing mines. Almost two-thirds of the phosphate from new mines in the United States that could be produced for under $50 per ton would cost in the $40 to $50 range, whereas most phosphate rock in Morocco from existing mines can be produced for under $40 per ton. Therefore, although current produc- tion costs are similar, the United States might have to spend large amounts of cap- ital to maintain production, while Moroc- co will not. As a result, the cost ad- vantage in the world phosphate export industry will likely shift from Florida to Morocco. There are numerous factors, however, that could greatly enhance the outlook for phosphate availability from the United States, particularly over the long run. In addition to the demonstrated re- sources evaluated in this study for the United States, an estimated 7 billion tons of potentially recoverable phosphate rock exists at the inferred level (over 80% is in the Southeast), and over 24 billion tons of potentially recoverable phosphate rock exists at the hypothet- ical resource level (over 60% is in the Southeast) . New deposits will likely be discovered (particularly offshore deposits along the eastern seaboard) , low-grade material could become economically minable, or technological advances could enable pro- cessing high-magnesium oxide material or the mining of deep deposits by the bore- hole mining technique. Each of these factors could greatly increase the amount of phosphate available in the future. Of immediate interest to the U.S. phos- phate industry is more than 2 billion tons of recoverable phosphate rock in 50 Florida at the identified resource level that contains high-magnesium-oxide mate- rial and is presently considered unac- ceptable by the industry owing to the higher benef iciation costs of producing an acceptable acid plant feed. Given the progress several phosphate companies and the Bureau of Mines have made in develop- ing benef iciation technologies to lower the grade of magnesium oxide in the phos- phate rock product, this additional 2 billion tons of rock could likely become available in the near future, but at a higher cost. differential between mines and deposits determined on an f.o.b. mill or an f.o.b. port or acid plant basis is significant, this differential is fairly consistent in all of the producing countries, A more important measure of the cost of phos- phate is the cost of shipping phosphate from individual producing to consuming countries. Although shipping costs from producing to consuming countries were not included in the analysis that went into the construction of the availability curves for phosphate, they are presented for comparison purposes in table 14. EFFECT OF TRANSPORTATION The foregoing analyses determined the average total production cost for phos- phate rock, including a transportation charge for each deposit to the nearest port or acid plant (or to market in some cases). The assumed destinations of the rock product (port, acid plant, or mar- ket), by country, are shown in table 12. Figure 27 provides a cost comparison between phosphate rock production from each mine or deposit both f.o.b. port or acid plant and f.o.b. mill. Table 13 presents a more definitive breakdown, showing average total production costs (including a 15% DCFROR) , both f.o.b. mill and f.o.b. port or acid plant, on a weight-averaged basis. Although the cost 100 60 "o 40 Costs ore iab, port or acid plont CostSQreiQb.mil , T' 20 -f 5 10 15 20 25 30 35 TOTAL RECOVERABLE PHOSPHATE ROCK, billion metric tons FIGURE 27. - Phosphate rock potentially recover- able from all mines and deposits in market economy countries. The reader can ascertain a more accu- rate cost of phosphate rock to a consum- ing nation by taking the production cost data presented in table 13 and adding from table 14 the relevant shipping cost to the consuming country. In this way, a general comparison can be made as to the cost of phosphate rock from competing suppliers to a particular consumer. Of paramount interest for the U.S. phosphate industry are the relative costs between the United States and north African (primarily Moroccan) phosphate rock pro- ducers when freight charges to various major phosphate markets are included. For phosphate rock delivered to the port of Amsterdam, Moroccan phosphate rock has a $12 per ton cost advantage (exclusive of any tariffs) over U.S. phosphate rock. This differential increases to $19 between deposits in Morocco that are not yet producing and undeveloped deposits in the Southeastern United States. Con- sidering that Morocco is gearing up to produce much more phosphoric acid for ex- port, it appears that Morocco should fur- ther dominate the European market in the future. The same situation exists for exports to Eastern European countries. The United States should maintain its comparative advantage in supplying its domestic market and the Canadian market and appears to have a relative cost ad- vantage in the Far East. Both the United States and Morocco will likely lose the Brazilian market since Brazil is becoming self-sufficient in phosphate. 51 TABLE 12. - Assumed destinations for phosphate rock, by country Country North America: United States: Florida , North Carolina. Tennessee Idaho Montana , Utah Wyoming Canada Mexico South America: Brazil Colombia Peru Venezuela North Africa: Algeria Morocco ■ Tunisia Western Sahara Other African countries: Angola Senegal South Africa Togo Zimbabwe Middle East: Egypt Iraq Israel Jordan Syria Turkey Oceania: Australia Christmas Island Nauru Miscellaneous countries: China Finland India U.S.S.R Market^ E E IC IC IC IC IC IC IC IC IC E IC E E E E E E E E IC E E E E E IC E E E IC E IC IC Location of port or acid plant Tampa or Jacksonville. Morehead City. Mount Pleasant. Pocatello or Soda Springs, ID; Silverbow, MT. British Columbia. Pocatello or Soda Springs, ID. Do. Port Maitland. Port Belcher or Lazaro Cardenas. Uberaba, Santos, Imbitumba, Fortaleza, Rio de Janeiro, or Recife. Pesca. Port Bayovar. Moron. Annaba. Casablanca, Safi, or Jorf Lasfar. Sfax or Gabes. El Aalun. Lacunga River mouth. Port Dakar. Maputo. Port Kpome. Salisbury, Safaga. Khor-Al-Zuber Port. Port of Ashdad. Aqaba. Port Tarfous. Elazig. Port at Gulf of Carpentaria or Townsville. Christmas Island. Nauru. Local. Leningrad, or port in Gulf of Finland. Udaipur. Local. E Export. IC Internal consumption. 52 TABLE 13. - Comparison of average total costs per metric ton of phosphate rock, f .o.b. mill and f.o.b. port or acid plant, by major producing region Potential phosphate rock production, 10^ metric tons Average total cost of production Region and country f.o.b. mill f.o.b. port or acid plant United States: Southeast: Producers ................. 981 2,925 361 2,112 412 242 7,125 14,170 2,823 10,000 1,360 773 207 344 $25.40 44.30 31.30 92.70 61.00 98.40 32.00 40.90 30.90 50.00 40.00 60.50 29.90 27.40 $28.90 48.30 Nonproducers • West: Producers 43.00 Nonproducers 104.30 South America: Producers 64.30 Nonoroducers ................ 105.30 North Africa: Producers 34.60 Nonproducers ................ 46.60 Other African countries: Producers 37.70 Nonproducers 59.50 Middle East: Producers 50.60 Nonproducers ................ 69.40 Oceania: Producers 53.90 Nonproducers 53.80 ^ Costs are weighted high the West. owing to the effect of high costs at underground mines in CONCLUSIONS The agricultural industry worldwide is dependent upon the supply of fertilizers derived from phosphate rock. In an at- tempt to assess worldwide phosphate rock resources , the Bureau of Mines evaluated 201 mines and deposits in market economy countries and investigated the resource potential of 17 mines and deposits in China and the U.S.S.R. The selected mines and deposits include all known re- sources of phosphate rock at the demon- strated resource level that met the cri- teria of the study and that can be mined and milled with current technology. Approximately 34.2 billion tons of phosphate rock is potentially recoverable from the demonstrated resources of 201 mines and deposits evaluated in market economy countries. An additional 1.5 billion tons of phosphate rock is poten- tially recoverable from 17 mines and deposits in China and the U.S.S.R. Mor- occo and Western Sahara have the largest resource, with 21 billion tons of recov- erable phosphate rock, followed by the United States with 6.4 billion tons. Of the approximately 1.6 billion tons of phosphate rock that is potentially recov- erable at total production costs (includ- ing a 15% DCFROR on all investments) of under $30 per ton, 55% is in the United States and 39% in Morocco. All of this potential low-cost resource is from mines that are currently producing. Approxi- mately 10.6 billion tons of phosphate rock is potentially recoverable at pro- duction costs under $40 per ton, includ- ing 6.9 billion tons from Morocco (66%) and 1.4 billion tons from the United States (13%). Of this 10.6 billion tons, 7.2 billion tons (68%) is from currently producing mines, including 5.9 billion tons from producing mines in Morocco and OS 0) bO u to s: o /-^s -o bO Q) c a. 1-1 D, a. •H o. J= •H CD x: CO c o ^ 4-1 o o o iJ 1-( Vj 0) XJ JJ -i TJ to •H l-( U l-( o o 3 T3 CO Ed 5 ,~^ ► cn e T3 c 0) CO C l-l a- 13 CO O o. 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Vacuum jets FILTER Gypsum JA steam- EVAPORATOR EVAPORATORS 52% to 54% P^O^ 'acid STORAGE Some 30% acid Merchant acid Pond DAP disposal AGING AND CLARIFICATION 54% acid DAP GTSP Acid sales Sludge acid to triple superphosphate FIGURE A-1, • Wet-process phosphoric acid (J). 59 from a stockpile to merchant-grade acid facility, and disposing of the byproduct in storage tanks, producing sulfuric gypsum, acid from liquid sulfur delivered to the TABLE A-1. - Phosphoric acid production costs, by region Region Cost' North America $192 South America 203 Western Europe 203 Region Cost' Asia $202 Middle East 188 Africa 197 Costs are in 1981 U.S. dollars per metric ton of P2O5. 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