Aurora Phosphate Mine, NC, USA

The Aurora phosphate operation located Lee Creek Beaufort County Carolina USA. largest integrated phosphate chemical world wholly owned Potash Corporation Saskatchewan (PotashCorp) capacity 6.6mt/y phosphate ore 1.3 mt/y phosphoric acid 0.2mt/y phosphate feed.

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PotashCorp bought Aurora Texasgulf 1995 its phosphate operation purchased agricultural products division Occidental Chemicals months later.

GEOLOGY RESERVES

The phosphates deposited receding 15My ago. phosphate zone approximately 30m beneath low-grade phosphate sand covered sand silt beds. zone averaging 13% P2O5 12m thick consists phosphate sand (35%) quartz (45%) clay silt. phosphate occurs rounded pellets usually 1mm diameter containing organic matter fluorine trace elements.

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As end-2005 Aurora estimated proven probable reserves approximately 356Mt phosphate average grade 30.7% P2O5. company rights 8,900ha phosphate-bearing reserves sufficient support its operations 75 years. June 2009 PotashCorp received permission Army Corps Engineers mine reserves within extra-territorial jurisdiction boundaries 30 years.

MINING

Bucket excavators (BWEs) supplied German company PWH – PHB Weserhutte (now Krupp F?rdertechnik) remove 10m overburden convey active mined-out pit. remaining 18–21m overburden removed draglines expose phosphate ore. consists SR630 compact BWEs transfer conveyors 4km shiftable conveyor round-the-pit overburden haulage rail-mounted tripper cars slewing conveyors.

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Water pumped underlying Castle Hayne formation aquifer pit recycled phosphoric acid cooling systems.

Preparations opening NCPC 2000 dragline stripping beginning 2001. pit produces lowest-cost phosphate US.

PROCESSING

The Aurora complex designed following:

Dry phosphate (67% bone phosphate lime BPL)Technical/feed-grade phosphoric acid (56–62% P2O5)Di-ammonium phosphate (DAP)Ammonium polyphosphate solution Superphosphoric acid (SPA 68–71% P2O5) Merchant-grade phosphoric acids (MGA 52–54% 56–58% P2O5)

The facility includes sulphuric acid plants phosphoric acid plants liquid fertiliser (11-37-0) plant superphosphoric acid plant DAP plants solid fertilizer producing DAT GTSP (granular triple superphosphate) (monoammonium phosphate). 2004 PotashCorp committed $73m further 82,000t/yr expansion purified-acid plant aim diverting P2O5 capacity higher-value end-uses. expansion completed 2006 installation 82,000t additional capacity.

"The company rights 8,900ha phosphate-bearing reserves sufficient support its operations 75 years."

The mixed recycled slurry pumped processing screened remove coarse materials washed remove clay floated remove sand. stage phosphate rock. subsequent phosphate processing operations require sulphur sulphuric acid ammonia.

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The company maintains research development facilities Saskatoon Canada methods improving mine operations quality developed.

PRODUCTION

The Aurora facility not working its capacity years. 2008 mine produced . 6.6 Mt phosphate ore generating 1.3Mt phosphoric acid. Annual production records defluorinated phosphate purified phosphoric acid ammonium polyphosphate.

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In 2007 company initiated $260m debottlenecking project expand production phosphoric acid 180,000t/y. project included construction sulphuric acid plant.

During quarter 2008 silicon tetrafluoride units commissioned enabling register production silicon tetrafluoride. period phosphoric acid evaporators commissioned producing hydrofluorosilicic acid.

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TRANSPORTATION

The complex located waterway barge slip PotashCorp's tugs barges Morehead City. company leases shipping terminal receives stores raw materials products manufactured Aurora facility. 50km railroad spur connects complex Norfolk Southern CSX railways trucks loaded liquid products 24 hours day seven days week.

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ENVIRONMENT

Phosphate operations focus emission control management solid waste disposal reclamation focusing forests wetlands. process waters recycled contained site. addition solid waste-minimising programme emphasises recycling. 2005 awarded Carolina's Stewardship Award reclamation.

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In 2008 PotashCorp undertook initiatives reduce environmental impact. minimise biological consumption cadmium heavy metals gypsum clay mixed reclamation soil nearly acres R-2 reclamation zone covered 3ft soil.

The 713-acre Bay restored planting 220,000 shrub seedlings. November 2008 restoration 217-acre Creek Restoration project initiated.

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The company decided replace sulphuric acid plants energy efficient plant. equipped recovery existing turbo generator upgraded generate electricity using steam released plant. wastewater treatment project 2008.

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