Kropz South Africa
CASE STUDY 248
Emerging Phosphates rock producer saves millions on infastructure costs with high-capacity Derrick Superstack
Simplified
Flowsheet
Increased
Grade Classification of Phosphates
Lower
Carbon Emissions
Millions
Saved on infrastructure & Power Consumption
Why Derrick?
Derrick’s mission to empower our customers to maximize resource efficiency for a greener world is closely aligned with Kropz’s mission to set a new standard in the green mining of fertilizer feed materials. Fertilizer producers have relied on Derrick’s fine screening technology for decades. Derrick® equipment’s high capacity and smaller footprint reduce installation and infrastructure costs while increasing product recovery and grade.
Background
Issues with existing machinery and customer dissatisfaction regarding the quality of the product led to the shutdown of a phosphate plant after only a few years of operation. Fluidized bed separators (FBS) were used, which were unsuitable to produce efficient and consistent classification. Kropz approached Derrick to optimize the grinding circuit’s performance and improve the recovery and classification of phosphate particles. Our decades-long reputation for innovating in fine screening technology, coupled with a 5-years long relationship with Kropz, made Derrick an easy choice for their solution.
The Challenge
The first challenge was identifying the needs of Kropz and understanding how their existing closed grinding circuit featuring FBS and Hydrofloat® technology failed to produce the product with necessary specifications. Derrick assisted in conducting full-scale lab test work to establish a performance baseline of their grinding circuit and to pinpoint the accurate Derrick equipment solution.
The Solution
Following the full-scale lab testing, Derrick identified the SuperStack® as the proper solution for Kropz’s phosphate plant needs. The unrivaled capacity and performance of the SuperStack would answer for product classification and customer quality assurance. At the same time, the equipment’s reduced footprint and low power consumption would save on short-term infrastructure expenditure and long-term operating costs for Kropz, leading to low total cost of ownership.
Michelle Lawrence
COO of Kropz South Africa
“ The four SuperStacks offer an elegant and costoptimized solution to increasing throughput of the milling circuit and top-size presentation to the flotation circuit. We look forward to recommissioning the plant and working together with Derrick to maximize overall efficiencies.”
The Results
Derrick’s proposed solution simplified the plant’s flowsheet (Reference Figure 1) and assisted in achieving its carbon emission reduction goals while producing higher-quality fertilizer to meet its customers’ needs. Kropz ordered four high-efficiency, high-capacity SuperStacks – as opposed to more than double the units from the Chinese competitor – saving millions in infrastructure costs as well as commissioning costs. With lower operating expenditures and a generous payback schedule, Kropz could recommission a derelict plant with top-of-the-line technology built to withstand the harshest environments.
Key Installation Benefits
Millions Saved on Infrastructure (low CAPEX) and Power Consumption (low OPEX)
4 SuperStacks vs. 10 Competitor Units