Blog-News
Optimizing Mill Systems for Low Grade Rock
Ian Hancock, Bradley Pulverizer, UK, discusses several machine wear enhancement options for mills, classifiers, and milling systems for phosphate fertilizer production. Click Here to download the complete article in pdf format as published by World Fertilizer Magazine – Oct 2024, pp. 31-33.
While technology and design have advanced over the years, the general function of Bradley mills to provide continuous grinding of hard friable minerals has remained relatively unchanged since first being used for fertilizer production in 1873. The mills are engineered for operating at lower speeds to reduce the degree of wear commonly encountered from high impact milling, with a key design feature being the ability to custom enhance the wear resistance of the mill and system.
Zaki Hussaini and Osamh S. Alshahed Presenting at 11th International CHoPS Conference
We are pleased to announce that Zaki Hussaini, MEng, Design Engineer – Bradley Pulverizer, and Dr. Osamh S. Alshahed, Design Engineer – Bradley Pulverizer, will both be representing Bradley Pulverizer at the 11th International Conference on Conveying and Handling of Particulate Solids (CHoPS) – from 2nd-4th of September, 2024 in Edinburgh.
Zaki Hussaini will be presenting results from his research titled Ultrafine Air-Classification of Plant based Proteins: A Step Towards Reducing Carbon Footprints.
Dr. Osamh S. Alshahed will present results from his research titled, Model Predictive Control Simulation of Pneumatic Conveying of Plastic Pellets Using Nonlinear Dynamics Analysis and Sparse Identification of Nonlinear Dynamics with Control.
The CHoPS conference presents a unique forum to promote the exchange of technical and scientific information across the academic and industrial sectors in the fields of solids flow, mechanical behavior of bulk materials, powder testing, segregation and mixing, modelling, etc. It is also intended to foster business and collaboration opportunities around the world. The scope of the conference is wide-ranging from pharmaceuticals to mining and minerals, food and chemicals and all other sectors that process powders and bulk solids. If you deal with particulates – you have to be at CHoPS! Few other conferences in the area are as large, as international, and as wide ranging in both industry and academic participation.
Classifier Comparison Chart Explains Differences in Particle Classifier Technologies
Optimization of an airswept milling system for highest yields, efficiencies, and smooth operation can only be achieved when classifier technology is properly aligned with the specifications of the application. Bradley Pulverizer addresses the diverse needs of airswept milling systems by offering several different types of air classifiers, each implementing technology designed to achieve optimal particle classification for a given range of specifications. While some milling applications dictate a clear choice of particle classifier, in most cases, selecting the right air classifier involves considering the total cost of ownership, including overall yield rates and system profitability.
Bradley’s air classification solutions are versatile and compatible with mills from most OEMs including airswept mills, pendulum mills, ball mills, table and roller mills. Our classifiers can be seamlessly integrated with the mill with the added advantage of being retrofitted into existing systems.
OEM Replacement Wear Parts Offer Long-Term Savings
Keeping your equipment online and running is key to maintaining production rates and profits. While “volume pricing” or reverse engineered spares from third-party vendors may seem like a win for short term cost savings, the perceived value may not be as great in the long term. The long-term costs of machine breakdowns and reduced productivity is far higher than short term savings.
At Bradley Pulverizer, we aim to help our customers maintain optimal performance of their machines. Our experts are available to help you order the right OEM replacement parts designed exactly for your Bradley machine. Bradley OEM parts provide consistent, reliable performance so you get the most from your investment.
Buying direct from Bradley ensures you receive the following benefits:
- Highest quality parts – engineered from alloys specified for optimal machine operation
Ian Hancock from Bradley Pulverizer to Present “Use of Low Grade Phosphate for Superphosphate Production” at CRU Phosphates 2024
Come see our own Ian Hancock, VP Sales and Operations at Bradley Pulverizer, deliver his technical innovation presentation focused on the “Use of Low Grade Phosphate for Superphosphate Production”, at the CRU Phosphates 2024 Conference & Exhibition in Poland on Feb 27, 2024 from 12:15-12:45.
This presentation looks at how the decline in the quality of available phosphate rock sources is affecting the ability to produce high grade superphosphate fertilizers, even after beneficiation after mining (Fertilizer International 517, p53).
Minimizing Heavy Metals in Superphosphate Manufacturing
Part 1 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”
The cadmium and heavy metal content of sedimentary phosphates are of great concern. This has seen industry raw material consumption shift towards igneous phosphates or the blending of phosphate rocks from different sources. While rock blending can successfully reduce the heavy metal content of superphosphates, it needs to be accompanied by careful process adjustments Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.
Introduction
The manufacture of single superphosphate (SSP) and triple superphosphate (TSP) fertilizers, through acidulation of fluorapatite rock, continues to evolve. Process adaptations have been necessary, for example, in response to the consumption and depletion of known phosphate rock resources worldwide. In addition to the more obvious economic consequences, the environmental impacts of declining phosphate rock quality also demand attention and must be compensated for by the production process. Avoiding the presence of unacceptable levels of cadmium and other heavy metals in phosphate fertilizers is a particular concern and priority – as this can eventually lead to soil contamination.
Environmental Consideration in Superphosphate Production
Part 2 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”
Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.
Environmental considerations
Most phosphate rock sources used in superphosphate production worldwide contain concentrations of heavy metals (cadmium, uranium, radium, lead, mercury, etc.). Such elements are known to be toxic to both livestock and humans and injurious to health if ingested at high levels. High cadmium (Cd) levels tend to be most prevalent, making this element the heavy metal of most concern. Care is therefore taken to minimize its concentration in superphosphate fertilizers. Cd levels are typically kept to below a threshold of 280 ppm, although regulations do vary from country to country.
Using Rock Blending to Regulate Heavy Metals in SSP Fertilizer Manufacturing
Part 3 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”
Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Part 2 provided a background to the environmental considerations that must be addressed in SSP manufacturing. Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.
Regulating heavy metals through blending
As stated in part 2 of this blog series, the typical target limit for cadmium in superphosphate fertilizers is <280 ppm. It might be concluded, therefore, that the answer is to simply source phosphate rock with cadmium levels (in fluorapatite) below this limit as a production feedstock. However, this apparently simple answer is not generally practical due to the different processing characteristics of low cadmium (igneous) and high cadmium (sedimentary) phosphate sources (Table 1).
Determining the Ideal Rock Blend in SSP Manufacturing
Part 4 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”
Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Part 2 provided a background to the environmental considerations that must be addressed in SSP manufacturing. Part 3 presented rock blending as the way to minimize heavy metals in the process. Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.
Determining the ideal rock blend
A stepwise approach for determining the optimal rock blend in superphosphate manufacturing is outlined below. Once the optimal blend is established, the production process tends to be straightforward and can run unimpeded with only relatively minor mechanical adjustments. However, any significant change in chemistry – due to a new phosphate rock source and/or sourcing from a new face in an existing quarry, for example – will potentially require a change to the blend.
In-Line Optimization of SSP Manufacturing in the Broadfield Process
Part 5 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”
Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Part 2 provided a background to the environmental considerations that must be addressed in SSP manufacturing. Part 3 presented rock blending as the way to minimize heavy metals in the process. Part 4 discussed the process for determining the ideal rock blend. Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.
In-line process optimization
Actual process conditions within the Broadfield superphosphate unit are only fully measurable during full scale production. In-line process sampling and testing is non-disruptive and the ideal way to maximize plant profitability by ensuring continuous production with minimal shutdowns.
