Source: JDC, INC. submitted to NRP
KILN PHOSPHORIC ACID PROJECT (SECOND PHASE I PROJECT)
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
SMALL BUSINESS GRANT
Reporting Frequency
Annual
Accession No.
0206489
Grant No.
2006-33610-16766
Cumulative Award Amt.
(N/A)
Proposal No.
2006-00204
Multistate No.
(N/A)
Project Start Date
May 1, 2006
Project End Date
Dec 31, 2007
Grant Year
2006
Program Code
[8.4]- (N/A)
Recipient Organization
JDC, INC.
P.O.Box 1224
NEW CUMBERLAND,WV 26047
Performing Department
(N/A)
Non Technical Summary
Farmers and industrial markets require liquid phosphate products at competitive prices. Current production technology has environmental concerns, restictive ore requirements, low overall yields, and high cost. This project carries out commercial devlopment activities for the Kiln Phosphoric Acid Process for producing liquid phosphoric acid product which promises higher overall yields, less restrictive ore requirements, lower cost, and a smaller environmental footprint.
Animal Health Component
100%
Research Effort Categories
Basic
(N/A)
Applied
100%
Developmental
(N/A)
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
40152102020100%
Knowledge Area
401 - Structures, Facilities, and General Purpose Farm Supplies;

Subject Of Investigation
5210 - Fertilizers;

Field Of Science
2020 - Engineering;
Goals / Objectives
JDC, Inc will perform development activities to demonstrate suitability of commercial equipment for implementing the Kiln Phosphoric Acid Process, and to determine the operating and equipment specifications for the selected equipment. JDC will also complete additional laboratory work to characterize more fully the effect of impurities and raw material specifications on the process. The objective of this work is to bring the process development to a level where a decision to proceed with a pilot plant can be made.
Project Methods
Each of the production steps in the process will be carried out in commercial equipment suppliers pilot laboratories. Ore from our commercial partner and other raw materials appropriate for a potential pilot plant for the process will be used in these tests. The tests are run to supply appropriate feed for a 2' diameter batch rotory kiln,where heat and mass transfer data critical to scale up of the process will be determined. The samples from these tests will be analyzed at commercial laboratories and at the PNNL Laboratories. Additional bench scale work involing the JDC bench scale pilot, TGA, EDAX,and XRD,will be preformed at the PNNL laboratories in Richland, WA to complete the impurity and raw material study portion of the work.

Progress 05/01/06 to 12/31/07

Outputs
OUTPUTS: Speech: Megy, Joseph Al, Kiln Phosphoridc Acid (KPA) Process Sponsered by SME-AIChF-AIPG-AFPC-FIPR, October 12, 2006. Extensive private discussions with Agrium in Soda Springs, Idaho. Includes several private written communications and reports. Private discussions with Mosaic.Includes several written communications. Vender test laboratory reports have been developed for several of the unit processes tested at vender laboratories. Many analytical reports developed by PNNL, Agrium, XRAL, WahChang and LECO laboratories. Radioactivity report developed by PNNL laboratory personel. TCLP report of solid waste characterization. Research and Development of project complete with improved process ready for pilot plant demonstration. Improved process will allow manufacture of phosphoric acid($20 billon/yr market) at lower cost, with higher quality lower grade resource utilization and smaller environmental footprint. PARTICIPANTS: Joseph Megy Donna Megy Larry Handman- Engineering Consultant. Agrium- Commercial Discussions. CEntry Engineers- Consultants. PNNL- User Laboratory. Metso- Vender Laboratory. Dan Neuman- Technical Liason. Ron Hartung- Consultant Aeroglide- Equipment provider. Testing Laboratories- XRAL, Agrum, WahChang, Leco, and several others. Wells St. John- Patent. FEECO- Equipment Provider. Jamegy- Laboratory support. Mark Vignovic- Environmental Consultant. Mosaic- Commercial Ciscussions. TARGET AUDIENCES: Fertilizer professionals. Phosphoric Acid Producers.

Impacts
The project has been conducted over a four year period with two Phase I SBIR grants. It has generated four major discoveries that have resulted in a new patent to be issued shortly(Notice of Allowance, Base Issue Fees paid.) The first publication of the Improved KPA Process has been acepted by Fertillizer International. I plan two more publications to follow shortly. In addition I have worked with two major phosphoric acid producers (Agrium and Mosaic) to forward activities toward a commercial pilot plant for the process. I plant to make further marketing efforts in the future. A commercial pilot plant will cost $5-25 million range depending on sizes being discussed and details. While there is some commercial interest, no commercial aggreements have matured to date.

Publications

  • Megy, J., 2008 "The Economic, Environmental and Quality Advantages of the Kiln Phosphoric Acid (KPA) Process over the Wet Acid Process for the Manufacture of Phosphoric Acid". Accepted for publication in the May/June issue of Fertilizer International.
  • J. Megy, 2008 "Phosphorus Pentoxide Producing Methods" Appl. No.11/818,115. Notice of Allowance and Base Issue Fees Paid.