Chatham Confirms Significant Progress In Its Monocalcium Phosphate Project

Chatham Rock Phosphate Ltd.’s wholly owned Australian subsidiary, Korella MCP Pty. Ltd., has taken a significant first step in its march to become the sole Australian producer of monocalcium phosphate (MCP).

The first step to produce MCP is to produce the precursor weak phosphoric acid (WPA), which has just been successfully accomplished in bench-scale tests at Monash University.

Background

Since early 2021, plans have been progressed by Chatham to enable production of 30,000 tonnes per annum (tpa) of MCP to meet the needs of primarily the cattle industry of northern Australia.

The severe phosphorus deficiencies in north Australian range land mean that for cattle production in this extensive region, supplemental feeding of phosphorus is an essential part of cattle raising and management.

MCP is a soluble and palatable form of phosphorus readily taken up by all farmed animals to build healthy bones. MCP, presently 100-per-cent imported, is an essential part of all cattle lick blocks and cattle dry lick. There are approximately 14 major lick block manufacturers in Queensland and NSW (New South Wales) serving the cattle industry in the north.

MCP is also the preferred phosphorus supplement for pigs and poultry.

With Australia importing all of its animal-feed-grade phosphorus supplements of around 50,000 tpa, the development of a Cloncurry-based manufacturing facility to produce 30,000 tpa will deliver a reliable, quality product into a resilient supply chain.

The inputs for production of MCP of phosphate, limestone and sulphuric acid will, apart from sulphuric acid, be sourced from the company’s Korella North mine. However, sulphuric acid will be manufactured on site utilizing prilled sulphur imported from Canada.

Alternative strategy

Although Korella MCP has already worked with Belgium phosphate technology company Prayon, an alternative strategy has been pursued to utilize existing technology in Australia to develop MCP production capability.

As part of this strategy, Chatham commissioned Monash University to work on this project.

Bench-scale tests have commenced and the first step in this three-stage process has been the successful production of weak phosphoric acid (WPA).

The second step is for the WPA to be partially neutralized using slaked lime to produce soluble monohydrated MCP. In the third step, the soluble monohydrated MCP is then heated at low temperature in acidic conditions to evaporate the water to crystallize the MCP.

Negotiations are under way with Monash University to use its pilot plant to undertake the full range of processes required to manufacture MCP.

Korella MCP will be produced to meet the highest international quality and consistency standards, which will enable Chatham to also supply overseas markets.

Project logistics and financing

The Cloncurry site for the manufacturing facility has been selected and preparation of a development application to Cloncurry Shire Council is under way.

At the same time, after an initial approach to the Northern Australia Infrastructure Fund, further discussions are expected to have the MCP project assessed for possible funding under the scheme, as the development of an MCP plant in Australia is of national importance.

Colin Randall, executive director, will present a paper entitled “The Top End Cattle Industry is dependent on MCP” to the annual Developing Northern Australia Conference being held in Darwin from July 24 to July 26, 2023.

Meanwhile approaches have been made to both European- and Malaysian-based MCP producers to become involved in the project.

Korella MCP plans to be the reliable and resilient supplier of choice for Australian consumers of quality MCP.