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SNAPSHOT OF HISTORY BEHIND JDC, INC.
- Historically phosphoric acid is liberated
from phosphate ore for commercial markets by reaction with
sulfuric acid in aqueous solutions (the Wet Acid Processes)
and by a high temperature electric furnace carbon reduction
(the Electric Furnace Process).
- The Electric Furnace Process
was optimized by the Tennessee Valley Authority and was producing
nearly half of the US phosphoric acid production by the middle
of the last century.
- The price of electricity became much higher
than the price of sulfuric acid and the Wet Acid Processes
came to dominate the industry.
- In 1981, Dr. Robert Hard of Occidental
Research Corporation (ORC), made an enabling technology breakthrough
that opened the door to replacing all of the heat generated
by electricity in the Electric Furnace Process with heat generated
by carbon. This general concept had been advanced by many researchers
over a long period of time. They had failed because of melting
problems which Dr. Hard overcame.
- The process employs a rotary
kiln reactor and was proven in pilot plant testing at the Allis
Chalmers Test Center in a continuous kiln pilot plant in 1981-2
under the direction of Dr. Joseph A. Megy.
- ORC was closed for
reasons unrelated to the phosphoric acid development program
shortly after Hard's discovery and the following pilot plant
runs.
- At the time ORC was closed the process was
far from optimized and projected capital and operating costs,
though promising, were not sufficient for Occidental to continue
development for fertilizer markets alone. The Electric Furnace
Process plant owned by Occidental was facing closure due to
the loss of the detergent market as formulators eliminated
phosphate builders due to environmental reasons.
- In 2003, Dr.
Joseph A. Megy restarted Research and Development on the Hard
Process, and made additional discoveries over the following
four years that led to the Improved Hard Process for which
a new patent has recently been granted.**
- The Improved Hard
Process has considerable capital and operating cost advantages
over the Hard Process, and is now very competitive with the
Wet Acid Process.
- The Improved Hard Process also has major
environmental and sustainability advantages, uses lower grade
ores, and produces a higher quality phosphoric acid that through
fertigation practices allows more efficient utilization in
crops and allows for less surface and ground water contamination
at the point of use.
- Being fully aware of the importance of
the new technology to fertilizer sustainability and environmental
stewardship, JDC, Inc. has expanded its research institute
to be able to complete the commercialization of this breakthrough
technology.
- The Improved Hard Process technology operates
(albeit at much higher throughput, yield, and efficiency) within
the temperature, composition, and operating envelope of the
earlier pilot plant, and therefore is all ready proven technology.
- The
JDC, Inc research institute intends to build a semi-commercial
demonstration plant which is an order-of-magnitude larger than
the earlier pilot plant where the ultimate yield and throughput
can be determined for various ores, and the process advantages
can be fully quantified.
- JDC has assembled industry's top talent
and "know how" by bringing together the technical team that
built the original ORC pilot plant. With this team JDC begins
commercialization by setting up semi-commercial demonstration
plant and scale up test labs to be strategically located to
support the world's major phosphate mining operations.
**Pictures showing Idaho phosphate feed balls
and spent solids exiting the kiln with the phosphorus removed
and batch pilot kiln where testing was performed on Improved
Hard Process. Spent balls pass TCLP environmental tests for unlimited
landfill and aggregate uses.
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