Monday, January 31, 2011


The Aurora phosphate operation is located at Lee Creek in Beaufort County, North Carolina, USA. The largest integrated phosphate mining and chemical plant in the world, it is wholly owned by the Potash Corporation of Saskatchewan (PotashCorp) and has the capacity to produce 6.6mt/y of phosphate ore, 1.3 mt/y of phosphoric acid and 0.2mt/y of phosphate feed.

The facility includes six sulphuric acid plants, four phosphoric acid plants, a liquid fertiliser (11-37-0) plant, a superphosphoric acid plant, two DAP plants, and a solid fertilizer plant producing DAT, GTSP (granular triple superphosphate) and MAP (monoammonium phosphate). In 2004, PotashCorp committed $73m to a further 82,000t/yr expansion to the purified-acid plant, with the aim of diverting some P2O5 capacity to higher-value end-uses. The expansion was completed in 2006 with the installation of 82,000t additional capacity.

Phosphate operations focus on air emission control, water management, solid waste disposal and land reclamation focusing on forests and wetlands. All process waters are recycled and contained on site. In addition, it has a solid waste-minimising programme that emphasises recycling. In early 2005, the plant was awarded North Carolina's Mining Stewardship Award for reclamation.

In 2008, PotashCorp undertook a number of initiatives to reduce environmental impact. To minimise the biological consumption of cadmium and other heavy metals from gypsum and clay mixed reclamation soil, nearly six acres of the R-2 reclamation zone was covered with 3ft of soil.

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