Kazphosphate LLP was founded on October 27, 1999 in accordance with the law system of Republic of Kazakhstan.
Head office of the company is located in Almaty. Main production facilities are concentrated in Zhambyl region, therefore operating activities of the company are managed from the office located in Taraz city.
Kazphosphate LLP is a unique company on the territory of Kazakhstan. It operates full cycle from mining and processing of phosphate rock to the final products using its own railway-transportation complex.
Kazphosphate LLP comprises:
- Mineral Fertilisers Plant
- Kazphosphate Mining and Processing Complex
- Chulaktau Mining and Processing Complex
- Railway and transport complex
- Stepnogorsk Chemical Plant
- Economic Management
- Trading houses in Kazakhstan, Uzbekistan, Turkey, Lithuania.
Our way
Kazphosphate LLP started its work by restoring the market for mineral fertilisers, yellow phosphorus and its derivatives. Working in market conditions required in-depth processing of yellow phosphorus, production of new types of products - edible acid, edible sodium tripolyphosphate, slow-hydrated sodium tripolyphosphate, production of low-myskyak phosphorus and new types of mineral fertilisers and feed phosphates: superphosphate 19% P₂O₅, nitroammophos 22% P₂O₅, tricalcium phosphate 37% P₂O₅. Along with the main direction of its own activity, Kazphosphate LLP has done a great work on reconstruction and modernization of existing facilities leaded to improving of production processes in order to increase overall production, to expand the sales market, to satisfy needs of enterprises in the production with various consumer attributes.
In 2003-2004 alone, the company's specialists developed and introduced such new products as ammoniated superphosphate, nitroammophos, hydrated tripolyphosphate, phosphoric acid and food-grade sodium tripolyphosphate. In order to increase productivity, improve the quality of phosphate fine grinding raw materials and reduce energy consumption, modern electric motors of the latest generation with a capacity of 2250 kW were installed in two ore-grinding tube mills ø 4.4x15m. The productivity of the mills increased by 1.2 times.
At the Company's former branch, the Novozhambyl Phosphate Plant, the product of yellow phosphorus processing was phosphoric acid of the 1st and 2nd grades and tripolyphosphate of the highest and first grades. In order to expand the possibility of using orthophosphoric acid at the branch, as well as to expand its sales market, Kazphosphatam reconstructed the double salts department to produce food grade "A" phosphoric acid and food grade sodium tripolyphosphate based on it, meeting all GOST indicators. To increase the competitiveness of sodium tripolyphosphate on the sales market, the technology of production of hydrated sodium tripolyphosphate with predetermined quality indicators was developed. For this purpose, the metal was replaced with NZ steel at two turbo calcinators. For the first time in the world practice, the throat of the AKM-312 sintering machine was reconstructed for the production of phosphate sinter. The reconstruction resulted in a 5-8% increase in productivity and a reduction in the consumption of energy resources (electricity, natural gas, compressed air), coke and phosphate sludge. Previously, phosphate sludge with a phosphorus content of 40-50% was burnt in cyclone units to produce phosphoric acid sludge. At present, the plant's specialists have launched and are operating a sludge utilisation scheme at ore-thermal furnaces.
To utilise furnace gas in production, it is necessary to reduce its phosphorus content. This can be achieved by cooling water at the 2nd, "cold", condensation stage to the temperature of 20-30°C. At present, the scheme of cooling the condensation water in heat exchangers in the furnace shop with recycled water of the clean cycle is chosen for cooling the condensation water. For this purpose, at cooling towers SK-400 instead of wooden drop-film sprinklers, which were out of operation and did not provide sufficient depth of cooling of circulating water in summer time, socket spray nozzles were installed, modern fan equipment, polymer sprinklers and drop eliminators were installed. The implementation of the condensation water cooling scheme reduced phosphorus losses with sludge and also had a significant environmental effect by reducing yellow phosphorus emissions into the atmosphere. The reconstruction of the cooling unit for tuyere and nozzles of the orethermal furnace had a great effect.
Implementation of this measure made it possible to extend the service life of slag liner blocks and to increase the overhaul time of furnaces from 5 - 6 to 8 - 10 months. Furnace downtime due to these reasons was significantly reduced. Stable operation of electrodes on furnaces plays an important role in yellow phosphorus production technology. The work carried out at the branch to change the design of electrodes has reduced the number of breakages and thus the number of accidents at the furnaces. When drying coke in drying drums, a large amount of fines is formed due to abrasion of coke. At the same time coke fines together with gas emissions get into the atmosphere. Restoration works have been carried out to put into operation FS furnaces, which are much more economical, consume less electric power, and atmospheric emissions during their operation are significantly reduced.
During more than 20 years of work in Kazphosphate LLP at the Mineral Fertilisers branch, work was carried out to expand production capacity and range of products with an increase in their quality, creation of low-waste production facilities, recycling of production waste. The phosphoric acid extraction department was reconstructed with the installation of two carousel filters KVF-50. Production capacity increased by 30 % Extraction phosphoric acid production was switched to dry phosphogypsum removal, which allowed to reduce phosphogypsum waste generation by 30 kg. A drainless water consumption scheme is being utilised, which will enable the future elimination of sludge reservoir usage.
Technologies for the production of ammonium sulphate and slow-release fertilisers have been developed with reference to existing equipment. Research is being conducted on purification of extractive phosphoric acid in order to produce fertilisers with higher nutrient content on its basis. The technology of production of superphosphate on the basis of non-thickening pulp, which has no analogues, has been developed, mastered and is in operation, which allowed to exclude unorganised emissions of harmful substances into the atmosphere, which take place at production of superphosphate by the classical method.
Besides, Kazphosphate LLP concluded contracts and completed works with the following research institutes:
- Subject: Amendments to the permanent technological regulation No. 3 for the production of phosphorite sinter for the production of yellow phosphorus using furnace gas (NZPP). Project designer - LENIIGIPROCHEM LLC, Moscow (Russia) Changes were made in the regulations of the shop for phosphorite agglomerate production for yellow phosphorus production using furnace gas.
- Subject: Development of rational technology for phosphate rock beneficiation at the Koksu deposit in the Karatau basin. Designer - Federal State Unitary Enterprise GIGHS, Lyubertsy (Russia). The technology of phosphorite ore beneficiation of Koksu deposit of Karatau basin has been developed. 9 kg of flotation concentrate with P2O5 - 30%, MgO - 1% was obtained. In laboratory conditions received on its basis EPC and ammophos with the sum of useful components 59%.
- Subject: Development of technology of processing of cottrell milk of the branch of Kazphosphate LLP (NZPP) for target products. Designer - subsidiary state enterprise "Institute of Chemical Sciences named after A.B.Bekturov" RSE on REM "Centre of Earth Sciences, Metallurgy and Enrichment" of the Committee of Science of the Ministry of Education and Science of RK, Almaty, (Republic of Kazakhstan) Together with scientists of the Institute of Chemical Sciences named after A.B.Bekturov the development of technology of processing of cottrell milk of Kazphosphate LLP (NZPP) on target products was carried out and finished. A colouring agent - blue pigment was obtained under industrial conditions. At present the question of further co-operation with the institute in the field of synthesis of wet precipitates from alkaline solutions of cattail milk is being worked out.
- Subject: Experimental laboratory work on filtration capacity, solid phase slip through the filter cloth, sludge humidity and selection of suitable filter cloth and equipment. Designer - "Trade House of Plant "PROGRESS", Kiev (Ukraine) Ltd. Experimental-laboratory works on increase of filtration productivity, on purification of phosphoric acid from impurities and selection of filtering equipment for food acid production have been carried out. Currently the issue of equipment purchase is being worked out.
- Subject: Introduction of technology for increasing fertility of saline irrigated soils by phosphogypsum application. Designer - KazAgroInnovation JSC, Taraz city (Republic of Kazakhstan) Together with specialists of the Kazakh Research Institute of Water Management (KazAgroInnovation JSC) the technology of increasing fertility of saline irrigated soils by phosphogypsum application was introduced. Implementation of improved technology of phosphogypsum application was carried out on irrigated lands of peasant farm of Sh.D.Dautov on the territory of Zhambyl district, Zhambyl region. Research results showed that maize yield in variants with phosphogypsum application increased by 20-30ts/ha. Recommendations on water saving, increase of soil fertility and maize yield were developed.
- Subject: Design and development of a vortex dust collector with counter swirling flows for cleaning ventilation emissions from industrial dusts and impurities. Designer - Taraz Professional Humanitarian-Technical College "Bilim", Taraz (Republic of Kazakhstan). Vortex dust collectors with counter swirling flows (CSF) were installed in ammophos production to clean ventilation emissions from industrial dusts and impurities. Emissions into the working area and the environment were reduced.