All Things Phosphate
Mining,
Stacks & Piney Point
Division of Water Resource Management
Dept. of Environmental Protection
March 10, 2005
February 2005
1
Industry Activities in Florida
 Phosphate rock mining
 Phosphate rock beneficiation/processing
 Land reclamation
 Phosphate fertilizer/concentrates
manufacturing
 Transportation terminals
January 2005
2
All Things Phosphate
Mining
Kevin Claridge, Environmental Manager,
Homeland Office
Division of Water Resource Management
Dept. of Environmental Protection
February 2005
March 10, 2005
3
Mining in Florida
 Phosphate
 Heavy Minerals, Fullers Earth,
Limestone, Shell, Gravel, Sand, Peat
and Other Solid Resources
 Department of Environmental
Protection
• Bureau of Mine Reclamation
• Protection of Water Resources
• http://www.dep.state.fl.us/water/mines/index.htm
January 2005
4
Phosphate Mining and
Reclamation
 Pre-Mining (Prospecting & Mine
Planning)
 Permits and Conceptual Plans
 Mining
 Reclamation
 Release from Regulatory Oversight
 Post Land Use
January 2005
5
Phosphate Mining in Florida
Hillsborough, Polk, Hardee & Manatee Counties
January 2005
6
Phosphate Rock Mining
Geology of the Deposit
Ground surface
Overburden (Sand and clay) up to 50 feet thick
Matrix (ore) 5-20 feet thick
January 2005
Bed (limestone or dense clay)
7
Phosphate Rock Mining
Prospecting
January 2005
8
Phosphate Rock Mining
Surface Clearing
Phosphate Rock Mining
Stripping Overburden
Phosphate Rock Mining
Mining Matrix
Phosphate Rock Mining
Ore Transportation
Phosphate Rock Processing
Mine Water Recirculation System
Oversize
Mine Water Recirculation System
Matrix
Mine
Sizing and
Conditioning
Feed
Washer
Coarse
Feed
Concentrate
Coarse
Float
Fine
Float
Reverse Floatation
Clay Slurry
Product
Tailings
sand
Clay Slurry
Clay Settling
Area
Reclamation
Tailings Water and Stormwater Return
January 2005
13
Phosphate Rock Beneficiation
Clay Settling Area
Washer
Product Bins
Flotation Plant
Shops and Warehouse
Product Stockpile
January 2005
14
Marketable Production of
Phosphate Rock, 1900-2002
120,000,000
Non-U.S.
U.S.
90,000,000
Metric
tons
60,000,000
30,000,000
1900
1906
1912
1918
1924
1930
1936
1942
1948
1954
1960
1966
1972
1978
1984
1990
1996
2002
0
The graph is based on data from "Phosphate Rock Statistics,"
by David A. Buckingham and Stephen M. January
Jasinski,2005
U. S. Geological Survey
15
Tailings Backfill
Sand
Surface Contouring
Revegetation
Clay Settling Areas
Dam constructed
Dam
Clay Settling Areas
Dam
Clay Settling Areas
Dam
Clay Settling Areas
Dam
Clay Settling Areas
Dam
Post Mining Land Use
 Conservation / Preservation
 Wetlands or Water Bodies
 Uplands
• Pasture or Agriculture
• Power Plants, Landfills and
Developments
January 2005
24
All Things Phosphate
Stacks
Sam Zamani, P.E., Phosphate Management
Division of Water Resource Management
Dept. of Environmental Protection
March 10, 2005
February 2005
25
Phosphogypsum stacks in Florida
 25 total stacks
 Of the 25 stacks, 10 are active, 13 are inactive,
and 2 are closed
 Of the 25 stacks, companies are providing
financial assurance for 18 stacks:
• CF Industries: 3 stacks
• Mosaic Fertilizer and Mosaic Phosphates: 9
stacks
• PCS Phosphate: 3 stacks
• U.S. Agri-Chemicals: 3 stacks
January 2005
26
Phosphogypsum Stacks in Florida
Company
CF Industries, Inc.
Cytec Industries, Inc.
Estech, Inc. (Agricola Stack)
Mosaic Fertilizer, LLC
Mosaic Phosphate, MP, Inc.
Mulberry Phosphates, Inc.*
PCS Phosphate, Inc.
Piney Point Phosphates, Inc.
U.S. Agri-Chemicals Corporation
Total Florida Phosphogypsum Stacks:
Stacks providing
Financial
Assurance
Stacks Not
providing
Financial
Assurance**
3
5
4
1-CP
1-C
1-C
1-CP
2-SF
3
1-SF
3
18
7
Stack Total
3
1
1
6
5
2
3
1
3
25
* Mulberry Phosphates, Inc. - Being closed but not owned by Mosaic
** Status Codes - Not providing Financial Assurance
CP, Closure Permit, Not subject to Chapter 62-673, F.A.C., as of 1993
C, Closed Stack, Not subject to Chapter 62-673, F.A.C., as of 1993
January 2005
SF, State funding supporting closure.
27
Phosphogypsum Stack Systems
NOT Subject to Chapter 62-673, F.A.C., as of 1993

Mosaic Riverview West Stack – Closed
Long-Term Care Renewal Permit In-House

Estech Agricola Stack – Closed

Mosaic P-21 Stack – Permitted for Closure

CYTEC Brewster Stack – Permitted for
Closure
Closure Renewal Permit In-House
January 2005
28
Phosphogypsum stacks in Florida
Status
Company
CF Industries, Inc.
Cytec Industries, Inc.
Estech, Inc. (Agricola Stack)
Mosaic Fertilizer, LLC
Mosaic Phosphate, MP, Inc.
Mulberry Phosphates, Inc.*
PCS Phosphate, Inc.
Piney Point Phosphates, Inc.
U.S. Agri-Chemicals Corporation
Total Florida Phosphogypsum Stacks:
Stacks providing
Financial
Assurance
Stacks Not
providing
Financial
Assurance**
Stack Total
3
1-CP
1-C
1-C
1-CP
2-SF
5
4
3
1-SF
3
18
7
* Mulberry Phosphates, Inc. - Being closed but not owned by Mosaic
** Status Codes - Not providing Financial Assurance
CP, Closure Permit, Not subject to Chapter 62-673, F.A.C., as of 1993
C, Closed Stack, Not subject to Chapter 62-673, F.A.C., as of 1993
SF, State funding supporting closure.
Florida Department of Environmental Protection, ABM ABM
Presentation,
March 10, 2005
Presentation,
March
2005
10,
Active Inactive Closed
3
1
1
6
5
2
3
1
3
1
0
0
3
2
0
3
0
1
2
1
0
2
3
2
0
1
2
0
0
1
1
0
0
0
0
0
25
10
13
2
Closure Permit Applications
Six Currently Under Review
1. CF Industries Plant City North Stack – LONG TERM CARE
PERMIT
•
•
Mulberry Phosphates North Stack – CLOSURE BY
STATE/MOSAIC
Mulberry Phosphates South Stack – CLOSURE BY
STATE/MOSAIC
•
U.S. Agri-Chemicals Ft. Meade South Stack– PERMITTED
FOR CLOSURE, RENEWAL
•
Mosaic Riverview West Stack – LONG TERM CARE
RENEWAL PERMIT
•
2005
CYTEC Brewster StackJanuary
– CLOSURE
RENEWAL PERMIT
30
Closed Stack
January 2005
31
Estech
January 2005
32
Estech
January 2005
33
Closed Stack at Active Facility
January 2005
34
Riverview
January 2005
35
Riverview
January 2005
36
Active Stack
Expansion Stacking on Liner
January 2005
37
CF Plant City
January 2005
38
Stacks
Closure in Process
January 2005
39
USAC Bartow
January 2005
40
Mulberry Stacks
 Mosaic operating and is the permit holder
 Mosaic consuming & transferring process water
from Mulberry stack system to Mosaic Bartow
 2 stacks:
• North Stack - Nearly closed
• South Stack - To be closed
January 2005
41
Mulberry (directly behind
trees)
January 2005
42
Mulberry
January 2005
43
All Things Phosphate
Piney Point Update
John A. Coates, P.E.
Division of Water Resource Management
Dept. of Environmental Protection
March 10, 2005
February 2005
44
WATER MANAGEMENT CHALLENGE
• 600 MGal of Ponded Process Water
• 600 MGal of Drainable Pore Water
• 160 MGal Added Each Year (Assuming Normal
Rainfall)
160 MGal/yr
Net Addition
600 MGal +
Ponded Process Water
600 MGal +
Drainable Pore Water
January 2005
45
January 18, 2002
Piney Point
Phosphogypsum
Stacks w/ Tampa
Bay in Background
January 2005
47
June 2004
January 2005
48
September 2004
Piney Point Closure
Progress w/ liner
installed in OGS
January 2005
January 2005
50
Piney Point Current Work
 Groundwater Seepage Cutoff Wall
• slurry wall construction along eastern
boundary of stack
• ahead of schedule, target: early April, 2005
 Spray Evaporation System
• construction of Spray Evaporation system for
water consumption
• Construction started in February, target:
Completion during May, 2005
January 2005
51
Piney Point Current Work
 Preparation - NGS-S
• initial dewatering and preparation of NGS-S
prior to final earth work and liner installation
• removal/stabilization of black gypsum material
• tasks completed during February, 2005
 ITN - NGS-S Closure & Related Work
• Operation and Maintenance
• Water Consumption, and
• Closure Construction
January 2005
52
November 2004
January 2005
53
December 2004
January 2005
54
February 2005
NGS-S Preparation
January 2005
55
February 2005
January 2005
56
Piney Point Status
Inches of Rainfall Runoff
Nominal Storage Capacity
80
70
60
50
40
30
20
10
0
03-03r-03r-03-03-03l-03 -03-03t-03-03-03 -04-04r-04r-04-04 -04l-04-04-04t-04 -04-04 -05 -05
n eb a p ay un u ug ep c ov ec an eb a p ay un u ug ep c ov ec an eb
a
A M J JA S O N D J F
J F M A M J J A S O N D January
J F M2005
57
Piney Point Status
15-Day Average Ammonia Loading - Since
January 2004
NH3 loading, lbs/day
Target loading lbs/day
350
300
250
200
150
100
50
0
04 -04 r-04 r-04 -04 -04 l-04 -04 -04 t-04 -04 -04 -05 -05
v ec an eb
n
n Ju ug ep c
y
b
o
Ja Fe Ma A p Ma Ju January
O
J
S
N
D
F
A 2005
58
PINEY POINT GYPSUM STACK CLOSURE
2006
2004
2004
NORTH COOLING
POND OR DAP
POND
(NCP)
SOUTH COOLING
POND NORTH
COMPARTMENT
(SCP-N)
2006
SOUTH COOLING
POND SOUTH
COMPARTMENT
(SCP-S)
2005
2004
2004
OLD GYPSUM
STACK-NORTH
(OGS-N)
2006
NEW GYPSUM
STACK-NORTH
(NGS-N)
2005
NEW GYPSUM
STACK-SOUTH
(NGS-S)
OLD GYPSUM
STACK-SOUTH
(OGS-S)
2005
January 2005
59
Piney Point ITN - Next Steps
 ITN Contractor Selected, BID Protests pending
 Operation and Maintenance undergoing smooth
transition
 Next Phase Construction equipment being
Mobilized to site, week of March 7
 ITN - Water Consumption
• Selected < 20 lbs/day NH3 (30 day rolling average)
loading scenario
• Plans include ceasing process water discharges* to
Bishop Harbor by end of 2006
 except for RO permeateJanuary 2005
60
END
 QUESTIONS?
January 2005
61