Blog-News

OEM Replacement Wear Parts Offer Long-Term Savings

Bradley Pulverizer Spare PartsKeeping your equipment online and running is key to maintaining production rates and profits.  While “volume pricing” or reverse engineered spares from third-party vendors may seem like a win for short term cost savings, the perceived value may not be as great in the long term.  The long-term costs of machine breakdowns and reduced productivity is far higher than short term savings.

At Bradley Pulverizer, we aim to help our customers maintain optimal performance of their machines.  Our experts are available to help you order the right OEM replacement parts designed exactly for your Bradley machine.  Bradley OEM parts provide consistent, reliable performance so you get the most from your investment.

Buying direct from Bradley ensures you receive the following benefits:

  • Highest quality parts – engineered from alloys specified for optimal machine operation
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Ian Hancock from Bradley Pulverizer to Present “Use of Low Grade Phosphate for Superphosphate Production” at CRU Phosphates 2024

Come see our own Ian Hancock, VP Sales and Operations at Bradley Pulverizer, deliver his technical innovation presentation focused on the “Use of Low Grade Phosphate for Superphosphate Production”, at the CRU Phosphates 2024 Conference & Exhibition in Poland on Feb 27, 2024 from 12:15-12:45.

Phosphates Banner for Ian Presentation - CRU 2024

This presentation looks at how the decline in the quality of available phosphate rock sources is affecting the ability to produce high grade superphosphate fertilizers, even after beneficiation after mining (Fertilizer International 517, p53). 

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Minimizing Heavy Metals in Superphosphate Manufacturing

Part 1 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”

The cadmium and heavy metal content of sedimentary phosphates are of great concern. This has seen industry raw material consumption shift towards igneous phosphates or the blending of phosphate rocks from different sources. While rock blending can successfully reduce the heavy metal content of superphosphates, it needs to be accompanied by careful process adjustments  Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.

Figure 1-Schematic of the Bradley Broadfield Den

Introduction
The manufacture of single superphosphate (SSP) and triple superphosphate (TSP) fertilizers, through acidulation of fluorapatite rock, continues to evolve. Process adaptations have been necessary, for example, in response to the consumption and depletion of known phosphate rock resources worldwide. In addition to the more obvious economic consequences, the environmental impacts of declining phosphate rock quality also demand attention and must be compensated for by the production process. Avoiding the presence of unacceptable levels of cadmium and other heavy metals in phosphate fertilizers is a particular concern and priority – as this can eventually lead to soil contamination.

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Environmental Consideration in Superphosphate Production

Part 2 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”

Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process.    Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.

 

Environmental considerations
limestone-quarryMost phosphate rock sources used in superphosphate production worldwide contain concentrations of heavy metals (cadmium, uranium, radium, lead, mercury, etc.). Such elements are known to be toxic to both livestock and humans and injurious to health if ingested at high levels. High cadmium (Cd) levels tend to be most prevalent, making this element the heavy metal of most concern. Care is therefore  taken to minimize its concentration in superphosphate fertilizers. Cd levels are typically kept to below a threshold of 280 ppm, although regulations do vary from country to country.

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Using Rock Blending to Regulate Heavy Metals in SSP Fertilizer Manufacturing

Part 3 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”

Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Part 2 provided a background to the environmental considerations that must be addressed in SSP manufacturing.    Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.

 

Table 1 - The Contrasting Characteristics if Igneous and Sedimentary Phosphate Rock Sources Used in SSP Production

Regulating heavy metals through blending
As stated in part 2 of this blog series, the typical target limit for cadmium in superphosphate fertilizers is <280 ppm. It might be concluded, therefore, that the answer is to simply source phosphate rock with cadmium levels (in  fluorapatite) below this limit as a production feedstock. However, this apparently simple answer is not generally practical due to the different processing characteristics of low cadmium (igneous) and high cadmium (sedimentary) phosphate sources (Table 1).

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Determining the Ideal Rock Blend in SSP Manufacturing

Part 4 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”

Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Part 2 provided a background to the environmental considerations that must be addressed in SSP manufacturing. Part 3 presented rock blending as the way to minimize heavy metals in the process.     Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.

 

Determining the ideal rock blend
A stepwise approach for determining the optimal rock blend in superphosphate manufacturing is outlined below. Once the optimal blend is established, the production process tends to be straightforward and can run unimpeded with only relatively minor mechanical adjustments. However, any significant change in chemistry – due to a new phosphate rock source and/or sourcing from a new face in an  existing quarry, for example – will potentially require a change to the blend.

Table 3 - Key Phosphate Source Rock Considerations in SSP Mfg

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In-Line Optimization of SSP Manufacturing in the Broadfield Process

Part 5 of a 5-part blog series: “Minimizing Heavy Metals in Superphosphate Manufacturing”

Part 1 of the blog series introduced the problems that heavy metals present in the SSP manufacturing process as well as a refresher of SSP production in the Bradley Broadfield Process. Part 2 provided a background to the environmental considerations that must be addressed in SSP manufacturing. Part 3 presented rock blending as the way to minimize heavy metals in the process.  Part 4 discussed the process for determining the ideal rock blend.   Click Here to download the complete article in pdf format as published by BCInsight Ltd in Fertilizer International Nov|Dec 2023, issue 517, pp. 53-57.

 

broadfield-mixer

In-line process optimization
Actual process conditions within the Broadfield superphosphate unit are only fully measurable during full scale production. In-line process sampling and testing is non-disruptive and the ideal way to  maximize plant profitability by ensuring continuous production with minimal shutdowns.

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Ian Hancock, Eng Tech MIET IEng FIMechE, of Bradley Pulverizer Elected Board Chair of IMechE Process Industries Division

ian-imecheBradley Pulverizer is pleased to announce the appointment of Ian Hancock as the newest Chair of the IMechE Process Industries Division Board. Hancock assumes the 2-year role after serving as an active member for 5 years and also as Chair of the IMechE Bulk Materials Handling Committee for the past 10 years. He has consistently demonstrated a commitment to excellence and a passion for IMechE’s mission, making him an ideal choice for the role of Chair.

Ian Hancock fulfills all criteria for Board Chair including involvement in STEM development in secondary schools and colleges, being an active fellow of the institute, and member for over 13 years.  As Chair of the Board, he will play a vital role in guiding the Process Industries Division of IMechE, which is concerned with primary production processes that are either continuous or batch produced.  With an extensive knowledge of the industry and a deep understanding of IMechE’s mission, Ian Hancock is well-positioned to drive the institution’s growth and make a positive impact within the industry.

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Top Considerations When Selecting a Milling and Classification System

Divorced Classifier SystemThere are 5 key questions to consider when selecting a milling and/or classification system.  Customers looking to improve or replace a current system typically have the answers on-hand or at least know the current conditions of their milling process and have defined performance goals.  However, those looking for new systems often have information available about the materials to be milled, and the desired end product specifications, but may not factor in the importance of the questions below.  There is quite a bit more information we require to provide a complete project proposal, but we’ve found that the answers to the 5 questions below significantly help in developing the quote, and often helps to determine the viability for manufacturing and commercial profitability.

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How a Divorced Classifier Generates Multiple Products Simultaneously from an Airswept Mill System

Divorced Classifier Schematic

Demand is on the rise for milling systems that can simultaneously produce multiple end products that meet different size specifications from a single feed continuous processing system.  The Divorced Classifier from Bradley Pulverizer is often the perfect solution to meet these demands, in fact, there are divorced classifiers currently in operation that are simultaneously producing 4 or more different sized commercial products!

Traditionally, airswept pendulum roller mills are employed to pulverize rigid/friable materials into fine powders from 50% passing 150 microns to 99.9% passing 30 microns  whereas vertical shaft impact crushers are employed to crush rigid and friable raw materials to coarse grit specifications.   Impact crushers require a capitol cost to purchase and have high energy demands to operate and cannot produce high yields of fine particles.  Divorced classification milling systems, on the other hand, can produce high yields of both fine powders and coarse grit in one operation, in one machine, with a much lower demand for energy consumption.  In fact, the same amount of power is required to generate fine powders as it is to generate both fine powders and coarse grits.  Yes, that’s right, zero additional power is required to generate 2 products simultaneously vs. just one!

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