PhosCo Ltd reveals a simplified single-stage flotation process for its Gasaat Phosphate Project that promises lower costs and reduced complexity, boosting prospects ahead of its Q3 2026 scoping study update.
- Single-stage flotation yields up to 31.4% P2O5 concentrate
- Elimination of three silica flotation steps cuts capital and operating costs
- Saline bore water usable with minimal treatment
- Reagent dosage linked to concentrate grade enables cost optimisation
- Results co-funded by European Bank for Reconstruction and Development
Simplified Flotation Cuts Costs and Complexity
PhosCo Ltd (ASX:PHO) has unveiled a metallurgical breakthrough at its Gasaat Phosphate Project in northern Tunisia that could materially reduce capital and operating expenses. First-pass flotation tests on the KM prospect demonstrate that a simple, single-stage flotation circuit can produce commercial-grade phosphate concentrate with up to 31.4% P2O5, eliminating the need for three silica flotation steps previously considered essential.
This streamlined process not only lowers technical risk but also simplifies the plant design to just crushing, grinding, single-stage flotation, and dewatering/drying. The use of saline bore water with minimal or no cleaning further trims operational complexity and costs, a notable advantage given the expense of reverse osmosis typically required in phosphate operations.
Strong Metallurgical Metrics Support Project Economics
Test results from Bureau Veritas Minerals in Adelaide show phosphate recoveries ranging from 75.1% to 83.7% P2O5 across different samples, with concentrate silica content between 4.38% and 5.16%. A particularly promising Minor Element Ratio (MER) of 0.087 was recorded in one sample, indicating suitability for producing high-quality phosphoric acid and fertiliser products like MAP and DAP.
PhosCo Managing Director Taz Aldaoud highlighted the significance of these findings, stating, "The ability to produce a saleable phosphate concentrate with a very simple flowsheet is a major breakthrough." This development complements the recent maiden KM and SAB resources announcement, which expanded the Gasaat resource base and underpins the upcoming scoping study update.
Optimising Reagents for Flexible Production
A linear correlation between flotation collector reagent dosage and final concentrate grade opens the door for tailored reagent application to balance concentrate quality and operating costs. Further bench-scale tests are planned to optimise this balance ahead of the pre-feasibility study phase.
The simplified single-stage flotation method removes the need for separate carbonate and silica flotation stages by employing new reagents capable of simultaneous removal of carbonates and silica. This approach leverages the Gasaat deposit's naturally low concentrations of impurities such as Fe2O3, Al2O3, and SiO2, which are significantly lower compared to other global phosphate deposits.
Building on a Decade of Metallurgical Work
The current breakthrough builds on extensive testwork dating back to 2012, including pilot metallurgical studies by Jacobs Engineering Group. The updated flowsheet reflects a deepening understanding of the Gasaat ore's characteristics and processing potential. The upcoming scoping study, due in Q3 2026, will incorporate these advances to refine technical and financial models.
PhosCo's progress at Gasaat is part of a broader strategic push, with recent drilling and resource updates at KM and SAB prospects confirming thick, high-grade phosphate mineralisation and expanding the project's scale and attractiveness in a tightening global fertiliser market strong drilling results at KM prospect.
Bottom Line?
PhosCo’s simplified flotation process could sharply improve Gasaat’s cost profile, but upcoming studies will be crucial to quantify the full economic impact.
Questions in the middle?
- How will the simplified flotation process affect final capital and operating cost estimates in the Q3 scoping study?
- What are the risks of scaling the single-stage flotation process from bench tests to full-scale operations?
- Could reagent optimisation lead to differentiated product grades tailored to diverse market demands?