Most phosphate is mined from shallow sedimentary deposits of phosphate rock, or apatite, a calcium-phosphate mineral, deposited in shallow marine environments over millions of years. Other sources are prehistoric marine creatures and calcified bird guano. A few ore sources are of volcanic origin. Dragline machines remove the top layers above the rock, usually a thin overburden, and mine the phosphate ore.

The phosphate matrix, a combination of sand, clay, and apatite is mined, crushed, and washed, creating a slurry that is pumped to a processing plant.

Phosphate rock is separated from the matrix and transported to a fertilizer plant. The sand and clay are pumped back to the mine site and used in land reclamation projects. [Watch on YouTube]

At the fertilizer plant, phosphate rock is ground, mixed with water, and reacted with sulphuric acid which forms phosphoric acid, the basis for all phosphate fertilizers.

Phosphoric acid is combined with anhydrous ammonia to produce dry and liquid fertilizers.

Phosphoric acid, diammonium phosphate (DAP), and monoammonium phosphate (MAP) are the principal fertilizer products.

The finished product is then distributed by rail, truck or ship.