Abstract
{ "background": "Morocco possesses the world's largest reserves of phosphate rock, a critical raw material for fertiliser and chemical industries. However, the beneficiation and subsequent acidulation processes for local phosphate production often operate in isolation, leading to suboptimal resource efficiency and increased environmental footprint. A systematic framework for integrating these unit operations is lacking.", "purpose and objectives": "This article presents a novel process integration methodology to optimise the coupled beneficiation and acidulation of sedimentary phosphate rock. The primary objective is to develop a modelling framework that maximises overall P₂O₅ recovery while minimising reagent consumption and gypsum by-product generation.", "methodology": "The methodology employs a systems engineering approach, integrating mass and energy balance models for comminution, flotation, and sulphuric acid acidulation. A key component is a predictive regression model for acid demand, $\\text{Acid}{\\text{demand}} = \\beta0 + \\beta1(\\text{CaO}) + \\beta2(\\text{SiO}_2) + \\epsilon$, where $\\epsilon$ represents process noise, estimated using robust standard errors to account for feedstock variability. The framework uses sequential modular simulation to identify optimal process setpoints.", "findings": "Application of the framework to a representative case study indicates that integrated optimisation can increase overall P₂O₅ recovery by an estimated 4–7 percentage points compared to sequentially optimised units. The model suggests a significant reduction in acid consumption per tonne of phosphoric acid is achievable, with a 95% confidence interval of 8–12%, primarily through tighter control of carbonate content during beneficiation.", "conclusion": "The proposed integration framework provides a systematic, evidence-based methodology for enhancing the sustainability and economic viability of phosphate processing. It demonstrates that significant gains in efficiency and resource utilisation are attainable through holistic process design.", "recommendations": "Implement pilot-scale validation of the integrated control loops. Future work should incorporate life cycle assessment modules