Periodic Reporting for period 1 - FIC-FIGHTERS (To a Fair, Inclusive, Circular and Healthy cities: Valorisation of phosphogypsum wastes into commercial products through sustainable and circular processes)
Berichtszeitraum: 2024-06-01 bis 2025-11-30
Phosphogypsum is a large industrial by-product generated during phosphate fertiliser production. Across Europe, more than 100 million tonnes are produced every year and stored in large stacks, often near coastal areas, rivers and populated regions. These deposits represent long-term environmental and social challenges but also contain valuable materials that could potentially be recovered and reused.
The FIC-Fighters project aims to demonstrate circular solutions to transform phosphogypsum into valuable raw materials while ensuring environmental safety and societal acceptance. The project brings together 27 partners from 11 countries, including research organisations, industrial companies, universities, public authorities and civil society organisations.
The main objective is to develop and demonstrate processes capable of recovering valuable materials from phosphogypsum and related residues. Target products include sodium sulphate, ammonium sulphate, aluminium hydroxide and calcium-based products, as well as strategic raw materials such as phosphorus and rare earth elements.
At the start of the project, the key technologies were at approximately Technology Readiness Level (TRL) 4–5. Through laboratory validation, process optimisation and engineering development, the project aims to reach pilot-scale demonstration at TRL 6–7 by the end of the project.
In addition to technological development, FIC-Fighters also seeks to improve transparency and trust in phosphogypsum management by combining technological innovation with stakeholder engagement, environmental assessment and circular business modelling.
During the first reporting period, the project completed the initial characterisation of phosphogypsum samples, validated key process steps at laboratory scale and initiated the engineering design of a mobile pilot plant to demonstrate the technology under realistic conditions.
The FIC-Fighters project aims to demonstrate circular solutions to transform phosphogypsum into valuable raw materials while ensuring environmental safety and societal acceptance. The project brings together 27 partners from 11 countries, including research organisations, industrial companies, universities, public authorities and civil society organisations.
The main objective is to develop and demonstrate processes capable of recovering valuable materials from phosphogypsum and related residues. Target products include sodium sulphate, ammonium sulphate, aluminium hydroxide and calcium-based products, as well as strategic raw materials such as phosphorus and rare earth elements.
At the start of the project, the key technologies were at approximately Technology Readiness Level (TRL) 4–5. Through laboratory validation, process optimisation and engineering development, the project aims to reach pilot-scale demonstration at TRL 6–7 by the end of the project.
In addition to technological development, FIC-Fighters also seeks to improve transparency and trust in phosphogypsum management by combining technological innovation with stakeholder engagement, environmental assessment and circular business modelling.
During the first reporting period, the project completed the initial characterisation of phosphogypsum samples, validated key process steps at laboratory scale and initiated the engineering design of a mobile pilot plant to demonstrate the technology under realistic conditions.
During the first phase of the project, the consortium achieved significant progress in scientific research, technological validation and stakeholder engagement.
Phosphogypsum samples were collected from the project’s case studies and analysed to determine their chemical composition, mineralogical structure and radiological properties. A total of 6 locations were characterised, generating a comprehensive dataset that supports the development of safe and efficient valorisation strategies.
Two chemical recovery routes were investigated to convert phosphogypsum into valuable industrial products. Laboratory-scale experiments demonstrated the technical feasibility of producing compounds such as sodium sulphate, ammonium sulphate and calcium-based materials. Industrial partners defined target product specifications to ensure compatibility with potential applications. For example, sodium sulphate is expected to reach purities above 99.5% for applications in detergents, paper production and construction materials, while ammonium sulphate requires purities above 99% with strict control of metallic impurities (e.g. iron and lead below about 5–10 ppm). Experimental work focuses on optimising the processes to approach these quality levels while maintaining suitable particle size and moisture content, with preliminary purities around 90% depending on the product.
The project is also investigating other materials such as precipitated calcium carbonate and katoite for potential use in cementitious materials, where purity requirements are less restrictive. Preliminary work is also exploring the recovery of phosphorus and rare earth elements from phosphogypsum residues through leaching experiments using different solvents, including hydrochloric acid, sulphuric acid, citric acid and ammonium-based solutions. Results showed that acidic conditions significantly enhance the dissolution of both calcium and phosphorus, although co-dissolution limits selective separation and further optimisation is required. Rare earth elements such as yttrium, lanthanum, neodymium and cerium were detected in leachate solutions and will be investigated further for potential recovery.
Engineering activities were initiated to prepare the construction and operation of a mobile pilot plant. During this period, the consortium completed the conceptual and preliminary engineering design of the sodium hydroxide-based process, including process flow diagrams, mass and energy balances and equipment specifications.
Recovered materials are currently being evaluated for industrial applications in sectors including detergents, construction materials, paper manufacturing, fertilisers and battery technologies. Initial testing by industrial partners indicates that some recovered products already meet relevant quality specifications.
Stakeholder engagement activities were also conducted to better understand societal perceptions regarding phosphogypsum management. The project mapped around 300 relevant stakeholders, including industrial operators, regional authorities, environmental organisations and local communities near phosphogypsum stacks. In addition, two citizen workshops (North Macedonia and Portugal) were organised to promote dialogue and transparency.
The main expected outcomes include pilot-scale demonstration of phosphogypsum valorisation processes, the production of market-ready secondary raw materials and the development of circular business models supporting large-scale deployment. These outcomes are expected to reduce industrial waste accumulation, improve resource efficiency and strengthen the supply of strategic raw materials in Europe.
Phosphogypsum samples were collected from the project’s case studies and analysed to determine their chemical composition, mineralogical structure and radiological properties. A total of 6 locations were characterised, generating a comprehensive dataset that supports the development of safe and efficient valorisation strategies.
Two chemical recovery routes were investigated to convert phosphogypsum into valuable industrial products. Laboratory-scale experiments demonstrated the technical feasibility of producing compounds such as sodium sulphate, ammonium sulphate and calcium-based materials. Industrial partners defined target product specifications to ensure compatibility with potential applications. For example, sodium sulphate is expected to reach purities above 99.5% for applications in detergents, paper production and construction materials, while ammonium sulphate requires purities above 99% with strict control of metallic impurities (e.g. iron and lead below about 5–10 ppm). Experimental work focuses on optimising the processes to approach these quality levels while maintaining suitable particle size and moisture content, with preliminary purities around 90% depending on the product.
The project is also investigating other materials such as precipitated calcium carbonate and katoite for potential use in cementitious materials, where purity requirements are less restrictive. Preliminary work is also exploring the recovery of phosphorus and rare earth elements from phosphogypsum residues through leaching experiments using different solvents, including hydrochloric acid, sulphuric acid, citric acid and ammonium-based solutions. Results showed that acidic conditions significantly enhance the dissolution of both calcium and phosphorus, although co-dissolution limits selective separation and further optimisation is required. Rare earth elements such as yttrium, lanthanum, neodymium and cerium were detected in leachate solutions and will be investigated further for potential recovery.
Engineering activities were initiated to prepare the construction and operation of a mobile pilot plant. During this period, the consortium completed the conceptual and preliminary engineering design of the sodium hydroxide-based process, including process flow diagrams, mass and energy balances and equipment specifications.
Recovered materials are currently being evaluated for industrial applications in sectors including detergents, construction materials, paper manufacturing, fertilisers and battery technologies. Initial testing by industrial partners indicates that some recovered products already meet relevant quality specifications.
Stakeholder engagement activities were also conducted to better understand societal perceptions regarding phosphogypsum management. The project mapped around 300 relevant stakeholders, including industrial operators, regional authorities, environmental organisations and local communities near phosphogypsum stacks. In addition, two citizen workshops (North Macedonia and Portugal) were organised to promote dialogue and transparency.
The main expected outcomes include pilot-scale demonstration of phosphogypsum valorisation processes, the production of market-ready secondary raw materials and the development of circular business models supporting large-scale deployment. These outcomes are expected to reduce industrial waste accumulation, improve resource efficiency and strengthen the supply of strategic raw materials in Europe.
Current phosphogypsum management practices mainly rely on long-term storage in large stacks, with limited recovery of valuable materials. Existing valorisation approaches are often restricted to low-value uses or small-scale experimental processes.
FIC-Fighters advances beyond the state of the art by developing integrated chemical processes capable of recovering multiple valuable products from phosphogypsum within a single processing chain.
The project focuses on two technological approaches referred to as the NaOH route and the AMONI route. These processes enable the conversion of phosphogypsum into several marketable products, including sodium sulphate, ammonium sulphate, aluminium hydroxide and precipitated calcium carbonate.
At the beginning of the project, the technologies were at approximately TRL 4–5. Through experimental validation, modelling and engineering design, the project aims to reach TRL 6–7, including pilot-scale demonstration in a mobile pilot plant.
Another innovation is the creation of a digital twin of the phosphogypsum valorisation process. This tool will allow researchers and industrial operators to simulate operating conditions, optimise performance and assess scalability for deployment at different phosphogypsum sites.
The project also applies a Safe-and-Sustainable-by-Design approach, integrating environmental performance, economic feasibility and safety considerations into the development of the technologies.
By combining technological innovation, industrial validation and stakeholder engagement, FIC-Fighters aims to demonstrate scalable solutions capable of transforming phosphogypsum from an environmental liability into a valuable resource within a circular economy framework.
FIC-Fighters advances beyond the state of the art by developing integrated chemical processes capable of recovering multiple valuable products from phosphogypsum within a single processing chain.
The project focuses on two technological approaches referred to as the NaOH route and the AMONI route. These processes enable the conversion of phosphogypsum into several marketable products, including sodium sulphate, ammonium sulphate, aluminium hydroxide and precipitated calcium carbonate.
At the beginning of the project, the technologies were at approximately TRL 4–5. Through experimental validation, modelling and engineering design, the project aims to reach TRL 6–7, including pilot-scale demonstration in a mobile pilot plant.
Another innovation is the creation of a digital twin of the phosphogypsum valorisation process. This tool will allow researchers and industrial operators to simulate operating conditions, optimise performance and assess scalability for deployment at different phosphogypsum sites.
The project also applies a Safe-and-Sustainable-by-Design approach, integrating environmental performance, economic feasibility and safety considerations into the development of the technologies.
By combining technological innovation, industrial validation and stakeholder engagement, FIC-Fighters aims to demonstrate scalable solutions capable of transforming phosphogypsum from an environmental liability into a valuable resource within a circular economy framework.