First economically-viable process for phosphate recovery

Project Information

SusPhos

Grant agreement ID: 190186984

DOI

10.3030/190186984

Project closed

EC signature date 6 February 2023

Start date 1 March 2023

End date 28 February 2025

Funded under

• The European Innovation Council (EIC)

Total cost

€ 4 823 750,00

EU contribution

€ 2 499 999,00

Coordinated by

NEPTUNA VENTURES BV
Netherlands

Periodic Reporting for period 2 - SusPhos (First economically-viable process for phosphate recovery)

Reporting period: 2024-03-01 to 2025-02-28

Summary of the context and overall objectives of the project

SusPhos is dedicated to tackling the critical challenge of phosphate scarcity through a patented process that recovers phosphate from waste in a sustainable manner. Phosphate, a vital element for food security and industrial applications, is depleting due to the current fossil mining practices, posing a threat to future supplies. Recognized as a critical raw material by the European Union, the urgent need for efficient recovery processes is paramount.
Our project focuses on developing a circular process to extract high-quality phosphate products from waste streams. 90% of used phosphorus (P) is irreversibly lost. Our solution converts P-rich waste streams, e.g. sewage sludge ashes (SSA), into phosphoric acid used in the fertilizer and flame retardant industries and chemicals for wastewater treatment and the construction industry. SusPhos will create Europe's independent supply of P. Flame retardants (FR) and fertilizer industries will readily consume these high-value products.
The SusPhos project is primarily dedicated to advancing this pioneering phosphate recovery process. Every resource and effort is allocated towards perfecting the process and preparing for the construction of a full-scale demonstration plant in the Netherlands.
Through collaboration with industry stakeholders, we aim to optimize our process to meet the stringent quality standards of potential customers. Additionally, our R&D-activities have resulted in the development of a circular cement binder from the of residual by-product of the primary process, ensuring a comprehensive circular solution.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During this reporting period, the SusPhos project has completed all the defined deliverables according to the project Work Packages. These deliverables are focussing on the technical development of the SusPhos process, on the pre-commercialisation of the produced end-products and on the project management.
Besides to the defined deliverables, SusPhos has been working on further optimization of the phosphate recovery process. Considerable time was spent on further development of the residual by-product, resulting in promising test results for the use of the by-product in the concrete industry as a circular cement binder. As part of the road towards the actual engineering and construction of our first full-scale factory, preferred vendors/suppliers of the unit operations for the individual steps of the SusPhos process have been identified. Together with our EPCM-contractor these vendor are now in the final stages of the (detailed) engineering phase leading up to the construction phase.
During this reporting period, SusPhos has been focussing on business development for the two products, but also on the preparation for financing of the factory. Together with a financial advisor, a financial model has been prepared and potential investors have been identified and approached. We achieved a major success by winning the European tender to jointly develop, engineer, construct, and operate our first factory with the largest sewage sludge incinerator of the Netherlands. This strategic partnership underpins the importance of our project.
An amendment was submitted and granted for a shift in timelines for the underlying deliverables of the SusPhos EIC Horizon project. Shifts proved to be necessary as result of the participation in the European tender process which by winning could result in a strategic cooperation with a large sewage sludge incinerator, but also because retained knowledge from our R&D-activities and our engineering activities resulted in an adjusted order of events compared to the initial drafting of the EIC project outline. Some of the earlier set deliverables, for instance the decision on the preferred location of the SusPhos plant, depended on the outcome of other processes. As a result of our successful product development, resulting in two marketable products with strong traction from major market players, related deliverables (for instance related to the number of products to be delivered) have been amended as well.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

SusPhos' solution provides benefits to large companies as well as industrial plants. SusPhos will recycle P in an economically viable way to ensure access to P, and prevent it from becoming an inaccessible constituent of e.g. concrete. By processing P-rich waste streams using our process, it is possible to synthesize P-based compounds, salts, and elements relevant to industrial players such as P-fertiliser manufacturers, the concrete industry and wastewater treatment plants. Our solution is the first process for phosphate recycling that is price-competitive with the state-of-the-art, i.e. imported phosphate ore.
The by-product of our solution is tested as a sustainable circular cement binder replacer, therefore avoiding the enormous CO2-emissions which erupt in the traditional fossil production process of this cement binder
On top of not using depleting fossil deposits, we positively impact P-rich waste management challenges and provide our customers with high-quality chemicals such as phosphates, phosphoric acid, magnesium- & ammonium salts, silica mixtures and iron salts.