The award-winning FlashPhos process is a high temperature fast reacting (flash) entrained flow gasification of sewage sludge and other phosphate-containing waste streams such as meat-and-bone meal. The inorganic waste components are melted or evaporated and are then separated in a refiner reactor to produce recycled P4 as the main product. Other output materials of the process are a climate-friendly alternative cement raw material, an iron alloy and a heavy metal concentrate as valuable outputs for the metal industry. The organic components serve as fuel for the gasification, in which they are converted into heat and a combustible gas. This gas and excess heat can be used in cement plants to substitute fossil fuels. Consequently, several valuable raw materials will be generated by the innovative and cost-efficient FlashPhos process with practically no emissions or waste.
During the four-year innovation action, the industrial FlashPhos process will be demonstrated in a pilot plant with up to 250 kg/h sewage sludge throughput. The first full-scale FlashPhos pilot plant in Europe will be built by 2025 and industrial scale white phosphorus production will start together with an industrial consortium, expecting market introduction by 2028.