The award-winning FlashPhos process is a high temperature fast reacting (flash) entrained flow gasification of sewage sludge and other phosphate-rich waste streams such as meat-and-bone meal. The inorganic waste components are melted and the contaminants evaporated. The slag is then separated in a refiner reactor to produce recycled P4 as the main product. Other output materials of the process are a climate-friendly cement substitute, an iron alloy and a heavy metal concentrate as valuable outputs for the metal industry. In the gasification, the organic components are converted into heat and a gaseous fuel. This gas and excess heat can be used to substitute fossil fuels. Consequently, several valuable raw materials will be produced by the innovative and cost-efficient FlashPhos process without generating solid waste.
During the four-year innovation action, we will demonstrate the industrial FlashPhos process in a pilot plant with up to 250 kg/h dried sewage sludge throughput. After demonstrating the process with the pilot plant, structured action will start to form the necessary industrial consortiums, to develop and build the first full-scale production unit.