WE ARE BUILDING TECHNOLOGY TO RECOVER SULFURIC ACID DIRECTLY FROM ABUNDANT WASTE
WE ARE BUILDING TECHNOLOGY TO RECOVER SULFURIC ACID DIRECTLY FROM ABUNDANT WASTE
WE ARE BUILDING TECHNOLOGY TO RECOVER SULFURIC ACID DIRECTLY FROM ABUNDANT WASTE
THE COST OF ACID
Industrial phosphate producers require massive volumes of sulfuric acid for digestion. Today, over 80% of domestic sulfuric acid is produced by the combustion of elemental sulfur, which is supplied by petroleum refining and natural gas processing. This dependence introduces uncertainty and volatility to phosphate unit economics. Acid production typically accounts for about 15% of the total operating cost of phosphatic fertilizer production, though this substantially increases during sulfur shortages.
THE COST OF ACID
Industrial phosphate producers require massive volumes of sulfuric acid for digestion. Today, over 80% of domestic sulfuric acid is produced by the combustion of elemental sulfur, which is supplied by petroleum refining and natural gas processing. This dependence introduces uncertainty and volatility to phosphate unit economics. Acid production typically accounts for about 15% of the total operating cost of phosphatic fertilizer production, though this substantially increases during sulfur shortages.
THE COST OF ACID
Industrial phosphate producers require massive volumes of sulfuric acid for digestion. Today, over 80% of domestic sulfuric acid is produced by the combustion of elemental sulfur, which is supplied by petroleum refining and natural gas processing. This dependence introduces uncertainty and volatility to phosphate unit economics. Acid production typically accounts for 15% of the total operating cost of phosphatic fertilizer production, though this substantially increases during sulfur shortages.
THE INEFFICIENCY
The industrial sulfur cycle is linear, with a continuous input of sulfur entering the system and an equal quantity permanently discarded as phosphogypsum waste. Sulfur recovery from phosphogypsum represents an opportunity to drastically reduce operating costs, logistical complexity, and waste management liability for phosphate producers.
THE WASTE LIABILITY
Phosphate production generates five tons of phosphogypsum waste per ton of P₂O₅ product. 150 million tonnes of phosphogypsum are produced every year, equivalent to 25 times the mass of the Great Pyramid of Giza. This material is 18% sulfur by mass. Currently, the sulfur is discarded along with the residual acidity, trace metals, and radionuclides after a single use, and maintained in regulated engineered stacks.
THE LIABILITY OF PHOSPHOGYPSUM
Phosphate production generates five tons of phosphogypsum waste per ton of P₂O₅ product. 150 million tonnes of phosphogypsum are produced every year, equivalent to 25 times the mass of the Great Pyramid of Giza. This material is 18% sulfur by mass. Currently, the sulfur is discarded along with residual acidity, trace metals, and radionuclides after a single use, and maintained in regulated engineered stacks .
THE LIABILITY OF PHOSPHOGYPSUM
Phosphate production generates five tons of phosphogypsum waste per ton of P₂O₅ product. 150 million tonnes of phosphogypsum are produced every year, equivalent to 25 times the mass of the Great Pyramid of Giza. This material is 18% sulfur by mass. Currently, the sulfur is discarded along with residual acidity, trace metals, and radionuclides after a single use, and maintained in regulated engineered stacks .
THE INEFFICIENCY
The industrial sulfur cycle is linear, with a continuous input of sulfur entering the system and an equal quantity permanently discarded as phosphogypsum waste. Sulfur recovery from phosphogypsum represents an opportunity to drastically reduce operating costs, logistical complexity, and waste management liability for phosphate producers.
THE INEFFICIENCY
The industrial sulfur cycle is linear, with a continuous input of sulfur entering the system and an equal quantity permanently discarded as phosphogypsum waste. Sulfur recovery from phosphogypsum represents an opportunity to drastically reduce operating costs, logistical complexity, and waste management liability for phosphate producers.
THE SOLUTION
THE SOLUTION
Sulfyr is developing a chemical process to modernize phosphate production by recovering concentrated sulfuric acid directly from phosphogypsum, an abundant on-site waste product. The process operates at mild temperature and pressure.
Sulfyr is developing a chemical process to modernize phosphate production by recovering concentrated sulfuric acid directly from phosphogypsum, an abundant on-site waste product. The process operates at mild temperature and pressure.
REACTION
Phosphogypsum is reacted with carbon dioxide to form a reactive sulfur-containing intermediate and stable carbonate byproduct.
SEPARATION
Clarification and filtration isolate the reactive fluid for downstream upgrading, while separating stable mineral solids.
RECOVERY
Clean sulfuric acid is recovered from the reactive fluid, reducing dependence on fossil-derived reagents.
RECYCLE
Intermediate chemicals and waste heat are recycled within the system to maximize efficiency and reduce material inputs.