Demonstrating unprecedented SYNthetic FLUORspar production method allowing for Circularity among three value chain, for CRM substitution, using fertilizer wastes, by-producing Industrial Green Silica.

Introduction

The LIFE-SYNFLUOR project aims to prove, optimize, and validate an innovative technology, developed and patented by Fluorsid in recent years, to recover synthetic calcium fluoride (or fluorspar) as a substitute for natural fluorspar, a critical raw material. This process starts from the FSA, a waste product from the fertilizers’ industry. As a by-product of the reaction, a greener precipitated silica will be available and tested as a reinforcing filler in the tire industry.

Project Goals

Starting from a TRL5, LIFE-SYNFLUOR will reach a TRL8 through the construction of a pilot plant for the production of:

1. 1,000 tons of synthetic calcium fluoride
2. 250 tons of precipitated silica

The prototype products will be used in specific industrial trials. To validate their performances and sustainability, a Life Cycle Assessment (LCA) will also be performed.

Market Impact

This novel and alternative source of calcium fluoride would be a fundamental support to the EU fluorine market due to:

• The scarcity of natural fluorspar
• The lack of alternatives
• The high number of fluorine-based products in daily life, including materials for Li-Batteries

Project Coordination

The project will be coordinated by Fluorsid, which will be responsible for:

• The construction and operation of the pilot plant
• The industrial trials for calcium fluoride use in circular Aluminum Fluoride production

Pirelli will participate by being responsible for the silica pre-industrial testing in tires. Fluorsid and Pirelli represent two main actors of the three value chains involved in LIFE-SYNFLUOR circularity and its possible future exploitation. Other stakeholders will support the project on the FSA side.

Future Plans

Once the technological and sustainability aspects of the process are validated, Fluorsid will industrialize the process through the construction of an industrial plant designed for producing:

• 120 ktons of calcium fluoride
• 30 ktons of precipitated silica

This will be achieved within 5 years from the end of the project.