Synthetic Gypsum and Coal Ash Contaminant Removal and Beneficiation

Spearstone Solutions proposes an innovative solution for the upcycling of waste from coal fired power and phosphoric acid producers. Over twenty-five million tons of FGD gypsum, a by-product of coal-based electricity production, are generated each year with about 25% of that being stored in large, unlined landfills. FGD gypsum contains contaminants like mercury, cadmium and arsenic which are associated with cancer and other health issues. Improper management of these landfills can lead to heavy metals leaching into groundwater, impacting residents nearby. Similarly, coal ash, another by-product of coal-fired power generation, is one of the largest sources of industrial waste with over 100 million tons being generated in 2014 alone. Like FGD gypsum, coal ash contains contaminants which can pollute groundwater and water sources if not responsibly managed. Although significant amounts of FGD gypsum and coal ash are repurposed for industrial applications, a large quantity still ends up in landfills and ponds across the country. Phosphogypsum (PG), a radioactive byproduct from fertilizer production, must be stored in areas called stacks with proper and require continuous management due to its radioactive content. There are about 70 PG waste stacks that contain several billion tons of PG, with an additional thirty million tons generated annually. Only 15% of the PG produced worldwide is recycled while the remaining is stored. These stacks require large acreages of land, incur high maintenance costs, and pose significant environmental risks. These stacks are a concern for nearby communities since the radium contained within can decay to form radon, a radioactive gas that has been linked to lung cancer and these stacks also have a history of structural failures, sinkholes, and other breaches, impacting the water nearby.Spearstone solutions offers a solution to managing these wastes through cleaning them to remove the contaminants, heavy metals, and radioactive elements. Once cleaned, Spearstone's technology allows for the conversion of the Gypsum into fertilizer and calcium carbonate. The U.S. fertilizer market is being projected to see record growth during the forecast period for 2022 to 2027 per Global Market Insight due to predicted global population growth driving a need for more food. Estimates say that by 2050, our world will need to feed approximately 10 billion people which is 5 times today's amount. Particularly with most phosphogypsum going unused and left stacked year after year, this Phase I project will explore the removal of radionuclides, impurities, and rare metals, from phosphogypsum, without harsh chemicals, high pressures, or extreme temperatures. The project aims to implement safe handling and disposal of radioactive waste, remove/isolate radioactive elements and contaminants from the waste, then convert the waste product into viable products a fertilizer (ammonium sulfate) and calcium carbonate, a product with universal application across multiple industries. This process not only reduces the amount of PG and synthetic gypsum added to waste stacks or landfills but also enables the cleanup of existing stacks and landfills, benefiting local water quality, ocean biology, and public health. By cleaning and transforming industrial waste into valuable products, Spearstone meets an unmet market need, while supporting a efficient, eco-friendly approach to atmospheric resource management and landfill waste. This Small Business Innovation Research Phase I project will be transformative in safely decreasing waste stacks, landfills, and ash ponds in the U.S. and globally and providing another source of fertilizer for food production.