Material recovery and a structured takeback system for VK sulfuric acid catalysts
“The catalyst itself and the manufacturing process is already highly optimized. The real challenge lies in the end-of-life phase, which is often outside our control. Through this project, we hope to identify a realistic pathway for catalyst regeneration or recovery of active materials that could be scaled across different regions.”
– Edith Buhl, LCA Specialist at Topsoe.
Opportunity
Topsoe has the opportunity to transition to circularity by recovering vanadium and silica from spent catalysts. Reusing these materials reduces virgin material demand and secures the supply chain against market volatility. By leveraging their established logistics department and offering financial incentives for returns, Topsoe can transform a waste stream into a secondary resource, gaining a competitive edge in the global B2B market.
Path
The transition involves establishing a pick-up takeback system in coordination with internal logistics and third-party recovery experts like LCR or AMG Vanadium. Topsoe’s R&D department will define the purity requirements for integrating recovered vanadium and silica back into production. This phased strategy focuses on circular supplies and collaborative value creation, moving the company away from linear landfill models toward systematic resource recovery.
Outcome
The primary outcome is the elimination of landfill waste and the establishment of a secure, circular supply of vanadium. By closing the loop with third-party partners, Topsoe enhances its resource efficiency and brand reputation as a sustainable leader. These interventions provide a scalable model for catalyst recovery that aligns economic profitability with long-term environmental stewardship.
Context
Topsoe A/S is a global provider of high-end catalysts and advanced technologies, employing over 2,800 people. This case focuses on the VK sulfuric acid catalyst line, which uses a silica carrier with a vanadium-based active material. Currently, the value chain is linear; spent catalysts are landfilled after use, representing a significant source of structural waste. Topsoe aims to change this status quo to ensure vanadium stock security and explore the profitability of material recirculation without compromising the shape and composition of the catalysts as these are highly optimised through years or R&D.
Opportunity
The primary opportunity lies in reusing material from spent catalysts, which provides economic gains by saving on raw material sourcing and creates a more resilient, reliable supply system. Since vanadium is the key value driver due to its cost, recovering it from deactivated catalysts captures significant residual value that is currently lost to landfill.
Two prerequisites for this are a takeback system and a recovery method and facility; the second aspect must be handled by a third-party company. Topsoe already has a well-established transport and logistics department, so designing a takeback system should be feasible within a short timeframe. Topsoe can differentiate itself by offering a sustainability-driven service where customers return catalysts to avoid landfill fees or receive discounts on future purchases.
Furthermore, two technical approaches are possible: grinding catalysts into a homogeneous powder for new mixtures or isolating the vanadium and silica for high-grade reuse or downcycling into concrete. The first option would reduce the number of steps in the recovery process. If the second option is chosen, the remaining silica can be used to create new carriers if the material grade is high enough. Alternatively, it can be downcycled into concrete where the requirements are lower.
Transition path
The recommended transition path focuses on establishing a steady supply of used catalysts through a structured takeback system. Topsoe should first consult its internal logistics department to implement a pick-up system for customer returns. Simultaneously, the R&D department must investigate the technical feasibility of integrating recycled content, determining required purity levels for both vanadium and silica.
A critical step involves establishing partnerships with third-party recovery facilities, such as London Chemicals & Resources (LCR) or AMG Vanadium, to handle the specialised material extraction. This collaborative model ensures value recovery without requiring Topsoe to build internal recycling infrastructure, creating a circular foundation through material reuse.
Outcome
Implementing this path will create a solid circular foundation by reducing the large amount of landfilling and associated structural waste. Environmentally, it minimises metal leaching risks and lowers the carbon footprint of production through material reuse.
The Transition Path is high-level, and must be refined from within the company, both regarding the logistics of the takeback system and the details of the partnership company interaction. Although there are several financial incentives, it is not expected that 100% of customers will agree to the takeback system. The minimum viable percentage for success must also be specified before the transition is scaled up.
Assuming, that the costs associated with the transition path steps do not exceed the savings on vanadium sourcing, the company will have created a solid circular foundation for the company. The material recirculation strategy is generally less favourable compared to product recirculation, so the economic gain is not expected to be of large orders of magnitude. However, a larger degree of circularity will also improve the company image, possibly facilitating other partnerships down the line.
Reflections
A key reflection is that Topsoe's implementation will depend heavily on the profitability of vanadium recovery; if transition costs exceed material savings, the strategy may be dropped. Additionally, a clear cost/benefit assessment is needed to weigh the benefits of supply security against the financial commitment of long-term recovery partnerships.
Next step
The company should request pricing estimates from specialised recovery firms to evaluate the short-term financial viability of the takeback system. Topsoe should consult with its internal logistics department to design the most efficient pick-up routes and introduce incentives to encourage product returns from catalyst customers.
Micro-Accelerator. January 2026 - offered by ready2LOOP & DTU Course, Design for Circular Economy
Company
TOPSOE
Focus area for transition path
Manufacturing & Value Chain
Product Manufacturers
Takeback & End-of-Life Strategies
Product Manufacturers
