RecoveRy of nutrients for a SuStainable agricultural fertilization
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1 FraunhoFEr InstIt ute F o r IntErFacIa l EnGInEErInG and BIotEc hnology IGB RecoveRy of nutrients for a SuStainable agricultural fertilization 1
2 nutrient supply by synthetic fertilizers withdrawal of nutrients by harvesting processing food/animal feed, bioenergy, biomaterials consumption solid and liquid waste loss of nutrients by disposal 1 nutrient Recycling as final stage for total use of crop Nutrients such as nitrogen, phosphorus, potassium or calcium are essential for the growth of all living organisms. Today, these nutrients flow in a non-sustainable system (Fig. 1). The nutrient flow begins with withdrawal from the plant soil ecosystem via harvesting, is continued via processing and use of the plant as food or animal feed, industrial raw material or for the production of bioenergy, and finally proceeds to a loss of the nutrients in the established disposal system. In order to compensate for the withdrawal of the nutrients by the crop, additional nutrients in form of industrially manufactured mineral fertilizers or organic fertilizers such as liquid manure or compost are added to the soil. The industrial production of mineral phosphorus fertilizers is based on non-renewable raw phosphates, the availability of which is decreasing more and more. At the same time, the production of nitrogen fertilizers by means of the Haber- Bosch process requires a very high consumption of energy, especially in the form of natural gas. Since the demand for food worldwide and the changeover to bioenergy and renewable raw materials is increasing, there is growing demand for fertilizers to meet the need for plants for the production of food and the production of bioenergy carriers. For these reasons, mineral fertilizers have already become more expensive in recent years and it is to be expected that the prices for synthetically manufactured mineral fertilizers will continue to rise. Loss of nutrients At the same time, large quantities of nutrients are lost as they must be removed from wastewater in accordance with the law. The state of the art in most communal wastewater treatment plants is that nutrients are removed by means of nitrification / denitrification or phosphate precipitation with aluminium or iron salts. Aluminium and iron phosphate salts can be toxic for plants even in a low concentration and are out of the question for use as fertilizers. According to estimates, approximately 4.3 million tonnes 1 of phosphorus are lost per year worldwide in communal wastewater treatment plants as a result of disposal. A further loss of nutrients is caused by overfertilization in agriculture. 2 1 General nutrient flow diagram in a non-sustainable system. 2 General nutrient flow diagram in a sustainable cyclical system.
3 balancing nutrient supply by synthetic fertilizer withdrawal of nutrients by harvesting processing food/animal feed, bioenergy, biomaterials consumption solid and liquid waste nutrient recycling partial loss by disposal 2 Excess mineral fertilizers are washed out of the oversaturated soil and consequently leach into the groundwater or into bodies of surface water, where the input of nutrients results in an undesirable eutrophication. A loss of nutrients can also occur in the direct use of liquid manure or fermentation residues from biogas production, as they normally contain an unfavorable nutrient ratio for example, nitrogen and phosphorus that is not optimal for the growth requirements of different crops. With the direct use of liquid manure or fermentation residues as fertilizer agents, a nutrient balance is required. However, this can only be calculated with reference to one nutrient (normally nitrogen). The use of uncontrolled quantities of nutrients in organic fertilizers can result especially in areas with intensive livestock husbandry in an oversaturation with nutrients and thus be harmful to the environment. For example, over 70 % of the nitrogen and 50 % of the phosphorus input in the surface waters in Germany in the period from 2003 to came from agriculture. In future, the optimal use of fermentation residues from biogas plants will play a central role, as was emphasized in 2010 by the German Federal Environmental Agency 2. On the other hand, nitrogen and phosphorus are found in many residual and waste substances both in inorganic form and in the form of organic compounds. These organic nitrogen and phosphorus compounds can not be assimilated by the plants. The natural process of mineralization, during the course of which these organically bound nutrients are made available to the plants, depends on specific local conditions. The dosage of the nutrients can therefore hardly be controlled with the direct application of liquid manure or fermentation residues. Since neither the mineralization processes because of their complexity nor the local conditions themselves can be controlled, the prediction of the nutrients release is difficult to establish. 1 T. Dockhorn (2009). About the economy of phosphorus recovery. Conference proceedings: International Conference on Nutrient Recovery, Vancouver 2 V. Mohaupt et al. (2010). Gewässerschutz mit der Landwirtschaft, Umweltbundesamt 3
4 1 2 SUSTAinABle nutrient MANAgeMent AT THE FRAunHofeR igb Due to the ecological and economic significance of inorganic and organic nutrient recovery, the Fraunhofer IGB is developing sustainable, energy- and cost-effective strategies and technologies for closing the nutrients loop (Fig. 2, p. 2). Research activities At present, we are developing new technologies for the recovery of nutrients from wastewater and organic residues. For this purpose the characterization and evaluation of various solid and liquid wastes (for example residues from the production of olive oil and from livestock husbandry or wastewater) are carried out identifying their nutrient content and the potential for the recovery and recycling of nutrients. In our processes the nutrients are precipitated or pelletized so that they can be marketed by industrial partners as a full-fledged and specific product (Figs. 1 and 2). Depending on the soil characteristics and the plants cultivated, they can be used in various sectors of agriculture. A process for the electrolytic recovery of magnesium ammonium phosphate (struvite) can be mentioned as an example. Moreover, we are researching the recovery of nutrients from olive oil waste (Fig. 3) in a project funded by the EU (En-X-Olive, Funding-No ) together with partners from Spain, Italy, Greece and France. The recovery of nutrients from animal manure and their recycling as a fertilizer for the cultivation of cabbage is being investigated in a further project funded by the EU (EcoBug, Funding-No ) together with partners from Norway, Hungary, Spain and Lithuania. 4
5 3 4 Formulation and stability studies of leaf-fertilizers Plants can be fertilized both by way of their leaves and the soil. Unlike fertilization of the soil, so-called leaf-fertilization permits the targeted and precise metering of various nutritional elements at a fixed time without the influence of the soil (specification of the nutrients, washing-out, etc.). The nutrients are sprayed in a diluted form (Fig. 4) directly onto the leaves of the plant and absorbed by it. To prevent and eliminate deficiencies in the plant, leaf-fertilization is thus generally becoming more and more important in agriculture as a business undertaking. For an industrial client the Fraunhofer IGB has examined the composition of leaf-fertilizers on the basis of natural raw materials. In addition, stability studies are carried out in order to guarantee that these products have the ideal composition and can be certified in accordance with EU Eco-Regulation 834/ Recovered product that can be used directly as organic fertilizer. 2 Recovered product that can be used directly as fertilizer: struvite crystals. 3 Nutrients can also be recovered from olive oil residues. 4 Micro-nutrient suspension for leaffertilization. 5
6 6 1
7 services offered nutrient recovery Feasibility studies Studies of the raw material with regard to its nutrient content and organic substance Development of technologies, to recover nutrients from solid and liquid waste Development of specific strategies for optimum nutrient recovery depending on the characteristics of the waste product studies Stability tests of liquid fertilizers Online particle measurement (1 µm 2.5 mm) of nutrient crystals Online particle characterization of nutrient crystals formulation and processing of fertilizers Development of multicomponent fertilizers Formulation and chemical analysis of liquid fertilizers Developing methods of separating, drying and pelletizing fertilizing agents contact Dr.-ing. Maria-Soledad Stoll Phone Struvite crystals recovered after a biological treatment process. Dipl.-ing. Siegfried egner Head of Department Physical Process Technology Phone siegfried.egner@igb.fraunhofer.de 7
8 Fraunhofer Institute for Interfacial Engineering and Biotechnology IGB (Fraunhofer-Institut für Grenzflächen- und Bioverfahrenstechnik IGB) Nobelstrasse Stuttgart Germany Phone Fax Director Prof. Dr. Thomas Hirth Phone Fraunhofer IGB brief profile The Fraunhofer IGB develops and optimizes processes and products in the fields of medicine, pharmacy, chemistry, the environment and energy. We combine the highest scientific quality with professional expertise in our fields of competence Interfacial Engineering and Materials Science, Molecular Biotechnology, Physical Process Technology, Environmental Biotechnology and Bioprocess Engineering, as well as Cell and Tissue Engineering always with a view to economic efficiency and sustainability. Our strength lies in offering complete solutions from laboratory scale to pilot plant. Customers benefit from the constructive cooperation of the various disciplines at our institute, which is opening up novel approaches in fields such as medical engineering, nanotechnology, industrial biotechnology, and wastewater purification. The Fraunhofer IGB is one of more than 80 research units of the Fraunhofer-Gesellschaft, Europe s largest organization for application-oriented research.
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