Closing the Phosphorus (P) cycle and manure processing

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1 Closing the Phosphorus (P) cycle and manure processing Oscar Schoumans Alterra Wageningen UR

2 Content 1. Dutch Phosphorus (P) balance 2. Strategies for closing the P balance 3. Recovery of Minerals 4. Conclusions

3 Background Netherlands has a high intensive agriculture High import of feed and chemical fertilizers Manure production expressed in P is much larger than the room for P on land Livestock farms have to transport manure to other (cropping) farms and other countries Concerns about limited phosphate rock reserves Increasing need for manure treatment / better closure of P cycle

4 Phosphorus flows NL (2008): Import 115 mill. kg P Feed Fert. Other 65% 11% 24% Agric. IMPORT (100%) 45% Food & Non-Food Industries 32% 11% Export Manure 18% Households Waste Industry 9% 18% 3% 1% 18% 11% 2% 28% 5% 22% Soil Diffuse P Water/Sea Landfill Controlled P ash (incineration waste & sludge) 43% Export Products 45% EXPORT Products 2% Export Products 55% LOSSES Source: De Buck et al., 2012

5 Agricultural P cycle 5 P- recovery P export Intervention scheme technical solutions Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P 2 O 5 Mineral concentrates Manure separation 4 3 Livestock Arable Akkerbouw land 2 Bio-refinery Concentrated feed fertilizer P import Non-food Reduction P input 1 Source: Schoumans et al. (2010)

6 Agricultural P cycle P export Intervention scheme technical solutions Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P 2 O 5 Livestock Arable Akkerbouw land Concentrated feed fertilizer P import Reduction P input 1 Source: Schoumans et al. (2010)

7 1. Reducing P inputs via fertilizers and feed Reduction of P content animal feed (cows & pigs) Overall Reduction P in feed: dairy cattle 20-25% pigs 25% No negative effects on animal performance, health and fertility. Effective at short term Limited increase of feeding costs (< 4%) Reduction of amount of P in manure by about 10 million kg P 2 O 5 Source: Van Krimpen et al. (2010)

8 Agricultural P cycle P export Intervention scheme technical solutions Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P 2 O 5 Livestock Arable Akkerbouw land 2 Bio-refinery Concentrated feed fertilizer P import Non-food Reduction P input 1 Source: Schoumans et al. (2010)

9 2. Bio-refinery Separation of phosphates (and protein) from feed resources Water Animal feed Acid extraction Alkaline extraction Washing Low N/P/K wet feed Phosphates Proteins Digestible K-rich water stream May contribute to lowering the amount of P in manure by 1 5 million kg P 2 O 5 But effects on feed quality and costs not yet known. Source: Meesters et al. (2011)

10 Agricultural P cycle P export Intervention scheme technical solutions Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P 2 O 5 Manure separation 3 Livestock Arable Akkerbouw land 2 Bio-refinery Concentrated feed fertilizer P import Non-food Reduction P input 1 Source: Schoumans et al. (2010)

11 3. Manure separation Aim: (i) to replace P fertilizers by manure fractions, and (ii) to fill-up the room set by limits Separation: many technical options available Better N/P-ratio both liquid and solid fraction Liquid fraction fraction: N- & K-rich en H 2 O Solid fraction: P- and organic matter rich Energy costs separation << energy costs of transport of water Reduction of the amount of P in manure by 1 5 Manure separator million kg P 2 O 5 sieve belt Source: Schröder et al. (2011)

12 Agricultural P cycle P export Intervention scheme technical solutions Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P 2 O 5 Mineral concentrates Manure separation 4 3 Livestock Arable Akkerbouw land 2 Bio-refinery Concentrated feed fertilizer P import Non-food Reduction P input 1 Source: Schoumans et al. (2010)

13 4. Mineral concentrates Aim: to produce mineral NK concentrates (substitute for fertilizers) from the liquid fraction of manure However, the EU-Nitrate Directive states that all products derived from animal manure is animal manure, and has to comply with the manure rules of the Nitrate Directive Pilot with 8 installations are being tested: Technique: reversed osmoses (RO) Source: Velthof et al. (2012)

14 Production of mineral concentrate

15 End products Mineral concentrate Liquid N-K fertiliser Solid fraction P fertiliser Organic N fertiliser Soil conditioner Permeate (water)

16 Average composition of mineral concentrates Mineral concentrates: High N and K contents; Low P content NH4: ± 90% of total N ph >7.5 Large differences between treatment plants Pilots: Perspectives, but not yet approved by Brussels Plant A B C D E F H N-total N-NH4 g/kg g/kg P K % Ntotal g/kg g/kg

17 Agricultural P cycle 5 P- recovery P export Intervention scheme technical solutions Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P 2 O 5 Mineral concentrates Manure separation 4 3 Livestock Arable Akkerbouw land 2 Bio-refinery Concentrated feed fertilizer P import Non-food Reduction P input 1 Source: Schoumans et al. (2010)

18 5. P recovery from solid manure fractions Aim: to recover P from manure and process it into secundary P fertilizers by fertilizer industries, for export or elementary P4 Industries are interested Fertilizer industries (inorganic and organic P fertilizers) Incineration / biomass plants Phosphorus producer Possible reduction of the amount of P in manure by million kg P2O5

19 Phosphate and Phosphorus recovery Duckweed Algae animal feed Effluent Communal waste water WWTP (Waste Water Treatment Plant) Mineral concentrates Pretreatment (N,K & P) Agriculture Liquid fraction Short term Household waste SNB (sludge treatment) (incineration & energy production) Fertilizer industry Phosphate Fertilizer Incineration/Biomass plant (incineration & energy production) Source: Schoumans et al., 2011 Phosphorus (P4) Production of secondary P for industries with an existing international market Biogas/ CHP/ residual heat Wet solid fraction Drying Long term P producer Phosphate ash Fertilizer Pig slurry Dry solid fraction Pyrolyses Plant Export P-Biochar

20 Public-PrivateCollaboration Duckweed Algae animal feed Phosphate and Phosphorus recovery Communal waste water Mineral concentrates Ministries (Brussels) Waterboards Effluent Agriculture WWTP (Waste Water Treatment Plant) Pretreatment (N,K & P) Pig slurry Farmers organisations Liquid fraction Short term Biomass plants SNB (sludge treatment) (incineration & energy production) Fertilizer industry Household waste Incineration/Biomass plant (incineration & energy production) Biogas/ CHP/ residual heat Wet solid fraction Drying Long term P producer Dry solid fraction Pyrolyses Plant P requiring industries (fertilizer and P industries) Phosphate Fertilizer Phosphate ash Fertilizer Source: Schoumans et al., 2011 Phosphorus (P4) Production of secondary P for industries with an existing international market Export P-Biochar

21 Potential value of pig slurry -3 Table Potential value of pig slurry ( m ) based on average composition 1) lower and upper content 3 (kg/m ) Nitrogen anorganisch (N) Potassium (K 2O) Phosphate (P 2O 5) Organic matter (solid phase) -3 Total ( m ) 1) ) market price ( /kg) Total 3 Total 3 ( /m ) ( /m ) Römkens and Rietra (2008); content of inorganic N, P 2 O5 and organic matter; content of K 2 O 2) LEI land- en tuinbouwcijfers 2008; % of the fertilizer market prices: KAS (N), TSP( P 2 O5 ) and K60 (K 2O) and value of energy production of organic matter (based on per kwh) Source: Schoumans et al. (2010)

22 Agricultural P cycle Intervention scheme technical solutions P export Precovery mill. kg P2O5 Manure The Netherlands: P out of agriculture P cycle: 40 million kg manure P2O5 Mineral concentrates mill. kg P2O5 Manure separation Livestock 3 Arable Akkerbouw land 2 Bio-refinery Non-food 1-5 mill. kg P2O5 Concentrated feed fertilizer P import Reduction P input 1 10 mill. kg P2O5 Source: Schoumans et al. (2010)

23 Conclusions About 40 million kg manure P2O5 in the agricultural P cycle has to be reduced. Decreasing P in animal feed and manure separation may lower the surplus by ~10 15 million kg P2O5 (short term). Bio-refinery may remove 1 5 million kg P2O5 (mid term) Recovery of nutrients (N and P) from manure is possible (mid-long term), but costs needs to be reduced Thank you for your attention

24

25 5. P recovery from solid manure fractions Different P products can be produced Chemical P-fertilizer (inorganic) P rich ashes as secondary P resource to produce e.g. P4 Organic fertilizers P-rich bio-chars duckweed/algea-> animal feed

26 5. P recovery from solid manure fractions Different stakeholders and end-users are involved in a publicprivate-collaboration Farmers (organisations) Waterboards Governmental organisations (National and European) Biomass plants Fertilizer industry

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