Alternative uses of Rice Stubble

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1 Alternative uses of Rice Stubble This document is a summary of the information presented during project CLG The rice stubble dilemma Rice crops produce a significant amount of stubble (in rice 12 t grain = 15 t straw) which provides many challenges. Burning stubble is a quick fix with minimal cost that enables good establishment of the following crop. However burning is perceived as being detrimental to the environment and nutrients and organic matter are lost from the system. Stubble smoke can also impact on third parties. The uptake of alternative management practices to burning involves justifying the significant extra costs of the machine operations involved against the soil health benefits and the resultant environmental benefits. Stubble Management and the timing of planting the next crop The management options involve the consideration of the timing or interval between rice harvest and the planting of the next crop. Full incorporation of stubble will delay the next crop by up to 12 months. For planting immediately after harvest the options include; baling and removal of the stubble and shredding or mulching the stubble and direct drilling through the crop residues. Retaining stubble in the paddock There are significant nutrient losses when stubble is burned or removed from the paddock. These are described below in Table 1. What are these lost nutrients worth? If we assume that all of 63kg/ha of N as shown in the table above can be returned to the soil (by incorporation) for future use is lost through burning this equals 137kg/ha of Urea. Based on a price of $600/ton for Urea ($1.30kg of N) the cost of this loss would be $82.20 per ha. For phosphorus the loss is shown to be 5 kg/ha. Assuming this is replaced by MAP (price $ or $3.50kg of P) the cost of this would be $17.50/ha. Even if 50% of both the Phosphorus & Nitrogen is retained by retaining stubbles there is saving of approximately $50.00ha. More research is needed to accurately quantify the potential savings. Anecdotal evidence from several farmers practicing incorporation based on yield improvements support the view that significant nutrient savings are achieved

2 Table 1. Showing the Nutrient Balance for a 12/ha rice crop in South Eastern Australia. Reproduced from; Production of Quality Rice in South Eastern Australia ( RIRDC2000) Incorporation of rice stubble Farmers and manufacturers are striving to come up with stubble mulching and tillage machinery that will provide cost effective and timely stubble incorporation. One current method in use is to mulch the stubble after harvest, disc the mulched stubble in September, cultivate the paddock twice during the summer and complete the operation by smudger boarding in autumn prior to sowing a winter cereal crop. The total costs for incorporation based on a cost of $50/ha for each operation will be in the order of $ /ha. New machines incorporating angled discs at narrow spacing and heavy rollers may reduce the number of machinery passes.

3 Farmers incorporating stubble have found that waiting until the soil dries when discing for the first time gives the best results. The advantages of incorporation include; improved soil health and increased water holding capacity. The disadvantages include; delaying the planting of the next crop and the cost of the machinery operations. Photo showing the effect of one pass of a K-Line Speed tiller immediately after harvest Stubble Incorporation at Amarran Harry Kooloos owner of the property Amarran at Mayrung has been incorporating rice stubble for many years. Until this season Harry incorporated rice stubble using a mouldboard plough. Mouldboard ploughing cultivates to a depth of around 37 cm and turns and buries the stubble in one pass. It is a slow process and requires soil moisture at the time of ploughing. In good conditions Harry could plough 1 ha/hr with an 80 horsepower tractor pulling a 4 shank plough. The cost of this operation would be in the order of $80-$100/ha. The incorporation would be completed by another two discings plus a grader board pass to complete the seedbed preparation. This season Harry decided to reduce costs and save time by using his heavy offset disc with a rice ridge rolling hitched behind. Two passes of this combination were required for satisfactory incorporation. The incorporation was achieved at the rate of 3.4 hectares an hour using a 150 horsepower tractor pulling 4.5metre offset disc-ridge roller combination. The cost of each cultivation is in the order of $40-$50/ha. Based on $150/hour tractor and machinery cost with fuel & driver. In 2015 Harry used 183 litres for 21 ha. 8.71litres/ha or 29.63lites/hr. This supports the $40-$50/ha cost. = Harry Kooloos costs versus savings Operation costs for 2 passes with the disc roller combination Potential nutrient savings estimate assuming not all nutrients are returned to the soil Saving on summer weed control costs, Glyphosate plus 24D amine plus boom spray Summer weed control costs can be significantly higher than this. Additional soil water holding capacity (unknown at this time) Potential savings estimate $ 90.00/ha $ 70.00/ha $ 28.00/ha $ 8.00+/ha

4 Harry Kooloos offset disc and ridge roller combination as used for rice stubble incorporation harvest rice stubble incorporated on Amarran. (Photo taken 11/02/15)

5 Retaining stubble on the surface With the high stubble loads farmers are in search of innovative equipment that will enable the surface retention of stubble while allowing seeding equipment to establish the next crop. Machines like the Happy Seeder where the drill rows are cleared in front of the seeding tines may offer a solution. An option tried by some rice farmers is to harvest the crop as low as possible with a cutter bar front with the straw chopper operating distributing the chopped straw evenly across the full width of the header front. This method improves the traffic-ability for seeding equipment however the stubble loads still make crop establishment difficult and this slows harvest progress and increases harvesting costs. It should be noted that Trial plot harvester manufacturer Yanmar incorporate straw cutting technology that leaves rice straw evenly distributed across the harvested paddock. This technology is enabling successful new crop establishment after harvest by disc drill machines. It should be noted that when stubble is retained on the surface and the new crop planted within weeks of harvest there is a risk of paddock water logging due to the increased soil moisture store and seasonal rainfall. Yanmar Harvester harvesting trials at Rice Research Australia The Excel disc seeder used to plant cereal crops straight into harvested rice at RRAPL

6 Retaining stubble on the surface at Wandarra The Hick s family from Pretty Pine have been both incorporating and mulching rice stubble for a number of years. They believe the improved moisture holding capacity of their soils and avoidance of unnecessary nutrient loss improves the productivity of their farming system. Rice is the main crop grown on Wandarra with winter cereals only grown after there is full soil profile of moisture. As there is not time pressure for stubble to break down the number of machine passes is reduced. In some years stubble has been mulched and incorporated by discing, however most recently rice stubble from the 2014 harvest was mulched at harvest time and then been left to sit on the soil surface. On inspection in early February 2015 this paddock had a full profile of moisture, whereas other paddocks on the farm were dry. Andrew Hicks believes even when cereals crops are not grown their stubble management benefits their system as it reduces their rice crop water use rice crop stubble mulch and left lying on the surface at Wandarra Pretty Pine (photo 12/02/15) Soil moisture under mulched stubble at Wandarra (photo 12/02/15)

7 Stubble Mulching Costs Steve McGrath operates stubble mulching contracting business. Steve charges $30/ha plus fuel for rice stubble mulching immediately after harvest. Fuel figures established for Steve s 300 horsepower John Deere tractor (March 2015) are around 30 litres an hour (covering 2.5ha/hour) costs to the farmer of mulching would be in the order of $42.00/ha. Base on a net (after rebate & GST) diesel price of $1.00/litre. McGrath s Mulcher at work in 2015 harvested rice Happy Seeder The original Happy Seeder incorporated a forage harvester that cut and cleared the stubble in front of the seeding tynes and blew the chopped stubble over the machine where it was spread over the seeded ground. The third generation Turbo Happy Seeder (Turbo HS) developed by Damesh Mechanical Works in conjunction with Punjab Agricultural University greatly reduces the amount of dust generated and leaves the sowing rows more exposed thus overcoming most of the difficulties of the earlier models. Initial trials of this seeder, sowing wheat into rice have showed excellent establishment, however the Turbo HS requires further evaluation to record stubble handling performance, power requirements and crop establishment in the range of conditions experienced in Australian rice fields. Removal of stubble Removing stubble from paddock by cutting and baling enables the end product to be used for a range of uses leaving the rice field ready to drill the new season s crop. Current uses of rice straw include; garden mulch, building construction, sediment control, pollution management, composting, fodder in dry times and bedding for livestock. Advantages; minimal delay in new crop planting and a possible source of income. Disadvantages; the loss of nutrients and organic matter and the cost, if sufficient income can t be generated from the straw. The total cost of baling rice straw and removing from the field is in the order of $60.00 to $70.00 per ton (based on mower conditioning, raking, baling and cartage from the paddock to the stack for large square bales).

8 Rice straw markets A brief desk top study uncovered several businesses processing rice straw for resale for end uses, including; garden mulch, stock food and building materials. One of these, Trent & Jenny Gardiner s Straw.com.au specialises in the production of small square bales of straw. This Coleambally based business produces about 40,000 bales of rice straw a year supplying half for straw bale building and half for stock feed. This straw is produced by mower-conditioning immediately behind the stripper front header then baling as per hay. The end product is green in colour and palatable to cattle. Moisture content 9-12% Protein 4% Rice Stubble as garden Mulch Innovative farmers from Griffith NSW the Collis family have recently installed a garden mulch packing facility. Here they process baled rice straw into 10 kilogram bags for retail through hardware-garden supply outlets. Prior to baling the rice straw is mulched rather than cut with a mover conditioner. The use of a stubble mulcher eliminates further chopping before packaging. This is an exciting new development for rice straw however it needs to be remembered that an annual average rice crop produces 800,000 to 1,200,000 tons of straw with the market currently only requiring a small percentage of this volume. Package rice straw from the Collis family s plant near Griffith NSW

9 Rice Stubble Feed trial A feed test trial using Nathan Pate s Sherpa rice stubble from property Oxford Tocumwal was conducted in conjunction with the Snowdon family in 2013 The table below describes the treatments Treatment Type of treatment Application Wrapping Number of Bales Number method 1 Control Nothing None 12 2 Untreated silage Nothing 6 layers with 30 2 micron film 3 9kg of Dry Urea Applied directly on to row immediately before baling. 6 layers with 30 micron film kg urea dissolved in 1200 litres of water. Water applied to centre of row via a hose. 2 applications prior to baling kg Sovereign Diluted in water added to baler pick up by twin nozzles. 6 layers with 30 micron film 6 layers with 30 micron film 6 1 litre of HY-SI 6 layers with 30 micron film

10 Feed test results from the Sherpa stubble feed test trial

11

12

13 Rice Straw Compost Trial at John Tippet s Tooleybuc Potato Farm By Ross O Halloran owner of Waterhold Composting rice straw has been an interesting journey. It differs, not greatly to other types of material used to make compost but is different enough that it commands special attention whilst been made. Temperature patterns, moisture content and general behaviour of the batch are some of the things that were observed during the making of this batch. Keeping these factors in mind experience was useful in keeping the rice compost from going anaerobic. However every batch made is watched and monitored closely to ensure that they stay aerobic though out the entire process. The Rice compost needed an extra keen eye to make sure it didn t go off track. The cost for the machine operation (turning) for the barley stubble compost versus the rice compost was the same. The first 2 turns of the rice compost were slower than the first turns for the barley compost however this time was made up later as the later turns were faster for the rice compost. The starting material used in the windrows that were tested had Rice straw, rice hulls with pig manure, orange pulp, pistachio hull waste, red gum saw dust and compost teas. The cost of producing the rice straw compost was $ The reduced turning hours for the rice based compost compared to the barley straw compost made the cost of both batches the same even though most of the ingredients brought in for the rice stubble compost had to travel a lot further than the barley stubble compost. If you have the stubble on hand then your costs are going to decrease as would other cost of material if it is close by. Both batches were tested for biological activity (Foodweb analysis) and chemical analysis. The Rice stubble compost showed greater diversity of biological species than the barley but lacked in behind the barley in the chemical analysis. Experience has shown me that the rice stubble compost should outperform the barley stubble compost due to the diversity of microbes and how active they are. Nutrient levels can be off in testes performed but as long as there is reasonable diversity they the compost it will do well. Reason being, once the compost is in the soil the microbes go to work harvesting and creating nutrients, breeding and grazing on other microbes and create an environment that microbe and plants can happily coexist to exchange nutrients. The conclusion from Water hold Pty Ltd is that rice stubble compost has the ability to be very cheap and potentially very effective if the batch has good number of starting materials and is close to the paddock it is intended to be applied too.

14 Spreading compost The cost for spreading compost can be significant with spreading rates varying from 1.5 ton/ha to 7ton/ha. Spreading costs contractor rates $150.00/hr (rate provided by Deni Fertilisers 2/02/2015) There are many variables in spreading costs. As an example 4ha/hr (7 ton/ha) cost would be $37.50/ha Lower rates would be much cheaper as the loading time is reduced. Compost production and use at Equity Park Why we make compost? Soil health improvement and savings on other fertiliser inputs. Increased soil moisture holding capacity We have the piggery waste available to compost Composting process The pig eco-shelters have bedding made up of rice hulls with rice straw from round bales rolled out on top of the hulls. The rice straw is baled from rice grown on the Ryan s properties. The pigs are moved from the pens after weeks. At this time the bedding material including the pig urine and manure is removed from the pens by a telehandler and the laid out in rows to start the compost process. The compost is turned by the telehandler several times during the process. The turning operation is based more on available time rather than at fixed intervals. The time it takes to make compost varies from batch to batch. This variation is due to the number of turns, the moisture content of the compost and the time of the year it is made. Nothing else is added to the compost, it comprises only the bedding and waste from the piggery. Each batch size is around 1000m 3. Spreading takes place usually in February and March at the rate of 7 ton/ha (12m 3 /ha)

15 Soil test show an increase in Phosphorus levels over time leading to lower fertiliser application rates. Compost breaking down at Ryan s property Equity Park Compost ready to spread

16 Equity Park Compost Analysis

17 Soil test Results from the Ryan s property Piney Park Test taken in 2013 before lime and compost applications

18 Soil test taken in February 2015 after lime and compost application.

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