Final report- Better use of sugarcane mill waste streams on farm through education and development of improved farming practices in the Herbert cane growing region. Authors: L.Di Bella, A.Benson, M. Sefton, A.Royle, G.Holzberger and S. Sellick. Research and Development supported by: Report date: 30/12/2013. Copyright 2013 by HCPSL All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior permission of HCPSL. Disclaimer: Except as required by law and only to the extent so required, none of HCPSL, its directors, officers or agents makes any representation or warranty, express or implied, as to, or shall in any way be liable (including liability in negligence) directly or indirectly for any loss, damages, costs, expenses or reliance arising out of or in connection with, the accuracy, currency, completeness or balance of (or otherwise), or any errors in or omissions from, any test results, recommendations statements or other information provided to you.
Contact Information Name: Name of group or organisation Herbert Cane Productivity Services Limited (HCPSL) Herbert Cane Productivity Services Limited (HCPSL) Postal address: PO Box 135 Town/Suburb: Ingham State: QLD Postcode: 4850 Email address: ldibella@hcpsl.com.au Daytime phone number: (07) 47761808 Mobile phone number: 0448084252 Fax number: (07) 47763468 Website address www.hcpsl.com Project background Mill mud and mill ash are produced during the sugarcane milling process. Currently sugar mills regard mill mud and ash as a waste stream from the sugar milling process. These products are currently disposed of onto cane properties near to the sugar mill in large quantities simply as a means of getting rid of the waste product. Mill mud contains top soil (from harvesting cane), high levels of nitrogen, phosphorus, calcium, some trace elements, and approximately 50-80% water. The mill ash is waste from when cane fibre is burnt in the milling process; it contains high levels of potassium, silica and other micro trace elements and approximately 40% water. The high water content makes it expensive to transport long distances from a sugar mill. To date it is only distributed to farms, as a soil ameliorant and organic fertiliser, within a 15km radius of the mill (Di Bella, 2009). Recent research has also suggested that long-term use of high application rates of mill mud and/or ash may build up levels in the soil of some undesirable constituents. For example, mill muds and ash contain trace amounts of certain heavy metals. While the amounts are small, large application rates over long time frames could lead to build-up in the absence of compensating loss mechanisms (Qureshi, 2000). Large applications and frequent applications of mill mud on fields within a 15km radius of most Australian sugar mills has caused high levels of soil phosphorus (Di Bella, 2009).
Effective nutrient and soil management: This project attempted to address effective management of soil and nutrients at a landscape scale that is critical to ensure minimal impact to adjoining environmentally sensitive areas; the Wet Tropics World Heritage Area which forms the northern Project area boundary and the Great Barrier Reef World Heritage Area (including Hinchinbrook Island and channel) which is immediately downstream (<10km). Efficient use of mill by-product nutrient sources: The project worked with individual growers of the Herbert River cane growing region and the contractor (SnE Plant Hire) responsible for the distribution of the mill by-products from Victoria Mill. Adoption of reduced application rates of mill mud and ash was slow to be accepted by growers because of the lack of reduced rate application equipment and lack of data to support the farming system change. SnE Plant Hire modified its fleet of truck applicators in 2011 and commission a tractor pulled precision variable rate applicator in mid- August, 2013. Farmer knowledge and skills: Traditionally management practices fails to acknowledge the nutrients found in mill mud and mill ash. Most farmers still apply artificial fertilizer to the same paddocks at industry recommended fertilizer rates and do not take into account the nutrients applied in the mill mud or mill ash. This project attempted to educate the local industry on best practice nutrient management practices associated with organic and inorganic nutrient sources. Progress against planned milestones Location of field trials Two demonstration sites were set up at the following locations: o RGS Farming s property in the Foresthome area. Refer to figures 1, 2 and 5. o L. Biasi s property in the Hawkins Creek area. Refer to figures 3 and 4. Mill mud was applied to all block during October- early November 2012. A replicated trial at V. Russo s property in the Trebonne area was funded by Sugar Research Australia (formerly Sugar Research and Development Corporation). Funds from SRA and this project were used to support the Grower Group project- Improvement of internal soil drainage and yield on heavy clay soils in the Herbert.
Figure 1. Mill mud contractor S. Gileppa (from SnE Contracting) and HCSPL Manager Lawrence Di Bella at the RGS Farming site. Figure 2. Reduced rate mill mud application equipment used at the RGS Farming site, in October 2012.
Figure 3 (left). Zonal application beside the cane row of mill mud at ~100t/ha wet weight, at the Biasi site. Figure 4. (right). Application of mill mud at ~250 t/ha wet weight in the interspace, at the Biasi site. Figure 5 (below). Crop growth in late January, 2013 at the RGS Farming Company site. The left side of the picture is the high application rate and the right side is the zonally applied rate. There was a crop height difference at this site between the treatments in January, 2013.
Trial results RGS Farming Demonstration site The traditional application rate had the highest cane and sugar yield when compared to the zonal application treatment; however the results were not significant (P 0.05). The higher application costs associated with the higher rate applied (in the traditional application rate treatment) would mean that the zonal application rate would be more cost effective because of the lower rates applied in the zonal application treatments. Refer to figure 6 for results from the RGS Farming demonstration site. Figure 6 are the results of the RGS Farming demonstration site. Treatment CCS TCPH TSPH Zonal application 14.9 90.58 13.49 rate @~100 t/ha wet weight of mill mud. Traditional application rate @ ~250 t/ha wet weight of mill mud. 14.8 91.33 13.56 L. Biasi demonstration site The zonal application rate had the highest cane yield (tcph) of 61.76, while the traditional application rate had a lower yield of 43.95 tcph. There was no difference in CCS at this site. The zonal application rate had a higher sugar yield of 8.39 tsph compared to 5.97 tsph for the traditional application rate. Refer to figure 7 for the trial results for the L. Biasi demonstration site. The significant differences in cane yield maybe due to the placement of the mill mud in proximity to the cane row. At this site it was noted that a significant amount of the mill mud had not broken down and had been incorporated into the soil profile; this was probably due to the low rainfall experienced after application and prior to harvest. It is suspected that the nutrients released from the mill mud in the zonal application treatments were more readily available to the crop because the mill mud was applied near the root zone.
Figure 7 are the results of the L. Biasi demonstration site. Treatment CCS TCPH TSPH Zonal application 13.6 61.76 8.39 rate @~100 t/ha wet weight of mill mud. Traditional application rate @ ~250 t/ha wet weight of mill mud. 13.6 43.95 5.97 V. Russo Grower Group trial Refer to Appendices 1 and 2 for a copy of the Grower Group project- Improvement of internal soil drainage and yield on heavy clay soils in the Herbert trial results. The mill ash treatments in this trial out performed non treated plots, indicating that there is significant opportunities for growers to effectively use mill ash in a farming system. The financial analysis report (Appendix 2) highlights that the broadcast ash treatment had the highest average gross margin of all three scenarios up until the price of mill ash reaches $5.35 per tonne. At $5.35 per tonne and higher, the ash filled slot (at the reduced application rate) scenario has a higher average gross margin than the broadcast ash treatment. This is due to the higher application rate of mill ash under the broadcast scenario (200t/ha compared to 100t/ha). At prices above $6.55 per tonne, the broadcast ash treatment has a lower average gross margin than the conventional treatment. The ash filled slot treatment continues to have the highest gross margin up until the price of mill ash reaches $7.75 per tonne, at which point the average gross margin of the conventional treatment is higher (Collier, 2013). Nutrient monitoring Barry (1998) highlights that there is considerable variation in these products making it difficult when attempting to account for nutrients applied from mill and ash. Variation in nutrient content of mill mud, mill ash (from Victoria Mill) and mill mud/ash mix (from Macknade) was studied as a part of the project. HCPSL and Wilmar Sugar mill staff collected mill mud and ash samples on a weekly basis between the 2/10/12 and the 9/11/12, to investigate the differences in the nutrient content of these products in the Herbert cane growing region (refer to figure 8). Additional samples were taken between June and August 2013, but the results of these tests are yet to be analyzed and reported (at the time of publication of this report). The samples were analyzed by the ASPAC accredited Sugar Research Australia (SRA) lab; at no cost to this project.
Figure 8. Differences in nutrient contents of mill mud and mill ash from Herbert River District sugar mills between the 2/10/12 and the 9/11/12. Location / product Moisture % N %dm C %dm Ca %dm Mg %dm P %dm K %dm S %dm 30.0-35.6 10.0-26.1 18.6-28.8 Zn mg/kg dm Victoria- mill mud 0.015-1.147 23.5-32.0 108.4-163.3 Victoria- mill ash 0.136-18.3-29.1 54.1-0.245 102.6 Macknade- mill 0.02-0.105 16.8-24.2 80.7- mud/ash mix 135.7 4815-7319 2568-9361 5064-10940 1205-1497 558-1269 812-1224 Victoria- mill mud 68.99-79.92 Victoria- mill ash 51.41-65.87 Macknade- mill 65.97- mud/ash mix 79.58 Na mg/kg dm 0.992-1.426 0.047-0.121 0.334-0.795 Cu mg/kg dm 1.84-2.709 0.464-0.784 0.709-2.050 Fe mg/kg dm 0.265-0.381 0.345-0.495 0.255-0.387 Mn Mg/kg 0.839-1.147 0.231-0.333 0.322-1.020 0.177-0.405 0.965-1.447 0.409-0.988 0.099-0.119 0.18-0.365 0.094-0.164 The data in figure 8 aligns with the figures reported in Barry (1998). This information is now being used by industry for nutrient management budgeting purposes. How you are monitoring and evaluating progress Regional data analysis As a part of this project, HCPSL staff undertook analysis of cane productivity trends comparing blocks treated with the mill mud/ash mix and non-treated fields in the Macknade Mill area. GPS tracking data for the mill mud/ash distributing trucks operating from the Macknade Mill site and regional cane productivity data were combined in a GIS program and then analyzed for productivity trends. Figures 9 and 10 highlights the yield differences over years following an application of mill mud/ash mixtures from Macknade Mill for blocks treated in plant cane and those treated in ratoon cane. The graphs in figures 9 and 10 highlight that there are significant increases in yield following the application of mill mud / ash mixtures in the Macknade Mill area for plant and ratoon applications. It is proposed to undertake similar data analysis after this project has concluded, to monitor the use and distribution of mill mud and ash within the Herbert sugarcane industry.
Yield Increase TCH Yield Increase TCH 20 M Sefton 2013 Mud Applied to Plant (Mkd) - Yield Carry Over Benefits 15 14.88 15.45 15.49 10 5 6.40 0 1 2 3 4 Years Mud Previously Applied Figure 9 (above). Yield benefits in the following years post mill mud/ash applications when applied to plant cane, for the Macknade Mill area. Figure 10 (below). Yield benefits in the following years post mill mud/ash applications when applied to ratoon cane, for the Macknade Mill area. 25 20 Mud Applied to Ratoons (Mkd) - Yield Carry Over Benefits M Sefton 2013 21.20 15 10 9.32 5 0 3.80 1 2 3 Years Mud Previously Applied
Information & resources produced, & events held Field day On Monday the 2 nd of September, 2013 a field day was conducted at Stephen Gileppa s farm at Helen s Hill (south of Ingham). Figures 11 and 12 were taken at the field day. The event was well attended with 54 growers and industry personnel attending the event. At the field day the following activities were undertaken: Demonstration of the new precision variable rate mill mud and mill ash applicator. Presentations on the nutrient management concerning the use of mill mud and mill ash. Discussion concerning the use of lower rates of mill mud and mill ash in relation to environmental management and financial implications. Figure 11. The 2 nd of September, 2013 field day held at Stephen Gileppa s farm in the Helen s Hill area (south of Ingham). Figure 12. Growers viewing the precision variable rate mill mud and ash application demonstrated at the 2 nd of September, 2013 field day. Printed resources A factsheet was developed as a part of the project, refer to appendix 3. Growers can access the factsheet on www.hcpsl.com under the factsheets section. An article was featured in the 2012 Herbert Sugar Industry Report. This report was sent to all growers in the Herbert cane growing region and other industry stakeholders. Refer to appendix 4 for a copy of the article.
Project Outcomes This project has given growers in the Herbert cane growing region the data to confidently reduce mill mud, mill ash and mill mud/ash mixture rates without compromising cane yield or impacting on financial returns. Technology to strategically apply mill by-product in bands has not only improved the costeffectiveness for current users, but has opened the door for those growers who may not have previously used the products. Strategic applications allow lower volumes of product to be applied per hectare, which in return has reduced the cost per hectare of application. The project has also provided information on the nutrient content of mill mud, mill ash and mill mud/ash mixture for sugar mills operating in the Herbert region. This data will allow growers and industry agronomy support personnel to develop nutrient management strategies for the use of these products in a farming system. It is expected that reduced rates applied of these nutrient rich products, application of these products further away from the sugar mill and better utilisation of these products will lead to improvements in soil health and environmental outcomes. Improvements in productivity and resource use efficiency The project has highlighted that grower will not sustain significant productivity or financial losses (in most cases) by reducing the application rates at which the mill mud, mill ash or mill mud/ash mixtures are applied. Since the introduction of the precision variable rate and modified truck reduced applicators growers are now able to apply these products over a larger area than previously. The reduction in application costs associated with the reduced rate applied makes it cost effective for growers greater than 15kms away from a sugar mill. Di Bella (2009) indicated that the soils that could benefit the most from applications of mill mud or ash are generally located 15kms or greater from a sugar mill in the Herbert. The application of reduced rates has now made it cost effective to transport and apply these products in areas.
New information or ideas The results from this project where recently report to North Queensland technical staff and industry personnel at the Sustainable Farming Systems Group meeting that was held on the 14 th of September, 2014. Thirty-four participants attended this information meeting. Since the field day held in early September, two additional trials have been established in the region to investigate the opportunity to utilize the precision variable rate application equipment at different times within the plant cane period. These trials will be harvested in 2014. There has also been numerous enquiries from growers interested in hiring the precision variable rate applicator or using mill mud and mill ash at lower rates. Possible future projects that maybe considered: Investigate the opportunity of pelletizing the mill mud to reduce the moisture content for ease of handling and to reduce transport costs. Mixing mill mud or ash with other products like dunder (a waste product from sugarcane derived ethanol production), inorganic fertilizers, soil amendments (like gypsum) or other organic waste products (like manures or bio-solids) to make a complete nutrient product that meets the whole crops requirements. Investigate the affect on soil biology and soil chemistry following the application of mill mud or ash. There has been very little research undertaken in the field to date.
Financial Report Figure 13 (below) is the financial report for the project. Figures CONFIDENTIAL to the project. Figure 13. LANDCARE/WOOLWORTHS PROJECT Financial report- duration of project. One off Payment Funding Received Amount Total Expense Amount Total
Other Funding Funding was also received from Sugar Research Australia (formerly Sugar Research and Development Corporation) to undertake the Grower Group project- Improvement of internal soil drainage and yield on heavy clay soils in the Herbert. Funding from both funding sources was utilized to undertake the extension activities undertaken for the Grower Group project. Refer to figure 14 listing funds from other sources. Figure 14. Funding from other sources. Name of organisation/funding source Amount In-kind SRA (formerly SRDC) $ 47,000 $ 14,900 Media coverage and promotional material The following media coverage occurred concerning the project: A feature story appeared in the Herbert River Express on the 15 th of December, 2012 announcing the commencement of the project. Refer to appendix 5 for a copy of the article. An article was featured in the 2012 Herbert Sugar Industry Report. This report was sent to all growers in the Herbert cane growing region and other industry stakeholders. Refer to appendix 4 for a copy of the article. An advertisement for the field day was placed in the Herbert River Express on Saturday the 31 st of August, 2013. The project is featured on the HCPSL website- www.hcpsl.com A follow up article for the 2013 Herbert Sugar Industry Report is proposed for distribution in early 2014. Figure 15 highlights the signage erected at trial sites.
Figure 15. Signage at the L.Biasi demonstration site. References Barry, G.A., Price, A.M. and Lynch, P.J. (1998). Some implications of the recycling of sugar industry by-products. Proceedings of the Australian Society of Sugar Cane Technologists Conference, Ballina, pp. 52-55. Collier, A. (2013) SRDC Project #GGP053 Subsection to Milestone Report 4: Economic Analysis, Department of Agriculture, Fisheries and Forestry (DAFF), Queensland. Di Bella LP, Coventry RJ, Sefton M, Moody PW, Hanks M, Stringer JK and Kerkywk R (2009) The use of geo-referenced soil test data in the Herbert District. Proceedings of the Australian Society of Sugar Cane Technologists Conference, 31, pp.296-306. Qureshi ME, Wegener MK and Mason FM (2000). An Economic Study on Recycling Sugar By-Products for the Mackay Region. CRC SUGAR Occasional Publication, Townsville, Queensland.
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