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DIGES TATE FROM MA NURE R ECYCLING T ECHNOLOGIES Digesmart project – DIGES tate from MA nure R eciclying T echnologies Contract Nr. ECO/12/332882
Content 1. INTRODUCTION 2. DIGESMART TECHNOLOGICAL SOLUTION 3. BENEFITS: ECONOMICAL AND ENVIRONMENTAL 4. PRACTICAL RESULTS 5. COMING ACTIVITIES 6. PARTNERS
1. INTRODUCTION ENVIRONMENTAL IMPACT OF ANIMAL MANURE/SLURRY FROM INTENSIVE LIVESTOCK FARMING
MANAGEMENT ANIMAL MANURE/SLURRY HIGH TRANSPORT COSTS IN AREAS WITH HIGH LIVESTOCK DENSITY
1. INTRODUCTION BIOGAS TECHNOLOGY � NON REDUCTION OF NUTRIENTS (NPK) AND LOW REDUCTION OF INITIAL VOLUME OF ANIMAL MANURE/SLURRY USE OF EFFLUENT FROM BIOGAS PLANTS ( DIGESTATE ), MEANS ALSO: HIGH TRANSPORT COSTS IN AREAS WITH HIGH LIVESTOCK DENSITY
RISING COSTS OF AT THE SAME TIME 1. INTRODUCTION FERTILIZERS ARTIFICIAL
1. INTRODUCTION RISING COSTS OF ARTIFICIAL FERTILIZERS NEED OF SOLUTIONS TO FACILITATE LOCAL USE OF NUTRIENTS FROM DIGESTATE
2. DIGESMART TECHNOLOGICAL SOLUTION P mainly in solid fraction, while N and K are mainly retained in the liquid fraction (effluent from biogas plants)
2. DIGESMART TECHNOLOGICAL SOLUTION LIQUID FRACTION OF DIGESTATE DIGESMART: SOLUTION OF VALORIZATION OF DIGESTATE FROM BIOGAS PLANTS PROCESSING ANIMAL MANURE AND SLURRY MAINLY
2. DIGESMART TECHNOLOGICAL SOLUTION
2. DIGESMART TECHNOLOGICAL SOLUTION. STRIPPING. N-RECOVERY. PRODUCT = GREEN FERTILIZER % 5 7 , 8 f o n o i c t u d g e n R i p � p i r s t o t s k Product n a h t N . f t ) o / 4 H N - N g k 5 , 0 a 4 ( Ammonium nitrate a GREEN FERTILIZER (GF) 1. STRIPPING ( temperature >60ºC) 2. ABSORPTION (nitric acid) Main innovations from DETRICON: a) Lower costs of the stripping plant b) High energy efficiency of the process
2. DIGESMART TECHNOLOGICAL SOLUTION ADVANTAGES 1. Lower transports costs of residual fraction of digestate after stripping 2. Production GF replacing artificial fertilizers. Extra incomes for biogas plants + lower fertilizers prices for farmers 3. Treatment capacity of stripping plant : Plant located in Belgium 4000 – 60 000 t/year liquid digestate fraction
2. DIGESMART TECHNOLOGICAL SOLUTION HIGHLIGHT OF DIGESMART SOLUTION (SOLAR DRYING) Still not ready – under test at DISAFA – University of Turin 1. Lower transports costs of residual fraction of digestate after solar drying 2. Production of a K-rich fraction 3. Treatment capacity / Performance
1. - Circular economy . Facilitating rational use of all the 3. BENEFITS different waste streams from intensive livestock farming/biogas plants 2. - Reduction of environmental impact of animal manure of intensive livestock exploitations 3. Reduction of Nitrogen pressure in the area where the plant is located 4. - Fostering BIOGAS using animal manure 5. - Green fertilizers (product) with low carbon footprint 6. - Rural development encouragement and diversification of activities in rural areas. New jobs related to green fertilizers production. 7. - Improvement of competitiveness of biogas plants and livestock exploitations – agrifood companies
3. BENEFITS. ESTIMATION OF BENEFITS FOR EACH DIGESMART PLANT CONNECTED TO A SMALL-MEDIUM SIZE BIOGAS PLANT (30 000 t/year liquid digestate fraction). Environmental indicators � Nutrients recovered (N) for each installation (stripping): 239 976 kgN/ year � Reduction of more than 87,5% of ammonia emissions (stripping process make possible to reduce 87,5% of ammonia from digestate) � Fostering BIOGAS at small-medium size. A biogas plant running mainly with animal manure, 350 kWe installed � Energy production 7000 MWh/ year � New direct (1 biogas plant+digesmart plant operator) and indirect jobs (maintenance service of the plant, local providers) 16
4. PRACTICAL RESULTS. USE OF GREEN FERTILIZER ON AGRICULTURAL FIELDS � Nitrogen content: 16-18 % N. (50% nitric, 50% ammonia) � Sustainable source of nitrogen � Without odours or impurities � Chemically stable: easy storage and transport � Low environmental impact � Application in fertigation or as a foliar fertilizer (no spreading on land).
4. PRACTICAL RESULTS. USE OF GREEN FERTILIZER ON AGRICULTURAL FIELDS. OPTIONS � Use in fertirrigation � Use as foliar fertilizer � Crops: � Maize � Tomato for processing industry � Horticultural crops on the field � Horticultrual crops in greenhouse � Floriculture 18
4. PRACTICAL RESULTS. EXAMPLE: TRIALS IN ITALY � Trials fertirrigation: � Maize fertirrigated on the field � Lettuce cultivation in spring and winter ( greenhouse ) � Trials foliar fertilization � Common wheat to increase grain quality 19
4. PRACTICAL RESULTS. EXAMPLE: TRIALS IN ITALY Trials on lettuce (spring) fertilized with conventional fertilizers and alternative fertilizer (green fertilizer) shower very similar results in respect of weight 20
4. PRACTICAL RESULTS CONCLUSIONS USE OF GREEN FERTILIZER � The green fertilizer is a liquid product and has a low concentration of nitrogen (18% N) in comparison with existing artificial fertilizers. � After trials of work package 3, it is important to mention that a possible solution can be horticulture (both open field and in green-house), because fertilizer amount are smaller and there is a higher probability to find small tank of liquid fertilizers. Nevertheless, the GF can be applied in fertirrigation in combinable crops as well. � Also, the low carbon footprint of the GF could be valorised over the value chain, as the harvested product, mainly fresh consumed, can hold a label telling the consumer “ Produced with S ustainable inputs” . � The product can be used by the owner/producer by complying to the legislation on digestate management .
4. PRACTICAL RESULTS. REGULATIONS, COMMERCIALIZATION AND DISTRIBUTION OF THE PRODUCT � Registration of the product (ammonium nitrate/k-rich fraction) � Storage � Transport � Commercialization (network of distributors managed by Detricon) � Distribution of the product: (microirrigation, liquid type very pure) � Seasonality to spread the product (no problem on this potentially � Potential problems of use of the K-rich fraction (hygienic quality, amount of heavy metals, etc.)
3. Life cycle assessment � LCA of 1 kg Ammonia � S till preliminary results Process Electricity [MJ/kg N] Other [MJ/kg N] Total energy requirements [MJ/kg N] Average ammonia productionprocess Europe ‐ 43 43 Detricon ammonia stripping 6,3 13,9 34,2
Which economic value? ... Digestate distribution costs Distance reduction � distribution cost reduction � www.bi oenergy Padiglione 2 – stand 214 farm.eu
Digestate distribution costs distance km 5 10 15 20 25 30 Distribution cost €/ ha 337,58 501,43 665,28 829,13 992,98 1156,83 Area and distances ha 130 100 70 50 20 10 Digestate distribution cost (total) €/ year 43885,4 50143 46569,6 41456,5 13901,72 8097,81 Digestate distribution cost €/ m3 dig 4,05 6,02 7,99 9,95 11,92 13,89 Total cost €/ year 204054,03 total costs (unitary) €/ m3 dig 6,80 The advantage is for location where the nitrogen has to be moved far away Saving 89000 EUR/year for 30000 m3/year of processed digestate www.bi oenergy Padiglione 2 – stand 214 farm.eu
Potential sales of green fertilizer Plant 30000 m3/ year � selling of fertilizer 170 EUR/ t (1300 t/ year) � 221 000 EUR/ year – � 40000 EUR/ year distribution cost � The distribution costs could be avoided if sold to a fertilizer producer (but may be we have to lower the price as well) Total investment (plant for 30 000 m 3 / year) � 353 000 EUR � � Net present value of investment 277 000 EUR (11 years amortization plan) www.bi oenergy Padiglione 2 – stand 214 farm.eu
Advantages and problems � Potential advantages � What the value for the market? � Is the product use sustainable and logistically viable? � Could we have some label (e.g. green..) on our main business process or on the fertilizer? � Potential problems � It is economically sustainable j ust the internal use? (reduction of transportation costs) � Registration process of the green fertilizer and costs? 27
REGULATIONS (Major driver in Europe on many issues) � ITALY � Decreto Legislativo 29 aprile 2010, n.75 � In addition, any fertilizer producer should subscribe to the “ Fertilizer producer Registry” � Today, it is possible to submit the registration request through an on-line form called “ S IC procedure” , linked to MiPAAF website � Moreover, for the Italian Legislation, the Green Fertilizer might be considered as a digestate, and therefore subj ected to all limits and legislation concerning it � Digestate cannot be sold to other farms, but only applied to the land with special permit and application plans. � The registration is free but the analysis has an average cost comprised between 3000 and 4 000 € and it can take from 2 to 3 years 28
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