Theme 3 Production of biofertilizer, feedstocks and methods from Denmark. Anne-Belinda Bjerre, senior scientist, Ph.D. Biomass SP April 2012

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1 Theme 3 Production of biofertilizer, feedstocks and methods from Denmark Anne-Belinda Bjerre, senior scientist, Ph.D. Biomass SP April 2012

2 14 essential plant nutrients in a complete biofertilizer Macro-elements: N, P, K, Mg, Ca, S Micro-elements: Cu, Zn, Mo, Mn, B, Fe, Ni, Cl All are essential for life cycle of plants, for biomass production (mainly macro-elements), vitamins and enzyme production (mainly-micro elements)

3 Role of macro nutrients N,P,K Nitrogen (N) The role of Nitrogen in plants cannot be emphasized enough; Nitrogen encourages development of plants, it is responsible for healthy green leaf growth which is the result of the formation of chlorophyll, which is the main unit for the production of carbohydrates, proteins and oxygen. Therefore, plants that exhibit a Nitrogen deficiency will show symptoms like stunted growth and pale green and yellow leaves. There are also claims that Nitrogen controls, the efficient utilization of phosphorous and Potassium. The plant's dependency on Nitrogen can also lead to retarded root growth and resulting in the foliage turning yellow and pale green and increasing the plant s susceptibility to disease. Phosphorous (P) Phosphorous is responsible for cell development and the promotion of good root growth, particularly in fibrous roots, the vigor of the plant. Plants that suffer from a phosphorous deficiency will have poor root development and show symptoms like stunted growth, though it is not as easily recognizable at those symptoms of Nitrogen deficiency. Phosphorous deficiency is also manifested in the leaves that turn purplish in color when it is not the natural foliage or leaf color of that plant, mainly due to the abnormal increase in the sugar content and the formation of anthocyanin. Potassium (K) Potassium is responsible for chlorophyll formation which plays an important part in the strength of cells and encourages flower and fruit formation. Thus Potassium can enhance the ability of the plant to resist plant diseases, insect attacks and cold conditions as Potassium performs a vital role in the formation of starch as well the production and translocation of sugars in the plant. Plants that exhibit symptoms of Potassium deficiency will have like weak stems. Other symptoms of Potassium deficiency include older leaves that are floppy with yellow tips and brown margins. A note of caution though; an excess of Potassium may tend to delay maturity, though, not to be the same extent as nitrogen. From:

4 Types of fertilizers Organic fertilizer bat guano compost peat moss wood ash bone meal manure Biofertilizer (organic fertilizer with added microorganisms) Inorganic Most common is NPK

5 Examples of European Biowaste starch, crops and forrest residues, manure waste, household waste, MSW All feedstocks for biofertilizer

6 Sustainability - Recycle (or renewable) times for biomass feedstocks Feedstocks Algae Agricultural crops Grasses Shrubs Trees Oil, Gas and Coal Recycle time 1 month 3 month 1 year 1 year 1-5 years 5-80 years 200 million years From : The enginnering of chemical reactions. 2 nd ed. Pp532 Oxford, 2005

7 EU27 biowaste generation

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9 Biowaste and crop fertilizer potential N P K Dry matter Other amounts Straw - - 0,8-3 % 90% Lignin 5,4 mio tons Manure 0.4% 0.09 % 0,32% 4,5 % 27 mio tons Algae 0.5% 0.04% 0.02% 15 % Presently low in Denmark Clover 0.72% % Alfalfa 23 kg/ha* Compost % Guano % *plouged in as green crop 0.4-0,8 % % 0.023% 17,5 % Lignin 0,68 % Relativel y high % 3 % 1-3 % % high 25 % 436 million tons in 2006 Worldwide (not much in DK) ideally 70 %

10 Other important plant constituents Protein (nitrogen resources) examples: Legumes (peas, beans, soya, cassava leaves) Algae (micro and macro algae) Grasses (clover, other species) Special crops and herbes (lucerne, lupines) Clover grass is a nitrogen fixating plant and lives in symbioses with mycoriza

11 Nutrient elements in plants Straw stems and leaves contain plant nutrient elements of Macro-elements: K, Na, Ca, Si, Micro-elements: Zn, Cu, Mo, wood biomass wheat straw, corn stover, rape seed straw Rice straw low level medium level high level

12 Straw yields and utilization in Denmark

13 Potassium (K) products Produkt Flydende vinasse Protamylass e Tørret vinasse Kvælstof (N), Kalium (K), Svovl (S), Fosfor (P), Magnesium pct. pct. pct. pct. (Mg), pct. 0,8 21,0 7, ,8 0,8 0,5 0,4 <0,4 21,0 16,0 - -

14 Plant cell walls contain mainly sugar polymers and lignin Sugars are substrate in a biogas reactor and in a compost process Cellulose C6 sugars Hemicellulose C5 sugars

15 Lignin the basic structure of humic acid in soil Lignin has large ion exchange capacity Lignin is similar to humic acid Humic acid/lignin is responsible for fertility in soil Lignin/humic acid is responsible for retainment of inorganic plant nutrients in soil Lignin is hardly biodegradable Lignin is inert in a biogas and bioethanol process

16 Manure and compost are recognized fertilizers and soil improvers in all EU countries

17 Content of nutrients in manure [Ecochem, 2012]

18 Methods for construction of an organic fertilizer in Denmark Combining a biogas and compost facility Production of biogas a renewable energy carrier Recycling of biowaste resources Utilization of energy crops from the fields Production of a mature biological fertilizer Pasterised - free of pathogens Free of unwanted seeds

19 Clark & Deswarte 2008 Lignocellulose biorefinery: Phase I Energy and Fertilizer

20 FEEDSTOCKS (NUTRIENT BASED, SUGAR BASED) Process diagram Biogas Separation Composting Pelletizing Bagging

21 Biogas facility Separation unit Composting facility MANURE CLOVER GRASS Biogas Fiber Fertilizer

22 Biogas process Optimizing the substrate composition Manure (nutrient elements, 6% organic matter, 94% water, phosphorous, all other elements) Plant and plant residues (nutrient elements (K,N), 50-90% organic matter mainly sugars, 50-10% water) Biogas (CH4 + CO2) Nutrient enriched fiber fraction (P, microelements) Water with soluble nutrients (NH3, K,..)

23 Bio-fertilizer production via composting Organic matter is used as a substrate and decomposed by aerobic microorganisms (bacteria, fungi and actinomycetes). Optimization of compost quality is directly linked to the composition and succession of microbial communities in the composting process The process occurs normally for 9 to 12 weeks and it is maintained under aerobic condition as shown in the reaction scheme below. Composting process is controlled by many factors such as carbon/nitrogen (C/N) ratio, physical structure of raw material ventilation rate, moisture content, ph level, temperature, and the provision of essential nutrients. Fresh organic waste + O 2 microbial metabolism stabilized organic mat. (compost) + CO 2 + H 2 O + heat

24 Compost proces Optimizing degassed biofibres from biogas plant to a fertilizer by composting: Addition of straw facilitates air challens and add more nutrient elements (especially K and Si) Addition of other feedstoock and biogas liquid to ajust and optimise the fertilizer with nutrients Addition of a biocatalyst converts NH3 to NH4 by ph reduction and removes odour (Patent Thomsen & Goul, 2006) Semi-drying the final product Pastaurising the final product (no pathogens and seeds left)

25 Pelletetizing Bagging Process continued Fertilizer in pellets Final product Marketing Addition of nitrogen fixating bacteria

26 Proces development Fertilizer standard product to penetrade the market Special designed fertilizer to be used at diffrent climate and soil conditions Design og sale of equipment and plants in EU and Worldwide