Manure management and processing Fridtjof de Buisonjé fridtjof.debuisonje@wur.nl Wageningen UR Livestock Research, the Netherlands Rednex Bucharest, 16-17 May 2013
The Netherlands: a small country on the North Sea 450 inhabitants per km2
Our research: livestock and environment We work on the following themes: atmosphere (gaseous emissions, particulate matter, low-emission animal housing systems); soil (soil quality, water, minerals and fertilisation, pasturing, grassland and feed crops); closing mineral cycles (animal-manure-crop cycles, manure technology). Measurements of gaseous emissions and PM
The issue: meat and fertilizer consumption rising
Manure is a valuable fertilizer. if applied correctly and in the right quantities! But an environmental risk in a surpluss-situation Europe Asia US Corn Belt The densely populated coastal regions of Asia, Africa, America s
Challenge: a better distribution of Phosphorus! G. K. MacDonald, E. M. Bennett, P. A. Potter, N. Ramankutty. Agronomic phosphorus imbalances across the world's croplands. Proceedings of the National Academy of Sciences, USA, 2011
And less nitrogen application...
Phosphorus and nitrogen cause nutrient enrichment and low oxygen levels in coastal waters
EPA (US): Increasing nutrient loads in sweet and salt waters gives increase in algal blooms worldwide..
Effect of excess nutrients on beaches in France and China
The Netherlands: Rapid growth of animal production after WW II (ca. 1950 1980) Increasing incomes, increasing meat consumption + export Uncontrolled manure emissions to air and surface waters; problems (eutrophication, acidification) from ca. 1965 onward Manure policy adopted in 1984. Production rights (poultry & pigs) and milk quota sets limits to animal numbers and milk production. EU-Nitrates Directive adopted in 1991 (groundwater monitoring) EU-Water Framework Directive adopted in 2000 (surface water quality) Environmental improvements since the 1980 s but slowing down 2014: Mandatory manure processing and export or continuing restrictions on animal numbers?! A decision will be taken!
Manure production in the Netherlands Solid poultry manure 1.400.000 tonnes/year Pig slurry Cattle slurry 12.400.000 tonnes/year 54.800.000 tonnes/year Agricultural land 2.300.000 hectares... Surplus nitrogen 119 kg/hectare/year Surplus phosphate 28 kg/hectare/year
Key elements of the NL manure policy: Control of animal numbers (pigs & poultry) and milk production (but what will happen after abolition in 2014/2015?!) Application standards for nitrogen (N) and phosphate (P 2 O 5 ) from animal manure and from chemical fertilizers Manure application ban in autumn and winter Mandatory low-emission storage and application methods Monitoring of manure distribution and export (incl. weighing, GPStracking and chemical analyses of N and P 2 O 5 content of every load) Financial support for R&D on manure management and processing technology Measurement of the environmental effects of the manure policy, feedback and adjustments if necessary...
Nitrate in groundwater, EU-Nitrates Directive 1991 350 measuring points EU-standard: 50 mg NO 3- /liter Nitrate levels in upper groundwater in sandy, clay and peat soils, 1992-2009
Application limits for nitrogen (N) and phosphate (P 2 O 5 ) from animal manure (EU-Nitrate Directive / Water Framework Directive) Nitrogen (N) max 350 kg/ha/year (crop dependant), from animal manure & from chemical fertilizer! max 170 kg N/ha/year from animal manure ( Derogation = max 250 kg for cattle farms with grassland) Phosphate application rate depending on soil phosphate condition: 55 100 kg P 2 O 5 /ha/year (P 2 O 5 = P * 2.29) In the Netherlands the phosphate application rate is limiting >> mandatory export and processing of manure (phosphate)!
Nitrogen efficiency of animal manures and fractions (Chemical fertilizers have 100 % nitrogen efficiency by law!) Cattle slurry (with/without grazing) 45/60 % Pig slurry (on clay and peat/sand and löss) 60/70 % Liquid fraction and muck water ( gier ) 80 % (also for mineral concentrate from Reverse Osmosis) Solid cattle manure (depending on system) 30-60 % Solid pig and poultry manure 55 % Phosphate (P 2 O 5 ) from animal manure / fertilizer 100 %
Example of calculation of fertilizer allowance (on top of the nutrients from animal manure) Arable land (potatoes): max. 170 kg N/ha/year from animal manure Total N-application standard for potatoes: 225 kg N/ha/year Phosphate application standard on arable land: 85 kg P 2 O 5 /ha/year. Pig slurry: 7 kg N/ton and 4 kg P 2 O 5 /ton N: 170 : 7 = 24 ton pig slurry per hectare P 2 O 5 : 85 : 4 = 21 ton pig slurry per hectare Phosphate is limiting! 21 * 7 = 147 kg N from pig slurry, N-efficiency 60 %: 0.6* 147 = 88 kg effective N per hectare, 225 88 = 137 kg N-fertilizer allowance
Slurry spraying is not allowed anymore... Low-emission manure application is the standard
Maximum numbers of animals per hectare (estimates) 2 dairy cows / hectare 20 fattening pigs / hectare 7 sows with piglets / hectare A farm with 200 dairy cows needs approx. 100 hectares A farm with 5.000 fattening pigs needs approx. 250 hectares Not enough land?! Manure distribution or export or processing!
Too much pig and cattle slurry Most livestock farms in the Netherlands produce more manure than is allowed to be applied on their own land Transportation of surplus manure at high cost (5-20 /ton) Dry poultry manure suitable for export and incineration Pig and cattle slurry not suitable for long distance transport Transported pig slurry: 10.000.000 tons per year Transported cattle slurry: 7.000.000 tons per year Slatted floors with slurry storage underneath
Annual slurry production by NL cattle and pigs: Dairy cattle: Fattening pigs: Sows with piglets: 25 tons per dairy cow per year 1.2 ton per pig(place) per year 4.3 tons per sow per year One truck load: 35 tons...
Comparison of some slurries and broiler manure (average figures; beware of variation!) Dry matter (%) Org. matter (%) N-total (g/kg) N-NH 3 (g/kg) P 2 O 5 (g/kg) K 2 O (g/kg) Pig slurry (fatteners) 9,0 6,0 7,2 4,2 4,2 7,2 Pig slurry (sows) 5,5 3,4 4,2 2,5 3,0 4,2 Cattle slurry 9,0 6,8 4,9 2,6 1,8 6,8 Broiler litter 61 51 30 6 17 23
Green Electricity or pellets from dry poultry manure, discussion about sustainability... Poultry manure incineration plant BMC Moerdijk 400.000 t/year, 36 MW e 25 % phosphate in ash > fertilizer Nitrogen & organic matter lost... Subsidized Poultry manure pellets for export 80 % organic matter NPK 5-3-3 + Ca + Mg + S + trace elements Not subsidized
High water content of pig and cattle slurry... % 100 90 80 70 60 50 40 30 20 10 0 Water Pig and cattle slurry Salts Organic matter Water
Manure legislation and anaerobic digestion: Digestate = animal slurry, so the same rules apply! Slurry transport with manure sampling, data registration and GPS
Manure distribution: application only during the growing season Nearby if possible Precision farming with GPS Slurry injection in order to prevent emissions (ammonia, smell)
No manure application during winter!
No manure application in autumn and winter: covered manure storage capacity for 7 month! Manure storage under the barn or outside the barn
Mechanical separation: screw press and decanting centrifuge (as examples) Low separation efficiency Cheap ( 30.000) Low energy consumption Less maintenance Low throughput High separation efficiency Expensive ( 200.000) High energy consumption More maintenance High throughput
Solid fraction, high in phosphate, 25-40 % dry matter Suitable for export, (co)composting, drying and pelletizing or anaerobic digestion
Composting ( biothermal drying ) of solid manure Stable organic matter Reduction of weed seeds and pathogens Suitable for transport and storage (export) High in nutrients N,P, K and other (trace) elements (Mg, Ca, S, Cu, Zn, B, etc.) Attention for nitrogen loss during composting (up to 60 %!)
Processing solid and liquid fraction Solid fraction (high in P) Liquid fraction (most of the N, K) Application as organic fertilizer Anaerobic digestion Drying/composting/pelletizing Incineration (like sewage sludge) Obstacles Cost of drying (=energy) High ash-content Cu and Zn from feed Application as organic fertilizer Biological purification Membrane filtration Evaporation and condensation Obstacles Cost of evaporation (=energy) Disposal of sludge /concentrates Effluent quality (Waterboards) Location (receiving waterbody)
Biological treatment of veal calf slurry (800.000 tons/year) Slurry transport by pipelines to 4 regional installations Nitrogen removal by nitrification and denitrification, phosphate is precipitated into sludge, similar to municipal Waste Water Treatment Plants
Pilot Mineral Concentrate: fertilizer and water from pig slurry Animal slurry Separation Solid fraction (org. fertilizer) Liquid fraction Conditioning (VS removal) Reverse osmosis RO concentrate (NK-minerals) RO permeate (water)
Utilisation of nitrogen from manure surplus (mineral concentrate from reverse osmosis) Crop uptake of nitrogen (max 350 kg N/ha/yr) Nitrogen from manure (170 or 250 kg N/ha/yr) Actual Artificial fertilizer Manure Desired Artificial fertilizer Minerals from manure surplus Manure
Pilot plant for the production of biogas and mineral concentrate from pig slurry and agricultural byproducts Production of NK-concentrate by reverse osmosis
Composition of mineral concentrate, example: Dry Matter g/kg 36.0 Org. Matter g/kg 15.8 N total g/kg 6.9 N NH4 g/kg 6.4 N org. g/kg 0.5 P g/kg 0.2 K g/kg 7.6 RO-concentrate is a N-K fertilizer 7.5% of Total nitrogen is organic... Low content of P
Application of mineral concentrate in potatoe crop
Pilot project Mineral Concentrate Products from animal manure will only be allowed as a substitute for artificial fertilizer if: Nitrogen efficiency comparable to common artificial fertilizer Volatile solids (organic matter) as low as possible ( absent ) Minimal mineral content (e.g. 20 % N) (EU-Fertilizer Directive 2003/2003) European Commission will decide in 2014 whether Mineral Concentrate can be accepted as an EU-fertilizer
Conclusions and outlook (NL perspective): Export of phosphorus is necessary for maintaining actual animal numbers and animal production levels in NL, Decreasing manure space in Germany and France, Only dry and concentrated manure products are fit for long distance transport (dried, composted, pelleted), Poultry manure has the highest potential (energy & export) Incineration of solid fraction from slurry separation is an option, the ashes can be used as a phosphate source Mandatory processing of pig and cattle slurry (2014?) must result in products that can be exported (phosphorus!)
Please remember: groundwater and surface water are used for the production of drinking water!