H2020 NewFert Project: Nutrient recovery from biological waste for fertilizer production
- Type Project
- Status Filled
- Execution 2015 -2018
- Assigned Budget 1.209.520,5 €
- Scope Europeo
- Main source of financing H2020
- Project website NewFert
The first step was an intensive survey of the European industrial landscape (municipal and agricultural waste management) to identify promising sources of bio-based waste. The result was a total of 23 different waste samples, which were analyzed and chemically and physically characterized. Acceptability criteria for potential bio-based waste were defined in order to identify potential new raw materials for fertilizer production.
Much of the work was devoted to studying nutrient recovery from solid waste, providing potentially suitable materials for application and feedstock for fertilizer production. Its primary objective was to identify viable biosolid residues (such as waste incineration ash) to extract phosphorus, nitrogen, and potassium suitable for use as NPK fertilizers, select the optimal chemical extraction process, and design an industrial process for chemical nutrient extraction suitable for use in the existing NPK fertilizer plant. A major outcome of the project was the design of a new chemical nutrient extraction process, including the design and construction of a test bench for its commissioning. The results were used to design an industrial process for chemical nutrient extraction suitable for use in existing NPK fertilizer plants.
Regarding liquid waste, a semi-industrial-scale pilot project was implemented in an anaerobic digestion unit on a pig farm in Morbihan, France, to recover struvite. The resulting bio-based raw materials were granulated to produce NEWFERT NPK fertilizers.
Finally, agronomic trials indicated that the substitution of raw materials generally produced fertilization efficiency similar to that of conventional NPK fertilizers with the same balance.
Regarding the operating results, NEWFERT has developed an innovative technology for recovering nutrients from biowaste in the fertilizer industry. One of these nutrient recovery technologies has been patented by D&M and Fertiberia (EP17382535.7: PROCESS AND INSTALLATION FOR RECOVERING PHOSPHORUS FROM WASTE INCINERATION ASH, embargo date: 02/02/2019).
Proman will expand its consulting expertise in waste as a source of raw materials for fertilizer design.
IRSTEA has developed a new, more efficient technology for phosphate recovery through struvite production. The University of León will develop a more efficient technology for nitrogen reduction using bioelectrochemical systems.
KWB will expand its knowledge of the fertilization process and its consulting capabilities in this area.
Project partners have participated in more than 90 activities throughout the project's lifespan: organizing a conference and workshop, developing a press release, developing a brochure, developing a website, and participating in various conferences, workshops, and a trade fair.
Biowaste represents a significant challenge, as it is underutilized as a potential source of valuable chemical compounds. Turning waste into resources is key to a circular economy. In particular, biowaste valorization is an attractive approach that can offer potentially useful alternatives for waste treatment.
It is essential to contribute to maximizing nutrient management for global sustainable development. From this perspective, the aforementioned advanced valorization strategies, which enable the recovery of valuable chemical compounds from biowaste, are the primary objective in response to the transition toward sustainable and environmentally friendly nutrient management. In this regard, the project's main objective is to develop an innovative concept for the fertilizer industry, strengthening European competitiveness and boosting the potential of the bioeconomy in Europe by developing a new value chain based on bioprocesses for nutrient recovery from waste streams for the manufacture of bio-based NPK fertilizers.
The NEWFERT project involves the design and development of various enabling technologies that allow for the reuse and recovery of biowaste, making it suitable as a secondary raw material in the fertilizer industry.
In this regard, two main processes have been developed: a more efficient technology for phosphate recovery through the production of struvite from liquid streams, and a nutrient recovery process from solid waste that also provides materials for the fertilizer plant.
The main outcome of the project is the development of a new family of bio-based NPK fertilizers, which will be produced at the fertilizer plant. The resulting NPK fertilizers have been agronomically tested in plant trials, leading to the conclusion that, in general, it is possible to replace conventional raw materials with new bio-based ones without reducing fertilizer efficiency.
Biowaste valorization is an attractive approach within the framework of EU waste management policies and the development of a circular economy. Waste from biological streams and various bio-based sources is underutilized as a potential source of valuable compounds. Fertilizers play an important role as suppliers of nutrients, the production of which relies heavily on fossil mineral resources. Furthermore, the European fertilizer industry is heavily dependent on imports of these raw materials, making it vulnerable to supply and pricing policies.
The main objective of the proposal is to develop an innovative concept for the fertilizer industry, strengthening European competitiveness and boosting the potential of the bioeconomy by developing a new value chain that transforms solid and liquid waste, specifically ash from various sources and livestock effluents, into valuable, high-quality products: a new generation of fertilizers.
NEWFERT will focus on a viable and cost-effective industrial nutrient recycling system, developing novel biorefining technologies aimed at increasing nutrient recovery rates and mitigating the environmental and socioeconomic impact of current fertilizers by replacing fossil and non-renewable nutrients with bio-based materials in their composition. Projected benefits also include substantial energy savings and reduced CO2 emissions.
NEWFERT seeks to reduce dependence on raw materials, prevent resource depletion, and reduce environmental impact, significantly increasing the sustainability of the fertilizer industry. The work organization has been designed to connect and achieve successful industrial integration, supported by a robust life-cycle cost analysis. The work plan strategy is based on eight work packages.
The NEWFERT consortium is led by FERTIBERIA and comprises a balanced group of six partners from four European Union member states: bio-based industries, SMEs, research and technology organizations (RTOs), and academic institutions covering nutrient recovery from bio-based waste.
Biowaste suitable for processing as commercial fertilizers by industrial companies has been identified, ensuring the project's potential for significant industrial impact. A 15-20% replacement of the total nutrient volume has been achieved using only recycled nutrients. Conventional solubilization processes have been modified and optimized to achieve maximum extraction capacity and a suitable product for the industry. New technologies for the recovery of P and N from pig slurry have been developed and optimized. These processes will contribute to the technological development of the project thanks to the innovative nature of both extraction methods.
Nutrient recovery may be a preferred option for systems with excess nutrients and streams with high COD, N, and P. In cost estimation, P recovery with a struvite reactor is the most economical option to address excess nutrients.
The introduction of bio-based materials into an NPK plant not only replaces nutrients but can also lead to an environmental benefit due to the production of substituted primary nutrients; however, this margin is initially low, especially in the case of potassium. Given the raw material and energy prices, producing 1 ton of NPK 15-15-15 fertilizer with primary raw material costs €284/t. If nutrients from bio-based secondary waste are used, specific production costs are reduced by 2% to 11%, depending on the secondary material.
To promote large-scale nutrient recovery, it is necessary to ensure that material availability is not limited. Only with certain treatment methods (as demonstrated with AshDec or DMphos) can larger quantities of nutrients be recovered and recycled in the fertilizer industry.
For FERTIBERIA, these and other processes that convert unavailable nutrients into available forms must be specifically evaluated due to the availability of chemicals and energy, as well as in relation to the amount of secondary nutrients that FERTIBERIA needs in Huelva for future projects.
New technologies, products, and value chains will have a socioeconomic impact. The planned transformation in Europe toward a sustainable circular economy will depend largely on sustainable value chains. The project will contribute through sustainable and resource-efficient production schemes, as well as improved fertilizers compared to traditional ones. Improved fertilizer products and fertilization procedures will provide benefits for both human health and the environment.
- FERTIBERIA SA (FERTIBERIA)
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