Success stories in nutrient recycling and stewardship by the European Sustainable Phosphorus Platform (ESPP)

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www.phosphorusplatform.eu
Success Stories in nutrient recycling and stewardship
by the European Sustainable Phosphorus Platform (ESPP) info@phosphorusplatform.eu
1. Overview success stories
2. Véolia UK: fertilisers from wastes
3. Newtrient manure processing technology catalogue
4. Phytase in animal feed
5. COOPERL / Brittany farmers’ cooperatives manure
processing
6. ”La Belle Bouse” (beautiful cowpat)
7. Géotexia pig manure processing
8. Véolia Struvia struvite phosphorus recovery
9. Suez Phosphogreen struvite phosphorus recovery
10. Italpollina plants nutrition and recycled nutrients
fertilisers
11. Fibrophos UK chicken litter fertiliser
12. SARIA UK – Kalfos animal by-product fertiliser
13. cnp-Technology Water and Biosolids GmbH struvite
phosphorus recovery
14. Mephrec Pilot Plant Nürnberg sludge smelting
nutrient recycling
15. Kanton Zürich ash phosphorus recycling
16. Fertikal, Antwerp, processed manure organic
fertilisers
17. NuReSys struvite phosphorus recovery
18. Waternet Amsterdam West struvite phosphorus
recovery
19. Thames Water – Ostara Pearl struvite
phosphorus recovery
20. Ostara Pearl® Chicago struvite phosphorus
recovery
21. Ecophos P-recycling from sewage sludge ash
22. NutriTrade Baltic local fish nutrient trapping
23. Polonite filter beds for nutrient recovery
24. Romerike Biogas Plant Oslo for household
foodwaste based fertilisers
25. Timac: struvite for maize starter fertiliser
26. Recophos – ICL electrothermal white phosphorus
production
27. REVAQ sewage treatment Certification for sludge
land application
28. KOTO AlgaeBioGas, Llubljana algae farming and
nutrient recycling
29. Friesland Campina milk cooperative phosphorus
recovery from manure
30. Italy bio-waste collection for nutrient rich
compost
31. WWF Baltic Sea Farmer of the Year Award
32. ICL fertilisers fertiliser production using struvite
and meat and bone meal

2European Sustainable Phosphorus Platform
Success story:
Véolia UK: fertilisers from wastes
Pro-Grow:
• 10 UK composting sites producing 200 000 t/year soil conditioners
from green & food wastes
• All grades have “product” status and PAS100 certified
Granulation factory at Livingstone, near Edinburgh – capacity 20 000 t/y
Currently: fertilisers from food industry by-product ashes
liming materials, micro-nutrient fertilisers
Under development:
recycled fertilisers
(End-of-Waste target 2018)

Success story:
Newtrient
manure processing technology catalogue
• Brings together more than half of US dairy production
• 260 manure processing technologies independently evaluated
- Operational on farm? After-sales service? Cost? Case study? …
• 100 now in online catalogue
• 2/3 address nutrient recycling
• Objective to extend to Europe
www.newtrient.com/Catalog/Technology-Catalog

Success story:
Phytase in animal feed
• Enzyme
• Improves phosphorus digestibility (uptake) for non-ruminants
- by 15 – 40% for pigs
- by 20 – 30% for poultry (EU BAT BREF, 2015)
• So reduces P in manure
• Today used in ¾ of Europe’s livestock farms
• DSM: phytase from bio-sourced materials by fermentation
https://www.dsm.com/markets/anh/en_US/products/products-feedenzymes/products-feed-phytases.html

Success story:
COOPERL / Brittany farmers’ cooperatives
• 400 000 t/y manure processed to organic fertiliser product
- 150 000 t composted poultry litter
- 150 000 t dried poultry manure
- 100 000 t pig manure (1 100 farms)
• Adapted to specific crops and exported to other regions of France
• Positive farmer acceptance
• TRAC Emeraude stabling system
Supported by EU Investment Plan
http://www.cooperl.com/en/environmental-solutions

Success story:
”La Belle Bouse” (beautiful cowpat)
• Lyon based startup
• Locally sourced organic fertiliser for households
from cattle manure
• “matured for 9 months like a great cheese”
http://www.labellebouse.fr/

Success story:
Géotexia
• Saint Gilles du Mené, Brittany
• 33 pig farmers
• Methanisation of 70 000 t(wet weight)/y
- pig manure (c. 50% of input), sludges, chicken litter and other agri-food wastes
• 14 000 MWh electricity = 4 600 households
• digestate
- solid-liquid separation (centrifuge, coagulation)
- drying of solids to 80% DM
- osmosis of liquids to < 10mg/l N, irrigation willow energy crop (58 000 m3/y, 14 ha)
- evapo-concentration to mineral concentrate (20% DM)
• French fertiliser homologation obtained for digestate 2013
https://www.anses.fr/sites/default/files/documents/FERTIXIANK_FSIM_2013-0856_Ans.pdf
https://geotexia.wordpress.com/le-digestat/

Success story:
Véolia Struvia
• Struvite recovery
for small-medium sewage works
operating biological P removal
• Compact footprint, limited height (3,5m)
• Turbomix struvite reactor, lamella settler
& bag draining of struvite prills
• Helsingor Denmark 2016
- 70 000 p.e. sewage works
- 60 m3/day treats 100% of works digestate after centrifuge
- produces 36 t/y struvite
http://technomaps.veoliawatertechnologies.com/struvia/fr/

Success story:
Suez Phosphogreen
• Struvite recovery from sewage
• Biological P removal sewage works
with anaerobic sludge digestion
- 2013, Aby wwtp, Aarhus, 84 000 p.e.
- 2015, Herning, Denmark, 150 000 p.e.
- 2017, Marselisborg, Denmark 200 000p.e.
• Advantages
- struvite sale: 250€ - 300€ /tonne
- reduced P-removal chemical costs
- avoidance of nuisance deposits
- reduced sludge volumes
- reduced energy consumption for biological N removal
https://www.suezwaterhandbook.com/degremont-R-technologies/sludge-
treatment/recovery/recycle-phosphorus-from-effluent-to-produce-a-
valuable-fertilizer-Phosphogreen

Success story:
Italpollina plants nutrition
• Range of organic and organo-mineral
fertilisers (liquid & solid),
biostimulants and plant nutrition products
• For conventional and organic farming
• Input materials include:
- processed manures and animal by-products
- food industry by-products, e.g. stillage
- vegetal cakes and meals
- micro-organisms like P solubilizers
• Sales in 80 countries
• 5 plants and R&D laboratories,
• 200 000 t/y organic fertilisers
• 5 Ml/y biostimulants
www.italpollina.com

Success story:
Fibrophos UK
• Bioenergy and fertiliser (ash) from chicken litter
• Since the 1990’s
• Phosphorus, potassium, sulphur, trace elements
• 800 000 t/y chicken litter processed annually
• P shows both immediate and durable crop effectiveness
http://www.fibrophos.co.uk/phosphate-in-fibrophos-fertiliser/

Success story:
SARIA UK – Kalfos
• P-fertiliser and soil conditioner
from combustion of animal by-products (MBM)
• Authorised for arable and grazing land
• 12 000 tonnes/year
http://www.kalfos.co.uk/

Success story:
cnp-Technology Water and Biosolids GmbH
SME, Germany
• 4 installations recovering
Phosphorus as struvite
• Municipal waste water
• Berlin Wassmannsdorf
• Mönchengladbach (DE)
• Echten (NL)
• Amsterdam
http://cnp-tec.com/

• Thermal process for sludge smelting
and transfer of phosphates to the
slag
• CAPEX 3.5 M€
• 500 kg/h sludge
• 12% P2O5 in the slag
• Commissioning Qu3/2017
www.nuernberg.de/internet/krn_mephrec
Success story – 3.5 M€ Investment
Mephrec Pilot Plant Nürnberg

Success story – Kanton Zürich
• 50 M€ Investment
• 72 wwtps now deliver
100 000 t/y dewatered sludge
to central mono-incinerator
- 94% vote “Yes” in local referendum
- commissioned 2015
- delivers 15 000 t/y ash for P-recycling
- 40% operating cost savings by energy efficient dryer
• 3,3 M CHF pilot P-recovery installation under construction
- acid P leaching P, solvent extraction  phosphoric acid
See SCOPE Newsletter 119 and http://www.awel.zh.ch

Success story:
Fertikal, Antwerp
• 180 000 t/y (wet weight) manure
processed to organic fertilisers:
• solid/liquid separation
dried, pelletised
• For agriculture, horticulture
• Distributed
to 25 countries worldwide
www.fertikal.be

Success story:
NuReSys
• SME, Belgium
• 8 installations recovering
Phosphorus as struvite
• Potato processing, dairy,
pharmaceuticals,
municipal waste water

Success story:
Waternet Amsterdam West sewage works
• AirPrex struvite precipitation
• Upstream of sludge digesters
• Operational savings:
150 000 € / year
• Improved sludge dewatering:
250 000 € / year
• Increased methane production
• Achievement of 1 mgP/l discharge

Success story:
Thames Water – Ostara Pearl®
• Slough municipal wastewater treatment plant, UK
• 150 tonnes Crystal Green® fertiliser / year
• High quality slow release fertiliser
www.ostara.com
http://www.aljazeera.com/programmes/earthrise/2014/12/recycling-
phosphorus-2014121693225616272.html

Success story:
Ostara Pearl® Chicago
• Stickney Water Reclamation Plant, Cicero (Chicago), Illinois
• Gulf of Mexico eutrophication sensitive zone
• World’s largest struvite recovery facility
• Three Pearl® reactors
• Treating all digestate
from 4,5 million inhabitants
• Nearly 10 000 tP/year recovered
• WASSTRIP installation underway/
 objective increase P recovery
to 50% of wwtp inflow
www.ostara.com

Success story:
Ecophos P-recycling from sewage sludge ash
• Pilot plant operational Varna, Bulgaria
• Produce DCP (Di Calcium Phosphate) for fertilisers, animal feed
• Full-scale plant under construction Dunkerque, France
capacity: 200 000 t/y DCP from low grade P-rock and ash
• Contract to treat 60 000 t/y ash from Netherlands (SNB – HVC Groep) = 4 000
t/y P
See SCOPE Newsletter 111 and www.ecophos.com

Success story:
NutriTrade Baltic local fish
• Local fisherman incited to catch cyprinids
- restore food web (algal grazing zooplankton)
- remove nutrients from the sea
• Promote new markets for local fish products:
- recipes, chefs, new processing routes & consumer products
• Biogas production from processing by-products
• Cost: c. 66 €/ kgP removed (not inc. sales)
Launched 2015. John Nurminen Foundation / NutriTrade
http://nutritradebaltic.eu/pilots/pilot-fish/

Success story:
Polonite filter beds
Natural calcium silicate
Binds P and reduces pathogens
P-enriched = fertiliser
Use in farm drainage ditches, manure,
septic tank discharge, sewage treatment
 EcoFiltration AB http://ecofiltration.se/
 PhosphoReduc LLC http://phosphoreduc.org/

Success story: Romerike Biogas Plant Oslo
• Since 2012
• 100 000 t/y fertiliser
from commercial & household food wastes
• Sorting (optical, mechanical) –
Thermal hydrolysis (THP) –
Anaerobic digestion
• Biogas used to fuel city buses
1 kg food waste = 0,13 l diesel
http://www.mita.lt/uploads/documents/food_was
te_recycling.pdf

Success story:
Timac: struvite as maize starter fertiliser
• Fertiliser industry added-value for recycled nutrients
• NuReSys recovered struvite from potato processing
• Non-burning, enabling “ultra localisation” next to roots
• Micro-granulation
• Ammonium addition for nutrient balance

Success story:
Recophos – ICL
• Electrothermal production
of white phosphorus (P4)
from sewage sludge / ashes
• High-value raw material for chemicals:
fire safety, electronics, …
• Recophos FP7 pilot project
• Technology acquired by ICL March 2016
www.icl-group.com
http://www.prnewswire.com/news-releases/icl---next-step-towardssustainable-innovation-571973381.html

Success story:
REVAQ sewage treatment Certification
• > 50% Sweden’s sewage goes to REVAQ Certified sewage works
• Sludge digestate quality, monitoring,
information transparency criteria
• 3000 t/year phosphorus recycled to agriculture
http://www.iea-biogas.net/case-studies.html?file=files/daten-redaktion/download/case-studies/REVAQ_CAse_study_A4_1.pdf

Success story:
KOTO AlgaeBioGas, Llubljana
• 13 000 t/y household and industry food waste
converted to biogas
• 30 m2 pilot algae pond fed with digestate
• Algae used for energy production,
fertilisers or bioplastics

Success story:
Friesland Campina milk cooperative, NL
• Biogas production and P-recovery from manure
• Bonus/malus in milk purchase prices
• Funding support for farmers’
manure treatment
investments
www.frieslandcampina.com

Success story:
Italy bio-waste collection
• Novamont bio-degradable polymers
• Separate collection of food waste
• Green garden wastes
• Biodegradable bags
 4.5 million t/year collected
 1.3 million t/y compost
https://waste-management-world.com/a/italian-lessons-in-biowaste-collections
www.novamont.com

Success story:
WWF Baltic Sea
Farmer of the Year Award
www.panda.org/baltic_farmer

Success story:
ICL fertilisers Amsterdam & Ludwigshaven
• Use of secondary materials
in fertiliser production:
- meat and bone meal ash
- struvite
• Objective: 100% by 2025
• Pilot testing successful
• Industrial installations
(storage, handling) planned
www.icl-group.com

Success stories in nutrient recycling and stewardship by the European Sustainable Phosphorus Platform (ESPP)

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