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Description
Nitrogen and phosphorus fertilisers widely used in agriculture directly contribute to excessive eutrophication of water bodies, such as lakes and rivers, and consequently also of sea waters. That is a result of rapid leaching of nitrogen and phosphorus compounds into groundwater. WKG is planning to launch a fertiliser to reduce this phenomenon – based on limestone with mineral (clay) additives, to deacidify, mineralise and increase the water capacity of the soil. The new fertiliser will have the ability to bind and then gradually release nitrogen and phosphorus in the soil, and to increase the level of phytoabsorption of these elements for crops. It will significantly slow down and reduce the process of their leaching into groundwater. The most important groups of recipients for our new product will be individual farmers and intermediaries in the fertiliser trade. Next, we are planning to license foreign entities for know-how related to the production of the innovative fertiliser.
The project includes the purchase of mobile mining machines enabling the production of fertiliser in the WKG mining plant. Also, we will purchase development services aimed at adapting our original fertiliser formula to applications in horticulture, and at conducting bench tests on the reduction of cyanobacteria growth and the phenomenon of eutrophication in cold waters. These services will be carried out by our project partner, NIBIO - The Norwegian Institute of Bioeconomy Research.
For the production of this new fertiliser, we will use limestone clay material, which is a waste product from our current production, and that increase the amount of waste reused by our plant by approx. 10,000 tons per year.
Summary of project results
The main objective (technological challenge) of the project was to market an innovative fertilizer (product innovation) based on limestone with the addition of activated meals of clay minerals, which include kaolinite, calcite and other aluminosilicates. This product will contribute positively to neutralizing the phenomenon of water eutrophication. In modern agriculture, modern tillage must meet a number of conditions that allow not only to protect the soil and improve its parameters, but also to have a positive impact on the water environment. Thus, it is very important not only to supply the soil with mineral substances, but it is equally important to improve the soil structure and reduce the soil''s waterlogging and tendency to become sodden. Due to increasingly frequent droughts and water shortages, it is important to reduce water losses in the soil and improve its infiltration capacity. WKG has an innovative lime feed washing plant, where chemical activation with flocculants results in activated kaolinite, which has the ability to bind and then gradually release nitrogen and phosphorus in the soil. With such a product, it will be possible to increase the level of phytoavailability of nitrogen and phosphorus compounds to crops, while maintaining the primary role of fertilizer lime, which is to deacidify and regulate soil water management. The innovative fertilizer also gained new functionalities such as soil mineralization and nutrition, improvement of water retention, and extended duration of action. The addition of the clay fraction in the form of activated kaolinite to the fertilizer improves the physical and physical-chemical properties of the soil, including soil structure, increases the sorption and water holding capacity of the soil, and thus improves water-air relations, important in the context of climate change, including increasingly frequent periods of drought in Europe. It is also important that the formulation of the innovative fertilizer is based on carbonate and silt components that are currently a by-product of the Raciszyn deposit exploitation processes (in accordance with the concept of a sustainable economy with a closed loop and the European Green Deal, and taking into account national and EU legislation). All this accounts for the advantages of the new product over products previously available on the market.
The realization of the project''s objective was achieved through activities related, on the one hand, to the realization of a development service for the creation of an additional technological option for the new product, and, on the other hand, to the realization of investment activities aimed at launching the production and marketing of the new innovative product - a fertilizer based on limestone and activated kaolinite. In addition, a scientific partner from Norway (NIBIO of Tromsoe) tested the possibility of using the product from a cold-water point of view. The implementation of the investment part of the project focused on the purchase of the necessary mobile equipment and the launch of the technological line for the production of the new innovative fertilizer. Purchased were:
- mobile screening machine;
- mobile impact crusher.
The above-mentioned fixed assets are elements of a complete technological line for the production of a new, innovative product. After the commissioning of the completed technological line, the production process of the new product was launched. The project also included a promotional and marketing campaign for the new product and the project.
As part of the information and promotion campaign, four information events were organized, involving, among others, leading Polish scientific institutions involved in the subject of fertilizers, such as the Agricultural University of Cracow, the Polish Academy of Sciences, and the Cracow University of Technology.
The implementation of the project enabled WKG to expand its offer for the agricultural industry with a new, innovative calcium fertilizer with the addition of activated kaolinite, which is a novelty both from the point of view of the Applicant, as well as the market of fertilizer manufacturers and target customers.
The main result of the project is the implementation of an innovative fertilizer based on limestone with mineral (clay) additives in the form of an activated meal of clay minerals (including kaolinite, calcite, etc.), intended for use in agricultural and horticultural production, including organic production. The product is a novelty both from the point of view of the Beneficiary, as well as the market of fertilizer manufacturers and target customers. Thanks to such a product, it is possible to increase the level of phytoavailability of nitrogen and phosphorus compounds to crop plants, while maintaining the basic role of fertilizer lime, which is to deacidify and regulate soil water management. The use of the innovative fertilizer in agriculture will contribute to reducing the adverse phenomenon of leaching of nitrogen and phosphorus compounds into groundwater, which ultimately causes eutrophication of groundwater and seas.
The implementation of the project has brought the company tangible benefits such as:
-proper and effective use of its limestone resources,
-expanding the product range with a high-end fertilizer,
-diversification of production and risk of business operations,
-development of cooperation with scientific units.
In addition, the implementation of the project brought added values on the socio-economic level, such as, among others: an increase in employment and a positive impact on the local environment and community (optimization of the use of owned limestone resources, use and further reduction of the storage of raw materials on the dumps of the production plant).
Summary of bilateral results
As part of the project, Partner Norwegian Institute for Bioeconomic Research (NIBIO) conducted development work on the effectiveness of an innovative fertilizer in offsetting the adverse phenomenon of eutrophication, particularly for the cold sea areas of northern Europe. In particular, the cooperation consisted of:1) Implementation of specific development work within the framework of the project - working in search of common solutions to project challenges. The Norwegian partner carried out within the framework of the project bench tests of the impact of the innovative fertilizer on the reduction of cyanobacteria growth and the occurrence of eutrophication in cool waters (phyto-availability and leachability studies of fertilizers).2) Provide its contribution to the project to the extent of actual expenses incurred under the project.3) Provide the WKG with all information and data required for coordination, auditing, monitoring of project implementation and for reporting purposes.The project has developed a good practice for the fertilizer industry of incorporating the problem of eutrophication into fertilizer operations, something that has been overlooked by the industry to date. WKG and the Norwegian Partner took into account the purpose of calcium fertilizer not only in its nutritional function for crops, but also in its function of preventing the migration of NPK compounds into groundwater and reducing the risk of eutrophication of waters, which is an important novelty in the fertilizer industry. Another important novelty was the consideration of the specificity of cool and warm waters for this phenomenon, which increases the commercialization potential of the product.In addition, the partner''s role was to develop scientific materials and promote the results of the project as part of its scientific and teaching activities. The partner also participated in project events, where he presented, among other things, the results of his research.