Smart modular mobile biorefining of manure to zero-waste maximising resource and nutrient recovery for feed and fertiliser bioingredients in rural areas

Project Information

MANUREFINERY

Grant agreement ID: 101157679

DOI

10.3030/101157679

EC signature date 3 May 2024

Start date 1 September 2024

End date 31 August 2028

Funded under

• Food, Bioeconomy Natural Resources, Agriculture and Environment

Total cost

€ 9 337 440,00

EU contribution

€ 7 236 512,50

Coordinated by

INSTITUTO TECNOLOGICO DE ARAGON
Spain

Periodic Reporting for period 1 - MANUREFINERY (Smart modular mobile biorefining of manure to zero-waste maximising resource and nutrient recovery for feed and fertiliser bioingredients in rural areas)

Reporting period: 2024-09-01 to 2026-02-28

Summary of the context and overall objectives of the project

Livestock farming is a crucial pillar of the rural economy in Europe. However, it is also a significant source of pollution, with considerable impacts on air quality and climate change. Each year, Europe produces more than 1.4 billion tonnes of manure, with cattle accounting for 75%, while pigs and poultry contribute around 12% each. The livestock sector is by far the largest primary European subsector responsible for ammonia (NH₃, ~1.5 Mt/year) and methane (CH₄, ~166 Mt/year) emissions. Despite substantial efforts over the past decades, current manure management practices—particularly the direct application of manure to farmland as fertiliser—continue to cause serious environmental problems, including soil degradation, eutrophication of surface waters and contamination of groundwater. In this context, small-scale biorefineries represent a promising opportunity to address these challenges while creating new diversification pathways for rural stakeholders. ManuREfinery aims to deploy a smart, modular, mobile and sustainable small-scale decentralised biorefinery capable of converting livestock manure into value-added bio-based products. These include feed ingredients such as microbial protein, caproic acid and protein-enriched grass cake, as well as bio-based fertiliser ingredients such as sodium nitrate, ammonium bicarbonate and phosphorus-rich ashes. The ManuREfinery solution offers strong scalability and replicability potential through the integration of advanced thermochemical and biochemical modular and mobile feedstock conversion units; digital twin technologies and data science tools to support multicriteria decision-making, process optimisation, scaling-up and replication; a comprehensive sustainability and circularity assessment framework covering economic, environmental and social dimensions; strategies to foster engagement among livestock stakeholders and enhance social acceptance of the solution; and innovative, sustainable and replicable business models to support income diversification in the livestock sector. The ManuREfinery concept will be demonstrated at TRL 6–7 in four real farming environments: two pig farms (Romania and Spain), one dairy farm (Slovenia) and one poultry farm (Romania). By showcasing the solution in diverse livestock systems, the project aims to accelerate the transition of Central and Eastern European regions towards a more sustainable and circular bioeconomy.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the first 18 months, the technical and scientific work focused on the design, engineering, modelling and initial deployment of the three ManuREfinery valorisation lines: liquid, solid and gas. The work has confirmed the technical feasibility of the integrated concept and has provided the basis for the subsequent pilot demonstration phase.
For the liquid valorisation line, manure from the pig demo farm was characterised to define the technical requirements of the processes. This supported the design of the thermophilic anaerobic digester, the biogas fermentation unit, and the nitrogen and phosphorus recovery systems.
For the solid valorisation line, cow manure digestate from the cow demo farm was characterised to support the design of the dryer, gasifier, U-loop fermenter and aerobic fermentation unit for microbial protein production. The work also included the development of a CHP model to evaluate heat and electricity generation from syngas according to farm needs. The solid line has therefore advanced from conceptual design to a fully engineered system for transforming dried digestate into syngas, biochar/ashes and microbial protein.
For the gas valorisation line, ammonia and CO2 emissions were assessed, and the 1 m³ ammonia biotrickling filter was designed as the central technology. The work included pH control, preparation of a nitrifying inoculum with non-pathogenic bacteria, and development of a hybrid model to support predictive operation.
A major achievement is that the basic and detailed engineering of the three valorisation lines has been completed, with P&IDs finalised for the pilot units. In parallel, hybrid models of the main processes have been developed to simulate mass and energy flows and support design, operation and scale-up. These models are being integrated into BioSteam through a dedicated user interface to build the ManuREfinery digital twin.
Initial demonstration activities have also started, including site preparation, construction and installation of pilot units at the demo farms. Although some limited delays have occurred, the main technical objectives remain achievable, and sufficient time remains for pilot operation, validation and calibration of the digital twin with real demo data.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The results achieved during the reporting period already demonstrate significant potential for impact, particularly in advancing circular bioeconomy solutions for the agricultural sector. The completion of the technical design and engineering of the three valorisation lines (liquid, solid and gas), together with the development of hybrid models and the ManuREfinery digital twin, represents a major step towards the deployment of an integrated and scalable manure biorefinery system.
From a technological perspective, the project is expected to deliver a flexible and modular solution capable of converting livestock manure into valuable bio-based products, including fertilisers and protein-rich feed ingredients. The integration of biological, chemical and thermochemical processes within a single system, supported by digital modelling and automation, has the potential to significantly improve process efficiency, operability and scalability compared to existing solutions.
In environmental terms, the project contributes to reducing nutrient losses, greenhouse gas emissions and pollution associated with livestock farming. By recovering nitrogen and phosphorus and reintroducing them into agricultural cycles, the system supports the transition towards more sustainable nutrient management and helps mitigate impacts on water and soil quality.
From an economic and societal perspective, the project opens opportunities for the creation of new value chains in rural areas, enabling farmers to transform waste streams into marketable products. The decentralised and potentially mobile nature of the system enhances its replicability and supports local deployment across different regions. In addition, the production of alternative protein sources contributes to reducing dependency on imported feed and strengthens the resilience of the agri-food system.
Overall, the results obtained so far provide a solid foundation for achieving the expected impacts, with strong potential to support EU policies on circular economy, sustainable agriculture and climate neutrality.