New! The FuelCal® technology – now available for everyone

Sewage sludge and organic waste (post-production biomass) management is a problem to solve by every sewage treatment plant, food processing plant, dairy or abattoir. One of the best ways, recommended by law, is to convert the waste on site into a finished marketable product. Not all of the above entities need large and high performance systems.

Many of them, due to the various constraints and conditions, for example, the small volume of sludge or waste produced, poor infrastructure or limited investment budget, are looking for simpler and more cost-effective solutions. Aiming at the producers with this profile, Evergreen Solutions has developed the containerised FuelCal® Mobile line. We come and process waste and the producer, in addition to having the waste problem solved, can also enjoy the profit from selling the finished and renowned OrCal® series product.

Mobile containerised FuelCal® lines – for whom?

Small sewage treatment plants, biogas plants

The containerised FuelCal® Mobile lines are perfect for small, municipal and industrial sewage treatment plants that produce up to several hundred tonnes of sludge per year, for example, 300 tonnes. With the FuelCal® technology, a treatment plant does not have to cover the costs of sludge transport and disposal outside the production site. A finished product of the OrCal® series is produced in the treatment plant, which can be contracted in advance by local farmers.

Medium and small processing plants

In Poland, there are many small and medium processing companies, for example, packing plants, processed fruit and vegetables manufacturers and wineries.

The waste generated by such entities is most often sent for processing for a fee, for example, to disposal, composting and biogas plants. The use of a mobile FuelCal® line can solve this problem in a simple manner: once a month, a containerised FuelCal® line arrives to convert the waste into the OrCal® series product, which is collected by Evergreen Solutions or sold (may be subject to bartering arrangements) to the farmers that supply agricultural products to the processing plant.

Agricultural production facilities

Agricultural facilities often have highly developed production that generates huge amounts of plant and animal waste. What matters is how they manage it. For example, in large pig farms, the FuelCal® technology solves the slurry management problem without the need to build covered lagoons and creating nuisance in the surrounding area. For farms specialised in plant production, waste processing is only possible in their growth periods, for example, after harvesting, and the generated OrCal® product can be used on the farm itself, to improve the soil quality and yield.

Why choose the containerised FuelCal® Mobile line?

• Low infrastructural investment costs
• No need for additional documentation, for example, an environmental report, a building permit design, a site development project etc. (in most cases)
• Investment without building permit (not applicable to the version with a silo with the capacity above 30m3)
• Can be transported on public roads with conventional equipment, such as truck tractor
• Mobility enabling the support of several branches of the plant producing the waste
• Small footprint for operation on small area sites
• Modular line design for long-term, trouble-free and easy operation
• Control and parameter monitoring from a multifunctional control panel or wireless tablet
• Low labour costs
• Favourable return on investment
• Compact design for easy funding with financial instruments, for example, leasing, rent etc.

FuelCal® Mobile – containerised waste treatment line. How does it work?

Version of the set with a reagent silo (with a silo capacity below 30m3, no building permit is required). Evergreen Solutions’ offer also includes kits with a system for unloading a big bag with reagent (this version also does not require a building permit).

OrCal® – the resulting product of the FuelCal® line

Deacidification, fertilisation, nourishment

The FuelCal® process results in organic and mineral products with active calcium hydrate of the OrCal® and OrCal® pHregulator® series. Their characteristics are a perfect match for the problem of degradation of agricultural land in Poland. Much of it is highly acidic and poor in humus layer. OrCal® products dissolve in water almost 100 times better than traditional calcium carbonates, for example, chalk or dolomite. As a result, they increase the soil pH efficiently and quickly by up to 1 pH point in three months, which is a revolutionary result. In addition, with their organic matter content, they are excellent in soil fertilisation and plant nourishment. The application results are already visible in the first crop. This has been recognised by Polish farmers, thousands of whom have already decided to purchase OrCal® products.

Established market position

The unique characteristics of OrCal® products cause the demand for them to increase every year. Evergreen Solutions prioritises their quality, so the production sites follow a strictly defined technological regime. In addition, periodical control tests in science and certification centres are conducted, as well as field tests in the agricultural advisory centres. This appreciated by the farmers, who use OrCal® not only to improve the soil quality, but also to obtain tangible farming gains. The reputation of the OrCal® brand is also a major selling point and profit for production sites.

Winner of numerous industry awards

The investment in quality and reputation pays off. OrCal® products have been repeatedly recognised by farmers and experts, as evidenced by the industry awards, for example, Złoty Żuraw Rolnictwa – an award won at the Central Agricultural Trade Fair in 2016, the Cup of the Managing Director of the National Support Centre for Agriculture in 2019.

Process requirements of the FuelCal® Mobile line

During the two days of the congress, five substantive sessions were held, culminating in panel discussions with more than 30 experts from various fields, including the representatives of the highest authorities in Poland. The total number of participants exceeded 150.

The participants presented the latest trends in the water supply and sewerage industry, discussed the directions of the legislative action and the increasingly stringent requirements of the European Union and the public, among other things. The inspiring best practices in environmental education and model examples of management activity in the water supply and sewage industry were presented at the congress as well.

At the invitation of the organisers, Evergreen Solutions participated in the congress as well. During the formal gala, Vice-President Tomasz Chabelski received a special award for an outstanding company from the organisers. We are very pleased with this award, as it proves that our long-standing collaboration with water supply and sewage entities is much appreciated. Our patented eco-friendly FuelCal® technology for converting post-production biomass from the agricultural and food industry and sewage sludge into calcium and organic agents for agriculture (OrCal® series products) is increasingly popular with customers, want comprehensive and eco-friendly solutions to their waste problem.

How to use biomass to produce valuable fertilisers? How to quickly and safely increase the soil pH level by up to one in three months, how to improve the soil structure and increase the humus level by up to 1%, how to unlock the nitrogen, phosphorus and potassium stored in the soil for the cultivated plants, how to recover up to 500 kg of macro-nutrients from crop residues, how to improve the management economics and make agricultural production more effective and profitable for the farmer? How to reduce the costs related to the transport of fertilisers? How to keep product prices competitive in the era of rising prices? The selection board judged that Evergreen Solutions can respond to all these questions with one single answer, OrCal®. OrCal® is a product that is being systematically developed, made increasingly available to the farmers, included in educational programmes and aimed at healing of the Polish soil.

We are very pleased that such important institutions have noted the activities of Evergreen Solutions under the leadership of President Janusz Zakrzewski, the value of the OrCal® product and its impact on the development of Polish agriculture. The award was granted by:

– the Ministry of Agriculture and Rural Development

– the National Support Centre for Agriculture

– the Agency for Restructuring and Modernisation of Agriculture

– the Agricultural Social Insurance Fund