Innovations in 2022

Projects implemented in 2022 included:

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Agricultural innovations

• Satellite crop monitoring 

Analysis of satellite images providing farmers with information on the condition of field crops and their temporal and spatial variation. In this way, we support precision farming across soil analysis, fertilizer application, sowing, and plant protection. Introduced in collaboration with SatAgro, the service helps farmers keep track of agricultural treatments and maintain yield maps. In 2022, the programme covered 229 farms cooperating with the Grupa Azoty Group, spanning approximately 63,000 hectares. 

• Soil scanners

Our goal is to precisely match fertilizers with specific farmlands. To this end, we use SoilCares, advanced soil scanning devices, through which we can precisely communicate fertilizer recommendations to our farmer partners within minutes, helping them choose the best fertilizer based on the crop and timing, and boosting agricultural productivity. In 2022, 769 farms used our soil scanning service, with 5,616 soil scans performed. 

• Precision farming in Peru

We engaged in discussions with the Embassy of Peru regarding potential cooperation in the field of precision farming. The Peruvian agricultural sector aims to align its local regulations with the requirements and commitments of the European Green Deal. 

• New products based on urease inhibitor – AZOVILEN® S and AZOVILEN® G 

In 2022, Grupa Azoty CHORZÓW began to market two new products: AZOVILEN® S and AZOVILEN® G, developed in cooperation with the Research and Development Centre of Grupa Azoty S.A. through the ‘Research to develop new formulas for preparations based on urease inhibitor’ project.

AZOVILEN® G is a liquid nitrogen stabilizer, an additive to solid nitrogen fertilizers containing urea nitrogen. The EU fertilizing product is based on NBPT as an active substance, its concentration fine-tuned to optimise the product’s efficacy. Its application reduces urease activity in soil, which prevents excessive (quick) transformation of urea into ammonia and carbon dioxide, reducing their emissions into the atmosphere. This increases the efficacy of nitrogen in the fertilizer, improving crop yields and quality. Having secured a positive decision from the Polish Centre for Testing and Certification, AZOVILEN® G may be placed on the European market and sold in all member states of the European Union without additional registration.

AZOVILEN® S is a liquid nitrogen stabilizer, an additive to nitrogen fertilizers containing amide nitrogen. It is designed for use with urea-ammonium nitrate solutions and to coat urea granules.

• New fertilizer product Polist

Grupa Azoty Police is preparing the market launch of Polist, a liquid foliar fertilizer with an 18% amide acid content (absorbed through the leaf surfaces instead of the roots). The fertilizer is recommended for all species of crop plants, including winter and spring cereals, winter rape, maize, potatoes, grassland, as well as vegetables and fruit. Rapidly releasing nitrogen into plants, Polist does not replace but supplements the soil application of nutrients. 

• Biodegradable anti-caking agent

We conducted industrial production tests on a biodegradable anti-caking agent for fertilizers. In 2022, the project was in the pre-investment analysis phase, as many Group companies had expressed interest in adding the product to their portfolios.

• Utilisation of by-pass dust from cement plants 

In 2022, we validated our technology for obtaining potassium chloride from by-pass dust generated at cement plants. We also commenced technical and economic analyses of its industrial-scale deployment.

• Humic acid line 

In 2022, we launched commercial production of humic acids for Tohumus® (the main product). The new line was developed through research work carried out at the Grupa Azoty Research and Development Centre in Tarnów. We are developing further products, and we have confirmed that Tohumus® can be applied with Polist foliar fertilizers containing selected microelements. The project is an element of our process of aligning with the requirements of the European Green Deal.

Tohumus makes it possible to introduce humic compounds into soil and produce more quality food, while improving soil fertility. The product supports regenerative agriculture by recreating and maintaining crop yield potential. The efficacy of Tohumus was confirmed by the Institute of Soil Science and Plant Cultivation – State Research Institute in Puławy and by the National Institute of Horticultural Research in Skierniewice.

We obtain humic acids by using our proprietary technology to produce growth stimulants from lignite, a natural raw material. 

• Granulated fertilizer unit 

In 2022, we started the pre-commissioning and commissioning procedures on the second line for mechanical granulation of nitrate at Grupa Azoty Puławy. Both lines are expected to achieve an estimated daily production capacity of 1,200 tonnes of mechanically granulated nitrate or 1,400 tonnes of CAN. The first line was launched in June 2021, as one of the largest fertilizer projects completed over the recent years in Poland, creating new jobs at Grupa Azoty Puławy.

The plant’s output of mechanically granulated ammonium nitrate and calcium ammonium nitrate is expected to satisfy the growing demand from large-scale agriculture in Poland and Europe. The application of fertilizers in the form of larger-diameter granules allows a wider spread pattern, which improves sowing efficiency, especially on large farms. Such fertilizers are products of first choice for foreign customers, and demand for them is expected to grow also in the Polish market given the ongoing land consolidation process.

• Technology for obtaining potassium thiosulfate 

Grupa Azoty Puławy introduced an innovative technology for the production of potassium thiosulfate using flue gases from sulfuric acid plants and production of potassium thiosulfate-based compound liquid fertilizers. It helps reduce emissions of sulfur dioxide and nitrogen oxides into the atmosphere by approximately 90%, aligning with the circular economy model. In May 2022, the final report on the project work was accepted by the National Centre for Research and Development (NCBiR). In November 2022, Grupa Azoty Puławy started an upgrade of its alkaline absorption unit at the Sulfuric Acid Department and construction of an industrial-scale potassium thiosulfate unit. 

Production innovations 

• NOx reduction technology

A new technology was developed to reduce emissions from the ammonium nitrite unit. The solution, which involves re-reacting NOx emitted by the unit to obtain an additional amount of ammonium nitrite, has successfully passed the pilot phase. Its implementation was started in 2022, with technical documentation process now under way. 

• Adipic acid production

In 2022, work was continued at Grupa Azoty Puławy to restore domestic production of adipic acid, implemented as a collaborative project with the Silesian University of Technology. In 2022, the project team was additionally joined by Consultchem Design. The new acid production method is expected to be environmentally friendly, significantly reducing nitrogen oxide emissions compared to the conventional process. 

• Fifth line of the nitric acid unit

In 2022, Grupa Azoty Puławy continued the construction of a fifth line of its nitric acid unit. The production, auxiliary, and engineering facilities were completed, and process equipment was installed. The work progress is estimated at 70%. Under the same project, the Group has completed the construction of a new neutralisation unit and is upgrading one of the four nitric acid lines. 

• Utilisation of hydrogen 

In 2022, Grupa Azoty Police was implementing a project to utilise hydrogen from its propylene production unit, part of the ammonia facility. It will reduce the amount of natural gas consumed in the ammonia production process, bringing down carbon dioxide emissions. The project is scheduled for completion at the end of 2023.

• Expansion of the Oxoplast™  segment’s product portfolio

In 2022, Grupa Azoty Police launched commercial production of the Oxoplast™ segment’s new products: Oxofine™ TOTM and Oxofine™ Poly2K, the first polymeric speciality plasticizer to be offered by the Group. The former’s main applications are in the production of electric cables and wires, the automotive industry and medicine. It is highly resistant to chemicals and high temperatures. As for Oxofine™ Poly2K, it is intended for use in plastics processing, including the production of toys, cables, wires, garden hoses, textiles, paints, varnishes, etc. 

Other innovations:

• Laboratories of the Future

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Grupa Azoty S.A. signed a cooperation agreement with SEB-COMP under the Laboratories of the Future programme implemented by the Polish Ministry of Education and Science together with the GovTech Centre at the Prime Minister’s Chancellery. The cooperation is to involve initiatives raising the awareness of incremental technologies, in particular FDM/FFF, among teachers and students. The training aids will include materials and filaments produced by Grupa Azoty S.A. 

• New Energy Concept in Kędzierzyn-Koźle

Two projects were completed within the New Energy Concept framework, with a total investment value of PLN 36.1 million, located on the premises of the Ammonia Department at Grupa Azoty Kędzierzyn. The ‘Upgrade of the ammonia liquefaction unit’ and ‘Replacement of K-2 and K-3 ammonia gas compressors with electric units’ are part of the New Energy Concept, one of the company’s key investment programmes.

• Development of 3D printing technology 

In 2022, we added recycled filaments to our range of 3D printing materials to meet the demand from 3D print users. The new Tarfuse® rPLA line comprises filaments made from 100% industrial recyclate granules derived from residual waste recycling. In addition, we expanded our portfolio of 3D printing products to include light-curing resins. We also validated the use of the SLS polyamide powder technology in 3D printing and initiated work to enhance the process economics. 

• Biodegradable and compostable polymers line

Grupa Azoty S.A. is the first company in Poland to have launched a line of biodegradable and compostable polymer granules. The new envifill® line has been developed based on the Grupa Azoty Group’s with no plasticizer content for obtaining thermoplastic starch made from bio-renewable and compostable materials with no plasticizer content. Envifill® products are designed for applications in extrusion blow moulding, injection moulding, and other technologies, including 3D printing. In 2022, we launched a pilot plant for the production of envifill®, with a particular focus on the product range dedicated for blow moulding and injection moulding applications. Thanks to the relevant certification process, the products can be sold on the market of dry food packaging. A TUV certification process was also initiated in 2022 to confirm that the products are biodegradable, meeting the expectations of our business partners. 

• KAPROPOL 

In 2022, Grupa Azoty Puławy was completing work on the KAPROPOL project, an innovative technology to obtain ε-caprolactone – a biodegradable monomer for the production of polycaprolactone (PCL), which is used, for instance, in medical applications. Front-end engineering is now under way for a pilot plant with an annual capacity of 200-500 tonnes, operating in a continuous system. At the same time, a preliminary estimate of capital expenditure was prepared for a commercial-scale plant with an annual capacity of 5,000 tonnes. In order to obtain missing data for the design, additional testing was conducted on specific parameters of individual processes within the technology under development. 

• Green amber

We continue our efforts to develop an environmentally friendly technology for the production of succinic acid. We aim to develop a succinic acid biosynthesis method using a safe and highly efficient microbiological biocatalyst that could be used to process renewable and waste materials. In 2022, we began scaling up the succinic acid production process to a demonstration bioreactor level. The research will underpin a separate investment project involving the construction and commissioning of a production facility based on the developed biosynthesis technology.

• Plastics Application Design and Development Centre 

The Plastics Application Design and Development Centre is an organisational unit of Grupa Azoty S.A., established in 2022 following transformation of the former Plastics Laboratory. Its role is to develop and adapt the plastics portfolio to constantly evolving market needs and requirements in close cooperation with our customers buying engineering plastics and with the Grupa Azoty Group’s production units. The Centre’s activities include: 

• plastics design and testing, 
• cooperation with customers throughout the process – from product inquiries to final application, 
• technical support services concerning material selection, processing, and use, 
• offering innovative materials, 
• quality control and assurance for the offered materials, 
• assessing conformity with the requirements of various industries. 

The Centre operates based on an Integrated Quality, Environmental and Safety Management System certified according to ISO 9001, 14001, 45001, as well as the IATF 16949 automotive system, which is now being implemented. The Centre’s offering includes commercial services involving specialist research and analysis of engineering plastics. 

In 2022, the Centre researched and developed new types of modified plastics, based mainly on polyamide 6 produced by the Group. 

• Introduction of ISCC+

The Grupa Azoty Group has successfully passed a certification audit of the International Sustainability & Carbon Certification Plus (ISCC+) system. With this system, the Group will be able to deliver to its customers certified plastics with a significantly lower carbon footprint, produced from bio-based feedstocks such as biophenol, biocyclohexanone, and biocaprolactam. The standard covers the use of sustainable feedstocks, semi-finished products and products (including circular ones) in industrial production. The objective of the ISCC Plus standard is to reduce the consumption of fossil resources in favour of renewable materials. 

• Development of new generation catalyst

In 2022, we developed a new generation catalyst for a low-temperature hydrogen and syngas production process. Its performance was confirmed in industrial settings, in a low-temperature water-gas shift reaction, on one of Grupa Azoty S.A.’s operating industrial reactors. Deliverables of the project, which was co-financed by the National Centre for Research and Development, are expected to be commercialised in the coming years.