Whole farm assessment of nutrient extraction from dairy manure

Purpose

While animal manure contains nutrients and organic material that are beneficial for crop production, the concentrations of those nutrients are typically too low to allow economically viable transportation of bulk manures over long distances to where crops are sometimes produced. Therefore, dairy manure tends to be applied to soils near where it is generated. Since phosphorous (P) is conserved during manure handling compared to nitrogen, P concentrations in soils where dairy manure is applied tend to exceed crop demands. Due to the implication that P runoff from agricultural operations plays an important role in the eutrophication of streams and other water bodies, farmers are experiencing increasing pressure and regulation to not apply animal manures to fields that are already overloaded with P.

A possible solution to P overloading is to remove some of the P from manure before it is applied. In testing the MAnure PHosphorus EXtraction (MAPHEX) System Church et al. (2016, 2017, 2018), found that by treating liquid dairy manure with a screw press followed by a decanter centrifuge, 38 – 60% of the P could be removed from the manures of a wide variety of farms. A benefit to this approach is that the P removed, is concentrated into a stackable solid (about 72% moisture) that can be more economically transported to distant fields where P may be in deficit. The remaining liquid and course solids, containing greater than 90% of the manure N, can be beneficially used nearer the source without loading those soils with P. A comprehensive farm-scale evaluation of manure nutrient extraction is needed which can be done using the Integrated Farm System Model (IFSM; USDA, 2022). The IFSM has been used to assess other manure handling strategies along with many farm-scale options for crop, animal and feeding management.

What Did We Do?

We evaluated the whole-farm performance, environmental effects, and potential economic benefit of extracting P from dairy manure using a decanter centrifuge (Rotz et al., 2022). A farm in Pennsylvania with distant cropland was simulated with the IFSM to evaluate the feasibility of extracting P to reduce transport requirements on-farm or to produce a concentrated P product for off-farm use. Three production systems were evaluated with and without the use of centrifuge extraction. The first was the current farm with manure collected by flushing, next was the same farm with manure collection by scraping and the last was a modified farm with scraped manure where only forage crops were produced and concentrate feeds were purchased. Collection by scraping greatly reduced the volume of manure handled by the centrifuge thus reducing operating time and electricity use. Reducing the crop land and removing grain production created an imbalance in nutrient utilization with potential accumulation of P in the farm soil. Under this constraint, use of the centrifuge provided a method for removing a portion of the manure P for export from the farm.

Farm simulations estimated all forms of nitrogen, P, and carbon losses. This included erosion of sediment and runoff of sediment-bound and dissolved P across the farm boundaries. Costs for owning and operating the manure handling systems were determined using the economic component in IFSM. All equipment and facilities were amortized over an economic life and the annualized cost was added to other operating costs to get a total. Manure handling costs included fixed and operating (repair and maintenance, fuel, and labor) costs of the rotary screen, screw presses, and centrifuge. Manure hauling was also an important cost in the assessment because the number of trucks required and hauling distance varied among systems. Hauling cost included the amortized initial cost of trucks and annual costs for truck repair and maintenance, fuel, and operator labor.

What Have We Learned?

On a large dairy farm of 2,000 cows and 3,450 acres of land where manure must be transported to distant cropland to obtain uniform distribution, P extraction with a centrifuge provided a better ratio of nitrogen and P contents in manure used on nearby cropland and reduced transport costs for nutrients applied to more distant cropland. Centrifuge extraction was found to be more practical and economical when used with manure scraped from the barn floor than with flushed manure. Use of the centrifuge was not economically justified with the flush system where large volumes of low concentration liquid manure were handled. When barn floors were scraped, the benefit received through reduced manure volume more than offset the increased costs of owning and operating the centrifuge. To avoid long-term accumulation of soil P on the farm with less land (2,000 cows and 2,720 acres) where concentrate feed (27% of total feed) was imported, centrifuge extraction provided a material with a high P concentration that could be exported from the farm for other uses. Extracting the P in excess of crop needs cost about $1.14/lb P. This was generally greater than the price of phosphate fertilizer, but the extract also included other nutrients and micronutrients of value to crops.

A centrifuge provides a useful tool for extracting and concentrating manure P, but the economic benefit to the producer depends upon the value of the full array of nutrients contained, manure handling practices, and the end use of the extracted material. Although marketing this material for its P content alone may not be economical, the material may have other value and the reduction in long-term risk of surface water eutrophication has a less well-defined economic benefit to society.

Future Plans

The IFSM provides a tool for evaluating the performance, environmental impacts and economics of beef cattle and dairy production systems. The addition of the new component for modeling manure nutrient extraction technologies provides a tool for evaluating the whole farm costs and benefits of various technologies being developed or proposed for on-farm use. These can include manure processing based upon dissolved air floatation, evaporation, ultrafiltration, and the full MAPHEX system.

Authors

Alan Rotz, Agricultural Engineer, Agricultural Research Service, USDA

Corresponding author email address

al.rotz@usda.gov

Additional authors

Michael Reiner, Support Scientist, Agricultural Research Service, USDA; Sarah Fishel, Support Scientist, Agricultural Research Service, USDA; Clinton Church, Chemist, Agricultural Research Service, USDA

Additional Information

Church, C. D., Hristov, A., Bryant, R. B., Kleinman, P. J. A., & Fishel, S. K. 2016. A novel treatment system to remove phosphorus from liquid manure. Appl. Eng. Agric. 32: 103 – 112. doi:10.13031/aea.32.10999

Church, C. D., Hristov, A., Bryant, R. B., & Kleinman, P. J. A. 2017. Processes and treatment systems for treating high phosphorus containing fluids. US Patent 10,737958.

Church, C. D., Hristov, A. N., Kleinman, P. J. A., Fishel, S. K., Reiner, M. R., & Bryant, R. B. 2018. Versatility of the MAnure PHosphorus Extraction (MAPHEX) System in removing phosphorus, odor, microbes, and alkalinity from dairy manures: A four-farm case study. Appl. Eng. Agric. 34: 567 – 572. doi: 10.13031/aea12632

Rotz, C.A., Reiner, M., Fishel, S., & Church, C. 2022. Whole farm performance of centrifuge extraction of phosphorus from dairy manure. Appl. Eng. Agric. In press.

USDA-ARS. 2022. The Integrated Farm System Model, version 4.7. University Park, PA: USDA-ARS. Retrieved from https://www.ars.usda.gov/northeast-area/up-pa/pswmru/docs/integrated-farm-system-model

Acknowledgements  

This work was supported by the U.S. Department of Agriculture, Agricultural Research Service.  USDA is an equal opportunity provider and employer. The authors thank the producer who contributed characteristics of their farm for this assessment.

 

The authors are solely responsible for the content of these proceedings. The technical information does not necessarily reflect the official position of the sponsoring agencies or institutions represented by planning committee members, and inclusion and distribution herein does not constitute an endorsement of views expressed by the same. Printed materials included herein are not refereed publications. Citations should appear as follows. EXAMPLE: Authors. 2022. Title of presentation. Waste to Worth. Oregon, OH. April 18-22, 2022. URL of this page. Accessed on: today’s date.

Farm-System Modeling to Evaluate Environmental Losses, Profitability, and Best Management Practice Cost-Effectiveness

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Abstract

To meet Chesapeake Bay Total Maximum Daily Load requirements for agricultural pollution, conservation districts and farmers are tasked with implementing best management practices (BMPs) that reduce farm losses of nutrients and sediment. The importance of the agricultural industry to the regional economy highlights the need for determining cost-effective BMP solutions given the geographical and operational characteristics of these farms. This study evaluated both the environmental risk and farm profitability of common farm-level management practices for three major farm types in the region: crop, tractor-based (“English”) dairy, and horse-drawn (“Amish”) dairy.

Whole-farm simulations were conducted with the Integrated Farm System Model, a multi-year, process-based simulation model, to facilitate a broader understanding of the challenges for the farmers in finding financially feasible and environmentally sustainable solutions. Strip cropping, conservation tillage, cover cropping, and nutrient management BMPs generally reduced nutrient and sediments losses from all three farm types. However, scenarios that reduced phosphorus and sediment losses generally promoted more leaching of nitrogen. Double cropping corn with winter wheat combined with improved nutrient management was the most profitable practice for the crop farm, increasing average farm profitability by 92% over the baseline condition, while reducing combined nitrogen and total phosphorus losses by 13% and 23%, respectively.

Net profitability of the dairy farm was increased only by decreasing manure storage or using improved nutrient management. For the horse-drawn dairy, cover-cropping and harvest of rye silage combined with increased nutrient management provided the greatest increase in farm profit (+8%) and also reduced phosphorus and nitrogen losses.

Horse-drawn machinery through puts and increased human labor hours were required to simulate a typical Lancaster Old Order Amish dairy operation in Southeastern Pennsylvania.

Why Study Farms As a System?

Because southeastern Pennsylvania is a significant environmental contributor of the Chesapeake Bay, agricultural land management is under intense scrutiny by restoration groups. It is imperative to improving water quality that economically and culturally acceptable nonpoint source control practices be explored, developed, and evaluated. This is true for “contemporary” crop and dairy farms in the region as well as those that are more conservative in their use of electrical- or gas-powered farming equipment, described in this study as “Lancaster Old Order Amish”. Evaluation from a whole-farm perspective enables practical assessments of tradeoffs among management practice combinations and is particularly relevant when effectiveness relies on the willingness and dedication of the farm operators.

What Did We Do?

The expertise of regional conservationists and pooled results from farmer surveys were used to determine three major farm types in southeastern Pennsylvania and design potentially acceptable management combinations for each type. Three baseline farms were described: 400 ha corn-soy-wheat crop farm; 100 cow, 120 ha contemporary dairy; and 24 ha Lancaster Old Order Amish dairy. Whole-farm impacts were assessed with the Integrated Farm System Model (IFSM), a multi-year, process-based simulation model. Environmental tradeoffs between nitrogen, phosphorus, and sediment losses were evaluated and financial cost-benefits through change in annual net return for the farmer were analyzed.

What Have We Learned?

Strip cropping, conservation tillage, cover cropping, and improved nutrient management generally reduced nutrient and sediment losses from all three farm types. However, scenarios that reduced phosphorus and sediment runoff losses generally increased nitrogen leaching to groundwater. Double cropping corn and winter wheat under improved nutrient management was the most profitable combination for the crop farm, increasing average farm profitability by 92% over the baseline while reducing combined nitrogen and total phosphorus losses by 13% and 23%, respectively. Net profitability of the contemporary dairy farm was increased only by decreasing manure storage or using improved nutrient management. For the Lancaster Old Order Amish dairy, cover-cropping and harvest of rye silage combined with increased nutrient management provided the greatest increase in farm profit (+8%) and also reduced phosphorus and nitrogen losses.

Future Plans

Cost-effective recommendations from a whole farm perspective that account for unique characteristics of particular farm types can aid officials in determining locally agreeable methods for efficiently addressing regional priority pollutants. As farms adopt and implement suggested management changes, additional management practices of interest can be evaluated. Also, IFSM is being expanded to consider air emissions and carbon sequestration effects of the management practices.

Authors

Tamie L. Veith, Agricultural Engineer, USDA-ARS, tamie.veith@ars.usda.gov

Andrew D. McLean, Water Resources Designer, McCormick Taylor, Inc.

C. Alan Rotz, Agricultural Engineer, USDA-ARS

James M. Hamlett, Professor of Agricultural and Biological Engineering, The Pennsylvania State University

James S. Shortle, Distinguished Professor of Agricultural and Environmental Economics, The Pennsylvania State University

Additional Information

Integrated Farm System Model: http://www.ars.usda.gov/Main/docs.htm?docid=8519

McLean, A. D., 2012. Modeling best management practices on representative farms in Southeastern Pennsylvania. Master’s thesis, PA State University, University Park, PA. https://etda.libraries.psu.edu/paper/14093/, available Dec. 05, 2012.

Acknowledgements

This work contributes to the Conservation Effects Assessment Project (CEAP), jointly funded, coordinated, and administered by United States Department of Agriculture’s Natural Resources Conservation Service, Agricultural Research Service, and National Institute for Food and Agriculture. We would like to thank Mike Hubler and Larry Baum from Dauphin County Conservation District and officials at Lancaster and Lebanon County Conservation Districts for their advice and guidance categorizing and characterizing farms of Dauphin County and southeastern Pennsylvania. Thanks also to Kristen Saacke-Blunk and Matt Royer from Conewago Creek Collaborative Conservation Initiative for their time and input.  Mention of trade names or commercial products in this publication is solely for the purpose of providing specific information and does not imply recommendation or endorsement by the U.S. Department of Agriculture. USDA is an equal opportunity provider and employer.

The authors are solely responsible for the content of these proceedings. The technical information does not necessarily reflect the official position of the sponsoring agencies or institutions represented by planning committee members, and inclusion and distribution herein does not constitute an endorsement of views expressed by the same. Printed materials included herein are not refereed publications. Citations should appear as follows. EXAMPLE: Authors. 2013. Title of presentation. Waste to Worth: Spreading Science and Solutions. Denver, CO. April 1-5, 2013. URL of this page. Accessed on: today’s date.