manure case studies – Livestock and Poultry Environmental Learning Community

March 5, 2019August 14, 2019

Blue Flame Boiler on Windview Farm in Snyder County, Pennsylvania

The Blue Flame boiler was installed by Total Energy Solutions on Windview Farm in Snyder County, PA, in 2015 as a demonstration project for the Farm Manure-to-Energy Initiative. This technology has the longest track record for using poultry litter as a fuel in the Chesapeake Bay region.

The boiler installed in 2015 was designed to deliver 1.5 to 2.0 MBtu/hr of heat to poultry housing via hot water. It replaced an earlier Blue Flame boiler that had been running on the farm for several years and improved the hot water distribution system.

The Farm

Windview Farm, owned by Mac Curtis, produces antibiotic-free broiler chickens. Since 2010, he has been using a boiler manufactured by Blue Flame to generate heat from the 400 tons of poultry litter that are produced on the farm every year.

Performance Evaluation

The Blue Flame boiler was evaluated for technical, environmental, and financial performance. An overview of the findings is available in the main body of the 2016 Final Report. Details are in Appendix D.

The report includes an evaluation of air emissions from this and other systems, as well as the potential for transporting and marketing the ash co-product as a crop fertilizer.

More Manure-Based Energy Case Studies

This case study was funded by the National Fish and Wildlife Foundation (NFWF), the USDA, U.S. EPA, and Chesapeake Bay Funders Network. The views and conclusions contained in materials related to the Farm Manure-to-Energy Initiative are those of the authors and should not be interpreted as representing the opinions or policies of NFWF, the USDA, U.S. EPA, or Chesapeake Bay Funders Network. Mention of trade names or commercial products does not constitute endorsement by project funders.

March 5, 2019March 20, 2019

How Farmers and Ranchers Are Adapting to Local Weather Extremes

Most farmers and ranchers are acutely aware of weather and how it factors into their risk management planing. Climatologists have indicated that the trend toward more extreme events and greater extremes is going to continue. This has many implications for animal agriculture producers. The farmers featured in this Waste to Worth panel all provided their perspectives on adapting to extreme events through diversity, building resilience, and keeping an eye toward long-term profitability.

Diversity, Resilience and Manure Management with Cover Crops

A former ag teacher, Keith Berns understands that you need to be open to multiple ways of achieving a goal. His desire to build resilience into his farm system led to a business selling cover crop seeds that emphasize diversity. He outlines several scenarios where he uses cover crops on his farm and also several ways his seed customers utilize diverse cover crop and annual forage mixes. High stocking densities naturally incorporate manure, and residue helps conserve and hold valuable moisture during/after extreme rainfall events. [Nebraska/Kansas]

Perspectives On a Changing Climate

Dr. Sandra Matheson, DVM (retired) raises grass-fed beef cattle on her northwestern ranch. Weather extremes have created more dust, mud, and she has seen an increase in disease and health issues with cattle. She utilizes the decision-making process, holistic management, and planned grazing to create a system with the greatest amount of adaptability and resilience for her environment and its potential extremes. Her goals converge around building the soil. [Washington]

Grazing Dairy Finds Plants that Work in Low Water Environments

Michael DeSmet watched his cows when they entered a new paddock and noticed something surprising – they liked weeds. Upon further investigation, he found out that the weeds they were selecting were high-protein, palatable, and could survive on very small amounts of precipitation. Michael was no stranger to making changes; he had already converted the family dairy operation into a grazing-based system selling milk into niche markets. He continues to examine forage options for his pastures that allow the farm to utilize limited water, extend the grazing season, and improve soil quality. [New Mexico]

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. 2015. Title of presentation. Waste to Worth: Spreading Science and Solutions. Seattle, WA. March 31-April 3, 2015. URL of this page. Accessed on: today’s date.

March 5, 2019August 14, 2019

Global Re-Fuel Furnace on Rohrer Farm, Lancaster County, Pennsylvania and Weaver Farm, Pendleton County, West Virginia

The Technology

The Global Re-Fuel furnace (PLF-500) by Wayne Combustion Systems was installed on two farms in 2014 as demonstration projects for the Farm Manure-to-Energy Initiative. The furnace uses poultry litter as a fuel and was designed to deliver heat via hot air to poultry housing.

The Farms

Mark Rohrer’s poultry houses in Lancaster County, PA, are on land that has been farmed by his family for generations. Mr. Rohrer owns two broiler houses with a solar panel array to offset the poultry operation’s electricity usage. He purchases propane independently and, except for a modest contribution from the integrator, pays for heating out-of-pocket. (See upper slideshow)

Mike Weaver grows broiler chickens in two poultry houses in Pendleton County, WV, that are retrofitted with energy efficiency improvements. His farm includes a pond, 80 acres of pastures, and upland wildlife habitat conservation. The farm produces approximately 300 tons of excess litter every year that are stored in the covered litter shed and sold off of the farm. (See lower slideshow)

Performance Evaluation

The Global Re-Fuel combustion system was evaluated for technical, environmental, and financial performance. An overview of the findings is available in the main body of the 2016 Final Report. Details are in Appendix A.

The report includes an evaluation of air emissions from three thermal manure-to-energy systems, as well as the potential for transporting and marketing the ash co-product as a crop fertilizer.

More Manure-Based Energy Case Studies

March 5, 2019August 14, 2019

Bio-Burner 500 on Riverhill Farm, Rockingham County, Virginia

The Technology

The Bio-Burner 500 by LEI Products was installed in 2015 on Riverhill Farm in Rockingham County, VA, as a demonstration project for the Farm Manure-to-Energy Initiative. The Bio-Burner 500 is a combustion system that uses poultry litter as a fuel.

Hot water from the Bio-Burner delivers heat to a turkey poult house via a radiant floor heating system that is used to supplement heat from a traditional propane heating system.

The 2015 installation modified an existing system, previously fueled by woodchips, to accept poultry litter. These modifications included the addition of a wet scrubber to control particulate matter emissions, as well as modifications to the fuel and ash handling systems.

The Farm

Glenn Rodes grows turkeys for Cargill, raising chicks in a 50’x 624’ brooder house before they are moved into one of four grow-out houses. Each year, the farm produces 240,000 birds, 8 flocks, and 1,560 tons of litter. In 2016, Glenn and Sheri Rhodes, owners of Riverhill Farm, were selected as winners of U.S. Poultry & Egg Association’s Farm Family Environmental Award for the Northeast Region of the United States.

Performance Evaluation

An overview of the project is available in the main body of the 2016 Final Report. Details are in Appendix C. Although long-term technical performance of this unit using poultry litter as a fuel is currently not available, the report includes an evaluation of air emissions from this and other systems.

More Manure-Based Energy Case Studies

March 5, 2019August 14, 2019

Ecoremedy Gasifier on Flintrock Farm, Lancaster County, Pennsylvania

The Technology

The Ecoremedy gasifier ® by Enginuity Energy was installed on Flintrock Farm in Lancaster County, PA, in 2014 as a demonstration project for the Farm Manure-to-Energy Initiative.

The gasifier is a fixed feed rate, chain-grate, air-blown system that uses poultry litter as a fuel. The system is designed to deliver between 0.8 and 1.2 MBtu/hr of heat via hot water to four poultry houses. Syngas generated from the gasification process enters a separate oxidation chamber where it is combusted and delivered to a boiler and used to heat water that is delivered to the poultry houses via a Landmeco hydronic heating system.

The Farm

Flintrock Farm has been in Dan Heller’s family since the 1940s. The 80-acre farm now includes 12 poultry houses with capacity for 330,000 birds. Mr. Heller was one of six poultry producers to receive the 2012 Family Farm Environmental Excellence Award from the U.S. Poultry & Egg Association.

Performance Evaluation

The Ecoremedy gasifier was evaluated for technical, environmental, and financial performance. An overview of the findings is available in the main body of the 2016 Final Report. Details are in Appendix B.

The report includes an evaluation of air emissions from this and other systems, as well as the potential for transporting and marketing the ash co-product as a crop fertilizer.

More Manure-Based Energy Case Studies

Farm Manure Energy Initiative logo This case study was funded by the National Fish and Wildlife Foundation (NFWF), the USDA, U.S. EPA, and Chesapeake Bay Funders Network. The views and conclusions contained in materials related to the Farm Manure-to-Energy Initiative are those of the authors and should not be interpreted as representing the opinions or policies of NFWF, the USDA, U.S. EPA, or Chesapeake Bay Funders Network. Mention of trade names or commercial products does not constitute endorsement by project funders.

March 5, 2019March 28, 2019

Farm Manure-to-Energy Case Studies

Case studies on thermal manure-based energy are an important way for farmers and service providers to learn from each other’s experience. You may also be interested in a summary of interviews with ten farmers who are using manure-to-energy technologies.

To add a case study to this list, please contact Kristen Hughes Evans kristen@susches.org or Jill Heemstra jheemstra@unl.edu.

Ecoremedy Gasifier

Flintrock Farm

Lancaster Co., PA

Read More…

Bio-Burner 500

Riverhill Farm

Rockingham Co., VA

Read More…

Global Re-Fuel Furnace

PA & VA

Read More…

Blue Flame Boiler

Windview Farm

Snyder Co, PA

Read More…

Development of this information were funded by the National Fish and Wildlife Foundation (NFWF), the USDA, U.S. EPA, and Chesapeake Bay Funders Network. The views and conclusions contained in materials related to the Farm Manure-to-Energy Initiative are those of the authors and should not be interpreted as representing the opinions or policies of NFWF, the USDA, U.S. EPA, or Chesapeake Bay Funders Network. Mention of trade names or commercial products does not constitute endorsement by project funders.

March 5, 2019March 3, 2020

Grid Soil Sampling to Guide Manure Application

Why Consider Grid Sampling for Manure Application?

Grid soil sampling for phosphorus and potassium can identify areas in fields with nutrient deficiencies and other areas with sufficient or excess nutrients. Nutrient maps can be used to define areas for manure application or exclusion, using supplemental fertilizer where manure is not applied or does not meet the crop requirements. The overall effect is to increase the fertilizer-replacement value of the manure, conserving its use for nutrient deficient fields and field areas. Related: LPELC Manure Nutrient Management

Each of the case studies was conducted on a Minnesota farm and presents the method to:

determine crop nutrient needs
create manure application and exclusion zones from nutrient maps
estimate the value of manure under whole-field vs zoned application, and
evaluate practices to reduce off-site soil and nutrient loss for the specific field analyzed.

Videos

The case studies do not discuss variable rate manure application, but do assume capability for supplemental fertilizer application, with or without variable rates.