Manure processing – Livestock and Poultry Environmental Learning Community

Purpose

Advanced manure processing technologies offer the potential to enhance the sustainability of these systems by separating manure into various streams for more efficient post-processing management. This presentation will synthesize findings from multiple full-scale studies on manure processing systems, focusing on separation technologies. It will also include recent evaluations of systems designed to treat manure to a quality suitable for discharge into surface waters. The data presented will cover separation efficiencies of key components, system performance, operational challenges, barriers to adoption, and the results of life cycle assessments of the environmental impacts when integrated into dairy facilities. These insights can provide valuable guidance for producers and stakeholders on how to integrate these systems effectively to achieve targeted environmental and operational outcomes.

What Did We Do?

A number of full-scale manure separation systems were analyzed over time to assess the nutrient separation efficiency of each component. This included systems from previously published data as well as two new sites analyzed in 2024-2025.

Site 1. A total of 45 manure samples were collected over 37 weeks from the Aqua Innovations treatment system located in Middleton, WI. Samples were collected from the (1) influent manure (following digestion), the (2) separated solid (screw press)and (3) liquids from the separator (screw press), (4) separated solid (centrifuge), (5) liquids from separator (centrifuge), (6) ultrafiltration (UF) concentrate and, (7) UF treated liquid, and the (8) reverse osmosis concentrate, and (9) clean water discharged.

Site 2. Samples were also collected from a dairy with a Livestock Water Recycling system located in Kiel, WI. Similarly, samples were collected over 45 sampling events from (1) liquid influent entering the inclined screen/roller press (raw manure), (2) liquid effluent following the inclined screen/roller press, (3) solids following the polymer assisted inclined screen/roller press, (4) liquid effluent following polymer assisted inclined screen/roller press, (5) outflow from clarifier, (6) liquid effluent following reverse osmosis (“clean” water), and (7) nutrient concentrate following reverse osmosis.

Samples were collected and shipped to Great Lakes Labs after each week of sampling and manure analyzed for manure total solids (or dry matter), total phosphorus, total nitrogen, ammoniacal nitrogen, potassium among many other sample parameters. Nutrient separation efficiencies were then compared for the entire system and each system component to previously collected data and data reported in literature.

What Have We Learned?

Separation efficiencies vary significantly for each nutrient through the system. Mutiple separation systems in series reduce variability in separation efficiency. Manure nitrogen is primarily removed from advanced treatment components, ultrafiltration and reverse osmosis, while solids and phosphorus are primarily removed in the initial separation stages.

Future Plans

Data will be further analyzed and published in a peer-reviewed journal. The data will also be integrated into a partial life cycle assessment to determine the impact to various environmental impact categories. This will be useful in aiding farmers in selecting processing systems for targeted outcomes in terms of nutrient separation and environmental outcomes.

Authors

Presenting & corresponding author

Rebecca A. Larson, Professor, Nelson Institute for Environmental Studies, University of Wisconsin-Madison, rebecca.larson@wisc.edu

Additional author(s)

Tyler Liskow, Engineer, Nelson Institute for Environmental Studies, University of Wisconsin-Madison; Brian Langolf, Researcher, Nelson Institute for Environmental Studies, University of Wisconsin-Madison; and Horacio Aguirre-Villegas, Scientist, Nelson Institute for Environmental Studies, University of Wisconsin-Madison

Acknowledgements

Newtrient and the USDA NRCS Conservation Innovation Grants for the funding to complete system sampling.

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. 2025. Title of presentation. Waste to Worth. Boise, ID. April 7–11, 2025. URL of this page. Accessed on: today’s date.

Purpose

Manure produced at livestock facilities contains plant essential nutrients, such as nitrogen and phosphorus, which is typically land applied as a fertilizer source for crops near where it is generated. However, in areas of high livestock density, due to the imbalance of nitrogen and phosphorus in manure compared to crop requirements, soil phosphorus concentrations have increased. This has resulted in soil phosphorus legacy issues throughout the Midwest, contributing to water quality issues in surrounding waterways. To reduce phosphorus application near livestock facilities, advanced manure management systems are needed to separate and concentrate manure nutrients, particularly phosphorus, to expand transport distances. In this study, we investigated converting separated anaerobically digested manure solids into biochar through pyrolysis to densify manure nutrients. In addition, we examined the availability of phosphorus from manure derived biochar in a soil incubation study to evaluate its fertilizer potential.

What Did We Do

We collected anaerobically digested manure solids from a screw press separator at a local dairy facility. Manure solids were dried and converted to biochar at two different temperatures (662°F and 932°F). The mass of the dried manure and biochar were determined and samples analyzed for total nitrogen, total phosphorus, and available phosphorus to evaluate densification of manure nutrients.

We additionally evaluated nutrient availability of manure solids and biochar in a soil incubation study. In the study manure solids and biochar were applied at equal agronomic phosphorus rates to two different soil textures (loam and sandy loam). Soils were then incubated for 182 days with samples collected and analyzed Every week for four weeks throughout the period to evaluate phosphorus release over time.

What Have We Learned

We found that converting manure solids to biochar is an effective method for reducing manure mass while retaining the original manure phosphorus content (as shown in Figure 1). However, manure derived biochar had lower available phosphorus following pyrolysis than the original separated manure solids, with the available P decreasing as the pyrolysis temperature increased.

Figure 1: Mass reduction and P content following drying and pyrolysis of manure.

During the soil incubation study, while soils with manure derived biochar application had lower available phosphorus at the start of the incubation period, within 28 days available soil phosphorus reached similar levels to those amended with separated manure solids in both soil textures. While nitrogen was applied at different rates, making comparisons difficult, there were minor changes in soil available nitrogen for manure derived biochar, suggesting no additional nitrogen availability during the incubation period.

Future Plans

We plan to further investigate manure derived biochar as a potential advanced manure processing pathway, by evaluating whether manure derived biochar can provide additional soil benefits, such as reducing nitrogen leaching when amended to agronomic soils and increasing crop yields in field studies.

Authors

Joseph R. Sanford, Assistant Professor and Wisconsin Dairy Innovation Hub Affiliate Researcher, School of Agriculture, University of Wisconsin-Platteville
sanfordj@uwplatt.edu

Additional Authors

Rebecca A. Larson, Associate Professor, Biological Systems Engineering, University of Wisconsin-Madison

Additional Information

Sanford, J., H. Aguirre-Villegas, R.A. Larson, M. Sharara, Z. Liu, & L. Schott. 2022. Biochar Production through Slow Pyrolysis of Animal Manure. University of Wisconsin-Extension, Publication No. A4192-006/AG919-06, I-01-2022.

Acknowledgements

This material is based on work that is supported by the National Institute of Food and Agriculture, U.S. Department of Agriculture, under award number 2017-67003-26055. Partial support was provided by the Wisconsin Dairy Innovation Hub. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the U.S. Department of Agriculture or Wisconsin Dairy Innovation Hub.

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.