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.

Related: Introduction to Thermal Technologies…

More Manure-Based Energy Case Studies


Farm Manure Energy Initiative logoThis 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.

A Novel Multiple Staged Leachbed Digestion System for the Treatment of Dry-lot Feedlot and Dairy Manures

A multiple staged digestion system capable of digesting drylot manures is currently under development. The system is currently being validated at the pilot scale with three 1.5 cubic meter batch reactors. The system shows promise with various animal manure wastes as well as other common waste products. The first stage of the process is a dry digestion leachbed process in which the hydrolysis of solid waste products is optimized. The liquid leachate produced by the first stage is then transferred to a storage tank where the leachate is accumulated before use in the last stage. The last stage is optimized for methanogenesis and consists of a high rate methane reactor. 

What Have We Learned?

This configuration of system components lends itself to a variety of potential advantages for regional digestion of animal wastes. Wastes of various solids contents can be segregated into the appropriate reactors, with high solids wastes placed in the first stage, moderate solids in the second stage, and primarily soluble wastes can be sent straight to the last stage. This inherent substrate flexibility could enable the construction of regional digesters capable of treating a wide array of wastes. As the solid wastes are dry digested dewatering at the end of the process is less challenging and leads the production of a high nutrient content soil amendment. 

Future Plans

 Plans are currently in the works to begin scaling this pilot system to build a 100-500kw on farm digester system. 

Author

Lucas Loetscher  lloetscher@gmail.com   Colorado State University

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.

Poultry Digestion – Emerging Farm-Based Opportunity

While EPA AGSTAR has long supported the adoption of anaerobic digestion on dairies and swine farms, they have not historically focused on the use of anaerobic digestion on egg laying and other poultry facilities. This has been because the high solids and ammonia concentrations within the manure make anaerobic digestion in a slurry-based system problematic. Development of enhanced downstream ammonia and solids recovery systems is now allowing for effective digestion without ammonia toxicity. The process also generates dilution water, avoiding the need for fresh water consumption, and eliminating unwanted effluent that needs to be stored or disposed of to fields. The system produces high-value bio-based fertilizers. In this presentation, a commercial system located in Fort Recovery Ohio will be used to detail the process flow, its technologies, and the co-products sold.

Why Examine Anaerobic Digestion on Poultry Farms?

The purpose of this presentation is to supply a case study on a commercial poultry digestion project for production of combined heat and power as well as value-added organic nutrients on a 1M egg-layer facility in Ohio.

What did we do?

In this study we used commercial farm information to demonstrate that poultry digestion is feasible in regard to overcoming ammonia inhibition while fitting well into an existing egg-layer manure management system. Importantly, during the treatment process a significant portion of nutrients within the manure are concentrated for value-added sales, ammonia losses to the environment are reduced, and wastewater production is minimized due to recycle of effluent as dilution water.

What have we learned?

In this study, commercial data shows that ammonia and solids/salts levels that are potentially inhibitory to the biology of the digestion process can be controlled. The control is through a post-digestion treatment that includes ammonia stripping and recovery as ammonium sulfate as well as fine solids separation using a dissolved air flotation process with the addition of a polymer. The resulting treated effluent is sent back to the front of the digester as dilution water for the high solids poultry manure. The separated fine solids and the ammonium sulfate solution are dried using waste engine heat to produce a nutrient-rich fertilizer for off-farm sales. The stable anaerobic digestion process resulting from the control of potential inhibitors that might accumulate in the return water, if no post-treatment occurred, leads to production of a significant supply of electrical power for sales to the grid.

Demonstration at commercial scale shows the promise anaerobic digestion with post-digestion treatment and effluent recycle can play in a more sustainable poultry manure treatment system including managing nutrients for export out of impacted watersheds.

Future Plans

Future plans include continued work with industry in developing and/or providing extension capabilities around novel digestion and post-treatment processes for a variety of manures and on-farm situations. Expansion of such processes to poultry and other on-farm business plans will allow for improved reductions in wastewater production, concentrate nutrients for export out of impacted watersheds and do so within a positive economic business plan.

Authors

Craig Frear, Assistant Professor at Washington State University cfrear@wsu.edu

Quanbao Zhao, Project Engineer DVO Incorporated, Steve Dvorak, President DVO Incorporated

Additional information

Additional information about the corresponding author can be found at http://www.csanr.wsu.edu while information about the poultry project and the industry developer can be found at http://www.dvoinc.net. Numerous articles related to anaerobic digestion, nutrient recovery and separation technologies for climate, air, water and human health improvements can be found at the WSU website using their searchable articles function.

Acknowledgements

This research was supported by funding from USDA National Institute of Food and Agriculture, Contract #2012-6800219814; National Resources Conservation Service, Conservation Innovation Grants #69-3A75-10-152; and Biomass Research Funds from the WSU Agricultural Research Center. 

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.

 

Effects of Mixing Duration on Biogas Production and Methanogen Distribution in Dairy Manure Anaerobic Digesters

Why Did We Study Mixing Duration?

Mixing is an important parameter for anaerobic digesters for both design and operation. This is especially true for digesters that treat diary manure, which is a mixture of feces, urine, blood, food wastes, and bedding. Many of the solids fed to the digester have no or low degradability, and some of the large fibers can clog pumps or pipes in the transfer system. Mixing also plays an important role in maintaining a uniform environment for biological processes. However, the energy input for operating mechanical mixers requires a large part of the total energy for a biogas plant. Previous studies have suggested that optimum biogas production does not require continuous active mixing. It is essential to evaluate the mixing duration in order to balance energy inputs and biogas production rates.

What Did We Do?

The study was designed as a one factor (mixing duration) experiment with three levels and was carried out in triplicates. Three pilot scale anaerobic digesters were used to compare the impact of different mixing duration (continuous – CON, intermittent – INT, and no mixing – NO) on the performance of biogas production from dairy manure, Figure 1.

Figure 1. a laboratory scale digester

Figure 1: Digester Design

During the experiment, all digesters were fed 8 kg of dairy manure daily (total solid content = 5.5%), and operated at 37oC with a hydraulic retention time (HRT) of 21 days.  The mixing and feeding were controlled by an automated computer system, Figure 2. Mixers were set at a speed of 450 revolution per min (RPM). Biogas production was recorded three times a week and the percentage of methane content was analyzed weekly. Manure samples were collected weekly from the feed tank, top, middle & bottom of the digester, and from the effluent tank for volatile solids (VS), chemical oxygen demand (COD), pH, carbon to nitrogen ratio (C/N), and violate fatty acids (VFAs).  The concentration of archea and five common methanogens found in digesters was also determined using quantitative polymerase chain reaction (qPCR).

Figure 2. A closeup of the top of the lab-scale digester

Figure 2: Digester Mixing System

What Have We Learned?

The cumulative biogas production from digesters with no mixing was statistically significantly higher than intermittent and continuous (CON) mixing at the same loading rate. However, CON had a higher methane production rate per kg of volatile solids destroyed, Figure 3.

Figure 3: Methane Production Rate per Volatile Solids Destroyed

Future Plans

We are currently exploring the settling of manure solids in digesters with different mixing duration through a tracer study. The impact of different settling time on the hydraulic retention time (HRT), would help us better understand the performance of the anaerobic digesters with different mixing duration.

Authors

Hui Wang, Graduate Research Assistant, University of Wisconsin-Madison, hwang355@wisc.edu

Rebecca A. Larson, Assistant Professor and Extension Specialist, University of Wisconsin-Madison, ralarson2@wisc.edu

Acknowledgements

This material is based upon work supported by the National Institute of Food and Agriculture, United States Department of Agriculture, under ID number WIS01693.

Institute for Environmentally Integrated Dairy Management (Marshfield, WI), United States Dairy Forage Research Center

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.

Low Tech Waste to Energy Applications in Developing Countries


Abstract

Animal waste is fully utilized in most developing countries, particularly in Afghanistan, Pakistan and Sri Lanka.  Utilization of animal waste for energy, cooking and heating is often of greater importance than use for soil conditioning and fertilization.  The simplest processing of manure, including gut waste from slaughter operations, is to sun-dry the material which is then burned in small, efficient clay burners.  Specialized cooking equipment such as pressure cookers designed to derive the maximum benefit from these low energy fires are also used.Natural gas burners are also employed where the gas is available and offer a much healthier and sanitary option.

A variety of very simple and efficient digesters have been built, and are now employed in many homes, to convert animal waste to useable gas by employing low cost materials. Most of these digesters serve a single home producing cooking, heating and even lighting energy from the waste of a single animal or a small flock or herd.

This presentation will present examples of these systems and discuss how they can be effectively employed by others around the world, including small and hobby farmers in the Pacific Northwest.

Author

BLEDSOE, GLEYN              GLEYN@WSU.EDU          School of Food Science, WSU-UIdaho

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.

The Importance of Markets for Co-products and Innovations for Farms of All Sizes (Innovative Technologies for Managing Manure – Part 1)

Why Are Co-Products Important in Manure Treatment Technologies? Do These Technologies Work for Large and Small Farms?

Livestock and poultry operations face considerable logistical and financial challenges to manage over a billion tons of nutrient-laden manure generated in the U.S. each year. This manure has the potential to impact the environment adversely if it is not managed responsibly, but both producers and the environment can benefit from innovative technologies that alleviate manure management challenges.  Technologies that yield new revenues or offer flexibility in managing manure are of particular interest.  This panel will discuss two factors vital to the long-term success of waste-to-worth technologies:

  1. The importance of markets for co-products from innovative technologies
  2. The importance of developing waste-to-worth innovations for farms of all sizes

The Importance of Markets

Innovative technologies can make it possible for producers to export manure nutrients off-site more readily, which can benefit both their bottom line and the environment. This is particularly true for larger livestock farms, many of which lack sufficient land to be able to apply all their manure at agronomic rates. Some manure-to-energy and nutrient recovery technologies are already in place at animal agriculture operations. However, anecdotal evidence suggests that producers can have difficulty finding markets for the outputs of these systems. This panel will address the viewpoint that, in addition to approaching innovation with the question, “Technically speaking, what commodities can be derived from manure?” it is also important to ask, “For what types of co-products and services does a market exist, and how can optimized manure treatment systems meet this demand?”

The Importance of Innovations for Farms of All Sizes

More than half of all U.S. livestock (including poultry) animals are held by farms smaller than 1,000 beef cattle or equivalent in size. Although these farms may have adequate land for applying manure nutrients at agronomic rates, storage constraints and labor shortages may impact the operation’s ability to apply manure at agronomically optimal times. These constraints can sometimes result in harmful losses of manure nutrients into the environment.

Smaller farms can benefit from innovative technologies that are less capital intensive and improve the logistics of manure storage, transport, and application. For smaller operations, one way to approach innovation is by asking the question “What innovations add value for producers at smaller operations by providing a greater degree of manure management flexibility?”

What will the audience take away from this presentation?

In this panel, the moderators will provide a brief overview of the need for innovative manure management systems. Moderators will then pose a series of questions to panelists. First, we will hear “real world” experiences with innovative manure management technologies from technology developers and users. Second, we will hear about the specific operational and financial challenges livestock producers face and what types of technologies could respond to these challenges. Finally, we hope to identify scenarios in which innovative manure management technologies could have the greatest likelihood of success.

Panelists

  1. Josh Frye, Frye Poultry, Wardensville, WV.  Josh Frye runs a 700,000 plus broiler operation.  His company owns a fixed bed gasifier that can convert poultry litter into energy at the rate of 5 million btu per hour, per 1,000 lbs of litter.
  2. Matt Freund, Cowpots, East Canaan, CT. Matt Freund of Freund’s Family Farm in Connecticut runs a 275 cow dairy. Mr. Freund’s dairy produces biogas with an anaerobic digester and uses a process that Mr. Freund developed to manufacture biodegradable planting pots, CowPotsTM, out of separated manure fibers.
  3. Dr. Mark Johnson, EPA Corvallis Lab, Corvallis, OR.  Mark Johnson is a Research Soil Scientist with EPA’s Office of Research and Development (ORD) Corvallis Lab. Dr. Johnson is researching custom biochars generated from a variety of biomasses.
  4. Dr. Craig Frear, Washington State University, Puyallup, WA.  Craig Frear is an Associate Professor at Washington State University. Dr. Frear has extensive experience with anaerobic digestion and advanced nutrient recovery systems. Dr. Frear has developed and implemented these systems on dairies and other animal operations with a focus on optimizing total system performance and long-term financial sustainability.
  5. Dr. Ariel Szogi, USDA/ARS Coastal Plain Soil, Water and Plant Conservation Research Center, Florence, SC.  Ariel Szogi is a Research Scientist with USDA’s Agriculture Research Service (ARS). Dr. Szogi has developed a process called Quick Wash for extraction and recovery of phosphorus from poultry litter and animal manure solids.
  6. Kraig Westerbeek, Vice President of Environment, Engineering, and Support Services, Murphy-Brown LLC (livestock subsidiary of Smithfield Foods).  In this capacity he is heavily involved in the evaluation of current and new technologies for manure management. He is from Warsaw, NC, and has been employed by Murphy-Brown for 22 years, primarily in the environmental area.

Moderators

  1. Joseph Ziobro, Office of Wastewater Management, U.S. EPA (ORISE fellow). Joseph Ziobro is an O.R.I.S.E. Research Participant at U.S. EPA, Office of Wastewater Management, Rural Branch. Mr. Ziobro supports the National Permit Discharge Elimination System (NPDES) permit program for concentrated animal feeding operations.
  2. Nina Bonnelycke, Office of Wastewater Management, U.S. EPA. Nina Bonnelycke is a Policy Analyst at the U.S. Environmental Protection Agency, Office of Wastewater Management, Rural Branch.  Ms. Bonnelycke has extensive experience in cost/benefit analysis of environmental programs.

Image of moderator, Joseph ZiobroJoseph Ziobro

U.S. Environmental Protection Agency

Joseph is a Research Participant at the Oak Ridge Institute for Science and Education (ORISE) research program at the US Environmental Protection Agency (EPA) in the Office of Wastewater Management. He supports the implementation of the National Pollutant Discharge Elimination System (NPDES) permitting program for concentrated animal feeding operations. Joseph also supports collaborative initiatives with the animal agriculture industry that protect and restore water quality. In 2013, Joseph earned a Master’s degree in Environmental Science from the State University of New York (SUNY) College of Environmental Science and Forestry (ESF), with a focus on coupled human and natural systems.

Image of moderator, Nina BonnelyckeNina Bonnelycke

U.S. Environmental Protection Agency

Ms. Bonnelycke is a Policy Analyst at the U.S. Environmental Protection Agency, Office of Wastewater Management, Rural Branch.  She has served EPA for close to 25 years and has extensive experience in cost/benefit analysis of environmental programs.  Ms. Bonnelycke has supported EPA’s efforts on water quality issues connected to animal agriculture since 2001.  She has worked in a variety of other program areas including solid and hazardous waste, stratospheric ozone protection, and climate change.  Ms. Bonnelycke has a Master’s in Public Policy from the University of California, Berkeley.

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.

Calcium Enhanced Precipitation Of Swine Manure: Supporting Concepts And Lab Scale Trial Findings


Can Solid and Liquid Manure Fractions Be Treated to Enhance Nutrient Management?

An important consideration of liquid manure solids separation is the fate and economic value of the resulting liquid and solids fractions. The desired properties of the separated fractions, operator preferences, regulatory considerations, and economics should determine the type and degree of treatment.

Research has shown that treatment with aluminum, iron, and calcium chemicals can concentrate phosphorus and manure solids into a lower moisture manure product. This research focuses on calcium to enhance phosphorous and solids precipitation. Concepts leading to this research were: creating calcium phosphorus compounds with liming and phosphorus fertilizer soil amendment value; retaining nitrogen for on farm use; enhancing/maintaining manure market value to offset treatment/transportation costs; reducing phosphate extraction from global mineral reserves; and investigating the impacts on energy and bio-char production from manure solids.

This research treated liquid swine manure with hydrated lime [Ca(OH)2] and agricultural lime [CaCO3]. The hydrated lime was added as both a liquid slurry and as a dry powder. The agricultural lime was added as dry granules. The 3 calcium sources were added to the manure at 3 treatment levels with 3 replicates. A non-treatment control for each chemical source and additional final non-treatment control were also processed. The resulting 31 mixtures were sampled prior to separation via filter bags. After separation, the filter bag contents and the leachate were also sampled. The filter bags and leachate were then stored under ambient conditions but protected from precipitation for 10 days before being sampled again.

The analysis of all 155 samples included % solids, TKN, NH4-N, NO3-N, P, WEP, K, and Ca. This manuscript presents an analysis of the results of the analytical tests performed. An associated provides an assessment of the separated solids as a feed stock for thermo energy conversion and bio-char production.

Author

VanDevender, Karl          kvan@uaex.edu                               Univ of Ark, Div of Ag, Extension, BAEG

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.

Development of Pilot Modules for Recovering Gaseous Ammonia from Poultry Manure

Purpose?

There is major interest from producers and the public in implementing best control technologies that would abate ammonia (NH3) emissions from confined livestock and poultry operations by capturing and recovering the nitrogen (NH3-N).

What did we do?

In this study, we continued investigating development of gas-permeable membrane modules as components of new processes to capture and recover gaseous ammonia inside poultry houses, composting facilities, and other livestock installations. The overall research objective was to improve poultry houses with the introduction of nitrogen emission capture technology. There were two milestones during the initial phase of the study: 1) to test ammonia recovery with gas-permeable membranes in a bench system using Maryland’s poultry manure; and 2) to construct and install a pilot ammonia recovery system at the UMES Poultry Research facility.

Figure 1. System for the recovery of gaseous ammonia from poultry waste using gas-permeable membrane module.

Figure 1. System for the recovery of gaseous ammonia from poultry waste using gas-permeable membrane module.

What have we learned?

The prototype ammonia recovery bench system using gas-permeable modules was moved from ARS-Florence to ARS-BARC in Sept. 2013 and tested during three consecutives runs using turkey and chicken manure mixes. The bench unit had two chambers: one was used with recirculating acid solution (1 N H2SO4) and the other was a control that used recirculating water. The control, which used water as the capture solution, was very effective at recovering the ammonia. This finding may lead to more economical ammonia recovery systems in the future.

Figure 2. Prototype ammonia recovery system using gas-permeable modules.

Figure 2.  Prototype ammonia recovery system using gas-permeable modules.

Two pilot ammonia recovery systems using gas-permeable membranes were constructed at ARS-Florence and installed at the UMES poultry research facility in June 2014.  One ammonia recovery module was developed using flat membranes mounted on troughs. The other module was developed using tubular gas-permeable membranes.  The recovery manifolds were placed inside the experimental barns (400 chickens) hanging from the roof and close to the litter. Both systems were installed with the ammonia concentrator tanks outside the barns. They were tested continuously for four months without chickens in the barns. The first flock of birds was placed in the facility Feb. 2015 and also in a control facility without the ammonia recovery modules.  The installed modules will demonstrate the ammonia recovery and the potential poultry production benefits from cleaner air.

Figure 3. Pilot ammonia recovery systems installed in a chicken barn at UMES Poultry Research Facility. At left is a recovery module that uses tubular gas-permeable membranes. At right is a recovery module that uses flat gas-permeable membranes.

Figure 3.  Pilot ammonia recovery systems installed in a chicken barn at UMES Poultry Research Facility.  At left is a recovery module that uses tubular gas-permeable membranes.  At right is a recovery module that uses flat gas-permeable membranes.

Future plans?

The N recovery modules are being demonstrated at the University of Maryland Eastern Shore’s Poultry Research facility.

USDA seeks a commercial partner to develop and market this invention (Gaseous ammonia removal system.  US Patent 8,906,332 B2, issued Dec. 9, 2014). http://www.ars.usda.gov/business/docs.htm?docid=763&page=5

Authors

Matias Vanotti, USDA-ARS, Florence, South Carolina matias.vanotti@ars.usda.gov

Vanotti, M.B.1; Millner, P.D.2 ;Sanchez Bascones, M.3 ;Szogi, A.A.1;  Brigman, P.W.1; Buabeng, F.4; Timmons, J.4 ; Hashem, F.M.4

1USDA-ARS Coastal Plains Soil Water and Plant Research Center, Florence, SC, USA

2USDA-ARS Environmental Microbial and Food Safety, Beltsville, MD, USA

3University of Valladolid, School of Agric. Engineering, Palencia, Spain

4University of Maryland Eastern Shore, Dept. of Agriculture, Food and Resource Sciences,  Princess Anne, MD, USA

Additional information

Szogi, A.A., Vanotti, M.B., and Rothrock, M.J. 2014. Gaseous ammonia removal system.  US Patent 8,906,332 B2, issued Dec. 9, 2014. US Patent and Trademark Office, Washington, DC.

Rothrock Jr, M.J., Szogi, A.A., Vanotti, M.B. 2013. Recovery of ammonia from poultry litter using flat gas permeable membranes. J. of Waste Management. 33:1531-1538

“Recovery of ammonia with gas permeable membranes” research update at USDA-ARS-CPSWPRC website  http://www.ars.usda.gov/Research/docs.htm?docid=22883#ammonia

Acknowledgements

We acknowledge NIFA Project “Novel Integration of Solar Heating with Electricity Generation Technology and Biofiltered Poultry Litter Biofertilizer Production System” and  ARS Project 6657-13630-001-00D “Innovative Animal Manure Treatment Technologies for Enhanced Environmental Quality”. Funding by University of Valladolid/Banco Santander for participation of Dr. Sanchez Bascones as Visiting Scientist is also acknowledged.

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.

Farm-Based Anaerobic Digestion Projects – Wastewater Disposal and Nutrient Considerations

While anaerobic digestion is often touted for producing renewable energy/fuels, producers at concentrated animal feeding operations (CAFOs) are often most concerned about nutrient loading, an issue that has garnered increasing regulatory scrutiny. Anaerobic digestion, while a carbon management tool capable of producing carbon fuels, does little in regard to nitrogen and phosphorus management. Thus digestion projects, if they are to meet producer needs, must incorporate downstream separation to recover nutrients and protect soils. This presentation highlights the key environmental issues and hurdles facing manure management and disposal and lays the framework for a needed focus on combined anaerobic digestion and nutrient recovery systems capable of meeting producer and regulatory needs regarding nutrient management.

Why Review Nutrient Recovery Technologies for Anaerobic Digestion?

A literature review and conversations with dairy farmers both suggest that improving manure nutrient management is a major concern for dairy producers. This supports the conclusion that ongoing research and development efforts to support development of nutrient recovery technologies, including those that can be used in concert with anaerobic digestion (AD), will be key to enhancing adoption rates for AD technology.

What did we do?

A literature review was used to support and enhance findings from conversations with farmers about anaerobic digestion technologies.

What have we learned?

Managing manure is major consideration for dairy producers, and one that comes with high potential costs in areas where there are few crop producers willing to accept manure (USDA ERS 2009). Dairies in many regions of the U.S. are facing increased pressure from growing public concern about nutrient-related water and air quality issues. In some cases, regulation of dairies has increased.

As a result, there is increased interest from dairy producers and others in nutrient recovery technologies. Although no technologies are widely commercialized at present, several emerging nitrogen and phosphorus recovery technologies exist. Some of these technologies are most appropriately used on specific forms of untreated dairy manure (e.g. scrape, flush), while others are more appropriate when combined with AD as part of an AD system (Figure 1).

Figure 1. Nutrient recovery fact sheet diagram

Figure 1. Nutrient recovery fact sheet diagram

figure 2. overhead view of nutrient recovery system

Figure 2. Overhead view of a nutrient recovery system for nitrogen and phosphorus.

Approaches also vary in that some recover both phosphorus and nitrogen (Figure 2), while others focus on only one nutrient (Figure 3). Some nutrient recovery processes dispose of these nutrients in form that is non-reactive, and therefore not problematic environmentally. However, most nutrient recovery technologies produce concentrated nutrient products that can be transported more easily, and economically, than manure. The most promising technologies also make products with characteristics (e.g. homogenous and predictable nutrient content, easy to handle, reduced pathogen counts or pathogen-inert chemicals) that make them more appealing to crop producers than manure.

figure 3. commercial scale recovery of phosphorus

Figure 3. Commercial scale recovery of phosphorus.

With further technological and market development, these technologies have the potential to transform dairy manure nutrient management. They may also become a cost-effective approach to improving nutrient management at a watershed level, through the replacement of imported chemical nutrients by crop-farms with manure-derived nutrients already in the watershed. However, nutrients can still be lost from nutrient recovery products or from the wastewater that normally is a by-product of nutrient recovery. This is especially true if these are applied with improper application rates or timing. Nutrient recovery technologies therefore need to be used as part of a comprehensive watershed-level strategy that addresses nutrient balance, equitable distribution of costs and benefits, and improved nutrient application timing and methodology.

Nutrient recovery could also encourage adoption of anaerobic digestion technologies. Although anaerobic digestion changes the form of nitrogen and phosphorus in manure, it does not appreciably decrease the total amount of nutrients, most of which are concentrated in the liquid effluent that is a product of the AD process (Frear et al. 2012). Also, co-digestion of dairy manure with additional organic food wastes can import nutrients to the farm, exacerbating existing nutrient management issues. Nutrient recovery can make AD more appealing to dairy producers by addressing one of their most important concerns. Meanwhile, potential income from the sale of recovered nutrients can contribute to the economic feasibility of an AD project.

Future Plans

The authors and collaborators are continuing efforts to review existing information about nutrient recovery systems (see talk by Jingwei Ma et al., Nutrient Recovery Technologies—A Primer on Available and Emerging Nitrogen, Phosphorus, and Salt Recovery Approaches, their Performance and Cost). They are also continuing technological development and commercialization efforts for specific nutrient recovery technologies.

Authors

Georgine Yorgey, Research Associate at Center for Sustaining Agriculture and Natural Resources, Washington State University yorgey@wsu.edu

Craig Frear, Assistant Professor in the Department of Biological Systems Engineering, Washington State University, and Chad Kruger, Director, Center for Sustaining Agriculture and Natural Resources, Washington State University

Additional Information

The topics covered in this presentation are covered in more depth in a factsheet that is available from Washington State University Extension. The Rationale for Recovery of Phosphorus and Nitrogen from Dairy Manure is available at https://pubs.extension.wsu.edu/the-rationale-for-recovery-of-phosphorus-and-nitrogen-from-dairy-manure-anaerobic-digestion-systems-series. This document is part of a series of extension documents on Dairy AD Systems, being prepared by the authors and other colleagues at Washington State University.

References:

Frear, C., W. Liao, T. Ewing, and S. Chen. 2012. Evaluation of Co-digestion at a Commercial Dairy Anaerobic Digester. Clean Water, Air, and Soil, 39 (7): 697-704.

USDA-ERS. 2009. Manure Use for Fertilizer and for Energy. Report to Congress. United States Economic Research Service. Washington, DC.

Acknowledgements

This work was supported by funding from USDA National Institute of Food and Agriculture, Contract #2012-6800219814; National Resources Conservation Service, Conservation Innovation Grants #69-3A75-10-152; and Biomass Research Funds from the WSU Agricultural Research Center.

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.

Improved Recovery of Ammonia From Swine Manure Using Gas-Permeable Membrane Technology and Aeration

Why Study Nitrogen Recovery from Manure?

Significant efforts are required to abate NH3 emissions from livestock operations. In addition, the costs of fertilizers have rapidly increased in recent years, especially nitrogen fertilizer such as anhydrous ammonia which is made from natural gas. Thus, new technologies for abatement of ammonia emissions in livestock operations are being focussed on N recovery. This presentation shows a novel system that uses gas-permeable membranes to capture and recover ammonia from liquid manure, reducing ammonia emissions from livestock operations, and recovering concentrated liquid nitrogen that could be sold as fertilizer.

What Did We Do?

Nitrogen recovery from swine manure was investigated using a new technology that uses gas-permeable membranes at low pressure. The new process includes the passage of gaseous ammonia contained in the liquid manure through a microporous hydrophobic membrane and capture and concentrate with circulating diluted acid on the other side of the membrane.   The membranes can be assembled in modules or manifolds.  Membrane manifolds are submerged in the manure and the ammonia is removed from the liquid before it escapes into the air. The process involves manure pH control to increase ammonium recovery rate that is normally carried out using an alkali chemical. In this study a new strategy was tested to avoid the use of alkali chemicals.  Instead of the chemical, we applied low-rate aeration and nitrification inhibitor to raise the pH and promote ammonia capture by the membrane system.

Diagram of ammonia recovery system using with gas permeable membranes and low-rate aeration

Figure 1. Diagram of ammonia recovery system using with gas permeable membranes and low-rate aeration

What Did We Learn?

Two studies were conducted to recover N from liquid swine manures containing high ammonia concentrations using a USDA patented gas-permeable membrane system. One study used raw liquid manure from the pit under slatted floor of a farrowing sow’s barn in Segovia, Spain.  The second study used liquid swine manure effluent from a covered lagoon digester in North Carolina, USA.  The new strategy that used low-rate aeration and nitrification inhibition worked quite well in both situations. In the first study using raw manure,  the pH increased and the ammonium concentration was almost depleted: it declined from 2270 mg N/L to 20 mg N/ in 18 days. The ammonia that was removed was recovered efficiently in the concentrator tank (99% recovery efficiency).  Using the same membrane manifold without the aeration protocol, the ammonium concentration in the manure decreased at a slower rate from 2330 mg N/L to 790 mg N/L in 18 days. The results obtained were consistent in the second study that used digested swine effluent.  When low-rate aeration and nitrification inhibitor were added to the gas-permeable membrane reactor, ammonium concentration in the digester effluent decreased rapidly, from 3130 mg N/L to 96 mg N/L, in 5 days.  The recovery efficiency was 98%.  This N removal rate was 5 times faster than a control that used the same membrane reactor and conditions but operated without the aeration protocol.  Overall results obtained in this work indicate the low-rate aeration is an economical alternative to chemical addition to increase ammonia availability and the capture of ammonia by gas-permeable membrane systems. This conclusion is supported by the very high removal and recovery efficiencies obtained resulting in an overall recovery of 95 to 98% of the initial ammonia in the manure.

Future Plans

On-farm demonstration studies will be conducted in 2015 in cooperation with Dr. John Classen, North Carolina State University, through an NRCS Conservation Innovation Grant (CIG) “Ammonia recovery from swine wastewater with selective membrane technology”.  A mobile pilot unit will demonstrate recovery of ammonia from liquid manure effluents using the gas-permeable technology in three different manure collection systems: under floor belt system, scraper system, and anaerobic digester.

USDA seeks a commercial partner to develop and market this invention (Systems and Methods for Reducing Ammonia Emissions form Liquid Effluents and for Recovering Ammonia. US Patent Appl. SN 13/164,363 allowed Dec. 19, 2014)  http://www.ars.usda.gov/business/docs.htm?docid=763&page=5

Authors

Matias Vanotti, USDA-ARS, Florence, South Carolina matias.vanotti@ars.usda.gov

Matias B. Vanotti1, Maria C. Garcia-Gonzalez2, Patrick J. Dube1, Ariel A. Szogi1

1 USDA-ARS, Coastal Plains Soil, Water, and Plant Research Center, Florence, SC

2 Agriculture Technological Institute of Castilla and Leon (ITACyL), Valladolid, Spain

Additional Information

“Livestock Waste Management 2.0: Recycling Ammonia Emissions as Fertilizer” published in the November/December 2012 issue of Agricultural Research magazine  http://www.ars.usda.gov/is/AR/archive/nov12/livestock1112.htm

“Recovery of ammonia with gas permeable membranes” research update at USDA-ARS-CPSWPRC website  http://www.ars.usda.gov/Research/docs.htm?docid=22883#ammonia

Vanotti,M.B., Szogi,A.A.  “Systems and Methods for Reducing Ammonia Emissions form Liquid Effluents and for Recovering Ammonia”. US Patent Appl. SN 13/164,363,  filed June 20, 2011, allowed December 19, 2014.  US Patent and Trademark Office, Washington, DC.

Garcia-Gonzalez, M.C., Vanotti, M.B., Szogi, A.A. 2015. “Recovery of ammonia from swine manure using gas-permeable membranes: Effect of aeration”. Journal of Environmental Management 152:19-26

Acknowledgements

This research was part of USDA-ARS National Program 214 Agricultural and Industrial Byproducts, Research Project 6657-13630-005-00D “Innovative Bioresource Management Technologies for Enhanced Environmental Quality and Value optimization”. Funding by INIA/FEDER Project CC09-072 is gratefully acknowledged.

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.