phosphorus removal – Livestock and Poultry Environmental Learning Community

March 5, 2019July 14, 2020

Results of Nutrient Recovery System Installed on Large Scale Dairy Operation After 2-years of Operation

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Purpose

For centuries, farmers have disposed of manure by simply spreading it on the land. It is a natural fertilizer. Today, that practice is no longer considered the best solution. Field spreading is now understood to contribute to a growing global problem of the pollution of water, soil, and air. Consequently, U.S. dairy farmers face increased fiscal and operational pressure from the progression of ever tightening environmental regulations. Conventional handling of manure also imposes a number of operational challenges (limitations for storage, land application and irrigation, settlement in lagoons, high manure hauling costs, etc.) and typically requires a relatively large land base to allow adequate nutrient management.

In Indiana, a dairy that was daily producing thousands of tons of livestock waste was investigating how technology could capture the valuable nutrients remaining in their cow manure after it had gone through the farm’s anaerobic digestion process. Their goal was to convert the manure/digestate into a nutrient rich cake that could be easier managed and made into fertilizer, and the liquid clean enough to be used unrestricted for land application.

The farm’s key operational deliverables were 1) to reduce the manure’s handling and transportation costs, 2) allow for precision applications of the processed manure as carbon-based fertilizer and 3) allow for re-use of nutrient reduced liquid for field irrigation.

What did we do?

The dairy farm chose to implement a nutrient recovery technology from Trident Processes LLC. The technology separates the manure/digestate into three fractions: 1) cellulosic fiber, 2) a concentrated cake of nutrient enriched solids, and 3) water with about 1% remaining solids.

Trident’s turn-key system, consisting of different mechanical and chemical components, processes the manure and diverts each separated fraction into their separate spaces. Sensors and programmable controls (PLC) allow for smooth operation, requiring minimal operator attendance. The entire system can be monitored, controlled and diagnosed remotely.

The manure is fed into the system following the digestion process. The initial step is the extraction of the large fiber, which is done via a rotary screen conditioner. The wetted material separates, with the effluent water and fine solids sifting down through the screen while the larger fiber is retained. This step is critical as it ensures the fine particles, which contain the nutrients, are sent down stream for further treatment.

FIBER: The extracted fiber is sent to a screw press for further dewatering. This renders it as a 30% dry cellulosic fiber biomass that is ideal for recycling as cow bedding or other biomass use. Any liquid squeezed from the fiber is diverted to join the fine solids stream.

SOLIDS: The effluent water and solids are sent to a dissolved air flotation (DAF) tank. Polymerization ensures effective flocculation of the feedstock, resulting in a concentration of the nutrient rich particles that float to the surface. The sludge formed on the surface is skimmed off the top and gravity fed into a multi-disc press for second-stage dewatering. The press gently dewaters and thickens the recovered solid/nutrient sludge into a 25% solids, nutrient rich cake.

WATER: The final effluent water, now nutrient reduced, contains less than 1.2% solids and is sent to the lagoon for storage. The water is then reused for irrigation through efficient pivot systems or as operational water on the farm.

What have we learned?

By implementing Trident’s Nutrient Recovery System, the farms’ objectives have been met and/or exceeded. After running for nearly two years the system is producing the following statistics:

• Fully automated operation requiring about 1 hr/shift for operator attendance (visual checks)

• 98% system uptime

• Polymer costs: $0.06 – $0.08/day/cow

• Reduction of handling and irrigation costs: $ 0.01/gal (conventional) vs $0.003/gal (center pivot)

• $250,000/yr electrical power savings with MD Press vs. centrifuge

• 73,000+ ton/yr nutrient cake produced

• 81% P, 70% organic N (54% TKN), and 20% K is the average nutrient capture rate

• 1% (max.) solids in the effluent water sent to lagoons

• 99% Suspended solids captured

Future Plans

Dairy farm: A fertilizer plant will go live in the near future, allowing the farm to sell their concentrated nutrients to the plant as feedstock for custom fertilizer production.

Technology provider: 2nd Phase effluent treatment to capture and retain the solid and nutrient fraction of the existing process, allowing to meet stream discharge standards and comply with BOD / COD levels. Bench scale testing is completed. Farm scale pilot testing is scheduled to run from March 2017-December 2017.

Corresponding author, title, and affiliation

Richard Shatto (Senior Partner at Point Nexus Consulting), Frank Engel (Director Marketing at KPD Consulting Ltd.)

Corresponding author email

frank.engel@kpdconsulting.ca

Additional information

https://youtu.be/PvaTGmyws-w (Carl Ramsey’s presentation at Indiana Dairy Forum)

http://www.progressivedairy.com/topics/manure/prairie-s-edge-dairy-on-pa… (Progressive Dairyman article)

http://tridentprocesses.com/documents/case-study-trident-nutrient-recove… (Newtrient case study)

https://are.wisc.edu/manure-processing/ (manure management project with University of Wisconsin)

http://www.foodqualityandsafety.com/article/nutrient-recovery-improves-s… (Nutrient Recovery Improves Sustainability article in Food Quality & Safety Magazine)

Acknowledgements

Carl Ramsey, Environmental Manager at Prairie’s Edge Dairy Farm

Soil Net LLC, Dr. Aicardo Roa (strategic partner for chemical separation process)

Leap Tech, R.C. Ludke (strategic partner for automation)

March 5, 2019July 14, 2020

Removing Phosphorus from Drainage Water: The Phosphorus Removal Structure

Purpose

To illustrate a case study design and construction of a phosphorus removal structure on a poultry farm, and to present the basics of how to properly design a structure.

What did we do?

We constructed a phosphorus (P) removal structure on a poultry farm in Eastern OK; this is a BMP that can remove dissolved P loading in the short term until soil legacy P concentrations decrease below levels of environmental concern. A P removal structure contains P sorbing materials (PSMs) and are placed in a location to intercept runoff or subsurface drainage with high dissolved P concentrations. As high P water flows through the PSMs, dissolved P is sorbed onto the materials by several potential mechanisms, allowing low P water to exit the structure. While they vary in form, P removal structures contain three main elements: 1) use of a filter material that has a high affinity for P, 2) containment of the material, and 3) the ability to remove that material and replace it after it becomes saturated with P and is no longer effective.

A site was identified which met all criteria for justification of construction of a P removal structure: 1) elevated dissolved P concentrations in runoff (>0.2 ppm), 2) hydraulic connectivity between the runoff/drainage produced and a surface water body, and 3) flow convergence: the site possessed potential to channel the runoff water to a single point in order to treat the water. This site was located on a poultry farm in Eastern OK.
The site was surveyed in order to obtain the necessary inputs for properly designing the P removal structure. This involved a basic NRCS survey to estimate watershed size, peak flow rates, and average annual runoff volume. In addition, several runoff grab samples were taken and analyzed for dissolved P. This information was used to determine the average annual dissolved P load, which was 45 lbs.

Knowing flow and P load parameters, we additionally chose P removal targets and desired lifetime of the structure. We chose to design a structure that would remove 20 lbs of dissolved P during the first year and be able to handle 700 arial site view and map gpm flow rate. Several hypothetical designs were made based on the available P sorbing materials (PSMs), such as drinking water treatment residuals, acid mine residuals, and gypsum. We chose to use a treated steel slag material as the PSM in the structure; this required about 35 tons of material.

After construction, the performance of the structure was monitored by measuring flow rates and dissolved P concentrations at the inlet and outlet. In addition, we developed software to aid in proper design of a site specific P removal structure using any PSM, in order to meet desired P removal goals and lifetime. Alternatively, this software can be used to predict the performance and lifetime of a P removal structure that has been already constructed. Licensing of software is available for private industry.

completed p removal structure We constructed a P removal structure on a poultry farm in Eastern OK; this is a BMP that can remove dissolved P loading in the short term until soil legacy P concentrations decrease below levels of environmental concern. A P removal structure contains P sorbing materials (PSMs) and are placed in a location to intercept runoff or subsurface drainage with high dissolved P concentrations. As high P water flows through the PSMs, dissolved P is sorbed onto the materials by several potential mechanisms, allowing low P water to exit the structure. While they vary in form, P removal structures contain three main elements: 1) use of a filter material that has a high affinity for P, 2) containment of the material, and 3) the ability to remove that material and replace it after it becomes saturated with P and is no longer effective.

The site was surveyed in order to obtain the necessary inputs for properly designing the P removal structure. This involved a basic NRCS survey to estimate watershed size, peak flow rates, and average annual runoff volume. In addition, several runoff grab samples were taken and analyzed for dissolved P. This information was used to determine the average annual dissolved P load, which was 45 lbs.

Knowing flow and P load parameters, we additionally chose P removal targets and desired lifetime of the structure. We chose to design a structure that would remove 20 lbs of dissolved P during the first year and be able to handle 700 gpm flow rate. Several hypothetical designs were made based on the available P sorbing materials (PSMs), such as drinking water treatment residuals, acid mine residuals, and gypsum. We chose to use a treated steel slag material as the PSM in the structure; this required about 35 tons of material.

What have we learned?

p removal performance The P removal structure has removed approximately 67% of all dissolved P that has flowed into it over a 16-month time period. In addition, it has handled all flow volume from every event, including a runoff event that resulted in 600 gpm. That single event delivered 2/3 lb of dissolved P, in which the structure removed 66%. While the structure is removing P as predicted based on P loading, the structure has greatly outlasted the goal of removing 45% of cumulative dissolved P in one year. This is due to the below average rainfall received over the last two years.

We also learned about the potential positives and negatives of using certain PSMs. For example, although we could have used other PSMs, in much smaller quantities (2-10 tons) that would remove equal amounts of P, we would have had to build a structure that was much larger in surface area, due to the fact that the hydraulic conductivity of these PSMs is relatively low. It is also possible to build these structures with other materials for the frame, such as concrete, earth, or wood. Structures can be constructed in ditches or potentially in the subsurface to treat tile drainage.

Last, we have some sense of economics for P removal structures and the general cost of P removal compared to other BMPs.

Future Plans

phrog design software We will continue to monitor the structure. In addition, we are cooperating with several people throughout the US in helping to design P removal structures. We are also releasing design software for licensing in an attempt to promote commercialization of this BMP through private industry. A NRCS standard is currently underway and the goal is for this BMP to become cost-shared. Last, we are continuing to investigate the economics of P removal structure over a large scale area.

Authors

Chad Penn, Associate professor of agricultural and environmental chemistry, Oklahoma State University chad.penn@okstate.edu

Josh Payne, Animal waste specialist, Oklahoma State University; James Bowen, graduate assistant; Stuart Wilson, senior research specialist, Oklahoma State University; Josh McGrath, associate professor of nutrient management, University of Kentucky

Additional information

Chad Penn; chad.penn@okstate.edu; 405 744 2746

www.p-structure.blogspot.com

http://www.jswconline.org/content/69/2/51A.full.pdf

http://pods.dasnr.okstate.edu/docushare/dsweb/Get/Document-9345/L-447%20Phosphorus%20Removal.pdf

Acknowledgements

NRCS for funding of this demonstration

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, 2019July 15, 2020

Economical Anaerobic Digestion of CAFO Animal Waste

Purpose

The application of manure on croplands is increasingly under regulatory scrutiny, especially from impaired watersheds. The challenge facing many small farms is to find cost-effective and innovative solutions for manure reuse whilst responding to environmental, regulatory and public concerns. One option is to install an anaerobic digester (AD) in which microorganisms break down biodegradable material in the absence of oxygen. However, not all farmers are financially able to install an AD but do need the AD’s benefits to keep their livestock operation sustainable. This paper discusses a novel, cost effective and patented manure treatment system which can reduce the volume of manure for field application (see Figure 1). Earthmentor N2RTS Schematic

What did we do?

The EarthMentor® Natural Nutrient Reclamation and Treatment System (EMS), uses a combination of innovative sand separation technology (if necessary) and anaerobic treatment to concentrate manure nutrients into solid phases and treat approximately 70% of manure liquids into a product which can be applied to active cropland as low-nutrient liquid using irrigation methods. The primary economic advantage of using an EMS to treat livestock manure prior to land application is lower total manure disposal costs. The total manure handling costs are reduced because up to 75 % of the original manure volume can be handled as low-nutrient value irrigation quality liquid in bulk instead of hauling it by tanker for land application. This fact alone reduces total manure handling costs by over 50 %. Other tangible benefits of using an EMS include low odor, minimized environmental risks, and greater flexibility in proper land application of the treated manure. It can be installed at farms with as few as 250 cows. Depending on farm size, operators can realize a return on investment in as little as three years. Compared to a traditional AD installed to generate biogas the EMS is simple to operate, requires less energy, requires no chemicals or substrates to treat the waste, and reduces manure disposal costs.

The EMS involves six major steps: 1) collection of raw manure and transport to the processing center, 2) sand bedding is separated from the manure stream, 3) coarse manure components are removed from the liquid manure stream, 4) additional settling of the fine manure solids and sand particles occurs in a settling basin to a concentration of 8 to 10 percent solids, 5) AD treatment of the liquid manure and dissolved solids occurs in anaerobic treatment lagoon (ATL), and 6) The ATL effluent is stored in a Storage Pond for eventual discharge to active growing crops; additional natural treatment of the liquid manure occurs while in the Storage Pond.

All settling basins and ATL lagoon must meet state guidelines, such as Natural Resource Conservation Service technical guidelines or state requirements for waste storage facilities.

The ALT of the EMS system has a smaller footprint compared to traditional ALTs (primarily use in the south and western United States) because the majority of the nutrient-rich semi-solids are removed from the manure before discharge to the ATL. Due to this major operational change the EMS is economical to install and operate even in the northern climates of the United States where many of the top producing dairy states are located. While many facilities separate solids before land application, the EMS is different because is adds the AD step which converts the manure into a low-nutrient liquid capable of irrigation-style land disposal. The method of solid separation can be as simple as a sloped screen followed by additional gravity separation as described in Step 4 above. The EMS ATL must be sized to account for reduced biodegradation during the colder weather. The EMS has successfully operated at multiple swine facilities and several Midwestern dairy farms.

If there is sufficient land near the farmstead, the EMS can be installed at existing dairies with minimum difficulty since the treatment system works equally well with multiple bedding materials and varying manure collection methods. Another benefit of the EMS is that is allows application on fields that may be high in phosphorus since much of the phosphorus will be stored in the accumulating ATL sludge. For dairies bedding with sand, a patented sand removal system can be provided that relies on a decanting method of sand separation. Once the sand is removed, it can be reused in the barn.

What have we learned?

Typical Cost Savings for Manure Application Using EMS
Component	Disposal Method	Conventional Manure Handling		EarthMentor^® Treatment System Handling
Liquid Manure	Land Application	100%	$0.02/gallon	0%	$0
Separated Solids	Land Application	0%	$0	10%	$0.016/gallon ($4/ton equiv.)
Heavy Slurry	Land Application	0%	$0	20%	$0.02/gallon
Treated Wastewater	Center Pivot over Crop	0%	$0	70%	$0.002/gallon
Combined Cost		100%	$0.02/gallon	100%	$0.007/gallon (weighted average of all components)

Using financial data from 2010 for a 2,000-cow Michigan dairy, it was estimated that the cost to handle manure using an EMS is reduced from $0.02/gallon to $0.007/gallon. The cost saving using the EMS is based on the assumption that the average dairy cow produces nearly 25 gallons/day of manure, including wastewater but excludes bedding since farms used different types and volumes of bedding for their dry and lactating cows. Based on the financial analysis, installation of an EMS benefits the farm’s economic sustainability while providing other benefits including reduced environment risk associated with manure land application.

Far beyond the obvious cost savings associated with the EMS installation, a livestock producer will realize many other benefits. A partial list is provided below:

This practical and manageable manure treatment system requires little or no additional farm labor commitments yet greatly reduces overhead expenditures to keep the farm sustainable and competitive,
All manure is treated prior to land application (environmentally sound),
The more consistent high solids slurry can be precisely applied to fields with the greatest need as opposed to the highly variable manure nutrient concentrations recovered from a traditional manure pond,
Minimizes the environmental risks (ecologically viable) and farm nuisance potential,
The window of opportunity for manure application is extended to over 200 days instead of being limited to spring and fall applications for typical liquid manure,
Can provide a safe unlimited recycled bedding source for cattle, if so desired, by the dairy owner,
Permits farmer to follow BMPs for soil conservation,
Permits farmer to follow timing, rate, source, and place for fertilizer/crop nutrient applications,
Benefits the non-farm neighbors and community through reduced nuisance odors, and
Continues using the farm’s manure as a soil amendment for crop production, the most efficient use known.

Future Plans

The immediate future plans for EMS is to target small livestock producers, especially those within impaired watersheds. Since many ADs need a substrate material imported from outside the farm to be economically sustainable, the EMS is ideal for those farms that want to be good neighbors with reduced farm air emissions, need greater convenience in manure management, and desire to maximize the real cash value of their manure.

As the EMS adapts well to any bedding material, by investing time and dedicating property for the ATL any size operation can begin to treat their manure prior to land application and reduce their overall cost for manure management.

In addition to small farms we envision four possible adaptations of EMS; these examples are provided to show the transferability of this technology to farms desiring various outcomes from an EMS:

Installation of an Energy-Generating AD – if a farm wishes to generate energy using a traditional AD, it would be installed prior to the EMS system whereby the AD digestate discharges into the settling ponds. Since the residence time of a traditional AD is measured in days, there is a great deal of additional treatment that can occur so that the cost savings for land application can still be realized.
Use manure solids for other uses besides land application – if the livestock producer decides to bed their cattle on manure solids or to compost the manure solids for sale off-farm to landscapers or bag and sell direction from the farm then the solids from the SS can be further treated with a screw press or roller then composting by various means.
Greenhouse gas capture and sale of carbon credits – a geosynthetic liner cover can be added to the ATL and all captured gases burned through a flare. However, it should be noted that by removing a significant amount of high organic solids during the initial fiber solids separation step, much less organic material is subject to organic degradation into methane gas.
Greenhouse gas capture and burning of the gases – to generate electricity or heat water (typically for on-farm use or export to an adjoining business, such as a greenhouse).

One future issue to resolve includes educating state governments on the benefits of installing an EMS, especially for those farms that may be under a Consent Order or other regulatory actions or those farms that may need to implement a manure treatment system to mitigate odors from the livestock operation. The duration to install an EMS and get it operational is much shorter than the lead time to design and install a traditional AD so the EMS can help when farms need to implement changes quickly. A second issue to overcome is to properly educate producers on the benefits of EMS and differences between traditional ADs. Swine, beef, and dairy producers who already have a farm irrigation system will have a lower capital investment to begin achieving the reduced manure management costs referenced above.

Author

Matthew J. Germane, P.E., President at Germane Environmental Consulting, LLC MGermane@GECEnvironmental.net

Additional information

https://www.gecenvironmental.com, Envirolytic Technologies, LLC

Acknowledgements

Acknowledgements to Envirolytic Technologies, LLC, Greenville, OH manufacturer of the Earthmentor® N2RTS system and RAM Technologies, LLC, manufacturer of the sand separation equipment used in the EMS for their assistance in providing the laboratory data used in this paper.