Power: A Guide To Harnessing The Energy in Livestock Waste
Power: A Guide To Harnessing The Energy in Livestock Waste
Power: A Guide To Harnessing The Energy in Livestock Waste
ow Cwer Po
A guide to harnessing the energy in livestock waste.
Contents
Understanding How to Turn Waste into Watts .................................. 2 A Brief Background on Biomass to Energy Conversion.................... 3 Whats In It For Us? Taking Everyones Perspective into Account .... 4 How Biomass to Energy Conversion Works Anerobic Digestive System ............................................................ 5 Incineration ................................................................................... 10 Gasification................................................................................... 10 Pressing ........................................................................................ 10 Pros and Cons of Biomass Energy Options .................................... 11 Case Studies ................................................................................... 12 Successful Projects, One Step at a Time ........................................ 14 Excess Energy: Sell or Store ........................................................... 15 Glossary .......................................................................................... 16 Sources and Resources .................................................................. 16 About icast and the Autors.............................................................. 17
What is biomass?
When organic material decomposes, it emits gases like methane and carbon dioxide. The combination of these gases is flammable and is called biogas.
License This intellectual work is licensed under Creative Commons Attribution-Noncommercial-Share Alike 3.0 United States. You are free: to Share to copy, distribute, display, and perform the work to Remix to make derivative works Under the following conditions: Attribution. You must attribute the work in the following manner: iCAST - International Center for Appropriate and Sustainable Technology (2009). Cow Power, a guide to harnessing the energy in livestock waste. Funded in part by the Colorado Department of Agriculture. Colorado, USA. Noncommercial. You may not use this work for commercial purposes. Share Alike. If you alter, transform, or build upon this work, you may distribute the
resulting work only under the same or similar license to this one. - For any reuse or distribution, you must make clear to others the license terms of this work. - Any of the above conditions can be waived if you get permission from the copyright holder. - Apart from the remix rights granted under this license, nothing in this license impairs or restricts the authors moral rights. - Your fair use and other rights are in no way affected by the above. Legal Notice While all attempts have been made to verify information provided in this publication, neither the authors nor the publisher assumes any responsibility or liability whatsoever on the behalf of any reader of these materials. The reader of this publication assumes responsibility for the use of these materials and information.
What are greenhouse gases and why are they important to me?
Green house gases (GHG) are carbon dioxide, methane, and other gases which trap heat in the atmosphere, thus contributing to climate change. Methane, produced by cattle, is 23 times more powerful than carbon dioxide and is responsible for 14% of the total GHG concentration in the atmosphere. The Colorado Climate Action Plan will lead the establishment of a carbon credit market through which farmers and ranchers may receive revenue for reducing GHG emissions.
1
Moo.
www.biogas.psu.edu/pdfs/ShortHistoryAD.pdf www.colorado.gov/energy/in/uploaded_pdf/ColoradoPorkcasestudy.pdf
Planet
People
Usually feedlot manure is full of straw and grit. This makes it really hard to use a digester to convert it into energy. However, recent developments are looking very promising, so dont discard digesters if you have a feedlot!
Profit
You can offset the cost of the energy on your farm.
1. Anaerobic Digestion
Mix manure with liquid (which doesnt necessarily mean water) and let the bacteria feast begin. The anaerobic digestion method is the most popular method used in the livestock industry in the U.S. and especially in Europe. There are more than one hundred farms3 in the U.S. using this technology: Colorado Pork (see Case Studies section), Huckabay Ridge Dairy (Texas)4, Vintage Dairy (California)5, and Gordondale Farms (Wisconsin)6, just to name a few.
3
mixer
a. COveredLagOON
This method is quite simple and can work from the septic/waste management system most dairies and other livestock farmers already have in place. Waste is mixed with liquid and piped into an anaerobic covered pond. The pond must be covered to keep oxygen from enteringwhich inhibits biogas productionand the biogas from escaping. This method provides an added benefit that eliminates the odor of the manure from getting into the air or into the ground water. This is true for all three anaerobic digester types.
Digesters use generators to transform the biogas
Waste
Plug Flow System substrate inflow biogas effluent gas effluent substrate fluid
Additionally to the biogas, anaerobic digesters produce solid remnantswhich are also known as digestateand wastewater. After an additional maturation process, digestate can be turned into a high quality soil conditioner that has the potential to reduce the need for inorganic fertilizers. Wastewater can be used to increase the moisture content of the manure entering the process. However, not all wastewater can be used this way, and further treatment is often required.
sludge
C.pLug FLOw
ground injection pipe
mix
Fresh manure is piped into one end of a cylindrical air tight tube and exits out the other end as cow power gas. This tank is also heated and requires the same type of heating equipment, storage, and gas handling system as the complete mix system. However, unlike the other two anaerobic systems we have discussed, this system requires the least amount of liquid and works below ground level. In addition, the heating system is narrower, which takes up less space. The amount of liquid required for the plug flow system is between 87-89% and will provide a steady gas flow all year round. The cost is $200-400 per AU. Furthermore, the EPA reports that the plug flow models are the most efficient and cost effective of all the anaerobic designs.
Covered lagoons are particularly well suited for dairies. Generally the warmer the air the faster the digester will produce methane (within certain limits, of course.) Therefore, in the warmer months farmers will be producing more energy from the waste. This system requires 97% or more liquid to process the manure effectively into methane. The cost is between $150 and $400 per Animal Unit (AU). While this technology is one of the least expensive, it works best in wetter and warmer climates.
Mixer
Digester feed
Digester Effluent
Storage
system size
(see page 11)
water needs
gas
government grants
(see pages 14 - 16)
steam
electricity
unbiased expert
briquettes
technology
(methOds OF CONversiON)
business model
+ Relatively low upfront investment. Simple technology. + Can produce different forms of energy, such as bio High use of water. Somewhat fragile biological bal=
Most suitable for wet manure, and small to large-scale operations. Relatively easy operation. ance. Longer processing periods. Wastewater is not easy to dispose of.
aNaerOBiC digestiON
gasiFiCatiON/syNgas
gas, steam, and electricity, more efficiently. Plumbing of manure not required. Waste can be reused.
iNCiNeratiON
Plumbing of manure not required. Clean handling and storage. No waste: ash can be used as fertilizer.
BriquettiNg / pressiNg
different devices. Simple technology. Easy operation. Low investment. Easily scalable.
3. Gasification
Gasification has been around since the 19th century. Before electricity and natural gas were as popular as they are today, this process was used to produce gas for
10
11
Case Studies
There are a number of case studies that have used many of the technologies mentioned in the guide: Colorado Pork (covered lagoon digester), Five Star Dairy (WI) (complete mix digester), and Emerald Dairy (WI) (mixed plug flow). We provide you these real life examples so you can learn from their experiences. Colorado Pork is tied to Southeastern Colorado Rural Electric, where they produce approximately 43,000 kWh (kilowatt hours) of electricity a month. The farm has 5600-6300 sows that produce 15,000-18,000 gallons of manure a day. That pig power saves the farm $38,700 in electricity and $10,000 for lagoon clean-outs every year. The total cost of the system was $338,000. Colorado Pork received a $75,000 grant from the EPA AgSTAR program, so the system will pay for itself in around 6 to 9 years, possibly earlier if the energy prices continue to rise. ity from the gas and sells it to coop members. The money raised is then used by the farm to pay down the debt on the digester.
Emerald Dairy
In this case Emerald uses a mixed plug-flow system that was designed by GHD, Inc., which has been in operation since 2005. This dairy is twice the size of Five Star and has approximately 1,600 head of dairy cows, which produce 45,000 gallons of waste a day. The dairy owns the system and compresses the methane, which is then hauled to a facility where St. Croix Electric Coop sells it to their customers as natural gas.
Colorado Pork
This farm located in Lamar, Colorado decided to address the issues of their wastes after stringent regulations on hog waste management were passed into law in 1998. Colorado Pork has one of the earliest covered lagoon digester systems in the state. It is used to generate electricity from the waste. They compress the biogas collected from the lagoon to power a combined heat and power system (CHP) that generates 80 kW. This system then recaptures excessive heat, water, and exhaust from the engine and places it back into the digester. They have since added a 30 kW microturbine to their system for more efficiency.
Mmm...
produce waste that is still full of noxious substances. Make sure you ask your provider what kind of waste and byproducts are produced by their technology.
12
13
generated to dry the manure before it enters the gasifier. Solid wastes that are rich in nutrients may constitute a good fertilizer. If this is the case, the possibilities of marketing need to be considered during the feasibility analysis. Independently from the system you are planning to use, an intelligent design will always include a smart strategy to deal with excess energy.
1. shop around.
Find out who has the best prices and the best systems. Talk to your neighbors, county officials and unbiased experts, like the folks at CSU Extension, or iCAST.
2. plan ahead.
A feasibility analysis and business plan will help you compare your different options, forecast possible earnings, and identify potential weaknesses and challenges that you havent considered. Examples of points to take into account are: Who will own the system? What if you and other farmers get together? The provider could own the system and then sell you energy back at a discounted rate. Will other sources of waste increase the efficiency? Are they readily available? Tax credits and other government incentives. Negotiate a profitable utility contract to sell the excess energy. Potential markets for your by-products: liquids, solids, fertilizers. Etc.
energy/renewables/biomass-anaerobicdigestion.asp
In addition, the federal government has even more funding opportunities for farmers. Check out the programs from the USDA found at: www.rurdev.
usda.gov/rbs/busp/bprogs.htm
4. design.
Work together with your technology provider to ensure you understand the benefits, and other implications of your new waste to energy system. Again, you dont have to know it all, seek the help of unbiased experts.
5. Construction.
Understand whats going to happen once the system is running. What if theres a malfunction?
15
gLOssary OF terms
anaerobic digestion: decomposition of organic materials in an environment deprived of oxygen. animal unit (au): 1,000 pounds of live weight Biogas: The combination of mostly methane and carbon dioxide that results from organic decomposition. Biomass: Organic waste used as an energy source. gasification: Any process to transform biomass into syngas. incineration: The process of burning any material, particularly biomass in the context of this guide. methane: A flammable gas; one of the by-products of organic decomposition. syngas: A flammable gas with half the energy density of natural gas.
aBOut iCast
iCAST, International Center for Appropriate & Sustainable Technology, is a non-profit 501(c) (3) organization located in Lakewood, Colorado. We began as an initiative from the Engineering College at the University of Colorado at Boulder and later became registered as an individual organization in 2002. We are dedicated in establishing relationships with local organizations to develop sustainable solutions for underserved populations. Our mission is to promote environmental health, economic viability, and social responsibility. iCAST projects are designed to encourage self-sufficiency based on the development, application and commercialization of appropriate and sustainable technologies. iCAST also provides opportunities for university students to learn how academic studies and concepts such as sustainable development can be practically applied to the real-life problems facing disadvantaged communities. Through participation in service learning projects, students enhance technical and business skills while learning valuable lessons in teamwork, communications and ethics that will help create more valuable professionals. iCAST projects bring together a variety of partners representing industry, government agencies, re-search facilities and educational institutions to serve the needs of local communities. By leveraging available technical, financial and intellectual resources, iCAST helps meet the challenges of the future by building stronger communities and a well-prepared workforce. iCAST has partnered in a number of projects in Colorado and New Mexico: Rialto Theater Adaptive Reuse Feasibility Study in Alamosa, Jemez-Pueblo Waste Water Treatment Project, Affordable Arsenic Filters for drinking water in the San Luis Valley, among many others. To learn more about current or future iCAST projects or if you have questions about any of the technologies mentioned in this guide, please visit our web site at www.icastusa.org Contact iCAST directly: Francisco Flores sustainability project manager email: [email protected] phone: (303) 462-4100 x811
sOurCes
A short history of Anaerobic Digestion: www.biogas.psu.edu/pdfs/ShortHistoryAD.pdf Greenhouse gas emissions, EPA www.epa.gov/climatechange/emissions Ruminant Livestock contribution to Climate Change, Frequently Asked Questions, EPA www.epa.gov/rlep/faq.html Cullar, A., & Webber, M. (2008). Cow power: the energy and emissions benefits of converting manure to biogas (Department of Chemical Engineering, The University of Texas at Austin, USA) AgSTAR Guide to Anaerobic Digesters: www.epa.gov/agstar/operational.html Frequently Asked Questions: www.epa.gov/agstar/faq.html Srivastav, R., & Bielefeldt, A. (2008). Biomass to Energy: A Farm Biomass Management Resource Guide. (Department of Civil, Arch. and Environmental Engineering, University of Colorado at Boulder, USA) Briquette presses for alternate use: www.echotech.org/technical/technotes/Briquete.pdf An Assessment of Technologies for Management and Treatment of Dairy Manure in Californias San Joaquin Valley, Prepared by the San Joaquin Valley Dairy Manure Technology Feasibility Assessment Panel, December 2005 www.arb.ca.gov/ag/caf/dairypnl/dmtfaprprt.pdf
resOurCes
National Renewable Energy Laboratory Renewable Energy Basics Biomass: www.nrel.gov/learning/re_biomass.html Biopower: www.nrel.gov/learning/re_biopower.html Basics of Anaerobic Digestion, Department of Agricultural and Biological Engineering, Penn State University: www.biogas.psu.edu Governors Energy Office Anaerobic Digestion: www.colorado.gov/energy/renewables/biomass-anaerobicdigestion.asp Support for AD feasibility study: www.colorado.gov/energy/resources/funding-opportunities.asp#AD CSU Extension, Animal Manure Management: www.extension.org/animal+manure+management The Intermountain CHP Center www.intermountainchp.org iCAST - International Center for Appropriate and Sustainable Technology www.icastusa.org AgSTAR Loans and Grants for farmers: www.epa.gov/agstar/resources/funding.html Advancing Colorados Renewable Energy Program www.epa.gov/agstar/resources/incentive/ COadvancingcoloradosrenewableenergypro.html
tant was missing in the picture: a purpose. Various experiences showed him that what he wanted to do the most is to contribute to make this a better world, both socially and environmentally. At iCAST he found a place to work for social empowerment and She holds a degree in Visual Communications from the Alberta College of Art & Design and has now worked for design firms and independently nearly seven years.
environmental conservation while having fun as an engineer. He has a B.S. in Telecommunications Engineering from the Instituto Tecnolgico y de Estudios Superiores de Monterrey.
Gillian believes that good design can create a positive impact on society. It is her hope that her graphic design work will help people understand an important message, feel inspired by what they learn, or even act and create positive change.
16
17
You may freely reproduce any part of this guide for non-commercial purposes, we ask only that you properly cite the source. Cite as: iCAST International Center for Appropriate and Sustainable Technology (2009). Cow Power: A guide to harnessing the energy in livestock waste. www.icastusa.org/publications/cowpower.pdf. Colorado, USA.
We want to thank Crowley County and Ordway Feedyard for their participation in the project.
photo Credits Some Rights Reserved Pages 12, 13: Methane Pipe, isnoop/Ian Maddox: www.flickr.com/photos/isnoop/ Full Scale Anaerobic Digester, Waste to Power: Step 2, KQED QUEST: www.flickr.com/photos/kqedquest/ Anaerobic Digesters, Cesar Harada: http://cesarharada.com/ Pages 14: The cows, whose manure produces the biogas, ECOSAN: www.ecosan.nl/