Integrated Manure Biogas Systems:Impacts on Farmers & Their Rural Communities
Bruce T. BowmanExpert Committee on Manure Management
Canadian Agri-Food Research Council
Presented to: Enhancing Biogas Opportunities in Alberta
Edmonton, AB
April 3, 2006
Objective 1
To identify and discuss links between:
Environmental issues,
Economic issues, and
Societal issues …..
…. challenging livestock farming that can be mediated by manure processing. (e.g. treating the entire manure volume)
Farm Bio-Industries
A.D.Manure
Processing
Rural Society Benefits
FarmEconomic
Benefits
Objective 2
To demonstrate the central role of manure processing & farm bio-energy systems for
revitalizing rural economies
- GHG’s- Odours- Pathogens- Deadstock - Conservation
- Recycling- Nutrient availability
EnvironmentalRemediation
NutrientIssues
Biogas
Large water volumes Carbon (O.M.) - new use
Three primary issues to manage:
Nutrients Odours Pathogens
Priority Issues for Manure Management
............................. but also …….
Energy = $$$ Soil Quality
Two major loss pathways:
As volatile ammonia (NH3)
Rapid losses can occur at any stage of handling with continued exposure to air.
As nitrous oxide (N2O) (GHG – 310x effect of CO2)
More prevalent under reducing/denitrifying conditions.
Conserving Nutrients:Gaseous Nitrogen losses from Manure
pH 9.4 [NH3] / [NH4+] = 0.50 (50.0%) @(20°C)pH 7.5 [NH3] / [NH4+] = 0.018 ( 1.8%)pH 7.0 [NH3] / [NH4+] = 0.0056 ( 0.56%)
Keep pH near 7 (neutrality) to minimize NH3 losses
Conserving Nutrients:Ammonia losses from Manure
Ammonium (NH4+) - non-volatile; Ammonia (NH3) - volatile
Ammonia losses are rapid from bare floors; Remove manure when fresh to closed storage to minimize NH3 losses.
Why should we minimize these losses?
Increasing replacement costs for commercial N = $$$- Urea production energy intensive + GHG emissions
Ammonia emissions receiving more scrutiny from both animal and human health perspectives (smog potential – aerosols - lower Fraser Valley in BC)
Ammonia - a toxic substance under CEPA (Canadian Environmental Protection Act)
Secondary source for nitrous oxide (N2O) production.
Conserving Nutrients:Ammonia losses from Manure
Trends in the Fertilizer Industry -- Post WWII (1945) --
Cheap & plentiful mineral fertilizers helped spur intensification and specialization in production agriculture after 1945.
Cereal production (cash-cropping) is often separate from livestock production, relying only on mineral fertilizers.
Has created some regional nutrient surpluses (Quebec, North Carolina, mid-west USA).
Consequence: Nutrients in livestock manures originating from imported feeds - not recycled back to source for next cash-crop production cycle.
Food Products
HumanConsumptionCereal Production
LARGE SCALE ONE-WAY NUTRIENT FLOWSRecycling Nutrients & Organic Matter
AnnualMineral
FertilizerAdditions
Nutrients & O.M. NOT recycled
Regional nutrient excesses
Local Farm
Manure
Odour Pathogens
Wastes
Landfills
Nutrient inputs
Conditions for exporting surplus manure nutrients:1. Odour-free2. Pathogen-free3. Dried (dewatered) for transportation
Manure processing (anaerobic digestion) can remediate these issues. Composting also… BUT without renewable energy component.
Exporting Surplus Livestock Nutrients
The need to export surplus nutrients will increase with continuing intensification of livestock operations.
Mimicking fermentation in a ruminant stomach (no oxygen). (most digesters are mesophylic ~ 37°C – body temp.)
Closed system – no nutrient or gaseous losses (e.g. N) closer N:P ratio than with raw manure – better for crop growth
~ 50% of carbon biogas (CH4 + CO2, 65:35, tr. H2S)
Labile fraction of carbon biogas (easily converted in soil)
Biogas generate electricity by co-gen units or for thermal uses
Digested nutrients in more plant available, predictable form
~ 25% C blown off conventional slurries by bacterial decomposition
Anaerobic DigestionA Few Facts
Certain antibiotics can STOP digestion processes
Processing Time: 20 – 35 days @ 37°C
Odour Reduction: ~ 90% or more
Pathogens Reduced to: ~ 1/1000 to 1/10,000 (37°C) Eliminate pathogens of concern by pasteurizing
(1hr @ 70°C)
Anaerobic Digestion…….. More Facts
Economics
Renewable energy generation
- energy independence
Export surplus Livestock nutrients Emission reduction trading credits Tipping fees – food-grade wastes
- 20 – 30% energy boost
Environmental
Reduce odours & pathogens - flexibility to export surplus nutrients
Conserve nutrients (N)- reduce mineral fertilizer use
Reduce gaseous emissions - GHGs, ammonia, hydrogen sulfide
Societal
Reduce siting / zoning problemsRegain public support
Opportunity for new rural partnerships
Why Digest Manure?Potential Benefits
Yield / Productivity
Environmental Issues
S
oci
etal
Co
nce
rnsBalancing Issues
in a Sustainable Farming Operation
1. Yield/Productivity (Economics)
2. Environmental Issues
Both are science-based
3. Societal Concerns
Perception-based, emotional
Can over-ride other 2 factors.
Opposition difficult to reverse once initiated
Pre-1965 1-D
Since 1970s 2-D
Since 1990s 3-D
Challenges Facing Confined Livestock Operations
Increasing price volatility (S.E. Asia demand)
Less reliable supplies (Declining fossil reserves) Result Escalating N fertilizer & fuel costs
Continuing vulnerability of farm incomes Increasing costs of compliance Global market competition
Increasing regulations – nutrients, pathogens Municipal waste issues (biosolids) Rendering / deadstock – limited uses/value GHG emission reductions – Kyoto protocol Increasing livestock intensities – odour
Energy
Environment
/ Health
Economics
Co-Digestion of Livestock Manures Co-mingling of different manure sources (on-farm, off-farm)
and / or the addition of other organic wastes to the on-farm manure stream. Purpose increase digester efficiency. – Safest option: food-grade wastes (beverage wastes, cooking oils, vegetable wastes, etc.)
Benefits Increases biogas output at minimal cost (20 – 30%) Facilitates recycling of organic wastes from the food &
beverage industry (tipping fees?)
Limitations Current regulations for importing off-farm manure or wastes
require Certificate of Approvals – Ontario changes to allow up to 20% off-farm inputs.
Know your inputs – Keep them consistent. Sudden changes disrupt digester performance.
Pre-mix + equilibrate input wastes before digestion.
Digester bacteria are highly sensitive to some antibiotics
(e.g. tetracyclines) and to some feed additives.
Best to pasteurize inputs before digestion (70°C for 1hr). Minimizes competition with digester bacterial culture. Minimizes pathogens in digestate final product.
Co-Digestion of Livestock Manures
1. Investment, Incentive & Payback Issues
2. Managing Regulatory Issues
3. Developing Reliability, Trust & Expertise
4. Managing Complexity
Barriers to Adoption of
Anaerobic Digestion Technology
1. Investment, Incentive & Payback Issues
$300K - >$5M, depending on scale of operation – Plant Life –- 20 – 30 yr before reconditioning – Payback –- <7 yr (electricity, solids sales, emission credits)– Breakeven –- 110 cow dairy; 1200 hog; 25,000 poultry
Policy Issues – Need complimentary policies & incentives across 3 levels of government - Environ. Loan Guarantees to manage risk (US. Farm Bill) - Standard Purchase Offers for green electricity (Ontario - 11¢/Kwh) - Business Energy Tax Credits (Oregon) – up to 35% of cost
Feasibility Assessment - value of odour & pathogen-free manure? A Switch” - Change from societal opposition Opportunities for new partnerships.
Overcoming Barriers to Adoption of
Anaerobic Digestion Technology
Sale of Processed Solids (Org. Fertilizers) – Surplus nutrients exported – promotes nutrient re-use
Emission Trading System (currently developing)- sell credits for reducing emissions – 2 cases in USA (Jan. 2006)- recent value of e-CO2 in Europe ~ $10/tonne
Tipping Fees for Receiving Food-Grade Wastes – boost biogas output (20 – 30%) increases revenue
1. (cont’d) Payback - Establishing Revenue Streams
Electricity Purchase Agreements– Std. Purchase Offers – single most important long-term stable planning and ability borrow capital
Overcoming Barriers to Adoption of
Anaerobic Digestion Technology
2. Managing Regulatory Issues
Electrical generation – interconnects for net/dual meteringPower Utilities starting to change policies for small renewable energy generators (up to 500 kw) (2-phase/3-phase lines)
Off-farm biomass inputs (boost biogas production)can result in C. of A.’s – regulations being changed to allow up to 20% food-grade wastes
Managing emissions / dischargesBiogas flare, fugitive GHGs, liquid discharges
Fertilizer/amendment products - quality assurance, certification; labeling requirements
Overcoming Barriers to Adoption of
Anaerobic Digestion Technology
3. Developing Reliability, Trust & Expertise
Small number of installed Ag digesters in Canada (< 2 doz. in advanced design or already built)
Limited knowledgeable Canadian design/build firms- very limited track record
Demonstration Program – AAFC/NRCAN - 3 yr - Energy Co-generation from Agricultural/Municipal Wastes (ECoAMu) 4 digesters (AB – Beef; SK – Hogs; ON – Beef; QC - Hogs)
ECoAMu Program On ManureNet http://res2.agr.gc.ca/initiatives/manurenet/en/hems/ecoamu_main.html
Overcoming Barriers to Adoption of
Anaerobic Digestion Technology
4. Managing Complexity
A.D. adds yet another new technology to be
managed by farmer – Time; Skill-sets
Service agreements Co-Generation – Power Utility – electricity export
Remote monitoring & process control in real-time – practical technology now available from several Canadian companies
Overcoming Barriers to Adoption of
Anaerobic Digestion Technology
Resource Centre
Electricity
Clean Water
Heat CO2
Co-Located Industries
Greenhouses(Veg., Flowers)
Fish FarmSlaughterhouse
Bio-ethanol plant
A Centralized Co-op Rural Energy System
Potential Components
LiquidDigestate
DewateredDigestate
Food GradeOrganics
Local MunicipalOrganics
Rendering, Deadstock
Organic Fertilizers
water
Co-gen
Wet Distillers Grain - 15% savings
Farm Bio-Energy Systems: The Concept
ElectricityManure solids
Emission credits
Tipping fees
Heat Electricity
Clean waterCO2
Municipal Organic wastes
Co-located industriesLocal biomass inputs
OdoursPathogens
Nutrient export & Recycling
Reduce herbicide
use
GHG reductionsDeadstock
EnvironmentalSolutions
IncomeStabilization
Rural Revitalization
Farm Bio-Energy
EnergyIndependence
Independent
ofLivestock
prices
1. A.D. livestock manure processing system Biogas electricity + excess thermal energy used in bio-
fuel production facility – increases efficiency
2. Bio-Fuel Plant (output ≤ 10 M L/yr alcohol/bio-diesel) Biomass sources – corn, sweet potato, switchgrass, etc.
< 10,000 acres local inputs per facility Byproducts from alcohol plant – value-added animal feed
3. Local Bio-Fuel Refueling Centre Refueling Network Decreased transportation costs Decreased GHG emissions, air pollution
1 Rentec Renewable Energy Technologies
Components of Integrated Farm Energy System:Anaerobic Digester – Bio-Fuel Facility1
Lynn Cattle Turnkey Integrated Manure Processing Facility
Indoor Beef Feedlot: 5,500 head (11,000/yr throughput)
Farm Owner/Operator: Mr. Phil Lynn & Family
Farm Size: 4,500 ac Location: NW of Lucan, Ontario
Project Start: Early 2003; Expected Startup: Spring 2006
Design/Builder: Rentec Renewable Energy Technologies
Lynn Cattle Integrated Manure Processing Facility
Rentec Renewable Energy Technologies www.rentec.ca
Expected Outputs 11,000 head/yr beef (2 cycles of 5,500) 7,000 Mwhr/yr electricity surplus (=1600 users @350Kwh/mo) 9,000 tonnes/yr organic soil amendment/fertilizers 10M L/yr alcohol production Direct GHG emission reductions – 25,000 tonnes/yr e-CO2
Lynn Cattle Integrated Manure Processing Facility
Partnerships
Local Municipality – will purchase green electricity for municipal buildings, street lighting, sports complexes. A “Green Community”
Lynn Cattle Integrated Manure Processing Facility
1. Centralized Bio-Fuel Production (> 200 M L/yr) Controlled by large energy companies or large co-ops Large source area for biomass inputs high transportation costs
(GHG emissions & air pollution) Most benefits accrue corporate investors
2. Distributed Farm-based Bio-Fuel Production (<10 M L/yr) Large single farm operations or small farm co-ops Local sources for biomass inputs (↓Transportation/GHG emissions) Increased local employment + Municipal tax base Distributed production facilitates re-fueling centre network Most benefits accrue local farms & rural communities
Comparison ofBio-Fuel Production Models
Once-in-lifetime transition from fossil bio-fuels happening NOW…. Farmers & rural commmunities need to get involved to benefit.
Examples of Manure-Powered Bio-fuel Production
Panda Energy, Dallas, TX is building three, $120M 100 M gal/yr manure-powered ethanol plants in Texas, Colorado and Kansas.
E3 Biofuels LLC, Omaha, NE is building a $45 M closed loop alcohol-from-manure facility at a Mead, NE 30,000 head feedlot (8 M bu. of corn/yr 24 M gal/yr) – to be in production Fall 2006.
ManureNet Digester Compendium:
http://res2.agr.gc.ca/initiatives/manurenet/en/man_digesters.html
Future livestock operations will be structured around bio-energy energy independence & financial stability for farmers, using anaerobic digestion/co-generation technologies.
1. Facilitates conservation and recycling of resources (nutrients, carbon = $$$)
2. Income stabilization through diversification (New revenue streams independent from cyclic commodity prices, providing stable base for income!)
In Summary - Benefits
3. Reduces environmental footprint Reduced odours, pathogens diminished societal concerns Flexibility for applying/exporting processed manure products Kills weed seeds – reduces herbicide usage
4. Strengthens rural economy using local inputs (employment, resource inputs – biomass crops)
Municipality can be a partner (green wastes, buy energy) Farmer co-ops take increased control of rural businesses
ADD value to products BEFORE leaving farm gate Reduced transportation costs for manufacturing (bio-based)
In Summary - Benefits
Conclusions
Economics are rapidly improving, but policies, incentives & regulations need to be coordinated across 3 levels of government to facilitate adoption. Environ. Loan guarantees, long-term std. purchase offers, etc Access to electrical grids for small renewable generators Farmland energy & conservation subsidies considered by WTO as
legitimate “green box” programs – not subject to trade sanctions.
Need to increase technical support and assistance to foster timely adoption of the technology.
Agriculture sector needs to get involved in bio-fuels production at farm-scale – one-time transition from fossil sources benefits to rural communities.
Micro CHP (Combined Heating and Power)Distributed Power Generation
Electricity + Heat generated at each residenceSmall engine + generator replace furnace & water heater
Grid
85 % Efficiency
Centralized Gas-Fired Plant Micro CHP
INPUT 100 100
Waste Energy 57 <15
Line Losses 4 - 7 0
Electricity 39 20
Useful Heat Energy 0 >65
Net Useful Energy 36-39 85+
Micro CHP (Combined Heating and Power)Distributed Power Generation
Micro CHP units run on natural gas or biogas
More efficient use of resources (15% vs 60% loss)
(39 vs 85 % efficiency)
Excess electricity exported to grid (10 kw units - $$)
Blackout & Terrorist proof (totally distributed generation)
Significant GHG reductions
Almost eliminate line losses (electricity used on-site)
In Ontario – 2 million homes would produce 10,000 Mw
– equivalent to several nuclear power plants
No environmental assessments required – minor impacts
Several thousand units being tested in Europe & Japan;
USA senate holding hearings on technology potential
Micro CHP (Combined Heating and Power)
Advantages
Resource Information on
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