Anaerobic Digestion of Livestock Maure for Pollution

233 Pages·2007·2.3 MB·English

by  Peter Ciborowski

Anaerobic Digestion of Livestock Manure for Pollution
Anaerobic Digestion of Livestock Manure: A Feasibility
Control and Energy Production: A Feasibility Assessment
Assessment

By Peter Ciborowski
Minnesota Pollution Control Agency

March 2001

Report prepared in completion of USEPA Grant CX 825639-01-0
Although the information in this document has been funded wholly or in part by the
United States Environmental Protection Agency under assistance agreement (CX
825639-01-0) to the Minnesota Pollution Control Agency, it may not necessarily reflect
the views of the Agency and no official endorsement should be inferred.
2
Conversion Factors

Volume and Weight
1 cubic meter (m3) equals 35.315 cubic feet (ft3)
1ft3 equals 0.0283 m3
1 liter (l) equals 0.035 ft3
1 l equals 0.001 m3
1 m3 equals 1000 l
1 ft3 equals 28.317 l
1 kilogram (kg) equals 2.2046 lb.
1 lb. /ft3 equals 16 kg/m3
1 ft3/lb equals 0.062 m3/kg
Manure
1 ft3 manure equals 62 lb.
1 kg solids/m3 equals 0.1% manure solids content
Biogas
1 ft3 biogas equals 0.0716 lb. biogas
1 ft3 biogas equals 0.55 to 0.7 ft3 CH
4
1 ft3 CH equals 0.04235 lb. CH
4 4
1 ft3 CO equals 0.1154 lb. CO
2 2
1 ft3 biogas equals 560 to 713 Btu
1 ft3 CH equals 1018 Btu
4
Energy
1 kWh equals 3412 Btu
1 kWh equals 0.03412 mmbtu
1 mmbtu equals 293 kWh
(thermal)
1 mmbtu equals 61.5 kWh
(electric-diesel generation)
1 kWh equals 0.016 mmbtu or 26.67 ft3 biogas
(electric-diesel generation)

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Table of Contents

Part 1. Technology Description and Literature review

Introduction and General Description of the Technology
Biochemistry of Anaerobic Digestion
Anaerobic Digestion in Waste Processing
Farm Digester Applications
Digester Applications in Minnesota
Physical Make-Up of a Farm Digestion System
Farm Digester Stability: Medium-Rate Farm Reactors
Farm Digester Volatile Solids Degradability
Pollution Control with Anaerobic Digestion
Greenhouse Gas Control Aspects of Anaerobic Digestion
Digester Effluent: Fertilizer Value and By-product Use
Farm Biogas and Energy Potential from Anaerobic Digestion
Digester Design Criteria for Conventional Medium-Rate Farm Reactors
Volumetric Productivity: Medium-Rate Farm Reactors
Net Energy Aspects of Digester Feasibility: Conventional Medium-Rate Farm
Digesters
Recommended Design Criteria for Medium-Rate Farm-Based Digesters
Operational Means to Relax Constraints to Farm Digester Biogas and Energy
Productivity
Digester Sizing for Conventional Medium-Rate Farm Reactors
Biogas Uses
Digester Construction, Materials and Subcomponents
Operating a CSTR, Plug Flow or Slurry-Loop Farm Digester
Economics of Anaerobic Digestion for Conventional Medium-Rate Farm
Digesters
Alternative Reactor Design

Part 2. Study Design

Part 3. Inventory of Livestock on Minnesota Dairy and Swine Feedlots

Dairy Inventory
Swine Inventory

Inventory for Swine Finishing Operations
Inventory for Nursery Pig-to-Finishing Operations
Inventory for Nursery Pig-Only Operations
Inventory for Farrow-to-Wean Operations
4
Inventory for Farrow-to-Finish Operations
Inventory for Farrow-to-Nursery Pig Operations
Inventory for Farrow-and-Finish Operations

Part 4. Economic Assessment of Digester Feasibility on Minnesota Feedlots

Approach to the Economic Analysis of Digester Feasibility
Dairy Assessment
Swine Assessment

Economic Assessment for Finishing Swine Operations
Economic Assessment for Nursery Pig-to-Finishing Swine Operations
Economic Assessment for Nursery Pig-Only Swine Operations
Economic Assessment for Farrow-to-Finish Swine Operations
Economic Assessment for Farrow-to-Nursery Pig Swine Operations
Economic Assessment for Farrow-and-Finish Swine Operations
Summary of Feasibility Assessment for Swine Production

Part 5. Renewable Energy and Methane Control Potential

Renewable Energy Analysis
Methane Control Potential

Part 6. Policy Options

Conclusion

Appendices

List of Reviewers

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List of Figures and Tables

Figure 1. Anaerobic Digestion
Figure 2. Schematic Representation of Farm Digester Set-up with a Conventional Medium-
Rate Reactor
Figure 3. Milk Cows on Minnesota Dairy Farms
Figure 4. Milk Cows on Minnesota Dairy Farms by Herd Size
Figure 5. Swine on Minnesota Swine Farms

Table 1. Necessary Conditions for Mesophilic Digestion
Table 2. Anaerobic Digester Types
Table 3. Digester Type Suitability Based on Housing and Manure Management
Table 4. Environmental Benefits of Digestion
Table 5. Estimates of Anaerobic Digester Effects on Various Measures of Water and Air
Pollution for Conventional Medium-Rate Farm Reactors
Table 6. Biogas Productivity per Head of Livestock for Conventional Medium-Rate Farm
Anaerobic Digesters
Table 7. Biogas Productivity per Lactating Cow from Anaerobic Digestion of Dairy Manure
for Conventional Medium-Rate Farm Reactors
Table 8. Anaerobic Digester Productivity per 1,000 lb. of Livestock Liveweight:
Conventional Medium-Rate Farm Reactors
Table 9. Digester Biogas Productivity: Literature Point Estimates for Conventional Medium-
Rate Farm Reactors
Table 10. Potential Energy Production per Lactating Cow from Farm Anaerobic Digestion of
Dairy Manure
Table 11. Potential Energy Production per Head of Livestock from Anaerobic Digestion with
Conventional Medium-Rate Farm Reactors
Table 12. Biogas Productivity in Relationship to Waste Type and Collection and Digester
Configuration: Conventional Medium-Rate Farm Reactors
Table 13. Digester Productivity: Conventional Medium-Rate Farm Digestion
Table 14. Digester Net Energy Status in Relation to Influent Manure
Total Solids: Conventional Medium-Rate Farm Reactors
Table 15. Digester Net Energy Considerations: Conventional Medium-Rate Farm Digester
Design
Table 16. Design Parameters for Optimal CSTR Net Energy Production
Table 17. Digester Design Parameters: Range of Estimates Typically Found in the Literature
for Conventional Medium-Rate Farm Reactors
Table 18. Operational Means to Raise Digester Biogas and Energy Productivity
Table 19. Summary of Biological and Design Limits to Anaerobic Digestion, Conventional
Medium Rate Farm Reactors
Table 20. Approximate Digester Size in Relation to Waste for Processing: Conventional
Medium-Rate Farm Digesters
Table 21. Farm Digester Components: CSTR. Plug Flow and Slurry-Loop Design
Table 22. Feasibility Thresholds for Various Physical Digester Parameters: Conventional
Medium-Rate Farm Reactors
Table 23. Potential Sources of Public and Private Benefit from Anaerobic Digestion:
Monetized and Nonmonetized Benefits
6
Table 24. Digester Capital Costs: Conventional Medium-Rate Farm Digestion, Dairy Feedlots
Table 25. Digester Capital Costs: Conventional Medium-Rate Farm Digestion, Swine
Feedlots, Slatted Floors, Below Barn Pit Storage
Table 26. Estimates of Herd Size Thresholds for Economic Viability of Digester with
Conventional Medium-Rate Farm Reactors
Table 27. Estimates of Herd Sizes Not Economically Viability for Digester Deployment with
Conventional Medium-Rate Farm Reactors
Table 28. Preconditions for Successful Digester Deployment on Farm
Table 29. Economic Factors in the Analysis of Anaerobic Digester Feasibility
Table 30. Trends Favoring Digester Deployments in the US Livestock Industry
Table 31. Summary Statistics for Dairy Herd, Dairy Manure and Volatile Solids
Production, and Methane Generation: 1998
Table 32. Dairy Herd Inventory by Herd Size
Table 33. Swine Production Systems
Table 34. Swine Characteristics
Table 35. Distribution of Swine in Minnesota Feedlots
Table 36. Summary Statistics for Swine Producing Feedlots in Minnesota
Table 37. Summary Statistics for Swine Production in Minnesota by Animal Type
Table 38. Potential Methane Generating Capacity of Minnesota Swine Feedlots by Production
Type and Manure Storage and Handling System
Table 39. Summary Statistics for Finishing Swine Systems
Table 40. Finishing Swine Inventory: All Manure Management Systems
Table 41. Finishing Swine Inventory: Below Barn Pit Storage Systems
Table 42. Summary Statistics for Nursery Pig-to-Finishing Swine Systems
Table 43. Nursery-Pig-to-Finisher Inventory by Number of Finishers
Table 44. Nursery Pig-to-Finisher Inventory for Below Barn Pit Storage Systems by Number of
Finishers
Table 45. Nursery Pig-to-Finisher VS Inventory for Below Barn Pit Storage Systems by
Number of Finishers
Table 46. Nursery Pig-to-Finisher Maximum Potential Methane Generation Inventory for
Below Barn Pit Storage Systems by Number of Finishers (in mmcf)
Table 47. Nursery Pig-to-Finisher Emission Inventory for Below Barn Pit Storage Systems by
Number of Finishers (in mmcf of CH )
4
Table 48. Summary Statistics for Nursery Pig Swine Systems
Table 49. Nursery Pig-Only Swine Inventory: All Manure Management Systems
Table 50. Nursery Pig-Only System Inventory: Below Barn Pit Storage
Table 51. Summary Statistics for Farrow-to-Wean Swine Systems
Table 52. Farrow-to-Wean System Inventory: All Manure Management Systems
Table 53. Farrow-to-Wean Systems Inventory: Below Barn Pit Storage Systems
Table 54. Summary Statistics for Farrow-to-Finish Swine Systems
Table 55. Farrow-to-Finish Inventory by Number of Sows
Table 56. Farrow-to-Finish Inventory for Below Barn Pit Storage Systems by Number of Sows
Table 57. Farrow-to-Finish VS Inventory for Below Barn Pit Storage Systems by Number of
Sows
Table 58. Farrow-to-Finish Maximum Potential Methane Generation Inventory for Below Barn
Pit Storage Systems by Number of Sows (in mmcf)
Table 59. Farrow-to-Finish Emission Inventory for Below Barn Pit Storage Systems by Number
of Sows (in mmcf of CH )
4
Table 60. Summary Statistics for Farrow-to-Nursery Pig Swine Systems
7
Table 61. Farrow-to-Nursery Pig System Inventory by Number of Sows
Table 62. Farrow-to-Nursery Pig System Inventory for Below Barn Pit Storage Systems by
Number of Sows
Table 63. Farrow-to-Nursery Pig System VS Inventory for Below Barn Pit Storage Systems by
Number of Sows
Table 64. Farrow-to-Nursery Pig System Maximum Potential Methane Generation Inventory for
Below Barn Pit Storage Systems by Number of Sows (in mmcf)
Table 65. Farrow-to-Nursery Pig System Emission Inventory for Below Barn Pit Storage
Systems by Number of Sows (in mmcf of CH )
4
Table 66. Summary Statistics for Farrow-and-Finish Swine Systems
Table 67. Farrow-and-Finish Inventory by Number of Sows
Table 68. Farrow-and-Finish Inventory for Below Barn Pit Storage Systems by Number of
Sows
Table 69. Farrow-and-Finish VS Inventory for Below Barn Pit Storage Systems by Number of
Sows
Table 70. Farrow-and-Finish Maximum Potential Methane Generation Inventory for Below
Barn Pit Storage Systems by Number of Sows (in mmcf)
Table 71. Farrow-and-Finish Emission Inventory for Below Barn Pit Storage Systems by
Number of Sows (in mmcf of CH )
4
Table 72. Policy Initiatives Investigated
Table 73. Sources for Parameter Estimates Used in Default Screening in This Study
Table 74. Significant Parameter Estimates Used in this Study
Table 75. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.06/kwh Farm Electric Rates, $0.015 Electricity Sale Price to Utilities, 14%
Internal Rate of Return Hurdle
Table 76. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.06/kwh Farm Electric Rates, $0.015 Electricity Sale Price to Utilities, 10%
Internal Rate of Return Hurdle
Table 77. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.07/kwh Farm Electric Rates, $0.015 Electricity Sale Price to Utilities, 14%
Internal Rate of Return Hurdle
Table 78. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.07/kwh Farm Electric Rates, $0.0275 Electricity Sale Price to Utilities, 14%
Internal Rate of Return Hurdle
Table 79. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.07/kwh Farm Electric Rates, $0.04 Electricity Sale Price to Utilities, 14%
Internal Rate of Return Hurdle
Table 80. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.07/kwh Farm Electric Rates, $0.015 Electricity Sale Price to Utilities, 10%
Internal Rate of Return Hurdle
Table 81. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.07/kwh Farm Electric Rates, $0.0275 Electricity Sale Price to Utilities, 10%
Internal Rate of Return Hurdle
8
Table 82. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Feed Apron and Scrape Rest,
$0.07/kwh Farm Electric Rates, $0.04 Electricity Sale Price to Utilities, 10% Internal
Rate of Return Hurdle
Table 83. Sensitivity Analysis for Dairy Digesters: Threshold Herd Size, Free Stall, Flush
Parlor and Feed Apron and Scrape Rest, $0.07/kwh Farm Electric Rates, $0.04
Electricity Sale Price to Utilities, 10% Internal Rate of Return Hurdle
Table 84. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.06/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 85. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.06/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 86. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 87. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.0275 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 88. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.04 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 89. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 90. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.0275 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 91. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Free Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.04 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 92. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.06/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 93. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.06/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 94. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
9
Electric Rates, $0.015 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 95. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.0275 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 96. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.04 Electricity Sale Price to Utilities, 14% Internal Rate of Return
Hurdle
Table 97. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.015 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 98. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.07/kwh Farm
Electric Rates, $0.0275 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 99. Threshold Herd Size for Dairy Operations for Economically Viable Deployment of
Anaerobic Digesters: Tie Stall, Flush Parlor and Scrape Rest, $0.06/kwh Farm
Electric Rates, $0.04 Electricity Sale Price to Utilities, 10% Internal Rate of Return
Hurdle
Table 100. Summary of Threshold Herd Size for New Dairies with Free Stall Housing and
$0.04/kwh Electricity Buyback Rate
Table 101. Threshold Herd Size for Finishing Operations (Growing Pig Train Included) for
Economically Viable Deployment of Anaerobic Digestion: $0.06/kwh Farm Electric
Rates, $0.015 Electricity Sale Price to Utilities, Default Total Solids, 14% Internal
Rate of Return Hurdle
Table 102. Threshold Herd Size for Finishing Operations (Growing Pig Train Included) for
Economically Viable Deployment of Anaerobic Digestion: $0.06/kwh Farm Electric
Rates, $0.015 Electricity Sale Price to Utilities, Default Total Solids, 10% Internal
Rate of Return Hurdle
Table 103. Threshold Herd Size for Finishing Operations (Growing Pig Train Included) for
Economically Viable Deployment of Anaerobic Digestion: $0.06/kwh Farm Electric
Rates, $0.04/kwh Electricity Sale Price to Utilities, Default Total Solids, Net Energy
Accounted for, 14% Internal Rate of Return Hurdle
Table 104. Herd Size for Finishing Operations (Growing Pig Train Included) for Economically
Viable Deployment of Anaerobic Digestion: $0.06/kwh Farm Electric Rates,
$0.04/kwh Electricity Sale Price to Utilities, Default Total Solids, Net Energy
Accounted for, 10% Internal Rate of Return Hurdle
Table 105. Threshold Herd Size for Finishing Operations (Growing Pig Train Included) for
Economically Viable Deployment of Anaerobic Digestion: $0.07/kwh Farm Electric
Rates, $0.04/kwh Electricity Sale Price to Utilities, Default Total Solids, Net Energy
Accounted for, 10% Internal Rate of Return Hurdle
Table 106. Threshold Herd Size for Finishing Operations (Growing Pig Train Included) for
Economically Viable Deployment of Anaerobic Digestion: $0.06/kwh Farm Electric
Rates, $0.015/kwh Electricity Sale Price to Utilities, 3% Total Solids, Net Energy
Accounted for, 14% Internal Rate of Return Hurdle
Table 107. Threshold Herd Size for Finishing Operations (Growing Pig Train Included) for
Economically Viable Deployment of Anaerobic Digestion: $0.07/kwh Farm Electric
10