5-year status for an on-farm anaerobic digester – money ...€¦ · • manure/nutrient...
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
USCC 21st Annual Conference | January 30, 2013
Jeffrey H Heath, PE | Principal Manager – Organics Management
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Purpose: Share results of an operating AD
• Project inception & expectations • Status today – changes • Current and future opportunities • Conclusions
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Project inception (2006)
• Location: Sheland Farms, family owned, Adams, NY (cold!)
• Initially 750 cows • Dairy farm looking to control
expenditures • Proactive owner • Manure/Nutrient Management
Adams, NY
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Project inception (2006)
• Incentives for energy recovery and reuse • Siemens Technologies (developer)
– Performance contract – Guaranteed (lower) electric rate – Capital funding – REC incentives – GHD design team
• New York State Energy Research & Development Authority (NYSERDA) – Grants and assistance
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Project inception (2006)
• Develop combined heat and power synergies
• 230,000-gallon AD: 12 to 17-day retention
• 100 kw engine-generator set • Some heat recovery • Net metering • Animal bedding needs
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Project inception (2006)
• Capital budget $1.6M • Annual utility savings ~ $55,000 • Other REC Incentives • Expected payback ~ 16 years • Grant participation - $1.3M!
– NYSERDA – USDA – State
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Project schematic
Power (Net Metering)
Barn Reception Pit (Mixer)
Anaerobic Digestion
Moisture Removal
(H2S) Gen-Set
Flare
Boiler (Propane)
Heat Exchanger
Solids Separation
Effluent to Lagoon
Rotary Drum (Composter)
Animal Bedding
Liquid
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
So how is it going today?
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Still cold in the North Country!
• Insulated digester • Pursuing exhaust heat
exchanger • Added bedding storage
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Animal bedding – an unexpected benefit
• Solids separation very effective • Drum still going strong • 24 / 7 operation • 100% of animal bedding needs • Somatic cell count lowest ever • Greater savings than energy
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Things happen …
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Other “stuff” happens, as well…
• Why clean-outs are important…
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Anaerobic digester mixing
• Hydraulic (water) mixing • Rotomixer • Higher power consumption but less
“scum” accumulation • Works well but requires regular
maintenance
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Seemed like a good idea at the time …
• Private company interested in carbon credits
• Covered lagoon (flare) – methane to CO2
• Carbon credits – Started at $6.00 per metric ton – Now at $0.05 per metric ton
• With cover – can’t mix lagoon
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Developing opportunities
• Additional substrates – Whey – Fat, oil, grease (potential) – Other liquid food waste
• Improve heat recovery – reduce propane use
• More solids recovery • A second digester and Gen-Set
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Immediate impacts
• Whey – 6600 gpd (6 days per week) • Constructing separate holding tanks • Annual income ~ $80,000
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Results: Was it worth it?
• Capital cost higher ($2.0M vs. $1.6M) • Grants help! • 16-year payback? • $55,000 per year electrical savings
(70% of site need) • Can be done in cold climate • Higher maintenance $’s than
anticipated but still not bad • No land spreading – nutrient
management successful
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Unexpected results
• Bedding cost savings > energy savings ($65,000)
• Farm expanded to over 850 cows • Whey generating $80,000 per year • Expansion to merchant waste • Ready to double energy production
capacity
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
Was it worth it?
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5-Year Status for an On-Farm Anaerobic Digester – Money Well Spent?
www.ghd.com
Jeffrey H Heath, PE [email protected]
(315) 679-5800
Thank you!