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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