2/10/15  

1  

Thank you for participating in SowBridge 2012-13.

To start this presentation, advance one slide by pressing enter or the down or right arrow key.

The following documents also are on this CD.

Breeding Herd Education Series 2012-2013

Timely, relevant & convenient learning

Tracking the energy use on your farm PM2089C.PDF Energy efficient fans for swine production fertility PM2089E.PDF Sizing minimum ventilation … swine housing PM2089j.pdf Energy fundamentals for farm lighting PM2089N.PDF Conserve heat energy in the farm shop PM2089P.PDF Indoor lighting for livestock, poultry, and farm shop facilities PM2089R.PDF Managing controller settings … save energy PM2089T.PDF Using localized heating in swine buildings PM2089V.PDF

Energy Efficiency for the Swine Operation - Sows

Jay D. Harmon, Ph.D., P.E. Professor & Extension Ag Engineer

Agricultural and Biosystems Engineering Iowa State University

200 Davidson Hall Ames, IA 50011

jharmon@iastate.edu

Sowbridge  September  4,  2013  

 

•  Sow Farm – Fuel & Oil $0.58 per pig produced – Utilities $0.28 per pig produced

•  Sow Farm Energy/Utilities $0.86/pig – 2.9% of total expenses – 4.5% of non-feed expenses

Why is Energy Important?

2  

2006-2010 average from: www.finbin.umn.edu

•  Energy is a significant part of expenditures that you CAN do something about

•  Many energy savings can be implemented with very little expense and some with NO additional expense.

Energy is Important

3  

Benchmarks are not well documented. Based on small data set from cooperators.

•  Sow Farms – Electricity: ~240-300 kWh/sow – LP: ~2-3 gal/sow

•  Establish your own benchmarks – Track monthly usage – Helps to know if changes were effective – Raises red flags when usage is abnormal

Annual Benchmarks (Iowa)

4  

Lighting Terminology

•  Lumens: –  Quantity of light output

(lm)

•  Average Rated Life: –  Number of hours for half

of the bulbs to burn out in a laboratory setting.

•  Efficiency: –  Lumens/Watt

•  1200 lm/20W = 60

5  

2/10/15  

2  

Indoor Lighting Choices

6  ISU PM 2089N

Lighting Example

•  Incandescent (long life) –  75 W –  1065 lumens –  1500 hr rated life (assume

750) –  84 cent initial cost

•  Compact Fluorescent –  20 W –  1250 lumens –  12,000 hr rated life (assume

6000) –  $1.79 initial cost

Operating 8 hrs per day all year (2920 hours) • 219 kWh or $21.90/yr

• Need 3.89 bulbs/yr = $3.27

• Total cost = $25.17/yr

• 58 kWh or $5.80/yr

• Need 0.49 bulbs/yr = $0.87

• Total cost = $6.67/yr $18.50 Saving per year per bulb

7  

•  FAR and AWAY the biggest potential for wasted energy

•  80 to 90% of heating energy lost through ventilation when done properly

•  Controller setting and fan selection have a big influence on energy

Ventilation

8  

•  Sample: 24 head farrowing room •  Assume:

•  @ 20 cfm/head & 68 F setpoint •  Mason City, IA •  Minimum fan – 12” rated at 1447 cfm @ 0.05

– Questions: •  How much does over-ventilating cost?

Proper Ventilation Rate?

9  

0

200

400

600

800

1,000

1,200

1,400

Ventilation  Rate

Proper10%  Over20%  Over30%  Over40%  Over50%  OverDouble

Annual LP Usage Estimate 24 Crate Farrowing Room

10  

1-­‐12

”  @  39%

 

1-­‐12”  @  43%

 

1-­‐12”  @  47%

 

1-­‐12”  @  51%

 

1-­‐12”  @  55%

 

1-­‐12”  @  59%

 

1-­‐12”  @  78%

 

Gal

lons

LP

/ per

yea

r

•  Variable speed fans make delivering a prescribed minimum rate difficult. – Too much ventilation = excess LP – Too little ventilation = poor air quality

•  So WHY use them???

Why is Proper Rate so Difficult?

11  

2/10/15  

3  

Why do we use variable-speed fans?

•  Example: 24-crate farrowing room – Needs 480 cfm for minimum – Smallest fan available is about 1,000 cfm

•  Example: 1000-head, B&G barn – Needs ~ 12,000 cfm for minimum – 24” fan = 6,000 cfm

12  

Example 24” Fan Data Sta$c  Pressure  Inches  of  water  

Speed  RPM  

Airflow  cfm  

Efficiency  cfm/W  

0.00   1101   6490   16.1  

0.05   1094   6090   14.7  

0.10   1089   5740   13.4  

0.15   1083   5250   12.2  

0.20   1082   4760   10.8  

0.25   1082   3950   9.0  

0.30   1082   2330   5.6  

Source:  BESS  (2009)  –  www.bess.illinois.edu  

13  

How Efficient Should You Choose?

Diameter  of  fan  (in)   Efficiency  Ra$ng  (cfm/W)  @  0.1  inches  of  water  

Median  RaHng   Top  ¼  RaHng  

<16   7.9   8.7  

16  to  20   10.3   11.2  

22  to  35   13.0   14.6  

36  to  46   15.9   17.2  

48  to  56   18.9   20.4  

>56   20.1   21.5  

Source:  BESS  (2009)  

Look  for  rebates  from  your  electricity  provider  

14  

Fan Efficiency Comparison

Highest Efficiency •  Uses 33,400 kWh/yr •  ~ $3300 @ 10 cents/kWh

Lowest Efficiency •  Uses 60,000 kWh/yr •  ~ $6000 @ 10 cents/kWh

1000  Head  Tunnel  B&G  (250  cfm/head)  •   8  fans  –  24”  ~  7000  cfm  •   X  fans  –  50”  or  51”  –  enough  to  reach  250  cfm/sow  

Savings  of  ~  $2700/yr    

15  

Dirty Fans and Shutters

•  1/8 inch of dirt/dust can cause up to a 40% reduction in fan and shutter air flow. –  Triggers next

ventilation stage sooner costing more energy.

16  

How Does this Impact Performance?

Air  Short-­‐Circuits  

Air  is  lazy  and  follows  the  easiest  path…  therefore  air  comes  from  here  instead  of  the  room.  

Result  is  poorer  air  quality  and  possibly  sicker  pigs.  

17  

2/10/15  

4  

Loose  fi^ng  pit  covers  and  fan  shrouds  allow  short-­‐circuiHng  and  loss  of  venHlaHon    

18   19  

Effect of Drive Belt Tension 48-inch Fan

0

5000

10000

15000

20000

25000

0 20 40 60

Airf

low

(cf

m)

Static Pressure (inches of water)

BESS lab

Airflow before belt adj.

Airflow after belt adj.

Linear (Airflow beforebelt adj.)

Linear (Airflow after beltadj.)

0.08   0.16   0.24  

Sunken Belt 1/4” Due to Worn Pulley

Reduction in fan Speed

20  

Air flow with a worn pulley on a 48” fan

Static Pressure

CFM w/ 3” Pulley

CFM w/ 2.7” Pulley

% loss

0.0” 23,800 19,800 17%

0.05” 22,700 18,500 19 %

0.10” 21, 600 17,100 21%

0.15” 20,300 15,300 25%

21  

Preven$ng  Belt  and  Pulley  Wear  

Improper  alignment  

22  

Preventing Belt and Pulley Wear

University  of  GA  

23  

2/10/15  

5  

Check Electrical Systems

•  At  the  fan  and  in  the  electrical  panel.  

•  ConnecHons  tend  to  loosen  over  Hme  with  heaHng  and  cooling.  

24  

Poorly Maintained Fans:

•  Reduce air quality in winter •  Cause higher stages to run earlier and use

more electricity •  Cause curtains to drop when it is colder

outside •  Reduce the ability to cool animals in summer

25  

•  Annual energy saving of $36 per unit or $5,500 per 1,000 sows

•  Improved livability, 284 extra pigs per 1,000 sows per year

•  Reduced lamp failure rate, 50%

•  Slightly higher ADG of piglets

•  More uniform resting pattern of piglets under the lamp

Energy-efficient 175W lamp vs. conventional 250W lamp - Xin Study

26  

250 W - 7 d

250 W - 14 d

175 W - 7 d

175 W - 14 d

Location Indicates Comfort

27  

Lamp or Mat Control

Variable output allows the creep temperature to be managed while saving energy

28  

Rheostats do not do the same thing. They “chop” voltage… only reducing output, not input.

•  Begin by tracking your energy usage •  Ventilation Management is critical to

energy management •  Controller Settings are an important part of

efficient operation. – No investment in many cases .. Only

management

Summary

29  

2/10/15  

6  

•  Lighting – Lighting is an easy savings – quick payback but questions about bulb life

•  Use proper heat lamp sizes •  Fan maintenance improves air quality and

energy efficiency

Summary

30  

What questions do you have?

31  

ISU  Extension  Farm  Energy  IniCaCve  Farmenergy.exnet.iastate.edu