Anaerobic Digesters
www.AnaerobicDigesters.com
Biomethane
- Best Renewable Fuel?
Anaerobic Digesters
- Best
Renewable Energy Technology?
BIOMETHANE FACTS
1.
Biomethane is One of the Most Common and
Harmful of All
Greenhouse
Gas Emissions.
2. Biomethane is 21 Times More Harmful
to the Climate than
Carbon
Dioxide Emissions. Stated another way, Biomethane
Causes Global Warming and Climate Change to
Increase
21 Times Faster than Carbon
Dioxide Emissions.
3. Biomethane Is A "Renewable
Natural Gas."
4. Biomethane is One of the Easiest and
Most Profitable of all
Greenhouse
Gas Emissions to Recover and Control.
We
Help Cities, Counties and the Agricultural Community Reduce Their Greenhouse
Gas Emissions & Carbon
Dioxide Emissions By Recovering Valuable Biomethane
from
Wastewater Treatment Plants and Landfills
For
more information, call (512) 220 - 1498 or
email: info @ cogeneration . net
California and Sweden Sign Agreement to Jointly Develop
Biomethane and Other Renewable Fuels
Thursday, 29 June 2006
Sacramento, California USA and Sweden
In a ceremony held at the Ministry of the Environment in Stockholm, representatives of the Kingdom of Sweden and the State of California signed an agreement pledging the two governments and their related industries to work together to develop
bioenergy, with a particular emphasis on Biomethane.
“Through a strong working relationship between its industry and government, Sweden is showing how bioenergy can be developed in a cost-effective manner that benefits its economy and environment. We are extremely pleased to have signed this Memorandum of Understanding
(MOU) that will provide a basis for intensified collaboration between Swedish and California officials to develop a thriving bioenergy industry in California,” said Joe Desmond, Undersecretary for the California Resources Agency.
In particular, Sweden has been a global leader in terms of converting
biowaste, largely agricultural material and residues, into usable Biomethane. This gas is then used to either generate electricity, residential heating, or as a transportation fuel.
More than 8,000 vehicles in Sweden are powered by a combination of natural gas and
Biomethane. The vehicles include transit buses, refuse trucks, and more than 10 different models of passenger cars. There are more than 25
Biomethane production facilities in Sweden and 65 filling stations. The Swedish
Biomethane industry has been growing at an annual rate of about 20 percent over the last five years.
According to the Swedish Gas Association, more than 50 percent of the methane used to power Sweden’s natural gas vehicles now comes from biological sources, up from 45% last year. Natural gas vehicle sales in Sweden are increasing at the rate of 25% per annum.
Sweden was motivated to develop its Biomethane industry because it has no natural gas reserves, to more efficiently manage its waste, and to meet its obligations under the Kyoto Accord. Since
Biomethane is developed from methane sources that would normally release into the atmosphere, it’s considered one of the most climate friendly fuels. Methane
(and Biomethane) is 21 times more reactive as a greenhouse gas than carbon dioxide (CO2). Sweden is currently meetings its objectives and schedule as outlined in the Kyoto accord.
Biomethane is developed by heating up and breaking down biomaterials in an
(Anaerobic Digester) digester. Among other raw materials, Swedish operators feed their
Anaerobic Digesters with slaughterhouse waste, swine manure, and even grassy crops. After the materials breakdown over a 20 day period, technology is then used to remove the impurities and produce
Biomethane. Once cleaned-up, Biomethane is 98 percent methane and easily meets the Swedish and California pipeline standards.
The Memorandum of Understanding can be accessed on the California Resources Agency Web site:
http://resources.ca.gov/press_documents/CaliforniaSwedenBiofuelsMOU.pdf
We
are designing and engineering the world's best Anaerobic
Digesters.
Anaerobic
Digesters recover valuable and toxic Biomethane from
organic materials and prevents the Biomethane -
which has a Global Warming
Potential that is 21 times more harmful to our climate than Carbon
Dioxide Emissions - from entering the atmosphere.
Biomethane,
which we also
refer to as "Renewable
Natural Gas" is used as a renewable fuel for our cogeneration
and trigeneration power plants.
Alternatively, we may sell the Biomethane to
a customer and transport it to them from our Anaerobic
Digesters via natural gas pipelines.
We believe Anaerobic
Digesters and Biomethane represent
exciting opportunities for generating renewable
natural gas and profits - for multiple reasons:
1.
Anaerobic
Digesters take an existing liability and waste (Biomethane)
and convert it into an asset and "profit generator."
2.
Anaerobic
Digesters mitigate and reverse climate change and global warming by preventing Biomethane
to escape into the atmosphere, which is one of the major causes of climate
change and global
warming.
Of all Greenhouse
Gas Emissions, Biomethane is 21 times
more harmful to the environment than Carbon
Dioxide Emissions.
3.
Anaerobic
Digesters are vital for renewable energy production and helping our
country's drive for energy independence.
4.
EVERY wastewater treatment plant as well as ALL Concentrated
Animal Feeding Operations (CAFO's) - IN EVERY COUNTRY - will soon be installing Anaerobic
Digesters to prevent Biomethane from
entering the atmosphere and help reverse climate change as well as for use
as a renewable fuel.
5.
The country of Sweden is the global leader in Biomethane
production. Sweden has identified the Biomethane
opportunities and is converting biowaste derived from agricultural material and residues into usable
Biomethane. The Biomethane is used to generate
clean, renewable electricity, residential heating, and also as a transportation fuel. Biomass sources make up 45% of Sweden’s
Biomethane. Sweden's Biomethane industry has been growing at an annual rate of around 20% over the last five years.
Biomethane powers more than 8,000 transit buses, garbage trucks, and 10 different models of passenger cars in Sweden.
Sweden now has more than 25 Biomethane production facilities and 65 filling stations.
The country believes that since Biomethane is developed from
natural, organic sources that would have been released into the atmosphere,
that Biomethane is considered one of the most climate-friendly fuels.
Biomethane is 98% methane and easily meets the Swedish and California pipeline standards.
Anaerobic Digesters
www.AnaerobicDigesters.com
Sales, Engineering, Products, Services and Information
We
are designing and engineering the world's best Anaerobic
Digesters. Anaerobic Digesters
recover Biomethane from organic materials and
prevents the Biomethane - which has a Global
Warming Potential that is 21 times more harmful to our climate than Carbon
Dioxide Emissions - from entering the atmosphere.
The Biomethane, which we also refer to as
"Renewable Natural Gas"
is then used as a fuel for our cogeneration
and trigeneration power plants.
Alternatively, we may sell the Biomethane to
a customer and transport it to them from our Anaerobic
Digesters via natural gas pipelines. We believe Anaerobic
Digesters are so vital for renewable energy production and preventing
climate change, that all wastewater treatment plants as well as most
CAFO's (concentrated
animal feeding operations) - no matter what country - will be
installing Anaerobic Digesters to
prevent Biomethane from entering the
atmosphere and help reverse climate change.
Biomethane
is "Renewable
Natural Gas" and is generated from organic sources. Biomethane
is used just like natural gas and is one of the best and cleanest of all
renewable fuels. "Biogas
Plants" are being built for processing organic wastes which
produce Biomethane.
A Biogas
Plant may have one or more of the following Biomethane
technologies for Biomethane
production; Anaerobic Digesters, Anaerobic
Lagoons, Biomass Gasification, Biogas
Recovery, Concentrated
Animal Feeding Operations Landfill
Gas to Energy, and Methane Gas
Recovery.
We
provide Anaerobic Digester, Anaerobic
Lagoon, Biogas Recovery, BioMethane,
Biomass Gasification, and Landfill
Gas To Energy project development services.
Unlike
most companies, we are equipment supplier/vendor neutral. This means we
help our clients select the best equipment for their specific application.
This approach provides our customers with superior performance, decreased
operating expenses and increased return on investment.
Renewable
Energy Technologies provides the following power and
energy project development services:
-
Project
Engineering Feasibility & Economic Analysis Studies
-
Engineering,
Procurement and Construction
-
Environmental
Engineering & Permitting
-
Project
Funding & Financing Options; including Equity Investment, Debt
Financing, Lease and Municipal Lease
-
Shared/Guaranteed
Savings Program with No Capital Investment from Qualified Clients
-
Project
Commissioning
-
3rd
Party Ownership and Project Development
-
Long-term
Service Agreements
-
Operations
& Maintenance
-
Green
Tag (Renewable Energy Credit, Carbon Dioxide Credits, Emission
Reduction Credits) Brokerage Services; Application and Permitting
We
are Renewable Energy
Technologies specialists and develop clean power and energy projects
that will generate a "Renewable
Energy Credit," Carbon
Dioxide Credits and Emission
Reduction Credits. Some of our products and services solutions
and technologies include; Absorption
Chillers, Adsorption Chillers, Automated
Demand Response, Biodiesel
Refineries, Biofuel Refineries, Biomass
Gasification, BioMethane, Canola
Biodiesel, Coconut Biodiesel, Cogeneration,
Concentrating Solar Power, Demand
Response Programs, Demand Side
Management, Energy
Conservation Measures, Energy
Master Planning, Engine Driven
Chillers, Solar CHP, Solar
Cogeneration, Rapeseed Biodiesel,
Solar Electric Heat Pumps, Solar
Electric Power Systems, Solar
Heating and Cooling, Solar
Trigeneration, Soy Biodiesel, and Trigeneration.
Unlike
most companies, we are equipment supplier/vendor neutral. This means we
help our clients select the best equipment for their specific application.
This approach provides our customers with superior performance, decreased
operating expenses and increased return on investment.
For more information: call us at: 832-758-0027
What
is an Anaerobic Digester?
An Anaerobic Digester is a device for optimizing the anaerobic digestion of biomass and/or animal manure, and possibly to recover biogas
also referred to as BioMethane for energy production. Digester types include batch, complete mix, continuous flow (horizontal or plug-flow, multiple-tank, and vertical tank), and covered lagoon.
What is Anaerobic Digestion?
Anaerobic digestion is a biological process that produces a gas principally composed of methane (CH4) and carbon dioxide (CO2) otherwise known as biogas. These gases are produced from organic wastes such as livestock manure, food processing waste, etc.
Anaerobic processes could either occur naturally or in a controlled environment such as a biogas plant. Organic waste such as livestock manure and various types of bacteria are put in an airtight container called digester so the process could occur. Depending on the waste feedstock and the system design, biogas is typically 55 to 75 percent pure methane. State-of-the-art systems report producing biogas that is more than 95 percent pure methane.
The
U.S.
EPA AgSTAR Program Background
The
U.S. EPA AgSTAR is an outreach program designed to reduce methane emissions
from livestock waste management operations by promoting the use of biogas
recovery systems. A biogas recovery system is an anaerobic digester with
biogas capture and combustion to produce electricity, heat or hot water.
Biogas recovery systems are effective at confined livestock facilities that
handle manure as liquids and slurries, typically swine and dairy farms.
Anaerobic digester technologies provide enhanced environmental and financial
performance when compared to traditional waste management systems such as
manure storages and lagoons. Anaerobic digesters are particularly effective
in reducing methane emissions but also provide other air and water pollution
control opportunities. AgSTAR provides an array of information and tools
designed to assist producers in the evaluation and implementation these
systems, including:
-
Conducting farm
digester extension events and conferences
-
Providing “How-To”
project development tools and industry listings
-
Conducting performance
characterizations for digesters and conventional waste management
systems
-
Operating a toll free
hotline
-
Providing farm
recognition for voluntary environmental initiatives
-
Collaborating with
federal and state renewable energy, agricultural, and environmental
programs
Biomethane Emissions from Animal Waste
Management
Biomethane
emissions occur whenever animal waste is managed in anaerobic conditions.
Liquid manure management systems, such as ponds, anaerobic lagoons, and
holding tanks create oxygen free environments that promote Biomethane
production. Manure deposited on fields and pastures, or otherwise handled in
a dry form, produces insignificant amounts of Biomethane. Currently, livestock
waste contributes about 8 percent of human-related Biomethane
emissions in the
U.S.
Given the trend toward larger farms, liquid manure management is expected to
increase. For more information on international emissions, projections, and
mitigation costs, see International
Analyses.
Biomethane
from Anaerobic Digesters
Biomethane
is a gas that contains molecules of methane with one atom of
carbon and four atoms of hydrogen (CH4 ). It is the major component of the
"natural" gas used in many homes for cooking and heating. It is
odorless, colorless, and yields about 1,000 British Thermal Units (Btu)
[252 kilocalories (kcal)] of heat energy per cubic foot (0.028 cubic
meters) when burned. Natural gas is a fossil fuel that was created eons
ago by the anaerobic decomposition of organic materials. It is often found
in association with oil and coal.
The same types of anaerobic bacteria that produced natural gas also
produce Biomethane
today. Anaerobic bacteria are some of the oldest forms of
life on earth. They evolved before the photosynthesis of green plants
released large quantities of oxygen into the atmosphere. Anaerobic
bacteria break down or "digest" organic material in the absence
of oxygen and produce "biogas" as a waste product. (Aerobic
decomposition, or composting, requires large amounts of oxygen and
produces heat.) Anaerobic decomposition occurs naturally in swamps,
water-logged soils and rice fields, deep bodies of water, and in the
digestive systems of termites and large animals. Anaerobic processes can
be managed in a "digester" (an airtight tank) or a covered
lagoon (a pond used to store manure) for waste treatment. The primary
benefits of anaerobic digestion are nutrient recycling, waste treatment,
and odor control. Except in very large systems, biogas production is a
highly useful but secondary benefit.
Biomethane
produced in anaerobic digesters consists of methane (50%-80%),
carbon dioxide (20%-50%), and trace levels of other gases such as
hydrogen, carbon monoxide, nitrogen, oxygen, and hydrogen sulfide. The
relative percentage of these gases in biogas depends on the feed material
and management of the process. When burned, a cubic foot (0.028 cubic
meters) of biogas yields about 10 Btu (2.52 kcal) of heat energy per
percentage of Biomethane
composition. For example, Biomethane
composed of 65%
methane yields 650 Btu per cubic foot (5,857 kcal/cubic meter).
Digester Designs
Anaerobic digesters are made out of concrete, steel, brick, or plastic.
They are shaped like silos, troughs, basins or ponds, and may be placed
underground or on the surface. All designs incorporate the same basic
components: a pre-mixing area or tank, a digester vessel(s), a system for
using the biogas, and a system for distributing or spreading the effluent
(the remaining digested material).
There are two basic types of digesters: batch and continuous. Batch-type
digesters are the simplest to build. Their operation consists of loading
the digester with organic materials and allowing it to digest. The
retention time depends on temperature and other factors. Once the
digestion is complete, the effluent is removed and the process is
repeated.
In a continuous digester, organic material is constantly or regularly fed
into the digester. The material moves through the digester either
mechanically or by the force of the new feed pushing out digested
material. Unlike batch-type digesters, continuous digesters produce biogas
without the interruption of loading material and unloading effluent. They
may be better suited for large-scale operations. There are three types of
continuous digesters: vertical tank systems, horizontal tank or plug-flow
systems, and multiple tank systems. Proper design, operation, and
maintenance of continuous digesters produce a steady and predictable
supply of usable biogas.
Many livestock operations store the manure they produce in waste lagoons,
or ponds. A growing number of these operations are placing floating covers
on their lagoons to capture the biogas. They use it to run an
engine/generator to produce electricity.
The Digestion Process
Anaerobic decomposition is a complex process. It occurs in three basic
stages as the result of the activity of a variety of microorganisms.
Initially, a group of microorganisms converts organic material to a form
that a second group of organisms utilizes to form organic acids.
Methane-producing (methanogenic) anaerobic bacteria utilize these acids
and complete the decomposition process.
A variety of factors affect the rate of digestion and biogas production.
The most important is temperature. Anaerobic bacteria communities can
endure temperatures ranging from below freezing to above 135° Fahrenheit
(F) (57.2° Centigrade [C]), but they thrive best at temperatures of about
98°F (36.7°C) (mesophilic) and 130°F (54.4°C) (thermophilic). Bacteria
activity, and thus biogas production, falls off significantly between
about 103° and 125°F (39.4° and 51.7°C) and gradually from 95° to 32°F
(35° to 0°C).
In the thermophilic range, decomposition and biogas production occur more
rapidly than in the mesophilic range. However, the process is highly
sensitive to disturbances such as changes in feed materials or
temperature. While all anaerobic digesters reduce the viability of weed
seeds and disease-producing (pathogenic) organisms, the higher
temperatures of thermophilic digestion result in more complete
destruction. Although digesters operated in the mesophilic range must be
larger (to accommodate a longer period of decomposition within the tank
[residence time]), the process is less sensitive to upset or change in
operating regimen.
To optimize the digestion process, the digester must be kept at a
consistent temperature, as rapid changes will upset bacterial activity. In
most areas of the United States, digestion vessels require some level of
insulation and/or heating. Some installations circulate the coolant from
their biogas-powered engines in or around the digester to keep it warm,
while others burn part of the biogas to heat the digester. In a properly
designed system, heating generally results in an increase in biogas
production during colder periods. The trade-offs in maintaining optimum
digester temperatures to maximize gas production while minimizing expenses
are somewhat complex. Studies on digesters in the north-central areas of
the country indicate that maximum net biogas production can occur in
digesters maintained at temperatures as low as 72°F (22.2°C).
Other factors affect the rate and amount of biogas output. These include
pH, water/solids ratio, carbon/nitrogen ratio, mixing of the digesting
material, the particle size of the material being digested, and retention
time. Pre-sizing and mixing of the feed material for a uniform consistency
allows the bacteria to work more quickly. The pH is self-regulating in
most cases. Bicarbonate of soda can be added to maintain a consistent pH,
for example when too much "green" or material high in nitrogen
content is added. It may be necessary to add water to the feed material if
it is too dry, or if the nitrogen content is very high. A carbon/nitrogen
ratio of 20/1 to 30/1 is best. Occasional mixing or agitation of the
digesting material can aid the digestion process. Antibiotics in livestock
feed have been known to kill the anaerobic bacteria in digesters. Complete
digestion, and retention times, depend on all of the above factors.
Producing and Using Biogas
As long as proper conditions are present, anaerobic bacteria will
continuously produce biogas. Minor fluctuations may occur that reflect the
loading routine. Biogas can be used for heating, cooking, and to operate
an internal combustion engine for mechanical and electric power. For
engine applications, it may be advisable to scrub out hydrogen sulfide (a
highly corrosive and toxic gas). Very large-scale systems/producers may be
able to sell the gas to natural gas companies, but this may require
scrubbing out the carbon dioxide.
Using the Effluent
The material drawn from the digester is called sludge, or effluent. It is
rich in nutrients (ammonia, phosphorus, potassium, and more than a dozen
trace elements) and is an excellent soil conditioner. It can also be used
as a livestock feed additive when dried. Any toxic compounds (pesticides,
etc.) that are in the digester feedstock material may become concentrated
in the effluent. Therefore, it is important to test the effluent before
using it on a large scale.
Economics
Anaerobic digester system costs vary widely. Systems can be put together
using off-the-shelf materials. There are also a few companies that build
system components. Sophisticated systems have been designed by
professionals whose major focus is research, not low cost. Factors to
consider when building a digester are cost, size, the local climate, and
the availability and type of organic feedstock material.
In the United States, the availability of inexpensive fossil fuels has
limited the use of digesters solely for biogas production. However, the
waste treatment and odor reduction benefits of controlled anaerobic
digestion are receiving increasing interest, especially for large-scale
livestock operations such as dairies, feedlots, and slaughterhouses. Where
costs are high for sewage, agricultural, or animal waste disposal, and the
effluent has economic value, anaerobic digestion and biogas production can
reduce overall operating costs. Biogas production for generating cost
effective electricity requires manure from more than 150 large animals.
Below-ground, concrete anaerobic digesters have proven to be especially
useful to agricultural communities in parts of the world such as China,
where fossil fuels and electricity are expensive or unavailable. The
primary purpose of these anaerobic digesters is waste (sewage) treatment
and fertilizer production. Biogas production is secondary.
Accomplishments
The AgSTAR Program has been very successful in encouraging the development
and adoption of anaerobic digestion technology. Since the establishment of
the program in 1994, the number of operational digester systems has doubled.
This has produced significant environmental and energy benefits, including Biomethane
emission reductions of approximately 124,000 metric tons of carbon
equivalent and annual energy generation of about 30 million kWh. The graph
below shows the historical use of biogas recovery technology for animal
waste management.
The
development of anaerobic digesters for livestock manure treatment and energy
production has accelerated at a very fast pace over the past few years.
Factors influencing this market demand include: increased technical
reliability of anaerobic digesters through the deployment of successful
operating systems over the past five years; growing concern of farm owners
about environmental quality; an increasing number of state and federal
programs designed to cost share in the development of these systems; and the
emergence of new state energy policies (such as net metering legislation)
designed to expand growth in reliable renewable energy and green power
markets.
In
the past 2 years alone, the number of operational digester systems has
increased by 30%. For more detailed information on anaerobic digester use in
the
U.S.
,
go to the Guide
to Operational Systems or see the AgSTAR
2003 Digest
The process of anaerobic digestion consists of three steps.
The first step is the decomposition (hydrolysis) of plant or animal matter. This step breaks down the organic material to usable-sized molecules such as sugar. The second step is the conversion of decomposed matter to organic acids. And finally, the acids are converted to
Biomethane
gas.
Process temperature affects the rate of digestion and should be maintained in the mesophillic range (95 to 105 degrees Fahrenheit) with an optimum of 100 degrees F. It is possible to operate in the thermophillic range (135 to 145 degrees F), but the digestion process is subject to upset if not closely monitored.
Many anaerobic digestion technologies are commercially available and have been demonstrated for use with agricultural wastes and for treating municipal and industrial wastewater.
At Royal Farms No. 1 in Tulare, California, hog manure is slurried and sent to a Hypalon-covered lagoon for biogas generation. The collected biogas fuels a 70 kilowatt (kW) engine-generator and a 100 kW engine-generator. The electricity generated on the farm is able to meet monthly electric and heat energy demand.
Given the success of this project, three other swine farms (Sharp Ranch, Fresno and Prison Farm) have also installed floating covers on lagoons. The Knudsen and Sons project in Chico, California, treated wastewater which contained organic matter from fruit crushing and wash down in a covered and lined lagoon. The biogas produce is burned in a boiler. And at Langerwerf Dairy in Durham, California, cow manure is scraped and fed into a plug flow digester. The biogas produced is used to fire an 85 kW gas engine. The engine operates at 35 kW capacity level and drives a generator to produce electricity. Electricity and heat generated is able to offest all dairy energy demand. The system has been in operation since 1982.
Most anaerobic digestion technologies are commercially available. Where unprocessed wastes cause odor and water pollution such as in large dairies, anaerobic digestion reduces the odor and liquid waste disposal problems and produces a biogas fuel that can be used for process heating and/or electricity generation.
Technology
assessment
This section
describes the anaerobic digestion (AD) process, outlines guidelines for
assessing the feasibility of AD and biogas usage at a swine facility and
provides summary information on AD system performance and reliability.
Anaerobic
Digestion Technology Description
AD promotes the
bacterial decomposition of the volatile solids (VS) in animal wastes to
biogas, thereby reducing lagoon loading rates and odor. The primary
component of an AD system is the anaerobic digester, a waste vessel
containing bacteria that digest the organic matter in waste streams under
controlled conditions to produce biogas. As an effluent, AD yields nearly
all of the liquid that is fed to the digester. This remaining fluid
consists of mostly water and is allowed to evaporate from a secondary
lagoon, land-applied for irrigation and fertilizer value or recycled to
flush manure from the swine building to the digester.
The benefits of AD
include:
-
Odor
reduction;
-
Reduction
in the biological oxygen demand of treated effluent by up to 90
percent, reducing the risk for water contamination;
-
Improved
nutrient application control, because up to 70 percent of the nitrogen
in the waste is converted to ammonia, the primary nitrogen constituent
of fertilizer;
-
Reduced
pathogens, viruses, protozoa and other disease-causing organisms in
lagoon water, resulting in improved herd health and possible reduced
water requirements; and
-
Potential
to generate electricity and process heat.
AD takes place in
three steps: hydrolysis, acid formation, and Biomethane
generation. During
the first step, hydrolysis, bacterial enzymes break down proteins, fats
and sugars in the waste to simple sugars. During acid formation, bacteria
convert the sugars to acetic acid, carbon dioxide and hydrogen. Then the
bacteria convert the acetic acid to methane and carbon dioxide, and
combine carbon dioxide and hydrogen to form Biomethane
and water.
Digester
technologies that can be used to collect Biomethane
from swine facilities
include:
Although a
sequencing batch reactor has been used for AD at one swine facility in the
United States
, this technology is considered to be experimental, and thus is not
included in this report. This report focuses on technologies that have
verifiable performance characteristics, namely, covered anaerobic lagoons
and complete mix digesters.
Appendix B provides
contact information that can help producers find AD system
designers/installers, odor control technologies, generators, heating and
cooling equipment, and other information to help manage air and water
quality at hog facilities.
Covered lagoon
digesters are the simplest AD system. These systems typically consist of
an anaerobic combined storage and treatment lagoon, an anaerobic lagoon
cover, an evaporative pond for the digester effluent, and a gas treatment
and/or energy conversion system. Figure 1 shows a typical schematic for a
floating covered anaerobic lagoon.

Source: EPA. (July 1997). AgStar Handbook: A Manual for Developing Biogas
Systems at Commercial Farms in the
United States
. EPA 430-B-97-015.
Washington
,
DC
. pp. 1-3.
Figure 1 .
Covered anaerobic lagoon digester
Covered lagoon
digesters typically have a hydraulic retention time (HRT) of 40 to 60
days. The HRT is the amount of time a given volume of waste remains in the
treatment lagoon. A collection pipe leading from the digester carries the
biogas to either a gas treatment system such as a combustion flare, or to
an engine/generator or boiler that uses the biogas to produce electricity
and heat. Following treatment, the digester effluent is often transferred
to an evaporative pond or to a storage lagoon prior to land application.
Climate affects the
feasibility of using covered lagoon digesters to generate electricity.
Engine/generator systems typically do not produce sufficient waste heat to
maintain temperatures high enough in covered lagoon digesters in the
winter to sustain consistently high biogas production rates. Using propane
or natural gas to provide additional heat for the lagoon contents is
typically not an economically viable option. Without that additional heat,
most covered lagoon digesters produce less biogas in colder temperatures,
and little or no gas below 39 FACE= "Symbol">° F. As a
result, covered lagoon digesters are most appropriate for use in warm
climates if the biogas is to be used for energy or heating purposes.
Complete mix
digester systems consist of a mix tank, a complete mix digester and a
secondary storage or evaporative pond. The mix tank is either an
aboveground tank or concrete in-ground tank that is fed regularly from
underfloor waste storage below the animal feedlot. Waste is stirred in the
mix tank to prevent solids from settling in the waste prior to being fed
to the digester. The complete mix digester is essentially a
constant-volume aboveground tank or in-ground covered lagoon that is fed
daily from the mix tank. Complete mix digesters with in-ground lagoons
often employ covers similar to those used in covered lagoon digesters. In
the digester, a mix pump circulates waste material slowly around the
heater to maintain a uniform temperature. Hot water from an
engine/generator cogeneration water jacket or boiler is used to heat the
digester. A cylindrical aboveground tank, such as that shown in Figure 2,
optimizes biogas production, but is more capital intensive than in-ground
tanks. The only operating AD system in
Colorado
that recovers Biomethane
for energy use is a complete mix
digester, located
at Colorado Pork LLC near
Lamar
,
Colorado
.
Source:
EPA. (February 1997). AgStar Technical Series: Complete Mix Digesters –
A Biomethane
Recovery
Option for All Climates. EPA 430-F-97-004.
Washington
,
DC
.
Figure 2 .
Complete
mix digester schematic
Complete mix
digesters have an HRT of 15 to 20 days, which means that complete mix
digesters can reduce the overall lagoon volume required for waste storage
and treatment. This makes complete mix digesters comparable to covered
lagoon digesters in cost, despite the increased complexity of stirring,
mixing and plumbing components. In addition, biogas production rates, and
therefore heat and electricity production, are greater and more consistent
than for covered lagoons. This can help reduce system payback periods
compared to covered lagoon systems. Like covered lagoon systems, digester
effluent from complete mix digesters is frequently stored in evaporative
ponds or storage lagoons.
System
Requirements
This section
provides guidelines for conducting a preliminary assessment of the
feasibility of using AD at a swine facility. Although AD system
requirements will vary depending on the application and system design,
there are some rule-of-thumb measures that should be noted when assessing
the feasibility of AD at a given location. For AD to potentially be
technically feasible and cost-effective, a swine facility should:
-
Simultaneously
house at least 2,000 animals with a total live animal weight of at
least 110,000 pounds,
-
Have
no more than 20 percent variation in animal population throughout the
year,
-
Collect
waste at one central location such as an underfloor pit,
-
Collect
waste daily or every other day, or can convert to an equivalent
collection system,
-
Have
manure free of large amounts of bedding or other foreign materials,
and
-
Have
some manure storage capability to maintain a steady digester feedstock
supply
If the above
characteristics are present, the facility is a possible candidate for AD.
Many pre-existing waste storage and treatment lagoons are too large to
practically or cost-effectively employ covers over their entire area.
Partial covers may be an option to recover Biomethane
from these older
systems, as an alternative to installing a completely new storage and
treatment lagoon system.
If energy recovery
is to be employed, Biomethane
production and gas quality should be considered
and compared to energy requirements at the facility. Daily biogas
production at installed farm-based anaerobic digesters in the
United States
varies from 24,000 to 75,000 cubic feet, or an energy equivalent of 13 to
42 million British thermal units (Btu) (assuming 55 percent methane
content for Biomethane). Covered
anaerobic
from anaerobic digesters should be chosen
according to the end-use objective for the system. Complete mix digesters
can produce heat and electricity at a constant rate throughout the year
because heat recovery can be used to heat the digesters in the winter.
Covered lagoon digesters can consistently produce biogas only in months
when the temperature exceeds 39 degrees Fahrenheit.
Facilities that are
located south of the line of climate limitation in Figure 3 are usually
warm enough for cost-effective energy recovery from covered lagoon
digesters. In most cases, facilities north of the climate line in Figure 3
are too cold for cost-effective energy recovery from covered lagoon
digesters. Complete mix digesters can be used in cold or warm climates. If
odor control is the only objective, either covered lagoon or complete mix
digesters may be used, but odor control will be less effective in the
winter for covered lagoon digesters south of the line of climate
limitation in Figure 3. In general, complete mix digesters are the most
appropriate choice for use in
Colorado
.

Source: EPA. (July 1997). AgStar Handbook: A Manual for Developing Biogas
Systems
at Commercial Farms in the
United States
. EPA 430-B-97-015. pp. 4-12.
Figure 3 . Line of
climate limitation for biogas energy recovery
Table 2 shows which
digesters are appropriate for the waste collection strategies at covered
swine facilities. Complete mix digesters can operate with a waste total
solids (TS) percentage between 3 and 10 percent, while covered lagoon
digesters can use waste with a TS percentage less than 2 percent.
Table
2 . Matching a digester to existing waste collection practices
|
Collection
system
|
Percent TS
required
|
Digester type
|
Suitable
climate
|
|
Scrape
|
3-8
|
Complete mix
|
Warm or cold
|
|
Pit storage
|
3-8
|
Complete mix
|
Warm or cold
|
|
Flush
|
<2
|
Covered lagoon
|
Warm
|
|
Pit recharge
|
<3
|
Covered lagoon
|
Warm
|
|
Gravity
drainage
|
|
|
|
|
Pull
plug
|
<2
|
Covered lagoon
|
Warm
|
|
Managed
pull-plug
|
3-6
|
Complete mix
|
Warm or cold
|
Source – Adapted
from: EPA. (July 1997). AgStar Handbook: A Manual for Developing Biogas
Systems at Commercial
Farms in the
United States
. EPA 430-B-97-015. pp. 4-15.
Appendix C describes
each of the various waste collection technologies listed in Table 2.
Biogas
Utilization Options
This section
discusses some of the biogas utilization options that are available for
use with AD. Electricity generation with waste heat recovery
(cogeneration) and direct combustion and use in equipment that normally
uses propane or natural gas are the two primary options for biogas
utilization. Electricity generated using biogas can be generated for
on-farm use or for sale to the electric power grid if an economically
attractive power purchase agreement can be negotiated through the local
utility or rural electric cooperative. Direct combustion allows the gas to
be used in existing equipment that normally uses propane or natural gas
such as boilers or forced air furnaces with minor equipment modifications.
Combustion is usually a seasonal use for biogas, as most boiler and
furnace applications are only required during the winter. The EPA FarmWare
manual describes some characteristics of engine/generator and direct
combustion systems that can be used with biogas. The following subsections
draw from the FarmWare manual to provide some basic information about the
use of these systems at covered swine facilities and other farm
applications.
Electricity
Generation
Commercial
electricity generation systems that use biogas typically consist of an
internal combustion (IC) engine, a generator, a control system and an
optional heat recovery system.
IC engines designed
to burn propane or natural gas are easily converted to burn biogas by
adjusting carburation and ignition systems. Such engines are available in
nearly any capacity, but the most successful varieties are industrial
engines that are designed to work with wellhead natural gas. A
biogas-fueled engine will normally convert 18 to 25 percent of the biogas
Btu value to electricity.
Two types of
generators are used on farms: induction generators and synchronous
generators. Induction generators operate in parallel with the utility and
cannot operate as a stand-alone power source. Induction generators derive
their phase, frequency and voltage from the utility. Synchronous
generators operate as an isolated system or in parallel to the utility,
and require more sophisticated intertie systems to match output to utility
phase, frequency and voltage.
Control systems are
required to protect the engine and the utility. Control packages are
available that can shut the engine off due to mechanical problems, utility
power outage or utility voltage and frequency fluctuations, or in the
event that excess power is generated that the utility will not accept.
Generators that operate in parallel with the utility system, such as
induction generators, require an intertie system with safety relays to
shut off the engine and disconnect from the utility in the event of a
problem. Intertie negotiations with a utility for induction generators are
typically much easier than for a synchronous generator, due to the level
of control the utility has over the characteristics of power entering the
grid from an induction generator. The primary advantage of a synchronous
generator is its ability to act as a stand-alone power source. However, if
operated as an isolated system, a synchronous generator must be oversized
to meet the highest electrical demand, while operating less efficiently at
average or partial loads. Due to the system size and more complicated
control requirements, a synchronous generator operating as an isolated
system is typically more expensive than an induction generator.
Biogas engines
reject approximately 75 to 82 percent of the energy input as waste heat.
This waste heat can be used to heat the digester and/or provide water or
space heat to the facility. Commercial heat exchangers can recover waste
heat from the engine water cooling system and the engine exhaust,
recovering up to 7,000 Btu/hour for each kW of generator load. Waste heat
recovery increases the energy efficiency of the system to 40 to 50
percent.
Emerging new
digester and distributed electricity generation technologies could create
new opportunities for on-farm electricity generation using Biomethane.
Numerous companies are now able to use the Biomethane
from anaerobic digesters installed at farms where the manure is
converted into Biomethane.
Ongoing research and
development is focusing on the use of microturbines and fuel cells for
converting biogas to electricity. Microturbines are high-speed,
small-scale (typically less than 100 kW) gas-driven turbine systems that
produce electricity efficiently, have low emissions and require little
maintenance.
Other
companies are using Biomethane
produced from
landfill gas and biomass gasification as its
fuel source. Fuel cells are an emerging technology that operate, in
principle, like a battery, but do not run out of charge. Instead, fuel
cells equipped with a fuel reformer can use any type of hydrocarbon fuel,
and run continuously as long as fuel is available. Fuel cells can convert
fuel to electricity at efficiencies close to 40 percent, compared to 30
percent for the most efficient engine. In addition, fuel cell emissions
include heat, some of which can be recovered for other applications,
water, and carbon dioxide.
The Department of
Energy’s WRBEP funded a project in fiscal year 2000 in
San Luis Obispo, California
that will demonstrate electricity generation from methane using a
prototype microturbine at a 350-cow farm. The project will be using a 25
kW microturbine prototype to generate electricity at the
California
Polytechnic
State
University’s demonstration farm.
Direct
Combustion
Direct combustion of
biogas on-site in a boiler or forced air furnace can provide seasonal heat
to nurseries, farrowing rooms and other facilities at a swine facility. A
cast iron natural gas boiler can be used for most farm boiler
applications. The air-fuel mixture will require adjustment and burner jets
will need to be enlarged for use with low-Btu gas. Cast iron boilers are
available in many sizes, from 45,000 Btu/hour and up. Untreated biogas may
be used, but all metal surfaces of the boiler housing should be painted to
prevent corrosion. Flame tube boilers with heavy gauge flame tubes may be
used if the exhaust temperature is maintained above 300 FACE=
"Symbol">° F to prevent condensation. Forced air furnaces
can be used in place of direct fire room heaters, but biogas must be
treated to remove hydrogen sulfide because of potential corrosion problems
in metal ductwork.
System
Performance and Benefits of AD
There are several
measures of waste management system performance that are relevant for
producers considering the use of AD. These include:
-
Odor
control,
-
Water
quality protection
-
Energy
production.
AD is the only waste
management strategy available that provides the option to recover methane
for energy production.
The APCD has
determined that the minimum standard for compliance with odor control
regulations for waste vessels and impoundments is an 80 percent reduction
in all odor-causing gases, including hydrogen sulfide, ammonia and
volatile organic compounds from waste vessels or impoundments. Table 3
compares the effectiveness of some of the odor control methods being
implemented at covered swine facilities in
Colorado
. Lagoon covers and AD are among the most effective means of reducing
odors from waste storage and treatment systems. However, several
strategies may be combined to increase the effectiveness of individual
odor control strategies at a facility. As an example, feed additives can
be used in conjunction with biofilters, surface aeration or solids
separation to increase overall odor control from waste storage and
treatment lagoons. In addition, any lagoon odor control technology should
be accompanied by an overall odor management program using best management
practices as described in Appendix D.
Table
3 . Odor control effectiveness of management strategies for
anaerobic lagoons
|
Odor control
technology
|
Percent (%)
odorous gas emissions reduction
|
|
Feed
processing/additives
|
|
|
Grinding
feed
|
5-12
|
|
Wet-feeding
hogs (3:1 water to feed)
|
23-31
|
|
Reducing
sulfur-containing amino acids
|
49-63
|
|
Adding
fiber (soybeans, hulls to diet)
|
Up
to 68
|
|
Biofilters
|
50
|
|
Solids
separation
|
50-60
|
|
Soil injection
of waste upon land application
|
50-80
(land application odors only)
|
|
Surface
aeration
|
Up
to 85
|
|
Aerobic cap
|
Up
to 90
|
|
Lagoon
additives
|
Up
to 90
|
|
Lagoon covers
|
80-90
|
|
Anaerobic
digestion
|
80-90
|
|
Composting
|
Up
to 100 for well-managed systems
|
Source: Iversen,
Kirk and Jessica Davis. (February 1999). Innovations in odor management
technology.
Colorado
State
University
. Agricultural and Resource Policy Report. APR-99-02.
Fort Collins
,
CO
.
In addition to
regulating odors from waste lagoons, the new odor control regulations have
requirements for waste that is applied to agricultural land. The new
regulations for waste treatment at covered swine facilities require that
waste applied to agricultural land and not injected be treated to remove
at least 65 percent of the TS and over 90 percent of the total volatile
fatty acids or 60 percent of total VS. If not treated, waste applied to
agricultural land must be injected or knifed into the soil upon
application. Land application is not permitted between November 1 and
February 28. Of the waste management strategies in Table 3, four will help
reduce the TS and VS content prior to land application.
-
Wet-feeding,
-
Solids
separation,
-
AD
and
-
Composting.
Wet feeding can
reduce the TS and VS by a value equal to the dilution rate of the feed
(i.e., 3:1 ratio of water to feed). However, introducing this type of
feeding system increases water requirements and may increase required
anaerobic lagoon volumes. Solids separation can reduce TS by 30 to 45
percent. Solids separation methods include screen separators, mechanical
presses, settling tanks, settling basins, vacuum filters and many other
means. An efficient AD installation will reduce the TS percentage by up to
76 percent and VS by up to 90 percent. Of the above technologies, AD with
covered anaerobic lagoons is the only one the APCD considers a proven
technology because of their odor control effectiveness. Therefore, unlike
the other options above, covered anaerobic digesters do not have to meet
the additional testing requirements for technologies that the APCD
considers experimental.
Composting may or
may not meet the TS requirement because it often involves the addition of
a bulking agent to increase TS to optimize waste decomposition. However,
composting can be effective at controlling odors and reducing pathogens.
The APCD is presently reviewing the compliance status of one facility that
uses composting. Composting has applications besides manure treatment for
livestock facilities. The Colorado Governor’s Office of Energy
Management and Conservation is currently supporting the demonstration of
composting technology for hog mortality disposal at a hog farm in Colorado.
In an AD system,
most of the organic nitrogen (N) from the digester is converted to
ammonium, an easily manageable fertilizer with slow release properties
when compared to mineralized fertilizers. This is an advantage over
anaerobic lagoons alone. Organic N in the form of protein and urea is
mineralized in soil solution after land application. This mineralized N
can pose a groundwater problem when land-applied because mineralized N can
be converted to nitrates and leach into groundwater in the spring and fall
when plant uptake of N is low.
A disadvantage of
reducing the nutrient content of lagoon effluent via AD is the loss of the
value of nutrients. Reducing the use of lagoon effluent as fertilizer
increases the need for industrial fertilizers, the manufacture and
transportation of which uses significant quantities of petroleum. However,
this loss is balanced by the benefits of increased control farmers have
over the nutrient content of effluent used for irrigation purposes.
System |