Re-Defining Confined Livestock Farming:

Making Carbon Work for Us

Bruce T. Bowman

Expert Committee on Manure ManagementCanadian Agri-Food Research Council

Presented at:CARC Annual Meeting

Ottawa, Ontario

April 21, 2005

Farm Bio-Energy

A.D.Manure

Processing

Rural Society Benefits

FarmEconomic

Benefits

Presentation Objective

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

Water volumes

Carbon = Energy $$$

Three priority issues to manage:

Nutrients Odours Pathogens

Priority Issues for Manure Management

............................. but also …….

Two major loss pathways: As volatile ammonia (NH3)

- Adjust pH to near 7.0 to minimize ammonia losses- Rapid losses from freshly-exposed manure

As nitrous oxide (N2O) - Processed manure less N2O emissions following land application – 50% less C (energy) for microbes)

Conserving Nutrients:Gaseous Nitrogen losses from Manure

In this section I will be developing linkages between nutrient conservation/recycling and manure processing.

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. (Mixed farming systems tend to be more sustainable).

Intensification has created some regional nutrient surpluses (Quebec, N. Carolina, Chesapeake Bay area, Lower Fraser, BC).

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 NUTRIENT FLOWSRecycling Nutrients & Organic Matter

AnnualMineral

FertilizerAdditions

Nutrients & O.M. NOT recycled

Regional nutrient excesses

Local Farm

Manure

Nutrients O.M.

Wastes

Landfills

Nutrient inputs

Many confined livestock operations import more nutrients than they export, resulting in localized nutrient accumulations. (US studies - NE, WA, PA) … not sustainable in long term.

Can’t continue increasing N loadings in environment & maintain current nitrate water quality standards. Human activities doubled global N fixation rate in 20th century.

(Barton & Atwater, U.B.C., 2002)

In many countries, P is considered a non-renewable resource – finite supply, some sources have high heavy metal contents (e.g. Cd in phosphate from Idaho).

Reasons to Recycle Livestock Nutrients

Balancing Nutrient INPUTS & OUTPUTS at farm-scale or at small watershed-scale. – Next stage in Nutrient Management Planning & Source Water Protection.

As more precise nutrient management planning is implemented, many farmers will discover nutrient surpluses somewhere within their land base.

Recent studies in U.S.A. show that majority of farms studied have nutrient surpluses, esp. Nitrogen. (INPUT/OUTPUT > 1.5) (Koelsch & Lesoing, 1999; Cogger, 1999)

Whole Farm Nutrient Balances(Budgets)

Three Options:

1. Reduce nutrient inputs to balance nutrient exports from the land base (e.g. improved feeding strategies – nutrient use efficiency e.g. phytase).

2. Increase land base for applying manure nutrients (buy, rent more land or contract for exporting excess manure; Exporting liquid manure nutrients < 15 km radius (economics).

3. Export surplus nutrients from the farm in the form of value-added products (new revenue source - organic fertilizers/amendments).

Managing On-Farm Nutrient Surpluses

Conditions for exporting manure nutrients:

1. Odour-free

2. Pathogen-free

3. Dewatered (dried) for transportation

Manure processing can address these issues.

Exporting Surplus Livestock Nutrients

The need to export surplus nutrients will increase with further intensification of livestock operations.

…. “Treating the entire manure volume” …. to reduce odours & pathogens.

Two best technologies: Anaerobic digestion – high cost, greater revenue

Composting – low-cost, limited revenue

Manure processing can provide the farmer with increased flexibility for managing surplus nutrients, by remediating key environmental problems.

What is Manure Processing?

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

Economic

Renewable energy generation

- energy independence

Export surplus Livestock nutrients Emission reduction trading credits Tipping fees – food-grade wastes

- 20 – 25% energy boost

Why Digest Manure?Potential Benefits

Yield / Productivity

Environmental Issues

S

oci

etal

Co

nce

rns

Balancing 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

Since 1970s 2-D

Since 1990s 3-D

Mimicking fermentation in a ruminant stomach. (most digesters are mesophylic ~ 37°C – body temp.)

Kills weed seeds – reduces herbicide use.

pH often increases about 0.5 unit during digestion.

Closed system – no nutrient or gaseous losses (e.g. N)

- closer N:P ratio than with raw manure – better for crops

About 50% of carbon biogas (CH4 + CO2, 65:35, tr. H2S);

- (nutrients in more plant available, predictable form)

(~ 25% C blown off conventional slurries by bacterial decomp.)

Anaerobic Digestion

A Few Facts

Certain antibiotics can HALT digestion processes

Solids range: up to ~ 13% (easily pumpable)

Hydraulic Retention Time: (processing time): - 20–35 days @ 37°C

Odour Reduction: ~ 90% or more

Pathogens Reduced to:~ 1/1000 – 1/10,000 (mesophylic); - Eliminate pathogens by pasteurizing (1hr @ 70°C)

Anaerobic Digestion

…….. More Facts

Managing Dead StockA Waste + Nutrient Issue

A waste issue that now costs the farmer to manage – end products have lost their value since BSE crisis – can’t recycle animal protein through feed system e.g. bonemeal has lost much of its former value

Current disposal methods have limitations Burial – limited capacity, point source pollution potential Incineration – N and C lost, minerals?; emission issues

renewable energy recovery possible Composting – cost recovery for composted solids

Anaerobic Digestion – best solution for deadstock and for animal rendering – 2 valuable end products

Renewable energy recovery (heat, electricity) Organic solids end product (fertilizer, amendment)

Managing Dead StockA Waste + Nutrient Issue

Pre-Treat = shredder + Pressure/Temperature - treated waste virtually all digestible

- possible elimination of BSE prions

Conserves N, P & some C for recycling back to land Minimizes odour problems; eliminates pathogens

High Tech

Manure Processing Anaerobic Digestion

Low Tech

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 = <10 yr (electricity, solids sales, emission credits)– Breakeven – 110 cow dairy; 1200 hog; 25,000 poultry

Policy Issues – Need consistent policies & incentives across 3 levels of government - Environ. Loan Guarantees (manage risk) - Tax Incentives for green electricity

Feasibility Assessment - How does the farmer put a realistic value on odour & pathogen-free manure products? – changes from societal opposition to opportunities for new partnerships.

Overcoming Barriers to Adoption of

Anaerobic Digestion Technology

Sale of Processed Solids/ Org. Fertilizers – excess nutrients exported – promotes nutrient re-use

Emission Trading System currently developing- sell credits for reducing emissions- current value of e-CO2 in Europe ~ $10/tonne

Tipping Fees for Receiving Food-Grade Wastes – boost biogas output (20 – 30%) increases revenue

1. Establishing Revenue Streams

Electricity Purchase Agreements– Net Metering, Dual Metering – Peak Demand Generation– Nova Scotia, Ontario, Saskatchewan - leading provinces– may be sufficient to be energy independent; delivered power ~ 2 x generating costs (ON = 12 - 15¢/kwh)

Overcoming Barriers to Adoption of

Anaerobic Digestion Technology

2. Managing Regulatory Issues

Electrical generation – interconnects / net meteringPower Utilities starting to change policies for small renewable energy generators (up to 500 kw)

Off-farm biomass inputs (boost biogas production)can result in C. of A.s – regulations being changed to allow <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 installed digester base in Canada (12 – 18 in advanced design or already built)

Limited knowledgeable Canadian design/build firms- 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

Overcoming Barriers to Adoption of

Anaerobic Digestion Technology

Revenue #2Electricity

Export

Revenue #1Nutrient Export

Integrated Livestock Farming System

Closed Loop Single Farm Energy Centre

Local Farm

Organic Fertilizer

Non-Ag UsesHome gardens

Turf/golfParks

Nutrient

SurplusCo-Located Industries

Bio-ethanol plantGreenhouses

(Veg., Flowers)Fish Farm

Cereal Production

- 15% feed costs

Revenue #3Optional

Nutrient

Recycling

Loop Anaerobic

Digester

<20% Off-Farm Food-Grade Wastes

Nutrient inputs

Co-gen

SurplusElectricity

Heat

CO2

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

Challenges Facing Confined Livestock Operations

Increasing price volatility (The China factor)

Less reliable supplies (Declining fossil reserves) Will also increase N fertilizer costs

Continuing vulnerability of farm incomes Increasing costs of compliance

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

Future livestock operations will be structured around bio-energy energy independence using co-generation technologies.

Facilitates conservation and recycling of resources (nutrients, carbon = $$$)

Income stabilization through diversification (new revenue streams independent from commodity prices!) - Green Electricity - Processed manure solids- Emission Trading Credits - Co-located integrated industries- Tipping fees for food-quality wastes (energy boost)

Re-Defining Confined Livestock Farming

Substantially reduces existing environmental issues

– reduced odours, pathogens diminished societal concerns

– greater flexibility for applying/selling processed manure

Strengthens rural economy utilizing more local inputs (employment, resource inputs – biomass crops)- Municipality can be a partner (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)

Re-Defining Confined Livestock Farming

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

Farm Bio-Energy CentresAs Integrators & Facilitators

EnvironmentalSolutions

IncomeStabilization

Rural Revitalization

Farm Bio-EnergyA.D. Processing

EnergyIndependence

Independentof

Livestockprices

In Summary

A.D. manure processing is the key to: Remediating environmental problems (odours, pathogens) Improving community relations Providing flexibility for managing surplus nutrients Generating bio-energy (thermal, electrical) energy

independence & rural business opportunities

Economics are rapidly improving, but policies, incentives & regulations need to be coordinated across 3 levels of gov’t to facilitate adoption of this technology.

Efforts to increase technical support and assistance are required to foster adoption of the technology.

Resource Information on

http://res2.agr.gc.ca/initiatives/manurenet/manurenet_en.html

6,000 external web links Several hundred digital technical/research reports

Manure TreatmentDigester CompendiumNutrient RecoveryAmmonia EmissionsNutrient ManagementEnvironmental IssuesGHG EmissionsOdour ManagementLand Application

Storage & HandlingHousing / FeedlotsFeeding StrategiesCodes, Acts,

RegulationsHealth & SafetyLinksDigital LibraryExpertiseEnvironmental Archive

(>165 digital reports)

Micro CHP (Combined Heating and Power)

Distributed Power Generation

Electricity + Heat generated at each residenceSmall engine + generator replace furnace & water heater

Grid

85 % efficiency

Micro CHP (Combined Heating and Power)Distributed Power Generation

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+

More efficient use of resources (15% vs 60% loss) (39 vs 85 % efficiency)

Micro CHP units run on natural gas or biogas 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