2 – BAE Alumni & Friends

3. Solids separation/constructed wetland system4. Sequencing batch reactor system5. Upflow biofiltration system7. Solids separation/reciprocating water technology system8. Belt system for manure removal9. Solids separation/gasification for energy and ash recovery centralized system

BAE’s former extension leader, Dr.Frank Humenik, directs CALS’ AnimalWaste Management Programs office onCentennial Campus. Along with MarkRice and Craig Baird, Humenik is PI forfour of the technology candidates. As leaders of the National Center for Manureand Animal Waste Management, they oversee projects on alternative swinewaste treatment systems and techniques for decommissioning anaerobiclagoons. The high interest in their lagoon closing project resulted in manynewspaper articles and farm show interviews across the United States andCanada. A synopsis of one of the articles is on page 6.

Dr. Garry Grabow is experimenting with alternatives to land application ofanimal wastes. One technology is a hose drag system that applies wastewaterclose to the ground in an effort to reduce drift and odor. Grabow also intends toexamine the feasibility of applying wastewater through subsurface drip systems.

Dr. Sanjay Shah delivers extension programs on agricultural air quality andpoultry litter management. He is developing an improved wind tunnel thatmay be used to measure gas emissions from land and lagoon surfaces. Incollaboration with West Virginia University faculty, Shah is evaluating a heatexchanger-biofilter system in a poultry house for its ability to improve air qualityand conserve heat energy. Dr. Shah is also evaluating the impact on waterquality from stockpiling poultry litter on bare soil and developing a machine forbanding poultry litter beneath the soil for improving environmental quality.

Dr. Bob Rubin recently retired after spending 26 years working on wastewa-ter management. He has helped homeowners, businesses, and municipalitiesthroughout the state to correct their wastewater problems. Rubin has searchedout the latest technologies for handling wastewater and advocated for theirapplication in North Carolina. In recent years, Rubin has worked closely withthe U.S. EPA on national wastewater education programs. He had a substantialrole in developing “The Voluntary National Guidelines for the Management ofOn-site and Clustered Wastewater Management Treatment Systems.”

Rhonda Sherman has been a BAE extension specialist for 11 years, educat-ing people statewide about vermicomposting, composting, recycling, and solidwaste management. Sherman works with businesses, institutions, municipali-ties, schools and individuals to divert waste from landfills. Sherman is develop-

Department Head James YoungWriter Carolyn MitkowskiGraphics/Layout Carolyn MitkowskiProof and Editing Rhonda ShermanAdvisor Mike Boyette

BAE Alumni&Friends is a semi-annualpublication of the Biological andAgricultural Engineering Department,North Carolina State University, Box7625, Raleigh, NC 27695-7625.

If you would like to contribute to the nextissue of BAE Alumni&Friends, please sendyour contributions to the above address oremail: [email protected].

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○continued on page 4

Bringing Waste to Life continued from page 1Faculty NewsDr. Bill Hunt was recognized as

an “Outstanding Extension Special-ist” for NCSU and NCA&T for thesupport of county programs. Theaward was given by the NCSUAssociation of Extension Specialists.

A great honor for an east coastextension specialist, Dr. Robert Rubinwas chosen to be the keynote speakerat the Western Onsite WastewaterConference held in Riverside, Califor-nia, in May.

Rubin also received a Distin-guished Service Awardfrom the AmericanSociety of AgriculturalEngineers for his work

with the Wastewater Industry.Dr. Bowers was awarded an

honorary State FFA degree June 9that a ceremony held in conjunctionwith the FFA annual Contest.

Dr. Harold Pattee, USDAPeanut Researcher in the depart-ment, retired May 16th. !

Lagoons have been the technology ofchoice for holding and assimilatinganimal waste during this last century.There are efforts underway to usenewer technologies with improvedeffectiveness.


Department Head’s Comments

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James H. Young

Alumni Updates

continued on page 6

In this issue I wish to thank three recent retirees fortheir many contributions to the Biological andAgricultural Engineering Department and to wishthem much happiness in their retirement. They are:Roger Rohrbach, Bob Rubin, and Ann Griffin.

Dr. Roger Rohrbach retired on March 1st afterserving on the BAE faculty for more than 35 years.Roger joined the Department in 1968 with a PhDfrom The Ohio State University. His appointmentwas split between research and teaching. His researchincluded work on precision planting, blueberry

harvesting, sorting of grapes and blueberries, singulation of pine seedlings, andrapid chemical analysis of blueberries. During his career he published threebooks, received eleven patents, and either authored or co-authored 114 publica-tions and papers.

For twenty-seven years, Roger taught the senior design course in the BAEdepartment. The experience which undergraduates received in the course isfrequently mentioned by our alumni as a high point in their undergraduateprogram at NCSU. As a mentor to students, Roger took pride in sharing boththe frustrations and the successes of students as they worked on their designprojects.

For the past three years, Dr. Rohrbach's academic program activities haveprimarily involved planning for our ABET accreditation review which will takeplace October 24-26th; chairing the Computer Committee in the College ofEngineering where a great deal of effort has been put into a student ownedcomputing initiative; and working with a University-wide group to developplans for student "Learning in a Technology Rich Environment." Roger has verycapably led our planning efforts for ABET and has planned teaching facultyretreats during the past three years to evaluate and modify our curricula to meetthe objectives established by the Department. We are happy that Roger,although retired, has agreed to continue to work half-time through the remain-der of 2004 in order to complete ABET review reports and keep us "on track"throughout the review process.

Dr. Bob Rubin retired June 30th after serving the Department since 1978. Hewas first appointed as an extension specialist and progressed through the ranks tobecome professor in 1996. Bob has conducted one of the most dynamic and farreaching programs in wastewater management and biosolids recovery/disposalin the United States. His innovative technology transfer efforts, aimed attraining operational personnel, regulators, and government officials, weresecond to none and were extremely well attended. Bob provided nationalleadership in the critically important areas of rural water quality and wastewatermanagement, as evidenced by his invitation to address Congressional commit-tees that deal with those problems.

In June of 2003, Dr. Rubin was presented the "Bronze Medal for Com-mendable Service" by the United States Environmental Protection Agency.

continued on page 6

Gregory Alan Walker sent abrief note just to say “hi!” Hegraduated in 1982 and is workingfor USDA-NRCS in NC. He hastwo daughters; one is a teen andthe other is 15 months old.

On the other side of the worldis MS 1996 graduate Russ Merz,consulting with the firm ofGolder Associates in Brisbane,Australia (http://www.golder.com/). He says, “Mycareer has led me into theexciting field of water resourcesengineering consulting where Ihave worked on projects intwelve countries. I conduct anddirect work on the water man-agement aspects of projects asdiverse as hydroelectric schemesin the Himalayas and erosioncontrol of tropical soils for nickelmines in Indonesia and NewCaledonia. My job involves workthat is always changing andinteresting. I work with greatpeople every day. The work hasa good mix of technical analysis(sometimes modeling) alongwith client and public interaction.I also have an opportunity forinvolvement in strategic businessplanning.”

In addition to technical workwith Golder, Merz is the WaterResources Market Sector Leaderfor Australia and Asia. He isresponsible for identifying anddeveloping consulting work inthe water sector for Golder's 12offices in the Asia Pacific region(Australia, China, Thailand,New Zealand, and Indonesia).

Originally from westernCanada, Merz is enjoying the


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continued on page 5

The BAE ASAE club’s studentbranch had a very successful trip tothe ASAE Southeast Rally heldApril 1-3 at the University ofGeorgia in Athens. Nine studentsand an advisor attended the meet-ing. The department’s group wonthe "Ag Olympics" competitionand received a plaque. AndrewSmith won the "milk chugging"contest, Jackie Cotter won the"football throw," and John Long,James Gregg, Joe Deal, JessicaBridges and Jackie Cotter won the"tug of war." Others making goodshowings in events included ToddFlippen, Scott Shore and LauraShearin. Besides having oldfashioned fun, students toured theMayfield milk processing plant,and BAE student John Long waselected next year’s president. NCState will host next year’s rally.

The Quarter Scale TractorDesign Contest was held June 3-7th. This is an activity sponsoredby the American Society of Agri-cultural Engineers. Students fromuniversities across the countrydesign and build ¼ scale tractorsthen travel to compete in thecontest. There are four mainjudging categories: a writtendesign report, a team presentation,individual tractor design, and aperformance competition. Theperformance competition is

Student Event’s

Students’ pro-engineeringdesigndrawing

ing a Compost Training Facility at Lake Wheeler labs to conduct research andto demonstrate how to divert organic materials from disposal and convert themto quality soil amendments that promote plant growth. There is so muchinterest in vermicomposting (using earthworms to process organic waste)worldwide, that people from 25 countries have contacted Sherman for informa-tion. Sherman can be seen regularly on the television cable channel AnimalPlanet talking about vermicomposting.

Dr. Tom Losordo is removing and treating waste and renovating andrecycling water in aquaculture. We don't generally think of fish production ashaving a lot of waste, but like any other livestock production process it cangenerate waste containing excess nitrogen. Developing treatment processes thatcan be used on existing and new aquaculture farms, Losordo and DennisDeLong (extension aquaculture specialist) arefield testing new technologies that remove solidwaste from the water and convert nitrogen inthe waste water to harmless nitrogen gas thatgoes back to the atmosphere.

Dr. Phil Westerman has evaluated eightinnovative animal waste treatment technologiesover the past seven years. He recently collabo-rated with Ekokan LLC to evaluate a system ofbiofilters to reduce pollutants. Liquids areseparated from solids then passed throughupflow aerated biological filters in stages. Plasticmedia in the biofilters provides surface area for abiofilm of bacteria to perform biological degra-dation that reduces odor by converting ammo-nia to nitrate nitrogen. Westerman is also collaborating on a centralized systemof solids separation/gasification for energy and ash recovery. More informationabout both of these projects may be found at http://www.cals.ncsu.edu/waste_mgt/smithfield_projects/.

Dr. John Classen’s research focuses on using digesters to process waste. Byobserving how waste breaks down, Classen hopes to develop new uses forresiduals and understand the microbial processes in action for different types ofwaste. He is currently working with a research technology that uses a sequenc-ing batch reactor designed to treat manure produced by 2,700 animals. In thereactor, waste cycles between aerated and anoxic conditions, converting much ofthe nitrogen to gas, which is released harmlessly into the atmosphere. Thecycling also creates conditions favorable for microbes to concentrate phosphorusfrom the waste stream into a microbial cell mass.

Dr. Jay Cheng is researching better systems for swine waste management.One of his projects involves an ambient-temperature anaerobic digester, consist-ing of an impermeable cover over an in-ground digester. Methane gas producedduring the digestion process is recovered and delivered to a generator, whereelectricity is produced for use on the farm. Heat from the generator is capturedand used to produce hot water. Nutrients in the effluent are used to fertilizeplants in an adjacent greenhouse. Another research project is high-temperature

continued on page 7

Bringing Waste to Life continued from page 2

Prototype denitrification filterreactor filled with wood chips toconvert nitrate to nitrogen gas.


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Student Event’scomprised of a multi-stage tractorpull using a progressive weightsled, and is the highlight of thecompetition.

This year’s event was held atQuad City Downs in East Moline,Illinois. Our tractor team, theNCSU Pack Pullers, consistedof 8 students under the directionof extension specialist GrantEllington.

Praise is well deserved for ourteam for designing and fabricating aprototype tractor and competing inthis year’s event after an NCSUabsence dating to 1999. This event isextremely competitive andmany tractors were four-wheel drivedesigns with very advanced electro-hydraulic drive train components.

Our students showed greatpresentation skills and did very

from page 4

continuedon page 7

Students; Joe Deal, John Long,Andrew Smith, Todd Flippen, JustinMacialek, David Woodall, JackieCotter, and Heather Schaetzle

See more pictures at: http://www.bae.ncsu.edu/news/event_pictures.html

We all know manure provides nutrientsthat enhance the growth of crops, but whencombined with organic carbon, it has extravalue in crop production. The goal then inengineering animal waste uses is finding,repeating, and monitoring the bestmanure-to-soil/crop ratios which eliminateenvironmental stress caused by under orover use conditions.

Animal Manure

Note the dark rich color of worm castings ascompared to regular soil. Above, the turnip on theleft was grown in regular soil. The other turnipswere grown in soil amended with worm castings.

Dr. Shah demonstrates a newtechnology. The Nasal

RangerTM can be used tomeasure odor strength from

many sources, includinganimal farms. This kind of

information is valuable whenmonitoring odor events.

Above, animal waste water is recycledand sprayed close to the ground forimproved effectiveness and control.Properly maintained equipment andcertified operators who follow correctpractices will reap the bounty ofenvironmental stewardship.

NC State Fish Barn at LakeWheeler Rd. composts sludgeand fish mortality as part of itswaste handling and disposalpractices. Duckweed

plant use isexplored for

nutrientrecovery fromanaerobically

pretreatedswine

wastewater.

Trials are ongoing at the animalcomposting unit at Lake Wheelerwhere researchers are looking ateffective solutions for animalmortality disposal.

Waste Technology Innovation...


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Rejuvenating Lagoon AreasThe federally-mandated way to close a lagoon is to transport sludge

from the site and apply it elsewhere using established land applicationpractices. However, a test of a new emerging technology will close a lagoonby covering it with dirt and trees. The first experiment of this kind is takingplace on a hog farm in Nash County. The concept applies the patentedprocess of an Iowa company named Ecolotree to lagoon sludge. Generally,Ecolotree uses its process to clean contaminated soils in landfill areas, butthis project expands the use to include sludge waste reuse.

Fast-growing poplar trees will be planted to soak up the sludge. Thetrees will process the phosphorous and nitrogen and emit reduced residualwaste into the atmosphere through transpiration.

Closing a lagoon in this way has the potential of being environmentallysafe while using the abundance of fertilizer that sludge contains. Thesuccessfulness of this process is being monitored jointly with NCSU’sCollege of Agriculture and Life Sciences, Ecolotree and professors ofbioengineering at Oregon State University.

Dr. Humenik says, “We’re looking at the benefits of keeping the sludgeat the point of origin and eliminating handling the waste. This project alsoestablishes cooperative working habits with others and monitors wastereduction rates.” The potential benefits of this technology are its low-cost,easy implementation, trees for timber in a projected 15 years, no handlingof waste and its general friendliness to the environment. Humenik says,“It will take years before the real benefits will be known as the research isexpected to take five to ten years. It will test tree survival, groundwatercontamination and the rate that moisture uptakes from the soil. The re-search was sponsored with grants from the N.C. Pork Council and theNCSU Animal and Poultry Waste Management Center.” !

Alumni Updatescontinued from page 3

Donnie Ellis wrote to tell ushe retired from the Air Force andis enjoying hunting, fishing,RVing, snow skiing, boating,gardening and participating in anumber of Air force and flightorganizations.

He had an interesting careerin the Air Force and is thankfulfor the education he received atBAE-NCSU. Ellis says, “Thescientific and technical nature ofthe BAE-SBE program I com-pleted prepared me well tounderstand and operate compli-cated aircraft and even interconti-nental ballistic missile systems.”

Ellis graduated in 1975,completing Air Force ROTC,and then entered the U.S. AirForce as a Second Lieutenant.His initial assignment took himto Malmstrom AFB, Montana as

opportunity to visit and live indifferent places. He enjoysexperiencing the differences inculture and surroundings. Merzsays, “In Australia, not only haveI had the chance to pet kangaroosand koalas, but I’ve also been toTasmania and can attest to theexistence of Tasmanian devils!”

Merz has P.Eng. (Canada)CPEng (Australia), CPESC,belongs to the InternationalErosion Control Association, andis a member of the, AustralianNational Committee on Irriga-tion and Drainage and theAustralian Water Association.Merz and his wife have twoyoung children.

a Minuteman Missile Launch Officer with training enroute at VandenbergAFB, California.

While in the Air Force, Ellis traveled to Africa, Europe, Far East/PacificRegion, Central America, and all across the U.S. as a C130 Hercules aircraftnavigator, accumulating over 2900 hours of flying time in various militaryaircraft. In ‘78 he completed a MS in Systems Mgt. from the University ofSouthern California. His last position was with Headquarters Air MobilityCommand, Tanker Airlift Control Center, Scott AFB, Illinois where asDeputy Director for Resources he managed a 750 member organization.Ellis earned numerous awards and decorations in his 28 yr. career, with thehighest being the Defense Meritorious Service Medal while serving withthe Joint Special Operations Command at Fort Bragg, NC.

Ellis’s wife, Phyllis, is currently employed in an elementary schoolsystem. She earned a degree while raising two children to adulthood.Their daughter, Bobbi, teaches first grade and son, Steve, is working inthe computer science field. !

Alumni Updates

continued right column

continued from left column


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Student Event’scontinued from page 5

This year’s BAE AwardsBanquet was a catered luncheonheld April 30th to recognizeBAE’s outstanding students. Seethe list at: www.bae.ncsu.edu/newsflash. !

well in most categories. In thestatic design judging, consistingof serviceability, ergonomics,manufacturability, safety, and dataacquisition, they finished 8th. Anunexpected mechanical problem,and omission from one of themajor pulling categories, placedthem 24 out of 26.

This contest has support of theAgricultural Equipment Industry.Corporate sponsors for the eventinclude Briggs and Stratton, JohnDeere, Caterpillar, New Holland,Case, Firestone, Cub Cadet, Camp-bell Scientific, and Midwest SuperCub.

This year our local sponsorshelped with the team’s budget of$5,000. They were Capitol Cycle,Sprer Outdoor Equipment, CrossHose & Fittings, KnightdaleTractor and Equipment Co. Inc.,Capital Hydraulics Inc., LowesHome Improvement, Agri-Supplyof Garner, Amadas, Farm Bureau,John Deere Turf Care, and indi-viduals Don Smart, Jimmy Cole,Dr. M. Boyette and Dr. W. Skaggs.Cost of travel was supported byNCSU Campus groups theStudent Senate, Agri-life Counciland Engineers Council.

We plan to be back on thetrack next year and are lookingfor sponsors. If you or yourcompany is interested, pleasee-mail extension [email protected]

anaerobic digestion of animal waste. Both ofthese projects are described in detail at http://www.cals.ncsu.edu/waste_mgt/smithfield_projects/. Cheng is also workingon nutrient removal from animal wastewaterin an intermittent aeration system, nutrientrecovery from wastewater using duckweed,and conversion of agricultural residues intorenewable energy sources such as biogasand ethanol.

For more information about the wastemanagement research and education effortsbeing conducted by BAE faculty listed above,go to www.bae.ncsu.edu, click on Peopleand then on the individual’s name. !

Bringing Waste to Life continued from page 4

Pilot-scale anaerobic digesters foranimal waste treatment and biogasproduction.

This was a very deserved and fitting honor for an individual who has devotedhis professional career to enhancing the performance and reliability of wastewa-ter treatment systems. Bob plans to continue some consulting work and tocontinue working with the USEPA as a visiting scientist. As an emeritusfaculty member, Bob will continue to contribute to the mission of the BAEdepartment.

Ms. Ann Griffin retired on July 1st. She joined the BAE department in1976 as a clerk/typist. In the twenty-eight intervening years, she became aninvaluable employee of the department as well as a "memberof the BAE family." Her responsibilities increased from providing secretarialservices for 6-8 faculty members to providing word processing support for alarge percentage of our faculty and their graduate students, to becomingAdministrative Assistant to the department head and directly supervisingother clerical staff within the department. !

Department Head’s Comments

Links_____________________

NC State University Environmental Sustainability -http://www.ncsu.edu/environmental_sustainability/NC Division of Waste Management -http://www.wastenotnc.org/EPA WasteWise - http://www.epa.gov/wastewise/EPA- Enviro Facts Data Warehouse - http://www.epa.gov/enviro/EPA National Waste Minimization - http://www.epa.gov/epaoswer/hazwaste/minimize/Zero Waste America - http://www.zerowasteamerica.org/index.htmlWaste Management - http://www.natpaper.com/Waste News - http://www.wastenews.com/headlines.htmlEnvirolink - http://www.envirolink.org/Dump and Run - http://www.dumpandrun.org/garbage.htmAir and Waste Management - http://www.awma.org/NC Recycling Business Assistance Center - http://www.p2pays.org/rbac/Organic Recycling and Compost - http://www.p2pays.org/compost/Local Govt. Assistance - http://www.p2pays.org/localgov/PAYT/ncwaste.asp

Learn more...

Invitation to a Field Day -Join us Aug. 12th. 10 a.m. tonoon for a tour of the lagoonclosing at the Hanor Farms site.Information on the WasteManagement web site at:www.cals.ncsu.edu/waste_mgt/

continued from page 3


College of Agriculture and Life SciencesDepartment of Biological and Agricultural EngineeringCampus Box 7625Raleigh, NC 27695-7625

NONPROFIT ORG.U.S. POSTAGE PAID

Raleigh, NCPERMIT No. 2353

Name Curriculum

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Spring 2004 Grads○

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View graduation pictures at:www.bae.ncsu.edu/news/event_pictures.html

Graduating students and alumni havethe opportunity to purchase a brick inthe CALS walkway. To learn more see

http://www.cals.ncsu.edu/alumni/activities/brick.html.

Ackles, Kelly Jean .......................... BE, BMEAlkadhi, Yousif Zaid ..................... BE, BMEAppelboom, Timothy William ..... PhDArnold, Laura Ann ....................... MSBowen, Tabitha Rae ..................... BE, BMEBradford, Jessica Cortney ............. BE, BMEBridges, Jessica Lee ....................... BEBuie, Reagan Nicholl ................... BE, BMECannon, James Michael ............... BEClose, Christopher Allan .............. BE, BMECoates, Stephanie Genese ............ BE, BME

Cotter, Jacqueline Louise ............. BE, BMECranford, Jonathan Preston ........ BE, BMEDeal, Joseph Charles .................... BEDeschamps, Mireille Claire .......... BE, BMEDiggs, Jonathan Andrew ............. MSDinola, Nicole Elizabeth .............. BE, BMEDulaney, Katherine Olsen ........... BE, BMEEarle, Alexander Bradford ........... BE, BMEFair, Lesley Marie .......................... BEFlippen, Todd Bryant .................. BEGoldstein, Seth Daniel ................. BE, BMEGrace III, Johnny McFero ............ PhDGrater, Jennifer Lynn ................... BE, BMEHendrix, William Earl ................. AETHoeger, Catherine Elizabeth ....... BE, BMEHoke, Robert Leagon ................... BE, BMEInman, Kelly Lee .......................... BE, BMEJarnagin, Scott Patrick ................. BE, BMEJohnson, April Naomi .................. BEJoyner, David Andrew .................. BE, BMEKimball, Jeremiah Theodore ........ BE, BMEKhadye, Shogun Jay .................... BE, BMEKuykendal, Lydia Banks ............. BE, BMELossing, Jennifer Aimee ................ MSMacialek, Justin Alan ................... BEMartin, Penney Jayne ................... BE, BMEMcDonald, Jennifer Ann ............. BE, BME

McManus, Lindsay Ann .............. BE, BMEMoran, Amy Christine ................. MSO’Quinn, Ryan Patrick ................ BE, BMEParzel, Cheryl Anne ..................... BE, BMEPatnode, Charles Brian ................ BE, BMEPittman, Joanna Lynn ................. BE, BMEReames, Daniel Franklin .............. BE, BMERogers, Hailey Brooke .................. BE, BMERoposh, Carolyn Michelle ............ BE, BMESchaller, Meredith Rose ................ BE, BMESmith, Stephen Andrew .............. BESoneja, Sutyajeet Inderjeet .......... BE, BMEStrickland, Shelly Ronita ............. BE, BMEVenkatesh, Kiran ........................... BE, BMEWalls, Amanda Alissa ................... BE, BMEWard, Troy Wayne ........................ AETWatkins, Preston Anthony ........... BE, BMEWeile, Catherine Charlene ........... BEWong, Richard Yee Fay ................ BE, BMEWoodall, David Wayne ................ BEYeago, Carolyn Ann ..................... BE, BME

Largest BAE graduating class to date!

summer 2004, ncsu, bio and ag alumni and friends newsletter

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