Dairy farm anaerobic lagoons without covers

The first large scale biogas plant linked to a beef feedlot, could make a more significant contribution to renewable energy in South Africa than the planned 3.8 MW of electricity, by advancing the technology in South Africa.

The Business

Independent power producer (IPP) Lesedi Biogas Project (LBP) is planning to build one of the world’s largest open-air feedlot manure-to-power plants, in Heidelberg, near Johannesburg, South Africa. Such plants use the anaerobic fermentation (bacterial fermentation of organic waste, with little or no oxygen present) to produce a methane rich gas which can be used to produce electricity or burn for heat.

The plant will be situated at the Karan Beef feedlot, which will supply the manure from its feedlot to the LBP. This would initially amount to 110,000 tons per year of manure, which would allow the production of 3,8 MW of base-load power reaching 6,2 MW of peak power.

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My earlier blog about greenhouse gas emissions from composting generated a lot of good discussion so I am writing to respond.

• Yes, composting is certainly better than some outcomes like food scraps going into a garbage dump which does not do anything to capture the methane

• Yes, an anaerobic digester would be a very good thing to use for most waste streams.  A recent example is what was done at Gill’s Onions

• Many wastes can also be put through a fast-pyrolysis process to form syngas and biochar.  This is another way to get at the carbon-neutral energy that is in the manure or other waste

• Greenhouse gas emissions are not the only metric that matters as was pointed out, but manures in particular are undesirable fertilizers based on multiple other metrics as well: tendency to leach more nitrates because of extended release, more nitrous oxide emissions for the same reason, and excess levels of phosphorus relative to nitrogen leading to water pollution

• Compost is indeed a very good way to build soil carbon and that is a super important thing to do for true sustainable farming, but there are other ways to accomplish that that don’t have the greenhouse gas issues.  One is the use of biochar.  The other is to practice no-till farming and grow cover crops which I describe in another post.

• There may be ways of composting that don’t emit as much methane, but I’ve seen far more theoretical arguments that way with no actual measurements taken.  As a microbiologist I have a hard time imagining how you could avoid having some anaerobic conditions in a big pile of manure.  Starting from 14 times as much carbon equivalents as synthetic nitrogen, the process would have to be vastly improved to be acceptable

• Un-composted manure has similar drawbacks as a fertilizer.  When it is stored for later use on a farm, at least 1-2 percent of its total methane potential gets released even with very good manure management practices

• Chicken manure is more attractive to farmers as a nitrogen source because the levels are higher, but there is every reason to believe it would generate methane in storage and during composting if someone bothered to measure it

Composting is a really green thing to do, right? I’ve always thought so since my Grandfather taught me to do it in the early sixties. Large-scale composting is getting to be quite the rage. The City of San Francisco attracted a great deal of attention with it’s mandatory food scrap recycling program and lots of local wineries are bragging about their use of that compost to fertilize their vineyards.

I just read today about how the Langley Parish Council in England is setting up a village compost and “set an example to small villages as the UK strives to battle climate change.”  Unfortunately, I recently learned that they and San Francisco and the Napa wineries might actually be doing is contributing to climate change.

Climate change science often ends up challenging things we think we know.

Inconvenience

The idea of composting is to provide plenty of moisture and oxygen so that microbes will digest the easily available organic matter and generate a great deal of metabolic heat in the process.  What is left at the end is a sterilized source of more resistant organic matter that can enrich a soil. 

Composting

of wastes is done with very good intentions, but there is the inconvenient truth that even a very well run large-scale compost operation emits some methane.

But if you stop to think about it, as much as you intend to have oxygen available to the whole pile (aerobic conditions), there are definitely going to be micro-sites that are going to lack oxygen (anaerobic conditions) particularly when there is huge oxygen demand during the peak of the process. That is where methane gets made.

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Soil is one of a gardener’s most important resources, and preserving its health and vitality one of our most crucial responsibilities. Nourish the soil sustainably and you’ll be rewarded with healthier plants and bountiful harvests for years to come.

I was reading National Geographic the other day, and came across an article on soil called “Our Good Earth.” The article discusses the problems facing soils all over the planet, and made me realize just how precious healthy soil really is. We’re losing topsoil rapidly as we consume more and more land to house and feed the ballooning human population. It can take nature over a thousand years to produce just one inch of soil, but erosion, compaction, and contamination can wipe it away much faster. This precious resource, the means to sustain and feed us and the entire planet, is often just treated like dirt. It’s time that changed. And it can start in your very own backyard.

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Dairy products are part of most American diets on a daily basis, but what is the health and environmental impact of this high demand for milk?

The production of much of the milk in this country is done in large scale-operations, some having thousands of cows.

That’s a lot of manure to be dealt with, this reduces the air quality (especially for people living near the dairy operation), and consistently finds its way into our rivers, streams, and groundwater.

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Besides the comical slant of the titles, it is surprising that biogas is often presented as something amazing & unknown although it has been around for hundreds of years, is used in tens of millions of rural household and is a significant contributor to Europe’s renewable energy production.

Biogas - Amazing Natural Technology

The fermentation of organic material such as biomass, manure, sewage, farm waste, municipal waste, green waste and energy crops in the absence of air produces biogas. The same anaerobic fermentation produces swamp, marsh and landfill methane.

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After years of debate and planning, the St. Paul, MN city council has voted unanimously to move forward with a unique plan to produce biogas from manure and ethanol waste in rural farms and pump it miles to power an enormous paper recycling plant.

The energy-efficiency of recycling paper is not the best, so this plan is a welcome alternative-fuel twist to the standard process.

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Researchers at Michigan State University are working on technology that could help small farms transform animal waste from pollutant to fuel. Through funding from both public and anonymous, private sources, MSU is planning an Anaerobic Digestion Research and Education Center. The Center will test methods for efficiently using bacteria to turn animal waste into biogas, which farms can in turn use in place of fossil fuels for things like electricity and heat. The aim is to make this an affordable option for small- to mid-sized farms. This technology simultaneously addresses two issues that farmers face: farm waste management and increased energy prices.

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A Government Accountability Office report, however, has come out against the proposed EPA change. The report explains that one facility can produce up to 1.6 million tons of manure each year, which causes 1.5 times more pollution to water and air than a city like Philadelphia. In Congress, a House oversight committee convened today to try to convince the EPA away from the change.

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It’s lunchtime, baby. Panda Garden. Porky goodness. Mooshu style.

The “other white meat” in your takeout container falls behind beef and chicken in American consumption, but we do pig out on pig—on average, each of us consumes 51 pounds of Wilbur annually. That translates to big impact on our water and air.

Due to the high variety of bacteria, worms and other undesirables in pig flesh, and because of the quick-spread disease potential of crowded pig farms, heavy doses of antibiotics are administered routinely. Those same drugs end up in your body via waste streaming into our water supply, and via that Mooshu pork to go. Other side dishes you might not have ordered include growth hormones to encourage meat-heavy livestock and vaccines injected to avoid profit-damaging disease.

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Last week, I wrote about a farm in China that will power itself entirely with chicken manure. Now poop power has made it to mainstream America with an announcement that the California State Fair will play host to the first known amusement ride powered by cow manure.

The Barnyard Animal Train will use excrement from California dairy cows to create renewable biogas. Kids taking a ride on the train will also have the opportunity to learn about renewable energy— and of course, will get to experience it firsthand.

At first glance, this may not seem like a big deal. But state fairs around the United States are joining the alternative energy wagon, albeit not always by using cow manure.

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In the race to implement new energy sources, farms have an advantage: lots of manure. A large chicken farm north of Beijing is taking advantage of this fact by using its chicken manure to generate power and heat. And this isn’t just a small-time farm—the 3 million chickens on the farm produce 220 tons of manure and 170 tons of wastewater each day.

The Deqingyuan Chicken Farm Waste Utilization Plant, which is replacing a coal-fired plant, will reduce CO2 emissions by 95,000 tons a year. It will also provide 14,600 MWh of electricity each year.

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That scent is so rich, so savory, so earthy, so pungently sweet that just one whiff seems to bury you in an olfactory pleasure dome. And if you keep basking in the aroma, you may well feel driven to grab a pitchfork, plop a straw hat on your head, stick a blade of grass in your mouth, and head on out to the fields. This is especially true on those oh-so-humid mornings in the peak of summer, when the air is so moist and dense that you almost have to put on scuba gear. But any old day is a great day for cow poop.

I confess that I am no connoisseur of creaturely caca, but I would bet that none can compare with the quality of a cow’s. Horse manure comes close, but it pushes pungency at the expense of sweetness, plus it is not very good for fertilizer. The feces of fowls is not even in the same league; it is far too acrid, not to mention slimy and sticky and all around offensive. Elephant excrement is similarly versatile (for example, it makes a great alternative source for paper), yet so far it lacks the time-tested dependability and widespread availability of cow dung; pachyderm poo is thus still an exotic delicacy rather than a common staple. (I cannot speak to its odoriferous character, alas.) And nobody would sing paeans to dog and cat poop. Look at how tenderly people carry those telltale plastic bags when walking their dogs–usually with one arm extended as the dog pulls the leash and the other arm, hand, and pinching fingers extended as far away as possible with the bag bobbing in the air. When it comes to the felines, we have managed to train them to go potty in specified places, cover it with “fresh scent” granules, and graciously shake off anything sticking to their paws. I suppose “domestication,” in part, means proper toilet training…or “house training,” as it is called. And as for “humanure”…I am not even going there.

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1. Energy Prices

Fertilizers are a very energy intensive product. Nitrogen fertilizers are commonly made from petroleum or natural gas. The potash and phosphates in the fertilizers are derived from mining, which also requires a lot of energy. Finally, the finished product needs to be transported and we know all about high gas prices.

2. Fertilizer Demand in China and India

China and India have increasingly been depending on fertilizer, causing a spike in demand. The price of fertilizer has climbed to $750 a ton.

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As if cooking, cleaning, and child-rearing were not enough, the women of Santa Fe also lead a powerful organization, the Santa Fe Women’s Group, which fulfills many vital roles for the community. One of the group’s biggest projects has been producing biogas.

The Project

The Santa Fe Biogas project, in its initial stages, was simply a concern communicated in Women’s Group meetings: “How can we avoid buying expensive tanks of gas and inhaling smoke in the kitchen?”

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Cow manure has been discovered as an energy source: it has power and it’s being used to make electricity and ethanol. Take for example the E3 BioFuels Genesis plant in Mead, Nebraska. The $80 million facility began operation this summer, turning out some 25 million gallons of ethanol a year (a rather small amount, compared to other ethanol plants around the country). What makes this facility unique is it’s patented closed-loop system, the first of its kind in America, and quite possibly in the world.

The plant is old news, really, but here’s how it works. A nearby beef cattle feedlot provides 150,000 pounds of manure every day, which is processed through an anaerobic digester, and that produces methane. The methane is used to fire the plant’s boilers, replacing expensive natural gas, resulting in a large reduction in operating expenses. Company officials say the Genesis plant produces 46 units of energy for every unit of fossil fuel energy required, a 46:1 efficiency ratio. Conventional ethanol plants are rated at a ratio of 3:1.

A byproduct of ethanol production, wet distiller’s grain, is fed to the cattle in the feedlot and the process begins all over again. Now this is a very brief explanation of what’s happening at the Genesis plant. Their website explains it very well..

So why am I writing about this? Well, there’s more to cow manure, as you probably know. Millions of tons are produced every day by the estimated 1.5 billion cattle populating our planet. Let’s put this into some sort of perspective. The University of Wisconsin at Green Bay estimates the average dairy cow drops 148 pounds of manure each day. Do the math: that’s a lot of BS! And you thought it was all in Washington!

Dairy Farms

Haubenschild FarmSeveral dairy farms in America use the output of their cattle in much the same way as the Nebraska plant, with one exception. The Haubenschild Dairy Farm in Princeton, Minnesota, is a shining example. Instead of using the methane to create heat for boilers, it’s used to run generators that provide electric power for the operation, and supply electricity to surrounding homes as well. Anaerobic digester systems are expensive though, ranging from $200,000 to $1,000,000 depending on the size of the herd, so farmers with smaller herds have been reluctant to make that kind of investment. The USDA has free software for download that will determine digester size and cost based on the size of a farm’s herd. I found it fun, and very informative.

Hopefully, as the science of digesters improves, the process will become less costly, and more farmers and commercial operations will be able to take advantage of poop power. I was surprised to learn from The AgSTAR Program website that several pig farms are using digesters, and there’s even a duck farm in Wisconsin using a digester.

Belching

Here’s the capper: while manure provides greenhouse gasses, a cow’s breath introduces far more methane and other gasses into the air. According to the Intergovernmental Panel on Climate Change, the six million tons of methane burped by cattle in the US each year is equivalent to 36 million tons of carbon dioxide. If you add the output of sheep, goats and other ruminants, they all account for more than 18% of the greenhouse gasses that cause global warming, and that, according to the IPCC, is more than cars, planes and all other forms of transportation.

So, is the world’s cattle population contributing to global warming? It would seem so with all the belching and pooping, and the IPCC makes a strong case.

While we’re beginning to discover applications for animal manure, what about the burping? I doubt gas masks would work well on cows, and there’s no way we’ll be decreasing herd sizes anytime soon. Diet seems the best way to reduce production of greenhouse gasses produced by livestock, along with more efficient and productive methods of dealing with manure.

I’m so proud of myself; I didn’t once say “shit."