energy efficient tech and funding for swine and poultry › mrec › files › 2017 › 06 ›...

© 2013 Regents of the University of Minnesota. All rights reserved.

Energy Efficient Tech and FUNDINGfor Swine and Poultry

Fritz Ebinger

Rural Energy Development Program Manager

(612) 626-1028 ebing007@umn.edu

© 2013 Regents of the University of Minnesota. All rights reserved.

OVERVIEW1. ABOUT EXTENSION, RSDP & CERTS

2. FUNDING

3. POULTRY TECHLIGHTING & BIOMASS

4. SWINE TECHFANS, CREEP MATS, LAMPS

CERTs

EXTENSION

RSDP

UNIVERSITY OFMINNESOTA

© 2013 Regents of the University of Minnesota. All rights reserved.

EXTENSION TRIVIA

• MN started Extension in 1909 before the rest of the country

• Smith-Lever Act of 1914: Established cooperative extension services with land-

grant universities to inform folks about:• New ag techniques• Home economics• Leadership• 4-H • Econ development

© 2013 Regents of the University of Minnesota. All rights reserved.

© 2013 Regents of the University of Minnesota. All rights reserved.

© 2013 Regents of the University of Minnesota. All rights reserved.

ABOUT RSDP• 1997 Regional Sustainable Development

Partnerships

• Connects Greater Minnesota solutions to UMN in order to replicate and scale up

• Leverages local ideas and talent along with UMN resources in four focus areas:

• Agriculture and food systems• Tourism and resilient communities• Natural resources• Clean energy

© 2013 Regents of the University of Minnesota. All rights reserved.

RSDP – flips the Extension Education Model:

• UMN learns from communities and practitioners…then optimizes

© 2013 Regents of the University of Minnesota. All rights reserved.

ABOUT RSDP – A Local Laboratory

Mission: We connect individuals and their communities to the resources they need to identify and implement

community-based clean energy projects

CERTs: Minnesotans Building a Clean Energy Future

Statewide Partnership & Collaboration

Provide seed grant funding and more

Deliver research-based campaigns

Spur other statewide programs

What Does CERTs Do?

Host events, tours, and conferences

Help with community organizing

Connect people to technical resources

Write blog posts & case studies

Create educational guides

Manage diverse web-based tools

CERTified Campaigns

The Efficiency ParadoxIncreased energy efficiency tends to increase energy consumption by two means:

First, increased energy efficiency makes the use of energy relatively cheaper, thus encouraging increased use (the direct rebound effect).

Second, increased energy efficiency leads to increased economic growth, which pulls up energy use for the whole economy.

W. S. Jevons

Khazzom-Brookes Postulate

Rebound Effect

The Efficiency ParadoxAs the cost of energy use decreases with efficiency gains, the consumption of energy increases.

PROJECT BARRIERS

Market Conditions

Farm Business Exit

No time

Not a priority

Number 1

FUNDING OPTIONSUtility CIP Rebates

Minn. Livestock Investment Grant Program

USDA Rural Energy for America Program (REAP) Grant

Property Assessed Clean Energy (PACE)

Compatibility: Use with any other funding source.

Eligibility: Member-owner of the cooperative or utility.

Funding Amount: Varies by utility. A formula provides the

dollar amount per kW or kWh saved. Ranges from 10% to

40% of the project depending on the utility and its priorities.

Project Timing: Discuss funding amount with utility before

starting project. Receive payment within a few weeks after

completing the project and submitting CIP paperwork to

utility.

Competitiveness: No competition. Easy application process.

Electric Utility CIP Rebates

Eligibility: Raise livestock in Minnesota (25% of gross income from agriculture); aim to improve livestock production

Grant: 10% of project cost. Minimum investment of $4,000

Projects Types: Any improvements, primarily energy efficiency, herd expansion, new parlor, new vent fans…

Application Window: Mid-September. Closes mid-December.

Project Timing: Wait for the letter – notice by early Feb.Start project after funding is awarded.

Competition: Low to moderate. 50-60% are successful and application is easy.

Minn.Livestock InvestmentGrant Program

Eligibility: Farmer anywhere with at least 50% of farm income from ag production, or rural small business (pop. < 50,000)

Grant: 25% of project cost. Minimum request of $1,500 for efficiency

Guaranteed Loan: backing up to 75% of project costs.

Projects Timing: Start project after application is submitted.

Deadlines: March 31 (all projects) and October 31 (small projects)

Competition: Steep. Only 25-30% are successful nowadays.

USDA REAP

Eligibility: Legal owner of property. Must be current on mortgages. No liens. Located in a jurisdiction with PACE.

Loan Funding Amount: Loan cannot exceed 20% of

property value. Loan term up to 15 years.

Loan terms <10 years usually under 5% APR.

Project Timing: Apps accepted continuously.

Prep takes a month- start after loan terms set.

LGU assessment request is in the loan terms.

Level of Effort: Quick and easy. No competition.

Pre-Reqs: Energy audit by an energy auditor

must be completed prior to submitting application.

Reporting : No – just pay your property tax bill!

PACE: Property Assessed Clean Energy

• #1 Turkey Producer in US

• 46 mil turkeys yearly

• 250 farmers, 600 farms

• #12 for chicken and eggs

• 47 mil broiler chickens

• 300 farms

Minnesota Poultry

Distribution and Density of Turkey Production

Average 13 hours lighting each day (range of 5 to 24 hours depending on season and barn

Brooder barn = heavy lighting because of enclosed environments, ≈ 40,000+ poults

HPS: Light efficient, not energy efficient

CFLs: Some hesitant to install

LEDs: Viable alternative, high upfront cost…but coming down

Finisher barns – side curtains, 20,000+ turkeys each, 2 barns usually

Minnesota Turkey

Conservation Applied Research & Development (CARD) Grant

April 2011 – December 2013

12 farmers , 23 barns

ONCE Innovations

AgriShift 12W

Studied Poultry LEDs for:

Potential energy savings

Cost-effectiveness

Practical performance

CARD Grant Study

Turkey Barn Lighting

Bulb Type Key Attributes

High Pressure Sodium (HPS)

• Orange/red spectrum

• Each bulb provides a lot of light

Incandescent

• Dimmable

• High burn out rate

• Phasing out

CFL

• Poor dimmability

• Fail early in jelly jars

• Mercury concerns

LED

• Dimmable

• Directional

• High installation cost

150W250W

40W ballast

60W75W

100W

13W23W26W 12W

Bird’s Eye View

Poultry see more of the visible light spectrum than humans

LEDs more closely match poultry’s spectral response curve

LEDs might appear as 500 lumens to humans / 800 lumens to poultry

Turkey Barn Lighting (Cont’d)

Bulbs Life (hours)

Life (years)

Lumens/Watt

Power Consumption

(watts)

BulbCost

(each)

HPS 24,000 5.6 100 150 + 40 (ballast) = 190 $14

Incandescent 1,000 0.23 15 100 $0.75

CFL 10,000 2.3 70 23 $3

LED 50,000 11.6 100 12 $35

Annual Lighting Runtime: 2,000 – 7,500 hours per year, 4,300 hours on average

Maintenance costs reduced when switching to more efficient lighting

Study Results:

Energy Savings

Switch to LEDs from…

Number of Barns

Range of Energy

Savings (%)

Average Energy

Savings (%)

Average Energy Savings (kWh/yr)

HPS 4 76% - 79% 78% 32,500

HPS/Incan. 4 NA 77% 10,300

Incandescent 6 84% - 88% 86% 15,300

CFL 4 8% - 48% 34% 1,900

Switching from incandescent and HPS bulbs result in greatest savings

Study Results:

Cost-Effectiveness

LED bulb costs continue to decline

Upgrade from CFL to LED is not cost effective

Switch to LEDs from…

No. of Barns

Total LED Installation

Cost ($)

Range of Energy

Savings ($)

Range of Simple

Payback (yrs)

HPS 4 $9,200-12,200 $1,500 - $5,900 1.6 - 8.3

HPS/Incan. 4 $4,700 $1,100 4.2

Incandescent 6 $2,100-3,100 $1,300 - $3,000 1.0 - 2.1

CFL 4 $3,200-15,800 $150 - $260 14 - 92

Different LEDs for Different Barns

Corncob LEDs: 120 W with 16,800 lumens (275 W replacement) $160

54 W E39 Base 5600 lumens (250 W equivalent, $87

LED tube lighting (connect together like a chain) 25 W (T-12 equivalent) $26

Reduce lighting costs by $1,000s each year

Save up to 85% on lighting energy

Pay for project with energy cost savings as soon as 1 year(3 yrs without utility rebates)

Reduce maintenance time/cost

Use poultry-specific lighting

Dimming, color, intensity

Why Upgrade to LEDs?

© 2013 Regents of the University of Minnesota. All rights reserved.

Minnesota Swine• #3 in production behind IA and SC• 3,300 hog farms statewide

• Top Counties – 2012 Ag Census• Martin (#6), Blue Earth (#16), Mower (#36),

Freeborn (#37), Nobles (#38)

© 2013 Regents of the University of Minnesota. All rights reserved.

Minnesota Swine Priorities1. Biosecurity2. See 1 above3. Biosecurity protocols4. Biosecurity5. Re-visitation of 3 above6. Biosecurity7. Veterinary costs/antibiotics8. Antibiotic regulations9. Feed costs10. Energy costs

© 2013 Regents of the University of Minnesota. All rights reserved.

Hog Barns!Farrowing Barn• Sows and piglets • Nursing pigs ≈ 20 lbs or

less, 0-2 weeks old• Piglets need ≈ 95 degrees!

Nursery/Grower Barn• Weaned pigs• 3 – 8 weeks old• Ballpark 30 – 80 lbs

© 2013 Regents of the University of Minnesota. All rights reserved.

Hog Barns!Grower Barn• Weaned pigs• 8-12 weeks old• Ballpark 80-150 lbs• High ventilation

Finisher Barn• Big pigs 150 – 250 lbs• 12-16 weeks old• High ventilation

Note – barns are not categorical• Farrow to finish• Wean to finish• Farrow to wean, etc.

© 2013 Regents of the University of Minnesota. All rights reserved.

FARROWING BARNS

• New piglets need 85-95 degrees

• Sows need 60 degrees• Creates an energy

zoning mess• Heat lamps ≈ 45% of

kWh consumption

60° 95°

© 2013 Regents of the University of Minnesota. All rights reserved.

Farrowing: Microclimates are necessary• Basic: Check the heat lamp wattage• 250 W heat lamps are too hot• 175 W heat lamps (and less) are better, save 360 kWh/crate/year• Faster piglet weight gain under cooler lamps

250 W 175 W

“Conserving Energy by Using Localized Heating in Swine Housing, “ Jay Harmon, professor, ag and biosystemsengineering; Hongwei Xin, professor, ag and biosystems engineering; and Dana Petersen, program coordinator, ISU Farm Energy Initiative; Iowa State University Extension and Outreach. Sponsored by the Iowa Energy Center.

© 2013 Regents of the University of Minnesota. All rights reserved.

HEATED CREEP MATS vs. HEAT LAMPS

• 200 W pad for 30-35 degrees above room temp• 2x4 mats

• Stanfield 200 W -- $190• Kane 170 W -- $174

© 2013 Regents of the University of Minnesota. All rights reserved.

HEATED CREEP MATS vs. HEAT LAMPSStinn, John P. and Xin, Hongwei (2014) "Heat Lamp vs. Heat Mat as Localized Heat Source in Swine Farrowing Crate," Animal Industry Report: AS 660, ASL R2931

• 2014 side-by-side comparison

• Three 40 crate rooms

• Half with 125 W heat lamps

• Other half with 290 W creep mats

© 2013 Regents of the University of Minnesota. All rights reserved.

HEATED CREEP MATS vs. HEAT LAMPS

Average Weight Gain? NO DIFFERENCE

Percent Mortality Rate?NO DIFFERENCE

kWh Consumption?36% kWh SAVINGS with heated mats

© 2013 Regents of the University of Minnesota. All rights reserved.

Controlled Creep Mats AND Heat Lamps

Best of both efficiency worlds?

• Sensors automatically adjust heat lamp and creep mat power supply according to room temp and age of piglets

• Power modulator operates 1 20-amp circuit

• Controller manages up to 12 power modulators

3rd Party study would be nice, but sources say this works very well

but for piglets

© 2013 Regents of the University of Minnesota. All rights reserved.

FINISHER BARNSDeep-pit, side curtain

Photos Courtesy of New Modern Concepts – Iowa Falls, IA

© 2013 Regents of the University of Minnesota. All rights reserved.

Deep Pit Finisher BarnsPit Fans – research says turn them OFF

• (Wrong) idea is that pit fans pull fresh air down and then out to keep barn air clear

• Reality: barn floor is too porous; does not have sufficient static pressure

• Pit fans actually do nothing to decrease barn NH3 and N2S emissions

Jacobson, L.D., B.Pl. Hetchler and D.R. Schmidt. 2008. Reducing H2S, NH3, PM, and odor emissions from deep-pit pig finishing facilities by managing pit ventilation.In: Mitigating Air Emissions from Animal Feeding Operations, Technology Summaries of the 19-21 May 2008 Conference (Des Moines, IA). p. 26.Iowa State University, Ames, IA.

© 2013 Regents of the University of Minnesota. All rights reserved.

FINISHER BARNSTunnel ventilated – becoming more common for biosecurity

© 2013 Regents of the University of Minnesota. All rights reserved.

FINISHER BARNSFAN BASICS – BEHAVIOR CHANGE!

• Keep them clean: Dirty fans waste up to 40%• Keep them lubed with graphite dust: higher

temp tolerance, reduces dust intrusion• Keep them tight: Bad or loose belts waste up

to 30% energy

© 2013 Regents of the University of Minnesota. All rights reserved.

ENERGY EFFICIENT FANS• For small fans (≤ 24 in), fans should have an

efficiency of 12 cfm/watt or higher at 0.10 in static pressure

• For moderate sized fans (36”-48”), fans should have an efficiency of 17 cfm/watt or higher

• VSDs and VSD Controllers

• BESS Labs for CFM/Watt andperformance: bess.Illinois.edu

© 2013 Regents of the University of Minnesota. All rights reserved.

HOLD THE DATE

Midwest Farm Energy ConferenceJune 13-14, 2017

West Central Research & Outreach CenterMorris, MN

Focus on Swine Systems with new data!

© 2013 Regents of the University of Minnesota. All rights reserved.

THANK YOU!

FRITZ EBINGEREBING007@UMN.EDU(612) 626-1028