environmental management plan gd pork kojonup...3 | p a g e office address: 8/19 norwood crescent,...

Environmental Management Plan

GD Pork Kojonup

Property Address: Cnr Albany Hwy and Crapella Rd

Boscabel

Crown Allotment: Lot 10 Plan 23562

Shire: Kojonup

Client: GD Pork PTY LTD

2 | P a g e office address: 8/19 Norwood Crescent, Moonee Ponds, Victoria Australia 3039

postal address: 16 Learmonth Street, Moonee Ponds, Victoria Australia 3039 telephone: +61 (0) 3 9326 0106 facsimile: +61 (0) 3 9372 7576 email: [email protected]

Disclaimer

This document has been prepared by Scolexia Pty Ltd with all reasonable skill, care and diligence.

Information reported herein is based on the interpretation of data collected, which has been accepted

in good faith as being accurate and valid.

This report is for the exclusive use of GD Pork Pty Ltd. No warranties or guarantees are expressed or

should be inferred by any third parties. This report may not be relied upon by other parties without

written consent from Scolexia Pty Ltd.

Copyright © Scolexia Pty Ltd, 2018

This template for the report remains the property of Scolexia Pty Ltd. Except for the specific purposes

of this document you may not disseminate, distribute or reproduce of this document without the

express written consent of Scolexia Pty Ltd.

DOCUMENT CONTROL

Reference Status Date Prepared Checked Authorised

SCL Version 0 10/05/18 Janine Price

Version 3 7/06/18 Janine Price

FINAL 8/06/18 Janine Price



Contents

1.0 Introduction ............................................................................................................................................ 5

Scope ....................................................................................................................................................... 5

Piggery description .......................................................................................................................... 6

Production Overview ....................................................................................................................... 8

Legal requirements .......................................................................................................................... 8

Environmental outcome .................................................................................................................. 9

2.0 Site Description ..................................................................................................................................... 10

Property ......................................................................................................................................... 10

Planning Zone ................................................................................................................................ 11

Climate ........................................................................................................................................... 12

Topography .................................................................................................................................... 13

Surface water ................................................................................................................................. 13

Groundwater .................................................................................................................................. 14

Soils ................................................................................................................................................ 17

Vegetation ...................................................................................................................................... 18

Cultural Heritage ............................................................................................................................ 18

3.0 Separation Distances and Buffers ........................................................................................................ 18

Separation distances-amenity ....................................................................................................... 18

Buffers-natural resources .............................................................................................................. 20

4.0 Cleaner Production...................................................................................................................... 21

5.0 Piggery Facilities design and management ................................................................................... 23

Housing .......................................................................................................................................... 23

Feed system ................................................................................................................................... 28

6.0 Nutrient Content of Piggery by Products ...................................................................................... 32

7.0 Effluent Management ................................................................................................................. 34

Collection and conveyance ............................................................................................................ 37

Biogas system................................................................................................................................. 42

Evaporation Pond ........................................................................................................................... 48

Reuse/land application .................................................................................................................. 49

8.0 Carcass Management .................................................................................................................. 50

9.0 Natural Resources and Amenity ................................................................................................... 51

Surface water ................................................................................................................................. 51

Stormwater .................................................................................................................................... 51

Groundwater .................................................................................................................................. 52



Odour ............................................................................................................................................. 53

Dust ................................................................................................................................................ 56

Noise .............................................................................................................................................. 57

Road and traffic .............................................................................................................................. 58

Landscaping and Visual Amenity ................................................................................................... 59

10.0 Environmental Monitoring and Assessment ................................................................................. 60

11.0 Chemical Storage and Handling ................................................................................................... 61

12.0 Fire Protection ............................................................................................................................ 62

13.0 Gaseous Emissions- reporting ...................................................................................................... 63

14.0 FIGURES LIST ............................................................................................................................... 64

15.0 TABLES LIST ................................................................................................................................. 65

16.0 APPENDICES ................................................................................................................................ 66

17.0 REFERENCES ................................................................................................................................ 66



1.0 Introduction

Scope

This Environmental management plan (EMP) has been developed to accompany the licence application

for the GD Pork Kojonup Grower unit located at lot 10 Crapella Rd, Boscabel, WA, 6394. It is a revision

of the original EMP submitted and accepted as a requirement of works approval W5865

The EMP is designed for the use of the farm operator in regards to the day to day management of the

piggery. It does not cover workplace occupational health and safety issues associated with the

operation or management of site infrastructure. These are covered in other guidance documents and

legislation and are outside the scope of this plan.

The EMP identifies site specific environmental and amenity risks and details the environmental

objectives, management practices, and mitigation strategies and contingency actions where required.

The contingency actions identify measures that should be implemented in such events as equipment

failure, breakdown, and natural incidents that could increase risk of impacts to the surrounding

environment or community amenity. These contingencies can be found in the plan and in Appendix 7.

The EMP outlines, site specific management practices that are integral in ensuring the piggery operates

at or above industry best practice to ensure risks to the environment and amenity are minimised.

The EMP outlines a description of the operation, along with objectives that need to be met to minimise

impacts on the environment and community. The risks of the facility or operation are identified and

management practices are identified that achieve the objective and reduce risks. Mitigation and or

contingency actions are identified in the event that a risk event occurs.

The EMP Covers:

• Piggery description

• Site Description

• Separation and Buffer distances

• Cleaner Production

• Facilities design and management

o Housing management

o Feed system management

• Nutrient content of piggery By Products

• Effluent Management

o Collection and conveyance

o Biogas system

o Evaporation Pond

o Reuse/land application

• Carcass Management

• Natural Resource and Amenity

o Stormwater management

o Odour, dust, noise management

o Road and traffic management

o Landscaping management

o Fire Protection

• Monitoring and Assessment

• Chemical storage and handling

• Gaseous Emissions reporting



Piggery description

GD Pork Kojonup is owned and operated by GD Pork holdings Pty Ltd and GD Pork Pty Ltd and is located

at lot 10 Crapella Rd, Boscabel, WA.

The piggery currently operates as a grower unit for GD Pork’s state-wide piggery operation with 36

straw based ecoshelters. These ecoshelters are classified as extensive and do not require a licence

under current WA requirements. (Figure 1)

The piggery expansion will incorporate the existing 36 extensive sheds and 7 new conventional indoor

sheds for weaners and finishers (utilising a pull plug system) with a total capacity of 28,368 SPU. (Figure

2 and Appendix 1) Pigs will arrive at the piggery at approximately 8kg and leave at approx. 100kg.

Piggery manure (spent straw bedding and liquid effluent) will be treated in an effluent management

system that incorporates a biogas plant. The biogas plant will generate electricity from the by-products

produced at the piggery. Remaining digestate from the biogas plant will enter evaporation ponds or if

possible be utilised as a soil conditioner and fertiliser on neighbouring land. Spent bedding and solid

digestate generated from the site are reused off site as a soil conditioner and fertiliser. Spent bedding

can also be put through the biodigester to generate energy. All new infrastructure is be built on

impermeable concrete pads.

Existing infrastructure (Figure 1) includes:

• Pig reception (arrival) facility

• 36 Ecoshelter straw based housing each 26x12m

• Feed silos-these will cease to be used but remain as a contingency measure

• Abattoir loading facility--these will be used for internal movement of pigs in the future

• 2 Stormwater ponds

• Managers house

New infrastructure (Figure 2)

• Internal gravel roads- all weather access

• Entrance-access via Crapella Rd

• 7 (3 weaner and 4 finisher) Weaner sheds 101.5 x 10m and Finisher sheds-101.5 x 13.0m

• Feed Mill and liquid feed shed facilities

• Effluent management system-anaerobic digester, separator, hardstand areas, sump and 2

evaporation ponds.

• Abattoir loading facilities

• Employee housing- single men’s quarter with 8 bedrooms



Figure 1: Existing Site Layout

Figure 2: New site layout



Production Overview

Piglets arrive once a week at the site from the GD Pork’s Pinjarra breeder unit. To avoid GD Pork’s

delivery truck using the same internal roads as the pickup truck from the abattoir, the GD Pork truck

enters from the entrance on Albany Hwy. The separation of truck movements is to enact best practice

biosecurity practices to avoid common areas/roads which could increase risk of disease transfer.

Abattoir trucks pick up from multiple farms and are a known vector of disease transfer. The truck

movements will be limited to 1 to 2 times per week.

Piglets are introduced at around 3weeks of age (8kg) and grown as weaners for approx. 6 weeks until

they reach approx. 22kg. They are then treated as growers for 8-9 weeks until they reach 65kg. Finally,

they are treated as Growers until they reach approximately 100kg. Diets are formulated for each of

the pig classes to match nutritional and growth requirements.

The conventional finisher and weaner sheds are located away from the existing ecoshelter sheds to

create two separate and distinct operating units on the site. This is a biosecurity measure to ensure

any potential disease outbreak can be contained to a single unit.

Finished pigs will be moved from the finisher sheds and ecoshelters to a dispatch shed prior to being

picked up for delivery to the abattoir. The location of this shed is away from the two operating units

which avoids the 2 separate trucks (one for ecoshelter and the other from the conventional sheds)

having close contact to the sheds and allows the abattoir truck to use a separate road away from the

operating units.

The piggery will produce 71,000 Finishers, use 16,900 tonnes of feed per year, 55,000m3 of water for

drinking and washdown and 31,505 tonnes of slurry each year. Appendix 2 outlines the Farms Inputs

and outputs. Appendix 3 outlines water consumption and slurry produced in the new sheds.

Legal requirements

The current piggery is classed as extensive due to pig numbers (less than 1000 animals) and the use of

the use of ecoshelter housing. The increase to above 1000 animals and incorporation of conventional

sheds means the site is now classed as an intensive piggery and subject to the requirements of Schedule

1 of the Environmental Protection Regulations 1987. Works approvals are required for intensive

piggeries of 500 pigs or more. A licence is required for premises which contain pig numbers of 1000

pigs or more. The upgrades to this site have been constructed in accordance with works approval

W5865 and a will require a licence to operate. This updated EMP forms the supporting documentation

for the licence and for ongoing management (objectives, practices, mitigation and contingencies)) to

ensure the piggery operates in a manner that minimises impacts on the environment and amenity of

the area. The piggery will operate in accordance with the objectives set out in the National

Environmental Guidelines for Piggeries 2010 2nd ed revised or as updated. It will also operate in a

manner that meets the general provisions of the Environment Protection Act 1986 and associated

regulations.



Environmental outcome

This piggery aims to operate in an ecologically sustainable manner and incorporate siting, design,

management, new technologies and mitigation strategies to minimise impacts on the environment

such as soils, groundwater, surface waters, biodiversity. It will also consider the amenity of its

operations on the surrounding community.

Groundwater and surface waters will be protected through good siting, design and management of the

piggery facilities including, housing, biogas plant, by product storage, effluent management, carcass

disposal and stormwater management.

By product reuse will take advantage of the resource value of the effluent and solids generated on site.

It will utilise the value to reduce its energy footprint by generating electricity and heat from the by-

products and reducing its reliance on the grid. The digestate will be evaporated or will be utilised as a

fertiliser and soil conditioner subject to appropriate approvals.

Vegetation will be managed to protect flora and fauna species and habitat.

The surrounding communities’ enjoyment of life and property should not be affected by the operations

of the piggery. Siting, design, management and mitigation strategies will consider the effects on odour,

dust, noise, visual impact, flies, vermin and traffic movements.

Items, sites or places of cultural heritage significance should be protected.

The following document outlines how these outcomes will be achieved.



2.0 Site Description

Property

The property is located as Lot 10 on plan 23562 on the corner of Albany Hwy and Crapella Rd, Boscabel,

WA. (Figure 3) It is located within the shire of Kojonup. It is 52ha in size and surrounded by other

agricultural activities such as broadacre cropping. To the west is dense established vegetation. A thick

stand of vegetation is also located directly to the north of the corner of Crapella rd and Albany highway.

There is also established vegetation set back slightly to the north of the site.

The property will be only operated as a Grower piggery with associated infrastructure such as feed

mill, loading facilities, biogas plant, evaporation and stormwater ponds and staff accommodation. The

site is currently separated into 2 production units for biosecurity purposes and comprise of the 36

ecoshelters and 7 conventional sheds.

Figure 3: Aerial of property and surrounding land uses: Source Google earth



Planning Zone

The site is located in the rural zone of the Shire of Kojonup (Green). (Figure 4)

The use of land in the Rural Zone shall be consistent with the following objectives:

(a) The zone shall consist of predominantly rural uses.

(b) To protect land from urban uses that may jeopardise the future use of that land for other planned

purposes which are compatible with the zoning.

(c) To protect the land from closer development which would detract from the rural character and

amenity of the area.

(d) To prevent any development which may affect the viability of a holding.

(e) To provide for limited commercial accommodation opportunities in a rural environment consistent

with the Council’s policy for ‘Farmstay’, ‘Bed and Breakfast Accommodation’ and ‘Chalet’ facilities.

There are no environmentally significant overlays and no overlays indicating land subject to inundation

or flood overlays.

Figure 4: Kojonup North local scheme zones



Climate

Climate affects many aspects of a piggery operation. Rainfall and evaporation affect surface waters,

the size and type of effluent system, options for reusing effluent, cropping and nutrient stripping

abilities and potential amenity impacts. This site has utilised BOM data (Table 1) to design the size of

the evaporation pond system.

Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec Annual Years

Mean Max temp (0C) 29.5 28.8 26.1 22.2 18.1 15.1 14.4 14.9 16.8 20.1 23.5 27.7 21.4 26

Mean Min Temp (0C) 13.1 13.7 12.6 10.6 8.1 6.7 5.9 5.8 6.2 7.7 9.7 11.8 9.3 25

Mean Rainfall (mm) 14.6 14.3 22.5 32.4 66.1 86.0 86.4 73.9 52.9 39.9 23.7 15.8 532.2 127

Mean Daily

Evaporation (mm)

7.7 6.8 5.3 3.1 1.9 1.4 1.4 1.8 2.5 3.6 5.2 7.2 4.0 18

www.bom.gov.au/climate/averages/tables/cw_010582_All.shtml

Table 1: BOM Average Climate Data for Kojonup

The annual wind roses below (Figure 5) indicate that the Kojonup observations at 9am and 3pm

experience calm conditions on average around 10% of the time and range from 4% to 19%. Calm

conditions are generally when odour impacts can occur. The 9am wind roses indicate it would be

favourable to undertake any potential activities that could generate odour in the morning for the

majority of the year and for May, June, July the afternoon appears to be more favourable. This area

has a low percentage of calm and thus favours dispersion of any potential odour sources. The wind

direction on average are fairly evenly spread but a monthly breakdown provides direction data as to

predominant wind direction.

http://www.bom.gov.au/climate/averages/tables/cw_010582.shtml

Figure 5: BOM Average Wind Rose Data for Kojonup

http://www.bom.gov.au/climate/averages/tables/cw_010582_All.shtml

http://www.bom.gov.au/climate/averages/tables/cw_010582.shtml



Topography

The site relatively flat with rise towards the eastern third of the property. (Figure 6)

Figure 6: Site Topography: Source Landgate

Surface water

The Shire of Kojonup planning overlay indicates no land subject to inundation or a flood overlay on the

property. The site is located 8-10m above nearby Fitzes Salt Lake which is located 190m to the North

of the site. (Figure 7)

There is a Salt Lake/pan located within the site boundary. This is located 95m from the evaporation

ponds, 400m from the stormwater ponds and 390m from the biogas plants, 85m from sheds.

A number of swamps /lakes are located to the north and southeast of the site which are over 460m

and lake to the east is over 850m from the property boundary.

The Blackwood floodplain is located 2.7km from the site and the nearest river is the Beaufort River

located 4km from the property.



Figure 7: Aerial photo showing nearest salt pans and lakes: Source Google Earth

Groundwater

The site is located on the southern edge of an alluvium and colluvium surficial aquifer with minor to

moderate groundwater resources comprised of clay, silt, sand and gravels with minor silcrete, calcrete

and ferricrete. The surficial aquifer in this area conceals palaeochannels or directly overlies weathered

basement. Immediately to the north of the site (north of Crapella Road) is a sedimentary palaeochannel

aquifer with moderate-major groundwater resources. The aquifer comprises alluvium and lacustrine

sedimentary rocks of sandstone, siltstone, shale, and basal conglomerates within the palaeochannels.

Nearby off-site production bores targeting this aquifer have been reported to be artesian. (360

Environmental 2018)

Within the Kojonup piggery, groundwater is abstracted for use as stock water, and for non-potable

uses (i.e. washdown, toilets, showers). Neighbouring properties also undertake agricultural land uses.

The potential exists for other users to abstract the groundwater for short-term and/or long-term

irrigation purposes. (360 Environmental 2018)

The Groundwater risk assessment prepared by the Department of Agriculture and food shows that the

site will straddle both hydrogeological zones indicated as Cz and Ag, with the majority of the piggery

being located in the Ag zone. (Table 2 and 3)) Onsite assessment indicates the groundwater is likely to

be 10-14m below the surface. (DAFWA, 2015)



Table 2: Aquifer and Hydrology Characteristics (DAFWA, 2015)

Figure 8: Hydrology Zones (DAFWA, 2015)



Bore data from 270m North of the site indicates groundwater at 5.29m below ground level. Data from

other nearby bores indicates that there is likely to be permanent groundwater under the site at

somewhere between 5m and 10m below ground level. There is also likely to be shallow perched

groundwater at up to 2m below ground level in lower slope landscape positions. (Table 3)

On site there are currently 3 monitoring bores and 3 production bores. Additional bores are proposed

within the GD Pork Groundwater Management Plan prepared by 360 Environmental.

Table 3: Existing Monitoring Network details (360 Environmental, 2018)

The results of the samples collected by 360 Environmental on 28 March 2018 indicated that: E.coli

was not reported in the groundwater associated with the production bore (P1) located in down

hydraulic gradient to the new ponds or the distal downgradient KOJ1 but it was reported at low

concentrations in KOJ2 and KOJ3, located west and east of the new evaporation ponds respectively

Nutrient concentrations in the production bore were all below guidelines with the exception of nitrate

and nitrite which was above freshwater guidelines but may be overly conservative for any down-

gradient receptors The downgradient KOJ1 reported ammonia above non-potable use guidelines and

total phosphorus above fresh water guidelines.

Refer to The GD Pork Groundwater Management Plan prepared by 360 Environmental for further

information on groundwater for the site.



Soils

The site comprises of two unit soil types: Boscabel 1 Sandy Phase and Boscabel 1 subsystem (Figure 9

and 10)

Boscabel 1 Sandy Phase: Extensive areas of pale deep sands associated with sandy gravel uplands. Pale

deep sand, pale shallow sand, gravelly pale deep sand and shallow gravels make up this unit.

Boscabel 1 Subsystem: Sandy gravels, usually pale coloured on broad hill crests and upper slopes, small

swamps and lunettes scattered on this unit. 17 soil groups were found in this unit including: with 62%

of the mapping unit comprising of Duplex sandy gravel, deep sandy gravel and shallow gravel

Figure 9: Soil types on site; Green: Boscabel 1 Sandy phase and yellow: Boscabel 1 Subsystem

(NRInfo, DPIRD)

Figure 10: Soil profile pit: May 2018



Vegetation

The site is mainly cleared with scattered remnant trees found across the site. Predominantly the

vegetation is located west of the site towards the Albany Hwy. There is vegetation comprising of low

shrubs, native grasses and rushes that has been maintained in low lying areas in the centre of the

property. There is no proposed clearing of vegetation.

Cultural Heritage

The site was predominately cleared prior to the expansion and has been operating as a piggery for over

30 years. No overlays of cultural significance were identified.

3.0 Separation Distances and Buffers

Outcome: The community, water resources and vegetation are protected by providing separation

distances and buffers the mitigate potential run-off and odour impacts

Good siting, design and management are important factors for reducing impacts on sensitive receptors

and locations. Providing separation distances and buffers between a piggery and sensitive receptors

is an important secondary control measure to reduce the risks. Recommended distances in the NEGP

are a guide only and reduction in distances may be justified if site specific siting, management or

mitigation can be demonstrated to reduce the impact on a location.

Separation distances-amenity

The separation distance is the distances provided between a piggery complex and a sensitive receptor

is an important secondary measure for reducing the risk of amenity impacts. Separation distances are

measured as the shortest distance from the piggery complex to the nearest part of a building

associated with the sensitive land use.

The separation distance is calculated using the odour assessment process in the National

Environmental Guidelines for Piggeries 2010 end ed revised (NEGP). The assessment aims to establish

whether an odour will have an unreasonable impact on off-site receptors. An unreasonable odour

impact is assumed to occur when separation distances between a piggery and receptor are less than

those calculated using the methods set out in the NEGP. The separation distances were calculated

using the level 1 S- factor method which is a more conservative method than level 2 and 3. The

guidelines assume all piggery odour sources are accurately represented as either area sources (eg

ponds) or volume sources (eg sheds)



The nearest receptor and town to the piggery is outside the recommended S-factor distance. There

are no rural residential zones in proximity to the piggery. (Table 4 and Figure 11). The distances to

neighbouring housing, towns and rural all meet the minimum recommended separation distances

Sensitive receptor S factor recommend distance

Actual distance

Rural dwelling 1.5km 2.3km

Rural residential 2.0km Not applicable

Town site 3.3km > 17km

Table 4: Site Separation Distances using NEGP S-Factor Method

Figure 11: Nearest Sensitive receptors: source Google earth

Minimum recommended distances are provided to account for inaccuracies at close distances. In

most instances including this site the S-factor is larger than the minimum recommended distances.

The conventional sheds are approx. 180m from Albany Hwy from Crapella Rd. Landscaping along

Albany Hwy will assist to visually screen the sheds from the highway. The conventional sheds are high

technology, monitored tunnel ventilated shed with the fans orientated away from the road. The

ecoshelters are not subject to retrospective separation distances as they are existing sheds. The

distances to neighbouring housing, towns and rural all meet the minimum recommended separation

distances. (Table 5)

2300

m

2570

m



Table 5: Minimum recommended distances NEGP 2010 2nd ed revised

Buffers-natural resources

Buffers are the distances provided between the piggery complex or reuse areas and sensitive natural

resources (eg. Bores, waterways, water storages) and are an important secondary measure for

reducing risk. The site meets all the recommended buffers (Table 6). The evaporation pond system

has mitigation strategies (2 pond system, freeboard, conservative sizing) in place to reduce risk of

overflow to the on-site salt pan.

Table 6: Natural Resource buffers (NEGP)

The site does not spread spent litter or digestate or liquid effluent on site so no surface water or

groundwater buffers are required for reuse.

Natural Resource Recommended

Buffer

Actual Buffer

Potable Water Supply 800m N/A

Waterway- Beaufort River 100m 4000m

Floodplain- Blackwood 100m 2700m

Salt Lake on property 100m 95m evaporation

ponds

400m stormwater

ponds

390m Digester

Fitzes swamp 100m 160m

Groundwater Pond base 2m >2m

And 1x 10-9



4.0 Cleaner Production

Objective: Efficient use of resources, minimal waste production and reuse and recycling of by-products

where appropriate.

Management Addresses

Environmental

Risks

Contingency

Reduce Feed wastage

Provide pigs with fresh feed, matching feed

delivered to the amount required and use well

designed feeders. A fully automated computer

program calculates daily feed delivery

requirements for grower and finisher pigs in the

conventional sheds. Growth curves are calculated

to determine formulations in both production

units.

Odour

Vermin

Feed rations are cut down if feed

wastage is detected.

Check for feed wastage and spills daily Odour

Vermin

Remove food wastage and spills

from sheds

Shed design

New conventional sheds are fully insulated climate-

controlled tunnel ventilated sheds. Program

triggered by climate influences such as humidity

and temperature. Alarmed system.

Energy efficiency Sheds can be manually operated in

the event of system malfunction

Backup generator onsite,

additionally a generator can be

hired or brought in from another

GD Pork site.

Have a readily accessible

contractor list available for

emergency breakdowns or

replacement parts on site.

Ecoshelters to utilise natural ventilation and are

oriented east west to reduce heat from the sun

Energy efficiency

Resource reduction

Generation of energy via engineered biogas

digester on site for the site and Feed Mill

Reduce energy Backup generator onsite,

additionally a generator can be

hired or brought in from another

GD Pork site. Test generators

regularly to ensure operational in

the event of digester failure. Have

a readily accessible contractor list

available for emergency



breakdowns or replacement parts

on site.

Feed will be milled and mixed on site and reduces

transport costs and food mileage

Reduce

transport,

external energy

resources

In the event of a breakdown of the

feed mill, feed will be brought in

from external feed mills

Piggery By-Product Reuse

Piggery reuse will not occur on site due to land

availability. Investigate options to utilise digestate

and liquid by products as a soil conditioner and

fertiliser source.

Reuse, waste

hierarchy,

reduce fertiliser

resources

Discharge to evaporation ponds

Table 7: Cleaner Production- Management, Risks addressed and Contingencies



5.0 Piggery Facilities design and management

Housing

The piggery is divided into 2 production units- 36 ecoshelters and 7 fully automated conventional

sheds.

Ecoshelters- Design and Management

Pigs are housed within 36 ecoshelters. These comprise of a 100mm thick concrete floor covered with

straw bedding within hooped metal frames covered in waterproof plastic. (Figure 12) Each shed is 26m

x 12m. The straw absorbs spilt drinking water and manure and the impermeable base makes clean out

easier and prevent ingress of nutrients to the groundwater. The Sheds have 1 m high walls on both

sides and part of West end. These are walls are connected to the floor and impermeable. The middle

part of west end is closed by 1 m high moveable concrete blocks for cleaning purposes. The sheds are

oriented east west to take advantage of the natural ventilation and positioning of the sun during

warmer weather. In cool weather the west end can be closed by top mounted curtains and in warm

weather the climate inside shed can be partly regulated with water sprinklers placed below top of shed.

Each shed has 6 eating places feeder and drinking facilities placed on outer wall in each side (total of

10 drinking bowls per shed) Feeders are filled with a tractor and feeding trailer or an automatic feed

system. Between each batch sheds are cleaned out and floor sprayed with lime in a water solution for

disinfection purpose before new pigs are placed. Water from the clean out is captured in a concrete

spoon drain running outside of the ecoshelters (Figure 13) and is captured in the 2 existing stormwater

ponds. The bedding is removed after each batch and collected for off-site use as a soil conditioner and

fertiliser. Spent bedding can also be used as a feedstock for the biodigester.

Figure 12: Ecoshelter with straw based bedding Figure 13: Concrete apron outside ecoshelters



Conventional Shed- Design and Management

There are 7 conventional sheds. The 4 finisher sheds are 101.5m long and 13m wide. The remaining 3

weaner sheds are 101.5m long and 10 m wide. The sheds are orientated north south and are connected

with a 2.5m enclosed passage running through the center (Figure 14). The floors are concrete and fully

impermeable. There are 14 sections with each section containing a total of 36 pens in 2 rows. Each

pen 6.0m x 2.75 for the finishers and 4.5m x2.75 for the weaners. The floors are fully slatted in which

the effluent and the manure falls through into a pit underneath the floor (Figure 15 and 18). The pull

plug system is pulled once the effluent builds up and flows through to a sump and biogas digester. The

pens are cleaned out at the end of each batch. During the batch the pens remain quite clean due to

the effluent and manure falling through to the underfloor pits. The sheds are fully insulated

automated tunnel ventilation system which are programmed to take into account climatic factors such

as temperature and humidity and adjust the ventilation rates to ensure optimal conditions for the pig’s

health (Figures 15 and 16). This also reduces the concentration of odour emissions and thus amenity

impacts.

Figure 14: Inside of a conventional shed Figure 15: Conventional slatted floor (weaners)

Figure 16: Automated Climate Control Panel Figure 17: Tunnel Ventilation Fans



Figure 18: Inside of conventional grower/finisher sheds

Dispatch Shed- Design and Management

Finisher pigs are moved to the dispatch shed from the finisher sheds and ecoshelters prior to being

picked up for delivery to the abattoir. The location of the shed is positioned away from the 2

production units which allows 2 separate trucks (one for ecoshelter and the other from the

conventional sheds) to avoid coming in close contact to the sheds. It allows the abattoir truck to use a

separate entrance on Crapella Rd.. The pigs are delivered via two side entrances to keep the ecoshelter

deliveries separate from the conventional sheds. The pigs are housed in this dispatch shed for approx.

1hr prior to pick up. The shed is naturally ventilated and is fully slatted, with an underfloor pit and pull

plug system similar to the conventional sheds. Due to the short amount of time the pigs are in the

shed, the effluent is composed of more liquid from the washdown water than solids. This washdown

effluent is integrated into the sites effluent system via the evaporation pond (discussed in section 7).

Due to the dilute nature and small volumes of the effluent it is not recommended to put through as a

preference to the digester as the dilute nature could slow the digester affecting efficiency and energy

production. The effluent will be diverted straight to the evaporation ponds. Trucks that deliver pigs to

the dispatch shed are washed down with a high-pressure hose on a concrete slab adjacent to the shed.

The area around the pad will contain crushed blue metal to reduce erosion around the slab and

facilitate evaporation of the washdown water to avoid pooling of water.



Objective: Pig housing designed, constructed and managed for optimal hygiene to prevent adverse

impacts to the environment and community amenity

Management Measure Risk Mitigation Contingency

Avoid cleaning sheds with bactericides as

these can affect digester and pond functions

odour

Ecoshelters

A concrete base is provided in each shed.

This ensures that the shed floor remains dry

and that there is no moisture uptake from

the surrounding soil.

Groundwater

Odour

Drinkers within the sheds to be inspected

daily to ensure they are adequately supplying

water and are not leaking and creating wet

litter.

Odour Turn off supply to leaking

drinkers and provide

alternative water supply.

Remove wet litter from the

sheds. Spare drinkers and

parts kept on site for

immediate replacement

Cleaning of ecoshelters conducted with high

pressure low volume sprays to minimise free

flowing water.

Surface water

Any run-off from cleaning will be captured

and redirected to stormwater ponds

The flooring and drainage system will exclude

the ingress of clean stormwater by

maintaining impermeable walls and floors

Surface water,

Groundwater

Odour

If water enters the sheds

remove wet litter as soon as

possible

Prevent the discharge of effluent, solid

materials to adjacent waters by directing any

run-off to the existing stormwater ponds.

Surface waters

Groundwater

Odour

Clean up any spilt bedding

during clean up as soon as

possible.

Daily inspection of bedding undertaken to

maintain dry, low, odour conditions

Odour If wet litter identified,

remove and replace with

fresh bedding

Hardstand extension of concrete floor pad

>1m beyond shed to capture any spilt

bedding during clean out.

Surface water,

groundwater and odour

Conventional

Regular cleaning to ensure lanes, pens and

handling areas remain clean

Odour

Regularly inspect computer programmed

climate system to ensure system functioning

optimally in regards to temperature,

humidity and ventilation rates. Adequate

ventilation removes excess heat and

Odour Computer to trigger alarm

should ventilation rates,

temperature or humidity

deviate or system

malfunctions. Ensure

multiple staff receive



moisture, dilutes and removes airborne

organisms and maintains oxygen levels.

notification of alarms.

Manual override to be

enabled.

Generator available in the event of power

failure from the biodigester. A regular

protocol for generator testing will be in place

to ensure reliability.

Odour Backup generator onsite,

additionally a generator can

be hired or brought in from

another GD Pork site

Test generators regularly to

ensure operational in the

event of digester failure.



emergency breakdowns of

digester (specialist area)

Regularly inspect cooling pads to ensure

optimal efficiency and for signs of vermin

damage

Odour

Clean ventilation fans regularly to ensure

dust does not significantly build up. Dust can

increase energy use and efficiency

significantly.

Odour, energy efficiency

Ensure pens are cleaned out at the end of

each batch

Odour

Daily inspection of pens for manure build up.

If needed remove manure from the pen or

push through to the underfloor storage.

Odour

Regularly inspect the pull plug system to

ensure adequate underfloor storage

available.

Odour

Consider pulling the plug more regularly to

maximise methane potential in the biogas

digester.

Odour

Sheds have been constructed of materials to

minimise vermin entering the sheds. Regular

inspections to be taken around sheds to

identify any entry points for birds or vermin.

Vermin

Regular use of target specific,

environmentally safe rodent baits will be

placed around the exterior walls and doors.

Vermin



water and are not leaking

Odour



Dispatch Shed

Ensure pens are cleaned out at the end of

each batch

Odour

Ensure and maintain the area around the pad

contain crushed blue metal to reduce erosion

around the slab and facilitate evaporation of

the washdown water to avoid pooling of

water.

Erosion

Groundwater

Replace blue metal when

depleted



water and are not leaking

Odour Have a readily accessible




Table 8: Housing- Management, Risks addressed and Contingencies

Feed system

Feed Mill

The new feed mill (Figures 19 and 20) including silos is located to the west of the site adjacent to the

Albany Hwy. The feed Mill includes:

• weighbridge and grain intake placed adjacent to shed

• 1,400 tonne of grain and meal storage silos placed adjacent to shed

• A 10 tonne per hour grinder placed inside the shed

• Minerals and vitamins dosing system placed inside the shed

• A mixer placed inside the shed

• 297 tonne of ready-made feed silos placed adjacent to shed

• A control room

The location of the feed mill ensures external trucks delivering feed and taking products to be separate

from the 2 piggery production units. Delivery trucks making multiple external farm visits are known

potential disease vectors.

Figure 19: New feed Mill Figure 20: New Feed Mill



Ecoshelters- Feed System

At the east end of the sheds is a 5m long concrete repos the width of the sheds. A 6-place feeder is

positioned in the middle of the repos (Figure 21). There are 10 drinking bowls per shed positioned on

the outer walls (5 per side). The feeders are filled with a tractor and feeding trailer as per Figure 22.

Growers and Finishers have different nutritional requirements and are fed different feed to optimise

growth during their specific stages.

All of the pigs (weaners, growers and finishers) are fed ad libitum via feeders that permanently contain

feed. This means pigs can eat as much they want, when they want which reduces noise and dust as

there is no excitement or struggle at specific feed times.

Each day every pig is checked to ensure they are receiving sufficient feed and water and to ensure good

health.

Figure 21: Feeders inside the Ecoshelters

Figure 22: Feed truck delivery feed inside the ecoshelters



Conventional Sheds- Feed System

In weaner period pigs are fed with 2 different type of dry feed according to their weight/age composed

of ingredients to encourage the pigs to eat. The conventional shed feeding system for grower and

finishers is fully automated and determines the feed requirements based on a pig growth curve and

daily intake. This system can be adjusted per feeding based on intake and feed wastage. As per the

ecoshelter production unit, specific feed formulations are developed for each of the various growth

stages. Both dry and wet feed is fed in the conventional sheds. The wet feed is blended in a room

(Figure 23) adjacent to the conventional sheds in fully contained mixers located on a concrete floor.

Immediately adjacent to this room is the control room that houses the computerised automated feed

system that develops the formulations. The feed is delivered to each individual pen via a fully enclosed

deliver system on the internal ceiling (Figure 24). The fully enclosed system reduces dust associated

with other forms of feed delivery. The fully automated targeted feed system significantly reduces feed

wastage, which reduces odour in the sheds, reduces the attractant to vermin and reduces the amount

of feed entering the effluent system which can alter the characteristics of the effluent in terms of odour

and methane generation.

Figure 23: Enclosed Feed Mixer Room Figure 24: Conventional Feed system in shed



Objective: Manage the feed manufacturing and delivery system in a manner that minimises odour, dust

and noise generation.


Feed Mill

Feed will be delivered from the feed mill to

the production units via a fully enclosed above

ground piping system to reduce truck

movements.

Traffic, Dust Above ground pipes makes

accessibility for maintenance

and un blocking.

Use trucks to cart feed in an

emergency situation.

Feed spills in and around the feed mill, will be

promptly cleaned up.

Dust, Vermin

Silos have been constructed to best practice

design and construction to prevent feed

contamination or generation of dust during

delivery or distribution.

Dust

Access to feed mill will be via the Albany Hwy

entrance and trucks are to use internal roads

positioned away from the production units to

minimise biosecurity risks.

Traffic

The feed mill will only accept deliveries

between the hours of 6am and 6pm

Noise Vegetative screening along

Albany Hwy to reduce visual

impact and noise

Feed Mill constructed on an impermeable

concrete pad.

Groundwater




Vermin

Ecoshelters

Ensure feed is augured from the trailer

and/or delivered with automatic feed system

into the ecoshelter feeders which are

situated within the sheds to reduce dust.

Dust Feed manually distributed to

feeders in the event of

feeder truck issues

Clean up any spilt feed from the adjacent

laneway or area surrounding ecoshelters

Vermin




Vermin

Conventional sheds

Wet feed is mixed in the fully enclosed mixer

shed to minimise dust and noise.

Dust, noise

Clean up any spilt feed from the adjacent

laneway or pens

Vermin



Regularly inspect and maintain feed lines

and associated infrastructure to ensure

system remains fully enclosed

Dust, Noise Manually distribute feed

Daily inspection of computer program Odour (feed wastage) Manually calculate feed

requirements using growth

curve data




Vermin

Table 9: Feed System- Management, Risks addressed and Contingencies

6.0 Nutrient Content of Piggery by Products

Outcome: Identification of nutrient content and quantity of by-products enabling appropriate

treatment, containment and sustainable re-use

The manure and waste feed produced by one Standard pig Unit (SPU) is equivalent to 90kg/volatile

solids/yr. (Table 10) This site has 28,368 SPU’s which is equivalent to an estimated 2.5mill kg/VS/yr.

This calculation assumes the pig is fed typical diets, has typical feed wastage and is not fed with

advanced feeding technologies such as phase feeding.

Table 10: Standard Pig Unit Conversion Table (NEGP 21010)



The piggery by products include: deep litter from ecoshelters, effluent from conventional sheds (slurry)

and mortalities. These have been calculated in regards to volume and nutrient content. See Table 11

below. Nutrient volumes and mass balance calculations for various pig classes can be found in the

NEGP.

Table 11: Piggery Nutrient Outputs/year

The fate of the nutrients is similar in a biodigester to an effluent system although the availability of

nutrients from a biodigester are more bioavailable to plants. AD results in minimal reduction in N with

the majority of P ending up in the remaining digestate.

Appendices 2 and 3 outline inputs into the piggery and biogas plant.

Input Tonne/year

Mortalities 126

Dry matter 53

Deep litter manure 2,924

Deep litter manure dry matter 965

Slurry 31,505

Slurry dry matter 1,922

Nutrients from manure, slurry and mortalities

Dry matter 2,940

Total nitrogen (N) 179

Phosphorus (P) 53

Potassium (K) 130



7.0 Effluent Management

The piggery produces two effluent/manure streams. The conventional weaner and finisher sheds

produces a liquid slurry-based stream which comprises of manure, urine, spilt feed and washdown

water from the sheds. (Figure 24) Solids based spent bedding (straw mixed with manure and urine) is

produced from the ecoshelter production unit (Figure 25). The two effluent manure streams are

handled differently due to their characteristics and current regulatory requirements.

Spent ecoshelter bedding is removed from the sheds at the end of each batch. This is stored on an

impermeable concrete collection pad prior to removal for off-site use as a soil conditioner and fertiliser.

Spent litter can also be macerated and put through the digester if required as an additional feedstock.

The conventional sheds utilise an underfloor storage pit and pull plug system. The pull plug is released

and slurry is transferred to a sump via gravity where it is then pumped to a feeder tank. This feeder

tank transfers the slurry into an engineered tank style digester which utilises microbes under heated

anaerobic conditions to breakdown the effluent and manure into biogas. This biogas is then

transferred back to a generator located near the conventional sheds to generate power to supply the

sheds and feed mill. The digestate is the remaining by-product of the biodigester.

The original mass of the product entering the system is significantly reduced with approximately

approx. 60% broken down in the biodigester. This remaining digestate is pumped to a screw press that

removes a further 25% of the solids.

The remaining liquid digestate is pumped to the first of 2 evaporation ponds where the liquid

evaporates and solids are eventually removed once volume in the pond is reduced.

The digestate significantly lower in odour than straight piggery slurry due to the anaerobic processes

undertaken in the biodigester which removes the majority of Volatile solids. Lower odour and nutrient

characteristics of the digestate make it a valuable soil conditioner and fertiliser. The aim is to utilise

this valuable resource in the future as an off-site fertiliser and soil conditioner as per best practice

reuse management.

The effluent from the dispatch sheds which only have pigs for approx. an hr at a time collect the effluent

and manure in a fully slatted pull plug scenario as per the conventional sheds. This effluent is diluted

with washdown water and is captured and conveyed to the evaporation ponds rather than the biogas

plant as the dilute nature may slow the system, effecting the efficiency and biogas production.

The following sections will explain the individual siting, design and management principles associated

with the effluent system.



Conventional Effluent and Manure Flow

Figure 24: Conventional Effluent and Manure Diagram



Ecoshelter Manure Flow

Figure 25: Ecoshelter Manure Diagram



Collection and conveyance

Ecoshelter- Collection and Conveyance

Solids based spent bedding (straw mixed with manure and urine) is produced from the ecoshelter

production unit. Between each batch (approx.5-6 weeks for growers and finishers) the spent bedding

is cleaned out with a front-end loader (Figure 25)) and loaded into a truck which transports the spent

bedding to a concrete holding pad that has been designed for a solids storage capacity of 90 days.

(Figure 26). Standard practice will be for these solids to be picked up on a regular basis so the storage

area does not reach full capacity. Stormwater run-off from the concrete holding area is captured via a

small sump and is conveyed via pump to the first of the evaporation ponds. The spent bedding is

collected and utilised off site by as a soil conditioner and fertiliser. Currently it is collected by an

adjacent landholder for reuse on an extensive cropping production system. The spent bedding can

also be put through the biodigester (via macerator to breakdown fibre length) as a feedstock to

produce energy for the site.

Figure 25: Cleaning out Ecoshelter spent bedding

Figure 26: Spent Ecoshelter bedding on concrete hardstand area



Having a solid concrete floor and walls allows the front-end loader to scrape and push all the material

into the corners allowing for all of the material to be collected. Once this material is removed the floors

are sprayed with a lime water solution for disinfection using a high-pressure hose to minimise water

use and run-off from the sheds.

The run-off water from shed clean out is conveyed via a concrete spoon drain along the front of the

sheds to a sump. This sump also captures stormwater from the laneways between the shed. (Figure

27)

Figure 27: Washdown water drain from ecoshelters

The stormwater is conveyed from the sump to 2 stormwater basins. (Figures 28 and 29). These ponds

are planned to be taken off line to allow for evaporation and clean out once the new evaporation ponds

a fully commissioned. Following this process, the Stormwater basins are intended to be reinstated to

capture run off from the Ecoshelter site. This is in preference to the digester as the volume and dilution

will potentially slow the digester and impact on its efficiency.

Figure 28: Primary stormwater pond Figure 29: Secondary stormwater pond



Conventional Sheds- Collection and Conveyance

The conventional sheds comprise of pens with fully slatted floor. (Figures 30 and 31) The manure,

effluent and small amounts of spilt feed drop down through the slats into an underfloor collection pit.

The pens are washed down after each batch and this washdown water containing manure and effluent

also collects in the under-floor pit. This system is known as a pull plug system. These systems are

drained on a regular basis (depends on capacity and need for biogas as to frequency) using gravity

release pipes in the along the centre of sheds/pits. These sheds are serviced by a number of cells (16

per weaner and 14 per grower shed of approx. 25m3 and approx. 35m3 respectively) serviced by

individual pull plug systems.

Figure 30: Slatted floor in conventional shed -weaners

Figure 31: Slatted floor in conventional shed -growers/finishers



Once released from the sheds the effluent is conveyed in 300mm PVC pipes via gravity to a concrete

sump system. (see Picture below). The sump capacity is 90m3 and is constructed from 250mm thick

concrete walls and 200mm base over a waterproof membrane. The sump is the same as the biogas

feeder tank but submerged into the ground. The sump has been designed to hold 3 flushes from the

weaner sheds and 2 from grower sheds and has a capacity to store the effluent for up to 3 days. The

sump system has a pump (7.5kW) and float switch positioned approx. 300 mm from the top of the

sump. The sump is positioned close to the southern evaporation pond system allowing for a diversion

as a contingency if the pump or float switch malfunction.

The float switch triggers the pump to convey the effluent from the sump via 150mm HDPE pipes to the

biogas feeding tank. The feeding tank will be discussed in the biogas system.

Dispatch shed-Collection and Conveyance

The dispatch sheds are fully slatted floors with a pull plug system as per the conventional sheds. Pigs

are only in these sheds for up to 1hr prior to collection for transport to the abattoir. After every delivery

the dispatch shed is pressure washed and disinfected for biosecurity. Due to the short amount of time

the pigs are in the shed, the effluent is composed of more liquid from the washdown water rather than

solids. This washdown effluent is integrated into the sites effluent system via the evaporation ponds

in preference to entering the biodigester as the dilute nature of the effluent may slow down and impact

the efficiency of the digester.



Objective: Effluent is collected and moved from sheds to collection/treatment facilities or reuse area with

minimal odour generation and no release to surface water and groundwater


Observe sump depth prior to pulling plugs

Pull when 80-90% filled

Odour, groundwater 30ays holding in shed plus 3

days in sump. Sump can be

redirected to southern

evaporation pond upon

approval

Pull no more than 3 pits at a time Odour, groundwater

Empty pull plug pits regularly and consider

more frequently for the biodigester

Odour

Empty pits in rotation on different days to

promote even flow of effluent.

Odour

Schedule pit emptying at times of the day

neighbours are less likely to be at home and

when good odour dispersion expected- mid

morning and afternoon usually good times

Odour

Ensure concrete drains at the front of the

ecoshelters self-drain and remove any solid

build up regularly

Odour

Avoid sump agitation under still conditions Odour

Inspect drains, sumps daily or as required

depending on frequency

Odour

Inspect pits at least weekly Odour

Ensure agitation speeds on sumps and tanks

is not too fast as this can promote odour

generation

Odour

Provide overflow access from the sump to

the second evaporation pond as a

contingency option

Groundwater

Capture solids within a controlled drainage

area with an impermeable base.

Groundwater

Ensure regular pick up of solids to limit the

mass kept on site

Odour Redirect ecoshelter bedding

through the biodigester

Maintain a clean area around the hardstand

area and pick up any spilt or excess solids

Groundwater

Avoid handling where possible ecoshelter

bedding and digestate under windy

conditions.

Dust, Odour

Separating solids and liquids allow for greater

flexibility for reuse

Odour, groundwater,

surface water

Table 12: Conveyance and collection System- Management, Risks addressed and Contingencies



Biogas system

The biogas system for the purposes of this EMP comprises of a feeding tank, macerator, biogas tank,

chillers, flare, generators and screw press system. Inputs and outputs into the system are summarised

in Appendices 4 and 5.

The effluent is pumped from the sump (discussed in collection/conveyance section) into an initial

collection tank known as the feeding tank. The feeding tank receives all of the effluent from the

conventional sheds and mortalities generated on the site. (Figure 32)

Prior to entry to the tank is a macerating machine that shreds some of the materials prior to entry into

the feeding tank and ultimately the biodigester. Mortalities from the site are put thorough the

macerator to breakdown the carcasses into smaller components with a larger surface area which are

more suitable for the biodigester. Other solid materials such as spent bedding could be put through

the macerator to breakdown volume and increase surface area availability for the microbial action in

the biodigester. The smaller the particles, the increase in microbial digestion and subsequently biogas

and energy generation.

This tank is constructed from 250mm thick concrete walls and 200mm base over a waterproof

membrane and has a capacity of 90m3. The tank is mixed by a is submerged stirrer to ensure

homogenisation and avoid stratification. Installed on the tank rim is the macerator as mentioned

above

Figure 32: Biogas Feeder tank with macerator



The liquid material is then introduced into the digester (Figure 33). The digester has a diameter of 23m

and a total height of 6m. The effective height of 5.3m provides an available volume of 2,492m3 with

an estimated total time of retention of 25 days. The digester is made of stainless steel 316L and is

completely insulated to ensure less thermal interaction with the external environment. An elastic

gasometrical dome covers the top of the digester ensuring the complete absence of oxygen and the

total collection of greenhouse gases developed in the storage phase.

The power supply system of the digester is composed of a grinding machine and a volumetric pump.

The loading system is equipped with recirculation in the load tank, thus the material in the tank can be

homogenized and reduced to the desired size by a continuous passage in the shredder. All pumps and

associated equipment are housed within enclosed sheds to protect from the weather and reduce noise.

The process is fully automated and computerised to ensure an adequate system of inputs, outputs,

mixing and heating occurs. (Figure 34) This maintains the essential parameters required for the

microbes to actively undertake anaerobic digestion and maximise biogas production.

In the event of a malfunction effluent can be stored in the sump for 3 days and a further 30 days in the

underfloor pits.

The code of practice for on-farm biogas production and use (piggeries) 2015 is a handy reference

document

Figure 33: Biodigester



Figure 34: Automated control system for Biodigester

Excess biogas can be flared in the enclosed solar spark flare (Figure 35). The flare allows for the

minimisation of direct venting of unburnt biogas and for emergency and maintenance events. The flare

provides for the safe combustion of biogas that does not yield usable energy. It coverts biogas into

less harmful carbon dioxide and water.

The collected biogas is cooled in a chiller to drop any condensate out of the gas (Figure 36). Condensate

affects the energy generators. The biogas is scrubbed to remove Hydrogen sulphide which is harmful

to humans but also corrosive to generators and biogas infrastructure. It is scrubbed using air injection

into the tank and via a ferrous oxide injection.

Figure 35: Enclosed Flare system Figure 36: Chiller system to remove condensate



Biogas is transported via below ground pipes to a generator located near the conventional shed. The

co-generation system generates electricity for use within the conventional sheds and for the feed mill

allowing the site to be independent from the local electricity distribution network. (Figure 37) The heat

generated from the cogeneration process is re used to heat the digester. There is potential to utilise

this excess heat for replacing electric heating in the sheds, warming the ponds to accelerate

evaporation or groundwater desalinisation. The co-generation system is located within an enclosed

container system to reduce noise.

Figure 37: Co-generation unit for producing heat and power

The material remaining after undergoing of anaerobic digestion in the digester is known as digestate.

This material has a reduced volume of approx. 60% of input and a significant reduction in volatile solids

>70%. This digestate is pumped from the digester to a screw press system. (Figure 38) The screw press

system screws the digestate against a filter which retains the solid component and allows the liquid to

pass through. (Figure 39). This takes place on the large concrete hardstand area that also houses the

spent ecoshelter bedding prior to collection offsite. The hardstand area has been designed with a

capacity to store 90 days’ worth of solid material. The solid digestate is also collected for offsite use as

a soil conditioner and fertiliser. Standard practice will be for these solids to be picked up on a regular

basis so the storage area does not reach full capacity on a regular basis. The digestate (solid and liquid)

contains nutrients more bioavailable to plants than raw or pond effluent due to the AD process and is

less odorous due to the reduction in volatile solids.



Figure 38: Screw press Figure 39: Solid digestate after screw press

The liquid component of the digestate is collected and pumped to the evaporation ponds. Best practice

is to utilise the nutrients in the digestate as a fertiliser and soil conditioner. This will be explored as an

option.

Table 13: Biogas System- Management Risks addressed and Contingencies

Objective: Biogas system and associated components designed and constructed to optimise biogas

production, reduce volatile solids and remove solids while minimising impacts on community amenity

and surface waters and groundwater


Daily visual checks of the effluent system

including biogas plant.

In the event of a breakdown.

Effluent to be stored in pull

plug system, sump and

feeder tank.

Quality of methane gas measured daily

Methane gas production metered and

recorded daily

Ensure real time monitoring of the biogas

system is sending data to the appropriate

staff. Ensure alarms are tested regularly.

Odour

Regular maintenance schedule in place for

blower and pumps

Odour, noise

Once a month or when necessary clean the

macerator to ensure efficiency

Odour

Minimise storage times of feedstock in sumps

and feeding tank prior to entering the

digester to reduce pre-fermentation, fugitive

gas emissions and odour

Odour



Consider additives to the system. Some

Antimicrobials and chemicals can affect the

microbial population and digester health

Odour Adjust chemical inputs

Biogas yields are related to the quantity of

biodegradable organic matter entering the

system. Avoid upsetting the balance of the

system by adding dilute sources into the

system

Odour, energy generation,

resource reduction

Add additional solids if

required

Biogas vents to be located above head height

to minimise hazardous exposure

Odour

Exclude no authorised people access to the

evaporation ponds and biogas system.

Ensure only suitably qualified contractors

undertake maintenance on the biogas system

Selection of scrubbing media needs to

consider disposal options when spent. Some

media such as iron sponge or activated

carbon can be recycled on-farm Dispose of

appropriately to avoid impacts.

Groundwater, Surface

water

Condensate should be recycled into the

evaporation pond and not back into the

system as sulphur entrained in the

condensate can reform into hydrogen

sulphide which increases its content in the

biogas.


water, Odour

Spent generator motor oil should be stored

in enclosed sumps prior to disposal at a

suitable location that can process the oil.


water

Regularly inspect flare. Ensure a

measurement device such as a thermocouple

or flare eye is installed to confirm flare is

operational

Odour If un operational back up

vent in digester will pass

excess biogas into the

atmosphere at height

Maintain solids separator by regular checks

to ensure efficient solids separation

Odour

Capture solids within a controlled drainage

area with an impermeable base.

Groundwater



Evaporation Pond

There are 2 evaporation ponds on site with the following dimensions. (Table 14 and Appendix 6)

Evaporation

Pond

Capacity Dimensions Depth Freeboard Crest Internal

Batter

Design

Parameter

North 18,400m3 120 x 165m 1 0.5m 3m 2.5:1 1:20

South 14,800m3 190 x 85m 1 0.5m 3m 2.5:1 1:20

Table 14: Evaporation pond dimensions

The pond capacities were designed based on a water balance taking into account monthly balances for

• Highest 1 in 20-year winter rainfall data each year

• Median evaporation

• PAN factor 0.85

The water balance determined that for 20 years with a 1 in 20-year rainfall event every winter the pond

does not overflow. A full water balance was undertaken and can be obtained in the works approval

information.

The two ponds are located in the area of the farm known as the Ag zone which has sandy gravel-clay.

Geotechnical testing indicated that the majority Northern pond had material that was suitable for

compaction to 1 x 10-9.

The area of the pond that didn’t meet the soil parameter indexes had additional soil material brought

in to achieve the permeability requirement of 1x10-9

The southern pond is currently undergoing additional testing to confirm that the permeability can be

achieved.

Data from other nearby bores indicates that there is likely to be permanent groundwater under the

site at somewhere between 5m and 10m below ground level. The height of the pond wall above

groundwater is 0.75m for both ponds. Taking into account pond depth of 1m plus freeboard there is

approximately 0.75 below ground level.

Current bores around the dam will be likely taken off line and new bores located on site according to

the groundwater management plan. These bores will monitor long term the integrity of the ponds.

The digestate from the biodigester after solids removed (via screw press) will enter the Northern pond

first and flow to the southern pond if needed. The southern pond is to be managed more as a

contingency measure and for maintenance when the first pond needs cleaning out.



Ultimately the digestate would like to be re used as a soil conditioner and fertiliser for nearby

properties. When this occurs both ponds will only be used as contingencies in the event the digestate

cannot be removed.

Objective: Evaporation ponds designed, constructed and managed to contain liquid by-products in a

manner that does not impact groundwater, surface water tor the amenity of the surrounding community


Maintain a freeboard of 0.5m at all times to

both ponds


water

Divert from Northern pond to

southern pond to allow for

reduction in liquid and

desludge

Remove solids when availability suits or when

pond volume is substantially reduced


water

Regularly inspect outer backs of the ponds to

ensure no cracking or bank instability


water

Bring in additional clay-based

material to stabilise

If possible maintain grass to the outer banks

to prevent weed infestation, cracking and

erosion


water

Trees, shrubs and woody weeds should not

be allowed to establish on the banks as they

can compromise the integrity.


water

Remove excess vegetation

via herbicide spraying.

When desludging, divert the effluent into the

second pond and consider seasonal

conditions and prevailing winds

Odour

Table 15: Evaporation ponds- Management, Risks addressed and Contingencies

Reuse/land application

Piggery effluent, manure, spent bedding and compost can be a valuable source of nutrients and organic

matter for improving soils, crop and pasture production. The benefits of reusing manure and effluent

include increased organic matter and crop yields, improved soil structure, rainfall infiltration, water

holding capacity, enhanced soil fertility (better cation exchange capacity and nutrient retention) and

reduced or replaced fertiliser costs.

Materials including piggery effluent and manure that go through anaerobic digestion in digester

systems has been found to enhance the bioavailability of nutrients. That is the plants can readily take

up the nutrients rather than being slow release. This allows end users to minimise or totally eliminate

the need for conventional fertilisers.

Any off-site users should be directed to the Piggery Manure and Effluent management and Reuse

Guidelines 2015, APL or Getting the Best Value from Manure Nutrient booklet 2015, APL for duty of

care statements and management practices for responsible reuse.



8.0 Carcass Management

Mortalities are removed from the production facility on a daily basis and taken to the biogas facility.

The carcasses are deposited in a macerator which shreds the bodies into small pieces prior to entering

the feed tank for the biodigester. The feed tank mixes the carcasses which the other material (effluent

and manure) in preparation for pumping to the biodigester undergoing anaerobic digestion. The

carcasses are fully broken down in the biodigester to produce energy.

Mass Mortalities/ Disease outbreak

The mode of disposal in a mass incident depends on the cause of death and site location. A suitable

area should be identified that is separated from watercourses, sensitive uses. The previous area used

for burial should be considered in regards to an option if needed. In the event of a mass disposal the

local government and State department should be notified to assist in confirming the location.

In the event of a suspected or confirmed disease outbreak the state government veterinary officers

will be notified and the method of disposal carried out in accordance with their direction. AUSVET Plan

manuals and Animals Health Australia provide useful information for managing mass mortality disposal

incidents.

Table 16: Carcass management- Management, Risks addressed and Contingencies

Objective: Carcass management practices that prevent groundwater and surface water contamination,

odour generation, disease transfer and vermin.


Collect mortalities within 24hrs of discovery Odour Identify alternate

arrangements in the event of

the biodigester/macerator or

feed tank break down. Such

as on-site vessel storage, skip

bin removal or short-term

burial with approval.

Mortalities to be disposed of via maceration

into the feeding tank for biodigestion

Odour

Identify a suitable location on the site in the

event of a mass disposal incident

Odour, groundwater,

surface water

Contact local government and relevant state

government departments in the event of a

mass mortality to assist with disposal options

and site identification/confirmation.

Odour, groundwater,

surface water

Ensure veterinary contacts available for each

staff in the event of a suspected disease

outbreak.

Odour, groundwater,

surface water

Follow veterinary disposal advice in the event

of the disease outbreak

Odour, groundwater,

surface water



9.0 Natural Resources and Amenity

The natural resources and amenity of the site should be protected by the siting, design and

management of a piggery along with secondary measures such as separation distances and buffers.

This site meets all the required buffer distances as recommended in the NEGP. The management,

mitigation and contingencies for surface water, groundwater, odour, dust, noise, traffic and

landscaping have been incorporated into the siting, design and general management of the site

(housing and facilities, feed system, biogas, effluent and manure management systems).

Surface water

Buffer distances have been provided to the Salt Lake/pan located within the site boundary. This is

located 95m from the evaporation ponds, 400m from the stormwater ponds and 390m from the biogas

plants, 85m from sheds.

No effluent or manure is reused on site. The liquid piggery by products are contained on site within

the evaporation ponds and biodigester. Solid by-products are removed from site. All chemicals are

stored within bunded areas and washdown waters captured. General management practices that

reduce effluent spills as per groundwater management will minimise risks to the Salt Lake on the

property and to waterbodies off site.

Stormwater

Stormwater is captured from the ecoshelter production unit catchment area along with shed

washdown water to 2 stormwater ponds. This ensures this source is directed away from the

evaporation ponds system and biodigester to ensure clean diluted water does not overload or slow

down the digesters or pond drying. The conventional and dispatch roofs shed the clean water to non-

sensitive areas around the sheds for infiltration into the ground.

Objective: Stormwater to be managed captured or directed to non-sensitive environmental areas.


Stormwater from the Ecoshelter catchment

and shed washdown diverted from

biodigester and evaporation pond system

Groundwater During maintenance of

stormwater ponds, divert

stormwater and shed

washdown to evaporation

ponds only.

Flooring and any drainage systems be

maintained to prevent ingress of stormwater

into sheds.

Groundwater

Buildings located above the 1-100 year flood

line


water

Table 17: Stormwater- Management, Risks addressed and Contingencies



Groundwater

Groundwater has been identified in the site as ranging from 5-14m below the surface. The majority of

the pig infrastructure and activities is carried out on impermeable concrete pads which reduce the risk

of groundwater impacts. The evaporation ponds (see section ???) which are constructed half above

and half below the ground level have been geotechnically tested prior to use to confirm 1x10-9

permeability and is situated in an area of the farm identified as the AG zone which has sandy gravel -

clay soils. Additional material was bought in to meet the 1x10-9 requirement on the northern pond.

Carcass burial, which is standard practice among existing piggeries has ceased and mortalities will be

put through the biodigester. All solid storage of spent bedding and digestate is carried out on a

concrete hardstand area. The sump and feeding tank are constructed from concrete with a waterproof

membrane underneath. All generators and biogas associated equipment is located on concrete pads

and hardstands.

A groundwater management plan has been prepared for the site that identifies current monitoring and

production bores. It identifies new bores to be constructed based on the flow of groundwater under

the site and a monitoring plan to confirm the integrity of the evaporation ponds and any impact of the

operation on the groundwater resource.

Objective: Protect groundwater resources on the site by minimising nutrients and other contaminants

leaching into groundwater


All shed floors must be concrete or

maintained to 1x10-9 permeability

Groundwater

Bi annual monitoring of monitoring bores on

site as per the groundwater management

plan (360 environmental 2018)

Groundwater

Bores to be constructed and maintained as

per the groundwater management plan (360

environmental 2018)

Groundwater

Avoid spills of effluent or other chemicals on

site. Clean up immediately any spills.

Groundwater

All biogas components containing effluent

and manure to be constructed and

maintained on concrete bases.

Groundwater

All solid manures to be stored on the

designated hardstand area and any spill

cleaned up promptly.

Groundwater

Table 18: Groundwater- Management Risks addressed and Contingencies



Odour

The main odour source from a piggery is the sheds and effluent system. In traditional piggeries approx.

80-90% of odour generated on site is from open pond systems. The addition of a fully enclosed

biodigester significantly reduces odour on site and can eliminate odours by up to 70-90% and reduce

greenhouse gases by up to 70%. Volatile solids (VS) contribute significantly to odour generation. The

digester on site will reduce the mass of the effluent and solids by approx. 60% and significantly reduce

VS loadings (>70%) in digestate (end product of digester) which contribute to odour generation when

broken down by microbes. As a result, digestate contains reduced or broken-down VS and thus reduced

odour. This digestate then enters an evaporation pond which has a large surface area and promotes a

large aerobic zone (wind/ oxygen over pond) which further reduces anaerobic breakdown of the

remaining digestate. The reuse of this digestate as a fertiliser off site will be sought in the future.

Ecoshelter sheds have significantly lower odour than traditional conventional sheds due to the fact

they do not have an effluent stream (liquid and solids absorbed in the bedding) and the system remains

aerobic. Anaerobic conditions cause microbial action to generate compounds such as mercaptans that

correspond to odorous conditions.

The new conventional weaner and finisher sheds are fully enclosed climate-controlled tunnel

ventilated sheds. This system automatically adjusts ventilation rates based on climatic factors to

provide optimum conditions in the shed. Having good conditions in the sheds reduces the potential for

upset conditions or elevated odour emission rates by ensuring the influences of odour such as humidity

are monitored and adjusted when necessary.

The movement and dispersion of odour depends on the topography and climate of a site. Under stable

conditions, concentrated odour can linger and gravitate down to lower points in the landscape. Stable

conditions therefore generate the most odour impacts. This site experiences on average 90% of the

time in non-stable conditions which supports dispersion and reduces the risk of odour impacts.

The site also adequately meets the conservative S-factor separation distance for odour as per the

National Environmental guidelines for Piggeries 2010 2nd ed revised further providing a secondary

control measure to reduce the impact of odour on sensitive uses.



Objective: Piggery facility, associated infrastructure and operations to be designed constructed and

managed to prevent adverse odour impacts on community amenity


Stocking densities allow for minimum space

allowances for weaners, growers and finishers

housed in doors in conventional sheds and

deep litter systems (Model Code of Practice

for the welfare of Animals: Pigs)

Odour

Regularly clean lanes, pens and handling

areas of all sheds

Odour

Climate controlled ventilation provided to

conventional sheds

Manual operation in the

event of an automated

failure Backup generator

onsite, additionally a

generator can be hired or

brought in from another GD

Pork site.

Regularly inspect and clean up spilt feed Odour, dust, vermin

Ensure clean dry pigs- body warmth and

effluent on skin can encourage AD

breakdown

Odour

Maintain animal health to minimise loose

stools

Odour Remove ill pigs from herd

and provide specialist care

Use water with low sulfate and nitrate

content

Odour If water becomes unsuitable

investigate purification

options or truck water in on a

short-term basis.

Formulate diets for pig feed and minimise

feed wastage

Odour Automated feed calculations

can be done manually from

growth curve data.

Regularly clean flooring and other surfaces.

Slatted floors will stay drier than solid floors

Odour

Empty pull plug systems regularly. Consider

more frequently for biodigester

Odour Storage capacity in sheds is

30 days in the event of sump,

feeder tank or biodigester

malfunction.

The sump also has 3 days

storage and overflow can be

redirected to southern

evaporation pond upon

approval



Avoid cleaning sheds with bactericides as

these can affect digester and pond functions

Odour

Maintain adequate bedding in ecoshelters

(guide: 0.5-1kg straw/pig/day)

Odour Replenish spent bedding if

levels are low or bedding

needs replacing due to

becoming wet.

Immediately repair any water leaks that may

wet ecoshelter bedding

Odour Turn off water supply to

shelter and provide manual

watering. Remove wet

bedding and replace with

fresh bedding.

Collect and dispose of mortalities promptly. Odour Identify alternate

arrangements in the event of

the biodigester/macerator or

feed tank break down. Such

as on-site vessel storage, skip

bin removal or short-term

burial with approval.

Schedule short duration, regular activities

such as pit flushing at times of the day when

neighbours are less likely to be home and

good odour dispersion is expected. Mid-

morning or mid-afternoon are usually good

times.

Consider the installation of weather station

to work out wind direction and how it may

impact on nearby sensitive receptors.

Odour

Avoid undertaking potentially odorous

activities such as pond cleaning on weekends

or public holidays when neighbours are likely

to be home.

Odour

Maintain an odour complaint register and

investigate what activities were being

undertaken and the weather conditions at

the time of complaint.

Odour

Table 19: Odour- Management, Risks addressed and Contingencies



Dust

Dust should be minimised through good siting, design and management. Separation distances for

odour generally provide sufficient protection from dust impacts on sensitive area. There are some

considerations to further reduce potential impacts.

Objective: Piggery facility, associated infrastructure and operations to designed, constructed and

managed to prevent adverse dust impacts to the environment and community amenity


Provide good shed ventilation to prevent dust Dust Provide manual ventilation in

the event of fan malfunction.

Backup generator onsite,



another GD Pork site.





Deliver feed to the ecoshelters to enclosed

feeders within the shed

Dust Manual delivery option

Deliver feed from the feed mill to sheds in

fully enclosed pipework

Dust

Ensure feed deliveries and trucks entering

the site have enclosed systems to prevent

feed loss

Dust

Ensure staff and delivery trucks maintain

speeds on internal roads to prevent dust

generation

Dust Addition of speed signage

Pelletised feed and wet mixes reduce feed

dust

Dust

Mixing sheds are totally enclosed reducing

feed bourne dust generation

Dust

Automated feeding system will reduce feed

borne dust

Dust

Ad libitum feeding will be maintained which

reduces excitement and competition for food

which in turn reduces feed borne dust

Dust

Table 20: Dust- Management, Risks addressed and Contingencies



Noise

Noise is generated on a piggery from the sheds, associated equipment, feed mills, and traffic accessing

the site. The odour separation distance is generally sufficient in most cases to provide adequate

mitigation for any noise generated on a site. The majority of noise generating equipment associated

with the biogas system are totally enclosed in sheds such as pumps, engines and co-generation unit.

This site more than adequately meets the odour separation distance to the nearest receptors so noise

should be of little risk. However, there are considerations on site that can minimise noise.

Objective: Piggery facility, associated infrastructure and operations to be designed, constructed and

managed to prevent adverse noise impacts on the community amenity


Ad libitum feeding will be maintained which

feeding reduces excitement and competition

for food reducing noise generated at feed

times

Noise

Noise generation biogas equipment will be

housed in enclosed system including blowers,

engines, co-generation unit

Noise

Production machinery to be operated within

the hours of 6am to 6pm unless extenuating

circumstances ie excessive heat/animal

welfare issues

Noise

Arrival and departure of trucks entering the

site within 6am-6pm unless extenuating

circumstances ie excessive heat/animal

welfare issues

Noise

Table 21: Noise- Management, Risks addressed and Contingencies



Road and traffic

The site will experience overall an increase of traffic movements to the site. All traffic to the site will

enter via Albany Hwy either through the Albany Hwy entrance or via Crapella Rd. Both entrance are

on a straight stretch of road with no bends offering good line of site for both approaching and turning

vehicles. The majority of the increased traffic is associated with the feed mill and will enter from Albany

Hwy. On site milling means that trucks travelling to the site delivering feed will cease and local trucks

carrying grain to the feed mill will increase. The volume of traffic will be more evenly distributed

throughout the year as required whereas previously truck volumes concentrated around harvest times.

Table 22: Traffic movements

Objective: Provide a vehicle access in a manner that is safe for external and internal road users whilst

minimising adverse amenity impacts such as noise and dust


The majority of truck movements to occur

between 6am and 6pm

Noise

Roads maintained to provide all weather

access

Dust

Speed signs installed at the Albany Rd and

Crapella Rd to minimise speed

Dust

All vehicles entering the site to report to

main office to be briefed on access area ie to

maintain separation of ‘clean’ and ‘dirty’

areas

Dust, Biosecurity

Table 23: Traffic- Management, Risks addressed and Contingencies

Trucks and heavy vehicle transportations:

Existing Expansion

Weaners (15 tonne HR truck) loads/year 52 104

Feed/grain transports (50 tonne truck)

loads/year 145 550

Straw transports (50 tonne truck)

loads/year 35 22

Deep litter manure/WTP fertilizer (50 tonne truck)

loads/year 100 12

Finishers, abattoir (25 tonne truck)

loads/year 110 200

Others (25 tonne truck) loads/year 18 24

Total transports loads/year 460 912



Landscaping and Visual Amenity

The site requires no clearing of vegetation. To reduce the clear line of site to the piggery and feed mill

and to enhance the visual appearance of the site, it is proposed to plant additional indigenous species

along the boundary of Albany Hwy. The shed material is made from non-reflective material and blends

into the topography of the surrounding landscape. Borrow mounds from construction has been used

to provide additional screening on site.



10.0 Environmental Monitoring and Assessment

Environmental monitoring provides a tool to assess the effectiveness of management practices and

mitigation strategies used on site to minimise environmental impacts. Below are the monitoring

parameters based on the site specific potential risks including groundwater and biogas system.

Monitoring Parameter Frequency

Groundwater Monitoring

(as per Groundwater monitoring plan)

Biannual monitoring (i.e. during post-summer

and post-winter when groundwater elevations

are expected to be lowest and highest

respectively) of the three existing and five newly

installed groundwater monitoring wells and

three production bores is proposed to be

undertaken for 1 year after which a risk-based

evaluation of the need for on-going monitoring

will be undertaken.

Nutrients (total nitrogen, total Kjeldahl nitrogen,

nitrate, nitrite, ammonia, total phosphorus, total

suspended solids (TSS), total dissolved solids

(TDS), E. coli (production bores only)

(360 Environmental, 2018)

Noise Complaints Register Maintained

Odour Complaints Register maintained

Weather Station Review against complaints

Ventilation Fans Inspect monthly- clean when dust build up to

improve energy use and efficiency

Sumps Inspect prior to pull plug system release

Daily visual inspection of levels and pump float

switch

Evaporation ponds Daily visual re levels

Biogas system Real time monitoring systems are in place for

continuous monitoring of the essential

parameters for digester operation ie

temperature, pH and volume.

Quality of methane measured daily

Methane gas production metered and recorded

daily

Digestate analysis (if off site reuse)- annually

Table 24: Monitoring and Assessment



11.0 Chemical Storage and Handling

The site stores and uses potentially hazardous materials such as herbicides, veterinary chemicals,

disinfectants, insecticides and rodenticides. Only minimal amounts materials will be stored on site at

any one time. Approximate volumes as an example include 60L of herbicides, disinfectants and

insecticides and 40 kg of rat poison. All potentially hazardous materials will be stored in well-

constructed, clean and safe chemical storage and handling facilities with concrete floors. Facilities will

be locked and only accessible by suitably trained staff.

Objective: Chemicals are stored, handled and used to protect the community, air, water and soils


Minimise use and storage of chemicals on site Groundwater, Surface

water

Store chemicals in impermeable bunded area Groundwater, Surface

water

Have an emergency response

plan and spill kit available

Store and use chemicals, veterinary

chemicals and fuels in accordance with

workplace, health and safety codes of

practice


water

Use chemicals in a manner registered for the

intended purpose


water

Select chemicals with low toxicity and water

contamination potential where possible


water

Maintain in an accessible location all Material

Safety data sheets for chemicals used on site


water

Avoid spray drift when using farm chemicals Groundwater, Dust

Maintain pesticide records Groundwater, Surface

water

Train staff in the safe handling and use of

chemicals including veterinary and baits


water

Ensure fly and rodent baits are not assessable

to pigs


water

Dispose empty chemical drums and

containers in accordance with

manufacturer’s instructions


water

Dispose of sharps in a manner to protect staff

and avoid entering the effluent stream.


water

Use accredited chemical contractors when

required


water

Table 25: Chemical Storage- Management, Risks addressed and Contingencies



12.0 Fire Protection

Objective:


Ensure backup generators are regularly

tested

Fire, Odour Backup generator onsite,



another GD Pork site. Have a

readily accessible contractor

list available for emergency

breakdowns or replacement

parts on site.

Ensure staff are trained in the location and

operation of fire suppressants and hydrants

Fire Have local fire brigade

contact available to all staff

Ensure flammable liquids are appropriately

stored and handled

Fire, Groundwater,

Surface water

Maintain the area around the flare to be free

of vegetation

Fire

Flares may be prohibited during days of total

fire ban. Clarify requirements with the local

fire brigade. Inform local brigade of biogas

system and location on site.

Fire Turn off ignition source and

allow excess gas to be

diverted from the emergency

valve on the top of the

biodigester.

No unauthorised access to the biogas system Fire

Maintenance on the biogas system to only be

carried out by a qualified contractor

Fire

Table 26: Fire- Management, Risks addressed and Contingencies



13.0 Gaseous Emissions- reporting

Piggeries emit gases that may be reportable under various reporting schemes. Common emission

include greenhouse gases (GHG’s), carbon dioxide (CO2), methane (CH4), nitrous oxide (N2O) and

ammonia (NH3).

National Greenhouse Energy Reporting Scheme (NGERS)

Any facility that produces 25kt of CO2-e/yr or more of scope 1 emissions (direct emissions from sources

owned or controlled by a business or facility) or Scope 2 emissions (indirect emissions associated with

off-site generation of electricity etc purchased for consumption by a business/facility) must report

emissions or energy consumption to the Department of Climate Change. Corporations have higher

thresholds. NGERS does not include agricultural emissions such as CH4 and N2O released from

piggeries at this stage. However, any facility or corporation which exceeds the thresholds through the

use of fossil fuels must report the associated GHG emissions and energy use or consumption. (NEGP

2010)

National Pollutant Inventory (NPI)

Piggeries are required to report to the NPI if they emit over 10t/yr ammonia or for emissions to air

associated with fuel or waste combustion exceeding 400t/yr or 1t/hr in the reporting year. A

conventional piggery with a capacity of 1100-1200 SPU’s is likely to trigger reporting for ammonia. A

deep litter piggery that stockpiles spent bedding on farm will likely trigger reporting at a capacity of

approx. 2000SPU’s. A deep litter piggery that does not stockpile spent bedding is likely to trigger

reporting requirements at approximately 7000 SPU. NPI emissions are reported to the NPI office in the

applicable state or territory. Refer to NPI website for further details. (NEGP 2010)

---------------End of Main Body---------------



14.0 FIGURES LIST

FIGURE TITLE

1 Existing Site Layout

2 New site layout

3 Aerial of property and surrounding land uses

4 Kojonup North local scheme zones

5 BOM Average Wind Rose Data for Kojonup

6 Site Topography

7 Aerial photo showing nearest salt pans and lakes

8 Hydrology Zones

9 Soil types on site; Boscabel 1 Sandy phase and Boscabel 1 Subsystem

10 Soil profile pit

11 Nearest Sensitive receptors: source

12 Ecoshelter with straw based bedding

13 Concrete apron outside ecoshelters

14 Inside of a conventional shed

15 Conventional slatted floor (weaners)

16 Automated Climate Control Panel

17 Tunnel Ventilation Fans

18 Inside of conventional grower/finisher sheds

19 New feed Mill

20 New feed Mill

21 Feeders inside the Ecoshelters

22 Feed truck delivery feed inside the ecoshelters

23 Enclosed Feed Mixer Room

24 Conventional Feed system in shed

25 Cleaning out Ecoshelter spent bedding

26 Spent Ecoshelter bedding on concrete hardstand area

27 Washdown water drain from ecoshelters

28 Primary stormwater pond

29 Secondary stormwater pond

30 Slatted floor in conventional shed -weaners

31 Slatted floor in conventional shed -growers/finishers

32 Biogas Feeder tank with macerator

33 Biodigester

34 Automated control system for Biodigester

35 Enclosed Flare system

36 Chiller system to remove condensate

37 Co-generation unit for producing heat and power

38 Screw press

39 Solid digestate after screw press



15.0 TABLES LIST

Table TITLE

1 BOM Average Climate Data for Kojonup

2 Aquifer and Hydrology Characteristics

3 Existing Monitoring Network details

4 Site Separation Distances using NEGP S-Factor Method

5 Minimum recommended distances NEGP 2010 2nd ed revised

6 Natural Resource buffers

7 Cleaner Production- Management, Risks addressed and Contingencies

8 Housing- Management, Risks addressed and Contingencies

9 Feed System- Management, Risks addressed and Contingencies

10 Standard Pig Unit Conversion Table

11 Piggery Nutrient Outputs/year

12 Conveyance and collection System- Management, Risks addressed and

Contingencies

13 Biogas System- Management Risks addressed and Contingencies

14 Evaporation pond dimensions

15 Evaporation ponds- Management, Risks addressed and Contingencies

16 Carcass management- Management, Risks addressed and

Contingencies

17 Stormwater- Management, Risks addressed and Contingencies

18 Groundwater- Management Risks addressed and Contingencies

19 Odour- Management, Risks addressed and Contingencies

20 Dust- Management, Risks addressed and Contingencies

21 Noise- Management, Risks addressed and Contingencies

22 Traffic movements

23 Traffic- Management, Risks addressed and Contingencies

24 Monitoring and Assessment

25 Chemical Storage- Management, Risks addressed and Contingencies

26 Fire- Management, Risks addressed and Contingencies



16.0 APPENDICES

APPENDIX TITLE

1 Kojonup Infrastructure- New and Existing

2 Piggery Inputs and Outputs

3 Future water consumption and slurry production in new conventional

sheds

4 Summary by-product production

5 Predicted Outputs from Biogas Plant

6 Evaporation Pond details

7 Contingency plans submitted in Works Approval

17.0 REFERENCES

Bureau of Meteorology (BOM) website

Groundwater Risk Assessment at the proposed GD Pork site in Kojonup, DAFWA, 2015

GD Pork Groundwater Management Plan, 360 Environmental, 2018

Google Earth, 2018, website

Kojonup Shire Planning scheme, 2018,

National Environmental Guidelines for Piggeries 2nd ed, revised, 2010, APL

Piggery manure and Effluent management and Reuse Guidelines, 2015, APL

South West Agriculture Region Soils Report, Department of Primary Industries and Regional

Development, 2018 web download from Katanning survey (Project KLC, Percy 2000) revised in 2001,

land units revised in Feb 2004

---------------------------------End of Document -----------------------------------

Appendix 2 - Piggery inputs and outputs fact summary

Table 1 Units Existing

production Production

after expansion

Standardized Production Size Standard Pig Units 11,820 28,368

Input:

Weaners received numbers/year 26,200 75,000

weaners tonne/year 210 600

Feed tonne/year 5,800 16,900

Dry matter tonne/year 5,200 15,200

Total nitrogen (N) tonne/year 160 475

Phosphorus (P) tonne/year 300 870

Potassium (K) tonne/year 365 1,070

Water, total cubic metre/year 20,000 55,000

Straw bales (2.4mx1.2mx1.2 m) bales/year 2,000 1,250

Straw tonne/year 1,000 625

Electricity kWh per year 50,000 900,000

Output:

Finishers delivered to abattoir numbers/year 22,600 71,000

Live weight, finishers to abattoir tonne/year 2,300 7,100

Meat tonne/year 1,600 4,900

Deceased animals tonne/year 50 126

Dry matter tonne/year 25 53

Deep litter manure tonne/year 4,254 2,924

Deep litter manure dry matter tonne/year 1,404 965

Slurry tonne/year - 31,505

Slurry dry matter tonne/year - 1,922

Nutrients from manure, slurry and deceased animals

Dry matter tonne/year 1,429 2,940

Total nitrogen (N) tonne/year 48 179

Phosphorus (P) tonne/year 17 53

Potassium (K) tonne/year 57 130

Trucks and heavy vehicle transportations:

Weaners (15 tonne HR truck) loads/year 52 104

Feed/grain transports (50 tonne truck)

loads/year 145 550

Straw transports (50 tonne truck)

loads/year 35 22

Deep litter manure/WTP fertilizer (50 tonne truck)

loads/year 100 12

Finishers, abattoir (25 tonne truck)

loads/year 110 200

Others (25 tonne truck) loads/year 18 24

Total transports loads/year 460 912

Appendix 3: GD Pork FUTURE water consumption and slurry production in NEW FULLY SLATTED SHEDS*)

Background actual GD Pork figures*): 70,931 finishers

Production system Fully

slatted Source

Growth period 40-100 kg

Average number of on farm heads 11,595 GD Pork

Finishers per year, 40-100 kg 70,931 GD Pork

Feed consumption, 1000 Feed Units per year 11,704 GD Pork

Drinking water, m3 per year 30,757 AUS

Wasted drinking water, m3 per year 4,614 DK

Water for wash of stables, m3 per year 1,773 DK

Total water consumption, m3 per year 37,144 DK

Water consumption per produced animal, litre 524

Water consumption per head, litre per day 8.8

Water from feed conversion, m3 per year 7,022 DK

Evaporation from animals and stables, m3 per year -11,704 DK

Gain in animals, m3 per year -2,880 DK

Water in waste (6.1 % DM) from fully slatted sheds, m3 per year 29,583 DK

Total waste from fully slatted sheds, m3 per year 31,505 DK

*)Expected future GD Pork production figures inserted in "Yearly production, water consumption and amount of waste based on norms given in DJF-report number 36. Husdyrbrug, Danmarks JordbrugsForskning, 2001, updated 2014".

Water consumption and produced amount of waste can differ very much from norms, but will normally be within +/- 25 %.

The Danish Agricultural Advisory Centre, Department of Pig Production, Sept. 2003, ERN

Source: Hanne Damgaard Poulsen (ed): Norms for animal manure - 2014, 33

pages (Danish language) http://anis.au.dk/fileadmin/DJF/Anis/normtal2000.pdf

http://anis.au.dk/fileadmin/DJF/Anis/normtal2000.pdf

Appendix 4. Summary By-Product production

Input Biogas Plant

Deep litter manure, tonne per year:

Produced weaners per year 73,125 Dry matter: 33.0% Tonne 2,924

Slurry, tonne per year:

Produced finishers per year 70,931 Dry matter: 6.1% Tonne 31,505

Mortality:

Dead animals per year 3,950 Dry matter: 42.1% Tonne 126

Total amount of waste, tonne per year 34,555

Output from Kojonup Biogas Plant

Corrected for Methane and CO2 production plus biological processes in WTP

Pressed manure (30% DM), tonne per year 6,390

To evaporation pond/reuse, tonne per year 25,560

Appendix 5: Predicted Outputs from Kojonup Biogas Plant

Input material: -Solid and liquid

SLURRY Tonne/year 31,505

MANURE Tonne/year 2,924

DECEASED ANIMALS Tonne/year 126

Inlet material Dry matter content

%

S.S. (dry matter

content)

Losted S.S.

transformed into

Biogas

Mass loss

estimated average

94.7 tonne/day 8.5 % 8.1 tone/day 2.8 tonne/day 3.1 tonne/day

Outlet: -Solid and liquid (from digester)

Digestate (effluent

materials)

Dry matter content

%

S.S. (dry matter

content) Water content Biogas density

87.5 tonne/day 5.6 % 4.9 tonne/day 82,6 tonne/day 1.25

-Solid and liquid (from separator)

74.1 m3 digested/day Solid fraction Liquid fraction

Distribution 20%* 80%*

Tonne/day 17,5 70,0

Dry matter content, % 30%* 2%*

Dry matter, tonne/day 5,3 1.4

*There will be some variation depending on the final machine set up and environment conditions.

Gas:

Expected production Equivalent methane CH4 Electricity production Electricity production

2476 Nm3 biogas /day* 1614 Nm3/day 6200 kW/day** 258kW/hour

*Biogas expected composition:

CH4: 55-60%

CO2 + CO: 40-45%

H2S: 0.1%

Other gases

**The engine’s electrical efficiency is 0.4

Engine exhaust gas (each unit):

Exhaust gas temperature °C 457 (200 with recovery system on)

Exhaust gas volume Nm3/h 3.650

kg/h 4.910

Combustion air volume Nm3/h 3.766

kg/h 4.868

Exhaust gas composition (*)

Nitrogen oxide (Nox) mg/Nm3 <450

Carbon oxide (CO) mg/Nm3 <500

Ultra small particolate (PST) mg/Nm3 <10

COT mg/Nm3 <150

(*) exhaust gas 5% O2

Appendix 6 – Evaporation Pond details

Evaporation Pond (Plot 5) size

Kojonup farm

Evaporation pond internal dimensions

Depth ex freeboard 1 m

Freeboard 0.5 m

Length at crest 165 m

Width at crest 120 m

Internal Batter 2.5 :1

Surface area 19,800 m2

Internal capacity 18,400 m3

Evaporation pond foot print

Width of crest 3 m

External batter 3 :1

Height of pond wall above ground level 0.75 m

Length of pond outside at ground level 175.5 m

Width of pond outside at ground level 130.5 m

Total foot print of evaporation pond 22,930 m2

Evaporation Pond (Plot 6) size

Kojonup farm

Evaporation pond internal dimensions

Depth ex freeboard 1 m

Freeboard 0.5 m

Length at crest 85 m

Width at crest 190 m

Internal Batter 2.5 :1

Surface area 16,150 m2

Internal capacity 14,800 m3

Evaporation pond foot print

Width of crest 3 m

External batter 3 :1

Height of pond wall above ground level 0.75 m

Length of pond outside at ground level 95.5 m

Width of pond outside at ground level 200.5 m

Total foot print of evaporation pond 19,148 m2

Appendix 7: Contingency measures submitted as part of the works approval

Area/Section Management Action Trigger Point Action Contingency 1 Contingency 2

Effluent/Manure and

Biogas System

Whole system.

Daily visual check of the

entire WTP system intact

with optimal function.

Quality of methane gas

measured daily

Methane gas production

metered and recorded daily

Any failure or malfunction in

the plant

e.g.:

- blower fails

- back up flare fails

- leak in pipes

- gas generator fails

Farm Manager to be

notified immediately.

Stop pumping waste into

digester until further notice.

Organise immediate repair

of failed component (a list

of suitable contractors/

service providers and their

contact details is displayed

in farm office).

Normal routine of flushing

effluent from sheds to

collecting pit will for storage

purpose be continued.

Maintenance records of

WTP are kept as part of

farm QA system.

Use the capacity of

collecting pit and maintain

normal routine of flushing

from sheds to collecting pit

as long as possible (to avoid

storing effluent under sheds

longer than normal routine).

There is enough holding

capacity in the sump pit for

three days effluent

production and in sheds for

another 30 days (effluent

level levelled).

Transport effluent of farm in

tankers.

(Estimated 81 m3 per day of

effluent would require four

semi tanker trucks for

removal).


Mixing of effluent and dry

material from sump

pit/concrete area to Biogas

Plant

At regular daily basis a

number of effluent pits in

sheds will be “pulled” when

they are 80-90 % filled. It

will give a continuous inflow

through PVC pipes into the

covered collecting pit just

outside WTP. Effluent

(slurry), deep litter manure

and shredded dead animals

will on demand be mixed

and pumped by manually

operated pump be pumped

in digester tank in WTP.

There will be no long term

storage of effluent in sheds,

and WTP collecting pit will

be permanently covered

which means that odour is

contained as much as

possible even while

collecting pit is mechanically

stirred.

Leak/break in effluent pipe.

Effluent pump break down.

Contact Farm Manager.

Manually turn of effluent

pump.

Organise repair of effluent

pipe/and or pump.

Utilise spare effluent pump

until pump is fixed.

The sump pit can be used to

store the effluent from the

shed pits for up to three

days capacity or until the

issue is rectified. Should the

issue go beyond three days

effluent can be stored in the

sheds, as a last resort.

There is minimum 30 days

of storage capacity in pits

under sheds if the content is

levelled.

Transport effluent of farm in

tankers.

(Estimated 81 m3 per day of

effluent would require four

semi tanker trucks for

removal).


Ventilation system of new

finisher sheds (no forced

ventilation in originally

sheds)

Sheds are ventilated by an

automatic ventilation

system called ’tunnel

ventilation’. Fans in one end

of the shed pull air from the

other end of the shed. The

temperature is then lowered

by the addition of water

resulting in evaporative

cooling.

The system operates

automatically based on

inside and outside air

temperature and will step in

fans according to cooling

required. As such on a cold

day with still wind condition

when there is most risk of

odour travelling beyond

property boundary there

will only be one fan

operating and odour from

shed will be absent.

Ventilation system

computer to send alarm to

mobile phone when trigger

temperature reached.

Alarm from ventilation

computer


Ventilation system

adjustment needs to be

determined by Managing

Director and/or Farm

Manager to ensure no

impact on the welfare of

livestock.

Repair and change of

broken components to take

place

n/a n/a


Cleaning of sheds after

emptying and before new

animals arrive.

Cleaning will be undertaken

using high pressure water

cleaners with a pressure in

excess of 3000 psi and a

rate of 21 litres per minute.

As clean water is used there

is no additional odour

associated with this

practice.

When the piggery is

operating normally there is

up to two sheds being

pressure washed weekly.

Before pressure washing all

remaining effluent is flushed

out of the sheds like normal

flushing of pits.

Any above mentioned

trigger points that are

relevant to flushing out the

effluent (“pulling the pits”)

before washing must be

adhered prior to

commencing pressure

cleaning.

There is no risk of odour

from the actual pressure

washing.

n/a n/a n/a

Damage to housing sheds

resulting in compromised

management.

If a shed is significantly

damaged in such a way that

management impacting the

environment is

compromised the DER will

be consulted and if

necessary livestock will be

temporarily vacated from

the shed and relocated The

damage will be repaired

before re-stocking.

Structural or mechanical

damage resulting in impact

on animals and/or

surroundings.

Destocking of pigs n/a n/a


Power Outage

Ventilation and effluent

pumping systems are

dependent on electricity.

The site will have a diesel

back-up generator with

automatic change over

switch.

In the event of power

failure backup generator

will activate automatically.

The back-up diesel

generator will be

maintained and checked

once every week including

topping up diesel and oil.

The generator will be fully

serviced every six months.

A power failure will be

simulated weekly to ensure

that the contingency system

works.

Power failure and back-up

generator failure.


Hire generator for use while

back-up generator is

repaired.

If no hire generator is

available. The back-up

generator from other GD

Pork site can be brought in

temporarily.

n/a

Education of Staff All staff will be trained in all

aspect of pig production

relevant for GD Pork,

Kojonup branch. They will

be trained in good

management practices such

as housing, feeding, health

check and treatment,

cleaning, washing,

maintenance of equipment,

ventilation and contingency

responses in respect to

odour management.

New personnel to GD Pork,

Kojonup branch.

When changes occur in

management procedure or

contingency plans.

All new personnel to be

trained in all type of

management and

contingency procedures.

All existing staff to be

advised of any changes to

management and

contingency plans.

n/a n/a


Complaints Register All complaints to GD Pork,

Kojonup branch received in

respect to any type of

management will be logged

on a complaints register and

investigated. Where

corrective actions are

possible, GD Pork will

ensure these are

undertaken.

Any complaint received in

respect to any type of

inconveniency caused to

surroundings from GD Pork,

Kojonup branch.

Consecutive complaints (i.e.

more than one valid

complaint in 24 hours).

Complaint will be logged

and investigated.

Corrective action taken

where possible.

Communication will be

undertaken with the

complainant to identify the

time and severity of the

issue to ensure the problem

is identified and addressed.

A follow up with the

complainant will be

undertaken to ensure they

are satisfied with the

response and if not what

options are available to

address the concerns.

n/a n/a

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