manure separation: bedding and nutrient recovery
TRANSCRIPT
GEA Farm Technologies
Andy Lenkaitis, P.E.
Environmental Systems Engineer
Manure Separation: Bedding and Nutrient Recovery
GEA Farm Technologies2
Nutrient Limitations
• Build-up on close fields
• Nutrient distribution
Proper Lagoon Agitation
Efficiency
• Limited window to apply
• Time to set-up,
application rate, distance
to fields
Manure Application Challenges
Nutrient Management and Separation
GEA Farm Technologies3
Nutrient Management Process
Nutrient Management and Separation
Transfer Transfer Agitate, Transfer
& Load
Spreading
Primarily Solid
Separation
Secondary Solid
Separation
GEA Farm Technologies4
Primary Separation
• Bedding production
• Process liquid
Separation Systems
Nutrient Management and Separation
GEA Farm Technologies5
Cows on Green Bedding
GEA Farm Technologies6
Primary Separation Capture Rates
• Sacrifice Capture Rates
• Less efficient Separator to make a quality product
• Large variance in nutrient capture rates
Primary Capture
Rates
Dairy TR Dairy GM Dairy CVT
Total Solids 20 43 55
Total Nitrogen 4.2 15 20
Phosphorus 3.5 5 37
Potassium 2.6 10 15
GEA Farm Technologies7
Green Bedding Material-Equipment
GEA Farm Technologies8
Secondary Separation
GEA Farm Technologies9
Secondary Separation
• Nutrient partitioning
• Reduced solids to long term
storage
Following Primary
• Increased capacity of secondary
system
• Reduced volume (10%)
• Process flow rate
• Trash screening
Separation Systems
Nutrient Management and Separation
GEA Farm Technologies10
Lagoons after Primary Separation
GEA Farm Technologies11
• Slope Screen System-1.8% to lagoon
Secondary Separation-Slope Screen
GEA Farm Technologies12
Slope Screen
• 30% Solids Capture Rate
• <10% of all Nutrients
Can run Slower process time
Secondary Separation Systems
Nutrient Management and Separation
GEA Farm Technologies13
Centrifuge Separation Technology
Solids
Discharge Clarified
Liquid
Discharge
Feed
Drive
Scroll Bowl
GEA Farm Technologies14
2014 Testing
Centrifuge Separation in Livestock Manure
GEA Farm Technologies15
Secondary Separation-Centrifuge Results
3800 rpm, 40 gpm DM Dry
Matter
Suspended
Solids
Total
Nitrogen
lb/ton
Total P as
P2O5
lb/ton
Primary Liquid
Infeed Houle
System SW
4.30% 2.59% 4.67 1.42
Centrate SW 2.6% 1.00% 4.07 1.01
Solids Cake SW 34.20% 34.20 10.8 8.2
Capture rate
Centrifuge-
Secondary
Separation, after
2-Stage Primary
45.2% 66.4% 22.6% 34.9%
Flush Reception Pit
GEA WS Centrifuge
Centrate SW Solids Cake SW
GEA FT 2-Stage
Separator w/Roller
Press
Primary
Solids for
Bedding
SW
Primary Liquid Infeed SW
GEA Farm Technologies16
DM Dry
Matter
Suspended
Solids
Total
Nitrogen
lb/ton
Total P
as P2O5
lb/ton
Primary Liquid
Infeed Houle
System AA
4.40% 2.54% 4.48 1.83
Centrate AA 1.9% 0.89% 4.27 1.01
Solids Cake AA 28.90% 28.90% 12.4 10.6
Capture rate
Centrifuge-
Secondary
Separation, after
digestion
67.0% 71.2% 7.3% 54.2%
Secondary Separation-Centrifuge Results
Digester
GEA WS Centrifuge
Centrate AA Solids Cake AA
GEA FT 2-Stage
Separator w/Roller
Press
Primary
Solids for
Bedding AA
Primary Liquid Infeed AA
Digestate Infeed
GEA Farm Technologies17
Nutrient Capture
• Up to 25% of Organic Nitrogen,
up to 50% with chemicals
• Up to 50% of Phosphorus,
up to 95% with chemicals
• Variability in results:
• Infeed to system
• Equipment technology
• Equipment Tuning
• Flowrate
• Torque / Differential Speed
• G-Force
Experienced Results
Centrifuge Separation in Livestock Manure
GEA Farm Technologies18
High solids capture rates (50%+)
• Cleaner liquid for irrigation
• Reduced need to agitate and clean
solids from lagoon
Experienced Results
Centrifuge Separation in Livestock Manure
GEA Farm Technologies19
30% Dry Matter Solids Cake
• Easy to store or compost
• Can be directly applied to fields
• Transported to fields further away
Experienced Results
Centrifuge Separation in Livestock Manure
GEA Farm Technologies20
Manure Application
• Centrate Liquid: 90% of volume, 50% nutrients
• Solid Cake: 10% of volume, 50% of nutrients
• Spread liquid close to home at higher rates
• Solid cake transported to further fields
Direct Application Costs
• Manure spreading cost:1.0₵+ per gallon
• Irrigation cost: 0.1₵ per gallon
• 500 cow dairy: 5 Million gallons * 90%
* 0.9 ₵ per gallon = $40,000/year
Milk more cows at home!
Economic Factors
Centrifuge Separation in Livestock Manure
GEA Farm Technologies21
Indirect Application Benefits
• Lagoon agitation
• Compaction
• Timing of nutrient application
Nutrient Use Efficiency
• More efficient placement of
Phosphorus-less buildup
• $0.43/lb of Phosphate (value
from the market)
• 56 lb/acre =$25/acre
Economic Factors
Centrifuge Separation in Livestock Manure
GEA Farm Technologies22
• Increased interest in staged separation
• Produce bedding solids
• Staged system for growth of the farm
• Integrated with farm system
• Only create products that can be used
• Bedding
• Nutrient Rich Solids
• Mechanical Processes
• Redundancy and overflow paths
• Significant Potential for Nutrient
Partitioning
• Aid in moving nutrients where needed
Staged Separation Summary
GEA Farm Technologies23
Thank You!