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The engine generator and switching equipment was purchased used for $15,000. Additional costs were $6,000 to rebuild the engine, $2,000 to rebuild the generator, $9,000 for other plumbing, electric, and mechanical systems, $8,000 to run 265 feet of parallel 3 phase cable to the utility hook-up, $18,000 for an electrical engineer consultant, and $5,000 to obtain the utility permit. This system is sized for an ultimate herd size of 1,000 cows. Five hundred cows will produce about 55 kW; 1,000 cows will produce about 110 kW. The maintenance cost of the digester and cogeneration system is expected to be about 1.5 cents per kW hour or about $15,000 per year. This includes oil changes, parts, replacing the digester cover and grit removal. The normal maintenance may average one half an hour per day. The effluent leaving the digester is 6.7% solids. It is pumped to a screw press separator with a 7.5 Hp pump. This pump cost $1,800 and has a $1,200 variable speed drive. The screw press separator will produce about 0.6 cubic foot of 30% solid recycled manure every half minute of operation. That rate will handle about two cows daily manure production per minute. This rate may change depending on the size of the solids, the moisture content of the manure slurry, and the internal wear on the auger vanes. The separator does seem to work better with digested manure than with raw manure. The remaining slurry is reduced in volume by about 15% allowing more storage time for existing storage facilities. The slurry has 4.5% solids remaining in it so it pumps much easier than unseparated raw manure. The separation equipment costs about $25,000 for the machine, and is housed in a $25,000 existing building. The separator uses 4 kW to turn the auger, and 0.15 kW to run a vibrator to keep the manure entering smoothly. There is a definite ammonia odor during this process. Ammonia is lighter than air so this will not be an off site odor problem. The solids are sold to a bulk soil amendment processor for $8 per cubic yard. The liquids flow by gravity to a 2,400,000 gallon lined waste storage pond to be stored or pumped to an existing 2,200,000 gallon waste storage pond convenient to some of the crop fields. The lined pit cost $18,000 for the excavation, fence, pipe, and outlet structure, and $42,000 for the liner. The liner was needed because of the gravel soils at the farmstead. Five miles of 6 inch diameter plastic pipe will be buried to move the effluent to the remote waste storage pond and to the fields. This pipe cost $2.50 per foot installed with valves and risers for access. An irrigation pump and reel with a hard hose and big gun applicator will be purchased to apply the manure to growing crops. The digestion process should reduce the weed seeds and pathogens present in the manure. Effects of unpalatableness from manure spread on growing crops should also be reduced. The anaerobic digestion to remove odors, and lowering the solid content with anaerobic digestion, solid removal and dilution should make the irrigation equipment run smoothly. Irrigation costs have been estimated from other operations at thirty-four dollars per hour. They were calculated from a 100 Hp chopper pump, 1.23 operators, 1 mile of portable pipe, and a tractor run 23 % of the time to set up the traveling gun reel. The costs of irrigation will not be included in the process evaluation. Samples of manure were taken at the end of each process in this system. The manure before and after anaerobic digestion was sampled, as well as both flows from the separator. The manure storage pond was sampled prior at the surface after winter storage. There could be significant variation in these samples especially the one from the waste storage pond. Dilution by 5PDF Image | ANAEROBIC DIGESTION AND WETLAND TREATMENT CASE STUDY: COMPARING TWO MANURE ODOR CONTROL SYSTEMS FOR DAIRY FARMS
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