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METHANE RECOVERY FROM ANIMAL MANURES: THE CURRENT OPPORTUNITIES CASEBOOK According to the design report, the farm’s waste management system incorporates a conventional anaerobic lagoon supplied by a hydraulic flush system consisting of 31 840-gal flush tanks that each operate on a 2-hour cycle (i.e., 12 cycles/day). Thus, every day the farm uses a total flush volume of 312,480 gal of water, giving the effluent a 0.3% TS concentration. It was assumed that all manure generated was collected. With these inputs, FarmWare estimated that the total amount 8 ofmanurecollectedwas170,539lb/d.Withanaveragevolatilesolids (VS)productionofaround 5.4 lb/1,000 lb LAW, the FarmWare program estimated that the total daily VS production was 8,340 lb. The next step was to obtain an estimate of the lagoon size. The key values for determining lagoon size are HRT and loading rate. The assumption was to let the FarmWare program select the 3 defaultbetweenaHRTof40daysoraloadingrateof10lbVS/1,000ft ofdigestervolume, fairly standard for preliminarily lagoon size estimates. Using these key variables and a number of other implicit assumptions found in the FarmWare 3 program, the total lagoon volume was estimated to be 2.02 million ft . Assuming a depth of 24 ft, the linear surface dimensions were estimated to be 348 x 348 ft, presenting a total surface area of 2 121,104ft tobecoveredwithanindustrialfabricsuchasHDPEorXR-5. 3 FarmWareestimatedthatthedigesterwould,onaverage,produce32,401ft ofmethane/day.The program estimated that this would be sufficient to fuel an engine/generator of 113-kW. With a heat rate of 14,000 Btu/ kWh, daily electricity production was estimated to be 2,592 kWh/day. Assuming an annual capacity factor of 90%, it was estimated that 851,472 kWh could be produced during the course of a year. A tremendous amount of thermal energy is produced by combusting biogas in an engine/generator, and much of this energy is available for recovery. On a swine farm, heat is commonly used for the nursery and other barns for almost the entire year. To help maximize coproduct use, it was also assumed that the hot air produced from engine cooling was ducted into the hog buildings to provide space heat. As will be discussed in the next section, this type of hot air recovery system has been used successfully for more than 10 years on several farms in California. Assuming that 2,800 Btu can be recovered per kWh generated, and that space heat was required for 9 months in the course of the year, 1.79 million Btu could be recovered. Excluding the cost of lagoon construction, the digester capital costing information represented the total “turn key” cost of all materials, labor, and engineering services required to bring a project on-line. Engineering costs were estimated to be $25,000. The cost of constructing the digester was estimated to be $224,519, including the cost of the cover, as well as all gas handling and transmission costs. The engine and induction generator were estimated to cost $82,800, including the switchgear and intertie components required by most electric utilities. The add-on hot air recovery system was estimated to cost $25/kW of engine capacity, a total of $2,825. Thus, the total capital expense was estimated to be $335,114. 8 n.b., VS is the organic fraction of TS, of which a portion is converted into biogas. 3-5PDF Image | Methane Recovery from Animal Manures The Current Opportunities Casebook
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