Progress 07/01/22 to 02/29/24

Outputs
Target Audience: Nothing Reported Changes/Problems:The team encountered a few notable challenges during the project as follows: Computational Ammonia Modeling. The lack of prior studies on poultry indoor air quality and ammonia has led to limited computer modeling software and unique challenges in computational fluid dynamics (CFD) custom modeling. Initially, StaldVent software was identified as a potential solution but lacked customization for ammonia emissions. The team then explored CFD, which proved useful for ventilation simulations but difficult for two-phase gas modeling of ammonia. As the importance of vertical ammonia stratification diminished, the team pivoted to a numerical model based on the industry-standard ISO 13790 building hourly heat model. Although limited, this model was the most effective and easily customizable for MOVA. Overcoming this challenge took twice as long as expected. Aqueous Ammonia Production. The original approach of washing sorbent beads to produce aqueous ammonia was effective but led to excessive water absorption, hindering seamless solution concentration plus up. A new approach, recovering gaseous ammonia and bubbling it through water, proved successful in achieving the desired high-concentration aqueous ammonia. To evaluate this method, MOVA created new sorbent bead formulations with a different binder and tested them at 25ppm and 10ppm ammonia using a vacuum and temperature swing (VTSA) process. The data confirmed the absorption capability and successful ammonia recovery through VTSA, solidifying an improved process for the CAATCHER system. Sorbent Flow. As a result of the alginate binder utilized to form the sorbent beads, the beads absorbed more water than anticipated which did not provide optimal flow through the system. Although MOVA was still able to complete testing with it, it provided a notable challenge to address for scale-up. MOVA decided to study three additional binders which were successfully fabricated. These binders were mixed with water to determine their flowability. Two of these new formulations were found to overcome this challenge while maintaining the desired adsorption capture rate. These beads will be scaled and utilized in Phase II. Regeneration. The current sorbent's flow challenges complicated the regeneration system's autonomous operation. The team fabricated a simpler, compact unit for testing, requiring a more manual approach to evaluate system integration. Despite this, 30 days of cyclic testing determined system feasibility. After establishing feasibility and the effectiveness of a VTSA process, a VTSA regeneration module was designed, fabricated, tested, and integrated with the absorber module. CAATCHER was then successfully tested with Zeolite, a commercial secondary ammonia capture sorbent, achieving autonomous operation over four weeks. The challenge was ultimately overcome, resulting in a small-scale system that advances commercialization efforts. Lab Commissioning. One obstacle encountered in the lab was the humidity plus-up of the air stream and the operation of the regeneration module. Achieving the highest humidity rates found in poultry houses proved challenging. However, it was noted that given the large amounts of water utilized in the cyclic process, additional water from the air stream would not provide any further benefit. Despite these challenges, the team successfully managed and overcame them, achieving technical feasibility for this Phase I project. Subsequent Use of Equipment Purchased: MOVA purchased one piece of equipment on the project, an Aqua Ammonia Concentration Analyzer. We will likely use it for future testingas we work to find the ideal disposition for our captured ammonia to obtain the proper concentration of ammonia for use as a fertilizer. What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest? Nothing Reported What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? IMPACT STATEMENT: This Phase I project established the technical and economic feasibility of ammonia abatement in CAFOs using MOVA's air filtration technology. We successfully captured ammonia in challenging conditions and met key performance metrics. Numerical modeling, validated with experimental data, identified the optimal flow rate and expected commercial performance. The poultry industry stands to benefit from improved animal welfare, increased production, and higher profits. Moreover, society will benefit from reduced atmospheric ammonia emissions, lower lung cancer incidence, and decreased nitrogen pollution in sensitive watersheds. This project successfully sets the development path for Phase II. MOVA demonstrated technical feasibility by achieving both technical objectives. Key outcomes/accomplishments include: Our novel sorbent formulation is effective as a trace ammonia sorbent, with nearly 100% breakthrough capture efficiency, effective aqueous ammonia desorption, and low sorbent degradation, meeting stability objectives. The current binder's moisture adsorption challenges suggest a need for a new binder for improved commercial performance. Modelingshows our system maintains <10 ppm indoor ammonia levels year-round, with recirculated air for heat savings. Feasible target air flow rates were identified to maintain effective ammonia reductions. System benefits diminish after about 28 days due to increased ventilation needs as birds grow larger, reducing ammonia levels naturally. An effective cost/flow rate/performance balance was identified; high emissions reductions are possible but with higher cost. Recovering ammonia in gaseous form and bubbling through water is the most effective method for producing aqueous ammonia byproducts. TECHNICAL OBJECTIVE 1: MOVA demonstrated the feasibility of its CAFO Ammonia Abatement Technology for Capture, Harvesting, and Emissions Reduction ("CAATCHER") system using simulated poultry air with 10 ppm ammonia. A novel ammonia sorbent was formed into 2 mm pellets with an alginate binder, demonstrating scalability. MOVA designed, procured, and commissioned a testing rig to provide simulated poultry air, integrating the prototype for system demonstration and evaluation. An aqueous regeneration method enabled desorption in the system. The system was fully instrumented with sensors for ammonia, relative humidity, temperature, pressure, and velocity at the inlet and outlet to characterize the flow before and after absorption. Component evaluation began by testing the ammonia capture and regeneration sections individually. Simulated poultry air flowed at 120 CFM (0.2 m/s superficial velocity) through the filtration media, measuring ammonia capture rates over ten cycles based on inlet and outlet concentrations. Testing consistently showing a 99.76% capture rate until breakthrough, followed by a gradual decrease. The system's pressure drop, monitored throughout the test, showed a maximum of 82.73 Pa and an average of 38.83 Pa. These tests marked the first major technical achievement in low partial pressure gas adsorption, addressing a significant technical risk. The first two success criteria were reached with this testing showing pressure drop <150 Pa and 90% capture at 10 ppm ammonia levels. The regeneration module was tested using saturated beads from the absorber tests. The beads (1.92 kg) were stirred in 3 gallons of water for 20 minutes to desorb ammonia. The beads were used in subsequent absorptioncycles to confirm regeneration,and over 10 cycles, the beads regained their original absorption capacity. To achieve 20-25% ammonia concentrations, ammonia was bubbled through water for five and ten minutes in three trials each, arriving at desired concentrations of 20-25%, thus achieving the success criteria for technical grade ammonia. A cyclical testing experiment was conducted over 48 runs to assess breakthrough adsorption, desorption, and sorbent capacity degradation. A regression analysis of breakthrough ammonia capture was also performed to determine expected degradation more thoroughly. The results indicated a 4.402% degradation over 100 cycles, successfully achieving the Technical Objective success criteria of <10% degradation. TECHNICAL OBJECTIVE 2:MOVA developed an hourly model from ISO 13790 (using the 5R1C method) that was used to predict energy consumption in poultry houses. The model included one specifically for a control house and one with the control house modified for the CAATCHER system ("CAATCHER MODEL"). The model is fully customizable based on house sizes, equipment ratings, environmental inputs, and structure building factors such as insulation. Using past literature (Costantino et al., "Climate Control in Broiler Houses"), we calculated hourly ventilation rates, broiler heat and moisture production, and mass and energy balances. These rates were paired with ammonia emission data (Wheeler et al.) to determine ammonia removal. MOVA modified this base model for the CAATCHER system, determining total ammonia filtered and emitted through the main ventilation, allowing evaluation of different airflow rates, heat recirculation, system integration, and off-times. Alongside our SBIR Phase I project, MOVA validated its computational model with a self-funded "Poultry Ammonia Removal Pilot" at a commercial broiler farm in Delaware (Jan-May 23). Using two identical houses, one control and one test, the project aimed to validate heat consumption and ammonia concentration models, monitor environmental factors, and assess flock productivity at reduced ammonia levels. Porous ducting and a blower in the test house reduced ammonia concentration by 5-10ppm over two flocks, demonstrating improved animal welfare metrics. The findings validated the CAATCHER concept and informed our economic model. Our heat consumption model was validated with physical data from the pilot project. There was a total of 655.1 hours of heater run-time with an average BTU rating of 133,000 BUTs/hr. This provided a total of 93,310 MJ over the course of the flock. Removing pre-flock heating of 4%, which our model does not account for, the total heat use was 89,578 MJ. MOVA's model calculated a heat use of 86,454 MJ. This is an accuracy of 3.48%, providing the confidence in the model to utilize it for evaluations. Our ammonia concentration model was validated using experimental sensor data from 12 different points and heights in both the Test and Control house during the Pilot project. To determine accuracy, a two-tail confidence interval compared average daily ammonia levels between experimental and model data for both the Control and CAATCHER models. Standard deviations were 5.24ppm for the Control Model and 5.36ppm for the CAATCHER Model. While the model needs further refinement based on physical data, it provided a sufficient initial basis to evaluate the CAATCHER system's effect, as well as sufficient correlation for hourly use. Our model enabled successful accomplishment of the TO-2 success metrics of: 80% ammonia emissions reductions and <10 ppm ammonia concentrations at bird height for all seasons. A 10,000 CFM scaled modelwas created as per the work plan. Although the deployment model has evolved, the economic estimates still demonstrate initial feasibility. An economic analysis using broiler performance data from a parallel project was conducted with component cost data. Flock improvements are based on actual data and literature, while sorbent life, electricity, and maintenance estimates are based on MOVA's analysis for desorption requirements. MOVA established initial economic feasibility for profitable economics, successfully achieving the final success metric of TO-2.

Publications

Progress 07/01/22 to 06/30/23

Outputs
Target Audience:The successful adoption of our poultry ammonia harvesting technology hinges on its acceptance within the poultry community, encompassing growers and integrators, such as Perdue, Tysons, and Mountaire Farms. These growers and integrators, specific to the production of broiler chickens, are the target audience. Beyond its primary goal of mitigating poultry emissions within poultry houses and enhancing overall farm productivity, the technology must exhibit ease of installation, utilization, and maintenance, all while minimizing the burden on poultry growers. To achieve these objectives, the MOVA team has undertaken an extensive industry engagement initiative, comprising interviews aimed at comprehending the daily operations of poultry farms and the key determinants of success within the poultry industry. Our efforts have encompassed over 20 interviews with poultry farmers located in Delaware, Maryland, and Virginia. Additionally, we have engaged in discussions with three of the top 10 broiler producers, known as 'integrators,' to gain insights into their success metrics and the impact of ammonia on their operational efficiency and profitability. With one of these top 10 integrators, we have established a strategic partnership, culminating in a self-funded on-site, proof-of-concept at one of their commercial poultry facilities. This endeavor yielded invaluable knowledge and promising results. These interactions have provided us with excellent comprehension of the design space and critical success factors. This understanding has significantly influenced our technical and product development efforts, promising the delivery of a valued product poised for a positive reception within the poultry marketplace. Changes/Problems:The team encountered a few notable challenges during the project as follows: 1. Computational Ammonia Modeling. Few prior studies have been conducted to model and evaluate poultry indoor air quality and ammonia. This has limited available computer modeling software and has provided unique challenges in computational fluid dynamics (CFD) custom modeling. The team found CFD was very useful in ventilation simulations to map air flow patterns, but it was very difficult to utilize for two phase gas modeling of ammonia. Additionally, with the determination that the vertical stratification of ammonia was not as important a factor as previously thought, the requirement for CFD faded and made way for a more easily implemented model. An Excel model following the international standard 13790 was found to be the best case. Although the model has its limits, it was the most effective and offered the easiest approach to customize the model for MOVA. This ultimately overcame the challenge but took about twice as long as expected. 2. Aqueous Ammonia Production. The original approach to aqueous ammonia production was through washing of the sorbent beads. Although this was found to be effective in desorbing the ammonia, the sorbent absorbed much more water than anticipated which required additional water to be added between each cycle, providing an obstacle for the seamless solution plus up than desired. The new approach of recovering the ammonia in gaseous form and then bubbling it through water proved effective and ultimately allowed achievement of the high concentration aqueous ammonia desired. 3. Sorbent Flow. As a result of the alginate binder utilized in the sorbent, it absorbed more water than anticipated which did not provide optimal flow through the system. Although MOVA was still able to complete testing with it, it provided a notable challenge to address for scale-up. MOVA decided to study three additional binders which were successfully fabricated. These binders were mixed with water to determine their flowability. At least two solutions were found to overcome this challenge while maintaining the desired adsorption capture rate. These beads will be scaled and utilized in a later project. These challenges have been managed appropriately and have been overcome. What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest? Nothing Reported What do you plan to do during the next reporting period to accomplish the goals?We will complete the economic modeling of the system, which will complete the project.

Impacts
What was accomplished under these goals? Ammonia has long been a challenge for the poultry industry as both an air emissions hazard and as a toxic compound inside the house that is harmful to bird health and productivity. The purpose of MOVA's research is to advance a sustainable and economically viable ammonia abatement solution that will keep the cost of production stable, reduce atmospheric ammonia emissions, create an improved growing environment, increase bird performance indicators (weight and mortality), and generate positive environmental stewardship and improved public perception for the poultry industry. Our target audience for the technology is the poultry industry, most specifically the growers and large poultry integrators that produce broiler chickens. This work can further be expanded to other concentrated animal feeding operations. During the reporting period, we completed Objective 1, System Testing and Evaluation. We commissioned a testing lab to evaluate our ammonia abatement solution and evaluated our filtration media, ammonia capture section, and sorbent regeneration section. The lab was fully outfitted with instrumentation to collect data on performance and characterize the flow to enable in-depth technical analysis. We completed the evaluation of the various components within the system by evaluating the ammonia capture section and regeneration section individually. We ran a simulated ammonia flue gas across our filtration media to observe the capture rate which was determined by the difference in outlet and inlet concentrations of ammonia over ten cycles. All trials followed the same pattern where a capture rate of 99.76% was observed, indicating excellent low partial pressure ammonia adsorption until breakthrough, followed by a slow stepped decrease in the rate over the remainder of the time. This is a significant technical achievement as low partial pressure gas adsorption remains a continual challenge and almost no media exist for low partial pressure ammonia capture. The data was analyzed and indicated that the filtration bed is likely capable of being optimized to prolong the high capture rate and increase efficiency of the filtration bed. Pressure drop was measured across the sorbent bed, an indicator of energy efficiency, and was noted to average 38.83 Pa, far surpassing the Objective 1 technical goal of 150 Pa, indicating an efficient design for filtering a large air flow. To evaluate the regeneration module, a cyclic test was required to evaluate if the media was capable of being desorbed. To accomplish this, the sorbent was saturated utilizing the panel-bed adsorber, and then the saturated filtration media was removed and placed in the regeneration module where it was mixed with water to desorb ammonia. The filtration media was then continually reused with similar results, indicating similar adsorbed ammonia for each cycle, which concludes that regeneration was successful for each cycle. To determine the feasibility of reaching 20-25% ammonia concentrations, which is desirable for ammonia fertilizer, ammonia was injected into water to rapidly simulate numerous sorbent regeneration cycles. This determined that ammonia concentrations above 25% were feasible, establishing the technical feasibility to providing a value added ammonia fertilizer from the system. We completed an integrated system evaluation of major components by conducting a cyclic testing experiment for 48 test runs over 30 days. The testing consisted of cycles defined by ammonia adsorption by the filtration media until breakthrough and regeneration of the sorbent in an aqueous system. Collected data was used to determine sorbent capacity, capture efficiency, desorbed ammonia, and sorbent degradation. The testing indicated near 100% ammonia adsorption and desorption over 48 cycles. A regression analysis was completed for breakthrough ammonia capture to determine expected degradation. The results indicated a 4.402% degradation over 100 cycles, successfully achieving the technical objective's goal of <10% degradation, indicating the likelihood of an economical sorbent lifespan. During the reporting period, we made great progress on Objective 2, Modeling and Technical Feasibility Analysis. The team pivoted from using commercial software to model the system to an Excel model. To build the model, the hourly model detailed in ISO 13790 was utilized to predict energy consumption of poultry houses. We calculated the ventilation rates required for every hour of growth as well as heat and moisture production of the broilers to calculate the mass energy balances of the system. We further modified this base model and modeled the filtration system and ammonia emissions, allowing us to evaluate air flow rates, heat recirculation options, ventilation system integration, and off-times. The model was utilized to provide an estimation on heat cost differences and indoor air quality improvements with the use of MOVA's ammonia abatement solution. The model was validated from results from a parallel project that conducted physical experimentation at two live commercial broiler facilities. MOVA replicated the model from the report titled, Climate Control in Broiler Houses: A Thermal Model for the Calculation of the Energy Use and Indoor Environmental Conditions, by Costantino, Fabrizio, Ghiggini. MOVA utilized this model to determine target airflow, ammonia emissions, and resulting ammonia concentrations based on the ability to maintain an ammonia level <10 ppm. The model was validated from the physical experiment data and was compared to model data. Heat predictions were found to be within an accuracy of 3.48%, providing confidence in the model to utilize it for evaluations. For validation of the ammonia levels, MOVA collected physical data of ammonia concentrations at 12 points and heights in the commercial house. The average ammonia concentration remains within 1.78 ppm across the flock, indicating good correlation with experimental modeling. The small difference provided the confidence to utilize these calculations in concentration reduction and emissions calculations. The model was utilized to evaluate the average indoor ammonia concentration at varying ventilation rates to represent the various seasons. The results indicated that low ammonia levels were able to be achieved and maintained. The final portion of the modeling was to determine reduction in ammonia emissions with a goal to show the ability to successfully capture 80% of emitted ammonia. The model determined 80% of emissions were possible with the system if the system was utilized throughout the flock and captured 60% of airflow from the main ventilation system. With this concept, a total of 80.3% of emissions were captured, achieving the success criteria for objective 2. However, the main determination from this modeling was that an air flow rate of about 5% of the chamber volume per minute was required to adequately reduce ammonia levels to improve production., which would provide a low-cost option to improve bird performance when lower emissions reductions can be accepted. This further means that an increase in system size would not equal a proportional indoor ammonia improvement, but would equate to a proportional ammonia reduction. This clarified an important technical distinction for MOVA and a vital factor for the business case. Completion of the economic modeling will be completed in the remainder of the project. Conclusively, MOVA's project has advanced an ammonia abatement solution for the poultry industry. The project technically validated a new filtration formulation and physical capture system to affect the capture of ammonia, which has proven difficult in trace ammonia levels and not prevalent with current technologies. The project also determined the ideal system size, indoor environment improvements, and emissions reductions that directly assist in commercial unit sizing and economic predictions.

Publications