Progress 10/01/01 to 09/30/06
Outputs
Phosphorous separation by chemical means was evaluated for liquid dairy manure. Manure samples were collected at Green Meadow Farms, Elsie, MI, a 3200-cow dairy that uses sand for bedding freestalls and has a sand manure separation system. Chemical coagulants tested were hydrated lime, ferric chloride and alum. Ferric chloride and alum met the project goal of 80% phosphorus reduction. Biochemical methane potential (BMP) tests, using the serum bottle procedure, were used to evaluate biogas production. Untreated sand laden dairy manure scraped from the alley (SM), effluent from a mechanical sand manure separator (SMS), effluent from a settling basin (SMSG), and effluent from the belt filter press of the on-farm chemical phosphorus separation system (P) were tested. Total solids (TS) were 15.2-46.4%, 4.6-7.7%, 2.0-4.4% and 1.2-1.3%, respectively. BMP trials lasted about 40 days. The more dilute SMS generated more biogas than the more concentrated SM. Total biogas
production ranges were 6,700-9,100, 8,800-10,800, 3,400-5,700 and 2,500-2,800 cm3/100 ml, respectively. Trace metals (iron, zinc, nickel and manganese) did not improve but, in most cases, hindered biogas production. SMS, the best, produced approximately 60% methane. A small-scale anaerobic digester constructed at Green Meadow Farms was successfully operated for six months. Significant quantities of grit and manure solids accumulated in the digester cone as intended. Nevertheless, problems created by the sand in the manure stream emphasized that grit must be removed before the manure stream enters a digester. The concept of combining an ultrafiltration system with a conventional anaerobic process is being studied. An anaerobic membrane bioreactor (AnMBR) enables the production of an anaerobic effluent devoid of solids and sets the stage for further downstream processing to promote nutrient fractionation and water reuse. A complete manure management economic model that considers
sand-laden manure collection, sand separation, anaerobic digestion, nutrient management and water re-use could be part of a decision support system will aid in the design of integrated manure management systems. An anaerobic digester is being constructed on a 3200-cow dairy farm in Michigan that uses sand for freestall bedding. This facility will provide a location and basis for ongoing applied research, demonstration and education programs conducted by Michigan State University personnel on innovative manure treatment technologies and related topics. Biogas production using commingled organic waste streams (dairy, beef and swine manure, post-consumer waste from campus cafeterias and abattoir waste from the Meats Lab) at Michigan State University was evaluated. The results of a study to determine the quantities of food waste generated in campus cafeterias are currently being analyzed. The feasibility of establishing at MSU an integrated treatment system, based on an anaerobic
digester, is being studied.
Impacts
Manure system design is no longer subordinate to dairy facility design and cannot be left as a task to address at the end of the design process. The traditional approach to manure system design--production, collection, storage, transport, land application--is now obsolete. It does not meet the needs of the dairy farm nor does it satisfy the interests of society. Integrated manure management systems that incorporate innovative treatment technologies present opportunities for cost recovery from the manure system, even possibly offsetting necessary investments sufficiently to move manure management from a cost of operation to an enterprise that results in a net profit. For example, recovering sand for reuse as bedding, finding a profitable use for biogas from a digester, selling phosphorus removed from the manure stream for fertilizer and marketing composted manure solids are means of recovering costs. Moreover, alternative treatment methods, properly integrated into
conventional animal manure handling systems, may allow farmers to profitably implement practices that lessen the social pressures associated with animal manure--less odors, reduced pathogens, minimal biosolids. With the tenets of sustainability--social, environmental and economic--as a guide to integrated manure system design, society will be the ultimate beneficiary.
Publications
- Kirk, D.M., W.G. Bickert, S. Hashsham & S. Davies. 2002. Chemical Additions for Phosphorus Separation from Sand Free Liquid Dairy Manure. ASAE Annual Meeting, Las Vegas, NV. ASAE Paper No. 034122.
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Progress 01/01/05 to 12/31/05
Outputs
An anaerobic digester to be constructed on a 3200-cow dairy farm in Michigan i) will demonstrate the use of an anaerobic digester on a dairy farm that uses sand for freestall bedding and ii) will provide a location and basis for ongoing applied research, demonstration and education programs conducted by Michigan State University personnel on innovative manure treatment technologies, biomass utilization and renewable energy. Characterizing the biogas production and composition of cafeteria food wastes on the Michigan State University campus sets the stage for design of a collection and treatment system, likely to be based on anaerobic digestion. Related to alternative treatment technologies, the concept of combining an ultrafiltration system with a conventional anaerobic process for the treatment of liquid dairy manure sets the stage for further downstream processing to promote nutrient fractionation and water reuse via separation processes such as reverse osmosis,
evaporation or struvite recovery. The membrane in an anaerobic membrane bioreactor (AnMBR) enables the production of an anaerobic effluent devoid of solids. Based on these tools, a complete manure management economic model that considers sand-laden manure collection, sand separation, anaerobic digestion, nutrient management and water re-use may be developed. This model will be part of a decision support system will aid in the design of integrated manure management systems.
Impacts
An anaerobic digester to be constructed on a 3200-cow dairy farm in Michigan i) will demonstrate the use of an anaerobic digester on a dairy farm that uses sand for freestall bedding and ii) will provide a location and basis for ongoing applied research, demonstration and education programs conducted by Michigan State University personnel on innovative manure treatment technologies, biomass utilization and renewable energy. Characterizing the biogas production and composition of cafeteria food wastes on the Michigan State University campus sets the stage for design of a collection and treatment system, likely to be based on anaerobic digestion. Related to alternative treatment technologies, the concept of combining an ultrafiltration system with a conventional anaerobic process for the treatment of liquid dairy manure sets the stage for further downstream processing to promote nutrient fractionation and water reuse via separation processes such as reverse osmosis,
evaporation or struvite recovery. The membrane in an anaerobic membrane bioreactor (AnMBR) enables the production of an anaerobic effluent devoid of solids. Based on these tools, a complete manure management economic model that considers sand-laden manure collection, sand separation, anaerobic digestion, nutrient management and water re-use may be developed. This model will be part of a decision support system will aid in the design of integrated manure management systems.
Publications
- No publications reported this period
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Progress 01/01/04 to 12/31/04
Outputs
A small-scale anaerobic digester at Green Meadow Farms was operated successfully for six months. Significant quantities of grit and manure solids were retained in the digester cone, acting as a grit control device. Digester effluent was similar to other systems. A biogas boiler installed to burn gas produced by the digester generates heat that will be used to heat the digester using a heat exchanger. Learning opportunities with the grinder pump and heating system caused setbacks and limited the digester operation. In the spring of 2005, the digester heating system will be overhauled and the anaerobic digester will be put back in operation. A project designed to evaluate biogas production using commingled waste streams generated at Michigan State University was begun. Commingling involves the mixing of organic waste streams that would generally be treated separately. The possible benefits of commingling include increased biogas production, improved biogas quality,
consolidation of organic wastes and the eventual utilization of the organic waste as fertilizer. Three waste streams suitable for digestion were identified: i) animal manure, ii) post-consumer waste from campus cafeterias, and iii) abattoir waste from the MSU Meats Lab. Three of the campus farms have animal manure with acceptable characteristics for anaerobic digestion; namely, dairy, beef, and swine. Several campus cafeterias have year-round food service that would generate a steady flow of post-consumer waste. At this time, post-consumer waste is routed to the East Lansing municipal wastewater treatment plant for disposal. The campus abattoir generates significant quantities of offal, currently rendered at a substantial cost to the Meats Lab. With the future of rendering of offal in doubt, digestion offers a potentially environmentally sound disposal method. An audit, to be conducted in earlier 2005, will estimate the quantity of post-consumer food waste and abattoir waste available
for anaerobic digestion. A series of biochemical methane potential (BMP) tests will be used to evaluate different commingled mixtures. The BMP experiments will provide valuable information related to biogas generation and biogas quality that will aid in system design. A Chemical Engineering group used lab space and equipment to conduct research on biodegradable composite materials. The end goal of that research is to design biodegradable plastics for the auto industry.
Impacts
Characterizing the biogas production and composition dairy manure at various stages of treatment with the addition of various additives will allow design of the most effective anaerobic digester system. The resulting integrated manure management system will be more affordable to the dairy farmer.
Publications
- No publications reported this period
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Progress 01/01/03 to 12/31/03
Outputs
Biogas production of dairy manure in various stages of treatment was evaluated based on the biochemical methane potential (BMP) tests completed in 2002. The serum bottle procedure used for the evaluation is recognized and used widely in the municipal and industrial waste treatment industries. The various dairy manures used in the experiments included; untreated sand laden dairy manure as scraped from the alley (SM), effluent from a mechanical sand manure separator (SMS), effluent from a settling basin (SMSG), and effluent from a chemical phosphorus separation system using a belt filter press (P). The total solids (TS) range for each stream was 15.2 to 46.4%, 4.6 to 7.7%, 2.0 to 4.4% and 1.2 to 1.3%, respectively. Several trials were conducted with the four manures listed above. Further experiments evaluated the benefits of trace metal additions to SM and SMS. The trace metal addition included iron, zinc, nickel, cobalt, and manganese. Pathogen degradation, biogas
production, and biogas composition were monitored regularly throughout the BMP trials. Each anaerobic BMP trial lasted for approximately 40 days. The total biogas production range for each of the four manures was 6,700 to 9,100, 8,800 to 10,800, 3,400 to 5,700 and 2,500 to 2,800 cm3/100 ml of manure for SM, SMS, SMSG and P, respecitively. Deionized water, used as a control, generated 228 to 380 cm3/100 ml. The more dilute SMS consistently generated more biogas than the more concentrated SM. The addition of trace metals did not improve but, in most cases, hindered biogas production. Biogas composition consisted primarily of carbon dioxide (CO2) and methane (CH4). During the first three weeks of the trials, carbon dioxide concentration in the biogas was typically above 60%. After the first 20 days or so, methane concentration increased to 50% or more in the majority of the serum bottles. The SMS manure type preformed the best averaging approximately 60% CH4. On the other hand, SM
average only 32% CH4, well below expected levels. Trace metal additions showed only marginal improvements in biogas composition. E. coli and coliform were closely monitored during the BMP trials. In the tests where no trace metals were added, E. coli and coliform were undetectable after 4 and 6 days, respectively. The addition of trace metals appeared to slow the degradation of E. coli and coliform by approximately 4 days.
Impacts
Characterizing the biogas production and composition dairy manure at various stages of treatment with the addition of various additives will allow design of the most effective anaerobic digester system. The resulting integrated manure management system will be more affordable to the dairy farmer.
Publications
- Kirk, D.M., W.G. Bickert, S. Hashsham, & S. Davies. 2002. Chemical Additions for Phosphorus Separation from Sand Free Liquid Dairy Manure. ASAE Annual Meeting, Las Vegas, NV. ASAE Paper No. 034122.
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Progress 01/01/02 to 12/31/02
Outputs
Recent research has focused on further developing treatment technologies that improve the profitability and sustainability of manure management on Michigan dairy farms. Phosphorus separation by chemical means, used for decades to remove phosphorus from and provide final treatment for effluent from municipal wastewater treatment plants, was evaluated for treatment of liquid dairy manure. The chemical coagulants tested on the liquid dairy manure included hydrated lime, ferric chloride, and alum. The project goal of 80% phosphorus reduction in the liquid manure was reached using ferric chloride and alum. The liquid manure used in the testing was effluent from a sand manure separation system. Since this research began, two Michigan dairy farms have purchase commercial chemical phosphorus separation systems. A paper summarizing the phosphorus separation research has been accepted for the 2003 ASAE Annual meeting. Presently, research focused on anaerobic digestion of liquid
dairy manure is being planned. Anaerobic digestion is the cornerstone for advanced manure treatment. The stabilized manure slurry resulting from anaerobic digestion is low in odor and in a form that optimizes other advance treatment options, such as chemical phosphorus separation. Initially, manure from several points in a manure treatment system will be evaluated for methane generation potential under controlled laboratory conditions. During the methane generation tests, pathogen levels and volatile fatty acid production will be closely monitored. The second phase of the project will focus on designing an upright fixed film anaerobic digester that will continuously remove settled grit that remains in the manure stream after sand-manure separation. Grit removal is a crucial to digester development as most Michigan dairy farms house cattle in barns with sand based freestalls. The third phase of the project will be the development and operation of a field scale digester. The field scale
digester will be constructed on a commercial dairy farm in central Michigan. A poster presentation on the methane generation tests has been accepted for the 2003 ASAE Annual meeting.
Impacts
Phosphorus separation from liquid dairy manure by chemical means allows dairy farmers to spread the resultant manure stream on land already having high levels of available phosphorus. A field scale, fixed-film anaerobic digester designed for continuous grit removal will allow dairy farmers with sand-laden dairy manure to realize the benefits of odor reduction and gas generation resulting from anaerobic digestion of the manure.
Publications
- No publications reported this period
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Progress 01/01/01 to 12/31/01
Outputs
Based on laboratory tests on removing phosphorus from manure streams using lime, chemicals or polymers, a prototype settling device (100 gallons capacity) with a stirring mechanism was constructed for testing with the manure stream at Green Meadows Farm. Data from the prototype device are being analyzed--preliminary results are encouraging. Concurrently, laboratory testing was begun i) to evaluate the potential of operating manure storage ponds as biological removal systems and ii) to optimize physico-chemical removal of phosphorus using chemical agents Based on preliminary results, a theoretical model, using GPS-X (Hydromantis, Inc.), was developed to evaluate the suitability of this simulation package for modeling nuturient management processes in dairy manure systems.
Impacts
Reducing bacteria counts in sand reclaimed from dairy freestall barn manure will avoid a negative impact on high producing cows. Removing phosphorus from the manure stream allows the manure to be applied to land where phosphorus levels already exceed those necessary to support crop production.
Publications
- No publications reported this period
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Progress 01/01/00 to 12/31/00
Outputs
Sand reclaimed by a commercial sand-manure separator had lower E. coli counts than sand taken from a barn freestall. Adding chlorine to the final rinse spray water of a commercial sand-manure separator reduced E. coli presence in reclaimed sand. Preliminary studies on removing phosphorus from manure streams using lime, chemicals or polymers showed promising results.
Impacts
Reducing bacteria counts in sand reclaimed from dairy freestall barn manure will avoid a negative impact on high producing cows. Removing phosphorus from the manure stream allows the manure to be applied to land where phosphorus levels already exceed those necessary to support crop production.
Publications
- Wedel, A.W. 2000. Hydraulic conveyance of sand-laden dairy manure in collection channels. Paper No. 004106, ASAE, St. Joseph, MI.
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Progress 01/01/99 to 12/31/99
Outputs
Settling history of sand in sandladen dairy diluted with various rates of water was studied in laboratory-size columns. With sand added to manure at the rate of about 45 lbs of sand to about 140 lbs of manure, minimal settling of sand occurred with time. A dilution rate of at least 1:1, water to sandladen manure by weight, followed by agitation, was necessary for significant settling of sand. The propensity of sand to settle was more sensitive to dilution rate than to initial sand:manure ratio. A commercial sand-manure separator has been fitted with chlorination equipment to study the effect of adding a disinfectant to reclaimed sand.
Impacts
Knowledge about the behavior of sandladen dairy manure will allow improved handling equipment and storage facility design, lowering cost. Reclaiming sand for reuse as freestall bedding can be a cost-saving to a dairy farmer.
Publications
- Bickert, W.G. 1999. Factors affecting dairy manure system design. Paper presented at the Relocation and Expansion Conference (Monsanto), March 30-31, Ontario, CA.
- Bickert, W.G. 1999. Freestall design and management. Proceedings of Western Canadian Dairy Seminar. March 9-12. Red Deer, Alberta.
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Progress 01/01/98 to 12/31/98
Outputs
Four sand-manure separators, available commercially and installed on a 2,000-cow dairy in MI, have been monitored. Flow rates of makeup water, fresh water, air, sandladen manure, reclaimed sand and effluent were measured. The separators themselves have operated satisfactorily, but the devices used to meter sand-laden manure into the separators--inexpensive manure augers originally, now pumps--have presented major problems. To permit optimal operation that will assure reclaimed sand essentially free of organic material, the manufacturer is now manufacturing a specially-designed auger that will accurately meter the flow of sandladen manure into a separator. Settling history of sand in sandladen manure diluted with various rates of water is being studied in laboratory-size columns.
Impacts
(N/A)
Publications
- Wedel,A.W. and W.G. Bickert. 1998. Performance characteristics of a sand-manure separator. Proc. Fourth Intl. Dairy Housing Conf., ASAE Publ. 01-98, St. Joseph, MI.
- Bickert, W.G. and A.W. Wedel. 1998. Manure management systems using sand-manure separation. Proc. Fourth Intl. Dairy Housing Conf., ASAE Publ. 01-98, St. Joseph, MI.
- Bickert, W.G. and J.F. Smith. 1998. Freestall barn design and management for cow comfort. Proc. Midwest Dairy Mgmnt. Conf., Aug. 17-18, Minneapolis, MN.
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Progress 01/01/97 to 12/31/97
Outputs
Sand continues to increase in popularity for dairy cow freestall bedding for reasons of good udder health and cow comfort, both especially important to high-producing cows. A manufacturing prototype sand-manure separator was successfully operated on two commercial dairy farms. Preliminary tests showed reclaimed sand to be low in volatile solids and bacteria counts when compared to sand taken from freestalls on commercial dairy farms. Several manure management systems based on sand-manure separation were designed. A preliminary procedure for making measurements to compare flow characteristics of dairy manure with various concentrations of sand has been developed and tested. Variable flow characteristics of the sand-laden manure coming from a barn impact the control of various operating parameters and the resulting efficacy of a sand-manure separator.
Impacts
(N/A)
Publications
- No publications reported this period
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Progress 01/01/96 to 12/30/96
Outputs
For cow health and comfort, sand is the preferred bedding in dairy freestall barns. A survey of sand-based freestalls on 50 Michigan dairy farms gave mixed results with respect to coliform counts and volatile solids in samples of sand collected at the rear of the stalls. Although coliform counts were generally acceptable, even in stalls deemed less well- managed, using sand does not in itself assure low counts. Frequent maintenance, grooming and refilling of beds are essential for clean and comfortable stalls. A prototype separator developed for removing bedding sand from sand-laden manure recovered sand containing less than one percent volatile solids. The manure stream, now with no sand, was more amenable to conventional manure handling and storage methods including pumping, irrigation and injection. Separation involves three distinct phases: i) metering of the sand-laden manure, ii) dispersion and washing of both organic and inorganic solids through dilution with
water and mixing, and iii) differential settling. A commercial company has been licensed to manufacture separators based on concepts developed. Patent Application No.: 08/707,657. Date: September 4, 1996.
Impacts
(N/A)
Publications
- WEDEL, A. W., BICKERT, W.G. 1996. Separating sand from sand-laden dairy manure: factors affecting the process. Paper No. 96-4016, ASAE, St. Joseph, MI.
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