TECHNOLOGY OF TRANSFORMING WASTE HEAT AND MOISTURE INTO ENERGY IN POULTRY BARNS

• Sponsoring Institution: National Institute of Food and Agriculture
• Project Status: EXTENDED
• Funding Source: SMALL BUSINESS GRANT
• Reporting Frequency: Annual
• Accession No.: 1010384
• Grant No.: 2016-33610-25486
• Project No.: MO.W-2016-00706
• Proposal No.: 2016-00706
• Program Code: 8.3
• Project Start Date: Aug 1, 2016
• Project End Date: Jul 31, 2017
• Grant Year: 2016

Project Director
Xu, Y. S.

Recipient Organization
ENERGY AMERICAS LLC
1220 11TH ST
BOONVILLE,MO 65233

Performing Department
(N/A)

Non Technical Summary
Intensive usage of fossil fuel for heating of poultry barns is the largest operation cost for most of poultry growers. High humidity of indoor air is the biggest challenge for farmers to produce healthy food due to moisture induced ammonia generation from manure and disease problems. Proposed research is to transforming waste heat from high temperature of exhaust air and latent heat from moisture into energy to reduce or replace fossil fuel in poultry, including turkey, broiler, layer and other types of barns.The objective of the proposed research is to develop (a) high efficient thin-wall heat exchanger for poultry applications, which can be manufactured with advanced method in US, and (b) innovative dehumidifying system to transfer waste heat from exhaust air and latent heat from moisture as heating sources of poultry farm.Success of the research and development of the technology is expected to bring the following impact to the poultry industry and public: (a) saving energy (fossil fuel for heating) cost by 70-80% in turkey and broiler house, and replace 100% of fossil fuel in egg layer barns; (b) active dehumidifying and accurate moisture control to reduce ammonia generation inside poultry houses. Improved indoor air quality will benefit the poultry production effectiveness and farming profitability (including higher average bird weight, higher feed conversion rate and lower mortality rate); (c) Assist healthy food through clean, dry and comfort air which will lead to less diseases and less antibiotic medicine usage; (d) remove dust from poultry facility and offer opportunity of odor control, which will improve local environment and benefit farmers, their facility and their neighbors living surround the farm; (e) developed heat exchanger and dehumidifying products will be manufactured in rural Missouri and offer job opportunities, and (f) production of healthier food with significant lower cost will make American farmers more competitive in global market.The technology development will be based on applicants' recent success in reducing propane by 50% in poultry houses. It can be possibly used in commercial farms. It is planned to have the technology filed tested in a small or medium size poultry farm for organic and/or free range barns in the phase II research. It is also expect to be applied in other farming facilities including hog and aquaculture farms. It address global issues and will have potential international applications.

Animal Health Component

0%

Research Effort Categories

Basic

0%

Applied

30%

Developmental

70%

Classification

Knowledge Area (KA)	Subject of Investigation (SOI)	Field of Science (FOS)	Percent
315	3299	2020	100%

Knowledge Area
315 - Animal Welfare/Well-Being and Protection;

Subject Of Investigation
3299 - Poultry, general/other;

Field Of Science
2020 - Engineering;

Keywords

energy saving

food quality

poultry farm

Goals / Objectives
The objective of the proposed research is to develop (a) high efficient thin-wall heat exchanger for poultry applications, which can be manufactured with advanced method in US, and (b) innovative dehumidifying system to transfer waste heat from exhaust air and latent heat from moisture as heating sources of poultry farm.

Project Methods
Phase I research will be focus on feasibility study. it will include information analysis, scientifical calculations, marketbdata summary and ecinomic analysis. field testing data in previous research will be used for the purpose of technical and economical feasibility study.

Progress 08/01/16 to 11/30/16

Outputs
Target Audience:Poultry Farmers:Turkey and chicken broiler growers in Missouri, Nebrask, Minnisota, Activities: Commerication and understanding of poultry operation, information of production, energy, and environment Poultryproduction and retail business leaders:Walmart VP for poultry, Cargill VP for Agriculture, discussion about air qualityand energy and its impact on production and animal welfare. Funding of the pilot ptoject, futurte supportin adoption of the technology Investors: International andUS investors who are interested in investment in foodand sustainable agriculture (New York, Singapore, and Midwest) Changes/Problems:In comparison with current products, the changes of the new technology under the project include: Significantly reduce cost of the products and improve energy efficiency, which will directly reduce payback years of investment. It will make the products to be economic viable not only to turkey farm, but to chicken and other farm, not only in North states buy in central and south states; Change from manually manufacturing to automatic machine production, which will make MADE IN USA possible. Additional dehumidification system will first time have active moisture control of the poultry farm and bring impact on farming profitability, food quality and animal welfare. Reduce poultry farming working hours and working stress and support sustainable workforce for agriculture. What opportunities for training and professional development has the project provided?Education and training on energy efficiency for poultry farming has been given to Students at the University of Missouri, Missouri High School Agriculture and Science Instructors; Missouri Farm Association Poultry growers in Missouri Environmental commission of Cargill How have the results been disseminated to communities of interest?Information disclosed to poultry grower's results in sales of the concept machines of waste heat recovery in Missouri. One grower who installed waste heat recovery system won Nation Family Farmer Environmental Award by US Poultry Federation. What do you plan to do during the next reporting period to accomplish the goals? Apply for SBIR Phase II grant to prototyping new technology/products Manufacturing of the products in rural Missouri to create jobs in high unemployment area. Develop a third party investment program: "pay through saving" to completely remove risk from growers. Quick pack of the technology through innovative design and manufacturing make this feasible.

Impacts
What was accomplished under these goals? 1. Concept design and feasibility study completed, including thin-wall waste heat recovery system and dehumidification system. Material has been identified, and manufacturing methodology bas been investigated and evaluated. 2. Scientific calculation has been conducted for heat transfer and hydronic performance of waste heat recovery system, and thermal dynamic analysis for dehumidification system 3. Production cost, energy saving data collected, Economic analysis has been performed as function of fuel price and climate zones. 4. Market potential analysis including different sectors (turkey, chicken and egg layer) in US, Canada and Europe 5. Commercialization plan has been created including detailed marketing plan and new business financing model. 6. Connection with industry and possible support from leading poultry production and retail business.

Publications

• Type: Other Status: Under Review Year Published: 2017 Citation: Products concept design, thermal calculation model (heat transfer and dehumidification), market report, economic analysis for Phase II

Progress 08/01/16 to 11/30/16

Outputs
Target Audience:Target Audience Poultry Farmers: Turkey and chicken broiler growers in Missouri, Nebrask, Minnisota, Activities: Commerication and understanding of poultry operation, information of production, energy, and environment Poultry production and retail business leaders: Walmart VP for poultry, Cargill VP for Agriculture, discussion about air quality and energy and its impact on production and animal welfare. Funding of the pilot ptoject, futurte support in adoption of the technology Investors: International and US investors who are interested in investment in food and sustainable agriculture (New York, Singapore, and Midwest) Changes/Problems:In comparison with current products, the changes of the new technology under the project include: Significantly reduce cost of the products and improve energy efficiency, which will directly reduce payback years of investment. It will make the products to be economic viable not only to turkey farm, but to chicken and other farm, not only in North states buy in central and south states; Change from manually manufacturing to automatic machine production, which will make MADE IN USA possible. Additional dehumidification system will first time have active moisture control of the poultry farm and bring impact on farming profitability, food quality and animal welfare. Reduce poultry farming working hours and working stress and support sustainable workforce for agriculture. What opportunities for training and professional development has the project provided?Education and training on energy efficiency for poultry farming has been given to Students at the University of Missouri, Missouri High School Agriculture and Science Instructors; Missouri Farm Association Poultry growers in Missouri Environmental commission of Cargill How have the results been disseminated to communities of interest?Information disclosed to poultry grower's results in sales of the concept machines of waste heat recovery in Missouri. One grower who installed waste heat recovery system won Nation Family Farmer Environmental Award by US Poultry Federation. What do you plan to do during the next reporting period to accomplish the goals?The next step: Apply for SBIR Phase II grant to prototyping new technology/products Manufacturing of the products in rural Missouri to create jobs in high unemployment area. Develop a third party investment program: "pay through saving" to completely remove risk from growers. Quick pack of the technology through innovative design and manufacturing make this feasible.

Impacts
What was accomplished under these goals? 1. Concept design and feasibility study completed, including thin-wall waste heat recovery system and dehumidification system. Material has been identified, and manufacturing methodology bas been investigated and evaluated. 2. Scientific calculation has been conducted for heat transfer and hydronic performance of waste heat recovery system, and thermal dynamic analysis for dehumidification system 3. Production cost, energy saving data collected, Economic analysis has been performed as function of fuel price and climate zones. 4. Market potential analysis including different sectors (turkey, chicken and egg layer) in US, Canada and Europe 5. Commercialization plan has been created including detailed marketing plan and new business financing model. 6. Connection with industry and possible support from leading poultry production and retail business.

Publications

• Type: Other Status: Under Review Year Published: 2017 Citation: Product concept design, scientific calculation model, cost and economic analysis model, and market analysis report.