Source: COMPOST PLANT, L3C, THE submitted to NRP
TESTING FEASIBILITY AND SCALABILITY OF A NEW ENGINEERED DESIGN OF AN AERATED STATIC PILE COMPOSTING SYSTEM.
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
SMALL BUSINESS GRANT
Reporting Frequency
Annual
Accession No.
1012721
Grant No.
2017-33610-26988
Cumulative Award Amt.
$97,575.00
Proposal No.
2017-00779
Multistate No.
(N/A)
Project Start Date
Sep 1, 2017
Project End Date
Apr 30, 2020
Grant Year
2017
Program Code
[8.6]- Rural & Community Development
Recipient Organization
COMPOST PLANT, L3C, THE
21 MOUNT HOPE AVE
PROVIDENCE,RI 02906
Performing Department
(N/A)
Non Technical Summary
Food waste is a significant and complex problem for the United States. Americans generate over 250 million (short) tons of trash a year, and organic materials such as paper and paperboard, yard trimmings, and food waste continue to make up a large component of the waste stream. These organic materials collectively account for a significant portion of U.S. methane emissions, as organic waste produces methane in landfills, and landfills are the third largest source of methane in the United States. Food waste recycling (composting and anaerobic digestion) offers the most scalable path to reducing food waste nationally, but on-the-ground infrastructure to manage food waste is seriously underdeveloped, especially in New England. The reality is that composting infrastructure in particular is lagging far behind policy drivers and community interest in diverting food waste and organic materials.We are in need of innovation in the organics management sector to develop replicable, scalable cost-effective solutions for organics, with an emphasis on decentralized approaches to managing food waste, leaf/yard waste, and other organic waste. Forced air composting offers distinct advantages over traditional windrow composting or static piles in terms of efficiency of land use and ability to control odor, but generally at a significantly higher capital cost. While different types of forced air composting systems are in use across the country, they tend to be cost-prohibitive for agricultural operations or small to mid-size compost operators, increase time and labor of operations by requiring manual removal and reset of air pipes, or provide uneven air flow to compost piles, resulting in pockets of unfinished material.This SBIR Phase 1 Research project will test a new technological design for an aerated static pile (ASP) composting system, one that presents an improvement to these systems with regard to cost, ease of use, and consistency of airflow, bringing high potential for commercialization.There are four core criteria by which our ASP composting system will be evaluated for this project: air distribution, capital cost, durability of materials, and operational labor/time cost.Our ASP unit is designed with the intention of scalability and replicability: at a small scale, we believe this would be a viable model for a farm to deal with on-farm waste, have increased revenue from food waste tipping fees and/or collections, and produce a high-quality compost for on-farm use or sale. At the larger end of the processing spectrum, the unit could be scaled to process food waste feedstocks from high-density areas in an industrial-scale facility.Rural areas, with a broader land base and more familiarity with agricultural-manufacturing technology, have the opportunity to connect directly with critical sources of nitrogenous material (food waste), which are primarily generated in areas of high density populations. A decentralized approach to food waste and organic waste processing and management would serve as a model for rural communities, increasing rural economic development opportunities, and enhancing environmental quality. Food and organic waste is one of the largest, yet least recovered, waste streams in the U.S., and it is time to catalyze a change in our thinking. By turning this waste stream into an environmental and community resource, we can extend the life of our landfills, close the loop with our local food systems, and enhance the economic vitality of rural communities.
Animal Health Component
70%
Research Effort Categories
Basic
20%
Applied
70%
Developmental
10%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
4025299202070%
1010110107030%
Knowledge Area
101 - Appraisal of Soil Resources; 402 - Engineering Systems and Equipment;

Subject Of Investigation
5299 - Agricultural supplies, general/other; 0110 - Soil;

Field Of Science
2020 - Engineering; 1070 - Ecology;
Goals / Objectives
Goal: To test a new technological design for an aerated static pile (ASP) composting system, one that is cost-effective for agricultural and industrial use, easy to set up and remove,delivers more even and consistent air flow,and is scalable in its design based on needed processing capacity.Objectives:Cost-effectiveness: ASP unit provides equal processing volume capacity at lower capital cost versustraditional below-gradeASP composting systemsAir Flow: Provideeven and consistent air flow to static composting pile, reducing the risk of uneven air distribution and pockets of unfinished materialSet up/Removal: Reducelabor and operator time to set up and remove aeration delivery unit versus traditional above-grade ASP composting systemsScalability: Optimize unit design and engineeringto allow for scalable use (fromsingle-unit to multi-unit)Environmental/Socio-economic benefits: Assess broaderenvironmental and/or socio-economic benefits to the local community
Project Methods
Compost site (approximately 1 acre) will be prepared for research (clearing and grading). Concrete blocks will be delivered for creation of 2 static pile bays, and a site will be established for receiving and mixing feedstocks. Two aeration delivery units will be constructed for the research trials. Blower and manifold system for the bayswill be installed, and unit will be dry-tested to check air flow rates. Setup of the unit in the bay and removal from the baywill be observed and timed, without any material loaded. Based on feedstock tests conducted,appropriate volumetric and nutrient recipes (C:N ratio, moisture content, bulk density) for testing with the system will be finalized, mixed, and loaded. TheBeltsville approach (in which aeration is controlled solely by time, with blowers on continuously for a set period of time or set number of minutes per hour) and the Rutgers approach (in which aeration is controlled by temperature, with temperature feedback sensors turning blowers on and off to keep pile temperatures in the 130-140F range) will both be trialed, and the relationships between moisture, temperature, and airflow will be tracked wtih each method. A minimum of 10 batches will be processed, on a four-to-six week rotation cycle in each bay.After each ASP cycle, batches will be moved to a windrow at the site for curing, and labeled to document timeline for stabilization and maturity.Solvita Compost Maturity Tests will be conducted on the material on a regular 4 week cycle, and when mature, finished samples will be sent in for comprehensive lab analysis (bulk density, pH, conductivity, TS, TVS, NO3-N, NH4-N, total C, total N, total P, K, Mg, Ca, B, Cu, Fe, Mn, Zn, plus compost maturity level).

Progress 09/01/17 to 04/30/20

Outputs
Target Audience:Primary audiences reached during the grant period: 1) farmers and landscape operators; 2) staff from the Solid Waste and Agriculture Divisions at the Rhode Island Department of Environmental Management; 3) food waste generators (including university staff, hospitals, restaurant chefs/owners) interested in compost processing innovations from The Compost Plant's work; 4) constituents, non-profit organizations, and elected officials in Newport and on Aquidneck Island interested in The Compost Plant's work and connected to the Healthy Soils, Healthy Seas RI initiative to increase compost diversion and processing on Aquidneck Island and in Rhode Island. Changes/Problems:The SBIR Phase 1 project's ability to move forward has been stymied at multiple stages based on a combination oflack of site control and local political and zoning challenges to on-farm composting in Rhode Island. We have attempted to move forward with completion of project at threedistinct farm sites in Rhode Island since the SBIR project wasapproved for award in 2017. Given these challenges and the economic impact of the COVID-19 pandemic on The Compost Plant's operations and staffing as of spring/early summer 2020, we are unable to continue with the project and fully achieve goals outlined and are submitting Final Report with termination of the project. Our proposal to pilot test a new engineered design for an aerated static pile composting was granted in 2017for a municipal site, owned by the Town of Warren, Rhode Island at 21 Birch Swamp Road, Warren, RI. After completing further due diligence on the original municipal site with the Rhode Island Department of Environmental Management (RIDEM), we learned that the former municipal landfill site was never properly or formally closed by the Town of Warren. Given this fact, no expanded use of the site was allowed by RIDEM or the Town of Warren. An initial Phase 1 grant extension was approved by USDA/NIFA on March 1, 2018, with end date for the grant extended to April 30, 2019. We were also approved by USDA/NIFA in March 2018 to change the location of the project to a two-acre parcel at Chace Farm (less than 1/2 mile from the original proposed site) at 68 Birch Swamp Road, Warren, RI. No project scope or budget changes were requested at that time. During this period, The Compost Plant was able tosigna 3 year MOU to take over management of an existing, permitted compost operation at Buxton Hollow Farm in North Smithfield, RI, located on a 33-acre farm between Providence and Worcester that has been producing high-quality, certified organic compost since 2002. (The property was part of a larger farm established in the 18th century when the Continental Congress awarded land to Captain James Buxton for his service in the Revolutionary War). During the remainder of 2018, the proposed site at Chace Farm was excavated of topsoil and graded with gravel, and two concrete bays (20' x 20' x 10') were constructed from 2' x 2'x 6' pre-formed concrete blocks. Electrical conduit was trenched and connected to the closest utility pole to provide power for the wireless unit and blower system. Given the two sites, The Compost Plant's intentionwas to field test the unit at the Chace Farm site, with baseline comparison data against the windrow recipes/methods we employed at the Buxton Hollow Farm site. Piles at Buxton Hollow Farm in a traditional windrow method weremonitored for temperature and ambient conditions in order to establish baseline metrics agains which the the efficacy of the aeration unitcould be evaluated. (We have summarized this baseline datain the "Other Products" section of this Final Report). In January of 2019, we began engaging the Division of Agriculture and the Office of Waste Management at the Rhode Island Department of Environmental Management to finalize permitting for the Chace Farm site and to formally start the pilot research with the ASP system. Given the delay on the project and theextenuating circumstances with the initial project site, we requested and were approved for an additional extension from USDA/NIFA in the spring of 2019 (toApril 30, 2020). Unfortunately, that fall, as we were about to formally extend the lease agreement with the owner of Chace Farm, her financial and legal circumstances changed suddenly with a neighbor dispute over right of way to an adjacent property. The continuation of the pilot was no longer viable at Chace Farm, and we were forced suddenly to move all infrastucture and equipment to Buxton Hollow Farm in North Smithfield. Our plan was to request an additional 1-year extension on the project and a 2nd request for a location change. Beginning in October 2019, we engaged a landscape architecture team to researchexisting conditions at the Farm and to develop a schematic design and long-term site plan for the property, with a dedicated area for completing the project. As we were preparing to finalize schematics in early2020 and seek additional investment for phase 1 infrastructure improvements, the owner of Buxton Hollow Farm and The Compost Plantwere issued an immediate Cease and Desist Order from the Town of North Smithfield for zoning violations. The Town's position is that farm-based composting is not specifically allowed as anagricultural use in the Town's Zoning Code, and is therefore not allowable without a special use permit. As we evaluated our legal options with the owner, COVID impacts hit our business severely starting in the middle of March.Within a two-week period, The Compost Plant lost 60-70% ofcustomer accounts, with the statewide closure of restaurants, schools, universities, and other hospitality establishments, and we were forced to lay off half of our staff. After meeting with our Advisory Board and evaluating the financial viability of the business moving forward, we made the difficult decision to sever our lease with Buxton Hollow Farm and focus on maintaining the food waste collections side of the business and developing new composting and anaerobic digestion partners capable of accepting larger volumes oforganic material. Given all of the challenges outlined andthe economic impact of the COVID-19 pandemic, we are unable to continue this project and are submitting our Final Report. What opportunities for training and professional development has the project provided?We are continuing to work with 4differentfarm-based compost operations in Rhode Island and Massachusetts (Earth Care Farm in Charlestown, RI; Rhode Island Nurseries in Middletown, RI; DiCenzo Brothers in Smithfield, RI; and Hidden Acres Farm in Medway, MA). We have shared processing information and recipe development information based on experience during our Phase 1 period, but were not able to showcase or provide professional development training related to the ASP system. How have the results been disseminated to communities of interest?See Changes/Problems, but our interest in hosting tours and field trip groups of different communities of interest was stymied by our inability to move forward with final testing of the Quadpod system compared to standard windrow methods due to site control issues. We continue to work with the Division of Agriculture and Solid Waste at the RI Department of Environmental Management on technical assistance for farmers and composters in the State, and will testify at the Town of North Smithfield's hearing on zoning at Buxton Hollow Farm in North Smithfield, which will set a critical precedent for on-farm composting in Rhode Island going forward. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Primary goal and objectives of the project were not fully accomplished as proposed.The SBIR Phase 1 project's ability to move forward has been stymied at multiple stages based on a combination oflack of site control and local political and zoning challenges to on-farm composting in Rhode Island. We have attempted to move forward with completion of the project at 3 distinct farm sites in Rhode Island since our SBIR project wasapproved for award in 2017. Given these challenges and the economic impact of the COVID-19 pandemic on The Compost Plant's operations and staffing in spring/early summer of this year,we are unable to continue with the project and fully achieve goals outlined and are submitting Final Report with termination of the project.

Publications


    Progress 09/01/17 to 08/31/18

    Outputs
    Target Audience:Primary audiences reached during this reporting period: 1) farmers and landscape operators; 2) staff from the Solid Waste and Agriculture Divisions at the Rhode Island Department of Environmental Management; 3)food waste generators (including university staff, hospitals, restaurant chefs/owners) interested in processing innovations from The Compost Plant's work; 4)municipal Public Works staff (primarily from the Town of Warren, Rhode Island), and 5) constituents, non-profit organizations, andelected officials in Newport and on Aquidneck Island interested in The Compost Plant's work and connectedto the Healthy Soils, Healthy Seas RI initiative to increase compost diversion and processingon Aquidneck Island and in Rhode Island. Changes/Problems:An initial Phase 1 grant extension was approved on March 1 2018, with end date for the grant extended to April 30, 2019. We have now requesteda final additional extension to April 30, 2020 given extenuating circumstances with the initial project site. The project faced an initial major hurdle at the onset of the project with a need to change location of the pilot completely. Our proposal to pilot test a new engineered design for an aerated static pile composting was granted for a municipal site, owned by the Town of Warren, Rhode Island at 21 Birch Swamp Road, Warren, RI. After completing further due diligence on the original municipal site with the Rhode Island Department of Environmental Management (RIDEM), we learned that the former municipal landfill site was never properly or formally closed by the Town of Warren. Given this fact, no expanded use of the site was allowed by RIDEM. We were approved by USDA/NIFA in March 2018 to change the location of the project to a 2 acre parcel at Chace Farm, less than 1/2 mile down the same road in Warren, at 68 Birch Swamp Road, Warren, RI. No project scope or budget changes were requested. The project has advanced and we are ready to move forward with field testing the unit. We will be monitoring operation of the blower and pile activity using loggers (temp, moisture, humidity), which will give us the ability to evaluate the efficacy of the aeration unit compared with a traditional windrow composting method. Based on anticipated results, we will be planning to close our SBIR Phase I and submit an SBIR Phase II proposal in 2020. What opportunities for training and professional development has the project provided?The project provided a semester-long opportunity for a Captone Team of 4undergraduate students in Mechanical and Industrial Engineering to make final adjustments and run air flow and stress test simulations of the aeration unit. In addition, The Compost Plant hosted anintern from URI's School of Mechanical and Industrial Engineering (Joe Zebleckas), who helped with site work andcalculated how CFM and blower requirements would need to be adjusted based on the potential for different sized processing bays. 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 have requested an additional no-cost extension on this project through April 30, 2020 will give us the opportunity to finally field test the unit at the Chace Farm site, with baseline comparison data against the windrow recipes/methods we have employed at the Buxton Hollow Farm site. We will be monitoring operation of the blower and pile activity using loggers (temp, moisture, humidity), which will give us the ability to evaluate the efficacy of the aeration unit compared with a traditional windrow composting method. Based on anticipated results, we will be planning to close our SBIR Phase I and submit an SBIR Phase II proposal in 2020. We anticipate hosting a number of information tours and field trips at Chace Farm to showcase the site: we are scheduled to host a Young Farmer Network night in late September to showcase our work, and will also be engagingnon-profit organizations, foundations, andelected officials in Newport and on Aquidneck Island interested in The Compost Plant's work and connectedto the Healthy Soils, Healthy Seas RI initiative to increase compost diversion and processingon Aquidneck Island and in Rhode Island.

    Impacts
    What was accomplished under these goals? Final adjustments to the conceptual design of the ASP system (called the Quadpod) were made in partnership with a URI Capstone Team from the School of Mechanical and Industrial Engineering between January and May 2018. During the end of that period, the full-scale aeration unit was constructed in PVC, and the blower was dry tested with the manifold at The Compost Plant's workshop in Providence. The 2 acre test site at Chace Farm was excavated of topsoil and graded with gravel, and two concrete bays (20' x 20' x 10') were constructed from 2' x 2'x 6' pre-formed concrete blocks. In June 2018, a conduit was trenched and connected to closest utility pole to provide power for the wireless unit and blower system. In the fall of 2018, we began engaging the Division of Agriculture and theOffice of Waste Management at the Rhode Island Department of Environmental Management to discuss permitting for the site given a tiered permitting system for compost facilities in the State.

    Publications