Progress 07/01/19 to 06/30/24
Outputs
Target Audience:This projecttargetedswine producers and crop growers in the state of North Carolina (NC) and states with similar swine production systems that rely on lagoons for manure treatment and storage. In addition, we targeted extension agents and technical service providers (manure haulers, consultants, etc.) and any personsassisting swine producers in planning and executing lagoon maintenance tasks including sludge removal and cleanout. Other audiences we engaged through the project report include: regulatory and producer assistance programs, i.e., NC Department of Environmental Quality (DEQ) and NC Department of Agriculture and Consumer Services (NCDA&CS), as well as swine integrators and entities responsible for making diet decisions for swine producers.The project activities engaged topic experts on manure management in other land-grant institutions and federal research centers (USDA NRCS and USDA ARS)in the southeastern region of the US, and across the country. Changes/Problems:The awarded project included a specific goal targeting the investigation of thermochemical conversion of sludge as a pathway of inquiry. However, in the course of executing earlier project steps we identified key challenges to this goal. The main barrier is the physical and chemical properties of sludge, as observed through the sampling and characterization steps. Sludge was found to contain high ash content (>40% on a dry-weight basis), as well as low calorific (energy) value, ranging from 9 to 11 MJ per kg dried sludge. This is equivalent to 55% of the energy density of wood. Combined with this observation is the high water content in the recovered sludge, typically between 92% to 80%, which require additional drying. Expending energy to dry the sludge, or otherwise resources to blend it with dry feedstocks such as wood shavings or grasses, will not contribute to the overall value of the blend and will add additional steps to the proposed management that reduce likelihood of economic adoption. Additionally, the presence of high ash content is associated with operational problems in thermochemical conversion reactors (pyrolyzers and gasifiers) due to the formation of glass-like residue that can interrupt feeding and operations. Due to these complications, the exploration of sludge conversion through thermochemical conversion was not further pursued. What opportunities for training and professional development has the project provided?A series of training events (classroom presentations and activities, field tours and demonstrations) were conducted throughout the life of the project to share knowledge and information gathered in the course of the project. Annual training events conducted in key swine production counties, i.e., Duplin, Sampson, Bladen, and Wayne between 2019 and 2023 featured annual project updates to report to the audience of technical specialists and producers findings from the project. Audiences for these training events range from 25 to 100 attendees, in addition to state-wide Zoom trainings recorded for producers unable to attend in person. Several demonstrations and field tours were conducted for technical specialists and extension agents to provide high technical detail information and collect questions and concerns regarding technology uptake and producer key needs. Webinar series, LPELC (https://lpelc.org/webinar-series/) was used as delivery mechanism to share findings and updates on the project with the broad audiences of the learning community to share discoveries and solicit insights/recommendations. How have the results been disseminated to communities of interest?As a result of the project activities and disseminationof our findings, the community of NC swine producers have accepted the use of non-conventional methods for sludge removal and land application, notably the excavation of sludge for further processing and sale. More than one entity in NC has developed the concept of sludge drying for distribution as a finished product, including Smithfield Foods and Phinite. These implementations have incorporated the concept of centralization to streamline the drying and remove the burden of oversight and management from the animal producers. Department of envionmental quality (DEQ) in NC started permitting the construction of sludge drying beds on-farm. The NC State General Assembly has approved a $4,000,000 program titled, "Livestock Waste Management: Innovative Fertilizer Production" that particularly lists "turning generated sludge in on-farm lagoons into fertilizer products, intermediaries, and soil additives". The lead PI on this project served as the subject matter expert (SME) in evaluating and scoring proposed technologies/projects. What do you plan to do during the next reporting period to accomplish the goals?
Nothing Reported
Impacts
What was accomplished under these goals?
Through the activities of this project, the following was accomplished: Variability of chemical and physical characteristcs of swine lagoon sludge across farms was captured through a sampling campaign. Through sampling and analyses conducted, a consistent profile of nutrients in the lagoons was discovered showing low volatile solids (VS) in the recovered solids, around 50% of the recovered solids. These findings highlight the effective operations of anaerobic lagoons in NC, particularly in reducing the biological oxygen demand (BOD) in the fresh manure through anaerobic microbial activities. Concentrations and ranges of nutrients were captured in factsheets developed and published by the research team. The effects of sludge removal method on composition of removed lagoon sludge was quantified Through a series of sampling and sludge removal activities that the project team has participated in, we captured data representing sludge properties as well as process parameters. Sludge removal through [1] slurrying and pumping, [2] vacuum removal, [3] dredging, and [4] excavation have been observed with data collected to capture rates, composition, and cost of the process. The team developed a techno-economic assessment (TEA) model to compare the most competitive techniques, i.e.,slurrying and pumping, andexcavation to showcase to compare these technologies. Evaluating composting as a viable sludge conversion technologies under different conditions and using different carbon-rich amendments Composting of lagoon sludge was investigated using various locally available carbon sources, including bermuda hay, poultry litter, and tree clearing waste. We studied the inclusion of different rates of sludge into composting to assess inclusion rate impacts on process performance and finished compost quality. Results point to a good quality compost product for both inclusion rates evaluated, 10% and 20% by weight. Fate and transformation of manure carbon (C) and nitrogen (N) was captured through the process and reported to facilitate conducting a LCA assessment of the process. The findings are documented in peer-reviewed project publication and the student dissertation. Characterizing products from lagoon sludge conversion and screening potential In this task, we compare the chemical and physical properties of slurried sludge to composted sludge as well as dried sludge to evaluate cost of transport, application, and recommended rates to avoid overapplication of nutrients. Compare different sludge removal and utilization strategies (pathways) from technical, environmental and economic perspectives. A life-cycle assessment (LCA) and technoeconomic assessment (TEA) of different sludge utilization pathways were compared. The analysis showed the management of sludge as slurry to be the most economic approach where cropping acreage are readily available to producers (within 1 mile from the farm). In situations where acreages are not readily accessible and require a transportation of few miles, alternative sludge management approaches become more economically attractive, particularly sludge excavation. In scenarios reflective of NC context, the excavation and drying of sludge proved to be the most economic for managing sludge nutrients. Thermochemical conversion of sludge and sludge-based products proved to be a challenging and an non-ideal practice. This is primarily due toits high ash content (>40% on a dry-weight basis), limited energy content in the sludge (11 MJ/kg dried sludge), and the energy required to dry the sludge to acceptable conversion levels, often exceeding the sludge energy content.
Publications
- Type:
Theses/Dissertations
Status:
Published
Year Published:
2023
Citation:
Patil, P. S. (2023). Evaluation of Valorization Pathways for Swine Lagoon Sludge Management. North Carolina State University.
- Type:
Peer Reviewed Journal Articles
Status:
Published
Year Published:
2023
Citation:
Patil, P., Sharara, M., Shah, S., Kulesza, S., & Classen, J. (2023). Impacts of utilizing swine lagoon sludge as a composting ingredient. Journal of Environmental Management, 327, 116840.
- Type:
Peer Reviewed Journal Articles
Status:
Published
Year Published:
2025
Citation:
Simulation Model For Swine Lagoon Sludge Drying in Solar-assisted Greenhouse Systems. Environmental Technology & Innovation, 104057.
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Progress 07/01/22 to 06/30/23
Outputs
Target Audience:This project targeted swine producers and crop growers in the state of North Carolina (NC) and states with similar swine production systems that rely on lagoons for manure treatment and storage. In addition, we targeted extension agents and technical service providers (manure haulers, consultants, etc.) and any persons assisting swine producers in planning and executing lagoon maintenance tasks including sludge removal and cleanout. Other audiences we engaged through the project report include: regulatory and producer assistance programs, i.e., NC Department of Environmental Quality (DEQ) and NC Department of Agriculture and Consumer Services (NCDA&CS), as well as swine integrators and entities responsible for making diet decisions for swine producers. The project activities engaged topic experts on manure management in other land-grant institutions and federal research centers (USDA NRCS and USDA ARS) in the southeastern region of the US, and across the country. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?• Annual training events conducted in key swine production counties, i.e., Duplin, Sampson, Bladen, and Wayne in 2021, 2022, and 2023featured annual project updates to report to the audience of technical specialists and producers findings from the project. Audiences for these training events range from 25 to 100 attendees, in addition to state-wide Zoom trainings recorded for producers unable to attend in person. • Demonstrationsand field tours were conducted for technical specialists and extension agents to provide high technical detail information and collect questions and concerns regarding technology uptake and producer key needs. How have the results been disseminated to communities of interest?• Annual training eventsconducted in key swine production counties, i.e., Duplin, Sampson, Bladen, and Wayne in 2021, 2022, and 2023featured annual project updates to report to the audience of technical specialists and producers findings from the project. Audiences for these training events range from 25 to 100 attendees, in addition to state-wide Zoom trainings recorded for producers unable to attend in person. • Demonstrationsand field tourswere conducted for technical specialists and extension agents to provide high technical detail information and collect questions and concerns regarding technology uptake and producer key needs. What do you plan to do during the next reporting period to accomplish the goals?The following goals are targetted for the coming reporting period 7. Characterizing products from lagoon sludge conversion and screening potential utilization routes according to products physical, chemical and agronomic properties. 8. Compare different sludge removal and utilization strategies (pathways) from technical, environmental and economic perspectives. ?
Impacts
What was accomplished under these goals?
• Evaluating composting as a viable sludge conversion technologies under different conditions and using different carbon-rich amendments o Composting of lagoon sludge was investigated using various locally available carbon sources, including bermuda hay, poultry litter, and tree clearing waste. We studied the inclusion of different rates of sludge into composting to assess inclusion rate impacts on process performance and finished compost quality. Results point to a good quality compost product for both inclusion rates evaluated, 10% and 20% by weight. Fate and transformation of manure carbon (C) and nitrogen (N) was captured through the process and reported to facilitate conducting a LCA assessment of the process. The findings are documented in peer-reviewed project publication and the student dissertation. • Characterizing products from lagoon sludge conversion and screening potential o In this task, we compare the chemical and physical properties of slurried sludge to composted sludge as well as dried sludge to evaluate cost of transport, application, and recommended rates to avoid overapplication of nutrients. ?
Publications
- Type:
Peer Reviewed Journal Articles
Status:
Published
Year Published:
2022
Citation:
Patil, P. S., & Sharara, M. A. (2022). Impacts of sonication on biomethane potential (BMP) and degradation kinetics of pig lagoon sludge. Biosystems Engineering, 223, 129-137.
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Progress 07/01/21 to 06/30/22
Outputs
Target Audience:During this reporting period, our project activities targeted (1) extension agents and staff with responsibilities involving animal manure management on-farm, (2) technical consultants and 3rd party service providers who assist NC swine producers in developing nutrient management plans and schedule lagoon operations, (3) Technical staff affiliated with swine integrators in NC (e.g., Smithfield Foods, Prestage) supporting company farms, and (4) NRCS state-level conservation teams working to assist swine producers in managing and closing swine lagoons. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided? A research presentation was delivered at the international meeting for the American Society of Agricultural and Biological Engineers (ASABE) in 2022 (Houston, Texas). The presentation highlighted project findings and collected feedback regarding scaling up of the process andutilization avenues for end-product (compost). How have the results been disseminated to communities of interest? Routineannual training events for operators in charge (OIC) responsible for managing swine farms in NC are held in various counties. These events were leveraged for training opportunities to provide producers with data and information regarding the opportunity to use composting to manage lagoon sludge. Data regarding recipe, feedstock properties, temperatures and product yield were shared. What do you plan to do during the next reporting period to accomplish the goals?In the nextreporting period, we will evaluate the gasification process performance for dewatered lagoon sludge solids, and conduct a technoeconomic and life cycle assessment study to compare conventional sludge management strategy (agitation and hauling to fields) with alternative management approaches, including: Excavation of lagoon sludge solids to move high-solid product for land application, Composting of lagoon sludge solids to create a stable, nutrient-balanced product, Drying lagoon sludge solids to create a nutrient-dense product for land application, and Gasification of lagoon sludge solids to condense manure nutrients.
Impacts
What was accomplished under these goals?
This goal will be addressed through pursuing the following objectives: 1. Quantify the effects of swine farm type, lagoon age, and size on the variability of chemical and physical composition of swine lagoon sludge. 2. Quantify the effects of sludge removal method on composition of removed lagoon sludge. 3. Compare passive and active sludge dewatering methods from technical and economic perspectives. 6. Evaluating composting as a viable sludge conversion technologies under different conditions and using different carbon-rich amendments. 7. Characterizing products from lagoon sludge conversion and screening potential utilization routes according to products physical, chemical and agronomic properties.
Publications
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2022
Citation:
Patil, P. S., & Sharara, M. A. (2022). Impacts of Swine Lagoon Sludge Inclusion rate on the Composting Process and Compost Quality. In 2022 ASABE Annual International Meeting (p. 1). American Society of Agricultural and Biological Engineers.
- Type:
Journal Articles
Status:
Accepted
Year Published:
2022
Citation:
Patil, P. S., & Sharara, M. A. (2022). Impacts of sonication on biomethane potential (BMP) and degradation kinetics of pig lagoon sludge. Biosystems Engineering, 223, 129-137.
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Progress 07/01/20 to 06/30/21
Outputs
Target Audience:During this reporting period, our project activities targeted (1) extension agents and staff working to support producers and consultants, (2) technical consultants and 3rd party service providers who help NC swine producers develop nutrient management plans and schedule lagoon operations, (3) Technical staff affiliated with swine integrators in NC (Smithfield Foods, Prestage) supporting company farms (4) NRCS (National Manure team) and state-level conservation team working to assist swine producers in managing and closing swine lagoons. Changes/Problems:COVID-19 delays caused signficant delays to project milestones due to disrupted lab operations and inability to carry out research activities during long periods in adherence with University, state, and county guidances. These delays require an extension to the project duration to accomplish committed tasks. What opportunities for training and professional development has the project provided?A series of state training events were conducted as part of existing credit hour requirement for operators in-charge (OIC), as well as dedicated events for technical specialists, Eastern North Carolina Technical Assistant Group (ENCTAG), to demonstrate researchedtechnologies and findings. These training events were held quarterly to showcasedata collection, demonstrations of sludge removal/decanting technologies along with sludge composting. In addition, tours to a commercial facility already carrying out sludge composting was coordinated to increase technology awareness to identify key reserach needs by such facilities. How have the results been disseminated to communities of interest?Findings have been dessiminated through training and seminars to stakeholders, as well as posts on web portal to communicate these activities to non-scientific audiences working in this space. What do you plan to do during the next reporting period to accomplish the goals?During the following reporting period, we are planning to: Complete sludge composting trials and report yields, compost quality, as well as GHG emissions associated with the process, Evaluate thermochemical conversion of sludge on commercial-scale gasifier to report yields, product qualities, and net energy ratio (NER). Compare different sludge removal and utilization strategies (pathways) from technical, environmental and economic perspectives.
Impacts
What was accomplished under these goals?
The following objectives have been accomplished: 1. Quantification ofeffects of swine farm type, lagoon age, and size on the variability of chemical and physical composition of swine lagoon sludge. 2. Quantification of effects of sludge removal method on composition of removed lagoon sludge. 3. Evaluating passive and active sludge dewatering methods from technical and economic perspectives. 4. Evaluate the viability of thermochemical conversionas a sludge mineral and metal concentration method.
Publications
- Type:
Journal Articles
Status:
Published
Year Published:
2020
Citation:
Owusu-Twum, M. Y., & Sharara, M. A. (2020). Sludge management in anaerobic swine lagoons: A review. Journal of Environmental Management, 271, 110949.
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2020
Citation:
Patil, P. S., & Sharara, M. A. (2020). Evaluating anaerobic digestion kinetics for swine manure using BMP assay tests. In 2020 ASABE Annual International Virtual Meeting (p. 1). American Society of Agricultural and Biological Engineers.
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2021
Citation:
Patil, P. S., & Sharara, M. A. (2021). Investigation of the Impact of Sonication on organic matter solubilization and Biomethane potential (BMP) of swine lagoon sludge. In 2021 ASABE Annual International Virtual Meeting (p. 1). American Society of Agricultural and Biological Engineers.
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Progress 07/01/19 to 06/30/20
Outputs
Target Audience:Our sludge-focusedproject is currently in data collection stage (sampling) andearly outreach phase. The project activities, progress and activities have been shared through various outreach events. We made contact with the following following stakeholder groups: (a) extension agents and specialist with livestock production duities assisting producers across N.C., (b) extension agents and specialists with no-livestock production duities who are primarily focused on crop and pasture prodction, (c) Individual producers and contract growers who licensed to operate and run livestock facilities (d) consultants and advisors used by producers for sludge-related survices, including dredging, hauling and land-application (e) Integrators and production supervisors who oversee a large number of swine operations and are responsible for scheduling lagoon maintenance and sludge removal. (f) Technology developers and supporting-industry participants attending training and selling additives and products to help producers improve waste management systems. Changes/Problems:Disruption due to COVID-19 closures has significantly slowed down field and sampling activities which pushed our time-line back. Sludge drying is a critical/under-studied aspect of swine manure management, particularly in nutrient-dense and humid regions such as North Carolina. Accordingly, the research scope of this project will benefit greatly from including an assessment of the drying process and its potential to facilitatetransport and processing of sludge, beyond gasificaiton and composting, towards organo-mineral fertilizer/soil conditioner products. What opportunities for training and professional development has the project provided??[a] Four (4) training sessions, each 1 hour plus Q&A after the event, on sludge management topics were conducted: Two (2) were part of N.C. Pork Council Conferences ((1) Northeast N.C. Annual Meeting, and (2) N.C. State-wide Annual Meeting), while the other Two (2) were part of N.C. Annual Extension Conference and regular training sessions. [b] A workshop/field-day (3-hours) was conducted in Raleigh, N.C. (November 2019) to specialists on sludge drying technology challenges and opportunities. How have the results been disseminated to communities of interest?The results have been shared through in-person training meetings with extension ain key production counties: Sampson Co, and Duplin Co. The findings are currently being compiled into peer-reviewed factsheets and manuscripts to dissemenate results as they arebeing generated. What do you plan to do during the next reporting period to accomplish the goals?Complete sampling activities Conduct composting and gasificaiton testing activities Post results and media content to online portal and publicize it in training/outreach activities
Impacts
What was accomplished under these goals?
Goals (1) is almostcompleted after most of the lagoon sampling has been carried out with preliminary data analysis is underway. Four types of swine oeprations (Grow-Finish, Farrow-wean, Nursery, and Sow) will be sampled and compared. Goal (2) is being accomplished by comparing records of removed sludge and method of removal, against our first-hand sampling data to assess impacts of removal on composition of removed sludge.
Publications
- Type:
Conference Papers and Presentations
Status:
Submitted
Year Published:
2019
Citation:
Sharara, M. 2019. Challenges and Opportunities in Swine Lagoon Sludge Management. (Presentation). 2019 Annual International Meeting (AIM) of the American Society of Agricultural and Biological Engineers. July 7-10, 2019, Boston, MA.
- Type:
Other
Status:
Awaiting Publication
Year Published:
2020
Citation:
Sharara, M., Owusu-tuwum, M., Sludge Sampling in Anaerobic Treatment Swine Lagoons,(Number pending), NC Extension Publication Factsheet.
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