next generation technology swine waste-to-energy project
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Next Generation Technology Swine Waste-to-Energy Project
Renewable Energy Generation and GHG Emission Reductions via Innovative Waste Management
Presented To:BioEnergy Symposium
2013 Anaerobic TechnologiesApril 9, 2013
Presented By: William G. “Gus” Simmons, Jr., P.E.
Cavanaugh & Associates, P.A.
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Why is NC Looking at Alternative Energy / Fuels from Ag Waste???
• NC Ranks 2nd in the US in pigs produced, with 15% of the US pig crop (IA)
• NC Ranks 2nd in the US in turkeys produced, with 13% of the US turkey crop (MN)
• NC Ranks 4th in the US in broilers produced, with 9% of the US broiler crop (GA)
• NC Ranks 10th in the US in residential electricity consumption, per capita
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North Carolina Swine Energy Potential
Data provided by Duke University Carbon Offsets Initiative
Asheville
Triad Raleigh/RTP
Charlotte Wilmington
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How to turn pig waste into electrons?
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Case Study:Digester Systems for Animal Waste Solids –
Loyd Ray Farms Project
GHG Emission Reductions and Renewable Energy Generation via Innovative Waste Management
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Step 1: Establish the TargetProject Goals: (2006) • Make it “Market Feasible” – farm owners perspective• Energy Generation + Water Quality Improvement + Air
Emissions Improvement• Make it flexible - different farm sizes & types• Process based, not technology based• Innovative waste management : Achieve
environmental performance standards as described by NC legislation– Substantial elimination of odor, ammonia, total nitrogen,
and pathogens
BioEnergy Digesters in North Carolina
Commercial-Scale Demonstration Project:Loyd Ray Farms Swine Waste-to-Energy ProjectConverts waste from 9,000 pigs into electricityImproved Environmental Management
Raw
Was
teMixed Digester
Biog
as Liqu
ids
Treated Water
How it Works
Existing StorageLagoon
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How it Works:~65% CH4
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Photos by: Marc Deshusses, Duke University, 2011
What it looks like… After Construction
What it looks like… Steady State
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Covered Anaerobic Digester
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Aeration System
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Gas Conditioning System & Microturbine
Microturbine Specifications:•65 kilowatt Generative Capacity•First Scheduled Service @ 8,000 Hrs•Only one moving part @ >90,000 RPM•Air bearings – no lubricant or coolant required
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Expected Outcomes:5,000± Carbon Offsets per Year, registered with Climate
Action Reserve Duke University & Google: Retire to meet carbon
neutrality goal, retire for immediate internal demand, and/or sell when strong market signal arises
500± Renewable Energy Credits per Year Utility: Motivated by NC Renewable Energy and Energy
Efficiency Portfolio Standard Swine Waste Set AsideElectricity Generation
Farm: Energy to offset increased demand from innovative system and offset baseline electricity demand (projected to offset up to half of farm’s existing electricity demand)
Compliance with Environmental Performance Standards for New & Expanded Swine Farms (ammonia, nutrients, pathogens, odors, metals and zero discharge of waste to surface and groundwater); Ensures compliance with offset standard to meet all air and water quality standards by controlling nutrient loads
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RESULTS
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6/1/
2011
5:1
56/
4/20
11 1
7:15
6/8/
2011
5:1
56/
11/2
011
17:1
56/
15/2
011
5:15
6/18
/201
1 17
:15
6/22
/201
1 5:
156/
25/2
011
17:1
56/
29/2
011
5:15
7/2/
2011
17:
157/
6/20
11 5
:15
7/9/
2011
17:
157/
13/2
011
5:15
7/16
/201
1 17
:15
7/20
/201
1 5:
157/
23/2
011
17:1
57/
27/2
011
5:15
7/30
/201
1 17
:15
8/3/
2011
5:3
08/
6/20
11 1
7:30
8/10
/201
1 5:
308/
13/2
011
17:3
08/
17/2
011
5:30
8/20
/201
1 17
:30
8/24
/201
1 5:
308/
27/2
011
17:3
08/
31/2
011
5:30
9/3/
2011
17:
459/
7/20
11 5
:45
9/10
/201
1 17
:45
9/14
/201
1 5:
459/
17/2
011
17:4
59/
21/2
011
5:45
9/24
/201
1 17
:45
9/28
/201
1 5:
4510
/1/2
011
17:4
510
/5/2
011
5:45
10/8
/201
1 17
:45
10/1
2/20
11 5
:45
10/1
5/20
11 1
7:45
10/1
9/20
11 5
:45
10/2
2/20
11 1
7:45
10/2
6/20
11 5
:45
10/2
9/20
11 1
7:45
11/2
/201
1 6:
0011
/5/2
011
18:0
011
/9/2
011
6:00
11/1
2/20
11 1
8:00
11/1
6/20
11 6
:00
11/1
9/20
11 1
8:00
11/2
3/20
11 6
:00
11/2
6/20
11 1
8:00
11/3
0/20
11 6
:00
12/3
/201
1 18
:00
12/7
/201
1 6:
0012
/10/
2011
18:
0012
/14/
2011
6:0
012
/17/
2011
18:
0012
/21/
2011
6:0
012
/24/
2011
18:
0012
/28/
2011
6:0
012
/31/
2011
18:
00
0
10
20
30
40
50
60
70
Electricity Production Rate - 2011Po
wer
(kW
)
Condensate flooded compressor,
required rebuild
Controls system issues, supplier
‘tweaks’
Condensate pump issues
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1/1/
2012
7:0
01/
6/20
12 9
:00
1/11
/201
2 11
:00
1/16
/201
2 13
:00
1/21
/201
2 15
:00
1/26
/201
2 17
:00
1/31
/201
2 19
:00
2/5/
2012
21:
002/
10/2
012
23:0
02/
16/2
012
1:00
2/21
/201
2 3:
002/
26/2
012
5:00
3/2/
2012
7:1
53/
7/20
12 9
:15
3/12
/201
2 11
:15
3/17
/201
2 13
:15
3/22
/201
2 15
:15
3/27
/201
2 17
:15
4/1/
2012
19:
304/
6/20
12 2
1:30
4/11
/201
2 23
:30
4/17
/201
2 1:
304/
22/2
012
3:30
4/27
/201
2 5:
305/
2/20
12 7
:45
5/7/
2012
9:4
55/
12/2
012
11:4
55/
17/2
012
13:4
55/
22/2
012
15:4
55/
27/2
012
17:4
56/
1/20
12 1
9:45
6/6/
2012
21:
456/
11/2
012
23:4
56/
17/2
012
1:45
6/22
/201
2 3:
456/
27/2
012
5:45
7/2/
2012
7:4
57/
7/20
12 9
:45
7/12
/201
2 11
:45
7/17
/201
2 13
:45
7/22
/201
2 15
:45
7/27
/201
2 17
:45
8/1/
2012
20:
008/
6/20
12 2
2:00
8/12
/201
2 0:
008/
17/2
012
2:00
8/22
/201
2 4:
008/
27/2
012
6:00
0
10
20
30
40
50
60
70
Electricity Production Rate - 2012Po
wer
(kW
)
Compressor cooler failure, controls
Manual Operation Only – Gas Skid Replacement
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ScorecardParameter Goal Actual Success Gauge
RECs learned that we have more potential
500 344 69%
Carbon Offsets deductions due to venting, metering
5,000 Tons 2,500 Tons 50%
Environmental Performance - Surface Water Protection
Substantial Elimination Accomplished by Permit
Passed
Environmental Performance - Ground Water Protection
Substantial Elimination Accomplished by Permit
Passed
Environmental Performance - Odor Emissions
>7:1 D/T 2:1 D/T Passed
Environmental Performance - Ammonia Emissions
WWTP =Farm =
106 kg/wk476 kg/wk
23 kg/wk341 kg/wk
460% (Passed)140% (Passed)
Environmental Performance - Vector Reduction
<7,000 mpn/100mL <5,000 mpn/100mL
140%(Passed)
Costs and BenefitsCosts• Capital: $1.7M • O&M: $80,000/year
Funding sources• NCACSP LCP• CCPI/EQIP• Sale of RECs to Utility• Sale of Carbon Offsets
(voluntary market)
Benefits• Cash flow for farm owner• Improved animal health• Other ecosystem services (N, P
control)• Variability in nitrogen output for
fertilizer• Reduced sludge management
cost• Improved air quality on-site• Reduction of odors off site• More choice in cropping plan• Sustaining NC Agriculture• Reduced GHG Emissions
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A couple of firsts…• First Swine Waste-to-energy project in the State
of North Carolina to place RECs on the North Carolina Utilities Commission REC Tracking System
• First Transfer of RECs from a NC Swine Farm to Duke Energy
• First ‘Innovative Swine Waste Treatment System’ permitted that utilizes digester
• First Expansion Permit Since 1997???
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Ongoing Research & Analysis:• Digester Performance – DU is conducting continuous
research of digester biogas composition, loading rates, and carbon destruction efficiency (monthly)
• Environmental System Performance – Water quality analysis by DU and Private Labs (monthly / quarterly)
• Emissions – DU performing flux analysis of ammonia and odor emissions (twice annually)
• Animal Productivity – Mortality rates, feed conversion rates, days to market, etc.
• Economic Performance – DU / DE / Cavanaugh
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Challenges & Lessons Learned:• Gas Skid Challenges – Gas skid has suffered from
multiple outages, which prevents REC generation. Numerous issues with gas skid controls system and condensate removal.
• Abundance of Gas – Very conservative on gas production expectations – have not been able to utilize all gas produced.
• Electrical Load Balancing – Environmental system operating at full capacity requires more electricity (demand) than MT produces. Adjusted operational schedule to resolve.
• CAR Protocol Requirements – Adding additional gas flow meters, thermocouples on flare, etc.
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Special Thanks
Mr. Loyd Bryant, Loyd Ray FarmsLNH Farms
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