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© 2013 Regents of the University of Minnesota. All rights reserved.
Energy Efficient Tech and FUNDINGfor Swine and Poultry
Fritz Ebinger
Rural Energy Development Program Manager
(612) 626-1028 [email protected]
© 2013 Regents of the University of Minnesota. All rights reserved.
OVERVIEW1. ABOUT EXTENSION, RSDP & CERTS
2. FUNDING
3. POULTRY TECHLIGHTING & BIOMASS
4. SWINE TECHFANS, CREEP MATS, LAMPS
CERTs
EXTENSION
RSDP
UNIVERSITY OFMINNESOTA
© 2013 Regents of the University of Minnesota. All rights reserved.
EXTENSION TRIVIA
• MN started Extension in 1909 before the rest of the country
• Smith-Lever Act of 1914: Established cooperative extension services with land-
grant universities to inform folks about:• New ag techniques• Home economics• Leadership• 4-H • Econ development
© 2013 Regents of the University of Minnesota. All rights reserved.
© 2013 Regents of the University of Minnesota. All rights reserved.
© 2013 Regents of the University of Minnesota. All rights reserved.
ABOUT RSDP• 1997 Regional Sustainable Development
Partnerships
• Connects Greater Minnesota solutions to UMN in order to replicate and scale up
• Leverages local ideas and talent along with UMN resources in four focus areas:
• Agriculture and food systems• Tourism and resilient communities• Natural resources• Clean energy
© 2013 Regents of the University of Minnesota. All rights reserved.
RSDP – flips the Extension Education Model:
• UMN learns from communities and practitioners…then optimizes
© 2013 Regents of the University of Minnesota. All rights reserved.
ABOUT RSDP – A Local Laboratory
Mission: We connect individuals and their communities to the resources they need to identify and implement
community-based clean energy projects
CERTs: Minnesotans Building a Clean Energy Future
Statewide Partnership & Collaboration
Provide seed grant funding and more
Deliver research-based campaigns
Spur other statewide programs
What Does CERTs Do?
Host events, tours, and conferences
Help with community organizing
Connect people to technical resources
Write blog posts & case studies
Create educational guides
Manage diverse web-based tools
CERTified Campaigns
The Efficiency ParadoxIncreased energy efficiency tends to increase energy consumption by two means:
First, increased energy efficiency makes the use of energy relatively cheaper, thus encouraging increased use (the direct rebound effect).
Second, increased energy efficiency leads to increased economic growth, which pulls up energy use for the whole economy.
W. S. Jevons
Khazzom-Brookes Postulate
Rebound Effect
The Efficiency ParadoxAs the cost of energy use decreases with efficiency gains, the consumption of energy increases.
PROJECT BARRIERS
Market Conditions
Farm Business Exit
No time
Not a priority
Number 1
FUNDING OPTIONSUtility CIP Rebates
Minn. Livestock Investment Grant Program
USDA Rural Energy for America Program (REAP) Grant
Property Assessed Clean Energy (PACE)
Compatibility: Use with any other funding source.
Eligibility: Member-owner of the cooperative or utility.
Funding Amount: Varies by utility. A formula provides the
dollar amount per kW or kWh saved. Ranges from 10% to
40% of the project depending on the utility and its priorities.
Project Timing: Discuss funding amount with utility before
starting project. Receive payment within a few weeks after
completing the project and submitting CIP paperwork to
utility.
Competitiveness: No competition. Easy application process.
Electric Utility CIP Rebates
Eligibility: Raise livestock in Minnesota (25% of gross income from agriculture); aim to improve livestock production
Grant: 10% of project cost. Minimum investment of $4,000
Projects Types: Any improvements, primarily energy efficiency, herd expansion, new parlor, new vent fans…
Application Window: Mid-September. Closes mid-December.
Project Timing: Wait for the letter – notice by early Feb.Start project after funding is awarded.
Competition: Low to moderate. 50-60% are successful and application is easy.
Minn.Livestock InvestmentGrant Program
Eligibility: Farmer anywhere with at least 50% of farm income from ag production, or rural small business (pop. < 50,000)
Grant: 25% of project cost. Minimum request of $1,500 for efficiency
Guaranteed Loan: backing up to 75% of project costs.
Projects Timing: Start project after application is submitted.
Deadlines: March 31 (all projects) and October 31 (small projects)
Competition: Steep. Only 25-30% are successful nowadays.
USDA REAP
Eligibility: Legal owner of property. Must be current on mortgages. No liens. Located in a jurisdiction with PACE.
Loan Funding Amount: Loan cannot exceed 20% of
property value. Loan term up to 15 years.
Loan terms <10 years usually under 5% APR.
Project Timing: Apps accepted continuously.
Prep takes a month- start after loan terms set.
LGU assessment request is in the loan terms.
Level of Effort: Quick and easy. No competition.
Pre-Reqs: Energy audit by an energy auditor
must be completed prior to submitting application.
Reporting : No – just pay your property tax bill!
PACE: Property Assessed Clean Energy
• #1 Turkey Producer in US
• 46 mil turkeys yearly
• 250 farmers, 600 farms
• #12 for chicken and eggs
• 47 mil broiler chickens
• 300 farms
Minnesota Poultry
Distribution and Density of Turkey Production
Average 13 hours lighting each day (range of 5 to 24 hours depending on season and barn
Brooder barn = heavy lighting because of enclosed environments, ≈ 40,000+ poults
HPS: Light efficient, not energy efficient
CFLs: Some hesitant to install
LEDs: Viable alternative, high upfront cost…but coming down
Finisher barns – side curtains, 20,000+ turkeys each, 2 barns usually
Minnesota Turkey
Conservation Applied Research & Development (CARD) Grant
April 2011 – December 2013
12 farmers , 23 barns
ONCE Innovations
AgriShift 12W
Studied Poultry LEDs for:
Potential energy savings
Cost-effectiveness
Practical performance
CARD Grant Study
Turkey Barn Lighting
Bulb Type Key Attributes
High Pressure Sodium (HPS)
• Orange/red spectrum
• Each bulb provides a lot of light
Incandescent
• Dimmable
• High burn out rate
• Phasing out
CFL
• Poor dimmability
• Fail early in jelly jars
• Mercury concerns
LED
• Dimmable
• Directional
• High installation cost
150W250W
40W ballast
60W75W
100W
13W23W26W 12W
Bird’s Eye View
Poultry see more of the visible light spectrum than humans
LEDs more closely match poultry’s spectral response curve
LEDs might appear as 500 lumens to humans / 800 lumens to poultry
Turkey Barn Lighting (Cont’d)
Bulbs Life (hours)
Life (years)
Lumens/Watt
Power Consumption
(watts)
BulbCost
(each)
HPS 24,000 5.6 100 150 + 40 (ballast) = 190 $14
Incandescent 1,000 0.23 15 100 $0.75
CFL 10,000 2.3 70 23 $3
LED 50,000 11.6 100 12 $35
Annual Lighting Runtime: 2,000 – 7,500 hours per year, 4,300 hours on average
Maintenance costs reduced when switching to more efficient lighting
Study Results:
Energy Savings
Switch to LEDs from…
Number of Barns
Range of Energy
Savings (%)
Average Energy
Savings (%)
Average Energy Savings (kWh/yr)
HPS 4 76% - 79% 78% 32,500
HPS/Incan. 4 NA 77% 10,300
Incandescent 6 84% - 88% 86% 15,300
CFL 4 8% - 48% 34% 1,900
Switching from incandescent and HPS bulbs result in greatest savings
Study Results:
Cost-Effectiveness
LED bulb costs continue to decline
Upgrade from CFL to LED is not cost effective
Switch to LEDs from…
No. of Barns
Total LED Installation
Cost ($)
Range of Energy
Savings ($)
Range of Simple
Payback (yrs)
HPS 4 $9,200-12,200 $1,500 - $5,900 1.6 - 8.3
HPS/Incan. 4 $4,700 $1,100 4.2
Incandescent 6 $2,100-3,100 $1,300 - $3,000 1.0 - 2.1
CFL 4 $3,200-15,800 $150 - $260 14 - 92
Different LEDs for Different Barns
Corncob LEDs: 120 W with 16,800 lumens (275 W replacement) $160
54 W E39 Base 5600 lumens (250 W equivalent, $87
LED tube lighting (connect together like a chain) 25 W (T-12 equivalent) $26
Reduce lighting costs by $1,000s each year
Save up to 85% on lighting energy
Pay for project with energy cost savings as soon as 1 year(3 yrs without utility rebates)
Reduce maintenance time/cost
Use poultry-specific lighting
Dimming, color, intensity
Why Upgrade to LEDs?
© 2013 Regents of the University of Minnesota. All rights reserved.
Minnesota Swine• #3 in production behind IA and SC• 3,300 hog farms statewide
• Top Counties – 2012 Ag Census• Martin (#6), Blue Earth (#16), Mower (#36),
Freeborn (#37), Nobles (#38)
© 2013 Regents of the University of Minnesota. All rights reserved.
Minnesota Swine Priorities1. Biosecurity2. See 1 above3. Biosecurity protocols4. Biosecurity5. Re-visitation of 3 above6. Biosecurity7. Veterinary costs/antibiotics8. Antibiotic regulations9. Feed costs10. Energy costs
© 2013 Regents of the University of Minnesota. All rights reserved.
Hog Barns!Farrowing Barn• Sows and piglets • Nursing pigs ≈ 20 lbs or
less, 0-2 weeks old• Piglets need ≈ 95 degrees!
Nursery/Grower Barn• Weaned pigs• 3 – 8 weeks old• Ballpark 30 – 80 lbs
© 2013 Regents of the University of Minnesota. All rights reserved.
Hog Barns!Grower Barn• Weaned pigs• 8-12 weeks old• Ballpark 80-150 lbs• High ventilation
Finisher Barn• Big pigs 150 – 250 lbs• 12-16 weeks old• High ventilation
Note – barns are not categorical• Farrow to finish• Wean to finish• Farrow to wean, etc.
© 2013 Regents of the University of Minnesota. All rights reserved.
FARROWING BARNS
• New piglets need 85-95 degrees
• Sows need 60 degrees• Creates an energy
zoning mess• Heat lamps ≈ 45% of
kWh consumption
60° 95°
© 2013 Regents of the University of Minnesota. All rights reserved.
Farrowing: Microclimates are necessary• Basic: Check the heat lamp wattage• 250 W heat lamps are too hot• 175 W heat lamps (and less) are better, save 360 kWh/crate/year• Faster piglet weight gain under cooler lamps
250 W 175 W
“Conserving Energy by Using Localized Heating in Swine Housing, “ Jay Harmon, professor, ag and biosystemsengineering; Hongwei Xin, professor, ag and biosystems engineering; and Dana Petersen, program coordinator, ISU Farm Energy Initiative; Iowa State University Extension and Outreach. Sponsored by the Iowa Energy Center.
© 2013 Regents of the University of Minnesota. All rights reserved.
HEATED CREEP MATS vs. HEAT LAMPS
• 200 W pad for 30-35 degrees above room temp• 2x4 mats
• Stanfield 200 W -- $190• Kane 170 W -- $174
© 2013 Regents of the University of Minnesota. All rights reserved.
HEATED CREEP MATS vs. HEAT LAMPSStinn, John P. and Xin, Hongwei (2014) "Heat Lamp vs. Heat Mat as Localized Heat Source in Swine Farrowing Crate," Animal Industry Report: AS 660, ASL R2931
• 2014 side-by-side comparison
• Three 40 crate rooms
• Half with 125 W heat lamps
• Other half with 290 W creep mats
© 2013 Regents of the University of Minnesota. All rights reserved.
HEATED CREEP MATS vs. HEAT LAMPS
Average Weight Gain? NO DIFFERENCE
Percent Mortality Rate?NO DIFFERENCE
kWh Consumption?36% kWh SAVINGS with heated mats
© 2013 Regents of the University of Minnesota. All rights reserved.
Controlled Creep Mats AND Heat Lamps
Best of both efficiency worlds?
• Sensors automatically adjust heat lamp and creep mat power supply according to room temp and age of piglets
• Power modulator operates 1 20-amp circuit
• Controller manages up to 12 power modulators
3rd Party study would be nice, but sources say this works very well
but for piglets
© 2013 Regents of the University of Minnesota. All rights reserved.
FINISHER BARNSDeep-pit, side curtain
Photos Courtesy of New Modern Concepts – Iowa Falls, IA
© 2013 Regents of the University of Minnesota. All rights reserved.
Deep Pit Finisher BarnsPit Fans – research says turn them OFF
• (Wrong) idea is that pit fans pull fresh air down and then out to keep barn air clear
• Reality: barn floor is too porous; does not have sufficient static pressure
• Pit fans actually do nothing to decrease barn NH3 and N2S emissions
Jacobson, L.D., B.Pl. Hetchler and D.R. Schmidt. 2008. Reducing H2S, NH3, PM, and odor emissions from deep-pit pig finishing facilities by managing pit ventilation.In: Mitigating Air Emissions from Animal Feeding Operations, Technology Summaries of the 19-21 May 2008 Conference (Des Moines, IA). p. 26.Iowa State University, Ames, IA.
© 2013 Regents of the University of Minnesota. All rights reserved.
FINISHER BARNSTunnel ventilated – becoming more common for biosecurity
© 2013 Regents of the University of Minnesota. All rights reserved.
FINISHER BARNSFAN BASICS – BEHAVIOR CHANGE!
• Keep them clean: Dirty fans waste up to 40%• Keep them lubed with graphite dust: higher
temp tolerance, reduces dust intrusion• Keep them tight: Bad or loose belts waste up
to 30% energy
© 2013 Regents of the University of Minnesota. All rights reserved.
ENERGY EFFICIENT FANS• For small fans (≤ 24 in), fans should have an
efficiency of 12 cfm/watt or higher at 0.10 in static pressure
• For moderate sized fans (36”-48”), fans should have an efficiency of 17 cfm/watt or higher
• VSDs and VSD Controllers
• BESS Labs for CFM/Watt andperformance: bess.Illinois.edu
© 2013 Regents of the University of Minnesota. All rights reserved.
HOLD THE DATE
Midwest Farm Energy ConferenceJune 13-14, 2017
West Central Research & Outreach CenterMorris, MN
Focus on Swine Systems with new data!
© 2013 Regents of the University of Minnesota. All rights reserved.
THANK YOU!
FRITZ [email protected](612) 626-1028