usda-ars developed technologies for recovering manure ... · kellogg, r.l., c.h. lander, d.c....
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USDA-ARS Developed Technologies for
Recovering Manure Phosphorus
AGRICULTURAL RESEARCH SERVICE
Coastal Plains Soil, Water and Plant research Center
Florence, SC
Ariel A. Szogi
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Summary
Environmental issues – animal production
Recoverable manure nutrients
Phosphorus recovery from:
- liquid swine manure
- poultry litter
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Environmental IssuesSustainability of Animal Production
Pollution concerns because of excess soil N & P
Export or spatial transfer of nutrients with animal feed
Imbalance of N:P ratio in animal waste
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Percent of Agronomic Crop and Forage Phosphorus Needs
Supplied by Recoverable Plant Available Manure Phosphorus at the
County Level in North Carolina
0 - 10
10 - 40
40 - 70
70 - 100
> 100
Barker & Zublena, 1995
Animal Manure – Excess P
Barker, J.C., and J.P. Zublena. 1995. Livestock nutrient assessment in North Carolina. p. 98–106. In Proc. 7th Int. Symp. on Agric. & Food Proc Wastes.
Am. Soc. Agric. Eng., St. Joseph, MI.
%
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N:P Ratio – Selected Crops
Crop N:P ratio
Bermudagrass 13.4:1
Tall fescue 11.9:1
Corn 7.5:1
Cotton 6.2:1
Ryegrass 3.3:1
Liquid swine manure 3.2*
Poultry litter 2.1:1 to 2.6:1
Source: Edwards and Daniels, 1992; *Barker and Zublena, 1995
Edwards, D.R., and T.C. Daniel. 1992, Environmental impacts of on-farm poultry waste disposal. Bioresour. Technol. 41:9-33.
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Manure PRecycling
Utilization
Valuable byproducts?
Livestock Manure
Recycling of Excess P
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Recoverable Manure P
How much?
Quantity of the nutrient available for land application or utilization for other purposes
Mass of nutrient per ton of manure remaining after nutrient losses during manure collection, transfer, storage, and treatment
Total U.S. annual production of recoverable P2O5 = 650 M kgwith 480 M kg in excess of on-farm needs
Annual U.S. consumption P2O5 =1,680 M kg (PPI, 2002)
Recovery of manure P couldsubstitute about 25% of annualU.S. consumption of P
Source: USDA-ERS (Kellog et al. 2000)
18%
17%
8%
19%
38% Cattle
Dairy
Other
Swine
Poultry
Kellogg, R.L., C.H. Lander, D.C. Moffitt, and N. Gollehon. 2000. Manure nutrients relative to the capacity of cropland and pastureland
to assimilate nutrients: Spatial and temporal trends for the United States. NRCS and ERS GSA Publ. No. nps00-0579. Washington, D.C.
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Source: Keplinger and Hauck, 2006
Manure Transfer How Far?
Keplinger, K.O., and L.M. Hauck. 2006. The economics of manure utilization: Model and application. J. Agric. Resour. Econ. 31, 424-440.
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Global Use of Fertilizers World fertilizer prices soar:
merge of food and fuel economies
Average U.S. Farm Prices of Selected Fertilizers
0
100
200
300
400
500
600
700
800
900
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010
Time in years
Co
st in
Do
llars
pe
r To
n
Urea 45- 46%Nitrogen
Super-phosphate 44-46% phosphate
Source: USDA-ERS, Fertilizer Use and Prices. http://www.ers.usda.gov/Data/FertilizerUse/
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UtilizationValuable byproducts?
Compost
Phosphates
Organic soil amendments
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Nutrients Recovered from Swine Manure
Compost – N & P
Phosphate
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USDA-ARS Wastewater Treatment SystemPhosphorus Removal and Recovery
from Liquid Swine Manure
NITRIFICATION
BIOREACTOR
LIME OR
CA/MG HYDROXIDE
DISPENSER
PHOSPHORUS
SEPARATION
REACTOR EFFLUENT
WITH
NITRATE
PHOSPHATE
PRECIPITATE
FIG. 1
INFLUENT WITH
AMMONIA
PHOSPHORUS
ALKALINITY
Wastewater Treatment System
U.S. Patent 6,893,567 B1
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Enhanced Phosphorus Removal from Swine ManureUsing New Process
1 5 10
Calcium hydroxide rates (Moles / mol P)
0
10
20
30
40
50
60
P removed from liquid (mg/L)
New Process Conventional
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Environmentally Superior Technology (EST)
State of North Carolina
Permitable by government authority Technically, operationally and economically feasible
Meets these environmental performance standards:Eliminate discharge to surface and groundwaterSubstantially eliminate ammonia emissionsSubstantially eliminate odor emissions beyond farm
boundariesSubstantially eliminate pathogensSubstantially eliminate nutrient and heavy metal
contamination of soil and water.
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Goshen Ridge Farm, Duplin Co., NC
4,360-finishing pig production unit
Solid-liquid
Separation
Nitrification/
DenitrificationPhosphorus
Recovery
Raw ManureTreated: 39 m3/day
New manure treatment system developed to replace hog lagoons
in North Carolina. NC Attorney General – Smithfield Foods/PSF
Agreement
Wastewater Treatment System
US Patent # 6,893,567
Vanotti, Szogi and Hunt
EST – 1st generation, Super Soils USA System
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Calcium
Phosphate
Solid-liquid
Separation
Module
Nitrification
Denitrification
Module
Phosphorus
Removal
Module
Swine
Houses Separated
solids
Reuse
Effluent
EST On-Farm Treatment System
70% TP Mass
Removed w/Solids
Compost
25% TP Mass
Removed from
Liquid
Stream
95% TP Removed from Farm
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System Performance INFLUENT
(mg/L)
EFFLUENT
(mg/L)
Efficiency
(%)
Suspended
Solids11,051 264 98
Volatile
solids8,035 85 99
TKN 1,584 23 99
TAN 872 11 99
COD 16,138 445 97
BOD 3,132 10 100
TP 576 29 95
Cu 26.8 0.36 99
Zn 26.3 0.25 99
2003-2004
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Separated Solids
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Manure solids processed into plant growth media
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Step 3: Phosphorus Removal
P Separation Module
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P sludge production = 700 kg/year
Recovered P in sludge = 99.5%
4,360 Finishers Production Unit
Dewatering and bagging of calcium phosphate
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2nd Generation EST
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2nd Generation System: 5600-finishing pigs in North Carolina
Homogenization tank
Nitrification/denitr.
Solid-liquid
Separation
Phosphorus
and pathogens
System
Effluent
Vanotti, Szogi, Fetterman, U.S. Patent 7,674,379 B2. U.S. Patent and Trademark Office. 2010.
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Benefits of new technology have potential
to pay for all the cost of treatmentAnaerobic
Lagoon
Technology
2nd
Generation
Superior
Technology
$ / 1000 lb SSLW / year
Treatment Cost 90 132
Carbon Credits
Benefits
0 32
Productivity
Enhancement
Benefits
0 120
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Benefits of new technology have potential
to pay for all the cost of treatmentAnaerobic
Lagoon
Technology
2nd
Generation
Superior
Technology
$ / 1000 lb SSLW / year
Treatment Cost 90 132
Carbon Credits
Benefits
0 32
Productivity
Enhancement
Benefits
0 120
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Separated solids composted
with cotton gin residue
Compost – Swine Manure Solids
Constituent Percentage
Total N 5.3
Total P 4.0
Calcium 2.3
Potassium 0.5
Magnesium 2.1
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Constituent Percentage
P2O5 24.4
Calcium 27.3
Potassium 0.9
Magnesium 1.8
Chemical Composition
Recovered Phosphates
SEM
X 1200
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Recovered P
Compacted
Crushed
Recovered P – Swine Manure
Fertilizer Manufacture
Photos: ARS & IFDC
Sieved
Final Product
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Poultry LitterManure + Bedding Material
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Nutrients Recovered from Poultry Litter
USDA-ARS Florence, SC
Washed Solids
Recovered P
•Process selectively extracts up to 80
percent of the phosphorus from poultry
litter, but little of the nitrogen
•It produces two useful materials:
- The washed solids, with a
balanced N:P ratio for crop
production
- A "slow-release” phosphorus
fertilizer
•ARS has granted an exclusive license
to Renewable Organics LLC, of N.C., for
the commercial development of the
process
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Poultry Litter
Phosphorus Removal and Recovery Quick Wash (Chemical) Process
Washed
Litter
P extraction
Acidic solution
Poultry
Litter
P removal
Alkaline pH
P precipitation
enhancement
Recovered P
Liquid
Effluent
1 2 3
Szogi et al. Process for removing and recovering phosphorus from animal waste. Patent Appl. No. 20090193863.
U.S. Patent Office. Washington, DC.
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Water (pH 8.1) Acid (pH 4.5)
0
20
40
60
80
100Left in Solids
Extracted
% o
f In
itia
l To
tal
P
Water (pH 8.1) Acid (pH 4.5)
0
20
40
60
80
100Left in Solids
Extracted
Control Treatment
% o
f In
itia
l To
tal
N
Phosphorus
Nitrogen
N:P 1.8:1 5.8:1
A)
B)
Quick
Wash
Selective
Extraction of
Phosphorus
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Manure Wash Pilot Experiment
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Step 2
P removal
Lime addition
pH 9 - 10
Step 3
P enhancement
Flocculant addition
(PAM -)
Quick Wash
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.
P recovered from
poultry litterPoultry litter after
quick wash
Quick Wash
Products
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Phosphorus material recovered from
poultry litter using the Quick Wash
process
Constituent Mean
g per 100 g
Phosphorus 5.9
P2O5 13.5
Carbon 23.8
Nitrogen 2.4
Calcium 13.4
Magnesium 1.0
Potassium 1.1
Sodium 0.3
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Use of Recovered Phosphate as Fertilizer• Green house tests using P recovered from: 1) pig
manure (RPM), and 2) from poultry litter (RPL)
• Applied at 0, 20, 40, 80 and160 mg/kg soil
• Commercial triple super phosphate (TSP) was
used as fertilizer control
Plant : Annual ryegrass
Soil: Uchee sand
Amendment: Lime (pH ~6.5)
Air temperature: 25.5 – 32.0 oC
Biomass harvested @:
19, 34, and 47 d after planting
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0 22 44 88 1760.0
1.0
2.0
3.0
4.0
5.0
6.0
RPM
RPL
TSP
ControlLSD0.05
P Rate (mg P kg soil-1
)
Bio
mass (
g p
ot-1
)
Effect of fertilizer material and P
rate on ryegrass biomass
RPM, P recovered from pig
manure;
RPL, P from poultry litter;
TSP, triple superphosphate.
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Conclusions Nutrient recovery technologies offer the
opportunity to resolve problems of excess application of manure phosphorus to land.
N & P concentration in manure byproducts should be sufficiently high to allow long distance transportation.
The aspect of P recovery and reuse is important for the global cycling of these nutrients (e.g.: energy savings and limited resource).
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Relevant References: USDA-ARS Developed Technologies for Recovering Manure
Bauer, P., A.A. Szogi, and M.B. Vanotti. 2007. Agronomic effectiveness of calcium phosphate recovered from liquid swine manure.
Agron. J. 99:1352–1356.
Szogi, A.A., M.B. Vanotti, and P.G. Hunt. 2006. Dewatering of phosphorus extracted from liquid swine waste. Bioresour. Technol.
97:183–190.
Szogi, A.A., and M.B. Vanotti. 2008. Removal of phosphorus from livestock effluents. J. Environ. Qual. 38:576-586.
Szogi, A.A., M.B. Vanotti, and P.G. Hunt. 2008. Process for removing and recovering phosphorus from animal waste. Patent
Application Serial No. 20090193863. U.S. Patent Office. Washington, DC.
Szogi, A.A., M.B. Vanotti, and P.G. Hunt. 2008. Phosphorus recovery from poultry litter. Trans. ASABE 51:1727-1734.
Szogi, A.A., and M.B.Vanotti. 2009. Prospects for the recovery of phosphorus from poultry litter. Bioresour. Technol. 100:5461-5465.
Szogi, A., P. Bauer, and M. Vanotti. 2009. Agronomic effectiveness of phosphorus materials recovered from manure. Bulgarian
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