20 Mazur ENG

Poznan University of Life Sciences

Robert Mazur Ph.D., Jakbu Mazurkiewicz M.Sc. eng.Andrzej Lewicki M.Sc. Eng, Sebastian Kujawiak M.Sc. Eng

Poultry manure as a substrate for methane fermentation: problems and solutions

Poland

Number of agricultural holdings, by NUTS 2 regions, 2010 [thousand holdings], by NUTS 2 regions, 2010 Eurostat.

Some facts about Poland

National and European obligations for Poland before 2020: i) 15% of reduction of CO2 emissionii) 15% of energy produced from renewable energy

sources (RES)

. but: Relatively bad geographical conditions for investment in

hydro- and wind power

In consequence: Biomass used as renewable energy source seems to be one

of the main factors which can help to reach Polish obligations at 2020

The potential of biomass fromagricultural sources in Poland

1. The total technical potential for the productionof agricultural biogas from manure in Poland is674 million m3 of biogas i.e. 26,2 PJ, whichrepresents approximately 21% of thetheoretical capacity from all RES in Poland.

2. The economic potential of agricultural biogas iseven more limited.

The potential of biomass fromagricultural sources in Poland

The calculation includes the sources such as: Cattle farms with stocking density more than 100

animals

Pig farms with stocking density more than 500 animals

Poultry farms with stocking density of over 5000 birds.

Poultry farms with stocking density of over 5000 birds

Laying hens population - annual data

4 2.000

4 3.000

4 4.000

4 5.000

4 6.000

4 7.000

4 8.000

4 9.000

5 0.000

2003 2004 2005 2006 2007 2008 2009 2010

PL - Poland [thous.]

Laying hens population in Poland - annual data (Eurostat)

Laying hens population - annual data

00

1 0.000

2 0.000

3 0.000

4 0.000

5 0.000

6 0.000

7 0.000

2003 2004 2005 2006 2007 2008 2009 2010

DE - Germany FR - France PL - Poland

Laying hens population in De., Fr., Pl. in thousand - annual data (Eurostat)

Production of chicken meat, 2012

14%

13%

12%

11%11%

10%

29%

Fr UK Pl De Es It OtherMembers

Production of poultry meat, 2012 (% share of EU-28 total) AgriPB13.png

Production of chicken meat, 2012

Poland already surpassed UK last year as the leading producer of chicken meat in the EU.

Poultry production in Poland

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1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

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Poultry production in Poland 2012

Chicken manure biogas potential

The enormous potential of biogas production also results from the possibility of using manure from poultry farms.

Chicken manure gas efficiency (about 32% dry matter) is estimated at 70-90 m3 of biogas per tone of FM (with 60% methane).

Poland is one of the leading poultry producers in Europe, with some large chicken farms with up to 2.000.000 birds for meat or egg production.

According to data from Professor Zbigniew Dobrzaski(Wroclaw University of Life Sciences), the annualamount of manure generated by poultry consists of 2.7million tons of chicken manure, 0.72 million tons ofturkey manure and nearly 0.38 million tons of otherpoultry manure.

The result is a composite theoretical performance of 170,38 and 20 million m3 of methane per year, or a totalelectrical capacity of over 105 MW. With a standardworking time of cogeneration units of 8.000 hours, theseproduce 840 MWh of energy per year.

Chicken manure biogas potential

Problems with biogas production based on chicken manure:

1. In Europe, there is no technology fermenting100% chicken manure

2. Biogas plants that generates biogas based onchicken manure only, have a very low yield ofmethane (China).

3. The Wabio Company - has developed a 5stages (5 chamber) technology, operating onhighly concentrated chicken manure (tooexpensive and not profitable for investors).

What the sources of problems in biogas fermentation of chicken manure:

Excessive concentration of nitrogen in thesubstrate

Too much mineral matter Antibiotics and steroids might be a serious

threat to many cultures of methanefermentation bacteria

Excessive concentration of sulfurcompounds (from proteins)

All of the above factors should leadpotential investors to particular care ininvestments associated with the productionof biomethane from chicken manure.

The scale of production of chicken manurein Poland and Europe leads to a deep takean interest in this market, and the possibilityof management of this type of substrate forenergy purposes.

Problems with poultry manure methanefermentation

Poultry manure and poultry litters:

Poultry manure is the organic wastematerial from poultry consisting of animalfeces and urine.

Poultry litter refers to the manure mixedwith some of the bedding material or litter(wood shavings or sawdust) and feathers.

Poultry manure from chicken farm in China

Poultry litter from chicken farm in Poland

Nitrogen is the main inhibitor of the process

Many authors report that ammonium nitrogen(i.e. the dissolved form of ammonia to formNH4+) becomes an inhibitor for the properdevelopment/propagation of methane bacteriaand therefore inhibits the production ofbiomethane.In concentration of 2.7 g/kg of solution.

Average nutrient composition of poultry manures

Manure Type Total N Ammonium(NH4-N)Phosphorus

(as P2O5)Potassium(as K2O)

Broiler lb/tonFresh (no litter) 26 10 17 11

Broiler house litter 72 11 78 46Breeder house litter 31 7 54 31

Stockpiled litter 36 8 80 34Layer

Fresh (no litter) 26 6 22 11Undercage scraped 28 14 31 20

Highrise stored 38 18 56 30lb/1,000 gallons

Liquid slurry 62 42 59 37Anaerobic lagoon sludge 26 8 92 13

lb/acre-inchAnaerobic lagoon liquid 180 155 45 265

1Source: Biological and Agricultural Engineering Dept., North Carolina State University, as reported in "Poultry Manure as a Fertilizer Source," 1997, Soil Facts fact sheet AG 439-5 authored by J.P. Zublena, J.C. Barker, and T.A. Carter,http://www.soil.ncsu.edu/publications/Soilfacts/AG-439-05/

Chicken manure and poultrylitter case study

The study on chicken manure in the Laboratoryof Ecotechnologies in Poznan University of LifeSciences

The study of biogas efficiency from chickenmanure and poultry litter

The study was carried out in bioreactors inaccordance with DIN 38 414

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Figure: Scheme of bioreactor (Section of 5-chambers): 1. Water heater with a temperature controller, 2. Isolated pipes with heating liquid, 3. The water jacket at a temperature of 36-38oC, 4. Bioreactor with a load capacity of 1,4-2 dm3, 5. Biogas tank, 6. Shut-off valves, 7. Gas Flow Meters, 8. Gas analyzers (CH4, CO2, NH3, H2S, O2), 9. pH sensors, 10. Temperature sensor, 11. The control panel and registration, 12. Magnetic stirrers for batch mixing.

Methods and MaterialsThe physical-chemical parameters of chicken manure. Dry matter: 32,2% Total nitrogen concentration 18,1 g/kg of

FM, ammonium nitrogen 13,94 g/kg of FM.

pH 8,1

The biogas laboratory facilities at ourUniversity

Methods and MaterialsWater dilution method for chicken manure: In experiment used chicken manure diluted in

five levels up to: 10, 8, 6, 4 and 2% of dryweight.

After dilution, was added 10% fermentationbacteria inoculates. As a result of different levelsof dilution of the chicken manure, there wereobtained pulpy with different concentration oftotal and ammonium nitrogen.

The biogas laboratory facilities at ourUniversity

Changes in the content of total nitrogen and ammonia, depending on the dilution of chicken manure

4,38

3,522,81

1,75

0,88

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Dry matter of pulpe [%]

N-totN-NH4

2,7 g/kg

Production of biogas and methane, depending on the dilution and calculated on the dry matter of the pulp

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10% 8% 6% 4% 2%

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Dry matter of pulp [%]

biogas

methane

Changes in the content of total nitrogen and ammonia, depending on the dilution of chicken manure with bacteria, characterized with a higher tolerance to nitrogen content

4,123,45

2,94

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Dry matter of pulp [%]

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Production of biogas and methane, depending on the dilution and calculated on the fresh weight of the pulp with bacteria,

characterized with a higher tolerance to nitrogen conten

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biogas

methane

Production of biogas and methane, depending on the dilution and calculated on the fresh weight of the pulp with regular inoculum and inoculum containing bacteria with a

higher tolerance to nitrogen

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without bacteriawith added bacterial inoculum

Production of biogas and methane rom different type of poultry litter

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Fermentation time [days]

Ch. M. 9% T. L. 9% Ch. M. 6%

Ch.M. - chicken manure, T.L. turkey litter

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Fermentation time [days]

Ch. M. 9%Ch. M. 6%

90%(163)

100%(181)

100%(264)

90%(235)

80%(145)

80%(211)

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46 days

Production of biogas and methane rom different type of chicken manure

Ch.M. - chicken manure

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Type of poultry manure /litter

biogas

methane

Production of biogas and methane rom different type of poultry manure /litter

Water consumption in the process of the substrate dilution

1 ton of chicken manure to be diluted to 32,2% of dry matter requires 0 m3 of water

1 ton of chicken manure to be diluted to 10% of dry matter requires 2,2 m3 of water

1 ton of chicken manure to be diluted to 8% of dry matter requires 3 m3 of water




The biogas plant operating on 100% chicken manure in China

Chinese solution for the production of biogas from poultry manure

Raw chicken manure from farm

Digested poultry manure

Digested poultry manure facilities

Dried digested poultry manure as a valuable fertilizer

Dried digested poultry manurefacilities

Dried digested poultry manure as a valuable fertilizer

The first plug flow digester of chicken manure from the 1990

Biogas plan - Complex of digesters

Biomethane to the gas network

Compressed biogas station

Pressure pump station

The final utilization of the biogas

Field application of afterdigest fertilizer

Greenhouse crop production

Outloock for futureTo ensure an effective biogas production processbased on poultry litter and poultry manure shouldbe: To develop an appropriate method of N stripping

from the substrate and percolate in the recycling(chemical or biological technologies).

Outloock for future It should be selected appropriate bacteria highly

tolerant to high concentrations of NH3 in thesubstrate, and other negatives factors(antibiotics and steroids)

Whenever possible, use a method of co-substrates to balance the ratio of C:N (100:33).

It should be introduced the appropriate rearingconditions at the poultry farm in order to obtainstable parameters for the final chicken manure

Thank you for your attentionVielen Dank fr Ihre Aufmerksamkeit

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20 Mazur ENG