Executive Briefing Digestate Treatmentamericanbiogascouncil.org/pdf/Digested Organics-ABC Digestate... · Executive Briefing ... •The NCWR concentrates nutrients into 30% of the

Sustainable Manure Treatment for the 21st Century Dairy

Executive Briefing – Digestate TreatmentAmerican Biogas Council – San Diego CA

April 2016

Harvest Energy | Capture Nutrients | Reclaim Water™

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Farm Heat & ElectricityWet or Dry Fertilizers No Waste Discharge Clean Drinking Water

Lowers Operating Costs | Environmentally Sustainable | Enables Expansion

Integrated Manure Management System™

Market Drivers• Continued drought conditions throughout much of the region

• Expected DWR ground water regulations

• Enables herd expansion to increase milk production revenue without buying more land

• Decreases demand on wells

• Carbon credits revenue

• Lowers the farm’s carbon footprint

• Creates a more sustainable operation – using renewable power and recycling waste to high value nutrients and clean water

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The IMMS Value Proposition

• Environmentally sustainable – low operating costs - optimizes the value chain in manure;

• Fully Integrated Manure Management System (IMMS) that harvests energy and generates biogas, concentrates and captures nutrients for crops, and reclaims clean water for farm use

• Scalable to 20,000 cows plus - Lowest CAPEX/OPEX manure treatment system on the market today – highly automated

• The IMMS combines a high efficiency/low residence time anaerobic digester (BioEliminator™) with a highly automated ultra-filtration/reverse osmosis/ion exchange/UV system (NCWR™)

• The NCWR concentrates nutrients into 30% of the volume without the use of chemicals or polymers while removing the remaining 70% as clean water suitable for drinking water for the animals, washing and flushing on the farm, or can be discharged into the local waterway with the appropriate DNR permit. The nutrients can also be dried or pelletized for easy storage or transport out of the watershed.

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Digested Organics | US Projects~ 4,043,200 GPD

CONFIDENTIAL

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Majestic Crossing Dairy

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Majestic Crossing DairyHarvest Energy | Capture Nutrients | Reclaim Water

• On-line Spring 2016• Fully integrated/automated IMMS to

process 20,000 GPD manure• Coarse solids removal for bedding

and/or compost • BioEliminator™ treatment system for

biogas recovery • Nutrient Concentration & Water

Reclamation System (NCWR™)

Sheboygan Falls, WI

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MicronizeDisintegrateFine Solids

Digest Produce

Biogas & Digestate

BiogasConcentrate & ReclaimUF | RO | ION-EX | UV

Combust BiogasHeat + Electricity

Coarse Solids

Clean Water (~70%)

Nutrients(~30%)

Screw-Press / Sand Separator

CHP

BioMicronizer™ BioEliminator™ NCWR™

Liquid with Fine Solids

BioSupport™

Integrated Manure Management System™

Raw Manure

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Digest Produce

Biogas & Digestate

Biogas


Coarse Solids Screw-Press /

Sand SeparatorCHP

BioMicronizer™ BioEliminator™


BioSupport™

DO “Front End”

Raw ManureNCWR

Separation & Digestion


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BioMicronizer™

BioSupport™

Bedding or Compost

NCWR™

BioEliminator™

FAN Separators

Can be dried to reduce somatic cell count and moisture

Biogas

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Digest Produce

Biogas & Digestate

BiogasConcentrate & ReclaimUF | RO | ION-EX | UV


Coarse Solids

Clean Water (~60%)

Nutrients(~40%)


CHP



BioSupport™

DO “Back End”

Raw Manure

Ultrafiltration (UF)

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• 2 major components: the recirculation pump and the stainless steel module containing multiple porous tubular membranes

• The pump moves manure through the tubes with high velocity to keep them clean and forces the liquid out while retaining all solids (and pathogens) larger than 0.1 microns.

• A variety of sensors detect pressure, temperature and flow rates to control and optimize the operation of the system.

• The system runs continuously 24 hours a day and automatically goes through a cleaning cycle when necessary

• 10 year expected lifetime for module

Reverse Osmosis (RO)

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• The tea-colored UF permeate is pumped through RO membranes to remove dissolved solids and recover clean water

• These are industry-standard 8” membranes in pressure vessels

• 5 year expected lifetime for modules

• The RO system produces permeate or clean water that can be used for barn flushing, equipment wash down, and/or irrigation - it still contains ~ 150-200 mg/L ammonia-N and is not suitable for discharge or drinking water yet…

Polishing & Disinfection

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• In order to make the RO permeate drinkable for the animals or dischargeable, you must go thru this final step

• Ion-exchange to remove ammonia

• Aerating the water to meet likely discharge requirements for dissolved oxygen

• Adjusting the pH to neutral while adding hardness

• Activated carbon filtration to remove chlorine, odors and small organics

• UV disinfection to ensure complete pathogen removal

R&D – Mobile Testing Systems

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100,000 GPD Example

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UF RO

UF Permeate90,000 GPD

90%

RO Permeate72,000 GPD

72%

Clean Water Storage Tank

Polish + Disinfect

UF Concentrate10,000 GPD

10%

RO Concentrate18,000 GPD

18%

Lagoon A Reuse Onsite

Discharge

Manure100,000 GPD

100%

~70% Total Recovery of Clean Water

Lagoon B

System can be designed to blendcrop-specific fertilizers


Fiber*3,000 cf/day

*Assuming negligible volume reduction in digestate from fiber removal

15%

85%

40%

60%

Parameter Analysis

TN ≤2.0

TP ≤1.0

TSS ≤5

BOD ≤5

Nutrient Partitioning

Material TKN P2O5 K2O

Digestate 20 6.5 19

UF Concentrate 47 35 19

RO Concentrate 40 0 55

Approximate Nutrient Partitioning (% of nutrients in starting digestate)

Nitrogen Phosphorus Potassium

Final Treated Water (mg/L):Composition of Typical Scrape Dairy Streams (lbs. per 1000 gallons)

95%

5%

Nutrient Needs per Acre (Midwest)

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Alfalfa:

• ~13# of P2O5 per ton dry (average crop 4.5--5.5 ton per acre)

• ~60# of K2O

• ~24# of Sulfur per season

Corn/Silage

• ~4# of P2O5 per ton wet (average crop 18-23 ton per acre)

• ~8# of K2O

• ~15# of Sulfur per season

Corn/Grain

• ~70# of P2O5 and 50# K2O (average crop is 170-190 bushel)

Soybeans

• ~1# of P2O5 and 1# of K2O (average yield ~50 bushel)

Benefits Summary?

• Fully integrated treatment delivers “complete” system: 5 day HRT digestion | 100% captured/separated nutrients in 30% of volume | reclaims 70% clean water for reuse

• Lowest CAPEX/OPEX of any treatment system on the market today

• Environmentally sustainable – optimizes renewable opportunities & value chain

• Better lagoon management

• Reduces hauling and spreading costs

• Enables herd expansion without requiring more land

• Enables targeted delivery of nutrients with greater crop uptake

• Highly automated system requires minimal staff intervention

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For more information

Ann Arbor, MichiganLake Forest, IllinoisMilwaukee, WisconsinMiddleton, WisconsinMiddlebury, VermontVisalia, California

USA Offices:

For more information or to request a quote, please contact: Chris Maloney | 847-431-6826http://www.digestedorganics.com

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Harvest Energy | Capture Nutrients | Reclaim Water

http://www.digestedorganics.com

Appendix

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R&D – Mobile Testing Systems

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Step #1

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BioSupport™Coarse solids can be recycled for compost or reused for bedding

or

Bedding Compost

Remove Coarse Solids/Sand from Manure; Creates Valuable By-products


Sand Separator


Raw Manure

Drying the coarse solids post separation helps lower

somatic cell count and improve cow comfort

Step #2

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BioMicronizer™


BioSupport™

Bacteria are ~1-5 microns

Fine sand is ~50-200 microns

Straw is ~10,000 microns wide

• Disintegrate solids in manure• Increases surface area for microbes to digest waste faster• Homogenizes manure to reduce settling and build-up in

digester• Highly concentrated BioSupport- excellent source of essential

trace elements and bio-activators• Custom-formulated based on what’s missing in your manure

In lab testing, our system increased the concentration of organics smaller than 1.5 microns by more than 200%!

Energy-efficient Feedstock Preparation


Sand Separator

Raw Manure

Step #3

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Coarse Solids

Bedding orCompost


BioMicronizer™

BioSupport™

BioEliminator™

• 5-day retention time—shortest in industry

• Underground concrete, plug-flow reactor

• Contains plastic media inside to provide surface for microbes to grow

• Generates biogas for heat and power• Reduce odors and pathogens• Recovers more bio-available nutrients

Highly Efficient – Attached Growth Reactor

DisintegrateFine Solids

Raw Manure

Modular Sectioned Tank

Bio-Support Generate Biogas & Digestate


Step #4

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Generate Biogas & Digestate

Biogas

Coarse Solids

Bedding orCompost


CHP

BioMicronizer™ BioEliminator™

Combined Heat and Power for the Farm

• Heat and electricity for BioEliminator/barns/farm

• Gas for drying solids/feed• Electricity for NCWR

Raw Manure


Step #5

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Ultrafiltration | RO | IONEX | UV

Coarse Solids

Bedding orCompost

Clean Water (~60%)

Nutrients(~40%)



BioSupport™

Nutrient Concentration & Water Reclamation (NCWR)


Samples from treated dairy manure digestate

Raw Manure

Biogas

Generate Biogas & Digestate

CHP


Ultrafiltration | RO | IONEX | UV

Clean Water (~60%)

Nutrients (~40%)NCWR™

Unique Competitive Advantages:• 26 years of commercial filtration experience• Easy bolt-on addition to any existing digester• Integrated + fully automated 3-step process to

produce reusable water: Ultrafiltration (UF) Reverse Osmosis (RO) Polishing & Disinfection

• Uses no polymers, flocculants or coagulants• 60% volume reduction at less than your current

cost to haul and spread• Comprehensive service plan available to cover all

operational expenses besides electricity

Step #5 Nutrient Concentration & Water Reclamation (NCWR)

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Digested Organics Operational Dashboard

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The Digested Organics Leadership Team

• Ian CHARLES, Chairman

• Bobby LEVINE, Ph.D., Chief Executive Officer

• Christopher MALONEY, Chief Operating Officer

• David SCHMIDT, Construction and Installation (Contracted CGS)

• Matthew BIETTE, Business Development (Vermont)

• Don HEILMAN, Business Development (Wisconsin)

• Shane MATHIS, Project Management, R&D (Wisconsin)

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Strategic Partners

• CG Schmidt | Wisconsin• Founded in 1920, CG Schmidt is a Wisconsin based engineering, construction and operations company. A

family owned business, CGS has a reputation for excellence and uncompromising execution. Their CG Schmidt Solutions Group is also a regional leader in managing and operating anaerobic digestion based WTE facilities.

• Provost & Pritchard | California• Provost & Pritchard Consulting Group offers a wide range of engineering & consulting services to

agricultural clients including the dairy sector. Founded in 1968, the firm has developed a solid reputation for client service, and engineering and consulting excellence.

• Tilth Agronomy | Wisconsin• With over 50 years of experience, Tilth Agronomy provides comprehensive nutrient management

planning and a host of other technical and consulting services to over 200 dairies in Wisconsin.

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Separation by increasingly smaller pore size...Lowest CAPEX/OPEX per gallon processed in the market today

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Dryer add-on to produce fertilizer

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• The UF concentrate is about 12-15% total solids and can be dried to <10% moisture to produce a slow-release fertilizer rich in nitrogen and phosphorus.

• We utilize a high efficiency belt dryer to produce a flake material (can run on electricity, natural gas, propane, or biogas)

• Based on typical fertilizer prices, product worth about $115/ton.

ParameterContent

(%)Value ($/lb.)

Value ($/ton)

Total N 4.47 0.57 $50.96

P2O5 2.72 0.65 $35.36

K2O 1.89 0.38 $14.36

S 0.88 0.8 $14.08TOTAL $114.76

Documents

Executive Briefing Digestate Treatmentamericanbiogascouncil.org/pdf/Digested Organics-ABC Digestate... · Executive Briefing ... •The NCWR concentrates nutrients into 30% of the