PROJECT# 5.07
Integrated Advanced Nutrient Management and Flushwater Management On a Sand Bedded Dairy
Mercer Vu Farms Mercersburg, Pennsylvania
FINAL REPORT
Prepared By: Kyle B. Rife – INTEGRITY Ag Systems Submitted By: INTEGRITY Ag Systems
July 2010
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TABLE OF CONTENTS
1. INTRODUCTION.………………………………………………………………….... 3 2. PROJECT SITE LOCATION………………………………………………………….3 3. PROJECT DESCRIPTION……………………………………………………….…...6 4. SYSTEM PRIOR TO UPGRADES…………………………………………………….6 5. OPERATIONS AND MONITORING………………………………………………....9 6. NUTRIENT TRADING…………………………………………………………….…9 7. UPGRADES AND CURRENT SYSTEM OVERVIEW………………………………11 7.1 McClanahan Hydrocylone………………………………………………... .14 7.2 INTERGRITY Tapered Screw Press………………………………………15 7.2.1. TSP-1408 Screw Shaft and Screen Service……………………...17 7.3 Primary Separation System Capacity Upgrade………………………….....22 7.4 Composting Program…………………………………………………….....22 8. ADVANCED SEPARATION/NUTRIENT CAPTURE SYSTEM TESTING AND ANALYSIS…………………………………………………………………...... 27 8.1 INTEGRITY AQ-2000 Solid-Liquid Separator with Chemically Conditioned Manure Influent……………………………………………....27 8.2 Kemira 712 P Bandfilter Chemical/Mechanical Separation Plant………....34 8.3. Vincent FF-6 Fiber Filter……………………………………………….....45 8.4. Decanter Centrifuge…………………………………………………….....48 9. TECHNOLOGY COMPARISON AND CONCLUSIONS…………………………57 10. LOOKING FORWARD…………………………………………………………...58 APPENDIX………………………………………………………………………….i
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DEFINITIONS
Term Definition Mercer Vu Mercer Vu Farms, Inc. NRCS National Resource Conservation Services N Nitrogen P205 (P) Phosphorous K2O (K) Potassium The comparison between the original nutrient level in % Nutrient Capture the feed material to that in the treated and/or processed effluent (N, P, K) TSS Total Suspended Solids TDS Total Dissolved Solids HP Horsepower
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Mercer Vu Nutrient Management Project Plan of Work
1. INTRODUCTION
The Mercer Vu Nutrient Management Project has demonstrated the effectiveness of various technologies in achieving nutrient reductions for a 1,400 head dairy farm located in the Chesapeake Bay watershed. The system has exhibited capabilities of capturing more than 90% of the phosphorus in the manure and producing a composted product for distribution of nutrients off the farm. The project has demonstrated how livestock producers can effectively reduce phosphorus levels by more than 90% in a reliable manner that is cost effective and beneficial for the environment.
2. PROJECT SITE LOCATION
Mercer Vu Farms is one of Franklin County, Pennsylvania’s premiere dairy farms, known for its state-of-the-art approach to environmentally responsible agriculture. Located just west of the Borough of Mercersburg in Montgomery Township, the farm has been in operation by the Hissong family for over 55 years. Mercer Vu Farms is located within the West Branch Conococheague Creek watershed, which drains to the Potomac River and ultimately to the Chesapeake Bay (see maps 2.1 and 2.2 on page 5). According to the Natural Resource Conservation Services (NRCS), Franklin County livestock producers generate between 500,000 to 2,000,000 pounds of excess Phosphorus and over 2,000,000 pounds of excess Nitrogen annually. Already a showcase visited by local, state and national representatives of the agricultural community, Mercer Vu Farms has become a complete demonstration farm with the addition of a nutrient management system. (NCRS)
Mercer Vu Farms – Ariel View (Google Earth)
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Map 2.1
Johnson Run to Conococheague Creek
Mercer Vu Farms Town of Mercersburg
Mercer Vu Farms – Location to Conococheague Creek Watershed and Mercersburg Town Center (Google Earth)
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Map 2.2
Potomac River
Chesapeake Bay
Mercer Vu Farms – Location to Potomac River and Chesapeake Bay Watershed (Google Earth)
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3. PROJECT DESCRIPTION
The Integrity Advanced Nutrient Management System for Mercer Vu Farms includes features designed to make the treatment of manure more operationally friendly and cost effective than has been demonstrated to date. This goal was achieved through the testing and close study of multiple systems, while working close with farm operators, to find the best fit for Mercer Vu. The proposed system will be permanently installed as an upgrade to the existing manure treatment system at the farm and will make full use of equipment and facilities already in place.
4. SYSTEM PRIOR TO UPGRADES
Mercer Vu Farms milked 1000 cows that were housed in two free stall barns. The cows are bedded with sand, and a flush system is used for cleaning the alleys and removing manure from the barns. Each alley was flushed three times daily with approximately 11,600 gallons of recycled water from a storage lagoon. This totaled 208,800 gallons a day, plus 28,000 gallons of manure from the 1000 cows (estimating 28gal/day per cow), and 10,000 gallons of parlor waste, giving a total volume of 246,800 gallons to be treated per day. The sand-laden manure that was flushed from the barns flowed through a channel designed to settle out the sand. The farm solely operated a mechanical sand separator for washing and recycling the sand bedding that settled in the channel. Approximately 90% of the sand was recovered. The flushed manure then flowed over a weir at the end of the channel into a collection pit. The collection pit was equipped with two 10-Hp Houle Electromix agitators to keep solids in suspension, and a Houle 6" feed pump to transfer raw flush influent to two INTEGRITY™ Roller Press separators. A spare 6" emergency overflow Houle pump is installed next to the separator feed pump in the event a failure should occur with any equipment in the separation system. This pump was used to feed the separators or transfer raw flush manure directly into a settling cell. The separators captured coarse manure solids and produced a stackable separated manure product that was stockpiled in a stacking area conjoined to the separation building. Untreated solids were then direct land applied to the farm’s 700 acres of corn, alfalfa, soybeans and double crop rye.
The raw flush manure tank prior to upgrades. The flush channel with adjustable weir is seen on the left, one agitator in the back left corner, and second agitator with feed and emergency pumps on the right. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# IMG_0003)
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The two INTEGRITY AQ- 2000D Roller Press Manure Separators with solids stacking area. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# IMG_0004)
Liquid from the separators flowed to a concrete settling cell where some fine solids and sand accumulated. Contents of the cell were land applied approximately three times a year by a local custom farming company using 6500-gal manure tankers. Overflow from the settling cell was pumped to the farm's 8.0 million gallon geo-synthetic lined storage lagoon. The lagoon is equipped with six floating 5-horsepower aspirating inductive aerators. The aerators maintained an aerobic condition at the surface of the lagoon to control odors and maintain water quality for flushing the free stall barns. Liquid manure from the lagoon was applied on contiguous cropland through an irrigation system consisting of buried line, strategically positioned hydrants and INTEGRITY PulseJet traveling irrigation guns. This low-rate irrigation system is designed specifically to virtually eliminate the risk of ecologically harmful run-off. An INTEGRITY Eco-Safe Control system automatically shuts Pumping Well Flow In the system down should the supply line become blocked or burst. The liquid manure was applied from spring through fall on growing crops and open fields. This style of treatment system reduced nutrient concentrations and odors in the liquid manure that is used for irrigation, however not enough to keep up with phosphorous based nutrient management requirements and increasing herd size.
Separated flush manure effluent in the concrete settling cell. Liquid flows from the far end of the first cell on the right, and overflows into a small pump pit at the far end of the second cell on the left. Liquid is then pumped to the lagoon. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# IMG_0242)
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The 8-million gallon geo-synthetic lined lagoon at Mercer Vu Farms stores separated, settled flush manure effluent, which is aerated, irrigated, and used for flushing the free stall barns. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# CAM_0535)
Mercer Vu Farms Process Flow Diagram (Original System) Flush
Sand Separation
Coarse Flush Manure Solids Land Collection Pit Separation Application
Storage Lagoon PulseJet Land Clarification Cell with Application Aeration
Recycle water for flush and washing sand Land Application
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5. OPERATIONS AND MONITORING
Mercer Vu Farms has operated the various systems for twelve months with maintenance and operational support from Integrity Ag Systems. Data collection has been performed by Integrity Ag Systems with the following guidelines.
1. Tracking mass volume flows through the system including • Manure solids and liquids (weight, volume, total solids, volatile solids) • Nutrients (Total Nitrogen, Ammonia Nitrogen, Potassium, Phosphorous, and Potassium) • Fresh water usage 2. Tracking performance of the system components compared to the design specifications for throughput capacities, material characteristics, and operating requirements.
6. NUTRIENT TRADING
In recognition of the need to develop innovative methods to cost effectively improve water quality in the Chesapeake Bay watershed; the Pennsylvania Department of Environmental Protection (PADEP) has established guidelines for Nutrient and Sediment Reduction Credit Trading. This program will enable wastewater treatment plants and other new nutrient dischargers to mitigate water quality impact through the purchase of nutrient reduction credits from other producers that reduce discharges. Livestock producers are eligible to participate in the program and represent a significant potential source of nutrient reduction for the Bay. The trading program will provide revenue livestock producers that will enable them to install and operate nutrient reduction practices.
The system at Mercer Vu Farms has the potential to generate both nitrogen and phosphorus credits that can be traded through the program and return revenue to the dairy.
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7. UPGRADES AND CURRENT SYSTEM OVERVIEW
Mercer Vu added a third free stall barn during the summer of 2006, expanding the milking herd to 1400 cows. The farm has continued to use sand bedding and a flush system to clean manure from the alleys.
The sand separation system has been upgraded with a McClanahan Hydracyclone to capture fine sand that previously by-passed the sole mechanical sand separator. Keeping fine sand out of down-stream processes has improved the performance of the overall system and equipment within.
The primary solids separation system has been upgraded to improve solids capture and produce a dryer product for composting. The existing INTEGRITY™ AQ-2000D Roller- Press Separators have been reconfigured to function as pre-thickeners and fitted with finer screens, changing from 1/8" to 1/16" hole sizes. An INTEGRITY™ Tapered Screw Press (TSP) has also been installed to further press the thickened separated manure solids. Manure solids production from the TSP has been at a sustainable 35-40% dry matter. A newly constructed conveyor system transports the separated and pressed manure solids to a truck for transport to the composting area and/or use as bedding of heifers at another location.
Effluent from the separation system is plumbed to the existing settling cell, which has been equipped as an aerated flush water tank. The aeration system provides odor control and maintains water quality sufficient for flushing the alleys. A volume of liquid equal to the daily production of manure from the 1400 cows (approximately 50,000 GPD) has been treated with various advanced separation techniques. Four types of advanced separation equipment systems have been assessed during a 12-month operations period; an INTEGRITY AQ-2000D Thickener in conjunction with chemical inputs, a bandfilter with chemical input, Vincent Fiber Filter, and a Decanter Centrifuge with and without chemical input. Dewatered solids have been conveyed to a truck for transport to the composting area. Press filtrate is pumped to the storage lagoon for irrigation on contiguous acreage. Some of the advanced treatment systems tested have been found to have the capabilities of removing more than 90% of the phosphorus and suspended solids from the manure before gravity clarification and irrigation.
To enable more efficient treatment of the flush system at Mercer Vu, a closed-loop flush system is being utilized. A Houle 6" pump was installed into the second separated manure settling cell, positioned three feet from the bottom, allowing for build-up of fine solids prior to cleanout tanking. This greatly reduces the volume of manure needing to be treated in the system. Instead of treating a total volume of six to seven million gallons when incorporating flush water from the farm's storage lagoon, only 300,000 gallons requires treatment. Biological stability is also improved, necessary for chemical treatment to remove nutrients. (See "new system" flow diagram on page 11 for details.)
An Oxygen Release Compound (ORC) is being injected into the first settling cell to further increase and maintain flush water quality in the closed loop. An engineered buffered peroxide solution, this compound enhances the aeration of the flush water as it is cycled through the system. The ORC infuses the entire manure storage top to-
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bottom with measurable oxygen by the simple addition of a specialized chemical oxidant which inhibits odor causing microorganisms. This stimulates an Aerobic Bio-Reaction enabling oxygen loving microorganisms to digest organic material at a very high rate without producing noxious odors. The initial reaction takes place within minutes of application. The components of the ORC are beneficial to the environment throughout their entire life path.
A 1.5 acre uncovered pad has been constructed for composting and storage of manure solids from the two dewatering operations. Solids are stacked in windrows on the pad and periodically turned with a tractor-mounted PTO driven turner. Turning mixes and aerates the solids to facilitate the aerobic stabilization of volatile organic compounds in the manure. The composted manure solids contain the nutrients removed by the treatment system. The nutrient-rich compost is applied to cropland requiring nutrients and distributed to lawn and garden markets off the farm. Mercer Vu has an agreement with a local turf management contractor, Four Seasons Crop Care, to market the compost. However, currently the compost carries too much nutrient value for the farm's sole use and is not being distributed. In the long run the compost may be used to generate revenue as a value-added product and/or to obtain nutrient credits to cover the operating cost of advanced treatment at the dairy.
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Mercer Vu Farms Process Flow Diagram (New System) Flush
Windrow Land Application Sand Composting or Marketing Separation
Solids Flush Manure Separation Centrifuge Collection Pit with Screw Press
Chemical
Aerated Flush Water PulseJet Land Storage Lagoon Application Recycle water for flush Tank and washing sand
Overflow
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The first steps for Mercer Vu Farms were to upgrade the existing manure separation system. This system was efficient and simple, had the luxuries of automation, but was not originally designed for high rate nutrient capture and to produce solids for efficient composting, and fully utilize the potential of the farm's new composting operation.
7.1 McClanahan Hydracylone
The use of sand bedding at the project site is very important to the dairy's operators, to ensure optimum cow health and comfort. A Hydrocyclone (McClanahan Corp. ULTRA) was added to remove the fine sand particulate that the existing mechanical screw style separator did not capture. This equates to an average of 5%, bringing the total sand recovery efficiency in the system to 95%. The flush manure reception tank has been divided into two separate tanks; a primary raw flush manure reception tank and a The McClanahan Hydracyclone separates secondary solids separation fine sand particulate not able to be captured reception tank. Flush manure from by the conventional screw style separator. the three free stall barns flows as (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms, previously through a primary gravity Image# IMG_0775) separation channel where most of the sand is separated out. From the channel, manure flows into a primary reception tank where it is mixed using a 10HP propeller style agitator (Houle Electromix), keeping the fine sand particles and solids suspended. Raw flush manure gets pumped via a 6" electric vertical centrifugal pump (Houle) through a six-inch diameter reinforced rubber hose to the infeed flange of the Hydracyclone at approximately 450 GPM. Feed pressure is also regulated through this flow rate. As raw infeed rapidly enters the side of the unit into the cylindrical "feed box" centrifugal forces cause the sand particulate to be thrown outward. The heavier sand particles, known as "underflow" fall via gravity down through the "underflow regulator" at the bottom of the unit. Water containing lighter manure fiber, know as "overflow", is siphoned off the top and flows out through a 6" pipeline. Sand separated manure then gravity flows into the secondary solids separation reception pit through an 8" I.D. pipeline. Fine sand separated by the Hydracyclone is directed into the inclined dewatering auger (McClanahan) where it is conveyed with the more coarse sand and stacked for redistribution to freestall beds. Manure is fed from this location directly to the primary solids separation system. (LPT Separators, a Division of McClanahan Corporation)
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FPPC – INTEGRITY Ag Systems 14 The new sand separation process ensures 90+% sand recovery from raw flush manure infeed. Costs to replenish sand bedding supply on the dairy have been greatly reduced from this upgrade. Previously Mercer Vu had been using 48 tons of sand per week, or 192 tons per month. At a cost of $24 per ton, this totaled $4,608.00 a month. Since the installation of the Hydracyclone, the dairy now uses only 48 tons per month, a 75% decrease. Total cost to bed the 1400 cows per month is now $1,152.00, a total savings of $3,456.00 per month, and $41,472.00 annually. In addition, sand wear has been greatly reduced for solids separation equipment, lowering operational costs and minimizing downtime by 50-75%. (Mercer Vu Partner/Operator Rick Hissong, Conversation on 1/18/2010)
Raw flush manure flows in from the sand settling channel and is agitated and pumped up through the McClanahan Hydrocylone; then flows through a 12" pipeline to the primary solids separation system reception pit. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# IMG_0770)
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The implementation of a screw press was the second upgrade at Mercer Vu. Traditionally, the use of a "tight-tolerance" screw press, even with the utilization of a highly efficient sand separation system, can prove to be costly. Screens cost an average of $3,000-$4,000 and screw augers on such presses can cost upwards of $13,000. INTEGRITY had previously developed an economical screw press that would fit this application. (FAN Separator, PSS 3.2 Parts Price List 2010)
The INTEGRITY TSP-1408 Tapered Screw Press is of a simple yet efficient design. The press features a screen-lined perforated stainless steel corrosion resistant tapered compression barrel, in which is contained a tapered auger screw. This tapered design allows for pressure application in both the x-axis and y-axis to effectively dewater the influent material to a maximum dry matter content of 35-45%. As influent is transported through the barrel, it becomes increasingly compressed as the diameter decreases towards the discharge opening. A pneumatic compression cone applies axial pressure to the pressed material for increased dewatering as it begins to exit. The screen of the perforated compression barrel is specified to enable effective solids capture and water removal for each specific application. For Mercer Vu, 3/32" perforated screens are utilized and offer effective solids capture and moisture removal for composting, keeping in mind that pressed solids would also be used for bedding of the dairy's heifers. These screens are of a heavier gauge material for prolonged reliable operation under increased pressure to achieve desired solids dry matter; resistance to sand wear is increased as well. A sloped collection tray catches the water effluent and allows it to flow to the discharge pipe. A 10-horsepower electric motor drives a 50:1 reduction gearbox. This specifically designed power and speed reduction combination increases torque availability to levels of 5000-ft-lbs to the driven screw to convey pressed material during the dewatering process. A keyless compression coupler connects the gearbox output shaft to the screw shaft to assure constant no-slip torque transfer.
For electrical and mechanical overload protection, the INTEGRITY TSP-1408 screw press is driven by a specifically programmed variable frequency drive. The electrical system at Mercer Vu was upgraded with a new drive. Communication wires were added to connect the drive with existing controls and manage the other equipment in the system based upon screw press torque load. If the press begins to overload due to excessive material infeed, the three thickeners, thickened solids feed auger, and feed pump temporarily shut down until motor torque decreases to a set acceptable level. These torque parameters can be easily adjusted at any time if the consistency of the barn flush manure changes. Screw RPM is also adjusted using the VFD if increased dry solids matter production is desired. Dry matter results of 50% have been achieved at Mercer Vu by slowing screw RPM without significantly affecting processing capacity.
The TSP-1408 Tapered Screw Press was designed to be robust, reliable, and reduce downtime. A hardox-steel screw auger is abrasive resistant to the sand content presented to it at Mercer Vu. Flighting of the screw auger assembly is constructed in welded sections. Primary wear occurs at the discharge end of the press where the most pressure is applied to the sand laden manure solids. When these sections
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FPPC – INTEGRITY Ag Systems 16 become worn they may be removed and replaced with new, rather than having to replace the complete screw, or have it rebuilt and machined as with a tight tolerance machine. If the flighting is not overly worn and needing replacement, it can be built up using a MIG welder to the correct tolerances. Both flighting build-up and complete replacement of flighting sections can be performed in the field in a few hours, greatly reducing downtime and costs.
Funding from the FPPC allowed for the use of different sand resistant flighting coatings to be tested. The first a ceramic two part epoxy, which was applied directly over the last 18-inches of hardox flighting. This coating offered protection from sand wear for 30-45 days before wearing down to the hardox material. The coating could be easily re- applied, however would take 24-hours to cure in the field, a major disadvantage when minimal downtime is of high importance. This method was deemed impractical.
A hard surfacing MIG wire was also tested at Mercer Vu. This material could be applied to the screw flighting in the field in an hour on average. With a Burrell hardness of 55- 57, this surfacing had excellent sand wear resistance traits, lasting 60-days on average, before being reduced to the point of needing reapplication. Grinding of the hard surfacing proved to be challenging to fine tune the screw flight to screen tolerances. In addition, smooth and consistent hard surface field application on the face of the flighting was difficult at the discharge end due to minimal space to maneuver a MIG welding gun.
The most practical screw flight maintenance program for Mercer Vu is to build-up the last few sections of screw auger flighting at a period of every 30 days. This process when performed regularly at this interval takes three to four hours to complete in the field at a cost of $438.75. This includes disassembly and assembly of the compression barrel to access the screw. On average, the last two flighting sections of the screw shaft have been replaced in a year's time at a total expense of $488.00. The discharge end screens are replaced three times per year at a cost of $637.54 per set. The total annual maintenance costs of the TSP-1408 screw press at Mercer Vu are $6,788.12. This is $14,211.99 less on average than operating a conventional screw press separator, estimating that the screw and screen will have to be replaced only once per year. (FAN Separator Screw and Screen Pricing)
Initially an INTEGRITY TSP-1005 Tapered Screw Press was installed at Mercer Vu. This press is of a similar design to the TSP-1408 model press, tapering from a diameter of ten-inches the infeed end to five-inches at the discharge end. With an observed average capacity of 10 GPM of pre-thickened manure solids, the TSP-1005 did not prove to have the capacity to satisfy the raw flow. This triggered an upgrade to the larger TSP-1408.
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7.2.1. TSP-1408 Screw Shaft and Screen Service
Worn TSP-1408 screw shaft flighting after 45 days of operation. 1-2" of material has been worn from the last two end sections of flighting, requiring complete replacement. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 352sm (left), and 349sm (right))
Excessively worn flighting is easily removed with an oxy-acetylene torch. Slag deposits and excess flight material are ground smooth on the screw shaft after flighting removal has been completed. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 401sm (left), and 410sm (right))
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New flighting is positioned and tack welded in place, then inspected to assure proper positioning has been achieved. Once confirmed, the flighting is welded in place to the screw shaft. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 412sm (left), and 416sm (right))
Precision welding practices are used to assure sufficient weld penetration is acquired without distorting the pitch of the flight sections or the integrity of the screw shaft. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 430sm (left), and 419sm (right))
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Screw shaft flighting that is not excessively worn may be built up with one or two passes with a MIG welder, using standard 0.35" mild steel wire. The welded flight edges are ground smooth and screen to flight tolerances are inspected and maintained at 1/16". (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 438sm (left), and 435sm (right))
The screw shaft flighting rebuild of the INTEGRITY TSP-1408 has been completed to factory specification without the costly replacement of the entire screw shaft assembly. A total time of 4.5-hours by a single trained service technician is required for a complete rebuild as demonstrated. If the flighting and screens does not require complete replacement, service time is reduced by 50%. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# IMG_5460sm)
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The 3/32" perforated screens periodically wear thin due to sand wear and begin to break apart. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 354sm (left), and 353sm (right))
A new 3/32" screen insert is fitted into the tapered compression barrel half of the TSP- 1408. Tack welds are applied to the outer edges and at either end of the screen insert to secure it to the compression barrel. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 356sm (left), and 373sm (right))
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Tack welds are placed every 1.5" to ensure a reliable service life under extreme pressures. The welds are ground smooth prior to assembling the compression barrel halves back together for an even, tight fit. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 362sm (left), and 393sm (right))
A 3/32" perforated third stage screen insert is shown (left), and is manufactured to easily be fitted and secured into the compression barrel half (right). Other screen perforation sizes are available to satisfy various solids capture requirements. (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# 426sm (left), and 425sm (right))
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7.3 Primary Separation System Capacity Upgrade
Upon increasing from a total milking heard size of 1000 cows to 1400, and the addition of a third free stall barn, the two existing INTEGRITY AQ-2000D manure separators did not offer the capacity required to keep up with all of the daily flush manure flow. A third AQ-2000D thickener was installed to satisfy this requirement. An addition to the existing separator building was constructed with a bay for a fourth thickening separator should future heard expansion occur at Mercer Vu in the coming years. The TSP-1408 Tapered Screw Press had been sized to handle this increased flow and if need be, can handle the flow from a fourth thickener in the future. The addition of the thickener also allowed for the potential use of smaller screen perforation sizes to increase capture efficiency while sustaining the desired processing capacity to satisfy flow demand. Total flow through the primary separation system was increased by 25%. Current average primary separation system processing rates are on average 13,500 gallons per hour, or 225 gallons per minute. (Primary system operating rate, Mercer Vu Farms Manure System Manager)
The addition to the separation building (left) allowed for the installation of the third INTEGRITY model AQ-2000D manure thickener, placed inline with the existing two thickeners (right). (Photos: INTEGRITY Ag Systems Archive, Mercer Vu Farms, Image# IMG_0847 (left), and IMG_0855 (right))
7.4 Composting Program
Mercer Vu's 1.5 acre composting pad in conjunction with a tractor mounted 3-point hitch windrow turner have become a valuable assets to the dairy. Pressed solids from the primary separation system are loaded into a truck via a specially designed conveyance system with overhead plow distribution conveyor. The solids are then transported and offloaded in the center of the composting pad. Every seven to ten days the composting windrows are turned to the outside using a 3-point mounted compost windrow turner (Brown Bear Model PTOPA35D-10.5), driven by a 170-HP tractor (John Deere 7920 IVT). The outermost rows are turned first, eventually reaching the fresh solids in the center of the pad. This large row is split into two separate rows. When the composting
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FPPC – INTEGRITY Ag Systems 23 process has been completed on the outside rows, these nutrient rich solids are removed and transported to distant cropland.
The compost produced at Mercer Vu may also be resold to the surrounding community as a value added product to home, business, and landscape company owners to be used in garden beds. However, at this time Mercer Vu is not actively selling the compost as a value-added product as its nitrogen and other nutrient qualities are thought to be too valuable to farmland management. Nitrogen levels from the start of the composting process have been tested and show a 374.45% rise; starting with green pressed solids produced by the INTEGRITY TSP-1408 at 7.79 lbs/ton and ending as fully aged compost at 36.96 lbs/ton. Compost lbs/ton nitrogen value analysis provided by Four Season's Crop Care showed an increase from $5.27 to $27.65, a 424.66% increase from green solids to the finished compost product. Please refer to graph 7.4.1 below. (Compost Value Analysis, Four Seasons Crop Care)
A specifically designed leachate drain and distribution system has been incorporated in to the pads design. Storm waters are directed to the lower corner of the pad into a 24" x 24" grated drain. A 4" ID "V" distribution pipe is constructed in a lower field adjacent to the composting pad where leachate drains via gravity across the field.
60 50 51.59 40 30 27.65 20 Pressed Solids Compost 10 9.09 5.27 0 $ $ Value/Ton Value/Ton (Total (Nitrogen Nutrients) Only)
Graph 7.4.1 (Compost Nitrogen Value Analysis, Four Seasons Crop Care)
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"Green" separated and pressed solids are offloaded in the center of the composting pad, then are turned to the outside. The reduction of physical mass of the solids is reduced significantly as the compost matures. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Composting Operation, Image# IMG_0859)
The compost pad leachate distribution system automatically applies captured storm waters to an adjacent field. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Composting Operation, Image# IMG_0945)
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 25
The 3-point mounted, 1000RPM PTO-driven, compost windrow turner used at Mercer Vu. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Composting Operation, Image# IMG_0863)
The windrow turner mounted to a 170 rated-HP tractor. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Composting Operation, Image# IMG_0918)
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 26
The windrow turner in operation, distributing an inside row towards the outside of the composting pad. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Composting Operation, Image# IMG_0912 (top), Image# IMG_0892 (bottom))
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 27
8. ADVANCED SEPARATION/NUTRIENT CAPTURE SYSTEM TESTING AND ANALYSIS
One of the main issues facing the 1400-cow dairy is the slow but steady increase of nutrient levels in cropland soil. With and without the use of coagulants and flocculants, INTEGRITY Ag Systems has tested and developed four advanced separation systems designed specifically to remove the nutrients the primary system could not. The ability to analyze multiple nutrient removal technologies gave accurate insight into the best system for this application, and not simply "making" one system work. These four systems included: Injection and dwelling of chemistry into the feed line of one of the existing INTEGRITY separators; a self-contained band filter press unit equipped with chemical injection ports and mixing tanks; a Vincent model FF-6 Fiber Filter; and a decanter centrifuge, operated with and without chemical input.
8.1 INTEGRITY AQ-2000 Solid-Liquid Separator with Chemically Conditioned Manure Inffluent
The first advanced system tested by INTEGRITY utilized a modified model AQ-2000D separator; a similar machine to what the dairy already had in use as raw manure thickeners into the screw press. The AQ-2000D is a patented solid-liquid rotary arm separator (US Patent 7,051,962 B2). The AQ-2000D has a generally small footprint, with over dimensions of 111.6875 long x 70.0625 wide x 73.4375 high. As previously discussed, the unit can be equipped with wear-resistant UHMW rollers for stackable solids production at 20-25% dry matter. The separator when set-up at as solids thickener with roller assemblies removed, greatly increasing overall system efficiency when combined with a screw press. Infeed material is pumped in from the rear of the machine through a four-inch inlet pipe into a weir box. The adjustable weir allows for excess raw influent to backflow and return to the reception pit, eliminating the need for the supply pump to be driven by a variable frequency drive (VFD) on a basic system. Manure then flows into the first of two stages of separation where most the liquid is allowed to flow through a perforated screen with an area of 2101.875in2. Perforation hole sizes and overall percent open area vary as well as screen material gauge thickness depending upon application. For maximum nutrient capture, the machine used for chemically conditioned manure was fitted with fine perforated 1/32" perforated screens to enable the most solids removal. All separated effluent is captured in a sloped drain pan, integrated into the frame of the unit, and drains through three six-inch outlets. A rotating arm and brush assembly comprised of eight 24" poly-fill brushes, four per side, moves captured solids to the second stage of separation where a second perforated screen is located with an area of 2009.25in2. The second-stage rotary arm assembly, equipped with four 24" poly-fill brushes positioned behind four 24" UHMW polyethylene rollers, completes the liquid separation process and discharges the pressed solids product. The UHMW rollers ride on a stainless steel shaft inside a frame attached to each arm assembly. Pressure is applied to the roller assembly via specifically designed and positioned springs; spring tension may be adjusted if required. The second-stage rotary assembly is driven by a reduction gearbox, mounted directly on the rotary shaft. A 1725rpm c-face motor provides power to the gear reducer, coupled by a polyethylene bushing to the gearbox input shaft, creating a replaceable
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 28 wear surface between the shafts. The second stage rotary is connected and driven in unison by a drive chain on the opposite side of the machine. Timing of the rotary arm assemblies is important to assure that solids are conveyed from the first to the second stage in a manner that allows the most moisture removal by gravity before the product is rolled and discharged. This guarantees the highest overall moisture removal. For increased moisture removal when necessary, one brush may be removed diagonally from one another on each side of the second stage rotary assembly. This will allow separated solids to be rolled and pressed twice before being discharged.
INTEGRITY AQ-2000D Flow Diagram (AQ-2000D Process Flow, NCS Engineering)
A MonoFlo model CAE progressive cavity screw pump was fitted with a flow meter and driven by another variable frequency drive. The pump could be sped up or slowed down to obtain the required flow rate. Two-inch inside diameter HDPE pipe with quick- disconnect cam-lock fittings, assembled in sections of different lengths, increased or decreased chemical input dwell time. Ten and twenty foot length dwell pipe sections were used; chemical injection nozzles were fitted into one-foot pipe sections. Coagulant and flocculant input sections could be relocated with ease during testing to determine the best contact time with the manure infeed and reaction with one another. Manure feed rate also determined dwell and reaction time. (Please see the drawing on appendix page xxvi for further details)
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FPPC – INTEGRITY Ag Systems 29
The system was temporarily set-up on the level concrete floor of existing commodity building enclosing primary manure separation system. Three-phase power was acquired from a nearby breaker panel. Dwell piping sections were assembled and laid out in a manner that could be easily disassembled and rearranged. The INTEGRITY AQ-2000D separator was placed on a stand at a height to enable easy solids discharge capture by a skid-steer loader.
To make down and inject the cationic polymer solution into the dwell piping, an EXCELL Mixer Series 6000PSA2 system was used. This complete compact system included everything required to take raw liquid emulsion polymer and covert it into the 0.5% solution required to be fed directly into the waste stream to the AQ-2000D separator. The 6000PSA2 is a motorless polymer make–down and aging system that utilizes incoming emulsion make-down water pressure and a patented "high energy" polymer activation nozzle (US Patent 6,451,265 B1). To guarantee constant polymer solution levels, the nozzle is self-compensating for solution flow variations. A manually adjusted peristaltic pump feeds liquid polymer emulsion at a feed rate of 1-20 gallons per day to the injection nozzle. Here it is introduced with dilution water at a flow rate of 10-300 gallons per hour. A primary water control valve adjusts water flow from 10-150GPH while a second valve is adjustable from 0-150GPH. If water flow decreases below an acceptable level for the polymer solution desired, a field adjustable flow switch will shut the 6000PSA2 system down. Operation automatically resumes once water flow is acceptable again. A solenoid valve is used to control water flow. Water and polymer solution is aged in a one-gallon capacity cylindrical chamber for up to five minutes, depending upon flow rate. A solution chamber drain valve is provided as standard. Made-down, aged polymer solution flows through a sight chamber where solution quality can be monitored and thorough mixing is confirmed. From here it flows to be injected into the waste stream for treatment. Once the desired polymer emulsion feed and water flow settings are made, the entire system can be turned off and on via a single switch, simplifying operation. As an option, the system can also be activated and deactivated by an electronic signal, such as when operating other equipment in a complete separation and treatment system. This option was not required during temporary testing for the dwell piping system and INTEGITY AQ-2000D at Mercer Vu. The peristaltic pump and small electrical control components make up the electrical requirements of the system, only requiring power from a 120V source. This greatly increased set-up simplicity and saved time. For longevity, all components are made of corrosion resistant poly compounds and are mounted on a stainless steel frame. Total weight of the Excell 6000PSA2 is seventy pounds. (EXCELL 6000PSA2 Technical Information, Excell Feeders)
Ferric Sulfate coagulant was injected into the dwell piping system via a Beta Technology model P-6100T variable speed, dual roller, self-priming, peristaltic pump. Speed could be varied from 10-100%, 5-50oz per minute, at a rate of 10-100 RPM, by easily accessing the control dial located inside the type 304 stainless steel casing of the pump. Stainless steel construction gave the pump superior corrosion resistance against the acidic properties of the Ferric Sulfate. Similar to the EXCELL polymer make-down system, if installed in a permanent set-up, an outside electronic signal could start and
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 30 stop the pump. For pilot testing purposes, the coagulant injection was activated and deactivated manually via a standard equipped toggle switch on the outside of the control casing. (Model P-6100T Spec. Sheet, Beta Technology)
Overall performance of this system showed a significant increase in nutrient capture efficiency. A maximum flow rate of 25GPM was achieved, enabling the best chemical contact time with the raw manure to acquire flocculation and nutrient removal with the amount of pipeline available. An advantage of this system is its simplicity and generally low cost to construct. In addition, the pipeline with chemical injection could be adapted to the existing primary solids separation system, utilizing INTEGRITY model AQ-2000D separators if desired. The disadvantage of the system is that its maximum nutrient capture efficiency is not enough to satisfy Mercer Vu's requirements.
Testing of this system was performed during a period where freezing conditions could occur. Special care had to be taken to make sure feed and discharge lines did not freeze and were completely drained at the end of each day. The cast iron body of the progressive cavity pump had to be drained of liquid as well to assure no damage would occur to the casing or to the rubber stator material. The flock quality achieved during testing was acceptable, however never reached a point where the fine particulate matter in the feed product was captured. More advanced chemical mixing methods may be required to achieve this goal when using this more primitive system, exposing more of the coagulant and/or polymer to the solid particulate surfaces in the manure infeed.
Nutrient removal findings of this system were found to be significant, however lower than required. When comparing the nutrient capture of the INTEGRITY AQ-2000D separator without using chemical inputs, a maximum increase in phosphorous and potassium capture figures of 33.88% and 16.69% were achieved. In addition, a maximum increase in volatile solids capture of 21.10% was acquired, from 2.37 to 1.87 lbs/1000gal. Chemical input levels to achieve this were 0.0125gpm of Ferric Sulfate and 0.0025gpm of neat cationic polymer made-down to a 0.05% solution. Maximum nitrogen capture was acquired at a chemical input rate of 0.0025gpm neat cationic polymer and no Ferric Sulfate. A percent increase of 15.43 was observed, being reduced from 21.84 to 19.57 lbs/1000gal. Total observations showed that both a coagulant and flocculant were required for achieve the best nutrient capture. As expected, the Ferric Sulfate had the most importance in removing phosphorous from the raw manure influent. Please refer to charts 8.1.1 and 8.1.2.
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FPPC – INTEGRITY Ag Systems 31
Nutrient Capture Analysis - AQ-2000D with Coagulation/Flocculation Dwell Piping
Chart 8.1.1 Influent Draw Location: Settling Cell 1 - Primary Separation System Effluent Operational and Chemistry Dosage Rates: Raw Manure Infeed: 25 GPM Coagulant: Ferric Sulfate (FeSO4) Floculant: Kemira SF-4512
INTEGRITY AQ-2000D Separator Operational Characteristics: Screen Perforation Size: 0.033" with 28% Open Area Rotor Speed: Reduced by 25% to allow for flocked manure to be conveyed without breaking apart
Coagulant/Polymer Input (GPM): No Chemical Input 0.0125 / 0.0025 0.088 / 0.0018
Sample ID: Effluent Solids Effluent Solids EffluentSolids % Solids (DM) 3.45 3.57 3.08 4.42 3.46 4.38 % Moisture 96.55 96.43 96.92 95.58 96.54 95.62 Total N 21.84 27.57 19.57 28.21 20.40 25.17 Ammonia N 13.11 9.86 9.38 9.19 9.25 11.47 P2O5 8.50 8.19 5.62 8.88 7.43 9.04 K2O 18.63 18.57 15.52 17.71 17.65 17.66 Ca 11.82 11.17 8.25 12.05 10.45 12.00 Mg 5.05 4.91 3.93 5.01 4.78 5.06 Na 7.88 7.56 6.41 7.18 7.58 7.57 Cu 0.36 0.33 0.27 0.40 0.41 0.47 Mn 0.16 0.15 0.12 0.17 0.15 0.17 Fe 0.73 0.66 4.22 9.27 3.67 7.79 Zn 0.15 0.15 0.10 0.15 0.12 0.14 Density (Lbs/ 1 gal.) 8.38 8.43 8.40 8.41 8.50 8.35 Volatile Solids 2.37 2.19 1.87 2.91 2.19 2.92 P Index 0.10 0.30 0.29 0.15 0.33 0.27 pH 7.47 7.03 7.23 7.22 7.29 7.24
% Increase in P Capture - - 33.88 - 12.59 - % Increase in N Capture - - 10.39 - 6.59 - % Increase in K Capture - - 16.69 - 5.26 - % Increase in Volatile Solids Reduction - - 21.10 - 7.59 - (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal) **Nutrient capture compared to solids and effluent samples captured without using a flocculant or coagulant. ***Effluent flow rate was on average 15% less than influent rate.
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FPPC – INTEGRITY Ag Systems 32
Nutrient Capture Analysis - AQ-2000D with Coagulation/Flocculation Dwell Piping – Continued…
Chart 8.1.2 Coagulant/Polymer Input (GPM): 0.000 / 0.0025 0.125 / 0.000
Sample ID: Effluent Solids Effluent Solids % Solids (DM) 3.00 4.17 3.66 4.90 % Moisture 97.00 95.83 96.34 95.10 Total N 18.47 24.65 20.85 28.22 Ammonia N 9.21 9.82 10.23 9.73 P2O5 6.50 8.54 7.83 8.82 K2O 17.03 17.56 18.41 19.12 Ca 8.47 11.65 11.24 11.43 Mg 4.22 4.98 5.02 5.00 Na 7.26 7.30 7.82 7.79 Cu 0.33 0.42 0.41 0.42 Mn 0.12 0.16 0.16 0.17 Fe 0.48 0.97 4.43 13.39 Zn 0.11 0.15 0.13 0.18 Density (Lbs/ 1 gal.) 8.40 8.51 8.36 8.43 Volatile Solids 1.98 2.90 2.30 3.24 P Index 0.39 0.25 0.43 0.14 pH 7.50 7.62 7.22 7.31
% Increase in P Capture 23.53 - 7.88 - % Increase in N Capture 15.43 - 4.53 - % Increase in K Capture 8.59 - 1.18 - % Increase in Volatile Solids Reduction 16.46 - 2.95 - *All figures unless otherwise noted are represented as Lbs/1000Gal. **Nutrient capture compared to solids and effluent samples captured without using a flocculant or coagulant. ***Effluent flow rate was on average 15% less than influent rate. ****An input rate of 0.000 denotes no chemical input.
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FPPC – INTEGRITY Ag Systems 33
Graph 8.1.1
INTEGRITY AQ-2000 with Chemical Input - Increase in Nutrient and Total Volitile Solids Capture Over Non-Use of Chemistry
40
35
30
25 % Increase in P Capture % Increase in N Capture 20 % Increase in K Capture
% Increase 15 % Increase in Volitile Solids Reduction
10
5
0 0.0125 / 0.088 / 0.000 / 0.125 / 0.0025 0.0018 0.0025 0.000 Coagulant / Polymer Input (GPM)
Graph 8.1.2
INTEGRITY AQ-2000 with Chemical Input - Total Nutrient Content In Effluent
25
20
15 Total N Ammonia N P2O5 10 K2O
5 Nutreint Content (lbs/1000 gal.)
0
8 5 25 1 2 Input l a 0.00 0.00 0.00 / / / mic 5 8 0 12 0.125 / 0.000 .0 0.08 0.00 0 No Che Coagulant / Polymer Input (GPM)
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FPPC – INTEGRITY Ag Systems 34
8.2 Kemira 712 P Bandfilter Chemical/Mechanical Separation Plant
The main objective of operating the 712 P mobile plant was to obtain a sustainable economical operating status that meets or exceeds the requirements for nutrient capture for Mercer Vu Farms. If permanent operation was feasible, a plan would be developed to successfully integrate the Kemira system into the existing manure management system. The plant was operated and tested, making adjustments to chemical, mechanical and product inputs. Product inputs included raw sand separated flush manure and settling cell manure (effluent from the thickeners and TSP-1408).
The Kemira 712 P Mobile Advanced Separation Plant (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Kemira Operation)
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 35
KEMIRA 712 P Flow Diagram with Nutrient Sampling Points (NCS Engineering)
Material enters the plant through a 4" HDPE line, drawn by a Netzsch model XB-1 rotary lobe pump. A ferric or aluminum based coagulant is added as infeed material enters the line. Flow then travels through a Borger Multichopper 1 horizontal rotor and screen style macerator to break up large solid items, homogenizing the material for a more consistent chemical reaction. The macerator has a built-in rock trap to prevent damage to the cutters, screen, or pump should large heavy or hard objects enter the system. From the macerator, influent passes through the rotary lobe pump, through a flow meter and into a primary mixing tank containing a fence stirrer. Further coagulant mixing and dwell time occurs here. The flow reading is communicated directly to the system controls and automated software that automatically adjusts chemical input based upon flow rate.
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 36 Once infeed material has coagulated in the primary mixing chamber, it flows over a diagonally placed weir in the corner of the tank. Feed flows over into a high speed/high shear mixer where polymer solution is simultaneously injected. This flocculant solution is made down and aged constantly during plant operation as needed via a plant chassis mounted polymer make-down unit. Water and neat emulsion polymer are injected into a mixing pump manifold where they are sheared together and pushed into an aging chamber. During aging, polymer is drawn back down into the mixing pump and remixed with new polymer and water solution. After polymer is mixing into the coagulated influent, flock formation occurs in a second larger mix tank containing two fence stirrers. Polymer solution and influent is mixed further to increase flock formation and water separation and clarity. From the Polymer injection into the high-speed mixer. mixing tank, flocked manure influent (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms flows onto a 500-micron inclined Kemira Operation, Image# IMG_4860) bandfilter press. The speed of the second mixer in the mixing and flocculation chamber may be adjusted based upon flock quality and formulation.
Flocked manure is allowed to gravity dewater as it is conveyed up the bandfilter. A roller is located at the top of the bandfilter to further dewater the flocks. Clean effluent is captured by a drain pan and flows to a tank in the back of the bandfilter. This water is used to wash fine particulate from the bandfilter media during operation. Excess effluent overflows via a 4" Rolled solids at the end of the 712 P drainpipe at the top of the tank into a bandfilter fall into a level controlled hopper second smaller pumping tank, where for transport to the screw press via a it is pumped away via a small progressive cavity pump. (Photo: INTEGRITY Ag centrifugal pump controlled by a float Systems Archive, Mercer Vu Farms Kemira Operation, switch. Bandfilter wash water flows Image# IMG_4865)
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 37 into an identical tank set-up separate from bandfilter effluent as it contains larger particulate matter and can be pumped back into the reception pit for recirculation back through the plant. Solids fall off and are removed from the filter media by a horizontal scraper.
These solids fall into a progressive cavity worm-screw pump where they are conveyed and pumped into a screw press. The screw press features a 250-micron wedgewire screen with a screw rotational speed of 12 RPM. Pressure is applied at the discharge opening of the press using a compression cone attached to a hydraulic cylinder. Pressure is increased or decreased with a hand pump and bleeder valve. For shock load protection, gas filled hydraulic accumulators have been implemented into the system. Effluent produced by the screw press naturally contains particulate matter due to mechanical filtering inefficiencies. Press effluent is plumbed into the pumping tank for the bandfilter wash water. Solids are conveyed out the side of the container trailer in which the plant is located into a truck for removal and later distribution to cropland.
Over one year of Kemira 712 P Chemical/Mechanical separation plant operation resulted in the following observations. The screw press provided with the bandfilter is not suitable for dewatering solids off the band press that do not have significant fiber content. The result is a slightly more dewatered material than directly off the band press, however this material (sludge) is not stackable and causes handling and disposal/composting issues. Increasing the pressure on the compression cone only causes the very wet, sloppy material, to shoot out at a high velocity.
When the 712 P band filter was operated at locations other than Mercer Vu where the fiber content and particle size in the infeed was greater, solids production from the provided screw press was much drier. These solids are stackable with minimal leachate discharge at a dry matter content of 26-28%. Fine solids capture remained sustainable as these solids were conveyed through the press, creating a "clay-like" texture in the finished product. Of the two other dairies where the band filter has been tested, both used recovered manure solids for bedding from a primary separation system. One location was a scrape operation and the other a flush. The maximum solids content processed by the band filter at the scrape dairy was 7.08%. This level of solids was found to be close the maximum that the machine could process. At flow rates up above 6m3/hr (1584gal/hr) the in-line macerator could not process all solids in the waste stream and would cause sporadic flow as solids would get built The 712 P bandfilter with 1400-micron poly- against the screen before being woven band. (Photo: INTEGRITY Ag Systems Archive, ground. The implementation of a Mercer Vu Farms Kemira Operation, Image# IMG_4724) larger in-line macerator to handle
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 38 larger solids at high flow rates would be a simple solution to this problem.
Lowering the ferric chloride dosage rate resulted in a reduction in P2O5 capture efficiency as the fine particulate matter did not bind to the larger flocks and were allowed to flow through the band in the effluent water. Up to a 20% capture efficiency loss was noted by reducing the dosing rate from 8000ml/m3 to 2500ml/m3. Fine particulate matter in the effluent water was also observed to float and build-up on top the effluent surface in the effluent tank at the back of the band on the side opposite the drain head. This situation is remedied in model 2008 and later units as there are two drain heads, one per side of the effluent tank. This occurrence was still observed to be minimal if the ferric chloride dosing was at a higher level.
Increasing band filter hole size from 500micron to 1000micron, to 1400micron, did not result in a significant capture efficiency loss, if much of any. As previously stated, the ferric chloride dosing rate has more effect here.
Overdosing the influent material with polymer results in large flocks that are slippery and slide backwards on the band filter. This results in a buildup of material at that bottom if the band, eventually causing the band to overflow due to the lack of proper material conveyance. Increasing the speed of the second mixer in the polymer mixing tank before the manure flows onto the band will sometimes remedy the situation where large flocks are being developed that slide backwards onto the band. This assists in assuring total mixing and use of all polymer charge and full contact with manure surface area. In addition, excessive coagulant dosing results in foam formulation on the surface of the manure in the ferric mixing tank, and in the effluent water. Minimal foaming formulation was observed in the polymer mixing tanks.
Sludge produced by the bandfilter system can be mixed into pressed fiber produced by the Integrity TSP-1408 screw press to create a stackable highly nutrient rich product, which can be composted. However, in discussion with the farm's manure system manager, if the ratio of the sludge content in the fiber is too high, the product will stack, but is difficult to turn with the windrow turner. It was noted that Chemically separated sludge and the tractor had to be driven at half the speed pressed solids from the primary than normal, and wore out a rotor bearing on separation system are mixed via a the turner when attempting to turn a pile of the mixing auger. (Photo: INTEGRITY Ag mixed solids. This issue was remedied after Systems Archive, Mercer Vu Farms Kemira installation of the third thickener, increasing Operation, Image# IMG_4836) fiber input and output if the TSP-1408, causing more fiber availability for mixing and
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 39 composting.
An attempt was made to feed sludge produced by the bandfilter through the INTEGRITY TSP-1408 in combination with separated fiber from the INTEGRITY thickeners. Sludge product was added into the far end of the collection auger before manure solids were discharged from the thickeners. This allowed as much mixing as possible before the combined material entered the screw press hopper. The feeding through and pressing of this mixed material was unsuccessful. Conveyance of material through the press was only successful if the sludge content in the fiber is minimal (estimated 1:4 ratio). Once sludge content exceeded this level, the material would begin to convey through the press, and then would stop mid-way between the 2nd and 3rd stage compression barrels. Plug build-up gradually increased back from the discharge end until the press jammed. One cause of this could be due to the "slippery" nature of the bandfilter-produced sludge which when combined with the thickened manure would begin to "churn" in the compression barrel around the flighting, instead of being pushed forward in a constant conveying manner. Eventually enough material would be present in the compression barrel to cause the press to overload and jam. The VFD protective parameters were increased to levels to allow for the press to jam to determine when and how much material would cause this scenario.
Flocked raw manure influent flows from the mixing tanks onto the bandfilter where the dewatering process begins via gravity. Clean water separation is apparent between the flocks. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Kemira 712 P Operation, Image# IMG_4569 (left), Image# IMG_4572 (right))
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 40
Chemically treated manure effluent clarity in the hose on the left is compared to fresh well water in the hose on right. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Kemira 712 P Operation, Image# IMG_4591)
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 41 Chart 8.2.1 Bandfilter Operation Nutrient Capture Analysis – Settling Cell 1
Influent Draw Location: Settling Cell 1 In Front of Aerator Operational and Chemistry Dosage Rates: Infeed: 6m3/hr Coagulant: 4500ml/m3 Floculant: 475ml/m3 Band Size: 1400 micron Samples Taken on 7/14/08 Influent Effluent Decantered Effl. Sludge Mixed Solids Thickener Influent Lagoon Water % Solids (DM) 2.78 1.12 1.10 8.63 16.43 3.62 2.98 % Moisture 97.22 98.88 98.90 91.37 83.57 96.38 97.02 Total N 14.12 10.92 12.78 38.21 28.30 13.18 14.11 Ammonia N 7.36 6.41 6.46 8.45 6.93 7.34 8.03 P2O5 6.91 0.70 0.67 27.1330.22 10.40 7.70 K2O 15.27 14.66 14.95 16.0315.93 21.76 16.44 Ca 7.95 2.34 2.30 26.1930.09 10.93 10.33 Mg 4.37 3.03 3.02 7.88 8.62 5.21 4.44 Na 6.18 5.66 5.50 5.06 4.97 9.63 6.92 Cu 0.27 0.01 0.01 1.04 1.03 0.48 0.25 Mn 0.11 0.02 0.02 0.49 0.54 0.14 0.13 Fe 0.42 0.14 0.13 12.7011.44 0.62 0.53 Zn 0.15 0.02 0.02 0.50 0.60 0.46 0.15 Density (Lbs/gal.) 8.45 8.36 8.35 8.36 8.68 8.32 8.40 C:N - - - 8;1 25;1 - - Volitile Solids 1.93 0.57 0.56 6.52 14.19 2.60 1.98 Water Soluable P 4.60 4.54 4.11 2.92 3.00 3.63 3.52 P Index 0.54 0.53 0.48 0.34 0.35 0.42 0.41 pH 7.54 8.00 8.03 7.88 7.20 8.09 7.95 % P Capture - 89.87 90.30 - - - - % N Capture - 22.66 9.49 - - - - % K Capture - 3.99 2.10 - - - - % Solids Reduction - 59.71 60.43 - - - -
Solids Production Analysis - Mixed Solids Ratios
Raw Sludge Output Rate (Gal/Min): 5.24 Averge Pressed Fiber Output (Gal/Min): 13.16 Total Combined Solids Output (Gal/Min): 18.40 Total Combined Solids Output (Yd3/Hr): 5.47
Sludge:Pressed Fiber Ratio 1;2.5 % Sludge Content 40.00 (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal.)
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 42 Graph 8.2.1
Bandfilter Operation - % Nutrient Capture and Solids Reduction - Settling Cell 1
100.00
80.00 % P Capture 60.00 % N Capture 40.00 % K Capture % Solids Reduction 20.00 Solids Reduction
% Nutrient Catpure and 0.00 Effluent Decantered Effl. Sample ID
Graph 8.2.2
Bandfilter Operation - Total Nutrient Content Comparison - Settling Cell 1
18.00 16.00 14.00 12.00 Total N 10.00 Ammonia N 8.00 P2O5 6.00 K2O (lbs/1000gal) 4.00 Nutrient Content 2.00 0.00 Influent Effluent Decantered Effl. Sample ID
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 43
Chart 8.2.2 Bandfilter Operation Nutrient Capture Analysis – Settling Cell 2
Influent Draw Location: End of Settling Cell 2 Operational and Chemistry Dosage Rates: Infeed: 6m3/hr Coagulant: 6450ml/m3 Floculant: 360ml/m3 Band Size: 1000 micron
Influent Effluent Band Wash Effl. Sludge Thickener Influent Lagoon Water % Solids (DM) 3.67 1.25 1.49 9.35 3.97 3.61 % Moisture 96.33 98.75 98.51 90.65 96.03 96.39 Total N 34.33 25.59 26.75 53.80 35.51 34.1 Ammonia N 8.52 7.46 7.54 8.60 8.35 8.77 P2O5 7.02 0.39 1.13 18.937.21 7.21 K2O 15.49 13.83 14.41 14.8316.07 15.72 Ca 9.63 3.54 4.27 20.439.90 9.73 Mg 4.92 3.68 3.97 5.83 5.06 5.06 Na 8.05 7.10 7.25 6.74 8.41 8.22 Cu 0.30 0.01 0.05 0.85 0.27 0.33 Mn 0.15 0.08 0.11 0.47 0.15 0.15 Fe 0.54 0.47 1.16 18.820.53 0.52 Zn 0.14 0.01 0.03 0.42 0.15 0.16 Density (Lbs/gal.) 8.61 8.35 8.42 8.22 8.53 8.48 C:N - - - 6;1 - - Volitile Solids 2.68 0.64 0.84 7.27 3.04 2.68 Water Soluable P 2.72 9.16 1.68 3.86 5.09 2.85 P Index 0.32 1.00 0.20 0.45 0.60 0.33 pH 7.11 7.00 7.20 7.16 7.16 7.08 % P Capture - 94.44 83.90 - - - % N Capture - 25.46 22.08 - - - % K Capture - 10.72 6.97 - - - % Solids Reduction - 65.94 59.40 - - - (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal.)
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FPPC – INTEGRITY Ag Systems 44
Graph 8.2.3
Bandfilter Operation - % Nutrient Capture and Solids Reduction - Settling Cell 2
100.00
80.00 % P Capture 60.00 % N Capture 40.00 % K Capture % Solids Reduction 20.00
% Capture / Reduction 0.00 Effluent Band Wash Effl. Sample ID
Graph 8.2.4
Bandfilter Operation - Total Nutrient Content Comparison - Settling Cell 2
40.00 35.00 30.00 Total N 25.00 Ammonia N 20.00 P2O5 15.00 K2O
(lbs/1000gal) 10.00 Nutrient Content 5.00 0.00 Influent Effluent Band Wash Effl. Sample ID
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 45 8.3. Vincent FF-6 Fiber Filter
The Vincent Fabric Filter Model FF-6 operates continuously using a woven polymer fabric filter to remove solids from incoming feed substrates. This polymer fabric is durable and corrosion resistant for operation in dairy manure. Influent is thickened to solids contents of 6-14% depending upon the initial solids content of the manure. Clarification of effluent is can range and may be very high with the use of fabric media ranging from 20 to 200 microns (.001" - .008"). Infeed is plumbed into the back on the unit, where it is flung against the filter media in a pulsation manor as an internal paddle impeller rotates inside the cylindrical fiber filter. The filter is fixed in a frame; media tension can be adjusted as needed from the outside of the unit. Filter backwashing may be periodically required based upon infeed material. The inclination at which the entire filter and rotor operates may be easily adjusted. Generally, increasing the inclination angle will produce a dryer cake while decreased flow; a lowered angle will increase moisture content in the manure cake while allowing for an increased flow rate. The FF- 6 features a circular wash nozzle bar that surrounds the fabric filter. This wash bar can be moved back and forwards along the length of the filter either manually or pneumatically. A wash water booster pump and control panel are supplied for the backwash system. (Inclination, Vincent Fiber Filter Operating Hints) (Theory of operation of Vincent FF-6, Vincent Corporation)
Vincent Fiber Filter (Diagram of Vincent Fiber Filter, Vincent Corporation)
Temporary set-up of the Vincent FF-6 at Mercer Vu was generally simple. Vincent supplied everything required to operate the machine except for a feed supply pump, plumbing and electrical supplies. INTEGRITY supplied a feed pump, 2" flexible suction and discharge hoses, and electrical cable. An existing spare motor contactor with thermal protection, located in a nearby control panel, drove the FF-6 motor. The well water system in the location testing took place was found to have substantial flow and pressure for the filter backwash system; therefore the booster pump and control panel were not required. Manure infeed was drawn after being separated by the primary solid separation thickeners and screw press, from the center of the first settling cell lane. A 3" throttle controlled gas powered suction pump performed this action and directed infeed into the 2" inlet at the back of the FF-6.
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 46 Testing of the Vincent FF-6 was performed at various inclination levels. At 0-degrees (horizontal) cake production was very wet. This was primarily due to the fine solids content of the infeed not being able to build-up within the unit and flowing directly out the discharge opening. At the maximum angle of 30-degrees, solids production was most dry, however working load on the unit was greatly intensified; overall feed rate had to be reduced to reduce the load. Finding the best inclination angle was overall the only challenge to operating the unit, and was generally simple. A maximum processing rate of 29.03 GPM was achieved during testing of the Vincent FF-6, consistent with the lower range of the capacity specified by Vincent. Of this, 28.86 GPM of liquid effluent and 0.19 GPM of cake discharge was observed. These flow rates were achieved at an inclination angle of 20-degrees, and gave the best solids production and overall influent throughput.
Two different fiber filter sleeves were tested, keeping the infeed rate and inclination angle constant; one a 190-micron and the other an 86-micron.
Solids produced by the Vincent FF-6 Fiber Filter equipped with a 190-micron filter. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms Vincent FF-6 Operation, Image# IMG_5164 (left), Image# IMG_5163 (right))
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 47
Chart 8.3.1 Nutrient Capture Analysis - Vincent FF-6
Influent Draw Location: Center of Cell 1 Operational and Chemistry Dosage Rates: Infeed: 30 GPM Rotor Speed: 1195 RPM
Sample ID: Influent - Cell 1 Effluent - 86 Micron Solids - 86 Micron Effluent - 190 Micron Solids - 190 Micron % Solids (DM) 3.90 3.30 9.60 3.40 8.80 % Moisture 96.10 96.70 90.40 96.60 91.20 Ammonia N 13.00 12.78 13.39 12.44 12.56 Total N 21.58 21.25 22.91 20.34 21.51 P2O5 6.61 7.40 6.90 6.65 6.93 K2O 14.74 17.42 16.92 15.34 17.31 % P Capture - -11.95 - -0.61 - % N Capture - 1.53 - 5.75 - % K Capture - -18.18 - -4.07 - % Solids Reduction - 15.38 12.82 (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal.)
Graph 8.3.1 Vincent FF-6 Nutrient and Solids Capture Analysis
20 15 % P Capture 10 5 % N Capture 0 % K Capture -5 Effluent - 86 Solids - 86 -10 Micron Micron % Solids Solids Reduction -15 Reduction
% Nutrient Capture and -20
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 48
8.4. Decanter Centrifuge
A fourth advanced nutrient separation technology tested was a decanter centrifuge. This technology has been proven effective in the municipal and industrial waste fields for several decades. A Sharples (Division of Alfa Laval) model P-3400 Super-D-Canter decanter centrifuge was utilized for the testing. Feed material is pumped into a rotating tapered cylindrical bowl, 14" in diameter by 48" long. The bowl is mounted on a horizontal axis and capable of operating at a maximum of 4000RPM. Due to the abrasive nature of the manure infeed at Mercer Vu, operation was limited to 3500RPM to reduce wear. Within the bowl is a screw conveyor operating at a lower speed, driven by a planetary gearbox and backdrive motor. This creates a rotational speed differential between the bowl and screw and can be adjusted based upon infeed profile and solids capture requirements. Feed is distributed inside the center of the bowl through a feed tube, located at the solids discharge end of the unit. Solids collected in the centrifuge are conveyed up the tapered conical end of the bowl and out one of four discharge ports. Decantered liquid effluent, also know as "centrate", flows back to the opposite end of the bowl and out four discharge ports measuring 1.5-inches in diameter. Liquid level within the bowl may be adjusted via stainless steel plate "dams" which are bolted in place over the centrate discharge openings; this is more commonly known as the "pond setting". The more the discharge ports are covered, the higher the liquid level within the bowl. (Kyte Centrifuge, Description of Centrifuge)
Bowl Scroll Drive Screw Conveyor Bowl Drive
Feed Inlet
Solids Liquid Discharge Discharge
Decanter Centrifuge
(Lochtec, Decanter Centrifuge)
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FPPC – INTEGRITY Ag Systems 49
A Sharples (Division of Alfa Laval) model P-3400 Super-D-Canter decanter centrifuge unit was rented and placed under operation at Mercer Vu; nutrient capture efficiencies were tested both with and without the use of a flocculant. A control panel was supplied with this unit, including all necessary drives to operate all equipment required for operation. INTEGRITY supplied a 2" centrifugal pump with suction and discharge hose to feed the centrifuge with product from the primary system effluent settling cells. A centrate discharge flange adaptor had to be A suction pump was utilized to supply the manufactured to plumb discharge progressive cavity pump that supplied infeed to liquid away from the test site to the the centrifuge. Effluent was plumbed to the second settling cell through a four- concrete settling cell and solids were stacked for inch PVC pipeline. The flange later removal. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms P3400 Decanter Centrifuge, Image# P1000022) included a one-inch pipe nipple with ball valve for capturing samples.
Initial tested was performed to acquire basic data to determine the capabilities of the decanter centrifuge on separated dairy manure effluent. Once acquired, the decanter was set into operation for a seven-day not-stop operation cycle at the best differential settings proven effective; this would test for endurance and durability with feed product containing sand particulate. With the exception of periodic inspection, the centrifuge was completely unmanned for this test, relying on the safety shutdown settings pre- programmed into the supplied controls. No adjustments were made. Upon arrival on day seven, no changes were noted in drive motor load or operational characteristics of the centrifuge. The unit was shutdown for further inspection. The hardened screw-flight wear tiles and solids discharge openings displayed no signs of wear, proving that this machine is capable of sustained operation at Mercer Vu Farms, with sand bedding conditions.
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 50
After several days on non-stop operation with manure infeed containing sand particulate, no wear was apparent on the scroll flight tiles or discharge wear surfaces. (Photo: INTEGRITY Ag Systems Archive, Mercer Vu Farms P3400 Decanter Centrifuge, Image# P1000051 (left) and P1000041 (right))
Primary testing with the P-3400 Super-D-Canter without the use of a flocculant proved to have significant solids removal from post separated raw flush manure by means of the primary separation system. Variables consisted of manure feed rate, bowl to scroll differential speed and bowl pond setting. Manure infeed rate ranged from 13-75gpm with differential speeds of 10, 15, and 20rpm. A number-four bowl pond plate dam of was utilized. Bowl speed remained at 3500RPM for all testing performed.
Several primary characteristics of operation were observed during testing. Generally, the amount of nutrient capture, particularly phosphorous, decreased as feed rate was increased. This is due to the fact that sedimentation within the centrifuge is decreased with as liquid flows through the machine at a higher rate. Additionally, as feed rate into the machine was increased from 13 up to 75gpm, solids cake discharge dry matter content decreased.
When operating the centrifuge with a the number 4 pond setting, a maximum Phosphorous capture of 57.70% was achieved at the lowest flow rate of 13gpm with differential speed of 10 RPM, with an infeed content of 7.808lbs/1000gal being minimized to 3.303lbs/1000gal in the effluent. The maximum nitrogen and potassium levels were removed at these settings, however minimal at 13.72% and 3.33%. The most total dissolved solids were also realized here of 59.55%. Maximum total suspended solids (TSS) reduction was achieved at 47gpm and a differential speed of 15rpm. With an initial content of 28,600mg/L in the infeed, TSS was reduced to 7167mg/L, for a total of 74.94%.
To enhance nutrient capture of the Sharples P-3400 decanter centrifuge further, a high charge cationic polyacrylamide emulsion polymer was utilized in combination with a deeper #4.5 pond setting plate dam. The same EXCELL model 6000PSA2 polymer make-down system as used with the AQ-2000D and dwell piping system was used for
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 51 polymer dilution. Made-down polymer was injected directly before the high-speed 2" centrifugal feed pump to "shear" the polymer into the raw manure and assure complete exposure of the solids surfaces to the polymer chains. Polymerized manure was then allowed to dwell through 25-feet of 2" discharge hose before entering the bowl of the centrifuge. This type of polymer injection set-up was ideal for testing the general affects of polymer as an enhancer to nutrient capture, and not for the most cost efficient chemical usage. A Ferric based coagulant was not used, first due to the fact that the centrifuge is effective enough in nutrient sequestration without it, and second due to the corrosive reaction of the acid with the stainless steel bowl. The absence of a coagulant was confirmed to not be significant to achieve elevated nutrient removal. In addition, flow rate of raw influent into the unit was decreased significantly to allow for the most sedimentation time and nutrient capture between 10gpm and 7.5gpm.
Neat polymer input ranged from 0.0142gal/min to 0.0285gal/min, from a 0.5% to 1.0% concentrated solution, at a raw influent flow rate of 7.5gal/min. Maximum overall nutrient removal during operation of the decanter centrifuge was acquired at a polymer infeed rate of 0.256gal/min. Phosphorous removal topped out at 96.21%, Nitrogen at 51.66%, and Potassium at 50.93%. At the same settings, a maximum overall TSS removal rate of 98.82% was achieved, from 21967mg/L in the infeed to 260mg/L in the effluent. .
Very few challenges were encountered during testing of the decanter centrifuge. Excessive polymer input caused "sticky" solids production and began to plug up the discharge ports of the bowl. Once polymer concentration was reduced, this issue was remedied. Secondly, towards the end of the two-week long operation of the decanter centrifuge, the 2" centrifugal feed pump began to wear out due to the abrasive sand. The pump had to be operated at a higher speed and priming the pump after it was shut down for a short period of time became difficult.
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 52
Sharples P-3400 Super-D-Canter Nutrient Capture Analysis – Pond #4 Without Polymer
Chart 8.4.1 Influent Type/Draw Location: Separated Effluent from Raw Flush Manure - Settling Cell 1 Operational Constants: Bowl RPM: 3500 Pond Setting: #4.0
Feed Rate @ Differential Speed 75 GPM @ 20 RPM 56 GPM @ 20 RPM 41 GPM @ 15 RPM Sample ID: Influent Effluent Solids Effluent Solids Effluent Solids
% Moisture 95.3 97.00 79.00 97.00 83.94 97.1 79.9 % Solids (DM) 4.7 3.00 21.00 3.00 16.06 2.9 20.1 Ammonia N 13.57 13.56 10.78 13.53 8.45 12.97 10.45 Total N 23.04 21.58 32.98 21.67 43.39 21.76 39.38 P2O5 7.808 4.88 29.286 4.307 35.93 4.251 49.481 K2O 14.936 15.167 14.84 14.522 21.41 15.028 16.446 Total Suspended Solids (mg/L) 28600 12050 - 12367 - 9467 -
% P Capture - 37.50 - 44.84 - 45.56 - % N Capture - 6.34 - 5.95 - 5.56 - % K Capture - -1.55 - 2.772 - -0.616 - % TSS Reduction - 57.87 - 56.76 - 66.90 - % TDS Reduction - 53.42 - 35.15 - 33.33 -
Feed Rate @ Differential Speed 41 GPM @ 15 RPM 47 GPM @ 15 RPM 37.5 GPM @ 15 RPM Sample ID: Effluent Solids Effluent Solids Effluent Solids
% Moisture - 97.1 76.7 97.1 77.2 97.1 77.2 % Solids (DM) - 2.9 23.3 2.9 22.8 2.9 22.8 Ammonia N - 14.1 10.51 13.85 6.81 13.7 12.36 Total N - 21.16 42.4 20.08 42.18 21.79 43.98 P2O5 - 4.129 55.664 3.997 56.864 4.051 57.187 K2O - 14.768 16.771 14.952 16.891 14.727 16.92 Total Suspended Solids (mg/L) - 8050 - 7167 - 9100 -
% P Capture - 47.12 - 48.81 - 48.12 - % N Capture - 8.16 - 12.85 - 5.43 - % K Capture - 1.12 - -0.11 - 1.40 - % TSS Reduction - 71.85 - 74.94 - 68.18 - % TDS Reduction - 57.74 - 48.12 - 54.67 - (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal).
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Sharples P-3400 Super-D-Canter Nutrient Capture Analysis – Pond #4 Without Polymer Continued…
Chart 8.4.2 Feed Rate @ Differential Speed - 37.5 GPM @ 10 RPM 13 GPM @ 10 RPM Sample ID: - Effluent Solids Effluent Solids
% Moisture - 97.1 75.1 97.2 75.4 % Solids (DM) - 2.9 24.9 2.8 24.6 Ammonia N - 13.99 9.95 14.34 5.54 Total N - 21.7 45.24 19.88 52.17 P2O5 - 3.924 62.698 3.303 70.21 K2O - 14.715 17.557 14.438 18.914 Total Suspended Solids (mg/L) - 11933 - 7950 -
% P Capture - 49.74 - 57.70 - % N Capture - 5.82 - 13.72 - % K Capture - 1.48 - 3.33 - % TSS Reduction - 58.28 - 72.20 - % TDS Reduction - 43.65 - 59.55 - (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal).
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 54 Graph 8.4.1
Decanter Centrifuge Pond #4 Without Polymer - % Nutrient Capture
70
60
50
40 % P Capture 30 % N Capture % K Capture 20
Nutrient Capture (%) Capture Nutrient 10
0 75 GPM 56 GPM 41 GPM 41 GPM 47 GPM 37.5 37.5 13 GPM -10 @ 20 @ 20 @ 15 @ 15 @ 15 GPM @ GPM @ @ 10 RPM RPM RPM RPM RPM 15 RPM 10 RPM RPM Flow Rate @ Differential
Graph 8.4.2
Decanter Centrifuge Pond #4 No Polymer - % TSS Reduction
80.00 70.00 60.00 50.00 40.00 % TSS Reduction 30.00 % Reduction 20.00 10.00 0.00 75 56 41 41 47 37.5 37.5 13 GPM GPM GPM GPM GPM GPM GPM GPM @ 20 @ 20 @ 15 @ 15 @ 15 @ 15 @ 10 @ 10 RPM RPM RPM RPM RPM RPM RPM RPM Flow Rate (GPM) @ Differential
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Sharples P-3400 Super-D-Canter Nutrient Capture Analysis - Pond #4.5 With Polymer Continued…
Chart 8.4.3 Influent Type/Draw Location: Separated Effluent from Raw Flush Manure - Settling Cell 1
Operational Notes:
Bowl Speed: 3500RPM Differential: 15RPM Flocculant: Cationic Polyacrylamide Pond Setting: #4.5
Feed Rate @ Neat Polymer Input (GPM) 10 @ 0.0142 7.5 @ 0.0214 Sample ID: Influent Effluent Solids Effluent Solids
% Moisture 95.60 98.80 74.00 99.30 74.60 % Solids (DM) 4.40 1.20 26.00 0.70 25.40 Total N 8.73 7.23 3.30 4.71 2.71 Ammonia N 19.160 11.430 82.330 6.670 84.240 P2O5 6.967 1.631 70.985 0.621 61.204 K2O 12.997 9.753 14.694 7.430 12.942 Total Suspended Solids (TSS mg/L) 21967 4000 - 620 -
% P Capture - 76.59 - 91.09 - % N Capture - 17.18 - 46.05 - % K Capture - 24.96 - 42.83 - % TSS Reduction - 81.79 - 97.18 - % TDS Reduction - 34.16 - 66.64 -
Feed Rate @ Neat Polymer Input (GPM) 7.5 @ 0.0256 7.5 @ 0.0283 Sample ID: Effluent Solids Effluent Solids
% Moisture 99.50 76.40 99.40 75.50 % Solids (DM) 0.50 23.60 0.60 24.50 Total N 4.22 2.29 4.60 5.54 Ammonia N 5.280 87.72 6.070 86.560 P2O5 0.264 52.962 0.337 60.487 K2O 6.378 11.041 7.246 13.208 Total Suspended Solids (TSS mg/L) 260 - 530 -
% P Capture 96.21 - 95.16 - % N Capture 51.66 - 47.31 - % K Capture 50.93 - 44.25 - % TSS Reduction 98.82 - 97.59 - % TDS Reduction 65.11 - 58.02 - (NOTE: All figures unless otherwise noted are represented as Lbs/1000Gal).
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FPPC – INTEGRITY Ag Systems 56
Graph 8.4.3
Decanter Centrifuge Pond #4.5 With Polymer - % Nutrient Capture
120.00
100.00
80.00 % P Capture 60.00 % N Capture % K Capture 40.00 Nutrient Capture (%) 20.00
0.00 10 @ 0.0142 7.5 @ 0.0214 7.5 @ 0.0256 7.5 @ 0.0283 Feed Rate @ Neat Polymer Input
Graph 8.4.4
Decanter Centrifuge Pond #4.5 With Polymer - Nutrient Content in Effluent
25.00
20.00
15.00 Total N Ammonia N P2O5 10.00 K2O
5.00 Nutrient Level (lbs/1000gal)
0.00 Raw Infeed 10 @ 0.0142 7.5 @ 0.0214 7.5 @ 0.0256 7.5 @ 0.0283 Infeed Rate (GPM) @ Neat Polymer Input
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 57
Graph 8.4.5
Decanter Centrifuge Pond #4.5 With Polymer - TSS Content in Effluent
25000
20000
15000 Total Suspended Solids (TSS mg/L) Mg/L 10000
5000
0 Raw 10 @ 7.5 @ 7.5 @ 7.5 @ Infeed 0.0142 0.0214 0.0256 0.0283 Flow Rate (GPM) @ Neat Polymer Input
9. TECHNOLOGY COMPARISON AND CONCLUSIONS
Of the four advanced separation technologies tested at Mercer Vu Farms, the decanter centrifuge has proven to be the most reliable, versatile and cost effective upgrade to increase the nutrient capture from the manure waste stream. The centrifuge has capabilities of phosphorous capture rates over 50% without the addition of a flocculant, or any other nutrient capture enhancer. With the addition of a flocculant, the decanter centrifuge had the capability to remove 95+% of the phosphorous, and 50+% percent of both the nitrogen and potassium without the use of a coagulant No other system tested had these abilities.
The Kemira 712P separation plant allowed for high nutrient removal levels however required the use of both a coagulant and flocculant to operate properly. In addition, if chemistry requirements fluctuated, periodic adjustments to the machine and frequent and frequent monitoring are required. Overall the 712P is best suited to fiber-based bedding dairies, and particularly digester effluents.
The AQ-2000D solids thickener combined with chemically conditioned manure through a dwell piping system, showed improvements in nutrient capture over the base separation system at Mercer Vu, but was not enough to meet the requirements of the 1400-cow dairy.
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FPPC – INTEGRITY Ag Systems 58
The Vincent FF-6 Fiber Filter was an effective machine for thickening the separated manure effluent after the primary separation system, however showed mixed nutrient capture results, and would not be effective as part of the advanced nutrient management system at Mercer Vu.
10. LOOKING FORWARD
After careful analysis of the four advanced nutrient capture technologies, a determination has been made that a decanter centrifuge would be most beneficial to Mercer Vu Farms. This system has proven to be robust and resistant to sand wear on the dairy, while sequestering acceptable levels of nutrients with no chemical input. A major advantage is that the decanter can be operated with and without the use of a flocculant with minimal to no adjustments to the unit. For example, if high levels of nutrient capture are desired, the operator may activate the polymer system without changing the parameters of the centrifuge, and vise versa. Overall this technology is less prone to the biological influence on chemistry levels observed when operating the bandfilter. A decanter centrifuge will be proposed to Mercer Vu; integration of the centrifuge will generally simple. The system will be place within the existing separation building, equipped with enough power to supply the unit. A separated manure feed pump with supply and discharge plumbing system will be constructed. A specifically designed polymer make-down system will be integrated into the feed plumbing with proper injection and mixing system to assure the most effective flocculation with the least amount of polymer input is obtained. Clarified centrate effluent will be directed to the second settling cell for further gravity clarification (if required) and used to enhance flush water quality.
One of the most important aspects of the separation system at Mercer Vu Farms is the implementation of a highly efficient sand separation system prior to solids separation and advanced nutrient capture. Not only has equipment wear downstream of the system greatly reduced, sand build-up in pipelines and containment areas has been greatly reduced as well. Additionally, primary separation of solids before nutrient capture reduces chemical inputs when incorporated and increases overall capture efficiency. Generally, the larger the surface area of solids in the manure, the more polymer is required to achieve complete water separation and drainage.
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 59
Sited Information and Drawings
1. Pennsylvania NRCS Nutrient Production Figures For Franklin County
2. Sand usage and cost savings figures, Conversation with Mercer Vu Partner/Operator Rick Hissong, 1/18/2010
3. Current traditional screw press rebuild pricing derived from current 2010 FAN Separator screw auger and screen costs for a comparable 780 model screw press.
4. Compost Value Analysis, Four Seasons Crop Care, Based on Spring 2008 Nitrogen values.
5. Inclination, Vincent Fiber Filter Operating Hints. http://www.vincentcorp.com/applications/fiber_filter/ff_hints2.html
6. Theory of operation of Vincent FF-6, Vincent Corporation Fiber Filter Brochure.
7. Diagram of Vincent Fiber Filter, Vincent Corporation Fiber Filter Brochure.
8. Locktec, Decanter centrifuge diagram (not including labels). http://www.lochtec.dk/Produkter/Centrifuger/si_a3_decanter-dz_r.jpg
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems i
APPENDIX
The Potomac River Watershed and the Chesapeake Bay Watershed…………...iii (Source: Interstate Commission on the Potomac River Basin) http://www.potomacriver.org/info_center/maps/Potomac_and_Bay_Watershed.pdf
Conococheague Creek Antietam Creek & Licking Creek Subbasin……………..v (Source: Interstate Commission on the Potomac River Basin) http://www.potomacriver.org/info_center/maps/ConoAntie.pdf
Agricultural Sources of Total Nitrogen, Delivered Yield to the Chesapeake Bay..vii (Source: Chesapeake Bay Program) http://www.chesapeakebay.net/content/maps/cbp_19208.pdf
Point Sources and Priority Agricultural Watersheds, Chesapeake Bay Watershed within Pennsylvania………………………………………………………………………….ix (Source: Chesapeake Bay Program) http://www.chesapeakebay.net/content/maps/cbp_34622.pdf
LPT Separators – How They Work (Hydrocyclone)…………………………………..xi (Source: McClanahan Corporation, Hollidaysburg, Pa, (814) 695-9807)
Mercer Vu Farms, Inc., HIGH VOLUME SAND-MANURE SEPARATION SYSTEM.. …………………………………………………………………………………………………xv (Source: McClanahan Corporation, Hollidaysburg, Pa, (814) 695-9807)
Mercer Vu Farms, Inc., Evaluation of Separated Solids Vs. Compost……….xvii (Source: Four Seasons Crop Care, Jeremy A. Yeager C.C.A)
Brown Bear, Compost Aerator for Tractors with PTO Drive (Brown Bear Model PTOPA35D-10.5)…………………………………………………………………………...xix (Source: Brown Bear Corp., Corning, IA, (641) 322-4220)
NEBRASKA OECD TRACTOR TEST 1835–SUMMARY 427 JOHN DEERE 7920 IVT DIESEL…………………………………………………………xxii (Source: Nebraska Tractor Test Laboratory, University of Nebraska, Lincoln, Nebraska) http://tractortestlab.unl.edu/Deere/JD_7920ivt.pdf
INTEGRITY Chemical Treatment System, AQ-2000 with Dwell Piping……………..xxv (Source: NCS Engineering, DWR# E070912-1A)
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems ii P-6100T Chemical Feed Pump (Peristaltic)..…………………………………………xxvii (Source: Beta Technology, Santa Cruz, Ca, (800) 858-2382)
Pump Tube Chemical Resistance Data, Equipment Information Sheet…………...xxx (Source: Beta Technology, Santa Cruz, Ca, (800) 858-2382)
EXCELL SERIES 6000PSA, Liquid Polymer Feeder………………………………..xxxiii (Source: EXCELL FEEDERS, INC., Somerset, NJ (800) 250-9037) http://www.excellfeeders.com/Page21222.htm
Vincent Corporation, Fiber Filter……………………………………………………..xxxviii (Source: Vincent Corporation, Tampa, Fl, (813) 248 2650) http://www.vincentcorp.com/brochure/fiberfilter.pdf
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems iii
The Potomac River Watershed and the Chesapeake Bay Watershed
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems
v
Conococheague Creek Antietam Creek & Licking Creek Subbasin
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems
vii
Agricultural Sources of Total Nitrogen, Delivered Yield to the Chesapeake Bay
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems Agricultural Sources of Total Nitrogen Delivered Yield to the Chesapeake Bay
Delivered Nitrogen (kg/hec/yr) 0.0 - 1.0 1.1 - 2.0 2.1 - 3.0 NY 3.1 - 4.0 4.1 - 5.0 5.1 - 6.0 6.1 - 7.0 7.1 - 8.0 > 8.0 PA Delivered yield (load per area) is the amount of nutrient that is generated locally for each stream reach and weighted by the amount of in-stream loss that would occur with transport from the reach to Chesapeake Bay. The cumulative loss of nutrients from generation to delivery to the Bay is dependent on the traveltime and instream-loss rate of each individual reach. This map shows estimates based on mean conditions for the late 1990's time period.
WV MD
DC DE
VA
Data Sources: U.S. Geological Survey SPARROW Model. Digital Data Used to Relate Nutrient Inputs to Water Quality in the Chesapeake Bay Watershed, Version 3.0 (2004) (http://md.water.usgs.gov/publications/ofr-2004-1433/) 0 25 50 100 Kilometers For more information, visit www.chesapeakebay.net Disclaimer: www.chesapeakebay.net/termsofuse.htm 0 25 50 100 Miles $
Created by JW, 2/12/08 UTM Zone 18N, NAD 83 ix
Point Sources and Priority Agricultural Watersheds, Chesapeake Bay Watershed within Pennsylvania
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems *# *#
*# *# *# *# *# Point Sources and Priority Agricultural Watersheds *# *# *# # Chesapeake Bay Watershed within Pennsy*#lva*#nia * *# *# *# *# *# *# *# *#*# *# *# *#*# *# Point Source Facility *# *# *# Priority Agricultural Watersheds - Phosphorus *# *# Priority Agricultural Watersheds - Nitrogen # Montrose * *# *# *#Wellsboro *#Towanda *# *# *# Emporium *# Tunkhannock *# *# *# *# Laporte *# *#Scranton *# *# *# *# *#Williamsport Wilkes-Barre *# *# *# *# *# *# *# *# *#Lock Haven *# *# Priority Agricultral Watersheds represent *# *# those areas with high nutrient yields to the C*#learfield *# *# *# *#*# Chesapeake Bay and nutrient-related *# *# *# *# *# local impairments *# *# *#LewisburgDanv*#ille * *# *#Bellefonte *# *#*# *# *# *# *# *# *#*# *#Sunbury *# *#*# *# *# Middleburg *# *# # Data Sources: *# *# *#*# *# *# * *# *# Chesapeake Bay Program Phase 5 WSM Land Use *# # USGS SPARROW v.3.0 *# * *# State 303d Data provided by State Contacts and EPA Region 3 *# # *# Lewistown *# *# Chesapeake Bay Program Point Source Data Base *#* *# Mifflintown *# *# *# For more information, visit www.chesapeakebay.net *# Huntingdon *# *# # *# Disclaimer: www.chesapeakebay.net/termsofuse.htm *# *#Hollida*ysburg *# *# New Bloomfield *# *#*# *# *# *# *# #*# Lebanon * *# *# *# *#*# *# *# Ha*#rrisb*#urg *# # *#*#**# *# *C*#arlisle *#*#*# *# *# *#*# *# *# *# *# *# # *#*# *# *# *# *# *# *# *# * *# *# Bedford *# # *#*# *# *# *# *# * *# *#Lancaster *# *#*# *# # *#*# *# McConnellsburgChambersburg *# *#York* *# *# *# *# *# *# $ *# *# *# Getty*#sburg *#*# *# 0 12.5 25 50 Kilometers *# *# *# *# *# *# *# # * *# *# *# *# 0 12.5 25 50 Miles *# *# *#*# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *#*# *# *#*# *# *# *# *# *# *# # Created by JW, 03/09/2009 *# *#*# * *# *# *# *# *# *# *# *# *# *# # *# * *# *# *#*# *# *# *# *# *# *#*# *# *# *# # *# *# *# *# *# * *# *#*# *# * *# *# # *# * *# *# *#*# # *# *# *# * *# *# *# *# *# # *# # * *# * # *# *# *# *# *# *# *# *# *#* *# *# *# # *# *# # * *# *# * *# *# *# *# *# *# *# *#*# *# *# *#*#*# *#*# *# *# *# *# *# *# *#*# *# *# *# *# *# *# *# *# *# *# *#*# *#*# *# *# *# *# *#*#*# *# *# *# *# *# *# *# *# *# *# *# # * *# *# *# *# # *# * *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *# *#*# # *# *# * *# *# *# *# *# *# *#*# *#*# *# *# *# *# *#*# *#
*# *# *# *# *# xi
LPT Separators – How They Work
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems
xv
Mercer Vu Farms, Inc, HIGH VOLUME SAND- MANURE SEPARATION SYSTEM
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems Rick and Rod Hissong, Mercersburg, PA MERCER VU FARMS, INC. (717) 328-3087 [email protected] NRAES FARM TOUR-02/20/2003 HIGH VOLUME SAND-MANURE SEPARATION SYSTEM
Flush System •15,500 gpm flush flowrate at valve (11,600 gallons released in approximately 45 seconds).
•Two 30’ tall, 10’ diameter tanks connected in parallel (looped) to control valves and gated pipe discharge units.
•Two alleys are flushed simultaneously three times per day and only while cows are out of barn.
•Flush is collected in 24” diameter pipe and discharged to SMS.
High Capacity Sand-Manure Separator (SMS) • Maximum flush flowrate through the SMS is approximately 8,000 gallons per minute.
• Constant water depth in the channel is 3’ and increases to approximately 4’ during maximum flush discharge.
• Collection Auger (18” in diameter and 56’ long) positioned at the bottom of the channel collects settled sand conveys it to an inclined Dewatering Auger. All Auger flighting is constructed from hardened steel (400 Brinell).
•Separated sand is discharged onto a belt conveyor then stacked on a concrete pad for storage prior to reuse.
MCLANAHAN CORPORATION 200 Wall Street www.mclanahan.com Hollidaysburg, PA 16648 [email protected] (814) 695-9807Office (814) 695-6684 Fax xvii
Mercer Vu Farms, Inc., Evaluation of Separated Solids Vs. Compost
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems Mercer Vu Farms, Inc. Evaluation of Separated Solids Vs. Compost
Manure Type Separated Solids Compost % Moisture 81.7% 26.0% % Organic Matter 16.5% 30.0% % Ash 1.9% 44.0% C/N Ratio 22:1 N Avail. 8:1 N Avail. Analysis On Pile (LB/Ton) 8.5 ‐ 3.6 ‐ 4.8 100% 44.6 ‐ 20.5 ‐ 32.8 100% Value Per Ton (Spring 2008 Prices) $9.09 $51.59 Value Per Ton (Spring 2008 Prices‐Nitrogen Only) $5.27 $27.65 Analysis In Field (Growing Cover Crop; OR Just Prior To Planting)(LB/Ton) 3.4 ‐ 3.6 ‐ 4.8 40% 22.3 ‐ 20.5 ‐ 32.8 50% Value Per Ton (Spring 2008 Prices) $5.93 $37.77 Value Per Ton (Spring 2008 Prices‐Nitrogen Only) $2.11 $13.83 Analysis In Field (No Cover,Applied Fall Or Winter)(LB/Ton) 2.6 ‐ 3.6 ‐ 4.8 30% 15.6 ‐ 20.5 ‐ 32.8 35% Value Per Ton (Spring 2008 Prices) $5.43 $33.61 Value Per Ton (Spring 2008 Prices‐Nitrogen Only) $1.61 $9.67
Tons Applied To Meet Corn Nitrogen Needs (Bare Ground) 69 12 Tons Applied To Meet Corn Nitrogen Needs (Cover Crop or At Planting) 53 8
Prepared By: Jeremy A Yeager C.C.A. Four Seasons Crop Care [email protected] home (717) 369‐3156 cell (717) 729‐5445 xix
Brown Bear, Compost Aerator for Tractors with PTO Drive
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems a: « w co COMPOST AERATOR FOR TRACTORS WITH PTO DRIVE
• Largest Capacity In Its Price Class • Composting Eliminates Flies & Odors
• Mount To Most Tractors W/Cat II or III 3 Pt. Hitch • Composting Produces Dry Granular Product
• Composting Reduces Volume By 50%
• PTO, ISO or Counter ISO Rotation • Affordable
• 85-160 PTO HP Tractors • Easy To Operate
• Compost Exempt From Manure Management Regs • Inexpensive To Maintain
• Assists in CAFO Compliance • Low Cost Per Ton From the Company with over 20 years of Experience
Rotor Options
USE AUGER AERATOR WHEN USE PADDLE AERATOR FOR FASTER USE PADDLE AERATOR WI OPTIONAL LARGE ROCK OR HEAVY DEBRIS IS DRYING & MORE AERATION. USE IN SPADE HI-CARBON OR CARBIDE TEETH ENCOUNTERED, CONICAL CARBIDE ORGANIC RESIDUE & LOOSE SOIL. FOR INSITU MILLING, WINDROW OR PARABOLIC TEETH OPTIONAL SAW-TOOTH OR SMOOTH OPTIONAL FORMATION & AERATION
The Brown Bear Model PA35 & AA35 are the only PTO drive windrow com posters capable of bUilding their own windrows and combining windrows as volume reduces. The Aerator thoroughly mixes the entire windrow in one pass. The unit's design aerates all material to ground level, and moves the complete windrow to the right of the machine's line of travel. This method of moving and reestablishing the windrow in one pass guarantees maximum oxygen incorporation and virtually eliminates the chance for anaerobic pockets or layers, common problems for two pass machines and machines that aerate in place.
SPECIFICATIONS
Model: PTOPA35-9.5 PTOPA35D-10.5 • Feed Lot Manure • Sheep/Goat Manure Rotor Diameter: 35" (.89m) 35" (.89) • Poultry Manure • Municipal Yard Waste • Dairy Manure • Municipal Solid Waste Width: 11' (3.36m) 12' (3.66m)
• Swine Manure • Municipal Sewage Sludge Effective Work 9.5' (2.9m) 10.5 (3.2m) • Horse Manure • Food Processing Waste Width:
, Recommended 85-150 100-160 PTO HP:
Primary Drive: Bevel Gear Bevel Gear
Final Drive: Roller Chain Roller Chain
Hitch: CAT II or III CAT II or III
PTO: Rotation: ISO ISO Counter ISO
PTO Speed: 540 RPM 1000 RPM NOTE: All specifications are stated in accordance with SAE Standards or recommended practices where applicable. Weight: 35001bs. 44001bs. IMPORTANT: Every attempt has been made to ensure the correctness (1587 kg) (1995 kg) of these specifications, however no guarantees are made as to accuracy. Brown Bear Corp. reserves the right to change these specifications without notice and without incurring any obligation relating to such change.
Three Brown stripes ... the sign of quality [JBRDwn~ xxii
NEBRASKA OECD TRACTOR TEST 1835– SUMMARY 427 JOHN DEERE 7920 IVT DIESEL
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems NEBRASKA OECD TRACTOR TEST 1835–SUMMARY 427 JOHN DEERE 7920 IVT DIESEL INFINITELY VARIABLE TRANSMISSION
POWER TAKE-OFF PERFORMANCE Location of Test: Nebraska Tractor Test Power Crank Laboratory, University of Nebraska, Lincoln, HP shaft Nebraska 68583-0832 (kW) speed Gal/hr lb/hp.hr Hp.hr/gal Mean Atmospheric rpm (l/h) (kg/kW.h) (kW.h/l) Conditions Dates of Test: April 1-22, 2004 MAXIMUM POWER AND FUEL CONSUMPTION Manufacturer: John Deere Tractor Works, 3500 Rated Engine Speed—(PTO speed—1077 rpm) East Donald Street, P.O. Box 270, Waterloo Ia, 171.26 2100 10.43 0.428 16.41 50704-0270 (127.71) (39.50) (0.260) (3.23) FUEL, OIL and TIME: Fuel No. 2 Diesel Standard Power Take-off Speed (1000 rpm) Specific gravity converted to 60°/60°F (15°/15°C) 185.59 1951 10.58 0.400 17.54 0.8432 Fuel weight 7.021 lbs/gal (0.841 kg/l) Oil (138.39) (40.06) (0.244) (3.45) SAE 15W-40 API service classification CF-4 Maximum Power (2 hours) Transmission and hydraulic lubricant John 192.77 1750 10.57 0.385 18.23 Deere Hy-Gard fluid Front axle lubricant John (143.75) (40.03) (0.234) (3.59) Deere Hy-Gard fluid Total time engine was VARYING POWER AND FUEL CONSUMPTION operated: 30.0 hours 171.26 2100 10.43 0.428 16.41 Air temperature (127.71) (39.50) (0.260) (3.23) ENGINE: Make John Deere Diesel Type six 153.30 2212 10.00 0.458 15.33 76°F (25°C) cylinder vertical with turbocharger and air to air (114.31) (37.85) (0.279) (3.02) intercooler Serial No.*RG6081H233741* 115.33 2220 8.37 0.510 13.77 Relative humidity Crankshaft lengthwise Rated engine speed 2100 (86.00) (31.70) (0.310) (2.71) Bore and stroke 4.56 x 5.06"(115.8 mm x 128.5 mm) 77.19 2227 6.67 0.606 11.58 34% (57.56) (25.23) (0.369) (2.28) Compression ratio 16.5 to 1 Displacement 496 cu in (8134 ml) Starting system 12 volt Lubrication 38.76 2236 4.74 0.859 8.17 Barometer (28.91) (17.95) (0.523) (1.61) pressure Air cleaner two paper elements and aspirator Oil filter one full flow cartridge Oil 1.09 2244 2.99 19.182 0.37 28.90" Hg (98.37 kPa) (0.82) (11.32) (11.668) (0.07) cooler engine coolant heat exchanger for Maximum Torque - 654 lb.-ft. (886 Nm) at 1148 rpm crankcase oil, radiator for hydraulic and Maximum Torque Rise -52.4% transmission oil Fuel filter one paper element and Torque rise at 1703 engine rpm - 38% prestrainer Fuel cooler radiator for pump inlet fuel Muffler vertical Cooling medium temperature control 2 thermostats and variable DRAWBAR PERFORMANCE speed fan UNBALLASTED - FRONT DRIVE ENGAGED FUEL CONSUMPTION CHARACTERISTICS ENGINE OPERATING PARAMETERS: Fuel rate: 72.3-79.8 lb/h (32.8 -36.2 kg/h) High idle: Power Drawbar Speed Crank- Slip Fuel Consumption Temp.°F (°C) Barom. Hp pull mph shaft % lb/hp.hr Hp.hr/gal cool- Air inch 2215 - 2265 rpm Turbo boost: nominal 17.4-20.3 (kW) lbs (km/h) speed (kg/kW.h) (kW.h/l) ing dry Hg psi (120-140 kPa) as measured 18.8 psi (130 kPa) (kN) rpm med bulb (kPa) Maximum Power—5.1 mph (8.2 km/h)-Manual Mode CHASSIS: Type front wheel assist Serial 146.06 11678 4.69 2098 3.49 0.478 14.68 190 59 28.87 No.*RW7920D010730* Tread width rear 60.0" (108.91) (51.94) (7.55) (0.291) (2.89) (88) (15) (97.77) (1524 mm) to 117.5" (2984 mm) front 60.0" (1524 75% of Pull at Maximum Power—5.1 mph (8.2 km/h)-Manual Mode mm) to 88.0" (2235 mm) Wheelbase 112.5" (2860 117.12 8748 5.02 2217 2.37 0.539 13.02 184 48 29.03 (87.34) (38.91) (8.08) (0.328) (2.57) (85) (9) (98.31) mm) Hydraulic control system direct engine 50% of Pull at Maximum Power— 5.1 mph (8.2 km/h)-Manual Mode drive Transmission Infinitely variable with two 79.19 5832 5.09 2225 1.45 0.629 11.17 176 48 29.03 mechanical ranges and automatic shifting between (59.05) (25.94) (8.19) (0.382) (2.20) (80) (9) (98.31) ranges. Nominal travel speeds mph (km/h) forward 75% of Pull at Reduced Engine Speed—5.1 mph (8.2 km/h)-Auto Mode - 0-25.0 mph, (0-40 km/h) reverse - 0-25.0 mph(0- 116.59 8748 5.00 1690 2.37 0.435 16.15 184 48 29.03 40 km/h) Clutch wet multiple disc hydraulically (86.94) (38.91) (8.04) (0.264) (3.18) (84) (9) (98.31) actuated by foot pedal Brakes wet multiple disc 50% of Pull at Reduced Engine Speed—5.1 mph (8.2 km/h)-Auto Mode 79.52 5827 5.12 1352 1.45 0.456 15.40 179 48 29.03 hydraulically operated by two foot pedals that (59.30) (25.92) (8.24) (0.277) (3.03) (82) (9) (98.31) can be locked together Steering hydrostatic Power take-off 540 rpm at 1950 engine rpm or 1000 rpm at 1950 engine rpm Unladen tractor mass 17965 lb (8149 kg) THREE POINT HITCH PERFORMANCE (OECD Static Test)
CATEGORY: III Quick Attach: Yes lift cylinders lift cylinders 2 x 90 mm 2 x 100 mm Maximum Force Exerted Through Whole Range: 10987 lbs (48.9 kN) 15574 lbs (69.3 kN) i) Opening pressure of relief valve: NA NA one outlet set two outlet sets combined Sustained pressure at compensator cutoff: 2905 psi (200 bar) 2910 psi (201 bar) ii)Pump delivery rate at minimum pressure and rated engine speed: 31.9 GPM(120.7 l/min) 32.0 GPM(121.1 l/min) iii)Pump delivery rate at maximum hydraulic power: 32.2 GPM(121.9 l/min) 32.2 GPM (122.0 l/min) Delivery pressure: 2200 psi (152 bar) 2610 psi (180 bar) Power: 41.3 HP (30.8 kW) 49.0 HP (36.6 kW)
HITCH DIMENSIONS AS TESTED—NO LOAD
OECD test SAE test THREE POINT HITCH PERFORMANCE inch mm inch mm Observed Maximum Pressure psi. (bar) 2910 (201) A 29.6 752 26.4 670 Location: lift cylinders B 16.7 425 16.7 425 Hydraulic oil temperature: oF ( 0C) 144 (62) C 25.6 650 25.6 650 Location: hydraulic sump D 23.9 608 23.9 608 Category: III E 11.1 283 7.5 190 Quick attach: Yes F 12.7 323 12.7 323 G 35.6 905 35.6 905 SAE Static Test —System pressure 2610 psi (180 Bar) H 4.7 120 4.7 120 with lift cylinders 2 x 90 mm I 20.9 530 20.6 523 Hitch point distance to ground level in. (mm) 7.9 (201) 16.0 (406) 23.9 (607) 31.8 (807) 40.0 (1015) J 22.9 582 22.9 582 Lift force on frame lb 13290 13349 13110 12120 10573 K 28.1 713 27.8 706 " " " " " " " (kN) (59.1) (59.4) (58.3) (53.9) (47.0) L 51.2 1300 47.4 1204 *L' -- -- 50.9 1293 with lift cylinders 2 x 100 mm M 24.7 628 20.9 532 N 44.1 1120 40.3 1024 Hitch point distance to ground level in. (mm) 7.9 (201) 16.1 (409) 24.0 (609) 31.9 (810) 40.0 (1017) O 9.0 230 8.0 203 Lift force on frame lb 18660 18544 17958 16558 14432 " " " " " " " (kN) (83.0) (82.5) (79.9) (73.7) (64.2) P 50.2 1275 45.2 1149 Q 40.4 1025 37.6 954 R 38.4 975 39.8 1010 *L' to Quick Attach ends
JOHN DEERE 7920 DIESEL
Agricultural Research Division Institute of Agriculture and Natural Resources University of Nebraska–Lincoln Darrell Nelson, Dean and Director xxv
INTEGRITY Chemical Treatment System, AQ-2000 with Dwell Piping
Integrated Advanced Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 0(5&(598)$506
( $ 2) ,17(*5,7< xxvii
P-6100T Chemical Feed Pump
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems P-6100T Chemical Feed Pump
The P-6100T industrial pump is designed for a wide range of chemical metering and dispensing applications. It uses the time-tested peristaltic pump principle, which ensures that the pump tube is the only thing that comes in contact with the chemical. The P-6100T pump speed is adjustable from 10 to 100 RPM using an internal control, and can be set up to run in a one of four different program modes: Relay, Pump Delay, Timed Run and Recycle Timing.
KEY BENEFITS
• Only tubing touches chemical • Self priming • No valves to corrode or clog • Four separate program modes for maximum flexibility Dwg # 14261-00, Rev A SPECIFICATIONS FUSE SIZE 24V, 5A - MTH or AGC type 12.75H x 7.75W x 8.0D (inches) 115V, 2A - MTH or AGC type 32.4H x 19.7W x 20.3D (centimeters) 208V, 1A - MTH or AGC type WEIGHT 230V, 1A - MTH or AGC type 14.5 lbs (6.6 kg) TRIGGER SIGNAL CABINET 24 - 230VAC, 50/60 Hz, 0.20 A Type 304 Stainless Steel 24 - 120VDC, 2.20 A PUMP PRIME/START SWITCH Peristaltic, Dual-Roller, Self-Priming Externally mounted, momentary contact push button PUMP DISPLACEMENT ORDERING INFORMATION Adjustable from 5 - 50 oz (0.15 - 1.48 ml)/minute Item # Description at 100 rpm. 039947 P-6100T, 24-230VAC, 50/60 Hz 017937 PCB OPERATING TEMPERATURE 040628 Motor/gearbox, 24 VDC, 98 RPM 36° to 120° F (2° to 50 C°) 018044 Transformer, 115/208/230 VAC primary, 24 VAC POWER secondary 24VAC (+/- 10%), 50/60 Hz, 2.4A 017708 Pump head, front 115VAC (+/- 10%), 50/60 Hz, 0.6A 017709 Pump head, rear 017710 Roller assembly 208VAC (+/- 10%), 50/60 Hz, 0.3A 017434 Pump tube, Silicone 230VAC (+/- 10%), 50/60 Hz, 0.3A 042566 On/off switch 042882 Fuse, 2A
Program/Prime Switch: Functions exactly like Program/Prime switch on the front panel. 24 Volt AC power input terminals Trigger Input Terminals Circuit Board Motor Drive Terminals (Reference) To Program/Prime Switch
Mode Select Switch: To Power Switch 7
9 8 N/C
100 1
Use 1/8" (or smaller) 6
0 0 0
1 0 standard screwdriver. 5
2
3 4
0 50 5
14261F01 Speed Control: Switch Position Pointer: Turn clockwise to increase pump Number pointed at indicates speed and counter-clockwise to present Program or Run Mode slow pump down. Use 1/4" (or status. Shown in Timed Run smaller) standard screwdriver. (With Delay) Mode. Pump runs at set speed when priming, programming, or in normal operation. Program Modes Operating Modes
Design and specifications are subject to change without notice. xxx
Pump Tube Chemical Resistance Data, Equipment Information Sheet
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems 3XPS7XEH 7R7HVW7XEH0DWHULDO 1. Measure the length, inside diameter, outside &KHPLFDO5HVLVWDQFH diameter and wall thickness of a sample piece of tubing. 'DWD 2. Weigh the sample. 3. Immerse the sample in the chemical to be used for This bulletin provides chemical compatibility 72 hours in a closed vessel. information for various pump tube materials. Not all 4. Dry the sample, then measure and weigh it. tube materials are available for all pumps. This data 5. Inspect carefully for signs of deterioration such as is provided by tubing manufacturers and is published swelling, softness, cracking, brittleness or changes as a guideline rather than a guarantee. The ultimate in weight and size. suitability of a tube for an application is the user’s 6. If there are no signs of deterioration, test sample in responsibility. All compatibility ratings indicate the pump under actual service conditions. tubing condition after exposure to the chemicals at 21°C (70°F). Both chemical resistance and Unless otherwise specified upon purchase, mechanical resilience determine which tube is best Beta Technology, Incorporated will ship pump for a given application. Pump tubing is not systems equipped with standard tubing. guaranteed. The best pump tube for a given application takes both factors into account. Beta /HJHQG Technology, Inc. doesn't warrant (neither expressed &KHPLFDO &RPSDWLELOLW\ 7XEH 0DWHULDOV nor implied) that the information contained in this A = Little or no effect Sili = Silicone publication is accurate or complete. B = Minor effect Norp = Norprene (Santoprene) C = Moderate effect (serviceable) Cflex U = Unacceptable (severe effect) BT = Beta Tube (Santoprene) Blank = No test information available Flex EPDM = Nordel Viton (Flourocarbon) BW = Bi-Wall CHEMICAL TUBING MATERIALS Sili Norp Cflex BT Flex EPDM Viton BW Acetaldehyde B A B A C B U C Acetate LMW A C A U U Acetamide C C A C A A Acetic Acid (< 5%) A A B A A A A A Acetic Acid (> 5%) A A C A A A B A Acetic Anhydride U A A A B U A Aceto Nitrile A U B U Acetone U U A U B A U B Acetyl Bromide U C U U U Acetyl Chloride C U C U U U A U Aliphatic Hydrocarbons C U C U U
(Dwg # 13745-00, Rev C) July 2002 CHEMICAL TUBING &KHPLFDO &RPSDWLELOLW\ Sili Norp Cflex BT Flex EPDM Viton BW A = Little or no effect Cyclohexane U U U U C A C B = Minor effect Diacetone Alcohol A B A A A U A C = Moderate effect (serviceable) Diethylamine A B U A U = Unacceptable (severe effect) Blank = No test information available Dimethyl Formamide U B U A B U A Essential Oils C B B B U U 7XEH 0DWHULDOV Ethyl Alcohol (Ethanol) B C B C A U A A Sili = Silicone Ethyl Acetate U C B C U B U U Norp = Norprene Ethyl Bromide U U B U U U A U Cflex Ethyl Chloride U U B U U A A U BT = Beta Tube Flex Ethylamine C U A U U U EPDM = Nordel Ethylene Chlorohydrine C U B U A B A A Viton Ethylene Dichloride U U B U U C A U BW = Bi-Wall Ethylene Glycol A A B A A A A A Ethylene Oxide U B B B A C U A Ferric Chloride B A A A A A A A Ferric Sufate C A A A A A A A Ferrous Chloride C A A A A A A A Ferrous Sulfate C A A A A A A A Fluoboric Acid A A A A A A A Fluoborate Salts A B A A A A A Fluosilisic Acid A A A A A Formaldehyde B A A A C A U C Formamide A A A A Formic Acid C A B A A A C A Glycerine A A B A A A A A Hydriodic Acid U B U A A Hydrobromic Acid (to 30%) UB BBAAAA Hydrochloric Acid (diluted) UA BAABBA Hydrochloric Acid (med conc) UBACAA Hydrochloric Acid (conc) UBAUAA Hydrocyanic Acid C A B A A A A A Hydroflouric Acid (to 10%) UA AAAAA Hydroflouric Acid (to 20%) UA AAAAA Hydroflouric Acid (to 50%) UA AABAA Hydroflouric Acid (to 75%) UB BBCBB Hydroflouric Acid (to 100%) UC CCUCC Hydrogen Peroxide (to 30%) BA AAAAAA Hydrogen Peroxide (to 50%) CA BAAAAA Hydrogen Peroxide (to 75%) UA CAABBA Hydrogen Peroxide (to 100%) UA CABCCB Hydrogen Sulfide C A B A A A A Hypochlorous Acid U A A A A B A A Iodine Solutions C A U A A B A A Isobutyl Alcohol B C C A A A A Isopropyl Alcohol C B B B A A A A Lactic Acid A A A A A A A A Lacquer Solvents U U U U U U U U
(Dwg # 13745-00, Rev C) July 2002 3 xxxiii
EXCELL SERIES 6000PSA, Liquid Polymer Feeder
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems SERIES 6000PSA
LOW POLYMER FEED CAPACITY
with PERISTALTIC PUMP
TECHNICAL INFORMATION
• The Series 6000PSA Polymer Feeder is engineered for low polymer feed applications, where the anticipated feed rate is less than 43 GPD. It provides the high energy needed to effectively activate all liquid polymers. • The polymer metering pump is a peristaltic type pump. It is available with manual or external control. The externally controlled pump can accept a 4-20 mA or a pulse signal. The pump maximum discharge pressure is 65 psi. The pump is self priming and can run dry. • A low water flow switch is standard on all EXCELL Feeders. It stops the metering pump whenever the water flow drops below minimum. The pump is automatically restarted when adequate water flow resumes. • A blending - aging chamber provides improved polymer effectiveness. • The sight tube is self-cleaning. The flow of the solution leaving the activating apparatus causes the patented cleaning assembly to operate continuously. The sight tube allows the operator to see how the feeder is operating. • The external injection valve is accessible without disturbing the activating apparatus. • Motor-less activation injects the polymer into the water stream and immediately makes the solution flow through a low pressure, high energy polymer activation nozzle. The Patented nozzle self- compensates for solution flow fluctuations. This assures that the polymer activation energy level remains adequate as the solution flow changes. • It's designed to require minimum maintenance. All components are modular and easy to access. There are no mixer motors to burn out. • All components are corrosion resistant. The support frame is made of welded stainless steel.
STANDARD FEATURES
• Polymer feed capacities of 0.1 to 43 GPD (0.02 to 6.8 l/h). • Dilution water capacities of 10 to 300 GPH (40 to 1140 l/h). • Blending / Aging chamber for improved polymer effectiveness. • Primary and Secondary dilution water flows • Easily accessed injection valve. • Motorless mixing system.
A patented high-energy nozzle activates the polymer.
The nozzle self-compensates for changes in water flow.
• Self cleaning sight glass (Patented). • Dilution water pressure range capacity of 20 to 60 psi (1.4 to 4.1 bar). • Polymer pump stops when dilution water flow drops below minimum. • Prepiped metering pump calibration cylinder system. • All components are easily accessed. • Compact, most units are 18"W x 16"D x 21"H (46 cm x 41 cm x 53 cm). • Lightweight, most units weigh less than 70 lbs (32 kg). • Electrical service: 120/240 VAC; 50/60 Hz; less than 300 watts. • Most units are available for FREE 30 DAY TRIAL (USA only).
SERIES 6000PSA STANDARD MODELS
MODEL POLYMER FLOW WATER FLOW
NUMBER GPD (L/H) GPH (L/H) 6005PSA-X 0.1 to 5 GPD ( 0.02 to 0.8 L/H ) 10 to 60 GPH ( 40 to 220 L/H ) 6005PSA2-X 0.1 to 5 GPD ( 0.02 to 1.6 L/H ) 10 to 120 GPH ( 40 to 440 L/H ) 6020PSA-X 1 to 20 GPD ( 0.2 to 3.2 L/H ) 20 to 150 GPH ( 75 to 570 L/H ) 6020PSA2-X 1 to 20 GPD ( 0.2 to 3.2 L/H ) 20 to 300 GPH ( 75 to 1140 L/H ) 6043PSA-X 2 to 43 GPD ( 0.4 to 6.8 L/H ) 20 to 150 GPH ( 75 to 570 L/H ) 6043PSA2-X 2 to 43 GPD ( 0.4 to 6.8 L/H ) 20 to 300 GPH ( 75 to 1140 L/H )
OPTIONS: 1. Metering pump can be controlled by a remote 4-20 mA signal. 2. Metering pump can be controlled by the dilution water flow to maintain solution concentration. 3. Solenoid water control valve. 4. Modulating water control valve to allow remote control of dilution water flow. 5. Hand-Off-Auto switch to allow remote start-stop control of the feeder. 6. Water flush timer to allow the dilution water to continue flowing after the feeder is turned off. 7. Local indicator lights and dry contacts for remote indication of: A. The metering pump is running. B. The switches are in auto mode. C. The dilution water flow is low. 8. High volume polymer strainer. 9. Explosion Proof for Class1, Group D installations. 10. Standard voltage is 120 VAC. Other voltages are available. 11. Custom instruments, including PLC control, to meet your needs.
EXCELL FEEDERS, INC. Somerset, NJ USA 800-250-9037 732-828-8655 Fax: 732-828-2611 EXCELL SERIES 6000PSA LIQUID POLYMER FEEDER
NEAT POLYMER CAPACITY
up to 43 GPD
DILUTION WATER CAPACITY
up to 300 GPH
COMPACT
16" x 18" x 21" deep
LIGHTWEIGHT
weighs only 70 lbs
EASY TO INSTALL - SIMPLE TO OPERATE - QUICK TO REPAIR
EXCELL FEEDERS, INC. Somerset, NJ USA 800-250-9037 732-828-8655 Fax: 732-828-2611 xxxviii
Vincent Corporation, Fiber Filter
Integrated Advanced Based Nutrient Management and Flushwater Management on a Sand Bedded Dairy
FPPC – INTEGRITY Ag Systems