Grantee Research Project Results
Final Report: A Biomass Energy Process for Poultry Growing Operations
EPA Contract Number: EPD07054Title: A Biomass Energy Process for Poultry Growing Operations
Investigators: Neathery, James K
Small Business: Neathery Technologies, Inc.
EPA Contact: Richards, April
Phase: I
Project Period: March 1, 2007 through August 31, 2007
Project Amount: $70,000
RFA: Small Business Innovation Research (SBIR) - Phase I (2007) RFA Text | Recipients Lists
Research Category: SBIR - Animal Waste and Waste to Energy , Small Business Innovation Research (SBIR)
Summary/Accomplishments (Outputs/Outcomes):
A comprehensive sampling program of PL from a typical poultry farm was completed. The composite samples were found to have moisture contents consistently higher than that cited in the literature. Because the feedstock moisture content can have a significant effect on the gasifier efficiency and also influence the reliability and consistency of the fuel gas, drying will be required in a commercial-scale operation. Computer simulations of several drying options were carried out. The most effective option for increasing the producer gas efficiency was using a fuel dryer to vent the moisture outside the gasifier; however, due to potential increases in ammonia and odor emissions, the most practical option was injecting the moist poultry fuel into the gasifier with heated air. This method would increase the equilibrium gasification temperature and thus minimize the formation of troublesome tars and oils.
The results of the bench-scale reactor experiments showed a large portion of the PL sulfur and chlorine reported to the char/ash fraction in the gasifier. The fraction of sulfur reporting to the ash/char was greater than 90 percent while the mass balance indicated that greater than 49 percent to 70 percent of the chlorine remained with the ash. Only trace amounts of H2S and HCl were captured in the condensate of the fuel gas. The available alkalinity of the ash samples was found to be in excess of the moles of sulfur and chlorine in the poultry litter. Therefore, even though the majority of the acid gases have been captured, there was an abundance of available alkalinity.
The process model of the Neathery Technologies, Inc. (NTI) gasification system accurately predicted fuel gas composition; however, the experimental results indicated that fuel nitrogen conversion to ammonia was two orders of magnitude higher than predicted. High ammonia levels in the producer gas condensate provide an opportunity for incorporation with the ash byproduct. Further work is needed to test the addition of admixtures to prevent gaseous ammonia from escaping the mixture. A preliminary test of mixing the ammonia/water condensate with the ash/char was quite positive. The resulting fertilizer mixture retained greater than 95 percent of the ammonia from the condensate, yielding a fertilizer with a 5-25-11 nitrogen, phosphorus, and potassium (NPK) fertilizer analysis (excluding the unburned carbon). Additionally, the resulting fertilizer by product contained a substantial amount of carbon (10 to 50% loss-on-ignition [LOI]), which has been shown to be an excellent soil amendment.
Retrofitting existing heating and electrical generation equipment was found to be technically and economically challenging. For heat production the most feasible option would be using separate convection heaters next to the propane heaters. The conversion of the existing power generator also would be cost prohibitive. A new spark ignition generator set, fueled by a combination of propane and producer gas, was recommended. This configuration would allow more producer gas to be used for the generator engine. Several diesel engine generator sets that have been converted to spark ignition for landfill gas applications are available commercially.
Conclusions:
The capture of acid gases liberated from PL gasification with byproduct char and ash proved to be technically feasible. The concentrated fertilizer byproduct has the potential to be marketed in a larger radius than that of the poultry litter. The results of a case study for a medium -sized poultry operation (containing eight houses) indicated that a complete gasification system with appropriate power generation equipment could result in a 2.5 -year payback. In summary, the PL gasification concept could increase the profitability of the poultry operation while substantially lowering the environmental impact to rural communities and surrounding farmlands.
Journal Articles:
No journal articles submitted with this report: View all 1 publications for this projectSupplemental Keywords:
small business, SBIR, bioenergy, recycling, small-scale power, environment, on-farm, poultry cooperative,, RFA, Scientific Discipline, Sustainable Industry/Business, Sustainable Environment, Technology for Sustainable Environment, Environmental Engineering, agricultural byproducts, poultry industry, poultry waste, biomass, alternative fuel, alternative energy sourceThe perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.